Chennai Metro Rail Limited: TENDER No. CP06/UG06/RT01

CHENNAI METRO RAIL LIMITED
CHENNAI METRO RAIL PROJECT PHASE 2, CORRIDOR 5

TENDER No. CP06/UG06/RT01
“CONSTRUCTION OF UNDERGROUND STATIONS AT

KOLATHUR JUNCTION, SRINIVASA NAGAR, VILLIVAKKAM
SUB-URBAN STATION (VILLIVAKKAM), VILLIVAKKAM
BUS-TERMINUS AND NATHAMUNI (VILLIVAKKAM MTH
ROAD) WITH ENTRY / EXIT, VENTILATION SHAFTS,
PLUMBING, EARTHMAT, ARCHITECTURAL FINISHES &
SIGNAGES ETC. INCLUDING TWIN BORED TUNNELS
FROM KOLATHUR JUNCTION RETRIEVAL SHAFT TO
NATHAMUNI (VILLIVAKKAM MTH ROAD) LAUNCHING
SHAFT AND RAMPS WITH U - SECTION IN CORRIDOR-5 OF
CMRL PHASE-II PROJECT”
PART 2
SECTION VI
EMPLOYER’S REQUIREMENTS
DECEMBER 2021

AMDIN BUILDING, CMRL DEPOT,
POONAMALLEE HIGH ROAD,
KOYAMBEDU,
CHENNAI – 600107, INDIA
CHENNAI METRO RAIL
LIMITED
TENDER DOCUMENTS
PART 1 Bidding Procedures
Section - I Instructions to Bidders (ITB)
Section - II Bid Data Sheet (BDS)
Section - III Evaluation and Qualification Criteria (EQC)
Section – IV A Bidding Forms
Section - IV-B Pricing Document
Section - V Eligible Source Countries
PART 2 Works Requirements

Section - VI.
Sub-Section – A – General
Sub-Section – B – Functional
Sub-Section – C – Design
Sub-Section – D – Construction
Sub-Section – E - Appendices
Section - VI A – OHS&E Requirements
Volume 1. Control
Volume 2. Safety Manual
Volume 3. Environment
Volume 4. Tunnelling Manual
Section - VII. Outline Construction Specifications
Sub - Section 1. Civil and Structural Works
Sub - Section 2. Tunnel
Sub - Section 3. Geotechnical, Instrumentation and Monitoring
Sub – Section 4. Architectural
Sub – Section 5. Plumbing & Earth Mat
Section - VIII. Employer’s Drawings
PART 3 Conditions of Contract and Contract Forms
Section - IX. General Conditions (GC)

Section - X. Particular Conditions (PC)
Section - XI. Contract Forms (CF)
PART 4 Reference Documents

A. Geotechnical Investigation Record
B. Existing Building Condition Survey Reports
C. Temporary Traffic Diversion Plans
D. Existing Utilities Drawings
TABLE OF CONTENTS
PART-2 SECTION VI EMPLOYER’S REQUIREMENTS

SUB-SECTION A EMPLOYER’S REQUIREMENTS – GENERAL A1- A2
SUB-SECTION B EMPLOYER’S REQUIREMENTS - FUNCTIONAL B1-B9
SUB-SECTION C EMPLOYER’S REQUIREMENTS - DESIGN C1-C8
SUB-SECTION D EMPLOYER’S REQUIREMENTS - CONSTRUCTION D1-D29
SUB-SECTION E EMPLOYER’S REQUIREMENTS - APPENDICES
LIST OF APPENDICES
APPENDIX 1 - DRAWINGS 1A-1
APPENDIX 2A- WORKS AREAS 2A-1 to 2A-2
APPENDIX 2B- CONTRACT KEY DATES AND COMPLETION DATE 2B-1 to 2B-9
APPENDIX 3 - PROJECT CALENDAR 3-1
APPENDIX 4 - PROGRAMME REQUIREMENTS 4-1 to 4-8
APPENDIX 5 - MONTHLY PROGRESS REPORTS 5-1 to 5-5
APPENDIX 6 - QUALITY ASSURANCE 6-1 to 6-21
APPENDIX 7A - DRAUGHTING AND CAD STANDARDS 7A-1 to 7A-18
APPENDIX 7B- BIM STANDARDS 7B-1 to 7B-18
APPENDIX 8 - WORKS AREAS & TEMPORARY POWER SUPPLY 8-1 to 8-5
APPENDIX 9 - RAILWAY ENVELOPE ACCESS AND TAKING OVER 9-1 to 9-2
APPENDIX 10 - APPROVED MANUFACTURERS / SUPPLIERS 10-1 to 10-4
APPENDIX 11 - CURVE AND GRADIENT DETAILS 11-1
APPENDIX 12 - UTILITIES 12-1 to 12-7
APPENDIX 13 - SITE ACCOMMODATION FOR THE EMPLOYER’S REPRESENTATIVE 13-1 to 13-2
APPENDIX 14 - CONTRACTOR’S SITE LABORATORY 14-1 to 14-5
APPENDIX 15 - DESIGN CONSOLIDATION UNIT REQUIREMENT -DELETED-
APPENDIX 16 - EARTHING AND GRID 16-1 to 16-20
APPENDIX 17 - ADJACENT WORKS CONTRACTS 17-1
APPENDIX 18 - SCHEDULE OF DIMENSIONS 18-1 to -48
APPENDIX 19 - DESIGN AND CONSTRUCTION INTERFACE MANAGEMENT 19-1 to 19-21
“CONSTRUCTION OF UNDERGROUND STATIONS AT KOLATHUR

JUNCTION, SRINIVASA NAGAR, VILLIVAKKAM SUB-URBAN
STATION (VILLIVAKKAM), VILLIVAKKAM BUS-TERMINUS AND
NATHAMUNI (VILLIVAKKAM MTH ROAD) WITH ENTRY / EXIT,
VENTILATION SHAFTS, PLUMBING, EARTHMAT,
ARCHITECTURAL FINISHES & SIGNAGES ETC. INCLUDING
TWIN BORED TUNNELS FROM KOLATHUR JUNCTION
RETRIEVAL SHAFT TO NATHAMUNI (VILLIVAKKAM MTH ROAD)
LAUNCHING SHAFT AND RAMPS WITH U - SECTION IN
CORRIDOR-5 OF CMRL PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SECTION A
GENERAL
DECEMBER 2021

KOYAMBEDU,
Chennai Metro Rail Project Phase 2, Corridor 5. Part-2 - Section VI
TENDER No. CP06/UG06/RT01 Employer’s Requirements

TABLE OF CONTENTS
SUB-SECTION A EMPLOYER’S REQUIREMENTS - GENERAL

SECTION PAGE
A1 INTRODUCTION A-1
A2 DEFINITIONS AND INTERPRETATIONS A-1
A3 RELEVANT DOCUMENTS A-2
A4 PHASES (DESIGN VALIDATION AND CONSTRUCTION) A-3
A5 SPECIFICATIONS IN METRIC AND IMPERIAL UNITS A-3
A6 WORKS PROGRAMME A-3
A7 MONITORING OF PROGRESS A-3
A8 QUALITY ASSURANCE A-4
A9 SOFTWARE SUPPORT A-4
A10 CO-ORDINATION WITH INTERFACING CONTRACTORS. A-4
A11 SURVEY AND SITE INVESTIGATIONS A-10
A12 CLIMATIC CONDITIONS A-10
A13 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS) A-10
A14 CONTRACTOR’S PROJECT ORGANISATION A-10
A15 TRAINING and TECHNOLOGY TRANSFER A-15
A16 MAINTENANCE REPORT A-16
A17 MEETINGS A-16
Attachment A1 – COPIES OF SUBMITTALS AND FORMAT REQUIREMENTS
Attachment A2 – TRANSMITTAL FORM
Attachment A3 – DOCUMENT SUBMISSION REPORT
Section VI – General Section A i December 2021

Part-2 – Section VI
Chennai Metro Rail Project Phase 2, Corridor 5. Employer’s Requirements
A1 INTRODUCTION
These Employer's Requirements are divided into five sections as follows:
(a) General: these apply throughout the Contract (Section A).
(b) Functional: these include the specific core requirements for the performance of the Works
(Section B).
(c) Design: these apply in respect of responsibilities and obligations relating to the design of the
Temporary Works (Section C).
(d) Construction: these apply in respect of responsibilities, obligations and other requirements
relating to the construction of the Works (Section D).
A2 DEFINITIONS AND INTERPRETATIONS
In addition to the words and expressions defined in the Conditions of Contract (CC), the following
words and expressions shall have the meaning assigned to them except where the context otherwise
requires:
“Employer’s Representative”: Shall be read as Engineer.
"As-Built Drawings": means those drawings produced by the Contractor and endorsed by it as true
records of construction of the Permanent Works and which have been given a Notice by the Engineer.
“Baseline Programme” means the first Works Programme issued with a Notice of No Objection by
the Engineer that is used solely to assess the Contractor’s progress.
"Construction Specification": means those parts of the Standard Outline Specification which relate
to construction.
“Core System” means the trainsets, catenary, electrification, signalling, communication, driving
simulator, wayside electrical and mechanical facilities, ventilation systems, escalators and lifts, and
any other related miscellaneous equipment.
“Employer’s Drawings” means those drawings included in Appendix-1 of this document.
"Employer's Requirements" means the requirements set out in this Part -2.
“Key Equipment” means items of Contractor’s Equipment (whether owned by the Contractor or not).
“Key Personnel” means those persons named or positions so specified in Part 1 and Part 2 of the
Contract or so designated by the Engineer at any time during the Contract.
“Monthly Progress Report” means the report referred to in General Conditions (GC) clause 4.21 to
be prepared by the Contractor, in the form and detail prescribed in Appendix 5 of this Part -2 and
submitted monthly to the Engineer.
"Notice": means a Notice of No Objection, as given in writing by the Engineer.
"Outline Specification": means the Outline Construction Specifications that specify standards issued
by the Employer for construction.
Section VI – General –Sub-Section A A-1 December 2021

“Project” means the construction, commissioning, operation and maintenance of a metro rail system
for the city of Chennai, including the Core System, E&M Works, Trackwork, Stations, Depot and
Stabling Yards and Civil Works.
“Quality Plan” means the quality plan, setting out the Contractor’s means of complying with his
obligations in relation to Quality Assurance provided and maintained in accordance with General
Conditions (GC) Clause 4.9, in the form and detail prescribed in Appendix 6 of Part-2 of the Contract.
"Railway Envelope": means the zone or zones within the Works which will contain the track-work
and equipment necessary for the operation of the railway.
“Safety Plan” means the safety plan setting out the Contractor’s means of complying with his
obligations in relation to safety provided and maintained in accordance with GC Clause 4.8, in the form
and detail prescribed in Appendix 20 of Part-2 (revised) of the Contract.
“Scope of Works” means the brief description of the Works.
"Structure Gauge": means the profile related to the designed normal co-ordinated axis of the track
into which no part of any structures or fixed equipment may penetrate.
"Working Drawings": comprise the Construction Reference Drawings and such other drawings and
documents, such as bar bending schedules and manufacturing drawings, as are necessary to amplify
the Construction Reference Drawings for construction purposes.
“Works Programme” means the time-scaled and resource-loaded critical path network, updated from
time to time in accordance with GC Clause 4.21 and Appendix 4 of this Part-2 of the Contract, depicting
activities, durations, sequences and interrelationships that represent the Contractor’s work plan, work
breakdown, schedule structure for constructing and completing the Works, distributed over the Time
for Completion of the Contract, as given a Notice by the Engineer.
A3 RELEVANT DOCUMENTS
The Drawings shall be read in conjunction with the Conditions of Contract (CC) Parts 3, the
Employer’s Requirements and any other document forming part of the Contract.
In the event of a conflict between the Employer’s Requirements and any drawings then drawings shall
prevail.
In the event of a conflict between any drawings and any other standards or specifications quoted, the
requirements of the drawings shall prevail.
Notwithstanding the precedence specified above the Contractor shall always immediately seek advice
from the Engineer in the event of conflicts between Specifications.
The order of precedence is:
• Employer’s Requirements
• Employer’s Drawings
• Outline Construction Specifications
• Indian and other International Standards referenced herein.

A4 PHASES (DESIGN VALIDATION AND CONSTRUCTION)

(1) The Contractor shall execute the Works in parallel for: (i) the design of Temporary Works as
defined in Section B, Clause B2 of this document: as well as (ii) the construction.
A5 SPECIFICATIONS IN METRIC AND IMPERIAL UNITS
(1) The Contract shall utilise the SI system of units. Codes and Standards in Imperial units shall not
be used unless the Engineer has given a Notice.
(2) Conversion between metric units and imperial units shall be in accordance with the relevant Indian
Standards.
A6 WORKS PROGRAMME
(1) The Key Dates are defined in Appendix 2B to these Employer's Requirements.
(2) The Contractor shall prepare and submit his Works Programme and three-month rolling
programmes in accordance with the detailed requirements contained in Appendices 3 and 4 to
these Employer's Requirements.
(3) In compiling his Works Programme and in all subsequent updating and reporting, the Contractor
shall make provision for the time required for co-ordinating and completing, testing,
commissioning and integrated testing of the Works, including, inter alia, temporary works design
co-ordination periods during which the Contractor shall co-ordinate with those of Project and
other Interfacing Contractors, the assessment procedures, determining and complying with the
requirements of all Government Departments and all others whose consent, permissions, authority
or license is required prior to the execution of any work.
(4) The Employer and the Engineer shall designate certain of their computers for installation, by the
Contractor, of software programmes that the Contractor intends to use for the construction
programme, production of as built drawings, BIM etc... All software shall be originals and
licensed by the manufacturer and issued at the Contractor’s cost.
(5) In addition, a time location diagram covering the critical activities drawn against the time in
vertical axis and the location in horizontal axis using a proprietary software shall also be prepared
and submitted along with the work programme submissions.
A7 MONITORING OF PROGRESS
(1) The Contractor shall submit to the Engineer six copies of a Monthly Progress Report (MPR), as
described in Appendix 5 to these Employer's Requirements, describing the progress and current
status of the Works. The MPR shall address the matters set out in the Works Programme.
(2) The MPR shall be submitted by the last day of each calendar month. It shall account for all works
actually performed from the twenty sixth day of the last month and up to the twenty fifth day of
the current month. The processing of the Interim Payment Certificate will only commence after
the receipt of the MPR on the due date. Late receipt will delay the processing of the Interim
Payment Certificate (IPC).

(3) The MPR shall cover progress and current status relating to construction.
(4) The MPR shall be signed by the following Key Staff: Project Manager, QA Manager, Safety
Manager, Planning Manager and Chief Interface Coordinator, who by signing the MPR shall
certify that all information contained in the MPR, as relating to their section of the Works, has
been accepted and verified by each signatory as being accurate, honest, true and meets the
requirements of the Contract.
(5) A monthly meeting to monitor the progress of the project shall be convened by the Engineer and
the Contractor and the representatives of the Interfacing Contractors shall also attend the meeting.
The Employer may also be present in the meeting. Refer to Clause A18 of this Employer’s
Requirements Part-2.
(6) The Employer shall arrange Quarterly Review Meetings for the Project which the Contractor shall
attend and participate in as required. Refer to Clause A18 of this Employer’s Requirements Part-
2.
A8 QUALITY ASSURANCE
The Contractor shall establish and maintain a Quality Assurance System in accordance with Appendix
6 to these Employer's Requirements for construction procedures and the interfaces between them. This
Quality Assurance System shall be applied without prejudice to, or without in any way limiting, any
Quality Assurance Systems that the Contractor already maintains.
A9 SOFTWARE SUPPORT
General
(1) The Contractor shall provide two licenses of all computer programs and full support to the
Employer and the Engineer for all computer programs used/proposed to be used, by the
Contractor under the Contract; also refer to Clause A6(4) this Employer’s Requirements,
Part-2.
(2) The Contractor shall submit a software support plan at least 90 days before commencement
of software installation. This plan shall require the Contractor to provide all changes, bug
fixes, updates, modifications, amendments, and new versions of the program as required
by the Engineer.
(3) The Contractor shall provide all tools, equipment, manuals and training as necessary for
the Employer / the Engineer to use, maintain and re-configure all of the software provided
under the Contract.
(4) The Contractor shall submit all new versions to the Engineer for a Notice at least 2 weeks
prior to their installation. New Versions of any program shall not result in any non-
conformance with the Specification or degrade the operation of the System. The Contractor
shall:
• ensure that all new versions are fully tested and validated on the simulation and
development system prior to installation.
• ensure that all new versions are fully tested and commissioned once installed on the
Site.

• deliver to the Employer and the Engineer any new version, together with the updated
Operation and Maintenance Manuals.
(5) The Engineer shall not be obliged to use any new version and that shall not relieve the
Contractor of any of his obligations. Any effect upon the performance or operation of the
computer-controlled system that may be caused by a new version shall be brought to the
Engineer’s attention including updating the files to suit the new version.
Software Obligations
(6) Within 14 days of the installation of any software by the Contractor, the Contractor shall
submit to the Engineer for retention by the Employer and the Engineer, two backup copies
of the software, which shall include, without limitation:
• all licenses in favour of the Employer for their use.

• all source and executable codes;
• all design documentation relating to the software; and
• any specified development tools required for maintenance of the software, including,
but not limited to, editors, compilers and linkers.
Error Correction
(7) When a fault is discovered within delivered software or documentation, the Contractor
shall take necessary steps to rectify errors or faults at the earliest.
(8) The Contractor shall provide written details as to the nature of the proposed correction to
the Engineer.
(9) The Contractor shall notify the Employer promptly of any fixes or patches that are available
to correct or patch faults.
(10) The Contractor shall detail any effect such fixes or patches are expected to have upon the
applications.
Training
The Contractor shall provide initial training for the Employer’s staff to enable them to make
proper use of any software and subsequent training for any new versions.

A10 CO-ORDINATION WITH INTERFACING CONTRACTORS.
(1) The Contractor shall be responsible for coordinating his own technical, programming and
construction activities and for coordinating these with the programming and construction activities
of other Project Contractors, Utility Agencies, Statutory Authorities, Public Service Providers,
Developers, Consultants and other Contractors whether or not specifically mentioned in the
Contract, that may be working on or adjacent to the site, to achieve fully coordinated construction
of the facilities. For the purpose of these Employer’s Requirements and the Contract, all of the
above parties shall be referred to as “Interfacing Contractors”.
The Engineer shall oversee, monitor, provide direction and clarification where required, attend
Interface meetings, in conjunction with the Contractor and other Interfacing Contractors. The
Contractor shall note that the Employer may engage other Contractors, Consultants, etc., from
time to time with whom the Contractor shall have to similarly co-ordinate. Such co-ordination
responsibilities of the Contractor shall include, but not be limited to, the following.
(i) To facilitate the Interfacing Contractors design development and report in writing to the
Engineer as soon as it is known that the Interfacing Contractor requests design changes to the
civil works. Such report must be issued within 72 hours of the Interfacing Contractor making
a design change request and contain full and detailed particulars of the change with an
assessment of all costs and time impacts to the Contractor.
(ii) To provide all information reasonably required by the Interfacing Contractors in a timely and
professional manner to allow them to proceed with their construction activities, and
specifically to meet their contractual obligations.
(iii) To ensure that the Contractor’s requirements are provided to all other Interfacing Contractors
before the cut off dates identified in the Interface Management Plan (IMP) to be developed by
the Contractor.
(iv) To obtain from the Interfacing Contractors information reasonably required to enable the
Contractor to meet the Construction Key Dates as identified in Appendix 2B of this Part-2.
(v) Where the execution of the work of the Interfacing Contractors depends upon the site access,
management or information to be given to them by the Contractor, the Contractor shall provide
to such Interfacing Contractors the services or correct, and accurate information required to
enable them to meet their programme or construct their work.
(vi) To co-ordinate access and delivery routes and ensure that all provisions for access and
delivery of plant are co-ordinated with and reflected in the Interfacing Contractor’s Delivery
Route Drawings. The Interfacing Contractor shall ensure that all plants are delivered at the
time agreed to allow openings left in the structure for such delivery to be sealed in accordance
with the Contractor’s programme.
(vii) To co-ordinate with the Interfacing Contractors on attendance.

(viii)To attend regular and quarterly co-ordination meetings convened by the Engineer with the
Interfacing Contractors. The Contractor shall conduct separate meetings with the Interfacing
Contractors as necessary to clarify particular aspects of the interfacing requirements of the
Works. The party who convenes the meeting shall prepare minutes recording all matters
discussed and agreed at the meeting.
(ix) To ensure a clear flow and exchange of information, direction and timings, copies of all
correspondence, drawings, meeting minutes, programmes, etc. relating to the Contractor’s co-
ordination with all of the Interfacing Contractors shall be issued to all concerned parties, four
(4) copies shall be issued to the Engineer no less than three (3) calendar days from the date of
such correspondence and meetings.
(2) The Contractor shall, in carrying out his co-ordination responsibilities, raise in good time, and
provide sufficient information for the Engineer to decide on, any disagreement between the
Contractor and Interfacing Contractors as to the extent of services or information required to pass
between them. If such disagreement cannot be resolved by the Contractors, despite the Contractor
taking all reasonable efforts, then the decision of the Engineer shall be final and binding on the
Contractor.
(3) Where an Interfacing Contract has yet to be awarded the Contractor shall proceed with the co-
ordination activities with the Engineer until such time when the Interfacing Contractor is available.
The Contractor shall provide the Interfacing Contractor with all information and documents
necessary to enable the Interfacing Contractor to follow on and proceed with their co-ordination.
(4) The Contractor has to include in his Interface Management Plan, as required in Appendix 19, the
latest dates for the Contractor to pass information to the Interfacing Contractors in order for them
to complete their design submissions to the Engineer. Any claims of additional costs by the
Interfacing Contractors as a result of the Contractor’s failure in adhering to these dates shall be
borne by the Contractor. The Contractor shall note that the information exchange is an iterative
process requiring the exchange and updating of information at the earliest opportunity and shall
be carried out on a regular and progressive basis so that the process is completed for each design
stage by the cut off dates.
Dedicated Co-ordination Team.
(5) The Contractor shall establish a dedicated co-ordination team, led by a Chief Interface Co-
ordinator permanently stationed in Chennai reporting to the Contractor’s Project Manager or
Representative. The primary function of the team is to provide a vital link among the Employer,
the Engineer, Contractor’s temporary work design team, Contractor’s construction teams and all
Interfacing Contractors.
(6) The Chief Interface Co-ordinator shall assess the progress of the co-ordination with Interfacing
Contractors by establishing lines of communication as indicated in the co-ordination model in

Figure-1 and promote regular exchange and updating of information so as to maintain the
Contractor’s programme.
(7) The complexity of the Project and the importance of ensuring that work is executed within time
limitations require detailed programming and monitoring of progress so that early programme
adjustments can be made in order to minimise the effects of potential delays.
(8) The Chief Interface Co-ordinator in conjunction with the Interfacing Contractors shall identify
necessary provisions in the Works for plant, equipment and facilities of the Interfacing
Contractors. These provisions shall be given due allowance by the Contractor in his construction
of the Works.
(9) During the course of the Contract, information will be obtained in a number of ways. These may
include direct inspection, regular site meetings, the obtaining of progress reports. Turnaround
documents shall be issued to the Interfacing Contractors, copied to the Engineer, to be returned
by the receiving party within a set time period, giving the current positions on their programme.
Interface
(10) The information cut off dates in the Interface Management Plan developed by the Contractor will
be critical for the timely completion of the Project. The Contractor shall commence interface with
the Interfacing Contractors as soon as he has been notified by the Engineer that such Interfacing
Contract(s) has been awarded. In the case of Utility Agencies and other Statutory Authorities,
interface shall commence as soon as possible. Where no interface date has been established,
whether because the Interfacing Contractor has not been identified, or for whatever reason, the
Contractor shall liaise with such Interfacing Contractor(s) as soon as they have been awarded.
(11) The interface is an iterative process requiring regular exchange and updating of interfacing
information. The Contractor shall ensure that the information he requires from the Interfacing
Contractors is made known at the outset of each interface, and vice versa, so that information can
be provided in time for the Interfacing Contractors to complete their designs to meet their various
design submission dates.
Construction Interface.
(12) Construction Interface will be necessary throughout the duration of the Works commencing from
the time the Contractor mobilises on site, to the completion of the Works. Construction interface
involves cast in and buried items such as pipes for electrical and mechanical services, supports,
brackets, plinths, ducts, service buildings, openings, cableways, trenches ,etc., that are to be
incorporated at the early stage of the construction up to provision of attendance during testing and
commissioning stage.
(13) The Contractor shall ensure that there is no interference with the works of the Interfacing
Contractors and shall maintain close co-ordination with them to ensure that his work progresses
in a smooth and orderly manner. The Contractor shall carry out and complete the Works, or part

thereof, in such order as may be Noticedby the Engineer or in such order as may be requested by
the Engineer from time to time. The Contractor shall, unless otherwise provided, be liable for and
shall indemnify the Employer against all costs, charges, expenses and the like resulting from the
failure of the Contractor to co-ordinate the Works as specified.
(14) The Contractor shall prepare a Station Installation Coordination Plan (ICP) for each station on a
room by room basis and section of tunnels covering the period of Interfacing Contractors’ access.
The ICP shall allow adequate time periods for each Interfacing Contractor to install their plant and
equipment in the station rooms/areas and tunnels, as per their specific requirements. The ICP shall
be agreed with and signed off by each Interfacing Contractor and then submitted to the Engineer
for a Notice no later than six months before the construction key dates as identified in Appendix
2B of this Part -2 document.
(15) The major public infrastructure works contracts currently planned to be undertaken in the vicinity
of the site areas include, but are not limited to, those as listed in Appendix 17 of this Part-2 . The
works contracts interfacing with the project are subject to change and additional contracts may be
added from time to time and the Contractor shall be responsible for identifying relevant contracts
THE ENGINEER
Figure – 1

(16) In preparation of the ICP, the Contractor shall arrange weekly meetings commencing at least 3
months before the submission date of the ICP. The Engineer and All Interfacing Contractors are
to be invited. The meetings shall be recorded by the Contractor and minutes issued within 24 hours
of the meeting. The Contractor shall give access to all areas at the earliest possible time and in
advance of the Key Dates where possible to allow the Interfacing Contractors to start work and as
directed by the Engineer. The Contractor shall share access with Interfacing Contractors where so
directed by The Engineer.
A11 SURVEY AND SITE INVESTIGATIONS
(1) The datum used for the Contract shall be Mean Sea Level Datum referenced to the Great
Trigonometrical Survey of India value of 5.398m taken from the South East corner of the Munro
Statue Dais at Mount Road opposite the Islands Grounds.
(2) The co-ordinates used for the Contract shall be based on a local coordinate system as defined by
the traverse reference points shown in the Employer’s Drawings.
(3) The Contractor shall carry out all further site investigations, including surveys, Existing Building
Condition Survey etc necessary for construction of the Permanent Works and to enable the
determination of the methods of construction and the nature, extent and design of the Temporary
Works.
A12 CLIMATIC CONDITIONS
Chennai experiences extreme climatic conditions and constructions and plans for the Works must take
this into account accordingly. The Contractor shall obtain information on the climatic conditions in
Chennai, such as temperature, rain fall, wind, sunshine, relative humidity, etc. from the Meteorological
Department and/or other authorities and shall make full provision for the effects of the local weather
conditions in his planning, programming and execution of the Works.
A13 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS)
The Employer is presently in negotiations to provide a PMIS which is going to be a web based platform
on cloud to monitor and track the progress of the whole project, tailored to match the specific needs of
the project.
The aim is to provide the Employer and the Engineer with insights critical for the smooth and timely
execution of the project. The Contractor will be required to submit the data and information for the
PMIS as described by the Engineer.
The contractor once awarded the contract will develop a Method Statement for the control of document
and management information as per the requirements of chosen system in co-ordination with the
Engineer which shall also detail various processes of the PMIS.
The information shall include but shall not be limited to:
(1) Schedule related information
(2) Progress related information
(3) Issues related to the project
(4) Safety related information

(5) Quality related information

The integrated system will also take inputs from Primavera and project the possible delays and
achievements of the various Contractors and also the overall project. The management team can review
the overall health and synopsis of the entire project on the master dashboard.
The contractor will be managing the PMIS for entire contract duration including the defects liability
period for their contract package including sharing the proportionate cost of
• Cloud based server (The Employer will be acquiring the common cloud based server for all
contract packages of phase 2 and back charge the proportionate cost of the Server, Cloud
services and the manage services of the cloud server to each contractor
• 3 nos user licenses cost for Primavera P6 Enterprise Project Portfolio Management Cloud
Service (1 No. each to be used by the Contractor, the Engineer and the Employer. Please note
that the Contractor can ask for more licenses if he wish to but strictly on his cost
• Min. 15 nos user licenses cost for Primavera P6 Enterprise Project Portfolio Management Web
Services Cloud Service (5 No. each to be used by the Contractor, the Engineer and the
Employer. Please note that the Contractor can ask for more licenses if he wish to but strictly
on his cost
• The Employer will be hiring a professional agency to implement P6 EPPM for whole project
and integrate it with PMIS. The contractor for each package will have to share proportionate
cost for their package. Any other software required to interact with PMIS for their contract
package needed to update the information as explained above.
PMIS, which will be containing, amongst many other modules, a module on document management
system, such that all documents generated by the Project and Interface Contractors can be transmitted
to the Employer and the Engineer, by electronic means, and vice versa, and that all documents
generated by all parties are electronically captured at the point of origin and can be reproduced later,
electronically and in hard copy. The Contractor shall note that a limited number of his staff will receive
specific training in the use of the PMIS system, which shall be organised by the Employer at a time
and location yet to be determined.
The number and format of the required document submissions is detailed in Attachment A1 to this
Section A. The Transmittal Form is given in Attachment A2 to this Section A and the Document
Submission Report, for the obtaining of a Notice of No Objection from the Engineer, is given in
Attachment A3 to this Section A.
The Method Statement for the control of document and management information to be submitted by
the Contractor shall also detail the uploading, maintaining, and archiving the following
submittals, included but not limited to:
(1) Contractual Works Programmes, Work Segment Programmes, and supporting reports (including
plans) as per the format and using the software as defined in the Contract,
(2) Drawings (including As build drawings), BIM Models and designs created by the Contractor as per
the construction asset (classification) and on the software platform defined in the Contract,
(3) Records of measurement or Contractor’s Statements or both, in a format defined in the Contract,

(4) Construction asset details needing to be updated in the Contractor’s Monthly Progress Reports,
(5) Geo-referencing of the alignment,
(6) Geo-referencing co-ordinates of assets into a geographic information system (GIS) which the
Contractor’s Monthly Progress Report has utilised,
(7) Contractor’s Monthly Progress Reports, and
(8) Source files for submittal as required by the Engineer.
The Contractor is required to assess the entire cost associated with all above requirements and include
the same in his Lump Sum price.
A14 CONTRACTOR’S PROJECT ORGANISATION
(1) The Contractor shall employ on this Project, a competent team of Managers, Engineers, Technical
staff, etc. so as to complete the work satisfactory as per the various requirements of the Contract.
(2) A site control room with ‘around the clock’ radio communication or telephone switch board links
with all safety offices, works sites, site offices, batching plants, casting yards, workshops,
fabrication yard, off site offices, Engineer’s site offices, testing labs etc shall be maintained and
manned 24 hours a day, seven days a week. Residence and mobile telephone numbers of the
Contractor’s Senior Project team members shall also be linked with the control room. Vehicles
for emergency use should be on stand-by at the control room around the clock.
(3) The designations of the various project organisations team members shall be subject to a Notice
from the Engineer before adoption so as to avoid any duplication of the designations with those
of the Employer or the Engineer.
(4) The Contractor shall submit his Staffing Proposal to the Engineer for a Notice, which shall
include:
(a) The Contractor’s proposed Staff Organization showing in chart form the names of his
proposed staff for each position;
(b) CVs of the Contractor’s proposed Key Staff, with adequate details and copies of documentary
proof on the qualification and experience (with contract titles, position held and dates) of
each staff to substantiate that he is competent for undertaking the proposed position;
(c) The scope of responsibilities of each staff and the reporting lines between individual staff;
(d) The documents that each staff is authorized to sign on behalf of the Contractor.
(5) The Staff Organization shall cover the Contractor’s Key Staff and Specially Required Staff as
specified in Sub-clauses A14(8) and (9) below, as well as other working-level staff, with a
narrative of the authorities and responsibilities of each staff member in directing execution of the
Works on Site, or in deciding technical details of the Contractor’s proposals.
The Contractor shall note that financial penalties can be levied for the failure to employ some of
the Key Staff required by this Clause. Reference shall be made to Part -3 of the tender document
for details.
(6) The Contractor’s Staffing Proposal shall include the Key Staff proposed in their Tender

submission, unless it is necessary to propose better qualified and more experienced staff in order
to meet the requirements of the Contract, in which case the Contractor shall include in the Staffing
Proposal an explanation for each change in Key Staff. Any such change in Key Staff shall require
a Notice from the Engineer.
(7) Each member in the Contractor’s Staffing Proposal, including the Key Staff and the Specially
Required Staff, shall be allocated to this Contract on a full-time basis on Site, until the activities
that he is responsible for have already been completed or have to be carried out off-site. Should
it be necessary to replace any staff before the activities he is responsible for have been carried out,
the Contractor shall submit the CV of the proposed substitute for the Engineer Notice of No
Objection, at least 30 days before the proposed change. The substitute shall not be less qualified
or experienced than the person he is replacing.
(8) Key Staff

(a) The Contractor’s Staffing Proposal shall include as a minimum Key Staff
No. of Key
SL. No. Position Personnel
Position
Project Manager who shall also be the contractor’s

1. 1
Representative
2. Chief Tunnel Manager 3
3. Station Construction Manager 5
4. Chief Interface Coordinator 1
5. Chief Quality Assurance & Control Manager 1
6. Chief OHS&E Manager 1
7. Planning Manager 1
8. BIM Manager 1
Total 14

(b) All the foregoing Key Staff shall hold, required qualification in Civil Engineering, or in a branch of
engineering appropriate to the nature of the work included in the Contract acceptable to the
Engineer.
(c) The Project Manager shall be authorized to represent the Contractor on all aspects under the Contract
and shall bear overall responsibility for the management, coordination and progress of the Contract.
The Project Manager shall be an expatriate tunnel expert and have relevant experience as per EQC
Part-1, Section III, including experience as a Main Contractor’s Project Manager on site with overall
responsibilities for large-scale construction projects similar to the Works under this Contract. The
proposed Project Manager shall have extensive knowledge in construction of Bored tunnels / cross
passages, NATM and underground stations in varying ground conditions below water table.
Proposed Project Manager with previous experience of working in Chennai’s geological condition
shall be preferred. The proposed Project Manager shall hold a University Degree acceptable to the
Engineer or an equivalent qualification, in civil engineering or in a branch of civil engineering
appropriate to the nature of the work included in the Contract.
The Project Manager must be bestowed with adequate authority to receive and carry out the
`directions and instructions from the Engineer.
The Project Manager shall have a fluent command of written and spoken English and shall be
employed fulltime on this site.
(d) Station Construction Manager for Stations shall be authorized to represent the Contractor on
construction aspects for their individual scopes and shall bear overall responsibilities on all aspects
within each scope, including site safety and should be capable enough to handle the risks provided
in Table 2 (Part 1, Section IVB, Clause 1.8). Each of them shall have relevant experience, including
experience in a key position on site for supervision or construction of Largescale underground
station construction in mixed varying ground conditions below water table, similar to the works
under this Contract, including at least 3 underground stations with station building services and
finishes;
(e) The Chief Tunnel Managers shall be authorized to represent the Contractor on construction aspects
for their individual scopes and shall bear overall responsibilities including safety and shall be
capable to handle Tunnelling Risks provided in Table-2 (Part 1, Section IVB, Clause 1.8) on all
aspects within their scope. Each of them shall have relevant experience as per EQC, including
experience in a key position on site for supervision or construction of large-scale bored tunnelling,
NATM and cross passage works including grouting for soil improvement and temporary supporting
of tunnel segments in varying mixed ground conditions below water table, works similar to the
Works under this Contract..
(f) Chief Interface Coordinator shall have a degree in civil / mechanical / electrical engineering and
have experience as per EQC including working knowledge in BIM (Revit) and CAD, and should be
able to understand vendors input and execute in site. A minimum ten years of experience in interface
co-ordination & Managements of tunnels, underground stations, MEP works, traffic, utility
diversion, track work, VAC, TVS and all system wide works

(g) The Chief Quality Assurance & Control Manager and Deputy Quality Assurance & Control
Manager shall be Professional Engineers with relevant years of experience as per EQC and as
QA/QC Managers on similar size and type of construction projects, which shall have included work
with the major trades which are expected in this Contract such as bored tunnels, segment production,
cross passages, diaphragm walls, Traffic decking, Temporary steel works, steel welding etc.
(h) Planning Manager shall have a degree in civil engineering and have experience as per EQC. His
experience shall include large scale construction projects similar to the Works under this Contract
such as bored tunnels, segment production, cross passages, diaphragm walls etc.
(i) The Chief OHS&E Manager shall be a professional and experienced engineer with relevant years’
experience as per EQC and as per Table 2 of Sec VI Section E , Volume 1 of Part 2. He shall be
experienced in the construction of underground civil works with direct relevant experience in
administering safety assurance programs of underground stations, tunnels and civil works of similar
scope. He shall be knowledgeable of, and have experience in, the development and application of
ISO 9001 standards for the construction of civil works.
(j) The Project Manager, Tunnel Managers and Station Construction Managers shall be assisted by
engineers and foremen of adequate number and experience for ensuring that the Works will meet
the requirements of the Contract from quality, progress, safety and environmental points of view.
Without prejudice to the generality of the above, the Contractor’s Staffing Proposal shall also
include Specially Required Staff as stipulated in Sub-Clause A14(9) below.
(k) Station Construction Manager shall have a degree in Civil Engineering and have experience as per
EQC. His Experience shall include construction projects of underground metro using Diaphragm
walls. The experience shall include at least two projects involving station works similar to works
under this contract.
(l) The BIM Manager Manager shall be a professional and experienced engineer with relevant years’
experience as per EQC and as per Table 2 of Sec VI Section E , Volume 1 of Part 2. Shall be
experienced in Leading the BIM Team, Preparing CSD models with clash report, Revit tool support,
Revit Template & Family creation, coordinating with all System, BIM Model review & Quality
check, Preparing BIM documents, Handling the BIM 360 and Coordinating with Client/GC.
(m) Any Key Personnel listed in 1.1.1 Personnel, EQC – Section III – Part if not employed / deployed
on the site within the time specified, a deduction shall be made for each month for each Key
Personnel position not deployed, or part thereof shall be under:
1. For Key Personnel in S. No. 1 Project Manager – INR 5 Lakhs
2. For Key Personnel in S. No.2 Chief Tunnel Manager S. no.5 Chief Quality Assurance &
Quality Control Manager & S. No. 6 Chief OHSE&E Manager - INR 3 lakhs
3. For Key Personnel in S. No. 3 Station Construction Manager & S. No. 4 Chief Interface
Coordinator – INR 2 lakhs
A15 TRAINING and TECHNOLOGY TRANSFER
(1) The Contractor shall ensure that all local Contractors and Sub-contractors engaged in the works
are given training, guidance and the necessary opportunity for transfer of technology in various

areas of construction such as, control of ground settlements, instrumentation, safety, quality
assurance, interface management, etc.
A16 MAINTENANCE REPORT
(1) The Maintenance Report based on the materials / vendor specific shall be submitted as part of the
handing over document and shall include full details of the long-term inspection and maintenance
operations for each major component of tunnel, station structure, station building services
equipment, station finishes, water supply, drainage and sewerage.
(2) The Contractor, as part of handing over document, shall provide inspection and maintenance
manuals for the civil, structural and building works and services covering the following areas: -
• Tunnel Structures
• Diaphragm Walls
• Cross Passage
(3) For each area an inspection checklist shall be supplied giving inspection frequency, items to be
inspected, criteria for acceptance, criteria for remedial works and details of the remedial works,
including proposed materials and method statements. The recommended regular maintenance
regime of each area shall also be given including cleaning methods and frequency for different
surfaces; removal of leakage borne salts from concrete surfaces; cleaning of drainage channels,
sumps and pipes; repainting of metallic items;
(4) A long-term monitoring regime shall also be included covering items such as
▪ Station and tunnel water leakage
▪ Differential movement at cut & cover / station / junctions or other areas identified in the
design
(5) All instruments necessary to carry out the inspections and monitoring that are identified in the
report shall be provided by the Contractor.
A17 MEETINGS
A17.1 General
The Contractor shall participate in meetings as indicated in this section. The Engineer shall record
minutes of all meetings and distribute them within 5 days of the meeting. Meetings will be chaired by
the Engineer.
A17.2 Initial Contract Meeting
The Engineer shall arrange an initial meeting within seven (7) days following the issue by the Employer
of the Letter of Acceptance.
The meeting shall take place at a location in Chennai, India, determined by the Engineer.
The agenda of the meeting shall include, but not be limited to, the following:
(a) Arrangements to be made for execution of the Contract Agreement;
(b) Submission of bonds, guarantees, undertakings, warranties, insurance policies, certificates,
etc.. if not already provided;
(c) Arrival of Key Staff and plant Equipment;

(d) Planned activities for the first 30 days and 60 days after the Commencement Date; and
(e) Other items as may be advised by the Engineer.
The Contractor shall be represented by all appointed Key Staff.
A17.3 Site Mobilisation Meeting

The Engineer shall arrange a meeting at the Engineer’s office prior to the Contractor being given
possession of any part of the Site. The agenda shall include, but not be limited to, the following:
(a) Proposed use of the Site by the Contractor;
(b) Employer’s Requirements;
(c) Temporary utilities and facilities;
(d) Pre-conditional surveys of existing buildings and structures, with reports;
(e) Security and “housekeeping”;
(f) Land and setting-out survey;
(g) Programme for establishing work areas, temporary facilities, and Site accommodation for
the Engineer;
(h) Temporary Works; and
(i) Contractor’s initial Three-Month Rolling Programme.
(j) Procurement and delivery dates for major items of plant.
The Contractor’s Key Staff, and those with responsibility for activities on the agenda, shall attend.
A17.4 Quarterly Review Meetings
Quarterly Review Meetings shall be arranged at a time and venue determined by the Engineer to
generally review progress and outstanding issues in regard to the Contract and the Project. They shall
be attended by the Project Manager and supervisory board members of the Contractor and Interfacing
Contractors. The agenda for these meetings will be advised by the Engineer, at least 5 days in advance.
The Engineer or his designated representative will chair the meeting and prepare and distribute the
minutes.
Attendance shall be limited to the Contractor’s Key Staff Nos. (i) to (vii) as relevant, as listed in Clause
A14 of this Section A of Part-2 .
A17.5 Monthly Progress Meetings
Monthly Progress Meetings shall be held throughout the progress of the Works. These meetings shall
normally be held at the Engineer’s Site office on the first Monday of the month, following receipt of
the Contractor’s Monthly Progress Report. Contractor’s Key Staff shall attend the Progress meetings.
The Engineer shall chair progress meetings and prepare and distribute the minutes. The Engineer shall
prepare and distribute the agenda at least 1 day prior to the meeting which may include, but not be
limited to, the following:
(a) Confirmation of minutes of the previous month’s meeting and matters arising there from;
(b) Review of construction work progress;

(c) Field observations, problems and decisions;

(d) Identification of issues affecting planned progress;
(e) Planned activities for the coming period;
(f) Quality assurance;
(g) Safety;
(h) Interface coordination;
(i) Status of variations, if any;
(j) Construction coordination.
The Contractor’s Project Manager must attend the Monthly progress meetings, other attendance shall
be limited to the Contractor’s Key Staff Nos. (ii) to (vii) as relevant, as listed in Clause A14 of this
Section A.
A17.6 Weekly Meetings
Weekly meetings shall be held on Site to discuss detailed technical and construction issues plus the
status of the Contractor’s submittals. These meetings shall be chaired by the Engineer, who shall also
prepare and distribute minutes. The Contractor’s Key Staff shall attend this meeting with the exception
of the Project Manager whose attendance is optional. Sub-contractor’s representatives shall also attend
these meetings when requested to do so by the Engineer.
A17.7 Other Meetings

Interfacing Contractors the Contractor’s Key Staff, superintendents and Sub-contractor’s
representatives shall attend other meetings as required with the Engineer.

ATTACHMENT A1
Required Number of Copies of Submittals and Format Requirements
No. of Paper Copies No. of

Electronic Reference
A1 A3 A4 Copies
Initial Programme and Works
Programme plus supporting 6 2
information and narrative
Monthly Programme Update 6 2
Three Month Rolling Programme 6 2
Three Week Rolling Programme 6 2
Monthly Progress Report 6 2
Works Drawings 3 3 2
Method Statements 6 2
Interface Management Plan 6 2
As built drawings 6 3 3 2
Materials Submissions (documentation) 6 2
Quality Plan 6 2
Quality Control Register 4 2
Reports of Quarterly Quality Audits 4 2
Materials and Workmanship Test
6 2
Results/Reports
Safety Plan 6 2
Environmental Plan 6 2
Traffic Management Submissions 3 6 2
Investigation and survey reports. 3 2
Monitoring, protection and replacement
3 2
proposal reports.
All other submittals 3 2 As applicable
Notes;
i) In case of any contradiction between the text and this table then the text shall prevail, unless
otherwise instructed by the Engineer.
ii) Drawings to support A4 text documents shall be of A3 size.

ATTACHMENT A2
TRANSMITTAL FORM
GC

ATTACHMENT A3
GC

GC
Section VI – General –Section A A-22 December 2021


SUB-URBAN STATION (VILLIVAKKAM), VILLIVAKKAM BUS-
TERMINUS AND NATHAMUNI (VILLIVAKKAM MTH ROAD) WITH
ENTRY / EXIT, VENTILATION SHAFTS, PLUMBING, EARTHMAT,
PART 2
SECTION VI
SUB-SECTION B
FUNCTIONAL
DECEMBER 2021
KOYAMBEDU,
INDIA

TABLE OF CONTENTS
SUB-SECTION B EMPLOYER’S REQUIREMENTS - FUNCTIONAL

SECTION PAGE
B1. GENERAL ......................................................................................................................... B-1
B2. SCOPE OF WORKS .......................................................................................................... B-1
B3. ALIGNMENT .................................................................................................................. B-14
B4. CLEARANCES................................................................................................................ B-15
B5. DESIGN LIFE .................................................................................................................... B-4
B6. DURABILITY AND MAINTENANCE ........................................................................... B-4
B7. OPERATIONAL REQUIREMENTS .............................................................................. B-15
B8. FUNCTIONAL REQUIREMENTS OF STATION ECS SYSTEM ............................... B-15
B9. FUNCTIONAL REQUIREMENTS FOR POWER SUPPLY SYSTEM ........................ B-15
B10. FUNCTIONAL REQUIREMENTS OF PUMPING INSTALLATIONS ....................... B-15
B11. FUNCTIONAL REQUIREMENTS FOR FIRE PROTECTION SYSTEM ................... B-16
B12. FUNCTIONAL REQUIREMENTS FOR LIFTS AND ESCALATORS. ....................... B-16
B13. AESTHETICS .................................................................................................................. B-16
B14. ENVIRONMENTAL CONSIDERATIONS ...................................................................... B-4
B15. URBAN PLANNING FUNCTIONAL REQUIREMENTS .............................................. B-5
B16. SAFETY AND SECURITY .............................................................................................. B-5
B17 TRAFFIC MANAGEMENT ........................................................................................... B-17
B18 SAFETY CERTIFICATION ............................................................................................. B-6
B19 STANDARDS .................................................................................................................. B-17
Section VI –Sub-Section B- Functional i December 2021

B EMPLOYER'S REQUIREMENTS - FUNCTIONAL
OBJECTIVE
The objective of the Contract is, Design Validation of provided Design and drawings,
construction completion, and testing of the permanent works by the Contractor, including without
limitation, the design, installation and removal of the Temporary Works, and the rectification of
defects appearing in Permanent Works, in the manner and to the standards and within the time
stipulated by the Contract. In full recognition of this objective, and with full acceptance of the
obligations, liabilities and risks which may be involved, the Contractor shall undertake the
execution of the Works.
B1 GENERAL
(1) The performance of the Permanent Works shall comply with the specific core requirements
contained in these Employer’s Requirements Part -2.
(2) The design of the Permanent Works shall be validated on the construction perspective in
accordance with these Employer's Requirements Section B - Functional, the Employer’s
Outline Construction Specifications, as included in this Contract, other requirements of the
Contract and the Contractor's Technical Proposals.
(3) The Permanent Works shall be constructed to the highest standards available using proven
up-to-date good practice employing the procedures established by the Contractor in his
Quality, Safety and Environmental and Interface management plans.
(4) The Contractor shall be responsible for obtaining all necessary approvals for carrying out
the Works from the Relevant Authorities.
B2 SCOPE OF WORKS
The scope of work in brief is provided below, but the scope includes all other requirements
stipulated in various parts/volumes of the contract document including appendices and
annexures.
1. The Permanent and Temporary works shall comprise the Design verification of provided
drawings on the construction perspective and Construction of all Civil Works and
Temporary services necessary to complete the underground section with Twin Bored
Tunnels from Kolathur Retrieval shaft to Nathamuni Launching shaft and associated
ramps with “U” sections, including five stations namely Kolathur Junction station,
Srinivasa Nagar Station, Villivakkam Sub-urban Station, Villivakkam Bus Terminus
Station, Nathamuni Station along with associated structures such as entry/exit structures
upto plinth level, Ancillary buildings, Utility galleries, Pump houses, water tanks,
ventilation shafts, Firemen Entry & Public escape structure, tunnel connection to Station
Diaphragm walls (Portals) etc. as per relevant drawings, and mitigation measures for the
risk associated with the underground construction work as per Table no. 2 is within the
scope of Contractor.
Section VI –Sub-Section B- Functional B-1 December 2021

2. Block works, Doors/ Fire Doors coming under the contract along with all plumbing
inserts and Earth mat as per drawings and documents. Architectural works at Stations
including finishes for the civil works such as screeding, floor finishes, wall finishes
including handrails, balustrades etc., as part of provisional sum.
3. Construction of cut and cover tunnel, open ramp between Kolathur & Retteri Station and
between Nathamuni & Anna Nagar station in all kinds of soils & rocks, and storm water
drainage sumps, including integration of cut and cover tunnel
4. Survey and investigation including soil investigation, topographic survey, existing
building survey, utilities investigation, providing recharge wells, existing water wells
investigation as necessary in addition to the information given in this Tender Document.
5. Site clearance, including tree felling, tree transplanting and the fencing, barricading and
securing of the site areas and works areas.
6. Pre-condition surveys and reports for, monitoring and protection of existing building
structures, including rebuilding, repair or resolution of any adjacent structures
7. The demolition and slicing of existing buildings/structures, roads, utilities and other
services etc. as necessary for the execution of the works.
8. All temporary works associated with construction of permanent works including
temporary decking for pedestrians, traffic, construction works etc. wherever necessary in
order to have minimal disruptions to general public and traffic flow.
9. Management of road traffic, road works, including diversion of roads and foot paths,
temporary decking, pedestrian walkways, subways and foot bridges.
10. Ground treatment, ground and building monitoring, risk analysis, settlement monitoring
underpinning and protection to existing building structures wherever required, preventive
and corrective actions wherever required.
11. The demolition of existing building, which may or may not be as shown on the drawings,
including the exact number and locations to be confirmed by the contractor.
12. Twin bored tunnels of minimum 5.8m internal diameter for single track railway,
including launching and retrieval shafts to be executed in mixed ground condition that
vary from weak alluvial deposits to competent rock under local ground water table.
13. Cross passages with and without sumps complete with ground improvement, temporary
excavation support system, permanent works including waterproofing, manhole covers,
steps inside sump, fire doors, and pipe insert to facilitate tunnel scupper to sump
connection to be executed in mixed ground condition that vary from weak alluvial
deposits to competent rock under local ground water table.
14. Temporary utilities systems for tunnels and cross passages including ventilation, lighting
etc.
15. Protection and relocation of utilities, both chartered and unchartered, which are not
required to be diverted. These works are not covered under the Provisional Sum
mentioned under item 16 below and to be included in quoted lumpsum price.
16. Diversion and reinstatement as necessary of existing utilities which will be paid under
Provisional Sum excluding storm water drain and handover to the utility department in
case of temporary or permanent diversion respectively, all to the satisfaction of Engineer.
Diversion of existing storm water drain shall be covered under the quoted lumpsum price.
Reference shall be made to Appendix 12 – Utilities, Part 2, Section VI. All works related
to identification of utilities, preparation of diversion proposals and obtaining necessary
approvals from the relevant authorities are under the Contractor’s scope of works, and to
be included in the lumpsum quoted price;

17. Traffic management and road works, both temporary and permanent including diversions
of roads and footpaths, temporary decking, pedestrian walkways, subways and
footbridges, and restoration of pavements and road facilities, etc.;
18. Monitoring, protection, etc. for structures adjacent and above the tunnels and stations;
and
19. Monitoring, protection and /or re-provision, removal of existing water wells;
20. All Temporary works necessary (including tunnel segment casting yard) and equipment,
including the tunnel boring machine;
21. First stage concreting and providing & Fixing of Shear Connectors for Installation of the
Rail Track in bored tunnel & Stations and embedded pipes of required size as per
drawings and specifications. Cleaning of invert and wriggle survey followed by design
of best fit alignment.
22. Survey, instrumentation, ground treatment, ground and building monitoring, risk
analysis, settlement prediction, underpinning and protection to existing buildings and
structures wherever required, preventative and corrective actions, pre-conditional
surveys and reports;
23. Construction and maintenance of new and existing roads and diversions, including
restoration to original condition;
24. Removal, storage and reinstatement of road and road facilities such as street lighting,
traffic signals, bus shelters/stands, footpaths including stone kerbs, boundary walls,
horticulture works, and any other work to restore the site to its original condition as stated
in the Contract as per current standards and site requirements, as and when possible; and
25. Other works as stated in the Employers Requirements, Outline Specifications and
Employer’s Drawings.
26. The employer has provided tentative scheme associated with TBM Break-in & Beak-out
at the launching / retrieval shafts. The contractor shall propose ground improvement
works (slurry walls, slurry piles, jet grouting etc.) associated with TBM break-out / break
in at launching / retrieval shafts at Kolathur, Srinivasa Nagar, Villivakkam Sub-Urban,
Villivakkam Bus Terminus and Nathamuni Stations,
27. The contractor shall identify the bore-wells/open-wells along the alignment and take
necessary mitigation measures during tunnel boring. In case some bore-wells are getting
affected, he should remove/relocate the bore-wells to the satisfaction of the
owner/resident.
28. Design of enabling/temporary works for site setups such as muck pit, gantries, cranes,
foundations for gantries and cranes, TBM shoving, reaction frame, cross passage
temporary support and all temporary work items not specifically covered under
BOQ/drawings.
29. Design of strengthening of buildings, after contractor’s building condition survey to
ensure structural integrity and safety of buildings as mentioned in Table-2: Risk Table of
Part-1 of these documents.
30. Implementation of instrumentation and Monitoring schemes in the influence zone as per
Employer’s requirement.
31. The Contractor shall be responsible for obtaining relevant certificates or clearance from
local civic Authorities if required.
32. Construction and maintenance of the site office for the Engineer’s staff, complete in all
respects as per the details given in the Employer’s requirements to the satisfaction of the
Employers representative for the duration of the contract.

33. Construction and maintenance of new and existing roads along with road diversions
wherever necessary and restoration to original conditions.
34. Removal and storage of road facilities such as street lighting, Traffic signals, bus shelters,
footpaths including kerb stones, boundary walls, horticulture works etc. as per contractual
requirements.
35. Reinstatement of roads and Relocation/Reinstatement of all removed road facilities to the
original conditions as stated in the contract as per current standards and site requirements.
36. The contractor will be responsible for obtaining approval for the construction of stations
and associated structures (both underground and above ground works) along with cut and
cover tunnels by all relevant civic authorities having jurisdictional authority wherever
required.
37. Sufficient number of dewatering system and drainage pump arrangements needs to be
provided at all work sites. Recharge wells, if required, shall be provided in sufficient
numbers to the satisfaction of the Employer / Engineer.
38. Provision of SWC’s Equipment Plinths / Pedestal, cable pull pits, sleeves for cables,
Permanent lifting Hooks embedded in concrete for equipment, supports for Air-curtains
& HVLS, supports for PSD’s etc.
39. Repairs / Rectification / Replacement of defective Diaphragm wall works, couplers and
base slab including providing a suitable method statement to obtain Notice of No
Objection from the Engineer; and
40. Repairs / Rectification / Replacement for all the Permanent and Temporary Works carried
out by the Contractor including providing a suitable method statement to obtain Notice
of no Objection from the Engineer; and
41. The Repairs / Rectification / Replacement shall be carried out to the satisfaction of the
Engineer; and
42. Defects Liability during the Defects Notification Period as per the Conditions of Contract
and Contract Data; and
43. All interface works as per Clause A10 and Appendix 19 of Part 2 Employer’s
Requirements including providing access, handing over of rooms / spaces and taking over
of rooms / spaces.
STATIONS
1. Embedded Building internal services for stations including Plumbing, drainage, earth mat
etc. to the stations.
2. Supply, delivery, installation and functional testing of earth mat and embedded earthing
cables
3. Water tanks for fire, domestic, drainage/sewerage etc
4. Providing and fixing shear connectors for installation of the rail track both in tunnel and
station areas.
5. Temporary ventilation, air conditioning, Plumbing and lighting in stations, tunnels and
ancillary structures
6. The contractor will be required to provide access from ground level to track level and
inside the underground station and cut and cover tunnel as per the requirements of the
interfacing contractors. Storage and access will be required for various activities
including unloading of rails, other track materials, vehicles for laying track, pulling
cables, other equipment and machineries to be installed in station etc. Any openings are

to be closed off by the contractor on completion of the access as per the programme
agreed with the interfacing contractors and duly noticed by the Engineer.
7. All cut-outs and openings required in the station diaphragm walls and other walls for
integration of entry exit structures with station, passing of shafts and ducts etc.
8. Water proofing of all underground structures and roof of above ground structures as per
construction specifications.
9. Provision of two deep tube wells of 5-6 m3/hr yield for each station including submersible
pumps of required capacity, including connecting them to main water supply work.
10. Installation of embedded pipes for water, sewage and drainage works of system
contractors is to be done by the civil contractor.
11. Drainage channels, sumps, pipes and pumps within the tunnels and cross passages if any.
12. Design of enabling works such as foundations for Gantries, Cranes, Chiller plants, fire
pumps and other works related with site set up etc. to perform the execution of permanent
works.
13. The followings works are to be designed, supplied and installed and commissioned by
others with whom the contractor shall co-ordinate all interface requirements during his
construction and integrated testing activities. However, making provision for all these
services including all openings/ cut-outs shall be in the scope of present contract as
stipulated in Employer’s requirement.
• Lifts and Escalators
• Railway electrification and HV power supplies
• Water supply in tunnel
• Track work
• Signaling, telecommunication
• MEP works
• Automatic fare collection
• Rolling stock
• Tunnel ventilation
• Building services including ECS, Power supply, Lighting, Firefighting etc.
14. Designing, Providing and fixing MS hooks for lifts and escalators, ASS rooms etc. as per
the requirements of designated contractor as stipulated in interface management plan
Appendix of the Employers requirement and removal of the same after the completion of
work, if required.
15. Providing airtight Overhead Traction Exhaust (OTE) Ducts as per drawings
TUNNEL
1. Providing and fixing security grills/railing on the underground ramp as per the details
shown in tender drawings.
2. Supply, Installation and testing of tunnel drainage works which includes embedded
drainpipe works, drain pits, etc.,
3. Cross passages and sumps complete with manhole cover, steps inside sump, water
proofing and pipe insert to facilitate tunnel scupper drawing to sump connection
INFERFACE

Opportunity for Interfacing Contractors and Other Contractors
1. Reasonable Opportunity
The Contractor shall, in accordance with the requirements of the Engineer, afford all reasonable
facilities for Interfacing Contractors and / or any other contractor who may be carrying out, on
or adjacent to any Site any Work within the contract boundary, any utilities undertaking or other
duly constituted Authority. The Contractor shall, as reasonably requested in a written manner
by the Engineer, make available to any such Interfacing Contractor, other contractors, or the
Engineer or any such authority, any roads or ways for the maintenance of which the Contractor
is responsible, for which no additional payment shall be made by the Engineer.
2. Inspection of Work of Interfacing Contractors
If any part of the Contractor’s work depends upon the work of an Interfacing Contractor,
he shall inspect and promptly report to the Engineer any defects in such work that may
render it unsuitable for such proper execution. The Contractor’s failure to so inspect and
report shall constitute acceptance of the Interfacing Contractor’s work as fit and proper
except as to defects which may develop in the Interfacing Contractor’s work after
execution of his work.
3. The Contract allows for continuous audits of the Contractor’s compliance with his
Interface Management Plan and the requirements given as Engineer’s Requirements, and
any failure of the monthly and/or quarterly audits shall result in the relevant payment
item in the Preliminaries section of Pricing Document being withheld. The decision of
the Engineer in this regard shall be final
4. The Contractor shall be held liable for any loss and expense incurred by the Employer
arising from any breach by the Contractor in fulfilling his obligations under the contract,
if the Contractor is deemed to have caused any delays, defects, damages or otherwise, as
a direct result of his design or construction activities, to the Interfacing Contractors in
respect of the whole of the Works.
SITE DATA:
The responsibility of the Contractor under Sub-Clause 4.10 of GCC is full and final and
no claim by the Contractor for additional payment or extension of time shall be allowed
on the grounds that of any misunderstanding or misapprehension by the Contractor or
that incorrect or insufficient information was given to the Contractor or that he failed to
obtain correct and sufficient information.
UNFORESEEABLE PHYSICAL CONDITIONS:
This clause is not applicable for geological and hydrological conditions. A detailed
geotechnical investigation has been carried out. Refer to Part 4 of this document.

Additional geotechnical investigation shall also be carried out by the Contractor. Refer
to Clause 3.5 of Sub-section 3 of Section VII of Part-2.
ACCESS ROUTE:
All operations for the execution of the Works shall be carried out so as not to interfere
unnecessarily with the convenience of the public or the access to public or private roads
or footpaths or properties owned by the Employer or by any other person.
The Contractor shall select routes, choose and use vehicles so that movement of
Contractor’s Equipment, Plant and Materials from and to the Site is limited so that traffic
is not delayed and damage to highways, bridges and other utilities is prevented. If there
is any delay or damage or injury, the cost of rectification or reconstruction of highways
or bridges shall be borne by the Contractor. The Contractor shall indemnify the Employer
in respect of all claims, demands, proceedings, damages, costs, charges and expenses
whatsoever arising out of or in relation to any such matters.
If during the execution of the Works the Contractor shall receive any claim arising out of
the execution of the Works in respect of damage to highways, bridges and other utilities
he shall immediately report the facts to the Engineer. The Contractor shall negotiate a
settlement in respect of such claims and indemnify the Employer in respect of all claims,
proceedings, damages, costs, charges and expenses in relation thereto.
TRANSPORT OF GOODS:
1. Existing roads and other public roads may be used by the Contractor at his risk and cost
to carry out construction activities, with prior approval of the concerned authority.
2. The Contractor’s heavy construction traffic or tracked equipment shall not travel on any
public road or bridge, unless the Contractor has made arrangements with the authority
concerned and has obtained the approval of the Engineer to such arrangements. The
Contractor shall include in his price the cost of strengthening any such public road or
bridge if he considers it would be necessary
3. The Contractor shall repair any damage to the road or bear the cost thereof due to
movement of contractor’s plants and equipment, vehicles etc. to the specifications and
satisfaction of road authorities as well as of Engineer.
4. The Contractor shall plan transportation of construction materials to work site in
accordance with traffic regulations enforced by local traffic authorities from time to time
and in such a way that road accidents are avoided.
5. No claim whatsoever shall be entertained on this account. The transportation of certain
plant, equipment and materials may not be possible during the daytime and may have to
be carried out within a time schedule as specified by the traffic police.
6. No extra payment will be made for construction and maintenance of temporary haul roads

if any needed including any special protection or strengthening required and all cost of
such works shall be deemed to have been included in the costs of items contained in the
Pricing Documents.
7. The Contractor shall be responsible for the design, coordination and carrying out all
necessary road works as per MORTH Specification and these works shall include, but
are not limited to, the following: Roads works including new roads, strengthening /
widening of existing roads, road diversions including repairs and making up diversion
works, new utility diversions, dismantling of central verges, footpaths, railings, drains
etc. and any other work;
CONTRACTOR'S EQUIPMENT:
Upon completion of the Works the Contractor shall remove from the Site the entire said
Contractor’s Equipment, Temporary works and his unused materials within 42 days after
the Issuing of taking over certificate, failing which the employer may remove them at
contractor’s cost.
ELECTRICITY, WATER AND GAS:
The Contractor shall be responsible for making his own arrangements at his own cost to
obtain supply of water, electricity or gas for the Works. The Employer where feasible
may at his discretion assist the Contractor in giving recommendatory letters etc.
EMPLOYER’S EQUIPMENT AND FREE ISSUE MATERIAL:
No material, tools, plant and equipment shall be supplied by the Employer. The
Contractor has to arrange all tools, plant, equipment as well as construction materials
required for the work.
UTILIZATION / DISPOSAL OF ECAVATED MATERIAL:
a. The Contractor shall be the sole custodian of the excavated material at the work site such as
earth, moorum, rock, boulder, construction debris etc. of whatever may be the nature. The
contractor is free to utilize on their own for commercial or any other use or to dispose-off to
their designated dumping yard as per his own convenience.
b. Requisite dumping site shall be arranged by the contractor at their own cost for dumping and
/or disposal of excavated earth and other materials to the any lead as per his own convenience.
Necessary permission / NOC / MoU of the concerned authority in this regard shall be arranged
by the Contractor on their own. All the associated costs including taxes, duties, levies, royalties,
octroi etc. required for the purpose shall be borne by the contractor on their own. Nothing shall
be paid extra by the Employer on this account. The Contractor shall also indemnify Employer
from any dispute/penalties arising out of disposal/utilization of excavated earth. The Contractor
shall consider the said requirement and potential commercial utilization during his quote for
excavation items.
c. The contractor shall submit a copy of intended utilization plan for the excavated earth well in
advance to the Engineer for their information.

d. The Contractor shall maintain the up-to-date records of excavated earth and other material
disposal and shall be available for inspection by Engineer as and when required. Contractor is
required to submit the reconciliation statement of utilization of the excavated material on
Quarterly basis.
e. Disposal of excavated earth and other waste materials at unauthorized locations shall be strictly
prohibited, any violation in this regard will attract severe disciplinary action with imposition of
others and ownership transferred to the Contractor during the period of the Works. All the
fencing, hoardings, gates and signs etc. shall be mopped a minimum of once a week and
thoroughly washed once a month.
f. The muck disposal sites shall be identified by the Contractor before start of construction in
consultation with SPCB, Municipal Corporation/Municipalities and CMDA, to ensure a safe
distance from residential areas, water bodies and ecologically sensitive locations as to avoid
disrupting natural drainage. The muck shall be filled in the dumping site in layers and
compacted mechanically. Suitable slopes will be maintained on the stockpile. Once the filling
is complete, it will be protected by low walls, provided with a layer of good earth on the top
and covered with vegetation. A muck disposal & utilization plan shall be prepared by
Contractor.
All the associated costs including taxes and royalty applicable as per State Government guidelines etc.
for utilization/disposal of excavated material shall be borne by the Contractor. The Contractor
shall consider the said requirement and potential commercial utilization in his quote
B2-2 Scope of Works under Architectural Provisional Sum (APS)
1. The Provisional Sum for Architectural Works (APS) is applicable only to Station and associated
works. All other works, including interfacing and coordination, shall be deemed as included in
the Contractor’s works.
2. The ER will finalise the drawings and specifications for the works under the Architectural
Provisional Sum (APS). Thereafter, the supply / fabrication and installation / construction of
the same shall be carried out by a separate APS Sub-Contract, the tender of which shall be
prepared and called by the Contractor, in accordance with this section of the Employer’s
Requirements.
3. The Contractor shall prepare all tender documentation including Bill of Quantities, submission
of list of proposed tenderers for the Engineer’s acceptance, including acceptance of tenderers
proposed by the Engineer, tender processes, calling of tenders, make recommendations to the
Engineer for acceptance, and thereafter administer the subcontracts as his domestic subcontract.
4. The Engineer shall have the right to include any tenderer in the list of tenderers to be invited to
tender by the Contractor subject to the Contractor having the right to raise a reasonable
objection to any tenderer as being unsuitable to undertake such work. Should the Contractor
raise a valid objection against any tenderer, he shall suggest an alternative tenderer for the
approval of the Engineer.
5. The Contractor shall open the tenders in the presence of the Engineer and the tender price shall
be duly recorded and be made known to all tenders. The Contractor shall make available copies

of the Tender Submissions for the Engineer’s own evaluation and proceed to evaluate the tender
proposals, resolve through clarification questions approved by the Engineer until the
contractual, technical and programming aspects are acceptable for entering into a Sub-Contract
and to make recommendations to the Engineer as to the acceptance of any particular tender
considering least cost to the Employer. Selection of Sub-Contractor strictly based on lowest
quote (L1). The Engineer’s decision in this regards will be final binding.
6. The successful tenderer recommended by the Contractor and accepted by the Engineer shall
enter into a Sub-Contract with the Contractor on such terms or conditions as provided for in the
Contract. The Contractor shall be responsible for the acts, defaults or neglect of the sub-
contractor. For the purposes of this Contract the sub-contractor is the Contractor’s direct sub-
contractor.
7. Key dates shall be as per the key dates provided in Appendix 2B.
8. The Contractor shall liaise, coordinate and provide all necessary provisions for interfacing with
the APS sub-contractor on all aspects of all APS works including providing access and all site
facilities to the sub-contractor for latter’s work. The Contractor shall be responsible for ensuring
the Quality and OHS&E requirements of the sub-contractor’s works.
9. The Provisional Sum for Architectural Works is exclusively limited to the following items and
any other / different items are included under this Contract price:
A. EXTERNAL WORKS (EXCLUDING ITEMS RELATING TO ROAD WORKS AND

REINSTATEMENT)
A1 Apron / surface elements and finishes around entrances and around above
ground structures of the Station.
A2 Railings / fencing / boundary around above ground structures of the Station.
A3 Plinth step / plinth ramp finishes and Tactile tiles.
A4 All landscaping and irrigation system around entrances and around above
ground structures.
A5 Gratings and drain covers around entrances and around above ground
structures.
A6 Entry and Exit related structures above plinth level.
A7 Rainwater drainage system.
B. FINISHES TO ABOVE GROUND STRUCTURES

B1 Glass screen, enclosures, railings, doors and rolling shutters.
B2 Curtain wall system with windows, fixed glazing, associated weather seals /
gaskets including wall structural system.
B3 Skylights and roofing materials inclusive of their proprietary fixings to
structures of entrances and all structures including any proprietary roof supporting
system.
B4 Floor finishes including tactile tiles.
B5 Ceiling finishes.
B6 Wall / column finishes including associated cladding, windows, fixed glazing
and associated weather seals/gaskets.

B7 Passenger / public facilities (new bus shelters, taxi and passenger pick-up point
shelters, covered linkways from Station entrances and associated paved areas) and
associated covered linkways to adjacent developments including structures, base slab,
paving, cladding, roofing, seats, notice-boards, painting and signage.
B8 Windows and associated aluminium and glazing works including associated
frame, purpose-built structural supports (if any), fixings and the like.
B9 Weatherproof air intake and exhaust duct grills at façade.
B10 Entrance / lift canopies
B11 Flood barriers
C. INTERIOR ENCLOSURES
C1 Operable cladding / partitions and access hatches provision to wet area sealed
space behind dry cladding including ironmongery.
C2 Glass partitions and glass doors.
C3 Wall / column finishes including their proprietary fixing e.g. hooks, brackets,
pins including wall structural system or any support system for the finishes and cladding
of doors and access hatches in public spaces.
C4 Acoustic treatment to walls and ceiling.
C6 Glazing and cladding work to lift shafts including structural works, subframes
and clamps.
C7 Non fire-rated fixed and movable partitions.
C8 Access hatches to wall cladding
C9 Painting of all surfaces such as walls, ceilings, metal works, etc,.
C10 Fire stopping / fire proof seal around cables and ducts in wall and floor
openings
D. FLOORS
D1 Floor / stairs finishes including associated finishes to movement control joints
and skirtings.
D2 Screeding for floor finishes.
D3 Floor gratings and covers.
D4 Floor trap covers.
D5 Floor removable panels.
D6 Finishes around escalator intermediate supports.
D7 Raised floor system.
D8 Lift car floor finishes.
D9 Interior gratings and drain covers.
E. CEILINGS
E1 Acoustic tiles / panels.
E2 Skim Coat / Gridded Plaster board.
E3 Gypsum board.
E4 Metal ceiling systems.
E5 Acoustic insulation to ceiling panel.
E6 Ceiling system inclusive of fixings including supports/suspension and tests.
E7 Ceiling access hatches and exposed catwalks or the like.
E8 Hinged access panels (with hook and chain).
E9 Gypsum ceilings / panels

E10 Bulk heads and smoke down stands
F. FABRICATIONS
F1 Stainless steel / mild steel railings and gates.
F2 Glass railings, balustrades and screens including braille rail.
F3 Cabinets.
F4 Shelving.
F5 Roller shutters along with motorised / manual operation system, closet,
collapsible gates, emergency gates and grilles, excluding fire shutters.
F6 Hardware and lock sets for the above items.
F7 Letter boxes with labels or word imprints.
F8 Fixed furniture and seating.
G. SPECIAL CONSTRUCTION AND OTHERS

G1 Removable railings along platform edge.
G2 Louvers and dummy air-conditioning grilles.
G3 All works related parking area development
G4 Entrance floor mat.
G5 Housings and cabinets (including ironmongery) for E&M equipment within
the public area.
G6 Signage including supports excluding statutory signage
G7 Advertisement panels
G8 Sanitary fixtures, fittings and accessories
G9 Water fountains
10. The following list is not exhaustive and only includes those items where additional clarity is
deemed necessary to define the scope of the items excluded from the Provisional Sum for
Architectural Works. The following items of work are not included in the Provisional Sum for
Architectural Works and are deemed included in this Contract Price:
X1 External waterproofing of structures.
X2 Waterproofing of internal slabs and water tanks.
X3 Protective screeding and other protection measures to waterproofing.
X4 Fire-rated partitions / shutters / floor / wall hatches.
X5 Demountable panels in Station and plant rooms.
X6 Permanent fire-rated doors and non fire-rated doors (other than non-fire rated
glass doors), and frames including ironmongery, temporary cylinders, hinges, hasp, end
staples to gates, airtight sealing gasket, mechanical seals around doors, painting and all
necessary hardware.
X7 Temporary doors mounted on permanent door frames complete with temporary

ironmongery complete with lock-sets and cylinders.

X8 Handrails, ladders, covers in station / escape shaft sumps.
X9 Ground level reinstatement such as road and related elements, drains, foot path,
bus shelter, signages, street lights, etc,.
X10 Drainage systems including scupper drains for seepage.
X11 Drains forming part of the drainage system at ground level.
X12 Lifting beams and hoisting blocks in ejector and sump pump rooms in Stations
including safe working load test and certification.
X13 Lifting hooks, lifting beams and lifting eyes for System Wide Contractor
(SWC) equipment delivery and installation including safe working load tests and
certification.
X14 Platform screen door (PSD) top support structure from concourse slab soffit to
top of platform screen door and end returns including fire-stopping board/insulation and
support framings.
X15 Platform edge facing/rubbing strip.
X16 Temporary ironmongery to permanent doors.
X17 Brick walls, concrete block walls and all non-structural reinforced concrete
walls and plastering.
X18 Sealing, repairing and otherwise making good all works not included in the
Provisional Sum for Architectural Works.
X19 Bus bays and taxi/passenger pick-up bays road surfacing, road markings and
kerbs.
X20 Rendering, plastering or other coatings to meet fire resistance requirements.
X21 Staircases and steps.
X22 Chequered cover plate for cable trenches in plant rooms.
X23 Floor Access Cover / Hatches with lifting rod.
X24 Access platform at airshafts.
X25 Caged ladders.
X26 Cat ladders, step rungs and handholds and catwalks.

X27 Grating covers for all pump sumps, lift sumps, airshafts at ground level and
trackside drains.
X28 Fire rated and non-fire rated floor and wall access hatches and frames.
X29 Fire Stops.
X30 Trees felling and transplanting, treatment to existing trees affected by the
Works such as propping, supporting, pruning of the roots etc.
X31 Ironmongery, temporary cylinders (for locking during construction), hinges,

hasp, end staples to gates, airtight sealing gasket, mechanical seals around doors, painting
and all necessary hardware to all permanent fire-rated doors, non fire-rated doors (other
than non-fire rated glass doors), fire rated and non-fire rated wall and floor access
hatches.
X32 Maintenance access equipment, ceiling gantry rail and maintenance gantries
over voids.
X33 Earthing and Equipotential bonding for all items.
X34 Temporary doors including temporary ironmongery.
X35 Structural framework / bulkheads including structural steelwork in plant rooms

for access platforms, walkways, ladders, step rungs, handholds and the like
X36 Structural supports for Systems equipment
X37 Forming openings for other contractors in blockwork and concrete walls
X38 Non-fire rated doors including ironmongery and door frames
X39 Back of house cementitious flooring including screeding.
B3 ALIGNMENT
(1) The alignment shall be as shown in the Employer’s Tender drawing. The alignment has been
developed by the Employer to meet operational and technical criteria. The Contractor is not
required to evaluate the alignment for compliance with these criteria but shall review it with
respect to his construction proposals and shall also satisfy himself that there is no conflict with
any existing structures (both underground and above ground) which are to be preserved.
(2) (DELETED)
(3) The Contractor should note the existing land constraints outside of the station boundaries as
shown on the drawings, and that no further land will be made available by the Employer.

B4 CLEARANCES
(1) The Permanent Works shall not infringe the Structure Gauge as shown on the drawings.
Extra clearance shall be provided on curved alignment as per the Schedule of Dimensions
in Appendix 18 of this Part-2.
(2) The Permanent Works shall provide for the installation by the Interfacing Contractors of
operating equipment for the railway and without infringement of the Structure Gauge.
(3) Railway clearances: Various clearances shall be provided as per the Schedule of
Dimensions in Appendix 18 of this Part-2.
(4) Construction limits:
(a) The limits of land for the Works are shown on the Employer’s Drawings. The
Contractor shall design any temporary works for construction to be contained totally
within these limits, respecting the regulations concerning construction and property
boundaries of the local Authorities.
(b) The limits of land as shown in the Employer’s Drawings may undergo changes after
final survey and the Contractor shall make any adjustments necessary to acknowledge
the changes to the limits as then defined.
B5 DESIGN LIFE
The design life of the Permanent Works for civil engineering structures shall be 120 years. The
Contractor shall submit a Durability Report in this regard for the Engineer’s Notice considering
the materials, additives, protection to structures etc used in the construction. All the works shall
be carried out to satisfy the design life requirments.
B6 DURABILITY AND MAINTENANCE

(1) The Permanent Works shall be constructed such that, if maintained reasonably and in
accordance with the Contractor's statement of maintainability contained in the Contract,
they shall endure in a serviceable condition throughout their minimum lives as described
in the Outline Design Specifications.
(2) The Permanent Works shall be constructed so as to minimise the cost of maintenance
whilst not compromising the performance characteristics and ride quality of the railway.
B7 OPERATIONAL REQUIREMENTS
(DELETED)
B8 FUNCTIONAL REQUIREMENTS OF STATION ECS SYSTEM
(DELETED)
B9 FUNCTIONAL REQUIREMENTS FOR POWER SUPPLY SYSTEM
(DELETED)
B10 FUNCTIONAL REQUIREMENTS OF PUMPING INSTALLATIONS
(DELETED)

B11 FUNCTIONAL REQUIREMENTS FOR FIRE PROTECTION SYSTEM

(DELETED)
B12 FUNCTIONAL REQUIREMENTS FOR LIFTS AND ESCALATORS.
(DELETED)
B13 AESTHETICS
Refer to Part 2, Section VII Employer’s Requirement, Outline Construction Specifications, Sub-
Section -4, Architectural.
B14 ENVIRONMENTAL CONSIDERATIONS

The construction of the Permanent Works shall be undertaken with high environmental standards
as given in Appendix 20 of this Part-2. During construction the requirements for Environmental
Protection and Impact Mitigation are also given in Appendix 20 of this Part-2.
B15 URBAN PLANNING FUNCTIONAL REQUIREMENTS
(1) The Station Site Plans shown in the Employer’s Drawings are based on the urban planning
design carried out by the Employer and specific land acquisition plans have been submitted
to the Government of Tamil Nadu State and to the Ministry of Railways for railway land,
for approval. The land acquisition initiated to date is therefore based on the entrance,
ancillary buildings and redevelopment of the site areas as shown on the Employer’s
Drawings.
(2) Requests for temporary power supplies for the construction of the works must be
submitted, by the Contractor to Tamil Nadu Electricity Board (TNEB). Alternatively,
separate power supplies may be arranged by the Contractor independent of TNEB subject
to compliance with any necessary statutes,
B16 SAFETY AND SECURITY
(1) Introduction
The objective is to minimize the potential impact on passengers and minimize dependence
on technology and equipment when formulating security and safety plans for each facility.
Issues may include, but not be limited to, the following;
(a) Station perimeter - definition of separation between station operating area and any
adjacent structures.
(b) Appropriate features to support life, safety and security strategy.
(c) Conformance with appropriate fire and life safety codes
(d) Provisions regarding sufficient areas and means of egress to facilitate safe
movement of passengers and staff at peak times, disrupted conditions and/or
emergencies.
(e) Provisions regarding maintaining tenable conditions during tunnel evacuation in the
event of an emergency

(2) Safety Management Methods

Safety in the rail transit industry involves:
(a) Hazard Identification and Management
(b) Quantitative Risk Assessment (QRA)
(c) Traceability from Initial Design to Acceptance Testing (Safety Certification)
(d) A Separate Safety Management and Reporting Function
(e) Training of station staff in assessment and management of emergency conditions.
B17 TRAFFIC MANAGEMENT
The Contractor shall carry out the Works so as to minimise disruption to road and pedestrian
traffic. The Contractor shall prepare his traffic management plan based on his proposed
construction methodology in co-ordination with Engineer and in conjunction with Chennai
Traffic Police. He shall comply strictly with the approved plan during construction of his works.
The design shall provide for a minimum of two lanes of traffic / presently available traffic width
in each direction, which may require temporary road decking where necessary, which must be
fully maintained and safe at all times and shall be approved by Chennai Police Traffic
Department. The traffic management plan shall also provide for a minimum of 2m of footpath
adjacent to buildings or thoroughfares for all road diversion schemes.
The Contractor should take into account that the construction of the stations may have to done in
phases to ensure that the traffic management plan provides the minimum requirement of traffic
lanes and footpaths in each direction.
The wheels of all vehicles shall be washed before leaving site to avoid depositing mud and debris
on the adjacent roads.
B18 SAFETY CERTIFICATION
The Contractor shall note that the Commissioner for Metro Railway Safety (CMRS) will inspect
the Works from time to time for the purpose of determining whether the Chennai Metro Rail
Phase II complies, in terms of operational and infra structural safety, in accordance with the Laws
of India. The Contractor shall note that CMRS approval is mandatory for commissioning the
system. Notwithstanding other provisions of the Contract, the Contractor shall ensure that the
Works comply with the requirements of CMRS in terms of being constructed to the drawings,
and shall assist the representatives of CMRS in carrying out their inspection duties and also
comply with their instructions regarding rectifying any defects and making good any deficiencies.
B19 STANDARDS
(1) Equipment, materials and systems shall be designed, manufactured and tested in accordance with
the latest issue of International and/or National codes and standards. The Contractor shall submit
copies to the Engineer of all codes and standards he intends to use for the Works.

Reference to standards or to materials and equipment of a particular manufacturer shall be

regarded as followed by the words “or equivalent”. The Contractor may propose alternative
standard materials, or equipment that shall be equal to or better than those specified. If the
Contractor for any reason proposes alternatives to or deviations from the specified standards, or
desires to use materials or equipment not covered by the specified standards, the Contractor shall
apply for a Notice from the Engineer. The Contractor shall state the exact nature of the change,
the reason for making the change and relevant specifications of the materials and equipment in
the English language. The decision of the Engineer in the matter of quality will be final.


ARCHITECTURAL FINISHES & SIGNAGES ETC. INCLUDING TWIN
BORED TUNNELS FROM KOLATHUR JUNCTION RETRIEVAL
SHAFT TO NATHAMUNI (VILLIVAKKAM MTH ROAD) LAUNCHING
SHAFT AND RAMPS WITH U - SECTION IN CORRIDOR-5 OF CMRL
PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SECTION C
DESIGN
DECEMBER 2021
KOYAMBEDU,
Chennai Metro Rail Project Phase 2, Corridor 5 Part-2 - Section VI

TABLE OF CONTENTS
SUB-SECTION C- EMPLOYER’S REQUIREMENTS - DESIGN
SECTION PAGE
C1 INTRODUCTION ................................................................................................................ DELETED
C2 REQUIREMENTS DURING DESIGN PHASE ..............................................................................C-1
C3 REQUIREMENTS DURING CONSTRUCTION PHASE ..............................................................C-1
C4 DESIGN INTERFACES WITH INTERFACING CONTRACTORS ................................. DELETED
C5 DESIGN SUBMISSIONS ................................................................................................................C-2
C6 DESIGN SUBMISSIONS - CONSTRUCTION REFERENCE DRAWING SUBMISSION .........C-4
C7 DESIGN SUBMISSIONS –CONSTRUCTION PHASE .................................................................C-5
C8 DESIGN SUBMISSION – REVIEW PROCEDURES ........................................................ DELETED
C9 DESIGN SUBMISSION PROGRAMME ............................................................................ DELETED
C10 PROGRAMME FOR SUBMISSIONS DURING THE CONSTRUCTION PHASE ......................C-6
C11 CALCULATIONS ................................................................................................................ DELETED
C12 DOCUMENTS REQUIREMENTS ...................................................................................................C-6
Section VI -Sub-Section C- Design i December 2021

C1 INTRODUCTION
DELETED
C2 REQUIREMENTS DURING DESIGN PHASE

DELETED
C3 REQUIREMENTS DURING CONSTRUCTION PHASE
(1) The principal requirements of the Contractor relating to design during the Construction
Phase are the production of Working Drawings, updating the BIM models, the preparation
of technical submissions as required under the Contract and the production of the As-Built
Drawings.
(2) Working Drawings shall be prepared by the Contractor as required under the Contract.
They shall be endorsed by the Project Manager of the Contractor as being in accordance
with the Good for Construction Drawings.
(3) Interfacing Contractors may request design modifications as part of the Interface
Coordination process. The Contractor shall assess such design requests and immediately
notify the Engineer of all such design changes including all impacts that the design change
will have to the Contractor. The Engineer may then instruct the DDC to modify the design
and issue revised drawings to the Contractor.
(4) The Contractor shall maintain all records necessary for the preparation of the As-Built
Drawings. Upon completion of the Works or at such time as agreed to or required by the
Engineer, the Contractor shall prepare drawings which, subject to the Engineer's Notice,
shall become the As-Built Drawings. All such drawings shall be endorsed by the
Contractor as true records of the construction of the Permanent Works and of all temporary
works that are to remain on the site. The Contractor shall also show the locations of utilities
exposed, relocated, diverted, new or retained.
C4 DESIGN INTERFACES WITH INTERFACING CONTRACTORS
DELETED
C5 DESIGN SUBMISSIONS
C5.1 PRELIMINARY DESIGN SUBMISSION
DELETED
C5.2 DEFINITIVE DESIGN SUBMISSION
DELETED
C5.3 TECHNICAL SUBMISSIONS
(1) DOCUMENTS
a) Contract Specification
The Contractor's Technical Proposals together with the Outline Construction Specifications
Section VI -Sub-Section C- Design C-1 December 2021

shall be amplified so as to specify comprehensively the construction of the Permanent Works.

b) Design Manual
DELETED
c) Interface Design Report on Interfacing Contractors
This will include the following:
Details of the construction of the Works adjacent to other Contracts. Details of provisions for
the Interfacing Contractors, indicating arrangements for accesses, fixings, casting-in,
openings, supports, plinths, decks, manholes, trenches and the like; updated interface
management plan relating to design integration and co-ordination.
Testing and Commissioning Report
DELETED
Maintenance Report
A report updating the Statement of Maintainability and detailing maintenance routines
necessary for the achievement of the required lives of the various elements of the Works.
Station Planning Report
DELETED
(2) SUPPORTING DOCUMENTS
a) Geotechnical Report
A report covering site investigation work to be undertaken by the contractor in sufficient detail
is to be submitted to the Engineer. The report shall include the full borehole logs for all
additional bore holes and confirmatory boreholes (to be decided by the Contractor to suit his
own construction methodology) drilled by the Contractor and all related field or laboratory
test required to collate and enhance the existing GIR.
b) Survey Report
A report on all survey work to be undertaken by the Contractor, including checks on mapping,
survey stations, co-ordinates and setting-out. Updated topographical and survey drawings
shall also be included.
c) Pre-conditional Survey of Existing Buildings
A report giving a review of the general condition of all existing buildings and structures within
the zone of influence, which is defined as 50m each side of the centre line of the track
alignment. The structural record surveys on the buildings and structures within this zone shall
be included in this report. Refer to Clause D8(9) of this Part -2 for further details.
d) Existing Buildings
Protective measures that can be deployed, based on the contractor’s existing building
condition survey, shall also be given.

e) Utilities Report
A report giving details of arrangements and working methods in respect of the existing
utilities, including protection measures, diversions, reinstatements and programme
allowances.
f) Water Well Protection and Replacement Report.
A report giving details of arrangements and working methods in respect of the existing water
wells along and adjacent to the alignment, including anticipated zone of influence, protection
measures, removals, replacements and programme allowances.
g) Temporary Works Design Report
A report which provides sufficient information on the design of the Temporary Works, not
covered in employer’s drawings, to allow the Engineer to assess their effects on the Permanent
Works.
h) Construction / Installation Analysis Report
A report containing a stage-by-stage construction / installation sequence for all structures /
equipment.
i) Construction Method Statement
Various reports which provide sufficient information on the methods of construction and
Contractor's Equipment to allow the Engineer to assess their effects on the Permanent Works.
j) Works Programme Review
• The Contractor shall provide details of submissions of the Construction Reference
Drawings and the proposed Working Drawings and their anticipated timing during
the Construction Phase and shall identify information required from or actions to
be undertaken by the Engineer or others which are necessary to permit the
completion of the Permanent Works and the Working Drawings. Desired Dates
for the receipt of such information or for the completion of such actions required
by the Contractor shall be included with appropriate justification.
k) Report on the Use of Works Areas

A report updating the proposals from those contained in the Contractor's Technical Proposals
for the use of Works Areas, site security and their reinstatement, detailing the station accesses
and access facilities.
l) Report on Tunneling Method

A report which provides sufficient information on the proposed methods of tunnelling,
including underneath existing buildings and structures.
C6 CONSTRUCTION REFERENCE DRAWING SUBMISSIONS
DELETED

C7 DESIGN SUBMISSIONS - CONSTRUCTION PHASE

(1) On the issue of Good for Construction Drawings, the Contractor shall produce Working
Drawings where necessary. The Working Drawings shall include the Good for
Construction Drawings, which may be supplemented by further drawings developed in
accordance with the Good for Construction Drawings such as site sketches, bar bending
schedules, bar reference drawings, fabrication and shop drawings, construction erection
sequences, finishes material list with accompanying specification, and the like. All such
drawings shall comply with the requirements of the Contract.
(2) Hard copies of the As-Built Drawings, endorsed by the Contractor, shall be submitted to
the Engineer for a Notice of No Objection in accordance with Clause 5 of GC and in
electronic format using a commercially available CAD program.
C8 DESIGN SUBMISSIONS - ASSESSMENT PROCEDURES (TEMPORARY

WORKS)
TEMPORARY WORKS – NOT COVERED IN EMPLOYER’S DRAWINGS

(1) Design submissions of Temporary Works, for Works not covered by the Employer’s
Drawings shall be undertaken by the Contractor, and assessed by the Engineer within 28
days of the date of submission. The form and detail of the assessment shall be as
determined by the Engineer and will not release or remove the Contractor’s responsibility
for the design of the Temporary Works under the Contract.
(2) The issue of a Notice shall be without prejudice to the issue of any future Notices.
(3) The Contractor shall, prior to the submission of the Design Data, obtain all required
statutory approvals that relate to that submission including, where appropriate, the
approval of the Concerned Government Authorities and utility undertakings, and
demonstrate that all required approvals have been obtained.
(4) All submissions shall be accompanied by two original copies of a `Design Certificate’ as
set out in Attachment C1 hereto and signed by the Contractor’s Engineering Manager.
(5) The Contractor shall establish a Quality Assurance Plan (QAP) and a system of internal
audit and approval of his designs, including calculations, drawings and other documents
prepared and issued to the Engineer for Notice. The purpose of the checking shall be to
ensure accuracy and consistency, as well as compliance with current requirements,
standards, codes and the requirements of the contract. Internal checks shall be carried out
by personnel who have experience and competence as far as possible equal or superior to
the originator, but who have not been involved in producing the original design. All the
design drawings and calculations shall be checked by the contractor’s Engineering Manager
and then to be submitted to the Engineer.
Design review checklist must include all calculations, drawings and other requirements for the

design of complete system for each discipline (civil, structural, MEP etc.,)
(6) The Contractor shall appoint a suitably qualified person(s) to act as the Engineering
Manager for co-ordination of various systems and disciplines like civil, structural, MEP,
signalling, Telecommunication, Automatic Fare collection etc.
(7) All calculations, including any amendments thereto, shall be endorsed as checked and
approved prior to issuing to the Engineer, being initialled and dated by both the Engineering
Manager. All the signatures on the cover sheet of authorised personnel including the
Engineering Manager shall be original handwritten signature unless agreed by the Engineer
otherwise.
Calculations shall be prepared according to the “best professional standards and practices”
compiled into sets that relate to particular aspects of design.
1. A brief description of the structure and its assumed mode of action;
2. The loads that will act upon the structure:
3. The allowable stresses of the structure:
4. A brief statement description of the method of analysis used:
5. A brief statement description of the method of design;
6. Details of the computer program used;
7. A key to symbols used: and
8. A design summary.
Each document and drawing, including any revisions thereto, shall be endorsed as checked and
approved prior to issue to the Engineer by being initialled and dated by Engineering Manager.
The person preparing the design and drawing will initial all documents prepared by him.
C9 DESIGN SUBMISSION PROGRAMME

DELETED
C10 PROGRAMME FOR SUBMISSIONS DURING THE CONSTRUCTION PHASE
In accordance with Clause A4 of Section A, of Part-2 of the Employer's Requirements - General,
the Contractor shall identify submissions required during the Construction Phase.
C11 CALCULATIONS
(1) Unless otherwise required by the Engineer, calculations relevant to the Contractor’s
Temporary Designs shall be submitted for assessment with the respective design packages
or submissions. The above calculations shall have been certified by the Contractor’s
Engineering Manager. The Engineer may require the submission of applicable software
including in-house software programmes/ worksheets developed by the Contractor,
computer input and programme logic for his assessment prior to the acceptance of the
computer output.
(2) The Contractor shall prepare and submit a comprehensive set of calculations for his
temporary designs in a form acceptable to the Engineer. Should the design of the Temporary

Works be revised by the Contractor he shall prepare and submit the revised calculations and
drawings.
(3) The Contractor shall submit all calculations necessary to support proposals relating to any
construction methods.
C12 DOCUMENT REQUIREMENTS

(1) Drawings shall be prepared generally to A1 size, but to ISO AO size where appropriate.
Appendix 7 of this Part -2 defines the Drawings and CAD Standards required for drawing
preparation and submittal.
(2) The Contractor shall submit 6 copies of his design and/or drawings for assessment by the
Engineer. After the receipt of a Notice of No Objection from the Engineer, the Contractor
shall submit 6 copies of design and/or drawing for the use of the Engineer.
(3) The submission of drawings may be by CAD Media files and Appendix 7 of this Volume
3 specifies the drawing submission requirements for CAD Media files.


PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SECTION D
CONSTRUCTION
DECEMBER 2021

KOYAMBEDU,
Chennai Metro Rail Project Phase 2, Corridor 5. Part D – Section VI
TENDER No. CP06/UG06 Employer’s Requirements

TABLE OF CONTENTS
SUB-SECTION D EMPLOYER’S REQUIREMENTS-CONSTRUCTION
PAGE SECTION
D1 CONTRACTOR'S SUPERINTENDENCE .................................................................. D-1
D2 CHECKING OF THE CONTRACTOR'S TEMPORARY WORKS DESIGN ............ D-1
D3 THE SITE ..................................................................................................................... D-1
D4 SURVEY ....................................................................................................................... D-3
D5 SAFETY, HEALTH AND ENVIRONMENTAL REQUIREMENTS ......................... D-4
D6 AVOIDANCE OF NUISANCE AND NOISE ............................................................. D-6
D7 CARE OF THE WORKS .............................................................................................. D-5
D8 DAMAGE AND INTERFERENCE ............................................................................. D-6
D9 WORK ON ROADS ..................................................................................................... D-8
D10 SITE ESTABLISHMENT .......................................................................................... D-12
D11 SECURITY ................................................................................................................. D-13
D12 TESTING .................................................................................................................... D-14
D13 RECORDS .................................................................................................................. D-18
D14 MATERIALS .............................................................................................................. D-19
D15 PROVISIONS FOR THE DESIGNATED CONTRACTORS ................................... D-20
D16 RESTORATION OF AREAS DISTURBED BY CONSTRUCTION ....................... D-20
D17 TUNNEL BORING MACHINES............................................................................... D-23
D18 SUBWAYS ....................................................................................................... DELETED
D19 DEMOLITION OF EXISTING STRUCTURES ...................................................... ...D26
Attachment D1 – Contractor’s Labour Camp
Section VI -Sub-Section D- Construction i December 2021

D1 CONTRACTOR'S SUPERINTENDENCE
(1) The Contractor shall submit a Staff Organisation Plan to the Engineer in accordance with
Clause A15 of this Part-2 This plan shall be updated and resubmitted whenever there are
changes to the staff. The plan shall show the management structure and state clearly the
duties, responsibilities and authority of each staff member.
(2) The Project Manager and his site team shall have experience and qualifications appropriate
to the type and magnitude of the Works. Full details shall be submitted of the qualifications
and experience of all proposed staff to the Engineer for his Notice, which shall be as a
minimum those given in Clause A15 of this Part-2.
D2 CHECKING OF THE CONTRACTOR'S TEMPORARY WORKS DESIGN
The Contractor shall, prior to commencing the construction of the Temporary Works not covered
in Employer’s Drawings, shall submit a certificate to the Engineer, `Design Certificate' signed
by the Contractors Designer, certifying that the Temporary Works have been properly and safely
designed and checked.
D3 THE SITE
(1) Works Areas are those areas identified in Appendix 2A of this Part-2and on the Employer’s
Drawings.
Use of the Site
(2) The Site or Contractor's Equipment shall not be used by the Contractor for any purpose
other than for carrying out the Works, except that, with a Notice from the Engineer, the
Site or Contractor's Equipment such as batching and mixing plants for concrete and
bituminous materials may be used for the work in connection with other Contracts under
the Employer.
(3) Rock crushing plant shall not be used on the Site.
(4) The location and size of each stockpile of materials, including excavated materials, within
the Site shall be as permitted by the Engineer. Stockpiles shall be maintained at all times
in a stable condition.
(5) Entry to and exit from the Site shall be controlled by 24-hour security and shall be only
available at the locations for which the Engineer has given a Notice. Notice will only be
given after the Contractor has provided evidence that he has obtained the necessary
approvals from the relevant authorities.
Access to the Site
(6) The Contractor shall make his own arrangements, subject to a Notice from the Engineer,
for any further access required to the Site.
(7) In addition, the Contractor shall ensure that access to every portion of the Site is continually
available to the Employer and the Engineer.
(8) Following the handover of the Works to the Employer, the Employer will be responsible
for all matters relating to security and safety therein. Access to the Site by the Contractor
shall be in accordance with any procedures, requirements and conditions defined in
Appendix 9 of this Part-2.
(9) The Contractor shall be responsible for ensuring that any access or egress through the Site
boundaries are controlled such that no disturbance to residents or damage to public or
private property occurs as a result of the use of such access or egress by its employees and
Section VI -Sub-Section D-
1 December 2021
Construction
sub-contractors.
Survey of the Site
(10) A survey shall be carried out of the Site to establish its precise boundaries and the existing
ground levels within it, as detailed in Clause D4 of Section D of this Part`2 document. This
survey shall include a photographic survey sufficient to provide a full record of the state
of the Site and adjacent areas/buildings before commencing the Works, with particular
attention paid to those areas where reinstatement will be carried out later on. The survey
shall be carried out before the site clearance and in any case prior to the commencement
of work in any Works Area. The survey shall be carried out by the Contractor and will
require a Notice from the Engineer.
Barricades and Signboards
(11) The Contractor shall erect barricades with gates around his areas of operations to prevent
entry by unauthorised persons to his Works and/or Site Areas and necessary identity cards
/permits should be issued to all of his workers and staff by the Contractor. The Contractor
shall submit a proposal for barricades/gates around the complete perimeter of all Works
areas for which the Engineer shall give a Notice. Painting of the barricades shall be carried
out to the design and colours as directed by the Engineer and the Contractor shall carry out
re-painting of the entire barricades on an annual basis or sooner as required by the
Engineer.
No work shall commence in any Works Area until the Engineer has issued a Notice
signifying that he is satisfied that the barricades installed by the Contractor are sufficient
to prevent, within reason, unauthorised entry. Project signboards shall be erected not more
than four (4) weeks, or such other period as the Engineer has given his Notice, after the
date for commencement of the Works.
The types, sizes and locations of project signboards shall be agreed with the Engineer
before manufacture and erection. Other advertising signs shall not be erected on the Site.
(12) A Notice of No Objection from the Engineer shall be obtained before hoardings, fences,
gates or signs are removed. Hoardings, fences, gates and signs which are to be left in
position after the completion of the Works shall be repaired and repainted as instructed by
the Engineer.
(13) Hoardings, barricades, gates and signs shall be maintained in clean and good order by the
Contractor until the completion of the Works, whether such hoardings, fences, gates and
signs have been installed by the Contractor or by others and ownership transferred to the
Contractor during the period of the Works. All the fencing, hoardings, gates and signs etc.
shall be mopped a minimum of once a week and thoroughly washed once a month.
(14) All hoardings, barricades, gates and signs installed by the Contractor shall be removed by
the Contractor upon the completion of the Works, unless otherwise directed by the
Engineer.
(15) Hoarding/ barricades can be reused after removing from one place to other locations / sites
provided they are in good condition and a Notice is issued by the Engineer.
(16) Damaged/worn-out barricades /hoardings shall be replaced by the Contractor within 24
hours. The Engineer ‘s decision regarding need for replacement shall be final and binding.
Clearance of the Site
2 December 2021
Construction
(17) All Temporary Works which are not to remain on the Site after the completion of the Works
shall be removed prior to completion of the Works or at other times instructed by the
Engineer. The Site shall be cleared and reinstated to the lines and levels and to the same or
better condition as existed before the Works started except as otherwise stated in the
Contract.
Casting Yard and Batching Plant
(18) The Contractor has to make his own arrangements for a casting yard/works area(s) and other
facilities without any liability to the Employer.
(19) Muck Disposal site
The Contractor shall make his own arrangements for a dumping yard and other associated
facilities to the any lead without any liability to the Employer. The contractor is free to use
the excavated earth for commercial or any other use including disposal to dumping yard
arranged by his own. Disposal of excavated earth and other debris / waste materials at
unauthorized locations shall be strictly prohibited, any violation in this regard will attract
severe disciplinary action with an imposition of penalty of Rs. 50,000/ violation. The
disposal of waste material, bentonite fluid and material contaminated with bentonite shall
be full responsibility of the Contractor and these materials shall be disposed by the
Contractor in a location approved by the Relevant Authorities. The dumping sites shall not
be used for disposal of waste material, bentonite fluid or material contaminated with
bentonite.
For disposing of the spoil/muck at a muck-disposal site, the Contractor shall take, but not be
limited to, the following measures to ensure proper muck/spoil disposal and adequate site
rehabilitation:
a) The muck disposal site shall be ecologically restored to the maximum extent possible duly
ensuring that the water quality, air quality and the Near habitations and traffic prone areas,
trenches and foundation pits or any other excavation work shall be fenced, provided with
proper caution signs and marked with red lights, reflectors at night to avoid accidents. The
contractor shall take all adequate protective measures to see that excavation operations do
not affect or damage adjoining structures.
(20) Excavated material in excess to the required quantity for backfilling or any other surplus
materials including debris etc. shall be the property of the Contractor and shall be utilized /
removed or carted away from the site in appropriate manner with prior intimation to the
Engineer for proposed utilization. Dumping of this surplus material shall be in an orderly
environmental friendly manner using tarpaulin cover, dumper, placer etc. and according to the
levels/grades. Necessary approval from the local authorities for carting and dumping surplus
material is to be obtained by the contractor.
(21) The Contractor shall notify to the Engineer when the excavation is completed and no base or
Concrete or Masonry shall be laid until the Engineer has inspected and approved of the soil
conditions obtained for each individual footing or the full raft area.
(22) The Contractor may dispose off the surplus earth from the project site to a place/ places
identified by the Contractor by giving intimation to the Engineer/Employer. The transportation
of the surplus earth shall be done by mechanical means only. The Contractor shall at his own
cost obtain necessary clearances/ permissions statutory or otherwise needed for the purpose.
Dumpers may be used for transporting slushy, material excavated from pile boring/ pile cap/
Open Foundation with precautions for non-spillage of muck.
(23) The Contractor shall make his own arrangements for identification of dumping yard and other
associated facilities for disposal without any liability to the Employer.
3 December 2021
Construction
(24) The muck disposal sites shall be identified by the Contractor before start of construction in
consultation with SPCB, Municipal Corporation/Municipalities and CMDA, to ensure a safe
distance from residential areas, water bodies and ecologically sensitive locations as to avoid
disrupting natural drainage. The muck shall be filled in the dumping site in layers and
compacted mechanically. Suitable slopes will be maintained on the stockpile. Once the filling
is complete, it will be protected by low walls, provided with a layer of good earth on the top
and covered with vegetation. A muck disposal & utilization plan shall be prepared by
Contractor.
(25) All the associated costs including taxes and royalty applicable as per State Government
guidelines etc. for utilization/disposal of excavated material shall be borne by the Contractor.
The Contractor shall consider the said requirement and potential commercial utilization in his
quote.
(26) A Mechanical Type Washing Plant shall be installed by the Contractor for the use of all vehicles
leaving the casting yard area to avoid any contamination or spillage on the connecting roads
D4 SURVEY
(1) The Contractor shall relate the construction of the Works to the Project Grid. To facilitate
this, survey reference points have been established and the Engineer will provide
benchmarks and Traverse points in the vicinity of the Site areas.
(2) Before the Contractor commences the setting out of the Works, the Engineer will provide a
drawing showing the position of each survey reference point and bench mark, together with
the co-ordinates and/or level assigned to each point. The Contractor shall carry out detailed
survey to check the proposed alignment maintaining vertical and horizontal clearances. In
case of any differences from the Employer’s drawings or data, the Contractor shall bring
these to the Notice of the Engineer immediately and submit his proposals for correction. The
Engineer shall either, issue a Notice, modify or ask the Contractor to resubmit the proposals
within a period of 14 days. The Contractor shall satisfy himself that there are no further
conflicts between the data given and shall establish and provide all subsidiary setting out
points, monuments, towers and the like which may be necessary for the proper and accurate
setting out and checking of the Works.
(3) The Contractor shall carefully protect all the survey reference points, bench marks, setting
out points, monuments, towers and the like from any damages and shall maintain them and
promptly repair or replace any points damaged from any causes whatsoever. The Contractor
shall recheck every three months, the position of all setting out points, bench marks and the
like, for a Notice by the Engineer.
(4) Upon handover to the Contractor, the survey reference points will become the responsibility
of the Contractor. The Contractor shall check the survey reference points every three months
to ensure that these survey points continue to remain consistent with the bench marks.
D5 OCCUPATIONAL HEALTH SAFETY AND ENVIRONMENTAL
REQUIREMENTS
The Contractor shall comply with the conditions and requirements stipulated in the Occupational
Health, Safety & Environment (OHS&E) Plan contained in Appendix 20 of this Part-2 -
Employer’s Requirements and in Volume 5 Reference Documents.
D6 OTHER SAFETY MEASURES
(1) The Contractor shall take all reasonable precautions and select appropriate tools,
equipment and installation methods to avoid causing a nuisance arising from his operations
4 December 2021
Construction
and shall minimise inconvenience to the public.

(2) The Contractor shall prevent dust from rising as a result of his activities and shall take all
necessary dust control and suppression measures.
(3) All Contractor's Equipment used on the Contract shall be fitted with a means of
suppressing radio and television interference and shall be operated and maintained in such
manner so as to minimise the emission of smoke and obnoxious fumes.
(4) The Contractor shall be responsible for the security of the Site at all times during the term
of this Contract. The Contractor shall control all entry and exit to and from the Site for his
personnel, personnel from the Employer, Engineer, Interfacing Contractors, Sub-
contractors and suppliers, by pedestrians and for all vehicles. All of the Contractor’s
personnel shall be required to carry an identity/security card or pass which provides a
positive photo identification and they shall be required to show the pass when entering or
leaving the Site. This shall apply to all personnel on the Site including, but not limited to,
the Contractor’s staff, all Interfacing Contractors, Sub-contractors staff, Suppliers,
Consultants, etc. and the staff of the Employer and Engineer. Provision shall be made for
issue of visitors’ passes for other personnel authorized to enter the Site as visitors. Visitors
on Site shall be escorted by appropriate Site based personnel at all times.
(5) The Contractor shall be deemed to have made allowance in his price and programme for
the impact on the Works as a result of any delay due to the provision of access to, and
through the site generally, for Interfacing Contractors, relocation of temporary works,
provision of security, lighting, signage, barriers, trackwork crossings, complying with all
government and local authority regulations, etc...
(6) No tunnel boring machine shall be used without a Notice of No Objection being issued
by the Engineer.
(7) The Contractor shall prepare a detailed specification for the operation of each tunnel
boring machine for submission to the Engineer for a Notice.
D7 CARE OF THE WORKS
(1) Unless otherwise permitted by the Engineer all work shall be carried out in dry conditions.
(2) The Works, including materials for use in the Works, shall be protected from damage due
to water. Water on the Site and water entering the Site shall be promptly removed by
temporary drainage or pumping systems or by other methods capable of keeping the Works
free of water. Silt and debris shall be removed by traps before the water is discharged and
shall be disposed of at a location or locations to which the Engineer has given Notice.
(3) The discharge points of the temporary systems shall be as per the Notice of the Engineer.
The Contractor shall make all arrangements with and obtain the necessary approval from
the relevant authorities for discharging water to drains, watercourses, etc. The relevant
work shall not commence until the approved arrangements for disposal of the water have
been implemented.
(4) The methods used for keeping the Works free from water shall be such that settlement of,
or damage to, new and existing structures does not occur.
(5) Measures shall be taken to prevent settlement, damage, flotation, etc.to new and existing
structures.
5 December 2021
Construction
Protection of the Works from Weather

(6) Work shall not be carried out in weather conditions that may adversely affect the Works
unless proper protection is provided to the satisfaction of the Engineer.
(7) Permanent Works, including materials for such Works, shall be protected from exposure
to all weather conditions that may adversely affect such Permanent Works or materials.
(8) During construction of the Works storm restraint systems shall be provided to ongoing
construction works, where appropriate. These systems shall ensure the security of the
partially completed and ongoing stages of construction in all weather conditions. Such
storm restraint systems shall be installed as soon as practicable and shall be compatible
with the right of way, or other access around or throughout the Site.
(9) The Contractor shall, at all times programme and order progress of the Works and make
all protective arrangements such that the Works can be made safe in the event of storms.
Protection of the Work

(10) The finished works shall be protected from any damage that could arise from any
activities on the adjacent site/ works.
D8 DAMAGE AND INTERFERENCE
(1) Work shall be carried out in such a manner that there is no damage to or interference with:
(a) watercourses or drainage systems;
(b) utilities;
(c) structures (including foundations), roads, including street furniture, or other properties;
(d) public or private vehicular or pedestrian access;
(e) monuments, trees, graves or burial grounds other than to the extent that is necessary for
them to be removed or diverted to permit the execution of the Works, as approved by
statutory authorities, etc...
(f) Heritage structures shall not be damaged or disfigured on any account.
The Contractor shall inform the Engineer as soon as practicable of any items which are
not stated in the Contract to be removed or diverted but which the Contractor considers
need to be removed or diverted to enable the Works to be carried out. Such items shall
not be removed or diverted until a Notice from the Engineer to such removal or diversion
has been obtained.
(2) Items which are damaged or interfered with as a result of the Works and items which are
removed to enable work to be carried out shall be reinstated to the satisfaction of the
Engineer and to the same or better condition as existed before the work started.
Utilities
(3) Refer to Appendix 12 of this Part-2 .
Any claims by Utility Agencies due to damage of utilities by the Contractor shall be borne
by the Contractor.
Structures, Roads and Other Properties
(4) The Contractor shall immediately inform the Engineer of any damage to structures, roads or
other properties at handover of the site(s) or during the Contract duration.
6 December 2021
Construction
Access
(5) Alternative access shall be provided to all premises if interference with the existing access,
public or private, is necessary to enable the Contractor’s Works to be carried out. The
arrangements for the alternative access shall be as agreed by the Engineer and any concerned
agency or building management. Unless agreed otherwise, the permanent access shall be
reinstated as soon as practicable after the work is complete and the alternative access shall
be removed immediately when it is no longer required, and the ground surfaces reinstated
to the satisfaction of the Engineer. Proper signage and guidance shall be provided for the
traffic / users regarding diversions.
Trees
(6) The Contractor is not permitted to cut or fell any trees without first obtaining approval from
the appropriate authorities and then obtaining a Notice from the Engineer. The Contractor
shall identify all trees that require cutting or felling and make applications to the appropriate
authorities and the Engineer for the necessary works at least 3 months in advance of the
required date for the cutting or felling works.
Removal of Graves and Other Obstructions
(7) If any graves and other obstructions are required to be removed in order to execute the Works
and such removal has not already been arranged for, the Contractor shall draw the Engineer
's attention to them in good time to allow all necessary arrangements and authorisations for
such removal, and the Contractor shall not remove them without first obtaining approval
from the appropriate authorities and then obtaining a Notice from the Engineer.
Protection of the Adjacent Structures and Works
(8) The Contractor shall take all necessary precautions to protect adjacent buildings and
structures, and works being carried out by others adjacent to and within the Site, from the
effects of vibrations, undermining and any other earth movements or the diversion of water
flow arising from its work.
Pre-Construction Surveys of Adjacent Buildings and Structures
(9) Based on the existing building condition survey carried out by the Contractor, the Contractor
shall submit details of the additional measures he intends to take to protect those buildings
or structures, as identified in the reports compiled under Clause C5.2(4) of this Part-2, as
potentially susceptible to damage during the construction of the Works,to the Engineer for
a Notice for the proposed measures.
Prior to commencing any work within the 50m zone of influence of the buildings and
structures, the Contractor shall complete a pre-construction survey to identify and record
any existing defects in the building structure and fabric. A separate pre-construction survey
report shall be prepared for each building/structure, in a format given a Notice by the
Engineer. The report shall include sufficient key plans, sketches and photographs to enable
easy location of existing defects and comparison with possible future ones. Two coloured
copies of all of the pre-construction survey reports shall be provided to the Engineer, and a
further copy of the appropriate pre-construction survey report shall be issued to the
building/structure owner for their information and a signed receipt form/letter
acknowledging the owners receipt of such shall be retained by the Contractor.
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D9 WORK ON ROADS
Traffic Management Plan
(1) The Contractor shall develop a detailed Traffic Management Plan for the work under the
Contract. The purpose is to develop a Traffic Management Plan to cope with the traffic
disruption as a result of construction activities by identifying strategies for traffic
management on the roads and neighbourhoods impacted by the construction activities,
which shall be submitted to the Chennai Traffic Police for their approval and to the
Engineer for his Notice of No Objection. The Contractor shall implement the Traffic
Management Plan throughout the whole period of the Contract and shall comply strictly
with the approved plan during the construction of his works.
All costs associated with Traffic Management shall be paid as detailed in the Pricing
Document.
Principles for Traffic Management
The basis for the Plan shall take into consideration eight principles:
• To minimise the inconvenience of road users and the interruption to surface traffic through
the area impacted by the construction activities;
• To ensure the safety of road users in the impacted area;
• To facilitate access to the construction site, and to maintain reasonable construction
progress.
• To ensure traffic safety at each construction site.
• To make the most efficient use of the restricted area available, whilst minimising disturbance
to the general public.
• The design shall provide for a minimum of two lanes of traffic in each direction, which may
require temporary road decking where necessary, which must be maintained at all times,
shall be approved by Chennai Police Traffic Department.
• The traffic management plan shall provide for a minimum of 2m of footpath adjacent to
buildings or thoroughfares for all road diversion schemes.
• The Contractor should take into account that the construction of the stations may have to
done in phases to ensure that the traffic management plan provides the minimum number of
two traffic lanes in each direction.
Integrated Traffic Management Plan
The Contractor shall prepare an integrated plan showing the arrangements to be made for
accommodating road and pedestrian traffic, at individual construction sites and continuously
along the alignment, including arrangements being implemented by other contractors, to smooth
traffic operations and for the safety of both construction workers and road users. The Plan shall
consider different measures such as:
• The use of suitable construction sequences and methods at station sites to reduce the period
of disruption to road users;
• proper phasing and timing of traffic signals;
• modifications to intersection geometry;
• changes in lane usage;
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• parking prohibitions;
• re-location of bus stops;
• maintenance of existing roads within the vicinity of the Works areas;
• reducing width of footpaths and median;
• right-turn prohibition;
• work site access management;
• minimising the duration of any road closure;
• reversible lane operations;
• modification of roadway alignment affected by the construction, which shall be in
conformance with the requirements and regulations defined by the relevant authorities;
• other engineering traffic measures as may be applicable.
Mitigation of Traffic Disturbances
(2) The Contractor shall manage the vehicular and pedestrian right of way during the period of
construction. The Contractor shall take account of the need to maintain essential traffic
requirements, as these may influence the construction process.
The Contractor shall include local traffic diversion routes and assess traffic impacts caused
by the construction in the affected areas. Signage layout shall be included to ensure that
adequate motorist information will be provided for traffic diversions.
Where it becomes necessary to close a road or intersection, or supplementary lanes are
required to satisfy the traffic demands, traffic diversion schemes to adjacent roadways shall
be developed with quantitative justifications. The Contractor shall co-ordinate with all
relevant authorities.
Other considerations include:
• The minimum lane widths for fast traffic and mixed traffic shall follow the regulations
of the different authorities.
• The design shall provide for a minimum number of two traffic lanes / presently available
road width in each direction, with a minimum of 2m of footpath adjacent to buildings or
thoroughfares.
• Any roads or intersections that have no alternative access shall not be fully closed for
construction.
• Emergency access to all properties shall be maintained at all times.
• The type, size, lighting, painting, etc. requirements for barricades, hoardings and fencing
shall be as detailed in Volume 3 or as required by the Engineer.
• Access to business premises and property shall be maintained to the extent that normal
activities are not seriously disrupted.
• Minimum footpath width shall be 2m, unless otherwise indicated. The footpath shall be
separated from vehicle traffic and not necessarily immediately adjacent to vehicle traffic;
• Where existing footbridges and underpasses are demolished or closed, provisions shall
be made for pedestrian crossing to minimise the conflicts between a traffic lane.
• Construction traffic shall be separated from other traffic wherever possible;
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• Any traffic related facilities (bus stops, parking, etc.) which are affected by the
construction works shall be maintained or relocated to appropriate locations;
• Motorists, pedestrians, workmen, plant and equipment shall be protected from accident
at all times;
• The Contractor’s temporary traffic management plan shall be coordinated with the works
and traffic arrangements of other contractors where these interface with this Contract.
• Roadway designs, traffic management schemes, and installation of traffic control devices
shall be in conformance with the requirements and regulations defined by the relevant
authorities; and
• Where applicable, utility diversions shall be incorporated in the traffic management plan.
Approval for Temporary Traffic Arrangements and Control
(3) The Contractor shall make all arrangements with and obtain the necessary approval from
the transport authorities and the Chennai Police Traffic Department for temporary traffic
arrangements and control on public roads. In the event that the Contractor, having used its
best endeavours, fails to secure the necessary approval from the transport authorities and
the Chennai Traffic Police Department for temporary traffic arrangements and control on
public roads, then the Employer will use its best endeavours to assist the Contractor to
secure such approval but without responsibility on the part of the Employer to do so.
Temporary Traffic Arrangements and Control
(4) Temporary traffic diversions and pedestrian routes shall be surfaced and shall be provided
where work on roads or footpaths obstruct the existing vehicular or pedestrian access. The
relevant work shall not be commenced until the approved temporary traffic arrangements
and control have been implemented.
(5) Temporary traffic arrangements and control for work on public roads and footpaths shall
comply with the requirements of the Chennai Traffic Police. Copies of documents
containing such requirements shall be kept on the Site at all times.
(6) Temporary traffic signs, including road marking, posts, backing plates and faces, shall
comply with the requirements of the Chennai Traffic Police and should be in accordance
with the requirements of Ministry of Surface Transport. All overhead traffic management
signs that are fixed to bridges and gantries shall be illuminated at night. Pedestrian routes
shall be illuminated at night to a lighting level of not less than 50 lux.
(7) Adequate number of traffic marshals shall be deployed for smooth regulation of traffic.
(8) Temporary traffic arrangements and control shall be inspected and maintained regularly,
both by day and night. Lights and signs shall be kept clean and legible. Equipment which
are damaged, dirty, incorrectly positioned or not in working order shall be repaired or
replaced promptly.
Particulars of Temporary Traffic Arrangements and Control
(9) The following particulars of the proposed temporary traffic arrangements and control on
public roads shall be submitted to the Engineer for his Notice of No Objection, at least 28
days before the traffic arrangements and control are implemented:
(a) details of traffic diversions and pedestrian routes;
(b) details of lighting, signage, guarding and traffic control arrangements and equipment;
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(c) any conditions or restrictions imposed by Chennai Traffic Police or any other relevant
authorities, including copies of applications, correspondence and approval.
(10) Where concrete barriers are used to separate flows of traffic, the barriers shall be in a
continuous unbroken line. No gaps shall be left between any section of the barrier.
(11) Site perimeter fencing and barriers along the roadway, shall have flashing amber lights
positioned on the top of them every 50 metres apart and at every abrupt change in location.
Directly below the flashing light shall be fixed, in the vertical position, a white fluorescent
light with a waterproof cover.
Use of Roads and Footpaths
(12) Public roads and footpaths on the Site in which the work is not being carried out shall be
maintained in a clean and passable condition.
(13) Measures shall be taken to prevent the excavated materials, silt or debris from entering
gullies on roads and footpaths; entry of water to the gullies shall not be obstructed.
(14) Surfaced roads on the Site and leading to the Site shall not be used by tracked vehicles
unless protection against damage is provided.
(15) Contractor's Equipment and other vehicles leaving the Site shall be loaded in such a
manner that the excavated material, mud or debris will not be deposited on roads. All such
loads shall be covered or protected to prevent dust being emitted. The wheels of all
vehicles shall be washed when necessary before leaving the Site to avoid the deposition of
mud and debris on the roads.
Reinstatement of Public Roads and Footpaths
(16) All street furniture, including signs, stone kerbs, boxes, lights, traffic lights, etc.., that has
to be removed due to the Contractor’s works or temporary traffic arrangements whereby
the Contractor shall arrange for their storage, either in the relevant Government
Departments or at the Contractor’s own works area(s), for which an agreed inventory,
including a photographic record, shall be submitted to the Engineer for a Notice. Existing
street furniture shall be reused where ever possible, and any street furniture that can’t be
reused shall be agreed in writing with the Engineer.
(17) Temporary diversions, pedestrian access and lighting, signing, guarding and traffic control
equipment shall be removed immediately when they are no longer required. Roads,
footpaths, street furniture and other items affected by temporary traffic arrangements and
control shall be reinstated to their original condition as existed before the work started or
as permitted by the Engineer immediately after the relevant work is complete or at other
times permitted by the Engineer. ’
The Contractor shall submit his design for the reinstatement to the relevant authorities and
obtain their prior approval to carrying out the work. Reinstatement works shall include,
but not be limited to, the following:
• Parking bays
• Footpath and kerbs
• Road Signage
• Street Lighting
• Landscaping
• Traffic Lights and Control Cable
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• Road painting
D10 SITE ESTABLISHMENT

Engineer’s Site Accommodation
(1) Within 30 days of the Commencement Date, the Contractor shall provide and maintain site
accommodation for the Engineer’s staff as set out in Appendix 13 and at a location given a
Notice by the Engineer. The accommodation shall be retained until 90 days after the issue
of a Taking-over certificate for the Works by the Engineer.
(2) The Contractor shall submit details of the site accommodation layout to the Engineer for a
Notice, prior to establishing the accommodation.
(3) The accommodation shall be cleaned and serviced daily and security shall be provided 24
hours a day, 7 days per week. Full capacity stand-by power shall be available during periods
when main power is unavailable. The Contractor shall also provide Uninterrupted Power
Supply equipment to the computer facilities provided by the Engineer in the site
accommodation.
Site Laboratory
(4) The Contractor shall provide, erect and maintain in a clean, stable and secure condition a
laboratory, equipped for the routine testing of concrete, soil and rock samples and for the
storage and curing of concrete cubes or cylinders only. This laboratory shall be located at
the Contractor's principal work site or at a location issued a Notice by the Engineer. Detailed
requirements for this laboratory are set out in Appendix 14 of this Part-2.
Contractor's Site Accommodation
(5) The Contractor shall provide and maintain its own site accommodation at locations issued a
Notice by the Engineer. Offices, sheds, stores, mess rooms, garages, workshops, latrines
and other accommodation on the Site shall be maintained in a clean, stable and secure
condition and shall comply with the requirements of Attachment D1 of this section. Under
no circumstances is living accommodation to be provided on the Site. The Contractor shall
comply with the requirements of Appendix 8 of this Part-2.
Latrines and Wash places
(6) The Contractor shall provide latrines and wash places for the use of its personnel and all
persons who will be on the Site. The size and disposition of latrines and wash places shall
accord with the numbers and dispositions of persons entitled to be on the Site, which may
necessitate their location on structures and, where necessary there shall be separate facilities
for males and females. The capacities and layout shall be subject to a Notice from the
Engineer. The Contractor shall arrange regular disposal of effluent and sludge in a manner
that shall be in accordance with local laws/ regulations.
(7) The Contractor shall be responsible for maintaining all latrines and wash places on the Site
in a clean and sanitary condition and for ensuring that they do not pose a nuisance or a health
threat. The Contractor shall also take such steps and make such provisions as may be
necessary or directed by the Engineer to ensure that vermin, mosquito breeding etc. are at
all times controlled.
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Site Utilities and Access

(8) (a) The Contractor shall be responsible for providing water, electricity, telephone,
sewerage and drainage facilities for the Engineer site accommodation, Contractor’s site
offices, structures and buildings and for all site laboratories and all such services that are
necessary for satisfactory performance of the Works. The Contractor shall make all
arrangements with and obtain the necessary approval from the relevant civil and utility
authorities for the facilities.
(b) The Contractor shall note the requirements for the supply and provision of power and
water services for all Interface Contractors, as noted in Appendix 19 of this Part-2.
(c) The contractor shall be responsible for provision of power supply for his works. The
Employer cannot guarantee provision of adequate, continuous power supply, however
assistance will be given in trying to obtaining the necessary permissions for site
generators and the like.
(9) Access roads and parking areas shall be provided within the Site as required and shall be
maintained in a clean, acceptable and stable condition. For lengths of roadway longer than
100 m and where vehicle movements exceed one hundred (100) movements/day and heavy
commercial vehicle are to ply the Contractor shall provide paved surfacing of adequate
thickness and quality to the satisfaction the Engineer.
(10) Any operation of the Works that interferes with the inspection of the Works and/or the
checking of lines and levels shall be temporarily suspended at the request of the Engineer
until the checking is complete.
Submission of Particulars
(11) The following particulars shall be submitted to the Engineer for his Notice of No Objection
not more than fifty six (56) days after the Commencement Date of the Works :
(a) drawings showing the formation works and the layout within earmarked area for the
Contractor's offices, project signboards, principal access and other major facilities
required early in the Contract, together with all service utilities;
(b) drawings showing the details to be included on the project signboards and diversion
boards.
(12) Drawings showing location of stores, storage areas, concrete batching plants and other
major facilities and their access roads/paths shall be submitted to the Engineer for his
Notice as early as possible but in any case not less than twenty eight (28) days prior to
when such facilities are intended to be constructed on the Site.
D11 SECURITY
(1) The Contractor shall be responsible for the security of the Site for the full time the Site is
in its possession, except for the specific cases as described under Clause D3(8) of these
Employer's Requirements – Construction (Section D) and defined in Appendix 9 of these
Employer's Requirements. He shall set up and operate a system whereby only those
persons entitled to be on the Site can enter the Site. To this end, the Contractor shall, with
a Notice from the Engineer, provide the specific points only at which entry through the
security fence can be effected, and shall provide gates and barriers at such points of entry
and thereby maintain a twenty four (24) hours, seven days a week security guard, and such
other security personnel and patrols elsewhere as may be necessary to maintain security.
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(2) The Contractor shall maintain all site boundary fences in a first class condition, and shall
so arrange site boundary fences at all access drainage points of work areas that it’s use of
such access points etc., are not restricted by the system or method of achieving the required
security measures. Notices shall be displayed at intervals around the Site to warn the public
of the dangers of entering the Site.
(3) During the progress of the Works the Contractor shall maintain such additional security
patrols over the areas of the Works as may be necessary to protect his own and his Sub-
contractor's work and equipment and shall co-ordinate and plan the security of both the
work under this Contract and the work of others having access to and across the Site and
the Works.
(4) In order to operate such a security system it will be necessary to institute the issue of unique
ID passes to personnel and vehicles entitled to be on the Site, and which may need to be
separately identifiable according to the shifts being worked on Site. The Contractor shall
at the outset determine, together with the Engineer, a system and the design of ID passes
to suit the requirements of the foregoing and to suit the methods of work to be adopted by
the Contractor. The Contractor shall at all times ensure that the Engineer has an up to date
list of all persons entitled to be on the Site at any time. The Contractor shall also introduce
a system for issuing passes to any visitors or persons/vehicles belonging to agencies other
than Employer/ Engineer /Interfacing Contractors who may have to visit the site in
connection with work
(5) The Contractor shall liaise with the Contractors responsible for the other Projects and other
Interfacing Contractors and ensure that co-ordinated security procedures are operated, in
particular in respect of vehicles permitted to pass through the Site and/or the adjacent sites
in the latter periods of the Contract.
(6) Security and checking arrangements as felt necessary shall be provided with advice and
help of the Police.
D12 TESTING
General
(1) The Contractor shall provide and perform all forms of testing procedures applicable to the
Works and various components and the interfacing of the Works with the other project
works and shall conduct all necessary factory, site and acceptance tests.
(2) All testing procedures shall be submitted at least thirty (30) days prior to conducting any
Test. The Testing procedures shall show unambiguously the extent of testing covered by
each submission, the method of testing, the Acceptance Criteria, the relevant drawing (or
modification) status and the location.
(3) The testing Procedures shall be submitted, as required, by the Contractor during the
duration of the Contract to reflect changes in system design or the identification of
additional testing requirements.
(4) The Engineer shall have the facilities for monitoring all tests and have access to all testing
records. Ample time shall be allowed within the testing programmes for necessary
alterations to equipment, systems and designs to be undertaken, together with re-testing
prior to final commissioning.
(5) The Contractor is reminded that at some point, the High Voltage Power Supply system
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Construction
will be energised and the additional precautions for the safety of staff and co-ordination of
activities after power-on shall be anticipated.
(6) All costs associated with the Testing shall be borne by the Contractor, unless otherwise
specified, including the services of any specialised personnel or independent assessors.
The Contractor shall also bear any expenses incurred due to resetting caused by defects or
failure of equipment to meet the requirements of the Contract in the first instance.
(7) Unless a Notice is issued by the Engineer, the personnel engaged on testing shall be
independent of those directly engaged in the design or installation of the same equipment.
(8) All testing equipment shall carry an appropriate and valid calibration labels.
Batches, Samples and Specimens
(9) A batch of material is a specified quantity of the material that satisfies the specified
conditions. If one of the specified conditions is that the material is delivered to the Site at
the same time, then material delivered to the Site over a period of a few days may be
considered as part of the same batch if in the opinion of the Engineer there is sufficient
proof that the other specified conditions applying to the batch apply to all of the material
delivered over the period.
(10) A sample is a specified quantity of material that is taken from a batch for testing and which
consists of a specified amount, or a specified number of pieces or units, of the material.
(11) A specimen is the portion of a sample that is to be tested.
Samples for Testing
(12) Samples shall be of sufficient size and in accordance with relevant Standards to carry out
all specified tests.
(13) Unless agreed otherwise by the Engineer samples taken on the Site shall be selected by, or
taken in the presence of; the Engineer and shall be suitably marked for their identification.
An identification marking system should be evolved at the start of works in consultation
with the Engineer.
(14) Samples shall be protected, handled and stored in such a manner that they are not damaged
or contaminated and such that the properties of the sample do not change.
(15) Samples shall be delivered by the Contractor, under the supervision of the Engineer, to the
specified place of testing. Samples on which non-destructive tests have been carried out
shall be collected from the place of testing after testing and delivered to the Site or other
locations instructed by the Engineer.
(16) Samples which have been tested may be incorporated in the Permanent Works provided
that:
(a) the sample complies with the specified requirements;
(b) the sample is not damaged; and
(c) the sample is not required to be retained under any other provision of the Contract.
(17) Additional samples shall be provided for testing if in the opinion of the Engineer:
(a) material previously tested no longer complies with the specified requirements; or
(b) material has been handled or stored in such a manner that it may not comply with the
specified requirements.
Testing
(18) The Contractor shall be responsible for all on-site and off-site testing and for all in-situ
testing. All appropriate laboratory tests shall be carried out in the Contractor's laboratory,
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unless otherwise permitted or required by the Engineer. Where the laboratory is not
appropriately equipped and/or staffed for some tests, or if a Notice has been issued by the
Engineer, tests may be carried out in other laboratories provided that:
(a) they are accredited for the relevant work to a standard acceptable to the Engineer; and
(b) particulars of the proposed laboratory are submitted to the Engineer for a Notice.
(19) Unless agreed otherwise by the Engineer in-situ tests shall be done in the presence of the
Engineer.
(20) Equipment, apparatus and materials for in-situ tests and laboratory compliance tests carried
out by the Contractor shall be provided by the Contractor. The equipment and apparatus
shall be maintained by the Contractor and shall be calibrated before the testing starts and
at regular intervals as permitted by the Engineer. The equipment, apparatus and materials
for in-the situ tests shall be removed by the Contractor as soon as practicable after the
testing is complete.
(21) The Contractor shall be entitled in all cases to attend the testing carried out in the
Employer's or other laboratories, to inspect the calibration certificates of the testing
machines and to undertake the testing on counterpart samples. Testing of such samples
shall be undertaken in laboratories complying with Clause D12(18) above and particulars
of the laboratory proposed shall be submitted to the Engineer for his Notice of No
Objection prior to the testing.
(22) Attendance on tests, including that by the Engineer, Contractor and Designer, shall be as
laid down in the Quality Assurance procedures.
Compliance of Batch
(23) The results of tests on samples or specimens shall be considered to represent the whole
batch from which the sample was taken.
(24) A batch shall be considered as complying with the specified requirements for a material if
the results of specific tests for the specified properties comply with the specified
requirements for the properties.
(25) If additional tests are permitted or required by the Engineer but separate compliance
criteria for the additional tests are not stated in the Contract, the Engineer shall determine
if the batch complies with the specified requirements for the material on the basis of the
results of all tests, including the additional tests, for every property.
Records of Tests
(26) Records of in-situ tests and laboratory compliance tests carried out by the Contractor shall
be kept by the Contractor on the Site and a report shall be submitted to the Engineer within
seven (7) days, or such other time stated in the Contract or in the Quality Assurance
Programme, after completion of each test. In addition to any other requirements, the report
shall contain the following details:
(a) material or part of the Works tested;
(b) location of the batch from which the samples were taken or location of the part of the
Works;
(c) place of testing;
(d) date and time of tests;
(e) weather conditions in the case of in-situ tests;
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(f) technical personnel supervising or carrying out the tests;

(g) size and description of samples and specimens;
(h) method of sampling;
(i) properties tested;
(j) method of testing;
(k) readings and measurements taken during the tests;
(l) test results, including any calculations and graphs;
(m) specified acceptance criteria; and
(n) other details stated in the Contract.
(27) Reports of tests shall be signed by the Project Manager or his assistant, or by another
representative authorised by the Contractor.
(28) If requested, records of tests carried out by the Employer's staff or by the Engineer shall
be given to the Contractor.
PRODUCTION TESTS (AT FACTORY)
(29) Should the Works include any equipment not previously proven in service the Contractor
shall undertake a thorough testing of the same at pre-production stage to the satisfaction
of the Engineer. The Contractor shall identify any equipment in this category, or equipment
that differs significantly from that already in service elsewhere.
(30) All materials, components, sub-assemblies, unit assemblies (including software, cables
and wiring) shall be subject to testing and certification. Notification .of these tests shall be
submitted to the Engineer thirty (30) days in advance of carrying out any tests, The
Engineer will then determine which items, if any, may be accepted based on previous
supply or experience.
(31) Factory Tests shall include but not be limited to:
• Physical inspection
• Dimension check
• Electrical check
• Calibration
• Output check
• Operational performance
• Full Load test
• Flash-over test
• Insulation test
• Soak test
• Non-destructive test to assess integrity or strength of parts
(32) Where processor based equipment is to be used then the Manufacturing Test shall include
also verification of software used in this application.
POST INSTALLATION TESTS (ON SITE)
(33) During and on completion of the installation, the Contractor shall undertake testing of all
cables, wiring and equipment, instrumentation and protection devices, in a progressive
sequence and in accordance with the overall testing programme. These tests shall
culminate in functional tests to verify the correct operation of all apparatus and, where
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appropriate, correct response to the respective control commands or monitored function.

(34) Following satisfactory completion of these Tests, the Contractor shall prepare the
installation for official demonstration in the presence of the Engineer.
ACCEPTANCE TESTS
(35) The Contractor shall prepare and organise a comprehensive programme of acceptance
Tests to demonstrate to the Engineer that all systems, sub-systems and apparatus defined
under the Contract meet the specified performance requirements in all respects.
(36) These Tests shall be conducted by the Contractor in the presence of the Engineer.
INTEGRATED SYSTEM TESTS
(37) The Contractor shall submit to the Engineer requirements and procedures, in respect of the
Contractor's scope of work for Integrated System Tests in conjunction with the Interfacing
Contractors to demonstrate that the complete system provided under the Contract is fully
operational and meets the specified performance criteria. The conducting of these
Integrated System Tests, by the Contractor and the Interfacing Contractors, shall include a
period of Test running.
TRIAL RUNNING
(38) Following satisfactory completion of the acceptance Tests and the Integrated System Test
the Employer will commence an extended period of trial running to prove all technical
systems in time table operation, to the satisfaction of the CRS, and to allow all technical
systems to settle and to train staff in working procedures.
(39) The Contractor shall allow for attendance in respect of the Contractor's scope of work over
the whole of this period, which may be expected including maintenance and repair
activities and also further opportunity for technical staff training.
D13 RECORDS
Drawings Produced by the Contractor
(1) Drawings produced by the Contractor including drawings of site layouts, Temporary Works,
etc., for submission to the Engineer shall generally be to ISO A1 size. They shall display a
title block showing the information detailed in Appendix 7 of this Part-2 . The number of
copies to be submitted to the Engineer shall be as stated in the Contract, or as required by
Engineer.
Progress Photographs
(2) The Contractor shall provide monthly progress photographs which have been properly
recorded to show the progress of the works to the Engineer. The photographs shall be digital
and taken on locations agreed with the Engineer to record the exact progress of the Works.
The number and size shall be as required in Appendix 5 of this Part-2 .
(3) The Contractor shall mount each set of each month's progress photographs in a separate
album of a type to which the Engineer has given a Notice, and shall provide for each
photograph two typed self-adhesive labels, one of which shall be mounted immediately
below the photograph and one on the back of the photograph. Each label shall record the
information detailed in Appendix 5 of this Employer’s Requirements.
(4) All photographs shall be taken by a skilled photographer using a digital single-lens reflex
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camera of at least 20 megapixels, whose name and experience shall be submitted to the
Engineer for his Notice of No Objection. Processing shall be carried out by a competent
processing firm to the satisfaction of the Engineer.
(5) The Contractor shall ensure that no other photography is permitted on the Site without a
Notice from the Engineer. The Contractor should be aware of the local regulations and
conditions with regard to Photography in some “RESTRICTED AREAS’ in Chennai.
Records of Wage Rates
(6) The Contractor shall keep monthly records of the average, high and low wage rates for each
trade/tradesman employed on the Site and records shall be made available to the Engineer
during inspection.
D14 MATERIALS
(1) Materials and goods for inclusion in the Permanent Works shall be new unless the Engineer
has issued a Notice otherwise. Preference shall be given to local materials where available.
These materials shall be procured only from approved Manufacturers/Suppliers.
(2) Certificates of tests by manufacturers which are to be submitted to the Engineer shall be
current and shall relate to the batch of material delivered to the Site. Certified true copies of
certificates may be submitted if the original certificates could not be obtained from the
manufacturer.
(3) Parts of materials which are to be assembled on the Site shall be marked to identify the
different parts.
(4) Materials which are specified by means of trade or proprietary names may be substituted by
materials from a different manufacturer which have received a Notice from the Engineer,
provided that the materials are of the same or better quality and comply with the specified
requirements.
(5) Samples of materials submitted to the Engineer for information or Notice shall be kept on
the Site by the Contractor in a secure dry storage room and shall not be returned to the
Contractor or used in the Permanent Works unless the Engineer has issued a Notice of No
Objection. The samples shall be used as a means of comparison which the Engineer shall
use to determine the quality of the materials subsequently delivered. Materials delivered to
the Site for use in the Permanent Works shall be of the same or better quality as the samples
which have received a Notice.
Provision of Earthworks Material and Disposal including Waste
(6) The Contractor shall be responsible for the provision of all classes of earthworks material
required for the Works, whether sourced from the excavations within the Contract or
obtained from any other sources, which are located outside the Site, for which the Engineer
has given a Notice. A Notice of No Objection will only be given after the Contractor has
provided evidence that the Contractor is legally authorized to extract material from the
source.
(7) For fill or dumping sites, the Contractor shall prepare a land plan with details of surface
drainage requirements, final formation levels, spreading and compaction of the fill during
dumping acceptable to the Engineer. The Contractor shall also provide security for such
sites. The dumping sites to be used by the Contractor shall be identified and provided by the
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Construction
Contractor and with the approval of the relevant authorities and having obtained a Notice
from the Engineer.
(8) All excavated material, excluding waste material, bentonite fluid and bentonite
contaminated material shall be disposed of at appointed sites only. This material shall be
placed and compacted in accordance with the Construction Specification for Earth Works
or as otherwise directed by the Engineer's Representative.
(9) The disposal of waste material, bentonite fluid and material contaminated with bentonite
shall be the full responsibility of the Contractor and these materials shall be disposed of by
the Contractor in a location approved by relevant authorities. The dumping sites provided
by the Employer shall not be used for disposal of waste material, bentonite fluid or material
contaminated with bentonite.
D15 PROVISIONS FOR INTERFACING CONTRACTORS
(1) The Contractor shall carry out all reasonable civil, structural and building works necessary
for the project as required by the Interfacing Contractors. These works shall include, but not
be limited to, forming holes, casting plinths and trenches, casting in components and forming
holes in pre-cast elements, etc...
(2) The Contractor shall make all reasonable provisions to accommodate the fastenings, fittings
and fixings of the Interfacing Contractors. Such provisions will be notified by the Interfacing
Contractors and the Engineer during interface. The interface responsibilities of the
Contractor and the Interfacing Contractors are identified at Appendix 19 of this Part-2
(Revised).
(3) The Contractor shall provide power, water, electric lighting, etc.to a standard which shall
facilitate safe working conditions for his works and works by the Interfacing Contractors.
(4) The Employer and Engineer will hold Project Quarterly Review Meetings at three monthly
intervals. The Contractor shall attend these QRM and shall report the progress of his works
and the state of his interface with other Interfacing Contractors and shall provide the
Engineer with the necessary assistance and information for conducting the QRM. Refer to
Clause A18 of Section A of these Employer’s Requirements.
D16 RESTORATION OF AREAS DISTURBED BY CONSTRUCTION

1) Unless otherwise directed by the Engineer, any areas disturbed by the construction activity,
either inside or outside the Project Right of Way or Site Areas, shall be reinstated as follows:
a) All areas affected by the construction work shall be reinstated to their original
condition, or better, with new materials, including but not necessarily limited to,
sidewalks, parking lots, access roads, adjacent roads, adjacent properties and
landscaping. Grass cover shall be provided for any bare earth surface areas, along with
proper provisions for surface drainage.
D17 TUNNEL BORING MACHINES

The Contractor shall deploy Four number of Tunnel Boring Machines complete with all back-
up equipment and spares to compete the Works within the Key Dates and completion time.
1) Out of which a minimum of 2 new TBM’s has to be sourced from Japan
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Construction
2) The other 2 Tunnel Boring Machine shall be either

a) New machine: or
b) Remanufacturing type.
The Remanufacturing type machines shall be as a minimum in accordance with ITAtech Report
No.5-V2- "Guidelines on Rebuilds of Machinery for Mechanized Tunnel Excavations”.
The Refurbishment type machines referred in the above said Report shall not be allowed.
The Remanufacturing machines shall be OEM certified, and OEM Certificate shall not
be more than one month old.
Reference may be made to https://about.ita-aites.org/wg-
committees/itatech/publications/1702/itatech-guidelines-on-rebuilds-of-machinery-for-
mechanized-tunnel-excavation
The Tunnel Boring Machines should have, as a minimum, the following facilities:
General
(1) Tunnel shields supplied by the Contractor shall be truly circular, strong enough to avoid
distortion during driving, and suitable for building the tunnel linings as shown on the
Contract Drawings.
(2) The Contractor shall supply, erect, drive, maintain, dismantle and remove the shields, which
shall remain the property of the Contractor upon completion.
(3) The machine design shall make adequate provision for the safety of the workmen and the
application of safe methods of tunnelling.
(4) The machines shall be shop manufactured in units of convenient size, suitable for field
erection, dismantling and reassemble under the site conditions of the Contract.
(5) The machines shall be of suitable design, capable of efficient excavation and installation of
support, meeting the desired requirements for expected geological, site, ground and hydro-
geological conditions and Contract time schedules. For example, the cutter drive system
shall be equipped with appropriate power for delivering the required rotational torque and
rotational speed of the cutter head and the cutter head having an appropriate housing
arrangement for disk cutters/picks etc.
(6) The machines shall be equipped with shove rams of sufficient capacity to move it through
all materials encountered, to the lines and grades shown. The rams shall be capable of
simultaneous and individual actuation, controllable individual pressure and variable
extension.
(7) Rams shall be fitted with proper shoes so placed that the reaction of the rams will be safely
distributed against the tunnel linings.
(8) The machines shall be equipped with a tunnel lining erector system capable of placing each
lining segment safely into its final position along the periphery of the ring being erected.
(9) The machine design shall permit removal of the structure from within the skin that may be
left in place at the completion of the tunnel drive.
(10) During the tunnelling operation, the Contractor shall provide and maintain CCTV systems
with 2 cameras placed strategically within the tunnels. The CCTV system shall be linked to
21 December 2021
Construction
the office of the Engineer and the 2 cameras shall move in tandem with the shield.
(11) Hand held extinguishers should be sited at suitable locations on the shield and the shield
back up.
(12) The Contractor shall use a hydraulic oil in the machines which will minimise to the utmost
the risk of an oil fire.
(13) The Contractor shall provide a backup power supply system for tunnelling machines and
emergency case hydraulic pressure control systems.
(14) Where slurry system TBMs are proposed, the slurry treatment plant shall be designed such
that the residual soil after treatment is suitable for filling and compaction in accordance with
the Earthworks section of the Construction Specifications.
Design Requirements - TBM and Closed Face Machines
(15) The cutter head of TBM and closed face machines shall be capable of clockwise and
anticlockwise rotation and shall only be able to excavate the ground whilst the hydraulic
rams are being actuated. The design of the machine shall ensure that the cutter head can be
retracted back from the unexcavated ground to minimise the risk of the machine jamming
and to facilitate maintenance.
(16) The cutting head discs/picks shall be able to be renewed from the rear of the cutter head and
be interchangeable.
(17) Where boulders could occur on the tunnel face, the machine head shall permit a minimum
300 mm boulder to be pushed through the cutter head. The machine shall have the capability
to handle, break up as required and remove such boulders through the screw conveyor or
slurry discharge aperture without special procedures.
(18) The machine tail-skin shall be fitted with an adequate tail seal to prevent the ingress of water
and/or grout. The tail seals shall be replaceable from within the tunnel. A grout seal, located
at the rear of the tail shield, shall be considered to limit grout migration along the shield
towards the cutter head.
(19) The machine shall be designed to allow forward drilling through the cutter head for the
purpose of probing ground conditions and to carry out ground treatment to the face.
(20) The machines shall be designed to enable the void behind the segments to be grouted from
the shield continuously as the shield is propelled forward by synchronise operation. The
design shall enable the control of the grouting volume and pressure, and for the pipes to be
cleaned in the event of a blockage. Grout pipes shall be integral within the thickness of the
tail skin and a minimum of 4 separate pipes shall be provided. External grout pipes will not
be permitted.
(21) Provisions shall be made throughout the length of the machine and back up facilities for the
detection and automatic suppression of fires. The system shall be maintained in an efficient
operating condition at all times.
(22) All closed face machines shall be designed to maintain pressure on the excavated ground at
all times. The pressure shall at least balance the insitu soil and hydraulic pressures making
up the total overburden pressure and shall be capable of varying the face pressure as the
overburden pressure changes. The design shall also take into account the soil type, density,
22 December 2021
Construction
gradation, strength and abrasion. A minimum of six (6) pressure sensors shall be provided
at the bulkhead and three (3) at the screw conveyor.
(23) Slurry and EPB Machines shall be designed for and equipped with a supplemental ground
stabilisation system. This system shall comprise regularly spaced grout ports built into the
shield for grouting the ground ahead of the tunnel face. The location and number of ports
shall be adequate for implementation of face stabilisation measures needed for access to the
face in all ground conditions. All ports shall be readily accessible and fitted with valves.
(24) All closed face machines shall incorporate a two-compartment air lock for man access to the
cutter head and face. A complete compressed air installation, including compressor, chiller
and medical lock shall also be provided and commissioned prior to the commencement of
tunnelling in soft ground. Work carried out under compressed air condition shall comply
with international standards and local safety regulations.
(25) An independent backup system of closing the gate to the screw conveyor shall be provided
in case of hydraulic failure.
(26) The machine operation panel shall monitor and where appropriate control the following:
a) Forward thrust.
b) Ram pressure and location used.
c) Main bearing grease and oil lubrication pressure flow and temperature.
d) Alignment and attitude of shield and segment
e) Electrical load characteristic and supply source
Depending on the type of machine chosen the following items shall be monitored:
f) Face pressure
g) Slurry pressure, gravity and flow rates
h) Earth pressure in the screw conveyor and opening ratio of gate.
i) Compressed air pressure in module.
j) Volume of soil removed correlated with forward advance of the shield.
The Engineer (one from GC and one from Employer) may inspect the fabrication of Tunnel
Boring Machine and witness factory testing at the offshore location(s). The cost for all
necessary assistance to facilitate the inspection and witnessing of tests, including
accommodation, flights, visas, permits, lodging, etc. associated with these visits will be paid by
the Contractor.
(27) The contractor is further advised to refer tunnelling related sections of Outline Construction
Specifications for more details regarding the subject.
D18 SUBWAYS
DELETED
D19 DEMOLITION OF EXISTING STRUCTURES
23 December 2021
Construction
1) The contractor shall be provided the site areas free of legal encumbrances to access,
fencing and the undertaking of the works. The works shall include the demolition of all
structures necessary for the constructions of the stations, tunnels and ancillary
structures required by the contract documents. The structures to be demolished include
buildings, boundary walls, water sumps, water wells, nus stops etc. The buildings to be
demolished include, but are not necessarily limited to, those listed in Building Survey
reports in Volume 4.
2) The contractor shall be responsible for obtaining necessary permits and approvals for
undertaking the demolition works. These will require the contractor to undertake a
structural inspection of all structures and prepare a demolition method statement. This
report shall detail the protective hoarding works required prior to the commencement
of the demolition, the sequence of demolition and any temporary strengthening/
protective works required to be added to the structures during the demolition. The
contractor should pay particular attention to the demolition of cantilevered structures,
3) The contractor shall ensure that all utilities, drainage and sewerage are properly
disconnected before commencing demolition.
4) Foundations and underground structures of the existing structures should be broken
down to 2 m below ground level, and voids under this level are to be filled with suitable
compacted material.
5) Where indicated on the Drawings in Volume 4 the Contractor shall partially demolish,
or slice, existing buildings to approximately the line shown. The slice works shall
include the demolition of part of the building and temporary sealing of the remaining
portion of the building. The final reinstatement of the remaining building shall be
undertaken by others. The exact slice line shall be as determined by the Contractor to
suit the structural system and functional requirements of the existing and sliced
building. The first step of the splicing works shall be a structural and functional survey
of the existing building to determine structural limits of the slicing and what
modifications are required to ensure functional, including normal and emergency
access, drainage and utilities operation of the building. Preferably the remaining
portions of the building should remain in operation during the slicing, but where this is
proven to be not possible the Employer will arrange the temporary vacation of the
building. The Contractor shall prepare a slicing method statement including detailed
proposals for the temporary and permanent works required. The works shall include
temporary protection hoardings, demolition works, new building sealing works. The
permanent reinstatement shall be done by others.
D20 REINSTATEMENT OF EXTERNAL AREAS
(1) The Contractor shall reinstate the external areas as affected by the works to same
condition as at the date of hand over except where shown differently in the intermodal
drawings for each station in Volume 4 or elsewhere in the Contract Document. The extent
of reinstatement shall be at least 150m in all directions from the edge of the station, tunnel
or shaft structure. At the commencement of Works the Contractor shall take an inventory
of affected features including a photographic/video record covering the area that will be
affected which shall be submitted to the Engineer for Notice. The details of the
reinstatement works shall be agreed with the appropriate Authorities and receive a Notice
from the Engineer before the reinstatement works commence.
(2) Reinstatement works shall include;
24 December 2021
Construction
i. Road, footpath and landscape area pavements,

ii. Kerbs, medians, railings, safety rails and other road furniture,
iii. Road signage,
iv. Road marking,
v. Traffic lights,
vi. Street lighting,
vii. Bus stops,
viii. Hard Landscaping including furniture,
ix. Soft Landscaping, and
x. Boundary walls.
(3) Except where shown otherwise the reinstatement of the following are not included in the
Works;
a. Buildings,
b. Water wells,
c. Water sumps and
d. Trees
(4) Contractor should provide assistance to others to transplant or reinstate trees within the
works area.
25 December 2021
Construction
ATTACHMENT D1
CONTRACTOR’S LABOUR CAMP
1. EMPLOYER WILL NOT PROVIDE QUARTERS FOR CONTRACTOR’S LABOUR
The Employer will not provide living accommodation for the use of the Contractor or any of
his staff or labour employed on the Works. Living accommodation shall not be established on
any land provided to the Contractor by the Employer.
2. PROVISION OF LABOUR CAMP
If necessary the Contractor, shall, at his own expense, make adequate arrangements for the
housing, supply of drinking water and provision of bathrooms, latrines and urinals, with
adequate water supply, for his staff and workmen directly or through Sub-contractors
employed on the Works at the location authorised by the Engineer. No labour camp shall be
allowed at any work site or any unauthorised place.
The Contractor at his own cost shall maintain all campsites in a clean and sanitary condition.
The Contractor shall obey all health and sanitary rules and regulations, and carry out at his
cost all health and sanitary measures that may from time to time be prescribed by the
Local/Medical Authorities and permit inspection of all health and sanitary arrangements at all
times by the Employer, Engineer and the staff of the local municipality or other Authorities
concerned. Should the Contractor fail to provide adequate health and sanitary arrangements
these may be provided by the Employer and the cost recovered from the Contractor.
The Contractor shall at his own cost, provide First Aid and Medical facilities at the Labour
Camp and at work sites on the advice of the Medical Authority in relation to the experience,
and number of the Contractor’s staff and workmen, employed directly or through Sub-
contractors.
The Contractor shall at his own cost, provide the following minimum requirements for fire
precautions:
• Portable Fire Extinguishers.
• Manual Fire Alarms.
• Water Supply for use by the Fire Service.
The Contractor at his own cost shall provide necessary arrangements for keeping the camp
area sufficiently illuminated to avoid accidents to the workers. He should also ensure that
electrical installations are done by Trained Electricians. These installations shall be
maintained and daily maintenance records must be made available for inspection of the
Engineer.
3. CAMP DISCIPLINE
The Contractor shall take requisite precautions, and use his best endeavours to prevent any
riotous or unlawful behaviour by or amongst his workmen, and others, employed directly or
through Sub-contractors. These precautions shall be for the preservation of the peace and
protection of the inhabitants and security of property in the neighbourhood of the Works. In
the event of the Employer requiring the maintenance of a Special Police Force at or in the
vicinity of the site, during the tenure of the work, the expenses thereof shall be borne by the
Contractor and if paid by the Employer, shall be recoverable from the Contractor.
26 December 2021
Construction
The sale of alcoholic drinks or other intoxicating drugs or beverages upon the work, in any
labour camp, or in any of the buildings, encampments or tenements owned or occupied by, or
within the control of, the Contractor or any of his employees directly or through Sub-
contractors employed on the work, shall be forbidden, and the Contractor shall exercise his
influence and authority to secure strict compliance with this condition. The Contractor shall
also ensure that no labour or employees are permitted to work at the site in an intoxicated state
or under the influence of drugs.
The Contractor shall remove from his camp such labour and their families, who refuse to
accept protective inoculation and vaccination when called upon by the Medical Authority.
Should Cholera, Plague or any other infectious disease break out, the Contractor shall at his
own cost burn the huts, bedding, clothes and other belongings of, or used by, the infected
parties. The Contractor shall promptly erect new huts on healthy sites as required by the
Employer, within the time specified by the Employer, failing which the work may be done by
the Employer and the cost recovered from the Contractor.
4. LABOUR ACCOMMODATION
The Contractor shall provide living accommodation that is equal to or exceeds the minimum
criteria established in the following sub-sections, needed to house his staff, workers
employed directly or through Sub-contractors. The buildings shall be constructed so as to
have a minimum life of not less than the length of the Contract.
(a) The roofs shall be watertight and laid with suitable non-flammable materials
permissible for residential use under local regulations and for which a Notice from the
Engineer has been obtained.
(b) Each hut shall have suitable ventilation. All doors, windows, and ventilators shall be
provided with security leaves and fasteners. Back to back units must be avoided.
(c) The minimum height of each unit shall be 2.10m and shall have separate cooking place.
(d) Suitable number of common toilets/bath facilities shall be provided.
5. WATER SUPPLY
The Contractor shall provide an adequate supply of water for the use of labourers in the Camp.
The provision shall not be less than two gallons of pure and wholesome potable water per
head per day for drinking purposes and three gallons of clean water per head per day for
bathing and washing purposes. Where piped water supply is available, supply shall be at stand
posts and where the supply is from wells or river, tanks of plastic, metal or masonry shall be
provided. The Contractor shall also at his expense make arrangements for the provision and
laying of water pipelines from the existing mains wherever available and shall pay for all the
fees and charges therefore.
6. DRAINAGE
The Contractor shall provide efficient arrangements for draining away spillage water so as to
keep the camp neat and tidy. Surface water shall be drained away from paths and roads and
shall not be allowed to accumulate into ditches or ponds where mosquitoes can breed.
7. SANITATION
The Contractor shall make arrangements for conservancy and sanitation in the labour camps
according to the rules and regulations of the Local Public Health and Medical Authorities.
27 December 2021
Construction
The Contractor shall provide a sewage system that is adequate for the number of residents in
the camp, and which meets the requirements of the Municipality Authority
28 December 2021
Construction

TERMINUS AND NATHAMUNI (VILLIVAKKAM MTH ROAD)
WITH ENTRY / EXIT, VENTILATION SHAFTS, PLUMBING,
EARTHMAT, ARCHITECTURAL FINISHES & SIGNAGES ETC.
INCLUDING TWIN BORED TUNNELS FROM KOLATHUR
JUNCTION RETRIEVAL SHAFT TO NATHAMUNI
(VILLIVAKKAM MTH ROAD) LAUNCHING SHAFT AND
RAMPS WITH U - SECTION IN CORRIDOR-5 OF CMRL
PHASE-II PROJECT”
PART-2
SECTION VI
SUB-SECTION E
APPENDICIES – 1 TO 19
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5. Part-2- Section VI

TABLE OF CONTENTS
LIST OF APPENDICES
APPENDIX 1 - DRAWINGS 1A-1
APPENDIX 2A- WORKS AREAS 2A-1 to 2A-2
APPENDIX 2B- CONTRACT KEY DATES AND COMPLETION DATE 2B-1
APPENDIX 3 - PROJECT CALENDAR 3-1
APPENDIX 4 - PROGRAMME REQUIREMENTS 4-1 to 4-8
APPENDIX 5 - MONTHLY PROGRESS REPORTS 5-1 to 5- 5
APPENDIX 6 - QUALITY ASSURANCE 6-1 to 6-20
APPENDIX 7 - DRAUGHTING AND CAD STANDARDS 7-1 to 7-8
APPENDIX 8 - WORKS AREAS & TEMPORARY POWER SUPPLY 8-1 to 8-5
APPENDIX 9 - RAILWAY ENVELOPE ACCESS AND TAKING OVER 9-1 to 9-2
APPENDIX 10 - APPROVED MANUFACTURERS / SUPPLIERS 10-1
APPENDIX 11 - CURVE AND GRADIENT DETAILS 11-1
APPENDIX 12 - UTILITIES 12-1 to 12-3
APPENDIX 13 - SITE ACCOMMODATION FOR THE EMPLOYER’S REPRESENTATIVE 13-1 to 13-2
APPENDIX 14 - CONTRACTOR'S SITE LABORATORY 14-1 to 14-5
APPENDIX 15 - DESIGN CONSOLIDATION UNIT REQUIREMENT -DELETED-
APPENDIX 16 - EARTHING AND GRID 16-1 to 16-17
APPENDIX 17 - ADJACENT WORKS CONTRACTS 17-1
APPENDIX 18 - SCHEDULE OF DIMENSIONS 18-1 to -48
APPENDIX 19 - DESIGN AND CONSTRUCTION INTERFACE MANAGEMENT 19-1 to 19-19
Section VI – Appendices List i December 2021



PHASE-II PROJECT”
PART-2
SECTION VI
SUB-SECTION E
APPENDIX-1
DRAWINGS
DECEMBER 2021
Section VI – Appendix-1 Drawings 1-1 December 2021

PLEASE REFER SECTION VIII EMPLOYER’S DRAWING
Section VI – Appendix-1 Drawings 1-1 December 2021


PHASE-II PROJECT”
PART-2
SECTION VI
SUB-SECTION E
APPENDIX-2A
WORKS AREAS
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5. Part-2- Section –VI
WORKS AREAS
(1) The Site and works Areas will be made available to the Contractor at different times. These Site
and works Areas are illustrated in the Employer’s Drawings
Refer Part 2, Section VIII – Employer’s Drawings
(2) The Employer may, however, give to the Contractor access to portions of the Site and works
Areas earlier than the time stated and the Contractor shall accept them. The Contractor shall
not be entitled to any additional payment for early access of any portion of the Site or works
Areas.
(3) The descriptions of the Site and Works Areas in this section are indicative and the Contractor
shall satisfy himself as to the exact nature of the various Site and works Areas and the extent of
works to be carried out prior to the execution of the Permanent Works or making use of the area
as working space and/or for temporary site facilities.
(4) The Contractor shall submit to the Employer’s Representative for a notice of no objection, a
written proposal for the use and occupation of these Site and works Areas at least 6 weeks prior
to the programmed use of the requested areas. The availability of Site and works Areas will
only be permitted for the actual duration of the permanent and temporary works within the
particular Site and works Areas. The Contractor shall comply with the Employer’s
Requirements as stated in Appendix 8 of this Volume 1 regarding the use of the Site and works
Areas.
(5) The Contractor is deemed to have acquainted himself with the actual location and conditions of
the Site and allow for any contingency with regard to the means of access and any special Site
restrictions including the requirement to reinstate all works disturbed or damaged to match with
the existing.
(6) Wherever full buildings are to be demolished the existing electricity, water and sewage
connection of the building should be properly disconnected by the Contractor in co-ordination
with the concerned departments. For buildings which are to sliced the existing utility
connections shall be suitably rearranged / relocated in co-ordination with concerned
departments.
(7) The Contractor shall propose controlled access points to the Site and works Areas from the
existing roads in different periods for a notice from the Employer’s Representative. The
Contractor shall not construct any temporary roadways which may be necessary to afford
access to his Site and working Areas without a prior notice from the Employer’s
Representative.
(8) The Contractor shall ensure that all approved accesses shall not impose any constraints and
hazard to existing establishments or to other works by Interfacing Contractors. If such accesses
are required to be relocated, deleted or closed as may be directed by the Employer’s
Representative, the Contractor shall do so at his own costs and time.
(9) The Contractor shall maintain at all times all existing roads, road traffic, road accesses, traffic
junctions, pedestrian routes and access to existing buildings within the Site and works Areas
during all stages of the traffic diversion schemes he may propose for the execution of the Works.
The Contractor shall submit his proposal, for a notice from the Employer’s Representative,
after having received approval from all Relevant Authorities, for the provision of temporary
accesses required at any existing building(s) to ensure continuation of access for the public and
to facilitate construction of the Works.
(10) Unless otherwise noted, the Contractor shall protect all existing buildings and structures, either
Section -VI – Appendix 2A- Work Areas 2A-1 December 2021

located within or adjacent to, the Site and works Areas to the satisfaction of the Employer’s
Representative.
(11) Work areas failing under the Road Right of Way which includes Road and footpaths shall be
accessed for work by the Contractor after obtaining necessary permission from the Regulatory
Authorities including Traffic Police Department.
(12) If any land and/or right of way, other than the Site and works Areas shown on the Employer’s
Drawings, is required by the Contractor for the purpose of the execution of the Works, such as
for temporary diversion, ground treatment, storage, site offices for the Contractor or the
Employer’s Representative, etc... the same shall be arranged by the Contractor at his own risk
and cost. The Employer where feasible may at his discretion assist the Contractor in this
respect.
(13) Schedule of Site Access Dates:
The table below sets out the earliest access dates when Site Areas are available together with
the dates by which they must be vacated. The Contractor shall take these dates into account in
his Works Programme.
Access Date from date of Vacate Date from date of

Location / Drawing commencement commencement
reference
No. of Days No. of Days
Kolathur Junction Station

KLR - 01 Date of commencement 1260
KLR – 02 180 1260
KLR – 03 180 1260
KLR – 04 180 1260
Srinivasa Nagar Station
SNV – 01 90 1380
SNV – 02 90 1380
SNV – 03 90 1380
SNV – 04 90 1380
SNV – 05 90 1380
SNV – 06 90 1380
SNV – 07 90 1380
SNV – 08 90 1380
SNV – 09 90 1380
SNV – 10 Date of commencement 1380

SNV – 15 180 1380

Villivakkam Sub-urban Station
VVM – 01 Date of commencement 1395
Villivakkam Bus Terminus Station
VBT – 01 Date of commencement 1260
VBT – 02 120 1260
VBT – 03 90 1260
VBT – 04 120 1260
VBT – 05 90 1260
VBT – 06 120 1260
Nathamuni Station
NTM – 01 Date of commencement 1360
NTM – 02 180 1360
NTM – 03 180 1360
NTM – 04 180 1360
NTM – 05 180 1360
NTM – 06 180 1360
NTM – 07 180 1360
NTM – 08 180 1360
NTM – 09 180 1360
NTM – 10 180 1360
Launching Shaft between
Nathamuni Station and
90 890
Anna Nagar Station and ‘U’
Ramp
Retrieval Shaft between
Kolathur and Retteri and 120 965
‘U’ Ramp


VENTILATION SHAFTS, PLUMBING, EARTHMAT, ARCHITECTURAL
FINISHES & SIGNAGES ETC. INCLUDING TWIN BORED TUNNELS
FROM KOLATHUR JUNCTION RETRIEVAL SHAFT TO NATHAMUNI
(VILLIVAKKAM MTH ROAD) LAUNCHING SHAFT AND RAMPS WITH
U - SECTION IN CORRIDOR-5 OF CMRL PHASE-II PROJECT”
PART – 2
SECTION VI
APPENDIX-2B
CONTRACT KEY DATES AND COMPLETION

DATE
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5 Part -2, Section VI
Appendix 2B - Contract Key Dates and Completion date

1. Key Dates
1.1 Construction Key Dates
Calendar days
Liquidated Damage
Key Date No. Key Date Description from date of
Amount
Commencement
Completion of setting up of Employer’s
KD-UG6-01 60 INR 1 Lakh / Day
Office Establishment
Submission of Detailed Work Programme
with all activities for the entire Work and
Completion of Utilities Surveys and Site
Surveys
Casting of 1000mm mm thick Station
Diaphragm Wall first panel in three
Stations
Completion of casting yard and casting

first tunnel segment
KD-UG6-05 Completion of All Major utility diversion 370 INR 1 Lakh / Day
works in all stations
Completion of 100% of Diaphragm Wall of

all Stations, entrances, Shafts & Ramps
KD-UG6-07 Base Slab Completion for all Stations 1020 INR 1 Lakh / Day
Completion of all tunnelling works

KD-UG6-08 between Retteri Ramp and Nathamuni 1080 INR 1 Lakh / Day
Ramp
Completion of overall Station Structures

including Street Level, Entry / Exits,
0.1 % of Contract
KD-UG6-09 Architectural Finishes for all stations and 1395
Price / Day
achieve issuance of Taking Over
Certificate
Section VI - Appendix -2B 2B - 1 December 2021

Contract Key Dates and Completion date
1.2 Key Dates – Access to Interface Contractors

Calendar days from date of
Commencement Liquidated
Key Date No. Key Date Description Damage
Any one of the All Amount
Station station
Provide Access to
INR 50,000 /Day
KD-UG6-10 Architectural Provisional 970 1155
for each Station
Sum Contractor
Provide Access to all
INR 50,000 /Day
KD-UG6-11 Station rooms to MEP 1070 1255
for each Station
Contractor
Provide Access to all
Station rooms to TVS &
VAC, PS & OHE,
INR 50,000 /Day
KD-UG6-12 Signalling & Telecom, 1170 1335
for each Station
L&E,PSD & AFC
Contractors with
Degree-3 Completion
Note:
1) The Access provided shall be shared access and used by all the Contractors and as
coordinated by the Contractor without affecting their respective Works.
2) In addition to the above LD, the Contractor Shall be obliged to compensate any losses
incurred by the Employer due to claims by the Interfacing contractors on delayed access, and
the same shall be notified accordingly.

1.3 Kolathur Station Intermediate Key Dates

Intermediate Calendar days from
Key Date Intermediate Key Date Description date of
No. Commencement
Excavation and completion of roof slab (excluding construction
KD-KL-01 openings and launch shafts on either end of station) including 515
utility diversion
Completion of Diaphragm Walls of Main Station, Entry / Exits
KD-KL-02 555
and Vent Shafts
Completion of all entry exit structures, vent Shafts, fireman
KD-KL-03 Staircase etc (Including above ground structures) up to level 730
Degree-1
KD-KL-04 Excavation and 100% completion of base slab 800
KD-KL-05 Completion of all entry exit structures up to level Degree-3 930
Casting of 100% of internal structures between base slab and roof

KD-KL-06 1065
with level Degree-1 completion
Completion of all station rooms and Entry Exit with level

KD-KL-07 1260
Degree-4 finishes
Note:
The contractor shall consider all the intermediate key dates in the construction programme
1.4 Srinivasa Nagar Station Intermediate Key Dates

No. Commencement
KD-SN-01 openings and launch shafts on either end of station) including 485
utility diversion
Completion of Diaphragm Walls for Main Stations, Entry / Exits
KD-SN-02 525
and Vent Shafts
Completion of all entry exit structures, vent shafts, fireman
KD-SN-03 staircase etc (Including above ground structures) up to level 700
Degree-1
KD-SN-04 Excavation and 100% completion of base slab 770
KD-SN-05 Completion of all entry exit structures up to level Degree-3 900
Casting of 100% of internal structures between base slab and

KD-SN-06 1240
Roof slab with level Degree-1 completion.
Completion of all station rooms and all Entry Structures with

KD-SN-07 1380
level Degree-4 finishes
Note:

1.5 Villivakkam Sub-Urban Station Intermediate Key Dates

No. Commencement
KD-VM-01 openings and launch shafts on either end of station) including 507
utility diversion
Completion of Diaphragm Walls for Main stations, Entry / Exits
KD-VM-02 540
and Vent Shafts
Completion of all entry exist structures, vent shaft, fireman
KD-VM-03 staircase etc (Including above ground structures) up to level 715
Degree-1
KD-VM-04 Excavation and 100% completion of base slab 910
KD-VM-05 Completion of all entry structures up to level Degree-3 915
Casting of 100% of internal structures between base slab and roof

KD-VM-06 1255
slab with level Degree-1 completion
Completion of all station rooms and all Entry exits with level
KD-VM-07 1395
Degree-4 finishes
Note:
1.6 Villivakam Bus-Depot Station Intermediate Key Dates

No. Commencement
Completion of roof slab (excluding construction openings)
KD-VB-01 515
including utility diversion
Completion of Diaphragm Walls for Station Box, Entry / Exits
KD-VB-02 555
and Vent Shafts
KD-VB-03 Completion of Excavation and 100% casting of base slab 800
Completion of entry structures, vent shaft, fireman staircase etc

KD-VB-04 800
(Including above ground structures) up to level Degree-1
KD-VB-05 Completion of all Entry Structures up to level Degree-3 1000
Completion of 100% internal structures between base slab and

KD-VB-06 1070
roof slab with level Degree-1.
Completion of all station rooms and all Entry structures with

KD-VB-07 1260
Note:

1.7 Nathamuni Station Intermediate Key Dates

No. Commencement
Completion of Diaphragm Walls for Station Box ,Entry / Exits
KD-NT-01 670
and Vent Shafts
KD-NT-02 openings and retrieval shafts on either end of station) including 705
utility diversion
Completion of all entry structures, vent shaft, fireman staircase
KD-NT-03 850
etc (Including above ground structures) up to level Degree-1
KD-NT-04 Excavation and 100% completion of base slab 1020
KD-NT-05 Completion of all entry structures up to level Degree-3 1050
Completion of 100% of internal structures between base slab and

KD-NT-06 1220
roof slab with level Degree-1
Completion of all station rooms and all Entry structures with

KD-NT-07 1360
Note:

Key milestones for Station Rooms

Degree 1 Degree 2 Degree 3 Degree 4
Structure complete, Complete fixing Complete wall Complete wall, ceiling
clean, dry and all works brackets for pedestal for plastering and painting and floor finishes
area watertight and raised floor
weatherproof Complete raised floor, Louvres and grilles
Earthing and bonding and false flooring installed
Cast-in and concealed complete except for locations
components complete where panels have to be Installation of all
Contractor’s Equipment installed after signage complete
Movement and removed completion of works by
expansion joints the Interfacing Complete handrails,
installed Temporary power and Contractors balustrade and barriers
lighting available
Partition walls complete Complete internal All openings and
with penetrations and Suitable work and glazing service penetrations
plant delivery openings storage areas available sealed
formed for Interfacing Permanent doors and
Contractors ironmongery installed All works complete and
Plant plinths complete ready for testing and
and survey accepted Drainage system and Plumbing and Sanitary commissioning
discharge connection fittings complete and
Complete floor screed complete ready for testing
Complete permanent Survey reference lines

framing for doors, available
hatches, and other
openings Lift shaft alignment,
location of openings
Complete sealant for surveyed and accepted
ceiling and floor
Temporary safety
barrier at escalator
landings and all
openings
Note:
1) The achievement of a Degree of Completion shall require the completion of works for that
particular Degree of Completion and all preceding ones. The order of completion of the work
may have to be revised in consultation with other Contractors wherever necessary.

1.8 Bored Tunnel Intermediate Key Dates

Intermediate Calendar days Liquidated
Key Date Intermediate Key Date Description from date of Damage
No. Commencement Amount
Launching of TBM-1 from Kolathur Station INR 50,000
KD-TL-01 395
towards Srinivasa Nagar Station – T1L1 /Day
Launching of TBM-2 from Villivakam Sub-
INR 50,000
KD-TL-02 Urban Station towards Villivakam Bus 415
/Day
Terminus Station – T2L1
KD-TL-03 510
towards Srinivasa Nagar Station – T3L1 /Day
INR 50,000
KD-TL-04 Urban Station towards Villivakam Bus 530
/Day
Terminus Station – T4L1
Launching of TBM-2 from Villivakam Bus
INR 50,000
KD-TL-05 Terminus Station towards Nathamuni 605
/Day
Station– T2L2
KD-TL-06 665
towards Retteri Ramp – T1L2 /Day
Launching of TBM-4 from Villivakam Bus
INR 50,000
KD-TL-07 Terminus Station towards Nathamuni 720
/Day
Station– T4L2
KD-TL-08 780
towards Retteri Ramp – T3L2 /Day
INR 50,000
KD-TL-09 Urban Station towards Srinivasa Nagar 825
/Day
Station – T1L3
Launching of TBM-2 from Nathamuni Ramp INR 50,000
KD-TL-10 835
towards Nathamuni Station– T2L3 /Day
INR 50,000
KD-TL-11 Urban Station towards Srinivasa Nagar 940
/Day
Station – T3L3
Launching of TBM-4 from Nathamuni Ramp INR 50,000
KD-TL-12 950
towards Nathamuni Station– T4L3 /Day
U' section ramp near Kolathur Station to
Srinivasa Nagar Station (inclusive) - First INR 50,000
KD-TL-13 1065
stage concrete completion & handover to /Day
trackworks
Completion of Cross Passages in all respects
INR 50,000
KD-TL-14 in bored tunnel section from Kolathur 1110
/Day
Station to Nathamuni Station
U' section ramp near Nathamuni to
Villivakkam Sub-Urban Station - First stage INR 50,000
KD-TL-15 1130
concrete completion & handover to /Day
trackworks
Srinivasa Nagar Station to Villivakkam Sub-
Urban Station (inclusive) - First stage INR 50,000
KD-TL-16 1140
concrete completion & handover to /Day
trackworks contractor
Note:


JUNCTION RETRIEVAL SHAFT TO NATHAMUNI
(VILLIVAKKAM MTH ROAD) LAUNCHING SHAFT AND RAMPS
WITH U - SECTION IN CORRIDOR-5 OF CMRL PHASE-II
PROJECT”
PART-2
SECTION VI
SUB-SECTION E
APPENDIX-3
PROJECT CALENDAR
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5. Part-2 Section VI
TENDER No. CP06/UG06/RT01 Employer's Requirements
PROJECT CALENDAR
(1) The Project Week shall commence on a Monday. A day shall be deemed to commence at 00.01
hour on the morning of the day in question. Where reference is made to the completion of an
activity or Milestone by a particular week, this shall mean by midnight on the Sunday of that
week.
(2) Requirements for the computation of Key Dates are given in Appendix 2B to the Employer's
Requirements.
(3) A 7 day week calendar shall be adopted for various (Work) programme schedules for scheduling
purposes. Any non-work restriction shall be deemed to have been taken into account in the
calendar to plan and programme the Works.
(4) For Project purposes, the presentation shall be in ‘Week”’ units.
Section VI-Appendix 3 - Project Calendar 3-1 December 2021

“Construction of Underground Stations at Kolathur

Junction, Srinivasa Nagar, Villivakkam Sub-urban Station
(Villivakkam), Villivakkam Bus-Terminus and Nathamuni
(Villivakkam MTH Road) with Entry / Exit, Ventilation shafts,
Plumbing, Earthmat, Architectural finishes & Signages etc.
including Twin Bored Tunnels from Kolathur Junction
Retrieval Shaft to Nathamuni (Villivakkam MTH Road)
Launching Shaft and Ramps with U - section in Corridor-5 of
CMRL phase-II project”
PART-2
SECTION VI
EMPLOYER’S REQUIREMENT
SUB-SECTION E
APPENDIX – 4
PROGRAMME REQUIREMENTS
DECEMBER 2021
Part-2 - Section VI
Chennai Metro Rail Project Phase 2, Corridor 5.
Employer's Requirements
PROGRAMME REQUIREMENTS
1. GENERAL
(1) Purpose of Programme
There are two primary purposes for the requirement of Programme (Scheduling)
information described in this document:
a. Evaluation of Tender
b. Progress Status Reports during Construction
To provide the Employer’s Representative with progress status reports for managing,
monitoring and coordinating the awarded contracts during their execution within the
overall multi-contract project schedule.
The requirements are organized in two stages. The first stage is a requirement for all
Tenderers and shall be submitted as part of Tender. The second stage is a requirement
of the Employer and describes a series of reports to be submitted by the Contractor to
the Employer’s Representative during the execution of the contract, following the
award of Contract.
(2) The Tenderer/ Contractor shall programme his work at all times to meet the Key Dates
and the Works Areas Access Dates stated in Appendices 2A and 2B to the Employer's
Requirements, and the specified interface periods for the design and installation of the
Works with those of the Interfacing Contractors. The Tenderer/ Contractor shall during
the progress of the Works constantly monitor his progress against the programmes
described below.
(3) The Tenderer/ Contractor shall include in all programmes his work obligations towards
shared access, shared Site areas and other coincident or adjacent work areas with regard
to all interfacing parties.
(4) The Works Programme, and all more detailed or revised versions, shall be submitted to
the Employer’s Representative for his notice in accordance with the provisions of the
Conditions of Contract.
2. METHODOLOGY
(1) The computerized Critical Path Method (CPM) network using the Precedence
Diagramming Method (PDM), has been selected by the Employer as the technique for
contract management system and in coordinating the multi-contract project. This
technique shall also be employed by the Tenderer in preparing their Tender submissions
and by the Contractor in their Construction Stage submissions.
(2) Unless otherwise agreed by the Employer’s Representative, all programs submitted by the
Contractor shall be produced using computerized Critical Path Method (CPM) Networks
developed implementing the Precedence Diagramming Method (PDM) with Cost Loaded
Charts and Tables, using the required software stated in Clause 3 below.
(3) The Contractor shall implement and use throughout the duration of the Contract, a
computerized system to plan, execute, maintain and manage the planning, design, pre-
construction, construction, and sub-contracts in executing the CPM scheduling by PDM.
The reports, documents and data provided shall be an accurate representation of the
current status of the Works and of the work remaining to be accomplished; shall provide a
sound basis for identifying problems, deviations from the planned works, and for making
Section VI -Appendix 4-Programme Requirements 4-1 December 2021

Part-2 - Section VI
decisions; and shall enable timely preparation of the same for presentation to the
Employer’s Representative.
3. PROGRAMME MANAGEMENT SOFTWARE
CPM programming software used shall be Primavera Project Planning (P6) Program or
latest version. Scheduling software and relevant instruction manuals, licensed for use in
connection with the contract, shall be provided by the Contractor according to the
Employer’s specifications. The Contractor shall supply the Employer’s Representative
with an original licensed copy, including manuals and approved training of the software
and any subsequent versions thereof at no extra cost.
4. (NOT USED)
5. POST CONTRACT AWARD
5.1 The Contractor shall develop his Tender Programme into the Initial Works Programme
including an outline Narrative Statement and submit within 4 weeks of the date of
commencement and a more detailed version within 7 weeks of receiving the Employer’s
Representative’s notice of no objection to the proposed Initial Works Programme. Refer
Clause 7.0.
5.2 The first Three Month Rolling Programme shall be submitted within 4 weeks of the date
of Commencement and all subsequent editions shall accompany the Monthly Progress
Report. The Monthly Progress Reports shall also include a Programme Update as
described below. These programmes shall subsequently be updated as described below.
Refer Clause 9.0.
5.3 Following the Contractor's Initial Works Programme submission but in any case no later
than 21 weeks from the date of commencement of the Contract, the contractor shall submit a
detailed Works Programme suitably amended to take into account the programmes of
Interfacing Contractors. It is the Contractor's responsibility to ensure timely co-ordination
with the Interfacing Contractors to review, revise and finalise his Initial Works Programme
so as not to affect the progress of the Works and/or the works of the Interfacing Contractors.
The resubmitted Works Programme when given a Notice by the Employer’s Representative
shall form the Baseline Programme which shall solely be used for monitoring and
evaluating all facets of the Contractor’s performance including, but not limited to, actual
progress and the effects of variations and delays. The Contractor shall monitor his own
performance against the Baseline Programme on a weekly basis and shall prepare and submit
to the Employer’s Representative written and computerised monthly reports including all
supporting data. As the work progresses, it may be necessary to update/ revise the Baseline
programme, but such updating shall only be carried out with the prior consent of the
Employer’s Representative or when directed by them.
5.4 For the Initial & Detailed Works Programme submission, one (1) original and six (6) colour
copies, with a softcopy on a CD, each of the following programmes and reports shall be
submitted to the Employer’s Representative:
a) Programme: Baseline CPM Network
b) Programme: Baseline Milestone based Cost Activity Schedule
c) Baseline Schedule Report
d) Narrative Statement

Part-2 - Section VI
e) Baseline Physical Progress 'S' curve
f) Baseline Resource Charts
5.5 The Employer’s Representative shall review and comment on the Contractor’s programmes
and information submitted under this Clause. The Employer’s Representative will issue his
notice or otherwise of the submissions within 4 weeks.
5.6 The Employer’s Representative shall require the Contractor to re-submit within 2 weeks if he
is of the opinion that the programmes and information submitted by the Contractor is
unlikely to meet the Contract key dates.
5.7 If in the opinion of the Employer’s Representative, any of the Contractor's revised
programmes and information submitted under the Works Programme is not acceptable, it
shall be construed as a failure of the Contractor to meet a Milestone.
5.8 Notwithstanding the above, the Employer’s Representative may at any time during the
course of the Contract require the Contractor to reproduce the computer-generated Baseline
Schedule Report described above to reflect actual activity dates and generate schedules based
upon "what if" statements. The initial computer-generated report after receiving the
Employer’s Representative’s notice will serve as the base against which the contract progress
will be measured. Any changes to the Report reflected in subsequent Baseline Schedule
Reports shall also require the Employer’s Representative’s consent.
5.9 Failure to include any element of work required for performance of the Contract shall not
relieve the Contractor from completing all works required under the Contract to achieve the
original or any extended key completion date.
6. WORKS PROGRAMME
(1) The Works Programme shall detail the full scope of the works taking into account the
complex nature and different phases of the contract, and shall be accompanied by
detailed supporting information to demonstrate through the sequence and duration of
the activities that the plans are achievable and realistic and that the works to be
undertaken can meet the requirements of the contract.
(2) The Works Programme shall be a computerised Critical Path Method (CPM) network
developed using the Precedence Diagramming Method (PDM) and shall be present in
bar chart and time-scaled network diagram format to a weekly or monthly time scale.
(3) Tasks in the Works Programme shall be sufficiently detailed to describe activities and
events that include, but are not limited to, the following:
(a) Key Dates, Works Areas Access Dates, any interface and handover dates
(b) All physical work to be undertaken in the performance of the Contract
obligations, including Temporary Works
(c) The requested date for issue of any drawings or information by the Employer’s
Representative
(d) Incorporation of principal aspects of the Design Programme and Design
Submission Programme, including achievement of Preliminary Design,
Definitive design and Construction Reference Drawings for temporary works.
(e) Due time allowance for review by the Employer’s Representative of the
Contractor’s submissions, as well as the subsequent amendment and re-
submission by the Contractor in the design review and comment process,

Part-2 - Section VI
(e) Due time allowance for complying with requirements of all Government
Departments and all others whose consent, permissions, authority or licence is
required prior to the execution of any work.
(f) Order, procurement, manufacture, delivery, testing and installation of major
materials and the delivery and/or partial delivery date on-Site of principal items
of Contractor's Equipment.
(g) Any off-site work such as production or pre-fabrication of components
(h) Installation of temporary construction facilities
(i) Interface periods with the Interfacing Contractors or utility undertakings
(j) Design, supply and/or construction activities of sub-contractors
(k) Testing, commissioning and integrated testing of the Works.
(l) Any outside influence which will or may affect the Project.
(m) Mobilization and demobilization
(n) Weather allowance
(o) Completion of core areas / rooms for access by interfacing parties.
(4) The Works Programme shall show achievement of all Key Dates. The programme
shall also show Milestones, but the Milestones shall not be taken as imposing any
constraints that in any way affect the logic or limit any other dates in the programme.
(5) Activity descriptions shall be unique, describing discrete elements of work. Any
activity creating an imposed time or other constraint shall be fully defined by the
Contractor.
(6) The Works Programme shall be organised in a logical work-breakdown-structure
including work stages and phases, and shall clearly indicate the critical path(s). Each
activity in the Works Programme shall be coded to indicate:
(a) Activity ID and Activity Code which structure should be agreed with the
(b) The Employer’s Representative may request additional activity coding to the extent
available without restraint to the Contractor’s utilisation of the programme software.
When requested, the Contractor shall add the required additional coding to the
Programme. The Contractor shall use additional code fields as requested to comply
with the requirements and for the use of the Contractor.
(7) Activity duration shall not exceed two (2) weeks, unless otherwise consented to by
the Employer’s Representative, except non-construction activities such as submittals,
submittal reviews, procurement and delivery of materials or equipment and concrete
curing. The Contractor shall submit a Programme/Project Calendar cross reference
clearly indicating the allowance for holidays.
(8) The Works Programme, in each submission, shall be accompanied by an Activity
Report and a Narrative Statement as described below in both electronic and hard copy
format (time scale logic diagrams in A1 size, reports in A4 size).
(9) Activity Report
Shall list all activities, and events in the Works Programme, sorted by activity
identification number.
The Activity Report shall include the following for each activity and event:
(a) Activity identification number and description,

Part-2 - Section VI
(b) Duration expressed in Days,
(c) Early and late start & early and late finish dates. Planned start and finish dates,
(d) Calculated total float and free float,
(e) Predecessor and successor(s), accompanying relationships and lead/lag duration,
(f) Imposed time or date constraints,
(g) Calendar.
(10) Narrative
The Narrative shall be a comprehensive statement of the Contractor’s plan and approach
for the execution of the Works and the achievement of key dates, handover dates,
submission dates and any intermediate dates. It shall incorporate outline method
statements in respect of major items of work including construction sequences and
primary items of plant, Construction Equipment, Temporary Works and the like. It shall
fully explain the reasons for the main logic links in the Programme and include
particulars of how activity durations are established. This shall include estimated
quantities, production rates, and hours per shift, work days per week and a listing of the
major items of Construction Equipment planned for use on the project. Activities, which
may be expedited by use of overtime or additional shifts, shall be identified and
explained. A listing of holidays, and other special non-work days being used for the
computer reports shall be included.
Supporting information and an accompanying narrative for the Programme that
details the basis and assumptions upon which the programme has been drawn shall be
prepared and submitted as detailed (but not limited to) below:
i. A narrative description of the sequence of all sections of the Works and in
particular a detailed identification and description of the critical path activities.
The narrative shall be supported by sketches illustrating the planning sequences
of construction phase of works;
ii. Marked up plans detailing the concreting and concrete our dates for major section
of each part of the structure;
iii. An overall manpower forecast detailing individual trades and other sub-contract /
indirect labour, commissioning teams in terms of the daily number of workers
planned to be engaged. The formats for these forecasts shall be in accordance
with the Employer’s Representative’s requirements;
iv. Typical cycle time analysis;
v. Planned production outputs for all major activities and areas of Works;
vi. List of major items of plant and equipment that are required to be procured
identifying the required lead times;
vii. Accumulative curves and histograms showing the planned weekly figures for
each principal quantity, major item of equipment and major power trades;
viii. Any programme constraints, giving details of the constraints and substantiation
thereto;
ix. Total float listing in order of total float;
x. Daily and weekly working hours, holidays and shift patterns;
xi. Other information that the Employer’s Representative may request;
(11) Physical Progress 'S' Curve
The Contractor shall also submit at the end of every month, for inclusion in the Monthly

Part-2 - Section VI
Progress Report as stated in Appendix 5, a forecast Cumulative Physical Progress 'S'
curve based on the time-phased distribution of cost in the CPM Network Logic Diagram,
expressed in percentage terms and plotted with the early and late dates. This ‘S’ curve
shall be generated from the computerised CPM Network Logic Diagram.
(12) Resources
The Contractor shall provide on the submission of the Baseline programme full resource
details for major activities including but not limited to the substructure, superstructure,
architectural and building services fit out stages of the works. These shall include
o Major manpower trades
o Number of items of major plant and equipment
o Principal quantities (i.e, volume of excavation, volume of concrete, tonnage of
steel work / reinforcement, area of formwork, length of pipe work, area of
internal partition walls of finishes / cladding for floor walls, ceiling and roof
etc.)
o Other details as appropriate or required by the Employer’s Representative.
o The Contractor shall also Resource Charts, generated from the Contractor’s
CPM Network Diagram, showing the anticipated manpower and main
Construction Equipment usage during the execution of the Project.
As an additional monitoring facility, indicator resources shall be assigned to relevant
activities for the major items of work. Indicator resources shall be directly allocated for
excavation (cu.m.), piling (no.), diaphragm walling (m.), concrete (cu.m.), tunnel lining
(m), etc. Resource indicators may be input as a daily rate, expected required rate, or as an
activity total in the relevant units. These are purely indicative quantities and do not form
part of contract.
(13) All submissions of proposed Works Programmes subsequently, after approval of the
Initial Works Programme, shall include the actual physical progress of work and
forecast of the remaining work. Actual progress shall be stated in percent complete,
remaining duration, and actual start and finish dates for each activity in the Works
Programme.
7. INITIAL WORKS PROGRAMME
(1) The Initial Works Programme submitted as under Clause 5.1 need not include the full
details given under Clause 6 above. It should be a condensed version with combined
activities of longer duration but must show clearly how the requirements of the
Contract are to be achieved. The outline Narrative Statement shall be in sufficient
detail to clearly show the Contractor's intention.
(2) Within 7 weeks of the Employer’s Representative’s consent to the Initial Works
Programme, the Contractor shall submit to the Employer’s Representative an
expanded and more detailed version of the Initial Works Programme containing all of
the information and detail required under Clause 6 above.
(3) Such submission shall make use of the Tender Programme submitted earlier but
refined to include the best estimates of dates for the work of Interfacing Contracts
which has impact on the Contractor's programme. Such programmes shall be
amended subsequently to incorporate the actual dates/ schedule of the affecting
contracts. It is the Contractor's responsibility to ensure timely co-ordination with the
Interfacing Contractors to finalise the Initial Programme, without affecting progress

Part-2 - Section VI
of the work.
8. WORKS PROGRAMME REVISIONS

(1) The Contractor shall immediately notify the Employer’s Representative in writing of
the need for any changes in the Works Programme, whether due to a change of
intention or of circumstances or for any other reason. Where such proposed change
affects timely completion of the Works or any other Key Date the Contractor shall
within fourteen (14) days of the date of notifying the Employer’s Representative
submit for the Employer’s Representative's notice its proposed revised Works
Programme and accompanying Narrative Statement. The proposed revised Works
Programme shall show the sequence of operations of any and all works related to the
change and the impact of changed work or changed conditions.
(2) If at any time the Employer’s Representative considers the actual or anticipated
progress of the work reflects a significant deviation from the Works Programme, he
may request the Contractor to submit a proposed revised Programme which together
with an accompanying Activity Report and Narrative Statement, shall be submitted by
the Contractor within fourteen (14) days after the Employer’s Representative's
instruction. The proposed revised Works Programme shall show the sequence of
operations of any and all work related to the change and the impact of changed work
or changed conditions.
(3) All activities that have negative float must be analysed by the Contractor to identify
the impact on the timely completion of the Works or on the achievement of Key
Dates.
9. THREE MONTH ROLLING PROGRAMME
(1) The Three Month Rolling Programme shall be an expansion of the current Works
Programme showing the activities completed in the last month and the activities that
are in progress or will start within the next three (3) months. The Three Month
Rolling Programme shall provide more detail of the Contractor's plan, organisation
and execution of the work within these periods. The Contractor shall expand each
activity planned to occur during the next three (3) month period, if necessary, to a
daily level of detail.
(2) The Three Month Rolling Programme shall be developed as a Critical Path Method
(CPM) network, and shall be presented in bar chart and time-scaled network diagram
format. Bar charts shall be presented on A4 sheets and time-scaled networks diagrams
A1 size. Tasks in the programme shall be derivatives of and directly related to tasks in
the approved Works Programme. One (1) original and six (6) colour copies, with a
softcopy on a CD, of the schedule shall be submitted
(3) The Contractor shall describe the discrete work elements and work element inter-
relationships necessary to complete all works and any separable parts thereof
including work assigned to sub-contractors.
(4) Activity duration shall not exceed two (2) weeks unless otherwise notice given by the
(5) Each activity in the Three Month Rolling Programme shall be coded, or described so

Part-2 - Section VI
as clearly to indicate the corresponding activity in the Works Programme.
(6) The three months Rolling Programme shall require the Employer’s Representative
notice for payment purposes.
10. THREE MONTH ROLLING PROGRAMME REVISIONS AND UPDATE
(1) The Three Month Rolling Programme shall be a progress update of the accepted
Baseline Programme. The Three Month Rolling Programme shall be extended
forward each month as described under Clause 9 above. Each submission of the
Three Month Rolling Programme shall be accompanied by a Programme Analysis
Report, describing actual progress to date, and the forecast for activities occurring
over the next three-month period.
(2) If the Three Month Rolling Programme is at variance with the Works Programme,
the Programme Analysis Report shall be accompanied by a supporting Narrative
Statement describing the Contractor's plan for the execution of the activities to be
undertaken over the three month period, including programme assumptions and
methods to be employed in achieving timely completion.
(3) The Contractor shall revise the Three Month Rolling Programme or propose
revisions of the Works Programme in accordance with Clause 8, or both, from time
to time as may be appropriate to ensure consistency between them.
11. THREE WEEK ROLLING SCHEDULE

(1) Once a week, on a day mutually agreed to by the Employer’s Representative and the
Contractor, a meeting will be held to assess progress by the Contractor during the
previous work week. The Contractor shall submit a construction schedule listing
activities completed and in-progress within the previous week and the activities
scheduled for the succeeding three weeks based on the detailed Works Programme.
One (1) original and six (6) colour copies, with a softcopy on a CD, of the schedule
shall be submitted on A3 sized paper.
(2) The 3-week rolling programme shall be in bar chart programme format. The
activities shown shall be a complete amplification of the activities in the 3-month
rolling programme and shall show breakdown of work in sufficient detail and on a
room by room / area by area and day to day basis. The 3-week rolling programme
shall be a working programme with sufficient data for reporting, monitoring,
measuring, and evaluating the Contractor’s progress of the Works and manpower
deployment to site. All activities shall be referenced back to the 3-month rolling
programme through the Activity ID. Activities that were scheduled to be completed
but remain uncompleted shall be captured by the 3-week rolling programme
notwithstanding that it may have fallen outside of the 4-week cycle. However,
activity bars need not be shown for such activities to retain the 4-week cycle in the
activity bar area. The 3-week rolling programme shall be submitted every Monday
morning on a weekly basis. The percentage completion shall be agreed by the
Employer’s Representative
(3) The first 3-week rolling programme shall be submitted within 2 weeks of the
contract commencement date, in colour on A3 paper.

Part-2 - Section VI
12. PROJECT CALENDAR
For the Project, the Contractor shall adopt 7 days a week calendar, identical calendar for
the purpose of programming and execution of Works. Official documents shall be
transacted during 5 days week - Monday through Friday, except for National (Govt. of
India) Holidays. For Project purposes, a week begins at 0001 hours on a Monday and
ends at 2359 hours on a Sunday. The completion of an activity or the achievement of an
event when given a week number shall be taken to mean midnight on the Sunday at the
end of the numbered week. An access date or activity start date when given as a week
number shall be taken to mean 0001 hours on a Monday of the Numbered week.
13. PROGRAMMING PERSONNEL

The Contractor shall submit, as part of its Staff Organisation Plan, the names and
experience and any required information for the staff to be employed on Works
Programming. The principal Works Programmer shall hold reputable professional
qualifications acceptable to the Employer’s Representative including at least five (5)
years relevant experience in programming civil engineering works. Others in the group
shall have at least three (3) years’ experience in such work. The programmers shall be
employed by the Contractor full time on the Contract until the completion or such earlier
time the Employer’s Representative may give his consent.
14. PROGRAMME AND REPORT SUBMISSION FORMAT

The Contractor shall submit one (1) original and six (6) copies in colour, and a softcopy on a
CD, of all submissions to the Employer’s Representative. All submissions shall be in A0,
A1, A3 or A4 size, as appropriate, except as may otherwise be agreed by the Employer’s
Representative.
15. FAILURE TO SUBMIT PROGRAMME

Failure of the Contractor to submit any programme, or any required revisions thereto
within the time limits stated for notice of no objection by the Employer’s Representative,
shall be sufficient reason for not making the relevant milestone on account payment by
the Employer’s Representative.


RETRIEVAL SHAFT TO NATHAMUNI (VILLIVAKKAM MTH
ROAD) LAUNCHING SHAFT AND RAMPS WITH U - SECTION IN
PART-2
SECTION VI
SUB-SECTION E
APPENDIX-5
MONTHLY PROGRESS REPORTS
DECEMBER 2021
MONTHLY PROGRESS REPORTS
1. GENERAL
(1) The Contractor shall submit to the Employer’s Representative six (6) coloured copiesand a
soft copy on CD of the Monthly Progress Report. This Report shall be submitted by the
last day of each calendar month and shall account for all work actually performed from
26th day of the last month and up to and including the twenty-fifth (25th) day of the
month of the submission.
(2) The Report shall be typed, printed and bound. It shall be supported by graphics and
photographs as specified in Clause 9 of this Appendix. It shall be submitted in a format to
which the Employer’s Representative shall have given his consent. Unless the Employer’s
Representative directs otherwise, the Contractor's Monthly Report shall contain
sections/sub-sections for, but not limited to, the topics described in this Appendix.
(3) The Contractor shall include in the Monthly Progress Report a record of monthly progress
of various major Works on Site in the form of colour photographs with appropriate
annotations and dates stated.
(4) The Contractor shall deliver daily to the Employer’s Representative a hard-signed copy, a
report as to the number of workmen, plant and equipment employed on the works in each
trade, etc. and a log of delivery notes for all goods and materials delivered to the Site.
This information shall be summarised as a monthly return for the monthly progress report
2. FINANCIAL STATUS
(1) A narrative review of all significant financial matters, and actions proposed or taken in
respect to any outstanding matters.
(2) A spread sheet summarising each activity, the budget, costs incurred during the period,
costs to date, costs to go (including potential variations), cost forecast (total of costs to
date and costs to go) and cost variance (difference between cost forecast and budget).
(3) A spread sheet indicating the status of all payments due and made.
(4) A report on the status of any outstanding claims. The report shall in particular provide
interim updated accounts of continuing claims.
3. PHYSICAL PROGRESS
(1) The introduction shall briefly summarise the progress that has been made during the past
month and how the actual progress relates to the planned progress in accordance with the
Works Programme.
(2) It shall describe the status of work performed, significant accomplishments, including
critical items and problem areas, corrective actions taken or planned and other pertinent
activities, and shall, in particular, address interface issues, problems and resolutions.
(3) It shall include a simplified representation of progress measured in percentage terms
compared with percentage planned as derived from the Works Programme.
Section VI- Appendix 5- Monthly Progress Reports 5-1 December 2021

(4) Physical Progress S-Curve

The Physical Progress S-Curve shall be in the form of a graph which compares the actual
progress with the planned progress in terms of percentage to show the project
performance.
The value of the physical progress achieved shall be assessed as the aggregate of the
values of those activities which are separately identified on the Works Programme and
which are:
1. in the opinion of the Employer’s Representative, wholly completed;
2. in progress, provided that the value attached to each such activity shall be agreed with
the Employer’s Representative. Notwithstanding any value agreed with the
Employer’s Representative shown on the S-Curve, the
S-Curve shall not be used for the purpose of Progress Payment Claim.
4. PROGRAMME UPDATE
Programme updating shall include:
(a) the monthly Programme Update which shall be prepared by recording actual activity
completion dates and percentage of activities completed up to the twenty-fifth (25th) of
the month together with estimates of remaining duration and expected activity completion
based on current progress. The Programme Update shall be accompanied by an Activity
Report and a Narrative Statement. The Narrative Statement shall explain the basis of the
Contractor’s submittal:
(i) Early Work and Baseline Submittals – explains determination of activity duration and
describes the Contractor’s approach for meeting required Key Dates as specified in
the Contract.
(ii) Updated Detail Programme Submittals – state in narrative the Works actually
completed and reflected along Critical Path in terms of days ahead or behind
allowable dates. Specific requirements of narrative are:
If the Updated Detailed Works Programme indicates an actual or potential delay to
Contract Completion date or Key Dates, identify causes of delays and provide
explanation of Work affected and proposed corrective action to meet Key Dates or
mitigate potential delays. Identify deviation from previous month’s critical path.
Identify by activity number and description, activities in progress and activities
scheduled to be completed.
Discuss Variation Order Work Items, if any.
(b) The Programme Status which shall :
(i) Show Works Programme status up to and including the current report period, display
Cumulative progress to date and a forecast of remaining work.
(ii) Be presented as a bar-chart size A3 and as a time-related logic network diagram on an
A1 media, including activity listings;

(iii) schedules of all significant activities tabulated in order of earliest starting date
showing the following:
3. the actual start dates for activities which have commenced together with the scheduled
start date for each activity and the time lapse;
4. the actual completion dates for activities which have finished together with the scheduled
finish date for each activity and the time lapse;
5. the forecast and scheduled start dates for activities scheduled;
6. the forecast and scheduled completion dates for activities which have commenced;
7. the percentage completion of each activity started but not completed;
8. the total float of each activity not completed;
9. Any known delays to activities.
(c) The Activity Variance Analysis which shall analyse activities planned to start prior to
or during the report period but not started at the end of the report period as well as
activities started and/or completed in advance of the Works Programme.
(d) The Resource Chart to show the actual resources mobilised for the works against the
baseline figures in the Baseline Resource Charts.
5. KEY DATES STATUS

A report on the status of all Key Dates due to have been achieved during the month and
forecasts of achievement of any missed Key dates, and those due in the next month.
6. THREE MONTH ROLLING PROGRAMME

Include a copy of the 3-month Rolling Programme for that reporting period.
7. PLANNING AND CO-ORDINATION

(1) Details of co-ordination of interface activities started or completed during the month and
shall include for internal co-ordination within the Contractor's own multi-disciplinary
team as well as external co-ordination with the Employer’s Representative, other
Interfacing Contractors, authorities and the like;
(3) A schedule of all submissions and consents/approvals obtained/outstanding;
(4) Details of design and drawing progress, including design interface coordination, started or
completed during the month as related to the Temporary Works, Permanent Works and
Shop drawings;
(5) Updated Drawing Register;
(6) Details of the progress of off-site activities such as design, production and/or fabrication
of any components or materials;
(7) Corrective actions either taken by or to be taken by the Contractor to maintain completion
dates, including details of any changes made or to be made to the Works Programme to
achieve this objective;

(7) Contractor’s organisation and resources;

(8) Details of any other items which the Employer’s Representative or the Contractor shall
consider to be necessary or desirable from time to time.
8. PROCUREMENT REPORT
(1) A summary of all significant procurement activities during the month, including action
taken to overcome problems, and details of any outstanding actions.
(2) A report listing major items of plant and materials which will be incorporated into the
Works. The items shall be segregated by type as listed in the Specifications and the report
should show as a minimum the following activities:
(a) Purchase order date - scheduled/actual;
(b) Manufacturer/supplier and origin;
(c) Letter of credit Issued date;
(d) Manufacturer/supplier shipment date - scheduled/actual;
(e) Method of shipment;
(f) Arrival date in India- scheduled/actual;
(g) Analysis of any delay happening/anticipated with proposal for corrective measures.
9. PHOTOGRAPHS
Two sets of photographs shall be provided with the Monthly Progress Report in colour and
shall be submitted in the following manner and format.
Digital colour photographs shall be 10cm x 15cm (4-inch x 6-inch), glossy prints, mounted in
protective clear plastic folders and contained in a lever-arch binder. The electronic files shall
also be provided in “.jpg” format on CD-ROM. The photographs and electronic files shall be
identified by a brief narrative indicating:
(a) Contract number
(b) A unique sequential number based on an agreed drawing numbering system
(c) Specific location and subject of photograph
(d) Date and time of photograph
Each month the Contractor shall propose, and the Employer’s Representative will confirm the
number of photographs to be supplied so as to accurately record progress on all parts of the
works. The number of photographs shall not be less than 30 per set unless otherwise agreed
by the Employer’s Representative.
10. SAFETY
A review of all safety aspects during the month including reports on all accidents, actions
proposed to prevent further occurrence and safety performance to-date, including results of all
audits undertaken during the reporting period.

11. ENVIRONMENTAL
A review of all the environmental issues during the past month to include all monitoring
reports, mitigation measures undertaken and activities to control environmental impacts,
including results of all audits undertaken during the reporting period.
12. QUALITY
A review of all major quality issues and non-conformances during the month including the
quality control register and reports on actions proposed to prevent further occurrence as
specified at Appendix 6 and also to include results of all audits undertaken during the
reporting period.

CHENNAI METRO RAIL PROJECT PHASE 2, CORRIDOR

JUNCTION RETRIEVAL SHAFT TO NATHAMUNI (VILLIVAKKAM
MTH ROAD) LAUNCHING SHAFT AND RAMPS WITH U -
SECTION IN CORRIDOR-5 OF CMRL PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SECTION E
APPENDIX-6
QUALITY ASSURANCE
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5. Part -2 Section VI
QUALITY ASSURANCE
Quality System Definitions
The following Quality Management System terms are used in these requirements. The
definitions given are derived from ISO 9000: 2005, clause 6.
Audit Systematic, independent and documented process
for obtaining audit evidence and evaluating it
objectively to determine the extent to which audit
criteria are fulfilled
Clause under the Conditions of Contract
Conformity Fulfilment of a requirement
Design and Development Set of processes that transforms requirements into
specified characteristics or into the specification of
a product, process or system. These are prepared to
support the Quality Plan for a particular element of
the Works
Hold Point (H) A point in time when a notice of permission,
consent or No Objection by the Contractor Quality
Assurance Team (or that the Employer’s
Representative may elect to witness), is required
before the Contractor can proceed with an activity
Inspection and Test Plan Plans specifying the activities required to establish
whether conformity is achieved. They identify the
responsibilities for executing the activities, the
documents controlling them and details
requirements for the production of records
Method Statements Documented procedures, concerning particular
aspects of the process, developed to define the
manner of production, installation and servicing
Nonconformity Non-fulfilment of a requirement
Observation Point (O) A stage identified on an Inspection and Test Plan
where the Employer’s Representative or authorised
third parties may observe activities and any
associated verification
Procedure Specified way to carry out an activity or a process
Quality Degree to which a set of inherent characteristics
fulfils requirements
Quality Management System Management system to direct and control an
organization with regard to quality as formally
expressed by top management
Quality Plan Document specifying the procedures and associated
resources shall be applied by whom and when to a
specific project, product, process or contract
Section-VI- Appendix-6 Quality Assurance 6-1 December 2021

Quality Plan shall specify the quality management
system of an organization
Requirement Need or expectation that is stated, generally implied
or obligatory
Record Document stating results achieved or providing
evidence of activities performed
Witness Point (W) A stage in the pre-construction or construction
activities in which a party is invited to witness
1. INTRODUCTION
1.1 The Contractor shall maintain and implement a Quality Management System that
shall remain in effect during the execution of the Works. Contractor’s organisation is
required to operate a Quality Management System based on International Standard
ISO 9001: 2008 for its scope of Works and in compliance with the requirements of
the Contract. The Contractor shall submit his Quality Management System
documentation for review and Notice of No Objection by the Employer’s
Representative as specified in this Section.
1.2 ISO 9001: 2008 Certification of the Contractor's organisation is required for this
Project. The Employer’s Representative may consider the alternative use of ISO
9001: 2000 Certification at his discretion. ISO Certification is a requirement of this
Project for the Contractor’s subcontractors, consultants, sub-consultants, suppliers
and Designers. The Contractor however cannot delegate or subcontract the
Employer’s Quality Assurance Requirements to subcontractors, consultants, sub-
consultants or suppliers without the Employer’s Representative written approval.
1.3 The Contractor shall implement a Quality Plan that shall incorporate a comprehensive
and documented approach to achieve the Project quality requirements that is capable
of ensuring that all aspects of the Works, including but not limited to, design,
procurement, fabrication, installation, inspection, construction and modifications will
comply with the requirements of the Contract.
1.4 The Contractor’s Quality Plan shall ensure that all goods and materials, whether on-
shore in India or off-shore before shipping, workmanship, plant and equipment
procured and supplied, inspecting, handling, assembling, testing, storing, fabrication,
suppliers and vendors are in compliance with the Contract requirements. Plan(s)
and/or Procedures to be prepared by others (suppliers, subcontractors, sub-
consultants) and their incorporation in the overall Quality Plan of the Contractor,
shall be identified.
1.5 The Capitalized terms used and to the extent not defined herein shall have the
meaning ascribed to them respectively, in the Conditions of Contract and the
Employer’s Requirements.
1.6 Construction / Installation shall be deemed to include manufacturing, fabrication,
assembling, testing & commissioning, integrated testing and commissioning and trial
runs wherever necessary.
1.7 The Contractor shall assist in the independent audit review, checking, sampling
testing and examination of the Works by the Employer’s Representative. The
Contractor shall provide full and timely access for such work by the Employer’s

Representative, including inspection of records and documentation. Such access shall
include direct access to the Site, work areas, storage facilities, fabrication sites,
Contractor’s offices, laboratories, manufacturers/suppliers facilities and similar areas
and facilities where any work is being conducted.
1.8 For design and/or activities occurring outside of India which require the Employer’s
Representative to inspect, the Contractor shall provide:
(a) Right to inspect;
(b) Facilities to carry out their work; and
(c) Assistance in travel and accommodation arrangements.
2. QUALITY MANAGEMENT SYSTEMS
2.1 Contractor’s Quality Management System shall be capable of demonstrating by self-
certification that all relevant standards, regulations, testing requirements etc are being
met. Self-certification is the process whereby the Contractor can demonstrate that all
requirements of the Contract have been fulfilled.
2.2 The Contractor shall designate a Quality Assurance Manager (QA Manager) who
shall be classified as one of the Key Personnel and shall be responsible for overseeing
the implementation of the overall Quality Plan for the Contractor. The Quality
Assurance Manager shall not report to the Contractor’s Project Manager, but shall be
directly responsible to and report to a joint venture board, senior management or
similar level of the Contractor’s organization that is not directly responsible for
design or construction.
2.2.1 Refer to Volume 1 – Section A, Clause A15 Key Staff Requirements.
2.3 The Contractor shall be required to provide the Quality Assurance Manager with
adequate resources and authority to enable the quality of the work on the Contract to
be managed effectively. Those resources shall be required to fulfil the requirements
for quality assurance, inspection and testing and self-certification as detailed in these
requirements.
2.4 The Contractor shall be required to provide appropriate training to all personnel in the
operation of the Quality Management System and maintain records to demonstrate
competence in its application.
2.5 The Contractor shall submit his Quality Management System documentation for
review and approval by the Employer’s Representative as specified in this Section.
2.6 It is anticipated that the Contractor’s Quality Management System documentation
shall include, but not limited to, the following:
(a) Quality Plan, identifying its Quality Procedures;
(b) Manufacturing Quality Plan;
(c) Design Quality Plan;
(d) Method Statements;
(d) Inspection and Test Plans; and
(e) Plan for compliance with Railways Opening for Public Carriage of Passengers,
Amendment Rules, 2001, Chapter II

2.7 The Contractor shall plan, perform and record all quality control activities to ensure
that all work is performed in accordance with the requirements of the Contract and of
his Quality Management System. Documentation which have been reviewed and
approved by the Employer’s Representative, such activities shall include, without
limitation, the inspections and/or tests implied or expressly required by the Contract.
2.8 The Employer's Representative shall designate, if necessary, Quality ‘Hold Points’
into the Contractor’s Inspection and Test Plans for the Contractor’s Quality
Department to adhere to, or for the Employer’s Representative to attend, on a case-
by-case basis at his discretion.
2.9 The Contractor shall coordinate the Inspection and Testing necessary to demonstrate
that all specified requirements have been met. All non-conformances are to be
documented and resolved, before final acceptance of the Works or any section of it.
2.10 The Employer, Stake holders, Employer’s Representative and third parties including
the Ministry of Railways and statutory authorities, reserve the right to and shall
conduct periodic audits and inspections on the Works and services provided either on
its own or through third party, and will sample, test and measure material used within
the Works completed by the Contractor or its subcontractors of all tiers and
suppliers/vendors and to observe the execution of these activities.
2.11 The Contractor, his consultant, subcontractors of all tiers and suppliers thereof shall
make available for audit all records necessary to demonstrate that the Works have
been executed in accordance with the Contract. They shall also provide the
Employer’s Representative with documents that demonstrate that the Works are
progressing in accordance with the specified requirements. These shall be provided in
a timely manner to enable non-conformities to be rectified satisfactorily.
3. QUALITY SYSTEM REQUIREMENTS
3.1 The organization of the Contractor’s Project Plan shall comply with ISO 10005
(2005): Quality Management-Guidelines for Quality Assurance Plan.
3.2 All on-Site and off-Site testing sampling in India is to be carried out by laboratories
accredited by NABL (National Accreditation Board of Testing and Calibration
Laboratories) or internationally accredited laboratory to ISO 17025: 2005.
3.3 A fully equipped concrete laboratory shall be installed at Site along with laboratory
technicians and support staff. Testing machines shall be periodically calibrated in
accordance with NABL requirements. Details included in clause 14.9.
3.4 The Employer’s Representative may require the Contractor to stop using a particular
laboratory and find an alternative if the Employer’s Representative has reasonable
grounds to be dissatisfied with its performance.
3.5 All testing of systems, software, plant and materials must be carried out by persons
accredited to meet the requirements and Standards.
3.6 Within thirty (30) days of the Commencement Date, Contractor shall submit to the
Employer’s Representative for his review, comment and Notice of No Objection the
following, as appropriate:
(a) Quality Plan;
(b) Design Quality Plan and Delivery Schedule; and

(c) Manufacturing Quality Plan and Delivery Schedule.
3.7 The Contractor shall promptly supply the Employer’s Representative with six (6)
controlled copies of his Quality Plans, Inspection and Test Plan(s), related procedures
/ instructions / forms upon such documents being reviewed and approved by the
Employer’s Representative. The Contractor shall maintain such controlled
documentation throughout the duration of the Contract. For any amendment to the
quality system documentation, the Contractor shall as soon as practicable prepare and
submit the proposed amendment for review by the Employer’s Representative. In
addition, the Employer’s Representative may request further copies of the quality
system documents and these documents shall reach the Employer’s Representative’s
office within fourteen (14) days of notification, at no additional cost to the Contract.
3.8 The Contractor shall maintain and make available for inspection by the Employer’s
Representative at its site, a complete, up-to-date, organized file of all submittals
(plans, procedures, Method Statements etc), including an index and locator system
which identifies the status of each submittal.
3.9 Pursuant to sub-clause 3.8, a ‘controlled copy’ means a document prepared and issued
in accordance with the provisions regarding document control contained in the
relevant ISO standard.
4. TYPES OF QUALITY PLANS
4.1 No design, procurement, construction, installation, commissioning or maintenance
activity shall commence without a suitable Quality Plan that has been submitted to
Employer’s Representative for review and comment, consent, approval of Notice of
No Objection.
4.2 The Contractor shall submit to the Employer’s Representative the following Quality
Plans for his review and approval:
(a) A Quality Plan for the control of all management related activities;
(b) Design Quality Plan(s) for the control of all design related activities for the
Permanent Works or Plant and/or Temporary Works;
(c) Manufacturing and construction Quality Plan(s), for the control of activities
within each category of work or discrete element of construction, manufacture,
installation, commissioning, maintenance or servicing of the Permanent Works or
Plant and/or Temporary Works or for the control of outstanding work during the
Contracts Period, as the same may be required by the Contract and/or directed by
the Employer’s Representative; and
(d) Method Statements and Inspection and Test Plans, for the control of all inspection
and test related activities as per clause 10 and clause 11.
5 FORMAT OF QUALITY PLANS
5.1 The Quality Plan(s) shall define all measures necessary to meet the objectives and
requirements of the Contract at all appropriate phases of the work.
5.2 The Quality Plan(s) shall have a standardised format and show clearly on each
page:
(a) The quality plan number or, in the case of attached documents, a reference to
the quality plan number;

(b) Whether the document is a draft or is approved by the authorised
representative of the Contractor; and
(c) The date of such approval.
6 QUALITY PLAN
6.1 The Contractor shall prepare construction Quality Plan(s) for the construction,
installation, testing and commissioning activities. Separate construction quality
plan(s) shall be prepared for other Contractor’s or subcontractor’s off Site activities.
Each construction quality plan shall identify the scope of work to be controlled.
6.2 The Quality Plan shall include a directory and organizational chart showing all of the
Contractor’s Key Personnel. The directory shall be kept updated throughout the
Contract as changes occur and submitted to the Employer’s Representative for his
approval. The directory shall include the names, titles, areas of responsibility, office
address and location, office phone and fax numbers, cellular phone number(s). The
Contractor shall provide information sufficient for the Employer’s Representative to
contact any of the Key Personnel on a twenty-four (24-hour) basis for the duration of
the Contract.
6.3 The Employer’s Representative will also provide a similar directory to the Contractor.
6.4 The Quality Plan shall define the Contractor's management structure for the execution
of the Works and for the control of the quality of the Works and shall, without
limitation, define:
(a) The organisation of the Contractor's managerial staff with particular reference to
any Joint Venture partners and main subcontractors. An organisation chart is to
be produced to illustrate the subdivision of the work into elements for effective
technical and managerial control, the reporting structure and the interface
relationship between all parties involved;
(b) The specific allocations of responsibility and authority given to identified
personnel for the day to day management of the work with particular reference to
the supervision, inspection and testing of the work;
(c) The interfacing or co-ordination required with the Contractor's other related
Quality Plans;
(d) The specific methods of construction to identify any relevant Method Statements
and develop those Method Statements to a degree of detail sufficient to permit the
Employer’s Representative to understand. Refer to clause 10;
(e) The appointment of a Quality Assurance Manager and Quality Control Manager
in accordance with clause 12;
(f) The audit procedure, audit schedule for each type of quality plans and list of
proposed auditors including details of their authority, qualifications and
experience in accordance with clause 9;
(g) The procedures for the control of receipt and issue of all correspondence, so as to
ensure traceability, shall be defined. Correspondence shall include letters,
internal memoranda, facsimiles and electronic transmittals (i.e. CompuServe,
Internet, SharePoint, Expedition etc);

(h) The procedures for recording Project related oral communications shall be
defined, i.e. records of telephone conversations, notes of informal discussions and
minutes of meetings;
(i) The procedures for the selection, indexing, filing, disposition and maintenance of
Project records for storage in the archives shall be defined. A list of items to be
archived shall be submitted for review by the Employer’s Representative on
periods of retention. In addition, the Contractor’s and subcontractor’s filing
systems shall be compatible as far as is necessary;
(j) The procedures for the identification, production, verification, approval,
distribution, implementation and recording of changes to all drawings, reports
and specifications shall be defined;
(k) The procedures for the evaluation, selection, engagement and monitoring of
subcontractors / suppliers shall be defined together with the means of application
of quality assurance to their work including audit and acceptance;
(l) The procedure for the regular review and revision of each type of quality plan and
its supplemental individual specific quality plans, to ensure their continuing
suitability and effectiveness shall be defined. In addition, the method to be used
for revision and issue of revised documentation shall be defined;
(m) The procedures for the control, calibration and maintenance of inspection, testing
and measuring equipment shall be defined;
(n) The procedures for identifying training needs and for the provision of training of
all personnel performing activities affecting quality shall be defined; and
(o) The quality control procedures to be implemented to verify conformance with the
Contract specifications. Verification is accomplished by examinations, tests,
measurement and inspection and by verifying records including those of his
consultant, subcontractors and suppliers by uses of forms to be applied to manage
and control the following:
(i) The purchasing of materials and ensuring they comply with the
requirements of the specification, including purchasing documentation and
specific verification arrangements for Contractor/Employer’s
Representative inspection of material or manufactured product prior to
release for use/installation;
(ii) The construction process including Temporary Works so as to ensure
compliance with drawings and specifications;
(iii) The construction and installation process so as to ensure clear identification
and traceability of material and manufactured parts;
(iv) The inspection and testing activities of incoming materials, in process and
final product;
(v) The identification of the inspection and test status of all material and
manufactured products during all stages of the construction and installation
process to ensure that only products that have passed the required
inspections and tests are dispatched for use and/or installation;

(vi) Record of non-conformities and the disposition of non-conforming material
or product, supported by applicable documentation, agreed remedial action
instituted prior to the initiation so as to avoid unintended use/installation.
Contractors Non-conformity system provides for the monitoring and
tracking of all Non-conformities that occur within his scope of Contract,
regardless of who identifies the Non-conformance;
(vii) The assessment and disposition of nonconforming material(s) and
product(s) and approval for reworking or rejection as scrap;
(viii) The identification of preventive action so as to prevent recurrence of
similar non-conformance; and
(ix) The handling, storage, packaging, preservation and delivery of products.
(p) The list of Inspection and Test Plans and Method Statements to manage and
control any test and inspection activities;
(q) All particulars of materials submitted for review by the Employer’s
Representative;
(r) Where required by the Contract, the quality control requirements for major
components in accordance with clause 16; and
(s) Lists of forms and formats to be used to record the activities under the
construction Quality Plan(s) shall be attached at the end of each section or
reference included to existing standard procedures.
6.5 The Quality Plan(s) shall ensure that conditions adverse to quality such as failures,
malfunctions, deficiencies and defects in materials and equipment shall be promptly
identified and recorded as Non-Conforming Product and specific procedures to rectify
non-conformities raised. This includes systems non-conformities raised as a result of
both internal audit by the Contractor and external audits by the Employer’s
Representative.
6.6 The Quality Plan(s) shall address the controls to be applied by its organisation to its
subcontractors, suppliers and lower tier contractors thereof, both directly and by
identifying the quality system documentation that subcontractors, suppliers and lower
tiers thereof are required to produce. The Contractor shall ensure that subcontractors,
suppliers and lower tiers thereof agree to and implement the applicable controls
specified in the Contractor Quality Plan and the identified Quality Management
System documentation.
7 DESIGN QUALITY PLAN

DELETED
8 MANUFACTURING QUALITY PLAN

DELETED
9 QUALITY AUDIT, REVIEWS AND UPDATES

9.1 Contractor shall submit with his Quality Plan a schedule of internal, consultant,
subcontractor and supplier audits that are to be conducted by his personnel at least

every six (6) months. The schedule, scope and method of the audits shall be sufficient
enough, such that the Contractor can verify that all aspects of the Works are being
conducted in accordance with the contractual requirements. The schedule and any
amendments are subject to the acceptance by the Employer’s Representative. The
schedule shall be reviewed every four(4) weeks by the Employer’s Representative.
9.2 The Contractor shall ensure that audits of all the activities in each quality plan are
carried out to ensure the continuing suitability and effectiveness of the Quality
Management System. Reports of each such audit shall be submitted promptly to the
Employer’s Representative for his information.
9.3 The Contractor shall audit his consultants, subcontractors, sub-consultants and
suppliers.
9.4 The Contractor shall allow the Employer’s Representative to observe/participate in
these audits and to conduct additional independent audits, as they consider
appropriate to provide assurance that the Works are being conducted in accordance
with contractual requirements. The Contractor shall provide the facilities and access
necessary for these audits to be carried out effectively.
9.5 All audits as described in this section are to be carried out in compliance with
established ISO 9001 auditing principles and in accordance with ISO 19011.
9.6 Plan reviews and updates:
(a) The Contractor shall conduct Management Reviews of its quality system, at least
annually. As work progresses, the Contractor shall update the Quality Plan to
reflect current conditions. The need for revisions to the Quality Plan may be
identified by the Contractor and/or the Employer’s Representative. The
Contractor shall submit any revisions or updates to the Quality Plan to the
Employer’s Representative for his Notice of No Objection within thirty (30) days
of the identification of the need for a revision.
(b) In addition, the Contractor shall submit its Quality Plan for review by the
Employer’s Representative annually even if no revisions have occurred during
the preceding twelve (12) months. The Contractor shall submit a certified copy of
the updated Quality Plan with revisions highlighted.
10 METHOD STATEMENTS
10.1 Contractor shall prepare Method Statements for each area and/or type of activity
conducted, and submitted to the Employer’s Representative for his review, comment
and Notice of No Objection prior to commencing construction on any Temporary or
Permanent Works. Methods Statements shall be prepared for all Temporary and
Permanent Works and shall be specific to the work being constructed and to the
location of work.
10.2 All Methods Statements shall be consistent with Design Drawings and Works
Specifications that have been subjected to checks and reviews as specified.
10.3 Any deviations from the requirements of the Design Drawings or Works
Specifications shall require written agreement of the Designer, certified by the Design
Checker and shall be submitted to the Employer’s Representative for his review and
Notice of No Objection.

10.4 Approved Methods Statements shall be available for examination by the Employer’s
Representative upon request at site.
10.5 Method Statements shall address the following items:
(a) Scope of work covered by the Method Statement;
(b) Relevant drawings and Works Specifications;
(c) Hazard analysis and the precautions to be taken to eliminate or mitigate identified
hazards;
(e) Methods to be used and programme for the work;
(f) Resources (plant and labour);
(g) Supervision to be provided (by name);
(h) Safety provisions;
(i) Environmental provisions;
(j) Traffic control and temporary diversions to be implemented; and
(j) Inspection and Test Plan.
10.6 The Contractor shall reference applicable portions of previously prepared plans, such
as the Safety Plan or Quality Plan, in its Method Statements.
11 INSPECTION AND TEST PLANS
11.1 The Contractor, and through him, his consultants, subcontractors and suppliers
engaged in supplying, manufacturing, construction, installation, commissioning and
testing or any other service connected with the Works, shall maintain Inspection and
Test Plans (ITP) appropriate for the services they provide that are accepted by the
Employer’s Representative. These accepted ITP’s will stipulate the necessary level
and frequency of tests and inspections for each aspect of the Works, and also
stipulate, without limitation:
(a) The personnel responsible and/or involvement of various parties for undertaking
and certifying the inspection and/or testing;
(b) The procedure or instructions for the inspection and/or testing;
(c) The test method or a reference to the relevant standard of testing;
(d) The inspection and/or testing required prior to commencement of an activity;
(e) The inspection and/or testing during an activity and its frequency;
(f) The inspection and/or testing required for the completion of an activity;
(g) All Quality ‘Hold Points’ (H), ‘Witness Points’ (W) and ‘Observation Points’ (O)
shall be identified by the Contractor for his Quality Department to inspect and
verify its acceptance;
(h) The Employer’s Representative can place additional Quality ‘Hold Points’ (H),
‘Witness Points’ (W) and ‘Observation Points’ (O) for the Contractor’s Quality
Department on a case-by-case basis; and

(h) Employer’s Representative may designate additional Quality ‘Hold Points’ for his
inspection on a case-by-case basis.
11.2 The Contractor shall conduct inspections and tests in accordance with his detailed
plans as stipulated in the ITP. Records shall be kept of the completion of the
inspections and tests that identify the record of the results which shall be made
available for review during Employer’s Representative audit.
12 QUALITY PERSONNEL
12.1 The Contractor shall appoint a suitably qualified and experienced person(s) as the
‘Quality Assurance Manager’ to be responsible for the task of ensuring that the
requirements of the Quality Management System are implemented and maintained.
The Contractor shall, at the time of submission of the proposed management Key
Personnel, shall submit for review by the Employer’s Representative details of the
qualifications, experience, authority and responsibility of the proposed Quality
Assurance Manager.
12.2 The Contractor shall ensure that the Quality Assurance Manager is able to discharge
his duties without hindrance or constraint. In addition, the Contractor shall make
available any such resources that are necessary to ensure the effective implementation
of the quality system and all quality plans.
12.3 The Contractor shall appoint a suitably qualified and experienced person as the
‘Quality Control Manager’ to lead teams of Quality Control Engineers for carrying
out, independent from other teams, inspections of the Works as identified as the
Quality ‘Hold Point’, ‘Witness Point (W), ‘Observation Point (O). The Contractor
shall, at the time of submission of the proposed management Key Personnel, submit
for review by the Employer’s Representative details of the qualifications, experience,
authority and responsibility of the proposed Quality Control Manager.
12.3.1 Refer to Clause A15 Section A, of this Volume 1 for the qualification requirements
for Key Staff.
12.4 The Contractor shall ensure that the Quality Control Manager is able to discharge his
duties without hindrance or constraint, including but not limited to the authority to
suspend works as considered necessary. In addition, the Contractor shall make
available any such resources that are necessary to ensure the effective implementation
of the quality system and all quality plans.
12.5 Quality Control Engineers:
The Contractor shall assign Quality Control Engineers for each shift for each
location/activities where work is being performed. Each lead inspector shall be
qualified by training and experience in all the construction activities being conducted
at the Site.
Quality Control Engineers shall have a minimum of ten (10) years construction /
installation experience with at least five (5) years experience in the inspection,
sampling and testing of works of the type being constructed. If required on the
request of Employer’s Representative additional inspectors shall be appointed, at no
additional cost to the Contract.
12.6 Materials Technicians:
The Contractor shall assign qualified materials technicians to conduct the sampling

and testing of materials, goods and supplies for the Contract.
12.7 Staffing Levels:
The actual size of the Site staff shall reflect the complexity, needs, shifts and
composition of Quality Control activities consistent with work in progress. The
staffing levels shall be consistent with the Contractor’s Quality Plan and the Project
Baseline Programme, the relative locations of work in progress and the nature of the
work.
The Quality Plan shall identify administrative/clerical support for the maintenance
and management of records/documents pertinent to Quality Control activities.
13 MONTHLY PROGRESS REPORT
13.1 The Contractor shall continuously monitor the performance of his Quality
Management System, which shall be included in each Monthly Progress Report
(MPR) in accordance with Volume 1 – Section 8, Appendix 5.
13.2 Quality Certifications:
The Contractor shall submit a written certification by the Quality Assurance Manager
certifying that:
(a) The Quality Plan and all of the measures and procedures provided therein are
functioning properly and are being fully complied with, except as specifically
noted in the certification.
(b) All work, including that of the Designer, and all other designers, subcontractors at
all tiers, suppliers and fabricators, has been checked and/or inspected by the
Contractor’s Designer Checker, except as specifically noted in the certification,
conforms to the requirements of the Contract.
Refer to Volume 1 - Section 3, Attachment C1.
13.3 Weekly
Weekly records shall be prepared and maintained that provide factual evidence that
required activities and/or tests have been performed, including the following:
(a) Type, number and results of quality assurance and quality control activities,
including but not limited to reviews, inspections, tests, audits, monitoring of work
performance and materials analysis;
(b) Qualifications of personnel, procedures and equipment used;
(c) The identity of the Quality Control Engineer or data recorder, the type of test or
observation employed, the results and the acceptability of the work and action
taken in connection with any deficiencies noted;
(d) Nature of nonconforming work causes for rejection, with photographs etc;
(e) Preventive actions;
(f) Proposed corrective actions;
(g) Corrective actions taken and with whose authority; and
(h) Results of corrective actions.
13.4 The Employer’s Representative reserves the right to inspect and audit these

documents at any time.
14 QUALITY CONTROL REQUIREMENTS
14.1 The Contractor shall, in accordance with the quality control requirements of the
Specification and other documents included in the Contract, prepare and maintain
quality item lists which establish the criteria for control of each major component or
activity during design, construction and/or manufacture and installation,
commissioning and servicing in accordance with the need to ensure the desired
quality requirements of the Works.
14.2 All inspection and testing shall be the responsibility of the Contractor, at Contractor's
cost. In all cases, the cost of materials for such tests shall be borne by the Contractor.
14.3 The work shall conform to high standards of material, design and workmanship. The
Contractor shall conform to the Quality standards prescribed in the Contract
document(s).
14.4 At Site, the Contractor shall arrange the materials, their stacking/storage in
appropriate manner to ensure that the quality of the materials is not compromised.
The Contractor shall provide all the necessary equipment and qualified manpower to
test the quality of materials, assemblies etc. The tests shall be conducted at specified
intervals and the results of tests properly documented.
14.5 The Employer’s Representative shall be free to carry out such additional tests as may
be decided by him at his sole discretion, from time to time, in addition to those
specified in this document. The Employer’s Representative shall also be free to
appoint any third party for inspection and testing of important items like stay cables
and steel work including welding etc, at his own cost. The Contractor shall provide
the samples and labour for collecting the samples. No extra payment shall be payable
to the Contractor for samples or for the collection of the samples. The results of such
additional tests and third party inspection shall be binding on the Contractor.
14.6 The test(s) shall be conducted at the Contractor’s Site laboratory which shall be
established by the Contractor or at any other standard external laboratory selected by
the Employer’s Representative. The Contractor shall transport the samples to the
laboratory for which nothing extra shall be payable. In the event of the Contractor
failing to arrange transportation of the samples in proper time, the Employer’s
Representative shall have them transported and recover two times the actual cost from
the Contractor. All sampling and testing shall be performed in the presence of
assigned Contractor Quality Personnel. Testing may be witnessed by the Contractor
or his authorised representative if permitted by the Standard External Laboratory.
Whether witnessed by the Contractor or not, the test results shall be binding on the
Contractor.
14.7 The Employer’s Representative shall have the right at all times to inspect all
operations including the source of materials, procurement, layout and storage of
materials, all equipment including the concrete batching and mixing equipment, and
the quality control system. Such an inspection shall be arranged and the Employer’s
Representative's approval obtained prior to starting of the particular item of work.
This shall however, not relieve the Contractor of his responsibilities.
14.8 All materials which do not conform to the Specifications shall be rejected and shall be
removed from the Site immediately. The Employer’s Representative shall have the

power to cause the Contractors to purchase and use materials from any particular
source, as may, in the Employer’s Representative's opinion, be necessary for the
proper execution of Works.
14.9 Field/Site Laboratory
14.9.1 All the materials to be used in the work and tested in the laboratory shall comply with
the Employer’s Requirements or such recognised specifications as acceptable to
Employer’s Representative as detailed in clause 3.2 and 3.3 respectively.
14.9.2 The testing machines shall be recalibrated periodically as per Contractor Quality Plan
and applicable regulatory Standards. The calibration shall be from an authorized
laboratory in accordance with clause 3.2 and approved by Employer’s Representative.
14.9.3 The Contractor or his authorised representative shall assist in the collection,
preparation, forwarding and testing of such samples. The cost of such samples and
tests shall be borne by the Contractor. The Contractor shall give not less than seven
(7) days notice for all tests in order that the Employer’s Representative. Two (2)
copies of all test certificates shall be supplied by the Contractor to the Employer’s
Representative for approval immediately after the completion of the tests. Test
certificates must be supplied to the Employer’s Representative before the materials or
components are used in the works, unless the Employer’s Representative directs
otherwise.
14.10 Frequency of Testing
All materials shall be tested as per the requirements specified in the Contractor’s
Quality Plan and Annexure I. All test reports shall be documented in hard copy as
well as soft copy.
14.11 Unsuitable Materials
If at any stage of execution of work, Employer’s Representative finds that the
particular material is not suitable to be used in any component of the work, the
Employer’s Representative may order retesting of the material from any approved
laboratory at the cost of the Contractor. The rejected material either after the initial
test or after re-testing, as the case may be, shall be immediately removed from the
Site by the Contractor at his own cost. In case of default on the part of the Contractor
in removing rejected materials and any work executed with such unaccepted
materials, the Employer’s Representative shall be at liberty to have them removed
and/or dismantled by other means at the risk and cost of the Contractor.
15 NOTIFICATION OF NONCONFORMITES
15.1 If the Contractor has used or proposes to use or repair any item of the Works which
does not conform to the requirements of the Contract, he shall immediately submit for
review by the Employer’s Representative a proposal for rectification, and supply full
particulars of the nonconformity and, if appropriate, of the proposed means of repair.
15.2 If the Employer’s Representative issues nonconformity reports, either product based
as a Non-Conformance Report (NCR) or procedural through quality audit as a
Corrective Action Request (CAR) or similar documents to notify the Contractor of
any item of the Works which does not conform to the requirements of the Contract,
the Contractor shall promptly investigate the matter and submit for review within
fourteen (14) days of notification by the Employer’s Representative of the remedial

measures to be taken and stating the reasons for the measures and the corrective and
preventive action.
15.3 The Contractor shall maintain a Non Conformity Register to indicate the status of all
nonconformities which have been identified by the Employer’s Representative and
the Contractor.
16 NOTICE OF PLACE OF MANUFACTURE AND/OR SOURCE OF SUPPLY
16.1 The Contractor shall notify the Employer’s Representative of the places of
manufacture and/or the source of supply of all goods and materials to be incorporated
into the Works and shall give reasonable notice (which shall not in any event be less
than fifty-six (56) days) to the Employer’s Representative before the start of any
manufacturing and/or the supply of goods and materials.
17 NOTICE OF INSPECTION, TEST, TRIALS BY THE CONTRACTOR
17.1 In relation to all Quality Control points and Quality ‘Hold Points’ involving
inspection and/or witness testing by the Employer’s Representative, the Contractor
shall give the Employer’s Representative notice of when the relevant work will be
inspected and/or tested. The period of notice shall be as follows; unless otherwise
agreed by the Employer’s Representative:
(a) In the case of on-Site work, such notice shall be given not less than forty-eight
(48) hours of normal working time before the work is to be inspected and/or
tested;
(b) In the case of work carried out off-Site in Chennai, such notice shall be given not
less than fourteen (14) days before the work is to be inspected and/or tested; and
(c) In the case of work carried out offshore outside of India, such notice shall be
given not less than twenty-eight (28) days before the work is to be inspected
and/or tested
18 WITNESS BY THE EMPLOYER’S REPRESENTATIVE
18.1 In relation to all Quality Control Points involving inspection and/or testing by the
Contractor, the Employer’s Representative may elect to witness such inspections
and/or tests but, on expiration of the period of notice pursuant to clause 17, the
Contractor may proceed with the inspections and/or tests notwithstanding the absence
of the Employer’s Representative or of any response to the said notice. Witness by
the Employer’s Representative shall not discharge the Contractor of the responsibility
to provide acceptable product, nor shall it preclude subsequent rejection by the
19 CERTIFICATE OF MANUFACTURED GOODS OR MATERIALS
19.1 The Contractor shall obtain certificates for each batch of manufactured goods and
documentary evidence that goods, supplies and materials and Contractor’s Equipment
conform to the Contract requirements for incorporation in the Works. Each certificate
and/or proofing document shall include all reports of inspections and/or tests carried
out at the place of manufacture.

19.2 The Contractor shall make available at the Site no less than twenty-four (24) hours
prior to installation or use of such goods, supplies or materials and Contractor’s
Equipment all certificates and/or proofing document(s).
19.4 Materials Certificate of Compliance:
Within seven (7) days of the issue of a Completion Certificate for a Section or for all
the Works, the Contractor shall submit a Certificate of Compliance signed by the
Project Manager and the Quality Assurance Manager indicating that all materials,
goods and supplies incorporated in the Works conform to the requirements of the
Contract.
20 REPORTS OF INSPECTIONS, TESTS AND TRIALS
20.1 The Contractor shall compile reports of each inspection and/or test. Such reports shall
show the results of all the inspections and/or tests carried out and shall certify that the
work has been inspected and/or tested in accordance with the requirements of the
Contract and that the work complies with the requirements of the Contract. Any
analysis of the results required to confirm that the work complies with the
requirements of the Contract shall be compiled in accordance with clause 21 and
reported to the Employer’s Representative in accordance with clause 23.
20.2 Each report of inspection and/or test shall be signed by a representative of the
Contractor who has been allocated the requisite authority under the relevant
Inspection and Test Plan and signed by the Contractor’s Quality Assurance Manager.
21 TIME LIMIT FOR FILING OF REPORTS FOR INSPECTIONS AND/OR
TESTS
21.1 The Contractor shall ensure that a signed copy report of each in-situ and each off-site
inspection / test is filed in his Records Office within 3 (three) working days and
within seven (7) working days of the date of completion of the test process
respectively.
22 QUALITY CONTROL REGISTER
22.1 The Contractor shall provide and maintain at all stages of the work a quality control
register or registers to identify the status of inspections, sampling and testing of the
work and all certificates. Each register shall:
(a) List the certificates received for each batch of manufactured goods or materials
incorporated in the Works and compares this against the certification required by
the Contract and the Contractor's Quality Plan(s);
(b) List the inspection, sampling and testing activities undertaken by the Contractor
on each element of the Works and compare these activities against the amount of
inspection, sampling and testing required by the Contract and the Contractor's
Quality Plan(s);

(c) Show the results of each report of inspection and/or test and any required analysis
of these results and compare these results against the acceptance criteria,
including:
(i) Standard deviation and coefficient of variation for each grade of concrete;
(ii) Summary of trail mix for each grade of concrete;
(iii) Summary of sample type and quantity that has been sent for third party
testing;
(iv) Summary of third party testing reports;
(v) Summary of calibration status of monitoring and measurement equipment,
batching plant/s; and
(vi) Summary of in-process testing for routine dynamic pile load test, static pile
load test, lateral load test (if required) and pile integrity test etc that have
been conducted that month.
(d) Cumulative quantity of each grade of concrete produced from RMC and/or
dedicated batching plant/s;
(e) Summary of Non Conformance Reports (NCR), raised internally by Contractor in
its Quality Management System and as directed by Employer’s Representative.
23 SUMMARIES OF INSPECTION AND/OR TEST
23.1 The Contractor shall submit to the Employer’s Representative for his information
summaries based on each quality control register showing the type and amount of
certification received and the sampling, inspection, and/or testing undertaken on each
element of the Works during the previous week as part of the Weekly Report, in
accordance with clause 13.3. The summaries shall identify and demonstrate the
compliance of such certification, sampling, inspection and/or testing with the
requirements of the Contract and shall identify any item which does not conform to
the requirements of the Contract.
24 SAMPLES
24.1 The Contractor shall ensure those concrete compression test specimens are controlled
as followed:
(a) each sample is identified in accordance with clause 24.3;
(b) all samples are protected, temporarily stored, handled and transported to the
laboratory under the direct supervision of a suitably qualified representative of
the Contractor’s laboratory;
(c) no samples are mislaid, damaged, or contaminated, and
(d) the properties of the sampled material are at no time adversely affected.
24.2 All samples for testing shall be fully prepared for transportation and testing by the
Contractor and shall be delivered by the Contractor to the place of testing.
24.3 The Contractor shall ensure that concrete test specimens are identified by a unique
reference which, at a minimum, shall contain at least four fields of reference. The

sample reference shall be in the form of ‘LLNN / LNN / NNNN / LLNN’ where:
(a) ‘LLNN’ is the alpha-numeric Contract number;
(b) ‘LNN’ is the alpha-numeric concrete design mix, for example M25 (‘M’ refers
mix and the number ‘25’ represents the characteristic compressive strength of
15cm cube at 28-days in MPa);
(c) ‘NNNN’ represents the date of sample with ‘day-month’; and
(d) ‘LLNN’ is the alpha-numeric Transit Mixer, for example ‘TM01’
24.4 For all test samples, the Contractor shall ensure that all samples are identified by a
unique number in accordance with its quality control procedure for inspection and
test status of materials and manufactures products and shall contain the required
identification for traceability. At a minimum, the identification reference shall consist
of:
(a) Contract number;
(b) Test identification code assigned by the Contractor;
(c) Date of sample with ‘day-month’; and
(d) Unique sequential number of the sample under the particular test identification
Code.
24.5 Additional fields may be added by the Contractor with the consent of the Employer’s
Representative for the control of the laboratory activities and analysis of test results.
25 ADDITIONAL SAMPLES
25.1 The Contractor shall provide additional samples for testing if in the opinion of the
Employer’s Representative:
(a) The material previously tested no longer complies with the specified
requirements; or
(b) The material has been handled or stored in such a manner that it is no longer
represented by the previously tested samples.
26 TRIALS
26.1 Trials shall be carried out as stated in the Contract to demonstrate that the proposed
materials, equipment or methods of construction comply with the Contract.
26.2 Trials shall be carried out before commencement of construction or manufacture of
the relevant work in order to ensure that proposed methods and materials comply
with the specified requirements.
26.3 Trials shall be carried out using types of materials and methods of manufacture,
construction and/or installation which have been reviewed and approved by the
26.4 Unless permitted by the Employer’s Representative, the materials and methods of
manufacture, construction and/or installation used in the trial to produce work
complying with the requirements of the Contract shall not be changed unless further
trials have been carried out to demonstrate that the proposed changes are satisfactory.
26.5 All references to ‘tests’ and ‘testing’ in the Contract shall, where the context so

permits, include trials and commissioning.
27 TIMING FOR INSPECTION BY THE EMPLOYER’S REPRESENTATIVE
27.1 The Contractor shall allow the Employer’s Representative a reasonable time to carry
out any inspection and/or witness testing and to assess the result of any inspection
and/or test before proceeding with the Works.
27.2 Unless the Employer’s Representative’s prior consent has been obtained, all
inspections and/or tests to be witnessed by the Employer’s Representative shall be
carried out between 0800 and 1800 hours, Monday to Saturday.
28 FAILURE OF CONTRACTOR TO INSPECT THE WORKS
28.1 The Employer’s Representative may reject the work in question, or require it to be
uncovered, in the event of any failure by the Contractor to inspect and/or test at a
Quality ‘Hold Point’ by Contractor’s Quality Department.
29 FAILURE OF THE CONTRACT TO TEST THE WORKS
29.1 If the Contractor fails to test, either type test or routine test or qualification test, for
each batch of goods or elements of the Works, then the Employer’s Representative
shall arrange for third party inspection at the Contractors risk and cost.

GC


PART 2
SECTION VI
SUB-SECTION E
APPENDIX-7A
DRAUGHTING AND CAD STANDARDS
DECEMBER 2021
DRAUGHTING AND CAD STANDARDS

1. INTRODUCTION
(1) The purpose of this document is to define the minimum Drafting and CAD standard to be
achieved by the Contractor for all drawings produced by the Contractor for the purpose of the
Works. The Contractor shall produce and obtain the Employer’s Representative’s Notice of
No Objection to a CAD Manual which defines the standards and procedures for producing
drawings. This will be co-ordinated with the CAD Manuals produced by the Interfacing
Contractors.
(2) By defining a common format for the presentations of drawings and CAD files, the exchange
of drawn information is improved and will maximise the use of CAD in the co-ordination
process.
(3) All submissions shall be made to the Employer's Representative in a format reviewed without
objection by the Employer's Representative and in accordance with the Contract
requirements.
(4) Paper and drawing sizes shall be “A” series sheets as specified in BS 3429.
(5) The latest available versions of the following software, compatible for use with Intel-
Windows based computers shall be used, unless otherwise stated, for the various electronic
submissions required:
Document Type Electronic Document Format
Text Documents MS Word, Ver. 2010
Spread Sheets MS Excel, Ver. 2010
Data Base Files MS Access, Ver. 2010
Presentation Files MS PowerPoint, Ver. 2010
Programmes Primavera P6 (now Oracle PPM) 8.1
AutoCAD Graphics CorelDraw ,Ver. 8.0/ AutoCAD Ver.15
Photographic Adobe Photoshop, Ver.6.0
Desktop Publishing Page Maker 6.5,5
CADD Drawings AutoCAD Ver. 15
(6) Media for Electronic File Submission
Two copies shall be submitted on separate DVDs, unless otherwise stated.
(7) Internet File Formats/Standards
(a) The following guidelines shall be followed when the Contractor uses the Internet browser
as the communication media to share information with the Employer / Employer’s
Representative.
(b) All the data formats or standards must be supported by Microsoft Internet Explorer
version 2010 or above running on Windows XP, Vista or Windows 7.
Section VI-Appendix-7A-Draughting & CAD Standards 7A-1 December 2021

(c) The following lists the file types and the corresponding data formats to be used on
Internet. The Contractor shall comply with them unless prior Notice is obtained from
the Employer's Representative for a different Data format:
File Type Data Format
Photo Image Joint Photographic Experts Group (JPEG)
Image other than Photo GIF or JPEG
Computer Aid Design files (CAD) Computer Graphics Metafile (CGM)
Video Window video (.avi)
Sound Wave file (.wav)
(8) The following states the standards to be used on the Internet when connecting to database(s).
The Contractor shall comply with them unless prior Notice is obtained from the Employer's
Representative for a different standard:
Function to be Implemented Standard to be Complied With
Database connectivity Open Database Connectivity(ODBC)
Publishing hypertext language on the Hypertext Markup Language (HTML)

World Wide Web
The hard copy of all documents shall be the contractual copy.

2. GENERAL REQUIREMENTS
2.1 General
(1) The Employer’s Representative shall provide a title block similar to that used in the Employer’s
Drawings.
(2) Each drawing shall be uniquely referenced by a drawing number, that shall define both the
current status and revision of the drawing, as described in Section 5 of Volume 8. The
current status of each drawing shall be clearly defined by the use of a single letter code as
follows:
P - Preliminary Design Drawing
D - Definitive Design Drawing
C - Construction Reference Drawing
W - Working Drawing
B - As-Built Drawing
M - As Manufactured Drawing
E - Employer's Drawing

2.2 Types of drawings

(1) "As-Built Drawings": means those drawings produced by the Contractor and endorsed by
him as true records of construction of the Permanent Works and which have been given a
notice from the Employer’s Representative..
(2) "Construction Reference Drawings": means those drawings referred to in Clause 2(8) of
the Employer's Requirements - Design in respect of which a Notice has been issued.
(3) “Design drawings” means all drawings except shop drawings and as-built drawings.
(4) “Site drawings and sketches” means the drawings, often in sketch form, prepared on site to
describe modifications of the Working drawings where site conditions warrant changes that
do not invalidate the design.
(5) “Shop drawings” means special drawings prepared by the manufacturer or fabricator of
various items within the Works to facilitate manufacture or fabrication.
(6) "Working Drawings" means the Construction Reference Drawings and such other drawings
and documents, such as bar bending schedules and manufacturing drawings, as are necessary
to amplify the Construction Reference Drawings for construction purposes, some of which
may be endorsed by the Employer’s Representative.
Numbering Summary
Each document shall be defined by 6 main items and its revision number as described below:
Table 1 : Revisable/non revisable documents
Client Code DDC503
Sub-Stage XX
Structure XXX
Discipline XX
Document
XX
Type
Document
00000
Number
Revision 0
*0 means that a digit will be provided

** X means that a letter will be provided
Example : DDC503-CD-GEN-AD-QA-00001-A0

All the aforesaid items are developed hereafter.

Sub-stage
Two digits are used for sub-stage definition as shown below:
Table 2 : Sub-stage numbering (revisable documents)
Stage Sub-Stage Code Used
Planning Planning & Initiation PL
Design Conceptual Design Phase CD
Design Preliminary Design Phase PD
Design Detail Design Phase DD
Note : All Definitive Design and Construction Reference Drawings (CRD) deliverables shall
be issued under Detailed Design Phase (DD).
Structure
Table 3 : Structure numbering (revisable documents)
Structure Code Used
General GEN
Survey & Investigation SUV
Geotechnical GEO
Track & Alignment TRA
Traffic Management/ Road Works ROW
Tunnel TUN
Ramps RMP
Elevated Viaduct ELV

All Underground Station UGS
All Elevated Station ELE
All At Grade Stations ATG
RETTERI JN. SRT
KOLATHUR JN. SKL
SRINIVASA NAGAR SSR
VILLIVAKKAM SUB URBAN STATION

SVM
(VILLIVAKKAM METRO)
VILLIVAKKAM BUS TERMINUS SVB
NATHAMUNI
SND
ANNA NAGAR DEPOT

SAN
THIRUMANGALAM STM
KOYEMBEDU JN. NORTH (KENDRIYA SKV

VIDYALAYA, ANNA NAGAR)
KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL

SKK
STREET)
CMBT. SCM
VENUGOPAL NAGAR
SVG
ASSISSI NAGAR
SAI

KILBURAN NAGAR (MANJAMBAKKAM)

SMB
VELUMURUGAN NAGAR
SVN
MMBT
SMM
SHASTRI NAGAR
SSN
Depot (at MADHAVARAM MILK COLONY) DMM
Installation & Services/ Utilities ISE
Discipline
Table 4 : Discipline numbering (revisable documents)
Discipline Code Used
All Disciplines AD
Survey SV
Geotechnical / Foundations GE
Track TK
Alignment AL
Traffic Management TM

Road Works RW
Architecture AR
Structural ST
Civil Works CW
MEP/Utilities EM
Landscaping Works LW
Finishing Works FW
Other Works OW
Type of Document
Table 5 : Type of document (revisable documents)
Type of document Code Used
Technical Specification TS
Technical Report TR
Technical Memo TM
Drawing DW
Organisation & Maintenance Manual OM
Bill of Quantities BQ
Document Numbering DN
Graphical Charter/Templates GC
Quality Assurance QA
Tender Documentation TD

X-REF files XR
Sketch SK
Document Number (last 5 digits)

5 digits are used for the document numbers
Two first digits are defining the location as defined in following para (for organization of work,
drawings will be stored in folder whose name is location number +“T”, hence for instance
00T for General Documents).
Last three digits provide the drawing and or reports number in that folder.
Location Code
Table 6 : Location code for Revisable Documents
Location Code Folder No.
Survey 01T
Track 02T
Alignment 03T
Traffic and Management/ Road Work 04T
Tunnel and Ramps 05T
Tunnel and Ramps 06T
Property Development 07T
Viaduct (Elevated Structures) 08T – 18T
Architecture (Elevated + UG Station) 20T – 27T
General Notes and Miscellaneous Details (Architecture) 19T
RETTERI JN. & KOLATHUR JN. 20T
SRINIVASA NAGAR & VILLIVAKKAM SUB URBAN STATION 21T

(VILLIVAKKAM METRO)
VILLIVAKKAM BUS TERMINUS & NATHAMUNI 22T
ANNA NAGAR DEPOT & THIRUMANGALAM 23T
KOYEMBEDU JN. NORTH (KENDRIYA VIDYALAYA, ANNA NAGAR)

24T
& KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL STREET)
CMBT & VENUGOPAL NAGAR 25T
ASSISSI NAGAR & KILBURAN NAGAR (MANJAMBAKKAM)

26T
VELUMURUGAN NAGAR, MMBT & SHASTRI NAGAR

27T
Depot (Architecture) 28T
General Notes and Miscellaneous Details (Structure) 29T
Structure (UG Station + Elevated Station + Depot Structure) 30T – 48T
VENUGOPAL NAGAR 30T
KOLATHUR JN. 31T
SRINIVASA NAGAR 32T
VILLIVAKKAM METRO 33T
VILLIVAKKAM BUS TERMINUS 34T
NATHAMUNI 35T
ASSISSI NAGAR 36T
MANJAMBAKKAM 37T
VELUMURUGAN NAGAR 38T

MMBT 39T
SHASTRI NAGAR 40T
RETTERI JUNCTION 41T
ANNA NAGAR BUS DEPOT 42T
THIRUMANGALAM 43T
KENDRIYA VIDYALAYA 44T
KALIAMMAN KOIL STREET 45T
Depot (Structure) 46T
CMBT 48T
MEP 50T – 80T
ELECTRICAL (RETTERI JN.+ KOLATHUR JN. + SRINIVASA NAGAR) 51T
ELECTRICAL (VILLIVAKKAM SUB URBAN STATION (VILLIVAKKAM

52T
METRO) + VILLIVAKKAM BUS TERMINUS + NATHAMUNI)
ELECTRICAL (ANNA NAGAR DEPOT + THIRUMANGALAM + KOYEMBEDU

53T
JN. NORTH (KENDRIYA VIDYALAYA, ANNA NAGAR))
ELECTRICAL (KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL STREET) +

54T
CMBT + VENUGOPAL NAGAR)
ELECTRICAL (ASSISSI NAGAR + KILBURAN NAGAR (MANJAMBAKKAM) +

55T
VELUMURUGAN NAGAR )
ELECTRICAL (MMBT + SHASTRI NAGAR) 56T
HVAC (RETTERI JN.+ KOLATHUR JN. + SRINIVASA NAGAR ) 57T
HVAC (VILLIVAKKAM SUB URBAN STATION (VILLIVAKKAM METRO) +

58T
VILLIVAKKAM BUS TERMINUS + NATHAMUNI)

HVAC (ANNA NAGAR DEPOT + THIRUMANGALAM + KOYEMBEDU JN.

59T
NORTH (KENDRIYA VIDYALAYA, ANNA NAGAR))
HVAC (KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL STREET) + CMBT +

60T
VENUGOPAL NAGAR)
HVAC (ASSISSI NAGAR + KILBURAN NAGAR (MANJAMBAKKAM) +

61T
VELUMURUGAN NAGAR )
HVAC (MMBT + SHASTRI NAGAR) 62T
PLUMBING (RETTERI JN.+ KOLATHUR JN. + SRINIVASA NAGAR ) 63T
PLUMBING (VILLIVAKKAM SUB URBAN STATION (VILLIVAKKAM

64T
METRO) + VILLIVAKKAM BUS TERMINUS + NATHAMUNI )
PLUMBING (ANNA NAGAR DEPOT + THIRUMANGALAM +

KOYEMBEDU JN. NORTH (KENDRIYA VIDYALAYA, ANNA 65T
NAGAR) )
PLUMBING (KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL STREET)

66T
+ CMBT + VENUGOPAL NAGAR )
PLUMBING (ASSISSI NAGAR + KILBURAN NAGAR

67T
(MANJAMBAKKAM) + VELUMURUGAN NAGAR )
PLUMBING (MMBT + SHASTRI NAGAR) 68T
BMS (RETTERI JN.+ KOLATHUR JN. + SRINIVASA NAGAR ) 69T
BMS (VILLIVAKKAM SUB URBAN STATION (VILLIVAKKAM

70T
METRO) + VILLIVAKKAM BUS TERMINUS + NATHAMUNI )
BMS (ANNA NAGAR DEPOT + THIRUMANGALAM + KOYEMBEDU

71T
JN. NORTH (KENDRIYA VIDYALAYA, ANNA NAGAR) )
BMS (KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL STREET) +

72T
CMBT + VENUGOPAL NAGAR )
BMS (ASSISSI NAGAR + KILBURAN NAGAR (MANJAMBAKKAM) +

73T
VELUMURUGAN NAGAR )

BMS (MMBT + SHASTRI NAGAR) 74T
FIRE PROTECTION (RETTERI JN.+ KOLATHUR JN. + SRINIVASA

75T
NAGAR )
FIRE PROTECTION (VILLIVAKKAM SUB URBAN STATION

(VILLIVAKKAM METRO) + VILLIVAKKAM BUS TERMINUS + 76T
NATHAMUNI )
FIRE PROTECTION (ANNA NAGAR DEPOT + THIRUMANGALAM +

KOYEMBEDU JN. NORTH (KENDRIYA VIDYALAYA, ANNA 77T
NAGAR) )
FIRE PROTECTION (KOYEMBEDU JN. SOUTH (KALIAMMAN KOIL

78T
STREET) + CMBT + VENUGOPAL NAGAR )
FIRE PROTECTION (ASSISSI NAGAR + KILBURAN NAGAR

79T
(MANJAMBAKKAM) + VELUMURUGAN NAGAR )
FIRE PROTECTION (MMBT + SHASTRI NAGAR) 80T
Depot (MEP) 81T
Systems 82T
BIM 85T – 90T
BIM (CSD/SEM (MEP)) 91T-93T
For these folders, last three digits are provided according to:
Table 7 : Documents number (revisable documents)
Item Last 3 Digit
Drawings 001 to 800
Calculation Notes/ Reports/ Specifications 801 to 999
2.5 Revision Number

Revision number shall be a combination of one letter and one digit. For instance, the
Deliverables issued initially to Lead Design Checker with the revision letter A0.

Letters define the origin of comments:

• A: comments issued by the Lead Design Checker
• B: comments issued by the Client (CMRL)
• C: changes requested by the Contractor
After their comments revision number shall be incremented to A1, A2. Once all comments have
been cleared internally, the deliverables shall be submitted to the Client at the corresponding
revision stage (for instance A2). Further request from the Client are recorded in revisions B0,
B1 ….
Here below is summarized the process for a given example (left hand column provides actual
status at the considered stage, right hand column mentions the action carried out on the
document at this revision level).
3. COMPUTER AIDED DESIGN & DRAFTING (CAD) STANDARDS

3.1 Introduction
Scope of Use; Data input procedures between the Employer’s Representative and Contractors must
be co-ordinated, and the key parameters used to form CAD data files must be standardised. The
Contractor shall be responsible for coordinating with the Employer’s Representative and Interfacing
Contractors to prepare, and obtain the Employer’s Representatives Notice of No Objection to a
CAD Manual setting out the production standards and procedures for CAD data files. The
production of all CAD data files shall comply with the following requirements.
3.2 Objectives
The main objectives of the CAD standards are as follows:
(a) To ensure that the CAD data files produced for the Project are co-ordinated and referenced in a
consistent manner.
(b) To provide the information and procedures necessary for a CAD user from one discipline or
external organisation to access (and use as background reference), information from a CAD
data file prepared by another discipline or external organisation.
(c) To standardise the information contained within CAD data files which may be common to
more than one discipline such as drawing borders, title boxes, grid lines etc.
(d) To establish procedures necessary for the management of CAD data files.
(e) To ensure all Contractors use ‘Model space’ and ‘Paper space’ in the production of their CAD
files’.
3.3 General
(1) To facilitate co-ordination between Contractors, it is a requirement that all drawings issued
by Contractors for co-ordination or record purposes shall be produced using CAD methods.
Drawings shall be issued in digital format in addition to the paper copies.
(2) The intent of the issue of digital information is to aid the related design by others. The
definitive version of all drawings shall always be the paper or polyester film copies which
have been issued by the Contractor or organisation originating the drawing.

(3) Drawings and drawing packages issued for co-ordination, record purposes or for acceptance
shall be accompanied by a complete set of the corresponding CAD data files.
(4) Any Contractor or organisation making use of the CAD data from others shall be responsible
for satisfying himself that such data is producing an accurate representation of the
information on the corresponding paper drawing which is satisfactory for the purpose for
which he is using it. Provided the general principles of this section have been achieved by
the originator of the CAD data, Contractors making use of the CAD data from others shall
not be entitled to require alterations in the manner in which such CAD data is being presented
to them.
(5) In particular, automatic determination of physical dimensions from the data file shall always
be verified against the actual figured dimensions on the paper or polyester drawings. Figured
dimensions shall always be taken as correct where discrepancies occur.
3.4 Terminology & Associated Standards / Guidelines
Any terminology used within this section that is ambiguous to the user shall be clarified with the
Employer's Representative. British Standard BS1192 is used in principle as a guide for drawing
practice, convention, CAD data structure and translation.
3.5 Paper Drawings
(1) Hard copies of the drawings, i.e. paper, are considered to be the main vehicle for the receipt
and transmittal of design and production information, typically plans, elevations and sections.
(2) The Project wide accepted media for the receipt and transmittal of “Paper” drawings will be
paper and polyester film of various standard ISO ‘A’ sizes. The composition of this
information shall be derived from a CAD “Model”, as noticed by the Employer’s
Representative.
(3) The CAD derived “Paper” drawing composition will reflect a window of information
contained within a CAD “Model Space” file together with a selection of information
contained within the associated CAD “Paper Space” file.
3.6 CAD Data Creation, Content & Presentation
A consistent method of CAD data creation, together with content and presentation is essential. The
method of CAD “Model Space and Paper Space” creation is as follows:
(1) Model Space Files
(a) Typically CAD “Model Space” files are required for general arrangement and location
plans and will consist of a series of other “Model Space” referenced CAD files covering the
total design extents at a defined building level (the number of referenced files should be
kept to an absolute minimum). Data contained within a CAD “Model Space” files is drawn
at full size (1:1) and located at the correct global position and orientation on the Project
Grid / or defined reference points.
(b) Each CAD “Model Space” file will relate to an individual discipline. Drawing border /
text, match / section lines or detailed notation shall NOT be included within a CAD “Model
Space” file. Dimensions shall be included within a CAD “Model Space” but located on a
dedicated layer. Elevations, Long Sections and Cross Sections shall also be presented in
CAD “Model Space” as defined above, but do not need to be positioned and orientated on
the Project Grid.
(2) Paper Space CAD Files

(a) Paper Space” CAD files are utilised to aid the process of plotting “Paper” drawings and are
primarily a window of the CAD “Model Space” file. A “Paper Space” CAD file will
typically contain drawing borders, text, match or section lines & detailed notation. Once
these files are initially set up and positioned the majority of “Paper Drawing” plots at
various approved scales are efficiently and consistently generated by displaying different
combinations of element layers and symbology contained within the “Paper Space” file and
the referenced “Model Space” files.
(b) The purpose is to ensure that total co-ordination is achieved between the CAD “Model
Space” file and the “Paper Drawing” output during the revision cycle of the design and
production process. Duplicated data in “Model and Paper Space” files will not be
acceptable unless an automatic update link exists between the two data sets. “Paper Space”
files are not typically required as part of the CAD Media Receipt from Contractors, unless
specifically requested by the Employer’s Representative.
3.7 CAD Quality Control Checks
(1) Random CAD Quality Control Audits will be carried out by Employer’s Representative on all
CAD media received and transmitted.
(2) These checks DO NOT verify the technical content of the CAD data received or transmitted, as
this is the responsibility of the originating organisation, however compliance with all CAD and
Draughting Standards shall be checked.
(3) In addition, all Contractors who transmit and receive CAD data relating to the Project shall
have CAD quality control procedures in place. A typical quality control procedure shall contain
CAD data quality checking routines coupled with standards for CAD data transmittal and
archiving.
3.8 CAD Data Transfer Media and Format
When CAD data is received & transmittal between the Employer, the Employer’s Representative,
the Contractor and Interfacing Contractors, the media shall be as follows:
(a) Data Exchange Format - AutoCAD Release 14 or latest version .DWG
(b) Operating System - Windows NT, Windows Vista or Windows 7
(c) Data Transfer Media shall be submitted on DVD-RW Discs, of at least 4.0 GB.
(d) All DVDs must be labelled with a stick-on circular data sheet with the following details:
(i) Name of Contractor and/or Company
(ii) Project Title
(iii) Drawing Filenames
(vi) DVD Reference No.& Total No. of DVDs
(e) All media shall be submitted with a completed Transmittal Form, refer to Attachment A2 of
Section A of this Volume 3.
(f) The Contractor must ensure the supplied media is free from all virus’s, spam, shareware, etc...
(g) Sub-directories on DVDs are not permitted. If CAD Data is created using UNIX, archive
commands must be unrooted.
3.9 CAD Media Receipt & Transmittal

(1) CAD Media Transmittal forms from the Contractor to the Employer’s Representative will
consist of the following:
(a) CAD Digital Media DVDs shall typically contain CAD “Model Space” and “Paper
Space” files.
(b) CAD data sheet
(c) CAD issue / revision sheet
(d) CAD Quality Checklist confirming compliance.
(e) Plot of each “Model Space” file issued on an A1 drawing sheet (to best fit).
(2) The above CAD media will be collectively known as “CAD Media Transmittal Set”. The
CAD data file transmittal format required by the Employer's Representative from all
contractors shall be AutoCAD Version 14 or latest version.
(3) All CAD media received from Contractors will be retained by the Employer’s
Representative, as an audit trail / archive of a specific Contractor’s design evolution.
(4) CAD Media Receipt, issued by the Employer’s Representative to the Contractor.
(a) CAD media should normally be obtained from the respective Interfacing Contractor(s),
but should the Employer’s Representative issue CAD media it will consist of the
following :
(i) CAD Digital Media DVDs typically contain only CAD “Model Space” files.
(ii) CAD data sheet.
(iii) CAD issue / revision sheet
(b) The above CAD media will be collectively known as the “CAD Media Receipt Set”. The
CAD data file transmittal format used by the Employer’s Representative to all
Contractors will be in AutoCAD (version 14)
(c) Each CAD transmittal disk / tape will be labelled with proper disk label as approved by
the Employer’s Representative. Any CAD data transmitted without this label is assumed
to be provisional information not to have been quality checked and therefore not formally
issued.
3.10 Revisions
(1) All ‘Revisions’, ‘In Abeyance’ and ‘Deletions’ shall be located on a common layer. This
layer can be turned on or off for plotting purposes.
(2) The following example text indicates the current CAD file revision, i.e. ‘Revision [A]’. This
shall be allocated to a defined layer on all CAD “Model Space” files, in text of a size that will
be readable when the CAD “Model Space” file is fitted to the screen, with all levels on.
3.11 Block Libraries, Blocks, & Block Names
(1) All Construction Industry symbols produced as CAD Cells shall typically conform to British
Standard BS1192 - part 3.
(2) All Blocks created shall be Primitive (i.e. NOT Complex) and shall be placed Absolute (i.e.
NOT Relative).
(3) The Contractor's specific block libraries shall be transmitted to Employer’s Representative

together with an associated block library list containing the filename (max. 6 characters) and
block description. The Contractor shall ensure that the library is regularly updated and
circulated to all other users, together with the associated library listing.
(4) All Blocks of a common type, symbols or details should initially be created within a CAD
“Model Space File” specifically utilised for that purpose. These files will be made available
on request by the Employer’s Representative.
(5) All Blocks created will typically be 2D unless 3D is specifically requested. In both instances
they shall have an origin at a logical point located within the extents of each Block’s masked
area or volume.
3.12 CAD Dimensioning
Automatic CAD Dimensioning will be used at all times. Any dimensional change must involve the
necessary revision to the model space file. If the CAD Quality Control Checks find that the
revisions have not been correctly carried out, the rejection of the entire CAD submission will result.
3.13 CAD Layering
All CAD elements shall be placed on the layers allocated for each different discipline. The layer
naming convention to be adopted by the Contractor shall be submitted for acceptance and inclusion
within these standards.
3.14 Global origin, Location & Orientation on the Alignment Drawing.
(1) Location or Plan information in “Model Space” files shall coincide with the correct location
and orientation on the Project grid for each specific contract.
(2) Location plans shall have at least three setting out points shown on each CAD “Model Space”
file. Each setting out point shall be indicated by a simple cross-hair together with related
Eastings and Northings co-ordinates.
3.15 Line Thickness and Colour
To assist plotting by other users, the following colour codes will be assigned to the following line
thickness / pen sizes.
Colour Code No Line Thickness

Red 10 0.18
White 7 0.25
Yellow 2 0.35
Brown 34 0.5
Blue 130 0.7
Orange 30 1.0
Green 3 1.4
Grey 253 2.0

3.16 CAD Utilisation of 2D & 3D Files

Although the project standard is 2D CAD files, certain disciplines and contractors may use 3D
CAD files for specific applications or where the isolated use of 3D aids the design and visualisation
process, i.e. Architecture, Survey and Utilities. In these specific instances 3D CAD data will only
be transmitted if all other users can use this data. If this is not the case, a 3D to 2D translation shall
be processed by the creator prior to issue.
3.17 CAD File Numbering
(1) Contractors CAD File Numbering shall be described in 2.2 above.
(2) The Employer will not be required to produce numerous CAD files, but if they issue any the
drawings shall follow the required Contract numbering system, except that the status of the
drawing in clause 2.1(3) shall be "E".
3.18 CAD File Naming Convention – General
CAD “Model Space” files shall be named in accordance with general drawing conventions.

Chennai Metro Rail Project Phase 2, Corridor 5 Part-2, Section VI


PART 2
SECTION VI
SUB-SECTION E
APPENDIX-7B
BIM STANDARDS
DECMEBER 2021
Section VI – Appendix – 7B i December 2021

BIM Standards

Table of Contents
1 Introduction and Purpose ...............................................................................................................1

2 General Requirements.....................................................................................................................1
3 BIM Execution Plan.........................................................................................................................2
4 BIM Roles and Responsibilities .....................................................................................................2
5 BIM Objectives, Responsibilities and Deliverables ....................................................................3
6 Provision of Modelling Services to SWC’s ..................................................................................5
7 Coordinated Combined Service Model (CCSM) Submission ................................................5
8 Clash detection Management.........................................................................................................7
9 Ownership and Rights to BIM Deliverables ...............................................................................8
10 BIM Specification and Level of Detail..........................................................................................8
11 BIM Modelling Requirements.......................................................................................................9
12 BIM Software and Formats for Exchange and Submittal ................................................... 10
13 BIM Processes and Procedures .................................................................................................. 11
14 Integration with Maintenance Management System (MMS).............................................. 11
15 Hardware & Software .................................................................................................................. 12
16 Annexure:1 The Project BIM Objective and Responsibility Matrix ................................. 13
Section VI – Appendix – 7B 7B-2 December 2021

BIM Standards
1 Introduction and Purpose
Building information Modelling is an intelligent 3D model-based process that gives architecture, engineering,
and construction (AEC) professionals the insight and tools to more efficiently plan, design, construct, and
manage buildings and infrastructure. It is a very powerful tool that when used properly will save money, time
and simplify the construction process.
The purpose of this document is to define the minimum requirements on BIM use to be achieved by the
Contractor’s in the Project.
2 General Requirements
The Consultant Shall develop, maintain, update and handover a Building Information Model (BIM) for the
works with a level of LOD 300.
The Contractor’s shall develop BIM Models from LOD 350 to till LOD 500 (As-Built).
The Contractor shall interface with the SWCs, Nominated Sub Contractor (if any), and any other
subcontractors, to obtain all necessary drawings, sketches, BIM services, models and other BIM related
deliverables/information.
The Contractor shall be responsible to integrate all such information into the As-Built Asset Model and ensure
its accuracy and consistency.
By defining this common format for the preparation and presentation of BIM models, the exchange of
information will improve and consequently maximize the use of BIM in the construction phase.
BIM Requirements (Construction) shall include modelling, visualization, documentation, coordination and the
collaborative use of these models throughout the project delivery as defined in this document.
In addition, the BIM Requirements (Construction) is defined to support the asset management framework of the
Employer. Employer shall issue BIM guidelines after award of work to successful bidder to adopt and
incorporate as-built models in compliance.
2D CAD submissions shall continue to adhere to the standards issued by the Employer and comply with the
requirements of Employer’s BIM guidelines. All drawings for submission to other authorities shall be prepared
in accordance with the requirements of the relevant Employer.

BIM Standards
3 BIM Execution Plan
The purpose of the BIM Execution Plan is to outline the plan and processes in which BIM will be
implemented throughout the project lifecycle to meet the BIM requirements of the Project. The
Contractor shall maximize the use and take full advantage of BIM for the purpose of the Project and
to enhance team collaboration and coordination. Team collaboration and coordination shall be
maximized using BIM.
The BIM Execution Plan shall be developed accordance with the BS1192:2007 and PAS 1192-
2:2013 Standards.
After award of the Contract, the BIM Execution Plan shall be submitted to the Employer for review
and acceptance, at times as indicated in Annex 1 – “BIM Objective and Deliverables”.
Modifications to an agreed BIM Execution Plan shall be agreed by all parties and the Employer.
4 BIM Roles and Responsibilities
A BIM Manager shall be appointed for the Contract as the main point of contact for BIM to overall
manage and coordinate the use and delivery of BIM for the Contract.
The BIM Manager shall ensure the appropriate implementation of the BIM Execution Plan and
deliverables as well as the effective and efficient collaboration and coordination of design. The
roles and responsibilities of the BIM Manager shall encompass those indicated in BS1192:2007
and PAS 1192-2:2013 Standards and Annex 1- Project BIM Objective and Deliverables of this
document. The responsibilities of the BIM Manager and BIM Coordinators shall be agreed and
documented in the BIM Execution Plan.
The BIM Manager shall transfer unconditionally to a successor BIM Manager, at such times as
directed by the Employer, all tangible and intangible property and information that came into his
possession, custody or control in its capacity as BIM Manager.
BIM Coordinators for each respective discipline of Architecture, Civil & Structure, M&E Service
& E&M Systems including Building Services shall be appointed by the Contractor.

BIM Standards
The roles and responsibilities of the BIM Coordinators shall include but not limited to those
indicated in the BS 1192:2007 and PAS 1192-2:2013 Standards and the following:
a) Point of contact and BIM expert responsible for the development, implementation and
management of BIM Execution Plan, BIM strategies, processes and standards for his
discipline/area of design works;
b) Coordinate with BIM Manager, other BIM coordinators, and consultants;
c) Oversee appropriate data flow internally and externally. Validate level of detail,
modeling content and quality control
d) Participate in design and model coordination meetings and reviews sessions.
Other than the Project Manager and Team Leaders of respective disciplines, the roles of BIM
Manager and BIM Coordinators may be undertaken by another existing project team member.
The appointed BIM Manager and BIM Coordinators shall have experience and qualification
subject to the Engineer’s acceptance.
5 BIM Objectives, Responsibilities and Deliverables
In general, BIM deliverables shall include a set of digital representations of the Project in the form
of BIM Models, reports, CAD Drawings and other non-geometrical data that describe the physical,
functional and performance characteristics of the Project for the purpose of visualization,
simulation, analysis, collaboration, planning, and documentation throughout the project lifecycle.
BIM models, BIM services and all other BIM related deliverables provided throughout the contract
phases shall at minimum meet the BIM objectives and requirements set out in this document.
The Project BIM Objective and Responsibility Matrix in Annex 1 defines the basic BIM
objectives, deliverables and responsibilities of the different parties applied in each phase of the
project.
Architect/Engineer shall prepare an as-built model for the purpose of submission to the relevant
authorities. The Contractor will produce an As-built Asset Model fit for the purpose of asset
management, with as-built details embedded (in 2D or 3D where applicable) for archival.

BIM Standards
The Contractor shall update, share and submit BIM deliverables in accordance with the
requirements, times and receiving parties as documented in the BIM Execution Plan.
The Coordinated Combined Service Model shall refer to the model comprising of all disciplines
involve throughout the project that is coordinated for purpose of construction by the Contractor and
interfacing parties.
All necessary BIM models and other BIM shall be provided to the SWCs as part of the information
exchange, as required. All such information shall be provided at no cost to the SWCs in a timely
fashion as specified in the BIM Execution Plan.
The Contractor shall ensure that the As-built Asset Model tallies with the Architects/Engineer
Model. This includes (1) geometries of BIM elements tally, and (2) any other common information
requirements between the two models.
Cut-off dates for exchange of Models by Model Authors to Model Users shall be the same as the
cut-off date for exchange of information and drawings as indicated in the Terms of Reference,
unless otherwise agreed. Agreed cut-off dates for exchange of Models or other deliverables shall be
documented in the BIM Execution Plan.
Upon award of the Contract, all Final Design Models shall be issued by the A/E to the successful
Contractor(s) for reference. The Contractor will issue the Final Design Models (Coordinated
Combined Service Model) or the latest coordinated Construction models to the SWC’s for
Reference.
During Construction stage, the Contractor’s is(are) to ensure that the latest issued updated Final
Design Model is incorporated into the As-built Asset Model at reasonable intervals for the purpose
of supporting construction coordination and design interfacing.
Data sharing and coordination amongst various parties shall be carried out interactively, leveraging
software technology. The process of coordination, collaboration and data sharing shall be led by
the Contractor and agreed among all parties involved in BIM Modelling and clearly documented in
the BIM Execution Plan.
The Contractor shall lead all parties and engage them in regular 3D review process throughout the
duration of the Project. Process may include regular meetings where both the Coordinators and
relevant design decision making the Employer are expected to attend.

BIM Standards
As-built models of Architecture, Civil and Structure works, MEPF/SWC’s Services shall be
developed and verified by the Contractor and finalized by the SWC’s and submitted to the
Employer.
The BIM Deliverables shall meet the quality assurance guidelines as stated in the BS1192:2007
and PAS 1192-2:2013 Standards. Any deviation of quality assurance guidelines shall be outlined in
the BIM Execution Plan for the Employer’s review and acceptance.
6 Provision of Modelling Services to SWC’s
Contractor shall provide architectural Design drawings to the SWC’s in DWG format for
implementing their Services.
System Wide Contractor’s (SWC’s) shall provide Entire Design Services / Components to the
Contractor in DWG format for converting into the 3D Model.
The Contractor shall continuously make BIM model based on the SWC’s Drawings Contractor
shall also model the services with sizes of diameter 32mm or more as shown in the drawings
submitted by SWC’s.
The Contractor shall coordinate with these SWC’s to verify and update the correctness of the
models. In an event where there are disputes between the Contractor and SWC’s, the decision of
the Engineer shall be final. The Contractor shall submit these models and its associated files by the
cut-off date for exchange of information indicated in Schedule of Key dates.
7 Coordinated Combined Service Model (CCSM) Submission
The Contractor shall obtain the Environmental Control System, Low Voltage System, Power and
Traction Supply, Tunnel Ventilation System and Fire Protection System models from the
respective designers if the SWC’s are not onboard. The Contractor shall coordinate and agree with
the interfacing parties on any proposed changes to the models for purpose of coordination and
development of the CCSM. The Contractor shall ensure all the changes developed and agreed by
the interfacing parties during the coordination process shall be properly documented.
The Contractor shall model all structural openings/ penetrations and embedment for the services.
The Contractor shall coordinate with the interfacing parties to identify the locations of the
structural openings that are less than diameter 50mm and model these in the CCSM. The CCSM
shall also capture and coordinate services that are of diameter 32mm or more using BIM. CCSM
color coding for MEPF disciplines will be provided upon award of the Contract.

BIM Standards
The Contractor shall model all services in the escape shaft, cross passages and all types of tunnels
etc. and be responsible to resolve all data losses due to conversion for the purpose of the production
of the CCSM. The Contractor shall coordinate with adjacent Civil Contractors to ensure that their
interfaces are spatially modelled.
A use of different BIM authoring tools for the station, depot, substation and tunnels is envisaged,
the Contractor shall be responsible to ensure full integration of their models on the different
platforms used. All limitations to this integration must be identified in the BIM Execution Plan and
demonstrated to be unfeasible for implementation.
The Contractor shall lead and conduct at least two (2) Virtual design review (VDR) workshops
after information exchange cut- off date and prior to the Combined Services Drawing (CSD) /
Structural Electrical Mechanical (SEM) submission. The Contractor shall invite all SWC’s and the
Employer's representatives to attend the workshop and shall demonstrate that clashes identified
during the coordination meetings were resolved.
The Contractor shall ensure that a zero clash CCSM is submitted. The Contractor shall attach a
clash analysis report if there are clashes in the CCSM submission. The clash analysis report shall
detail the BIM coordination and clash detection activities and submitted together with the
CSD/SEM submission.
The report shall include but not limited to:
i) Indication of clash detection / omission settings used in all clash detections.
ii) Clash detection matrix indicating the numbers of clash between various disciplines.
iii) Coordination and clash detection between Architectural/Structural design models.
iv) Coordination and clash detection between MEPF design models.
v) Coordination and clash detection between MEPF/SWC’s design models.
vi) Identification of all clashes with differentiation of valid and invalid clashes.
The Contractors shall provide viewpoints in the coordinated combined service model capturing
area with clashes and incompliance that requires the Employer’s attention. The annotations to these
viewpoints shall be in sync with the clash analysis report for ease of identification.

BIM Standards
For standardization purpose and to avoid missing data during the conversion from one software
format to another, the Contractor shall submit the Coordinated Combined Services model in
accordance with the software format adopted by the Employer’s Consultant during the design
stage.
The Contractor shall submit the CCSM, the clash analysis report together with CSD/SEM drawings
according to Schedule of Key dates.
8 Clash detection Management
The Contractor shall conduct and manage an adequate and thorough clash detection process before
commencing construction so that interferences between BIM elements will be detected and
resolved before installation.
The clash detection process shall uncover and address hard clashes (tolerance of 0.001 m) between
modelled elements and soft clashes such as infringements into code or maintenance required
clearances and necessary clearance for any non- modelled elements. Prior to each scheduled
coordination meeting, the BIM Manager shall issue an updated clash report to all interfacing
parties.
The Contractor shall use the soft clash function to identify and address the critical criteria which
shall include but not limited to the following requirements:
i) 150mm spacing between all services.
ii) 400mm spacing all services and the ceiling system in public areas
iii) 1700mm clearance in the UPV along the escape / access paths.
iv) 2100mm clearance in all Service corridor, Fireman and escape stairs.
v) 3000mm clearance along the equipment replacement routes.
The Contractor shall use coordination software for assembling various construction models to
electronically identify, collectively coordinate resolutions, and track and publish interference
reports between all disciplines. The Contractor shall be responsible for updating the CCSM on a
monthly basis to reflect the coordinated resolution.
The Contractor must review the CCSM and the clash reports in coordination meetings as required
by the BIM Execution Plan, until all spatial and system coordination issues have been resolved.
And update the CCSM for provide the interfacing parties.

BIM Standards
9 Ownership and Rights to BIM Deliverables
The Employer shall have the ownership and exclusive rights to all BIM Deliverables of the Project
unless otherwise agreed by the parties.
The Employer has the right to grant its appointed agents the rights to use the BIM Deliverables for
the purpose of the Project and subsequent operation and maintenance of the works at his discretion
10 BIM Specification and Level of Detail
The boundaries of the As-built Asset Model shall correspond to that of the Architect/Engineer.
Unless otherwise specified by the Employer, this shall cover the extent of engineering and
construction required of the Contractor’s scope of work. At minimum, this shall encompass
corridors of the railway and depot if any. BIM models shall include all Architectural, Civil,
Structural, Depot Building Services and any other specialist systems required to produce a
complete digital representation of all buildings and facilities.
Buildings and facilities shall at minimum include Elevated / UG stations, viaducts, bored tunnels,
Ramp as well as facilities, buildings and structures within the contract.
Temporary Works will not be included in the As-Built Asset Model, unless left in place by the
Contractor. However, submission of temporary works drawings for approval by the Employer will
still be necessary.
Existing utilities, structures and facilities that interface with the proposed contract shall be
modelled unless agreed otherwise, if any. Such existing elements shall be clearly demarcated in the
As-Built Asset Model and specified in the BIM Execution Plan.
Typical BIM elements to be provided in BIM Models shall be in accordance with BS1192:2007,
PAS 1192-2:2013 & BIM Forum LOD Specification Standards “Typical BIM Elements by
Discipline” and BIM elements of objects typically related to Rail Transit Systems and Trackwork.
BIM elements or objects not listed in BS1192:2007 and PAS 1192-2:2013 Standards and Annexure
1 of this document but are required to meet the BIM objectives or to describe the construction work
accurately shall be created with parametric BIM authoring software by the Contractor. The
Contractor shall liaise with the A/E and confirm with the Employer on the required parameter
variables.

BIM Standards
In general, the BIM elements shall be modelled according to its size, shape, location, orientation
and quantity. At the early stages of the Project, element properties are more generic and
approximate, but become more specific and increases in accuracy as the project progresses.
To the greatest extent practicable, the BIM shall model all items / elements that will be constructed
and installed. In the event if any of the items / elements that cannot be practicably modelled due to
software limitations, the Contractor shall identify and list out all such limitations in the BIM
Execution Plan also established in Model Production Delivery Table (MDPT) with justification and
shall be subjected to the acceptance by the Engineer.
At each project phase, BIM elements and its geometric properties (e.g. length, slope) and non-
geometric attributes (e.g. material, fire rating, functional information) shall be developed according
to the level of details.
The list of BIM elements and systems and the corresponding level of details required for each BIM
element including the unit of measurement, geometric and non-geometric properties at each project
phase shall be established and documented in the BIM Execution Plan.
The Contractor shall ensure that the As-Built Asset Model. The model should not lag during
routine operations using BIM Authoring tools.
11 BIM Modelling Requirements
The modelling guidelines in BS1192:2007 and PAS 1192-2:2013 Standards BIM Modelling
Guidelines (Appendix C) shall be the basic reference for modelling of BIM elements.
Model Quality Assurance. Clear directions for maintaining and controlling model quality shall be
established and documented in the BIM Execution Plan.
A common naming convention for model file names, model views, legends, schedules sheets and
links for the whole contract as per the BS1192:2007.
A standard folder structure convention will be provided after contract award. Both file naming and
folder naming convention shall be followed and if any additional layers required by the project is to
be developed by the Contractor’s BIM Manager and proposed in the BIM Execution Plan, in
consultation with the A/E’s BIM Manager and the Employer.

BIM Standards
Drawing and Document Standards. Links shall be maintained within the ABAM to enable
automatic generation of drawings. As-built drawings shall fully be derived and generated from As-
built Asset Model possible. Drawing shall include, but not limited to plans, sections, elevations,
quantities and schedules, and shall be delivered as representations of or extraction from BIM
models. All 2D CAD data and deliverables shall follow Employer’s Requirements and Design
Submission of Reports and Drawings.
Limitation and Constraints on Data Entries in Model. To facilitate the limitation and constraints on
codes in Data Registration Tools for MMS, a guide on coding will be provided upon award of
Contract.
12 BIM Software and Formats for Exchange and Submittal
The BIM Execution Plan must list the BIM software and computer operating system used by the
Contractor for this project. The software and operating systems shall be identified by vendor,
product name, version identifier, patch number and data architecture (32bit/64bit). Listed software
and listed operating systems shall not be changed or upgraded without the Engineer's acceptance.
BIM exchange formats and protocols shall be developed and agreed by all parties involved in
collaborating and contributing to the Model content. Agreed BIM exchange formats and protocols
shall be documented in the BIM execution Plan.
Software file formats and version to be used for the Project and for submission to the Employer
shall be agreed among the parties contributing to the Models before the start of the project. A list of
the BIM deliverables shall be submitted for acceptance of the Engineer and the corresponding
submission file formats shall be proposed in the BIM Execution Plan for the Employer’s
acceptance.
BIM Format for submission to the Employer. BIM Models submitted at various stages of
project development or as and when requested by the Employer shall be available in the format
suitable for its purpose. In general, the following formats are required and shall be provided:
a) RVT for Archiving
b) DWG & PDF for General Viewing & Archiving
c) NWD For Clashes Analysis
d) Construction-Operations Building Information Exchange (COBIE) for asset data, if requested.

e) Any other open standard format, as requested by the Employer.

BIM Standards
13 BIM Processes and Procedures
Processes and procedures required to achieve BIM objectives and to meet the requirements of BIM
Requirements (Design and Build) shall be established and implemented. Development of BIM
processes shall take into considerations the guidelines detailed in the BS1192:2007 and PAS 1192-
2:2013 Standards and include but not limited to the following:
a) BIM Workflow and Delivery methodologies
b) Individual Discipline Modelling
i. Revision Management
ii. Model Orientation and Site configuration
iii. Model division and Structure
iv. Model Guidelines
c) Inter Discipline Project Collaboration and data sharing
i. Data Sharing, collaboration and coordination review process, framework and protocol
including the data information and models to be shared, files format and frequency of data
sharing for coordination reviews.
d) Cross disciplinary Model coordination and Clash Detection
i) Coordination Process and Plan including use of BIM in the Employer’s Coordination
meetings.
ii) Clash detection procedure, Methodology and Plan
e) Quality Assurance and Quality Control.
14 Integration with Maintenance Management System (MMS)
The Civil Contractor shall interface with the MMS contractor.
As part of the requirements for Asset Management, the ABAM will serve as the interface between
the MMS and other digital systems.
The principle behind the integration is the unique identification of all modelled elements (called
asset tags), so that there is no ambiguity in different digital systems.
The Model Author is to tag each asset in the BIM Model as a property of the modelled element
within the BIM software. For example, the “Mark” property may be used to hold this asset tag
information.

BIM Standards
Civil Contractors are to reference the asset tags from AEM and its associated
drawings where given or are not provided within the AEM and its associated drawings, the Civil
Contractors may propose his own tags, subject to approval of the Employer.
A coding guide for the asset tags will be provided upon award of Contract
15 Hardware & Software
The Contractor shall provide one (1) set of hardware and software license to the Employer to carry
review and clash detection analysis of the Coordinated Combined Services model till Completion
of Whole Works.
The software shall be in accordance with the software format adopted by the Employer’s
Consultant during the design stage. The specifications of the hardware and software shall be
submitted to the Employer for acceptance.

BIM Standards
16 Annexure:1 The Project BIM Objective and Responsibility Matrix
Project Parties involved in fulfilling

Project BIM Objectives/ Uses of BIM Deliverables
the Objectives/Deliverables
A – Model Author
1) Construction Stage and Final Design U – Model User
1a) The following Objectives/Uses of BIM indicate the responsibilities of A/E and MEPF
Consultants during the construction phase, the development of revised Final Design Models
MEPF
Consu
In-hse
SWC
A/E
CC
1b) Part plans and Working drawings issued by A/E and MEPF Consultants and SWC’s
shall fully be derived from revised and updated Final Design Models possible.
1.1 Continuously update and revise Final Design

Models of (1)
Architectural, Civil, Structural, Building Services, (2)
MEPF Services, TVS & PS to reflect design changes
Updated Final Design
Models that affect or are required for coordination and A (1) A (2)
design interfacing shall be issued to the Civil Revised Final Design Models U U U
Contractor(s) and SWC’s Interfacing Parties for reference U (2) U (1)
at an interval needed for coordination or design
interfacing as determined by the Engineer. Updated Final
Design Models shall be issued with or provide references
to the associated part prints or working drawings
1.2 A/E shall coordinate with the Civil Contractor and be
responsible for ensuring that the Final Design BIM Model
tallies with the As-built Asset Model, and is accurate in Coordinated Revised Final Design BIM A A U U U
model
terms of: Size, Shape, Location, Quantity and Orientation.
Revised Final Design BIM models
comprising: -
(1) Architectural
1.3 A/E shall develop, verify, finalize, freeze and submit (2) Civil A
Revised Final Design BIM model to the Employer A A U U
(3) Structural U
(4) Building Services
(5) MEPF, TVS, PS, Systems and
Trackwork

BIM Standards
Project Parties involved in fulfilling the

Project BIM Objectives/ Uses of BIM Deliverables Objectives/Deliverables
2) Construction and Coordinated Combined Services Model A – Model Author
2a) The following Objectives/Uses of BIM indicate the responsibilities of Civil Contractor during U – Model User
the construction phase, the development of Coordinated Combined Services model
2b) Part plans and Working drawings issued by A/E and MEPF Consultants and SWC’s shall fully
MEPF
Consu
In-hse
SWC
A/E
CC
be derived from revised and updated Final Design Models possible.
2c) CCSM refers to Coordinated combined services model and the requirements shall be
referenced from BIM specifications.
2.1 Civil Contractor shall propose the objectives,
processes and outcomes of BIM for the project,
subject to the approval of the Employer. A BIM Execution Plan submitted to
Agreed cut-off dates for exchange of models or the Employer for review and U A
other deliverables shall be documented in the BIM acceptance within 30 days from award
Execution Plan. of contract or a mutually agreed date.
2.2 Civil Contractor will issue the Coordinated Final Design Coordinated Final Design Model
Models or the latest coordinated construction models to or latest coordinated construction A U
the SWC’s upon award of SWC’s contract for reference. model
2.3 Civil Contractor shall develop the model from design Signaling & Telecom Platform Screen
drawings and sketches provided by SWC’s Doors, TVS, ECS, MMS, Power, OHC, A U
Trackwork, AFC, Lift, Escalator, Depot
equipment and SCADA
2.4 Civil Contractor shall receive all Final Design Models
from A/E, and be responsible for: -
(1) Interim Final and Updated Final CCSM U U U A U
- Coordinating all Final Design Models with clash analysis report.

BIM Standards

2) Construction and Coordinated Combined Services Model A – Model Author
2a) The following Objectives/Uses of BIM indicate the responsibilities of Civil Contractor during U – Model User
the construction phase, the development of Coordinated Combined Services model
2b) Part plans and Working drawings issued by A/E and MEPF Consultants and SWC’s shall fully
MEPF
Consu
In-hse
SWC
A/E
CC
be derived from revised and updated Final Design Models possible.
2c) CCSM refers to Coordinated combined services model and the requirements shall be
referenced from BIM specifications.
- Checking final CCSM against latest Design Models
- Checking all 2D drawings issued by A/E corresponds
with the Final Design Model
- Civil Contractor shall coordinate with the A/E, E&M
consultants, LTA in house consultants and SWC to develop
the Interim Final and Updated Final CCSM BIM models for
submission as per the key dates specified in Appendix B of
the Particular Specifications.
2.5 Civil Contractor shall continuously update the changes
in the CCSM models via a process approved by the Updated CCSM with clash analysis report U U U A U
Engineer
2.6 Civil Contractor shall develop the As-built CCSM
and submit for approval. As-Built CCSM A

BIM Standards

3) Construction, and As-built Asset Management A – Model Author
U – Model User
3a) The following Objectives/Uses of BIM indicate the responsibilities of Civil Contractor during the
construction phase, the development of As-built Asset model.
3b) Part plans and Working drawings issued by A/E and MEPF Consultants and SWC’s shall fully be
derived from revised and updated Final Design Models possible.
MEPF Consu
3c) As-built Asset Model shall be modelled as specific building components and systems that are
In-hse
QP(S)
SWC
updated with changes made upon the completion of construction and accurate in terms of Size,
A/E
CC
Shape, Location, Qty, and Orientation. Unless otherwise approved by Employer, As-Built drawings
shall be derived from As-built models.
3d) As-built Asset model shall also include any left-in-place temporary ERSS works and any other works
designed by Civil Contractor or Civil Contractor’s QP. As-built BIM model for such works shall be
created and submitted by Civil Contractor.
3e) As-built Asset model shall also include system wide information from SWC’s.
- Individual Final Design Models

3.1 Civil Contractor shall receive all Final Design Models (coordinated) of (1) Architectural, Civil,
from A/E, and be responsible for: - Structural, BS, System and Trackwork
- Coordinating all Final Design Models (2) M&E Services (3) TVS & PS A
- Checking Pre-final CSD/SEM against Final Design U
Models - Single combinedcoordinate U
- Checking all 2D drawings issued by A/E d model(s)
corresponds with the Final Design Model combining all the above Final
Design models (1)
3.2 Civil Contractor shall propose the objectives, processes
and
outcomes of BIM for the project, subject to the approval
of the Employer. A BIM Execution Plan submitted to the
Employer for review and acceptance U A
Agreed cut-off dates for exchange of models or other within 30 days from award of contract or a
mutually agreed date.
deliverables shall be documented in the BIM
Execution Plan.
3.3 Civil Contractor will issue the Coordinated Final Design Coordinated Final Design Model or latest A U
Models

BIM Standards

U – Model User
MEPF Consu
In-hse
QP(S)
SWC
updated with changes made upon the completion of construction and accurate in terms of Size, Shape,
A/E
CC
Location, Qty, and Orientation. Unless otherwise approved by Employer, As-Built drawings shall be
derived from As-built models.
The latest coordinated construction models to the SWCs coordinated construction model
upon award of SWC’s contract for reference.
3.4 Civil Contractor will be responsible for verifying system- Coordinated As-built Asset Model
wide comprising: - A U U
information, and subsequently including these into the As- (2) System-wide Information
built Asset models. QP(S) will be responsible for validating (3) As-built Asset Model
the system- wide information in the models.
3.5 Civil Contractor shall coordinate with the A/E and be
responsible for ensuring that the As-built Asset Model
tallies with the Final Design BIM Model, and is accurate in Coordinated As-built Asset U U U A
Model
terms of: Size, Shape, Location, Quantity and Orientation.
3.6 Civil Contractor shall continuously update and revise
the As-built Asset Model to reflect the actual U A
construction.
3.7 Civil Contractor shall develop the As-built model for
Building Services and issue to A/E. As-built drawings shall U A
be derived from the As-built model as much as possible.

BIM Standards


U – Model User
MEPF Consu
updated with changes made upon the completion of construction and accurate in terms of Size, Shape,
In-hse
QP(S)
Location, Qty, and Orientation. Unless otherwise approved by Employer, As-Built drawings shall be
SWC
A/E
CC
derived from As-built models.
As-built Asset BIM models

comprising: -
(1) Architectural
(2) Civil
(3) Structural
(4) Left-in-place ERSS and
3.8 Civil Contractor shall develop, verify, finalize, freeze any other works designed by
and submit As- built Asset Model to the Employer U A
Contractor’s QP
(5) Building Services
(6) MEPF, TVS, PS, Systems
and Trackwork

BIM Standards
“Construction of Underground Stations at Kolathur Junction,

Srinivasa Nagar, Villivakkam Sub-urban Station (Villivakkam),
Villivakkam Bus-Terminus and Nathamuni (Villivakkam MTH
Road) with Entry / Exit, Ventilation shafts, Plumbing, Earthmat,
Architectural finishes & Signages etc. including Twin Bored
Tunnels from Kolathur Junction Retrieval Shaft to Nathamuni
(Villivakkam MTH Road) Launching Shaft and Ramps with U -
section in Corridor-5 of CMRL phase-II project”
PART 2
SECTION VI
SUB-SECTION E
APPENDIX-8
WORK AREAS & TEMPORARY POWER
SUPPLY
DECEMBER 2021
Part-2 Section VI
WORK AREAS & TEMPORARY POWER SUPPLY

1. INTRODUCTION
(1) The Contractor shall provide within the designated principal Works Areas, at locations
agreed with the Employer’s Representative, the compounds and facilities for the
Employer, the Employer’s Representative, the Contractor and Project Contractors of the
Employer as described elsewhere in this Contract and to the engineering conditions
defined under Clause 2 of this Appendix 8.
(2) The standard conditions applying to the use of any Works Area by the Contractor for its
site facilities are given under Clause 2 of this Appendix.
(3) The Conditions for supply of electricity by the Contractor to Interfacing Contractors are
given under Clause 3 of this Appendix.
(4) Other aspects of design, supply and construction within works areas, including structures
within works areas shall be covered by the relevant parts of the Specification.
2. STANDARD ENGINEERING CONDITIONS
The following standard engineering conditions apply to all Works Areas:
(1) Formation
(a) The Works Areas shall be formed to the levels that the Employer’s Representative
has issued a notice. No such levels shall be amended without a notice from the
(b) The Works Areas shall be surfaced in a manner agreed with the Employer’s
Representative, compatible with their intended use, and, in particular, footpaths and
roadways connecting facilities shall be clearly defined. Measures shall be taken to
the satisfaction of the Employer’s Representative to ensure all areas are properly
drained and kept free of standing water.
(c) The removal, diversion or reinstatement elsewhere as may be required of any
existing works or installation whatsoever within the Works Areas shall be carried
out to the satisfaction of the Employer’s Representative.
(2) Roads & Parking
(a) Space shall be provided within the Works Areas for parking, loading/unloading and
manoeuvring of motor vehicles.
(b) Any damage done to the adjoining public roads and fixtures and properties (public
or private) shall be made good to the satisfaction of the Employer’s Representative.
(3) Drainage & Sewerage
(a) All storm or rainwater from the Works Areas including any access roads thereto shall
be conveyed to the nearest stream course, catch-pit, channel or storm water drain as
required by the Employer’s Representative. All temporary and permanent works
shall be carried out in such a manner that no damage or nuisance are caused by storm
water or rain water to the adjacent property.
(b) No drain or watercourse shall be used without a notice issued from the Employer’s
Representative.
Section VI- Appendix 8 8-1 December 2021

Work Areas & Temporary Power Supply
Part-2 Section VI
(c) Damages or obstructions caused to any watercourse, drain, water-main or other

installations within or adjoining the Works Areas shall be made good to the
satisfaction of the Employer’s Representative.
Treatment and disposal of sewage and wastewater from the Works Areas shall be provided to
the satisfaction of the Employer’s Representative.
Buildings
No permanent structures other than those required for the Permanent Works shall be
temporarily permitted on the Works Areas.
Electricity, water, telephone and sewerage shall be provided by the Contractor, as required, for
all temporary buildings.
No public supply potable water shall be used for heating, cooling and humidification purposes,
or vehicle washing without a notice from the Employer’s Representative.
Pedestrian Access
Every existing pedestrian access throughout the Works Areas shall be maintained in a usable
condition at all times to the satisfaction of the Employer’s Representative including lighting,
signing and guarding.
Fencing
The Works Areas shall be secured against unauthorised access at all times. In particular fencing
or the like shall be maintained, removed and re-erected in the new location wherever and
whenever a Works Area is relinquished in stages.
3. ELECTRICAL SUPPLY CONDITIONS
3.1. Work on Site
The Contractor shall nominate a representative whose name and qualifications shall be
submitted in writing to the Employer’s Representative for review not later than 4 weeks before
the appointment and who shall be solely responsible for ensuring the safety of all temporary
electrical equipment on Site. The Contractor shall not install or operate any temporary Site
electrical systems until this representative is appointed and has commenced duties.
The name and contact telephone number of the representative having been reviewed with a
notice of no objection by the Employer’s Representative shall be displayed at the main
distribution board for the temporary electrical supply so that he can be contacted in case of an
emergency.
Schematic diagrams and the details of the equipment for all temporary electrical installations
shall be submitted by the Contractor, and these diagrams together with the temporary electrical
equipment shall be submitted to the Employer’s Representative for a notice.
All electrical installation work on Site shall be carried out in accordance with the requirements
laid down in BS 7375 and the Specification. All work shall be supervised or executed by
qualified and suitably categorised electricians, who are registered as such under the Electricity
Ordinance 1990 / Electricity (Registration) Regulations 1990.
3.2. Electrical General
Temporary electrical Site installations and distribution systems shall be in accordance with:-
Indian Electricity Rules

Part-2 Section VI
The Power Companies’ Supply Rules;

Electricity and its subsidiary Regulations;
IEE Wiring Regulations (16th Edition);
BS 7375 Distribution of Electricity on Construction and Building Sites;
BS 4363 Distribution Assemblies for Electricity Supplies for Construction and Building Sites;
and
Any other applicable national standards
3.3. Materials, Appliances and Components
All materials, appliances and components used within the distribution system shall comply with
BS 4363 and BS 7375 Appendix A.
3.4. Design Considerations
1. Distribution equipment utilised within the temporary electrical distribution system shall
incorporate the following features:-
(a) flexibility in application for repeated use;
(b) suitability for transport and storage;
(c) robust construction to resist moisture and damage; and
(d) safety in use.
2. All cabling shall be run at high level whenever possible and be firmly secured to ensure
they do not present a hazard or obstruction to people and equipment.
3. The installation on Site shall allow convenient access to authorised and competent
operators to work on the apparatus contained within.
3.5. Mains Voltage
1. The Site mains voltage shall be as per the Electricity Authority, 415V / 3 phase 4 wire
system.
(a) Single phase voltage shall be as per the Electricity Authority, 230V supply.
(b) Reduced voltages shall conform to BS 7375.
2. Types of Distribution Supply
The following voltages shall be adhered to for typical applications throughout the
distribution systems:
a) fixed plant - 415V/ 3 phase;
b) movable plant fed by trailing cable - 415V / 3 phase;
c) installations in Site buildings - 230V/1 phase;
d) fixed flood lighting - 230V/ 1 phase;
e) portable and hand held tools - 115V/1 phase;
f) Site lighting (other than flood lighting) - 115V/1 phase; and
g) portable hand-lamps (general use) - 115V/1 phase.

Part-2 Section VI
3. When the low voltage supply is energised via the Employer's transformer, any power
utilised from that source shall be either 415V 3 phase or / 230V. 1 phase as appropriate.
The Contractor shall carry out any conversion that may be necessary to enable him to use
power from that source.
4. Protection of Circuits
a) Protection shall be provided for all main and sub-circuits against excess current,
under and over voltage, residual current and earth faults. The protective devices shall
be capable of interrupting (without damage to any equipment or the mains or sub-
circuits) any short circuit current that may occur.
b) Discrimination between circuit breakers, and fuses shall be in accordance with:-
(i) BS 88;
(ii) BS EN 60898; and
(iii) BS 7375;
(iv) Any other appropriate Indian Standards
3.6. Earthing
1. Earthing and bonding shall be provided for all electrical installations and equipment to
prevent the possibility of dangerous voltage rises and to ensure that faults are rapidly
cleared by installed circuit protection.
2. Earthing systems shall conform to the following standards:-
(a) IEE Wiring Regulations (16th Edition);
(b) BS 7430;
(c) BS 7375; and
(d) IEEE Standard 80 Guide for Safety in AC Substation Grounding.
3.7. Plugs, Socket Outlets and Couplers
Low voltage plugs, sockets and couplers shall be colour coded in accordance with BS 7375,
and constructed to conform to BS EN 60309. High voltage couplers and 'T' connections shall be
in accordance with BS 3905.
3.8. Cables
1. Cables shall be selected after full consideration of the conditions to which they will be
exposed and the duties for which they are required. Supply cables up to 3.3KV shall be in
accordance with BS 6346.
2. For supplies to mobile or transportable equipment where operation of the equipment
subjects the cable to flexing, the cable shall conform to one of the following
specifications appropriate to the duties imposed on it:
(a) BS 6708 flexible cables for use at mines and quarries;
(b) BS 6007 rubber insulated cables for electric power and lighting; and
(c) BS 6500 insulated flexible cords and cables.
3. Where low voltage cables are to be used, reference shall be made to BS 7375. The

Part-2 Section VI
following specifications shall also be referred to particularly for underground cables:-

(a) BS 6346 for armoured PVC insulated cables; and
(b) BS 6708 Flexible cables for use at mines and quarries.
4. All cables which have a voltage to earth exceeding 65V (except for supplies from welding
transformers to welding electrodes) shall be of a type having a metal sheath and/or
armour which shall be continuous and effectively earthed. In the case of flexible or
trailing cables, such earthed metal sheath and/or armour shall be in addition to the earth
core in the cable and shall not be used as the sole earth conductor.
5. Armoured cables having an over sheath of polyvinyl chloride (PVC) or an oil resisting
and flame retardant compound shall be used whenever there is a risk of mechanical
damage occurring.
6. For resistance to the effects of sunlight, overall non-metallic covering of cables shall be
black in colour.
7. Cables which have applied to them a voltage to earth exceeding 12V but not normally
exceeding 65V shall be of a type insulated and sheathed with a general purpose or heat
resisting elastomer.
8. All cables which are likely to be frequently moved in normal use shall be flexible cables.
Flexible cables shall be in accordance with BS 6500 and BS 7375.
3.9. Lighting Installation
1. Where Site inspection of the Works is required during the nights, the Lighting circuits
shall be run separate from other sub-circuits and shall be in accordance with BS 7375 and
BS 4363.
2. Voltage shall not exceed 55V to earth except when the supply is to a fixed point and
where the lighting fixture is fixed in position.
3. Luminaries shall have a degree of protection not less than IP 54. In particularly bad
environments where the luminaries are exposed to excesses of dust and water, a degree of
protection to IP 65 shall be employed.
4. The Contractor shall upgrade the lighting level to a minimum of 200 lux by localised
lighting in all areas where required by the Employer’s Representative.
5. Mechanical protection of luminaries against damage by impact shall be provided by use
of wire guards or other such devices whenever risk of damage occurs.
3.10. Electrical Motors
1. Totally enclosed fan cooled motors to BS 4999: Part 105 shall be used.
2. Motor control and protection circuits shall be as stipulated in BS 6164. Emergency stops
for machinery shall be provided.
3.11. Inspection and Testing
3. Electrical installations on Site shall be inspected and tested in accordance with the
requirements of the IEE Wiring Regulations (16th Edition).

Part-2 Section VI
3.12. Identification
Identification labels of a type reviewed with a notice of no objection by the Employer’s
Representative shall be affixed to all electrical switches, circuit breakers and motors to specify
their purpose.
3.13. Maintenance:
1. Strict maintenance and regular checks of control apparatus and wiring distribution systems
shall be carried out by an electrician (duly qualified to carry out the said checks) to ensure
safe and efficient operation of the systems. The Contractor shall submit for a notice by the
Employer’s Representative details of his maintenance schedule and maintenance works
record.
2. All portable electrical appliances shall be permanently numbered (scarf tag labels or
similar) and a record kept of the date of issue, date of the last inspection carried out and
the recommended inspection period.


JUNCTION RETRIEVAL SHAFT TO NATHAMUNI (VILLIVAKKAM
MTH ROAD) LAUNCHING SHAFT AND RAMPS WITH U -
SECTION IN CORRIDOR-5 OF CMRL PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SETION E
APPENDIX-9
RAILWAY ENVELOPE ACCESS AND
TAKING OVER
DECEMBER 2021
1. RAILWAY ENVELOPE TAKING OVER
(1) The Railway Envelope is defined in the Employer's Requirements - General.
(2) The conditions for Taking Over of the Railway Envelope are as follows:
(a) The Contractor shall complete and allow the Employer to Take Over the Railway
Envelope on the Key Date defined in Appendix 2A of this Volume 1 –
Employer’s Requirements. From this date any access to the Railway Envelope by
the Contractor shall be in accordance with any procedures, requirements and
conditions laid down by the Employer as defined under Clause 1(3) of this
Appendix 9 of this document.
(b) At the time of Taking Over the Railway Envelope, the Contractor shall have
executed all necessary works on the structure and all other work within the
Railway Envelope, including the installation of all equipment fixings defined
within the Contract, and shall ensure that the Envelope is complete, secure, safe
for the operation of trains, and has the Employer's and Employer's
Representative’s notice of no objection for effective Taking Over.
(c) From the Railway Envelope taking over date, any access to the Railway Envelope
by the Contractor shall be in accordance with the conditions contained within
clause 3 of this Appendix.
(3) The conditions for access to the Railway Envelope after Taking Over are as follows:
(a) Access to the Railway Envelope after Taking Over will be controlled by the
Employer and priority will be given to the testing and trial running of rolling stock
and other operating components associated with the railway. Access will be given
to the Contractor and to other Contractors by the Employer for inspecting,
maintaining, adjusting and repairing, by prior arrangement and for limited periods.
(b) At the time of Taking Over, the Contractor shall provide the Employer with the
name of an individual charged with liaising with the Employer on a twenty-four
(24) hour contact procedure. The Contractor shall give two weeks’ notice of his
desired track possessions, and this appointed liaison officer shall attend, when
requested, the appropriate meetings where track possession allocations will be
made by the Employer. It may be necessary for the Contractor's work to be carried
out intermittently or at night if suitable possessions cannot be given during its
preferred hours. During all such operations the Contractor will be fully responsible
for safety of men, equipment and works.
(c) After the Taking Over, and prior to the completion of the Project, the Interfacing
Contractors may be undertaking, but not limited to, the following activities:
i. laying of tracks and other connected equipment.
ii. testing traction and signalling equipment together with other equipment and
facilities required for operation of the railway. During this period the
Employer and/or his contractors will be running works trains through the
Railway Envelope.
Section VI Appendix 9 9-1 December 2021

Railway Envelope Access and Taking Over
iii. undertaking acceptance tests, Integrated System Tests and test running:
During this period the Employer and/or his contractors will be running trains
through the Railway Envelope on a regular basis.
iv. undertaking trial running. During this period the Employer will be operating
trains and equipment on a trial basis, the frequency of which will increase as
the trials proceed until full operating frequencies are reached.
The Contractor shall take into account the Interfacing Contractors’ activities and
train operations in planning and programming his Works.
(4) Prior to the issue of the Taking over Certificate for the Project, the Contractor will be
given extended possessions of the Railway Envelope for the purposes of final
adjustment, tightening, touching up or cleaning up prior to the final inspection of the
Works. Such possessions shall be agreed with the Employer in accordance with the
procedure set out under Clause 1(3)(b) of this Appendix 9 of this document.
2. RAILWAY EQUIPMENT
(1) Nonstructural items.
Maintenance walkways within the Railway Envelope and any flooring, screens,
handrails and exit doors forming the boundary of the Railway Envelope required in
the terms of the Contract shall be supplied and installed by the Contractor before the
Railway Envelope is taken over by the Employer.
(2) Electrical and Mechanical Equipment Fixings.
(a) The Contractor shall be responsible for all co-ordination with the Employer and
Project Contractors for determining the detailed requirements for equipment
fixing provisions in accordance with the Contractor’s Works Programme.
(b) No additional holes or welding to structural members beyond those shown on
the Working Drawings, nor changes to hole or weld locations shall be permitted
without the notice of the Employer’s Representative.

Railway Envelope Access and Taking Over

PART 2
SECTION VI
SUB-SECTION E
APPENDIX-10
APPROVED MANUFACTURERS / SUPPLIERS
DECEMBER 2021
APPROVED MANUFACTURERS/SUPPLIERS
All materials and products shall conform to the relevant standard specification, BIS codes and other
relevant codes etc. shall be of make and quality as approved by engineer.
The list of approved makes for products and materials is given below. Other equivalent manufactures
may also be considered with prior approval of the engineer, if found conforming to all standards. Such
requests should be made with all documents concerned to the Engineer at least 45 days before the
material is required and any order shall be placed only after receiving the written approval of the
Engineer.
Approved Manufacturers / Suppliers (UG)
All materials and products shall conform to the relevant standard specification, BIS codes and
other relevant codes etc. shall be of make and quality as approved by engineer. The list of
approved makes for products and materials is given below. Better or other equivalent
manufactures may also be considered with prior approval of the engineer, if found conforming to
all standards in case of non-availability/ irregular supply etc. affecting the progress of work. Such
requests should be made with all documents concerned to the Engineer at least 45 days before
the material is required and any order shall be placed only after receiving the written approval of
the Engineer.
S. Details of Materials / Manufacturer's Name
N Products
o
1 Cement ACC, Ultratech, Ambuja Cement, Grasim, JK Lakshmi
Cement, Ramco Cement, Zuari Cement , Penna cement,
Bharathi cement, Dalmia cement, JSW cement, TANCEM,
Chettinad cement.
2 Admixtures Fosroc, MBT, Mc-Bauchemie, Sika, APEX, Pidilite, Polygon,
SWC Brother, STP, Master Builder solutions , MAPEI,
Durabuild, Clean Coats Pvt Ltd, CAC, Normet, ADO Additives,
CICO, Hindcon, Krishna Conchem products, Asian
paints, Asian laboratories, Sunanda Speciality Coatings Pvt.
Ltd, MYK arment, Growel, Tremco CPG, IWL, Padmaja
Construction Solution,Don construction products.
3 Reinforcement Bars SAIL, Rashtriya Ispat Nigam Ltd. Tata steel , Ispat Industries ,
JSW Steel, JSPL, MS Agarwal Foundries Pvt Ltd, Kamachi.
4 Mechanical Couplers for Dextra, Moment, JB , Sanfield, Geo-Constech.
Reinforcement
5 Structural Steel Tata Steel, SAIL, JSW Steel, JSPL.
6 Hollow Sections & Pipes Surya pipes, HI-Tech Pipes, JSW Steel, JSPL, Ravindra Tubes,
Tata Structura, VMC steel, Navaratan, APL Apollo tubes.

Approved Manufacturers / Suppliers
7 Structural steel Fasteners Pooja Forge, Sundram Fasteneres, Unbrako, Nelson

Panchsheel, Geo-constech, Atul Fasteners.
8 Welding Electrodes ESAB, Advani-Oerlikon Limited, Modi Arc Electrodes, Weld
Excel India, GEE, Honavar Electrodes, K.M. Crown Welding
Consumables, Superon Schweisstechnik, Dwekam Electrodes,
EWAC Alloys Limited, Victor, D&H Secheron, Maruti weld,
Modi Hitech, Alpha Welding & Allied Products.
9 Anchor Fastener HILTI, Fischer, Canon, Pooja Forge, AXEL Industries,
Panchsheel, Pioneer Nuts and Bolts (TUFF Brand), Boun
Group, Wuerth India Ltd,Indian Fasteners, JJ Bauch, Rawl
india services.
10 Fly Ash Ashcrete, Ultra pozz, star pozz.
11 Micro Silicam Sika, Elkem, Fosroc, MAPEI, Corniche, Star Silica, Normet,
CALIPAR Trading FZE, CICO,Rockfit.
12 Bonding coat CICO, Fosroc, Sunanda Speciality Coatings Pvt. Ltd , Master
Builder solutions, SWC Brother, Normet, Dr.Fixit, Don
construction products.
13 Curing Compound CCLEAN TECH, SINAK, FOSROC, ADO Additives, Normet, STP,
SWC Brother, CICO,Euclid Chemical, CHRYSO, Pinnacle, Geo-
constech ,Don construction products.
14 Formwork Release Agenet FOSROC, MC - Bauchemie, CICO, SWC Brother, Master
Builder solutions, ADO Additives, STP, Choksey Chemical,
Padmaja Specialities, Fibrex Construction Chemicals, Euclid
Chemical, CHRYSO, Pinnacle, Don construction products.
15 Epoxy Paints / Coatings FOSROC, Sika, Master Builder Solutions, CICO, Mc-
Bauchemie, Araldite, ACC, Fibrex Construction Chemicals,
STP, Padmaja Specialities, PALRAM Industries, Don
16 Expansion Joints kantaflex, Fosroc, Master Builder solutions, Penetron,
Alchimica Kanta Rubber Industries, MAPEI.
17 Polysuphide Sealant CICO , Pidilite, Master Builder solutions, Fosroc , SWC
Brother, STP, Sika, Fairmate, Chryso, Minova,Don
18 Non-shrink Grout Fosroc , Sika ,Master Builder solutions, Elkem, MBT, SWC
Brother, Choksey, Clean Tech, ADO Additives, Normet, STP,
CICO, Don construction products.
19 Acrylic Textured coatings Spectrum Paints, Renova, Wallz, Surfa Nova, Jotun, Asian
paints,Berger, Hempel.
20 Fire Resistant Paints Akzo Noble, PPG ,Jotun.
21 Acrylic Paints Berger, Apex, Asian, Nerolac, Jenson & Nicholson, Nippon.
22 Corrosion Resistance paints Berger, Nerolac , Asian, Jenson & Nicholson, Jotun, Shalimar,
3M, Fosroc.
23 Integral Crystalline Kryton Buildmat , Penetron, Vandex , Master Builder
Waterproofing solutions, Chryso, Xypex, Asian paints, Fosroc, Don
24 Liquid Spray applied / INTEGRITANK, Master Builder solutions, MAPEI, Pidilite,
Bonded HDPE DAVCO, CICO, Fosroc, Sunanda Speciality Coatings Pvt. Ltd,
waterproofing ALCHIMICA , Geo- constech, Normet , IWL, PADMAJA

Construction Solution, Asian paints,TREMCO CPG, Don

25 Water stopper / Bar Kanta Rubber, Greenstreak, Maruti, Duron, ACE Industries
FZC.
26 Drainage PVC/CPVC Pipes Tirupati Plastomatics, Duraline, REX, STIPL.
27 Raised access floor system TATE , ASM, Mero TSK, AET Flexible space, Nichias, UNITILE,
Promat.
28 Auto Claved Aerated Blocks Birla Aerocon, Fusion, Cellocon, Magicrete Renacon, Adithya
precast products, Literoof housing Ltd.
29 Vitrified Tiles Kajaria, Nitco, Euro, Asian, Sreeshan associates, Somany,
Varmora, Johnsons, Simpolo.
30 Full Body Vitrified Tiles Restile, Simpolo, Johnsons.
31 Ceramic Tiles Kajaria, Somany, Euro, Johnsons, VWS Building solutions ,
Varmora, Simpolo.
32 Enginered Stone Kalinga, Asian Granito India, Johnsons.
33 False Ceiling Fameline Daiken, Armstrong, Hunter Douglas, Saint Gobain,
Ramco, Durlaum, Bison board.
34 Calcium Silicate board Promat, Nichias, Fameline, Daiken, Armstrong, Hunter
Douglas, Ramco.
35 Aluminium glazed window Unifab, Schuco, Finesta.
36 Fire rated Doors Shakthi Hormann , MPP technologies , Steel Tech Industries,
Godrej , Indigatech, Saint Gobain, NAFFCO, Signum, Tata
Pravesh.
37 Hardware & Joineries - fire Sakthi Hormann, Arishtha, RNB Design Arc System, Steel Tech
dooors & glass door Industries, Hafele , Signum, Dorma, Union, NAFFCO, Godrej,
Saint Gobian.
38 Structural Glazing - Shrinathji, Unifab, Technoskill, Pyramid.
Semi-unitized, Spider
glazing, skylight glazing,
Spandrel panel
39 Glass Panels Saint Gobain, Asahi, Modi, Float glass India.
40 Stainless steel Jindal, Salem stainless steel,Tata , VMC steel.
41 Fire sealents Hilti , 3 M, Wuerth.
42 Tile fixing adhesive Wuerth, MYK laticrete.
43 Tiles gap filling sealent Wuerth, MYK laticrete.
44 Reflective tapes 3 M, Wuerth.
45 Alumininum Composite Acubond, Alu bond, Euro bond, Alstrong, Aludecor, Alstone.
panels (ACP)
46 Wall putty Birla white, JK white, Shalimar.
47 Tactile Tiles Palican, Unistone products ,Nimco Pro lab, Johnsons,
Somany, Simpolo.

APPROVED MANUFACTURERS / SUPPLIERS
All materials and products shall conform to the relevant standard specification, BIS codes and other
relevant codes etc. shall be of make and quality as approved by engineer.
The list of approved makes for products and materials is given below. Other equivalent manufactures
may also be considered with prior approval of the engineer, if found conforming to all standards. Such
requests should be made with all documents concerned to the Engineer at least 45 days before the
material is required and any order shall be placed only after receiving the written approval of the
Engineer.
List of Approved Makes of Plumbing Items
S.NO ITEM APPROVED MAKES
PIPES & FITTINGS
CAST IRON PIPE &

1 NECO/ KAPILANSH / SKF/ HEPCO
FITTINGS
LANCO (SRIKALAHASTHI PIPES LTD.,) /TATA

2 DI PIPES- K7 & K9 METALIKS / CHANDRANCHAL INFRASTRUCTURE
LTD / JINDAL SAW/ELECTROSTEEL
DI FITTINGS AND
3 ELECTROSTEEL / SUNLINE CHATRANJAL
FLANGES
GI PIPE AND JINDAL/ SURYA ROSHINI/ TATA/ ZETWERK/ RK

4
FITTINGS STEEL MANUFACTURING/ JAINSON/ SAIL/ APL
5 GI THREAD FITTING UNIX/ JAINSON INDUSTRIES/ R BRAND / HB

RAINWATER UPVC PRINCE /SUPREME /ASHIRVAD /AJAY / FINOLEX /

6
PIPES AND FITTINGS JINDAL PLAST(INDIA) / ASTRAL / HIL BIRLA
GI SUPPORTS &
7 HI-TECH SUPPORTS/ HILTI /FISCHER /MUPRO
FITTINGS
8 ANCHOR & FASTNERS FISCHER/ HILTI/ WUERTH
PRINCE / SUPREME / ASHIRVAD / AJAY / FINOLEX /

9 CPVC PIPES & FITTINGS
JINDAL PLAST(INDIA) / ASTRAL / HIL BIRLA
PRINCE / SUPREME / ASHIRVAD / AJAY /FINOLEX /

10 HDPE PIPE
JINDAL PLAST(INDIA) / ASTRAL / HIL BIRLA
PRAGATI CONCRETE/ K.K. SPUN

11 R.C.C. PIPES
PIPES/PRANALI/JAIN SPUN PIPE
PERFECT / BURN / ANAND/ PRIYA / RK / DEVRAJ

STONEWARE PIPES &
12 ANAND CERAMIC / PERFECT POTTERI JABAL PUR
GULLY TRAP
(MP) / BURN POTTERIES JABALPUR
VALVES & ACCESSORIES
ZOLOTO / LEHRY / P2V2 VALVES / LEADER / SANT /

13 BALL VALVE
KARTAR / ADVANCE / AUDCO
14 FLAP VALVE MUKTI ENTERPRICES / JASH / LEHRY
K. K. MANHOLE & GRATING CO. PRIVATE LIMITED /

C.I. MANHOLES COVER
15 BANGAL IRON COMPANY WEST BANGAL / SHINING
& G.I. GRATING
ENGINEERING WORKS (FOUNDRY) AGRA.

List of Approved Makes for Electrical Items
SL.No ITEMS APPROVED MAKES
KEI, RR KABEL, POLYCAB, FINOLEX, RPG,

1 LT POWER CABLES FRLS CU XLPE
LAPP, THERMO CABLE
CABLE LUGS / THIMBLES CU FOR
2 DOWELLS, JAINSON
1100 VOLT GRADE CABLES
LIST OF APPROVED MANUFACTURES/SUPPLIERS OR MAKES AND

MATERIAL OF PLUMBING WORKS.
All materials and products used in the Scope of Work shall conform to the Contract Document,
Employer’s Requirements - Technical specifications, relevant codes, relevant standards, etc. and shall
be of approved make and design.
The approval of a manufacturer/vendor shall be given only after review of the sample/specimen by the
Employer. The complete system and installation shall also be in conformity with the “Applicable Codes,
Standards and Publications
Vendor Approval
(a) It shall be obligatory for the Contractor to obtain Notice of No Objection from the Employer
for the selection of the vendors for all items of work, even if the name of the vendor is specified
in the Contractor’s Technical Submission and the works to be done including purchase of
materials and equipment is in accordance with the Technical Specifications and Standards
specified in the Contract.
(b) The contractor shall ensure the correct selection of the make meeting the specifications
and its application. Before placing the order for procurement, the sample of approved
make shall be verified for its suitability to the specification and application. In case
Employer (whose decision will be final and binding on both parties) considers that the
make/ model proposed by the contractor does not meet the tender requirement, the
contractor will be required to propose an alternative make acceptable to the Employer.
(c) The contractor will submit a list of vendors for all the items of the BOQ contract
(i) The list should include the items for which the contractor is proposing the product of the
approved vendor.
(ii) The contractor will be advised ‘No Objection’ with following caveat:- The model etc. to
be supplied will be the latest or superior one.The contractor will be required to submit

the technical proposal for the scrutiny. The contractor will submit the undertaking that
lists includes all the items required in the contract.
(d) Vendor to be selected who are capable to provide good after sales services available in
Chennai during DLP and thereafter
Vendor Approval and Selection Procedure
(1) In the event of contractor wanting to use alternate makes other than those stipulated for
any reason, the contractor can send a proposal after ensuring that what he proposes at least
meets the specifications both, the quality and safety standard of the stipulated makes, the
alternate proposed product should be a proven one. He shall also stand full guarantee to his
alternate proposal and if at any stage it is found that the material is not suitable or meeting the
tender requirement, the contractor shall replace the material and provide the material from the
approved vendor without any additional cost to the Employer. The alternate makes can be used
only after an approval accorded by the Employer, whose decision will be final in the matter.
(2) The approval of any equipment or product to be used shall be done in two stages: -
i. Stage-I
* Assessment of capability of proposed Vendor to supply a particular equipment or product,

with quality and performance requirements, as required by Specifications
as well as other contract conditions. The proposed product should be a proven
product in service for at least 5 years.
* Assessment of the financial and functional strength of the Vendor to supply the
requisite quantity of equipment and product as per delivery schedule acceptable
to contractor and Employer to deliver the project in time.
ii. Stage-II
Stage-II called as Technical Submission Approval Stage, selection of Equipment or product from
the equipment / products manufactured / supplied by the approved
vendor will be done. This stage includes thorough technical assessments about the

conformance of the offered equipment / product to the Specifications and other

requirements.
iii. To obtain Vendor Approval the Contractor must apply with the four sets of the
following documents to the Employer
(a) Company Profile and Experience of the Vendor
(b) Clause wise compliance of the relevant Clauses of Specifications.
(c) Details of supplies / orders executed in last ten years for the type of equipment /product
offered. Supplies / orders executed for Underground Metro Systems
shall be specifically mentioned
(d) Details of the facilities available at the Works / Manufacturing Unit where the
proposed equipment / product shall be manufactured.
(e) ISO 9000 Certification for the Works / Manufacturing Unit where the proposed
equipment / product shall be manufactured (The Works / Manufacturing Unit
where the proposed equipment / product shall be manufactured must have ISO
9000 Certification)
(f) Proof regarding compliance to Manufacturer’s Qualifications. The offered

products must be proven in service.
(g) BIS Certification (if applicable) for the proposed product.
(h) Type test certificates/ Performance certificate from accredited laboratories for the proposed
type of equipment / products to establish the technical
capability of the vendor (In case, specific requirements are mentioned in the
relevant sections of Specifications with regard to type testing, same shall also
be complied additionally).
(i) For type tests, the contractor can provide test reports performed according to the
corresponding standards at an NABL accredited third party Test Laboratories, on similar
equipment of same capacity and design but the same should not be more than five year old. If
the Type test reports are more than five years old , the same should have been revalidated
again by NABL accredited third party Laboratories
j) If the vendor/supplier had already supplied the materials to CMRL’s earlier projects, the
Performance Certificate from O&M Dept. of CMRL is required.
k) The vendor shall not have been blacklisted by any Govt. Agency in India.
(l) Any other item as required by Employer.
(m) Contractor must certify the check list provided that vendor Proposal is complete
and all the above documents are available in the Vendor Proposal. In addition, the

Contractor must check / certify compliance to the Specifications before forwarding

the same.
(i). Incomplete Vendor Proposal will not be treated as a submission and will be
returned.
(ii). Employer will give Approval to the Vendor Proposal (received complete with all the
documents mentioned above) expeditiously.
(iii). Technical submission shall be accompanied with the calculations / other technical
documents to justify the selection of any particular model of equipment / product, detailed
technical features / parameters of the selected product, type test certificates from the accredited
laboratories for the offered products, any other document required by the Employer.
(iv). Employer will give Approval to the Technical Proposal (received complete with all the
documents mentioned above) expeditiously.
(v). If the Technical Proposal submitted is not acceptable to the Employer, the Contractor has
to propose alternate vendor within 14 days’ time (from the date of rejection)
It may be noted that Approval of Vendors as per Point (3) above shall only be done by
Employer after the award of the work. Vendor submissions shall not be
evaluated during the tender evaluation. Conditional Tender offers received from
Tenderers with particular Vendors for supply of equipment/ products will not be
evaluated during evaluation and will be dealt with after award of the work.
It may further be noted that Employer shall be under no obligation to accept

equipment / products manufactured by the successful Tenderer, unless it meets the
entire criterion mentioned above.
Additional points
In addition to above, in design and build contracts the following shall also be ensured for the
Vendor Approval and Selection:-
(a) Proven Design
The Contractor shall develop the design based on this specification and on sound proven and
reliable engineering practices. The broad design details shall be submitted with technical
support data in the technical bid. Detailed calculations shall be submitted to the Employer
during the design process stage for review and approval.
(b) Systems and Sub-Systems
• Manufacturer shall have at least 5 years experience of design and manufacturing of

similar system. Proposed systems from the proposed manufacturing unit shall have
been in use and have established their satisfactory performance and reliability for 3
years in minimum.
• All sub-systems, equipment’s and major components etc. (hereinafter referred as
‘sub- systems’) shall be state-of-art and of proven design.
• Proposed Systems/ sub-systems shall have been in use and have established their
satisfactory performance and reliability on at least Two mass rapid transit systems
(including Railway or Airports) in revenue service over a period of three years or

more either outside the country of origin at an average in two different countries or
in CMLR. Systems/ Sub-systems/ components used in CMRL do not get
automatically qualified for use unless specifically approved by the Employer for this
project. If required by the Employer, Contractor shall provide certificate of
satisfactory performance and after sales service for a period of five years or more from
the Metro operators. In addition Contractor shall provide certificate of satisfactory
performance and after sales service if they have supplied similar materials to any of
the CMRL projects Where similar System/ Sub-systems of a different rating are
already proven in service as per the above criteria then the supply shall be based on
such sub-systems.
• All ‘sub systems’ shall be procured from the approved vendors and sourced from only
such manufacturing units that have supplied the sub-systems that fulfil the proven
design requirements as above.
• In case the contractor proposes to use systems or sub-system(s) that do not fulfil the
above said criteria then the contractor shall furnish sufficient information to prove
the basic soundness and reliability of the offered systems and sub-system(s) for
review of the Employer.
• The Employer’s decision on contractor’s proposal shall be final and binding.
For sourcing the equipment from indigenous manufacturing facilities, following

conditions shall be complied:-
(i) In case the vendor uses his own facilities for indigenization after part supply of
equipment from the approved manufacturing unit, no change in design, component
type/make, quality standards, manufacture procedure etc. shall be made without specific
approval of the Employer.
(ii) In case OEM wants to use manufacturing facilities in India (other than his own) for items
for which the OEM has been approved, it shall enter into an agreement with such selected
Indian equipment manufacturer and obtain prior approval from CMRL. No change in
composition, rating, type, model no., manufacturing process, quality standards, design,
etc. and make of the components used in assemblies/sub-assemblies of such equipment as
manufactured by the approved parent vendor shall be made without specific approval of the
Employer.
(iii) In case OEM wishes to change/make/type specifications, etc. of any sub-components

for supplies to be sourced from Indian facility, specific prior approval of the Employer shall

be obtained for changes made, model, specification, etc. Responsibility for obtaining such
prior approval shall rest solely with the contractor.
(iv). Format for submitting the vendor approval request shall be given to the contractor during
initial stages and approved format shall be followed throughout the contract.
TESTING AND INSPECTION
General
o As part of the preliminary design submission the contractor shall submit to the
Employer and the Employer's representative for acceptance a schedule of test giving
full details of all tests to be carried out.
o Test at place of manufacture to be witnessed by the Employer and the Employer's
representative shall be grouped together so far as can be arranged so that as many tests
as possible can be witnessed on each visit.
o The contractor shall make his own arrangement for “The Employer and the Employer's
representative” factory visit including travel, boarding and lodging for every
inspection.
o The contractor shall prepare and forward to the Employer and the Employer's
representative an original and four copies of all test reports as soon as practicable after
completion of each test whether witnessed by “the Employer and the Employer's
representative” or not. All test data shall be certified by contractor’s professional
Engineer.
o The contractor shall perform all applicable test specified in these specification as per
the relevant standards. Any test required as per the applicable safety standards but not
specified in this specification shall be performed without any extra cost to CMRL.
o The contractor has to take the EIG (Electrical inspector to Government) approval of
the E&M installation before commissioning of the same. The contractor has to comply
with all the requirements for the EIG inspection, make the necessary application and
should make all the arrangement, conduct test and submit the required compliance
certificate necessary for the approval. The application should be submitted with
approval of engineer in charge.
The contractor has to take the CMWSSB (CHENNAI METROOPOLITAN WATER
SUPPLY AND SEWERAGE BOARD) approval for their drinking water supply,
wastewater and sewage connections to the respective systems of CMWSSB. The
contractor has to comply with all the requirements for the CMWSSB inspection, make
the necessary application and should make all the arrangement, conduct test and submit
the required compliance certificate necessary for the approval. The application should
be submitted with approval of Employer's representative.
General requirement for type test and acceptance tests.

• The tender shall provide details of any type and acceptance test, which have been
carried out on equipment offered, or any additional tests recommended.
• In general, certificates of previous type test may be accepted at the discretion of the
Employer and the Employer's representative provided that they are for identical

equipment’s and condition. Where appropriate, new and or modified components to

meet the equipment’s of this specification shall be made available for type testing.
• All applicable types tests as per the relevant standards on equipment’s shall be carried
out strictly as specified in the specifications and procedure of testing shall be
submitted to the Employer and the Employer's representative for No objection.
• The Engineer shall have right to witness test and inspections on individual materials
components, or sub-assemblies, and details of these shall be agreed between the
contractor and the Employer and the Employer's representative”.
• At the conclusion of all type tests, the contractor shall compile all the test data together
with any observations made during the test, file them into a type test binder and submit
it to the “the Employer and the Employer's representative” for acceptance and record.
General requirement for test during manufacture
• The manufacture shall carry out all applicable tests during manufacture as specified
and propose any additional tests to be carried out as per relevant standards. These tests
shall be subject to the acceptance of the “the Employer and the Employer's
representative”. Routine tests shall be integrated with the manufacturing programme.
The Employer and the Employer's representative” will, at his discretion, witness the
routine tests during the period of manufacture, or accept the records of the
manufacture in-house quality control scheme, where appropriate, as sufficient
evidence for the execution of the routine tests.
• Routine tests shall be carried out strictly as specified in the test specification
• On Completion of the manufacture of items or sub-assemblies and following
completion of the manufacture’s own tests and inspection, the “the Employer and the
Employer's representative” shall be invited to witness such tests as he deems
appropriate. The contractor shall schedule the routine tests to meet the manufacturing
programme, whether or not the Employer / Employer’s representative will be present
at the tests, provided advance notice has been served to the Employer and the
Employer's representative” in accordance prior information’s.
• The engineer will determine and advice the contractor of those test where
certifications by the manufacturer may be acceptable in lieu of witnessed tests.
• Before equipment is dispatched, Employer / Employer’s representative will signify
his acceptance by signing certificates releasing such equipment from the place of
manufacture or test.
• Methods of packing and shipping shall be as specified in the Employer’s requirements,
the Engineer reserves the right to visit the manufactures or packers premises to ensure
that accepted method are employed.
Test specification.
• The contractor shall submit for acceptance by the Employer and the Employer's
representative test specifications for the type tests, routine test, on site final acceptance
tests and commissioning. The specifications shall detail the methods of conducting
the test, the tool and instruments used. Reference to the accepted documents and
drawing shall be included in these specifications. The record/results shall be tabulated
in a prescribed format applicable to this contract.
• Nothing in this specification shall prevent the Employer and the Employer's
representative from calling for extra tests.
• These test specifications shall include the design value of all quantities to be verified,
with allowable tolerance or limits. Summary drawings or diagrams shall be included
with test specifications to show the dimensions and tolerances of all structural

assemblies and sub-assemblies. In the case of welded fabrications, key diagrams

giving all weld data shall be provided to enable systematic inspection to take place.
• Verification of accuracy shall be required for all tools, apparatus, testing jigs,
measuring instruments and ‘go’ or nogo gauges used for purpose of routine tests.
• All test instruments shall be calibrated not more than one year prior to their use. The
contractor shall submit calibration certificate or other documents for proof of
compliance.
Testing of materials and details.
• Where materials or components used in this contract are not covered by separate test
specifications, samples of such materials or up two per cent of such components shall,
if desired by the Employer / Employer’s representative be tested at the contractor’s
expense an approved laboratory.
• The contractor shall supply the material required for testing free of charge and shall
supply and prepare the necessary test pieces, labour and appliance for making all tests,
and for carrying out all gauging and weighing on this premises in accordance with the
terms of this specifications. If the contractor is unable to provide approved facilities
at his own factory for making the prescribed test, the contractor shall bear the cost of
carrying out the test elsewhere, at place subject to the Employer and the Employer's
representative acceptance.
• Such radiographic examination of welds or casting as the Employer/Employer’s
representative deems necessary shall be carried out.
Interface and integrated tests.
• The contractor shall co-ordinate and carry out interfacing and integrated testing
together with other system – wide contractor to ensure that the integrated system function as
desired. The integral testing and commissioning will be carried out with other system
contractor such as traction contractor, S&T contractor, etc. The contractor has to interface
with all the contractors to get the test done. The system shall be taken over only after the
completion of the integral testing & commissioning done at all the stations of the
schedule/section.


PART 2
SECTION VI
SUB-SECTION E
APPENDIX-11
CURVES AND GRADIENT DETAILS
DECEMBER 2021
CURVES AND GRADIENT DETAILS

ALIGNMENT
Horizontal and Vertical Alignment
All details with regard to the Horizontal and Vertical Alignment are shown on the plan and profile
sheets of the Employer’s Drawings provided in Part-2 -Section VIII of the Contract.
No amendment shall be made to the alignment without a Notice of No Objection from the Employer’s
Representative.
Section VI– Appendix 11 11-1 December 2021

Curves & Gradient Details

PART 2
SECTION VI
SUB-SECTION E
APPENDIX-12
UTILITIES
DECEMBER 2021
Part-2 Section VI
UTILITIES
DEFINITIONS
Utilities
Utilities are defined as public utilities above or below ground and include all live water mains, sewer
mains, water wells, power cables, street lights, transformers, pillar boxes, telephone posts,
telecommunication cables, gravity sewers, storm water drains, gas lines which are either shown on the
Employer’s Drawings (charted) or identified on the site by the Contractor (uncharted).
Charted Utilities-
Charted Utilities are the utilities (as defined above) whose details may or may not be available prior to
execution but will be encountered during execution.
Uncharted Utilities-
Uncharted Utilities are the utilities (as defined above) which may be shown on the Employer’s
Drawings.
Responsibility of the Contractor.
1. The Contractor shall make his own enquiries and investigations, including excavating trial holes,
to ascertain the existence, nature, location and size of utilities. A schedule of utility diversions
and utilities to remain but to be supported (the utility diversion plan) shall be prepared and
submitted by the Contractor. The schedule will list out utilities that:
• will be diverted by the Contractor during the course of the Works, and
• will remain in place and require the use of specific construction protection methods to
complete the underground structures around and below the utilities including support of the
utilities during construction.
2. The Contractor shall take into consideration the time required for utility diversions into the overall
Works Programme for the Contract. However, efforts shall be made to avoid
diverting/disturbance of any utility and continue the Works by supporting the same but the
required services being provided by these utilities shall be maintained at all the times at the cost
of the Contractor. Any delay to construction work due to delay in Utility diversion
3. The diversion work shall be undertaken by the Contractor as per the approval of the Utility
owning Agencies and a notice from the Employer’s Representative. Temporary supports and
protection by methods proposed by the Contractor and agreed by the Utility Agency shall be
provided to the utilities. Permanent supports and protection shall be provided wherever required
for the safety and security of the utility service.
4. The Contractor shall immediately inform the Employer’s Representative and the Utility Agencies
of any
(a) damage to utilities;
Section VI -Appendix 12 -Utilities 12-1 December 2021

Part-2 Section VI
(b) leakage of utilities;

(c) discovery of utilities not previously identified;
5. When diverting and/or protecting sewerage and storm water lines the Contractor shall ensure that
drainage to the site and adjacent areas is maintained at all times and that no times flooding or
other nuisance occurs.
6. The Contractor shall inform the Employer’s Representative of the programme of all works of
utility diversion/ protection works and shall take all steps to enable the utility diversions to
proceed in accordance with the programme. The Contractor shall maintain close liaison with the
Utility Agencies. The Contractor shall set up and manage a Utility Liaison Group of experienced
personnel for the duration of the Contract.
7. Records of the existing utilities encountered shall be kept by the Contractor on the Site and a copy
provided for the Employer’s Representative. The records shall contain the following details :
(a) location of utility;
(b) date on which the utilities were encountered;
(c) nature and sizes of the utilities;
(d) condition of utility;
(e) temporary or permanent supports provided; and
(f) Diversions made –Temporary or permanent
8. The Contractor shall include the details (plan, location, ownership, size and material) of all such
utilities on the As Built Drawings.
9. The diversion/protection of utilities (Charted/Uncharted) shall be covered under the Provisional
Sum given in Pricing Centre, excluding storm water drain which shall be included in the
Contractor’s lumpsum quoted tender price.
10. Temporary diversion of each utilities are allowed for one time. If the utility is to be restored,
permanent restoration shall be considered in addition to the temporary diversion.
Diversion and Protection of Underground/Overhead Utility Lines
11. The work comprises of replacement, relocation, diversion and protection of existing sub-surface,
surface and overhead public utilities viz. sewer mains, water lines, water wells, storm water
drains, gully pits including connection pipes, house drains, gas pipe lines, electric and telephone
cables, optical fibre cables including their appurtenance structure, O.H. electrical transmission
line, electric poles, traffic signals, etc… which will be disturbed due to construction of the metro
stations, and tunnels, where applicable.
12. The Contractor shall effectively protect all public utilities falling within the metro station
locations and their immediate adjoining areas or which are likely to be exposed, disturbed or
damaged during the execution of the work or in consequence thereof, in such a manner and using

Part-2 Section VI
such materials as required or specified by the concerned public Utility Agencies and as per
instruction of the Employer’s Representative, and hold them in proper position without any
damage being caused to them during execution of work.
13. The contractor shall provide and laying pipes, water wells, gas mains/gully pit connections/house
drains and other electric, telephones, optical fibre cables and other cables or any other
underground structures or services falling within the metro station and tunnel locations, and their
immediate adjoining areas which may be found to have been disturbed or damaged due to the
Contractor’s fault and/or defective and careless workmanship. The decision of the Employer’s
Representative in this respect shall be binding and final and all costs of rebuilding or repairing of
such damaged services or structures as aforesaid shall be deducted from the Contractor, if the
same is not taken care of within a reasonable time frame, mutually agreed between the
Employer’s Representative and the Contractor.
14. The Contractor shall enquire of and collect information from all concerned public Utility
Agencies, owners, Government Departments and local bodies in connection with the sewer lines,
water mains, water wells, cables, wires and any other obstruction either overhead or on ground or
underground which may be encountered in the course of execution of the work and which are
likely to affect the progress of the work, at his own cost and risk. No idle labour charge will be
admissible on account of delay in collecting the above-mentioned information.
15. The Contractor shall have to excavate trial trenches of suitable sizes for satisfactorily exploring all
the underground utilities as required and as instructed by the Employer’s Representative before
commencement of any permanent work below ground level.
The time of completion for the project is inclusive of diverting and/ or protection (temporary as
well permanent) of utilities.
Additional Conditions for Diversion/Protection of CMWSSB Utilities
16. It is the responsibility of the Contractor to get the approval of the proposed water/sewer/storm
water/pipelines etc., diversion/shifting from the concerned Agency/Authority. However,
Engineer/Employer may facilitate the co-ordination work with the concerned agency for getting
the necessary approval.
17. In case the concerned utility agency/authority maintains a list of registered/approved contractors
for undertaking such works and desires such shifting/diversion of pipeline/utility etc. work to be
undertaken by such registered/approved contractors, then such shifting/diversion of
pipeline/utility etc. shall have to be carried out by engaging the registered/approved contractors.
18. In case the Engineers of concerned utility agency intend to supervise the work, the Contractor (or
sub-contractor engaged by the Contractor) have to carry out the work as per the instruction of the
utility agency during diversion work by the Contractor.
19. In case of permanent diversion of water/sewer/storm water/pipelines etc., it is the responsibility of
the Contractor to carry out such work without affecting water supply/without affecting sewage
disposal etc. If required alternative temporary arrangement shall have to be made by the

Part-2 Section VI
Contractor without any additional cost.

20. In case of temporary water pipe/sewer pumping mains (without manholes) diversion (which
means divert the pipeline temporary away from station box and brought back to the original
position after completion of station work), it is the responsibility of the Contractor either to use
the retrieved diverted pipes or new pipes to restore back the original place without affecting the
water supply/utility service.
21. In case of temporary diversion of gravity sewer pipelines with manholes are required, the
Contractor, initially before taking up the station work has to ensure that the flow is diverted by
laying sewer pipeline and constructing manholes away from the station box and then only divert
the flow. After completion of station work, the Contractor shall have to lay again another sewer
pipelines and again construct new manholes for restoring back to the original place.
22. In case of temporary supporting of water/sewer pipelines, if any damages occur during
construction period it is the responsibility of the Contractor to rectify the damages to the
satisfaction of concerned agency. The cost of the rectification works shall have to be borne by the
Contractor.
23. It is the responsibility of the Contractor to obtain completion certificate from concerned utility
agency for each diversion work. The payment for such diversion work will be made to the
Contractor after obtaining completion certificate from concerned utility agency.
24. The Contractor shall handover all the retrieved material to the stores of the concerned utility
agency /concerned department at the Contractor’s cost and submit the proof of handing over.
25. For diversion of pipes, Contractor to use the same type of material shown in the tender drawing.
Wherever, type of material is not mentioned following materials shall be used:
(a) For water pipes – K 9 Ductile Iron pipe

(b) For sewer pumping main pipe – Cast Iron pipe
(c) For Gravity sewer upto 2.5m below ground – Stoneware pipe.
(d) For Gravity sewer greater than 2.5m below ground – Cast iron pipe.
Electrical Utilities (TNEB / TANGEDCO)

26. The Contractor shall submit the utility diversion programme to Engineer / Employer with
diversion justification based on trial pit information.
27. The Contractor shall submit the diversion plan to Engineer at least 60 (sixty) days in advance of
work commencing to obtain approval from Electrical utility agencies. For utility diversion
proposals of TNEB/ TANGEDCO, the Contractor shall submit diversion justification with trail pit
information and drawing(s) with the proposed diversion route(s).
28. The Contractor would submit application of diversion works to electrical utility agencies with
diversion plans. The Contractor shall render necessary assistance.
29. The Contractor shall coordinate with the local officials to assess quantities and specifications of

Part-2 Section VI
materials required for diversion works. Necessary assistance would be provided by the Employer
and the Engineer.
30. The Contractor shall obtain necessary permission from the concerned departments/agencies to
carry out the diversion/shifting works and get necessary permission from Traffic Police
Department.
31. Wherever possible, horizontal directional drilling method shall be adopted at location where
utility diversion works crosses roadways and require lane closures for excavation to avoid
inconvenience to the traffic.
32. The electrical utilities diversion/ shifting should be carried out by the Contractors/agencies
registered with the electrical utility agencies / Tamil Nadu PWD and have the required grade
license from the Chief Electrical Inspector to Government. The Contractor should be well
acquainted with electrical works so as to maintain the standard. The Contractor shall inform the
same to CMRL/the Engineer for getting consent from the concerned electrical utility agency.
33. The Contractor shall identify the quantity of materials required for the contract such that the
material can be procured by the Contractor in bulk and in advance to the implementation of the
utility diversion works. The quality of materials to be procured shall be approved by the
concerned utility agency. Materials used for diversion/shifting shall be of quality conforming to
the applicable standard of the electrical utility agency and as per relevant BIS.
34. The source of materials and the guarantee for the materials to be used shall be submitted to
Engineer for obtaining approval from the concerned utility agency. Any failure of the material
within the guarantee period shall be replaced and installed free of cost by the Contractor.
35. Contractor shall inform the local officers/officials of the concerned utility agency about the
diversion works at least 15 (fifteen) days before the execution of diversion.
36. The diversion / shifting utility work shall be carried out under the direct supervision of officials
and the utility agency decision shall be final in this regard. The Contractor shall provide free
access to officers/ officials / workman for the purpose of inspection/supervision.
37. After restoration of regular service completion certificate shall have to be obtained from the
concerned departments/agencies. The regulations for working with utility agencies shall be as
follows;
(a) The diversion/shifting utility work should be carried out without causing any
inconvenience to the operation and maintenance of Sub - Station and other
departmental works of the concerned utility agency.
(b) The Contractor shall execute and complete the work strictly in adherence to the time
schedule and to the satisfaction of the engineers and adhere strictly the direction of
the utility agency in any matter.
(c) The Contractor shall be responsible to protect the public and the employees of the
utility agency against any accident that may arise during the execution of

Part-2 Section VI
diversion/shifting utility works. The Contractor shall indemnify the CMRL for any
claims for damages/injuries to the person/property resulting from any such accident.
The Contractor shall Compensation Act by the way of obtaining an accident risk
type insurance to meet all purpose of relief, failing which or otherwise the
Contractor shall be solely responsible for meeting the compensation awarded under
the said Act.
(d) The Contractor shall undertake to ensure free flow of traffic during execution of the
diversion/shifting works and shall be responsible for any accident/loss of
lives/property. Damage to the other existing utilities during diversion shall have to
be rectified by the Contractor at his own cost.
(e) The Contractor shall employ qualified technical personnel to carry out the
diversion/shifting of utility works.
(f) The Contractor shall apply well in advance for Line Clearance (LC) for carrying out
the joint works/shifting works. CMRL would authorise the Contractor to take LC
from the concerned utility agency. If needed, CMRL would provide assistance to the
Contractor to get the LC. LC will be given by the concerned utility agency
depending upon exigencies, which have to be strictly adhered to.
(g) The Contractor shall handover all the retrieved / unused material to the stores of the
concerned utility agency /concerned department at the Contractor’s cost.
(h) Contractor to pay the penalty/charges imposed by the utility agency for damage to
the utilities on their own.
(i) The Contractor shall undertake not to revoke the above conditions until the
completion of diversion/shifting works.
Greater Chennai Corporation Utilities Diversion

38. Diversion of Storm water drain shall be carried out as per the design, standard and general
specifications of Greater Chennai Corporation /concerned Highways Department.
39. The diversion route for storm water drain shall be approved by Greater Chennai Corporation
/concerned Highways Department.
40. The invert level of diverting drain shall be maintained on par with upstream/downstream of
connecting drains.
41. The Contractor shall make alternate arrangements to divert and ensure smooth flow of water from
upstream side during construction.
42. The Contractor shall provide the adequate sizes of drain or follow the existing sizes as agreed by
the concerned agency.
43. Diversion of storm water drain shall be carried out through the registered Contractors of Greater
Chennai Corporation / Highways Department (if such a list of approved/registered contractors is
maintained by the utility agency).
44. Street lights shifting shall be carried out as per the specification of Greater Chennai Corporation.

Part-2 Section VI
BSNL Utilities diversion

BSNL utilities such as copper cable and OFC cables which are likely to be affected to be
identified based on trial pit information.
Contractor to prepare the diversion plan in coordination with the BSNL utilities agencies and get
approval for the diversion plan. Employer/Engineer may provide assistance in this regard.
Contractor to assess the required quantities based on the diversion plan.
Cables procured to be Quality control checked by the concern wing of BSNL. Contractor to
coordinate and arrange for the Quality control check by BSNL.
Diversion of BSNL utilities to be done by the BSNL approved subcontractors and the completion
certificate to be obtained from BSNL for the utilities diversion done.
Private Telecom/OFC cable
Contractor to manage the existing private telecom and OFC cables.
General
The Contractor shall provide 6 months rolling programme every 3 months.


EARTHMAT, ARCHITECTURAL FINISHES & SIGNAGES
ETC. INCLUDING TWIN BORED TUNNELS FROM
KOLATHUR JUNCTION RETRIEVAL SHAFT TO NATHAMUNI
(VILLIVAKKAM MTH ROAD) LAUNCHING SHAFT AND
RAMPS WITH U - SECTION IN CORRIDOR-5 OF CMRL
PHASE-II PROJECT”
PART 2
SECTION VI
SUB-SECTION E
APPENDIX - 13
SITE ACCOMMODATION FOR THE
EMPLOYER’S REPRESENTATIVE
DECMEBER 2021
Part-2 Section VI
Employer’s Requirements
SITE ACCOMMODATION FOR THE EMPLOYER’S

REPRESENTATIVE
1. The Contractor shall provide following Site Accommodation for the Engineer Staff
Main office - 1 Number (total area approx.. 200 m2)
Site offices at each of stations and casting yard – 6 numbers (Approx. area 50m2 each)
Type No. of Staff Area m2 Total Area m2

Project Manager Office 1 10 10 with A/c
Senior Engineer Office 1 10 10 with A/c
Resident Engineer (Civil) Office 2 7.5 15 with A/c
Site Engineer (Civil) Common Office 2 7.5 15 with A/c
Site Inspectors Common 4 5 20 with A/c
General Office / Reception Area - 15 15 with A/c
Rest Rooms (washroom/toilet) - 5 10
Kitchen - 10 10
Meeting Room - 20 20 with A/c
Total 200 Approximate
2. Offices shall be accessible only from a corridor within the building. The corridor and reception
area entrances shall be provided with an external double door.
3. Materials for the construction shall be new, robust and durable. The building shall be
weatherproof, vermin proof, well insulated thermally and acoustically. Internal walls shall be
soundproofed. Electrical power and lighting, including all fixtures and fittings, power, telecoms
and internet sockets, shall be provided to each room, including air conditioning and heating to
maintain the internal temperature within the range of 20 to 24 degrees Celsius at all times. A
standby generator shall also be provided and installed with an automatic switchover.
4. Internal doors shall be flush, fitted with door closers, mortise locks with keys and lever handles.
5. External doors shall be a pair of solid core doors, external quality, hung on heavy duty hinges, one
leaf fitted with barrel bolts top and bottom and the other leaf fitted with a Yale or similar lock.
6. Windows, of area not less than 10% of the floor area, shall be provided to all rooms, securely
barred, fitted with blinds and having opening sections fitted with locks and mosquito screens.
7. The building shall be provided with a continuous water supply and drainage to Kitchen,
Washroom and Toilets. The Toilets shall be equipped with low level suites and be adequately
ventilated through the ceiling.
8. The Kitchen shall be fitted out with a 2 drainer stainless steel double sink unit, hot water heater,
worktop with cupboards under, tiling above the sink and worktop and wall mounted cupboards.

Site Accommodation for the Employer’s Representative
Part-2 Section VI
9. Fire and Safety regulations shall be complied with and fire fighting equipment shall be provided in
accordance with the recommendations of the Tamil Nadu Fire and Rescue Service.
10. The Contractor shall provide, erect and maintain appropriate name boards as specified, for each
of the offices. The wording shall be agreed with the Employer’s Representative.
11. The Contractor shall provide protective clothing and safety equipment for 12 persons,
comprising, as a minimum – Safety Helmets, Safety Harness, Steel-toed construction shoes/boots
(sizes to be notified), Day-Glo waistcoat, Industrial safety goggles, Industrial gloves, Breathing
Masks and Filters, Ear protectors, Heavy weight suits (sizes to be notified), Lamps (with
batteries), etc… as required by the Employer’s Representative.
12. The Contractor shall provide an adjacent shaded hard standing parking area for 12 cars.
13. The Contractor shall arrange for upkeep, service and security of the offices and compound. These
to be thoroughly cleaned and rubbish and waste to be removed at least once per day.
14. The Contractor shall submit a detailed office layout plan showing all relevant details of these site
offices, not limited to that described above, which will require a notice from the Employer’s
Representative.
15. The Contractor shall provide furniture for all the office room and office accessories like 4 nos. of
Desktop, 1 Printer, 1 Photocopier, 1 Refrigerator, Internet facilities to the desktop and 1 no. of
water dispenser with continuous water supply.

Site Accommodation for the Employer’s Representative

PART 2
SECTION VI
SUB-SECTION E
APPENDIX-14
CONTRACTOR’S SITE LABORATORY
DECEMBER 2021
CONTRACTOR’S SITE LABORATORY

1. LABORATORY AT CASTING YARD
1) The Casting yard Laboratory shall be approximately 350m2 in area. It shall consist of the
following accommodation:
1 concrete laboratory 100m2 floor area
1 Soil laboratory 50m2 floor area
2 office each 15m2 floor area
1 storeroom 10m2 floor area
1 kitchen 10m2 floor area
toilets, changing room & shower sufficient for 6 persons
2) The remainder of the 350m2 shall consist of storage area for concrete cube curing tanks. The
laboratory, office, etc., shall be in one building; the curing tank and storage building may be in a
separate building, but if so it shall be adjacent to the laboratory building and connected to it by a
level, weatherproof passageway. In addition, an area of covered hard pavement of 50m2 for
motor vehicles shall be provided adjacent to the laboratory.
2. LABORATORY AT SITE
1) In addition to casting yard laboratory, Contractor shall provide a site laboratory at all
the station locations. It shall consist of the following accommodation:
1 concrete laboratory
with airconditioned container room 30m2 floor area
1Soil laboratory 15m2 floor area
1office 15m2 floor area
1 storeroom 10m2 floor area
2) Site laboratory shall consist of storage area for concrete cubes and curing tanks. Site
laboratory shall have basic test equipment’s such as slump test, testing moulds, Compression
testing machine (simple hand operated) and other geotechnical related apparatus.
3. STANDARD OF CONSTRUCTION
1) The laboratory shall be constructed to the best Employer’s Engineering practice and the
Employer’s Representative shall issue a notice of no objection. Two independent telephone
lines with two extensions each shall be provided for the laboratory. Telephones shall be
located in areas as agreed with the Employer’s Representative.
2) A covered water tank with minimum capacity of 2000 litres shall be installed, as a source of
constant water pressure (15 kPa minimum) for each laboratory.
3) In the case of sinks used for washing samples, adequate trapping and/or separating devices
shall be provided to ensure the proper functioning of the facility.
Section -VI Appendix 14 14-1 December 2021

Contractor’s Site Laboratory
4. FURNISHINGS AND FIXTURES

The Contractor’s site laboratory shall be provided with required furnishings and fixtures.
5. LABORATORY EQUIPMENT
1) The laboratory equipment, as listed below, shall be issued a notice from the Employer’s
Representative. The Contractor shall submit for the Employer’s Representative's notice
within 2 weeks of the order to commence work the name of the supplier he intends to use for
each piece of apparatus together with the relevant catalogue and catalogue number.
2) The layout of the equipment in the testing laboratory shall require a notice of no objection
from the Employer’s Representative. The equipment shall be maintained to accuracy
appropriate to the required testing methods with routine calibration by an accredited
organisation as recommended by the appropriate Authority. The Equipment shall also be
calibrated after maintenance or relocation.
3) The Contractor's site laboratory shall be equipped with the following material testing
equipment as a minimum. The nature and quantity of equipment required for testing may be
varied by the Employer’s Representative depending on the detail of the Contractor's Design
and Construction methods or for any other reason which he deems to be valid and necessary
for the proper control of quality, all at the Contractor’s cost:
Determining Liquid Limit (1 complete set)

Liquid limit device (Casagrande type) 1 Set
Grooving tools 1 No.
Evaporating dish 1 No.
Spatula 100mm blade 1 No.
Laboratory balance, capacity 500 gm, 1 No.
(sensitivity 0.01 gms.)
Wash bottle, capacity 500 ml. 1 No.
Moisture cans, capacity 50 ml. 24 Nos.
Determining Plastic Limit (1 complete set)

Evaporating dish 1 No.
Spatula 100mm blade 1 No.
Glass plate 250mm x 250mm x 12mm 2 No.
Moisture cans, capacity 50 ml. 12 No.
Stainless steel rods, 3 mm dia. 2 Nos.
Determining Moisture Content (1 complete set)

Micro Oven, capacity 35 litres, control temperature
up to 200 °c 1 No.
Balance, capacity 200 gm., sensitivity 0.01 gm. 1 set
Lab. Tongs 1 No.
Moisture cans 75ml. with lid 36 Nos.

Compaction Characteristics (1 complete set)

Standard compaction mould 100mm dia. 1 No.
Modified compaction mould 150mm dia. 1 No.
Standard compaction Rammer, 2.5 kg. 1 No.
Modified compaction Rammer, 4.5kg. 1 No.
Straight edge 300mm long 1 No.
Sample ejector for 100mm and 150mm mould 1 No.
Sample tray 60 x 60 x 8 cm 3 Nos.
Wash bottle, 500 ml. 2 Nos.
Moisture cans 250 ml. 24 Nos.
Density of soil in-place by sand cone method (2 complete set)

Sand density cone apparatus, 150mm 2 Nos.
Plate, 300mm x 300mm with centre hold 150mm 2 Nos.
Glass jug for sand cone 2 Nos.
Chisel 25mm x 150mm 2 Nos.
Hammer 2 Nos.
One-gallon fieldcans 24 Nos.
Samplingspoon 2 Nos.
Soft hairbrush 2 Nos.
Moisturecans 250 ml. 48 Nos.
SieveAnalysis
Sieve shaker (portable) 1 unit
Coarse sieves In Sizes from 100mm to 10mm 1 set
Fine Sieves #4, #8, #16, #30, #40, #50, #100, #200 each) 1 set
Pans & Covers As required
Specific Gravity and Absorption of Coarse Aggregate

Wire basket, 200mm dia. 5 No
Heavy duty suspension balance, 20 kg x 1 gm. with accessories
for weight in water 1 set
Suitable water container 1 No
Unit Weight of Aggregate

Balance, 100 kg.Capacity with 10 gm precision 1 No.
Tamping rod 16mm diameter x 600mm long 1 No.
Measuring containers (3, 10, 15, 30 litres) 1 each
Flakiness and Elongation

Flakiness gauge, elongation index 1 set
Soundness Test
Sodium sulphate 25 kgs
Soaking tank 1 No.
Balance, Capacity 3 kg., Sensitivity 0.1 gm. 1 set
Sieves :Coarse 1 set
Fine 1 set
Concrete
Buckets for concrete sampling 12 Nos.
Slumpcone 12 Nos.
Tampingrod 12 Nos
Base plate 12 Nos.
Mixing pan for concrete 2 Nos.
Scoop for general purpose 2 Nos.
Concrete thermometer 1 No.
Concrete cylinder mould, 150mm * 300mm;
100mm * 300mm 10 each
Concrete cube mould, 100mm cube & 150mm cube 10 each
Adjustable spanners for dismantling cube moulds 6 No.
Capping set 2 Nos.
Capping compound As required
Concrete curing tank with capacity for 270 cubes, temperature
controlled, with circulation system drain and lockable cover 5 Nos.
Schmidt test hammer 1 No.
Compression testing machine (simple hand operated) 1 No.
Mould oil As required
Temperature chart recorder 1 No.
Miscellaneous
Vernier callipers to measure up to 200mm,
with elongated jaws 5 Nos.
Steel rule, 300mm long graduated 2 Nos.
Rubber gloves 10 pr.
Cotton working gloves 20 pr.
First aid kit 1 set
Wire brush 6 No.
Steel tape, 3m, 5m, 30m 3 each

Ballpeinhammer, 1 kg 2 Nos.
Paint scraper. Approx. 100mm wide 8 Nos.
Float, steel Approx. 280mm x 120mm 8 Nos.
Sack barrow 1 No.
Shovel: Square Mouthed 2 Nos.
: Round Mouthed 2 Nos.
24-wheel trolley, heavy duty, approx. 0.7m x 1.0m with
long pneumatic tyred type 1 No.
Wheelbarrow, rubber tyred 1 No.
Comprehensive tool kit. To include screwdrivers, pliers,
claw hammer, multi-grips, spanners (adjustable) 1 No.
Type NR Schmidt Hammer and tester with recording device 1 No.
Testing Anvil for Schmidt Hammer test (SHT) 1 No.
Chart recording paper for SHT 10 Pkts
Cover meter for detecting metal objects to depth of 100mm
Below the surface of non-magnetic objects 3 No.
Noise meter 1 No.
1. Digital / Latest cube testing Machine of Sufficient Capacity – as Per BIS

2. Cement quality testing equipments as per BIS
3. Water testing equipments


PART 2
SECTION VI
SUB-SECTION E
APPENDIX-15
DESIGN CONSOLIDATION UNIT REQUIREMENT
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5 Part -2 Section VI
DELETED
Section VI – Appendix 15 15-1 December 2021

Design Consolidation unit requirements

PART 2
SECTION VI
SUB-SECTION E
APPENDIX-16
EARTHING AND GRID
DECEMBER 2021
TENDER No. CP06/UG06/RT01 Employer’s Requirements -
CHENNAI METRO RAIL

LIMITED
TENDER NO. CP06/UG06/RT01
TABLE OF CONTENTS
1. INTRODUCTION 16-1
1.1 Introduction Scope 16-1
2 CATEGORIES OF EARTHING 16-1
2.1 General Requirement 16-1
2.2 Neutral Earthing 16-1
2.3 Protective Earthing 16-2
2.4 Adjacent Metallic Structures 16-2
2.5 Mitigation of Interference Effects 16-2
2.6 Treatment of Unearthed Systems 16-2
2.7 Earthing for Lightning Protection 16-2
3 GENERAL REQUIREMENTS 16-2
3.1 Legislation and Standards 16-2
3.2 Treatment of AC Power Supplies. 16-4
3.3 Treatment of Unearthed Auxiliary Supplies 16-4
3.4 Lightning Protection 16-5
3.5 Traction return current circuit system 16-5
4 OVERALL EARTHING STRATEGY FOR THE CHENNAI METRO
RAIL PROJECT 16-5
Section -VI Appendix 16 - Earthing and Grid i December 2021

4.1 Earthing, Bonding, Lightning Protection and Corrosion Protection Principles 16-5
4.2 Viaducts 16-5
4.3 Stations 16-6
4.4 Main Line and Depot External Track work 16-6
4.5 Depot Workshop Track work 16-6
4.6 Traction return current circuit 16-7
4.7 Interfaces 16-7
5 EARTHING OF POWER SUPPLY SYSTEMS 16-7
5.1 Supplies 16-7
5.2 Earth Electrodes and Earth Systems 16-7
5.3 System Earthing 16-8
5.4 Equipment Earthing (non-trackside) 16-9
5.5 Track and Trackside Equipment 16-11
6 EARTHING OF COMMUNICATION AND CONTROL SYSTEMS 16-12
6.1 General 16-12
6.2 Track side Equipment 16-12
6.3 Depot Equipment 16-14
7 EARTHING OF OTHER METALLIC STRUCTURES 16-14
7.1 General 16-14
7.2 Over ground Structures 16-15
7.3 Reinforced Concrete Track slab 16-15
7.4 Services to Metro system premises 16-16
7.5 Small Metallic Components 16-16
7.6 Depot Fencing 16-16
7.7 Lightning Protection 16-17
8 CORROSION CONTROL 16-17
8.1 Measures to reduce corrosion and other interference effects 16-17
Section -VI Appendix 16 - Earthing and Grid ii December 2021

1 INTRODUCTION
1.1 Introduction Scope
1.1.1 The purpose of this Earthing, Bonding, Lightning Protection and Corrosion Protection
Policy is to define the requirements for the earthing and bonding of the electrical power
supply systems and other parts of the Metro system to ensure, as far as possible:
i. the safety of operating personnel and other persons from electrical shock.
ii. the minimum of electrical interference between the electrical power supply and other
electrical and electronic systems and the protection of electrical equipment.
iii. the minimum of disturbance to existing statutory services and parts of the Metro
system due to any electrolytic corrosion effects arising from AC traction currents
flowing to and from the general mass of earth.
1.1.2 This document is divided into several sections. Sections 2 and 3 are of a general nature
whilst Sections 4 to 7 deal with specific items under system and equipment-specific
general headings and Section 8 deals with stray current corrosion control.
1.1.3 It should be noted that no Single section can be taken alone as being complete in itself in
covering all aspects of earthing under the general heading of that section. In the
implementation of the earthing policy account has to be taken of the interrelationship,
interface and integration of all systems comprising the Metro system.
1.1.4 The Contractor shall develop his own designs as required for Earthing, Bonding,
Lightning Protection and Stray Current Corrosion Control, using this document as a basis
for doing so, which shall require a notice of no objection from the Employer’s
Representative, prior to commencing any such works.
1.1.5 The Contractor shall coordinate his designs for earthing, Bonding, Lightning Protection
and Stray Current Corrosion Control as required with all Interfacing Contractors.
1.1.6 Reference in other documents to "Grounding" shall be taken to be synonymous with

'Earthing".
2. CATEGORIES OF EARTHING
2.1 General Requirement
2.1.1 The earthing system provided at any location may be common to two or more categories
of earthing, in which case all the earthing points on the individual items of equipment will
be bonded together to discharge any earth fault currents: In general, earthing and bonding
is required under one or more of the following categories.
Section -VI Appendix 16 - Earthing and Grid 16-1 December 2021

2.2 Neutral Earthing
2.2.1 Connection to earth at one or more nominally equipotential points of the current- carrying
conductors of each section of the power supply system shall be arranged to ensure that the
voltage at any point in the system relative to the general mass of earth will be within
defined limits and will provide a low impedance path for earth fault return currents.
2.2.2 For low impedance earth paths to be established the ground conditions must first be
measured (earth resistivity Ohms / m ) and the system designed according to the results.
Allowance shall be made for the fact that conditions may vary throughout the year due to
seasonal weather.
2.3 Protective Earthing
2.3.1 Connection to earth at one or more points of the non-current-carrying parts of electrical
equipment shall be arranged to ensure that, in the event of a failure of insulation or other
inadvertent connection between current and non-current-carrying parts, no dangerous
potential difference occurs between the non-current-carrying parts of the equipment and
the general mass of earth or adjacent equipment, and to provide a low impedance path for
earth fault currents.
2.4 Adjacent Metallic Structures
2.4.1 This relates to connection to earth of metallic structures, which are not part of the
electrical equipment but are in close proximity to the electrical system.
2.5 Mitigation of Interference Effects
2.5.1 This relates to the connection to earth of the screening of light current signal and control
cables. The connection to earth of the screening conductors of any light current cables
will, in general, be confined to one end in order to avoid circulating currents in the screen
causing interference on the signal chores.
2.5.2 There may be exceptions to this and EMC considerations will determine the solution to be
adopted in individual cases.
2.6 Treatment of unearthed systems
2.6.1 This relates to unearthed systems where the current carrying conductors are fully insulated
from earth at all points. No part of such a system need to be automatically disconnected
immediately on the occurrence of a single earth fault in that part. However special care
needs to be taken during design and installation when considering this type of earth
system.
2.7 Earthing for Lightning Protection
2.7.1 This relates to the protection of buildings and structures from lightning by the provision of
lightning arrester and hence connection to the earth electrode system. Account shall be

taken of the locality and lightning incidence rate and applied to the protection of the
Railway Systems as a whole from "Far" and "Near" strikes, individual structures and
personnel protection.
2.8 Traction return current circuit
2.8.1 This relates to the connection to earth of the track rails and the protection cables (Buried
Earth Cable, Aerial Earth Conductor, etc...).
3. GENERAL REQUIREMENTS
3.1 Legislation and Standards
3.1.1 Earthing, bonding, lightning and corrosion protection has to be in accordance with
applicable requirements related to the Metro system for the purposes of this Earthing
Policy, which shall be assumed to be no less onerous than the relevant requirements of the
following standards:
a European Standard EN50122-1 - 'Railway Applications Fixed Installations Protective

provisions relating to electrical safety and earthing'.
b European Standard EN50122-2 - 'Railway Applications - Protective provisions

against the effects of stray currents traction systems
c British Standard 7361, Part 1 - Cathodic Protection - Code of Practice for Land and
Marine Applications.
d. International Union of Railways Codes (UIC) 605 'Protection from Corrosion' -

Measures to be taken on catenaries to reduce the risk on adjacent piping and cable
systems.
e BS 7671 - Requirements for Electrical Installations
f IEC 60364 - Electrical Installations of Buildings
g IEC 61312 - Protection Against Lightning
h IEC 61024-1; Protection of Structures against Lightning, Part 1: General Principles.
i IEC 61024-4; Series protection against lightning electromagnetic impulses for

structure with electrical and electronic systems.
j IEC 61000-5 Edition1, Electromagnetic Compatibility (EMC) Part 5
k BS 7430 - Code of Practice for Earthing.
l ANSI/IEEE 80 - Earthing of Substations
m IS—3043—EARTHING

n BS-1013---SUBSTATION EARTHING
o NFPA-- 780-- LIGHTNING PROTECTION
p IEEE- 1100—EARTHING OF ELECTRONIC EQUIPMENT EN- 50122-2

Insulation from Earth
q EARTH RESISTANCE VALUES (ETI/PSI/EARTHING OF RDSO) RDSO’s Code

No: ET1/PS I /120 ( 2/91) Code of practice for earthing of Power Supply Installation
for 25kV ac single phase traction system
r European Standard EN50121-1 -Railway Applications – Electromagnetic

compatibility - General'.
s European Standard EN50121-4 - Railway Applications – Electromagnetic

compatibility – Emission and immunity of the signalling and telecommunications
apparatus'.
t European Standard EN50121-5 - Railway Applications – Electromagnetic

compatibility – Emission and immunity of fixed power supply installations and
apparatus'.
u RDSO/SPN/144/2004 Safety and reliability requirement of electronic signalling

equipment,
v Local Codes. These may however conflict with International Codes/Standards in

which case discussion and agreement with the employer representative will be
required.
3.2 Treatment of AC Power Supplies
3.2.1 The general policy followed in this document is to provide an earth farm for each of the
auxiliary substations and at other locations as required for purposes of earthing AC power
supply systems under the category of Clause 2.2 and metallic enclosures and structures
under Clauses 2.3 and 2.4.
3.2.2 The earth farms at each substation and other locations shall be multiple-interconnected by
provision of bonding connections cable sheaths, cable armouring, to adjacent earth farms
to form an incidental earth mat embracing the whole of the Metro system.
3.2.3 The armouring of HV power supply cables will not be connected to the incoming supply
to the bulk substation earthing system (this must be agreed with the local authority) or
other mitigation measures taken. However, there shall be provision to do so conveniently
on a temporary basis whilst work and testing requiring this is carried out.
3.2.4 The alternative solution of segregating the utility supplier and Metro system earth farm
and its associated earth system from utility supplier earth farms and earth systems could be
difficult to implement and to maintain.

3.2.5 Although segregation will tend to discourage the flow of stray traction currents through
the earth systems, this will not necessarily decrease the corrosion of particular electrodes
and may well encourage stray currents to pass from buried structure to buried structure,
leading to corrosion of the structures.
3.2.6 Two other difficulties could arise with segregation as follows:
a transferred potentials will appear across insulated joints used to segregate the systems
where there are interconnecting cables etc. and between adjacent structures bonded to
different earthing systems
b provision of earthing for the screening of telecommunications cables to reduce

interference (Clause 2.5 above).
3.2.7 For the reasons described above, the effects of the segregation will need to be monitored
closely.
3.3 Treatment of Unearthed Auxiliary Supplies
3.3.1 Certain low voltage auxiliary, signalling, control or indication systems come under the
category of Clause 2.6, where the ability to temporarily continue in operation with a single
earth fault gives increased security of supply. The signalling or control circuit can be
isolated from Earth to avoid maloperation or Nuisance Tripping of the control circuit
which will therefore need its own Alarm to draw attention to this fact and hence start the
fault rectification process (normally by manual investigation and maintenance operations).
3.3.2 The incoming power supplies to the control system however may have their own Earth
Fault detection.
3.4 Lightning Protection
3.4.1 The protection of above ground structures from lightning under the category of Clause 2.7
is included within this policy document..
3.5 Traction return current circuit System
3.5.1 The power supply contractor will have to handle a traction power supply simulation. The
traction return current circuit will be designed according to tender requirements, standards
and traction simulation results.
4. OVERALL EARTHING STRATEGY FOR THE CHENNAI METRO RAIL

PROJECT
4.1 Earthing, Bonding, Lightning Protection and Corrosion Protection Principles
4.1.1 Taking into account the previous general requirements in section 3:
a) A "Structure Earthing" strategy shall be applied throughout the Chennai Metro Rail

Project to ensure electrical safety and provide the basis of lightning protection;
b) All trackwork with workshop buildings shall be bonded to the structure earth of the
building.
4.1.2 All buildings I structures shall be connected to mass earth via earth farms which form part
of the building I structure foundations and this earth shall be continuous through all
building structures by the appropriate interconnection and bonding of all metalwork.
4.2 Viaducts
4.2.1 Earth farms shall be incorporated into the foundations of every column by the provision of
interconnected flat steel bars in the footings I piles, pile caps and up through the actual
columns. These shall be provided by the relevant civil contractor to a design provided by
the power supply contractor.
4.2.2 The reinforcement in the viaduct shall be bonded together throughout the entire length of
each span. Where post-tensioned segmental construction is used, all reinforcement in each
segment shall be bonded together with welded flat steel bars which shall be brought out to
two principal terminals on each side of each segment and every segment in the span shall
be electrically connected with a copper bonding cable which shall subsequently be bonded
to the earth bars in the supporting columns. The bonding of reinforcement with the civil
works shall be provided by the relevant civil contractor to a design provided by the power
supply contractor. The interconnection of segments by copper cable and connections to the
columns earths shall be provided by the power supply contractor.
4.2.3 Lightning interception facilities shall be provided along the sides of the viaduct which
shall be securely bonded to the structure earth of the viaduct. These shall be provided by
the civil contractor to a design provided by the power supply contractor.
4.3 Stations
4.3.1 Earth farms shall be incorporated into the foundations of every column by the provision of
interconnected flat steel bars in the footings I piles, pile caps and up through the actual
columns. These shall be provided by the relevant civil contractor to a design provided by
the power supply contractor.
4.3.2 The reinforcement in the building I structure shall be bonded together throughout by the
use of welded flat steel bars. The bonding of reinforcement with the civil works shall be
provided by the relevant civil contractor to a design provided by the power supply
contractor.
4.3.3 The flat steel bars shall be brought out into every auxiliary service substation and every
traction power substation to main earth bars located on a wall.
4.3.4 Further flat steel bars shall be brought out to earthing terminals in:

a Every Station Control Room
b Every Ticket Office
c Every plant and equipment room
d Other locations where required as an earthing point for metal work and lightning
protection. (It should be noted that general earthing of typical electrical equipment
should be through the reticulated earth of the low voltage power supply system or
back to the nearest earthing terminal.)
4.3.5 The flat steel bars shall be provided by the civil contractor to a design provided by the
power supply contractor.
4.3.6 Any distribution of earthing required beyond the above nominated locations shall be
provided by the respective contractor responsible for the provision of the particular
equipment.
4.3.7 Lightning interception facilities shall be provided on the roofs of buildings I structures
which shall be securely bonded to the structure earth of the building I structure. These
shall be provided by the civil contractor to a design provided by the power supply
contractor.
4.4 Main Line and Depot External Track work
4.4.1 In order to ensure electrical safety and prevent the potential of the running rails rising to
excessive potentials above the structure earth, proper earthing shall be used at appropriate
locations to clamp the running rails to the structure earth. These shall be provided by the
power supply contractor at an appropriate number of locations to control the rail potential
to safe levels. As a minimum, one shall be provided at each station and in each depot
external area
4.4.2 The Main Line track work and the depot external track work shall be electrically isolated
from each other by the use of insulation joints boundary
4.5 Depot Workshop Track work
4.5.1 The running rails and traction return system of the Chennai Metro rail Project within the
depot workshops shall be solidly bonded to the traction return earth.
4.5.2 The traction return rails for the depot workshop and the pit wheel lathe lane are
electrically isolated from the main line by means of insulated rail joints.
4.6 Traction return current circuit
4.6.1 The traction return current circuit of the Chennai Metro Rail Project will use the rail and
the following return current conductors:
- Buried Earth Cables

- Aerial Earth Cables

- Integral Transverse Bonds.
Cables cross sections will have to conform to EN 50122. Buried Earth cable, Aerial earth
cable, Integral Transverse Bond and Earth pit when available, will be bonded together:
- on earth bar provided at the bottom of OHE mast on viaducts and in Depot
- on earth connecting box in stations and in underground.
4.7 Interfaces
4.7.1 The design of the earthing, bonding, lightning protection and corrosion protection of the
Chennai Metro Rail Project shall be undertaken by the power supply contractor.
4.7.2 During the development of its design, the power supply contractor shall coordinate the
earthing requirements of all Interfacing Contractors.
5. EARTHING OF POWER SUPPLY SYSTEMS

5.1 Supplies
5.1.1 The electrical power supply systems comprise 110/33 kV, 110/25 kV and 415V, 3 phase,
3/4wire ac supplies, 240V and 110V, 1 phase, 2 wire ac supplies, at 50Hz and 110V dc
equipment control supplies.
5.2 Earth Electrodes and Earth Systems
5.2.1 Earth Systems for Bulk In-feed Substations
5.2.1.1 Each bulk In-feed substation will be provided with earthing farms for both utility supplier
and Metro system.
5.2.1.2 Connections to the earth farms will be through two 'Principal Connections' links by means
of stranded insulated copper cables with a cross- section area calculated for the worst case
conditions of earth current through marshalling earth bars in the area of the farms
5.2.2 Earth Systems for Substations
5.2.2.1 Each services Substation will be provided with an earth farm, of resistance less than 1
ohm, and connected to the substation earthing system through two 'Principal Connection'
links by means of stranded insulated copper cables with a cross- section area calculated for
the worst case conditions of earth current.
5.2.2.2 The substation earthing system is to be compliant with IEC 60364 and IEC 61312 or BS
1013
5.2.3 Earthing for Distribution Systems
5.2.3.1 Supplies at 415/240 V, or 110 V are made available for Depot and station equipment, and,

where applicable, trackside equipment. These supplies are derived from the Secondary
winding of the power source (Transformer/Generator etc) 415 V star-connected 3-phase
supplies, the star point of which is to be bonded to the auxiliary Substation earthing
system.
5.2.3.2 Continuity of this earth connection to the point of supply shall be provided by the cable
sheath / armouring and/or additional bonding cables.
5.2.3.3 All locations receiving such supplies, which are remote from the earth system of any
traction or distribution substation, are to be earthed by one of the following methods:.
a by low impedance connection to the trunk earth system such that the minimum earth
fault current is adequate to operate the over current protection in accordance with IEC
60364;
b where the requirement in (a) cannot be met, approved earth leakage protection is to
be provided;
c by connection of the earth terminal to the earth electrodes at any adjacent location via
cable sheaths and armouring and/or additional bonding cables such that the earthing
impedance meets the requirement in (a) above;
d by connection of the earth terminal via sheaths and armouring of the supply cables or
other bonding conductor to the earth system of the auxiliary substation, such that the
earth fault loop is entirely metallic and of sufficiently low impedance to meet the
requirement of (a) above.
5.2.3.4 The earthing of all distribution and sub-distribution systems is to be in accordance with
IEC 60364
5.3 System Earthing
5.3.1 General
5.3.1.1 This section describes the connection to earth of the neutral or negative, nominally equi-
potential points of the current carrying conductors in each section of the power supply
system.
5.3.2 110 kV Supplies
5.3.2.1 The method of earthing of 110kV, 3 phase supplies from utility supplier must be
coordinated with utility supplier.
5.3.3 415V Supplies
5.3.3.1 The star point of the 415V secondary winding of the auxiliary transformer will be
connected to the earth bar of the 415V switchboard.
5.3.3.2 The earth bar will be connected to the neutral bar via a neutral link in the switchboard

5.3.3.3 The neutral bar of the transformer is to be solidly earthed, via a bolted link to the earth
system.
5.3.4 240V Supplies
5.3.4.1 The 240 volt supplies are taken from one phase and the neutral of the above 415V
supplies. The neutral shall be earthed in accordance with Clause 4.3.5.
5.3.5 110V AC Supplies
5.3.5.1 The 110V supplies are obtained from 240/110Vtransformers. Each 110V winding of these
transformers is to be fitted with a centre tap which is to be solidly earthed.
5.3.5.2 Approved earth fault detection equipment is to be provided.
5.3.6 110V DC Supplies
5.3.6.1 Both poles of the 110V battery supplies used in traction and distribution substations and
elsewhere in connection with the power supply system are to be insulated from earth.
5.3.6.2 Approved positive pole and negative pole earth fault detection equipment is to be
provided.
5.4 Equipment Earthing (non-track side)
5.4.1 This section refers to the treatment of metal enclosures or supporting metalwork for the
equipment associated with the power supply systems covered in Section 4.3 above, with
the exception of the trackside equipment which is covered in Section 5.5 below.
5.4.2 Earthing and bonding of electrical equipment is required to reduce the effects of
interference, and to ensure the personal safety of the public, operational and maintenance
staff by limiting the step and touch voltages to within acceptable limits. Where there is a
conflict between these requirements, personal safety is always to take precedence.
5.4.3 33kV Cables / 25kV cables
5.4.3.1 The earthing of screens and armouring of all 33kV and 25kV cables is to be earthed at
both ends. Exception may be made at the extreme ends of the system to avoid any
circulating currents detected in service.
5.4.3.2 Means are to be provided for disconnecting the screen ends, individually, from earth for
testing purposes.
5.4.4 Other Power Supply Cables
5.4.4.1 This section covers the cables for the distribution of 415/240Vac supplies and 110Vdc
Supplies
5.4.4.2 The armouring of multicore cables (e.g. 3 phase or twin and earth etc.) is to be earthed at

both ends via an earth terminal provided with the gland, or via the metalwork of the cable
box and structure to the earth bar or terminal of the equipment at which the cable is
terminated.
5.4.4.3 Exceptions will be where the equipment at each end does not share the same earth system
as, for example, the dc switchgear for which the enclosures are insulated from the
substation earth and connected to it via a leakage current measuring shunt. In this case the
armouring will be earthed only at the distribution board end.
5.4.4.4 Single core cables are to be earthed in a similar manner but at one end only and must
avoid circulating eddy currents where the metallic cable sheath is connected to a metallic
cabinet.
5.4.5 110 kV/ 33 kV and 25 kV Switchgear
5.4.5.1 All ac switchgear will be earthed directly to the substation earthing system.
5.4.6 415V, 240v and 110 V Switchgear
5.4.6.1 All metallic components of the cubicles are to be bonded to an earth bar or terminal which
is to be connected to the substation earth system.
5.4.7 Battery Equipment
5.4.7.1 All metallic components of metal stands and cubicles for batteries, battery chargers and
DC distribution switchboards are to be bonded to an earth bar or terminal which is to be
connected to the earth system.
5.4.8 Transformer
5.4.8.1 All electrically separate parts of each transformer core are to be bonded together and the
core as a whole is to be insulated from the enclosure/tank. An accessible removable link is
to be provided between the core and the enclosure/tank for earthing the core for core
testing.
5.4.8.2 All metallic components of control compartments are to be bonded to an earth terminal or
bar, which is to be connected to the enclosure. The enclosure is to be connected to the
substation earth system with a suitable fault rated earth connection.
5.4.9 415/110VTransformers
5.4.9.1 Each transformer is to be provided with a screen between the primary and secondary
windings so that in the event of a fault the primary winding or its connections cannot be
connected to the secondary winding or its connections
5.4.9.2 The centre point of the secondary 110 V winding is to be connected to the substation earth
system.
5.4.9.3 This screen, the core and framework of each transformer is to be connected to the earth

bar or terminal of the enclosure in which the transformer is located.
5.4.9.4 The earth bar or terminal of the enclosure is to be connected to the substation earth
system.
5.4.10 Marshalling Panels
5.4.10.1 All metallic components of each cubicle are to be bonded to an earth terminal or bar,
which is to be connected to the earth system.
5.4.11 Instruments, Relays, Control Switches and other Electrical Components
5.4.11.1 All metallic cases and/or frames of instruments, relays, control switches and other
electrical components mounted on control panels or in cubicles are to be connected to the
earth bar or terminals of the cubicle in which the component is mounted.
5.4.12 Ancillary Equipment
5.4.12.1 Cubicles, cabinets, racks and panels are to be provided with a copper earth bar having a
suitable cross-sectional area for the possible fault current, placed at a convenient position
within the equipment. All metal parts, other than those forming part of an electrical circuit,
are to be earthed by connection to the earth bar.
5.4.12.2 When apparatus or instruments are accommodated on panel cubicle doors or swinging
frames, flexible cable or braid is to be used for earthing these items; the door hinges are
not acceptable as means of earthing this part of the equipment.
5.4.12.3 Except where otherwise approved, a stud type terminal of diameter not less than 12 mm,
or a tapped boss of equivalent size, is to be provided on the outside of each cubicle or
structure for the purpose of making the connection to earth. This terminal is to be
connected to the substation earthing system.
5.5 Track and Trackside Equipment
5.5.1 Traction Return Running Rails (Main Lines)
5.5.1.1 The track rails, where used for traction return purposes in main line and Depot areas, have
to be regularly bonded to the Buried Earth Cable. Maximum distance between two
bondings should not exceed 500m. In Track circuited areas, the bonding will be through
appropriate track circuit device.
5.5.1.2 As the Metro system uses the train wheels and track rails for the traction current return
circuit, the rails electrical continuity has to be ensured. Whenever the rails continuity is
not ensured, mechanical joints for signalling purpose, expansion joints for track purpose
only, the rail’s continuity shall be recreated using continuity bonds.
5.5.1.3 Concerning the expansion joints for track purpose only, the continuity will be ensured by
2* 70mm² (minimum cross section) cables bolted on the rails. The drilling and the
preparation of rail bonds shall be done in factory.

5.5.1.4 Concerning the mechanical joints for signalling purpose, the continuity will be ensured by
impedance bond.
5.5.1.5 As the Metro system uses the train wheels and track rails for the traction current return
circuit, the track rails will have volt drop along them as a result of the flow of traction
current. The rails are imperfectly insulated from earth or the structures on which they are
fixed and therefore a circuit parallel to the rails can occur by means of which current
driven by the volt drop flows out of and back into the rails. The current, which flows out
of the rails and returns at some other point, is referred to as stray current.
5.5.1.6 The most serious effect of the stray current is electrolytic corrosion at the point where
current flows out of a metal surface into concrete or soil. An equivalent of an Electrolytic
circuit is formed the same as a battery cell is set up at the interface, the potential of which
varies with the ground, structure and rail materials present. For corrosion to take place the
interface potential must exceed the potential of the cell.
5.5.1. 7 The rails shall be properly bonded to Buried Earth Cables so that Buried Earth Cable
nominally constitutes the return path and limits the stray currents.
5.5.1.8 Track rails, Buried Earth Cables, Aerial Earth cables, Earth pits will be connected together
via Integral Transverse Bonds provided:
- with a maximum 500 meter spacing
- at mechanical joints.
Spacing will be determined by the Contractor in his EMI study.
5.5.2 Clearance To Earthed Equipment or Structures
5.5.2.1 Any exposed, non live, conductive part (metallic structure or other equipment), which is
closer than 2.0m from vehicle static envelope shall be earthed to the Buried Earth Cable. If
already part of an earthing system, the conductive part should be connected to the buried
earth cable via voltage limiting device.
5.5.2.2 Screen doors on station platforms, where installed, will be bonded to the track by duplicate
insulated cables and insulated from the general body of earth. Metal enclosed electrical
equipment within 2.5 metres of the screens will not be earthed but the enclosed live
equipment 'double insulated' from the enclosure.
5.5.2.3 The station platform surface in the vicinity of the screen doors, where installed, will be of
insulating material.
6 EARTHING OF COMMUNICATION AND CONTROL SYSTEMS
6.1 General
6.1.1 There are several separate sub-systems which collectively form the control and
communications system. Equipment, enclosures and mountings associated with these sub-
systems are distributed throughout the Metro system at trackside, stations and depot

locations.
6.1.2 The equipment, enclosures and mountings associated with the control and
communications system are not anticipated to be located within 2m of any part of the
Metro system that is intentionally connected to the traction return system. Earthing of the
control and communications system will thus be by conventional methods to the protected
earth of the distribution switch board.
6.1.3 Should it become necessary, during construction, to locate any item of equipment
associated with the control and communication system within 2m of a part of the Metro
system that is connected to the traction return system then additional protective measures
will need to be adopted. In such instances the provisions of clause 7.1, to limit the touch
potential between the two earth systems, will apply, and the equipment enclosure will be
earthed to the Buried Earth Cable through voltage limiting devices.
6.1.4 Two separate clean earths of value not exceeding 0.5 Ohms required at each station for
signalling and telecommunication (including AFC), to be terminated in signal, telecom
and AFC equipment rooms as well as in telecom closets rooms at all stations, depot and
OCC.
6.2 Trackside Equipment
6.2.1 Trackside equipment is considered to comprise all equipment, enclosures and mountings
located at stations, substations and adjacent to the track but, remote from stations and
substations.
6.2.2 Integral Transverse Bonds and insulated joints
6.2.2.1 The integral transverse bonds have to be connected at a maximum spacing of 500m. These
integral transverse bonds will also serve the need of equipotential link.
6.2.2.2 Insulated joints are mandatory on track at traction substations
6.2.3 Station Locations
6.2.3.1 At each station a UPS and UPS distribution switchboard will be provided by a designated
contractor.
6.2.3.2 Each item of control and communications equipment that is connected to a 240V single
phase supply derived from this source is to have its earth terminal directly connected to
the main protected earth terminal at the distribution board by an appropriate protective
conductor.
6.2.3.3 All metalwork (including enclosures, mountings, racks, trays etc.), associated with an item
of control and communications equipment that is not intended to carry current is to be
bonded to the earth terminal within the equipment enclosure and extended to distribution
board by an appropriate conductor.
6.2.3.4 Alternatively, if the design of the equipment requires, a direct earth cable, to the station

earth farm principal earth connection, may be provided.
6.2.4 Trackside Locations
6.2.4.1 Control and communication equipment at trackside locations, e.g. points machines, are to
derive their power supply from the UPS of the nearest station or the depot as appropriate.
6.2.4.2 Each item of control and communications equipment that is connected to a 240V single
phase supply derived from this source or otherwise is to have its earth terminal directly
connected to the main system earth cable running between the earth systems of successive
auxiliary substations. In these cases the earth core of the supply cable will be left open at
the end remote from the supply to avoid excessive currents during fault conditions.
6.2.4.3 All metal work (including enclosures, mountings, etc.), associated with an item of control
and communications equipment that is not intended to carry current e.g. signal lamp
enclosures, is to be bonded to the main system earth cable running between the earth
systems of successive auxiliary substations.
6.2.4.4 The touch potential of the trunk earthing conductor will be controlled as described in
clause 5.5.2 above.
6.2.5 Substation locations
6.2.5.1 Control and communication equipment, housed within or immediately adjacent to Sub-
stations, are to derive their power supply by dedicated feed from the UPS of the station or
depot as appropriate.
6.2.5.2 Each item of control and communications equipment that is connected to a single phase
supply derived from this source is to have its earth terminal directly connected to the
protective earth terminal at the distribution board.
6.2.5.3 All metalwork (including enclosures, mountings etc.), associated with an item of control
and communications equipment that is not intended to carry current shall be bonded to the
equipment earth terminal.
6.2.5.4 The earth terminal of the distribution board will be connected to the distribution
switchboard protective earth.
6.3 Depot Equipment
Depot equipment comprises all control and communications equipment contained within
the Depot building and that located in the stabling yard and mounted on the depot
buildings.
6.3.1 Signalling and Telecommunications Room
6.3.1.1 Equipment contained within the signalling and communications is to be fed from the UPS
distribution board, installed complete with protective devices and earth terminal.

6.3.1.2 Power distribution to the various items of ancillary equipment and cubicles shall be by
means of several ring main circuits. Each circuit contains a dedicated protective conductor
(separate conductor or cable armouring) connected to the protected earth terminal at the
distribution Switchboard.
6.3.1.3 All items of control and communication equipment are to have a direct connection
between the equipment earth terminal and the circuit protective conductor.
6.3.2 Operations Control Centre
6.3.2.1 Equipment contained within the Control centre is to be fed from the UPS distribution
board, installed complete with protective devices including surge suppressor and earth
terminal.
6.3.2.2 Power distribution to the various items of ancillary equipment and desks shall be by means
of several ring main or radial circuits. Each circuit contains a dedicated protective
conductor (separate conductor or cable armouring) connected to the protected earth
terminal at the distribution switchboard.
6.3.2.3 All items of control and communication equipment are to have a direct connection
between the equipment earth terminal and the circuit protective conductor.
6.3.3 Other Depot Locations.
6.3.3.1 Control and communication equipment, located externally or on depot buildings, is to

derive its power from the control centre UPS.
6.3.3.2 Internal earthing of the equipment will be to a dedicated earth terminal connected to the
enclosure.
6.3.3.3 Where the equipment is outside the 3.0m limit to the vehicle static envelope an earthing
circuit for the metallic enclosure will be provided back to the protected earth of the
distribution switchboard. Where the equipment is within the 2.0 m limit the enclosure will
be earthed to the depot system earth. The touch potential of this earth system will be
controlled by strategically situated voltage limiting devices as described in 5.5.2 above.
7 EARTHING OF OTHER METALLIC STRUCTURES

7.1 General
7.1.1 Other metallic structures comprise those structures which do not form part of the Power
Supply or Communication and Control Systems covered in Section 4 and 5 above. They
include the reinforcing in concrete construction, pipes for other services and fixtures and
fittings in buildings and stations and depot.
7.1.2 Lightning protection of structures and buildings is also included in this Section.
7.1.3 The ac systems are generally arranged to operate with their neutrals earthed, and with

associated metallic enclosures also connected to earth, by conventional methods.
7.1.4 The Buried Earth Cable shall be regularly earthed and connected to earth pits.
7.1.5 Earth pits shall be provided at each stations and their spacing should not exceed 300m on
viaducts and in depot. Earth pits earthing value shall not exceed 1 Ohm.
7.1.6 Earth pit shall be provided with disconnecting bars so that their earthing value can easily
be checked.
7.1.7 Any exposed metallic structure, concerned by 7.1.1, which is closer than 10m from the
Over Head Line shall be earthed to the Buried Earth Cable as per clause 5.5.2.1.
7.1.8 The self-restoring properties of high voltage limiting devices avoid a permanent leakage
path for limited faults whereas a latched contactor needs to be manually reset or a device
needs to be physically replaced.
7.2 Over ground Structures
7.2.1 The frames of all buildings and other structural steelwork are to be bonded to the local
earth system unless all parts of the frame or structure are completely encased in concrete,
masonry or other non-metallic cladding.
7.2.2 Where a local earth system is not provided under the provisions of Clauses 4.2.1 such a
system is to be provided for the purposes of this Clause in those locations where
accidental contact with the traction system is possible. Such an earth system is to have an
overall resistance not exceeding 10 ohms between any point of the earthed frame or
structure and the general body of the earth. In addition a self-restoring spark gap device is
to be connected between each separate structure and the traction return system
7.2.3 In the case of the building structure of the Depot workshop, where the traction return
system is deliberately earthed, the structure E&M service and traction earthing systems are
all to be interconnected.
7.2.4 In general the reinforcing bars in concrete structures or foundations are not to be earthed
in those cases where the reinforcing bars are completely encased in concrete. This applies
to substation foundation slabs.
7.2.5 Where external connections are made to the reinforcing, for the purpose of providing studs
for securing metallic structures or components which are earthed, insulating sleeves and
washers are to be fitted to the studs if there is a possibility of traction return currents
passing into the reinforcing via the studs.
7.3 Reinforced Concrete Track slab
7.3.1 The reinforced track slab will incorporate separate dedicated stray current collection mats
of rebar construction, for each track.
7.3.2 These stray current collection mats will be linked to each other in succession by

disconnectable links. At each link position one side of the link will be connected to a trunk
'stray current collection/monitoring cable' of suitable section.
7.3.3 The trunk collection cable will be duplicated for each track and each terminated at both
ends on insulators adjacent to the station earthing system with the possibility of
connecting to the earth system through diodes for stray current collection if later deemed
beneficial
7.3.4 The diodes shall be provided at the outset and installed together with the connection
terminals such that they can be connected or not as may be required.
7.3.5 The stray current collection/monitoring cable will be insulated and protected from earthed
metal along its route.
7.3.6 All trackslab reinforcing in the workshop area, where the tracks are earthed, shall be
bonded to the earthed rebar and steel structures of the workshop building.
7.4 Services To Metro system premises.
7.4.1 Metallic service (I.e. water, gas, waste water etc) pipes entering the Metro system
premises, both over and underground, are to be provided with an insulated insert at the
point of entry, and the pipe work within the Metro system is to be bonded to the local
earth system.
7.4.2 Where both plastic and metal pipes are used, all lengths of exposed metal pipes, or those
connected to taps or apparatus, are to be bonded to the local earth system. A separate bond
is not required for the pipe if it is electrically continuous with earthed apparatus.
7.5 Small Metallic Components
7.5.1 Small metallic and isolated structural parts which are effectively segregated from any
electrical apparatus or cables etc. or earthed metallic enclosures and structures do not
require to be bonded to the local earth system.
7.5.2 For the purposes of this Clause the metal angle supports for trench covers and similar
metalwork in electrical traction and distribution substations are not effectively segregated
and are to be bonded to the substation earth system.
7.6 Depot Fencing
7.6.1 Metallic fencing associated with the Metro system within 2.0 metres of the track or any
part of any structure or other equipment which is connected to it, is to be earthed to the
depot slab structural earth system.
7.6.2 The depot Substations will also derive their earthing from the depot slab structural earth
system
7.6.3 Metallic fencing associated with the Metro system within 10.0 metres of the overhead
contact line, is to be earthed to the Buried Earth Cable.

7.6.4 Each separate section of fencing is to be separately earthed in the appropriate manner as
above.
7.6.5 All gate posts are to be bonded to each other across the gate opening by an underground
conductor, and the gates themselves bonded across the hinges.
7.7 Lightning Protection
7.7.1 The need for lightning protection for individual mass transit system buildings is to be
assessed in accordance with IEC 61024-1 or the local building code. Where lightning
protection is found to be necessary, it shall be provided in accordance with this Standard.
7.7.2 All building structures will be of steel or steel reinforced concrete with every pillar of the
structures bonded into the structure earth of the depot
7.7.3 Metal roofing will be multiple bonded into the metal of the building structure. Lightning
conductors will be provided to bridge any non-metallic roofing and conduct into the steel
structure in the most efficient manner.
7.7.4 Cables with metal sheaths and other metallic services entering the building are to be
bonded to the structure at the point of entry and to any electrodes provided for lightning
protection, if not already adequately bonded via the local earth system.
8 CORROSION CONTROL
8.1 The measures to be used to reduce corrosion and other interference effects are:
i) to ensure that the along-track resistance is as low as practicable;
ii) to ensure that the track-to-buried earth resistance is as low as possible,
iii) in slab track sections, to provide a substantial buried collector mat to intercept a high
percentage of traction leakage currents (stray current) and return them to buried
earth collector.


PART 2
SECTION VI
SUB-SECTION E
APPENDIX – 17
ADJACENT WORKS CONTRACTS
DECEMBER 2021
APPENDIX 17
ADJACENT WORKS CONTRACTS
The Construction Projects that are to be undertaken adjacent to the site areas includes those
listed in the following table. This list should be in no way construed as a complete list of
adjacent works Contracts with which the Contractor shall be required to interface.
The Contractor shall be fully responsible for identifying and interfacing with all adjacent
works projects.
No. Description By
Employer’s DDC SYSTRA MVA Consulting India

1
Pvt. Ltd
2 CMBT-Nathamuni Elevated package To be awarded
Kolathur – Madhavaram Underground/Elevated To be awarded

3
package
4 All future Civil, Track & System Contractors Various agencies (to be awarded)
Part-2 – Appendix 17 17-1 December 2021

Adjacent Works Contracts

PART 2
SECTION VI
SUB-SECTION E
APPENDIX-18
SCHEDULE OF DIMENSIONS
DECMBER 2021
“Construction of Underground Stations at Kolathur Junction,

Srinivasa Nagar, Villivakkam Sub-urban Station (Villivakkam),
Villivakkam Bus-Terminus and Nathamuni (Villivakkam MTH
Road) with Entry / Exit, Ventilation shafts, Plumbing, Earthmat,
Architectural finishes & Signages etc. including Twin Bored
Tunnels from Kolathur Junction Retrieval Shaft to Nathamuni
(Villivakkam MTH Road) Launching Shaft and Ramps with U -
section in Corridor-5 of CMRL phase-II project”
PART – 2
SECTION – VI
APPENDIX-19
CONSTRUCTION INTERFACE MANAGEMENT
DECEMBER 2021
Chennai Metro Rail Project – Phase 2, Corridor 5 Part 2, Section VI
TENDER No. CP 06/UG06/RT01
Table of Contents
1. DEFINITIONS AND ABBREVIATIONS ........................................................................................ 1

2. INTRODUCTION ............................................................................................................................... 2
3. CO-ORDINATION ............................................................................................................................. 5
3.1 Contractor’s Co-Ordination Responsibilities .................................................................. 5
3.2 Site Co-Ordination & Attendance ....................................................................................... 5
4. INTERFACE ....................................................................................................................................... 6
4.1 Co-Ordination of Contractor’s Scope of Work ................................................................ 6
4.2 Interfacing Contractors ......................................................................................................... 7
4.3 Interfacing Contractors - Communications and Information Exchange .................. 7
4.4 Resolution of Co-Ordination Difficulties......................................................................... 10
4.5 Interface Performance ......................................................................................................... 10
5. CONTRACTOR’S INTERFACE MANAGEMENT SYSTEM .................................................... 10
5.1 Interface Management System .......................................................................................... 10
5.2 Interface Management Team .............................................................................................. 11
6. INTERFACE MANAGEMENT PLAN & INTERFACE MANAGEMENT PROGRAMME ..... 12
6.1 General..................................................................................................................................... 12
6.2 Interface Management Programme (IMPG) .................................................................... 13
6.3 Interface Management Plan (IMP) ..................................................................................... 13
6.4 Requirements for The Interface Management Programme &Interface
Management Plan.............................................................................................................................. 13
6.5 Interface Specification. ........................................................................................................ 14
7. INTERFACE COORDINATION SHEET (ICS)............................................................................ 15
8. COORDINATION DRAWINGS ..................................................................................................... 15
8.1 Interface Drawings ................................................................................................................ 15
8.2 As Constructed Drawings ................................................................................................... 15
9. Annexures ....................................................................................................................................... 16
Volume – 1 Sub - Section B December 2021

Appendix -19 19-i
Construction Interface Management
CONSTRUCTION INTERFACE MANAGEMENT

1. DEFINITIONS AND ABBREVIATIONS
1.1 Chief Interface Coordinator means a suitably qualified person, assigned by a Contractor,
who is the Team Leader responsible for administrating, monitoring, managing, supervising
and resolving all interface issues between Interfacing Contractors for the Chennai Metro
Rail Project.
1.2 Interface means the region of interaction across the common boundary between two
adjacent but separately managed and controlled parts of the Works. The coordination and
management of the interaction regions is necessary to ensure that the overall scope and
definition of the Project works is complete and seamless across all such boundaries.
1.3 Interface Coordination point’s means a document produced by the Contractor which
defines the integration and interfaces between the various Interfacing Contractors
employed on the Project.
1.4 Interface Management Programme (IMPG) means the programme produced by the
Contractor, developed and updated on a quarterly basis, which describes the sequence
and timing of each of the Interfacing Contractors scope of work, and clearly describes
dependencies between the Works and the work of the Interfacing Contractors.
1.5 Interface Management Plan (IMP) means the Report prepared by the Contractor,
developed and updated on a quarterly basis that provides a clear description of his
interfaces both sequentially and technically as specified in the Contract. The report will be
reviewed in accordance with this procedure and is a pre-requisite to the Employer issuing
of a Notice of No Objection for the IMP.
1.6 Interface Specification (IS) means a document used by all Interfacing Contractors
participating in the construction of the project to record and monitor the status and progress
of any interface between any two Interfacing Contractors
1.7 Master Interface Log (MIL) means a document developed by the Contractor and
expanded to include input derived from the Interfacing Contractors. The purpose of the
Master Interface Log is to record the pertinent details of all interface requirements and
monitor the progress of the interface from inception to conclusion or ―Close-Out. The
Contractor‘s Master Interface Log (MIL) shall be complied by the Contractor using an Excel
spreadsheet as per approved format of Employer.
1.8 Master Interface Matrix (MIM) means the document developed by the Employer, which
may be updated, and/or expanded to include additional Interfacing Contractors, by the
Employer‘s Representative as the Project progresses. The purpose of the Master Interface
Matrix is to allocate which Interfacing Contractors are the lead party(s) for each contract.
1.9 Structural, Electrical and Mechanical Drawings (SEM) means those drawings produced
by the Employer, showing the locations, sizes and details for all structural openings, plinths,
embedment’s, sumps, floor chases, etc. required for the installation of all equipment, cable
trays, pipes, etc. However, those drawings can be reworked or modified according to the
interface requirements/ site constraints by the contractor with the approval of the Employer/
Employer’s Engineer.
1.10 Combined Services Drawings (CSD) means those drawings provided and approved by
the Employer’s, showing the locations, sizes and details of all of the Contractor’s
equipment, cable containment, pipes, etc. These drawings are to be used to enable all
Section VI - Appendix -19 December 2021
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equipment, pipes, cables, etc.. to be installed without conflict and to enable future changes
or modifications to be performed without impacting the existing installation.
1.11 Interfacing Contractors means any of the following whose activities or the works they are
engaged to carry out in any way or at any time affect or are affected by the Works:
(a) Elevated Civil Contractor – CP10 / EV03
(b) Depot Civil
(c) Underground MEP- CP12-C5-E&M-03.
(d) Underground TVS & VAC- CP32/ EM02
(e) System & Rolling Stock Contracts (SWCs)
(f) Any other Contract of CMRL having any interface requirement for the timely execution
of this project
(g) Project Contractors and specialist consultants engaged on the Project from time to
time by the Employer, the Government of Republic of India, the Government of Tamil
Nadu or the utility providers;
(h) utility providers;
(i) developers or franchisees appointed on the Project from time to time by the Employer;
(j) subcontractors of any tier of the contractors within category (a) above, and
contractors and subcontractors of any tier of utility providers, developers and
franchisees within categories (b) and (c) above;
provided that the definition shall exclude the Contractor and his subcontractors of any tier
in relation to the Works and in any other capacity which would otherwise fall within
categories (a) to (d) above in relation to other works.
1.12 Interface Coordination Sheet (ICS) means a document produced by the Contractor which
defines the integration and interfaces between his contract and the Interfacing Contractors
employed on the Project.
1.13 Zone of Interface means where two or more components of the railway provided by two
or more Interfacing Contractors combine to provide a single element.
2. INTRODUCTION
2.1 Interface and co-ordination of the works will include the co-ordination of all Construction,
technical and programming matters with the various Interfacing Contractors to achieve fully
co-ordinated construction and installation of the facilities.
2.2 This Appendix 19 describes the Contractor’s responsibilities with regard to interface
management and coordination with those Interfacing Contractors and who are responsible
for undertaking work, which interfaces with the Contract. The Contractor’s responsibility for
interface coordination shall include currently defined Interfacing Contractors and those who
may be identified in the future. This responsibility is not limited to a particular number of
2.3 The Contractor’s responsibility for interface co-ordination shall include interface coordinate
with Interfacing Contractors those who may be subsequently identified during the course of
the Contract.
2.4 The Employer will monitor and oversee the interface Management activities by the
contractor and will specifically provide direction or information in the following
circumstances.
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a) When the interfacing contract has not yet been awarded.

b) When common agreement cannot be reached between the interfacing parties.
c) When it is in the interest of the project programme, quality or safety to issue direction.
Direction or information provided by the Employer Representative wherever necessary,
shall not in any way relieve the contractor of his full responsibility to ensure the correctness,
accuracy and suitability of the interface implementation.
2.5 The Contractor shall at all times use his best endeavours to resolve all interfaces applicable
to the Contract and shall be proactive in seeking out interface issues and their solutions.
2.6 The Contractor shall ensure that all of the above Interface requirements are included in his
Interface Management Plan, refer to Clause 6 of this Appendix 15. Flow charts illustrating
the process of entering into an Interface agreement and Monitoring its progress with the
help of the Interface Coordination Sheet are provided as Annexures A & B of this Appendix.
Figure 1 gives a schematic presentation of the Interface Communication and Coordination
processes between the various role-players in the Project.
2.7 The Contractor’s internal sub-contractors’ and suppliers’ interfaces are the sole
responsibility of the Contractor and are not covered in this Appendix. However, the
Contractor shall co-ordinate and manage these interfaces in such a way as to identify and
cater for the requirements of the Interfacing Contractors and domestic interfaces, including
but not limited to, the avoidance of clashes and sequencing of Works. The Contractor shall
compile an internal IMP for his own use, a copy of which shall be furnished to the Employer
on request at any time.

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DDC

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3. CO-ORDINATION
3.1 Contractor’s Co-Ordination Responsibilities
The contractor shall co-ordinate with the Employer and required to attend meetings on
issues appertaining to interfacing contractor, Government authorities and utility agencies
regarding the services/facilities to be provided by them for the project. The Station & Tunnel
Civil contractor shall ensure that the work of all Interfacing Contractors can be carried out
in accordance with the Interface Management Plan prepared by the Contractor.
3.2 Site Co-Ordination & Attendance
3.2.1 The Station & Tunnel Civil contractor shall, at his own cost, provide all attendance on and
co-ordination with Interfacing Contractors. The following items are not a comprehensive or
exhaustive list of the co-ordination or interface attendance items to be provided for the
Interfacing Contractors’ use, but are intended to provide an outline of the content of
amenities, services and facilities for which the Station & Tunnel Civil contractor is
responsible:
a) Single point of contact for meetings, actions, planning, scheduling and co-ordinating.
b) Site access: The Contractor shall co-ordinate with the Interfacing Contractors and
provide access and use of temporary access roads to and from and within the Site.
The Contractor shall co-ordinate all vehicle movements, deliveries and other activities
with the Interfacing Contractors so as to ensure conflicts of use will be controlled on
and around the Site.
c) Storage area: The Interfacing Contractors will require limited temporary storage
areas. The Contractor shall agree with the Interfacing Contractors access and areas
for storage prior to their commencing work on Site.
d) Work space requirement and sequence of Works
e) Shared use of Contractor’s scaffold
The Contractor shall co-ordinate with the Interfacing Contractors and provide free use
and shared access of his erected scaffolding, ladders and hoists should they be
available at the time the Interfacing Contractor requires to use them. Not withstanding
this requirement, the Contractor shall at all times remain responsible for the
management of safety and the maintenance of such scaffolding, ladders and
landings. The Contractor will not be required to adapt or erect access scaffolds
specifically for the use of Interfacing Contractors.
If the Interfacing Contractor erects and uses his own scaffold, he will be required to
adhere to the Contractor’s safety rules and access routing for equipment and
materials. The Contractor shall ensure that all scaffolds of Interfacing Contractors are
erected in a safe manner and are subject to permits for use issued by the Contractor.
f) Setting out control points
g) Mark the track centre line on the soffit of the tunnel.
h) The Contractor will be required to install all temporary and permanent lifting hooks
and beams shown Temporary lighting requirements 100 lux minimum
i) Temporary power and water supplies have to be provided at agreed locations around
the Site for the Interfacing Contractors use

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j) Handover the tunnel temporary walkway, tunnel lights system and ventilation to the
interfacing contractor.
k) Water tightness. All rooms and areas handed over to Interfacing Contractors shall be
in a watertight condition and maintained as such.
l) Ensure all electrical supplies temporary have the correct testing and commissioning
certification.
m) Waste management and disposal
n) Programme agreement for mobilizing and demobilizing
o) Firefighting and supply and maintenance of fire extinguishing equipment and devices
pursuant to the Contractor’s obligations.
p) Temporary Drainage
q) The Contractor shall provide, operate and maintain all necessary temporary drainage,
sumps, silt traps and sump pumps to collect and dispose of wastewater from
Interfacing Contractors construction processes including installation, testing and
commissioning activities.
r) Sanitation facilities
s) The Contractor shall allow Interfacing Contractors use of his health, welfare and mess
facilities, and temporary background lighting. He shall liaise with the Interfacing
Contractors to determine their planned and actual manning levels and ensure that
sufficient facilities are provided prior to them commencing work on Site. The facilities
shall be maintained on Site until the Interfacing Contractors have completed their
Works and demobilised or such earlier time as the Employer may direct.
3.2.2 The Contractor is deemed to have ascertained for himself the full scope of his
responsibilities and obligations under the Contract in terms of attendance on and co-
ordination with Interfacing Contractors and shall not be entitled to any additional payment,
Cost or extension of time for completion should he have failed to do so.
3.2.3 The Contractor shall make due allowance for providing Attendance. including power and
other utilities supplies, throughout all phases of the Interfacing Contractors work including
testing and commissioning and where supplies to various Interfacing Contractors need
special consideration during testing and performance trials under peak load conditions. The
construction power shall be charged back to back basis.
4. INTERFACE
4.1 Co-Ordination of Contractor’s Scope of Work
In accordance with the requirements of the Conditions of Contract and other specified
requirements, the Contractor shall co-ordinate his own work with that of all Interfacing
Contractors and ensure that the construction, installation and testing requirements of the
Interfacing Contractors are incorporated into the Contractor’s co-ordinated programmes
and Works. The Contractor shall proactively seek out interface issues and solutions.
In addition to the Contractor’s obligations to the Interfacing Contractors contained
elsewhere in the Contract, the Contractor shall provide / handover occupation or access as
required, to the Interfacing Contractors to those parts of the Works which are subject to Key
Dates by the required Key Dates. The Contractor shall complete those parts of the Works,
which are subject to Key Dates, by the required Key Dates that may be specified in the
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Appendix 7 of Part 2 – Employer’s Requirements this Contract. Those parts of the Works
subject to Key Dates shall be completed to a state whereby any Interfacing Contractor can
immediately commence his works without the need to make any change, addition or
modification to the Contractor’s Works.
4.2 Interfacing Contractors
4.2.1 The Interfacing Contractors will require interface and co-ordination for information,
programming, handover/takeover, etc.. as shown on the Interface Coordination Sheet
enclosed in Annexure F of this Appendix. However, the Contractor should note the
Interface Coordination Sheet shown in the Appendix-F is indicative only.
The Contractor’s responsibilities in this respect are in no means restricted by the details
listed in such sheets and no warranty is given by the Employer or the Employer that all
interfaces and Interfacing Contractors have been included in such. The Contractor is to
confirm and verify all of the details included in the Interface Coordination Sheets, and his
review should ensure that all interfaces have been included.
The Contractor shall take overall responsibility for the Interface Coordination Sheets, which
must be submitted to the Employer for a notice of no objection.
4.2.2 The Master Interface Matrix (MIM), enclosed in Annexure E, assigns the Contractors which
have been designated as the Lead party(s) for each interfacing contractor. The MIM has
been developed by the Employer, which he may update and/or expand at any time to
include additional Interfacing Contractors, and the Contractor’s lump sum price for Interface
Management shall be deemed to include any such additional works related to interfacing.
The leading Interfacing Contractor shall be responsible for administrating, monitoring,
managing, supervising and resolving all interface issues between all Interfacing
Contractors.
4.2.3 In a situation when the Lead Contract has not yet been awarded and the Interfacing
contractor has commenced work, the Employer will perform the coordination activities
including preparation of tentative ICS/ Interface Specification, with the express
understanding that they may undergo changes as and when the Lead Contractor
commences his work on being awarded the Contract.
4.2.4 Where an interfacing contract has yet to be awarded, the Lead Contractor shall proceed
with the coordination activities (including preparation of ICS and Interface specification) as
instructed by the Employer until such time when the Interfacing Contractor is available.
4.3 Interfacing Contractors - Communications and Information Exchange
4.3.1 GENERAL
a) The Contractor shall communicate, co-ordinate and exchange information directly
with the Interfacing Contractors and the Contractor shall keep the Employer advised
at all times. Information necessary to fulfil the Contractor’s interface obligations shall
be directly requested and obtained from the Interfacing Parties, and receipt
acknowledged. Conversely, the Contractor shall provide directly to the Interfacing
Contractors information within the Contractor’s scope that is required by them.
b) All requests for information, acknowledgement of receipt of information, and any
official communication between the Contractor and the Interfacing Contractors shall
be made in writing, with a copy to the Employer for his information. The Employer
shall be invited to attend all interface meetings between the Contractor and the
Interfacing Contractors. Irrespective of whether these meetings were attended by the
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ER or not, the contractor’s monthly progress report to ER shall invariably include the
details of all interface meetings held and decisions arrived.
c) The Contractor’s programme shall allow time for the availability of necessary interface
information from the Interfacing Contractors and in this regard the Contractor shall,
where required, proceed on a late start basis to allow adequate time for others to
provide required information.
d) The Contractor shall allow for the fact that many of the construction activities for the
different contracts will be proceeding concurrently. In the event that certain interface
information is not forthcoming at the time targeted, the Contractor shall be responsible
to resolve the matter with the relevant Interfacing Contractor without recourse to the
Employer, and where necessary develop alternative interim arrangements such that
the interface information may be accommodated at a later date.
e) Definitive dates for transfer of information and particular interface actions shall be
confirmed between the Contractor and the Interfacing Contractors.
f) Where an interfacing contract has yet to be awarded, the Contractor shall proceed
with the coordination activities as instructed by the Employer until such time when the
Interfacing Contractor is available
4.3.2 INTERFACING FUNCTIONS
The Interfacing Contractors are responsible for, but not limited to, the following;
• the management of Contract to Contract Interfaces as required;
• preparing the Interface Management Plan and subsequent procedures;
• preparing their Interface Management Programmes in accordance with this
• procedure and submitting these to the Interfacing Contractors for concurrence;
• preparing the Interface Management Programmes and submitting these to the
Employer for a Notice of No Objection;
• preparing their Interface Coordination Sheets and Interface Specifications and
issuing same to the relevant Interface Contractors and Employer;
• maintaining their ICS updated continuously and attaching it to their Monthly Progress
Report submitted to the Employer in accordance with the requirements of the
Contract and this Appendix.
4.3.3 DOCUMENTATION REVIEW
The Contractor shall, as a minimum:
• review those portions of the Specification and Drawings relevant to the interface and
transmit such information to the Interfacing Contractors;
• co-ordinate and co-operate with Interfacing Contractors on all Site related matters
including, but not limited to, Site access and occupation, attendance, safety,
verification of work compatibility, survey control, etc...;
• review the interface information received and agree in writing with the Interfacing
Contractors that the interface information is adequate for that stage of that activity.
4.3.4 CONSTRUCTION PHASE

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During construction the Contractor shall, when a construction item is ready for field
inspection, advise the Interfacing Contractor in advance to verify compatibility with the
Interfacing Contractor’s needs.
The Contractor shall:
• advise the Interfacing Contractors in writing when the as-constructed interface-
related work can be inspected, and provide the necessary Site access and
occupation;
• request in writing and obtain from the Interfacing Contractors, interface information
required for that stage of the Contract;
• agree in writing with the Interfacing Contractors on the adoption of any applicable
comments on the constructed work;
• conduct on-Site inspections of the work elements, and give comments in writing to
the Interfacing Contractors;
• agree in writing with the Interfacing Contractors that the as-constructed work meets
the interface requirements.
Where the execution of work by Interfacing Contractors depends upon the Contractor’s site
management or upon information to be given by the Contractor, the Contractor shall provide
the Interfacing Contractors with the required services or the correct and accurate
information required to enable the Interfacing Contractors to meet their programme for the
construction or installation of their works.
The Contractor shall co-ordinate all installation works with the various Designated
Contractors, including The Employer and establish the Co-
ordinated Installation Plan (CIP). The CIP shall be developed by the contractor in a format
acceptable to the The Engineer. The Contractor shall co-ordinate with all
Interfacing Contractors to produce a detailed programme of access dates. The CIP shall
be signed off by each Interface Contractor and submitted to the Engineer not later than 3
(Three) months before basic structure is completed.
The key dates are critical to the timely completion of the project. The Contractor shall
commence interface with the The Employer/ Interfacing Contractors as soon as he has
been notified by the Engineer that such Interfacing Contract has been awarded. In the case
of utility agencies and other statutory boards, interface shall commence as soon as it is
practicable. Where no interface date has been established because any Interfacing
Contractor/s have not been identified or for whatever reason, the Contractor shall liaise with
such Interfacing Contractor/s as soon as they have been awarded.
Interface is an iterative process requiring regular exchange and update of interfacing
information. The Contractor shall ensure that the information he requires from the
Interfacing Contractors is made known at the outset of each interface and vice versa so
that the information can be provided in time for the Contractor and the Interfacing
Contractors.
4.3.5.INTERFACE COMMISSIONING
The Contractor shall co-ordinate all of his testing and commissioning activities with the
Interfacing Contractors. Interface commissioning shall demonstrate that the delivered
interface, part A of the interface, is ready and meets the interface requirements of the
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interface part B, and vice versa.

Successful completion of all interface commissioning shall prove its readiness for
commissioning of the overall contract scope and completion of the overall Metro-rail
Project, prior to handover to the Employer for their commercial operation.
4.4 Resolution of Co-Ordination Difficulties

When the Contractor identifies interface co-ordination difficulties, the Contractor shall
review the pertinent points of each Interfacing Contractor to determine possible compatible
solutions in terms of sequence, timing and technical details. The Contractor shall then meet
with the relevant Interfacing Contractor(s) to determine solutions, which are mutually
acceptable to each Interfacing Contractor and advise the Employer.
Where an acceptable solution has not been identified, the Contractor shall advise the
Employer in writing of the problems encountered. If, in the opinion of the Employer, an
interface is not proceeding satisfactorily, then the Employer will review the matter, and
establish a co-ordinated plan directing the Contractor and the Interfacing Contractor(s) on
the required action. In the event that no agreement can be made between the Contractor
and the Interfacing Contractor(s), the Employer shall determine the requirements to the
best of his knowledge, and his determination shall be final and binding on the Contractor
and the Interfacing Contractor(s).
4.5 Interface Performance
The Contractor’s performance in relation to his compliance with the interface requirements
under the Contract shall be assessed by the Employer 3 months after the commencement
Date and thereafter at three monthly intervals. The assessment will be in the form of an
audit of the Contractor’s interface management system. This audit will assess the
Contractor’s compliance with the responsibilities delineated in this Appendix and elsewhere
as related to interface management and the preparation of the Interface Management Plan
and Programme and other documentation and procedures associated with Interface
Management and Coordination.
The Contractor will be notified of non-conformances from the audit, which will require
rectification. Where, in the opinion of the Employer, the Contractor has failed to rectify a
non-conformance within a reasonable period from the date of notification, this may lead to
non-payment of any lump sums, until such time as the non-conformance has been rectified
to the satisfaction of the Employer, refer sub-clause below.
The Contract allows for continuous audits of the Contractor’s compliance with his Interface
Management Plan and the requirements of this Appendix 15 Part 2 Employer’s
Requirements, and any extreme or continuing failures shall result in a negative audit report,
which may lead to non-payment of the relevant payment item in the Preliminaries section
of the Pricing Document. The decision of the Employer in this regard shall be final.
5. CONTRACTOR’S INTERFACE MANAGEMENT SYSTEM
5.1 Interface Management System
The Contractor shall establish and maintain an Interface Management System to identify,
control and monitor the interfaces of the Contract, which shall include, but not be restricted
to, the following:
• Establishment and maintenance of an Interface Management Team suitably qualified
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and experienced in co-ordination and interface management.

• Provision, as one of his Key Personnel, of a Chief Interface Co-ordinator, to head the
Interface Management Team, suitably qualified and experienced as noted in Section
A of this Part 2 Employer’s Requirements, with the responsibility, experience and
authority to resolve interface matters in accordance with the Contract. The Chief
Interface Co-ordinator will develop a monitoring and reporting procedure to be
implemented by his team for the duration of the Contract.
• Implement and maintain a strict monitored control of information transfer to the
Interfacing Contractors, the Employer and the Employer utilising the official channels
of communication.
• Provide a comprehensive interface schedule of Interfacing Contractors identifying all
interfacing activities and timetables of events.
• Arrange all internal and external interface meetings. The Employer may arrange
regular meetings to monitor the status of interfaces, and may require special meetings
as may be necessary to resolve specific issues. The Contractor’s Interface
Management Team will be required to attend such meetings. The Contractor may
request assistance from the Employer to arrange meetings on particular subjects.
• Providing the Employer with all information and/or details of interfaces, including
copies of all correspondence and material.
• Providing the Employer with access to information for the purpose of conducting
audits on the interface system and for confirming that interface co-ordination is
proceeding consistently with the Project requirements.
• Establish interface dates for information, documentation, access or works completion
requirements.
• In the event that the Interfacing Contractor proposes a change to the design , then the
Contractor shall immediately notify the Engineer in writing of such change and the
reasons for the change. This notification shall include all cost and time implications
to the Contractor if the design change is instructed. The Contractor is responsible for
monitoring the Interfacing Contractor’s proposal up to closing out of the interface and
providing all information required by the Engineer who shall be responsible for
determining if the change in design shall proceed. The modified design (If required)
for the permanent works will be arranged from the Detailed Design Consultant (DDC).
5.2 Interface Management Team
• The Contractor shall establish a dedicated co-ordination team, led by an Interface
Manager in Chennai reporting to the Contractor’s Site Office. The primary function of
the team is to provide a vital link between the Contractor’s design and construction
teams and the CMRL/ other interfacing Contractors.
• The Interface Manager shall assess the progress of the co-ordination with CMRL/
other interfacing Contractors by establishing lines of communications as suggested in
the co-ordination model to be developed by the agency.
• The complexity of the Project and the importance of ensuring that work is executed
within time limitations, require detailed programming and monitoring of progress, so
that early programme adjustments can be made in order to minimise the effects of
potential delays.
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• The Interface Manager in conjunction with the CMRL/ other interfacing Contractors
shall identify necessary provisions in the Works for plant, equipment and facilities of
the CMRL/ other interfacing Contractors. These provisions shall be allowed by the
Contractor in the Works.
• During the course of the contract, information will be obtained in a number of ways.
These may include direct inspection, regular site meetings, the obtaining of progress
reports and the use of turn-round document to obtain design and programme data.
Turn-round document shall be issued to the Employer/ other interfacing Contractors
to be returned giving the current positions on their programme.
The Contractor’s Interface Management Team will undertake and fulfil the following tasks:
• Provide timely interface information when requested, anticipating the information
needs of the Interfacing Contractors and transmitting such information as soon as it is
available.
• Pro-actively keep the Interfacing Contractors informed of any development of the
Works related to the interfaces. Communicating and co-operating with the Interfacing
Contractors to identify and resolve potential interface problems.
• Advise the Interfacing Contractors on potential problems related to the interfaces,
together with proposed solutions likely to be acceptable to Interfacing Contractors and
which meet the needs of the Project.
• Arrange and/or attend meetings with the Interfacing Contractors as necessary to
resolve interface issues.
• During each stage of the Contract, the Contractor shall directly communicate and co-
ordinate with Interfacing Contractors as necessary to achieve a fully co-ordinated
construction / installation.
• Contractor shall issue true records of all interface meetings, with appropriate actions
and attendance lists, to all Interfacing Contractors, whether in attendance or not, and
to the Employer, within 3 days of the meeting. Minutes of meetings shall be signed by
all parties in attendance, signifying their agreement to the contents thereof, before
being formally issued by the Contractor.
The authority and responsibilities of all personnel involved in the Interface Management
Team must be clearly defined in the IMP.
6. INTERFACE MANAGEMENT PLAN & INTERFACE MANAGEMENT PROGRAMME

6.1 General
The Contractor shall prepare the proposed Interface Management Plan and proposed
Interface Management Programme, in accordance with CPA Clause 6, this clause 6 and
based on the formats noted in Annexure H and I, to which the Employer issues a notice of
no objection. The Interface Management Plan and Interface Management Programme shall
completely define the Contractor’s programme and methodology for interface co-ordination
and management, whilst complying with all Key Dates stated in the Appendix 7 of Part 2
Employer’s Requirements.
Subsequently they shall be kept up to date and submitted on a quarterly basis to the
Employer for scrutiny and notice of no objection, and a summary of the principal issues
shall be included in each Monthly Progress Report. The Contractor shall note that each
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submission of these documents is subject to regular audits and the issue of a notice of no
objection by the Employer.
6.2 Interface Management Programme (IMPG)
The Interface Management Programme describes the sequencing and timing of each of the
Interfacing Contractors’ scope of work, clearly describing the interdependencies for all
stages of the work between the Contractor's works and that of the Interfacing Contractors
and complementing the Interface Management Plan, whilst complying with all Key Dates
stated in the Appendix 7 of this Part 2 Employer’s Requirements.
The programme shall be structured to detail each of the primary zones of interface and of
the works requiring interfacing contribution from others. This Interface Management
Programme shall also be related to the Contractor’s Works Programme and shall show the
sequences and timing agreed with the Interfacing Contractors to the necessary degree of
detail to clearly illustrate each of the interfaces to be undertaken.
Targets to receive or supply information shall also be shown, with due allowance being
given for the design process of others. Information relating to Contractual Key Dates and
information exchange dates shall be shown for both the Contractor and the Interfacing
Contractors. A record of these interfaces, with current status and agreed dates for
information transfer, site inspections, access, occupation, handover, etc.. shall be
maintained and also identified on the ICS, refer Clause 7 below.
Refer to Annexure I - Guidance Notes for the Preparation of IMPG
6.3 Interface Management Plan (IMP)
The Interface Management Plan is that document which describes the Contractor’s
interface management in terms of providing a clear description of each of the interfaces,
both technically and sequentially, and represents an account of how the Contractor
proposes to achieve co-ordination of the Works. The description shall completely detail the
Contractor's work scope and interface with each of the Interfacing Contractors in terms of
technical description, sequence and timing for each of the elements required to achieve a
coordinated construction. This document is also required to demonstrate that the co-
ordinated construction details described therein fully comply with the needs of others, and
agreement in writing of these details by the Interfacing Contractors will be a pre-requisite
to the Employer issuing a notice of no objection.
Refer to Annexure H – Guidance Notes for the Preparation of IMP.
6.4 Requirements for The Interface Management Programme &Interface Management
Plan
The Interface Management Programme (IMPG) shall be a process-driven programme in a
format to be agreed with the Employer. The IMPG shall incorporate the key activities from
both the Interfacing Contractors’ and Contractor’s Works programmes that will enable the
Contractor to demonstrate that any Interface is being correctly managed and will result in
fully co-ordinated construction / installation of works.
The Interface Management Plan and Interface Management Programme shall:
• Follow the outline structure, numbering system, and related procedures in a format
to be agreed with the Employer.
• Be co-ordinated with the Interfacing Contractors to ensure compatibility of interface
identification and definition.
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• Comply with the Key Dates stated in the Appendix 7 of Part 2 Employer’s
Requirements.
• Be transmitted to the Interfacing Contractors concurrently with submittals to the
Employer.
• Support the Works Programme to which the Employer has given a notice of no-
objection.
• Address each zone of interface related to each stage of construction / installation.
• List all relevant interfaces in detail, their status, and the corresponding source(s) of
information.
• Include interface information transfer dates which have been agreed by the
• Accommodate comments and input required by the Employer.
• Include an account of how the interfaces are being managed.
• Identify the latest information regarding agreements with the Interfacing Contractors
and transfers of information.
• Review and address the construction programme of the Interfacing Contractors to
ensure that the Key Dates of each contract can be achieved, and highlight any
programme risks requiring management attention.
• Identify any problems related to co-ordination with Interfacing Contractors
6.5 Interface Specification.
6.5.1 The Interface Specification, proforma enclosed in Annexure C shall specify the proposed
method and schedule.
The interface sheets developed by the Employer are enclosed in Annexure D. The
attached interface sheets are not final and do not relieve the Contractor’s obligation to
identify any new interface to meet contract requirements. The interface sheets, which the
Contractor shall develop, shall be used as a basis to establish the Interface Specification.
Any revision to the Interface Specification shall be mutually agreed between the Contractor
and Interfacing Contractors, with submission to the Employer, and shall specifically -
• Determine the detailed interface works to be performed during the various stages and
• Agree on the interface works in reference to respective scope, with any agreements
reached to be formally documented in Interface Meeting Minutes, including an actions
item list.
6.5.2 The Interface Contractors shall mutually identify and agree the Interfaces that will exist
between them using the Interface Coordination Sheets, the format of which is contained in
Annexure F. These interfaces may be expanded to include all, and any other, interfaces
that develop during the execution of the Project.
6.5.3 The Interfacing Contractors shall mutually agree upon the information to be exchanged and
shall develop a unique Interface Specification for each interface identified. A sample
Interface Specification proforma is provided in Annexure C. The ICSs will be tracked and
monitored using an ICS Register to be compiled by the Contractor. This register will track
the progress of the ICS from inception through to closure and final processing by the
19-14
Contractor, prior to transmittal to the Employer as a complete Integrated Design. Each

interface shall have a unique reference number to enable the Interface to be readily
identified and tracked and monitored.
7. INTERFACE COORDINATION SHEET (ICS)
7.1 The Contractor’s Interface Coordination sheet, the format of which is shown in Annexure F
– Part 1, is required to be used by each of the Interfacing Contractors to record all of the
Contract Interfaces. The Contractor shall ensure that each Interfacing Contractor provides
input and maintains the ICS continually updated as required in this Appendix.
7.2 The Contractor shall ensure that the Interfacing Contractors demonstrate their co-ordination
efforts as required by the Contract. To achieve this, the Contractor and the Interfacing
Contractors shall identify their interface requirements which shall be input into the interface
documents, i.e. IMP, IMPG, ICS, etc.., by the Contractor.
7.3 The Contractor shall monitor the ICS to ensure that, as the Interface progresses, the
records show the appropriate Status (refer status codes indicated in Part 3 of Annexure F)
as agreed with the Interfacing Contractors. The Contractor will be responsible for confirming
the “Closing Out” of each ICS record, whilst ensuring that throughout the interface process
all Interfacing Contractors have agreed to the following:
a) The receiving Interfacing Contractor has received and accepted the Interface being
recorded.
b) All Interfacing Contractors have recorded the interface record as “Proposed Close
Out”.
c) The Confirmation of Co-ordination form in Annexure G to be updated and signed by
the relevant Interfacing Contractors, refer clause 7.4 below.
7.4 When documents are exchanged for review/comment with Interfacing Contractors, the
originator preparing these documents should ensure that they are accompanied by the
Confirmation of Coordination form in Annexure G. When the Interfacing Contractor returns
these documents with comments to the originator, they should be returned with the
Confirmation of Coordination form duly completed, confirming coordination and agreement
or comment as appropriate, as a record of them having coordinated the interface item. This
Confirmation of Co-ordination is to be transmitted to the Employer upon signing by the
Interfacing Contractor(s).
8. COORDINATION DRAWINGS
8.1 Interface Drawings
For the Interface Drawings, the Contractor shall prepare in diagrammatic format for each
interface the demarcation of scope of responsibilities between the Contractor and each of
the Interfacing Contractors. The Contractor shall submit all Drawings with interface
requirements for a notice of no objection from the Employer.
8.2 As Constructed Drawings
Upon completion of the Works the Contractor shall submit the final “As Constructed”
drawings.

19-15
9. Annexures
Annexure A – Flow chart for creation of Interface coordination sheet
Annexure B - Flow chart for progress monitoring of interface agreements
Annexure C - The Interface Specification Form
Annexure D – Indicative Interface Sheets
Annexure E - Master Interface Matrix
Annexure F - Interface Coordination Sheet
Annexure G - Confirmation of Coordination form
Annexure H – Guidance Notes for the Preparation of IMP
Annexure I – Guidance Notes for the Preparation of IMPG

19-16
Annexure A – Flow chart for creation of interface coordination sheet

19-17
Annexure B – Flow chart for progress monitoring of interface agreements

19-18
Annexure-C
INTERFACE SPECIFICATION FORM

INTERFACE
SPECIFICATION SHEET Ref:
Contractor contractor Date of issue

Designation Seq No.
Initiating Interface
Contractor Coordinator
Signature
Responding Interface
Contractor Coordinator
Signature
Interface Response
Specification required by
required for
Reviewed by
Deciplines
Civil Architecture others others
Description of Interface
Specific Details of interface Location
Drawings/Specifications attached
Title Drawing /Specification Ref Drg Issue

19-19
Annexure D – Indicative Interface Sheets
List of Indicative Interface sheets for CMRL-PH2- CP 06-UG06
Sl No Description
1 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - CP12-C5-

E&M-03
2 Contractor A – UG06 (Station & Tunnel) Vs Contractor B – CP 10 EV03
Contractor
3 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - TVS, VAC and
SCADA
4 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - Power supply
5 Contractor A – UG06 (Station & Tunnel) Vs. Contractor B - Signalling
&Telecom
6 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - PSD
7 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - AFC
8 Contractor A –- UG06 (Station & Tunnel) Vs Contractor B - Lift and
Escalator
9 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - Rolling stock
10 Contractor A – UG06 (Station & Tunnel) Vs Contractor B - Track works
Note:
These are currently identified interfaces to be dealt as a minimum by the Contractor, however
there may be many other Interfaces with these identified Interfacing contractors or some other
interfacing contractors, not explicitly listed here, which will be required to be managed by the
Contractor, for constructing the project within timeline fulfilling all the Employers requirement. The
contractor is obelized to include them in his interface management plan to be updated time to
time.

19-20
Annexure-D- Indicative Interface Sheets
1. Contractor A – UG 06 (Station & Tunnel) Vs Contractor B –CP12-C5-E&M-03
Contractor A – UG 06 Contractor B – CP12-C5-E&M-03

Sl. No
(Interface Lead) (Interface Follower)
Construction Interface Points
1 Technical rooms shall be ready as per the Shall jointly check the technical rooms made
requirements of the Contractor-A and shall ready by ‘Contractor ’A’ and to be confirmed
co-operate for joint check.
2 Shall provide plinths/pedestal to install E&M Shall request plinths/ pedestal to install E&M
equipment at stations equipment at stations.
3 Shall provide necessary openings, sleeves, Shall request necessary openings, sleeves, cut
cut outs and shafts as per BIM/CSD/SEM outs and shafts as per BIM/CSD/SEM drawings
drawings and requested by Contractor B to Contractor A and ensure.
4 Contractor-A Shall attend the joint test with Contractor-A Shall conduct a joint test with
E&M Contractor for testing of Earth mat Contractor-B for testing of earth mat resistance
resistance provided in UG station. provided in UG station structural and keep the
data in standard forms with joint signatures
wherever necessary.
5 Shall verify the requirements of statutory Shall install all the statutory signs and labels
signs and labels. except those relating to E&M equipment.
6 Shall provide temporary power (till a Shall utilize temporary power supply (from a
distribution panel) and water on chargeable distribution panel) and water for his installation
basis on a mutually agreeable rate. / testing activities in the stations.
7 Shall provide easiest/shortest access for Shall jointly check the access for lifting facilities
lifting facilities and easy maintenance of for E&M machineries for installation and easy
E&M equipment maintenance and agree.
8 Shall share the architectural finishes to Shall request the architectural finishes to
Contractor-B Contractor-A to finalise the E&M equipment
finishes for esthetical look.

19-21
Contractor A – UG 06 Contractor B – CP12-C5-E&M-03

Sl. No
9 Shall provide safe working atmosphere at Shall request safe working atmosphere at work
work site. site.
10 Shall request necessary embedded Shall provide necessary embedded materials

materials like pipes, boxes etc. to like pipes, boxes etc. to Contractor A in
Contractor B in advance before works start. appropriate/ requested time
11 After Earth mat work completion, details of Shall request Contractor-A details of earth mat,
the cable risers in the Under-croft level, cable rises provided in Under-croft level, Earth
Earth mat resistance value, Cable length mat resistance value, cable length along with
and as-built drawing for earth mat etc shall as-built earth mat drawings and keep the data
be provided to Contractor B in standard forms with joint signatures wherever
necessary.
12 Shall agree & provide as per the requirement Shall request permanent Access door/hatch for
of contractor B E&M services maintenance
Testing & Commissioning Interface Points
1 Shall attend joint testing Shall conduct joint load test with suitable loads
with temporary power supply.

19-22
2. Contractor A – CP 06-UG06 Vs Contractor B – CP10-EV03
Contractor A – UG 06 Contractor B – CP10-EV03

Sl. No
1 Jointly, check and verify the x, y, z co- Share the Topographical survey control points
ordinates of the control points shared by the with the UG Civil Stations contractor at the
Elevated Civil contractor at the interface interfacing UG Civil Station locations.
point and confirm.
Jointly Check & Verify the x, y, z co- Any mismatch in the coordinates shall be
ordinates of the control points shared by the coordinated and rectified on mutual agreement.
UG Civil Station contractor and confirm. Final topographic drawing shall be submitted to
Any mismatch in the coordinates shall be Employer’s representative.
coordinated and rectified on mutual
agreement.
Final topographic drawing shall be

submitted to Employer’s Representative.
2 Shall provide structural provisions at Shall check and take over from Contractor – A
interface points as per approved drawings
3 Shall coordinate and execute jointly Shall coordinate and execute jointly drainage
drainage and earthing arrangements and earthing arrangement including buried
including buried earth conductors earth conductors.
3 Shall agree the cable fixing arrangement at Shall agree the cable fixing arrangement at the
the interface location interface location
4 Shall coordinate with Contractor B Shall install expansion joint in the interface and
coordinate with contractor A

19-23
3. Contractor A – CP 06-UG06 Vs Contractor B – TVS, VAC and SCADA
Contractor A – CP 06-UG06 Contractor B – TVS, VAC AND SCADA

Sl. No
1 Contractor A shall provide the same. Contractor B shall request architectural / CRD
drawing BIM 3D model and 2D sheet with
annotation including room names, location of
rooms, plans and sectional view drawings for
all levels.
2 Contractor B shall provide the same. Contractor A shall liaise closely and get the
access dates for following rooms / area in
order to start the installation works as per the
architectural / CRD/ GFC drawings (not limited
to the following).
i. VAC Mechanical Equipment rooms M-09
ii. Tunnel ventilation fan and panel rooms
iii. VRF outdoor unit area
iv. Vent shaft louver opening for VAC and
TVS
v. Fire escape and Firemen stairs
vi. CER, SER, SCR, UPS battery room,
Ticket office and secure suite rooms
vii. Concourse public area
viii. Concourse entrance area
ix. Platform public area
x. All other Air conditioning rooms at
concourse level
xi. All other Air conditioning rooms at
Platfrom level
xii. Air conditioning / Ventilations rooms:
P01, P02 and P-05 and Toilet rooms
xiii. All other Ventilation rooms at concourse
level and Platfrom
Supporting arrangement for installation of
Air Curtain & HVLS (High Volume & Low
Speed) fan
Pedestal / Foundation heavy equipment
such as TVF, ODU, AHU & Smoke
Extract Fan, Over Track Exhaust Fan as
per contractor’s shop drawings.

19-24
xiv. Shall refer to architectural / CRD / GFC

drawings thoroughly.

Sl. No
3 Contractor to share his detailed works Contractor to provide his detailed works
program and coordinate access to meet key program in order to prioritise access to meet
dates / intermediate key dates the key dates / intermediate key dates.
4 Shall coordinate and provide the same. Shall coordinate and get the drain points with
sufficient slope near the VRF indoor & outdoor
units.
5 Shall co-ordinate. Shall co-ordinate and get the space for VRF
indoor unit and associated piping, ducting,
cable tray and air grilles / diffusers to avoid
clash between VAC services and other
services.
6 Shall co-ordinate and provide the same. Shall arrange and install the indoor units in air
conditioning rooms in such a way that
technical equipment will not fall below indoor
units.
7 Shall co-ordinate. Shall co-ordinate and provide the removable

access or inspection panel / tile for the indoor
units. Shall co-ordinate and get the colour and
finish for the panel / tile.
8 Shall co-ordinate. Shall coordinate for the bottom of air curtain
9 Shall co-ordinate jointly and provide the Shall co-ordinate jointly for the Cut-out / shaft /
same as per the requirements. opening in D wall/ wall / floor / ceiling for
installing ducts, refrigerant pipes, cable tray in
all levels as per the CSD / SEM / RCP and
CRD drawings.
10 Shall co-ordinate jointly and provide the Shall get the sleeves for the pipes.
same as per the requirements.

19-25

Sl. No
11 Shall jointly verify the CSD, SEM and RCP Shall jointly verify and validate the VAC and
requirements to avoid clash between VAC / TVS requirements in the CSD, SEM and RCP
TVS and other services and to avoid rework to avoid clash between VAC / TVS and other
and damage during the installation. services and to avoid rework and damage
during the installation.
12 Shall co-ordinate Shall co-ordinate for the bottom of duct, pipe

and cable tray support from finished floor level
prior to start of installation works.
13 Shall jointly check and provide the same. Shall coordinate and jointly check for the
location, colour and finish for grille/ diffuser.
14 Shall provide the same. Shall jointly check Shall co-ordinate and get the louver opening to
and measure the opening size. fix louvers. Shall jointly check and measure
the opening size prior to procure the louvers.
15 Shall provide the same. Shall coordinate for the colour and finish for
louvers.
16 Shall co-ordinate and provide the same. Shall co-ordinate and get the shaft for
Staircase pressurization fans and opening for
the pressure relief dampers.
17 Shall co-ordinate and provide the same. Shall co-ordinate and get the pedestal for
tunnel ventilation fans(if required), VAC
panels, Damper control panels and PLC
panels.
18 Shall coordinate and provide foundation for Shall coordinate for the requirements of
all VAC/TVS panel’s foundation for all VAC/TVS panels.
19 Shall provide necessary arrangements like Shall verify arrangements like wall/floor cutout,
wall/floor cut-out, plinths/pedestal to install plinths/pedestal to install VAC/TVS equipment
VAC/TVS equipment in various locations. provided by contractor A.

Sl. No

19-26
20 Shall provide safety gratings inside TVS Shall check and get the safety gratings be
shafts at street level, in line with the installed on all the TVS related openings and
requirements specified. confirm their acceptance. Shall check the
grating details such as material, size, location,
separation distance and pressure drop
requirement for each of the ventilation shafts.
21 Shall provide size & location of OTE Shall Check & get size and location of OTE
opening, TVS, VAC Shaft, Fire Doors as per opening, TVS, VAC shaft, Fire Door
drawings
22 Shall Coordinate Shall coordinate and ensure no clash between

nozzle and other services running in tunnel
from/to the station.
23 Shall take the information from Contractor- Shall provide the largest equipment size and
B and ensure requirements to avoid location to enable Contractor A to plan
rework and damage during the installation. corridors, openings and door details to facilitate
equipment removal / delivery in the
TVS/VAC/SCADA equipment rooms etc.
TVS/VAC contractor shall ensure there shall be
no damage to the equipment /Material during
installation
24 Shall provide Lifting hooks for Shall check, coordinate & ensure the same.
Ventilation fans in TVS & VAC rooms.
25 Shall construct the Tunnel Ventilation Fan Shall coordinate with Contractor A for smooth
air path from one TVS room to other side surface finish in wall and floor of Tunnel
with smooth surface finish of wall and floor Ventilation Fan air path from one TVS room to
other side.
26 Shall provide temporary power and water Shall get temporary power and water for
for construction/installation of TVS/VAC construction/installation of TVS/VAC works on
works on chargeable basis on a mutually chargeable basis on a mutually agreeable
agreeable rate. If Contractor A is not able rate.
to provide the same due to any constraint,
then Contractor B shall arrange the same.

Sl. No

19-27
28 Shall provide and jointly check smoke Shall jointly check to get smoke downstands as
downstands in stations as per design per approved shop drawings/ BIM model
requirement.
29 Shall co-ordinate for the same. Shall coordinate for the bottom of air curtain to
be flush with false celling.
4. Contractor A – CP06-UG06 Vs Contractor B – Power supply

19-28
Contractor A – CP06-UG-06 Contractor B – POWER SUPPLY

Sl. No
1 Shall co-ordinate with Contractor-B. Shall check requirements for cable laying works
like routing, sections, cross passages and
confirm.
2 Shall co-ordinate with Contractor-B Shall check the total space in the tunnel for
cable laying works and confirm.
3 Shall co-ordinate with Contractor-B Shall check the structural openings for cable
entries/exit in regard of the chainages.
4 Shall co-operate and agree with Contractor- Shall coordinate with Contractor A to get
B access free from obstacles and handed over for
cable laying works.
5 Contractor A shall receive the pegging plan Contractor B shall provide the pegging plan for
for OHE fixing arrangement and shall verify OHE fixing arrangement and shall supply &
/ coordinate for any modifications. install complete assembly for OHE including
inserts/ embedded items in concrete.
6 Complete the OTE duct installation and Request access to the track area for
mark the track center line on the soffit of installation of Traction support and lines.
OTE ducts
Rectify / modify the Traction support and
services if any which are infringing into
structure gauge mentioned in the schedule of
dimensions (SoD).
7 Shall coordinate with Contractor B and Contractor-A Shall install the rated capacity
provide suitable foundation / plinth for Transformer.
transformer
8 Technical rooms shall be made ready with Shall jointly check the technical rooms made
Architectural finishes and Shall be ready by ‘Contractor A’ and the same shall be
coordinated with ‘Contractor B’ confirmed.

Sl. No

19-29
9 All necessary arrangements shall be made Shall jointly check and confirm the
ready for the cable routing/Laying and shall arrangements made ready for cable
be coordinated with ‘Contractor B’. routing/Laying (HV and LV cables crossing to
be avoided) within the Station, cable crossing at
stations etc.
10 Shall coordinate and provide Shall jointly check the signage provided for all
the technical rooms and to be confirmed
11 Shall jointly check and confirm access provided

Access for lifting facilities and easy
maintenance for Electrical. equipment’s for lifting facilities for electrical machineries for
shall be made ready as per the installation and easy maintenance
requirements and shall be coordinated with
‘Contractor B’.
12 Shall Coordinate Shall check and confirm earthing works and

earth bus in the Technical rooms required for
High Voltage and Low Voltage power supply
systems including the building structures.
13 Shall coordinate and provide Shall request and confirm arrangements for
arrangements for cable crossing at station cable crossing at station
14 Contractor A shall provide Temporary Contractor B shall furnish temporary power

power supply. Power supply shall be supply requirement to Contractor-A. Power
metered and charged to Contractor B supply shall be metered and paid to Contractor
based on mutually agreed rates. A based on mutually agreed rates.
15 Shall study the space availability in the Shall request the temporary storage area in the
station and provide accordingly station building

Sl. No

19-30
1 Shall jointly check the resistance of all Shall jointly check the resistance of all earthing
earthing works made at station and shall be works at station required for High Voltage and
coordinated with ‘Contractor B’ in Low Voltage power supply systems including
coordination with E&M Contractor. the building structures and to be confirmed.
2 Shall arrange Space free from human Shall request Space free from human
interference and materials. interference and materials
5. Contractor A – CP06-UG06 Vs Contractor B – Signalling &Telecom
Sl. No Contractor A – CP06-UG-06 Contractor B – SIGNALLING & TELECOM

1 All corridors and doors shall be verified to Shall furnish the sizes & loadings of S & T
enable equipment delivery to SER, CER, equipment’s to be installed
SCR and Telecom Closets for installation
and replacements.
2 Shall coordinate Shall furnish the locations and details of

access control system and Intrusion detection
system.
3 Shall supply and install clean earth mats Shall furnish the requirements of earthing
below the base slab level as per the arrangement including earth impedance value
approved drawings. for different S &T systems to be installed in
SER, CER, Telecom closets and SCR and line
side equipment’s.
4 Shall provide all the statutory signs and Shall furnish the requirements of signs and
labels except for S & T equipment. labels except for equipment installed by
Contractor- B.


19-31
5 Shall provide the false flooring (for Shall verify that the requirements of false
prescribed load levels) and vertical cable flooring (for prescribed load levels) and vertical
risers in SER, CER, Telecom Closets and cable risers in SER, CER, Telecom Closets and
SCR. SCR are as per the requirement.
6 Shall provide all the statutory signs and Shall furnish the requirements of signs and
labels except for S & T equipment. labels except for equipment installed by
Contractor- B.
7 Shall install all signalling & communication

Shall ensure provision of cable ducts, main
cable crossing arrangements, including cables and provide the connections to
openings required for entry / exit individual devices
arrangements for main S & T cables in the
station.
8 Shall co-ordinate with Contractor-B. Shall install the line side S & T equipment’s
like signals, ATP/ATO equipment’s, antennas,
train stoppage beacons, location boxes, signal
post telephones and impedance bonds etc.
9 Shall co-ordinate with Contractor-B. Shall install the emergency communication

and help point equipment’s.
10 Shall coordinate to install access control Shall install the access control system and
and intrusion detection systems. intrusion detection system.
11 Shall coordinate. Shall verify that the requirements of earthing

system are met.
12 Shall coordinate. Shall verify the requirements of statutory signs

and labels.


19-32
1 Shall attend the joint testing of earth Shall conduct a joint test with Contractor A for
impedance with Contractor- B earth impedance of all earths provided for
tunnels & stations.
2 Shall provide necessary arrangement to

install PIDS/PAS and other telecom Shall install PIDS/PAS and other telecom
equipment’s. Shall provide Supporting equipment’s as required. Supporting
arrangement for all telecom equipment’s arrangement for all telecom equipment’s
inside the public area shall be provided by
inside the public area under Architectural
Contractor A
finishes work.
3 Shall attend the joint testing Shall conduct joint load test with suitable loads
with temporary power supply.
6. Contractor A – CP06-UG06 Vs Contractor B – PSD
Contractor A – CP06-UG-06 Contractor B – PSD

Sl. No
1 Shall validate the locations of Platform Shall furnish the specification of Platform
Screen Doors (PSD) Screen Doors (PSD) like dimensions, weight
and supporting & mounting details throughout
stations.
2 Shall provide necessary supports to install Shall install the Platform Screen Doors,
the platform screen doors and local control Emergency Escape doors, Track access doors
panels. and Platform screen door local control panels.
3 Shall co-ordinate Shall verify the requirements of earths and

earth bars
Contractor A – CP06-UG-06 Contractor B – PSD

Sl. No

19-33
4 Shall co-ordinate Shall install control panel, power and control

cable according to approved drawings
1 Shall co-operate. Shall conduct a joint test with Civil Contractor

(Contractor-A) for testing of earth impedance of
all earths provided for the PSD Equipment’s.
7. Contractor A – CP06-UG06 Vs Contractor B – AFC

19-34
Sl. No Contractor A – CP06-UG-06 Contractor B – AFC

1 All other signage at stations shall be

designed & incorporated Equipment related labelling and signage on
AFC equipment and cables shall be designed
by AFC contractor.
2 Shall provide Temporary power supply. Shall specify the requirement of temp power
Power supply shall be metered and for site works.
charged to Contractor B based on mutually
agreed rates
3 Shall make provision for temporary space Shall specify the temporary storage
at concourse level to store AFC equipment requirement for AFC equipment’s at the
on temporary basis during installation. stations during installation
4 Shall provide access to the Contractor B Shall request access from the station
as per key date. contractor (Contractor-A).
5 Shall Coordinate / co-operate. 1. To check and confirm that AFC specific

requirements for installation are made
available.
2.To install the electric cabinet and do the
cable termination.
3.To install the switches and do the data cable
termination.
4.To do the internal wiring at the AFC rooms.
5.To fix the AFC equipment’s at AFC rooms
and complete the installation.
6 To provide Granite Counter for TIW at To check the details of Granite counter for TIW
Ticket office as part of Architectural provided by the station contractor(Contractor
Provisional Sum. A).
7 To Coordinate To do the signage under the scope of AFC

Contract, specific to AFC equipment and
cabling.
8. Contractor A – CP06-UG06 Vs Contractor B – Lift & Escalator

19-35
Sl. No Contractor A – CP06-UG-06 Contractor B – LIFT & ESCALATOR

1 Contractor A shall provide ‘Contractor B’ Contractor B shall jointly check the availability
requirements in station. of requirement (shaft/site readiness) for Lifts
and Escalators installation, like mounting
facility, water resistant pits, access and delivery
space as per the drawing (provided by Lift &
Escalator Contractor) suitable for lifts &
Escalators erection and confirm.
2 Shall provide the station Shall request the station

architectural/structural drawings architectural/structural drawings
3 Contractor A shall provide free space for Contractor B shall request free space for
the temporary storage for limited period temporary storage in the Station building.
and ensure the space is free from human
interference materials
4 Contractor A shall provide a safe working Contractor B shall request a safe working
atmosphere at work site. atmosphere at work site.
5 Contractor A shall request for delivery and Contractor B shall provide delivery and
installation schedule before installation programme before commencement
commencement of works. of works.
1 Contractor-A shall co-ordinate with Contractor-B Shall Conduct test run jointly with
Contractor-B. Contractor-A
9. Contractor A – CP06-UG06 Vs Contractor B – Rolling stock

19-36
Contractor A – CP06-UG-06 Contractor B – ROLLING STOCK

Sl. No
1 Contractor-A shall give the details of Contractor-B shall obtain the details of Tunnel
Tunnel Drawings showing the indicative Drawings showing the indicative curves,
curves, dimensional clearances, gradients, dimensional clearances, gradients, chainages,
chainages, levels to rolling stock levels to design rolling stock suitably
Contractor-B
Shall obtain from the Contractor-B the

(b) Shall provide the required details to
Rolling Stock details such as length of train
cars, height and location of doors, loading Contractor-A
configuration (axle loads and
configurations) etc. for tunnel & station
2 Share the OTE duct cutout layout Review the OTE duct cutout layout drawing
drawings. Review the OTE cutout change and confirm the cutout opening with respect to
request from the rolling stock contractor the rolling stock requirement.
and make necessary changes in the OTE Change in OTE cutout layout if any required
cutout. shall be requested in advance to Contractor A
3 In tunnel maximum flood level (water Contractor-B shall design under slung
height) shall be provided to Contractor B equipment’s suitably
4 Contractor-A shall collect details of Contractor-B shall share the details of

kinematic, structural gauges and swept kinematic, structural gauges and swept
envelope on straight and curved tracks envelope on straight and curved tracks
5 Contractor-A Shall give details of the Contractor-B shall design the rolling stock with
emergency escape provision in tunnels to suitable emergency escape provision to match
Contractor-B tunnel provision

19-37
Contractor A – CP06-UG-06 Contractor B – ROLLING STOCK

Sl. No
6 Contractor A shall jointly check and Contractor B shall co-ordinate and confirm
confirm the curves, dimensional with Contractor-A
clearances, gradients, chainages, levels
and emergency escape provision
7 Contractor-A shall participate/attend test Contract-B shall be required to conduct test

run and do modifications, if required run with the train at low speed
8 Contractor-A facilitate to conduct test run Contractor-B shall conduct test run and
with one bogie at low speed. request contractor A for any modification if
required.
1 Contractor-A shall Coordinate Contractor B shall confirm the maximum

noise/echo level with respect to various
operating speeds of rolling stock
2 Contractor-A shall coordinate with Contractor-B shall conduct integrated tests

Contractor-B to complete testing and with all systems
commissioning work

19-38
10. Contractor A – CP06-UG06 Vs Contractor B – Track
Contractor A – CP06-UG-06 Contractor B – TRACK

Sl. No
UG Stations
1 Shall furnish correct chainages of Station Shall fix chainages of the Turnouts / Cross
centre line to Contractor- B. over based on the chainages of Station Centre
Line furnished by the Contractor-A
2 Shall ensure that the pillars / columns Shall coordinate with contractor A
supporting the station structure and all
other structures are located clear of the
minimum infringement clearances from
centre of track as stipulated in the
approved S.O.D.
3 Shall provide coordinates of the survey Shall receive, validate and agree upon the
control points in the stations used for the survey control points in the stations provided
construction of civil works to the Contractor by Contractor A – Any discrepancy shall be
B brought to the notice of Engineer.
4 Contractor A shall hand over to the Track Contractor B shall arrange for taking over
contractor(Contractor-B) the concrete base after joint verification with Contractor-A and
(duly providing 1st stage concrete with take up construction of the 2nd Pour concrete
shear connectors, for track laying within in the track above the 1st pour concrete done
the permitted tolerances) for track utilizing the provisions of shear connectors
structure and the station platform to done by Contractor-A.
designated levels / clearances with in the
tolerances permitted.
Shall hand over the track installation area

in the vicinity of Pillars / Columns and such
structures/obstructions clear of the
infringement distances stipulated in the
approved S.O.D

19-39

Sl. No
5 Contractor A shall provide the required Contractor B shall jointly decide with the
openings in the structures to lower the Contractor-A opening requirements, temporary
track materials/plants/equipment including storage spaces and Schedule of Access
rails for track construction and provide Periods and ensure implementation based on
temporary storage space for Track track construction program.
materials in consultation with Track
contractor (Contractor-B) and shall permit
Access to Track contractor for construction
of Track as per agreed Schedule of
Access Periods.
6 Contractor A shall provide Temporary Contractor B shall furnish details of temporary

water and power supplies for construction water and power supply requirement to
of Track. Water and power supply shall be Contractor-A. Water and power supply shall be
metered and charged to Contractor B metered and paid to Contractor A based on
based on mutually agreed rates. mutually agreed rates.
7 Contractor A shall ensure that levels of Contractor B shall check the levels of platform
platform and track base concrete in station and track base concrete at the time of taking
boxes conform to the design levels and over from Contractor-A and ensure that the
tolerance. Shall furnish completed levels, heights and clearances from rail level / center
curvature & cant if any, to track contractor of track are with inacceptable limits as per the
(contractor B) for any adjustment in rail/ approved S.O.D.
alignment while laying track
8 Shall provide access and temporary Shall coordinate with Contractor-A

openings etc to Contractor B for track
concrete works.
9 Contractor A shall use this information for Contractor B shall provide the as-built track
fixing the Coping Stone of Platform and geometry at stations (if the track is installed) or
structures on platform design track geometry (if the track is not
installed) to Contractor A
Tunnel

19-40
10 Shall provide coordinates of the survey Shall receive, validate and agree upon the
control points used for the construction of survey control points provided by Contractor A
tunnel to the Contractor B – Any discrepancy shall be brought to the
notice of Engineer.

Sl. No
11 Contractor A shall complete construction of Contractor B shall arrange for taking over after
the 1st stage concrete with shear joint verification with Contractor-A and take up
connectors over the sill of the Tunnel to construction of the 2nd stage concrete in the
specified levels (in consultation and track above the 1st stage concrete done.
coordination with Contractor-B) and within
permitted tolerances.
12 Contractor A shall provide as-built details Contractor B shall set the track to the survey
of the tunnel along with survey control control points provided by the civil contractor
points for setting the permanent track to its (Contractor-A) which will be verified prior to
correct position. Shall furnish completed laying/ concreting the Track
levels, curvature & cant if any, to track
contractor (contractor B) for any
adjustment in rail/ alignment while laying
track
13 Contractor A shall furnish levels/details of Contractor B shall provide the track Drainage
the Drainage system in the Tunnel to system in the 2nd pour concrete consistent
Track contractor (Contractor-B) duly with the General Drainage arrangements
ensuring that Track Drainage is compatible constructed by the Tunnel Contractor
with the General Drainage system (overall (Contractor-A).
drainage scheme).
14 Contractor A shall provide the required Contractor B to decide openings/way,

opening/way to take the track temporary storage spaces and schedule
materials/plant/equipment/concrete Access Periods jointly with Tunnel contractor
underground for track laying and provide (Contractor-A) and ensure implementation
temporary storage space for Track based on Track construction program
materials in consultation with track
contractor (Contractor B) and to permit
access to track contractor for construction
of Track as per agreed schedule of Access
Periods

19-41
15 Contractor A shall provide Temporary Contractor B shall furnish details of temporary

water and power supplies for construction water and power supply requirement to
of Track. Water and power supply shall be Contractor-A. Water and power supply shall be
metered and charged to Contractor B metered and paid to Contractor A based on
based on mutually agreed rates. mutually agreed rates.

Sl. No
16 Contractor-A shall provide temporary Contractor-B Shall jointly decide and ensure
storage facilities for the Track materials with contractor-A adequate temporary storage
and also permit access to contractor-B for facilities for the Track materials for installing
installing track works as per jointly agreed track works as per jointly agreed access
access schedule. schedule.
1 Contractor A – shall coordinate with Contractor B- shall carryout Gauge and

Contractor B for Gauge and Clearance Clearance Check in coordination with
Check Contractor A
2 Contractor A shall attend and assist in the

joint check with concerned interface Contractor B shall attend and assist in the
contractors to ensure that all permanent joint check with concerned interface
structures are clear of the structure gauge contractors to ensure that all permanent
specified in the approved S.O.D. structures are clear of the structure gauge
specified in the S.O.D.

19-42
Annexure-E Master Interface Matrix

19-43

19-44
Annexure F Part 2 - Interface Coordination Sheet Format
The following table provides the Interfacing Party Contract codes to be used when preparing /
updating the Contractors Interface Coordination Sheet, which should be prepared on the basis
of a separate Excel spreadsheet for each Interfacing Party.
Interface Party Codes:
CVT Civil Tunnels
CVE Civil Elevated
CSN Civil UG Stations
CVD Civil Depot
ARS Architectural UG Stations
ARD Architectural Depot
BSS Building Service UG Stations
BSD Building Service Depot
DEE Depot Equipment (* Refer Note 1)
AFC Automatic Fare Collection
SGC Signalling and Communications
LEC Lifts and Escalators
VAC Ventilation & Air Conditioning
PST Traction Power (Includes OCS &

SCADA)
RST Rolling Stock
TWK Track work
Notes : 1. Depot Equipment may be subdivided into individual items of equipment in which case
Contractors will be notified of designated interfacing codes.
2. Other document coding should be in accordance with the requirements of the Contract and
as agreed with Employer

19-45
Attachment F Part 3 - Interface Coordination Sheet Format
The following table describes the Interface Status with codes to be used in preparing / updating
the Interface Coordination sheet.
Interface Status Codes & Meanings

Interface Status Code for Description of Status
Log
To be coordinated TBC Both Contractor’s have not agreed the
conditions for this interface
Coordinated COR Both Contractor’s have agreed that the
interface is valid
Not coordinated NCOR One Contractor does not agree the conditions
for this interface
Received REC The Contractor responsible for the
design/construction element has received the
information/documents required
Provided PRO The Contractor responsible for providing the
information/documents to progress the
design/construction element has provided the
documents to the Interfacing Party
Accepted ACP The Contractor has accepted the proposed
Interface Construction element
Not Accepted NACP Either of the Contractors have not accepted
the proposed Construction element
Propose closeout PCO Both Contractor’s have accepted the
proposed Interface Design or Construction
element and no other requirements are
outstanding. Both Parties can agreed to sign
the Confirmation of Coordination Form
Closed out CO The final Interface Documentation together
with Confirmation of Coordination Form has
been sent to the Interface Coordination
Manager for closing the interface
Superseded SUP The Interface construction element has been
superseded

19-46
Annexure G – Confirmation of Coordination Form
CHENNAI METRO RAIL- PHASE2

Ref :
CONFIRMATION OF COORDINATION
CONTRACT: TRANSMITTAL NO:
TITLE:
ACTIVITY NO:
GENERAL DESCRIPTION:
SIGNATURES OF INTERFACING CONTRACTORS

Interfacing Contractor Authorised Signature Date Comment
Name Reviewed
1.
2.
3.
4.
5.
Signatures above confirm that this design document has been reviewed as part of the coordination
process.
NOTE: Where Contractors are not in agreement with the details on this submission, they are to
comment above and advise the interfacing party in question requesting accommodation of the
requirement and advise the Employer under separate cover and report progress in Monthly Report /
Coordination Meetings

19-47
Annexure H - Guidance Notes for the Preparation of Interface Management Programme.
1. The programme shall be prepared and submitted in bar chart format.

2. The bar chart shall be formed by activities grouped by major Zones of Interface.
3. The detail of each bar chart activity shall demonstrate the Contractor’s understanding of
the scope of work of any Interfacing Contractor who is to supply input to the Contractor, in
order for him to achieve an integrated coordinated design.
4. The bars shown on the bar chart shall be annotated with details of the information expected
from the Interfacing Contractors, and highlight any target dates to receive or produce
information.
5. Information relating to contractual milestone dates shall be shown on both the Contractor’s
and Interfacing Contractors schedules.
6. The prime purpose of the document is to assist with ensuring that a coordinated
construction, testing and commissioning is achieved. This document shall be forwarded to
Interfacing Contractors for comment and agreement on a regular basis.
7. A complementary table of activities and dates should be prepared for ease of reference

19-48
Annexure I - Guidance Notes for the Preparation of Interface Management Plan.
The purpose of this Plan is to demonstrate how the Contractor proposes to achieve a fully
coordinated construction with that of the construction carried out by Interfacing Contractors. The
document should also be complementary to the IMPG, which details the proposed schedule and
timings of each of the interfacing activities. The Plan shall:
i. Cover the whole duration of the Works and be complementary to the IMPG, which details
the proposed/agreed schedule and timings.
(ii) Be given by the Contractor to other Interfacing Contractors for their information and
agreement.
(iii) Be developed to reflect the agreements reached by the Contractor and the Interfacing
Contractors as the Project progresses. The Plan shall be updated on a quarterly basis
to reflect this developing status.
The Status of any interface at any point in time shall be identified by one of the following
conditions;
• to be coordinated
• coordinated
• not coordinated
• received
• provided
• accepted
• not accepted
• propose close-out
• superseded
• close

19-49

PHASE-II PROJECT”
PART 2
SECTION VI - A
APPENDIX-20
OCCUPATIONAL, HEALTH, SAFETY AND
ENVIRONMENTAL
VOLUME 1 - CONTROL
DECEMBER 2021
Chennai Metro Rail Project Phase 2, Corridor 5. Part -2 Section VI - A
Table of Contents
1. Scope .................................................................................................................................... 1
2 Reference publications .................................................................................................... 2
3 Terms and definitions ...................................................................................................... 2
4 OSH&E management system requirements............................................................... 4
4.1 General requirement .................................................................................................... 4
4.2 CMRL OHS&E Policy Statement of Intent ............................................................ 4
4.3 Planning ......................................................................................................................... 6
4.4 Implementation and operation .............................................................................. 10
4.5 Checking ..................................................................................................................... 25
4.6 Management review ................................................................................................. 33
4.7 External OHS&E Agency .................................................................................. 33
4.8 Penalty .................................................................................................................. 33
Section VI- A Volume -1,Control 1-i December 2021

1. Scope
The Employer’s Requirements OHS&E Volume 1 details the requirements of the Employer for
Occupational Health, Safety and Environmental control measures associated with the Contractor
and any other agency, to be practiced on all Chennai Metro Rail Limited (CMRL) construction sites
or associated premises.
1.2 Application of this document
1.2.1 The Employer’s Requirements OHS&E Volume 1applies to all aspects of the contractor’s
scope of work including that conducted by their appointed sub contractor’s and other
agencies on their behalf. There shall be no activity associated with the Chennai metro Rail
Project, which exempted from the purview of this document. The Employer’s Requirement’s
OHS&E Volume 1 is supplemented with a further 3 OHS&E Volume for ease of reference.
Their individual scope and applicability is as follows:
1.2.2 OHS&E Volume 1 is the controlling document for all Contracts and is fixed throughout the
term of the project. Compliance with the Employer’s Requirements OHS&E Volume 1 and
the Project Occupational Health and Safety Manual (OH&S) Volume 2 is mandatory. Volume
1 remains subject to revision by the Employer /Engineer in the event of new Legislation or
changing circumstances
1.2.2 OH&S Volume 2 provides Project Occupational Health & Safety Manual is mandatory
applies to all aspects of the Contractor’s scope of work, including that conducted by their
appointed sub-Contractor’s and other agencies on their behalf. The contents of OH&S
manual Volume 2 remains subject to revision by the Employer /Engineer in the event of new
Legislation or changing circumstances.
1.2.3 OHS&E Volume 3 provides Environmental guidance and procedural requirements for the
project. Volume 3 remains subject to periodic revision and updating.
1.2.4 OH&S Tunnel Manual - Volume 4 is specifically for projects involving tunnelling and its use
is mandatory. Volume 4 remains subject to revision by the Employer /Engineer and updating
during the project period in light of legislative or methodology changes.
1.3 Purpose of this document
The purpose of this document, the Employer’s Requirements, OHS&E Volume 1 is to provide
Contractors and other interested parties with the mandatory requirements relating to
Occupational Health, Safety and the Environment practices and performance expectations
on the Chennai Metro Rail Project.
This document:
a) Describes the OHS&E interfaces between the Employer, Engineer and the Contractor;
b) Details the processes by which the Contractor shall manage OHS&E issues while
carrying out the works under the contract and;
c) Describes by reference, the practices, procedures and requirements pertaining to the
Chennai Metro Rail Project.
1.4 Chennai Metro Rail OHS&E Objectives
Chennai Metro Rail Limited has identified five principle objectives for attainment during the
project. These long term objectives shall be supported with quarterly, short and medium term
objectives to enable structured advancement in overall performance. Our Short and medium
term objectives also aims to facilitate effective monitoring and measurement to identify where
a directional change may be necessary. Our Long term objectives are:
1. To eliminate or minimize the unwanted effects of hazards and risks to personnel,
members of the public and other stakeholders who may be exposed to the undertakings
associated with the construction of the Chennai Metro Rail project
Section VI- A, Volume – 1, Control 1-1 December 2021

2. Establish an effective and robust OHS&E management system that will enable
Contractors to achieve international recognition and registration to the ISO 45001:2018
Series.
3. Actively contribute to Contractors development through support, encouragement,
determination in control and transfer of knowledge and skills in order to make the move
from traditional compliance driven management through to risk managed processes.
4. To simplify the risk concept, to ensure a sensible approach to risk management and
simplify hazard awareness training through adoption of the ALARP (As low as
reasonably practicable) principles.
5. To practice ‘Best Practice’ within the construction industry - Establishing a work
environment that conforms to international Occupational health & safety standards and
make recommendation to improve effectiveness of regulations both nationally and
locally.
2 Reference publications
ISO 9000:2005, Quality management systems — Fundamentals and vocabulary
ISO 9001:2015, Quality management systems — Requirements
ISO 14001:2015, Environmental management systems — Requirements with guidance
ISO 19011:2002, Guidelines for quality and/or environmental management systems auditing
OHSAS 18001:2007, Occupational health and safety management systems Requirements
OHSAS 18002, Occupational health and safety management systems – Guidelines for the
implementation of BS OHSAS 18001
ISO 45001:2018 specifies requirements for an occupational health and safety (OH&S)
management system and gives guidance for its use, to enable organizations to provide safe
and healthy workplaces by preventing work-related injury and ill health, as well as by
proactively improving its OH&S performance.
PAS 99, Specification of common management system requirements as a framework for
integration
International Labour Organization:2001, Guidelines on occupational health and safety
management systems — ILO-OSH 2001
Health & Safety Guidance (HSG) Health and Safety Executive Publications United Kingdom
Occupational Safety and Health Administration(OSHA) publications USA
3 Terms and definitions

3.1 Acceptable risk. Risk that has been reduced to a level that can be tolerated by the
organization having regard to its legal obligations and its own OHS&E policy
3.2 Accident. Incident giving rise to injury, ill health or fatality
3.2 ALARP (As low as reasonably practicable) principles.
3.3 Audit. Systematic, independent and documented process for obtaining “audit evidence” and
evaluating it objectively to determine the extent to which “audit criteria” are fulfilled
3.4 BOCWA. Building and Other Construction Workers (Regular Employment and Conditions of
Service) Act, 1996
3.5 BOCWR. Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Central Rules, 1998
3.6 Chief Safety Expert. An officer appointed by Employer / Engineer who is the overall
responsible for monitoring all OH&S functions prescribed in this document.
3.7 CMRL. Chennai Metro Rail Limited

3.8 Competent person. Person with the appropriate combination of skill, knowledge,
qualifications and experience
3.9 Continual improvement. Recurring process of enhancing the OHS&E management system
in order to achieve improvements in overall OHS&E performance consistent with the
organization’s OHS&E policy
3.10 Corrective action. Action to eliminate the cause of a detected nonconformity or other
undesirable situation
3.11 Design Risk Assessments. Used to record the actions of designers when reducing risks in
construction and for future repairs and maintenance issues.
3.12 Employer. Chennai Metro Rail Limited (CMRL).
3.13 Hazard. Source, situation, or act with a potential for harm in terms of human injury or ill health,
or a combination of these
3.14 Hazard identification. Process of recognizing that a hazard exists and defining its
characteristics
3.15 Health surveillance. Monitoring health of employees to detect signs or symptoms of
work‑related ill health so that steps can be taken to eliminate, or reduce the probability of,
further harm
3.16 Ill health. Identifiable, adverse physical or mental condition arising from and/or made worse
by a work activity and/or work-related situation
3.17 Incident. Work-related event(s) in which an injury or ill health (regardless of severity) or
fatality occurred, or could have occurred. An accident is an incident which has given rise to
injury, ill health or fatality.
3.18 Interested party. Person or group, inside or outside the workplace, concerned with or
affected by the OHS&E performance of an organization
3.19 Nonconformity. Non-fulfilment of a requirement; A nonconformity can be any deviation from:
relevant work standards, practices, procedures, legal requirements, etc. or OHS&E
management system requirements.
3.20 OHS&E management system. Part of an organization’s management system used to
develop and implement its OHS&E policy and manage its OHS&E risks. A management
system is a set of interrelated elements used to establish policy and objectives and to achieve
those objectives. A management system includes organizational structure, planning activities
(including for example, risk assessment and the setting of objectives), responsibilities,
practices, procedures, processes and resources.
3.21 OHS&E objective. OHS&E goal, in terms of OHS&E performance that an organization sets
itself to achieve.
3.22 OHS&E performance. Measurable results of an organization’s management of its OHS&E
risks
3.23 OHS&E policy. Overall intentions and direction of an organization related to its OHS&E
performance as formally expressed by top management
3.24 Preventive action. Action to eliminate the cause of a potential nonconformity (3.19) or other
undesirable potential situation
3.25 Procedure. Specified way to carry out an activity or a process
3.26 Record. Document stating results achieved or providing evidence of activities performed
3.27 Risk. Combination of the likelihood of an occurrence of a hazardous event or exposure(s)
and the severity of injury or ill health that can be caused by the event or exposure(s)
3.28 Risk assessment. Process of evaluating the risk(s) arising from a hazard(s), taking into
account the adequacy of any existing controls, and deciding whether or not the risk(s) is
acceptable

3.29 Risk control. Selection and application of suitable measures to reduce risk
3.30 Shall. Indicates a mandatory requirement within this document
3.31 Stakeholders. Those with a vested interest in an organization’s achievements that includes,
but is not limited to, internal and “outsourced” employees, customers, suppliers, partners,
employees, distributors, investors, insurers, shareholders, owners, government and
regulators.
3.32 Status review. Formal evaluation of the OHS&E management system
3.33 Top management. Person or group of people who direct and control an organization at the
highest level
3.34 Worker representative. Representative of employee occupational health and safety
3.35 High Risk –A hazardous condition may cause frequency accidents which may result in
catastrophic equipment losses or buildings, severe injury, illness, disablement or possible
fatality.
3.36 Medium Risk-A hazardous condition resulting in injury /illness requiring absence from work
or equipment damage.
3.37 Low Risk-A hazardous condition is unlikely to cause accidents, minor injury, and even fit
does, result in only negligible damage.
4 OSH&E management system requirements

4.1 General requirement
4.1.1 The Contractor shall define and document the scope of its Occupational Safety Health and
Environmental (OHS&E) management system to meet legal requirements and the
requirements of Chennai Metro Rail Limited as stated within this document.
4.1.2 The Contractor’s OHS&E management system shall determine how the organisation shall
document, implement, maintain and continually improve upon performance in accordance
with the requirements of the International ISO45001:2018 Standard to which the Employer is
committed.
4.2 CMRL OHS&E Policy Statement of Intent

Chennai Metro Rail Limited consider that Occupational health, safety and environmental is of
equal importance in comparison to any other aspect of business management and as such
is committed to promoting high standards of Occupational health, safety ,environmental and
welfare on all of their sites and premises. To achieve this Chennai Metro Rail shall:
• Constantly work towards improving the safety culture at all levels.
• Ensure compliance with all relevant legal duties in respect of health and safety at work
legislation.
• Provide adequate resources for planning and controlling working conditions and safe
systems of work.
• Work with our Contractors and suppliers to improve their safety performance, by
measuring and monitoring their performance.
Responsibilities and performance requirements for Occupational health, safety and
environmental are available on the Chennai Metro Rail Limited website. In summary: -
• All Contractors, employees, sub-Contractors, consultants, suppliers and visitors have
A duty to play an active role in achieving our objectives through compliance with their
legal obligations and this OHS&E Policy.
• Participation and consultation are vital aspects of this Policy and to the achievement of

our objectives. Contractors and Staff are encouraged and expected to:
• Discuss Occupational health, safety and environmental matters with their managers, and
company Occupational health, safety and environmental Representatives who will offer or
obtain further expert advice, where necessary.
• Co-operate at all times; contribute good ideas and improvements; report defects and
short falls.
The correction of any breach of statutory provision or Chennai Metro Rail Limited
requirements on Occupational health and safety shall take priority. Should appropriate action
not be taken to meet the required standards, this will be taken seriously and may lead to
disciplinary action being taken.
This Policy Statement shall be displayed prominently on all Chennai Metro Rail Limited sites
and offices and will be kept under review to ensure its relevance.
____________________
Managing Director
Chennai Metro Rail Limited December 2019

4.3 Planning
4.3.1 Hazard identification, risk assessment and determining controls

4.3.1.1 The Contractor shall submit a procedure detailing the process in place for the identification
of Hazards and Risks and the determination of control measures including the relevant
standards as per clause 4.4.4.1.2. The Procedure shall incorporate the Employer’s
Requirements within this and other applicable OHS&E Volumes.
4.3.1.2 Management of Change

4.3.1.2.1 All temporary and permanent changes to organisational, personnel, systems, procedures,
equipment, products, materials or substances shall be evaluated by the Contractor and
managed to ensure that Occupational health, safety and environmental risks arising from
these changes remain at an acceptable level. Changes made by the Contractor are subject
to submittal and notice of no objection by the Employer /Engineer prior to adopting change.
4.3.1.3 Risk Register & Hazard Log

4.3.1.3.1 The Contractor’s Construction Occupational Health and safety Plan shall contain a detailed
‘Risk Register’ and ‘Hazard Log’ specific to the project. The register and log shall be
assessed against the CMRL OH&S Manual Volume 2.
4.3.1.3.2 The Hazard Log shall identify future method statement, risk assessment and operational
procedures pertaining to specific equipment and operations in relation risk and local
environmental constraints. Construction phase OHS&E Plans shall not be accepted without
a fully completed Hazard Log and Risk Register.
4.3.1.4 Method Statements and Lift Plan

4.3.1.4.1 Method statements are to be submitted to the Employer /Engineer a minimum of 28 days
prior to task commencement to ensure sufficient time is available for review and notice of no
objection.
4.3.1.4.2 Method statements shall contain the information requirements as prescript within the CMRL
OH&S Manual Volume 2.
4.3.1.4.3 Method statements shall incorporate the control measures within the process methodology
as identified within the risk assessment.
4.3.1.4.4 A copy of the relevant method statement for the activity being undertaken shall be available
on site for reference by all site management and supervisors.
4.3.1.4.5 Lift Plan are to be submitted to the Employer /Engineer a minimum of 28 days prior to task
commencement to ensure sufficient time is available for review and notice of no objection.
4.3.1.4.6 Lift Plan shall contain the information requirements as prescript within the CMRL OH&S
Manual Volume 2
4.3.1.5 Risk Assessment production & submittal

4.3.1.5.1 Risk assessments shall contain as a minimum, the information as specified within the CMRL
OH&S Manual Volume 2. The Contractor may choose to use their own format however the
risk tolerances, probability and consequences must be included.
4.3.1.5.2 Risk assessments shall be produced and submitted to the Employer /Engineer a minimum
of 28 days prior to task commencement for notice of no objection. Risk assessments may
be submitted independently or as part of a Method Statement.
4.3.1.5.3 Generic risk assessments other than routine activities of low risk shall not be accepted by
the Employer/Engineer.

4.3.1.5.4 Risk assessments shall be regularly reviewed to ensure they remain suitable and sufficient.
Risk assessment reviews shall be undertaken where an incident has occurred and when a
change in location may introduce additional risks from construction activities.
4.3.1.5.5 Substances hazardous to health shall be subject to assessment by the Contractor. Where
Hazardous substances are identified for use within a process the assessment and
determining controls shall be included within the relative method statement.
4.3.1.5.6 Designer’s primary role includes to minimise the risk to Occupational health and safety of
those who are going to construct, maintain, clean, repair, dismantle or demolish the
structures and anyone else like adjoining road users/general public, who may be affected by
the work.
4.3.1.5.7 When considering health and safety in designer’s work, they shall be expected to do what is
reasonable at the time the design is prepared. It may be possible for hazards, which cannot
be addressed at the feasibility stage to be looked at during detailed design. In deciding what
is reasonably practicable, the risk to health and safety produced by a feature of the design
has to be weighed against the cost of excluding the feature. The overall design process
does not need to be dominated by a concern to avoid all risks during the construction phase
and maintenance. However, a judgement has to be made by weighing up one consideration
against another so the cost is counted not just in financial terms, but also those of fitness for
purpose, aesthetics, buildability or environmental impact. By applying these principles, it may
be possible to make decisions at the design stage, which will avoid or reduce risks during
construction work. In many cases, the large number of design considerations will allow a
number of equally valid design solutions. What is important is the approach to the solutions
of design problems. This should involve a proper exercise of judgement, which takes account
of occupational health and safety issues.
4.3.1.5.8 Designers shall need, so far as reasonably practicable, to avoid or reduce risks by applying
a series of steps known as the hierarchy of risk control or principles of prevention and
protection. The steps to be adopted shall include the following:
i) Consider if the hazard can be prevented from arising so that the risk can be
avoided (e.g. alter the design to avoid the risk);
ii) If this cannot be achieved, the risk should be combated at source (eg, ensure the
design details of items to be lifted include attachment points for lifting);
iii) Failing this, priority should be given to measures to control the risk that will
collectively protect all people;
iv) Only as a last resort should measures to control risk by means of personal
protection be assumed (E.g. use of safety harnesses).
4.3.1.5.9 In case of situations were the designers have carried out the design work and concluded that
there are risks, which were not reasonably practicable to avoid, detailed information shall be
given about the health and safety risks, which remain. This information needs to be included
within the design assessment to alert others to the risks, which they cannot reasonably be
expected to know. This is essential for the parties who have to use the design information.
4.3.1.5.10 If the designers’ basic design assumptions affect health or safety, or health and safety risks
are not obvious from the standard design document, the designer shall provide additional
information. The information shall include a broad indication of the assumptions about the
precautions for dealing with the risks. The information will need to be conveyed in a clear
manner; it shall be included on drawings, in written specifications or outline method
statements. The level of detail to be recorded will be determined by the nature of the

hazards involved and the associated level of risk.
4.3.1.5.11 Job Specific Risk assessment shall be submitted to the Employer /Engineer a minimum of
28 days prior to task commencement for notice of no objection. (Example-Manual Handling,
PPE and Fire)
4.3.1.6 Design Risk Assessment

4.3.1.6.1 Design Risk Assessments shall be submitted to the Employer /Engineer for granting of no
objection. Design risk assessments shall accompany all drawing submittals for operations
involving;
• Temporary works,
• Formwork & false-work
• Heavy lifting equipment.

4.3.1.6.2 Drawings shall not be accepted by the Employers Representative without an
accompanying design risk assessment.
4.3.1.7 Employer/Engineer’s approval

4.3.1.7.1 Every structure like scaffold, falsework & Formwork, launching girder, Temporary work
(shoring system), earth retaining structures etc. shall have its design calculations included
in the method statements in addition to health and safety risks. The Employer /Engineer
designer or his approved proof check consultants as applicable as per the contract conditions
shall approve all these designs and issue a ‘No Objection for Use’.
4.3.1.7.2 Any non-standard structures like trestles made up of re-bars or structures which are very old,
corroded, repaired for many times etc. for which no design calculations can be made
accurately from any national standards, shall not be allowed to be used at sites even for
short duration.
4.3.1.7.3 If any of the above mentioned clauses are not adhered penalty shall be imposed depending
upon the gravity of the unsafe act and or condition.
4.3.2 Legal and other requirements

4.3.2.1 Contractor shall comply with all legal obligations and the requirements of Chennai Metro
Rail Limited as contained herein.
4.3.2.2 Indian statutory requirements

The Contractor shall abide by all national, state and local bye-laws. It is the duty of the
Contractor to ensure that all sub-Contractors appointed also comply with their legal
obligations as listed below but not limited to:
i.Indian Electricity Act 2003 and Rules 1956
ii.Tamil Nadu Building and other construction Workers (regulations of Employment and
conditions of service) Rules ,2006.
iii.National Building Code, 2005
iv.Factories Act, 1948,
v.The Tamil Nadu Factories Rules, 1950
vi.Motor Vehicles Act as amended in 1994, The Central Motor Vehicles Rules, 1989.
vii. Indian Road Congress Code IRC: SP: 55-2001 ‘Guidelines on Safety In Road
Construction Zones.
viii.The Petroleum Act, 1934 and Rules 1976

ix.Gas Cylinder Rules, 2003
x.Indian Explosives Act. 1884, along with the Explosives substance Act 1908 and the
explosives Rules 1983
xi.The (Indian) Boilers Act, 1923
xii.The Public Liability Insurance Act 1991 and Rules 1991
xiii.Minimum Wages Act, 1948 and Rules 1950
xiv.Contract Labour Act, 1970 and Rules 1971
xv.Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950
xvi.Environment Protection Act, 1986 and Rules 1986
xvii.Air (Prevention and control of Pollution) Act, 1981
xviii.Water (Prevention and Control of Pollution) Act, 1974
xix.The Noise Pollution (Regulation & Control) Rules, 2000
xx.Notification on Control of Noise from Diesel Generator (DG) sets, 2002
xxi.Recycled Plastic Usage Rules, 1998
xxii.Notification, Central Ground Water Board, Act January 1997
xxiii.Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
xxiv.The Hazardous Waste (Management & Handling) Rules, 1989
xxv.Hazardous Waste Management Rules 1989 (as amended in 1999)
xxvi.Batteries (Management and Handling) Rules
xxvii.Fly ash utilization notification, Sept 1999 as amended in August 2003
xxviii.Workman Compensation Act, 1923 along with allied Rules
xxix.The Mines Act 1952
4.3.2.3 International Standards, Guidelines & ISO Certifications
4.3.2.3.1 If the requirements stated in this document are in conflict or inconsistent with the
requirements of applicable laws or the Employer’s Requirements for the CMRL project, the
more stringent requirements shall apply.
4.3.2.3.2 The works shall be undertaken in accordance with the applicable international guidelines,
standards and specifications on OHS&E and every Contractor shall actively pursue the
achievement of:
• ISO 45001:2018 Occupational health and safety (OH&S) management system
• ISO 14001:2015 Environmental management systems
4.3.2.3.3 The process of international certification to ISO 45001:2018 and ISO 14001:2015 standard
shall commence immediately after the award of Contract through appointment of ISO
accrediting body for obtaining the certification. Should this not be undertaken by the
Contractor within 3 months of the Contract award, the Employer /Engineer shall appoint at
the Contractor’s cost.
4.3.2.3.4 Should the Contractor already posses such certification, the scope of the CMRL project must
be included on the Contractor’s certification within 1 year of Contract commencement and
proof of such attainment demonstrated to Chennai Metro Rail Limited.
4.3.2.3.5 If any of the above mentioned clauses are not adhered penalty shall be imposed as per details
given under penalty clause 4.8.3 of this document.
4.3.3 Objectives and programme(s)
4.3.3.1 The Contractor shall maintain procedures to establish detailed OHS&E objectives and
performance criteria. Such objectives and performance criteria shall be developed to
incorporate the Chennai Metro Rail policy and strategic OHS&E objectives. The Contractor’s

objectives shall be quantified, wherever practicable, and identified with defined timescales.
The Contractor is required to submit for notice of no objection their procedure and objectives
as per clause 4.4.4.1 of this control document.
4.4 Implementation and operation

4.4.1 Resources, roles, responsibility, accountability and authority
4.4.1.1 The Contractor shall detail within the Construction Occupational Health, Safety and
Environmental Plan the planned roles and resources allocated for the CMRL project. In
addition to the staffing arrangements the Contractor shall prescribe the responsibilities
specific to role, accountability and the authority under which they operate.
4.4.1.2 OHS&E resources shall be provided by the Contractor as per the Contract value in table 1.
Table 1 Mandatory Contractor OHS&E management resource requirement
1 2 3 4 5 6 7
Chief Senior Junior Safety Senior Junior Public
Awarded OHS&E OHS&E OHS&E Supervisor OHS&E OHS&E Liaison
Contract Manager Manager Manager (Electrical) (Electrical) Officer
value (in (Safety Manager Manager
Cr.) Manager)
(Key Staff)
Upto 100 1 - 1 - 1 1
Upto 200 1 1 1 1
Upto 300 1 1 1
Refer
Upto 400 1 Refer 1 Refer 1
Refer Note 3
Upto 500 1 Note 2 1 Note 4 1
Note 1
More 2
1 2
than 500
8 09 10 11 12 13
Occupational Environmental Manager Senior Barricade House Labour
Health OHS&E Maintenance Keeping Welfare
Awarded
officer with (Traffic) squad squad Officer
Contract
Necessary Engineer
value (in
Male Nurse
Cr.)
(Refer Note
9)
Upto 100 1 (PT) 1 1 1
Upto 200 2 (FT) 1 2 2
Upto 300 2 (FT) 1 with Support staff 2 2
Refer Note
Upto 400 2(FT) 1 with Support staff 2 Refer Note 7 2
8
Upto 500 2(FT) 1 with Support staff 2 2
More
2(FT) 1 with Support staff 2 2
than 500
Note 1: Qualified Senior OHS&E Manager as per table 2 OHS&E Personnel Qualifications &
Experience to be deployed at each worksite at each shift.

Note 2: Qualified Junior OHS&E Manager as per table 2 OHS&E Personnel Qualifications &
Experience to be deployed at each worksite at each shift.
Note 3: Qualified Safety Steward as per table 2 OHS&E Personnel Qualifications & Experience to
be deployed at each worksite at each shift.
Note 4: Qualified Junior OHS&E (Electrical) Manager as per table 2 OHS&E Personnel
Qualifications & Experience to be deployed at each worksite at each shift.
Note 5: (PT) means Part-Time and (FT) means Full-time.
Note 6: Senior OSH&E (Traffic) Engineer Post and Barricade Manager Posts are applicable to
contracts where the work has to be executed either below or over the right-of-way like Viaduct, UG
Station, UG Tunnel Contracts wherein erection and maintenance of barricades are paramount
important.
Note 7: One Barricade Manager supported by required supervisors and workmen at each worksite
at each shift.
Note 8: One Housekeeping Manager supported by required supervisors and workmen at each
worksite at each shift.
Note 9: Qualified Male Nurse as per table 2 OHS&E Personnel Qualifications & Experience to be
deployed at each worksite at each shift.
Note 10: The Chief OHS&E Manager (Safety Manager)-Key Staff shall be a professional and
experienced manager with at least fifteen (15) years’ experience in the construction of underground
metro rail Projects with at least 10 year’s direct relevant experience in administering of OHS&E of
tunnel boring machine (TBM) and UG stations of similar scope in professional experience in
OHS&E in international projects , preferably in TBM’s tunnel background .The Chief OHS&E
Manager should have minimum five years’ experience in similar position of similar works .
Note 11: No contractor shall engage OHS&E manpower from any outsourcing agencies in which
case the effectiveness would be lost. All OHS&E manpower shall be on the payroll of the main
contractor only and not on the payroll of any subcontractor or outsourcing manpower agencies etc.
This condition does not apply to positions like traffic marshals who are engaged almost on a daily
requirement basis.
Note 12: Environmental support staff shall be Govt. recognized PG Degree / Degree in
Environmental Engineering / Science with minimum of two years of experience of similar scope of
work.
Note 13: All the OHS&E Personal Shall be in the payroll of the main contractor.
Note 14: The conduct and functioning of the contractor OHS&E personnel shall be monitored by
the Employer. Any default or deficiency shall attract penalty as per details given under penalty
clause 4.8.3 of this document.
4.4.1.3 Responsibility
4.4.1.4 The Project Director or Project Manager of the Contractor is responsible and accountable for
compliance with the conditions and clauses within this document.
4.4.1.5 The Project Director or Project Manager is responsible to ensure that the necessary
resources are allocated and made available to meet the requirements as laid out within this
document and other referenced materials to include Legal Requirements (4.3.2).
4.4.1.6 For all works carried out by the Contractor and appointed sub-Contractor’s, the responsibility
for ensuring OHS&E resources remains with the main Contractor. Activities undertaken by
the Contractor’s Sub-Contractors shall be monitored by the Contractor at all times to ensure
compliance with agreed safe systems of working.
4.4.1.7 All Contractor’s OHS&E personnel shall report to the Chief OHS&E Manager who shall report
directly to the Project Director or Project Manager or Corporate Safety manager of the
Contractor’s organisation. This shall be reflected in the Contractor’s organisation charts
within the OHS&E plan and Quality Management Plan.

4.4.1.8 The Employer /Engineer shall monitor adherence to the provisions of Table 1. Where
deviation is evident this shall be recorded as a non-conformance.
4.4.1.9 The Contractor shall provide all OHS&E personnel with such facilities, equipment and
information that are necessary to enable them to dispatch their duties effectively.
4.4.1.10The Contractor’s OHS&E Managers are responsible for ensuring that reports on the
performance of the OHS&E management system are presented to top management for
review and used as a basis for improvement of the OHS&E management system.
4.4.1.11The Contractor’s OHS&E Managers are responsible for independently monitoring the
operations of the Contractor, where deficiencies are identified they are responsible to report
their findings immediately to the Site Engineer in charge who then must take action as
directed.
4.4.1.12 Accountability
4.4.1.13 In cases where the Contractor fails to provide the minimum required manpower as illustrated
in Table 1, or fails to fill vacancies created within 30 days, the same may be provided
by the Employer /Engineer at the Contractor’s cost. Any administrative expenses involved
in providing the same for example, vacancy advertisements or recruitment consultant
charges, shall also be at the cost of Contractor.
4.4.1.14 No OHS&E personnel shall be permitted to do any work which is unconnected to,
inconsistent with or detrimental to the performance of the OHS&E duties.
4.4.1.15 Supervisors must ensure that the employees under their direct supervision are working
incompliance with the approved safe systems of working.
4.4.1.16 Authority
4.4.1.17 The Contractor’s Safety Managers, Senior OHS&E Manager and Junior OHS&E Manager
authority shall be stated within the Construction Health and Safety Plan and the authority
level must be communicated to all Contractor’s Staff including sub-Contractors.
4.4.1.18 The Contractor’s Safety Managers, Senior OHS&E Manager and Junior OHS&E Manager
Officers shall have the authority as assigned by the Project Director or Project Manager to
suspend works where deviation from an approved method of working occurs that presents a
risk of injury, equipment or property damage.
4.4.1.19 The Engineer shall have the right to stop the work at his/her sole discretion, if in his opinion
the work is being carried out in such a way that a risk of injury, property and or equipment
damage may exist. The Contractor shall not proceed with the work until remedial works
have been complied with under the direction and satisfaction of the Employer. Should the
Contractor continue to work without implementing the Engineers instruction, clause 4.4.2.2
shall be applied to the individual responsible for the decision to proceed.
4.4.1.20 The Contractor shall not be entitled to any damages or compensation for stoppage of work,
due to safety reasons. The period of such stoppages of work shall not be taken as an
extension of time for completion of the facilities and will not be the ground for waiver of levy
of liquidated damages.
4.4.1.21 The contractor shall submit Daily Dairy report (FSAF 029-Volume 2 of OH&S Manual) with
the target date for the completion of the observation to the Employer /Engineer including any
subcontractor activity of both shift. This reporting shall be the primary duty of the Chief
OHS&E Manager of the contractor and reporting shall be through email. The report should
be submitted at the end of the day of shift. If the information is not received or delay in
submission of report. Penalty shall be levied as per relevant clause.
4.4.2 Competence, training and awareness

4.4.2.1 The Contractor shall ensure that the recruitment, selection and placement processes shall
be in place to ensure that personnel are qualified, competent, and physically fit for assigned
tasks. The Contractor shall produce a procedure that shall be made available to the Employer
/Engineer for notice of no objection as per Clause 4.4.4.1.2 of this document. The procedure
shall define the processes in place to ensure competence.
4.4.2.2 Whereby any person employed thereon, who in the opinion of the Employer /Engineer ,
misconducts himself or is incompetent or negligent or fails to conform with any particular
provisions with regard to Occupational health , safety or environment which is set out in the
Contractor’s OHS&E Plan or a requirement of the Contract, or persists in any conduct which
is prejudicial to Occupational health, safety , shall be removed from site immediately, and
such persons shall not be employed again upon the Works. The decision of the Employer
/Engineer in this regard shall be final.
4.4.2.3 The Contractor OHS&E Personnel-Notice of No Objection from the Employer
/Engineer.
4.4.2.3.1 The name, educational qualifications and work experience for all OHS&E persons intended
for a Contractor’s OHS&E role shall be submitted to the to the Employer/Engineer Employer
in the format prescribed (FSAF 31-Volume 2 of OH& S Manual) for notice prior to
employment. Only upon notice of no objection by the Employer /Engineer shall OHS&E
personnel be authorised to work on a CMRL site.
4.4.2.3.2The Original certificate of degree, mark sheet, course completed certificate and work
experience shall be maintained by the Contractor and be made available for inspection and
upon request shall be submitted to the Employer/Engineer prior to employment.
4.4.2.3.3 Age Limit: Contractor’s OHS&E persons shall not be exceeding 55 years on the date of
submission of proposal.
4.4.2.3.4 The conduct and functioning of the contractor OHS&E personnel shall be monitored by the
Employer/Engineer. Any default or deficiency shall attract penalty as per details given under
penalty clause of this document.
4.4.2.3.5The Contractor OHS&E personnel permitted to work only specific contract package as per
the NONO issued by the Employer / Engineer.
4.4.2.3.6 Only approved by the Govt of India Degree from recognized university /Diploma in Safety
Engineering from State board of Technical Education and Equivalent International Degree
in Safety engineering shall be considered as the valid qualification.
4.4.2.3.7 The Project Director or Project Manager shall certify that the OHS&E staff, original certificate
of educational qualifications and work experiences are verified by him and found competent
prior to the submittal to the Employer.
4.4.2.3.8 The minimum Employer’s requirements of such facilities / equipment’s to be provided for
OSHE personnel are given in the GSAF-53 of Volume 2 of OH&S Manual
4.4.2.3.9The Contractor shall appoint the required OHS&E personnel in accordance with the
qualifications and experience as listed in Table 2.

Table 2 OHS&E Personnel Qualifications & Experience
Item Experience
Designation Qualification
(Years)
1 Chief OHS&E Manager The Chief OHS&E Manager shall be 15

qualified in any of the following
qualifications
i)M. E/ M.Tech. in Industrial Safety
ii)B.E. in Fire and Safety Engg.
iii)A recognised degree in any branch of

engineering from recognized university with
a Minimum one-year Full Time PG Diploma
/Diploma from Central labour institute /
Regional Labour Institute Mumbai /
Chennai / Kolkata /Kanpur/ Diploma in
Safety Engineering from State Board of
Technical Education
iv) A recognised degree in any branch of

engineering from recognized university
with International qualifications like CSP
(Certified Safety Professional), Diploma in
NEBOSH
2 Senior OHS&E The Senior OHS&E Manager shall be 12

Manager qualified in any of the following
qualifications

Technical Education
iv) A recognised degree in any branch

of engineering from recognized
university with International
qualifications like CSP (Certified
Safety Professional), Diploma in
NEBOSH

6 for
3 Junior OHS&E Manager The Junior OHS&E Manager shall be
qualified in any of the following
Category (i) to
qualifications
(iv)

Technical Education
iv) A recognised degree in any branch of

engineering from recognized university
with International qualifications like CSP
(Certified Safety Professional), Diploma
in NEBOSH
v)Any Graduate with 8 years of work

experience in full-fledged OHS&E
department of any Public Sector / Leading
Private Sector / MNC / with prior approval
of Employer /Engineer on a case to case
basis
i)Degree in Science / Diploma in 3 for

4 Safety Supervisor
Engineering with Govt. recognized safety
Category (i)
diplomas from National and State
Productivity Councils, Other State
Technical Education Boards etc.
ii)Any Graduate with 5 years of work

experience in full-fledged OHS&E
department of any Public Sector / Leading
Private Sector / MNC / with prior approval
of Employer /Engineer on a case to case
basis
5 Senior OHS&E Degree in Electrical Engineering + Govt.
2
Electrical Manager Recognized Electrical “C” Licence holder
6 Junior OHS&E Electrical Degree in Electrical Engineering + Govt.

1
Manager Recognized Electrical “C” Licence holder
7 Public Liaison officer Any Degree with Govt. Recognized Degree

5
/ Diploma / P G Diploma in Labour Welfare
related fields like Law, Personnel / Industrial
Relations etc.
8 Occupational MBBS with Govt. recognized
1
degree/diploma in Industrial/ occupational

Health Officer health
9 Male Nurse Any Degree with Govt. Recognized Degree

1
/ Diploma / P G Diploma in in Nursing
10 Environmental Manager Govt. recognized PG Degree / Degree in

5
Environmental Engineering / Environmental
Science
11 Senior Traffic Engineer Govt. recognized PG Degree / Degree /
1
Diploma in Traffic/Transportation
Engineering or Planning
12 House Keeping Any Diploma in Engineering
1
Manager
13 Barricade Manager Any Diploma in Engineering

1
14 Labour Welfare Officer Any Degree with Govt. Recognized Degree

5
/ Diploma / P G Diploma in Labour Welfare
related fields like Law, Personnel / Industrial
Relations etc.
Note: In some extraordinary cases where the candidate had earlier worked in CMRL Projects they
can be considered for the following posts:
i)Junior OHS&E Manager
ii)Safety Steward
depending upon the qualification and no. of years of experience on a case to case basis
even if they do not possess the prescribed qualification as listed above.
4.4.2.3.10Where a p o t e n t i a l candidate has previously worked in a Metro Rail construction
environment and does not possess the qualifications and or the necessary experience as
listed in Table 2 for the particular role, the Employer/ Engineer may upon a successful
interview of the candidate grant a waiver subject to successful completion of a probation
period of 3 months..
4.4.2.3.11In order to effectively interact on labour welfare matters with the Employer /Engineer? and
the statutory authorities enforcing the labour welfare legislations every Contractor shall
employ a full time Labour Welfare Officer duly qualified and experienced as per clause
4.4.2.3.12.The Contractor shall ensure that all personnel working at the site receive an induction
OHS&E training explaining the nature of the work, reporting & communication routes the
hazards that may be encountered during the site work and the particular hazards attached
to their own function within the operation. The training shall cover as a minimum the contents
as directed within OH&S Manual Volume 2.
4.4.2.3.13Records of all inductions shall be maintained by the Contractor and be made available for
inspection by the Employer /Engineer upon request.
4.4.2.3.14The Contractor shall provide their workforce and management staff with an OHS&E
induction Handbook containing the information as per the induction training.
4.4.2.3.15A condensed induction shall be given by the Contractor to all visitors. The induction briefing
shall include the risk and hazards associated with the particular site and the operations being
conducted.
4.4.2.3.16All personnel shall be issued a temporary ID upon the completion of the Contractor’s’
induction. The temporary ID shall be signed by the Human Resource Manager or appointed

representative and limited to a 2 week validity period at which time the temporary ID shall be
replaced with a permanent ID including photograph.
4.4.2.3.17Individuals found on site by the Employer /Engineer without-dated temporary ID cards shall
be removed from site
4.4.2.4 OHS&E Training
4.4.2.4.1 The Contractor shall assess the training requirements for all the employees, plan and
initiate a training program to fulfil the training needs assessment. The assessment of
training needs shall incorporate all levels of staff including Sub-Contractor’s against an
individual’s role, responsibility, ability, language skill and risk.
4.4.2.4.2 The Contractor shall provide comprehensive training to all staff as mentioned in OHS& E
conditions of contract
4.4.2.4.3 The Training Plan shall provide a structured training programme to educate and train all
the personnel of the contractor in Safety aspects of all Construction activities. The training
plan can contain:
I. Objective, syllabus, format, class size and duration of each training course;
II. Training facilities to be provided by the Contractor;
III. List of training materials and documentation to be included with the training
course; and to be circulated in booklet format to each trainee
IV. Method of pre- and post- testing to be utilised;
V. Qualifications and experience level necessary for the trainees;
VI. Instructor’s qualifications; and Course evaluation methods.
VII. Training shall be carried out in the medium of the Hindi, English & Local
language and supplemented, if necessary, in other Language
VIII. Training shall consist of classroom (theory) training, and practical (hands on)
training wherever necessary.
IX. To meet this need, the training agency shall supply competent
trainers/instructors to carry out training to a high degree of proficiency in
areas where the trainer has the specialised knowledge.
X. In order to ensure that satisfactory standards are met, the contractor’s
relevant Training Department will monitor all training.
4.4.2.4.4The Contractor shall, at the conclusion of each training session, issue questionnaires to,
and/or set practical tests for all trainees directed at determining the level of satisfaction with
the course content and to assess the level of knowledge and understanding of the course
content by each trainee. Five Questions from each training module are to be selected and
assessment is to be conducted at the end of days training session.
4.4.2.4.5The Contractor shall review the responses to questionnaires and the trainees’ test results and
forward a summary to the Employer /Engineer.
4.4.2.4.6Trainees failing to achieve a minimum passing percentage of 40 percent will be regarded as
fail and retraining will be again given to trainee
4.4.2.4.7If the Employer /Engineer considers that the course has not achieved the required objectives,
he will instruct the Contractor who shall then organise and implement appropriate re-training.
4.4.2.4.8The Contractor shall, at the completion of each training course. A consolidated training record
listing the training course title, date of training, name of all trainees, training result and other
relevant information; and Issue an appropriate certificate to each trainee who has
successfully completed the course. He should issue the sticker for each completion of
Course.
4.4.2.4.9The Contractor shall produce a ‘Training Implementation Plan’ to incorporate the findings of
the needs assessment.
4.4.2.4.10The training needs assessment together with Implementation Plan shall be submitted to the
Employer /Engineer for notice of no objection within 4 weeks of commencement. The
Employer /Engineer shall evaluate the assessment and plan against the base line training
matrix contained within OH&S Manual Volume 2.

4.4.2.4.11Records of all training conducted shall be maintained and made available for inspection by
the Employer /Engineer upon request.
4.4.2.4.12Should the Contractor fail to provide the training identified within the Contractor’s
assessment, implementation plan and the Employer /Engineer Training matrix within the
agreed timescales, this shall be reflected in the potential scores awarded within the monthly
audit report.
4.4.2.4.13Specific training with regard to the provisions of the Construction Safety Plan, and
associated operational and system procedures shall be conducted by the Contractor for all
persons with supervision responsibilities. Records of training including duration shall be
maintained.
4.4.2.4.14All the Management training should be completed within six months from the date of the
contract awarded
4.4.2.4.15Contractors and sub-contractors are responsible for providing OHS&E training through
CMRL approved agency shall conduct training as per the training Implementation Plan to all
Staff and workers and for retention of records of such activities for inspection by the
Employer /Engineer.
4.4.2.4.16The Profile of the External OHS&E Agency (Training, Inspection and Testing) ISO
certifications, course details, the name, educational qualifications and experience for of the
trainers are to be submitted to the Employer/Engineer a minimum 28 days before prior to
appointment of the agency. Only upon notice of no objection by the Employer /Engineer shall
be authorised to deliver OHS&E Services on CMRL sites.
4.4.3 Communication, participation and consultation
4.4.3.1 Communication
4.4.3.1.1 The Contractor shall produce a ‘High Quality’ quarterly newsletter on a rotational basis with
other Contractors. Rotation shall be announced within the Employer /Engineer OHS&E
Committee meetings.
4.4.3.1.2 All Contractors including the Employer /Engineer shall provide input into the rotational
Contractor for the newsletter content such as details of accidents, incidents and near misses
together with any lessons learned; specific safety initiatives; internal competitions and
workforce awards etc.
4.4.3.1.3 The Employer /Engineer shall be issued the draft newsletter for review prior to the
Contractor’s publishing.
4.4.3.1.4 The OHS&E Newsletters shall publicise all Contractors OHS&E performances over the
previous 3 months in relation to OHS&E Audits and shall form the basis for the Employer
/Engineer Awards programme. Results of audits shall be provided by the Employer
/Engineer for inclusion.
4.4.3.1.5 The quarterly newsletters shall be issued to all interested parties and be promulgated at site
level. Where language barriers exists the contents of the newsletters shall be communicated
by the Workforce Representative to ensure understanding.
4.4.3.1.6 At site level the Contractor shall erect pertinent awareness signage and posters. Posters
shall be changed on a monthly basis to maintain impact.
4.4.3.1.7 Poster campaigns shall be discussed and agreed at the Employer /Engineer Committee
Meeting to maintain a consistent improvement programme across all CMRL Sites.
4.4.3.1.8 Informational posters, banners etc shall be provided in Hindi, Tamil and English.
4.4.3.1.9 Toolbox talks and Method statement , Risk Assessment , Task briefings shall be carried out
daily by the Contractor and correspond to the works activities being undertaken or to
communicate a specific awareness initiative. Toolbox talks shall not replace professional
training.

4.4.3.1.10 Records of all toolbox talks and Method statement, Risk Assessment , Task briefings
undertaken together with the date, topic, participant’s names and signatures shall be
maintained and made available for inspection by the Employer /Engineer .
4.4.3.1.11 Method statement and risk assessment briefings shall be carried out prior to the
commencement of a new task and or when a change to the method of working arises.
Records of all such briefings shall be maintained by the Contractor.
4.4.3.1.12 Visitor information signage shall be posted at site entrances detailing where to report and
contact information. Note: visitors shall be accompanied at all times by site security where
office locations require walking through operational areas.
4.4.3.1.13 Job specific poster, OHS&E policy statement, Employer’s Liability Insurance certificate,
Protective Equipment, Reversing Vehicles, Emergency procedure, Project Wages notice
board, BOCWR registration Licence, Labour licences, Insurance policies and Site rules shall
be displayed in the site entrance’s and site office’s
4.4.3.1.14 Public Liaison
4.4.3.1.15 Public informational signage and Contractor contact information shall be posted externally
to the site.
4.4.3.1.16 The Contractor shall appoint an individual as a Public liaison Officer to communicate directly
with members of the public regarding forthcoming operations, what to expect, noise
expectancy, duration of operations etc.
4.4.3.2 Participation and consultation
4.4.3.2.1. The Contractor shall establish a Safety Committee within 4 weeks of commencement that
shall be chaired by the Contractor’s Project Director.
4.4.3.2.2 The Contractor shall notify the Employer /Engineer of the establishment of the Committee
together with the committee members’ names and designation. The Contractor’s Chief Safety
Manager, Senior Safety Manager, Plant & procurement Manager and Human Resources
Manager shall form the minimum committee members. Site based personal shall be
represented within the Committee by the attendance of Site Manager(s) and the Workforce
OHS&E Representative.
4.4.3.2.3 The Employer /Engineer shall be invited to attend the Contractor’s Safety Committee
meetings.
4.4.3.2.4 The Contractor’s OHS&E Committee shall meet on a monthly basis throughout the duration
of the Contract.
4.4.3.2.5 The Terms of Reference for the Contractor’s OHS&E Committee shall be as follows;
i) To establish company safety policies and practices
ii) To monitor the adequacy of the contractor’s site OHS&E plan and ensure its
implementation
iii) To review OHS&E training
iv) To review the contractor’s monthly OHS&E report.
v) To identify probable causes of accident and unsafe practices in building or other

construction work and to suggest remedial measures.
vi) To stimulate interest of Employer/Engineer and building workers in safety by
organizing safety week, safety competitions, talks and film-shows on safety,
preparing posters or taking similar other measures as and when required or as
necessary.
vii) To tour round the construction site with a view to check unsafe practices and
detect unsafe conditions and to recommend remedial measures for their

rectifications including first-aid medical and welfare facilities.
viii) Committee team members should perform a site inspection before every
committee meetings and to monitor OHS&E inspection reports.
ix) To bring to the notice of the Employer /Engineer Employer the hazards associated
with use, handling and maintenance of the equipment used during the course of
building and other construction work.
x) To suggest measures for improving welfare amenities in the construction site and
other miscellaneous aspect of safety, health and welfare in building or other
construction work.
xi) To look into the health hazards associated with handling different types of
explosives, chemicals and other construction materials and to suggest remedial
measures including personal protective equipment.
xii) To review the last safety committee meeting minutes and to take action against
persons/sub-contractors for non-compliance if any.
4.4.3.2.6 The inspection shall review progress regarding the achievement of short term targets. The
Committee shall produce a report stating progress made together with any corrective actions
required and issue to the Employer /Engineer within 7 days following the Inspection.
4.4.3.2.7 Minutes of the Committee meeting shall be issued within 2 days and promulgated to all
members including the Employer /Engineer . The minutes of meeting shall also be posted on
all sites within the workforce area. The minutes intended for site communication shall be in
Hindi, Tamil and English.
4.4.3.3 Employer /Engineer OHS&E Committee
4.4.3.3.1 A Occupational health , safety and Environmental Committee shall be established by the
Employer /Engineer and shall sit every months throughout the project period. All Contractors
shall be required to attend the monthly meetings who shall be represented by their Project
director or Project Manager , Corporate Safety Manager and Chief Safety Manager.
4.4.3.3.2 The Committee shall review previous performances project wide and set short and medium
term objectives and targets for achievement within the next reporting period.
4.4.3.3.3 The Employer /Engineer reserves the right to call an Emergency Meeting of the Committee
members in the event of a serious incident that requires immediate change to the operational
methods of working.
4.4.3.3.4 Minutes of the Employer /Engineer OHS&E Committee shall be promulgated to all
Contractor’s within 3 days.
4.4.3.4 Workforce Representation
4.4.3.4.1 All workers shall have access to a Workforce OHS&E Representative who is responsible to
communicate directly with the labour force with regard to Occupational health and safety .
The representative’s name and contact number shall be posted on all sites externally to the
site office.
4.4.3.4.2 The Workforce OHS&E Representative shall be made a member of the OHS&E Committee
(FSAF 025 of OH&S Manual -Volume 2) and attend all meetings.
4.4.3.4.3 The OHS&E Representative shall meet the labour force on a monthly basis to discuss health,
welfare, safety initiatives and or concerns the workforce may have. Minutes (FSAF 026 of
OH&S Manual -Volume 2) are to be produced by the Representative and issued formally
within 2 days after the meeting date to the Contractor’s Project Director or Project Manager
and Employer /Engineer .

4.4.3.4.4The chairman shall inform the members of any outstanding issues in the meeting and in case
of repeated offence/ non-compliance by some members or other co/sub-contractors and
propose suitable disciplinary action including provisions of monitory penalty as per the
relevant contract clauses, the Engineer shall ensure that the same is implemented.
4.4.3.4.5 A lockable site suggestion box to which only the workforce OHS&E Representative shall have
access shall be installed on all sites and within any labour accommodation camps. The
suggestion box shall be located independent from any offices, in a public area and protected
from bad weather. The OHS&E Representative shall inform the workforce that the purpose
of the suggestion box is to provide a means of participation, communicating ideas and
initiatives and also for raising concerns without fear of reprisal.
4.4.3.4.6 The contents of all suggestion boxes shall be collected and collated on a weekly basis. Where
concerns or complaints regarding the standards of health, safety or welfare have been
reported these shall be immediately reported to the Chief OHS&E Manager and Project
Manager who shall investigate the concern(s). Records of such investigations and resultant
outcomes shall be maintained.
4.4.3.4.7 Ideas, suggestions and concerns raised by the workforce during the OHS&E representative’s
on site monthly meetings shall form an agenda item within the Contractor’s OHS&E
Committee meeting.
4.4.3.4.8 Where an idea or specific suggestion is subsequently adopted for use by the Contractor’s
OHS&E Committee, the individual shall receive an OHS&E award as determined by the
Contractor.
4.4.3.4.9 Where Employee awards are issued this shall be notified to the Employer /Engineer to ensure
inclusion within the Quarterly Newsletter.
4.4.3.5 Contractor Awards
4.4.3.5.1 The Employer/Employer’s Representative shall recognize the effort, participation and
commitment demonstrated by the Contractor by nominating awards. The award type shall
be at the discretion of the Employer.
4.4.4 Documentation
4.4.4.1 Management System procedures
4.4.4.1.2 The Contractor is required to submit for notice of no objection, the organisation’s top tier
Management System Procedures as listed in Table 3 that shall be adopted for use on the
CMRL project.
4.4.4.1.3 System procedures shall be submitted to the Employer /Engineer within 4 weeks of
commencement.
4.4.4.1.4 Construction works shall not commence until such time as a notice of no objection has been
received; applicable to all management system procedures as listed in Table 3. Should the
Contractor commence operations on site without notice, the Employer /Engineer shall award
a ‘Zero’ audit score for every month of non-compliance with this clause.
4.4.4.1.5 The Employer /Engineer shall evaluate the suitability of the Contractor’s system procedures
against the ISO 45001:2018 and ISO 14001:2015 standards.
4.4.4.1.6 The submitted procedures shall be individually identified with a unique reference and detail
in sequence the scope, purpose, referenced material and procedure processes.
4.4.4.1.7 Where such procedures as listed in Table 3 exist within other areas of the Contractor’s
organisational management systems such as quality management, these shall not be subject
to replication if the procedure makes specific reference to Occupational Health , Safety and
Environmental control.
4.4.4.1.8 Compliance standards against the Contractor’s management system procedures shall be
subject to audit by the Employer /Engineer.

Table 3 OHS&E Management System Procedures

Hazard identification, Communication,
Environmental Impact Objectives and
risk assessment and participation &
Aspect Assessment programme(s)
determining controls consultation
Training, awareness Implementation and Accident & Incident

Legal requirements
and competence operation Investigation
Monitoring & Emergency

Documentation Change control
Measurement Preparedness
Procurement Record keeping Audit Management review
4.4.5 Control of documents

4.4.5.1 All plans, procedures and method statements shall be controlled and subject to review and
formal approval by the Contractor’s Project Director prior to issue to the Employer /Engineer
4.4.5.2 All documents subject to review by the Employer /Engineer shall be signed by the
Contractor’s Construction Manager , Safety Manager and Project Director and issued
formally.
4.4.5.3 Documents shall be issued as per the Employer /Engineer requirements regarding Quality
Management.
4.4.5.4 OHS&E Documents shall be issued, maintained, traceable and available for retrieval
pursuant to the Contractor’s ISO accredited Quality Management System.
4.4.6 Operational control
4.4.6.1 Operational control shall be maintained through the implementation of the provisions stated
within the Contractor’s site specific Construction Occupational Health , Safety and
Environmental Plans, the contents of which are outlined in Occupational Health , Safety and
Environmental Volumes 2 and 3 and Tunnelling Volume 4 to which the Contractor shall
comply.
4.4.6.2 Construction Phase Safety Plan
4.4.6.2.1 The Contractor shall produce a Contract specific Construction Safety Plan and submit to the
Employer /Engineer within 28 days of commencement.
4.4.6.2.2 The Construction Safety Plan shall contain the informational requirements as per the CSP
contents as prescript within the CMRL OH&S Manual Volume 2, Safety Plan contents.
4.4.6.2.3 The CHSP shall be assessed by the Employer /Engineer against the provisions as stated
within OH&S Manual Volume 2. Where deficiencies exist to an extent where an objection is
raised, construction activities shall be suspended until such time as the deficiencies are
subject to corrective action, re-submittal and notice of no objection by the
Employer/Engineer.
4.4.6.2.4 Delays incurred as a result of the Contractor failing to achieve a ‘No objection’ status from
failing to submit within the specified timescale or non-compliance with OHS&E Volume 2
shall be entirely at the Contractor’s risk and cost.
4.4.6.2.5 The Contractor shall undertake a monthly review of the CSP. The review shall be recorded
and the Employer /Engineer notified of any updates.
4.4.6.2.6 The Contractor shall produce a Contract Specific Fire Evacuation plan and submit to the
4.4.6.2.7 The Contractor shall produce a Contract Specific Construction OHS&E tunnel plan and
submit to the Employer /Engineer within 28 days of commencement.

4.4.6.2.8 The Contractor shall produce a Contract Specific Construction contingency plan and submit
to the Employer /Engineer within 28 days of commencement.
4.4.6.2.9 The Contractor shall produce a Contract Specific Construction Health Plan and submit to the
4.4.6.2.10The Contractor shall produce a Contract Specific Traffic Management Plan and submit to
the Employer /Engineer within 28 days of commencement.
4.4.6.2.11The Contractor shall produce a Contract Specific Disaster Management Plan and submit
4.4.6.2.12The Contractor shall, from time to time and as necessary are required by the
Employer/Engineer to produce supplements to the OHS&E Plan such that it is at all times
a detailed, comprehensive and contemporaneous statement by the Contractor of his site
safety, industrial health and environment obligations, responsibilities, policies and
procedures relating to work on Site. Any and all submissions of supplements to the OHS&E
Plan shall be made to the Employer /Engineer in accordance with the agreed procedures.
4.4.6.2.13If at any time the OHS&E plan is, in the Employer /Engineer opinion, insufficient or requires
revision or modification to ensure the security of the Works and the safety of all workmen
upon and visitors to the Site, the Employer/Engineer may instruct the Contractor to revise
the OHS&E plan and the Contractor shall within 7 days submit the revised plan to the
Employer/Engineer for review.
4.4.6.2.14Any omissions, inconsistencies and errors in the OHS&E Plan or the Employer /Engineer
acceptance or rejection of the OHS&E Plan and/or supplements thereto shall be without
prejudice to the Contractor's obligations with respect to site safety, industrial health and
environment and shall not excuse any failure by the contractor to adopt proper and
recognised safety practices throughout the execution of the Work.
4.4.6.2.15The Contractor shall adhere to the OHS&E Plan and shall ensure, as far as practically
possible, that all sub-contractors of all tiers require that contracting parties each have a copy
of the Site OHS&E Plan and comply with its provisions
4.4.6.2.16The Contractor shall produce a Contract Specific Construction OHS&E new Austrian
tunnelling method (NATM)Plan and submit to the Employer /Engineer within 28 days of
commencement.
4.4.6.2.17The Contractor shall produce a Contract Specific transportation Plan and Risk assessment
and submit to the Employer /Engineer within 28 days of commencement.
4.4.6.3 Construction Phase Site Environmental Plan
4.4.6.3.1 The Contractor shall produce a Contract Specific Site Environmental Plan (SEP) and submit
4.4.6.3.2 The Site Environmental Plan (SEP) shall contain the informational requirements as per the
contents as prescript within the CMRL Environmental Management Arrangements Volume
3, Environmental Plan contents.
4.4.6.3.3 The SEP shall be assessed by the Employer /Engineer against the provisions as stated
within the Environmental Management Arrangements Volume 3. Where deficiencies exist to
an extent where an objection is raised, construction activities shall be suspended until such
time as the deficiencies are subject to corrective action, re-submittal and notice of no
objection by the Employer /Engineer .
4.4.6.3.4 Delays incurred as a result of the Contractor failing to achieve a ‘No objection’ status from
failing to submit within the specified timescale or non-compliance with Environmental
Management Arrangements Volume 3 shall be entirely at the Contractor’s risk and cost.
4.4.6.3.5 The Contractor shall undertake a monthly review of the SEP. The review shall be recorded

and the Employer /Engineer notified of any updates.
4.4.6.4 Operational procedures
4.4.6.4.1 The Contractor shall identify within the Hazard Log and Risk Register the operational control
procedures that shall be applicable for the CMRL project under their individual scope of
works.
4.4.6.4.2 Operational procedures shall be submitted for review to the Employer /Engineer for notice of
no objection together with the Construction Site Safety Plan within 4 weeks of
commencement.
4.4.6.4.3 The operational procedures shall be evaluated by the Employer /Engineer against the
requirements stated within OH&S Manual Volume 2, international safety standards such as
the International Labour Organisation, European Norms and British Standards where an
equivalent Indian Standard does not exist.
4.4.6.4.4 Construction works shall not commence until such time as a notice of no objection has been
received; applicable to all operational procedures as identified within Table 4 and the
Contractor’s Hazard Log & Risk Register. Should the Contractor commence operations on
site without notice, the Employer /Engineer shall award a ‘Zero’ audit score for every month
of non-compliance with this clause.
4.4.6.4.5 The submitted procedures shall be individually identified with a unique reference and detail
in sequence the scope, purpose, referenced material and procedure processes.
4.4.6.4.6 In the event that the Contractor is unable to comply with the 28 day timeframe for submittal
of the minimum operational procedures as detailed within Table 4, the Contractor shall
assign an individual identification reference for the outstanding procedure within the
Construction Health, Safety & Environmental Plan together with the statement ‘Under
process’. The ‘Under Process’ procedure shall be required to be submitted for notice of no
objection a minimum of 28 days prior to commencement of any activity that involves the
application of the procedure.
Table 4 Operational Procedures
Lifting Operations & Occupational Health Emergency Medical

Plant & Equipment
Lifting Equipment provisions Facilities & First Aid
Personal Protective Permit to Work Site Electricity & Welding & Cutting
Equipment Systems Distribution operations
Hazardous
Incident Investigation Traffic Management Working at Height
Substances
Site Security Fire Safety Manual Handling Site Set-up
Welfare
Abrasive Wheels Public Interface Noise and Vibration
Arrangements
4.4.6.4.7 The Contractor shall adopt the following colour code scheme across all CMRL Sites to ensure
efficient recognition of relevant personnel.
Safety Helmet
Designation
Colour with Logo

White CMRL Staff and Engineer
Violet Contractor’s Engineers & Supervisors
Blue Sub-Contractor’s Engineers & Supervisors
Red All Electricians
Green Safety personnel
Orange Security Guards & Traffic Marshals
Yellow General Workforce
White (With Visitors

VISITOR Sticker)
4.4.6.4.8 The PPE and safety appliances provided by the contractor shall be of the standard as
prescribed by Bureau of Indian Standards (BIS). The contractor shall obtain prior approval
by the Employer /Engineer Employer before procurement of PPE and safety appliances.
4.4.6.4.9 The contractor shall at all-time maintain a minimum of 10% spare PPE and safety
appliance stock. Stocks are to be recorded and made available for the Employer /Engineer
upon request. Failing to do so shall invite appropriate penalty as per the provisions of the
contract.
4.4.7 Emergency preparedness and response
4.4.7.1 Emergency Response Plan
4.4.7.1.1 The Contractor shall prepare a project specific Emergency Plan and submit to the Employer
/Engineer for notice of no objection. The Emergency Plan shall be submitted within 4 weeks
of contract Commencement.
4.4.7.1.2 The plan must identify the potential for emergencies and the provisions for responding to
such emergencies, particular to their environment and location. The Emergency planning
arrangements shall be assessed as per the provisions in OH&S Manual Volume 2 for
suitability.
4.4.7.1.3 The Contractor shall ensure that all persons including sub-Contractors on site are aware of
the emergency procedure to follow in the event of an emergency. Awareness training shall
commence at induction and thereafter through refresher training such as toolbox talks and
monthly emergency drills. Records of refresher training and emergency drills shall be
maintained.
4.4.7.1.4 Site signage shall be erected and detail the emergency process to follow and include
emergency telephone numbers, fire, ambulance, police, nearest hospital etc.
4.4.7.1.5 Arrangements shall be made by the Contractor for casualty evacuation and emergency
medical treatment. The Contractor shall enter into an agreement with a hospital to provide
ambulance services. Alternatively, the Contractor shall provide a fully equipped ambulance
on-site that shall be manned by a paramedic. This provision shall be subject to the Employer
/Engineer audit.
4.5 Checking
4.5.1 Performance measurement and monitoring
4.5.1.1 The Contractor shall submit a Monthly OHS&E Progress Report no later than 7th of each
month to the Employer /Engineer . The Report shall contain the minimum information

specified within OH&S Manual Volume 2. The report shall contain text, tables and colour
photographs.
4.5.1.2 Site Inspection
4.5.1.3 Independent of the plant and equipment inspection, testing and maintenance regimes that
shall be stated within the Contractor’s Plant and Equipment Procedures, the Contractor shall
carry out site monitoring exercises on a daily and weekly basis.
4.5.1.4 The Contractor shall ensure that all monitoring equipment is calibrated as per the
manufactures requirements. The Employer /Engineer shall be provided with test certificates
for such equipment
4.5.1.5 Site Engineers shall be required to participate in daily internal OHS&E inspections to facilitate
prompt communication and rectification of minor deviations. Records of such inspections and
rectification needs shall be maintained at site level and made available for review by the
Employer /Engineer other interested parties.
4.5.1.6 No loose electrical connections or tapped joints shall be allowed any where in the work site,
office area, stores and other areas. Penalty as per relevant clause shall be put in case of
observation of any tapped joints.
4.5.1.7 Formal site inspection reports shall be produced on a weekly basis by the Contractor’s
OHS&E personnel for each site and submitted to the Project Director or project manager and
copied to the Contractor’s corporate safety manager. The corporate Safety Manager shall
conduct site inspection on monthly basis and report shall be submitted to the Employer
/Engineer.
4.5.1.8 The Contractor may choose inspection format of his/her choice, however format shall contain
the minimum information as provided within FSAF-028 –OH&S Manual Volume 2 regarding
weekly inspection form.
4.5.1.9 The Contractor’s OHS&E Personnel shall be accompanied during a formal site inspection by
the Site Manager responsible for the particular site. The resulting inspection report shall be
signed by both the Site Manager and the OHS&E Manager.
4.5.1.10The Engineer shall formally inspect and report the Contractor’s site conditions against the
compliance criteria set within the Contractor’s operational procedures and the Engineer’s
requirements on a weekly basis. These inspections shall include batching plant and
associated yards.
4.5.1.11The Contractor shall undertake specific inspections at the Employer/Employer’s
Representative’s request where concerns have been raised regarding the suitability of
control measures and or plant or equipment condition as per the IS 13367-1 (1992), IS
14475-1(1997), ISO 12482-1:1995. The special assessment shall be carried out later
than the following number of years after manufacture for:
-Tower cranes, loader cranes, mobile cranes: 10 years;
-All other cranes: 20 years. Such inspections shall be carried out with immediate effect.
4.5.1.12The Profile of the External Inspection agency, ISO certifications, the name, educational
qualifications and experience in the field of testing and the certificate issued by Govt of Tamil
Nadu for testing are to be submitted to the Employer/Engineer a minimum 28 days before
prior to appointment of the agency. Only upon notice of no objection by the Employer
/Engineer shall be authorised to deliver OHS&E services on CMRL sites.
4.5.1.13 The First Generation Hydra crane shall not be strictly used in the CMRL projects.
4.5.1.14The Second Generation Hydra crane shall not be used for any lifting and lowering operation.
Second Generation Hydra can be used for the material handling as per the manufacture
manual.
4.5.1.15 The Piling rig shall not be used as lifting equipment.
4.5.1.16 Water logging or bentonite spillage on roads shall not be allowed. If bentonite spillage is
observed on road endangering the safety of road users, the contractor shall be

penalised as per Table -6.
4.5.1.17The contractor shall submit an electrical single line diagram, schematic diagram and the
details of the equipment for all temporary electrical installation. These diagrams together with
the temporary electrical equipment shall be submitted to the Employer /Engineer for
necessary approval. Failure to do so shall invite penalty as per relevant clause
4.5.1.18CCTV shall be installed in Administrative areas, Construction areas (general indoor, general
outdoor, tunnel and general underground work areas, mucking and scaling), Maintenance / Operating
areas, Mechanical/electrical equipment rooms, Warehouses and storage rooms/area, Casting yard,
Labour Colony, Health Centres and First aid stations and infirmaries, Parking areas, Visitor areas and
Laboratories. The contractor shall submit the CCTV installation and monitoring plan to
Employer /Engineer.
4.5.1.19Request for inspection form all High risk activity shall be verified by the Chief OHS&E
Manager before submitting to the Employer.
4.5.1.20Failure to do any of the above shall attract penalty from the Employer /Engineer as per
relevant clause.
4.5.2 Evaluation of compliance
4.5.2.1 The information submitted by the Contractor within the OHS&E Monthly Progress Report
together with the Engineers Reports shall be evaluated against the Employer’s compliance
requirements and OHS&E objectives.
4.5.2.2 Inspection reports shall be evaluated against the Legal Requirements (4.3.2) to which the
Contractor is bound to comply.
4.5.2.3 The Contractor’s OHS&E Committee shall formally evaluate reports and results of accidents
and or injury on a monthly basis. The results of this evaluation such as identified changes to
safe systems of working’ shall be included with the Committee minutes
4.5.2.4 The Engineer shall evaluate ‘Accident Injury Rates’ and ‘Frequency Rates’ per individual
Contractor and as a project to determine performance against the international rates. The
international rates used to benchmark performance shall be promulgated to all Contractor’s
and other interested parties.
4.5.2.5 A Project Monthly Progress Report shall be produced by the Engineer. Evaluation results
shall be included within the relevant sections for Health Safety & the Environment.
4.5.2.6 The Contractor’s External OHS&E Audits (4.5.5) shall be evaluated by the Employer
/Engineer against the internal Standards ISO 45001:2018 and ISO 14001:2015.
4.5.3 Incident investigation, nonconformity, corrective action and preventive

action
4.5.3.1 Incident investigation
4.5.3.1.1 The Contractor shall undertake accident investigation for all fatal accidents, major injuries
and dangerous occurrences as defined within the Employer’s Project OHS&E VOL 2.
4.5.3.1.2 In the event of a fatality, major injury or dangerous occurrence, the Contractor shall not
disturb the accident scene or remove equipment beyond that required to make the area safe
and/or for the treatment and/or removal of casualty(s) to hospital.
4.5.3.1.3 Should the Employer /Engineer find an accident scene disturbed beyond that reasonably
expected with making an area safe, this shall be subject to thorough investigation by the
Employer /Engineer .
4.5.3.1.4 The Employer /Engineer shall be informed immediately via Short Message Service or Email
of all fatalities, major injuries or dangerous occurrences. Any delay in reporting to the
Employer /Engineer may be subject to disciplinary action.
4.5.3.1.5 The Contractor is responsible to report accidents, incidents and dangerous occurrences to

the relevant governing bodies as per their statutory obligations. The Contractor shall maintain
responsibility for ensuring sub-Contractor’s under their direct control also comply with this
requirement.
4.5.3.1.6 A preliminary accident notification report shall be issued to the Employer /Engineer for all
fatal and major injuries and or dangerous occurrences within 24 hours as per OH&S Manual
Volume 2. This shall be followed by the detailed investigation report shall be issued to the
Employer /Engineer within 72 hours.
4.5.3.1.7 Any wilful delay in verbal or written reporting to the Employer /Engineer shall be penalised
as per relevant clause.
4.5.3.1.8 Near misses and minor accidents should also be investigated by the Contractor as soon as
possible as they are signals that there are inadequacies in the safety management system.
4.5.3.1.9 In case of fatal accidents, major injuries or dangerous occurrences the Employer /Engineer
shall conduct an independent investigation. The Contractor and his staff shall extend the
necessary co-operation.
4.5.3.1.10All persons summoned by the Employer /Engineer in connection to witnesses and statement
recording shall obey the instructions without delay. Any wilful suppression of information by
any person shall be removed from the site immediately and / or punishable as per relevant
penalty clause
4.5.3.2 Nonconformity, corrective action and preventive action
4.5.3.2.1 The Contractor shall conform to their internal procedures regarding nonconformity, corrective
action and preventive action. The Contractor shall be audited by the Employer /Engineer for
compliance with internal procedures.
4.5.3.2.2 Major and Minor non-conformances shall be raised by the Employer /Engineer as per the
Employer’s Quality Management requirements and the OHS&E Audit criteria as defined
within OH&S Manual Volume 2.
4.5.3.2.3 Open non-conformances shall be reflected in the Contractor’s Monthly Audit Report and are
subject to verification by the Employer /Engineer as detailed in OHS&E Volume 2. Failure to
successfully take corrective action and close out non-conformances will impact negatively on
the Contractor’s total quarterly audit score.
4.5.3.2.4 Where non-conformances have been raised by an External Auditor against the ISO
45001:2018 or ISO 14001 Standard, the Contractor shall produce and submit for review
within 2 weeks, an action plan of how and within what timescale shall the non-conformance(s)
be closed-out.
4.5.3.2.5 Where the corrective action and preventive action identifies new or changed hazards or the
need for new or changed controls, the proposed actions shall be taken through the risk
assessment process. The associated method statement and risk assessment shall be
amended and re-submitted to the Employer /Engineer for notice of no objection.
4.5.3.2.5 A change in work methodology shall be communicated to the workforce. Evidence of such
communications shall be made available for inspection by the Employer /Engineer . The
Employer /Engineer shall also make random enquiries at site level to establish workforce
awareness.
4.5.3.2.6 The following table indicates the risk rating for the non-compliance of the requirements
(unsafe acts/unsafe conditions).
Risk Topic Deductible amount
High Explosive Handling and Blasting , Plant & Any specific high risk activity non-
Machinery(Examination certificate of conformance (unsafe act/unsafe
Gantry crane, rope suspended powered condition) shall be immediately
platform, tractor mounted drilling rig ,No complied by taking corrective
legal documents, Erection/lifting mast, action by as low as reasonably

wire rope/web sling/dog clamp/chain practicable and specific high risk
pulley, rope pulley , air compressor, activity non-conformance work
Electrical trolley OTE duct installation ), shall be suspended until the
Equipment(Guarding arrangements , corrective actioned.
Excavations(Shoring, edge, material
stored on the edge of the excavation
protection) , Electrics , Work at
Height(Edge protection, fall protection
measures , Ladder , life line , working
platform, safe access/egress, double layer
net, provision of safety net, leading edge
protection ) , Floor Opening , Confined
Space ,Tunnelling Operations(Emergency
lighting ,Emergency preparedness and
response, emergency rescue basket
,emergency stop system in conveyors,
Locomotive movement Quality of
compressed air in working chamber,
hyperbaric, Emergency Equipment,
vibration,radation,fire and smoke
,compressed air works, pressure vessels,)
,Public Interface , Traffic Management
(Work area perimeter hoardings, public
protection from site operations, Height
barrier, Storage of material in public area ,
Vehicular Traffic) ,Lifting operations ,
Demolition , False Work/Form Work ,
Piling and Diaphragm Walls , Work
adjacent to live railways , Over Head
Protection , Site Transport , HT Line ,TBM
and Launching Operation ,Material Falling
Hazards ,Building demolition, Diesel
storage licence(statutory
documents),Tandem Lifting ,High risk
activity method statement approval and
implementation ,lift Plan for high risk
activity, harmful substances, Incident
reporting and investigation . work adjacent
to live railways, work adjacent to live
roadways, launching operation, barricade
/ cover to voids, trench, bored holes and
open edges of structure, flooding, site
security.
Medium Working at height (Harness, guard rails Rs 10,000/-per specific activity
and toe board), Tunnelling (Gas NCR
monitoring, Poor Illumination, means of
communication, temperature, transport
and loading, ventilation, response to
emergency (Tally board), Quality of air,
emergency lighting, Muck pit design
calculation, CCTV Emergency Under
Ground Drills,), Site security, Welfare
(Drainage arrangements, Rest Room,
Toilet, washing Facilities, bathing facility,
canteen. eating area ,fan, and light at rest
room, cooking facility ,drinking water)
,Medical Facilities , Site Tidiness , Fire
precautions(Labour camp) , PPE, House
Keeping(Poor housekeeping , Poor
storage of material , Muck disposal, poor

stacking, slush not disposed, waste debris
not removed , water logging , water
stagnation) ,Gases , Fumes Etc. , Training
/Induction , Reporting of accidents and
investigation , Sleeping at workplace,
Electrical(Trailing cable-Trip Hazard Poor
distribution board),Slippery
Floor,Denailing, reporting of accident
,corrective and preventive action, Traffic
management (Pedestrian walkway, barrier
lighting),Highway cleanness, provision of
silence equipment’s , Power tool and
condition of equipment’s ,Plant ,
equipment and machinery (Back hoe
loader , tyre condition, driving licence,
material hoist opening concrete bucket,
insurance certificate , safety sensor ,
ASLI, anemometer , safety devices,
banksman ASLI calibration, dumpers
),Access and egress, Disposal of waste,
debris ,Fire( arc welding, gas cutting set
,hot work ,First aid facility, wheel washing
facility, Mandatory contractor OHS&E
management resource, medical
examination, Monthly audit report, Drilling
machine, power tools , Manual Lifting and
Carring of excessive weight, Dangerous
and harmful environment, Corrosive
Substances, smoking , mobile phones
,radio’s and audio equipment.
Low Specific activity standard operating Rs 5000/-per specific activity
procedure , Working at height (Scaffolding NCR
inspection, competent person, , Notice
Display, COSHH ,Occupational health
Risk ,OHS&E Register’s , OHS&E
Documentation , Noise , Waste , Site
OHS&E Committees , Mobile phones ,
Radio , Audio Equipment , Dust and
CCTV, Signage’s(Emergency Exit,
Warning , cautionary and
information),Safety induction, Specific
activity safe work procedure ,risk
assessment ,RASI permit ,public liaison
signage,IRC Signage’s, PPE Examination
certification, provision of skips and
maintenance,ISO certification
audit,compentency training ,control of dust
,control of noise,COSHH, Display of
OHS&E policy and poster , CEIG Approval
Site illumination ,permits system,
Ambulance, External OHS&E Training as
per the Training Implementation plan ,
Quarterly External OHS&E audit, first aid
resources, ID card and First Day at Work,
OH&S Training, Labour licence,BOCW
registration, contract labour licence, legal
register, Name board display in crane
boom,OHS&E Hand book ,personal
protective equipment ,Vehicle operator
check, Inspection of Plant , Equipment

and machinery by the contractor plant
manager, Eye Wash Station, visitor to site
.Tunnelling(ID Card ,lock attendance
register, medical records), OH&S
Submittal to the Employer, Monthly OH&S
Report.
4.5.3.2.7 Non conformity compliance will be reviewed on periodical monthly basis and penalty clause
imposing in the tender for Non-compliance of NCR for a) Medium Risk and b) Low risk as per
below Table-5
Table-5
S.No Risk Days from the notice of Deductible amount
the event within which the
work should have are
commenced duly
mitigating the risk
A Medium i)The contractor complied Fore item i) No deduction
the specific activity NCR ii)Closure of the specific activity NCR Rs
(unsafe act/unsafe 7500/- per will be refunded and
condition) ≤24hours. Rs 2500/- will be a permanent deduction
ii) The contractor for each specific NCR.
complied the specific iii)Rs10,000 will be a permanent deduction
activity NCR (unsafe for each specific NCR.
act/unsafe condition)
more than 24hours ≤
7days
iii) The contractor failure
to comply the specific
activity NCR (unsafe
within the stipulated time
period of 7days
B Low i)The contractor complied Fore item i) No deduction
the specific activity NCR iii) Closure of the specific activity NCR Rs
(unsafe act/unsafe 4000/- per will be refunded and
condition) ≤24hours.
Rs 1000/- will be a permanent deduction
ii) The contractor for each specific NCR.
complied the specific
iii)Rs 5000 will be a permanent deduction
for each specific NCR.
7days
iii) The contractor failure
to comply the specific
within the stipulated time
period of 7days
4.5.3.2.8 The High Risk Non –compliance (Unsafe act/Unsafe condition) shall be suspended the
specific work activity immediately. The Contractor shall not proceed with the work until
remedial works have been complied with under the direction and satisfaction of the
Employer/Engineer. Request for inspection with the evidence of compliance shall be
submitted to the Employer/ Engineer for the verification

4.5.3.2.9 The Contractor shall not be entitled to any damages or compensation for stoppage of work,
due to safety reasons. The period of such stoppages of work shall not be taken as an
extension of time for completion of the facilities and will not be the ground for waiver of levy
of liquidated damages.
4.5.3.2.10Any non-conformance of unsafe act should be treated as disciplinary action towards the
person and department in charge and as well as recommended for tacking refreshment
training on the specific task.
4.5.3.2.11Closure of Non - conformance will be verified by the submission of photograph evidence or

physical verification on satisfaction of the Employer/Engineer.
4.5.4 Control of records

4.5.4.1 The Contractor shall maintain all OHS&E records in accordance with the Contactors ISO
9001 :2015 Quality Management System.
4.5.4.2 Records shall be made available to the Employer /Engineer upon request for the purpose of
incident investigation and management review.
4.5.5 Audit
4.5.5.1 Monthly Audit Report (MAR)
4.5.5.1.1 The Contractor shall undertake an internal monthly audit using the process and audit report
form (MAR) as prescribed within OH&S Manual Volume 2.
4.5.5.1.2 The Contractor shall submit the completed audit report no later than the 7 th of each month
within the Contractor’s monthly OHS&E Report. Failure to submit the monthly audit report
within the stipulated timescale shall result in the Employer / Engineer awarding a ‘Zero’ score
for the month.
4.5.5.1.3 The audit scores awarded internally by the Contractor shall be subject to review and
verification by the Employer / Engineer . The Employer / Engineer shall substantiate the
awarded scores through making comparison with the results of a physical site inspection
against the model audit scores criteria as provided within OH&S Manual Volume 2.
4.5.5.1.4 The Employer / Engineer shall formally verify that the Contractor’s self-awarded scores
comply with the audit scoring system and scoring criteria as defined within OH&S Manual
Volume 2. Where discrepancy exists the Employer / Engineer shall provide supporting
evidence (Photographic) and instruct the Contractor to amend the initial awarded score.
Following adjustment, the monthly audit report shall be re-submitted to the Employer /
Engineer within 3 days.
4.5.5.1.5 The Contractor shall be required to achieve a minimum 65% overall audit score on a monthly
basis .
4.5.5.1.6 If non-payment of the lump sum item in preliminaries occurs as a result of failing to achieve
the required 65% over a single quarterly reporting period, the Employer/Engineer may
reinstate the lump sum item at his discretion should the contractor achieve above 65% for
the following six (6) consecutive monthly OHS&E audits equating to two (2) quarterly
reporting periods. This repayment shall not occur if the quarterly aggregate of Monthly audit
scores is less than 50%.
4.5.5.1.7 In the event the Contractor fails to achieve a minimum of 65% on a monthly audit, an action
plan shall be submitted together with the audit results detailing the actions that shall be taken
within timescales.
4.5.5.1.8 Monthly audits shall be conducted prior to the sitting of the Contractor’s Safety Committee
and shall form part of the agenda.
4.5.5.1.9Contractor Recognizing
4.5.5.1.10The Employer/Employer’s shall recognize the effort if the contractor achieves above 75% for
the following three (3) consecutive monthly OHS&E audits of one quarterly reporting periods.

Only for the preceding three (3) months deducted amount of OHS&E NCR will be refunded.
4.5.5.2External OHS&E Audit
4.5.5.2.1The Profile of the External OHS&E Audit agency, the name, educational qualifications and
experience for of the auditors are to be submitted to the Employer/Engineer a minimum 28
days before prior to appointment of the agency. Only upon notice of no objection by the
Employer /Engineer shall be authorised to conduct audit on CMRL sites.
4.5.5.2.2The External OHS&E Audit template shall be submitted to the to the Employer/Engineer in the
format prescribed (FSAF 32-Volume 2 of OH& S Manual) a minimum 28 days before prior to
conducting of the audit. Only upon notice of no objection by the Employer /Engineer shall be
authorised to conduct audit on CMRL sites.
4.5.5.2.3 The Contractor is required to conduct external audits by ISO accredited 3rd party agency as
per the Indian Standards, ISO 45001 :2018 & ISO 14001:2015 international standards on a
quarterly basis throughout the Contract period.
4.5.5.2.4 External audit and follow up audit reports shall be submitted to the Employer /Engineer for
review within 7 days of audit completion.
4.5.5.2.5 Should the Contractor fail to undertake external audits within the 3 month period the
Employer /Engineer shall appoint an ISO accredited 3rd party agency to conduct the audit at
the Contractor’s cost.
4.5.5.2.6 Where ‘Major’ non-conformances with international standards are identified, a follow-up
external audit shall be carried out within 28 days for closing out of the non-conformance(s).
Follow-up audits shall continue on a 28-day rotation until such time as Major non-
conformances are closed to the satisfaction of the 3rd Party ISO accredited auditor.
4.5.5.2.7In case of non-conformity of items identified by auditor, the Employer /Engineer shall take
necessary steps including stoppage of work and or imposing of any penalty to ensure
satisfactory execution.
4.6 Management review

4.6.1 Management Reviews shall be undertaken annually by the Employer /Engineer in compliance
with ISO 9001:2015.
4.6.2 The Management Review Report shall make recommendations for improvement.
4.6.3 The Contractor shall carry out a formal Management Review on an annual basis as a
minimum. The Management Review may form part of the review under the organisations
Quality Management System.
4.6.4 The Contractor shall submit Management Review Report to the Employer /Engineer within 7
days after meeting completion together with the organisations new objectives.
4.7 External OHS&E Agency

4.7.1 The Contractor’s External OHS&E Agency thereon, who in the opinion of the Employer
/Engineer, incompetent or negligent or fails to conform with any particular provisions with
regard to OHS&E or the requirement of the contract or legal requirement, or persists in any
conduct which is prejudicial to OHS&E, shall be removed from site immediately, and such
external OHS&E agency shall not be employed again upon the Works. The decision of the
Engineer in this regard shall be final.
4.8 Penalty
4.8.1 CMRL has built an image of safety conscious organisation meticulously over a period of nine
years. Any reportable accident (fatality / injury) results in loss of life and/or property damage.
These accidents not only result in loss of life but also damage the reputation of CMRL. Most
of the accidents are avoidable and caused preliminary due to contractors’ negligence. Hence
CMRL shall recover the cost of damages from the contractors for every reportable incident
(fatality / injury).

4.8.2 In addition every CMRL work site is exposed to public scrutiny as the work is executed just on
the right-of-way. Any unsafe act / unsafe condition observed by public further damages our
reputation. Because of the non-voluntary compliance of contractors to the Employer’s
OHS&E requirements or Employer’s direct instructions and project OH&S manual, CMRL has
been forced to establish safety-enforcing organisation. The cost of established such
organisation is to be recovered from contractors for all observed safety violations at sites.
4.8.3 The following table-6 indicates the Occupational Health, Safety and Environment violation
(unsafe act / unsafe condition) and charges to be recovered from contractors.
Table-6
SI No TOPIC UNSAFE ACT/UNSAFE CONDITION DEDUCTIBLE AMOUNT *
i) OHS&E policy For item i) and item ii) Rs.

a) Non-compliance of CMRL OHS&E Contract 1,000 per single violation,
requirement compounded to a maximum of
b) Inadequate coverage, not
Rs. 5,000 at any single
signed
c) Not displayed it at conspicuous places at work instance.
sites in Hindi and a local language understood by
the majority of construction workers
ii) OHS&E plan:
a) Not as per Employers’ content and coverage
b) Not submitted to the ER within 28days of
commencement of work
c) Not updated as per CMRL OHS&E Contract
requirement
d) Copies not provided to all required supervisors
1 OHS&E Policy & / engineers
Plan e) Not undertake and not recorded a monthly
review of the construction occupational health
and safety plan
i) Not complying to the minimum manpower For item i) and ii) Rs. 50,000
requirements as per CMRL OHS&E Contract per month for first month and
requirement Rs.1,00,000 for
ii) Not filling up the vacancies created due to
OHS&E personnel leaving the contractor within subsequent months
30 days.
iii) OHS&E organisation not provided with
For items iii), iv), v), vi) and vii)
required Audio-visual and other equipment’s
CMRL OHS&E Contract requirement Rs. 50,000 for first violation
iv) Employing through outsourcing agencies and
OHS&E personal are not in the payroll of the main and Rs.1,00,000 for
contractor subsequent violations
v) Disobedience / Improper conduct of any
OHS&E personnel.
vi) Chief OHS&E Manager not reporting directly
2 OHS&E to PM of contractor.
Organisation vii) Non-compliance of any rule of schedule VI of
BOCWR within one month of commencement of
work
i) Failed to formulate or conduct OHS&E For item i) to vi) Rs. 1,000 for
Committee meeting for any month the first violation and Rs. 5,000
ii) Contractor and Sub-contractor representatives for the subsequent violations.
not attending OHS&E Committee meetings
3 OHS&E iii) Failed to conduct Site inspection before
conducting OHS&E Committee meeting
committee iv) Failed to send OHS&E Committee Meeting
minutes or Agenda to Employer /Engineer in time

v) A minimum period of 21 days not maintained
between any two OHS&E monthly committee
meetings
vi) Failed to formulate equal participants of
management and non-management staff for
OHS&E committee meeting as per BOCWR
i) ID Card not provided to all staff and workers For item i) to iv) Rs. 1,000 for
ii) Contractor not issued a personnel OHS&E the first violation and Rs. 5,000
handbook to all staff and workers, which provides for the subsequent violations.
information on OHS&E and emergency
procedures that all personnel working on contract
are required to know and the need to follow and
ensured that this is distributed and its content
introduced to all the personnel working at sites.
iii) The contractor not ensure that all personnel
working at the site receive an Induction OHS&E
training the nature of the work, the hazards that
may be encountered during the site work and the
particular hazards attached to their own function
within the operation
iv) All personnel no issued a phot identity of size
85mm x 55mm duly signed by the authorized
representative of the contractor before they are
4 ID card engaged for any work
Not complying to the requirements as mentioned For item a) to j) Rs.5,000 for

in CMRL OHS&E Contract requirement and first violation on and Rs.10,000
Employer OHS manual with regard to: for subsequent violations
a) Induction training not given
b) Supervisor/engineer/manager training not
conducted CMRL OHS&E Contract requirement
c) Refresh OHS&E training CMRL OHS&E
Contract requirement
d) Tool-box talk not conducted
e) Skill development training not conducted
f) Daily Safety Oath not conducted
g) Top management behaviour based OHS&E
training conducted
h) Not submitted a Training implementation plan
i) Not able to produce adequate records as per
the approved Training implementation plan
j) Not able to conduct training on construction
5 OHS&E Training safety plan, operational and systems procedures
with record of durations.
OHS&E inspection For item a) to h) Rs.5,000 for
a) Not complying to the requirements as first violation on and Rs.10,000
mentioned in CMRL OHS&E Contract for subsequent violations
requirement and Employer OHS&E manual
b) All inspection records and reports not properly
kept and filed for audit purpose, inspection
reports of Planned General Inspection and
Routine Inspection not used for discussion during
Safety Committee Meetings with MOM.
c) Not conducted independent of the plant and
equipment inspection, testing and maintenance,
that has been stated in the Contractor’s Plant and
Equipment Procedures with records.
d) Not calibrated any of the monitoring
equipment’s as per the manufacturing
requirements
e) Not conducting internal OHS&E inspections.
f) Site Engineers(contractors) not participating in
internal OHS&E inspections.
g) Not submitting the Formal site inspection
report for each site on weekly basis to Project
director

6 OHS&E h) Formal site inspection report not to be signed
Inspection by both the Site Manager and the OHS&E officer
Internal Audit: MARS and Electrical For item i) to viii)

Safety
i) Not conducted as per OHS&E Plan Rs. 25,000 for first violation
ii) Report not sent to Employer and Rs. 50,000 for subsequent
iii) Action not taken for any month violations.
iv) Fail to conduct MARS before the monthly
safety committee meeting to form a part of
agenda
External OH&S Audit For item ix) Rs 3,00,000 for

v) Not conducted first violation and Rs.6,00,000
vi) Report not sent to Employer for subsequent violations.
vii) Action not taken for quarter month
viii) Fail to conduct external third-party audit as
per BOCW Rule
7 OHS&E audit ix) Fail to conduct ISO certification audit for the
scope of the CMRL project
i) Important days to be observed for OHS&E For item i) to ix)Rs. 1,000 per
awareness as furnished by Employer / Engineer single violation, compounded
not observed to a maximum of Rs. 5,000 at
ii) Posters as furnished by Employer / Engineer
any single instance.
8 OHS&E not printed and displayed
Communication iii) Contractor failed to produce a ‘High Quality’
quarterly newsletter
iv) Contractor failed to change signage and
posters on a monthly basis to bring pertinent
awareness
v) Poster campaigns not discussed at the
Engineer’s Committee meeting and not recorded
with improvement program
vi) Informational posters, banners are not
provided both in Tamil/Hindi and English
vii) Records of all toolbox talks undertaken
together with the date, topic, participant’s names
and signatures are not mentioned on daily basis
viii) Not maintaining the records of
briefings/communications of Method statement
and risk assessment before commencement of a
new task or when a change to the method of
working arises
ix) Public informational signage and Contractor
contract information not posted externally to the
site including all legal communication
The contractor failure to submit the following For item i) to xix)Rs. 1,000 per
submittals to the ER a minimum 28days prior of single violation, compounded
task commencement to a maximum of Rs. 5,000 at
i) Risk Register & Hazard Log
any single instance.
ii) Operational Control Procedure not submitted
iii) Specific Method statement
iv) Specific Lift plan
v) OHS&E Management System Procedure
vi) Emergency Preparedness and Response plan
Vii) Traffic Management Plan
Viii) Fire Plan
IX) Health Plan
X) Onsite traffic Management plan
Xi) OHS&E Monthly Report
xii) External OHS&E report
xiii) Electrical safety audit
xiv) OHS&E inspection report
xv) Daily reporting of total no of workmen

09 OHS&E xvi) OHS&E Audit reports no later 7th of every
Submittals month
(Hazard xvii) Monthly Audit Score (MARS) report no later
7th of every month
identification,
xviii) Air and Noise Quality monitoring report
risk assessment xix) Changes in organizational, personnel,
and determining systems, procedures, equipment, products,
controls) materials, or substance not communicated by the
Contractor
10 Injury and Injury and Incidence reporting For item i) Rs.
Incidence i)Fatal accidents 1,00,00,000(One Crore) for
ii)Injury accident each fatality
Reporting iii)Abnormal delay in reporting accidents or wilful
suppression of information about any accidents / For item ii) Rs
dangerous occurrence
iv)Delay in informing about any accidents / 20,00,000(Twenty lakhs) for
dangerous incidents. each injury accident(Grievous
v)Not submitted a preliminary accident Injury as defined by Workmen
notification within 24 hours Compensation Act)
vi)Not submitted accident investigated report
within 72 hours For item iii) iv) and v) Rs
vii) Employers’ independent incident 5,00,000(Five Lakhs) for each
investigation
violations
a) Contractor and his staff not extend necessary
co-operation and do not testify about the
For items vi) and vii)
accident.
b) The contractor not take effort to preserve the
scene of accident till the Employer / Engineer Rs.50,000 for first violation and
complete the investigation. Rs.1,00,000 for subsequent
c) All persons summoned by the Employer / violations
Engineer in connection to witness recording not
obey the instructions
For item i) to xiii)Rs.5,000 for
i) The contractor not prepared an Emergency first violation on and Rs.10,000
Response Plan for all the work sites as a part of for subsequent violations
the contractor OHS&E Plan
ii) The contractor not ensured that an Emergency
Response Plan is prepared to deal with
emergencies arising out of
a) Fire and explosion
b) Collapse of lifting applications and transport
equipment
c) Collapse of buildings, or structures etc
d) Gas leakages or spillage of dangerous goods
or chemicals
e) Bomb threatening, Criminal or Terrorist attack
f) Drowning of workers
g) Landslides getting workers buried floods,
Earthquake, storms and other natural calamities
iii) Arrangements not made for emergency
medical treatment and evacuation of the victim in
the event of an accident or dangerous incident
occurring, the chain of command and the
responsible persons of the contractor with their
telephone numbers and addresses for quick
communication not adequately publicized and
conspicuously displayed in the workplace
11 Emergency iv) Contractor not tied-up with the hospitals and
fire stations located in the neighbourhood for
preparedness
attending the casualties promptly and emergency
Plan vehicle kept on standby duty during the working
hours for the purpose
v) contractor not conducted onsite emergency
mock drill once in every month for all his workers
and his subcontractor’s workers
vi) Contractor not keep the Local Law & Order
Authorities informed along with communication to

ER, CMRL to mitigate the consequences of an
emergency
vii) Not submitting the project specific Emergency
Plan within 4 weeks of Commencement of
contract
viii) Not provide training with records for
emergency preparedness and response
procedures on monthly basis with records
ix) Not conducted the mock drilled Emergency
preparedness and response procedures on
monthly basis with records
x) Not erected hording for Emergency Process
flow charts on conspicuous places
xi) Not erected hording for emergency telephone
numbers like fire, ambulance, police, nearest
hospital and any other legal relevant
xii) The contractor not provided a fully equipped
ambulance on-site as per legal requirement
xiii) The ambulance van not maned by adequate
number of paramedics
i) Housekeeping maintenance register not For item i) to xx)

properly maintained up to date
ii) Surrounding areas of drinking water tanks/taps
not hygienically cleaned/maintained
iii) Office, stores, toilet / urinals not properly Rs. 10,000 per single violation
cleaned and maintained. Compounded to a maximum of
iv) Required dustbins at appropriate places not
Rs. 20,000 at any single
provided / not cleaned.
v) Stairways, gangways, passageways blocked. instance for non- compliance
vi)Lumber with protruding nails left as such of any of the clauses
vii)Openings unprotected
viii)Excavated earth not removed within a
reasonable time.
ix)Truck carrying excavated earth not
covered / tyres not cleaned.
x)Vehicles / equipment’s parked / placed on
roads obstructing free flow of traffic
xi) Unused surplus cables / steel scraps lying
scattered
xii)Wooden scraps, empty wooden cable drums
lying scattered
12 Housekeeping xiii)Water stagnation leading to mosquito
breeding
xiv)Water stagnation leading to mosquito
breeding
xv)Full height fence, barriers etc not installed at
the site to preserve the surrounding area from
excavated soil and rubbish
xvi)Not maintained Drip pans for oil leakages and
splits of suitable size while servicing of
plants/equipment/machinery and disposed off
generated waste in approved manner.
xvii)Proper Housekeeping not carried out at work
sites, labour camps, stores and offices with
Housekeeping maintenance register
xviii)Supervisors and Engineers working at the
site not educated and trained on the necessity of
good Housekeeping
xix)Not treating still water once every week with
oil in order to prevent mosquito breeding
xx)Posters in both language and English not
displayed prominently to draw attention for the
dangers of permitting mosquito breeding
1)Work at Height/Ladders and Scaffolds For item 1) to 7)

i)Not using or anchoring Safety Belt

ii)Not using Safety Net
iii)Absence of life line or anchorage point to
anchor safety belt Rs.10,000 per single violation
iv)Using Bamboo ladders Compounded to a maximum of
v)Painting of ladders Rs.1,00,000 at any single
vi)Improper usage (less than 1m extension above
instance for non- compliance
landing point, not maintaining 1:4 ratio)
vii)Aluminium ladders without base rubber bush of any of the clauses
viii)Usage of broken / week ladders
x)Usage of re-bar welded ladders
xi)Improper guardrail, toe board, barriers and
other means of collective protection
xii)Improper working platform
xiii)Working at unprotected fragile surface
xiv)Working at unprotected edges
xv)Worker not passed Vertigo test
2)Contractor not carried out risk assessments for

all the work where workers or materials can fall
from more than two meters
3)Not provided Edge protection to work above
two meters as specified below
a) A main Guard rail at least 1 meter above the
13 Working at edge
Height / Ladders b) A Toe board at least 200 mm high
c)An intermediate guard rail or other barrier so
and Scaffolds that there is no gap more than 470 mm
4)All Scaffolds not inspected by a competent
person at least in every three days after erection
and not recorded
5)Tags not fitted to all scaffoldings to show they
are safe for use or not and all safe for use tags
not signed by senior site engineer
6)All scaffolds not constructed of sound materials
and not free from patent defect
7)The measures not taken by contractor
i)The scaffold not constructed for the correct use
(Light or Heavy Duty)
ii)Security not fixed to existing structures or
adequately buttressed
iii)The use of barrels, boxes, loose tiles or other
unsuitable material used as supports for working
platforms
iv)All working platforms not fully boarded and not
covered with net to prevent Height Phobia
v)All working platforms not provided guard rails at
one metre height and not provided an
intermediate rail at half height
vi)All working platforms not provided with Toe
boards
vii)All working platforms not kept free of
unnecessary obstruction or rubbish
viii)Secure ladder access shall be provided
ix)Metal ladders used near or adjacent to
overhead live power lines
x)Non-usage of full body harness at safe working
platform with secure anchorage points
i) Non-availability of fitness certificate For item i) to xxviii)
ii) Documents not displayed on the machine or
not available with the operator Rs.10,000 per single violation
iii) Maximum Safe Working Load not Compounded to a maximum of
written on the machine Rs.1,00,000 at any single
iv) Automatic safe load indicator not
provided or not in working condition instance
v) Age of the operator less than 21 years or
without any licence
vi) Failure to submit Lift Plan

vii) Person riding on crane.
viii) Creating more noise and smoke
ix) Absence of portable fire
extinguisher in driver cabin
x) No fencing of hoist rope movement area
xi) Hoist platform not in the horizontal position
xiv) Fail to guard hoist platform
xv) No fencing of hoist rope movement area
xvi) Hoist platform not in the horizontal position
xvii) All lifting appliances, including synchronized
mobile jacks, pit jacks, mobile cranes, lower
14 Lifting cranes, gantry cranes, launching beams and lorry
appliances and mounted cranes not inspected and not certified
gear by competent person
xviii) Competent person not approved by
ER/CMRL
xix)Lifting capacity of more than one ton not fitted
with Automatic Safe Load Indicators,
Anemometer and Audible warning devices with
no proper records of inspection
xx)Lifting appliances not maintained in
accordance with manufacturer’s instructions and
irregular preventative maintenance program with
available schedule
xxi)All lifting appliances not inspected every six
months by a third-party competent person with
records
xxii)The operators of lifting appliances not
conducted daily record of inspections of their
respective lifting appliances
xxiii)Load slewed over public areas without
stopping pedestrians and vehicles
xxiv)Working closer to any live overhead power
lines without the operation of a strict Permit to
Work system being in place
xxv)All lifting gear not properly stored and left
lying on the ground
xxvi)Untrained and unexperienced slingers and
riggers deployed to give directions to crane
operators
xxvii)Untrained and unexperienced person
deployed as Crane driver
xxviii)While working near isolated overhead
power lines, the lifting appliances not grounded to
earth as a secondary precaution against
accidental energization
Rs. 50,000 for first violation

Launching Non-adherence of any of the provisions and Rs.1,00,000 for
15 operation mentioned in Employer’s OH & S Manual subsequent violations
Site Electrical Safety For item i) to xviii)
i)The contractor not deploy qualified and

competent C Licence electrical personnel as per
law Rs.10,000 per single violation
ii)The main contractor not take consideration, the Compounded to a maximum of
requirements of the sub/petty contractor’s
Rs.1,00,000 at any single
electrical power supply and arrive at the capacity
of power supply from diesel supply from diesel instance
generators, small capacity diesel generators
allowed for whatever type of job to be executed
16 Site Electrical under this contract
safety iii)Unsafe noise making small capacity diesel
generators are found used by sub/petty
contractors

iv)The contractor not submitted electrical single
line diagram, schematic diagram and the details
of the equipment for all the temporary electrical
installation and those diagrams together with the
temporary electrical equipment not submitted to
the Employer’s for necessary approval
v)Cables not selected after full consideration of
the condition to which exposed and the duties for
which they are required. Supply cable up to 3.3
KV not in accordance
vi)Damage to
1.Civil utilities such as water pipe line, sewer
pipeline, storm water pipe line, drainage pipe line
and structures etc
2.Electrical and telecom utilities such as all types
of cable and installation, street lights, poles, and
panels, Bus Q shelters, Joints, feeder pillars,
cable ducts, junction boxes, transformers, ring
main and structures provided for both telecom as
well as telecom etc
3.Traffic signal cables, CCTV cables and CCTV
cameras and poles, LPG/LNG Gas pipelines,
petroleum tanks/pipeline, dispensers etc
vii)Inserting of wires directly into the sockets
viii)Improper grounding for the electrical
appliances
ix) Electrical cables running on the ground
x)The contractor not appointed an Electrical
engineer with certificate to comply IE act
xi)The name and contact telephone number of
the electrical engineer not displayed at the main
distribution board for all temporary electrical
installations, for approval
xii) All electrical work not supervised or executed
by qualified and suitably categorized electricians
as per the law
xiii)All cabling exposes a hazard or obstruction to
people and equipment
xiv)The installation on site not allow convenient
access to authorized and competent operatives
to work on the apparatus contained within
xv)Voltages not adhered to for typical
applications throughout the distribution systems
like
a) Fixed plant – 415V 3 Phase
b) Movable plant fed by trailing cable – 415V
c)Installations in Site buildings – 240V 1 Phase
d)Fixed flood lightning – 240V 1 Phase
e) Portable and hand-held tools – 110V 1 Phase
f) Site lightning (other than flood lightning) – 110V
1 Phase; and
g) Portable hand lamps (general use) – 110V 1
Phase
xvi)Protection not provided for all main and sub-
circuits against excess current, residual current,
earth faults an short circuits by protective devices
xvii)Earthing and bonding not provided for all
electrical installations and equipment’s to prevent
the possibility of dangerous voltage rises cleared
by installed circuit protection
xviii)Maintenance of control apparatus and wiring
distribution systems not carried out by an
approved electrician on weekly basis with records
xix)All portable electrical appliances not
numbered with records of date of issue, date of
last inspection carried out
xx)Inserting of bare wires into the socket

xxi)Improper grounding for the electrical
appliances and metallic barricades
xxii)Electrical live cables running on the ground
as per the IE act
xxiii)Not provided ELCB DP
xxiv)Not providing adequate earthing as per IE
act
xxv)Electrical live cable immersed in water
xxvi)Not maintain safe distance from HV on LV
lines while working as per the law
xxvii) Non-usage of rubber mat near HV or LV
distribution panels and switches for DG sets and
power utility
xviii)Use of inadequate capacity fuse wire/HRC
(High ruptured capacity fuse) as per the IE act
The contractor not ensure that From item i) to xxii)

i)Electric tools are properly grounded or / and
double insulated Rs.1,000 per single violation
ii)GFCI’s/RRCB’s shall be used with all portable Compounded to a maximum of
electric too operated especially outdoors or in wet Rs.5,000 at any single
condition
iii)Before making any adjustments or changing instance
attachments, his workers shall disconnect the tool
from the power source
iv)When operating in confined space or for
prolonged period, hearing protection shall be
required. The same shall also supply to working
with equipment’s which gives out more noise
17 Hand tools and v)Tools is held firmly and the material is properly
Power tools secured before turning on the tool
vi)All drills shall have suitable attachments
respective of the operation and powerful for ease
of operation
vii)When any work/operation need to be
repeatedly or continuously, tools specifically
designed for that work shall be used. The same
is applicable to detachable tool bit also
viii)Size of the drill shall be determined by the
maximum opening of the chuck n case of drill bit
ix)Attachments such as speed reducing
screwdrivers and buffers shall be provided to
prevent fatigue and undue muscle strain to his
workers
x)Stock should be clamped or otherwise secured
firmly to prevent it from moving
xi)Workers shall never stand on top of the ladder
to drill holes in walls/ceilings, instead standing on
fourth or fifth rung shall be recommended
xii)Electric plane shall be not be operated with
loose clothing or long scarf or open jacket
xiii)Safety guards used on right angle head or
vertical portable grinders must cover a minimum
of 1800 of the whole wheel and the spindle/wheel
specifications shall be checked
xiv)All power tools/hand tools shall have guards
at their nip points
xv)Low profile safety chain shall be used in case
of wood working machines and the saw shall run
at high RPM when cutting and also correct chain
tension shall be ensured to avoid “kickback”
xvi) Leather aprons and gloves shall be used as
an additional personal protection
xvii)Push sticks shall be provided and properly
used to hold the job down on the table while the
heels move the stock forward and thus preventing
kickbacks

xviii)Air pressure is set at a suitable level for air
actuated tool or equipment being used, before
changing or adjusting pneumatic tools, air
pressure shall be turned off
xix)Only trained employees shall use explosive
actuated tools and the tool shall also be unloaded
when not in use
xx)Usage of such explosive actuated tools shall
be avoided in case of places where
explosive/flammable vapours or gases maybe
present
xxi)Explosive actuated tools and their explosives
shall be stored separately and be taken out and
loaded only before the time of immediate use
xxii)Misfired cartridges of explosive actuated
tools must be placed in a container of water and
be removed safely from the project
Gas cutting and welding From item i) to xxv)
i) Wrong colour coding of cylinder.
ii) Cylinders not stored in upright position. Rs.1,000 per single violation
iii) Flash back arrester, non-return valve and Compounded to a maximum of
regulator not present or not in working condition. Rs.5,000 at any single
iv) Fail to put cylinders in a cylinder trolley.
v)Damaged hose. instance
vi)Using domestic LPG cylinders
vii) Fail to store cylinder 6.6m away
from fire prone materials
viii) Fail to use hose clamps
ix)Fire extinguisher not placed in the vicinity
during operation
x)Contractor not issued work permit for all
welding, cutting and gouging while working in
tunnels, welding over areas where others are
working and areas with increased fire risks or
hazardous environments
xi)All gas and welding equipment not inspected
by a competent person with records on weekly
basis
xii)Welders not wear the correct PPE like face
and eye protection with correct grade of shield,
Gauntlet gloves Safety footwear
xiii)Efficient ventilation and fume extraction
system not provided in enclosed areas and pits
xiv)Naked flames or high temperature surfaces
allowed in the vicinity (within 6 meter) of volatile
solvents
xv)Cylinders kept in enclosed areas
(unventilated) with unsecure upright position
xvi)Flash back arrestors not fitted to both the fuel
gas and oxygen cylinders
xvii)Non-return valves not fitted to the torch or
cutting torch
xviii)Screwed fittings and hoses are not screwed
properly and sealed to free from contaminants
18 xix)Daily checks for gas leaks not carried out by
Gas Cutting using soapy water
xx)Not removed all torches from enclosed areas
when not in use
xxi)Firewatchers not present if there is a
possibility of ignition unobserved by the operator
xxii)The equipment earthing and work piece
earthing is same
xxiii)Duckboards or rubber protection is not used
to avoid being in contact with water or wet floors
when welding
xxiv)Screens not provided to limit exposure of
others to glare from area

xxv)The correct codified eye and face protection
with the correct filter glass is not issues
i)Voltmeter and Ammeter not working From item i) to ix)

ii)Improper grounding and return path.
iii)Damaged welding cable Rs1,000 per single violation
iv)Bare openings in the cable. Compounded to a maximum of
v)Non-availability of separate switch in the Rs.5,000 at any single
transformer
vi)Non-availability of main switch control to switch instance
off power to the welding unit.
vii)Usage of reinforcement rod as return
conductor
viii)Damaged holder
19 Welding ix)Fire extinguisher not placed in the vicinity
during operation
i)Smoking and open flames in fire prone area From item i) to xxi)
ii)Using more than 24V portable electrical
appliances in the fire prone area Rs.1,000 per single violation
iii)Not proper ventilation in cylinder storage area. Compounded to a maximum of
iv)Absence of fire extinguisher Rs.5,000 at any single
v) Fire extinguisher not refilled once in a year.
vi) Fire extinguisher placed in a not easily instance.
accessible location
vii) The contractor not deployed specially trained
personnel to deal with fires due to electrical
causes, gas explosions etc as per the specified
law or manual
viii)Combustible scrap and other construction
debris not disposed off from site on a regular
basis with records
ix)Signage not erected at prominent positions
showing the correct use of portable first aid fire
extinguishers
x)Emergency plans and Fire Evacuation plans
not prepared
xi)Mock drills not conducted once in one months
to ensure the effectiveness of the arrangements
xii)Site clearly visible fire points not established
20 Fire precaution for use in an emergency either with Dry powder
type or water type extinguishers
xiii)Recharging of fire extinguishers and their
proper maintenance not done as per Indian
National Standards
xiv)Water not supplied for fire-fighting purposes
in the form of static water tank of adequate
capacity or a hydrant line with adequate water
pressure at outlet points as per Indian National
Standards
xv)Sufficient number of fire hoses with branch
pipes, emergency lights not provided at site as
per Indian National Standards
xvi)The Telephone Number of the site fire brigade
not prominently displayed near each telephone
on site
xvii)Supervisors and workmen at the site not
trained in the use of Firefighting equipment
provided at the site as per Indian National
Standards
xviii)All flammable liquids without any leaks and
proper stopper without marked “FLAMMABLE
LIQUID”

xix)Rags soaked in paints, kerosene and other
flammable liquids not disposed of daily under
supervision
xx)All Diesel fuel storage tanks not bunded
around in order to control any spillage or leakage
xxi)”NO SMOKING” signs not prominently
displayed at all areas of potential location of fire
1.Excavation Item 1 , 2 and 3 Rs. 10,000 per

single violation Compounded
i) The contractor not ensures to a maximum of Rs. 1,00,000
a) Whether any construction building worker
at any single instance.
engaged in excavation is exposed to hazard of
falling or sliding material or article from any bank
or side of such excavation which is more than
1.5m above his footing, such worker is protected
by adequate piling and bracing against such bank
or side
b) Where banks of an excavation are undercut,
adequate shoring is provided to support the
material or article overhanging such bank
c) Excavated material is not stored at least 0.65m
from the edge of an open excavation or trench
and banks of such excavation or trench are
stripped of loose rocks and other materials which
may slide, roll or fall upon a construction building
worker working below such bank
d) Metal ladders and staircases or ramps are
provided, as the case maybe, for safe access to
21 Excavation, and egress from excavation where, the depth of
Tunnelling and such excavation exceeds 1.5m and such ladders,
staircases or ramps comply with the relevant
confined space
National Standards
e) Trench and excavation are protected against
falling of a person by suitable measures if the
depth of such trench or excavation exceeds 1.5m
and such protection is an improved protection in
accordance with the design and drawing of a
professional engineer, where such depth
exceeds 4m
ii) The contractor not ensure that
a) Suitable warning signs or notices, required for
the safety of building workers carrying out the
work of an excavation or tunnelling, displayed or
erected at conspicuous places in Hindi and in a
language understood by majority of such building
workers at such building excavation or tunnelling
work
b) Such warning signs and notices with regard to
compressed air working include
1 The danger in such compressed air work
2 Fire and explosion hazard
3 The emergency procedures for rescue from
such danger or hazards
iii) The integrity of the excavation and the support
system not inspected prior to the commencement
of any works on a daily basis with records of
checklist
iv) Emergency pumping sumps and ladders not
placed for use in the event of an emergency
evacuation
v) The contractor not plan in excavation against
the following:
a) Collapse of the sides
b) Materials falling onto people working in the
excavation
c) People and vehicles falling into the excavation

d) People being struck by plant
e) Undermining nearby structures
f) Contact with underground services
g) Fumes and
h) Make sure the necessary equipment needed
such as trench props
vii) The contractor not taken following precautions
a) The sides battering them to a safe angle or
supporting them with timber, proprietary support
systems
b) Unsupported excavations
c) In shallow trenches contractor need to provide
support if the work involves bending or kneeling
in the trench
d) Prevention of materials falling in to the
excavation
e) Make sure the edges of the excavation are
protected against falling materials
f) Wear a hard hat when working in excavations
g) Provide substantial barriers, e.g. guard rails
and toe boards
h) Keep vehicles away from excavations use
brightly painted baulks or barriers
i) Where vehicles have to tip materials into
excavations, use stop blocks to prevent them
from over-running
j) Supervising excavation work of contractor does
not have service plans
2 Tunnelling
The contractor not ensures

a) Every compressed air system in a tunnel is
provided with emergency power supply for
maintained continued supply of compressed
supply of compressed air as per rule
b) Watering bulkhead doors are installed at the
entrance of a tunnel to prevent flooding
c) Reliable and effective means of
communication such as telephone or walkie-
talkie or any other audio-visual live media are
provided and maintained for arranging better
effective communication at an excavation or
tunnelling work as per rule
d) All portable electrical hand tools and
inspection lamp used in underground and
confined space at an excavation or tunnelling
work is operated at a voltage not exceeding
24V
e) Only flame proof equipment of appropriate
type and or another relevant national standard
is used inside the tunnel
f) Petrol or LPG of any other flammable
substances are used, stored inside the tunnel
except with prior approval from Employer, and
also oxy-acetylene gas is used in a
compressed air environment in excavation or
tunnelling
g) Adequate number of water outlets provide for
fire-fighting purpose, an audible fire alarm and
adequate number and types of fire
extinguishers are provided and maintained
h) Temperature in any working chamber in an
excavation or tunnelling work where workers
employed does not exceed 29°C as per rule

i) Vibration measurement on each movement
on each movement or any displacement in
nearby object to Tunnelling activities
j) All working areas in a free air tunnel are
provided with ventilation system as approved
by competent authority and the fresh air
supplied in such tunnel is not less than
6m3/min for each worker employed in tunnel
as per rule
k) The contractor not developed safety
procedures and methods (statements) of
working to be adopted during the course of
tunnelling operations
l) In more than 500 metres long tunnel, cleaned
and disinfectants sanitation facilities not
provided with suitable toilets of one unit for
every 50 men on the shift
m) In more than 500 metres long tunnel, 5 litres
of clean drinking water (tested and certified
monthly) per person inside the work location
n) Washing and cleaning facilities not provided
for all workers near the site
o) The contractor not provided lightning
minimum requirements as per contract.
p) Warning Signs, Notice board and Tally Board
-No Proper control of ingress and egress of
persons to and from tunnel under construction
in the worksite, no tally board and No
Accurately indicate the number and location
of persons underground at all times.
q) Industrial Health and Welfare - No pre-
employment health screening done and No
provision of cold water drinking and No sub-
contractor records. No records of checking
employee working under the influence of
alcohol/drugs. No mosquito breeding due to
water retain on site and records of fogging
done at site.
r) Gas detection Equipment –Faulty equipment
on site. Battery low, no equipment on site, no
monitoring.
s) Self-Rescue Equipment- No rescue
equipment on site and works in progress. No
Notices regarding the proper use of self
rescuers are posted near the storage area.
t) Training – No specific training conducted. No
sub-contractor training.
u) Work Permit- None in place, unsafe
acts/conditions.
v) Quality of Air- No Dry and wet-bulb
temperature instrument at Site. Not
maintained a record of the air quality, the
location, date, time, substances and amount
monitored.
w) Quality of illumination and Emergency
Lighting – No Emergency luminaires.
Emergency luminaires not installed along the
tunnels and intervals more than 50 m.
x) Communication Systems- No Means of
communication such as telephone are not
provided at intervals of hundred metres along
the tunnel No alarms and warning signals not
audible.
y) Fire Extinguishers, Fire Mains & Hose
Connections- No Hydrant Outlet or exceeding
50 M distance. No clearly marked and not
readily accessible.

z) Track and Locomotives- Track not properly
supported. Designated person not available
for maintenance of the track. Poorly
maintained equipment on site. Poor condition
of equipment & plant. No CCTV on
Locomotives.
aa) Rolling Stock- Poorly maintained equipment
on site. Poor condition of equipment & plant.
No man riding cars at site.
bb) Man lock and Medical Lock- No man-lock
attendant station is provided with a first-aid
box at a construction site of tunnelling work.
Medical not situated near to the man lock.
cc) Emergency Under Ground Drills- All site
personnel not made familiar with the site
emergency procedures.
dd) Medical Staff- None on site.
ee) Access and Egress- No Proper staircase and
lift.
ff) Electrical Equipment- No Flame proof
electrical equipment.
gg) Drinking Water- Quantity is not sufficient
hh) First Aid Provision-None on site. No records
of first aid boxes inspection. No records of first
aid training. No enough qualified /trained first
aiders are available at each site each shift. No
first Aid room /Ambulance room at site. No tie
with nearest hospital. No qualified doctor
available in each shift in site
ii) Noise- Not maintained, none recorded in
Hazard & Risk Log or Aspect Impact
assessment and Ear muffs/plugs not provided
to Workmen and staff. No employees training
and frequency of training not identified.
Sources documented, assessments not
completed
jj) Eye Wash Station- No Eye Wash Station.
kk) House Keeping- No attempt of housekeeping
control. Loose materials causing trip and fire
hazards in areas. No Housekeeping plan
ll) Temperature Monitoring - No Dry and wet-
bulb temperature instrument at Site.
3 Confined space
i) Contractors undertaken works in the confined

spaces without permit to work, prepared and
issued (unsigned)
ii) Unauthorised, untrained, unexperienced and
physically un-fit allowed to work in confined
spaces
iii) Persons with any of the following medical
conditions allowed to work in confined spaces:
a) A history of fits, blackouts or fainting attacks
b) A history of heart disease or disorder
c) High blood pressure
d) Asthma bronchitis, or shortness of breath on
exertion
e) Deafness
f) Meniere’s disease or disease involve in
giddiness or loss of balance
g) Claustrophobia or nervous or mental disorder
h) Backpain or joint trouble that would limit
mobility in confined spaces
i) Deformity or disease of the lower limbs limiting
movement

j) Chronic skin disease
k) Serious defects in eye site or lack of sense of
smell
iv) Suitable warning signs of “NO SMOKING” not
positioned
Work permit system For item 1 to 10

1) A permit system is not taken for construction
work Rs.1,000 per first violation and
a) Entry into confined spaces Rs.5,000 for subsequent
b) Wok in close proximity to overhead power lines violations
and telecommunication cables
c) Hot work
d) To dig where under-ground services maybe
located
e) Work with heavy moving machinery
f) Working on electrical equipment
g) Work with radio-active isotopes
h) Heavy lifting operation and lifting operations
closure to live power line
2) Woking to any live overhead power line is
permitted without the operation of a strict permit
to work
3) The contractor not develop a permit -To-work
system
4) The permit to work not issue for activities as
per CMRL OHS&E contract requirement
5) To permit-to-work system not covered
a) How the system works
b) The jobs it is to be used for
c)The responsibilities and training of those
involved
d) How to check its operations
6) The permit-to-work not forms the
communication between everyone involved of
respective site conditions and requirements
22 Work permit 7) The permit to work form does not contain as
system per the OHS&E contract requirements.
a) Authorised person for jobs (and any limits to
their authority)
b) Responsibilities for precautions (e.g. isolation,
emergency arrangement, etc)
c) Associated hazards
d) Plant and diagram its location and limitations
e) Precautionary measures
f) Procedure to control or abandon in the case of
an emergency
g) Time limitations
h) Job specific toolbox talk conducted by the
supervisor
8)A permit-to-work authorised more than a period
of twenty-four hours
9)A copy of each permit to work not displayed
during its validity in a conspicuous location in
close proximity to the actual works location to
which it applies
10)A pre-permit activation job specific toolbox-
talk not conducted by the supervisor with
following details
a) All identified hazards are explained
b) Risk mitigation process clarified
c)Method of work explained stressing points (a
&b above)
d)Emergency response procedure is clarified and
the person assigned tasks in the event of
emergency

f) Personnel Protective Equipment (PPE)
requirements including PPE serviceability checks
and training
Traffic Management From item i) to xix)
i) In all cases, the contractor not employ proper Rs. 10,000 per first violation
precautions. Wherever operation undertaken are and Rs.1,00,000 for
likely to interfere with public traffic, specific traffic subsequent violations
management plans not drawn up and
implemented by the contractor in consultation
with the approval of local police authorities and /
or the concerned metropolitan/civil authorities
/competent authorities
ii) A warning not installed at all secondary road
which merges with the primary road where the
construction work is in progress at sufficient
distance before it merges with the primary road
regarding the ‘Chennai Metro Work in Progress’
iii) Traffic cones of 500mm, 750mm, and 1000mm
high and 300mm to 500mm in diameter are in
square shape at base and are often made of
plastic or rubber and normally have retro-
reflectorizes red and white band not used
whenever required
iv) Drums about 800mm to 1000mm high and
300mm in diameter not used either as
23 Traffic channelizing or warning devices
v)The contractor not make arrangements keeping
Management low away van/manpower to low away any break
down vehicle in the traffic flow
vi)The contractor not ensure the cleanliness of
road and footpaths by deploying proper
manpower for the same. The contractor not
ensure proper grooming, cleaning washing of
roads and footpaths on all the time
viii)All barricade not conspicuously seen in the
dark/night time by the road users.
Ix)Conspicuously not ensured by affixing retro
reflective stripes of required size and shape at
appropriate angle at the bottom and middle
portion of the barricade at a minimum gap of
1000mm. In addition, minimum one red light or
red-light blinker not placed at the top of each
barricade.
i) Barricade and pedestrian walkway
a) Not Cleaned
b) Not in alignment
c) Not numbered
d) Not painted
e) Red lights / reflectors not working
f) Damages not repaired
g) Not secured properly
h) Barricade inspector not employed
i) Protruding parts / portions repaired
j) Barricades maintaining register not properly
maintained up to date
ii) Contractor Vehicles
a) Over loading of vehicles
b) Unfit drivers or operators
c) Unlicensed vehicles
d) Absence of traffic marshals
e) Absence of reversing alarm
f) Absence of fog light (at winter)
g) Power / hand brakes not in working condition.
iii) Splashing of Bentonite on roads / non-cleaning
of tyres of dumpers and transit mixers

i) Mishandling of bentonite like splashing of
bentonite outside specified width of barricading
ii) Non-cleaning of tyres of dumpers and transit
mixers before leaving the site and thereby
creating a traffic safety hazard to road users.
viii) Adequate and clear warning signs not
displayed at appropriate distance before the
commencement of the site working
ix) Prior warning not given concerning the
location of approaching site entry and exit points
x) All traffic signs, barriers, cones, and lighting not
kept maintained and cleaned
xi) Regular inspection of the traffic management
schemes not conducted by the contractors in both
the day time and night time hours with records
xii) The removal of excavated soil from the sites
not done by licensed vehicle
xiii) Unchecked medical examination of the
drivers allowed for removal of excavated soil
xiv) Overloaded vehicle allowed for movement
excavated soil
xv) Any vehicle leaving the sites carrying load
produce air borne contaminants during
transportation of the public highway
xvi) Any vehicle revised without the control of
trained banksman
xvii) Vehicles prior to leaving the site shall did not
wheels
xviii) Any soil removed from the work sites
disposed of at unauthorised dumping sites
xix) Not maintained and painted all the traffic
barriers on yearly basis
Batching plant/Casting yard From item i) to xi)

i) The batching plant/casting yard not effectively
planned for smooth flow of unloading and Rs. 1,000 for single violation
stacking the aggregates reinforcement and compounded to a maximum of
cement, batching plant, transport of concrete, Rs.5,000 at any single instant.
casting the segment, stacking the segment, and
loading the segment to the trucks
ii) The batching plant/casting yard not barricaded
and not made as compulsory PPE zone
iii) Electrical system not suitably not planned for
diesel-generator
iv) Drainage not effectively provided and waste
water not disposed after proper treatment as per
the law
v) Time office, canteen, drinking water, toilet and
rest place not suitably located for the easy access
to the workers
vi) Manual handling of cement not avoided to a
larger extent
vii) The PPE’s provided to the cement handling
workmen not conform to international standard
viii) Access roads and internal circulation roads
not well laid and maintained properly at all time
ix) Material stacking is not provided
x) Not provide 50 Lux of illumination or as per law
24 Batching xi) Batching plant/Casting yard
i) The contractor release dust due to their
plant/Casting
activities beyond the permissible limit as per the
yard relevant law
ii) The waste treatment plant not provided and the
ER/CMRL norms not followed
PPE (Personnel Protective Equipment) From item i) to vi).

i)Not having

ii)Not wearing (or) using and kept it elsewhere Rs.200 per single violation
iii)Using damaged one
iv)Using wrong type For item vii) to xi)
v)Using wrong colour helmet or helmet without
logo Rs. 1,000 for first violation and
vi)Using for other operation (e.g. Using safety Rs. 5,000 for subsequent
helmet for storing materials or carrying water from
violations for item
one place to other)
vii)Not conforming to BIS standard
viii)The contractor not pay cash amount in lieu of
PPE to the workers/Subcontractors and expect
them to buy and use during work
ix)The contractor not at all time maintain a
minimum of 10% spare PPE’s and safety
appliances and properly record and not showed
25 PPE to the Employer / Engineer during the inspections
x)Adequate quantity of PPE’s not kept always as
the security post
xi)The contractor not all times keep and maintain
an adequate supply of suitable PPE for use at all
times
a) Safety helmets
b) Hearing protection
c) Respiratory protection
d) Eye protection
e) Protective gloves
f) Safety footwear
g) High visibility clothing
xii) In all construction sites person identified other
without HARD HAT or SAFETY BOOTS or both
Industrial Health and Welfare From item i) to xxi)
i)Fail to conduct Medical examination to workers
ii)Absence of ambulance van & Rs.1,000 per single violation
room Compounded to a maximum of
26 Occupational iii)Workers not having ID card Rs.5,000 at any single
iv)Inadequate number of toilets
v)Toilets not cleaned properly instance
Health
vi)Absence of water facilities for
toilets and washing places
vii)Toilet placed more than 500m
from the work site
viii)Absence of drinking water
ix)Absence of first-aid person in work site.
x)Absence or inadequacy of first-aid box.
xi)Misuse of first-aid box.
xii)First-aid box not satisfy the minimum Indian
standard.
xiii)Smoking inside the construction site
xiv)Drink and drive or work
xv)Excessive noise and vibration
xviii)Creche not provided
xix)Accommodation not provided as per BOCWA
xx)Fumigation / insecticides not sprayed to
prevent Mosquito breeding
xxi)Contractor not maintain material safe data
sheet (MSDS) for all substances at the point of
inventory
xxii)Contractor not conducted an assessment of
the hazardous substances would be used in
confined space with assessment record
xxiii)For continuous exposure of noise, i.e. for
eight hours in any one-day, the sound level
exceeds 90DB
xxiv) Noise level exceed more than 120DB and
suitable hearing protectors not used
xxv) Contractor not introduced a noise control
programme. If noise levels exceed above 90DN

xv) The ventilation system not adequate to
maintain circulation of following any one:
a) Less than 19.5% oxygen by volume
b) More than 0.05% carbon dioxide by volume
c) More than 0.01% carbon monoxide by volume
by volume
d) More than 0.001% hydrogen sulphide by
volume
e) More than 0.005 oxides of nitrogen
f) More than 0.5% of methane at any place in the
tunnel
g) More than 0.0002% of aldehyde
h) Any other poisonous gas in harmful amounts.
xvi)The contractor not provided at least 6m3 of
fresh air per minute per employee
xvii)A regular analysis of the gases inside the
tunnel not done with advance of the tunnel
xviii)Tools made of light alloys (such as Al and
Mg) are used inside the tunnel
xix)Regular checking of gas at the faces not done
before each shift by using a multi gas detector
xx) Motive power other than electric or petrol
used
xxi)Diesel engines used underground without
filters to remove all carbon monoxide and oxides
of nitrogen
Labour welfare measures From item i) to xvi) Rs.1,000
i)Non-adherence of Labour welfare provisions of per single violation
BOCWA Compounded to a maximum of
ii)Fail to register establishment and display the
Rs.5,000 at any single
registration certificate at workplace
iii)Absence of workers register and records instance
iv)Absence of muster roll and wages register
v)Fail to display an abstract of
BOCWA and BOCWR
vi)Inadequate number of toilets
vii)Toilets not cleaned properly
viii)Absence of water facilities for toilets and
washing places
ix)Toilets placed more than 500m from the work
site
x) accommodation not provided as per BOCWA
xi)Absence of drinking water
27 Labour Welfare xii)Excessive noise and vibration
measures xiii)Canteen not provided
xiv)Food stuff not served on no loss no profit
basis
28 Floor Openings i)No Provision of Protection, From item i) to iii) Rs.10,000
ii)No Relevant Signage per single violation
iii)work Permit Procedure not followed Compounded to a maximum of
Rs.1,00,000 at any single
instance
i)Tyre wash facility not provided From item i) to viii) Rs. 1,000
ii)Spillage from vehicles not arrest per single violation
iii)Air monitoring not practiced Compounded to a maximum of
iv)Noise monitoring not practiced Rs. 5,000 at any single
Environmental v)The values of air monitoring and noise instance
29 monitoring not within acceptable limits
Management vi)Dust control measures at sites not
practiced
vii)Improper disposal of debris /
residues

viii)Non-compliance in legal provisions for
water treatment and disposal and
environmental loss.
4.8.4 Without limiting to the unsafe acts and or conditions mentioned above in the clause 4.10 the
Employer /Engineer shall have the right to deduct charges for any other unsafe act and or condition
depending upon the gravity of the situation on a case-to-case basis. The charges shall be in
comparison with that of the similar offence indicated in the above table-6.
* Maximum cumulative amount deductible for items at S.No. 1 to S. No. 29 during the entire contract
duration shall not exceed 1% of contract value.


SHAFT TO NATHAMUNI (VILLIVAKKAM MTH ROAD)
PART 2
SECTION VI - A
ENVIRONMENTAL
VOLUME 2 – SAFETY MANUAL
DECEMBER 2021
Table of Contents
1. STATEMENT OF INTENT................................................................................................... 1
2. REFERENCES, LEGAL REQUIREMENT’S AND DISTRIBUTION OF THIS MANUAL
2
3. DEFINITION OF TERMS ..................................................................................................... 3
4. GENERAL ............................................................................................................................. 4
5. GENERAL DUTIES OF CONTRACTORS AND OTHERS ............................................... 6
6. OCCUPATIONAL HEALTH AND SAFETY TRAINING AND OH&S PROMOTION ... 8
7. OCCUPATIONAL HEALTH AND SAFETY INSPECTIONS AND FOLLOW UP ACTION
11
8. CONTACTOR’S SITE OCCUPATIONAL HEALTH AND SAFETY COMMITTEES16
9. REPORTING OF ACCIDENTS AND DANGEROUS OCCURRENCES .................... 17
10.ACCIDENT INVESTIGATION.......................................................................................... 19
11.ACCIDENT STATISTICS .................................................................................................. 20
12.HAZARD IDENTIFICATION AND RISK ASSESSMENT .............................................. 20
13.EMERGENCY PREPAREDNESS PLAN .......................................................................... 23
14.OCCUPATIONAL HEALTH AND SAFETY SIGNAGE ................................................. 24
15.INDUSTRIAL OCCUPATIONAL HEALTH AND WELFARE ....................................... 25
16.WORKING AT HEIGHT .................................................................................................... 32
17.EXCAVATIONS ................................................................................................................. 34
18.LIFTING OPERATIONS .................................................................................................... 37
19WORK IN CONFINED SPACES ........................................................................................ 44
20SITE ELECTRICITY ........................................................................................................... 46
21WELDING AND CUTTING ................................................................................................ 50
22COMPRESSED GASES ....................................................................................................... 52
24PLANT AND EQUIPMENT OPERATIONS ...................................................................... 55
25TUNNELLING OPERATIONS ........................................................................................... 56
26BLASTING OPERATIONS ................................................................................................. 63
27DEMOLITION...................................................................................................................... 64
28FALSE WORK / FORMWORK........................................................................................... 64
29.0PILING AND DIAPHRAGM WALLS ............................................................................. 65
30.0WORK ADJACENT TO LIVE RAILWAYS ................................................................... 65
31.WORK ADJACENT TO LIVE ROADWAYS ................................................................... 66
32.0PERSONAL PROTECTIVE EQUIPMENT ..................................................................... 66
33.Medical Facilities ................................................................................................................. 67
34.0FIRE PRECAUTIONS ...................................................................................................... 70
35.0 Construction Machinery ................................................................................................. 72
36.0TRAFFIC MANAGEMENT ............................................................................................. 74
36.11 Spoil Removal .............................................................................................. 77
37.0 Housekeeping ................................................................................................................ 77
38.Overhead Protection ............................................................................................................. 79
39.0 Slipping, Tripping, Cutting, Drowning and Falling Hazards .......................................... 79
40.0Launching Operation.......................................................................................................... 80
41.0Machine and General Area Guarding ................................................................................ 81
42.0Manual Lifting and Carrying of Excessive Weight ........................................................... 81
43.0Hand Tools and Power Tools ............................................................................................. 82
Section VI- A, Volume -2, Safety Manual 2-i December 2021

44.0 Dangerous and Harmful Environment ............................................................................. 83
45.0 Corrosive Substances ........................................................................................................ 83
46.0 Batching Plant / Casting Yard ........................................................................................... 84
47.0 Radiation .......................................................................................................................... 84
48.0 Smoking ......................................................................................................................... 85
49.Mobile Phones, Radios and Audio Equipment .................................................................... 85
50.Dust, gases, fumes etc. ......................................................................................................... 85
51.0 Vehicular Traffic ............................................................................................................. 86
52.0 Handling of explosives................................................................................................... 86
53.0 Floor Openings ............................................................................................................... 87
54.0 Evaluation, Selection and Control of Sub-Contractors ................................................. 87
55.0 OH&S Sharing & Site Visits ........................................................................................ 87
56.0 CCTV ............................................................................................................................ 87
57.0 Barricade / Cover to Voids, Trench, Bored Holes and Open Edges of Structure ......... 88
58.0 General Safety ............................................................................................................... 88
59.0 Safety (Anti-Fall) Net ................................................................................................... 90
60.0 Site Transport ................................................................................................................ 90
61.0 Site Security .................................................................................................................. 92
62.0 Flooding ........................................................................................................................ 96
63.0OH&SSubmittals to the Employer/Engineer ..................................................................... 97
64.0Monthly OH&S Report ...................................................................................................... 98
65.0 Visitors to Site................................................................................................................ 98
Appendix ................................................................................................................................... 98
Section VI- A, Volume -2, Safety Manual 2-ii December 2021

1. STATEMENT OF INTENT
It is the intention of the Chennai Metro Rail Limited to build the second phase of the
Metro system for Chennai in a way that will further raise the standards of Occupational
Health and Safety on construction sites to a level that will be recognised as the best in
India and comparable to the highest standards achieved worldwide.
This can only be achieved if there is a commitment from all parties involved in the
construction and management of the Project, from the most senior level of managers
within the CMRL and the Contractors, to the workers on the sites.
This document shall have the full support of all of the CMRL Project Team and any
officer failing to give support to it shall be subject to internal discipline.
The Chennai Metro Rail Limited shall actively support the efforts and initiatives that are
instigated by the Contractors and sub-contractors in their efforts for achieving high
standards of Occupational Health and Safety on the Project.
The ingredients that are needed to make and achieve a high standard of Occupational
Health and Safety, are well known to most of us, it is however the level of commitment
that is demonstrated that shall determine whether or not we succeed.
This manual represents the minimum standards that the Chennai Metro Rail Limited will
accept on matters of Occupational Health and Safety. The Chennai Metro Rail Limited
will use its best endeavours to ensure that all of the Contractors employed on the Project
achieve these Standards
Managing Director
Chennai Metro Rail Limited
Section VI- A, Volume – 2, Safety Manual. 2-1 December 2021

REFERENCES, LEGAL REQUIREMENT’S AND DISTRIBUTION OF THIS MANUAL

2.1 References
2.1.1 The procedures in this manual should be read in conjunction with;
a) BOCWA means Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Act, 1996
b) BOCWR means Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Central Rules, 1998
c) Tamil Nadu building and other construction workers (regulation of employment and
conditions of service) rules, 2006.
d) The Factories Act, 1948 and Tamil Nadu Factories Rules 1950
e) Other Laws of India, Regulations, Rules and Codes of Practice on Occupational Health
and Safety that may be applicable.
f) The important Indian Standards and British Standards as applicable to the work of this
contract;
2.2 Legal Requirement’s

2.2.1 The Contractor shall comply with all applicable legislative OH&S requirements of India
including any new acts and regulations which may be gazetted during the Contract period
including any amendments or re-enactments thereto.
2.2.2. The Contractor shall comply with all the OH&S requirements contained in this specification
and supporting documentation, even where these impose a higher standard than that
required by current India legislation.
2.3 BOCWR Registration, Register of persons employed as building workers and Muster
roll
2.3.1 Upon award of the Contract, the Contractor shall register their works as a construction
Industry. A copy of the licence shall be submitted to the Employer/Engineer.
2.3.2 The Contractor shall maintain in respect of each registered establishments where
he employs building workers, a register in Form -XV under Schedule-XIII of TBOCWR
2006.
2.3.3 In respect of establishment to which the Payment of Wages Act, 1936 (Central Act
of 1936) or Minimum Wages Act, 1948 (Central Act 11 of 1948) or the Contract Labour
(Regulation and Abolition) Act. 1970 (Central Act 37 of 1970) applies, the following
registers and records required to be maintained by a contractor under any of such Acts or
TBOCWR 2006, shall be deemed to be the registers and records maintained by the
contractor under the TBOCWR 2006, namely: -
(a) muster roll;
(b) register of wages;
(c) register of deductions:
(d) register of overtime;
(e) register of fines: and

(f) register of advances.
2.4 Distribution of this Manual

2.4.1 Copies of this Employer Occupational Health and Safety Manual are distributed to
all Tenderers for Contracts where this has been shown as a part of a Contract document. It
will also be issued to all appropriate staff of CMRL and all other persons who have need
of it.
3. DEFINITION OF TERMS
3.1 Introduction
3.1.1 The following terms used in this manual are defined as follows and shall be
construed accordingly.
In this document
(a) ‘OH&S’ means Occupational Health and Safety
(b) Employer means Chennai Metro Rail Limited (CMRL).
(c) BOCWA means Building and Other Construction Workers (Regulation of Employment
and Conditions of Service) Act, 1996
(d) BOCWR means Building and Other Construction Workers (Regulation of Employment
and Conditions of Service) Central Rules, 1998.
(e) TBOCWR means Tamil Nadu Building and Other Construction Workers (Regulation of
Employment and Conditions of Service) Rules, 2006
(f) DG means Director General of Ministry of Labour, Govt. of India
(g) Occupational Health and Safety means the freedom from unacceptable risks of
personal harm, i.e. the avoidance of accidents and incidents.
(h) Health means the physical wellbeing of a person and the freedom from any illness
caused working conditions.
(i) Hazard means a situation with the potential to cause harm including human injury,
damage to property, plant or equipment, damage to the environment, or economic loss.
(j) Risk means the chance of something adverse happening and its severity. It is a
combination of the probability, or frequency, of the occurrence of a defined hazard and
the magnitude of the consequences of the occurrence.
(k) Shall. Indicates a mandatory requirement within this document
(l) Foreseeable means that which is likely or possible.
(m) Chief Safety Expert means an officer nominated by Employer /Engineer who is
the overall responsible for monitoring all OH&S functions prescribed in this document
(n) Site Occupational Health and Safety Plan means the contract specific Occupational
Health and Safety plan that the Contractor has produced from his Outline OH&S Plan.
(o) Accident means an unplanned event that results in personal injury or property
damage.
(p) Incident means an unplanned, undesired event that hinders completion of a task and
may cause injury, illness, or property damage or some combination of all three in
varying degrees from minor to catastrophic.
(q) Near miss means an incident in which no property was damaged and no personal
injury was sustained, but where, given a slight shift in time or position, damage or injury
easily could have occurred.
(r) Dangerous occurrence is defined as:
1) Collapse or failure of lifting appliances or hoist or conveyors or other similar;
2) Collapse or failure of a crane, derrick, winch, hoist or other appliance used in raising
or lowering persons or goods or any part thereof (except the breakage of chain or
rope slings), or the overturning of a crane;
3) Explosion or fire causing damage to the structure of any room or place in which
persons are employed, or to any machine or plant, resulting in the complete
suspension of ordinary work;
4) Electrical short circuit or failure of electrical machinery, plant or apparatus, attended
by explosion or fire, causing structural damage involving its stoppage or disuse;
5) Explosion of a receiver or container used for the storage at a pressure greater than
atmospheric pressure of any gas or gases (including air) or any liquid or solid resulting
from the compression of gas;
6) Collapse in whole or part from any cause whatsoever of any roof, wall, floor,
structure or foundation forming part of the construction site in which persons are
employed;
7) Total or partial collapse of any overburden, face, tip or embankment on the
construction site;
8) The overturning of, or collision with any object by any bulldozer, dumper, excavator,
grader, lorry or shovel loader, or any mobile machine used for the handling of any
substance on the construction site.
(s) Recordable injury or illness means one that requires medical treatment beyond first
aid, as well as one that causes death, days away from work, restricted work or transfer
to another job, or loss of consciousness
(t) First aid means any one-time treatment, and any follow-up visit for. the purpose of
observation of minor scratches, cuts, burns, splinters, or other minor industrial injuries,
which do not ordinarily require medical care.
(u) Reportable Accident / Incident means an Accident or Incident that is reportable to the
Employer/Engineer. It shall include all fatalities, major injury accidents, Near Misses /
dangerous occurrences and all accidents, which result in incapacity for more than
Twenty -Four hours or more immediately following the accident.
(v) Major Injury Accident is defined as:
1) Any fracture, other than to the fingers or toes;
2) Any loss of a limb or part of a limb;
3) Dislocation of the shoulder, hip, knee or spine;
4) Loss of sight (whether temporary or permanent);
5) Penetrating injury to the eye; or
6) Any other injury that:
• Leads to unconsciousness
• Requires resuscitation;
• Requires admittance to hospital for more than 24 hours;
• or which causes more than 10 days absence from work
4. GENERAL
4.1 Introduction
4.1.1 It is the objective of the CMRL to ensure that the Contract is completed on time,
within budget, and to conforming standards of Occupational Health and Safety.
4.1.2 This manual has system wide application, and therefore not all of the sections will
apply to all Contractors. Each Contractor shall develop his own contract specific
Site Occupational Health and Safety Plan, which will represent his approach to the
management of Occupational Health and Safety on his work, sites under the
Contract with CMRL.
4.1.3 It is the intention of CMRL to levy Penalties against contractors who do not comply
with the requirements of this Manual.
4.2 Purpose of the Manual
4.2.1 This manual has been produced in order to outline the minimum Occupational
Health and Safety, standards that shall be required by CMRL during construction of
the Chennai metro rail project. Furthermore, the manual has been developed to give
guidance and assistance to the respective Contractors in the development and
production of their Site Occupational Health and Safety Plans, to satisfy the required
OH&S standards established by the Contract Conditions and the Employer’s
Requirements. This manual represents the minimum standards required and each
Contractor is encouraged to expand and improve upon it.
4.2.2 This manual is not intended to replace existing standards that are currently in force
in India. However, it is intended to support the standards and to highlight to
Contractors the areas of concern that shall be addressed in their respective Site
Occupational Health and Safety Plans in order to establish good OH&S practices.
4.2.3 This document is intended to supplement the Section on Occupational Health and
Safety Measures as is contained in the Employer’s Requirements.
4.2.4 The obligations and requirements for Occupational Health and Safety set out within
this document are entirely without prejudice and do not derogate from the
Contractor’s obligations with respect to the Contract and his statutory obligations
with respect to Occupational Health and Safety.
4.3 Scope of the Manual
4.3.1 The Contractor is fully responsible for the Occupational Health and Safety of the
Works, his personnel, subcontractors’ personnel, the public and all persons directly
or indirectly associated with the Works or on or in the vicinity of the Site.
4.3.2 This manual provides relevant information and procedures to assist the Contractor
to ensure that his employees and sub-contractors work within Occupational Health
and Safety. Compliance with the procedures set out in this manual shall not relieve
the Contractor of any of his Statutory Duties or his responsibilities under the
Contract.
4.4 Policy Objectives
4.4.1 Every Contract should aim at zero fatal accidents.
4.4.2 Every Contract should aim at zero dangerous occurrences
4.4.3 Every Contract should aim at an Accident Frequency Rate (AFR) of less than 0.5
per 100,000 hours worked on the Contract.
4.5 Implementation of Policy Objectives
4.5.1 The following general approach has been adopted by CMRL with a view to
achieving the policy objectives set out above
(a) Secure a commitment to ÓH&S working practices by all parties involved in the
construction process, including consultants, Contractors, sub-contractors,
workers' unions, and utility providers.
(b) Develop contract provisions that require Contractors to prepare, implement and
monitor occupational Health and Safety plans, and ensure that sub-contractors
are also obliged to comply with the same.
(c) Arrange accident prevention, occupational Health and Safety management
training for all site staff supervising Contracts.
(d) Establish Site Occupational Health and Safety Management Committees to
monitor the implementation of occupational Health and Safety plans and keep a
record of the Meetings of the Committees.
(e) Oversee the occupational Health and Safety performance of the Contractors and
sub-contractors to ensure that their duties and responsibilities on occupational
Health and Safety under the Contract, this Manual, and other relevant Employer
and Government requirements are fully discharged.
(f) To publish and issue any further instruction / appendices needed for any specific
requirement of the Contract
4.6 Responsibility for the Manual
4.6.1 The Directors /Any Other nominated officials of CMRL are responsible for ensuring
that the contents of this Manual continue to meet the requirements of the CMRL
and that they are implemented rigorously.
5. GENERAL DUTIES OF CONTRACTORS AND OTHERS

5.1 Introduction
5.1.1 The Contractor shall be responsible for the OH&S of all operations in connection
with the Contract and shall take all necessary actions to ensure the safety of all
persons and property who may be on or adjacent to the Site.
5.1.2 The Contractor shall be responsible for ensuring that his sub-contractors; Interfacing
Contractors; and all persons entitled to be on the Site comply with all relevant legal
and contractual requirements including the Contractor’s site occupational Health
and Safety Plan and shall enforce its compliance.
5.1.3 Securing safe, healthy places of work requires the full co-operation of Contractors
and sub-contractors and the persons employed by them. It is imperative that there is
no ambiguity with regard to the responsibilities of any individuals in connection
with duties relating to occupational Health and Safety.
5.1.4 The responsibilities shall be clearly detailed in the Site Occupational Health and
Safety Plan from the level of the most Senior Manager downwards, these duties
shall be explained to the individuals concerned in order to ensure that they clearly
and concisely understand them.
5.1.5 Responsibilities for OH&S shall be allocated amongst others to the following
personnel of the contractors and sub-contractors:
(a) CEO / Managing Director:
(b) Project Director /Project Manager:
(c) Site Manager:
(d) Engineers:
(e) Chief OHS&E Manager:
(f) Supervisors:
(g) General Workers
5.2 General Duties of Persons Employed
Every person employed by Contractors and sub-contractors on construction sites are
obliged to comply with the general duties imposed on them under the Contract. Every
person employed should, not only avoid careless or reckless behaviour, but should also
take positive steps to understand workplace hazards. They must follow all necessary
OH&S rules and procedures, and ensure that their acts or omissions at work do not put the
occupational Health and Safety of self or others at risk.
5.3 Contractors and Sub-contractors: Responsibilities
5.3.1 Contractors and sub-contractors are responsible for complying with all statutory and
contractual requirements on OH&S including the general duties imposed on them
under the Laws and Regulations of the Government of India, Government of the
Tamil Nadu and other relevant authorities.
5.3.2 The Employer /Engineer shall only deal with occupational Health and Safety
matters through the Contractor and shall hold the Contractor responsible for all his
and his Sub-contractors, actions. All Sub-contractors shall be responsible to the
Contractor.
5.3.3 All Contractors and Sub-contractors shall ensure that an adequate level of competent
supervision is maintained at the workplace at all times with all supervisory staff
having the relevant knowledge, training, and job specific experience to enable them
to supervise the work in a proper manner.
5.3.4 Contractors shall ensure that all sub-contractors are able to demonstrate a successful
track record with regard to the management of occupational Health and Safety. The
type of information that shall be requested from the sub-contractors during the
tendering process in order to determine their suitability shall include amongst other
things the following information relating to their activities over the last five years
(a) Fatal accidents
(b) Major lost time accidents
(c) Accidents involving members of the public
(d) Dangerous Occurrences
5.3.5 Contractors and sub-contractors are responsible for submitting written statements
on their policies relating to construction occupational Health and Safety within 28
days of a requirement to do so by Employer/Engineer.
5.3.6 Contractors and sub-contractors are responsible for providing comprehensive
occupational Health and Safety plans for the review by Employer/Engineer, and for
subsequent implementation of the measures detailed in the occupational Health and
Safety plans.
5.3.7 Contractors and sub-contractors are responsible for the provision of suitably trained
and qualified occupational Health and Safety staff to carry out regular OH&S
inspections, OH&S promotion, and OH&S audits and for retention of records of all
such activities for inspection by Employer/Engineer.
5.3.8 Contractors and sub-contractors are responsible for providing OH&S third party
approved training agency shall conduct training to all workers and supervisors on
site, and for retention of records of such activities for inspection by the
Employer/Engineer.
5.3.9 Contractors and sub-contractors are responsible for organising site occupational
Health and Safety committees which shall meet at least monthly.
5.3.10 Contractors and sub-contractors are responsible for reporting Near Miss, dangerous
occurrences, First Aid Injury, Minor Injury, Major Injury, Incidents and accidents
to the Employer/ Employers Representative by the quickest practicable means.
5.3.11 The Contractor shall establish a set of in-house OS& H rules and regulations based
on industry standards and legislation for the Employer /Engineer’s acceptance. The
Contractor shall display sufficient copies of these rules and regulations on Site,
translated into languages understood by the workers.
5.4 Discipline
5.4.1 Any major breaches of the Site OH&S Plan, relevant Statutory Provisions and
Occupational Health and Safety Codes, or any other blatant disregard for the
occupational Health and Safety by any person directly or indirectly associated with
the works may result in the CMRL exercising their authority in requiring the
removal from the Site of the Contractor’s Site Manager and/or other personnel.
5.4.2 The Contractors shall develop a system of disciplinary measures and procedures,
which shall be implemented immediately that the site activities commence. These
measures and procedures should include amongst other things:
(a) The issue of Warning Notices.
(b) The removal from site of personnel who disregard occupational Health and Safety
instructions.
5.4.3 Any person who is removed from the site for breach of occupational Health and
Safety measures shall not be allowed to be re-employed on any other CMRL
worksite.
5.5 Occupational Health & Safety (OH&S) Personnel.
5.5.1 The Employer /Engineer shall require the replacement of the appointed OH&S
personnel if the performance of the OH&S personnel is not up to the Employer
/Engineer expectation.
6. OCCUPATIONAL HEALTH AND SAFETY TRAINING AND OH&S PROMOTION
6.1 Occupational Health and Safety Training
6.1.1 Occupational Health and Safety Training is an important factor in managing OH&S
on construction sites. All contractors shall provide as a minimum training as per the
OH&S contract requirement’s:
6.1.2 Induction Training shall be given to all persons prior to permitting them to go to
the worksite. The worker’s ID Card should not be issued until this training has been
given. Incorporate virtual reality (VR) technology for workers training. This
training should include at least the following:
(a) General occupational Health and Safety awareness
(b) First aid
(c) Emergency procedures
(d) Use of personal protective equipment
(e) Specific site hazards

6.1.3 Refresher Training shall be conducted at least every six months by the third party
agency approved by the Employer/Engineer to ensure that all workers on site are
kept up to date with occupational Health and Safety requirements on site.
6.1.4 Specific Training shall be conducted at least every six months by the third party
agency approved by the Employer/Engineer for Crane Operators, EOT Operators,
Gantry Operator’s, Fork Lift Operators, Piling Rig Operator’s, Grab Operator’s,
Lifting Supervisor, Banksmen, Slingers, Loco Operations and Plant Operators etc.
Provide personnel competency stickers to identify competent users.
6.1.5 Toolbox Talks shall be conducted so that every worker on site. These talks should
be designed to highlight relevant occupational Health and Safety issues to the
workforce on a regular basis in order to raise their level of awareness. These should
be prepared so that they can be presented by the Site Supervisors.
6.1.6 Tool Box Meetings shall be conducted daily specific to the work performed for the
day before work commences. Workers shall be briefed on the day’s activities, the
OH&S precautions to be observed, the safe work practices to be followed, and each
individual’s PPE will be checked as to its suitability, and its correct use explained
where necessary.
6.1.7 The Contractor shall setup a safety training centre to train workers on workplace on
OH&S capable of providing training to at least 20 workers at a time. The training
room shall be provided with all the necessary audio and visual training facilities.
6.1.8 The Contractor shall ensure that no personnel including Interfacing Contractors
work on site prior to the completion of the Contractor’s in-house safety induction
training and obtaining a security pass. The Contractor shall ensure that training
information is given in languages understood by the trainees.
6.1.9 The Contractor shall develop and implement a comprehensive assessment system
to assure the competency of his supervisory staff, lifting crew and machine operators
prior to their deployment for works. The assessment system shall include face-to-
face interviews and written tests that adequately evaluate appreciation of safety
hazards associated with respective works, Safe Work Practices etc.
6.1.10 The Contractor shall implement an identification system on site to clearly identify
all the qualified personnel and operators.
6.1.11 The Contractor shall ensure that all personnel and in particular new personnel, or
personnel transferred to new assignments are given proper safety training relevant
to their duties.
6.1.12 All training that is carried out shall be formally recorded on dated and signed
attendance records, with copies of the records being kept on the sites for inspection
by the Employer/ Engineer. Details of the respective training course programmes
shall be produced, on demand or as per intervals prescribed, which include the
following information:
(a) Course Title.
(b) Course Duration.
(c) Course Content.
(d) Target Audience.

6.1.13 Actual Audience with record of attendance.
6.1.14 The Contractor shall keep detailed records of all training undertaken, and shall keep
such records available for inspection by the Employer/ Engineer.
6.1.15 The minimum Employer’s requirement of training needs for various categories of
employees are given in general instruction GSAF 004.
6.1.16 The Profile of the training Agency, ISO certifications, course details, the name,
educational qualifications and experience for of the trainers are to be submitted to
the Employer/Engineer a minimum 28 days before prior to appointment of the
agency. Only upon notice of no objection by the Employer /Engineer shall be
authorised to deliver training on CMRL sites.
6.1.17 In case of failure on the part of the contractor for various categories of employees
are given in general instruction GSAF 004 training programs to all employees in
time, the same shall be provided by the Employer /Engineer through accredited
agencies if required by formulating a common scheme to all contractors. It is
mandatory for the contractors to participate in the common scheme. Any
administrative expenses and training fee towards the same shall be at the cost of the
contractor.
6.1.18 The Contractors may utilise the services of OH&S agencies empanelled under Rule
250 of TBOCWR 2006 and Rule 297 of TBOCWR 2006 for the purpose of training,
internal audit and any other OH&S services with prior approval of the Employer
/Engineer.
6.2 Occupational Health and Safety Promotion
6.2.1 The Contractor shall develop an annual OH&S promotional programme to
demonstrate his commitment to advancing the OH&S culture at the Site and
reinforcing the concept that OH&S and construction are inseparable. The
programme shall enhance personal OH&S awareness and influence all attitudes and
behaviour of all personnel on OH&S matters. The programme shall consist of
general promotional activities which are carried out as part of a day-to-day activity
and high impact promotion activities which are carried out as a campaign to
reinforce a particular OH&S point at the Site. The OH&S promotional programme
shall be revised and updated at least once a three months.
6.2.2 The Contractor shall organise a minimum of twelve campaigns covering OH&S
related topics for each calendar year.
6.2.3 In addition to clause 6.2.2, the Contractor shall conduct regular ‘Safety Time-out’
sessions. This is to allow Contractor to take stock and refocus on safety, review
current work activities and its associated hazards, as well as to identify additional
safety measures required to maintain high standards on the worksites. The
Contractor may conduct the ‘Safety Time-out’ sessions on a site-wide basis or to
focus on specific work activities or subcontractors at different stages of their works.
The Contractor shall submit a schedule and programme for the ‘Safety Time-out’ to
the Employer /Engineer for approval.
6.2.4 The Contractor shall divide the worksites into designated work areas, each lead by
his engineers or competent supervisors (including charge-hand/ foreman/team-
leader) who will be responsible for the area’s OH&S performance. The OH&S
performance for each work area shall be assessed monthly and corrective actions
shall be taken to raise safety performance. The monthly OH&S assessment shall
include, but not limited to accident statistics and substandard practices and
conditions recorded at various OH&S inspections for the particular work area. The
teams that meet OH&S targets shall be duly recognised and rewarded. The
recognitions shall includes both monetary and non-monetary rewards and be given
out at a suitable event attended by the workforce or as directed by the Employer
/Engineer.
6.2.5 The Contractor shall produce at least twelve OH&S digital one hour each videos to
raise the OH&S awareness and standards of its workforce. The topics and contents
for the OH&S videos shall be decided by the Employer /Engineer. The videos shall
be professionally produced, be of High Definition (HD) quality and translated into
the respective native languages of the workforce. The Employer /Engineer shall
have the rights to the OH&S videos produced.
6.2.6 Suggestions for such promotions may include such items as the issue of the
following as rewards to individuals for good occupational Health and Safety
performance:
(a) Key Rings.
(b) T-Shirts
(c) Holdall Bags
6.2.7 Other OH&S award and Safety incentive schemes should be considered.
6.2.8 Regular OH&S Poster Campaigns / Billboards / Banners / Glowsigns should be
devised, with posters displaying OH&S related issues being displayed around the
worksites as part of the effort to raise OH&S Awareness amongst the workforce.
Posters should be in Hindi, Tamil and English and other suitable language deemed
appropriate. Posters / Billboards / Banners / Glowsigns should be changed at least
once a month to maintain their impact.
6.2.9 The contractor shall also observe important days as listed in General Instruction
GSAF 017 and printing and displaying safety signage and posters as listed in
General Instruction GSAF 017.
6.2.10 The list indicated are the minimum requirements of the Employer and the contractor
is encouraged to further the OH&S communication activities by formulating
suitable reward schemes for safety performers and any other activities, which deem
fit for the purpose.
7. OCCUPATIONAL HEALTH AND SAFETY INSPECTIONS AND FOLLOW UP ACTION
7.1 Inspections by Contractor’s Occupational Health and Safety Supervisory Staff
7.1.1 The Contractor shall carry out internal OH&S inspections continuously. In addition,
informal spot checks should be carried out more frequently on critical site activities.
7.1.2 A written record shall be kept of the daily inspection findings and the results of
inspections should be brought to the line manager having responsibility in the area
concerned, together with the necessary remedial action and due date for completion.
Any corrective action shall be immediately implemented by the line manager, and
followed up by the OSH&E personnel. The Contractor shall submit records of
inspection report as deemed necessary by the Employer /Engineer.
7.1.3 Inspection of shoring of formwork, side supports of excavations and trenches,
cranes and scaffolds should be carried out after any episode of inclement weather
which may affect their stability / integrity.
7.1.4 The Contractor’s senior site management shall participate in the Employer
/Engineer weekly, monthly, quarterly, and annual ad hoc safety inspections. The
Contractor shall close out the inspection findings to the full satisfaction of the
Employer /Engineer.
7.1.5 The Employer /Engineer shall require the Contractor to suspend a part of the works
or the whole of the works if it is deemed to be unsafe. The Contractor shall be
required to rectify the substandard condition or practice till the satisfaction of the
Employer /Engineer. In such events, the Contractor shall not be entitled to any claim
for compensation or Extension of Time for Completion.
7.1.6 For each Contract the Contractor shall prepare a comprehensive occupational Health
and Safety inspection checklist, as a requirement of the OH&S Plan. This check-list
can then be used for:
(a) inspections by the Contractor's OH&S Managers;
(b) monitoring of the Contractors' OH&S inspections by the Site OH&S Management
Committee.
7.1.7 In relation to Works Contracts, the insurers providing insurance cover for
Contractor's All Risks and Third Party liability may visit the sites with a view to
checking whether the Contractors have taken adequate occupational Health and
Safety precautions against damage to the works.
7.1.8 The Contractor’s senior management shall give a presentation on their safety
commitments to the Employer /Engineer on a monthly basis or when deemed
necessary by the Employer /Engineer.
7.1.9 The agenda for the presentation shall be as follows:
a) The proposed OH&S targets, goals and strategies in achieving them;
b) A brief review on the past safety performance, including accident statistics,
incident/accident/near misses reported with actions taken to address the
shortcomings;
c) An overview of the safety challenges over the next six (6) months including
plans and strategies devised to mitigate these risks;
d) The OH&S hazards arising from these work activities; and
e) Any other critical OH&S related issues
7.2 Follow up actions
7.2.1 Remedial action to rectify any deficiency identified or unsafe practices discovered
during the OH&S inspections should be implemented immediately. Until the
remedial action is taken the task may be discontinued.
7.2.2 In cases where the Employer's /Engineer believe that the Contractor's or sub-
contractors' workmen are using unsafe working methods, the Contractor's
Representative should be informed by them as soon as possible. If the unsafe
activity continues, it shall be reported to the Employer's /Engineer.
7.2.3 If the Contractor's working method is deemed so unsafe as to represent a risk to life,
the Employer's /Engineer may require specific actions by the Contractor, such as
proposals on preventive/remedial measures, or suspension of relevant portions of
the works, and introduction of measures deemed necessary. All such instructions
shall be confirmed in writing and shall include a provison that the issue of the
instruction shall not relieve the Contractor of his responsibilities under the Contract
or Statutory obligations. The Employer/Engineer may also invoke a penalty on the
Contractor in accordance with OH&S contract Requirements
7.3 External OH&S Audit
7.3.1 General
7.3.2 External OH&S audits shall be conducted by external OH&S agency approved by
the Employer/Engineer that is competent with ISO 45001:2018 / ISO Lead Auditor
/DGFASLI qualified auditors.
7.3.3 The audit company engaged by the Contractor shall be accepted by the Employer
/Engineer. The audit company shall present and submit their audit methodology
including detailed resumes of their audit team and audit checklist for the
Employer/Engineer acceptance before commencement of any audits. The audit
company is required to give a presentation of the audit findings to the Employer
/Engineer.
7.3.4 The audit report and its corrective actions shall be brought to the attention of all sub-
contractors and copied to the Employer /Engineer.
7.3.5 Periodicity
7.3.6 External OH&S report.
7.3.7 For all audits done on a routine basis and audits undertaken due to the deterioration
or occurrence of a major incident, the cost shall be borne by the Contractor
7.4 Areas of competence of Audit team
7.4.1 Practical understanding of BOCW Act and Rules, statutory requirements on
health/medical and welfare of workmen, construction hazards and its prevention and
control, traffic management, electrical safety, rigging, safety of construction
equipment and environment management.
7.4.2 Audit shall be conducted as per the guidelines of ISO, ILO, national & international
standards. Audit report shall also be presented as per the referenced formats.
7.4.3 Targets of OH&S Audit:
7.4.4 The contents and coverage of the external audit shall include the following items;
7.4.5 OH&S management:
i) Organization
ii) Communication and Motivation
iii) Time office
iv) Inspection
v) Emergency preparedness
vi) Budget allocation
vii) Education and
Training
viii)Work permit system.
7.4.6 Technical:
i) Building and Structure
ii) Construction operational safety
iii) Design Safety
iv) Material safety
v) Hand tools and Power tools
vi) Electrical system
vii) Safety Appliances
viii)Fire prevention and control
ix) Housekeeping
x) Plant & Machinery safety
xi) First-aid and Medical Facilities
xii) Welfare measures
xiii)Environmental Management
7.4.7 Audit Documents:
7.4.7.1 Contractor shall make the below listed documents available for the review
by the Audit team.
i) OH&S policy
ii) Construction Phase OH&S Plan
iii) OH&S Rules and
regulation
iv) OH&S organization chart
v) Annual OH&S objectives / programs
vi) Accident / near miss statistics and analysis
vii) OH&S Training program / records for all personnel
viii) Operating manuals and maintenance manual of all plant and equipment
ix) Safe worthiness certificates of all lifting appliances and gears
x) Medical fitness record for all personnel

xi) Risk identification, assessment and control
details
xii) Environmental management reports
xiii) Emergency management records including mock drills
7.4.8 Audit Preparation:
i) Audit team members are required to gather information by observations

through interviews and by checks of hardware and documentation.
ii) Audit team shall prepare a checklist to cover all parts based on the OH&S
legislations rules and regulations and CMRL requirements.
iii) Audit team members shall verify the facts and findings leading to the
identified gaps and weakness.
iv) Audit leader has overall responsibility for reaching a conclusion.
7.4.9 Reporting:
7.4.9.1 Audit report shall be prepared and directly sent to the Employer/Engineer within 7 days of conducting
the audit with a copy to the contractor.
7.4.10 Report contents:
i) Executive summary - based on the finalized checklists as written the

findings to the Employer/Engineer by the audit team members, the audit
leader will compile a concise and accurate summary of observations
and findings.
ii) Introduction - this will contain basic information regarding the facilities
or organization audited, the specific audit dates (inclusion of those for
preparation and post-audit activities).
iii) Principal positive findings - This will contain the summary of positive
aspects as observed by the auditors. It will also contain highlights of
those issue, which may warrant dissemination as best practice regarding
methodology used or achievement.
7.4.11 Conformity Report & Action by Employer/Engineer
7.4.11.1In case of non-conformity of items identified by auditor, the Employer/Engineer

shall take necessary steps including stoppage of work and or imposing of any
penalty to ensure satisfactory execution.
7.4.11.2Failure of contractor to conduct External OH&S Audit

7.4.11.3If the contractor fails to conduct the external OH&S audit in time, the
Employer/Engineer at the cost of contractor shall implement through the
appointment of an external OH&S agency.
8. CONTACTOR’S SITE OCCUPATIONAL HEALTH AND SAFETY COMMITTEES
8.1 General
8.1.1 All employees should be able to participate in the making and monitoring of
arrangements for occupational Health and Safety at their place of work. The
establishment of site OH &S committees in which employees and Contractor and sub-
contractor management are represented can increase the involvement and commitment of
employees. The Contractor shall set up such site OH &S committees to promote and
monitor OH&S on their worksites. A copy of the agenda shall be forwarded to the
Employer/Engineer seven days prior to the meeting date, in order that they can decide if it
is necessary for them to attend.
8.2 Composition and Functions of Contractor’s Occupational Health and Safety
Committees
8.2.1 The Contractor should form a occupational Health and Safety committee for each
contract, however should the situation require more than one committee, or the
Employer/Engineer so requires, additional committees shall be created.
8.2.2 The Contractor shall adopt the following format for his OH&S Committee
Meeting.
i) To monitor the adequacy of the Contractor's Site OH&S Plan and ensure its
implementation
ii) Chairman’s review of OH&S performance/ condition;
iii) Report from the Secretary;
iv) Report from OH&S Representatives;
v) To monitor OH&S Inspection Report;
vi) To study of accidents & Incidents report;
vii) To study accident statistics and trends so as to identify unsafe practices and
conditions;
viii) To review the emergency and rescue procedures
ix) To review site safety training
x) To promote OH&S on site
xi) Reports on status of authorities visits, and discuss follow up actions;
xii) To discuss the Contractor's monthly safety report
xiii) OH&S Talk by Committee Members;
xiv) Report from the Employer /Engineer; and
xv) To take follow up actions on minutes of meeting /Any Other Business.
8.2.3 The Membership of the committee should be as follows;
Chairman: The Contractor’s Project Director/Project Manager for
the Contract.
Secretary: The Contractor’s Chief OHS&E Manager
Members: Contractor's and Sub-contractor’s management
representatives and occupational Health and Safety

staff. In attendance as and when they wish,
Representatives of the Employer and the Engineer
8.2.4 Meetings should be held at least once every month
8.2.5 The Committee shall inspect the Site at least one week before each month’s
meeting.
8.2.6 Minutes of the Site Occupational Health and Safety Committee shall be sent to all
members within two working days of the meeting. Copies of the minutes should be
displayed on notice boards so that employees are kept informed of the Site OH&S
Committee's activities and decisions.
8.3 OSH&E Coordination Meeting
8.3.1 The Contractor shall conduct weekly OSHE co-ordination meetings with his sub-
contractors and Interfacing Contractors to ensure that works are carried out on Site with
minimum risk to workers and to the public. The meeting shall plan and co-ordinate all
works on site including the movement of plant, equipment & hazardous materials and
also review safe work practices, permit to work procedures, training, PPE and incidents.
The meeting shall also inform personnel of potentially dangerous works operation at the
Site.
8.3.2 During co-ordination meetings on combined services drawings (CSD), Structural,
Electrical and Mechanical (SEM) & Co-ordinated installation programme(CIP), the
following items shall be included in the meeting agenda
i) Planning and sequencing of work activities and identify incompatible
works between contractors working in the same area;
ii) Identification of risks and hazards of the interfacing works, including
the conduct of site walk to verify these hazards;
Highlighting potential high risk zones during handing over; and
iii)
iv) Developing a site map to show delivery routes and designated storage
area for the Contractor and Interfacing Contractors
8.4 Employer /Engineer Project Safety Committee
8.4.1 The Employer /Engineer may require the Contractor’s Project Director /Project Manager and OSH&E
personnel to attend the Employer /Engineer Project Safety Committee meeting for reviewing their OSH&E
provisions on site.
9. REPORTING OF ACCIDENTS AND DANGEROUS OCCURRENCES

9.1 Contractors Responsibility
9.1.1 All accidents and dangerous occurrences including Near Misses shall be recorded,
regardless of whether or not personnel injury occurs.
9.1.2 The Employer and the Engineer shall be notified by the quickest possible
means, for example by SMS, telephone of the following classifications of accidents and
incidents and by subsequent written (Preliminary notification report) within 24 hours on the
Contractors Accident and Incident Reporting Form
a) Fatal Accident
b) Major Injury Accident
c) Near Miss / Dangerous Occurrence
d) Any Incident Involving a member of the Public

9.1.3 The Chief OHS&E Manager shall conduct in depth investigations into all fatal
accidents, major injury accidents, incidents involving a member of the public, dangerous
occurrences and Near Misses. Copies of these investigations shall be forwarded to the
Engineer within 72 hours of the incident.
9.1.4 The Contractor shall report immediately by telephone, SMS (Contract No,
Company Name, Location in charge, Date and time of the incident, Location, Witness,
description, Action taken, sent by) communication and in writing, all fatal accidents, and
other occurrences requiring reporting, to the police, at the police station in whose
jurisdiction the accident occurred.
9.2 Reportable Accidents

9.2.1 An accident shall also become reportable to the Employer /Engineer if it
causes incapacity for more than 24 hours excluding the day of the accident. The Contractor
must submit an investigation report to the Employer /Engineer within 72 hours of the incident.
9.2.1 The following information is required in reporting an accident to the Employer

/Engineer.
a)Particulars of the Contractor or Sub-contractor employing the injured person;
b) Particulars of the deceased or injured person: name, address, occupation,
sex, and age;
c) The date, cause or circumstances of the accident; and
d) The nature of the injury, stating whether death or incapacity was caused by
the injury.
9.3 Dangerous Occurrences
9..3.1 The Employer /Engineer requires that all dangerous occurrences on site must be
reported in writing (Preliminary accident notification report) to him within 24 hours,
irrespective of whether there are casualties or not. The following information has to be
provided:
a) The time of the occurrence;
b) Damage to any building, machinery or plant; and
c) The circumstances in which the accident occurred.
9.4 Reporting of Fires by Contractor
9.4.1 The Contractor shall report to the Employer /Engineer all fires which occur on site
including any fires that have been extinguished by the Contractor himself, and the
Employer /Engineer may send staff to investigate such fires. The following information
should be provided:
a) Time of fire;
b) Location of fire;
c) Means of extinguishing the fire;
d) Injury to any person/damage to any property; and
e) The probable cause of fire.
f) This action is in addition to reporting the incident to the Chief Fire Officer
and Police in accordance with local regulations.
9.5 Reporting to the Employer /Engineer
9.5.1 The Contractor shall duly complete standard forms on dangerous occurrences,
Near Miss, Major Injury, Minor Injury, First Aid Cases, Non Reportable Cases,
Fatal and accidents as required by the Employer /Engineer to enable the Employer
/Engineer to prepare a database on accident statistics. The Contractor shall deliver
to the Employer /Engineer a copy of any statutory reports he submits to the
Relevant Authorities.
9.5.2 The Contractor shall send a monthly report to the Employer /Engineer of all
accidents and dangerous occurrences, Near Miss, Major Injury, Minor Injury, First
Aid Cases, Non Reportable Cases, Fatal whether they are of a serious nature or
not.
10. ACCIDENT INVESTIGATION
10.1 General
10.1.1 Investigations should be conducted in an open and positive atmosphere that
encourages the witnesses to talk freely. The primary objective is to ascertain the
facts with a view to prevent future and possibly more serious occurrences. Accidents
are rarely just the fault of the worker. If the worker has not been trained, instructed
or properly supervised then the fault may well lie with management.
10.1.2 Accidents and Dangerous Occurrences which result in death, serious injury or
serious damage must be investigated by the Contractor immediately to find out the
cause of the accident/occurrence so that measures can be formulated to prevent any
recurrence. (Refer to the advice contained in 10.2.1 below.)
10.1.3 Near misses and minor accidents should also be recorded and investigated by the
Contractor as soon as possible as they are signals that there are inadequacies in the
occupational Health and Safety management system.
10.2 Recommended actions in incident investigation
10.2.1 It is important after any Accident or Dangerous Occurrence that information
relating to the incident is gathered in an organised way. The following steps are
recommended;
a) Take photographs and make sketches
b) Examine involved equipment, work piece or material and the
environmental conditions
c) Interview the injured, eye-witnesses and other involved parties
d) Consult expert opinion where necessary
e) Identify the specific Contractor or Sub-contractor involved.
10.2.2 Having gathered information, it is then necessary to make an Analysis of Incident
a) Establish the chain of events leading to the accident or incident
b) Find out at what stage the accident took place
c) Consider all possible causes and the interaction of different factors that led
up to the accident, and identify the most probable cause
Note: The cause of an accident should never be classified as carelessness. The specific act
or omission that caused the accident must be identified.
10.2.3 The next stage is to proceed with the Follow-up Action
a) Report on the findings and conclusions
b) Formulate preventive measures to avoid recurrence
c) Publicise the findings and the remedial actions taken

11. ACCIDENT STATISTICS
11.1 Introduction
11.1.1 Accident data, if properly collected and analysed, indicates trends, and can show
where and how problems arise. Comprehensive accident information enables accident
prevention efforts to be targeted at problem areas.
11.2 Collection of Accident Statistics
11.2.1 The procedures that apply for the reporting and collation of data in respect of
accident statistics are set out below.
11.2.2 The Contractors’ OHS&E Manager are required to send duly completed Report
Forms to the Employer / Engineer. The Construction Accident Statistics Monthly
Report Form must be submitted even if there are no injuries or dangerous
occurrences within the current month.
11.2.3 Man-hours' is defined as the man-hours worked by all persons employed on site.
(including site supervisory staff, management staff and clerical staff).
11.2.4 'Man-days' is defined as the man-days worked by all persons employed on site.
(including site supervisory staff, management staff and clerical staff).
11.3 Calculation of man-days lost - Construction Accident Statistics
11.3.1 When calculating the man-days lost for the Construction Accident Statistics
Summary Sheet, the following applies:
The number of man-days lost refers to the total number of man-days lost during the
reported month due to:
a) Non-fatal reportable accidents which happened within the reported month
b) Non-fatal reportable accidents which occurred in previous months.
The day on which the reportable accident occurred should be excluded in calculating
man-days lost but public holidays within the injured period should be counted.
11.4 Calculation of Accident Frequency Rate (AFR)
The Accident Frequency Rate (AFR) per 100,0000 man-hours worked shall be calculated
using the following formula
No. of reportable accidents
Man-hours worked x 100, 0000
12. HAZARD IDENTIFICATION AND RISK ASSESSMENT

12.1 General
12.1.1 The purpose of Hazard Identification and Risk Assessment is to identify all the
significant hazards, which may occur during the construction phase, and to rank
them according to their severity. Having ranked the risks by severity the Contractor
shall then introduce measures to mitigate the effects of that risk.
12.1.2 Prior to the commencement of any potential High-Risk operations the Contractor
shall conduct a detailed hazard analysis and risk assessment of the task and shall
record his findings on appropriate worksheets.
12.1.3 The worksheets should then show what measures the Contractor is going to take to
reduce the level of risk to acceptable levels.
12.2 Method Statements and Lift Plan
12.2.1 As a result of the Hazard Identification and Risk Assessment detailed method
statements shall need to be produced for medium and high risk activities including
amongst others the following:
a) Craneage of items in excess of 1 tonne lift plan shall be submitted to the Employer
/Engineer
b) Erection of steel structures.
c) Excavations deeper than 2m.
d) Erection and loading of formwork
e) Demolition.
f) Tunnelling operations.
g) Inflammable materials – the use and storage
h) Use and storage of explosives
12.2.2 Method Statements will usually be attached to Design Submissions but should be
cross-referenced to the Contractor’s Site Occupational Health and Safety Plan.
12.2.3 A method statement should contain sufficient information to enable the task to be
undertaken safely and should contain as a minimum the following information
(a) Introduction – A brief outline of the Task
(b) Details of the Risks involved and mitigation thereof.
(c) A step by step description of how the task is to be undertaken detailing
• What needs to be done;
• The order in which the task will be carried out;
• What plant or equipment is required;
• Who the task will be done by;
• Who will supervise the task;
• Where will the task take place;
• When will the task take place;
• The precautions which must be taken before the task is undertaken;
• What to do if things go wrong;
12.2.4 The Contractor shall identify all safety critical activities and ensure that a method statement
is prepared for each activity and accepted by the Employer /Engineer before
commencement of such activities.
12.2.5 The Contractor shall address all comments on the method statement arising from the
Employer /Engineer review. The Contractor shall fully comply with the method statement
approved by the Employer /Engineer. If there is any intention to change the method of
work, the Contractor shall seek approval from the Employer /Engineer.
12.3 Permits to Work
12.3.1 The Contractor shall develop a permit-to-work system, which is a formal written
system used to control certain types of work that are potentially hazardous. A
permit-to-work is a document, which specifies the work to be done, and the
precautions to be taken. Permits-to-work form an essential part of safe systems of
work for many construction activities. They allow work to start only after safe
procedures have been defined and they provide a clear record that all foreseeable
hazards have been considered. Permits to Work are usually required in high-risk
areas as identified by the Risk Assessments.
12.3.2 A permit is needed when construction work can only be carried out if normal
safeguards are dropped or when new hazards are introduced by the work. Examples
of high risk activities include but are not limited to:
a) Work close to 25kV overhead Catenery /contact system
b) Entry into Confined Spaces.
c) Work in Close Proximity to Overhead Power lines and Telecommunication Cables.
d) Hot Work permit.
e) To Dig—where underground services may be located.
f) Work with moving construction locomotives.
g) Working on Electrical Apparatus.
h) Work with Radioactive isotopes.
i) Lifting permit for critical activity
j) Permit to dig
12.3.3 The permit-to-work system should be fully documented, laying down:

a) How the system works;
b) The jobs it is to be used for;
c) The responsibilities and training of those involved; and
d) How to check its operation;
12.3.4 The permit-to-work form must help communication between everyone involved.
It should be designed by the Contractor issuing the permit, taking into account individual
site conditions and requirements. Separate permit forms may be required for different
tasks, such as hot work and entry into confined spaces, so that sufficient emphasis can be
given to the particular hazards present and precautions required.
12.3.5 The permit to work form should contain:
e) Clear identification of who may authorise particular jobs (and any limits to their
authority);
f) Clear identification of who is responsible for specifying the necessary precautions
(e.g. isolation, emergency arrangements, etc);
a) A detailed description of the task clearly identifying the work to be done and the
associated hazards;
b) Plans and diagrams be used if appropriate to assist in the description of the work
to be done, its location and limitations;
c) Identity of the hazards and the precautions to be taken;
d) Clear rules about how the job should be controlled or abandoned in the case of an
emergency;
e) The time limitations should be stated;
f) Job specific toolbox talk conducted by the supervisor
12.3.6 A Permit to Work authorisation form shall be completed with the maximum
duration period not exceeding twelve hours.

12.3.7 A copy of each Permit to Work shall be displayed, during its validity, in a
conspicuous location in close proximity to the actual works location to which it
applies.
12.3.8 A pre-permit activation job specific toolbox talk shall be conducted by the
supervisor including amongst others the following.
(a) All identified hazards are explained;
(b) Risk mitigation process clarified;
(c) Method of work explained stressing points (a) and (b) above;
(d) Emergency response procedure is clarified and persons assigned tasks in the
event of an emergency;
(e) Personal protective Equipment (PPE) requirements including PPE
serviceability checks and training if required;
All workers and supervision shall attend the toolbox talk and sign the toolbox attendance
register. Any person/s coming late to the work site shall be given the toolbox talk and sign
the attendance register
A copy of the toolbox talk and attendance register shall be displayed as per section 12.3.7
of this manual.
13. EMERGENCY PREPAREDNESS PLAN

13.1 Emergency Situations
13.1.1 Every Contractor shall formulate an Emergency Preparedness Plan for each of his sites.
These plans will address foreseeable emergencies that may arise during the construction
activities. Examples of activities for which plans should be prepared include amongst
other things:
(a) An Accident Which Results in Death or Major Injury.
(b) A Serious Fire That Threatens Life.
(c) A Flood That Threatens Life.
(d) Leakage of Any Dangerous Materials or Chemicals.
(e) Leakage / Short Circuit of any Electrical supply.
(f) Major Engineering Failures such as:
• Collapse of tunnels or structures
• Major utility collapse
• Unintended explosions
• Subsidence causing damage to structures or services
13.1.2 An Emergency Preparedness plan should include details of the following;
(a) The name, location and phone number of the Emergency Co-ordinator;
(b) Designated Personnel with locations and phone numbers;
(c) Details of the Emergency Response Team with locations and phone numbers;
(d) Functions of the Emergency Response Team;
(e) The means of Escape;
(f) Communication with the Emergency Services;
• Police
• Fire Services

• Ambulance and Hospital Services
(g) First-Aid Facilities;
(h) Site plans;
(i) Suppliers of emergency equipment such as sump pumps, lighting, craneage, etc.
13.1.3 Copies of the emergency procedures and the Contractor's rescue organisation
(reviewed without objection by the Employer /Engineer) should be displayed at each
place of work and notice boards. This information should be reviewed and updated
as often as is required, but at least once annually. Drills should be arranged to test
the efficiency in mobilising the necessary personnel and equipment. These Drills
should be carried out at least every month.
13.1.4 Regular joint exercises between the Contractor's rescue teams and the Tamil Nadu
Fire and Emergency Services should also be carried out for the major contracts.
13.1.5 Every Contractor shall formulate a Monsoon Preparedness Plan for each of his sites.
A Monsoon Preparedness Plan should include details of the following
a) Hazard During Monsoon Season in site premises
b) General Precaution
c) Role, responsibility, accountability and authority of responsible
d) Communication System
e) Pest Control
f) Emergency Flow Chart
g) Emergency Equipment’s and Safety Materials
h) Dewatering Pump Details
i) Emergency Contact Numbers
14. OCCUPATIONAL HEALTH AND SAFETY SIGNAGE
14.1 Occupational Health and Safety Signs
14.1.1 All occupational Health and Safety signage that is displayed in and around the
sites shall be in Tamil, Hindi and English, examples of signs that shall be required shall
include amongst others the following:
a) Wear Safety Helmets.
b) Permit to Work areas
c) Wear Safety Footwear.
d) Wear Hearing Protection.
e) Wear Eye Protection.
f) Danger Electricity.
g) Danger Crane Overhead.
h) Stop Look and Listen
i) No Smoking.
j) First Aid.
k) No Entry signs
l) Fire precautions.

m) Emergency Exit from underground works
14.1.2 All occupational Health and Safety signs shall comply with the Internationally recognised
Occupational Health and Safety Colours as indicated below:
• Blue :Mandatory.
• Yellow :Danger.
• Red :Prohibition.
• Green :Safe Condition.
15. INDUSTRIAL OCCUPATIONAL HEALTH AND WELFARE

15.1 Introduction
15.1.1 Hazards to Health on a construction site can arise from the use of a number of
materials, substances and processes if they are not properly controlled. Some of the
more serious risks are caused by the inhalation of dusts, fibres, toxic fumes, by the
misuse of chemicals, lasers and radioactive isotopes. Excessive vibration and
excessive noise can also cause ill health. Many man-days are lost as a result of
dermatitis, tenosynovitis, bronchitis and rheumatism.
15.1.2 The Contractor shall be responsible for maintaining healthy working conditions for
all his, and his sub-contractors, workers. In particular he shall pay attention to the
effects of noise, dust, air pollution and the use of chemicals. If it is not possible to
remove the cause of harm then suitable and sufficient Personal Protective
Equipment (PPE) should be provided to those workers who could be affected.
15.1.3 If the use of PPE is the only means of providing protection the Contractor shall
ensure that all the workers affected are properly trained in the use of the PPE and
that adequate supervision is provided to ensure its proper use.
15.2 Hazardous Substances
15.2.1 The Contractor shall obtain Material Safety Data Sheets (MSDS) for all substances
that are deemed to be hazardous to be used on site. An inventory shall be kept of all
such materials with the relevant MSDS and shall be available for inspection by the
Employer / Engineer who may require further MSDS’s to be obtained.
15.2.2 The Contractor shall conduct an assessment of the substance in relation to its
intended usage on site. Particular attention must be given to the actual location of
usage as a substance, which is safe for use in the open air, may be extremely
hazardous in a confined space. The results of all assessments shall be recorded and
method statements produced.
15.2.3 The objective of the assessment is to establish what precautions and control
measures shall be implemented in order that a safe system of work can be
established for the use of the substance on site.
15.2.4 The Employer /Engineer may require the removal of any hazardous substance or
chemical if there are safer alternatives. In such events, the Contractor shall not be
entitled to any claim for compensation or Extension of Time for Completion.
15.2.5 The Contractor shall ensure that all hazardous substance and chemical containers
are labelled, its movement is recorded and returned to the designated storage areas
when not in use.

15.3 Noise
15.3.1 Industrial deafness is caused by over exposure to high levels of noise from plant,
machinery or construction processes. Once a part of a persons hearing has been lost
it can never be recovered. Deafness can also lead to further accidents on site with
workers being unable to hear warnings and other instructions.
15.3.2 For continuous exposure, i.e. for eight hours in any one-day, the sound level should
not exceed 90dB(A). For non-continuous exposure a calculated equivalent
continuous sound level (Leq) should not exceed 90dB(A). Workers should not be
exposed to sound levels exceeding 90dB(A) unless they are wearing suitable hearing
protectors, which effectively reduce the sound level at the user’s ear to, or below,
90dB(A).
15.3.3 If Peak noise levels exceed 120dB(A) then the wearing of suitable hearing
protectors shall be Mandatory.
15.3.4 The Contractor shall carry out noise assessments to establish what noise levels his
workers are being exposed to. If excessive noise levels above 90dB(A) are found
then the contractor shall introduce a noise control programme to protect his workers.
15.3.5 Consideration should always be given first to reducing the noise level at source.
Examples of noise reduction methods include;
a) More efficient silencers on compressors and maintenance of exhaust
systems;
b) Fitting acoustic lining to machinery panels;
c) Use of Acoustic screens and sheds to protect other workers;
d) Using noise reduced tools;
e) Sighting of noisy plant away from the workplace
15.3.6 Where it is not possible to reduce the noise level to which the worker is exposed the
Contractor shall provide the workers with suitable and sufficient hearing protection
to protect them. The Contractor shall ensure that all the workers affected are
properly trained in the use of the Hearing Protection and that adequate supervision
is provided to ensure its proper use.
15.3.7 Occupational Noise
i) Protection against the effects of occupational noise exposure should be provided
when the sound levels exceeds the threshold values as provided in OH&S Manual.
ii) Personal protective equipment shall be provided and used to reduce sound levels
within the levels of the table.
iii) When the daily noise exposure is composed of two or more periods of noise
exposure of different levels, their combined effect should be considered, rather than
the individual effect of each.
15.3.8 The contractor shall ensure at a construction site of a building or other construction
work that adequate measures are taken to protect building workers against the
harmful effects of excessive noise, vibration etc. at such construction site and the
noise level in no case exceeds the limits laid down in Schedule-VI of TBOCWR
2006
15.3.9 Manual handling

15.3.9.1Risks involved in manual handling should be reduced where reasonably
practicable by the mechanization of the excavation and lining erection processes, the
breaking down of loads into smaller components, the provision of lifting points, and job
rotation.
15.3.10 Work-related upper limb disorders
15.3.10.1Mechanization and job rotation to reduce the risk of work-related upper limb
disorders;
15.3.11 Hand–arm vibration syndrome
15.3.11.1Mechanization and job rotation can reduce the risk of hand–arm vibration
syndrome (HAVS). In addition, there should be a programme of clinical examinations by
an occupational health specialist under the supervision of a medical practitioner
experienced in HAVS.
15.3.12 Heat stress and exhaustion
15.3.12.1Mechanization, ventilation and job rotation to reduce the risk of heat stress and
exhaustion. Adequate supplies of cold potable water should be made available.
15.3.13 Dermatitis etc.
15.3.13.1The Contractor must take steps to reduce the occurrence of ‘Skin problems’ such
as the use of remotely operated equipment, and the use of personal protective equipment
(PPE) such as gloves and overalls. When contact has occurred, contaminated skin should
be washed immediately with hot water and cuts covered with waterproof dressings.
Barrier creams should be used before work, and moisturizer creams to replenish skin oils.
Contaminated PPE should be disposed of or, if appropriate, cleaned before reuse.
15.4 Ventilation in Shafts and Tunnels
15.4.1 The contractor shall assign a Competent Person to perform all air monitoring
required to determine proper ventilation and quantitative measurement of
potentially hazardous gases. The atmosphere in all underground areas shall be tested
quantitatively by the contractor for toxic gases, dust, vapour, mist, and fumes as
often as necessary to ensure that prescribed limits given at 15.4.3 below are met.
Quantitative tests for methane shall also be performed in order to determine whether
an operation is potentially hazardous. For every test carried out the contractor shall
maintain a record of the air quality the location, date, time, substances and amount
monitored. These records shall be made available to the Employer / Engineer on
demand.
15.4.2 The ventilation system shall be adequate to maintain circulation of air in all parts of
tunnels and shafts and following conditions shall be taken care of:
15.4.3 Air shall be considered unfit for workmen to breathe if it contains any of the
following:
a) Less than 19.5% oxygen by volume.
b) More than 0.005% carbon dioxide by volume.
c) More than 0.01% carbon monoxide by volume.
d) More than 0.001% hydrogen sulphide by volume.

e) More than 0.005% oxides of nitrogen.
f) More than 0.5% of methane at any place in the tunnel.
g) More than 0.0002% of aldehyde.
h) Any other poisonous gas in harmful amounts.
In addition to the requirements given above, 2 m3 of fresh air per minute shall be
furnished for each brake horsepower of diesel engine used in the tunnel.
15.4.4 The Contractor will ensure the supply of fresh air to all underground work areas in
sufficient amount to prevent any harmful accumulation of dust, vapour or gases.
The fresh air supplied in such tunnel is not less than six cubic metre per minute for
each building worker employed underground in such tunnel, and the free air-flow
movement inside such tunnel is not less than nine metres per minute as per Rule 153
of TBOCWR 2006.
15.4.5 No inflammable materials or oil and grease shall be stored inside or near the tunnels
or shafts and all combustible rubbish from the tunnel or shaft shall be promptly
removed. A regular analysis of the gases inside the tunnel should be done with
advance of the tunnel.
15.4.6 Tools made of light alloys (such as Al and Mg) are not to be used inside the tunnel.
They may cause sparks.
15.4.7 Regular checking of gas (referred at 15.4.3) at the faces shall be done before each
shift. This should be carried out using a multi gas detector.
15.4.8 Motive power other than electric, shall not be used without prior authorisation from
the Employer/ Engineer. No petrol engines shall be used underground. Diesel
locomotives shall not be used in Underground.
15.5 Welfare measures for workers
15.5.1 General
15.5.2 A high standard of personal hygiene shall be practised and enforced by contractor
management team at all times.
15.5.3 The consumption of food and drinks shall be confined to the canteen /Workers Rest
Room area. No smoking is allowed on site.
15.5.4 The washing and changing facilities shall include storage for contaminated clothing,
footwear etc. and arrangements shall be made for the washing and drying of these.
15.6 Appropriate Personal Protective Equipment (PPE), which may include but not
limited to waterproof safety boots and gloves when handling wet material, shall be
provided for all personnel working on site.
15.7 A boot wash shall be situated immediately outside the entrance to the washing and
changing facilities, and this shall include running water and either fixed or hand
brushes to remove contaminated soils.
15.8 Install double storey worker’s rest room .
15.6 Latrine and Urinal Accommodation
15.6.1 The contractor shall provide one latrine seat for every 20 workers up to 100
workers and thereafter one for every additional 50 workers. In addition one urinal
accommodation shall be provided for every 100 workers.
15.6.2 Latrine and urinals shall be provided as per Section 33 of BOCWA and
maintained as per Rule 243 of TBOCWR 2006 and shall also comply with the
requirements of public health authorities.
15.7 Moving sites
15.7.1 In case of works like track laying, the zone of work is constantly moving at
elevated level or at underground level. In such cases mobile toilets with proper facility to
drain the sullage shall be provided at reasonably accessible distance.
15.7.2 In case if the contractor fail to provide required number of urinals and latrines or
fail to maintain it as per the requirements of Public Health laws, the Employer /Engineer
shall have the right to provide/maintain through renowned external agencies like “Sulabh”
at the cost of the contractor.
15.8 Canteen:
15.8.1 In every workplace wherein not less than 250 workers are ordinarily employed the
contractor shall provide an adequate canteen conforming to Section 37 of BOCWA, Rule
244 of BOCWR and as stipulated in Rule 247 of BOCWR the charges for food stuffs shall
be based on ‘no profit no loss’ basis. The price list of all items shall be conspicuously
displayed in such canteen.
15.9 Serving of tea and snacks at the workplace:
15.9.1 As per Rule 246 of TBOCWR 2006, at a building or other construction work
where a workplace is situated at a distance of more than 200 m from the canteen provided
under Rule 244(1) of TBOCWR 2006, the contractor employing building works shall
make suitable arrangement for serving tea and light refreshment to such building works at
such place.
15.10 Drinking water
15.10.1As per Section 32 of BOCWA the contractor shall make in every worksite,
effective arrangements to provide sufficient supply of wholesome drinking water with
minimum quantity of 5 litres per workman per day. Quality of the drinking water shall
conform to the requirements of national standards on Public Health.
15.10.2 While locating these drinking water facility due care shall be taken so that
these are easily accessible within a distance of 200m from the place of work for all
workers at all location of work sites.
15.10.3 All such points shall be legible marked “Drinking Water” in a language
understood by a majority of the workmen employed in such place and such point shall be
situated within six metres of any washing places, urinals or latrines.
15.11 Labour Accommodation
15.11.1The Contractor shall provide free of charges as near as possible, temporary living
accommodation for all workers. All provided accommodation shall conform to the
provisions made under Section 34 of BOCWA. These accommodations shall have
cooking place, bathing, washing and lavatory facilities. Welfare facilities must be
established and in working order before any works on site commence. All toilet, washing,
changing, personal storage and rest areas must be easily accessible and have adequate
heating, lighting and ventilation. Facilities may need to be provided at more than one
location on a large site to ensure workers have easy access.
15.11.2Contractor shall submit the labour accommodation site layout and design to the
Employer/Engineer for Notice of no objection
15.11.3The following measures shall be taken
i.Bathroom, laundry and cooking/ kitchen/ dining/ refrigerated food storage facilities
and adequate medical facilities should be provided
ii.Sites should be adequately drained, plumbed and graded to prevent flooding and
pooling of water.
iii.Buildings should be certified by a qualified engineer particularly in areas subject to
extreme weather this is to ensure compliance to local codes, statutes and by laws for
structural adequacy, fire precaution, firefighting, electrical grounding, lightning
protection and other regulations as required.
15.12 Living Space
i. No cooking should be allowed in rooms.

ii.Room doors should be fitted with one way locks to prevent workers being trapped inside rooms in the
event of an emergency.
iii. Accommodation should have adequate ventilation with fly screens fitted where practicable.
iv.Where not, other forms of insect protection may be employed such as mobile mosquito nets.
v. Different cultures should be catered for e.g prayer space.
vi.Adequate security should be in place to protect workers and their belongings e.g perimeter fencing
and patrols when unoccupied.
vii.Space should be provided to secure personal belongings (this can be either lockable cabinets or
ensuring that the room is lockable).
viii.Provision of recreation/ living areas is to be encouraged e.g TV’s and sporting equipment.
Facilities should be heated/ cooled/ ventilated naturally or mechanically to a reasonable level of
comfort (air conditioning is preferred).
ix.Spare space should be provided to prevent overcrowding in accordance with local laws with 6 people
per room as a maximum. The number of people per SQM should also be reviewed in compliance with
local regulations.
x.Bedding that is provided should be clean and appropriate to weather conditions.
Where beds are provided they should be spaced apart, raised off the floor and safe access provided.
Other forms of bedding, such as roll out mattress, are acceptable.
xi. Triple deck bunks should not be utilized due to risk of falls.
xii.There should be at least 1 refuse bin per 20 workers staying at the quarters to dispose their litter.
xiii.All key contacts including nearby hospital should be posted in a prominent place and in all languages
present e.g. at camp gate and throughout the camp (where appropriate, these contact details should
include a camp supervisor and site manager)
xiv.Age of the security person shall not be more than 55 years old at time of appointment at site.
15.13 Toilet / Washing Facilities:
i.Sufficient toilet facilities should be provided, in easy access of accommodation, and

plumbed into the mains.
ii.All toilets should be cleaned and serviced regularly with provision of adequate toilet paper,
soaps etc.
iii.Washing facilities with hot and cold water should be provided and be adequate for the
numbers of workers (as a guide 1 WC and basin for every 10 persons; 1 shower for every
10 persons; laundry tray / tub for every 10 persons).
iv.These areas should be made of impervious materials, water resistant, non-skid / slip and
easily washable.
v.Privacy should be provided for changing and toilet facilities.
vi.Toilets should be separated from sleeping and food preparation areas
15.14 Food Preparation/ Cooking Areas:
i.Clean, potable water should to be provided

ii.These areas should be made of impervious materials, water resistant, non-skid/ slip and easily
washable
iii.If food is provided, it should cater for different cultural needs e.g halal, vegetarian etc. and provide a
good balanced diet
iv.High standards of hygiene should be adopted
v.Persons / companies preparing food should be trained in proper food handling and preparation
techniques and hold appropriate qualification where required
vi.These areas should have adequate cupboards or similar for storage of wet and dry goods, they
should have adequate refrigeration and tubs / sink for cleaning and washing
15.15 Lighting and Ventilation
i.Areas should be well ventilated and kept free of damp and mould
ii.Areas should be well lit and able to be switched on or off at all hours
15.16 Evacuation:
i.All buildings should have lit, clear and signed means of escape in case of emergency and workers
should be made aware of evacuation
15.17 Evacuation Procedure:
i.Evacuation exits should be kept unlocked and clear of obstructions

ii.Evacuation drills should be implemented on a monthly basis
iii.There should be nominated and trained personnel to handle fire and emergency
evacuations
15.18 First Aid / Emergency

i.First aid facilities should be provided and accessible at all time
ii.Ramps for medical equipment should also be provided e.g. stretchers
iii.Contact details of the nearest emergency services should be clearly publicized
iv.The names and phone numbers of qualified nurses in the camp should also be publicized
v.Access should be provided to enable entry by emergency services eg ambulance or fire brigade
vi.Evacuation drills should be conducted regularly
vii.Evacuation plans should be posted throughout the camp and visible
viii.Potential health outbreaks should be monitored and measures taken to prevent spread
ix.Camp operators should be encouraged to vaccinate the workforce from communicable diseases
prevalent in the region e.g malaria, cholera etc.
15.19 Hazardous Areas
i.Generators should be on stable ground, with required clearances, ventilation etc.

ii.Fuel stores should comply with local dangerous goods laws and all combustible materials
are to be kept clear of buildings Industrial LPG stores should be external to occupied
structures
iii. Hazardous materials e.g diesel should be stored in a bunded area and spill kits provided
Clear and multilingual signage should be provided around hazardous storage areas
15.20 Fire Safety and Fire Fighting
i.Open fires/burning should be strictly prohibited

ii.Fire prevention and firefighting /control facilities should be provided, particularly in food
preparation areas
iii.Fire fighting hoses should be engineered to provide full coverage of camp perimeter and
be capable of delivering the appropriate water pressure to fight fire
iv.All structures should be constructed with fire resistant material (metal or fire retardant
treated wood form)
v.Fire and smoke alarms should be installed in all accommodation areas
vi.Where possible, buildings should be separated from each other by providing space or fire
resistant material
15.21 Mechanical and Electrical Safety
i.Electrical equipment and cords should be maintained and physically protected to prevent
the risk of electrocution or shock
ii.Mechanical equipment should be operated by trained personnel only
iii.Electrical circuit breakers should be fitted to all distribution boards
iv.Electrical register of equipment should be maintained and testing to be undertaken and
recorded by qualified Electrical Engineer
15.22 Housekeeping
i.Waste should be centrally located in a segregated, easily cleaned area, kept in rodent and
fly tight containers, collected regularly and grounds are to be kept free from rubbish,
debris and other refuse
ii.Effective housekeeping measures should be taken to ensure pests are not attracted to the
site eg removal of all food sources and breeding areas.
iii.No pets, birds or livestock should be kept.
iv.Areas should be kept free of hazards e.g slips, trip or fall hazards
15.23 Transportation
i.The transport facilities are to be provided to site, these should be safe, with trained drivers
and in accordance with local laws
15.24 Pest Control
i. In mosquito prone areas, checks for mosquito breeding, including the presence of larvae
in all stagnant water within the worker's quarter’s premises should be carried out at least
once a week. Thermal fogging of worker’s quarters premises should be carried out at
least once each fortnight.
ii. Adequate controls should also to be in place to prevent pest infestations e.g inspections
and preventative measures such as baits and other controls
15.25 Camp / Accommodation Supervisor
i.A camp supervisor should be appointed to coordinate all activities, communication and
inspections etc of the camp. This supervisor should speak at least two of the languages
spoken by the workforce.
ii. A team comprising of contractor’s Labour Welfare Officer and Chief OHS&E Manager
shall conduct a monthly labour colony Safety Audit and the report shall be submitted no
later than the 7th of each month within the Contractor’s monthly OH&S Report.
16. WORKING AT HEIGHT

16.1 General
16.1.1 Working at height is the largest single cause of serious accidents in the construction
industry and therefore the Contractor shall carry out risk assessments for all work
where workers or materials can fall more than two metres. The contractors will

ensure that no height work will be undertaken unless a Permit to Work, has been
prepared and issued.
16.1.2 Where work is being carried out above areas where there is public access such as
roads footpaths etc. particular care must be taken to ensure that no materials can fall
from the working area.
16.1.3 Edge protection shall be provided at all leading edges or openings where workers or
materials can fall more than two metres. Edge protection shall meet the minimum
standard of;
a) A main guardrail at least 1 metre above the edge
b) A toe board at least 200 mm high; and
c) An intermediate guard rail or other barrier so that there is no gap more than 470
mm.
d) Rebar shall not be used as edge protection only standard pipes should be used.
e) The pipes shall be painted in reflective paints.
16.2 Use of Scaffolds
16.2.2 All scaffolds should be erected and dismantled by workmen and Inspected by the scaffold
supervisor who are thoroughly trained by third Party agency and the training requirements
should meet the construction industry training board(CITB) UK, Construction Industry
scaffolders records scheme (CISRS) UK or Scaffolding Training Institute, USA. The Profile of
the training Agency, ISO certifications, the name, educational qualifications and
experience for of the trainers are to be submitted to the Employer/Engineer a minimum
28 days before prior to appointment of the agency. Only upon notice of no objection by
the Employer /Engineer shall be authorised to work on CMRL site.
16.2.3 All scaffolds should be inspected by a competent person at least every day after erection
and the results of inspections recorded and the records shall be kept available for checking
by the Engineer.
16.2.4 The Contractor shall develop a scaffold tagging system acceptable to the Employer
/Engineer to indicate:
a) Scaffolds under construction or demolition;
b) Scaffolds that are complete but have hazards associated with them; and
c) Scaffolds erected and safe for use.
16.2.4 Tags shall be fitted to all scaffolds to show whether they are safe for use or not. All Safe
for Use tags shall be signed by a third party trained scaffold inspector from the contractor.
16.2.5 The Contractor shall envelope all scaffolds with screen nets to prevent debris from falling
outside the scaffold.
16.2.6 Contractor shall use only proprietary access ladders and working platforms for system
formworks. No mix and match using conventional catwalks and monkey ladders is allowed.
16.2.7 All scaffolds shall be constructed of sound materials free from patent defect.
16.2.8 The following measures shall be taken;
the scaffold shall be constructed for the correct use (Light or Heavy Duty)
(a) securely fixed to existing structures or adequately buttressed;
(b) the use of barrels, boxes, loose tiles or other unsuitable material shall not be used as
supports for working platforms;
(c) all working platforms shall be fully boarded;

(d) all working platforms shall have guard rails at one metre height and shall also have an
intermediate rail at half height;
(e) all working platforms shall be provided with toe boards;
(f) all working platforms shall be kept free of unnecessary obstruction or rubbish
(g) secure ladder access shall be provided;
(h) Wooden Scaffold not allowed
(i) Worker shall not be allowed to work from scaffolds during storms or high winds. After
heavy rains or storm, the scaffolds should be inspected by the site-in-charge. Scaffolds
should also be inspected every fortnight, during use, by him and again before starting
use. Where the joints or members are found defective, the joint should be set right and
member replaced.
(j) In case both light and heavy duty scaffolds are used in close vicinity, conspicuously
placed notice boards shall indicate the light duty scaffolds and the limits on their
usages.
(k) Safety codes should be strictly followed. Standard safety requirements are just as
important for temporary structures as they are for permanent structures
16.2.9 A team comprising of contractor’s construction Manager and Safety Manager shall conduct
a monthly working at height Safety Audit and the report shall be submitted no later than the
7th of each month within the Contractor’s monthly OH&S Report.
16.3 Use of Ladders
16.3.4 All ladders shall be of sound construction and shall be free from patent defect.
Ladder should meet the IS standard requirements
16.3.5 The Contractor shall implement a step platform/ladder inspection procedure
requiring an identification method displaying company name, unique number,
inspection frequency and inspection status.
16.3.6 Ladders should be checked daily and defective ladders shall be promptly and
properly replaced.
16.3.7 Ladders shall not be used as working platforms.
16.3.8 Ladders shall;
(a) be secured at the top or footed at the bottom to prevent slippage;
(b) not be used if any rung is missing;
(c) not be used for any other purpose than to provide access;
(d) be set at an angle of seventy five degrees unless designed for vertical access;
(e) all vertical ladders shall be fitted with hoops to prevent falls;
(f) Wooden Ladder not allowed
16.4 Safety Harnesses / Fall Arresters

16.4.1. Where it is not possible to provide a safe working platform then the use of full
body safety harness with double lanyard with fall arrester may be considered. If safety
harness are used they should be of the full body type and secure anchorage points shall be
provided and used. Workers must be instructed in the proper use of harness.
17. EXCAVATIONS

17.1 General
17.1.1 The Contractor shall appoint sufficient number of banksman to coordinate
excavation activities at the pit and the haulage activities from the pit to the bank.
The banksman shall be appointed in writing and should have attended Signalman
training course approved by Employer/ Engineer. The banksman shall be properly
identified on site, stationed at-grade and have overall control of the excavation
works.
17.1.2 For excavations exceeding 4 metres in depth, the Contractor shall appoint one
banksman. If deemed necessary by the Employer /Engineer, the Contractor shall
appoint additional banksman. For excavations exceeding 10 metres in depth, the
Contractor shall appoint one banksman for every long-arm or telescopic excavator
at the bank.
17.1.3 Proper means of communication in the form of walkie-talkie sets should be
established between the banksman and the excavator operators. No one shall be
within any excavator's swing radius. In addition, all excavators shall be installed
with rear view camera that enables the operator to have a clear view of the back of
the machine
17.1.4 Long arm excavators shall be provided with an extended reflective mirror in front
of the operator's cabin to enhance operator's visibility and shall not operate without
the presence of the banksman.
17.1.5 Excavators within the excavation pit shall have suitably reinforced cabin roofs
capable of withstanding impact from falling objects from the top of the excavation
and its movement coordinated by one of its operator, who shall be appointed as a
leader by the Contractor.
17.1.6 The designated locations at walers and struts used by the instrumentation contractor
for instrumentation reading and monitoring shall be provided with 2 rows of
horizontal rigid guardrails to prevent persons falling from height. Openings within
struts are to be covered. The vertical distance between the 2 rows of horizontal
guardrail shall be not more than 600mm. Toe boards are to be provided accordingly.
Rebar shall not be used as edge protection only standard pipes should be used. The
guard rail pipes shall be painted in reflective paints.
17.1.7 An alternative source of power and emergency lighting system shall be provided to
allow emergency securing operations and evacuation safely in the event of a primary
power failure. An adequate number of lamps shall be located at key points
underground
17.1.8 Excavation is one of the important phases of any construction activity. Due to
insufficient attention to the safety aspects it frequently becomes the cause of many
accidents. Contractors are therefore required to plan and execute all excavations in
a safe manner.
17.1.9 The contractor shall ensure that all excavations are supervised by workers with
thorough knowledge and experience of excavation work.
17.1.10The integrity of the excavation and the support system shall be inspected prior to
the commencement of any works on a daily basis with the results of the inspections

being formally recorded. All such records shall be kept available for inspection by
the Employer/ Engineer.
17.1.11Where there is the possibility of any ingress of water then pumping sumps shall be
established with pumps being readily available for use and additional ladders placed
for use in the event of an emergency evacuation.
17.1.12The contractor should not store, or move, materials and equipment near the edge of
an excavation. Spoil and waste heaps should similarly be kept well one meter away
from the edges of excavations.
17.1.13Adequate and well-anchored stop blocks should be provided on the surface to
prevent vehicles being driven into the excavation while tipping. The blocks should
be placed at a sufficient distance away from the edge of the excavation to avoid the
danger of it breaking away under the weight of the vehicles.
17.1.14Make sure that there are safe means of access and egress, such as a properly secured
ladder, if you are working in an excavation. This is of particular importance when
there is a risk of flooding and rapid escape is essential.
17.1.15There should be adequate lighting around the area of an excavation, particularly at
access points and openings in barriers.
17.1.16Shoring should be erected, altered or dismantled only by a competent worker
operating under supervision. Wherever practicable, it should be installed before
excavating to the final depth of the trench – it is necessary to begin when the trench
is less than 1.2 m deep. The excavation and installation of shoring should then
proceed by stages until the full depth is reached. You should be fully aware of the
procedures to follow to rescue a fellow worker trapped by a fall of earth.
17.1.17A team comprising of contractor’s Construction manager and Safety Manager shall
conduct a monthly Excavation Audit and the report shall be submitted no later than
the 7th of each month within the Contractor’s monthly OH&S Report.
17.2 Planning
17.2.1 The correct planning of excavations is essential for occupational Health and Safety and
before digging any excavations Contractors should plan against the following;
(a) Collapse of the sides;
(b) Materials falling onto people working in the excavation;
(c) People and vehicles falling into the excavation;
(d) People being struck by plant;
(e) Undermining nearby structures;
(f) Contact with underground services.
(g) Fumes; and
(h) Make sure the necessary equipment needed such as trench sheets, props, etc.,
are available on site before work starts.
17.3 General Precautions
17.3.1 The following precautions should be observed;
(a) Prevent the sides and the ends from collapsing by battering them to a safe angle
or supporting them with timber, sheeting or proprietary support systems.
(b) Do not go into unsupported excavations.

(c) Never work ahead of the support.
(d) Remember that even work in shallow trenches can be dangerous. You may need
to provide support if the work involves bending or kneeling in the trench.
(e) Prevention of materials falling into excavations
(f) Do not store spoil or other materials within one metre of the sides of excavations.
The spoil may fall into the excavation and the extra loading will make the sides
more prone to collapse.
(g) Make sure the edges of the excavation are protected against falling materials.
Provide toe boards where necessary.
(h) Wear a hard hat when working in excavations.
(i) Take steps to prevent people falling into excavations. If the excavation is 2 m or
more deep, provide substantial barriers, e.g. guard rails and toe boards.
(j) Keep vehicles away from excavations wherever possible. Use brightly painted
baulks or barriers where necessary.
(k) Where vehicles have to tip materials into excavations, use stop blocks to prevent
them from over-running. Remember that the sides of the excavation may need
extra support.
17.4 Undermining nearby structures
17.4.1 The following precautions should be taken to prevent the undermining of nearby structures;
(a) Make sure excavations do not affect the footings of scaffolds or the foundations
of nearby structures. Walls may have very shallow foundations, which can be
undermined by even small trenches.
(b) Decide if the structure needs temporary support before digging starts. Surveys of
the foundations and the advice of a structural engineer may be needed.
17.5 Avoiding underground services
17.5.1 The following precautions should be taken to avoid underground services;
(a) Look around for obvious signs of underground services, e.g. valve covers or
patching of the road surface.
(b) Use locators to trace any services by utility detector kit. Mark the ground
accordingly.
(c) Make sure that the person supervising excavation work has service plans and
knows how to use them. Everyone carrying out the work should know about safe
digging practices and emergency procedures.
(d) Operate a “Permit to Dig” system.
(e) Safety practices in sewage and septage management issued by the Chennai
metropolitan water supply and sewerage board guidelines shall be followed.
18. LIFTING OPERATIONS
18.1 Lifting Appliances:
18.1.1 The Contractor shall ensure that all lifting appliances, including synchronised
mobile jacks, pit jacks, mobile cranes, tower cranes, gantry cranes, launching beams
and lorry mounted cranes, prior to being allowed to work on site shall have available
for inspection by the Employer / Engineer a current Certificate of Inspection issued
by a Competent Person approved by CMRL. The Profile of the Inspection Agency,
ISO certifications, inspection procedure, the name, educational qualifications and
the competent person certificate issued by the Govt of Tamil Nadu are to be
submitted to the Employer/Engineer a minimum 28 days before prior to
appointment of the agency. Only upon notice of no objection by the Employer
/Engineer shall be authorised to work on CMRL site. The approved competent
person is authorised to conduct inspection and issue certificate for lifting machines,
lifting appliances and lifting gears for two CMRL contract packages only.
18.1.2 Effective control must be exercised at all stages of a lifting operation through the
deployment of a competent lifting supervisor, a qualified signalman, a registered
crane operator and sufficient trained rigger.
18.1.3 The contractor shall ensure at a construction site of a building or other construction
work that a competent person issues a certificate for the purpose of test and
periodical examination of lifting appliances, loading of lifting appliances and lifting
gears, ropes and heat treatment of lifting gears only after actual testing. All lifting
machines, lifting appliances and lifting gears used on site must be suitable for the
task, used within their rated safe load capacity and must be in good repair.
18.1.4 The Contractor is to submit a weekly list to the Employer /Engineer of all cranes
permanently deployed on site detailing their ownership, make, identification
number, maximum safe working load and the corresponding radius, lifting Machine
(LM) certificate number and date of expiry.
18.1.5 All lorry loaders with articulating arm entering into the Site shall have an
interlocking system installed to prevent a lorry loader with articulating arm from
moving off before its articulated boom is fully retracted back to its “stored” position.
18.1.6 The boom of any lorry loader with articulating arm shall not be used for holding
down materials or equipment and it shall be retracted to its “stored” position before
it moves off.
18.1.7 Loading/ Unloading operations involving lorry loader with articulating arm shall
take place over the side of the main body and not in an arc over either the front or
rear of the chassis, in accordance with safe working practices.
18.1.8 No excavator shall be used as a lifting equipment and No Sheet piling activity by
the excavator.
18.1.9 The Contractor shall ensure that a Permit to Lift system is operated to evaluate all
routine planned lifting operations generically and all heavy or one-off lifting
operations individually. This latter category of lifting operations includes the raising
/ lowering of items of plant in excavations. Lifting plans shall be submitted to the
Employer /Engineer for acceptance in advance of any heavy or one-off lifting
operations.
18.1.10All lifting appliances with a lifting capacity of more than one tonne shall, where
practicable, be fitted with Automatic Safe Load Indicators, Anemometer and
Audible Warning Devices which shall be kept in an operable condition at all times
the lifting appliance is in use. Checks should be made to ensure that the Automatic
Safe Load Indicator and Anemometer is properly calibrated and is functioning
properly. The Profile of the calibration Agency to be submitted to the
Employer/Engineer a minimum 28 days before prior to appointment of the agency.
Only upon notice of no objection by the Employer /Engineer shall be authorised to
work on CMRL site.
18.1.11The crane operator is to ensure that the outriggers are fully extended, and any
adjustments made to the jacks to level the crane before the lifting operation
commences. All lifting machine with outriggers, including lorry loader with
articulating arm, shall have steel plates of minimum dimension 1m by 1m by 25mm
placed under all the outriggers deployed for a lifting operation unless that crane is
entirely sited on hard standing such as a reinforced concrete surface, with no void
underneath. Pieces of timber are not to be used.
18.1.12The Contractor shall ensure that no lifting operation shall be carried out on site using
the auxiliary hook of a mobile crane unless the SWL of this is shown on the Lifting
Machinery Certificate in addition to that of the main hook block, and is not
exceeded.
18.1.13The Contractor shall ensure that both the Lifting Supervisor and the crane operator
are able to understand the working load chart.
18.1.14Cranes fitted with a Automatic safe load indicator (ASLI) shall sound an audible
alarm in the crane cab if its safe working load is exceeded on either the main or the
auxiliary hook. A second alarm connected to the ASLI, shall be fitted external to
the cab and shall emit a signal of a sufficient volume to make it audible above the
ambient site noise levels during working hours. Visual warning shall also be
provided externally to indicate safe working range and overload conditions. ASLI
shall be connected directly to the start button and the ASLI should be enclosed with
Plastic box or steel box.
18.1.15load radius indicator shall be fitted with a limiting device, which disables the crane
from continuing with any lifting operation under overload conditions. Once
disabled, the device should only permit the crane to return to the safe working range.
The device shall be tamper proof, with no over-ride to disable it, and shall be
maintained in good working order. In case of provision of bypass switch for load
radius indicator, it shall be secured by a lock and kept with the lifting supervisor.
18.1.16The Contractor shall ensure that a sufficient number of qualified lifting supervisor
are employed on site, whether by himself or by his Subcontractors, to give adequate
cover for all lifting operations carried out both by day and by night including
loading/unloading. There must be one lifting supervisor present for one crane
including all minor and major operations. In addition the contractor shall also station
at least one additional worker to assist signalman for lifting operations carried out
near public areas.
18.1.17The contractor shall install warning devices/ flags at least 2 metres above top of
hoarding that are alongside roads, footpaths and adjacent structure.
18.1.18lifting supervisor shall supervise and co-ordinate all lifting operations under his/her
charge. lifting supervisor shall familiarise himself with the safe working load chart
of each crane for which he is responsible and has identified himself to the operator
of each such crane as being the only individual whose instructions concerning any
lifting operation are to be followed. This includes the positioning of the crane prior
to the lift as well as the slinging of the load.
18.1.19Before any lifting operation involving a mobile or crawler mounted crane is carried
out the lifting supervisor must satisfy himself that the crane is positioned suitably
close to the load and its destination to ensure that the operation can be carried out at
the safest appropriate radius.
18.1.20The lifting supervisor shall ensure that the load is safely rigged, and a tag line is
attached if appropriate, before signalling to the crane operator to start the lift. The
lifting supervisor is responsible for the load until it is safely resting at the intended
destination either by taking control of the operation himself for non-routine lifts or,
for routine lifting operations, by thoroughly briefing the crane operator, riggers and
signalman on the safe procedure to be followed.
18.1.21The Contractor shall put measures in place to discipline any person other than the
dedicated lifting supervisor, or one acting under his close supervision, who attempts
to take control of any lifting operation other than those of a routine nature where a
safe lifting procedure has already been established.
18.1.22The Contractor shall engage only qualified crane operators with at least 5 years of
experience in operating similar types of cranes with no record of crane toppling /
failure or barred from any site previously for a crane related incident.
18.1.23The crane operator shall enter the date, types of maintenance carried out and any
malfunction of the crane in a checklist or logbook. He shall not operate the crane
until any such defect is rectified, and the crane’s use is authorised by his lifting
supervisor.
18.1.24All cranes shall be checked by its operator at the start of any day / shift using a
checklist written in English and in a language comprehensible to the operator.
Copies of the checklist together with LM certificate, operator certificate, permits
should be retained in the crane cabin for verification.
18.1.25Automatic safe load indicator (ASLI) shall be calibrated six-monthly by an
approved agency and verified by the competent person during his six-monthly
inspections. Records of load radius indicator calibration shall be submitted to the
Employer /Engineer. If there is any doubt as to the accuracy of the load radius
indicator the machine shall be taken out of use until the calibration is carried out to
the satisfaction of the Employer /Engineer.
18.1.26If the crane is down rated by the competent person during his six monthly
inspections then the load radius indicator shall also be calibrated and a new capacity
chart should be drawn up and posted in the crane cab. The competent person shall
highlight the above details on the Lifting Machinery certificate.
18.1.27Lifting machine shall not be used for any unsafe operation that may affect its overall
integrity or stability.
18.1.28The Contractor shall ensure that every lifting machine capable of travelling /
tracking, including a gantry crane, or a slewing motion, such as a mobile crane, shall
be operated in such a manner that there is always an unobstructed passageway in
excess of 600mm between it and any fixture or other machinery.
18.1.29All Lifting machines that operate on CMRL sites shall be installed with a rear view
camera that enables the operator to have a clear view of the back of the machine.
18.1.30The use of fly jib of any Lifting machines shall be subjected to the approval of the
Employer /Engineer.
18.1.31The concurrent use of the crane’s main and auxiliary hooks during lifting shall be
prohibited.
18.1.32Before any crane is accepted onto site for use it must undergo a thorough mechanical
check by the plant Manager, and the findings verified by the Contractor’s Safety
manager.
18.1.33 Lifting of machineries and/or equipment’s shall be done as per
manufacturer's recommendations and shall be subject to a regular preventative
maintenance programme.
18.1.34All lifting appliances shall be thoroughly tested and examined by a competent
person approved by CMRL once at least in every six months or after it has
undergone any alterations or repairs liable to affect its strength or stability. Within
the validity, if the lifting appliances are shifted to a new site, re-examination by the
same competent person for ensuring its safety shall also be done. Certificates of
Inspection shall be available with the lifting appliance and a copy shall also be sent
to the Employer/ Engineer.
18.1.35The operators of lifting appliances shall conduct daily inspections of their respective
lifting appliances with the results of the inspections being recorded in the register
and kept available for inspection by the Employer/ Engineer.
18.1.36The Contractor shall ensure that only thoroughly third party agency trained and
experienced persons aged twenty-one years and over are allowed to operate lifting
appliances. The refresher training for Operator’s shall be conducted every six
months. The Profile of the training Agency, ISO certifications, course details, the
name, educational qualifications and experience are to be submitted to the
Employer/Engineer a minimum 28 days before prior to appointment of the agency.
Only upon notice of no objection by the Employer /Engineer shall be authorised to
work on CMRL site.
18.1.37First generation hydra banned and shall not be strictly permitted to use in CMRL
project sites.
18.1.38All lifting machines, lifting appliances and lifting gears shall meet the requirements
of Indian standards(IS).
18.1.39The following Crane safety Equipment shall be install in the equipment
a. As stipulated in Rule 57 of TBOCW Rules 2006, every lifting appliances
and gears like cranes, hydras etc, if so constructed that the safe working load
may be varied by raising or lowering of the jib or otherwise shall be attached
with an automatic indicator of safe working loads approved by Bureau of
Indian standards/ International certifying bodies which gives a warning to
the operator and arrests further movements of the lifting parts.
b. ASLI Interlocked with the equipment key and Bye pass button shall be
replaced with Key and the key shall be available with plant department. Log
register should maintain for the purpose of the key is used.
c. ASLI shall be covered with plastic or steel cover.
d. Motion limit Devices
e. Overload cut out devices
f. Level indicator
g. Anemometer
h. Machinery guarding
i. Proximity sensor
j. Visual Warning and alarm
k. Sensing devices
l. Boom angle indicator
18.1.40The special assessment as per IS 14475-1(1997) and ISO 12482-1:1995 shall be
carried out later than the following number of years after manufacture for:
-All other cranes: 20 years.
18.1.41Lifts involving two or more cranes are complex operations requiring considerable
skill and planning. As a result, multiple crane lifts (or tandem lifts) must be planned and
carried out under the supervision of a competent person.
18.1.42The exact weight each crane will carry must be determined in advance since all
cranes must operate in unison. Operator headset communications systems should be
implemented. For these more complicated lifts, no more than 75 percent of the net
capacity of any crane should be used. Because the load weight shifts from one crane to the
other during movement of the booms, these changes need to be considered during the
planning process. Pre-planned load considerations can also be disrupted if one crane lifts
its end of the load before the other crane lifts, causing the first crane to be overloaded. A
practice run without the load is recommended to help coordinate the process.
18.1.43Compliance with the crane manufacturer's recommended wind-velocity shutdown
limit is required for safe operations, though many operators halt work if the wind speed
reaches a generic 30 mph.
18.1.44 All lifting appliances including all parts and gears thereof whether fixed or
movable, are tested and examined by a competent person before being taken into use for
the first time or after it has undergone any alterations or repairs liable to affect its strength
or stability or after erection on a construction site and also once at least in every five
years, in the manner specified in Schedule-I of TBOCWR 2006.
18.1.45 Certificate in respect of the following is obtained from competent person in the
forms as per
the TBOCWR 2006 under schedule XIII mentioned below, namely: -
• Winches, derricks and their accessory gears in Form V.
• Cranes or hoists and their accessory gears in Form VI.
• ln case of test. examination and re-examination of loose gears Form VII.
• In case of test and examination of wire ropes Form VIII.
• In case of heat treatment and examination of loose gears Form IX.
18.1.46All alarms and signals like automatic safe load indicators (ASLI), boom angle
indicators, boom extension indicators, over lift boom alarm, swing alarm, hydraulic safety
valves, mechanical radius indicators, load moment indicators etc. shall be examined daily
basis by the operator. All devices shall be maintained in good working condition.
18.2 Lifting Gear:
18.2.1 Lifting Gear includes chain slings, rope slings, or similar gear and a ring, link, hook,
plate clamp, shackle, swivel or eye bolt.
18.2.2 The Contractor shall ensure that all lifting gear shall be in good condition and shall
be tested and certified every six months, with the Safe Working Load being stamped
or clearly displayed upon it. Records of test shall be kept available for inspection by
the Employer/ Engineer.
18.2.3 The Contractor shall ensure that Lifting Gear is not loaded beyond its SWL and this
includes multi leg chain slings being used at variable angles.
18.2.4 The Contractor shall ensure that Lifting Gear is not used for any purpose other than
the raising or lowering of a load. If an excluded activity takes place, such as the use
of a lifting chain for towing an item of plant / machinery, then the Contractor shall
ensure that this item of Lifting Gear is no longer used for any further lifting
operations.
18.2.5 The Contractor shall implement an inspection programme to thoroughly check all
Lifting Gear by a lifting supervisor prior to its first use on site and thereafter on a
monthly basis. A monthly colour coding system shall be adopted. Defective Lifting
Gear shall be discarded.
18.2.6 All lifting gear shall be visually inspected before any use and if any defects are
found then it shall be removed from site or dismantled / disabled in order to ensure
that it is not used in a defective state.
18.2.7 All lifting gear shall be properly stored and not left lying on the ground where it
could be damaged or used in an unsafe manner.
18.2.8 A lifting gear is initially tested for the manufacturer by a competent person, in a
manner specified in Schedule-1 of TBOCWR 2006 before taking into use or after
undergoing any substantive alterations which renders its any part liable to affect its
safety and such gear altered shall subsequently be re-tested for the use of its owner
at least once in every live years. Certificates of initial and periodical tests and
examination of loose gears under TBOCWR 2006 are obtained in Form VII under
Schedule – XIII of TBOCWR 2006.
18.3 Lifting Operations:
18.3.1 The Contractor shall ensure that during the course of any lifting operations the
following minimum requirements shall be followed:
(a) All lifting operations shall be under the control of a competent “Lifting Supervisor”
appointed by the contractor.
(b) Only thoroughly third party agency trained and experienced crane drivers shall be
allowed to operate cranes. The refresher training for operator’s, lifting supervisor,
banks Man and rigger etc. shall be conducted every six months.
(c) Only thoroughly third party agency trained and experienced slingers and riggers
shall be allowed to sling loads and give directions to crane operators.
(d) A standard code of hand signals shall be adopted for controlling the movements
of the crane and both the driver and the signaller shall be thoroughly familiar with
the signals.
(e) The driver of the crane shall respond to signals from only the appointed signaller

but shall obey the stop signal at any time no matter who gives it.
(f) Before commencing any lifting operations, the ground conditions on which the
crane is to stand shall be investigated in order to ensure that the load bearing
capabilities are adequate.
(g) The weight of the load must be known to the crane driver and the slinger/rigger
before lifting commences.
(h) No loads are to be slewed over public areas without stopping pedestrians and
vehicles first.
(i) No unauthorised persons are allowed into the lifting zone.
(j) No person is allowed to ride the hook of the crane or the loads being lifted.
(k) Any areas where a minimum clearance of six hundred millimetres from the rear of
the slewing kentledge of the crane cannot be achieved and where persons could
be trapped against obstacles then a fence shall be erected to prevent access.
(l) All crane hooks shall be fitted with an operable Safety Latch.
(m) Wherever practicable all loads shall have tag-lines attached in order to ensure that
the load can be controlled at all times.
(n) Provision shall be made to ensure that the lifting slings or chains can be safely
removed from the loads once they have been landed.
(o) All lifted loads and stacked materials shall be left in a secure and stable condition
at all times.
(p) Whenever working close to isolated overhead power-lines the lifting appliances
shall be grounded to earth as a secondary precaution against accidental
energisation.
(q) No close working to any live overhead power-lines is permitted without the
operation of a strict Permit to Work system being in place.
(r) Install wireless anti-collision sensory protection device and alarm system before
tandem lifting operation commences.
(s) (s)Operators, lifting supervisor and Riggers is medically examined periodically as
specified in Schedule-VII of TBOCWR 2006.
19. WORK IN CONFINED SPACES
19.1 General
19,1.1 The term 'confined space' has three defining features as , any space:
(a) in which a person can bodily enter;
(b) which has limited entry / egress; and
(c) which is not meant for occupancy.
Generally it is place which is substantially (though not always entirely) enclosed with a
reasonably foreseeable risk of serious injury from hazardous substances or conditions
within the space or nearby.
19.1.2 Some confined spaces are fairly easy to identify, for example, closed tanks and
sewers. Others are less obvious but may be equally dangerous, for example closed
and unventilated or inadequately ventilated rooms and silos, ducts, culverts, tunnels,
boreholes, bored piles, manholes, shafts, excavations, sumps, inspection pits,
cofferdams ,and building voids.
19.2 The hazards
19.2.1 The most likely hazards are as follows:
(a) Flammable Substances and Oxygen Enrichment;
(b) Toxic Gas, Fume or Vapour;
(c) Oxygen deficiency;
(d) The Ingress or Presence of Liquids;
(e) Presence of Excessive Heat,
(f) Excessive Humidity.
19.3 Entry Procedures
19.3.1 Contractors will ensure that no work will be undertaken in Confined Spaces unless
a Permit to Work, has been prepared and issued.
19.3.2 Only persons who have been thoroughly third party trained, experienced and are
physically fit shall be allowed to work in Confined Spaces. The refresher training
shall be conducted every six months. The Profile of the training Agency, ISO
certifications, course details, the name, educational qualifications and training
experience for of the trainers are to be submitted to the Employer/Engineer a
minimum 28 days before prior to appointment of the agency. Only upon notice of
no objection by the Employer /Engineer shall be authorised to deliver training on
CMRL sites.
19.3.3 Persons with any of the following medical conditions shall not be allowed to work
in confined spaces:
(a) A history of fits, blackouts or fainting attacks,
(b) A history of heart disease or disorder,
(c) High blood pressure,
(d) Asthma bronchitis, or shortness of breath on exertion,
(e) Deafness
(f) Meniers disease or disease involving giddiness or loss of balance,
(g) Claustrophobia or nervous or mental disorder,
(h) Back pain or joint trouble that would limit mobility in confined spaces,
(i) Deformity or disease of the lower limbs limiting movement.
(j) Chronic skin disease,
(k) Serious defects in eye sight or lack of sense of smell
19.3.4 Before any confined space work commences the following equipment shall be
available for use and the sample of the personal protective equipment to be
submitted to the Employer’s /Engineer for notice for no objection. Only upon the
notice of no objection by the Employer /Engineer shall be authorised to use on
CMRL site.
(a) Multi Gas Monitor; or other suitable gas monitoring equipment.
(b) Minimum 35 numbers of 60 minutes Self Contained Breathing Apparatus
(Approved by DGMS) at each Tunnel entrance shall available and Minimum 6
numbers four hours closed circuit breaker breathing apparatus (CCBA Approved
by DGMS) shall available for each tunnel to enable rescue to be carried out;
(c) Full Body Type Harness for each worker;
(d) Tripod and Lifeline Hoist Rope; for work in situations were a vertical exit from the
confined space is required.
(e) Flame-proof lighting. (Hand lamps not more than 24 volts.);
(f) Resuscitation Equipment and details of Emergency control centre and operating
Procedure to be submitted to the Employer’s /Engineer for notice for no objection
(g) Ventilation Equipment.
The persons involved in the confined space working operations shall need to be
thoroughly trained and certified as being competent in the use of the above detailed item
of equipment.
19.3.5 The Contractor shall have controlled access/egress points to confined spaces to
prevent unauthorised access. The Contractor shall ensure that there are at least two
readily accessible escape routes from each confined space.
19.3.6 The Contractor shall operate a tag system for entry so that all personnel entering the
confined space can be accounted for.
19.3.7 The Contractor shall ensure that there is an certified man-riding cage capable of
taking a stretcher and two persons, together with an identified crane equipped with
rescue equipment, on standby at all times whilst work is carried out in the confined
space.
19.3.8 Gas monitoring shall be conducted by a competent confined space assessor to certify
that the confined space is safe for workers to enter and thereafter at every four (4)
hours intervals.
19.3.9 In addition, the Contractor shall ensure that suitable atmospheric monitoring devices
such as anemometer and wet/dry bulb thermometer are made available for the
competent confined space assessor to determine the air flow, ambient temperature
and humidity level within the confined space.
19.3.10Provide noise enclosure for the ventilation fan and install silencer at the end of the
ventilation fan.
20. SITE ELECTRICITY
20.1 General
20.1.1 The Contractor shall nominate a representative whose name and qualifications
shall be submitted in writing to the Employer/ Engineer for review not later than 4 weeks
before the appointment and who shall be solely responsible for ensuring the Safety of all
temporary electrical equipment on Site. The Contractor shall not install or operate any
temporary Site electrical systems until this representative is appointed and has
commenced duties. The project specific CEIG shall be obtained by the contractor as per
Central Electrical Authority (Safety Requirements for construction, operation and
maintenance of Electrical plants and electric lines) Regulations, 2011.
20.1.2 The name and contact telephone number of the electrical C licence holder shall be
displayed at the main distribution board for the temporary electrical supply so that
he can be contacted in case of an emergency.
20.1.3 The Contractor shall submit schematic diagrams and the details of the equipment
for all temporary electrical installations, and these diagrams together with the
temporary electrical equipment shall be submitted to the Employer/ Engineer for
review.
20.1.4 All electrical installation work on Site shall be carried out in accordance with the
requirements laid down in the Specification. All work shall be supervised or
executed by an Govt recognized Electrical ‘’C’’ licence holder.
20.1.5 All temporary electrical installations, equipment and tools shall be checked and
certified safe for use prior to usage on site by a full-time an Govt recognized
Electrical ‘’C’’ licence holder and thereafter monthly and after any repairs. The
Electrical ‘’C’’ licence holder shall provide a sticker on the equipment and tools
indicating the date of inspection and is safe for use.
20.1.6 A current photograph of the Electrical ‘’C’’ licence holder’s and the contact
number(s) shall be displayed on the outside of all boxes containing electrical DBs
for ease of reference. These boxes must be secured with locks to prevent tampering
and the keys kept with the Electrical ‘’C’’ licence holder /Contractor’s Safety Dept.
20.1.7 The Contractor shall ensure that all portable electrical appliances used above and
below ground level, that are hand held tools and inspection lamps, are rated at 110
volts AC via a step down transformer centre tapped to earth (CTE).
20.1.8 The Contractor shall ensure that all generators and welding sets in use on Site are
adequately and effectively earthed at all times during operation.
20.1.9 All Temporary Electrical Site installations and distribution systems shall as a
minimum meet IP44/IP 65 standards and be in accordance with:
(a) Indian Electrical Regulations;
(b) The Power Companies’ Supply Rules;
(c) BS 7671 Requirements for electrical installation, the IEE Wiring Regulations
(d) (16th Edition);
(e) BS 7375 Distribution of Electricity on Construction and Building Sites;
(f) BS 4363 Distribution Assemblies for Electricity Supplies for Construction and
(g) Building Sites; and
(h) BS 6164 Safety in Tunnelling in the Construction Industry.
20.2 Design Considerations
20.2.1 Distribution equipment utilised within the temporary electrical distribution system
shall incorporate the following features:-
(a) Flexibility in application for repeated use;
(b) Suitability for transport and storage;
(c) Robust construction to resist moisture and damage; and
(d) Safety in use.
20.2.2 All cabling shall be run at high level whenever possible and firmly secured to ensure
it does not present a hazard or obstruction to people and equipment.
20.2.3 The installation on Site shall allow convenient access to authorised and competent
operatives to work on the apparatus contained within.
20.3 Distribution of supply
20.3.1 The Site mains voltage shall be as the Electricity Utility supplies, 415V 3-phase 4-
wire system.
(a) Single-phase voltage shall be as the Electricity Utility supplies, 240V supply.
(b) Reduced voltages shall conform to BS 7375.
20.3.2 The following voltages shall be adhered to for typical applications throughout the
distribution systems:

(a) Fixed plant - 415V 3 phase;
(b) Movable plant fed by trailing cable - 415V 3 phase;
(c) Installations in Site buildings - 240V 1 phase;
(d) Fixed flood lighting - 240V 1 phase;
(e) Portable and hand held tools - 110V 1 phase;
(f) Site lighting (other than flood lighting) - 110V 1 phase; and
(g) Portable hand-lamps (general use) - 110V 1 phase.
20.3.3 Protection shall be provided for all main and sub-circuits against excess current,
residual current and earth faults. The protective devices shall be capable of
interrupting (without damage to any equipment or the mains or sub-circuits) any
short circuit current that may occur.
20.3.4 Earthing and bonding shall be provided for all electrical installations and equipment
to prevent the possibility of dangerous voltage rises and to ensure that faults are
rapidly cleared by installed circuit protection.
20.3.5 Only plugs and fittings of the weatherproof type shall be used and they should be
colour coded in accordance with the Internationally recognised standards for
example as detailed as follows:
(a) 110 volts: Yellow.
(b) 240 volts: Blue.
(c) 415 volts: Red.
20.4 Cables
20.4.1 Cables shall be selected after full consideration of the conditions to which they will
be exposed and the duties for which they are required. For supply cables up to 3.3kV
the cable armouring shall be used as the earth return in conditions where the cable
is continuously extended and not subject to continuous movement after installation.
If cable laid in the above ground or underground should be laid as per the norms of
Indian electricity rules 1956.
20.4.2 For supplies to mobile or transportable equipment where operation of the equipment
subjects the cable to flexing, the cable shall conform to one of the following
specifications appropriate to the duties imposed on it:
(a) BS 6708 flexible cables for use at mines and quarries;
(b) BS 6007 rubber insulated cables for electric power and lighting; and
(c) BS 6500 insulated flexible cords and cables.
20.5 Maintenance
20.4.3 Strict maintenance and daily checks of control apparatus and wiring distribution
systems shall be carried out by an Govt recognized Electrical ‘’C’’ licence holder
(duly qualified to carry out the said checks) to ensure safe and efficient operation of
the systems. A team comprising of contractor’s senior Electrical Manager and
Safety Manager shall conduct a monthly Electrical Safety Audit and the report shall
be submitted no later than the 7th of each month within the Contractor’s monthly
OH&S Report.
20.4.4 All portable electrical appliances shall be permanently numbered (inspection tag
labels or similar) and a record kept of the date of issue, date of the last inspection
carried out and the recommended inspection period.
20.4.5 The Work area light mounting height was 25 ft (7.6 m) and the distance between
two work area light should be within 30 meters. The Lighting pole shall not be tied
on the barricading board.
20.6 Lighting:
20.6.1 The contractor shall provide sufficient site lighting, of the right type and at the
right place for it to be properly effective. Lighting ought not to introduce the risk of
electric shock. Therefore, 230V supplies should be used for those fittings, which are
robustly installed, and well out of reach e.g. flood lighting or high-pressure discharge
lamps.
20.7 Illumination
20.7.1 The contractor shall conduct a monthly illumination monitoring by lux meter for
all the locations and the report shall be sent to the Employer/ Engineer within 7th of the
next month and the same shall be reviewed during the monthly OSH&E committee
meeting.
20.7.2 The contractor shall take every effort to illuminate the work site is listed in the
below table
Minimum Lighting Requirements

Luminance – Ix
S.N. Facility or Function 2
(Im/ft )
Administrative areas (offices, drafting and meeting rooms,

1. etc.) 540 (50)
Construction areas
- general indoor 55 (5)
- general outdoor 33 (3)
2.
- tunnel and general underground work areas 110
(minimum 110 lux required at tunnel and shaft
heading during drilling, mucking and scaling) (10)
Access ways
3.
- exit ways, walkways, ladders, stairs 110 (10)
Maintenance / Operating areas / shops
- vehicle maintenance shop 325 (30)
- carpentry shop 110 (10)
55 (5)
4. - outdoors field maintenance area
55 (5)
- refuelling area, outdoors
540 (50)
- shops, fine details work 325 (30)
- shops, medium detail work
5. Mechanical/electrical equipment rooms 110 (10)
6. Hoists, Elevators, freight and passenger 215 (20)

Warehouses and storage rooms/area

- indoor stockroom, active/bulk storage 110 (10)
7.
- indoor rack storage 270 (25)
- outdoor storage 33 (3)
8. Health Centres and First aid stations and infirmaries 325 (30)
9. Toilets, wash and dressing rooms 110 (10)
10. Work areas – general (not listed above) 325 (30)
11. Parking areas 33 (3)
12. Visitor areas 215 (20)
13. Laboratories 540(50)
20.8 Monthly Electrical Safety Audit
20.8.1 A team comprising of contractor’s Senior OHS&E (Electrical) manager and the
Employer/ Engineer shall conduct a monthly electrical safety audit covering the following
and submit the report to the Employer/ Engineer.
i) Electrical accidents investigation findings and remedy
ii) Adequacy of power generation and power requirements
iii) Power distribution and transmission system in place
iv) Updated electrical single line diagram showing the current condition of power
source and distribution including the IP44, IP65 DBs arrangement.
iv) Electrical protection devices – selection, installation and maintenance.
v) Earth or ground connection and earth pit maintenance details
vi) Education and training of electrical personnel undertaken
vii) Routine electrical inspection details
ix) Electrical maintenance system and register.
x) Name plate details of major electrical equipment
xi) CEIG Approval
xi) Classified zones in the site, if any.
21. WELDING AND CUTTING
21.1 General
21.1.1 Contractors shall ensure that all welding, cutting and gouging is carried out so that
the risks are kept at a minimum. There will be some circumstances when Permits to Work
will need to be issued, such as
(a) Working in tunnels;
(b) Welding over areas where others are working;
(c) Working in areas with increased fire risks or hazardous environments;
21.1.2 All equipment must be in good condition, properly installed and routinely inspected
by a competent person, and records must be kept available for inspection by the
Employer/ Engineer.
21.1.3 Flexible hoses, cables and connections must be free from damage or risk of damage
in service. Cables and hoses shall have adequate carrying capacity.
21.1.4 Welders shall wear the correct personal protective equipment which includes the
following;
(d) Face and eye protection with correct grade of shield;
(e) Gauntlet gloves;
(f) Safety footwear
(g) Welders apron or fire retardant overalls;
(h) The atmosphere in the vicinity of work must be known to be safe to breathe and
free from flammable gases.
21.1.5 Adequate ventilation and fume extraction must be provided and used as required by
the risk assessment and especially in enclosed areas and pits.
21.1.6 Surfaces to be heated by the process must be cleaned of contaminants that may be
degraded by heat or give off noxious fumes (e.g. paints, plastics, zinc coating).
21.1.7 Naked flames or high temperature surfaces must not be allowed in the vicinity of
volatile solvents.
21.1.8 All moveable flammable materials must be removed from the vicinity of work and
fireproof covers placed over all flammable materials that cannot be removed.
21.1.9 During all welding the work piece and any access equipment must be safely secured.
21.2 Oxy-fuel Gas Processes
21.2.1 Handle cylinders carefully, keep outside enclosed areas and secure in an upright
position on a custom-built stand or trolley fitted. The metal cap shall be kept in place
to protect the valve when the cylinder is not connected for use.
21.2.2 Flash back arresters shall be fitted to both the fuel gas and oxygen cylinders;
21.2.3 Non return valves shall be fitted to the torch or cutting torch;
21.2.4 Hose clamp or clip shall be used to connect hoses firmly in both sides of cylinders
and torches.
21.2.5 Close cylinder valves when flame is extinguished.
21.2.6 Ensure any vessel, drum or tank that has contained flammable or toxic substances
has been properly cleaned and inspected before subjecting it to hot work.
21.2.7 Checks for gas leaks should carried out using soapy water.
21.2.8 Remove all torches from enclosed areas when not in use.
21.2.9 6kg fire extinguisher to be available at all places where hot work is being carried
out.
21.2.10Use firewatchers if there is a possibility of ignition unobserved by the operator (e.g.
on the other side of bulkheads).
21.3 Arc Cutting, Gouging and Welding Processes
21.3.1 Connect the welding current return cable to the work piece close to the arc point or
to a well electrically conductive support structure in good contact with the work
piece. Also, connect the work piece or the support structure to a separate earth
terminal.
21.3.2 Take precautions against the risk of increased fume hazards when welding with
chrome containing fluxed consumables or high current metal inert gas (MIG) or
tungsten inert gas (TIG) processes e.g. local exhaust ventilation.
21.3.3 Avoid being in contact with water or wet floors when welding. Use duckboards or
rubber protection.

21.3.4 Provide screens to limit exposure of others to glare from arcs.
21.3.5 Use the correct eye and face protection with the correct filter glass.
21.3.6 Use a low voltage open circuit relay device if welding with alternating current in
constricted or damp places.
21.3.7 All electrical installations shall meet the IS: 5571: 1997 and NFPA 70 for gas
cylinder storage area and other hazardous areas.
21.3.8 Transformer used for electrical arc welding shall be fixed with Ammeter and
Voltmeter and also fixed with separate main power switch.
21.3.9 Welding grounds and returns should be securely attached to the work by cable lugs,
by clamps in the case of stranded conductors, or by bolts for strip conductors. The
ground cable will not be attached to equipment or existing installations or apparatus.
21.3.10The current for Electric arc welding shall not exceed 300 A on a hand welding
operation.
21.3.11Use a low voltage open circuit relay device if welding with alternating current in
constricted or damp places.
22. COMPRESSED GASES
22.1 Storage
22.1.1 The Contractor shall ensure that all compressed gases, such as oxygen and fuel
gases, are stored in a safe manner in keeping with the following requirements.
22.1.2 When not in use compressed gas cylinders should preferably be stored in the open
air in a well ventilated area at ground level on a firm level surface at least 3m away
from any cellars, drains, excavations or other hollows where vapour may collect.
There should be good access to the area, which should be kept clean and clear of
combustible material, including wood, packing materials and vegetation. If any
protection is provided to prevent cylinders being exposed to the weather, it should
be of non-combustible material and should not inhibit ventilation. The area should
not be close to any source of heat.
22.1.3 Oxygen cylinders and flammable gas cylinders shall be stored separately, at least
6.6 meters (20 feet) apart or separated by a fire proof, 1.6 meters (5 feet) high
partition. Flammable substances shall not be stored within 50 feet of cylinder
storage areas.
22.1.4 It is important that the valves of so-called èmpty' cylinders are kept closed as well
as those of full cylinders and that plugs, shrouds and caps are kept in place on all
cylinders. This is necessary not only to prevent the escape of any residual
compressed gas into the atmosphere but also to ensure that air is not sucked into the
cylinder to form an explosive mixture inside it. All cylinders should be stored with
their valves uppermost.
22.1.5 The storage area should be enclosed by a fence approximately 2 metres in height.
The fence should be made of non-combustible material and should not inhibit
natural ventilation, particularly at low level - a wire mesh fence is particularly
suitable for this purpose. The fence should have at least two means of exit, which
should not be adjacent to each other. The gates should open outwards and not be
self-locking. Both exits should be unlocked when persons are within the storage
compound. At all times when the site is unattended the storage area should be
secured.
22.1.6 On sites where only small quantities of compressed gas are stored (i.e. less than 300
kg). Only one exit will be necessary providing there is no risk of a person being
trapped in the enclosure. The cage should be clearly marked "Highly Flammable
and notices prohibiting smoking and naked lights should be displayed.
22.1.7 portable first aid and 6kg fire extinguishers shall be positioned in close proximity to
the storage area for use in an emergency. Fire Extinguisher should confirm to IS
2190: 1992.
22.1.8 Industrial Liquefied Petroleum Gas or Domestic Liquefied Petroleum Gas cylinders
shall not permit to use in CMRL project sites.
22.2 Handling Compressed Gas cylinders
22.2.1 Cylinders should be handled with care and wherever practicable moved on specially
designed trolleys. The valve on a cylinder should not be used for lifting or to lever
the cylinder into position. Damage to the valve can result in highly dangerous
situations following the escape of gas. For the same reason throwing or dropping
cylinders should be prohibited as in such circumstances damage to the valve is even
more likely.
22.2.2 Before connecting any cylinder or container of compressed gas to equipment it is essential
that all fires, flames or other sources of ignition in the vicinity, including cigarettes and
pilot lights, are extinguished. Where practicable cylinders should be changed in the open
air. The cylinder should be examined and any damaged or faulty cylinder should NOT be
used. No attempt should be made to rectify any fault or damage. The cylinder should be
put in a safe place away from other cylinders or combustible materials until returned to
the supplier.
22.2.3 If a cylinder is found to be leaking and the leak cannot be stopped, the cylinder
should be carefully removed to a well-ventilated open space free from sources of
ignition. It should be left with the leak, usually at the valve, uppermost, marked
faulty and notices displayed prohibiting smoking or other naked lights. General
access should be prevented by barriers or otherwise. The supplier of the cylinder
should be informed immediately. Under no circumstances should users attempt to
dismantle or repair defective cylinders.
22.3 Regulators
22.3.1 Regulators should be suitable for the gas and pressure in use. Checks for leaks at
the regulator nuts should be made only by using soapy water. In the event of a defect or
of any damage to a regulator, no attempt should be made to repair it. Such repairs should
only be carried out by specialists.
22.4 Hoses
22.4.1 Flexible tubing should only be used for final connections to appliances. Flexible
hoses should comply with BS 3212, BS 5120 or other nationally recognised
standard. They should be additionally protected or of steel braid reinforced
construction wherever they might be subject to damage by abrasion and so sited that
they are not exposed to excessive heat. The length of hoses should be kept as short
as practicable
22.5 Training and Instruction
22.5.1 Many accidents involving compressed gas are due to ignorance of simple basic
precautions. It is essential that all persons using compressed gas are suitably instructed
about the hazards and the precautions to be taken in its use.
23. Machinery
23.1 Machinery Fencing
23.1.1 The Contractor shall ensure that all gears, revolving shafts, flywheels, couplings and
other dangerous parts of machinery shall be effectively guarded unless they are so
constructed, installed or placed as to be safe as if they were guarded.
23.1.2 Fencing of dangerous parts of machinery shall not be removed while the machinery
is in use or in motion. If the fencing is required to be removed for maintenance
purposes it shall be replaced before the machine is taken into use.
23.2 Maintenance
23.2.1 The Contractor shall ensure that all machinery used on site is in safe condition and
is properly maintained and repaired by duly authorised, thoroughly trained and
experienced persons.
23.2.2 No repair to machinery shall be carried out whilst it is in motion unless it is
unavoidable.
23.2.3 Maintenance records shall be kept available for inspection by the Engineer.
23.3 Air Receivers
23.2.4 All Air receivers shall be fitted with a pressure relief valve and shall have the safe
working pressure clearly marked upon them.
23.2.5 Every air receiver shall be subject to an annual test, which shall be carried out by a
duly authorised person. The results of all tests shall be recorded and the records shall
be kept available for inspection by the Employer/ Engineer.
23.2.6 The connection couplers on compressed airlines shall be securely fixed together and
have Safety chains or be wired at the joints in order to ensure that the joints do not
come apart when charged with compressed air.
23.4 Woodworking Machines
23.4.1 All woodworking machines shall be fitted with the following guards and devices;
(a) Top Guard;
(b) Riving Knife;
(c) Guards to protect all drive belts etc.;
(d) An emergency stop switch easily accessible by the operator;
(e) A push stick;
23.4.2 Woodworking machines shall be operated only by thoroughly trained and
experienced operators.
23.5 Abrasive Wheels
23.5.1 All Abrasive wheel machines shall be fitted with appropriate guards which shall be
kept in place at all times the machine is in use.
23.5.2 All abrasive wheel machines shall have the spindle speed clearly marked upon them
in revolutions per minute.
23.5.3 Only thoroughly trained and experienced persons are allowed to change the wheels
on the machines. Wheels must inspected and ring tested before mounting to ensure
that wheels are free from cracks or defects.
23.5.4 Safety Goggles or Face shields must be worn when grinding or cutting with abrasive
wheels.
24. PLANT AND EQUIPMENT OPERATIONS
24.1 General
24.1.1 The contractor shall ensure that only safe and well-maintained plant and equipment
shall be allowed to operate on any of the sites.
24.1.2 All operators of heavy plant such as, earth movers, piling rigs, etc. shall be medical
Examination and Vision Test over twenty years of age and be thoroughly trained
and experienced to operate the equipment. Vision test shall be carried out by the
ophthalmologist doctor.
24.1.3 No unauthorised person shall be permitted to ride on plant.
24.1.4 The operators shall conduct daily inspections of their respective items of plant with
the results of these inspections being recorded and the records kept available for
inspection by the Engineer.
24.1.5 All mobile heavy plant shall be equipped with at least one 6 kg Dry Powder Fire
Extinguisher, carried at a suitable position so as to ensure its easy availability.
24.1.6 Whenever heavy plant is operating in congested areas, thoroughly trained and
experienced banksmen shall be deployed to control the plant and personnel
movement and interface.
24.1.7 Any waste engine oil and filters following any on site servicing and maintenance
shall be removed from the sites and disposed of in an environmentally conscious
manner at authorised disposal locations.
24.1.8 All drums of fuel oil shall be stored on drip trays or the fuel shall be kept in bunded
bulk storage fuel tanks, with quantities stored being kept to a minimum.
24.1.9 The storage areas shall have dry powder fire extinguishers positioned in close
proximity to their location for use in an emergency.
24.1.10The Contractor shall assess the OSH&E risks especially in terms of age, noise,
emissions, condition, etc. associated with the plant, equipment or tool and only those
assessed with minimal OSH&E risks shall be brought to the Site.
24.1.11The Employer /Engineer shall stop the plant, equipment or tool from operation or
require its removal if he finds the OSH&E associated risks to be high. The
Contractor shall not be entitled to any claim for compensation or Extension of Time
for Completion.
24.1.12The Contractor shall implement a preventive maintenance programme to ensure that
all plant, equipment and tools are maintained in a safe and working order.
24.1.13The Contractor shall implement a monthly inspection program to inspect all plant,
equipment and tools. All plants, equipment and tools that have undergone repair or
maintenance shall be inspected and checked before being returned to service.
Stickers or tags shall be displayed to indicate its approval for usage or “Not for
Use”.
24.1.14The Contractor shall implement a lockout and tag-out system, Energy Lockout and
Tagout Procedure.
24.1.15Job-made or modified tools of any kind shall not be used on site.
24.1.16All new heavy equipment to be used in CMRL Worksites shall be subjected to
approval of the Employer /Engineer.
24.1.17On-site speed limits shall be applied as a mandatory standard and due diligence shall
be given to any operations which are likely to create a dust nuisance.
24.1.18All machinery/plant/vehicle used on site shall have enclosed air-conditioned cabs.
24.1.19The windows shall be provided with toughened safety glass and wipers.
24.1.20Seat belt for the driver shall be provided.
24.1.21All site plant and machinery shall be thoroughly washed down before leaving the
site.
24.1.22A team comprising of contractor’s senior plant Manager and Safety Manager shall
conduct a monthly plant and machinery Audit and the report shall be submitted no
later than the 7th of each month within the Contractor’s monthly OH&S Report.
25. TUNNELLING OPERATIONS
25.1 Detailed planning for Occupational Health and safety
25.1.1 General
25.1.1.1The aim of this manual is to encourage all parties to work together to reduce
Occupational Health and safety risk. At the detailed planning stage, the project risk
assessment will highlight areas of risk. These should be addressed by the parties to the
process. Throughout the detailed planning process, the risk assessment should be revised
to enable the parties to develop a construction-stage health and safety plan tailored to the
specific circumstances of the project.
25.2 Parties to the processes
25.2.1 The following parties to a tunnelling project have duties and responsibilities.
a) the principal contractor responsible for the execution of the construction stage,
the coordination of occupational health and safety activities on site and the effective
management of risks during all construction work;
b) The Contractors who have responsibility for the safe execution of part or parts of
the works.
c) the designer with responsibility for the design and specification of the works,
whether temporary or permanent;
25.2.2 Other parties, depending on the method of procurement, can include:
1) plant and equipment manufacturers and suppliers. These bodies have duties
under other legislation to supply plant and equipment that is safe;
2) the engineer who may, under the contract, have responsibility for the design and
supervision of the works and for checking compliance with the terms of the contract.
25.3 Integral nature of design and construction
25.3.1 The interdependence of the design and construction and their appropriateness to the
ground and environmental conditions is more safety-critical in the execution of

underground work than in any other construction activity. It follows that there should be
authoritative engineering continuity through the stages of planning, investigation, design
and construction. This is more effectively achieved by the involvement of a single
organization throughout. If, however, there is a change in the engineering direction of the
works, plans shall be devised to ensure that the essential continuity is maintained and that
the total planning, design and construction process is not fragmented.
25.4 Pre-construction-stage organization
25.4.1 As soon as practicable during the planning process, a Chief Safety Manager shall
appoint by the contractor. The Safety Manager shall ensure that foreseeable risks likely to
arise from shaft sinking or tunnelling work, and which might affect health and safety.
25.4.2 No contractor is allowed to carry out any tunnelling work unless they are able to
demonstrate competence in the type of tunnelling work that is proposed and shows a
willingness and ability to allocate sufficient resources to identify and manage risks
effectively and to comply fully with the occupational health and safety legislation and the
CMRL Contract requirements.
25.5 Construction stage
25.5.1 Organization
25.1.1.1The construction-stage health and safety plan is the fundamental document that
ensures safe working throughout the construction of a tunnel. This plan shall be based on
the information supplied by the client on the residual risks and should be prepared by
persons suitably experienced in the tunnelling operations likely to be involved, including
the types of plant and equipment to be used.
25.1.1.2The Engineer is obliged to ensure that the works do not commence until a
satisfactory construction-stage health and safety plan has been produced by the principal
contractor. At the same time, contractors should carry out an assessment of the risks posed
to their employees, and should use this assessment in devising and implementing safe
systems of work. The health and safety plan should define a clear chain of responsibility
and channels of communication on engineering safety matters. This is particularly
important in, for example, the choice of ground-support systems and decisions concerning
safety at the tunnel face.
25.1.1.3The principal contractor shall be responsible under the Conditions of Contract for
coordinating the activities of all other contractors and includes a requirement for the
provision, accessibility and maintenance of welfare facilities. This needs particular
consideration in long tunnels, deep shafts and in other remote locations. Where tunnel size
permits, welfare facilities should be located underground, including on TBMs.
25.1.1.4A system for accounting for site personnel in an emergency shall be implemented
and rigorously enforced. The system must accurately indicate the number and location of
persons underground at all times. This information is essential to the emergency services
in the event of an underground fire or other emergency. If the works have a single
entrance/exit, a simple tally board can be adequate. For works with multiple
entrances/exits, a more sophisticated system is necessary. Whichever system is used, it
must be supervised and monitored, and all persons using the system must be instructed in
its correct use.
25.1.1.5If the tunnelling operations form part of a multiple-contractor project, then the
tally system used must be uniform across the entire extent of the underground works, and
shall be built into the contract and safety case. The system must allow persons to be
accounted for across the entire project site, irrespective of the entrance or exit by which
they enter or leave.
25.1.1.6The contractor shall ensure

i) Every compressed air system in a tunnel is provided with emergency
power supply for maintained continued supply of compressed air as per
Rule 155 of TBOCWR 2006.
ii) Watertight bulkhead doors are installed at the entrance of a tunnel to
prevent flooding.
iii) Reliable and effective means of communication such as telephone or
walkie-talkie are provided and maintained for arranging better effective
communication at an excavation or tunnelling work as per Rule 136 of
TBOCWR 2006.
iv) All portable electrical hand tools and inspection lamps used in
underground and confined space at an excavation or tunnelling work is
operated at a voltage not exceeding 24V.
v) Only flame proof equipment of appropriate type as per IS: 5571:2000
and or other relevant national /International standard is used inside the
tunnel.
vi) Petrol or LPG of any other flammable substances are not used or stored
inside the tunnel. Oxy-acetylene gas is not permitted for use in a
compressed air environment.
vii) Temperature in any working chamber in an excavation or tunnelling
work where workers employed does not exceed 29°C as per Rule 165
of TBOCWR 2006.
25.6 Statutory & Contractual controls
25.6.1 OHS&E duties and responsibilities with respect to “construction work” are set out
in the CMRL OHS&E Volumes 1-4 including the “relevant statutory provisions”, which
are the various sets of Regulations and Rules that may apply to individual work activities.
Administration is by the Engineer appointed by CMRL and enforcement is undertaken by
the Inspectors of the Employer /Engineer.
25.6.2 All accidents and incidents, whether or not they result in personal injury or losses,
must be reported to the Employer /Engineer. Careful records shall be kept by the
contractor, and these records, together with the results of any associated investigation
work and details of similar incidents from elsewhere, should be studied and analysed, and
appropriate action taken.
25.7 Supervision and inspection
25.7.1 All tunnelling operations shall be subject to appropriate supervision.
Understanding, making engineering judgements, and taking action in response to varying
ground conditions can be as vital to safe working conditions as the anticipation of hazards
and risks. The contractor shall appoint appropriately qualified and experienced persons to
monitor the site activities on their behalf, and to assist in overall promotion of OH&S.
These appointments shall comply with the provision as directed in OHS&E Volume 1.
25.7.2 A team comprising of contractor’s Tunnel Manager and Senior Safety
Manager(Tunnel) shall conduct a monthly Tunnel Audit and the report shall be submitted
no later than the 7th of each month within the Contractor’s monthly OH&S Report.
25.8 Temporary works
25.8.1 Temporary works of a substantial character are invariably necessary in the
construction of shafts and tunnels. They can constitute an essential element of the
permanent construction, as in the case of, for example, a pilot tunnel, a working shaft or
the framing to form an opening. They can also be structurally independent incidental
works, such as working gantries, access systems, thrust pits and walls.
25.8.2 It is essential that OH&S issues relating to these works be taken into account early
in the design stage. Appropriate drawings, calculations, specifications and any
contributions to the construction-stage OH&S plan shall be prepared and submitted to the
Employer /Engineer for notice of no objection. Where any failure of these temporary
works would have a significant adverse effect on the OH&S of persons or on the
environment, they shall be the subject of an independent design check by the contractor.
Once checked, changes should only be made after direct consultation with the appropriate
designer.
25.8.3 The principal contractor shall appoint a person to ensure safety in the design,
checking, construction and use of temporary works.
25.9 Records and reports
25.9.1 The keeping of proper and adequate records of the physical aspects of the work is
of the utmost importance. This is not only for safety during construction, but for safety in
any necessary future maintenance and repair work. Such records shall be kept as part of
the health and safety file/Operations and Maintenance Manual for the project. It must
contain a longitudinal geological section record based on day-to-day records of the strata
encountered, correlated with any borehole records or other records, and with any
abnormal ground levels, tidal or river levels and rainfall. In addition, settlements and
movements of the tunnel lining and supports, and the ground above and adjacent to the
tunnel, shall be recorded. The records shall be made available for inspection at the request
of the Employer /Engineer and formally submitted as instructed by the Employer
/Engineer.
25.10 Recruitment of project personnel
25.10.1All persons employed should have a high standard of physical fitness. All persons
working underground and all plant operators and banksmen be not less than 21 years old.
Applicants for engineering and management posts must be assessed on their knowledge of
and expertise in OH&S issues relevant to the project. Key Personnel shall be subject to
notice of no objection by the Employer /Engineer.
25.11 Competence and training
25.11.1Competence
25.11.2All persons underground must be competent for the environment in which they are
working and for the work tasks and activities they are required to carry out. Engineers,
managers and supervisors should be competent both with respect to the work under
construction, and in the techniques of management, communications and supervision.
Evidence of competence such as the achievement of recognized qualifications should be
sought. This could include, for example, qualifications in project management or health
and safety management; or further education qualifications in tunnelling-related subjects.
25.12 Training
25.12.1It is a legal requirement for all persons at work to be given appropriate training in
health and safety related to the risks they might encounter at work. Special training
requirements apply, e.g. to first-aiders, plant operators, and, in the case of compressed-air
tunnelling, to all those exposed to pressurized atmospheres. Induction training must be
given before any person starts work underground, whether as a new employee or as a
person new to the project. Persons who are new to the industry are particularly vulnerable,
and their induction training and the degree of supervision of their work, particularly
initially, shall reflect this. Induction training should cover:
— likely hazards and risks;

— the devised safe methods of working;
— site rules and prohibited activities;
— the use of protective equipment;
— communications and responsibilities for health and safety;
— action in the event of any emergency, particularly egress from underground
workplaces.
25.12.2Persons employed for the maintenance of mechanical plant should have served an
appropriate apprenticeship or similar training; however, a reasonable proportion of these
persons may be trainees. Persons employed in the installation, operation and maintenance
of electrical circuits and equipment should be graded in accordance with the current
electrical contracting industry, and should be suitably trained for the work. They must
have access to professional electrical engineering advice and supervision.
25.12.3Persons trained in the use of specialized tunnelling plant shall also be experienced
in general procedures for tunnelling and must be familiar with both OH&S instructions
and operating instructions provided by plant manufacturers and suppliers. NOTE:
Specialized tunnelling plant includes items such as TBMs, segment erectors (including
winches), concrete spraying equipment, grout pans, drilling and coring equipment and
pipe jacking pressure systems.
25.12.4Toolbox talks are a valuable method of on-the-job-briefing and for imparting and
updating health and safety knowledge. Such talks shall be held regularly, and should
endeavour to cover each major work activity. The talks shall be repeated whenever
circumstances in the workplace change significantly or when new hazards are anticipated
or become evident. Visitors to underground projects should be given appropriate advice
and training.
25.13 Personal protective equipment
25.13.1General
25.13.1.1Reliance solely on personal protective equipment should be regarded as a last
resort. However, in tunnel construction works, the wearing of some personal protective
equipment is inevitable. The contractor shall carry out risk assessments for PPE.
25.3.2 Head protection
25.3.2.1All persons on site shall wear protective headgear conforming to BS EN 397:1995
or equivalent Indian Standard at all times.
25.13.3 Foot protection
25.13.3.1Strong boots, with steel sole plates and toe protection, conforming to BS EN ISO
20345-2004 or equivalent Indian Standard, shall be worn at all times. In wet tunnels,
heavy rubber knee boots with sole plates and toe protection may be required. Boots
without toe and sole protection shall not be considered acceptable by the Employer /
Engineer.
25.13.4 Hand protection
25.13.4.1Gloves of appropriate material shall be worn where a person is at risk from cuts,
abrasions, burns or contact with corrosive or irritant substances. Elbow-length gloves
should be worn when grouting or handling corrosive or irritant substances. Barrier creams
shall be made available and used by site personnel.
25.13.5 Eye protection
25.13.5.1Safety goggles, face shields and fixed shields shall be provided and used as
appropriate for protection against flying particles, hazardous substances or injurious light
rays. Eye protection must always be worn by site personnel engaged on sandblasting,
shot-blasting, pressurized air and water cleaning, spraying concrete, grinding or chipping
metal, cutting, burning and welding, grout mixing and placing. It shall also be worn where

there is a foreseeable risk of injury while breaking, cutting or drilling concrete or stone or
similar material, and by persons injecting liquids under pressure.
25.13.6 Whole body protection
25.13.6.1Protective clothing shall be provided and used where appropriate to the risk, e.g.
in wet conditions, when burning or welding or when handling hazardous substances.
25.13.7 Respiratory protection
25.13.7.1Where there is a risk of respiratory damage, ventilation shall be employed to
extract or dilute any hazardous materials. The use of respiratory protective equipment
shall only be employed as a last resort and shall be demonstrated through the contractors
risk assessment of the task and environment.
25.13.8 High-visibility clothing
25.13.8.1Suitable high-visibility clothing conforming to BS EN 471-2003 & A1-2007 or
equivalent Indian Standard shall be worn by all persons on site.
25.13.9 Hearing protection
25.13.9.1Guidance on the selection and care of hearing protection is given in Section 19.
25.13.10 Self-rescuers
25.13.10.1All persons underground shall have immediate access to a self-rescuer as
described in 14.10 and be trained in their use. Records of such training must be kept for
inspection by the Employer / Engineer.
25.13.11 First aid provision and procedures
25.13.11.1 General
25.13.11.2It is essential that persons trained in first aid and capable of responding rapidly
to any incident be available on each shift during working hours. All persons shall be
informed of the first aid arrangements of the project.
25.13.11.3All contractors shall train their on-site supervisory personnel in managing
emergencies involving first aid. All personnel should be told that, in the event of serious
injury, a casualty shall be moved only by a trained first-aider, unless there is the
immediate risk of further injury. A minimum of 1 first aider shall be available at all times
per 50 persons or part thereof.
25.13.11.4Good communications are essential between the working areas and the surface
facilities. A clear plan of action shall be formulated to speed up the transfer of any injured
persons from working areas and to ensure that ambulances can reach shaft tops or other
access points quickly. Lifting arrangements in shafts should take this into account. Clear
instructions should be given to all persons on the procedures to be adopted for evacuating
tunnels in an emergency and for ensuring that injured persons are not left behind or
unaccounted for.
25.13.12 First aid facilities
25.13.12.1Sufficient first aid boxes should be provided in accordance BOCW Central
Rules 1998. First aid boxes shall be made of suitable material, and designed to protect the
contents as far as possible from damp and dirt. They should be clearly identified; the
recommended marking is a white cross on a green background. Boxes should be readily
accessible to working areas and should be in the charge of designated first-aiders on each
shift. Appropriate eye wash facilities shall also be provided.
25.13.13 First aid rooms
25.13.13.1A properly constructed and equipped first aid room shall be provided as per
BOCW Central Rules 1998 to be used for treatment and rest. It should be in the charge of
a person trained in first aid and should be available during all working hours.
25.13.14 First aid training

25.13.14.1The CMRL OSHE Conditions of Contract require persons with first aid
responsibilities to have successfully undergone a course of training, and to be in
possession of a current certificate issued by an organization approved by CMRL.
25.13.15 Stretchers
25.13.15.1Stretchers (complete with blankets) suitable for the confined space of a tunnel
shall be provided and maintained. They must be readily accessible for use in working
areas in an emergency, and should be protected against dirt and damp. In particular, where
access to a tunnel is by a shaft, stretchers should, where practicable, be stored at tunnel
level. Appropriate means of transporting an injured person to the surface must be
provided (see 21.6.4).
25.13.16 Ambulances
25.13.16.1Ambulance services BOCW Central Rules 1998 should be notified of the
location of the site and the nature of the work to be carried out. All employees shall be
made aware of the procedure for calling an ambulance during the site specific induction.
25.13.16.2Notices shall be posted on site naming the first-aiders and giving instruction on
the making of emergency calls. A notice giving the address of the hospital dealing with
emergencies must be prominently displayed.
25.13.17 Transport underground
25.13.7.1Consideration as determined within a risk assessment, shall be given to the
provision of a rescue skip, train or dedicated vehicle to expedite the rescue of casualties
from long tunnels.
25.14 Procedures
25.14.1 The Contractor shall develop occupational Health and Safety procedures
and methods of working to be adopted during the course of tunnelling operations. These
procedures shall include but not be limited to;
(a) Shafts and Tunnels Entry Procedure. (Including visitors.)
(b) Blasting operations.
(c) Atmosphere Monitoring. (Oxygen Levels, Explosive Gases, Carbon Monoxide,
Hydrogen Sulphide, Oxides of Nitrogen, temperature, humidity, dust etc.)
(d) Portal Gantry Crane Operating Procedures.
(e) Emergency Preparedness Plan for the Shaft and Tunnels. (Including liaison with
the Emergency Services.)
(f) Work Train Operating Procedure.
(g) Tunnel Boring Machine Cutter Head Chamber Entry procedure.
A detailed method statement must be produced by the Contractor, and approved by the
Employer / Engineer before the commencement of any tunnelling operations.
25.15 Sanitation and Drinking Water
25.15.1 Toilets shall be effectively and regularly cleaned and disinfectants provided.
25.15.2At least 5 litres of clean drinking water shall be provided per person employed on
the shift. The water shall be sited near the portal and also inside tunnels over 500
metres in length. The water shall be contained in a clean container with a tight fitting
lid.
25.15.3Washing and cleaning facilities shall be provided for all workers near the portal.
25.16 Lighting

25.16.1The Contractor shall provide adequate lighting at the face and at any other point
where work is in progress. A minimum of 110 lux shall be provided at the face, walkways
and similar work areas.
25.15.4Emergency lighting shall be installed at the working faces and at 100m intervals
along the tunnel to help escape workmen in case of accidents.
25.17 Ventilation
25.17.1 The Contractor shall make provision for adequate ventilation of all shafts
and tunnels. The ventilation shall be sufficient to ensure proper dispersal of any dust or
fume.
25.18 Protection Against Fire
25.18.1As far as practicable, combustible materials shall not be used in the construction of
any room or recess containing electrical apparatus.
25.18.2No flammable material shall be stored in any part of the tunnel unless it is contained
in suitable flameproof containers.
25.18.3An adequate supply of suitable first aid firefighting equipment shall be kept at
convenient locations throughout the tunnel. This equipment shall tested at least once
a month and records kept available for inspection by the Employer / Engineer.
25.19 Warning Signals
25.19.1 The contractor shall install a suitable system of warning signals for the
movement of plant and materials within shafts and tunnels.
25.18.2 The system shall be checked daily immediately prior to the commencement of
tunnelling work under the supervision of a responsible person.
25.18.3 The Contractor shall make detailed emergency warning signals for cases of fire,
tunnel collapse etc.
26. BLASTING OPERATIONS

26.1 Authorisation for Blasting
26.1.1 The Contractor shall ensure that all blasting operations will only be permitted
following consultations with the relevant authorities and subsequent issuing of the
permission to blast permits. The Employer / Engineer must also give his consent in
writing before any blasting operations take place.
26.1.2 All blasting shall be conducted under the direct supervision of a Licensed Shot firer.
26.2 Risk Assessment and Method Statements
26.2.1 The Contractor shall produce a detailed hazard and risk assessment and an in
depth method statement for amongst others the following elements:
(a) Type of explosives to be used.
(b) Anticipated effects of vibration on nearby structures.
(c) Blasting patterns.
(d) Delivery of the explosives.
(e) Transportation and storage of explosives on site.
(f) Drilling and charging of holes.
(g) Warning sirens.
(h) Measurement of Vibration
(i) Provision of sentries.
(j) Use of blast screens.
(k) ALL CLEAR.
(l) Ventilation following blasting.
(m) Atmosphere monitoring.
(n) Procedure for miss-fires.
27. DEMOLITION
27.1 General
27.1.1 The Contractor shall ensure that all demolition works shall be carried out in a
controlled manner under the management of experienced and competent
supervision.
27.1.2 Prior to any demolition commencing, a survey shall be conducted to identify if there
are any hazardous materials present, for example the presence of materials such as
asbestos and lead.
27.1.3 If any hazardous materials are found, then consideration shall be given as to whether
they shall need to be removed by a Specialist Agency or Sub-contractor prior to the
main demolition works commencing.
27.1.4 Before the demolition commences all relevant notifications will need to be given to
the local authorities and media.
27.1.5 Measures for protection to the public shall be required to be put into place in order
to give protection from any possible falling debris and dust generation.
27.1.6 All power supplies and services shall be disconnected before any demolition work
commences.
28. FALSE WORK / FORMWORK
28.1 General
28.1.1 The contractor shall ensure that all false work / formwork has been properly
designed and is suitable for the purpose.
28.1.2 All designed false work / formwork shall be erected in strict accordance to the
design.
28.1.3 Prior to the loading and subsequent striking of false work / formwork, permission
shall be obtained from the Contractor’s Designer and Engineer who shall both
inspect and sign off on the structure in person.
28.1.4 Adequate provision shall be made on the working platforms for the concrete
placement operations, these shall include locations for vibrators and the
unobstructed movement of personnel controlling the rubber hose during the
concrete pumping operations or the concrete skip during any skipping operations.
28.1.5 The Contractor should use the following checklist to check that false work /
formwork is being used safely;
(a) Have the design and the supports for shuttering and false work / formwork been
checked?
(b) Is it being erected safely from steps or proper platforms?
(c) Are the props plumb and properly set out?
(d) Are the bases and ground conditions adequate for the loads?
(e) Are the correct pins used in the props?
(f) Are the timbers in good condition?
(g) Is it inspected by a competent person against the agreed design before permission
is given to pour concrete?
29.0 PILING AND DIAPHRAGM WALLS
29.1 General
29.1.1 The contractor shall prepare safe systems of work and method statements for all
work concerned with piling and diaphragm walls. He shall take the following points
into consideration.
29.1.2 Piling Rig is not a lifting equipment shall not be used for any lifting operation.
29.1.3 Any excavated piles or panels shall not be left unattended, unless they are
adequately fenced around to prevent accidental entry into the immediate vicinity of
the pile or panel.
29.1.4 Because of the use of heavy plant and equipment in generally congested work areas
then trained banksmen shall be deployed to control the movement of the plant and
personnel interface.
29.1.5 All lifting operations shall be conducted in accordance with the requirements as
detailed in Section 18 Lifting Operations.
29.1.6 Calcium Oxide shall not be used for stabilising the excavated spoil as it is an acute
irritant, unless an agreed method statement has been produced.
29.1.7 A method statement shall be produced by the Contractor, which details the process
for grab retrieval in the event of a grab becoming detached during the course of a
pile or panel excavation.
29.1.8 A method statement shall be produced by the Contractor, which details the process
for stop end recovery.
29.1.9 Wheel washing facilities shall be available on the sites for washing down the spoil
removal trucks and the concrete delivery vehicles.
29.1.10Bentonite and polymer storage tanks shall be bunded around to retain any
unintentional and uncontrolled spillage.
29.1.11The contractor shall submit to the Employer / Engineer, for approval, proposals for
the treatment of Bentonite slurry and its subsequent disposal.
29.1.12No Bentonite spillage shall be allowed on any roads.
29.1.13Regular site cleaning shall be carried out at all work-sites.
29.1.14The Contractor as part of his Emergency Plans shall develop procedures for the
collapse of piles and diaphragm walls.
29.1.15Install automatic water sprinkler system to wet vehicular access.
30.0 WORK ADJACENT TO LIVE RAILWAYS
30.1 General
30.1.1 Whenever work is to be conducted in close proximity to the live railways then the
following measures shall need to be addressed:
(a) The laws of India, State rules shall be followed.
(b) No persons are allowed to encroach onto the railway unless specific authority has
been given by the owner.
(c) Adequate protection shall be followed. (Provision of Block Inspectors, Flagmen
and Lookouts.)
(d) All persons shall wear high visibility clothing at all times.
(e) Any induction training requirements of the railway owner shall be strictly
observed
31. WORK ADJACENT TO LIVE ROADWAYS
31.1 General
31.1.1 Whenever working adjacent to any live roadways then the following aspects shall
be considered.
(a) Close liaison with the Police and Municipal Authorities.
(b) Production of an agreed traffic management scheme in accordance with the local
traffic laws. (Barriers, signs, lights and road markings.) this shall include adequate
provision for pedestrians.
(c) Provide traffic marshal /Traffic Controller high reflective safety vest fitted with led
lights by all personnel engaged in the activities.
(d) Traffic Marshals shall be appointed and deployed to ensure that all road
movement is carried out safely.
(e) Ensures that traffic Marshal/Traffic Controller is available at all times of the day
/Night to alert motorists of the temporary civil works ahead.
(f) Age of the traffic Marshal/Traffic Controller shall not be more than 55 years old at
time of appointment at site.
32.0 PERSONAL PROTECTIVE EQUIPMENT
32.1 General
32.1.1 The Contractor shall at all times keep and maintain an adequate supply of suitable
personnel protective equipment which shall be readily available for use at all times on the
sites, and would include amongst others the following items:
(a) Safety Helmets.
(b) Hearing Protection.
(c) Respiratory Protection.
(d) Eye Protection.
(e) Protective Gloves.
(f) Safety Footwear.
(g) High Visibility Clothing to BS EN 471 Class 3 standard
32.1.2 PPE’s shall be kept available for use by all staff, workers and authorised visitors to the sites.
32.1.3 The Contractor shall remove from the site any worker who consistently refuses to wear the
appropriate personal protective equipment.
32.1.4 The Contractor shall implement a hand protection programme subject to the acceptance of
the Employer /Engineer. The programme will:
a) Identify activities on site that can cause hand injuries;
b) Propose safety interventions such as engineering or administrative measures to reduce
the hazard;
c) Select, provide and maintain suitable hand protection devices and supervise their use;
d) Review and monitor the programme to test its effectiveness.

32.1.5 where hand gloves are used as added protection against hand injury, Contractor shall
assess the work hazards and ensure suitable hand gloves are provided and used. Latex
coated gloves shall be used for general works only.
32.1.6 The Contractor shall provide, maintain and enforce the usage of PPE for all the personnel
on site at all times. The following PPE shall be compulsory on site:
a) Safety helmets with chin strap conforming to BS EN or IS standards.
b) Safety footwear with steel toe cap conforming to BS EN or IS standards
c) High-visibility vest/clothing conforming to BS EN or IS standards.
d) Safety belts shall be provided for restraining falls or safety harness for fall protection.
Safety belts and harness conforming to BS EN or IS standards
e) Respirators / dust masks of the appropriate standard shall be provided for activities
generating dust or fume.
32.1.7 The Contractor shall maintain and update all PPE issuance records.
33. Medical Facilities
33.1 Physical fitness of workmen
33.1.1 The contractor shall ensure that his employees/workmen subject themselves to
such medical examination as required under the law or under the contract provision and
the record of the medical examination of every building worker employed by the
contractor shall maintained in a register in Form XII under Schedule-XIII of TBOCWR
2006 and such register shall be made available to the Employer/Engineer, on demand.
33.1.2 The contractor shall not permit any employee/workmen to enter the work area
under the influence of alcohol or any drugs.
33.2 Medical Examination
33.2.1 The contractor shall arrange a medical examination of all his employees including
his sub-contractor employees employed as drivers, operators of lifting appliances and
transport equipment before employing, after illness or injury, if it appears that the illness
or injury might have affected his fitness and, thereafter, once in every two years up to the
age of 40 and once in a year, thereafter.
i) The Contractor shall maintain the confidential records of medical
examination or the physician authorised by the Employer/Engineer.
ii) No building worker is charged for the medical examination referred
rule No 81 and rule No 223 of TBOCWR 2006 and the cost of such
examination is borne by the contractor, employing such building
worker;
iii) The medical examination shall include Full medical and occupational
history.
iv) Certificate of medical examination shall be maintained by the
contractor as per Form-XI under Schedule-XIII of TBOCWR 2006.

a) Clinical examination with particular reference to
i) General Physique;
ii) Vision: - Total visual performance using standard orthorator like
Titmus Vision Tester should be estimated and suitability for placement
ascertained in accordance with the prescribed job standards.
iii) Hearing: - Persons with normal must be able to hear a forced whisper at
twenty-four feet. Persons using hearing aids must be able to hear a
warning shout under noisy working conditions.
iv) Breathing: - Peak flow rate using standard peak flow meter and the
average peak flow rate determined out of these readings of the test
performed. The results recorded at pre- placement medical examination
could be used as a standard for the same individual at the same altitude
for reference during subsequent examination.
v) Upper Limbs: - Adequate arm function and grip
vi) Spine: - Adequately flexible for the job concerned.
vii) Lower Limbs: - Adequate leg and foot flexibility.
viii) General: - Mental alertness and stability with good eye, hand and foot
coordination.
ix) Any other tests which the examining doctor considers necessary.
33.2.2 If the contractor fails to initiate and continue medical examinations as stated
previously, the Employer / Engineer has the right to appoint a medical examiner
through an agency and deduct the cost and overhead charges against the
contractor.
33.3 Occupational Health Centre
33.3.1 The contractor shall ensure the provision of a site occupational health centre. This
may be mobile or static however, both must be maintained in good order and
complete with facilities as per the Schedule IX, Schedule-X of TBOCWR 2006.
33.4 First Aid Bases
33.4.1 The Contractor shall establish a First Aid Base, in accordance with the Employer
Requirements, at each of his principal work areas. If during the life of the contract
the Contractor’s principal work area moves from one location to another, the
Contractor shall be required to move his First Aid Base.
33.4.2 If the Contractor operates more than one principal work area, he will be required to
have a First Aid Base at each of his principal work areas.
33.4.3 The First Aid Base shall consist of as a minimum;
(a) A treatment room fitted with two treatment couches,
(b) A hand wash basin with running water;
(c) Lockable cupboards to contain sufficient medical supplies;
(d) Bed.
(e) Six Chairs with footrests
(f) Desk and chair.
(g) Six Stretchers (Which can be lifted and lowered by a crane.)
(h) Pillows and blankets.
(i) Refuse containers.
(j) Medical dressings. (Bandages, plasters, antiseptic wipes.)
(k) Eye irrigation sterile solution.
(l) Paper towels.
(m) Disposable gloves.
33.4.4 The first-aid unit shall be provided with air conditioning and shall be kept in a clean
and tidy state at all times.
33.5 Medical Staff
33.5.1 A qualified Doctor, Nurse and assistant Nurse shall be in attendance at the first aid
base during all times when work is being undertaken on the site.
33.6 Ambulance
33.6.1 A fully equipped ambulance and driver shall be provided at the first aid base
during all working hours. The ambulance shall be equipped with the articles specified in
Schedule-IV of TBOCWR 2006.
33.7 First Aid Boxes
33.7.1 Portable first aid boxes will be maintained and is equipped with the articles
specified in Schedule-III of TBOCWR 2006 at each local site offices and work locations
where 20 or more persons work at a time. Every first-aid box or cupboard is distinctly
marked 'FIRST AID’.
33.7.2 In each site office and location one employee, suitably trained in first aid, should be
available at all working hours for the purpose of attending to emergencies.
33.8 HIV/ AIDS prevention and control
33.8.1 The contractor shall also extend necessary organizational support to the appointed
agency for the effective implementation HIV/AIDS programme for workmen of the
Contractors.
33.9 Prevention of mosquito breeding
33.9.1 Measures shall be taken to prevent breeding at site. The measures to be taken shall
include:
i) Empty cans, oil drums, packing and other receptacles, which may retain water shall be
deposited at a central collection point and shall be removed from the site regularly.
ii) Still waters shall be treated at least once every week in order to prevent mosquito
breeding.
iii)Contractor’s equipment and other items on the site, which may retain water, shall be
stored, covered or treated in such a manner that water could not be retained.
iv) Water storage tanks shall be provided.
33.9.2 Posters in Hindi, Tamil and English, which draw attention to the dangers of
permitting mosquito breeding, shall be displayed prominently on the site.
33.9.3 The contractor at periodic intervals shall arrange to prevent mosquito breeding by
fumigation / spraying of insecticides. Most effective insecticides shall include SOLFAC
WP 10 or Baytex, The Ideal Larvicide etc.
33.10 Alcohol and drugs
33.10.1 The contractor shall ensure at all times that no employee is working under
the influence of alcohol / drugs which are punishable under Govt. regulations.
33.10.2 Smoking at public worksites by any employee is also prohibited unless
suitable amenities are provided in accordance with Govt. regulations.
33.10.3 Alcohol testing shall be carried out for all workers and the report should be
submitted on monthly to the Employer / Engineer.
34.0 FIRE PRECAUTIONS
34.1 General
34.1.1 The Contractor shall be responsible for supplying and maintaining adequate fire
precaution facilities on all his sites. The following minimum standards should be
adhered to.
34.1.2 The Contractor shall ensure that specially trained personnel are available to deal
with fires due to electrical causes, gas explosions etc.
34.1.3 A good standard of housekeeping shall be maintained at all times on the sites.
34.1.4 No accumulations of rubbish shall be allowed to gather.
34.1.5 Combustible scrap and other construction debris should be disposed off site on a
regular basis. If scrap is to be burnt on site, the burning site should be specified and
located at a distance no less than 12 metres from any construction work or any other
combustible material.
34.1.6 Signage shall be erected at prominent positions showing the correct use of portable
first aid fire extinguishers.
34.1.7 Emergency Plan and Fire plan shall be prepared and issued. Mock drills should be
held on a regular basis to ensure the effectiveness of the arrangements.
34.1.8 The Contractor shall ensure that all procedures, precautionary measures and safety
standards stipulated in the Fire Plan are implemented, communicated and complied
with by all workers including sub-contractors and Interfacing Contractors.
34.1.9 The Contractor shall review and ensure the adequacy of the Fire Plan as the Works
progress.
34.1.10The Contractor shall carry out monthly checks of fire fighting equipment and test
all alarms and detection devices installed on site. Tags/stickers shall be provided to
indicate the monthly checks.
34.1.11The Contractor shall conduct weekly inspections of escape routes, fire brigade
access, fire fighting facilities and work areas to ensure that the requirements
stipulated in the Fire Plan are complied with.
34.2 Fire Fighting Equipment
34.2.1 At various locations around the site clearly visible fire points shall be established
for use in an emergency and each fire point should have available as a minimum the
following type of equipment:
(a) Dry Powder Extinguisher.
(b) Water Type Extinguisher.
(c) Bucket of Sand.
34.2.2 Recharging of fire extinguishers and their proper maintenance should be ensured
and as a minimum should meet Indian National Standards
34.2.3 Water supply for firefighting purposes should be provided at the construction site.
This may be in the form of static water tank of adequate capacity or a hydrant line
with adequate water pressure at outlet points.
34.2.4 Sufficient number of fire hoses with branch pipes should be provided at site so that
the fire can be controlled until the arrival the arrival of the Fire Brigade.
34.2.5 The contractor shall need to give consideration to the provision of adequate
firefighting arrangements within the underground and tunnelling operations
including the provision of Fire Service compatible hose connections and emergency
lighting
34.2.6 The Telephone Number of the local fire brigade should be prominently displayed
near each telephone on site.
34.2.7 Supervisors and workmen at the site should be trained in the use of firefighting
equipment provided at the site.
34.3 Storage of Flammable Liquids
34.3.1 All flammable liquids shall be kept in a secure fire resistant store protected from
electrical sparks welding sparks open flames and smoking.
34.3.2 Only such amounts of flammable liquids should be issued as are required for
immediate use. Cans for carrying flammable liquids should be leakproof and
properly stoppered and clearly marked “FLAMMABLE LIQUID”.
34.3.3 Rags soaked in paints, kerosene and other flammable liquids should be disposed of
daily under supervision. Large quantities of such rags should not be allowed to
accumulate.
34.3.4 All Diesel fuel storage tanks shall be bunded around in order to control any spillage
or leakage that may occur.
34.3.5 All drivers of vehicles, foreman, supervisors and managers shall be trained on
operating the fire extinguishers and firefighting equipment
34.3.6 All lifting appliances’ driver cabin should be provided with a suitable 6kg portable
fire extinguisher.
34.3.7 If the Contractor intends to store petroleum more than the legal requirements and
flammable materials on site, he shall obtain a storage licence from the state
government and a copy of the licence shall be submitted to the Employer /Engineer.
34.3.8 The Contractor shall not store petrol on site. If they want to store they should obtain
licence from the govt of Tamil Nadu
34.3.9 All diesel stored on site shall be kept in drums or in bulk tanks which in either case
shall be located at a designated place away from any sources of ignition or open
drain which does not lead to an interceptor, and shall be properly labelled. A “No
Smoking” sign shall be displayed at the storage location and a charged fire
extinguisher of correct type kept on standby.
34.3.10All bulk diesel tanks shall be properly supported in an elevated position to facilitate
gravity discharge. They shall stand within a bund constructed to contain a volume
of 110% of the volume of the tank. There shall be no breaches in the bund wall, no
material shall be stored within the bund and rain water collecting in the bund shall

be regularly removed to prevent build-up. The inner face of the bund wall shall be
coated with a chemical resistant material. A chemical resistant valve, which shall
be closed at all times, except for releasing rainwater into a stormwater drain via an
oil intercepting system, shall be installed at the outlet situated outside the bund, in
accordance with the legal requirements.
34.3.11All drums of diesel on Site shall be in good condition and shall be kept closed with
a lid/cap when not being used. They shall be stored on end with the lid/cap
uppermost and kept within a tray of sufficient volume to contain the contents of the
largest drum in the case of accidental rupture, taking into account the presence of
other drums within the tray.
34.3.12Drums of diesel shall not be rolled along the ground. They shall be transported
vertically chained on a trolley; or by a forklift fitted with a drum handling device
and not standing unsupported on the forks or on a pallet; or by crane using a safe
slinging technique.
34.3.13Diesel shall be transferred from the storage drum to another container, or to the tank
of plant/machinery using a hand pump wherever practicable and at all times a drip
pan must be provided. Where the diesel container is light enough to be lifted by one
person it can be poured out by hand, using a funnel to guide the liquid.
34.3.14Any spillages of diesel shall straight away be absorbed using sand or other absorbent
materials, which shall be disposed of as contaminated waste. On no occasion should
diesel be allowed to enter the Site drainage system unless this is connected to an
interceptor prior to the Site waste being discharged into the public sewer system.
35.0 Construction Machinery
35.1 Construction machineries may include dumpers and dump trucks, lift trucks and
telescopic handlers piling rigs, vibro hammers, rail welding equipments, mobile elevating
work platforms, cranes, tipper lorries, lorry loaders, skip wagons, 360° excavators, 180°
backhoe loaders, crawler tractors, scrapers, graders, loading shovels, trenchers, side
booms, pavers, planers, chippers, road rollers, locomotives, tankers and bowsers, trailers,
hydraulic and mechanical breakers etc.
35.2 Safe worthiness certificate
35.2.1 All construction equipment shall be in sound mechanical working condition,
tested and certified every six months by either competent person under Factories Act or
manufacturers’ warranty in case of brand new equipment or authorized persons/ Charted
Engineer (Mechanical) / firms approved by the Employer / Engineer before induction to
any site.
35.2.2 Every such certificate shall have the date of purchase, main overhauling
undertaken in the past, any accident to the equipment, visual examination details, critical
components safety check, list of safety devises and its working condition, manufacturer’s
maintenance checklist, past projects wherein the equipment’s were used etc. as its
minimum content.
35.3 Reverse Horns
35.3.1 All Vehicles shall be fitted with audible reverse alarms/camera and maintained in
good working condition. Reversing shall be done only when there is adequate rear view
visibility or under the directions of a banksman.
35.4 General operating procedures
i) Drivers entering site shall be instructed to follow the safe system of work
adopted on site. These shall be verbal instructions or, preferably, written
instructions showing the relevant site rules, the site layout, delivery areas,
speed limits, etc.
ii) No passengers shall be carried, unless specific seating has been provided
in accordance with the manufacturer’s recommendations.
iii) Working on gradients beyond the equipments capability shall not be
permitted.
iv) Prevention of dumper and dump truck accidents should be managed by
providing wheel stops at a sufficient distance from the edges of
excavations, spoil heaps, pits, etc.
v) The manufacturer’s recommended bucket size must not be exceeded in
excavators.
vi) If excavators operating on a gradient which cannot be avoided, it must be
ensured that the working cycle is slowed down, that the bucket is not
extended too far in the downhill direction, and that travel is undertaken
with extreme caution. A large excavator must never be permitted to travel
in a confined area, or around people without a banksman to guide the
driver, who should have the excavator attachment close in to the
machine, with the bucket just clear of the ground. On wheeled
excavators, it is essential that the tyres are in good condition and
correctly inflated. If stabilizing devices are fitted, they should be
employed when the machine is excavating.
vii) When the front shovel of the 1800 backhoe loaders is being employed, the
backhoe attachment shall be in its “travel” position, with the safety
locking device in place.
viii) When operating the backhoe in poor ground conditions, the stabilisers
tend to sink into the surface of the ground, reducing stability. Therefore
frequent checks shall be made for the stability of the machine. The
loading shovel should always be lowered to the ground to stabilise the
machine when the backhoe is employed.
ix) The netting operation of the skip wagons should be carried out prior to
lifting the skip to reduce the risks of working on the rear platform.

x) If a tractor dozer is employed on clearing scrub or felling trees, it shall be
provided with adequate driver protection from rollover and falling
objects.
xi) When two or more scrapers are working on the same job, a minimum
distance of at least 25m shall be kept between them.
35.5 All wood working machines shall be fitted with suitable guards and devices such
as top guard, riving knife, push-stick, guards for drive belts and chains, and emergency
stop switch easily accessible by the operator.
35.6 Penalty
35.6.1 If any of the above clauses are not adhered, penalty shall be imposed as per
relevant clause depending upon the gravity of the unsafe act and or condition.
36.0 TRAFFIC MANAGEMENT
36.1 General
36.1.1 The Contractor shall provide, install and maintain all necessary traffic and directional signs,
barriers, blinkers, rotating beacons, cones, lane markings etc. in accordance with the legal
requirements. The Contractor must observe the minimum clearance required between the
working area and the trafficked carriageway and ensure that all plants and materials do not
intrude into any area reserved for pedestrians, cyclists or other traffic.
36.1.2 The Contractor shall regularly maintain the site road surfaces to keep them free of potholes,
unevenness, etc. Mill and patch method shall be required to repair any uneven surface
defects.
36.1.3 The basic objective of the following guidelines is to lay down procedures to be
adopted by contractor to ensure the safe and efficient movement of traffic and also to
ensure the safety of workmen at construction sites.
36.1.4 All construction workers must be provided with high visibility jackets with
reflective tapes as most of viaduct / tunnelling and station works are either located above
or under right-of-way. The conspicuity of workmen at all times shall be increased so as to
protect from speeding vehicular traffic.
36.1.5 At each entrance to the site the Contractor shall erect a large billboard warning all
persons who enter the site that they are required to wear the appropriate Personal
Protective Clothing and that no unauthorised access is allowed.
36.1.6 Wherever the fence runs adjacent to the highway with no buffer-zones then the
fence shall have traffic warning lights duly affixed to it.
36.1.7 Pedestrian route must be provided and separated to avoid mishap involving
workers crossing the roads from different directions ,wherever the fence borders on
pedestrian footpaths lighting shall be provided to illuminate the pedestrian routes.
Additional precautions must be taken and flash lights / flag man required to be placed
during foggy / adverse weather. The positioning of the fence-line shall not reduce the
width of the pedestrian footpath to less than 900 mm in order to be able to accommodate
disabled persons in wheelchairs.
36.1.8 Barricade Boards shall be washed at least once a week and repainted at least
annually. All barricading boards shall be properly pegged (12 pegs for each board)
& all inter connection between the adjacent boards (3 no’s) shall tied.

36.1.9 The site fencing shall need to be inspected on a regular basis in order to ensure that
the integrity of the fencing is maintained at all times as far as is practicable.
36.1.10The guiding principles to be adopted for safety in construction zone are to;
i.Warn the road user clearly and sufficiently in advance.
ii.Provide safe and clearly marked lanes for guiding road users.
iii.Provide safe and clearly marked buffer and work zones
iv. Provide adequate measures that control driver behaviour through
construction zones.
v. Materials and equipment such as pile cages shall not be transported via
Hydra on a public highway unless all access is closed to members of the
public.
vi. Impact protection vehicle(IPV) should be placed in advance while working
on live road.
vii. Vinyl(2x2.5meter) public /Traffic safety information poster shall be pasted
on the each barricaded board.
viii. Light mast should be placed at the start point of the barricaded board while
working on live road.
ix.Rope light shall be installed on all barricade board.
x. Traffic digital sign boards shall be installed at the entry, exit, diversion,
Warning, Road Crossing, Left/Right Carry Way Closed, Tunnel, Electric
Cable, Speed Bump, Men at work, Pedestrian Crossing etc.
xi. Pedestrian route shall be provided with top rail , midrail and the pipes shall
be painted in reflective paints.
36.2 Legal permission
36.2.1 In all cases, the contractor shall employ planned precautions specific to the
location of the site works. Wherever operations undertaken are likely to interfere with
public traffic, specific traffic management plans shall be drawn up and implemented by
the contractor in consultation with the approval of local police authorities and/or the
concerned metropolitan/civil authorities as the case may be.
36.2.2 Such traffic management plans shall include provision for traffic diversion and
selection of alternative routes for transport of equipment. If necessary, the contractor shall
carry out road widening before commencement of works to accommodate the extra load.
36.2.3 The primary traffic control devices used in work zones shall include signs,
delineators, barricades, cones, pylons, pavement markings and barrier lighting.
36.2.4 The road construction and maintenance signs which fall into the same three major
categories as do other traffic signs, that are Regulatory Signs, Warning Signs and
Direction (or guidelines) Reflective Signs shall only be used. The IRC: 67 (Code of
Practice for Road Signs) provide a list of traffic signs. The size, colours and placement of
sign shall confirm to IRC: 67. The contractor shall submit Traffic Sign design to the
Employer / Engineer for Notice of No objection.
36.3 Regulatory signs
36.3.1 Regulatory signs impose legal restriction on all traffic. It is essential, therefore,
that they are used only after consulting the local police and traffic authorities.
36.4 Warning signs

36.4.1 Warning signs in the traffic control zone shall be utilised to warn the drivers of
specific hazards that may be encountered.
36.4.2 The contractor shall place detour signage at strategic locations and install
appropriate warning signs. In order to minimize disruption of access to residences and
business, the contractor shall maintain at least one entrance to a property where multiple
entrances exist.
36.4.3 A warning sign shall be installed an at all secondary road which merges with the
primary road where the construction work is in progress at a sufficient distance before it
merges with the primary road so as to alert the road users regarding the ‘Metro Work in
Progress’.
36.5 Delineators
36.5.1 The delineators are the elements of a total system of traffic control and have two
distinct purposes:
i. To delineate and guide the driver to and along a safe path
ii. As a taper to move traffic from one lane to another.
36.5.2 These channelling devices such as cones, traffic cylinders, tapes and drums shall
be placed in or adjacent to the roadway to control the flow of traffic. These should
normally be retro-reflectors complying with IRC: 79 - Recommended Practice for Road
Delineators.
36.6 Traffic cones and cylinders
36.6.1 Traffic cones of 500mm, 750mm and 1000mm high and 300mm to 500mm in
diameter or in square shape at base and are often made of plastic or rubber and normally
have retro-reflectorised red and white band shall be used wherever required.
36.7 Drums
36.7.2 Drums about 800mm to 1000mm high and 300mm in diameter can be used either
as channelising or warning devices. These are highly visible, give the appearance of being
formidable objects and therefore command the respect of drivers. Drum delineators must
be sufficiently illuminated.
36.8 Barricades
36.8.1 Full height fence, barriers, barricades etc. shall be erected around the site in order
to prevent the working area from the risk of accidents due to public vehicular movements.
The barriers are also designed to protect road users from the dangers associated with
general construction operation material handling and temporary structures.
36.8.2 The structure dimension of the barricade, material and composition, its colour
scheme, CMRL logo and other details shall be in accordance with specifications laid
down in tender document.
36.8.3 All barricades shall be erected as per the design requirements of the
Employer/Engineer , numbered, painted and maintained in good condition and also
Barricade in- charge maintains a barricade register in site. All barricades shall be washed
at least once a week and repainted at least annually. The contractor shall submit barricade
design to the Employer / Engineer for Notice of No objection.
36.8.4 All barricades shall be conspicuously seen in the dark/night time by the road users
so that no vehicle hits the barricade. Conspicuity shall be ensured by affixing retro
reflective stripes of required size and shape at appropriate angle at the bottom and middle
portion of the barricade at a minimum gap of 1000mm. Red light blinker and Reflective
sticker plate should be placed at the top of each barricade.
36.8.5 The contractor shall ensure that all his construction vehicles plying on public roads
(like dump trucks, trailers, etc.) have appropriate licenses to ply on public roads from the

Govt. All drivers shall be medically fit and in possession of a valid and current driving
licence as per the requirements of motor vehicles act as amended in 1994, the central
motor vehicles rules, 1989 shall drive these vehicles on the public highway.
36.8.6 The contractor shall not undertake loading and unloading at carriageways
obstructing the free flow of vehicular traffic and encroachment of existing roads by the
contractor applying the excuse of work execution unless traffic management alternatives
have been installed e.g. diversion.
36.8.6 The Contractor shall undertake Barricade Board maintenance work and painting
etc. at the Engineer’s request where concerns have been raised regarding the suitability
of barricading board. Such Barricade Board maintenance shall be carried out with
immediate effect.
36.9. Tow away vehicle
36.9.1 The contractor shall make arrangements keeping tow away van / manpower to tow
away any breakdown vehicle in the traffic flow without loosing any time at his cost.
36.10 Cleaning of roads
36.10.1The contractor shall ensure the cleanliness of roads and footpaths by deploying
appropriate manpower to ensure efficiency in the cleaning task. Vehicle Control
36.10.2 Traffic Controllers shall be available for directing vehicles that are exiting
the sites directly onto the live carriageways. Any vehicles entering the sites that are
required to execute reversing manoeuvres shall do so under the strict control of a trained
and designated banksman.
36.11 Spoil Removal
36.11.1Any vehicles leaving the sites carrying loads which are liable to produce airborne
contaminants shall prior to leaving the site securely sheet the load over in order to
effectively contain any dispersement during transportation on the public highway.
36.11.2Vehicles exiting the site directly onto the live carriageway shall do so under the
control of the clearly identified Traffic Controller.
36.11.3Any vehicles that are required to reverse whilst on the site shall do so under the
control of a trained banksman.
36.11.4Any vehicles prior to leaving the site shall have their wheels washed and any loose
material removed.
36.11.5Any spoil that is removed from the work-sites shall be disposed of only at authorised
dumping sites.
36.11.6 A team comprising of contractor’s construction Manager and Traffic Engineer shall conduct
a monthly Traffic Safety Audit and the report shall be submitted no later than the 7th of
each month within the Contractor’s monthly OH&S Report.
37.0 Housekeeping
37.1 Housekeeping is the act of keeping the working environment cleared of all
unnecessary waste, thereby providing a first-line of defence against accidents and
injuries.
37.2 Contractor shall understand and accept that improper housekeeping is a primary
hazard in any construction site and ensure that a high degree of house keeping is always
maintained.

37.3 Housekeeping is the responsibility of all site personnel, and line management
commitment shall be demonstrated by the continued efforts of supervising staff towards
this activity.
37.4 General House keeping shall be carried out by the contractor and ensured at all
times at the Work Site, Construction Depot, Batching Plant, Labour Camp, Stores,
Offices and toilets/urinals. Towards this the Contractor shall constitute a special group of
house keeping personnel. This group shall ensure daily cleaning at work sites and
surrounding areas and maintain a register for inspection at the Employer /Engineer
request.
37.5 Adequate time shall be assigned to ensure that good housekeeping is maintained.
This shall be carried out by the housekeeping team.
37.6 The contractor shall be responsible to provide segregated containers for disposal of debris
at required places and regular cleaning of the same.
37.7 Full height fence, barriers, barricades etc. shall be erected around the site in order to
prevent the surrounding area from excavated soil, rubbish etc, which may cause
inconvenience to and endanger the public. The barricade especially those exposed to
public shall be aesthetically maintained by regular cleaning and painting as directed by
the Employer / Engineer. These shall be maintained in one line and level.
37.8 All stairways, passageways and gangways shall be maintained without any blockages or
obstructions. All emergency exits passageways, exits fire doors, break-glass alarm points,
fire fighting equipment, first aid stations, and other emergency stations shall be kept
clean, unobstructed and in good working order.
37.9 Lumber with protruding nails shall be either bent or removed and properly stacked. Un-
packed wooden strips shall be safely stored and disposed.
37.10 All surplus earth and debris are removed/disposed off from the working areas to officially
designated dumpsites. Trucks carrying sand, earth and any pulverized materials etc. in
order to avoid dust or odour impact shall be covered while moving. The tyres of the
trucks leaving the site shall be cleaned with water, wherever the possibility of spillage on
carriageways meant for regular road traffic exists.
37.11 No parking of trucks/trolleys, cranes and trailers etc. shall be allowed on roads, which
may obstruct the traffic movement.
37.12 Roads shall be kept clear and materials like: pipes, steel, sand boulders, concrete,
chips and brick etc.
37.13 Water logging or bentonite spillage on roads shall not be allowed. If bentonite spillage is
penalised as per Table -6 of Employer’s Requirements OHS&E Volume 1.

37.14 Proper and safe stacking of material are of paramount importance at yards, stores and
such locations where material would be unloaded for future use. The storage area shall be
well laid out with easy access and material stored / stacked in an orderly and safe manner.
37.15 Flammable chemicals / compressed gas cylinders shall be safely stored.
37.16 Unused/surplus cables, steel items and steel scrap lying scattered at different places
within the working areas shall be removed to predetermined locations(s).
37.17 All wooden scrap, empty wooden cable drums and other combustible packing materials,
shall be removed from work place to identified location(s).
37.18 Empty cement bags and other packaging material shall be properly stacked and
removed.
37.19 The Contractor shall ensure that all his sub-contractors maintain the site reasonably clean
through provisions related to house keeping
37.20The Contractor shall implement a 5S housekeeping method approved by the Employer
/Engineer. The method shall be based on a Japanese quality management concept based
on cyclical methodology. The 5S shall consist of Seiri (Sort/Organise), Seiton
(Straighten/Orderliness), Seiso (Sweep/Cleanliness), Seiketsu (Standardise) and Shitsuke
(Sustain/Discipline).
37.21The Contractor shall transport waste material directly from the excavation to the approved
dumping ground and shall discharge the waste directly into position. No stockpiles of
waste are allowed on site.
38. Overhead Protection
38.1 All contractors shall provide overhead protections as per TBOCWR 2006
i) Overhead protection (Fan) should be erected along the periphery of every building which is under
construction and the building height shall be 15m or above after construction.
ii) Overhead protection shall be minimum 2m wide and the outer edge shall be 150mm higher than the inner
edge and an angle not more than 20degree to its horizontal sloping into the building.
iii) Overhead protection shall not be erected more than a height of 5m from the base of the building.
iv) Areas of inadvertent hazard of falling of material shall be guarded or barricaded to prevent access and
appropriately signed.
39.0 Slipping, Tripping, Cutting, Drowning and Falling Hazards

i) All places should be free from dust, debris or similar materials.
ii) sharp projections or any protruding nails or similar objects shall be suitably guarded or shall even be avoided
to make the place safe to work.

iii) Contractor shall not allow workmen to work or use
platforms, scaffolds/passageways or any walkways, which has water, or oil or similar substances spilt and
has a slipping hazard, unless it is cleaned off or covered or sanded or saw dusted or make it safe with any
suitable material.
iv) When workers are exposed to areas where fall into water is possible, the contractor shall provide suitable
and adequate equipment for saving the workers from drowning and rescuing from such hazard. If the Employer
/ Engineer considers, the contractor shall provide well-equipped boat or launch, manned with trained
personnel at the work place.
v) Open side or opening where worker, equipment, vehicle or lifting appliance may fall at a building or outside
shall be guarded suitably except in places of free access by reasons of nature of work.
vi) Suitable safety net shall be provided at places of material / man falling is possible in
accordance with national standards
40.0 Launching Operation
40.1 The contractor shall take utmost precaution at all stages of a launching operation to
include but not limited to; planning, establishing casing yard, casting segments & girders,
transportation and load restrictions applicable, bridge and road conditions, fabrication and
erection of launching girders if any, launching of segments / lifting of segments, pre-
stressing, auto launching of girders and dismantling of launching girders.
40.2 The contractor shall prepare a comprehensive Method Statement for the launching
operation, Particular reference shall be made to the provisions on working at height &
heavy lift planning. As the process of launching/lifting may be required utilising the
public right-of-way, the safety of workers and the equipment serviceability is of
paramount importance. The following general guidelines shall be adhered throughout the
launching operation.
i) Necessary ‘working platforms’ and fall protection anchorage

arrangement shall be provided in the launching girder itself.
ii) Provisions for mounting light fittings shall also be made available in the
launching girder.
iii) The workmen engaged in fabrication of reinforcement, concreting the
segment shall be provided with necessary PPEs including compulsory
hand protection gloves.
iv) Casting and curing of segment / girder shall be undertaken under the
direct supervision of the responsible engineer of the contractor.
v) Trucks with valid registration, licence, safe worthiness certificate,
Employer’s approval certificate, and pollution under check certificate
shall only be used for transport of segments
vi) Drivers engaged for driving these trucks, shall receive refresher.
vii) Drivers shall also have undergone proper medical examination as per
relevant clause mentioned under ‘Medical Facilities’.

viii) The segments / girders shall rigidly secured to the truck with necessary
wooden wedges and necessary red indicators/safety tapes provided so
that the vehicle is clearly seen by other road users both in day / night
time.
ix) Every launching girder shall have a responsible engineer on duty all the
time.
x) All the time from erection to dismantling the area between the two piers
wherein launching is in progress shall always be barricaded.
xi) Unloading of segments / girders from trucks, lifting of loads, shifting of
segments / girders, gluing shall be done under the direct supervision of
the approved engineer of the contractor.
xii) Auto launching shall be done only after approval from the Employer /
Engineer. After every auto launching the stability of launching girder
shall be ensured.
xiii) The vertical deflection of launching girder shall be monitored at all
critical stages like with/without loads and after every auto launching.
xiv) A register containing all important operational details from erection to
dismantling of launching girders shall be maintained and made available
to the Employer / Engineer whenever called for.
xv) Test certificate for all lifting gears including Macalloy bars shall be
maintained at a location closer to the launching girder itself so that it can
be referred during all inspections.
xvi) Adequate lighting at all time shall be ensured in the entire area of
operation.
xvii) Access to drinking water & toilet shall be ensured to all workmen
engaged for launching process.
xviii) Proper access stairways shall be maintained for safe ascending and
descending of workmen / engineers.
40.3 Non-adherence to any of the clauses mentioned above shall be viewed seriously by the
Employer and penalty levied as per relevant clause.
41.0 Machine and General Area Guarding
41.1 The contractor shall ensure at the construction site all motors, cogwheels, chains and
friction gearing, flywheels, shafting, dangerous and moving parts of machinery are
securely fenced or legged. The fencing of dangerous part of machinery must not be
removed while such machinery is in motion or in use.
42.0 Manual Lifting and Carrying of Excessive Weight
42.1 The contractor shall ensure that no worker lifts by hand or carries overhead or over his
back or shoulders any material, article, tool or appliances of such a weight that may cause
injury from either a single lift or repetitive lifting. A Risk Assessment regarding suitable
loads to preventing injury must be carried out by the contractor.
Person Maximum weight in

kg.
Adult man 55
Adult woman 30

42.2 No building worker aided by other building worker shall lift or carry weight higher than
or exceeding the sum of total of maximum limits set out for each building worker
separately as mentioned in the table above.
43.0 Hand Tools and Power Tools
43.1 General
43.1.1 The contractor is wholly responsible for the safe condition of tools and equipment
used by his employees and that of his sub-contractors.
43.1.2 Use of damaged hand tools shall be avoided and the contractor shall ensure all his
hand tools used at his worksite are safe to work with or stored and shall also train his
employees (including his sub-contractors) in their correct use.
43.1.3 All hand tools and power tools shall be duly inspected before use for signs of
damage.
43.1.4 All hand tools and power tools shall have sufficient grip and the design
specification on par with national/international standards on anthropometrics.
43.2 Hand tools
43.2.1Hand tools shall include saws, chisels, axes and hatches, hammers, hand planes, screw
drivers, crow bars, nail pullers, scaffolders podge etc.
43.2.2The contractor shall ensure that,
i) For crosscutting of hardwood, saws with larger teeth points (no. of points per
inch) shall be preferred to avoid the saw jumping out of the work piece.
ii) Mushroom headed chisels shall not be used in the worksite where the
fragments of the head may cause injury.
iii) Unless hatchet has a striking face, it shall not be used as a hammer.
iv) Only knives of retractable blades shall be used in the worksite.
v) No screwdrivers shall be used for scraping, chiselling or punching holes.
vi) A pilot hole shall always be driven before driving a screw.
vii)Appropriate PPE shall be issued to the workforce as dictated by the equipment
and manufacturers recommendations.
43.3 Power tools
43.3.1 Power tools include drills, planes, routers, saws, jackhammers, grinders, sprayers,
chipping hammers, air nozzles and drills.
43.3.2 The contractor shall ensure that
i.Electric tools are properly grounded or / and double insulated.

ii.GFCIs/ RCCBs shall be used with all portable electric tool operated especially
outdoors or in wet condition.
iii.Before making any adjustments or changing attachments, the tool shall be
disconnected from the power source.
iv.All drills shall have suitable attachments respective of the operations and
powerful for ease of operation.
v.Tools shall be specifically designed for that work that shall be undertaken.
vi.Workers shall not stand on the top of the ladder to drill holes in walls / ceilings.
vii.Electric plane shall not be operated with loose clothing.
viii.Safety guards used on right angle head or vertical portable grinders must cover
as per the wheel specifications shall be checked.
ix.All power tools / hand tools shall have guards at their nip points.
x.Leather aprons and gloves shall be used as an additional personal protection
auxiliary to
withstand kickback.
xi.Push sticks shall be provided and properly used.
xii.Air pressures are to be set at a suitable level for air actuated tool or equipment
being used.
xiii.Before changing or adjusting pneumatic tools, air pressure shall be turned off.
xiv.Only trained employees shall use explosive actuated tools and the tool must also
be unloaded when not in use.
xv.Usage of such explosive actuated tools shall be avoided in case of places where
explosive/flammable vapours or gases may be present.
xvi.Explosive actuated tools and their explosives shall be stored separately and be
taken out and loaded only before the time of immediate use.
xvii.Misfired cartridges of explosive actuated tools must be placed in a container of
water and
be removed safely from the project.
xviii.No worker shall point any power operated / hand tool to any other person
especially during loading / unloading.
44.0 Dangerous and Harmful Environment
44.1 When internal combustion engines are to be used into a confined space e.g. excavation,
tunnel or any other workplace where neither natural or artificial ventilation system is
inadequate to keep carbon monoxide below 50ppm, exposure of building workers shall
be avoided unless suitable measures are taken and provided by the contractor.
44.2 No worker shall be allowed into any confined space, tank, trench or excavation wherein
there are dusts, fumes / vapours or other impurities which is likely to be injurious or
offensive, explosive, poisonous, noxious, gaseous or other harmful substance unless steps
are carried out by the contractor and certified by the responsible person to be safe
45.0 Corrosive Substances
45.1 Corrosive substances including alkalis and acids shall be stored and only used by
persons

who have received adequate training in dealing with such substances. Suitable
PPE shall be
provided by the contractor to the worker during such handling and work. In case
of spillage of
such substances on building worker, the contractor shall take immediate remedial
measures.
46.0 Batching Plant / Casting Yard
46.1 Contractor shall submit the Batching plant /Casting Yard site layout and design to
the Employer / Engineer for Notice of no objection
46.2 The contractor shall ensure that
i.The batching plant / casting yard shall be effectively planned and designed for
efficiency in: unloading and stacking of aggregates, steel, cement, batching
plant, transport of concrete, casting the segment / girder, stacking of segments /
girders, loading of segments / girders on the transporter.
ii.The batching plant / casting yard shall be barricaded and made as a compulsory
PPE zone with restricted access provisions.
iii.Electrical system shall also be suitably planned so that location of diesel
generator, if any, location of DBs, routing of cables and positioning of area
lighting poles/masts does not infringe on any other utilities.
iv. Drainage shall be provided and waste water shall be disposed after treatment
v. Time office, canteen, drinking water, toilet and rest place shall be suitably
located for the easy access to workers. All the facilities shall be properly cleaned
and maintained during the entire period of operation.
vi. Manual handling of cement shall be avoided to a larger extent. Whenever it is
absolutely necessary the workmen shall be given full body, hand and respiratory
protection.
vii. The PPE provided for cement handling shall conform to international standards.
viii.Access roads and internal circulation roads shall be well laid and maintained at
all times.
ix.The minimum height of stack to be provided with each generator set can be
worked out using the following. formula: H = h+0.2x ÖKVA. H =
Total height of stack in metre. h = Height of the building in metres where
the generator set is installed.
x.DG shall be silent type with acoustic enclosure.
xi. Non-adherence to any of the above provision shall be penalised as per relevant
penalty clause.
47.0 Radiation
47.1 The use of radioactive substances and radiating apparatus shall comply with the
Govt.
regulatory requirements .
47.2 Operations involving ionising radiation shall only be carried out after having been
reviewed
without objection by the Employer / Engineer and shall be carried out in
accordance with a method statement.
47.3 Each area containing irradiated apparatus shall have warning notices and barriers, as
required by the Regulations, conspicuously posted at or near the area.
47.4 Radioactive substances will be stored, used or disposed shall be strictly in
accordance with
the Indian legal requirements.
47.5 The contractor shall ensure that all site personnel and members of the public are
not exposed
to radiation.
48.0 Smoking
48.1 Smoking within the working areas is prohibited with the exception of designated smoking
areas near the site office. The Contractor shall provide suitably signed designated smoking
areas within the near the site office close to welfare facilities but away from the work
locations, site access routes and sensitive neighbouring properties. The Contactor shall
take all reasonable measures to prevent personnel under his control from smoking on the
streets adjacent to worksites.
49. Mobile Phones, Radios and Audio Equipment
49.1 All workers / operators are ban from using handphone/ MP3 devices at CMRL worksites. The
handphones are to be surrender to respective supervisors and stored away at rest areas
with lockers. Workers/ Operators are only allowed to use their handphones/ MP3 during
rest times and breaks.
49.2 The Contractor shall provide suitably signed designated areas which shall include offices and
welfare/rest facilities. The Contractor shall ensure that the use of mobile phones do not
create risks to the user or others.
49.3 Use of personal radios and portable audio equipment is prohibited within the Working Areas
with the exception of welfare/rest facilities.
50. Dust, gases, fumes etc.
50.1 The Contractor shall prevent concentration of dust, gases or fumes by providing
suitable means to control their concentration within the permissible limit so that they may
not cause injury or pose health hazard to a building worker at a building or other
construction work.
50.2 The contractor Shall look into the health hazards associated with handling
different types of
explosives, chemicals and other construction materials and to suggest remedial measures
including use of proper personal protective equipment
50.3 Provide a vacuum machine with water sprayer to wet vehicular access.
51.0 Vehicular Traffic
51.1 Whenever any building or other construction work is being carried on, or is located
in close
proximity to a road or any other place where any vehicular traffic may cause
danger to building
workers,
(1) The Contractor shall ensure that such building or other construction work is barricaded
and suitable warning signs and lights displayed or erected to prevent such danger.
(2) The Contractor shall ensure that all vehicles used at construction site of a building or
other construction work comply with the requirements of the Motor Vehicles Act, 1988
(Central Act 59 of 1988).
(3) The Contractor shall ensure that a driver of a vehicle of any class or description
operating at a construction site of a building or other construction work holds a valid
driving licence under the Motor Vehicles Act, 1988 (Central Act 59 of 1988).
52.0 Handling of explosives
52.1 The contractor shall ensure at a construction site of a building or other

construction work that,
(a) all explosives are handled, used or stored in accordance with the instructions and the
material data sheet supplied by the manufacturer of such explosives.
(b) the use of explosives is carried out in safe manner to avoid injury to any person and
under the direct supervision of a responsible person; and
(c) before using any explosive, necessary warning and danger signals are created, at
conspicuous places of such use to warn the building workers and the general public of the
danger involved in such use.
52.2 Precautions:
52.2.1 The Contractor shall ensure at a construction site of a building or other

construction work that.
(a) The following precautions are observed at the places of transporting, handling, storage
and use of such explosives, namely: -
(i) prohibition of smoking, naked lights and other sources of ignition in the vicinity where
explosives are handled, stored and used;
(ii) to keep safe distance and to use non-sparking tools while opening packages containing
explosives; and
(iii) to stop the use of explosives and handling thereof while the weather conditions are
not suitable for such use or handling;

(a) All measures and precautions required to be observed for use, handling, storing
or transportation of explosives under the rules framed under the Explosives Act.
1884 (Central Act 4 of 1884) are observed.
53.0 Floor Openings
53.1 Unprotected holes in the floor, deck, or roof have been responsible for a number
of very serious injuries. Yet, through planning and personal attention, falls through
openings under foot are very easy to prevent.
i) If you make a hole, guard it. Before cutting the hole, barricade the work area to
keep
people out.
ii) If the hole must be open, install permanent barricades around the perimeter.
Like
railings around the edge of a building or stairwell, these should be a minimum
of forty-two
inches high, have a mid-rail and be capable of withstanding a 200-pound load.
Toe boards
are recommended at all times and are required if anyone is going to work under
the hole.
iii) If the hole is not guarded, it must be covered. The cover must be capable of
supporting at least a 200-pound load, be larger than the opening, secured
against
displacement, and
iv) labelled "Floor Opening, Do Not Remove”. I you have a choice, make a round
opening and cover.
v) Never cover a hole with any type of non-substantial material such as paper,
cardboard or
plastic.
54.0 Evaluation, Selection and Control of Sub-Contractors
54.1 The Contractor shall include legislative and site specific OHS&E requirements in
tender
packages for their sub-contractor selection and conduct pre-job meetings to address job
OH&S expectation before awarding them.
54.2 The Employer /Engineer may participate in pre-tender meetings, selection

process, pre-job meeting reviewing the OH&S performances, etc.
55.0 OH&S Sharing & Site Visits
55.1 The Contractor shall facilitate and host visits by other Contractors to his worksites and to
share his OH&S management experiences with them.
55.2 The Contractor’s management team shall attend visits to other CMRL worksites with good
OH&S management initiates and skills when directed by the Employer /Employer’s
Representative and to learn and implement the good initiatives at his site.
56.0 CCTV

56.1 The Contractor shall implement a surveillance CCTV system in Administrative
areas, Construction areas (general indoor, general outdoor, tunnel and general
underground work areas, mucking and scaling), Maintenance / Operating areas,
Mechanical/electrical equipment rooms, Warehouses and storage rooms/area, Casting
yard, Labour Colony, Health Centres and First aid stations and infirmaries, Parking areas,
Visitor areas and Laboratories , with cameras strategically positioned at high-risk areas
for purpose of monitoring site conditions and deterring unsafe work practices. The
number and location of cameras installation shall be subjected to the acceptance of the
Employer /Engineer. The contractor shall submit the CCTV installation and monitoring
plan to Employer /Engineer.
56.2 The CCTV shall facilitate viewing of live and recorded images. Access to viewing and
controlling of all cameras shall be via a standard web browser and/or wireless Local Area
Network (LAN) by the authorized users. All cameras shall be weatherproof and come with
pan/tilt functions, zoom lens and the ability to operate under low light conditions.
56.3 All camera recordings shall have camera id and location/area of recording as well as
date/time
stamp which cannot be altered, ensuring the audit trail is intact for evidential purposes.
Sufficient storage (hard disk space) shall be provided for all the camera recordings for a
period of 30 days or more @ 30 frames per second (FPS), at 4 common intermediate format
(CIF) or better quality using the necessary compression techniques for all cameras. A
backup
system shall be maintained to protect against server or storage failure.
56.4 The storage system should allow retrieval of data instantaneously or any date/time interval
chosen through search functionality of the application software. The system shall have the
facility to export the desired portion of clipping (from a desired date/time to another desired
date/time) onto a CD, DVD or any other device in a format which can be replayed through
standard PC based software.
57.0 Barricade / Cover to Voids, Trench, Bored Holes and Open Edges of Structure
57.1 The Contractor shall barricade all excavation, bored holes, voids and open edges of structure
under construction where a workman is liable to fall with secured and effective guardrails /
barricades / floor coverings.
57.2 The Contractor shall provide “Danger” warning signs for barriers and barricades erected. All
floor opening covers shall be stencilled or painted with “Danger, Do Not Remove”.
57.3 Where traffic flow is to be maintained over temporary road opening or crossing, the
Contractor
shall provide suitably designed chequered steel cover / decking over it. The Contractor’s
professional Engineer shall design and submit the cover / decking proposal to the Employer
/Engineer for acceptance prior to commencement of the excavation.
58.0 General Safety
58.1 The Contractor shall provide, erect, maintain and finally remove, when instructed, Danger,
Warning, Caution or Information signs, located appropriate to the site layout. The signs
shall be no less than 1.5m x 1.0m in size written boldly in the three official languages.
These shall be erected on existing footpaths and at points of access likely to be used by
the public to warn or inform them of the existence of the Works. These notices shall be in
addition to any notices required to be put up to meet statutory requirements.
58.2 The Contractor shall ensure that all roads, pavements and public footpaths are kept clear
of
dust, silt and debris.
58.3 Unless otherwise agreed, the Contractor shall be responsible for the proper fencing,
hoarding,
lighting, guarding and watching of the Works. The Contractor shall also provide proper
temporary roadways, footways, guards, fencing and hoardings so far as the same may be
necessary for the accommodation and protection of the owners and occupiers of the
adjacent property, the public and others for a like period.
58.4 All platforms, covers, ladders, stairways, staging, scaffolding and other provisions for
access erected by the Contractor shall be installed in compliance with current legal
requirements and made available for use as early as possible during the construction
period. In cases where this is impracticable the Contractor shall provide all necessary
temporary access facilities which shall be constructed, installed and maintained in a safe
and secure manner.
58.5 Designated walkways along walers and struts shall be levelled, flushed without tripping
hazards and with rigid guardrails and toe boards securely provided.
58.6 Fall Arrest System, including but not limited to life lines and anchors, shall comply with the
BS
EN /IS requirements.
58.7 The Contractor shall provide capping on all protruding starter reinforcement bars with
individual plastic/ rubber caps or with hose /tube.
58.8 The Contractor shall ensure bar chairs supporting steel reinforcement bars shall be
designed by a Professional Engineer. In his design, the bar chair should only be welded to
temporary bars incorporated to support the bar chairs. Welding onto permanent bars will
not be permitted.
58.9 The Contractor shall ensure that horseplay, practical jokes, scuffling, wrestling or fighting
are strictly prohibited at the Site.
58.10 The Contractor shall ensure that the sale, keeping or consumption of liquor and prohibited
substances on site is prohibited.
58.11 The contractor shall organize community interaction programme with the general public
for the awareness of the projects.
58.12 Provide proper and durable wire mesh overlay across rebar surface.
59.13 Provide light–Emitting diode (LED) lights to highlight safe access and egress in the work
area.
59.14 Provide portable lighting detector for workers.
59.15 All contractors shall provide overhead protections as per Rule 41 of TBOCWR
2006
i) Overhead protection (Fan) should be erected along the periphery of every

building which is under construction and the building height shall be 15m or
above after construction.

ii)Overhead protection shall be minimum 2m wide and the outer edge shall
be 150mm higher than the inner edge and an angle not more than 200 to its
horizontal sloping into the building.
iii)Overhead protection shall not be erected more than a height of 5m from

the base of the building.
iv)Areas of inadvertent hazard of falling of material shall be guarded or

barricaded to prevent access and appropriately sign.
59.0 Safety (Anti-Fall) Net
59.1 The Contractor shall provide and maintain safety net system in compliance to BS EN / IS
Standards to catch persons falling whilst working in any location from where he would liable
to fall. The net shall be of sufficient size and strength to catch any person for whose
protection it is to be used and the net shall be so located to cover the area of the possible
fall/Material.
59.2 The Contractor shall conduct a sample test on the safety net system, comprising the net and
its supporting structures, before it is installed.
60.0 Site Transport
60.1 General
60.1.1 All vehicles driven on site shall be maintained in roadworthy condition and be registered with
the appropriate authority in accordance with the Motor Vehicles Act. Each driver of these
vehicles shall hold a valid driving licence authorising him to drive that class of vehicle. Such
vehicles include, but are not limited to Cement lorries; Pick-up and flat bed trucks; Lorry
loader with articulating arms; and Rough terrain forklifts.
60.1.2 Transportation of personnel on flat bed trucks, cranes, forklifts, dumpers and similar vehicles
not designed to carry passengers is prohibited.
60.1.3 Free-standing chairs shall not be used as seating. All passengers must be seated at all
times that the vehicle is in motion and shall not have any part of their body outside the
vehicle. No more persons shall be carried in the cab of any vehicle than the number for
which it is licensed.
60.1.4 An appropriate speed limit shall be set and enforced on site.
60.1.5 The Contractor shall appoint banksman to control reversing vehicles and congested
machinery movement. The banksman shall wear a high visibility vest clearly marked “Traffic
Controller” or similar and trained in the standard hand signals and always standing to the
side of the driver’s cab, not to the rear of the vehicle.
60.1.6 Any routes on the Site where headroom is restricted shall have appropriate warning signs
posted at the approach to such restriction.
60.1.7 The Contractor shall ensure that the drivers of all delivery vehicles to Site and those
removing materials from Site, wear appropriate PPE including, but not limited to, safety
footwear and safety helmets at all times that they are outside the cabs of their vehicles.
60.1.8 The Contractor shall ensure that there is daily co-ordination of the movement of mobile plant
and vehicles on Site to minimize the potential for an incident.

60.1.9 All Site access roads used by mobile plant / vehicles shall be constructed of hard standing
and suitable for its intended purpose.
60.1.10 No unauthorised parking shall be permitted on the site anywhere other than at the
designated parking area. Only cars bearing the contractor’s permit shall be allowed to park
there, and those of authorised visitors.
60.1.11 Site plant / vehicles shall be parked at designated locations only so that they do not cause
obstructions to Site traffic.
60.1.12Consideration shall be given at all times to the safety of the road users and gates should be
positioned so that they minimise the additional risk to traffic at such locations as road
junctions, bends, and etc.
60.1.13 A clear line of sight shall be maintained for all drivers of vehicles using the road, taking into
consideration the speed limit of that road and the position of existing street furniture and
trees / vegetation, to maximise the warning distance of approach.
60.1.14If deemed necessary by the Employer /Engineer suitable mirrors shall be positioned at these
points to enhance vision of traffic movement both on the roadway and on entering / leaving
the Site.
60.1.15Where the Site gates lead directly off a public street an effective method of controlling
vehicles entering / leaving the Site shall be employed. This shall be manned by workers
who have been trained in road safety and who are wearing high visibility vests bearing the
wording “Traffic Controller”. They should use recognisable hand signals and advice should
be sought from the Traffic Police if necessary.
60.1.16If deemed necessary by the Employer /Engineer a traffic lane may be coned off to allow for
safe deceleration.
60.1.17During the hours of darkness floodlighting of these Site entrances shall be provided to
enhance visibility of such traffic controllers, but care must be taken that these lights do not
dazzle any on-coming traffic or pedestrians or cause a nuisance to neighbouring residents.
The traffic controllers should utilise hand held batons or gloves incorporating reflective
material.
60.1.18Warning signs in compliance with the IRC standards shall be conspicuously displayed at
appropriate distances before such gates into the Site as to give all drivers a clear
understanding of the traffic hazard ahead
60.1.19If vehicles entering / leaving the site have to cross a public footpath or pavement then a
worker must be deployed to control pedestrians as well as road traffic. Suitable warning
signs should be deployed to alert pedestrians to possible traffic movement across the
footpath.
60.2 Spillages On Roads
60.2.1 A paved truck wash bay for washing vehicles leaving the worksite onto a roadway shall be
provided and maintained at each vehicular egress point before commencement of works on
Site. Each truck wash bay design must be approved by the Employer /Engineer Engineer
before it can be constructed on site.
60.2.2 Washwater from the wash bays shall be directed into a water treatment plant for treatment.
60.2.3 Preventative measures shall be taken to limit the incidence of earth droppings from earth
moving vehicles. In the event that any earth dropping occurs onto a public road/drain, such
earth shall be removed and the roads / drains washed by the contractor at his own expense
to the satisfaction of the Employer /Engineer.

60.2.4 Contractor shall assign personnel and establish a system of checks to ensure that all
vehicles and trucks leaving the worksite do not have the potential to litter the roads due to
its wheels or transportation materials.
60.2.5 Where it is foreseeable that water may drain out from a load of soft marine clay or similar
transported wet materials that will contaminate the road surface, the Contractor shall ensure
that specially designed and constructed watertight trucks are used to transport these
materials.
60.2.6 All cement mixer trucks servicing CMRL sites must have a containment system or a flap
installed to prevent spillage of cement.
60.2.7 Every vehicle or earth moving equipment shall have the following fully functional:
Silencers, Taillights , power and hand brakes , reversing alarm and search light forward and
backward.
60.2.8 In case of non-conformity of items identified by the Employer/Engineer shall take necessary
steps including stoppage of work and or imposing of any penalty to ensure satisfactory
execution.
61.0 Site Security
61.1 General
61.1.1 The Contractor is responsible for the security of the sites, works areas, material storage
areas,
site offices, facilities and the Works.
61.1.2 Security for the site and the works shall be maintained throughout the duration of the contract
or the extended period as provided in the particular specification.
61.1.3 The Contractor is to provide a detailed security plan which includes security proposals for
the various phases of the construction of the works.
61.1.4 The security for the various phases of the works shall include the set up phase, temporary
works phase, structural works phase, E&M works and architectural works phase as well as
the completion phase.
61.1.5 For each phase, the contractor shall detail the security measures, facilities, guards and
patrols to be implemented.
61.1.6 Within 28 days the contractor shall submit a fully detailed security Plan detailing the
contractor’s propose security measures and facilities he intends to implement throughout
the contract duration. The security plan shall include but not limited to the followings:
(a) Method of securing all site and works areas; offices and facilities, etc.;
(b) The security facilities to be set up and its locations;
(c) Lightings, alarms, communication equipment’s, cameras, surveillance equipment’s,
etc.;
(d) Layout and site plans;
(e) Personnel, manpower and the organisation chart;
(f) Guards and patrols, numbers, locations and frequency;
(g) Security for various phases or stages of the Works;
(h) Controls to be implemented for access by authorised personnel/ contractors/
Construction Equipment/ Plant/ vehicles/ materials;
(i) Control of access points for visitors and their vehicles entering the Site, issue of
entry permits and maintaining records for every visitor and vehicle into the Site,
including their stated purpose;

(k) Monthly review and reports;
(l) Incident report and review;
(m) Audits; and
(n) Others.
61.1.7 The plan shall include a central security post/ office manned at all times by a competent
uniformed supervising security guard and an assistant from a licensed Security Agency at
an agreed location. It shall be possible to communicate between each of the security
posts/office and the central security post/office.
61.1.8 The Contractor shall update the Security Plan regularly and when the Works enters a new
phase to ensure that the Site, facilities, and Works are adequately and sufficiently protected
against theft, wilful damages, misdemeanours, and other illegal or undesirable activities.
Sufficient deterrence shall be implemented to be in tandem with the progress of the Works.
61.1.9 The Contractor shall be aware that there may be other contractors employed or engage by
the Authority to carry out works within the Site. Security measures shall cover these works
carried out by other contractors, their site storage and facilities.
61.1.10 Security audit shall be carried at 3 monthly intervals to detect lapses and other inadequacies
of the Security Plan. Audit reports and propose corrective actions shall be submitted to the
Employer /Engineer.
61.1.11The Contractor shall improve his site security and or implement other measures required by
the Employer /Engineer when he is of the opinion that the security measure is insufficient
or where there are lapses in the security system.
61.2 Hoardings
61.2.1 The safety of vehicular movement onto and off site shall be planned before the site hoardings
are erected to allow for features to be incorporated maximising public safety in connection
with site activities.
61.2.2 The hoarding shall be well designed and secured in place to prevent it being blown over by
gusts of wind and shall be sufficiently robust to deter anyone from removing or displacing
any panels. Regular maintenance shall be carried out.
61.2.3 At all works areas; suitable and effective gates shall be provided and shall be locked during
non-working hours/days. Guard posts shall be constructed and guards shall be stationed at
these posts. It shall be illuminated to enable the guards to carry out checking at night. The
guard shall check persons, vehicles, materials and other equipment entering and leaving
site. Intercom or other communications shall be provided and maintained between the guard
post and the security guard office.
61.2.4 At strategic locations along hoardings, entrances, guard posts and other facilities, spot lights
shall be installed.
61.2.5 There shall be no unauthorised openings in the perimeter hoarding. All access and egress
shall be via gates which are manned by 24-hour security guards.
61.2.6 If for any reason the contractor authorises any panels to be moved to create a temporary
opening then a guard must be posted to restrict access to authorised personnel/
construction equipment/ plant/ vehicles only. It shall permanently close immediately after
works is completed.
61.2.7 Should there be any risk of materials, tools, waste material or similar escaping from any part
of the site either as projectiles or falling objects etc., then an effective extension for the Site
hoarding shall be designed and erected to prevent this. Where a public footpath or
pavement runs alongside the hoarding then overhead protection must be provided where
site activities pose a foreseeable risk of such occurrences.
61.3 Personnel Access

61.3.1 The contractor shall be responsible for controlling worksite security to prevent unauthorised
access, maintain public safety and other offences.
61.3.2 The contractor shall ensure that no illegal workers or unauthorised persons are allowed on
Site. The contractor shall conduct both internal and external raids to weed out any illegal
workers or unauthorised persons.
61.3.3 Security of the site shall also be maintained to ensure that only those persons who have the
skills and training to work safely on site and who are wearing the appropriate personal
protective equipment (PPE) may be admitted.
61.3.4 At the main Site office, the contractor shall set up a fully equipped security guard office at
the entrance to the offices. The security guard office shall be at least 6m x 3m with direct
view overlooking the entrance. A visitor book shall be maintained to record visitors
entering/leaving the site or offices. Workers’ security passes shall also be issued to all
workers entering the Site. Visitor shall be issued with temporary passes. Ingress and egress
of vehicles shall be logged.
61.3.5 A similar security pass system shall also be operated at the main entrance to all the sites.
This shall preferably incorporate a turnstile / swipe card reader but any other equally
effective means may be utilised with the prior acceptance of the Employer /Engineer.
61.3.6 Guard posts erected at the main entrances where access is to be so controlled are to be
staffed by trained employees of the Contractor or employees of a subcontract licence
security agency. Sufficient guards shall be on duty at any one time to give effective 24-hour
cover. These trained guards shall wear uniform to enable easy identifications.
61.3.7 All guard posts shall be equipped with a telephone / radio communication system, a panic
button and an audible alarm.
61.3.8 Two-way communication equipment shall be provided to the guards to maintain

communication between guards at other security posts or on patrol and the security guard
office. A general alarm system shall be installed for use in emergency. The Employer
/Engineer site offices shall be installed with intruder alarms, and protection systems. The
site offices surrounding shall be well lit
61.3.9 The access control system shall cover all staff, direct employees of the contractor,
Interfacing contractors and service providers such as canteen workers, cleaning workers
and similar as well as all subcontract staff / workers and those of sub-subcontractors etc.
including operators of rental construction equipment / plant.
61.3.10 Each security pass shall bear the photograph of the holder and his registration number as
appropriate. It shall be issued after completion of site safety induction training via a central
registry controlled by the contractor. Temporary visitor passes may be issued for those
personnel on authorised business, in which case their names must be recorded together
with times of arrival and departure plus signature.
61.3.11The contractor shall issue first time security passes to the Interfacing contractors. The cost
of subsequent replacement of security passes will be borne by the Interfacing contractors.
61.3.12Persons not wearing the correct PPE shall not be allowed onto site, unless they identify
themselves as visiting the site office only and the Contractor has provided a designated
safe access route to and from the site access control point for this purpose.
61.3.13An accurate headcount shall be kept of all persons entering the worksite so that they can all
be accounted for in case of an emergency.
61.4 Vehicular Access

61.4.1 Effective control shall be exercised over materials entering and leaving the site, to
check on the suitability / safety of construction equipment, plant and materials delivered
to site and to prevent theft. For all materials including waste and salvaged materials,
construction equipment and plants leaving the site a proper record of authorisations given
by the respective contractors issuing such removal chits shall be maintained.
61.4.2 Wherever practicable separate access and egress gates shall be provided. The control point
for access should be located a short distance inside the main gate to permit a vehicle to
pull off the road before halting to be checked.
61.4.3 A security post shall be provided at each vehicular access point, sited so that the checker
has a clear view of incoming vehicle registration plates and any passengers in the cabin.
61.4.4 The Contractor shall provide the following at all designated site entrances and exits for
vehicular access: -
i) Illumination of at least 100lux;
ii) Convex mirror (32 inch/ 24 inch) shall be provided at entrances/exit point adjoining
roads; and
iii) Revolving light (complying to BS3143 Part 4 or an approved equivalent).
iv) Vehicle lay-by at all site entrances/ exits point where possible.
61.4.5 Railings or similar should be erected inside the site to prevent workers and others on site
from walking into the path of vehicles entering / leaving the Site.
61.4.6 To prevent all lifting machines and vehicles from infringing the height limit of 4.5m in public
roads. The contractor shall install an effective and robust steel height barriers at ALL
vehicular access. The steel height barrier shall be constructed with a height infringement
gauge that limits the height of lifting machines and vehicles to less than 4.5m
61.4.7 Security drop-bars shall be maintained in the closed position at all vehicular entry and exit
points to the Site and every vehicle shall be stopped outside the barrier. The barrier should
only be raised after authority has been given to the driver of the vehicle to proceed. Hump
shall also be constructed at exit.
61.4.8 The registration numbers of all vehicles entering and leaving the site shall be recorded.
61.4.9 No goods shall be off-loaded at the site entrance in a manner that creates a hazard to other
vehicles entering / leaving the site.
61.4.10Vehicles waiting to get onto the site should be directed to a designated holding area which
minimises obstruction to other road users, and called forward by a flagman.
61.4.11 The main gates shall be closed and locked after construction work has ended for the day.
61.4.12The main gates and control points are to be well lit during the hours of darkness.
61.5 Site Patrols

61.5.1 Security guards shall patrol the site regularly during the night, non working days and public
holidays covering all locations within the site perimeter to deter, detect and follow up any
undesirable event such as theft, robbery, violence, damage to any property, trespass, etc.
The areas to be covered shall include, but not be limited to Site offices, labour colony,
canteen area, materials stockyards and perimeter hoarding.

61.5.2 Clocking points shall be installed to record their presence. Guard patrols shall visit
designated clocking points within the station and the perimeter of the station site at least 4
times during the night and extra 5 times during the day on non working day. A register is to
be kept to record the guards visits.
61.5.3 In addition to the above when the works are near completion, guards shall patrol inside the
station and clock at pre-determined clocking points at fixed intervals. Only 1 or 2 access
points into the station shall be used and manned. All persons entering or leaving the station
shall sign in or out and record their works or purpose. All materials and equipment (including
those belonging to the Interfacing Contractors) brought into or out of the station shall be
recorded. No materials or equipment shall be taken out of the station without authorisation.
61.5.4 All incidents shall be recorded and reported to the Employer /Engineer. In cases of
emergency, the correct persons or appropriate emergency services shall be notified.
61.6 Security Guards

61.6.1 Guards shall wear uniform so that they can be readily identified. They shall be able bodied,
adequately trained, approved by relevant authorities and shall have no criminal records.
Guards on patrol shall work in pairs.
61.6.2 Personal Protection Equipment (PPE) shall be provided to the guards by the Contractor and
they shall wear them when patrolling or visiting the sites areas. They shall also attend the
safety induction course.
61.6.3 Guards shall be fully trained to handle various situations such as unauthorized site entry,
theft, fire, accident, etc.
61.3.4 A full-time guard supervisor/superintendent shall be assigned to supervise and check on the
guards. He shall be trained and well versed in security procedures, measures and system,
including preparing monthly reports, incident reports, reviews and audits. He shall conduct
security briefing, site security campaign, provide information to workers on security and
other preventive measure or deterrents.
62.0 Flooding
62.1 General
62.1.1 The Contractor shall consider the risks of flooding due to nature or arising from the
construction activities.
62.1.2 The Contractor shall submit, within two (2) months of the award of the Contract a
comprehensive flood protection plan for the whole of his Works. In preparing this plan, he
shall carefully examine the surrounding topography to determine the probable nature and
extent of any flooding. Where relevant the Contractor shall also consider in his plan the
possible adverse effects of wind and tides and the risk from adjacent tunnel contracts.
62.1.3 The plan shall identify the areas that are at risk from flooding. The plan shall examine the
potential consequences of any flooding and shall make proposals to prevent flooding.
62.1.4 The flood protection measures provided shall comply with the requirements of National and
State legal requirements.
62.1.5 When pumping is proposed, the Contractor shall address the following:
• operating procedures
• provision of a secure power supply and back-up automation and/or reaction time required to
• start the pumps
• method and arrangement of discharge 1.6 Shafts shall be surrounded by topography sloping
away from shaft to direct rain water to a drainage channel. Shafts shall be equipped with a

minimum of 2 dewatering lines per shaft to ensure effective drainage in case of blockage.
62.2 Flooding Evacuation and Rescue Procedure
62.2.1 The Contractor must make adequate safety provisions in the event of flooding whether it is
due to inclement weather or the river bank bursting in order to minimise the loss of life and
property damage, where practicable.
62.2.2 The safety provisions to be put in place shall not be limited to providing of an emergency
evacuation and rescue plan, trained rescue teams and water rescue aid or equipment. The
trained rescue team and emergency procedure shall be in place before the start of any work.
The number of trained rescue teams and water rescue aid or equipment shall be increase
when deem necessary by the Employer /Engineer. The water rescue aids or
equipment shall be properly maintained throughout the lifetime of the project.
62.2.3 Emergency drills shall be conducted every month with the involvement of State Govt rescue
team where necessary.
62.2.4 The following are the minimum requirement of Emergency Equipment shall be available at
site.
S.No Equipment & Minimum qty

1. Motor Trolleys – 2 No.
2. Dip Lorry – 1 No.
3. Re-railing vehicle and Re-railing Equipment – 1 Set
4. Gas cutting equipment – 1 No.
5. Search Lights – 2 No.
6. Track continuity Jumpers – 2 No.
7. Fire Extinguishers – 3 No.
8. Hand Signals / Flags – 1 No.
9. Crank handle key, Clamps and Pad locks – 1 No.
10. First Aid Kits – 1 No. per station
11. Stretchers – 1 No. per station
12. Wheel Chair – 2 No. per station
13. Pick Axe - 2 No,
14. Self Contained Breathing Equipment – 2 No.
15. Inflatable tents – 1 No.
16. Collapsible lighting tower – 1 No.
17. Inflatable Air Bags – 2 No.
18. Automatic Spring loader – 1 No.
19. Track measuring gauges – 1 No.
20. Augmented First Aid Boxes – 2 No.
21. Wrist bands – As required
22. High visibility vests – As required
23. High Power torches – 2 No.
24. Nylon slings of 40 T capacity – 1 Set
25. Video Cameras – 1 No.
26. Tetra Sets, as required
27 Pumps
25HP-03Nos
10HP-05 Nos
05 HP-05 Nos
03HP-05 Nos
63.0 OH&SSubmittals to the Employer/Engineer
63.1 The contractor’s OH&S management shall send the following reports to the
Employer / Engineer:
i) Daily Reporting of total no of workmen and Daily Dairy of CSM
ii) Monthly OH&S Report
iii) OH&S Committee Meeting Minutes
iv) OH&S Inspection Reports
v) Monthly Audit Rating Score (MARS) report
vi) External OH&S Audit
vii) Electrical Safety Audit
viii) Monthly Tunnel inspection Checklist
ix) Working at height safety Audit
x) Plant and Equipment Safety Audit
xi) Labour colony safety audit
xii) Air and Noise Quality monitoring report
63.2 Daily Reporting of total no of workmen
63.2.1 The contractor shall report to the Employer the total no of workmen engaged
including any subcontractor within 2 hours of starting of any shift in any day. This
reporting shall be the primary duty of the Chief OHS&E Manager of the contractor and
reporting shall be through tele-fax / email. If the information is not received or received
more than 2 hrs after starting of the shift, penalty shall be levied as per relevant clause.
63.3 The Chief OHS&E Manager shall prepare and submit the daily dairy (FSAF 29) to
the Employer/Engineer on the end of each shift.
64.0 Monthly OH&S Report
64.1 The contractor shall prepare a monthly OH&S report are given in general
instruction GSAF 14 and submit by the 7th of every month to the Employer/Engineer.
65.0 Visitors to Site
65.1 General
65.1.1 All visitors to site shall report to the Contractors site offices where they shall be
issued with appropriate Personal Protective Equipment if they are to go out onto the site
work areas. Any visitors going out to the site work areas shall be accompanied at all
times by a member of the site personnel.
Appendix
The Contractor shall also comply with the following Section 1 & 2 to this appendix.
Section 1 –Standard Forms
Section 2 –Guidance Documents
SECTION 1
STANDARD FORMS

INDEX REFERENCE REVISION DATE
Pre-Task Check Form FSAF 01
General Permit FSAF 02
Hazard Log & Risk Register FSAF 03
Scaffold inspection register FSAF 04
scaffolding Handover certificate FSAF 05
Crane Operator Weekly Inspection FSAF 06

Check list
Excavation Permit FSAF 07
Hot Work Permit FSAF 08
Near miss report FSAF 09
Confined Space FSAF 10
MARS Score Sheet FSAF 11
First aid slip FSAF 12
CMRL Template Site Inspection Form FSAF 13
Record of Induction Training FSAF 14
Induction Checklist FSAF 15
Operations Induction FSAF 16
Visitors Induction FSAF 17
MEWP Checklist FSAF 18
Permit to work on electrical FSAF 19
Permit to excavate FSAF 20
Excavator Checklist FSAF 21
Oil storageRequirements FSAF 22
Harness Checklist FSAF 23

Monthly contractor’s Accident Statistic FSAF 24
Report
Formation of Site OHS&E Committee FSAF 25
Minutes of OHS&E Committee FSAF 26

Meeting
Electrical Safety Audit Inspection FSAF 27

Checklist
Contractor Monthly Inspection FSAF 28

Checklist
Chief OHS&E Manager Daily Dairy FSAF 29
CV Template FSAF 30
External Quarterly Audit Template FSAF 31

PRE-TASK CHECK
Site: Date:
TASK & LOCATION:
Supervisor Name (PRINT): Signature:
Item Control Measures YES or NO X

Is all equipment and correct tools available to undertake the task and in correct working order? E.g. crane, Rig, Hydra, JCB certification, launch equipment scaffold
1
etc.
2 Are men trained and competent to undertake the task including tools and equipment? E.g. crane / Rig operators, welders and certification available
Is all safety equipment available to do the task e.g. head, hand, eye, hearing protection, harness, concrete burn protection? Are men trained how to use it? E.g.,
3
harness fitting and use.
4 Have all men been briefed and instructed on the specific task to be undertaken by the task supervisor prior to commencing operations?
5 Are all safety precautions in place as identified in the risk assessment & method statement e.g. edge protection, access platforms, cordon & barriers etc?
6 Have all men been briefed on the safety precautions, procedures and controls that must be followed as per the method and risk assessment?
7 Is competent supervision in place? E.g. suitable knowledge, training & experience in specific task to be supervised
IF THE ANSWER IS ‘NO’ WORK CANNOT START !!!!!!!

GENERAL PERMIT
Number………
General Permit can be used where control of an operation is required to ensure safety to public and or operatives.
The type of operation that this permit could be used for includes:
Any high risk areas identified in the risk assessments
e.g. Work in or near public spaces, demolition
PART A – ISSUE PART D - COMPLETION OF WORK
Permit is issued to: ............................................................…. The work has been completed and the work area
and adjacent areas have been thoroughly checked
of: ……………………………………………. to ensure no hazards remain
All equipment and materials removed
for (specific work to be done) ............................................…... Safety equipment returned
............................................................................................... Area restored
Other
………………………………………………………
at (exact location of work) .....................................................
……………………………………………………………..
……………………………………………………………..
……………………………………………………………………..
……………………………………………………….........
Valid from: ……....... am/pm The work has been completed, and I have
undertaken
the checks and safety measures I have ticked in
Part D of this permit above.
to: .......... am/pm Date: …....................20....
I issue this permit subject to the minimum precautions
I have listed in Part B below. Time: ………………….………am/pm
Signed: ................................................................…… Date: ……………………….….20…………

(Issuer)
Signed: …………………………………….
(subcontractor once completed work)
PART B - PRECAUTIONS
Liaise with occupiers PART E - CANCELLATION OF PERMIT

Post warning notices
Provide suitable barriers This permit to work is cancelled and the relevant
Adequate competent supervision staff have been notified. No more work under
this
Other permits e.g. Confined Space permit.
Provide suitable traffic control
Location protected and sign marked
Other ……………………………………………. Time: ........................……...............am/pm
……………………………………………………
…………………….……………………………... Date: ..............................20....…..............
……………………………………………………
Signed: ....................................................
PART C - ACCEPTANCE (Issuer)
I accept this permit and will ensure the precautions

ticked above in part B have been undertaken before
starting work. I also understand the checks and
safety measures I am required to undertake after
completion of work.
Signed: .......................................……………. (Subcontractor undertaking work)

FSAF 04
Hazard Identification and Risk register
Minimum Mitigation
Method Statements
Risk Rating Location Procedure
Identified Hazard Applicable (Details to be Completed if Box ticked) Reference
Risk Assessment
(List Where Necessary) Number
Required
(E.G. Procedures to be followed)
H M L
Site (External)
Access and Egress
Existing roads
Contaminated ground
Unstable ground
Ground
water/conditions
Underground services
Overhead services
Existing traffic
Traffic restrictions
Existing plant or works
Residential buildings
Hotels

FSAF 04
Industrial buildings
Schools/hospital
Existing noise
Existing dust
Existing fumes
OTHERS List: -
Construction Operations:
Procedure
Identified Hazard Applicable H M L Location (List) MS/RA Minimum Mitigation Reference
Number
Scaffolding
Working at height
Steel erection
Confined spaces
Temporary works

FSAF 04
Site clearance
Bulk muck shift
Piling
Girder Launch
Concrete operations
Piers / columns
Excavations
Station Roofing Activities
Brickwork Block work
Cladding, glazing
Aluminium installation
M&E
Electrical works
Electrical works to site

distribution

FSAF 04
Plumbing inc, drainage,

pipework installation
Fan coil installation
Air handling units
Site Hoarding
Elevator installation
Escalator installation
Surfacing
Safety impact barrier

erection
Kerb Laying
Plant and equipment
Lifting Operations
Lifting Appliances and

equipment
Demolition

FSAF 04
Plant movement
Vehicle movements
Piling
Explosives
Waste Disposal
Housekeeping
Welding
Cutting/burning
Cartridge Tools
Trial Holes
Others List: -
Risks to public
Procedure
Number

FSAF 04
Access to site
Movements of plant
Live traffic
Noise/dust
Parking
Fire
Storage of materials
Falling materials
OTHERS List:-
Health Risks

FSAF 04
Procedure
Number
Weil's disease
Gas oil
Dusts
Vapours
Cement
Bitumen
Epoxy
Night Working
Chlorine Storage
OTHERS List:-
TEMPORARY ACCOMMODATION
Procedure
Number

FSAF 04
Office installation
Electrical installation
Drainage
Other services
Fire
Signing
Cleaning
Fencing
Security
Material storage
Sleeping
accommodation and
labour camps
OTHERS List:-

FSAF 04
Site Specific Risks (including Designer’s Risks)
Identified Procedure
Applicable H M L Location (List) MS/RA Minimum Mitigation
Hazard Reference Number
Risk Rating Tolerance
High severity and High probability of major injury, disablement or possible fatality. Work must cease immediately and additional control measures implemented prior to work
HIGH
commencement.
MEDIUM Probability that an incident will occur over time (Over 3 day injury) but not as serious as a major injury or fatality. Additional control measures to be implemented within 24 Hrs.
Negligible risk of injury, but task requires additional control measures to reduce likelihood of injury (Minor Injury not above 3 days off from employed role) Additional control
LOW
measures to be specified and implemented within 48 Hrs
Severity Minor Injury Over 3 day Critical
Likelihood First Aid Case injury Fatality or Major Injury
Probable High High High
Possible in time Medium Medium High

FSAF 04
Negligible
Low Medium Medium
Unlikely to occur

FSAF 04
SCAFFOLD INSPECTION REPORT

NOTES
General
1. The inspection report should be completed before the end of the relevant working period (every 7 Days)
2. The person who prepares the report should, within 24 hours, provide either the report or a copy to the person on whose behalf the inspection was carried out. Eg Safety Manager, Engineer etc
3. The report should be kept on site until work is complete.
Working Platforms Only

1. Any employer or any other person who controls the activities of persons using a scaffold shall ensure that it is stable and of sound construction and that the relevant safeguards are in place before his
employees or persons under his control first use the scaffold.
2. No report is required following the inspection of any mobile tower scaffold which remains in the same place for less than 7 days.
3. Where an inspection of a working platform or part thereof or any personal suspension equipment is carried out:
i. before it is taken into use for the first time; or
ii. after any substantial addition, dismantling or other alteration;
Checklist of typical scaffolding faults:
Putlogs & Guard-rails & toe-

Footings Standards Ledgers Bracing Couplings Bridles Ties Boarding Ladders
transoms boards
Soft and uneven Not plumb Not level Some missing Wrongly spaced Wrong fitting Wrong spacing Some missing Bad boards Wrong height Damaged
Jointed at same Joints in same Insufficient

No base plates Loose Loose Loose Wrong couplings Loose Trap boards Loose
height bay length
Wrongly No check
No sole plates Wrong spacing Loose Wrong fittings Damaged Not enough Incomplete Some missing Not tied
supported couplers
No check Insufficient
Undermined Damaged Damaged - - - - Brick guards No Ladder
couplers supports

FSAF 05
HANDING-OVER CERTIFICATE – SCAFOLDING
Date: ___________________ Site: ______________
Time: __
Description & location of section handed over:
Drawing No: (Where applicable)
Scaffolding as described above has now been completed and complies with Construction Codes of Practice. It is structurally sound and should be
used and loaded in accordance with the stated specifications within this certificate.
(a) Use only for (General, Light, Heavy, Access etc)
(b) Working lifts, with distributed Load of: (kn/m2) per lift.
The detailed requirements of the Codes of Practice with regard to handrails – working platform – toe board – bracing – and ties have been
complied with. This scaffold must be inspected once a week (or following exposure to wither conditions likely to have affected its strength or
stability) by the user and the inspection recorded in a scaffold register. This inspection is undertaken to ensure that the scaffold continues to
comply with the Codes of Practice.
N.B.Tarpauline sheets (or other wind sails) must not be fixed to a scaffold unless has been specifically designed to take them.
Scaffold Foreman: Signature:
(date:
DO NOT REMOVE TIES

FSAF 006
FSAF-06
CRANE OPERATOR WEEKLY INSPECTION CHECKLIST
Crane name/number Crane type: Crane capacity Date of inspection:
Location: Hour Meter: Start:___________________ Total hours operated:

Stop:___________________
Operator’s name: Oiler’s name:
INSTRUCTIONS: Check all items indicated. Inspect and indicate as satisfactory = S, Unsatisfactory = U, or not applicable = N/A
Walk around inspection U S N/A Operator Cab Inspection U S N/A
Safety guards and plates Gauges

Carrier frame, rotate base Warning & indicator lights
General hardware Control/brakes
Wire rope Visibility
Reeving Load rating charts
Block Safety devices
Hook Emergency stops
Sheeves List/trim indicators
Boom/Jib Boom Angle/Radius Indicator
Gantry, pendants, boom stops Machinery House Inspection U S N/A
Walks, ladders, handrails Housekeeping
Wind locks, chocks, stops Engine/Compressor
Tires, wheels, tracks Leaks -Fuel, lube, Oil, Water
Leaks-Fuel, oil, lube, water Lubrication
Radius indicator Battery
Outrigger/locking device Lights
Operation Inspection U S N/A Glass
Area safety Clutch/Brake linings
Unusual noises Electric motors
Control Action Warning tags
Brakes/boom/load/ rotate Fire extinguisher
Crane stability Comments:
No load test
Fleeting sheeve
Limit switches
Operator’s signature: Supervisor’s signature:

FSAF 07
EXCAVATION PERMIT
Number………
Excavation permits can be used where there are likely to be underground services or where the type / depth of the excavation will
involve high risks that need to be controlled.
The type of operation for which this Permit could be used includes:
Excavation Work around live services

Deep excavations where men have to work
Contaminated ground
Excavation in made up ground or in poor soil
Permit is issued to: ...................................................... The work has been completed and:
the work and adjacent areas have been
of:……………………………………… thoroughly inspected to ensure no hazards
remain
for (specific work to be done)....................................... Services re-instated
Route of excavation recorded
..................................................................................... Records of disposal of contaminated material

handed over
at (exact location of work) ........................................... All equipment and material removed

Area restored
……………………………………………………………. Other …………………………………………..

………………………………………………….
Valid from:…… ....... am/pm …………………………………………………
to:......… am/pm Date:…..................20…..

The work has been completed, and I have
undertaken the checks and safety measures
I issue this permit subject to the minimum precautions I have ticked in Part D of this permit above.
I have listed in Part B below.
Signed: ............................................................. Time:………………………..am/pm

(Issuer)
Date:…………………………20……
FSAF 007
Signed: ................................
Existing services identified (subcontractor once completed work)
Electrical supply isolated
Temporary trench supports available
Inspection regime in place PART E - CANCELLATION OF PERMIT
Traffic control in place
Protective clothing provided This permit to work is cancelled and the relevant
Suitable safe access provided staff have been notified. No more work under this
Location protected and sign marked permit.
Other
Time:...............................am/pm
PART C – ACCEPTANCE
Date: ..............................20...................
starting work. I also understand the checks and Signed: ..................................................................
safety measures I am required to undertake after (Issuer)
completion of work.
Signed: .......................................…………….(Subcontractor undertaking work)
HOT WORK PERMIT

Number………
Hot work permits are to be used where a significant risk of fire or erroneous triggering of a fire detection system has been identified.

FSAF 007
The type of heat, flame or spark producing operation for which this Permit may be used includes:
Welding – Cutting - Grinding - Soldering – Use of Bitumen boilers - Work using LPG – Burning off paint

Permit is issued to: ........................................ The work has been completed and the work area and
adjacent areas to which sparks and heat might have
spread such as opposite sides of floors and walls)
have been thoroughly inspected and found fire
for (specific work to be done)..........................
immediately following completion
........................................................................ 30 minutes later
1 hour after completion
Electrical equipment/supply switched back on
at (exact location of work) .............................. Smoke detector/s have been re-activated
All equipment and material has been removed
……………………………………………………. Area restored
Other
Valid from:…… ....... am/pm
to:...... am/pm Date: ….......20..….. The work has been completed, and I have
I issue this permit subject to the minimum precautions undertaken the checks and safety measures
I have listed in Part B below. I have ticked in Part D of this permit above.
Signed: ..........................................................
(Issuer) Time:……………………………..am/pm
Date: ..........................20....................
Before starting: Signed: ..................................……….
Combustible materials: removed (Subcontractor once completed work)
protected
Electrical equipment/supply isolated
Smoke detector/s: isolated PART E - CANCELLATION OF PERMIT
Extinguisher/s: readily available
Personnel: instructed in fire precautions This permit to work is cancelled and the relevant
know nearest fire alarm staff have been notified. No more work under this
Location: protected and sign marked permit.
Work area screened to contain sparks
Time:...........................................am/pm
Other Date: ..........................................20.......
Signed: .................................................
Following completion: (Issuer)
Work and adjacent areas to be checked immediately
30 minutes later
1 hour after completion
Smoke detector/s to be re-activated
Other
PART C - ACCEPTANCE
Completion of work.
Signed: .......................................…(Subcontractor undertaking work)
FSAF-09

FSAF 007
NEAR MISS REPORT

Near miss incidents should be regarded with the same seriousness as personal accidents as they are basically the same. The information
recorded below is not to proportion blame (unless a clear disregard of safe working caused the incident) but to enable the company to
learn and prevent similar occurrences.
Site/Location: Contract No.
Near Miss – Please describe what happened:
Was there an obvious cause of the incident:
Contributing Factors:
Time: Date:
Weather Conditions:
Company Involved:
Personnel Involved:
Plant Equipment Involved:

What has been done to prevent a re-occurrence:
Name of Person Making Report………………………………………………

Job Title………………………………………………………………………….
Signature:……………………………………………Date……………………………….
Distribution: Area Director, Company Safety Advisor, Sub-Contractor’s Office, Notice Boards
Attached: Photos Y / N / NA
Sketches Y / N / NA
Risk Assessments Y / N / NA
Statements Y / N / NA

FSAF 10
CONFINED SPACE PERMIT

Number………
Confined space permits are to be used where entry is required into an enclosed or partly enclosed space where because of its nature there is
foreseeable risk including dangerous levels of fumes, gases and/or oxygen deficiency.
The type of operation for which this permit may be used includes work in:
Deep Manholes – Tanks – Wells – Live Sewers – Basements – Roof Spaces -Trenches – Pits – Other Similar Spaces
ALWAYS: ASK – IS THERE A NEED TO ENTER?
IF ATMOSPHERE IS POTENTIALLY UNSAFE - TEST ATMOSHPERE PRIOR TO ENTRY
Permit is issued to: ............................................................….
The work has been completed and the works area
of:………………………………………………. and adjacent areas have been thoroughly checked
to ensure no hazards remain
for (specific work to be done)............................................….. Personnel accounted for
All equipment and materials removed
............................................................................................... Safety equipment returned
Area restored
at (exact location of work) ..................................................... Other
…………………………………………………………………….. The work has been completed, and I have

undertaken the checks and safety measures
I have ticked in Part D of this permit above.
Valid from:…… ....... am/pm
to:......…….. am/pm Date: …....................20..….. Time…………..…..am/pm
I issue this permit subject to the minimum precautions Date:…………….20………

I have listed in Part B below.
Signed: ................................................................……
Signed…………………………………………………………
(Issuer) (Subcontractor once completed work)
PART B – PRECAUTIONS
PART E – CANCELLATION OF PERMIT
Risk assessment undertaken and explained
Test atmosphere prior to entry This permit to work is cancelled and the relevant staff
Test atmosphere during works - gas detector have been notified. No more work under this permit.
Tripod, winch and harness
Topman/watcher posted Time…………..…..am/pm
Supervision
Emergency procedures Date:…………….20………
Communications
Competence and training
Medical condition of operatives Signed…………………………………
Isolation (Issuer)
Forced Ventilation
Pre-cleaning
Size of access (entry and escape)
Breathing apparatus
Protective clothing
Intrinsically safe tools and equipment
Suitable access and light
Location protected and sign marked
Other
PART C - ACCEPTANCE
completion of work.
Signed: .......................................…………….(Subcontractor undertaking work)

FSAF 11
MARS AUDIT SCORE SHEET FOR THE MONTH OF ………….2019
Date of Audit:
Contrator: Project Name:
Project Manager: Chief Safety Manager :
Site Conditions:
Points will be objectively awarded by the Group 6 personnel based upon site safety and environment
conditions.
Scoring will be as follows: Excellent (E) = 10, Good (G) = 8, Average (A) = 6, Fail (F) = 0, Non-
Conformance (NC) = -10 with the exception of those sections marked with an asterisk which will have a
factor of 2 thus doubling the score for that section.
All non-compliance within the heavy bordered areas will receive an Action Notice at the required level.
All Suspended Operations Notices will be referred to the Project Manager, who will visit site within 24
hours to carry out further safety inspections.
Any non applicable topic and the corresponding “possible score” will not be marked and the score will
be calculated by recognising the relevant possible score as being 100% and the actual score as a
percentage of this.
NOTICES DISPLAYED E G A F NC Actions
Occupational Health and Safety Information
Occupational Health and Safety Policy
Statements
Employer’s Liability Insurance Certificate
Protective Equipment Sign
Reversing Vehicles Sign
Emergency Procedure
First Aider(s), Male Nurse ,Doctor
Project Notice Boards
Site rules
TBOCWR registration
Labour Licence
Restricted Usage of Hand Phone Sign
SUB
TOTAL POSSIBLE
PLANNING E G A F NC Actions
Construction Phase Health and Safety Plan
Risk Register & Hazard Log
Risk Assessment & Method
Statements Completed
Risk Assessment & Method Statement
Briefings
Risk Assessments & Method Statement
Implementation
Occupational Health and Safety Organisation
Chart
Manual Handling Assessment
Manual Handling Training
Safe Operational Control Procedure
OH&S Management System Procedure
Emergency Preparedness and Response plan
International Certifications
Training Implementation Plan
Fire Evacuation Plan
Fire Risk Assessment
PPE Risk Assessment
Lift Plan and Risk Assessment
Transportation Plan and Risk Assessment
Safety inspection Reports
Designer's Role in Safety
ID card and First Day at Work
CCTV
Mock drills
Evaluation ,Selection and Control of Sub
contractor
SUB TOTAL POSSIBLE
EXPLOSIVE HANDLING AND

BLASTING E G A F NC Actions
Transport and handling
Magazine
SUB
TOTAL POSSIBLE
WELFARE E G A F NC Actions
Canteen
Toilets /Urnials
Drinking Water
Designated site eating areas
Labour Accommodation
SUB
TOTAL POSSIBLE
HOUSEKEEPING E G A F NC Actions
5S Housekeeping
Housekeeping squad
De-nailing
Storage
SUB
TOTAL POSSIBLE
FIRE PRECAUTIONS E G A F NC Actions

Site Offices
Work Place – Extinguishers
Hot Works Permits
Conditions on Site
Storage of Flammables
Requirements
Fire fighting personnel
Diesel / Petrol Storage
Relevant statutory signs
SUB
TOTAL POSSIBLE
PPE E G A F NC Actions
Helmets
Footwear
Hi Viz
Eye protection
Hearing Protection
Respiratory Protection
Protective Gloves
Fall Protection
PPE for visitors
Safety Belt
SUB
TOTAL POSSIBLE
COSHH E G A F NC Actions
File maintenance Assessment Briefings
SUB
TOTAL POSSIBLE
PLANT ,EQUIPMENTS AND TOOLS

(*X 2) E G A F NC Actions
Planning
Lifting Appliances and Lifting Gear Register
Plant and machinery inspection
Vehicle Control
Piling and Grab operations
Competent Personnel
On Site Traffic Management
Guarding Arrangements
Vehicle Checks
Lifting Operation(LA and LE)
Safe Use
Lifting Gear
Suitability and Specific PPE
Permits
Batching Plant and Casting Yard
Safety Devices
Welding Machine
Monthly Plant and Equipment Safety Audit
SUB
TOTAL POSSIBLE
EXCAVATIONS (*X 2) E G A F NC Actions

Planning
Excavations Register
Provision of Service Locators
Underground Service identification
Edge Protection
Shoring
Competent Workface
Temporary Work Assessment
Safe Working Procedure
Excavation Work Permit
Monthly Excavation Safety Audit
SUB
TOTAL POSSIBLE
ELECTRICS (*X 2) E G A F NC Actions

Power Assessment
Condition of Site Distribution panel
Overhead Lines Identified
Storage and Use of Power Tools
Plugs, Sockets and outlets
Competent Persons
Work Permit

illumination
Cables
Work On site
Earth Pit
Monthly Electrical safety audit report
Electrical Register
Lock out /Tag out
SUB
TOTAL POSSIBLE
WORK AT HEIGHT (*X 2) E G A F NC Actions

Planning
Scaffolding Register
Ladder Access
Scaffolding General
Scaffold access Towers and Platforms
Edge Protection and Toe-boards
Competent Persons
Other Precautions,Ladders,Stepladders,MEWPs
Temporary work Assessment
Recorded Inspections
Work Permit
Safety Net
Monthly Safety Audit for the Working at
Height
SUB
TOTAL POSSIBLE
FLOOR OPENINGS E G A F NC Actions

Planning
Provision of Protection
Relevant Signage
Work Permit Procedure
SUB
TOTAL POSSIBLE
TUNNELLING OPERATION (*X2) E G A F NC Actions

Planning
Warning Signs , Notice board and Tally Board
Industrial Health and Welfare
Gas detection Equipment
Self Rescue Equipment
Training
Work Permit
Quality of Air
Quality of illumination and Emergency
Lighting
Communication Systems
Fire Extinguishers ,Fire Mains & Hose
Connections
Walkway
Track and Locomotives
Rolling Stock
Man lock and Medical Lock
Emergency Under Ground Drills
Medical Staff
Access and Egress
Electrical equipment
Drinking water
First Aid provision
Noise
Eye Wash Station
House Keeping
Temperature monitoring
Monthly Safety Tunnel Audit
SUB
TOTAL POSSIBLE
SITE MANAGEMENT AND

SUPERVISION E G A F NC Actions
Resources
Monitoring
OH&S submittals to Employer
OH&S Committee
External OH&S Audit Quarterly
Management Review
Incident Reporting
Safety Promotion
Fire and Smoke
Employer /Engineer Non-conformance
Report
SUB
TOTAL POSSIBLE
TRAFFIC MANAGEMENT (*X 2) E G A F NC Actions

Safety of Traffic
Public Information
Safety of Public
Traffic Management

Highway Cleanliness
Visitor Safety
Work Permit
Relevant Site Signage
Barricade
Monthly Traffic Safety Audit
SUB
TOTAL POSSIBLE
NOISE E G A F NC Actions
Identification of Sources
Provision of Silenced Equipment
Monitoring
SUB
TOTAL POSSIBLE
OCCUPATIONAL HEALTH E G A F NC Actions

HAV’s Register
Malaria , Dengue , Silicosis, Skin Cancer ,
HIV AIDS , Leptospirosis , Tetanus and
Hepatitis Information
Medical examination
Occupational Health Centre
First-aid
Ambulance van and room
Alcohol and drugs
Radiation
Mosquito breeding
Vibration
SUB
TOTAL POSSIBLE
TRAINING/INDUCTION E G A F NC Actions
Management Competency
Supervisor Training
Driver/Plant Operator Training
Training Programme
Specific Training Competency Certificate
Toolbox Talks
Follow up training
Important days observed
OH&S Induction Training
SUB
TOTAL POSSIBLE
POINTS AWARDED
SITE EHS TOTAL POSSIBLE
EHS TOTAL % SAFE 0%
Comments:
Chief Safety Manager: Signed ……………………………
Project Manager: Signed ……………………………………
FIRST – AID TREATMENT SLIP
LOGO NAME OF THE SITE SLIP NO

FIRST-AID TREATMENT SLIP
NAME:_______________________
LOCATION:______________
DATE: _______________________
STAFF/CONTRACTOR (TICK)
IF SUB CONTRACTOR, NAME OF THE SUB CONTRACTOR :
__________________________________
MENTION BREIF CAUSE OF ACCIDENT:
TIME : am/pm NAME & SIGNATURE OF SITE
ENGINEER/SUPERVISOR
(TO BE FILLED BY ATTENDING DOCTOR/FIRST AIDER)
LOCATION OF BODY PART :
NATURE OF INJURY :
FIT UNFIT HOSPITALISED : YES/NO
ROOM NO : BED
NOSIGNATURE OF ATTENDING DOCTOR :
NAME &REGISTRATION NO. NAME & SIGNATURE OF FIRST-AIDER
SLIP RECIVED BY SAFETY MANAGER/SAFETY ENGINEER
DATE :
TIME : am/ pm SIGNATURE BY DUTY SAFETY
ENGINEER

FSAF 013
FSAF 13
Safety Inspection Report
(SITE)
CHENNAI METRO RAIL PROJECT
Issuing entity Discipline Area Document Nb. Revision Index

CMRL
0
DOCUMENT / DRAWING TECHNICAL
VERIFICATION AND REVISION RECORD
PROJECT NAME Chennai Metro Rail Limited
*DOC/ NO. DATE OF ISSUE

*DOC/ TITLE Safety Inspection Report
DATE OF PREPARED/
REV No. DESCRIPTION CHECKED APPROVED
ISSUE/REV. DESIGNED
1 Safety Inspection Report (SITE)

FSAF 013
Safety Inspection Report
Site: Completed by (PRINT NAME):
Date: Title: Safety

Summary
No Category Comments & Action Risk Rating Behaviour Action

S/U √/X
H M L
Leading Edge Protection (Double
N.A HML SU
Rails & Toeboards)
Void Protection
2 N.A HML SU
(Guard rails or securely covered)
Scaffolding
3 N.A HML SU
(Designed, Inspected &Tagged)
Temporary Works
4 N.A HML SU
(Compliant with design/drawing)
Ladder Use
5 (Short duration work only) (stable HML SU
and footed)
Mobile Towers
6 Guardrails, Toeboards N.A HML SU
Correctly braced
Electricity
(Condition, Protected) (Life risk
/Fire Risk)
7 BOCWR – R 47 HML SU
Clause 26 SHE Conditions of

Contract
Traffic Management (People &

Plant separated)(demarked)
8 HML SU
BOCWR – R 48
Plant & Equipment
(In good working order)
9 (Operated correctly) HML SU
BOCWR – R 130
Excavations
10 (Inspected / shoring in place) (Gas
Levels)
11 Permit systems HML SU

FSAF 013
(Permit in Place and being followed)

Fire Safety (Fire points, with
extinguishers & alarm available)
12 HML SU
BOCWR – R 35
Safe Access/Egress
13 HML SU
(Safe pedestrian route too all areas)
Housekeeping
14 (No waste build up) HML SU
(slip trip hazards)
Pile Rig
(Lifting Equipment)
15 HML SU
BOCWR – R 214,216 -221
16 Confined spaces HML SU
17 Storage of materials HML SU
Signage
(Erected and appropriate)
18 HML SU
BOCWA S - 44
BOCWR R – 5
Personal protective Equipment
(Correct for task & in use by staff)
19 HML SU
BOCWA and BOCWR
R – 45, R – 46; R – 54, C – XI; R –
96 to 107
Harmful Substances
20 HML SU
(Stored, Used correctly)
Dust Debris Suppression (Vehicles

21 HML SU
covered, Damp down)
Noise Suppression
22 (Enclosures Barriers in place HML SU
above 90 db)
Employee Trained and aware of
23 HML SU
tasks briefed on task & safety etc
Welfare facilities
24 HML SU
(Clean, Tidy & Hygienic)
Public Protection from site

25
operations
26 Site Security HML SU
Risk Rating Tolerance

High severity and High probability of major injury, disablement or possible fatality. Work must cease immediately and
HIGH additional control measures implemented prior to work commencement.
Probability that an incident will occur over time (Over 3 day injury) but not as serious as a major injury or fatality.
MEDIUM Additional control measures to be implemented within 24 Hrs.
Negligible risk of injury, but task requires additional control measures to reduce likelihood of injury (Minor Injury not
LOW above 3 days off from employed role) Additional control measures to be specified and implemented within 48 Hrs

FSAF 013
Minor Injury Over 3 day Critical

First Aid Case injury Fatality or Major Injury
Severity Likelihood
Probable High High High
Possible in time Medium Medium High
Negligible Unlikely to Low Medium Medium

occur
Distribution: Site Engineer /Contractor /CMRL
FSAF 14
RECORD OF INDUCTION TRAINING

Site Name:
Your Employer’s Name:
Site Safety Management Matters - Identify points covered by induction by ✓ in box
1. SUPERVISION site management structure. 11. CLIENTS RULES detail any client specific rules

FSAF 014
2. EMERGENCY alarm procedure/muster point. 12. ACCIDENT and INCIDENT reporting procedures
Including near miss incidents
3. SMOKING identify any smoking restrictions. 13. DISCIPLINARY ACTION for safety related failings
4. FIRST AID arrangements on site. 14. PPE requirements for boots, eye & hearing protection,
respirators & overalls etc.
5. ENTRY ROUTES TO SITE give details for both 15. SAFETY HELMET as directed by site management in
Pedestrian & Vehicle routes accordance with site rules
6. ACCESS RESTRICTIONS detail any areas which are 16. NOISE nuisance noise & restrictions on working hours
out of bounds (Section 60 notices) & noise assessment procedure
7. ALCOHOL consumption of alcohol, taking of non 17. NO RADIOS operating from leads. NO WALKMANS
prescribed drugs is not permitted. Note section 37 or other in ear audio device
8. HAZARD REPORTING detail procedures. 18. SECURITY arrangements & right of search etc.
9. WELFARE no eating on site. Site canteen/toilet 19. STATUTORY CERTIFICATES required for , lifting
Arrangements. Identify smoking restrictions appliances, electrical power tools etc.
Arrangements
10. SITE RULES give details
WORKING ARRANGEMENTS - Identify points covered by induction by ✓ in box
20. SAFE WORKING risk assessments & method 28. COSHH before using chemicals, cutting, grinding, or
statement explained mixing materials obtain assessment. If in doubt ASK!
21. SITE VEHICLES, PLANT & MACHINES only to be 29. SCAFFOLD not to be erected, dismantled or altered
operated by authorised person, with proof of training & except by authorised persons. Proof of training &
competence certificate (CITB etc competency is required. (Includes towers.)
22. TRAFFIC MANANGEMENT Vehicle/pedestrian 30. MATERIAL STORAGE & WASTE DISPOSAL
routes. Speed limits arrangements & procedures
23. FIRE PREVENTION location and type of fire fighting 31. MANUAL HANDLING maximum weights &
equipment. assessments.
24. PERMIT TO WORK describe procedure. 32. MATERIAL HANDLING to be lowered not thrown
25. TOOLS. Personal hand tools should be inspected 33. SAFETY MONITORING ARRANGEMENTS safety
regularly and any defects corrected. inspections & site instructions etc.
26. ENVIRONMENT conditions and special arrangements 34. CONSULTATION ARRANGEMENTS. You are
relating to this site. encouraged to discuss any constructive aspects of
safety.
To be completed by the person receiving induction training ✓
✓ Appropriate box YES No
35. Has your employer explained the safe system of work contained within your method statement and risk
 STOP
assessment?
36. Do you understand the Risk Assessment and Method Statement & agree to comply with its content?  STOP
37. Do you suffer from epilepsy, asthma, hearing or visual disability, (colour blindness etc.)?
Do you have any disability or condition, which requires special medical attention or treatment?
Are you taking any medication? (Give details overleaf in order to assist any first aid treatment)
38. Have you read and understood the site rules? and agree to comply with them?  STOP
39. I am 18 years of age or older  STOP
No means STOP - do not commence work. - see Rok site management before working
40. Which training certificate* do you Hold?
None
*Certificates will be required for examination & photocopying
I have been instructed on the above items
Operatives Name: Signature: Date: Trade:
Instructor’s Name Signature Contact No:

FSAF 014
FSAF 15
INDUCTION CHECKLIST
Explain to all in conjunction with the Company Standard Operatives Induction.
1. Site Management Team and responsibilities
2. The scope of the project and site details
3. Site layout, boundaries, security, any notice boards
4. Welfare facilities
5. Transport plan
6. Fire plan and actions in event of an emergency
7. Name and details of first aider and first aid facilities
8. Actions in the event of an accident/near miss and reporting procedure
9. Specific site wide hazards

eg. live building services
HV cables…overheads…..underground
contaminated land
confined spaces
working adjacent to public
10. Site Procedures

eg. reporting of unsafe acts, near misses and safety issues that require attention
permits required
restricted areas
PPE zoning
signing in and out as per site rules
11. Safe use of scaffolding
12. Housekeeping arrangements and material storage
13. Methods of consultation on H&S matters
14. Personal responsibilities, conduct and disciplinary measures
15. Questions and open discussion
In addition check operatives have had their risk assessments and any associated method statement
and COSHH assessments explained to them by their company, and that they understand what they
have to do. Also check they understand who is responsible for their immediate supervision.
All attendees should sign Operatives Safety Induction Form. Some sites may also use the
Operatives General Induction Register.

FSAF 014
Operations induction
1. Personal Protective equipment Starting On Site
a) Safety helmets, safety boots & hi-viz will be worn in accordance with site rules. Protective Equipment
b) Other items established by risk assessment must be worn. Has your manger supplied you with what you need?
c) Your immediate supervisor must tell you what is required for your work. i.e. helmet, hi-viz, safety footwear, RPE, gloves, goggles ear protection etc. Y N
2. Mobile Plant Site Hazards

Has your manager/ site manager explained to you where the hazardous
a) Only authorised &/or certificate holding operatives may drive plant.
areas are on site?
Y N
b) Use any designated vehicle routes and be aware of any pedestrian routes etc.
c) All reversing & manoeuvring near excavations must be overseen by a banksman.
3. Excavations Emergency Procedures
a) All excavations & manholes must be guarded or covered. Do you know who the first aid person is? Do you know where the fire exit Y N
b) When working below ground level ensure adequate steps have been taken to prevent collapse. routes are located and where the assembly point is?
c) Ensure location of any underground services are known.
4. Access / Scaffolds / Ladders Risk Assessment
a) Use & keep to proper pedestrian access routes when entering and moving around site. A risk assessment is needed for every job on site. Do you know what Y N
b) Use only completed platforms – guard rails / toe boards Precautions and protective equipment apply?
c) Do not interfere/alter or move any scaffold/ladders/access equipment.
d) All ladders must be tied or footed regardless of the duration of the work. Your Work
e) Only recognised scaffolder may erect or alter scaffolds. Has your work been properly explained to you? If working to a method Y N
5. Lifting Operations / Manual Handling statement do you understand it?
a) Lifting equipment/accessories must have current certificates of thorough examination.
b) Lifting operations must be planned and supervised. Accidents
c) Only authorised operators/banks men to be engaged in a lift. Do you agree to report all accidents and near misses to your manager Y N
d) Avoid manual handling heavy materials/plant if possible and site management immediately?
e) Use proper manual handling techniques at all times.
Site Rules
Are you aware of and do you agree to abide with the site rules? Y N
Medical conditions
Do you suffer from any medical condition that may affect your safety on site?
If so, please provide details. Y N
6. Generally Declaration
a) Make sure you are aware of the risks relating to your work. I have read (or have had read to me) these instructions & understand my responsibilities for working safely.
b) Find out the position and status of any building services and precautions required. I am over 18 years of age. * (delete if not applicable)
c) Be aware of how to deal with any hazardous materials/substances connected to your work
(COSHH and flammable/volatile substance issues. Name ……………………………………..(print) Date:……………………….
d) Think seriously about progressive injury. Noise above 85dB, dusty areas, using tools with
high vibration levels.
e) Work in a tidy manner, clear waste regularly. Company/S-C:…………………………………. Signed:……………………………….
f) We actively promote consultation on Health & Safety matters.
g) IF YOU SEE SOMETHING THAT IS A HAZARD – REPORT IT
Failing to follow these simple rules will result in your removal from site! Remember – Your actions could affect our future use of your company!

FSAF 014
VISITORS INDUCTION
The Health & Safety Policy requires you to act in a safe way and not put others at risk. A
copy of the policy is displayed on site for you to inspect. The requirements listed below
will help us to work together towards eliminating accidents and ill health on site.
AUTHORISATION
Please sign in and out of the visitor’s book.
ENTERING SITE
Please use and keep to proper access when entering and moving around site. Ask the Site
Manager to advise you of pedestrian routes/pedestrian free zones. Helmets and footwear
must be worn on site. Additional PPE may be required at certain times and/or in particular
areas of the site. The Site manager will advise you of any such requirement.
SITE HAZARDS
Ask the Site Manager to advise you of type and location of site hazards.
EMERGENCY PROCEDURES
Find out who is the First Aid Person, the location of alarms, exit routes and assembly
points. An emergency procedure sign is displayed – READ IT.
ACCIDENTS AND UNSAFE CONDITIONS
All accidents and near misses must be reported to the Site Manager, you have a duty to
advise the site staff of any potentially dangerous situation or unsafe condition you may
observe.
DECLARATION
I have read these instructions and understand my responsibilities.
Name:………………………………………………(print) Date: ……………………
Signed: …………………………………………………………………………………
Company Name: ……………………………………………………………………………..

FSAF 18
Mobile Elevating Work Platforms (MEWPS)

Site Contract No.
Machine/Equipment
Type (Scissor lift, Telescopic, Articulated Telescopic, Vehicle Mounted
Make: Model:
Plant/Serial No. Supplier:
Documentation Date of Examination/Inspection Comments
6 monthly thorough
examination
Weekly inspection register
Log of daily checks
Operator Training
All operators of MEWPS must have received training from appropriate training organisations and
be issued with a certificate indicating competence such as the CITB CTA card (not familiarisation
training). Enter details below
Certificate of competence Yes No Certificate issued by

Certificate registration No. Certificate expiry
date
Is the operator familiar with the equipment to be Yes No Comment if necessary
used?
General Checks (Tick boxes as appropriate) Yes No
Is SWL or Max No. of persons clearly marked on the lifting platform?

Are all dangerous parts adequately guarded?
Is the machine suitable for the ground conditions to be worked on?
Is the machine to be driven on a public highway?
If yes to above question; Does driver have a suitable licence?
Is machine taxed for use on public highway?
Are safety harnesses with restraint lanyards available for use during work
operations?
Form completed by: Date:
PERMIT TO WORK
FSAF 19
ON OR NEAR ELECTRICAL EQUIPMENT

It is intended that this form is for use by electrically competent persons only
Contract Title: Contract No:

Location of Works: Date of Work:
Risk Assessment: Yes No Stop Method Yes No 
Statement: STOP
Person in Charge: Name of
Contractor:
Part 1 Description of Work (Describe the work to be carried out)

Description of equipment:
Location of equipment:
Describe the work to be carried out:
Part 2 Precautions to be Taken Before Work (Provide further details to these questions in part 3)
“CAUTION “ notice to be displayed Yes No “DANGER” notice to be displayed Yes No
Equipment isolated Electrical circuits isolated
Any other precautions required
Part 3 Precautions During Work

Measures required for “Live” working
The equipment will be deemed safe and can return to normal use when work is complete and all persons, tools & equipment are
removed
Permit valid from: Time of Expiry:
Part 4 Authorisations:
All Signatories to this Permit confirm that they understand the precautions to be taken prior to and during the work. The Recipient of this
Permit is responsible for the safety of all persons and equipment involved. Only the Authorised Person can cancel this Permit.
Name Signature Time Date
Permit issued by (Authorised
Person):
Recipient of Permit:
Surrendered by:
Cancelled by (Authorised Person):

FSAF 21
PERMIT TO EXCAVATE
Contract Title: Contract No:
Location of Date of
Works: Work:
Risk Assessment: Yes NoStop Method Statement: Yes NoSTOP
Person in Charge: Name of
Contractor:
Part 1 Description of Work (Include if appropriate Safe Method of digging when within 0.5 metres of services)
Anticipated period that excavation will be open: Hours Days
Type of ground to be excavated- (Tick Rock Clay Sand Gravel Mixture Other
box)
Describe the work to be carried out:
Part 2 Precautions to be Taken Before Work (Provide further details to these questions in part 3)
Yes No Yes No
Service Utility records checked Stop Is there a danger of collapse or Stop
undermining adjacent structure/road etc.?
Site Maintenance Plans checked Will excavation support be required?
Electro-location (CAT scan) survey carried Stop Is ground support available on site? Stop
out by trained competent person.
Will underground services be marked on Stop Will anyone enter the excavation?
site?
Services marked on site drawings Could water enter the excavation? Stop
Supervision informed of location of services Stop Could gas enter the excavation? Stop
Trial holes dug if service identified Stop Will Confined Space Permit be required?
Are there any overhead cables or other Other
restrictions on the use of excavators/plant
What services have been identified? Gas Electricity Water Telecom Other (state)
(tick box & identify size, type and how
many)
Any other precautions required:
Part 3 Precautions During Work (Tick boxes as appropriate)

Type of Excavation support Drag Driven Piling Fully Hit/Miss Jacking Battered Other
box sheets sheets timbered sheeting system sides
Type of Edge Protection Type of gas monitoring
Adequate Access/Egress Yes No Are existing services marked out on site Yes No
Are other restrictions identified Stop Are existing services adequately supported Yes No
in Part 2 controlled
Note size and type of service
Any other precautions to be taken:

Permit Valid Time of
From: Expiry:

FSAF 21
Part 4 Authorisations
ONLY PERSONS AUTHORISED IN WRITING BY THE SENIOR RESIDENT
MANAGER MAY COMPLETE AND ISSUE THIS PERMIT.
The permit is not complete unless copies of the relevant service drawings are attached.
All Signatories to this Permit confirm that they understand the precautions to be taken prior to and during the work. The
Recipient of this Permit is responsible for the safety of all persons and equipment involved. Only the Authorised Person can
cancel this Permit.
Name Signature Time Date
Permit issued by (Authorised Person):
Recipient of Permit:
Surrendered by:
Cancelled by (Authorised Person):

FSAF 21
Site Excavator Checklist

Site Contract No.
Machine/equipment Supplier
Make Model
Capacity (lifting only) Plant/Serial No.
Condition - list obvious Tyres- any obvious
defects cuts/worn tread
Documentation Date of Examination/Inspection Date checked
6 month thorough examination
Lifting equipment test

certificates
(Before first use)
6 month thorough examination
of lifting equipment
Weekly inspection register
General information
SWL marked on boom or clearly displayed in cab
Are check valves fitted?
Is there a suitable lifting eye/point?
Operator Training
Name of operator (print name)
Card number Expiry date

Type of certificate issued
Categories of plant applicable 1 4

2 5
3 6
Checked by:
Print Name and Company:
Signature: Date:
Note: Excavators fitted with a rated capacity indicator should be treated as a crane and a Crane
Checklist used

FSAF-22
OIL STORAGE REQUIREMENTS

Above Ground Storage Tanks for Offices
MUST have - GO RA MUST NOT have - GO RA
Good integrity and condition. Walls not penetrated by valves or
pipes.
110% bund, with rainwater sump Inadequate bund.
in base.
Minimum clearance between bund Any valve, sight gauge, pipe
and tank not less than 750mm. work outside of the bund.
Suitable location to minimise Be within 10m of any
damage by impact. watercourse/drains.
Base and walls impermeable to Be within 50m of a water
water and oil. abstraction point.
Angle fillet at junction of base and
wall to deflect ice.
Sight gauge supported.
Sight gauge fitted with a valve
that automatically closes when not
in use.
Vent pipe located within the bund,
discharging vertically downwards.
Storage Tanks for Fuelling Mobile Plant (+ all the above list)
Flexible draw off pipe has Pipes must not hang out of bund.
automatic closure valve.
Delivery pipe must be locked
within the bund when not in use.
Mobile Bowser
Must have a hand pump or an
automatic cut-off nozzle.
Pump/valve must be locked shut
when not in use.
Pump/valve fitted with a lockable
tap where it leaves the tank. Kept
locked when not in use.
Sight gauge must have a lockable
valve where it leaves the tank, and
kept locked when not in use.
GO = Good order RA = Requires Attention
FSAF-23

HARNESS CHECKLIST
Contract......................................................................
Make/Supplier/ Date Webbing Stitching Buckles Karabiners & Checked Signature
Identification No. Snap hooks By
Here are the Do’s and Don’ts

DO
• Carry out a full visual inspection of your “Fall Arrest” system every time before use.
• Make sure that every part of your “Fall Arrest” system is fully compatible.
• Use anchorage that is located directly above the working position.
• Use approved permanent anchorage points that have been built or installed by professionals.
• Always ensure that the closing bar on the karabiner hook is locked shut. Kwiklok types do this automatically but should be
checked. Screwgate types must be screwed home manually and checked by applying pressure against the closing bar.
• Make sure that the space you would travel through in the event of a fall is free from protrusions and hazards.
• Ensure that your harness is fitted as close to your body as is comfortable to prevent it’s upward movement in the event of a
fall.
• Only use compatible ancillary equipment.
DO NOT
• Anchor to a structure that itself can fall, ie. a free standing ladder or other loose structures.
• Use an anchorage point that will not take a shock load of 1000kg.
• Use an anchorage point that is located below the point of attachment to your harness. (Special conditions apply to
Scaffolders)
• Use waist connection points on a harness for “Fall Arrest”. Waist connection points are for work positioning or restraint
only.
• Loop lanyards around structures with sharp edges. Do not use if less than 5mm or 7/32” radius edge.
• Use any “Fall Arrest” equipment without reading both the user manual and individual product fitting instructions.
• Use any “Fall Arrest” equipment without familiarisation training and if possible practical training.
• Mix different manufactured products into your “Fall Arrest” system without checking and confirming their compatibility.
• Use any “Fall Arrest” products that are showing signs of wear and tear. Return for formal inspection.
• Extend the length of your lanyard beyond 2M. For greater working distances use a Fall Arrester Block.
• If you have any doubts on any equipment DO NOT use it.
SAMPLE SAFETY
FORM FSAF- 24
LIMITED
REFERENCE:
FSAF 024
CONTRACTORS MONTHLY ACCIDENT STATISTICS REPORT

NAME OF CONTRACTOR CONTRACT NO
REPORT FOR MONTH ENDING:
COMMENCEMENT DATE: SCHEDULED COMPLETION DATE:

ACCIDENT STATISTICS SUMMARY FOR MONTH CUMULATIVE
1. Number of Man-hours
Worked
2. Number of Man days Worked
3. Number of Reportable Fatal Accidents
4. Number of Reportable Non-Fatal
Accidents
5. Number of Dangerous Occurrences
6. Number of Man-hours Lost
7. Number of Man days Lost
8. Number of Reportable Accidents per
100,000 Man-hours Worked
= [(3) + (4)] x 1000,000 =
Accident Frequency Rate
(1)
9. Average Number of Worker Daily
REMARKS:
Signed: Chief Safety Manager: Date: / /
Signed: Project Manager: Date: / /
NOTE: This form must be completed and returned to the Engineer within 5 days after the end of
each month.

FSAF 25
FORMATION OF SITE OHS&E COMMITTEE

Contract No
Contractor
Name
Contract Title
CIRCULAR
Committee
The following OHS&E Committee is constituted with immediate effect:
Chairman:
Members:
1)
2)
3)
4)
5)
Secretary:
Periodicity
The committee will meet at least once in a month on the day (specify date)
Agenda
Secretary will circulate agenda of the meeting at least two days in advance of the
schedule date of the meeting.
Circulation
the meeting will be minuted in the standard format and circulated to the following
under the signature of the secretary
1. Chairman 3. CMRL Representatives
2. Members
5. Others concerned
Date: Signed By: ---------------------------

CHAIRMAN

FSAF 26
MINUTES OF OHS&E COMMITTEE MEETING

Contract No.
Contractor Name
Contract Title
Meeting No. Date of
Meeting
Location of
Meeting
MEMBERS PRESENT INVITEES MEMBERS ABSENT
REPORT SENT TO
No. of Name / Dept. No. of Name / Dept. No. of Name / Dept.
Copies Copies Copies
Prepared by: Location: Date:

FSAF 26
MINUTES OF OH&S MEETING
Item
Description of Discussion Action By Target Remarks
No.
Complaints received from Clients
1 and corrective and preventive
action
Review of MOM of previous
2
meeting
NCR's / Observation from third
3
party
First - Aid cases / Reportable
4
accident cases
Future jobs and specific
5
requirement
Status of implementation of Safety
6
plan
7 Sub-contractor performance
8 Analysis of first-aid cases
Need for any specific system /

9
training / PPE's / resources
Observation of OHS&E committee
10
during last walk down
Next, OHS&E Meeting is scheduled on:
Date: Chief OHS&E

Manager
(Signature & Name)
Date: Project Director/Project

Manager
(Signature & Name)

CHENNAI METRO RAIL LTD. FSAF:27
ELECTRICAL SAFETY AUDIT INSPECTION CHECKLIST

Contract
Contractor No
Title
Contractor
Name
Name of Site
Job No.
Inspected by
Date
Recommendation
Sl. No. Points Observation
s
A. WHETHER METHOD STATEMENT IS AVAILABLE FOR THE FOLLOWING
1 Electrical Safety Education & Training
Procedures
2 Electrical Safety Motivation and Promotion
programs
3 New Electrical Equipments laying of
specifications, procurement, review / inspection
system
4 Electrical Safety Regulatory Compliance check
list
5 Electrical Accident & dangerous occurrences
reporting, analysis, investigation, and rating
6 List of Electrical duty Personal Protective
Equipments (PPEs), inspection
7 Electrical equipment Safe Operating Procedures
(SOPs) and Safe Maintenance Procedures
(SMPs), Safe start-up and shut-down and
emergency shut-down procedures
8 Safety Work Permit system and Electrical
Isolation system
9 Electrical single line diagram, schematic diagram
and the details of the equipment for all
temporary electrical installation

Recommendation
s
B. ELECTRICAL SAFETY AUDITS, CHECKS, INSPECTIONS, STUDIES & TESTS
1 Is there an internal Electrical safety audit system?
If so
i) Is there a formal procedure for it?
ii) Who does it?
iii) What is the periodicity?
iv) Produce a copy of the last internal

Electrical Safety audit report.
2 Is there a system of internal electrical safety

checks and inspections? If so:
i) What types of Electrical Safety
Inspections are carried out and what is
their frequency?
ii) Who does the inspections?
iii) Is there a structured system of Electrical

safety checks and inspections? If so:
iv) Provide samples of such safety inspection

formats (safety area wise e.g. House
keeping, fire protection, trips and lock-outs
etc.)
v) To whom are the Electrical safety checks

and inspections reported?
vi) How action on the recommendations of

electrical safety inspections carried out?
C. ELECTRICAL INSTALLATIONS
1 Do all electrical installations
conform to relevant standards
and codes of practice?
2 What are the observations made
by you on electrical installations
and fire safety of the same?
3 Are there any Fire-Resistant
cables installed? If so give
details

Recommendation
s
4 Have you any Oil cooled Transformers having
oil quantity exceeding 2300 litres? If so:
i) Have you segregated these transformers
from adjoining cubicles by means of baffle
walls/wired-glass windows in steel frame?
ii) Have you provided appropriate soak pits for

soaking up of leakages of oil?
5 Have your motors over current protection

systems?
6 Have battery-charging room? If so:
Is the battery charging room well ventilated to
prevent accumulation of hydrogen evolved?
7 Do you use High Rupture Capacity (HRC)
Fuses?
8 Dou you use Auto Circuit breakers for circuit
breakers carrying current above 30 amps. and not
depend on fuses only ?
9 Have you automatic circuit breaker trips? If so:
i) Do you set the circuit breaker trips below
the HRC-Fuse current level?
10 Are Electrical earthing conductors so designed as

to enable sufficient current to flow up to the
HRC-Fuse blow off current?
11 Do you ensure periodical testing of “Earth-fault
loop resistance” of all earthing connections? If
so:
i) What is the periodicity of such tests and
show register of such tests
D. CONTROL ROOM
1 Location of the Control rooms
i) Away from hazard zone?
ii) Upwind sources of ignition/ fire/

flammable storages/toxic releases?
iii) Blast proof design?

Recommendation
s
iv) Whether under positive pressure? Forced
draft blower in safe location?
v) Cable system fire resistant? And smoke

detection and alarm systems in cable
trenches entering control room?
vi) Fire protection and control system? Smoke

detectors?
vii) Safety glass panels?
E. CABLES
1 Whether the condition of Cable is checked?
2 Are Cables received form other site / previous
site checked for Insulation Resistance before
putting them into use?
3 Are all main Cables, taken either underground /
Overhead?
4 Are welding Cables routed properly above the
Ground?
5 Are welding & Electrical Cables overlapping?
6 Is any improper joining of Cables wires
prevailing at Site?
7 Whether all Flexible cords with a conductor
cross sectional area greater than 1.5 mm2?
8 Whether all OH cables are elevated 6 m above
ground or structure or object?
9 Whether plugs, socket-outlets, and couplers are
splash proof type or IP 44 type (Ingress
Protection for solids of more than 1 mm and
splashing of liquid)
10 Mention the mechanical damage protection for
Armoured cables
F. DBs / SDBs
1 Is earth conductor continued up to DB / SDB?
2 Whether DBs & extension boards are protected
from rain / water?
3 Is there any overloading of DBs / SDBs?

Recommendation
s
4 Are correct / proper fuses & CB’s (Circuit
Breakers) provided at main boards & sub-
boards?
5 Is energised wiring in junction boxes, CB panels
& similar places covered all times?
G. ELCB / GFCI
1 Whether the connections are routed through
ELCB / GFCI?
2 Is ELCB sensitivity maintained at 30 mA?
3 Are the ELCB / GFCI numbered & tested
periodically & test results recorded in a logbook
countersigned by competent person?
H. EARTHING
1 Is neutral earthing ensured at the source of power
(Main DB at Gen. or Transformer)?
2 Whether the continuity & tightness of earth
conductor are checked?
3 Mention the gauge of earth conductor used at
site.
4 Mention the value of Earth Resistance.
5 Whether Electrical equipments earthed through
insulated cables?
I. ELECTRICALLY OPERATED MACHINES
1 Are all metal parts of electrical equipment’s &
light fittings / accessories grounded?
2 Is there any shed / cover for welding machines?
3 Are Halogen lamps fixed at proper places?
4 Are Portable power tools maintained as per
norms?
5 Are Portable power tools provided separate
major switch / cut off switch?
6 Are portable Power-tools made double insulated
and marking towards that is visibly exist at all
tools?
7 Are portable power tools connected with ELCB /
GFCI?

Recommendation
s
J. ELECTRICAL INSTRUMENTS
1 i) All controls fail-safe.
ii) Dual indications, alarm systems and auto

correct/shutoff for critical controls and levels
and process variables.
iii) All instruments properly calibrated and

labelled. (Check calibration schedule and
records.)
iv) Tubing runs protected.
v) Response lag in instruments and alarm

systems affecting safety standards.
2 i) Safeguards provided when instruments have

to be taken out for maintenance.
ii) Any parameters controlled without

instruments in place.
iii) Equipment designed to permit lockout

protection.
iv) Emergency shutdown procedure is well laid

down and known to all concerned.
v) Electrical/cooling water/process water

failures cause hazards or safe shut down
possible or auto shut down of plant.
3 i) Circuit breakers adequate for circuit

protection.
ii) All equipments earthed and motor double

earthed.
iii) Special interlocks needed for safe operation.
iv) Emergency standby power on critical

equipments provided.
v) Emergency lighting provided wherever

required (emergency operations/exit).

Recommendation
s
vi) Emergency disconnects switches properly
marked.
K. HOUSE KEEPING
1 Are all Electrical area floors and stairways in
good condition (no damages, clean and non
slippery)
2 Do you have proper system to deal with spillages
of hazardous chemicals (Diesel, Petrol, oil and
etc.) giving details of covering to
neutralize/absorb/contain hazards of spills,
collecting and disposal of the
neutralized/absorbed spillage etc.? (Give a copy)
3 Are there sufficient waste disposal bins duly
marked for collecting wastes in a segregated
manner, emptied regularly and disposed of in a
safe and approved manner.
4 Are working areas always kept clean and after
maintenance area cleaned well by the
maintenance workmen themselves.
5 Is there adequate washing and toilet facility and
kept in clean and hygienic condition.
6 Are there adequate ventilation arrangements to
ensure comfort of the work environment in
respect of composition of air, humidity and
temperature..
7 Are all Sub-stations, MCC, Transformer rooms
free of fumes and dusts?
8 Are there any working conditions making floor /
work area slippery? If so arrangements made to
prevent the same?
L. ELECTRICAL PERSONAL PROTECTIVE EQUIPMENTS (PPEs)
1 Is there a laid down system of availability, use
and maintenance of Electrical personal protective
equipments (PPEs).
2 Are there adequate Electrical PPEs made
available and workmen do use them, wherever
required?
Recommendation
s
3 Are Electrical PPEs selected in consultation with
workmen using the same and the Safety
department?
4 Are there sufficient electrical insulation mats of
ISI-marking for specified Voltage conditions
wherever required?
5 Are all Electricians provided with appropriate
work uniform and Electrical safety shoes and
their wearing made mandatory?
i) What is the percentage of violation of this?
ii) What is the type of uniform provided?
6 Are all workmen aware of the danger of loose

clothing?
7 Is there availability of Resuscitator for Electrical
Shock treatment and Cardio Pulmonary
Resuscitation (CPR) training provided to
Electricians? If so:
i) Course details
ii) Name of the trainer
iii) Course contents
iv) Course duration
M. ELECTRICAL MAINTENANCE
1 Is the preventive Maintenance procedure
available for Electrical equipments?
2 What are the areas of Electrical Preventive
Maintenance system (PMS)?
3 Is there any system of monitoring and predicting
equipment condition and undertake Electrical
Predictive Maintenance? (Give details).
5 Is there a system of Scheduled Electrical
Maintenance and Overhauling? (Give details).
6 i) Do you have a codified system of recording
Electrical maintenance activities?

Recommendation
s
ii) Do you carry out computer aided Electrical
maintenance analysis and use it for Electrical
maintenance planning?
N. WORK PERMIT SYSTEM

1 What necessary Work Permit Systems exist in
your Unit? (Give details and one form of each).
2 Is there a comprehensive Electrical Isolation
procedure in your Unit for all process vessels and
all equipments? (Please show the procedure)
3 Do you permit Hot Work in flameproof areas of
the plant?
4 What are the hazardous chemicals handled?
5 What is the system of electrical lockout for
maintenance?
6 Are the keys kept for individual locks, which are
used for electrical lockouts with the supervisor
concerned?
O. INSPECTION AND TESTING FREQUENCY

MONTHL HALF ANNUAL
Y YEARLY
1 Electrical grounding & static device check
2 Transformer checking
3 Cable checking
4 Sub-Station checking
5 Electrical Instrument checking

Contractor Monthly Inspection Checklist FSAF-28
Contract No.: Contractor’s Name:
1.0 OSH& E Administration
Ye
1.1 OHS&E Organisation Yes No 1.1a OHS&E Organisation No
s
Adequacy of OHS&E personnel OHS&E manpower from outsourcing agency
Is OHS&E personal professionally qualified OHS&E personals reports to SHE manager
Employer’s approval for each OHS&E
OHS&E manager reports to Project Manager
personal
Intimation of OHS&E personals vacancy to Facilities and equipment gave to the OHS&E
Employer personnel
OHS&E personal lies with the main
OHS&E personnel can stop any unsafe act
contractor
1.2 OSH&E Committee 1.3 Construction OH&S Committee
Is site and construction OH&S Committee Does construction OS&S committee meet at
formed least weekly
Does PM Chairman of OH&S Committee Do all sub contractors attend
Committee members under gone monthly
Is agenda cover all the points
inspection
Does site OH&S committee meet at least Minutes of the meeting send to all committee
monthly with 21 days time gap members
Are Incident Reports discussed Minutes displayed in the notice board
1.4 ID card and first day at work 1.5 Designer’s role
Whether designers were informed about
Is ID card issued to all persons
Conditions of Contract on OH&S
Whether designers provide OH&S risk at the
Is ID card as per standard
drawing itself.
Whether hierarchy of risk control is indicated
Authority signed all ID cards
by the designer
All worker undergone orientation training Participation of designer in monthly SCM
Detailed supplementary information about
OSH&E hand book issued to all personnel
OH&S risk of the design given by designer.
1.6 OH&S submittals to Employer 1.6a OH&S submittals to Employer
Daily reporting of workmen External OH&S audit report
Monthly OH&S report Electrical safety audit report
OH&S committee meeting minutes Air monitoring report
OH&S inspection report Noise monitoring report
Accident, Incident and dangerous occurrence
Monthly internal OH&S audit score report
reporting
Sub total
1.7 Visitors to site
Visitor got the permission from Employer
Contractor have visitor PPEs
Responsible accompanied with visitor
Does visitor entering hazardous area
Visitor register maintain at site office

Contractor’s Observations:

FSAF-28 Monthly Inspection
Checklist
2.0 OH&S Training and OH&S Communication
2.1 Training Policy Yes No 2.2 Induction Training Yes No
Is training policy in OH&S Plan Does training take place in first week
Is policy implemented Induction Handout
Does it includes sub contractors Project related syllabus
Is training policy published Management participation
Does PM understand training policy Attendance records kept
2.3 Toolbox Talks 2.4 Supervisor Training

Are they held at least weekly Is there a recognized programme
Presented by supervision/safety Manager Project related
System monitored by management Senior management participation
Employee involvement Achievement test
Attendance records kept Attendance records kept
2.5 Follow up training 2.6 Driver/Plant Operator Training

Is follow up training organized Does Driver/PO training take place
Are all drivers undergone for defensive
Does it take place after six months
training .
Are all Drivers and Operators
Is syllabus project related
certificated
Attendance records kept Are records kept
Workers participation towards training Are all Drivers Operators retained
2.7 Promotional activities 2.8 OH&S posters

Is there a safety promotional programme Are posters adequate no’s
Are any incentive schemes used Are posters separately numbered
Are subcontractors included in
Are posters cover all topics
promotion
Had any worker rewarded so far. Are safety posters visible on site
Management’s participation towards this Are posters maintaining regularly
Sub total
2.9 OH&S Signage 2.10 Important days to be observed
Is signage in correct colours
Adequate number of signs
Suitable positioning of signs
Signs in Hindi and English and Local
Language
Are signage maintaining regularly

FSAF-28 Monthly Inspection Checklist
3.0 OH&S Inspection and Audit
Ye
3.1 Planned General Inspection Yes No 3.2 Routine Inspection No
s
Monthly contractor and subcontractors site Operator Daily Inspection of plant and
OH&S committee Inspection equipment
Weekly OH&S inspection by supervisors Monthly Inspection of electrical hand tools
Quarterly Inspection of temporary electrical
Daily OH&S inspection by site OHS&E team
systems
Employer’s and contractor’s representative Weekly Inspection of scaffold by scaffolding
involved in this OH&S E inspection supervisor
Half-yearly inspection of lifting appliances and
Records maintenance
gears by competent person
3.3 Specific Inspection 3.4 OH&S Inspection
Before a heavy lifting operation Is Contractor prepare checklist for all activity
Before & after entry into confined space Checklist mentioned in contractor OH&S plan
Before & after a welding & gas cutting All inspection reports registered
Before concreting formwork Inspection reports sent to Employer
All high-risk processes inspected by Planned and Routine Inspection used for
competent supervisor discussion in OH&S Committee Meeting
3.5 MARS 3.6 Electrical safety audit
Performed once in a month Covered all areas
Project Manager accompanied this audit Performed once in a month
Conducted at least 7 days prior to Monthly Team comprising of senior OHS&E(Elect)
OH&S Committee meeting engineer
Audit Report will be sent to Employer Audit Report will be sent to Employer
Corrective actions taken Corrective actions taken
3.7 External Audit (General) 3.8 External Audit
Conducted by external agencies Contents and coverage
Auditors ISO qualified and competent Available documents
Approval of the Employer Qualification of audit team members
Audit report as per ISO/ILO standard /CMRL
Had checklist prepared
Contract requirements
Conducted on a quarterly basis Status of NCR of external audit
Sub total
3.9 Audit Report
Audit report as per ISO/ILO standard /CMRL
Contract requirements
Audit conformity / non-conformity report to
the Employer
Report contents and coverage
Corrective action by contractors
Initial audit for checking the adequacy of
implementation


4.0 Hazard Identification, Risk Assessment and Emergency Preparedness
Ye
4.1 Policy for Identifying Hazards No 4.2 Risk Assessment Yes No
s
Procedure for identifying hazards Are risk assessment carried out
Is there a list of significant hazards Is there a formal process
Procedure for Risk Assessment Are worksheets used
Whether any schedule or hierarchy made Are records kept in site office
Ranking of hazards Whether control measures are planned
4.3 Method Statements 4.4 Permit to work in use

Are Method Statements produced Is there a procedure for Permits to work
Dot hey contain clear instruction Issued by Authorized person
Are they given to work supervisors Issued for defined period
Is correct information given to workers Workers instructed
Step by step description of task Are records kept of Permits issue
4.5 Emergency Preparedness Plan 4.6 Emergency control centre

Is there description within Safety Plan Available of first-aid box
Is it up to date Public addressing system
Is it well published Emergency phone numbers
Does Project Manager have copy Emergency alarm
Exercise within past three months Employees name list
4.7 Communication system 4.8 Plan Details

Public addressing system Details of emergency co-ordinator
Emergency power supply Designated personnel with Tel. Nos.
Mobile phone in Emergency care centre Are telephone numbers up to date
Warning boards Emergency response team identified
Records maintained for usage and maintenance
Functions of Team identified
of communication systems
4.9 Requirements 4.10 First Aid

Link to Police Is First Aid included in Safety Plan
Link to Fire Services Are adequate no. of First aiders appointed
Link to Ambulance and Hospital Record keep of qualification

Communication to employees First aid boxes supplied
Displayed on Notice Boards First aid boxes properly equipped

5.0 Reporting of Accidents and Dangerous Occurrences and Accident Investigations
5.1 Reporting to Employer Yes No 5.2 Reporting to Govt. organisation Yes No
Verbal information Reporting to Regional Labour Commissioner
Written information within 24 hrs Reporting to welfare board
Delay in reporting Reporting to director general
Are all accidents identified and recorded Reporting to police station
Are AFR rates calculated Reporting to District Magistrate
5.3 Incident Reporting 5.4 Follow up Action

Is there a proper reporting procedure Does Senior Manger review all reports
Is the procedure communicated to all Is result of investigation published
Are reports available for inspection Are workers advised of remedial action
Do reports accurately describe incident Are failure in Management recognized
Is standardised form used Whether statistics report prepared
5.5 Procedure for investigation 5.6 Incident Investigation

Made Photographs and sketches Are witness statement taken
Examine involved equipment Is the chain of events identified
Interviewed the eye-witnesses Is specific sub contractor identified
Consulted expert opinion Investigation kit available
Investigation report made available to
Environmental conditions
Employer


6.0 Housekeeping
Ye Ye
6.1 Procedure No 6.2 Organisation No
s s
Is it mentioned in OH&S plan Adequacy of housekeeping personnel
Responsibility classified Is housekeeping personnel trained
Employer’s approval for housekeeping
Housekeeping round the clock
personnel
Reporting of housekeeping personals to
Intimation of vacancy to Employer
OHS&E Manager
Housekeeping persons provided no. / badge Persons provided with suitable logistics / aid
6.3 Housekeeping squad 6.4 Barricades

Housekeeping plan Dimension of the board
Member list CMRL logo
Job allocation and time allocation Sequential Numbering
Periodicity of housekeeping Availability of protruding parts
Documentation of housekeeping Regular cleaning and painting
6.5 Access / Egress way 6.6 Dustbins

Free from debris Lumbar with protruding nails
Unprotected opening Unprotected projection
Free from obstructions Scattered unused materials
Slippery condition Spill of bentonite
Spillage of water or oil Fencing and guarding of equipments
6.7 Housekeeping at worksites 6.8 Housekeeping at roads

Lumbar with protruding nails Tyre cleaning of vehicles
Unprotected projection Parking of construction vehicles at road
Scattered unused materials Water logging or bentonite spill on road
Fencing and guarding of equipments Roads kept clean
Stacking and storing of materials Position of barricades lying at roads
6.9 Storage of cylinders

Full / empty separated
Gases separated
Protected from weather
Contents labelled
MSDS available for each gas

7.0 Working at Height
Ye
7.1 Organisation and planning Yes No 7.2 Fragile surface No
s
Adequate number of trained personnel Suitable working platform
Supervision Guard rails
Planning emergency and rescue Crawling boards
Work permit system Warning notice
Refresher training Work permit system to work
7.3a Scaffolding 7.3b Scaffolding

Is scaffolding included in OH&S Plan Scaffolds constructed for correct use
Are scaffolding erected and dismantled by Are scaffolds constructed of sound material
competent workmen without patent defect
Are records kept of inspections No unsuitable material
Security fixed or buttressed Working platforms fully boarded
Working platforms free from rubbish Guardrails and mid rails fitted
7.3c Scaffolding 7.4a Ladders

Secure ladder access provided Are ladders specified in Safety Plan
Toe board provided Is there a system for checking ladders
‘Safe for Use’ board erected Are records kept of weekly checks
Availability of base plate Using of Bamboo ladders
Free from rust / corrosion / debris Painting of ladders
7.4b Ladders 7.5 Guardrails

Safety procedure followed Present at all working platforms
Rubber bush in aluminium ladder Securely attached
Landing properly Sound material
Climbing procedure Designed as per standard
Rungs at proper intervals Maintained properly

7.6 Harnesses 7.7 Safety net
Is use of harnesses specified in OH&S Plan Approved type
Are harnesses of full body type Good construction
Are secure anchorage points used Adequate number to issue
Has instruction on correct use been given Testing
Maintenance and inspection Maintenance

8.0 Lifting Operations and Gears
8.1 Certification Yes No 8.2 ASLI / Other Indicators Yes No
Procedure is available in OH&S Plan Free from damage
Fitness / Test Certificates available In operable conditions
Daily inspection records maintained Overload device tested
Load chart for lifting appliances Overload device operable
Employer’s approval for lifting appliances Bypass key made available to Plant Manager
8.3 Wire Ropes 8.4 Safety Hooks

Free from damage Free from damage
Lubricated Safety latch fitted
Correctly anchored Safety latch in operable condition
Splicing method Other form of hook closure
Inspection & Testing Test certificates
8.5 Slings, Chains & Shackles 8.6 Outriggers (Mobile Cranes)

Properly stored when not in use Outriggers locked in position
In good condition without defects Jacks in good condition
Market with safe working load Jacks firmly supported
Bulldog clips correct fit/number Wheels clear/not supporting load
Correctly used Chassis level
8.7 Operator and Operator cabin 8.8 Rigging requirement

Licence for HMV Rigger qualification & experience
Competent & skilled Load assessment
Medical fitness certificate Type of slings to be used
Portable fire extinguisher Hocks & lifting assessment
Defensive driving Overhead power line

8.9 Alarms & signals 8.10 Accessories & controls
Overload alarm Side & rear view mirror
Over hoist alarm Clutch & brake
Reverse horn Swing & Extension control
Pressure indicators Illumination
Outrigger extension alarm Maintenance

9.0 Construction Machinery / Hand tools and power tools
Ye
9.1 Machinery Fencing No 9.2 Maintenance Yes No
s
All moving parts effectively guarded All maintenance properly maintained
Fencing not removed No maintenance whilst M/c in motion
Is procedure in OH&S Plan Records of maintenance kept
Warning board Work Permit System
Emergency stop switch Use of ‘Lock Out and Tag Out’ (LOTO)
9.3 Air Receivers 9.4 Wood working machines

Fitted with pressure relief valve Top guard fitted
Annual test carried out Working space
All couplers with safety chains/wired Guards to protect all drive belts
Condition of hoses Emergency stop switch
Noise level under permissible limit Push stick used
9.5 Grinding machine 9.6 General

Appropriate guards fitted Is procedure in OH&S plan
Correct size wheel/disc fitted All operator medically fir and above 21 yrs
Spindle speed marked on M/s Unauthorized riding on plant
Name plate for equipment specification Inspection and maintenance record
Test and maintenance Portable fire extinguisher
9.7 Safe Operating Procedure 9.8 Requirements

Available for all machines Manufacturer specification
Available in the working area Control switch
Operator trained GFCI / RCCB and other safety devices

Operator know the same IP 44 plugs, sockets & connectors
Updated regularly Guarding
9.9 Maintenance and Inspection 9.10 PPE

Daily inspection Ear protection
Lubrication Hand Protection
Pneumatic and hydraulic pressure Eye protection
Record maintenance Apron
Label displayed in the equipment itself. Nose / face mask

10.0 Site Electricity
10.1 Power assessment Yes No 10.2 Distribution Panels Yes No
Load calculation for power requirement Panel secure box to IP 44/IP65
Employer’s approval for execution of the job All cables enter box through glands
Is small capacity diesel generator present ELCB or RCCB/ GFCI fitted
Noise from diesel generator Proper earth connection and earth pit
Sub-contractor’s power requirement by main
Warning signs in appropriate position
contractor
10.3 Cables 10.4 Work on site
All cables free from damage Site electricity covered in the OH&S Plan
Cables lying on the ground / water Name posted on Main Distribution Board
Cable joints made by IP 44/IP 65 connectors Single line & Schematic diagram submitted
Correct storage when not in use Employer’s Approval for execution
Colour coding GFCI provided
10.5 Electrical professional 10.6 Earth Pit
Sufficient numbers As per standard
Professionally qualified Wet condition
Roles and responsibilities defined Pouring 5 litre water per days
Valid license to electrical persons Earth pipe free from corrosion
Training Earth resistance
10.7 Plugs, Sockets and outlets 10.8 Voltage / Current
Are all plugs, sockets and outlets IP 44/IP 65
Check voltage / current limit
type
Colour coding of plugs and sockets Rating clearly marked on all equipments
All cables fitted with IP 44 /IP65Plugs Monitored continuously
All equipments connected with plugs Mismatch of cable and equipments ratings

All equipments free from defects Properly earthed
10.9 Maintenance 10.10 Correct Disc. / Revolutions
Regular inspections carried out Information plate on tool
Records kept Information on Disc/Cutter
Suitable guards/security fenced Compatibility between Tool and Disc
Faults actioned Operator trained/competent to fit Disc
Record maintaining Safety check on condition

11.0 Fire prevention
Ye
11.1 Fire fighting personnel No 11.2 Requirements Yes No
s
Adequacy of Fire fighting personnel Emergency plan
Professionally qualified Fire excavation plan
Employer’s approval Mock drill
Intimation of vacancy to Employer Nearest fire brigade phone numbers
Adequate no of trained persons Reporting of fire accident to Employer
11.3 Combustible material 11.4 Fire Extinguisher

Used in site Adequate numbers
Handling of combustible material Appropriate type
Stored in separate place Easily accessible
Spillage of materials Frequency of recharge
Location of burning site Maintenance and inspection
11.5 Firefighting equipments

Sufficient quantity of water supply
Fire hose and nozzle
Fire alarm
Condition of fire hydrants
Sufficient no. available


12.0 Welding & Cutting
Ye
12.1 Gas Welding / Cutting No 12.2 storage of cylinders Yes No
s
Is procedure in Safety Plan Is procedure in Safety Plan
Are cylinders in cylinder-trolley Storage in upright position
Are pressure gauges fitted and operable Full/empty segregated
Are flashback arresters fitted Different gases separated
Are non return valves fitted Contents labelled
12.3 Condition of cylinders 12.4 Hose

No damage by misuse Colour coding
No rust/corrosion Hose clip and clamp
Protected from weather Is it free from leak and damage
Colour coding proper Hose lying on the ground
MSDS available Joints if any
12.5 Electric Arc Welding 12.6 Transformer

Are welding machines in good order Presence of voltmeter and ammeter
Welding leads free form defect Separate main power switch
Welding return free from defect Ground connection
Electrode holder properly insulated Specification plate or board

Dipping electrode in water when it is hot Protected from weather
12.7 Electrical Cable 12.8 Work Area

Cable lying on ground / water Area clear of flammable substances
IP 44 /IP 65 cable connectors instead of
Smoking inside the work area
insulation tape
Damaged and exposed wires Fire extinguisher fitted
Separate earthing connection from work piece
Welding screens available
to transformer
Electrical protection devices ELCB, RCCB,etc. Ventilation and fume extraction
12.9 PPE for welder, cutter and

helper
Face and eye protection
Gauntlet gloves
Safety footwear
Nose mask
Ear muff / plug

13.0 Excavations and Trenching
Ye Ye
13.1 Planning No 13.2 Access/Egress No
s s
Are excavations covered in OH&S Plan Suitable ladders provided
Examined by competent person Ladders properly secured
Records of inspection maintained Alternative ladders available
Underground cable and pipelines Staircase for excavation more 1.5 m depth
Backfilling and removal of trench Guardrail for staircase.
13.3 Shoring 13.4 Barriers and Warnings

Shoring as soon as earth is removed Rigid barrier around excavation
Suitable support Suitable warning notices
Regular monitoring Regularly checked by supervisor
Proper repair under taken Warning light & signs
Material stacked properly on removal Emergency exit board
13.5 Soil 13.6 Underground Services

Not closer than 1 metre Checks made with Utility providers
Properly stacked Safe digging procedures in use

Excavator clear of personnel Supervision has service plans
Storage of Excavated materials Dewatering procedures
Logistics for excavated soil Line of dewatering
13.7 Undermining Nearby

13.8 Portable Electrical Equipment
Structures
Survey carried out Are as per standard
Temporary support provided if required Proper repair and condition
Vibration measured Rating voltage more than 24 V
Regular monitoring Double insulation
Sufficient clearance provided Open bare wires
13.9 Ventilation and Illumination 13.10 Signals & Communication

Are as per standard Audio, Video signals
Exhaust fan arrangement Walkie-talkie / radio /mobile phones
Temperature management Head protection
Gas monitoring systems Arm protection
Lighting arrangement Leg protection

14.0 Tunnelling and Confined Space operations
Ye Ye
14.1 Procedure No 14.2 Equipments No
s s
Procedure in OH&S Plan Gas monitoring equipment
Permit Work system in use Rescue BA equipment
Only properly trained operatives Full body harness for each worker
Existing underground cables and pipelines Tripod and lifeline
Refresher training Resuscitation Equipment
14.3 Access and Egress 14.4 Procedure

Proper staircase and lift Inform to Director General before 30 days
Guardrail for staircase Emergency power generator
Staircase made of sound material Watertight bulkhead doors at entrance
Free from defects Reflective jackets for workers
Emergency exit Dewatering procedures

14.5 Warning / Communication
14.6 Electrical equipment
systems
Telephone / walkie-talkie Flame proof electrical equipment
Emergency Alarm Portable tools more than 24 V
Warning for Exit way and electrical panel Double insulation / earthing condition of
boards portable equipment
High visibility waist Transformer used in without compressed air
Warning lights Bare conductor or semi enclosed fuse
14.7 Illumination and Ventilation 14.8 Compressed air

Illumination / ventilation levels Adequacy of air supply
Air circulation Emergency power supply
Level of oxygen / other toxic gas Flame proof equipment
Temperature level (not more than 29 C) Available in man-locks and medical-locks
Emergency power supply for luminaries Hoses free from damage
14.9 Fire Prevention 14.10 Health and Welfare

Adequate water supply Man-lock and medical-lock
Fire alarm Drinking water
Flammable materials inside work areas Medical officer
Water outlet points First-aid room
Inspection and maintenance Shelter room

15.0 Traffic management
Ye Ye
15.1 Traffic marshals No 15.2 Vehicle operators No
s s
Sufficient numbers Driving licence
Professionally qualified or trained Medically fitness
Medically fit Defensive driving training
Driving licence Refresher training
Familiar with traffic signs Fire fighting training
15.3 Traffic control devices 15.4 Barricades

Cons Erected around the construction site
Drums Free from defects and protruding parts
Delineators Numbered
Traffic cylinders Painted and maintained in good condition

Traffic signs and barricades Barricade register
Rope Light and Reflective plate
15.5 Barricades 15.6 Regulatory Signs
Barricade inspector & supervisor appointed Approval from police and traffic authorities
Retro reflective strips shape and size Digital Warning signs
Reflective strips placed at a angle at bottom Red light / flag indicator
Minimum gap between retro reflective strips
Design as per employer’s approval
1000mm
One red light / blinker per barricade Material made of reflective type.
Back ground of IRC Signs made of reflective
plate of 900mm x 900 mm size
15.7a Vehicle 15.7b Vehicle
Vehicle number and company name Brakes in good working order
Inspection stickers & license plate Are wiper blades in good condition
Seat belts Rear view mirrors
Two reflective triangles on rear side Speedometer
Fog lights (front & rear) Vehicle’s horn and reverse alarm
15.8 Heavy motor vehicles 15.9 Operator cabin

Automatic safe load indicator and Calibration Made of fire resistance material
Load chart of the vehicle Protection from vibration
Fitness certificate Weather protection
Manufacturer details Adequate ventilation
Marking of safe working load Suitable fire extinguisher

16.0 Personal Protective Equipment
Ye Ye
16.1 Head Protection No 16.2 Foot Protection No
s s
Use enforced Use enforced
As per standard Suitable type
In good condition Toecaps effective
Colour and company logo Fair condition
Available for issue Available for issue
16.3 Eye protection 16.4 Hearing Protection

As per standard As per standard

Suitable type Suitable type
Good condition Available for issue
Available for issue Noise levels monitored
16.5 Respiratory Protection 16.6 Protective Gloves

Suitable type Correct type for operation
Good condition Good condition
16.7 High-Visible Waist 16.8 Fall Protection

In good condition In good condition
Warning signs displayed Warning signs displayed
16.9 PPE for visitors

Use enforced
10% PPEs for visitors in site office
In good condition
Colour and company logo
Available for issue

17.0 Industrial Health & Hygiene and Lighting & Ventilation
Ye Ye
17.1 Medical examination No 17.2 Occupational Health Centre No
s s
All worker under gone Construction medical officer & qualification
Covered all testes as per standard Availability nurse & sweeper
Conducted by qualified person Floor area minimum 15 m2 with two rooms
Confidential report for all workers Adequate equipment
Frequency of medical test maintained Medical emergency equipments
17.3 First-aid 17.4 Ambulance van and room

Equipped with all items as per standard Equipped with all items as per standard
Sufficient numbers Availability and numbers
First-aid room facility Maintained in good repair
First-aider & his qualification Equipped with standard facilities
Register for first-aid Record of all cases of accident & sickness
17.6 Alcohol and drugs & HIV /

17.5 Mosquito breeding
AIDS prevention
Employee working under the influence of
Water retain on the site
alcohol / drugs
Periodic interval Smoking at public worksites
Still waters Smoking at public worksites
Posters HIV / AIDS awareness training provided
Usage of insecticides Workers participation / co-operation
17.7 Noises 17.8 Vibration

Are procedures for noise evaluation in the
Monitoring method
Safety Plan
Are noise assessments carried out Frequency of monitoring
Are noise zones identified Vibration limits
Is correct PPE provided Report maintenance
Usage of PPE Control plan
17.9 Radiation
Method statement
Approval from Employer
Use and storage of radioactive substance
Disposal of radioactive substance
Appropriate PPE

18.0 Welfare amenities
18.1 Toilets / Urinals Yes No 18.1a Toilets / Urinals Yes No
Enough no available Is it properly illuminated
Separate for men and women Is it having separate and ample water facility
Access within 500m from worksite Is it having proper drainage system
Is it properly cleaned Water leaking or spillage
Is it washed regularly Records kept and available
18.2 Drinking water 18.3 Canteen

Quantity is sufficient Is canteen available
Quality is good Is it neat and clean
Laboratory test done Is the flooring dust free
Access within 200m from worksite Is the cost ‘no loss and no gain’ basis
Is it 6m away from toilets and urinals Lighting, ventilation and water facility
18.4 Labour Accommodation 18.5 Creaches

Cooking, bathing, washing and lavatory Is it free from mosquito and other biological
facilities agent
Is it free from mosquito and biological agent In-charge to keep the children.
Is it properly illuminated and ventilated Is it properly illuminated and ventilated
Is it adequate for all Is it adequate for all
Is it neat, clean and hygiene Is it neat, clean and hygiene
18.6 Shelter 18.7 Illumination

Adequate to all workers Minimum illumination requirement
Is it properly illuminated and ventilated Minimum 325(30) lux at work place
Minimum 55(5) lux on General Construction
Is it neat, clean and hygiene
Indoor
Is it free from mosquito and biological agent Minimum 110 (10)lux Access Ways
Drinking water and Toilet facilities Adequate Emergency lighting provided
18.8 Ventilation
Oxygen level less than 19.5
Air circulation of 6m3/min for each building
worker employed underground
Free air flow movement in work place
Ventilation system in operation
Maintenance records kept and available

19.0 Environmental management
Ye Ye
19.1 Air quality No 19.2 Water quality No
s s
Monitoring by competent person Monitoring by competent person
Monitoring equipment as per standard Monitoring equipment as per standard
Monitoring method Monitoring method
Report to Employer Report to Employer
Control plan Control plan
19.3 Noise monitoring 19.4 Illumination monitoring

Monitoring by competent person Monitoring by competent person
Monitoring equipment as per standard Monitoring equipment as per standard
Monitoring method Monitoring method
Report to Employer Report to Employer
Control plan Control plan
19.5 Temperature monitoring 19.6 Dust control

Monitoring by competent person Water sprinkler arrangement
Monitoring equipment as per standard Frequency water sprinkler inside the site
Monitoring method Dust screens
Report to Employer Dust level under permissible limit
Control plan Environmental monitoring
19.7 Waste Management 19.8 Felling of Trees

Dustbin in construction site Approval from forest department
Temporary dumping area Trees used for anchorage.
Separate dumping pit for disposable and non- Trees exposed or injured by construction
disposable wastes equipment
Frequency of removal of waste Protective barriers around tree
Burning of waste
19.10 Energy Management

Uniform illumination
Size and length of cable and wires
Efficient luminaries
Efficient motors and pumps
Efficient air-conditions

20.0 Batching Plant and Casting Yard
Ye
20.1 General Yes No 20.2 Layout No
s
Is procedure in Safety Plan Plan of layout
All operators medically fit/over 18 Drainage system
No unauthorized riding on plant Welfare amenities
Daily inspections / recorded Plan for vehicle moving area
Equipped with all Barrication
20.3 Material Handling & dust

20.4 PPE
protection
Handling of cement bag Hand protection
Loading and unloading cement Respiratory protection
Handling of launching segments Head protection
Is dust level under permissible limit Foot protection
Environmental monitoring Ear protection
20.5 Traffic management 20.6 Welfare facilities

Barricades Toilet
Warning boards Drinking water
Traffic marshals Canteen
Delineators Shelter
Lane warning Labour accommodation
20.7 Fitness certificate

Crane
Hydra and all equipment
Ropes and chains
Hooks and shackles
Rigger & Operator

FSAF-29 -Daily Dairy

Chief OHS&E Manager
Daily Dairy
Contract No:
Name of the Contractor:
Date:
Report By:
Report No :
Weather
Temperature Conditions
A.M P.M
High Temperature
Partly Cloudly Partly Cloudly
Cloudy Cloudy
Windy Windy
Rainy Rainy
Clear Clear
Low Temperature
Other Other
Contractor Labour Details
Contractor Plant /Equipment /Break Down/Third Party Inspection Details
Visitors to site

High Risk Activity RFI details
Public Complaints /Unusual Events
Incidents /Near Miss/Dangerous Occurrence / First Aid Injury /Major injury /Minor Injury
/Road Accidents /Lost Time Injury
High Risk Safety Observation and the status of compliance
Internal Safety High /Medium/Low NCR issued the contractor and the status
Site Safety Meeting Held
FSAF-30
CV Template

Position Title
Name
Date of Birth
Years with the firm
Country Of citizenship /Residence
Education
S.No Degree(s)/Diploma(s) College /University Year of passing
Employment Record:
Period Employing organization and Tile of position Held Location of
your title /Position Assignment
Contact Info for reference
with Email
Employing organization:
Title Held:
Employer Reference Name:
Email:
Contact:
Experience:
Name of the Assignment:
Year:
Location:
Client:
Main Project Features:
Position Held as per the client:

Activity performed:
Memberships:
Language Skills
Languages Read Write Speak
Certification:
I, the undersigned, certify that to the best of my knowledge and belief, this CV correctly describes
myself, my qualifications, and my experience.
I understand that any misstatement described herein may lead to my disqualification and immediate
dismissal.
Name Signature Date:
Name of the Authorized Signature Date:
Representative of the company
FSAF-31
External Quarterly Audit Template

Recom
Person
Key mended
Responsib
Finding Visual Action
Reason for le With
CMRL Criteria s / Evidence E G A F NC Location Plan
Failure Name and
Observ s(Attach) with
Designatio
ations Target
n
Date
Construction
Risk (W1)Why?
Assessment & (W2)What
Method ?
Statements (W3)Who?
Completed (W4)When
?(H) How?
Risk
Assessments &
Method
Statement
Implementatio
n
Transport and
handling
Magazine
General
Work Areas
De-nailing
Conditions on
Site
Means of
Escape
On Site Traffic
Management

Suitability and
Specific PPE
Permits
Planning
Excavations
Register
Provision of
Service
Locators
Underground
Service
identification
Edge
Protection
Shoring
Competent
Workface
Temporary
Work
Assessment
Safe Working
Procedure
Excavation
Work Permit
Planning
Scaffolding
Register
Ladder Access
Scaffolding
General

Scaffold access
Towers and
Platforms
Edge
Protection and
Toe-boards
Competent
Persons
Other
Precautions,La
dders,Stepladd
ers,MEWPs
Temporary
work
Assessment
Recorded
Inspections
Work Permit
Planning
Provision of
Protection
Work Permit
Procedure
Planning
Work Permit
Quality of Air
Quality of
illumination
and
Emergency
Lighting

Communicatio
n Systems
Fire
Extinguishers
,Fire Mains &
Hose
Connections
Walkway
Man lock and

Medical Lock
Resources
Monitoring
Action on
Safety
Advisers
Reports
Management
Review
Employer's
/Employer's
Respresentativ
e Non-
conformance
Report
Safety of
Traffic
Safety of
Public
Traffic
Management
Highway
Cleanliness

Work Permit
Relevant Site
Signage
Barricade
Identification
of Sources
Safety
Health and
Safety
Information
Health and
Safety Policy
Statements
Protective
Equipment
Sign
Emergency
Procedure
Site rules
Construction
Phase Health
and Safety
Plan
Risk Register
& Hazard Log
Risk
Assessment &
Method
Statement
Briefings

Manual
Handling
Assessment
Manual
Handling
Training
Safe
Operational
Control
Procedure
OHS&E
Management
System
Procedure
Emergency
Preparedness
and Response
plan
International
Certifications
Training
Implementatio
n Plan
Fire
Evacuation
Plan
Fire Risk
Assessment
PPE As per
Risk
Assessment

Transportation
Plan and Risk
Assessment
Safety
inspection
Reports
Work Place –
Extinguishers
Hot Works
Permits
Relevant
statutory signs
Helmets
Footwear
Hi Viz
Safety Belt
File
maintenance
Assessment
Briefings
Relevant
Signage
Warning Signs
, Notice board
and Tally
Board
Gas detection
Equipment
Self Rescue
Equipment

Training
Emergency
Under Ground
Drills
OH&S
Committee
External
OHS&E Audit
Quarterly
Incident
Reporting
Visitor Safety
Monitoring
HAV’s
Register
Information -
Malaria ,
Dengue ,
Silicosis, Skin
Cancer ,
HIV AIDS ,
Leptospirosis ,
Tetanus and
Hepatitis
Management
Competency
Staff
Training
Programme
Toolbox Talks

OH&S Induction
Training
Plant
Reversing
Vehicles Sign
Have reversing
Vehicles
posters
avialble in all
the location
where vehicle
reversing
carried out?
Do trained
Banksmen/
helper present
in each
equipment and
where heavy
traffic present
on site and off
site?
Do trained
Banksmen/
helper present
wear named
reflective
jacket on site
and off site?
Lift Plan and

Risk
Assessment
Approved Lift
Plan and Risk
Assessment

available for
all lift more
than 1 ton
Briefing
conducted for
Approved Lift
Plan and Risk
Assessment
Approved Lift
Plan and Risk
Assessment
available for
all lift more
than 1 ton
reviewed ,
monthly or
weekly or prior
to phase
change.
Planning
Approved
Operational
procedure
covering all
plant and
equipment
used at site
with Risk
Assesment.
Availability of
Masterlist of
Standard
Documents for
each plant and
equipments
with validity ?
A. Equipment
Documents(Th
ird
Party;Insuranc
e;RC/Tax;PUC
;Fitness.
B. Operator
Documents((Li
cense LMV <
7.5 T
Trans(HMV;H
TV;HGV;CRA
NE; CONST.
Equip
etc);Competen
cy Certificate
by Plant
DepartmentJob
Specific
Training;Eye
Test 1 year >
40 years
age;Eye test 2
year < 40 years
of Age;
Medical
Fitness.
Availability of
Competent
Lifting
Supervisor/
Rigger.
Maintenance
schedule.
Daily
Checklist
signed by
competent
person

Lifting
Appliances
and Lifting
Gear Register
Approved
Operational
procedure
covering all
lifting tools
and tackles
used at site
with Risk
Assesment.
Availability of
Masterlist of
Standard
Documents for
each lifting
gear with
validity ?
Availability of
Competent
Lifting
Supervisor/
Rigger and
daily checklist
signed by
them?
Approved
competent
person
availability?
Plant and
machinery
inspection
Pre- inspection
checklist for
plant and
equipment
before
allowing to
work the first
time?
Daily
Checklist
signed by
competent
person for all
plant and
equipment
including Sub-
contractor?
Plant and
equipment
register
showing
violation and
compliance ?
Violation
identified shall
be reflected in
plant and
equipment risk
assesment?
Vehicle
Control
Masterlist of
trained
banksmen
availability,lic
ensed operator
as per legal
requirement
and all

inducted
having age
more than 21
years?
Wheel wash
provided and
maintained in
each location
where there
has chance to
get the existing
road dirty?
Vehicle
leaving site
have reverse
horn and is
covered by
tarpoline to
avoid spillage
of muck on
existing road?
Piling
Availability of
Approved
Piling Method
statement and
risk assesment
by Employer's
/Employer's
Respresentativ
e?

Method
statement
include
emergency
procedure for
pile
collapse,dispos
al of
muck,lifting
plan,legal
documents
checklist and
availability of
documents,thir
d party
certificate, if
vertical lifting
by secondary
rope
arrangement of
caliberated
ASLI and third
party
certificate,
banksmen?
Availability of
Daily
Checklist ,
Mantainence
schedule and
maintenance
history?
Competent
Personnel
Third party
agency
approved by
Employer's

/Employer's
Respresentativ
e?
Availability of
Masterlist of
Standard
Documents for
each plant and
equipments
with issue date
and validity
date?
A. Equipment
Documents(Th
ird
Party;Insuranc
e;RC/Tax;PUC
;Fitness.
B. Operator of
age 21 having
Documents((Li
cense LMV <
7.5 T
Trans(HMV;H
TV;HGV;CRA
NE; CONST.
Equip
etc);Competen
cy Certificate
by Plant
Department,Jo
b Specific
Training to
driver/opeator
by competent
and approved
agency by
engineer;Eye
Test 1 year >

40 years
age;Eye test 2
year < 40 years
of Age;
Medical
Fitness.
Availability of
Trained
Competent
Lifting
Supervisor/
Rigger/slinger.
Guarding
Arrangements
Availability of
operational
procedure of
Machine
Guarding and
risk
assesment?
Guarding
Arrangements
training
documents
available and
awareness of
Guarding is
present on site
and daily
checklist
covers gurding
requirement?
Plant and
equipment
register
guarding
violation is
recorded and
compliance
evident?
Guarding
arrangement
implementatio
n noted on
site?
Vehicle
Checks
Masterlist of
vehicle register
with
equipment ,
driver details
with legal
documents and
all inducted
having age
more than 21
years?
Defensive
driving
training
conducted to
all drivers?
Daily checklist
of all vehicle
maintained?

Lifting
Operation
Availability of
third party
certificate with
three month
validity? Use
of crane more
than the age
without
assesment as
per IS
guideline(Asse
sment test ,
Caliberated
ASLI,Load
radius
indicator,Moti
on Limit
Devices, Over
Load Cut-off
device,Anneno
meter,
Machine
Guarding,
SWL Load
Charts ?
Issues
recorded in
Plant register
not complied?
Daily checklist
maintained and
leveled for
dumpers,
MEWP,
cranes, etc.
Safe Use

Plant and
equipment
operational
procedure
available
covering entry
and exit
rule,Importanc
e of car safety
belt,
importance of
stop block near
excavation,
failure of
equipment
while working
near excavator
or during
digging,
Importance of
banksmen and
communicatio
n for carrying
different
activity in safe
place by heavy
machinery?
Briefing
conducted for
Approved pant
and equipment
operational
procedure by
palnt and
equipment
head to
concern
operator and
banksmen?

Lifting Gear
Approved
Operational
procedure
covering all
lifting tools
and tackles
used at site
with Risk
Assesment.
Availability of
Masterlist of
Standard
Documents for
each lifting
gear with
validity ?
Availability of
Competent
Lifting
Supervisor/
Rigger and
daily checklist
signed by
them?
Welding
Machine
Availability of
welding
operational
procedure
covering
importance of
double
earthing to
welding
machine,impor

tance of hot
work permit by
fire watcher
,maintenance
,insulation of
electrode
holder,
importnance of
Ammeter and
voltmeter ,
Protection
from
Monsoonand
risk
assesment?
Availability of
hot work
permit and fire
watcher ?
Maintain daily
checklist for
welding
machine?
Welding
operator have
standard PPE
specific to
welding?
Track and
Locomotives

Availability of
Masterlist of
Standard
Documents for
locomotives
with issue date
and validity
date?
A. Equipment
Documents(Th
ird
Party;Insuranc
e;RC/Tax;PUC
;Fitness.
B. Operator of
age 21 having
Documents((Li
cense LMV <
7.5 T
Trans(HMV;H
TV;HGV;CRA
NE; CONST.
Equip
etc);Competen
cy Certificate
by Plant
Department,Jo
b Specific
Training to
driver/opeator
by competent
and approved
agency by
engineer;Eye
Test 1 year >
40 years
age;Eye test 2
year < 40 years
of Age;

Medical
Fitness.
Operational
procedure for
Track and
locomotve
with adequate
refuge space, a
nominated
lookout, and
flashing
warning lights
being placed at
either end of
the section of
track available
with risk
assesment
Daily checklist
maintained
Rolling Stock
Availability of
Man rider for
transporting
personnel ,
muck car for
transporting
muck and

segment car
for
transporting
segment?
Availability of
track work
permit and
maintenance
schedule?
Daily checklist
maintained for
man rider ,
segment
car,muck car
and track?
Electrical
Qualified/Com
petent
Electrical
Engineer
Name &
Contact
number of
Electrical
representative
shall be
displayed main
distribution
board for
the temporary
electrical
supply so that
he can be
contacted in
case of an
emergency.

Maintenance
schedule
available and
followed to
monitor
condition of
electrical
distribution on
site.
Site Electrical
single line
layout drawing
available
All faults
detected &
actions taken,
Maintenance
schedule to
monitor
defects in
control
measures
Overhead lines
identified
however poor
maintenance of
goalposts,
barriers
RA/MS
completed
agreed by local
electricity
authority.
Signs and
barriers in
prominent
position.
Briefings to
plant operators
All Temporary
Electrical Site
installations
and
distribution
systems shall
as a minimum
meet IP44
standards and
be in
accordance
with:-
(a) Indian
Electrical
Regulations;
(b) The Power
Companies’
Supply Rules;
(c) BS 7671
Requirements
for electrical
installation, the
IEE Wiring
Regulations
(16th Edition);
(d) BS 7375
Distribution of
Electricity on
Construction
and Building
Sites;
(e) BS 4363
Distribution
Assemblies for
Electricity
Supplies for
Construction

and
Building Sites;
and
(f) BS 6164
Safety in
Tunnelling in
the
Construction
Industry.
Monitor
compliance
daily
All portable
electrical
appliance
permanently
numbers
including sub-
contractor
Register of
tools on site.
Secure storage.
Inspection of
competent
person &
Authorised
issue and
return
Rechargeable
tools used

preferentially.
Task
assessment
sheets
confirms
condition
check before
use.
Authorised
users identified
for electrical
tools
Manufacturer
data used to
assist in
training
Equipment in
good
condition.
Evidence of
equipment
being in good
order, clearly
identifiable
and being used
correctly by
trained,
authorised
person
Good clear use

of registers.
Schedule of
inspection
periods
displayed
Maintenance
schedule/hire
status record
available to
monitor
condition of
electrical
equipment on
site and
completed.
Subcontractors
provide
records of
inspection and
procedure to
remove faulty
equipment
found on site.
Competent
person C
licence
appointed for
inspections
and tests etc.
Including Sub
contractor
activity
Competent
person
identified on
site notice
board.
Training
records on site
of competent
persons.
Permits
contents
communicated
to operative,
sign off
procedure in
place.
Records
maintained,
regular
monitoring and
recorded
inspection of
permits
Periodical
cleaning and
replacement of
light fittings
/lamps
Pole height
maintained as
per legal
requirements
Light fittings
installed & lay
out plan ,pole
number
displayed and
sufficient
illumination
maintained at
site
Register
available for
illumination
and regular
update
Distribution &
Electrics up to
date and good
records of
corrective
actions and
changes
recorded
Records of
weekly
inspections
and monthly
audit.
All work shall

be supervised
or executed
by qualified
and suitably
categorised
electricians.
All cabling
shall be run at
high level
whenever
possible and
firmly secured
to ensure it
does not
present a
hazard or
obstruction to
people and
equipment.
The
installation on
Site shall allow
convenient
access to
authorised and
competent

operatives to
work on the
apparatus
contained
within.
The following
voltages shall
be adhered to
for typical
applications
throughout the
distribution
systems:
(a) fixed plant
- 415V 3
phase;
(b) movable
plant fed by
trailing cable -
415V 3 phase;
(c)
installations in
Site buildings -
240V 1 phase;
(d) fixed flood
lighting - 240V
1 phase;
(e) portable
and hand held
tools - 110V 1
phase;
(f) Site lighting
(other than
flood lighting)
- 110V 1
phase; and
(g) portable
hand-lamps

(general use) -
110V 1 phase.
Earthing and
bonding shall
be provided for
all electrical
installations
and equipment
to
prevent the
possibility of
dangerous
voltage rises
and to ensure
that faults are
rapidly
cleared by
installed
circuit
protection.
Only plugs and

fittings of the
weatherproof
type shall be
used and they
should be
colour coded
in accordance
with the
Internationally
recognised
standards for
example
as detailed as
follows:
(a) 110 volts :
Yellow
(b) 240 volts :
Blue
(c) 415 volts :
Red
Tunnel - The
Contractor
shall provide
adequate
lighting at the
face and at any
other point
where work is
in progress.
Tunnel -
Emergency
lighting shall
be installed at
the working
faces and at
100m intervals
along
the tunnel to
help escape
workmen in
case of
accidents.
All lighting
shall be kept
maintained and
clean at all
times on the
traffic
diversion.

Use a low
voltage open
circuit relay
device if
welding with
alternating
current in
constricted or
damp places.
WORK IN
CONFINED
SPACES -
Flame-proof
lighting. (Hand
lamps not
more than 24
volts.);
Procedure of
LOTO
Procedure of
each type of
equipment
Standard
maintenance
procedure
The Site mains

voltage shall
be as the
Electricity
Utility
supplies, 415V
3-phase 4-wire
system.
(a) Single-
phase voltage
shall be as the
Electricity
Utility
supplies, 240V
supply.
(b) Reduced
voltages shall
conform to BS
7375.
Cables shall be
selected after
full
consideration
of the
conditions to
which they
will be
exposed and
the duties for
which they are
required. For
supply cables
up to 3.3kV
the
cable
armouring
shall be used
as the earth
return in
conditions
where the
cable is
continuously
extended and
not subject to
continuous
movement
after
installation.

For supplies to
mobile or
transportable
equipment
where
operation of
the equipment
subjects the
cable to
flexing, the
cable shall
conform to one
of the
following
specifications
appropriate to
the duties
imposed on it:
(a) BS 6708
flexible cables
for use at
mines and
quarries;
(b) BS 6007
rubber
insulated
cables for
electric power
and lighting;
and
(c) BS 6500
insulated
flexible cords
and cables.
Provision of
Silenced
Equipment like
D.G

Specific
Training
Competency
Certificate of
electrical
personals
Admin &
Stores
As per the
child labour
abolistion act,
are any body
employed
under the age
of 18 years?
Company /
Organization
registration
Certificate
available at the
Admin?
Contractor
registration
certificate
available at
office ?
Employer
Public
Liability
Certificate
available and
displayed
Permission/Cle
arence to
operate the
Casting Yard

Labour license
available?
Whether all the

workmen
covered under
ESIC?
Whether all the

workmen
covered under
EPF Policy?
Whether the
workmen
covered under
group
insurance
policy?
whether the
project
registered
under
BOCWR
Whether the
Contractor
having the
'CAR' policy?
Whether the
minimum
wages act
implemented
and being
followed in
practice?
Pre-
employement
medical fitness

is being carried
out for all the
workmen
Workmen
screening is
being done as
per their skills
and trade
Are Women
deployed as
per the
guidelines of
factories act /
BOCW rules-
2006
Sexual
harassment
prevention is
in place and
policy
formulated/dis
played?
Women
protection act
guidelines
being
implemented
Workmen
compensetion
policy is
available
Emergency
Contact
Numbers
displayed at

suitable
loctions.
Ambulance is
available
Qualified
Doctor is
available
Sufficient
numbers of
male nurses
are available at
all locations
Health Centre
is available as
per the
guidelines of
BOCW act
Bed and
blankets in the
Health Centre
are available
and are in
hygienic
condition
Sufficient
numbers of
toilets are
available at the
project
Sufficient
quantity of
drinking water
facility is
available

Sufficient
quantity of
Urinals are
available
Separate
washrooms
with pictorial
photos for
wormen are
made available
Rest rooms for

women are
available
Rain
protection
system is in
place
Mosquito
prevention
system during
the rainy
season is in
place
Fire
Prevention/Pro
tection systems
are adequte at
work place
Labour camp
set up is as per
the legal
requirement
Separate
kitchens in a
safe distance

for the
workmen at
Labour camp
is provided
Cleaning/white
washing frency
of Labour
camps, toilets,
urinals, wash
rooms
Fire
Prevention/Pro
tection systems
are adequte at
labour camp
Periodic Mock
drills at
workmen
camp
Hand wash
facility with
soap water
solution
Drinking water
test report
Security
arrangement at
workmen
camp
Medical care /
Doctor visit to
Workmen
camp

Fumigation,
Fogging,pest
control, Anti
larva treatment
at Workmen
camp
Vaccination
Transport
facility for
workmen from
workmen
camp to site.
Drinking water
tank cleaning
frequency and
other display
posters
Cloth washing
facility at
workmen
camp
Welfare,
Health &
Hygiene
posters at
workmen
camp
Health and
Hygiene
awarness
programes at
workmen
camp
Energy drinks,
ORS,Lemon

water, butter
milk during the
summer
Emergency
lighting
arrangement is
in place
Stores
License to
stock Diesel &
Gas Cylinders
if applicable as
per LR
HIRA for
stores
Store Layout
Stacking
arrangemnts of
material
Manufacturer
Test
Certificates for
lifting tools
and tackles
Calibration
certificates for
the measuring
equipments
Racks
arrangement
with safe
distance

Safe access /
egress in side
the store
Fire fighting
arrangement in
the store
Ladder
provision to
pick the
material
stacked at
certain height
Ventilation in
side the store
Illumination in
side the store
5 'S' system
implementatio
n
Separate
storage of
flammable
material and
precautions
First In / First
Out system
implementatio
n for material
Tag system for

all material
Emergency
evacuation
posters

Emergency
contact
number
display
flame proof
electrical
fittings in the
store
First aid box
Separate safe
storage facility
for wire ropes
and web slings
with test
certificate
Dispay of
MSDS for all
COSHH items
Emergency
lighting
arrangemnt in
side the store
Drinking water
facility
Stacking
arrangement of
Hazardous
material like
bentonite etc.
LED lighting
arrangement to
reduce power
consumption

Eye wash /
Shower facility
in case contact
with hazardous
chemical
Bund wall /
dyke wall for
diesel, petrol,
chemical
starage area
Mock drill for

store
Display of
OH&S Policy in
the store
Display of
Operational
Controls in the
store
Entry
restriction
posters
Informatory
posters
Dos & Don'ts

display
Smoke / Heat
detectors
Oil/Chemical
storage in
metal
containers

Waste disposal
provision /
plan
Trainings for
store staff
Calibration
certificate for
Weighing
machine
Loading /
Unloading
Procedures
Wedge blocks
/ wheel
chockers for
parked vehicle
at the store
during loading
/ Unloading

SECTION 2
GUIDANCE DOCUMENTS
INDEX REFERENCE REVISION DATE
Lifting Operations contents GSAF 01
Construction Method Statements

GSAF 02
contents
Working At Height contents GSAF 03
OHS&E Training Matrix GSAF 04
Emergency procedure Fire/ Bomb Alert GSAF 05
OH&S Audit measurement Criteria GSAF 06
Emergency Response Plan contents GSAF 07
Health Plan contents GSAF 08
On Site Traffic Management Plan GSAF 09

contents
Project OH&S Plan contents GSAF 10
Site Fire Plan contents GSAF 11

Traffic Management Plan contents GSAF 12
Training Implementation Plan contents GSAF 13
Monthly OH&S Report Contents GSAF 14
Minimum number of OH&S Posters GSAF 15
ID Card Format GSAF 16
Days to be Observed for creating GSAF 17

OHS&E Awareness
Minimum Lighting Requirements GSAF 18
Labour Camps GSAF 19
Accident Investigation & Reporting GSAF 20
First Aid Room / Facilities GSAF 21
Personal Protective Equipment GSAF 22
Storage of LPG Cylinders GSAF 23
Storage of Flammable Liquids GSAF 24
Manual Lifting GSAF 25
Permit to Work (PTW) GSAF 26
Excavation GSAF 27
Hand Tools GSAF 28
Arc Welding & Cutting GSAF 29
Gas Welding & Cutting GSAF 30
Bench Grinders GSAF 31
Circular Saw GSAF 32
Electricity at Site GSAF 33
Air Receivers GSAF 34

Confined Space Entry GSAF 35
Scaffolding GSAF 36
Mobile Scaffold GSAF 37
Working at Height GSAF 38
Mobile Cranes GSAF 39
Tower Cranes GSAF 40
Safe Use of Ladders GSAF 41
Fire Extinguishers GSAF 42
Access & Housekeeping GSAF 43
Hoists (Man & Material) GSAF 44
Material Loading Platform GSAF 45
Site Transportation GSAF 46
Contractor Surveillance Report GSAF 47
Non-Conformance Report (NCR) GSAF 48
Site Instruction GSAF 49
Emergency Action & Notification GSAF 50
Request for Inspection (RFI) GSAF 51
Minimum Requirements Of OHS&E GSAF 52

Monitoring and Audio-Visual
Equipment’s

GSAF 001
LIFTING OPERATIONS CONTENTS
Rev. Date Description

0 Reviewed/edited/amended in conjunction with management review
0 Issued for use

GSAF 01
Prepared by: Reviewed by: Approved by:
Name:
Date:
Signature:

Contents
1. Introduction
2. Scope
3. Glossary of Terms
4. Reference Documents
5. Rules for Safe Lifting Operations
6. Responsibilities, Competence and Training of Personnel Involved in Lifting
Operations
6.1 Responsibilities
6.1.1 Person Responsible for Lifting Operations
6.1.2 Competent Person
6.1.3 Crane Operator
6.2 Competence and Training
7. Planning of Crane Operations
7.1 Define the Lift
7.2 Planning
7.2.1 Lift Categorisation
7.2.2 Risk Assessment
7.2.3 Lift Plan
7.2.4 Assessment of a Lifting Operation
7.2.5 Tandem Lift Additional Factors of Safety
7.2.6 Crane Siting Considerations and Assessment
8. Crane Daily Checks and Inspections
8.1 Crane Access Ladders, Walkways and Hatches
8.2 Housekeeping
8.3 Pre-start Checks
8.4 Start-up of Prime Mover
8.5 Pre-Operations Checks and Function Tests
8.6 Safety Equipment
8.7 Checks to be carried Out During Operations of the Crane
9. Execution
9.1 Communications of Lift Plan
9.2 Communications
9.2.1 Hand Signals
9.2.2 Radio Communication
9.3 Controlling Access to the Lift Area
9.4 Conducting the Lifting Operation
9.5 Moving the Load
9.5.1 Load Handling
9.6 General Instructions for Crane Operators
9.6.1 The Crane Operator MUST NOT
9.6.2 The Crane Operator MUST
9.7 Banksman and Load Handler (Slinger) Procedures
9.7.1 General Instructions for Banksmen
9.8 Reacting to Changing Circumstances
10. Learn and Record
APPENDIX 1 – Example Task Based Risk Assessment
APPENDIX 2 – Example Lifting Plan & Lift Method Statement
APPENDIX 3 – Wire Ropes – Care and Inspection
A3.1 Introduction
A3.2 Construction
A3.3.1 Ordinary Lay
A3.3.2 Lang’s Lay
A3.3.3 Non-Rotating
A3.4 Wire Ropes Inspection
A3.4.1 Factors Causing Rope Deterioration
A3.4.2 Wire Rope Discard Criteria
APPENDIX 4 – Recommended Hand Signals
APPENDIX 5 – Lifting of Personnel
A5.1 Personnel Lifting with a Crane
A5.2 Personnel Work Cages & Baskets
A5.2.1 Work Baskets
APPENDIX 6 – Typical Adverse Weather Guidelines
APPENDIX 7 – Guideline on Use of Lifting Accessories
Table A7.1 Working Load Limit for Slings Using STEEL Cored Rope
Table A7.2 Working Load Limit for Slings Using FIBRE Cored Rope
Table A7.3 Working Load Limit for Round-Slings
GSAF 02

Construction Method Statement Contents
Identified
The headings and sub-headings listed below are not exhaustive
Yes / No
1. Purpose
2. Scope of Work (detailed)

Detailed description of Works to be undertaken. Limits of work and site
boundaries, including time limits / Completion criteria
3. References/Consents/Supporting Information
4. Hazards & Risks Identified

• List significant hazards with operation and as identified in the Project
Safety Plan.
• Consider health and safety implications
• Risk Assessments
• Hazardous substance assessments
5. 3rd Party/Arrangements/Protection/Communication & Liaison

Method
• Movement – storage of materials and equipment
• Restricted clearances – plant & equipment
• Reduced site lines for travelling public and construction plant
• Occupied premises within or adjacent to operations
• Over-flying work operations (cranes)
• Site security
• Road traffic management
• Pedestrian management
• Interface with public bodies and schools
• Public safety
• Temporary fencing and protection

Communication & Liaison
• Identify specific persons who must be contacted, additional to those
specific in the Project Safety Plan e.g. other section engineers
• Consider other contractors working nearby. Highway Authorities.

Occupiers of adjacent property. Client undertakings.
• Sub-standard conditions reporting
Supporting Information
Drawing and layout of initial, interim and final works. Temporary Works
design, support calculations, checking and approval Quality control
arrangements
6. Site Spatial Management Plan
Site Layout Plan shall include the following
• Worker’s Passage Route
• Vehicle Running Route
• Construction work area
• Workshop area
• Material storage area
• Construction waste storage area
7. Environmental
• Noise, dust, smoke, mud, vibration.
• Disposal of waste, frequency and method of disposal.
• De-watering arrangements and disposal of water
• Pollution controls
Fuels, oils etc., storage and containment

Environmental – liaison
8. Method: Briefing Arrangements, Plant, Personnel

Method
• Reference to programme chart showing sequence of separate tasks
• Standards and Procedures
• Sketches
• Access and egress arrangements
• Delivery of materials
• Details of temporary structures

• Method of authorising start of work
• Risk Assessments considering Health and Safety
Personnel
• Number of contractors and sub-contractors
• Communication methods
• Supervision arrangements, including names of person in charge
• Competence and training requirements. (especially in respect of plant

and equipment used)
• Working hours
• Shift hand-over arrangements
• Welfare and first aid
• Access requirements, special conditions
Briefing Arrangements
• Determine level and extent of briefing arrangements including
accompanying documentation.
• Detail how understanding is to be confirmed by contractors and or

individuals
Plant & Equipment

• Specify plant and equipment to be used
• Competence requirements to operate or erect plant and equipment
• Authority to work
• Operational Restrictions
• Permit systems
• Inspection and examinations
• Record keeping
• Temporary lighting
• Detail of cranes, lifting machines, appliances and lifting tackle; including
details of site access,
• Rigging and de-rigging
Infrastructure Protection
• Identify hidden services
• Use of approved Cable Locating Tools
• Identify infrastructure susceptible to damage e.g. power and
telecommunications equipment,
• pipes, air mains, fire detection equipment
• Sketch showing location of services or reference where information can
be found.
• Isolation and protection – safe working locations.

• Permits to work
• Lock out procedure and control.
• Hand over and re-energising
• Plant movements.
• Additional fire precautions
• Hot Work arrangements
• Structural considerations for existing buildings & structures.
9. Quality
• Quality Control arrangement
10. Safety
• Control measures for specific health hazards e.g. Leptospirosis
• Relevant contractor’s risk assessments, including COSHH and manual
handling
• Permit to work systems
• Personal protective equipment requirements
• Etc
11. Hold Points

Hold Points are trigger levels if exceeded then the work ceases.
This will include safety, quality and environmental issues.
12. Inspection & Test Plans

GSAF 03
WORKING AT HEIGHT CONTENTS
Rev Date Description

Reviewed/edited/amended in conjunction with management review
Issued for use
Prepared by: Reviewed by: Approved by:
Name:
Date:
Signature:

GSAF 03
1. Scope ...........................................................................................................................................
2. Definitions ..................................................................................................................................
3. Responsibility .............................................................................................................................
4. Procedure ...................................................................................................................................
5. Examples / Diagrams / Flow Charts ........................................................................................
6. General Assessments .................................................................................................................
7. working at Height (General) Risk Assessment ..........................................................................

GSAF 03
OHS&E Training Matrix

Management Supervisor Specific
Safety Training Observation Programme
Confined Space Testing & Certification

Behavioural Based Safety Management
Hazard Identification & Risk Analysis
Incident / Accident Investigation &
False-work Erection / Dismantling

Incident/Accident Investigation &
OHS&E Emergency Response &
OHS&E Promotion & Incentives
Job/Task Safety Analysis (JSA)
HAZMAT Handling & Control

Electrical/Mechanical Isolation
Electrical/Mechanical Isolation
Scaffold Erection & Inspection
Explosive Handling & Control
Scaffold Erection/Dismantling
Welding, Cutting & Bracing
OHS&E Audit & Inspection
OHS&E Improvement Plan
Power Actuated Hand Tool

Industrial First Aid & CPR
Painting in Confined Area

Confined Space Working
Labour welfare measures
OHS&E Communication
Environment Monitoring
Heavy Lifting Operation

Management of Change
Permit to Work System

Permit to work system
Wire Rope Inspection
Radiography (X-Ray)
Confined space entry
Traffic Management
OHS&E Orientation
OHS&E Leadership
Waste Management
Steel erection work

Types of training
Crane Inspection
Roofing Work
OHS&E Plan
Preparedness
Fire fighting
scaffolding
Reporting
Reporting
(BBSM)
Rigging
(STOP)
Project Director /Project
. . . . . . . . . . . . . . . . . . . . .
Manager
Construction
. . . . . . . . . . . . . . . . . . . . . . .
Managers/Engineer
Quality Manager/Engineer . . . . . . . . . . . . . . . . . .
Planning Manager /Engineer . . . . . . . . . . .
Public Liaison Officer /Labour
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welfare officer
Construction Supervisors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/Foreman
Senior/Junior Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manager / Engineer
Machinery Operators . . . . . . .
Material Handlers . . . . . . . . .
Station Building Workers . . . . . . . . . . . . . . .
Steel workers . . . . . . . . . . . . . . .
Mechanical workers . . . . . . . . . . . . . .
Other Civil workers . . . . . . . . . . . . . . . .
Electrical /Plant Foreman
. . . . . . . . . . . . . .
/workers
Radiographers . . . . . . . . . .
Transportation Drivers . . . . . .
Traffic Marshal /Security
. . . . . . . . . . .
Officers
Traffic Engineer /Barricade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manager /Housekeeping
Manager
Medical Doctor/Male
. . . . . . . . .
Nurse/First Aiders
Chief /Sr. OHS&E Managers . . . . .
Jr.OHS&E Managers/ OHS&E
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
supervisors /Stewards
Environmental Manager
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/Engineer

GSAF 06

GSAF 06
EMERGENCY PROCEDURE FIRE/BOMB ALERT
OPERATING COMPANY:
SITE / CONTRACT:
SITE ADDRESS:
SITE TELEPHONE No:
FIRE / BOMB WARDEN DETAILS

NAME AREA COVERED CONTACT TEL POSITION
PROCEDURE
1. A record of all personnel must be kept on site each day.( Visitors Register and
the Operatives Daily Register).
2. All personnel must be made aware of the fire drill during the Safety Induction.
3. All personnel must familiarise themselves with the location of Fire Extinguishers
Fire Alarm Call Points (temporary and permanent), Escape Routes and the
Designated Assembly Point.
4. If a fire or bomb is discovered warn others by shouting and ensure TEL 999 is called.
5. Send a colleague to advise the designated fire wardens /fire safety co ordinator/site manager.
6. If it is a fire raise the fire alarm at a Break Glass or by sounding any temporary
sirens / horns/ bells supplied for this purpose.
7. Try to put out the fire only if it is safe to do so, using the appropriate fire fighting
equipment.
8. On hearing the fire alarms evacuate the workplace leave tools,
equipment and personal belongings behind.
9. Proceed to the Assembly Point where a check will be undertaken to confirm all
personnel are out.
10. Inform the fire/bomb warden or those in authority if you know someone is missing.
11. Do not return to the work place until instructed by Rok Management.
DO
NOT PUT
Reminder -
In order
If you do

GSAF 06
CHENNAI METRO RAIL LIMITED PROJECT
OH&S Audit Measurement Criteria

GSAF 06
Points will be objectively awarded by Contractor based upon site safety conditions
Scoring will be as follows:
Excellent (E) = 10,
Good (G) = 8,
Average (A) = 6,
Fail (F) = 0,
Non-Conformance (NC) = -10
Non-Conformance (NC) = -10 with the exception of those sections marked with an asterisk which will
have a factor of 2 thus doubling the score for that section.
All non-conformances within the heavy bordered areas will receive an Action Notice at the required
level. All Suspended Operations Notices will be referred to the Project Manager, who will visit site
within 24 hours to carry out further safety inspections.
Any non-applicable topic and the corresponding “possible score” will not be marked and the score
will be calculated by recognising the relevant possible score as being 100% and the actual score as a
percentage of this
Chennai Metro Rail Limited
Key:
Contractor assigned score
Engineer’s Score

GSAF 06
1. Notices Displayed
ACTIVITY EXCELLENT GOOD AVERAGE FAIL NON
[An [Exceeding the [In line with [In Need of CONFORMANCE
Exceptional Norm] OSHE Improvement] [Unsatisfactory]
Standard] 8 Points Procedures] 0 Points -10 Points
10 Points 6 Points
1.1 Occupational Additional Accidents , Displayed on Limited visitor Not displayed
Health and Posters incidents and office notice information Health and Safety.
Safety displayed near misses board/all boxes signage, H&S
Information - i.e. mess together with completed. Posters, banners No safety
room, site any lessons Emergency etc. provided suggestion box at
entry and point learned contact both in Marathi each site and labour
of work area displayed on information /Hindi and colony
and changed notice board detailing where English. Work
on monthly and poster to report .Public force
basis campaigns information representative’s No smoking , No
conducted signage and name contact alcohol drinking at
contractor number posted public site poster
Safety contact on all sites not displayed and
promotional Safety Hand no awareness
book on safety information externally to site
conducted at posted office training
site & and health made
available and externally
participations
of staff , provided to Safety contents
workmen and employees organized in
sub-contractors sites
Safety incentive
schemes are in
place for
motivation
(awards and
rewards)
1.2 Occupational Additional Health & Safety Organisation Organization Policy not
Health and copies policy declared, signed policy having a Health complying with the
Safety Policy displayed in, adopted & Displayed on and Safety statutory provisions
Statements i.e. canteens Policy is made notice board/ Policy signed by and CMRL
etc know to all? policy reviewed the project OHS&E
and up to date. Manager in Requirements.
Hindi and/ or
local Language
1.3 Employer’s Additional Additional Displayed on Displayed in Not displayed or
Liability copies copies displayed office notice prominent expired.
Insurance displayed in in, i.e. canteens board/ up to position
Certificate other locations etc. date.
1.4 Protective Numerous Signs displayed Good clear Few signs No signs displayed.
Equipment signs on shows at site entrance sized signage in displayed, not
Sign inside the work and along site visible easily seen.
area. hoarding/ positions.
perimeter fence.
1.5 Reversing Banksmen Signs displayed Signs displayed Few or small No sings displayed.
Vehicles Sign wearing colour with contact at site entrance signage in place.
coded high number for and around site. Signs not easily
visibility vests/ named seen.
helmets. banksmen.
1.6 Emergency Also displayed Good content. Displayed but Not fully Not displayed.
Procedure in site areas. Displayed at poor in content. established,
Review dates both exits and some not No Emergency
set, drills inducted. contact numbers of
completed.
GSAF 06
Reviewed after fire points, all Emergency local bodies and

an alarm. inducted. team identified other organizations
Emergency and emergency are displayed at site
mock drill are Emergency evacuation plan No staff , workmen
conducted as control centre displayed at familiar with the
per emergency established and prominent plan
plan assembly points locations at site No emergency
provided at site lighting
1.7 First Helmet First aid points Named and Not identified. None on site.
Aider(s), stickers worn. clearly displayed, good No full time
Male Nurse Additional first designated. cover Safety, cover both day No records of first
,Doctor aiders on site. Fully equipped First aid box and night shift. aid boxes
Ambulance with available in Fully trained. In inspection
driver available each work site each site office
at site in all with trained and work
working hours personal location to No records of first
and emergency attending aid training
life support emergencies
equipment No enough
attached in qualified /trained
Ambulance first aiders are
available at each
site each shift
No first Aid room

/Ambulance room
at site
No tie with nearest

hospital
No qualified doctor
available in each
shift in site
1.8 Project Occupational Good EHS Minimal Some displayed Not displayed.
Notice health posters information, requirements not all
Boards HAV etc COSHH etc. site rules etc. requirements
displayed in Policies in met. Telephone
prominent CHSP no of local Fire ,
positions. Electrical and
other agency
1.9 Site rules Additional Additional Forms part of Not all site staff Unsafe acts and
copies copies displayed induction. inducted. conditions in breach
displayed in in, i.e. canteens Displayed on of rules.
other locations, etc office notice
i.e. work area. board.
1.10 BOCWR Additional Additional Displayed on Displayed in Not displayed or
Registration copies copies displayed office notice prominent expired.
displayed in in, i.e. canteens board/ up to position
other locations etc. date.
1.11 Labour Additional Additional Displayed on Displayed in Not displayed or

Licence copies copies displayed office notice prominent expired.
displayed in in, i.e. canteens board/ up to position
other locations etc. date.
1.12 Restricted Numerous Signs displayed Good clear Few signs No signs displayed.
Usage of signs on shows at site entrance sized signage in displayed, not
and along site easily seen.

GSAF 06
Hand Phone inside the work hoarding/ visible

Sign area. perimeter fence. positions.
2. Planning
[An Exceptional [Exceeding the [In line with [In Need of CONFORMANCE
Standard] Norm] OSHE Improvement] [Unsatisfactory]
10 Points 8 Points Procedures] 0 Points -10 Points
6 Points

GSAF 06
All reviews Reviewed more Reviewed Not reviewed Construction Phase

2.1 briefed to staff on frequently than monthly and regularly or Health and Safety
Construction site and recorded procedures up to date. All only going Plan for stations
Phase Health (i.e. tool box talk). dictate, i.e. prior sections through the and Tunnels not
and Safety Plan Plan updates to phase changes reviewed. motions (i.e. no reviewed.
available on site or weekly. Evidence of record of
changes made. appropriate
Employer changes)
/Engineer Employer
Notified /Engineer
not notified
Notice of no
objection not
received
Hazard & Risk
2.2 Risk Log Procedure in Company Hazard & Hazard Log & Hazard Log & Risk
Register & place for review Procedures Risk Log Risk Register Register not in
Hazard Log and change Key referenced within Schedule of not available place or
Task Schedule. Hazard & Risk Key Tasks on site. tasks/hazards
Employer Log. Procedures completed Notice of no substantially
available on site with dates objection not missing from
/Engineer required, RA’s received hazard/risk logs.
Notified of and MS on
Updates to Hazard site.
& Risk Logs.
Updates available
on site
2.3 Risk Review of RA/MS RA/MS Available Completed as RA/MS on site RA/MS not
Assessment & carried out on site. Schedule per Hazard but not suitable completed. No
Method following near of operative Log & Risk and sufficient Design Risk
Statements miss or briefings Register. for task. Notice Assessment
Completed incident/accident. identified. Suitable and of no objection
Review evidence sufficient for not obtained
provided to ER tasks. Notice from ER.
of no
objection
received from
ER
2.4 Risk Follow up Record of all Task Briefings Only the No briefings of RA
Assessment & briefings, recorded briefings carried for all occasional or MS carried out.
Method to show updates maintained. Risk RA/MA
Statement and change Signed proof of Assessments briefing carried
Briefings reviews. attendance and Method out. Task briefing not
Employer maintained. Statements. conducted
Task briefing
/Engineer not conducted
Notified of
change. Notice of no
objection not
received
2.5 Risk Briefing records RA/MS available Works carried Operatives not Provision as
Assessments & signed by on site. out as per the briefed on determined in the
Method operatives and RA/MS. contents of the RA/MS not
Statement available on site Operative trained RA/MS. available on site
Implementation and able to Designated Change in
explain supervisor methodology No supervision
Assessment. available not notified to
Employer Not following the
RA/MS safe system
/Engineer.
GSAF 06
Notice of no of work
objection not methodology.
received
List/ Names and Procedure HSE H & S personal
2.6 positions of key available on professional deployed at site Incomplete or not
Occupational competent persons authority given to provided such are professional up to date (i.e. no
Health and provided displayed OHS&E Personal facilities, qualified showing
Safety at point of work to STOP any equipment and including sub- management
Organisation and in other unsafe act and other Contractor up changes). No public
Chart locations i.e. Rest condition. facilities. Sub- to date liaison officer .No
Areas contractor All sections Labour Welfare
work completed officer
monitored by displayed in
Main prominent
contractor position
both day and Notice of no
night shift etc. objection not
A qualified received from
Doctor and Employer
nurse and
Assistant /Engineer
Nurse
deployed at
each work site
2.7 Manual Comprehensive Comprehensive Included in RA & controls No risk assessments

Handling controls specific risk task risk needs
Assessment designated. Daily assessments assessment. enhancement.
monitoring Where Control
recorded. Tool Briefings possible measures poor.
box talks carried recorded. mechanical Reliance placed
out, information aids are used on manual
posters displayed. handling rather
Briefings than
recorded. mechanical
Notice of no
objection not
received from
Employer
/Engineer
2.8 Manual Tool box talks. Additional Completed Some None.
Handling Guidance training, records with all staff completed poor
Training documents maintained. as per in content.
displayed at Guidance induction.
workface. documents Training being
displayed. put into
practice
Records
maintained.
Safe Operational Safe operating SOP reviewed Some of No safe operating
2.9 Control Procedure procedure and updated activity SOP procedure as per
Safe available for all displayed and file regularly. completed ER OHS&E
Operational activity available and prepared jointly contract
Control explained in the Training by the site team requirement of
Procedure local language to provided to and safety team CMRL OHS&E
the workers workmen to and available. Requirements.
identify the
unsafe act and Notice of no
unsafe objection not
condition received from

GSAF 06
Employer
/Engineer
2.10 OHS&E OH&S OH&S MSP reviewed Some of No OH&S

Management Management Management and updated activity MSP Management
System System Procedure system procedure regularly. completed system procedure.
Procedure available for all file available and prepared jointly
activity are per explained in the Training by the site team
Table 3 of staff provided to and safety team
OHS&E COC workmen to and available.
identify the
unsafe act and Notice of no
unsafe objection not
condition received from
Employer
/Engineer
All reviews Reviewed more Reviewed Not reviewed Emergency
2.11 Emergency briefed to staff on frequently than monthly and regularly or Preparedness and
Preparedness site and recorded procedures up to date. All only going Response Plan for
and Response (i.e. tool box talk). dictate, i.e. prior sections through the stations and
plan Plan updates to phase changes reviewed. motions (i.e. no Tunnels not
available on site or weekly. Evidence of record of reviewed.
Employer changes)
/Engineer Employer
Notified /Engineer
not notified
Notice of no
objection not
received from
Employer
/Engineer
Copy of No project International Appointed the No process of
2.12 certification specific certification accrediting certification. No
International displayed in site certification Audit body for appointment of
Certifications areas. Review conducted obtaining the accrediting body for
dates set, certification obtaining the
completed. and No audit certification
conducted.
Employer
/Engineer
not notified
Notice of no
objection not
received from
Employer
/Engineer
2.13 Additional Records of all No training Training No Training
Training Training Training conducted for Implementation Implementation
Implementation conducted and conducted Sub Plan .Notice of Plan. No
Plan Recorded including for all contractor’s no objection assessment done
sub contractor’s not received
and maintained from

GSAF 06
Employer
/Engineer
2.14 Fire Records of Reviewed prior to Plan Basic plan, not Not established
Evacuation briefing all phase changes. established displayed.
Plan maintained and or Plan displayed in and displayed
Fire drills carried critical areas, at at exit points Not included in
out. all fire points. and at fire induction.
Workforce aware points.
and briefed. Included
within
induction.
Reviewed
with health
and Safety
Plan.
2.15 Fire Risk Reviewed prior to Reviewed prior to Risk Poor content, Not carried out
Assessment start of all hot all phase changes. assessment not
work or tasks Records of completed and communicated
using flammable briefing available. to operatives.
materials. Records maintained. Task risk
kept. assessments
consider fire
risk.
Operatives
briefed.
2.16 PPE Specified, Operatives briefed PPE identified PPE not No risk assessment.
Risk enforced, on correct use and in risk specified in risk
Assessment monitored and maintenance assessment assessment.
recorded (random requirements. including
daily checks). relevant
Use monitored by standard.
supervisor.
Being used as
per RA/MS
In test.
2.17 All reviews Reviewed more Reviewed Not reviewed

Lift Plan and briefed to staff on frequently than monthly and regularly or No lift Plan and
Risk site and recorded procedures up to date. All only going Risk Assessment
Assessment (i.e. tool box talk). dictate, i.e. prior sections through the
Plan updates to phase changes reviewed. motions (i.e. no
Employer changes)
/Engineer Employer
Notified /Engineer
not notified
Notice of no
objection not
received
2.18 All reviews Reviewed more Reviewed Not reviewed
Transportation briefed to staff on frequently than monthly and regularly or No Transportation
Plan and Risk site and recorded procedures up to date. All only going Plan and Risk
Assessment (i.e. tool box talk). dictate, i.e. prior sections through the Assessment
Plan updates to phase changes reviewed. motions (i.e. no
Employer changes)

GSAF 06
/Engineer Employer
Notified /Engineer
not notified
Notice of no
objection not
received
2.19Safety
inspection Daily, weekly and Up to date, shows Up to date Record of Not up to date, or
Reports monthly remedial action with good contractor’s site inspections missed.
inspections taken. clear Manager and
records information. supervisory
maintained. Well Weekly
Including documented inspection
Subcontractors and dates of including
complete remedial subcontractor’s
inspection reports. action activity carried
required, as/ out
when and
submitted to
Project
Manager
2.20 Designer’s Detailed Participation of Hierarchy of designers not
Role in safety supplementary designer in risk control is provided OSHE designers were not
information about monthly Safety indicated by risk at the communicated
SHE risk of the committee the designer drawing itself. about their role as
design given by meeting per Conditions of
designer Contract on OSHE
2.21 ID card OSHE hand book All worker Authority No ID card as No ID card issued
and First Day issued to all undergone signed all ID per standard to all persons
at work personnel orientation cards
training
A backup system The storage All camera No facility The Contractor not
2.22 CCTV shall be system should recordings viewing of live implement a
maintained to allow retrieval of shall have and recorded surveillance CCTV
protect against data camera id and images system
server or storage instantaneously location/area
failure. of recording
Emergency Fire plan Drills No drills Copies of the
2.23 Mock
drills drills shall be carried out emergency
conducted prepared at least procedures and
with the approved by every the
involvement the Engineer month Contractor's
of State Govt Re Mock rescue
rescue team drills should organisation
where be held on a (Not reviewed
necessary regular basis by the
to ensure the Engineer)
effectiveness
of the
arrangements.
The The The Not The Contractor
2.24
Evaluation, Employer Employer Employer conducted not included
selection and /Engineer /Engineer /Engineer pre-job legislative and
control of participated participated may meetings to site specific
Subcontractor
in pre-job in selection participate address job OH&S
meeting process in pre- OH&S requirements
GSAF 06
reviewing the tender expectation in tender

OH&S meetings before packages for
performances, awarding their sub-
etc. them. contractor
selection
3. Explosive Handling and Blasting

6 Points

GSAF 06
3.1 All means of Reviewed more Reviewed Not reviewed No audible signal
Transport and entry guarded frequently than monthly and up regularly or only sounded before
handling against entry procedures to date. All going through firing activity
blasting area dictate, i.e. prior sections the motions (i.e.
to phase changes reviewed. no record of No shot fires
Follow up or weekly. Evidence of appropriate certificate
briefings, changes made. changes) recognised by
recorded to Record of all Employer Employer government
show updates briefings department
and change maintained. /Engineer /Engineer not
reviews. Signed proof of Notified notified No blasting
attendance Notice of no Management Plan
Employer Task Briefings objection not
maintained
/Engineer carried for all received Provision as
Notified of Explosives, Risk determined in the
change. blasting agents Assessments and Only the RA/MS not
or detonators Method occasional available on site
transported in Statements. RA/MA briefing
securely covered carried out. No supervision
cases or There is plan
container that showing the Task briefing not Not following the
provide safety. type of conducted RA/MS safe system
explosive to use of work
at the charging Notice of no methodology
area objection not
received No blast board
Separate showing firing
containers No proper times displayed in a
provided for warning signs on prominent location
transporting the vehicle
explosives , transporting the
detonators or explosives
blasting , fuses
3.2 Magazine Danger Earth strips SOP for the No records of No fire extinguisher
explosives , no fitted to each disposal of old explosive in and in place
smoking , no magazine or damaged out available
naked flames explosives No appointed
signs in place Initiators and The magazine person in charge of
explosives compound free the Magazine
Magazine doors stored separately from rubbish
securely locked No competent
person for handling
of explosives
4. Welfare
6 Points
4.1 Canteen Exceptional Clean and tidy

standards (i.e. with lighting,

GSAF 06
using existing Cleaned daily or adequate Untidy/grubby None or dirty

facilities) with more frequently benches/ tables, or cleaned by inadequate
additional as necessary. facility for site labourer facilities.
facilities heating food, infrequently.
available (i.e. supply cups/ Materials stored in
drinks drinking water. Overfull waste canteen/eating area.
dispensers bins. No facility for
cooked food heating food.
etc) Waste food left
lying
No clean canteen ,
floor is dust ,No
loss and no gain
policy not displayed
No adequate rest
room to all workers
No illuminated and
ventilated
No free from
Mosquito and
biological
agent
No fan and seating

arrangements
provided for
workmen
adequately
4.2 Toilets Exceptional Exceptionally Clean and tidy Untidy/grubby. None or dirty,
/Urinals standards (i.e. clean and with running Small wash hand inadequate facilities
using existing towels water, soap, basins (not able i.e. too many
facilities) with provided. Soap, flushable toilets, to fit forearms person per available
additional barrier cream towels and inside) water closets. No
facilities such as etc provided. facilities for washbasins.
showers, where ladies where in
a risk attendance. No access to toilet
assessment of within 300m from
site activities worksite
warrants their
provisions. Toilet not cleaned
properly and
records not
maintained
No drainage system
No enough no’s of
toilets available
4.3 Drinking Easy accessible Six meters of Drinking Insufficient No Drinking Water
Water location to away from marked in local arrangement are
worker .Tank washing place , language and made Quality of drinking
cleaned and urinal or latrine water calibrated is not good and not
well maintained and displayed tested as per
IS 10500
No laboratory test
records

GSAF 06
Not 6m away from

toilets and urinals
No access within
200m from
worksite
4.4 Exceptional Cleaned daily or Clean and tidy None or dirty

Designated site standards (i.e. more frequently with lighting, Untidy/grubby inadequate
Eating area using existing as necessary. adequate or cleaned by facilities.
facilities) with benches/ tables, site labourer
additional facility for infrequently. Materials stored in
facilities heating food, eating area. No
available (i.e. supply cups/ Overfull waste facility for heating
drinks drinking water. bins. food.
dispensers Waste food left
cooked food lying
etc)
No clean, floor is
dust, No loss and
no gain policy not
displayed
No adequate rest
room to all workers
No illuminated and
ventilated
No free from
Mosquito and
biological
agent
No fan and seating

arrangements
provided for
workmen
adequately
Neat , clean and Adequate for all properly Not free from No Cooking,
hygiene illuminated and mosquito and bathing, washing
4.5 ventilated biological agent and lavatory
Labour facilities and
Accommodation Labour Colony
Layout not
approved by the ER
5. House Keeping
[An [Exceeding the [In line with [In Need of CONFORMANCE
10 Points 6 Points
5.1 5S House Outside the site Good standard First impression The method The Contractor
Keeping perimeter and of housekeeping on arrival to site
inside site is evident on all of good not based not implement
standard of parts of the site housekeeping/ on a a 5S
GSAF 06
housekeeping (internal and storage. No Japanese housekeeping

excellent. external) wrapping/bags
left lying. quality method
management approved by
concept the Employer
based on /Engineer
cyclical
methodology
5.2 Records of No waste All waste debris Waste/debris No attempt of
Housekeeping daily materials left in is removed from moved to housekeeping
Squad inspection/ work area at the work areas and areas/stored in control. Loose
monitoring end of the day. left clean and one area for materials causing
from site Regular tidy. removal, trip and fire hazards
designated inspections. however it in areas.
persons are Job allocation remains a hazard.
available and Periodicity of and time No Member list No Housekeeping
actioned. housekeeping allocation plan
5.3 Surplus De-nailed Timbers to be Timber waiting Timbers left with

De-nailing timbers timbers stacked nailed de-nailing not protruding nails in
skipped or tidily. All nails segregated. segregated. open areas and on
transferred for cleared away to Evidence of access routes.
use elsewhere. skips. poorly
maintained
pallets, etc
5.4 Daily Regular Materials Poorly stacked Material storage is
Storage monitoring inspection. Good returned to materials and uncontrolled &
recorded. Very clear access. storage areas, stored in wrong untidy, unstable.
good standard Stable accessible dedicated lay- position.
of storage is lay-down areas. down area, Material storage
evident. applicable Safe movement blocking site
signage of operatives not access.
displayed. possible. Materials stored in
public area.
6. Fire Precautions
6 Points
Daily checks
recorded. Names Fire plan Appropriates Fire point not No extinguishers in
6.1 of Fire Wardens displayed in site No’s of clearly place No Fire
Site Offices identified at each offices/canteens. extinguishers at identified. Fire Warden checks
fire point. Fire Fire point boxes marked fire extinguishers carried out.
plan at each fire in place. points. Regular missing or out of
point. date. Fire
GSAF 06
fire checks Warden checks

carried out. incomplete.
6.2 Daily checks Fire Plan Minimum of 2 Fire points not No extinguishers in
Work Place recorded. Names displayed at exits extinguishers clearly place No Fire
Extinguishers of Fire Wardens and at fire points. stored in red box identified. Fire Warden checks
identified at each at marked fire extinguishers carried out.
fire point. Fire alarms points. Regular missing or out of
adequate and free fire checks date. Fire No proper
Records of fire from obstruction carried out. Warden checks maintenance as per
mock drill at site incomplete. IS standards
Records of fires Insufficient No fire points

incidents records of located in all
reported recharge /refill locations of work,
investigated and frequency fire plan available
corrective inspection and and displayed at
actions taken maintenance site.
schedule of fire
extinguisher No records of
awareness training
on fire fighting
6.3 Subcontractors Records of Permits issued Hot Work No Hot Work

Hot Work provide records monitoring Hot for all activities Permits issued Permit issued for
Permits of monitoring Work Permits including Sub- with incomplete hot work activities.
Hot Work maintained by contractors. All sections. No Housekeeping poor
Permits issued Site Manager. Hot Work monitoring of where hot works
daily. Permits signed compliance of are ongoing.
off and with end Hot Work
Warden records of shift Permit carried
inspections inspections. Fire out.
daily. extinguishers are
in place and
housekeeping is
good.
6.4 Excellent Regular Housekeeping is Housekeeping Housekeeping is

Conditions on housekeeping. inspection and good with could be poor and presents a
Site Records of daily monitoring of site effective control improved. fire hazard. Poor
monitoring conditions. of combustibles, compliance from
available. Proof paint, solvents, subcontractors.
of monitoring is etc.
provided by the
subcontractor.

GSAF 06
6.5 Storage of
Flammables Proof of daily Records of Adequate Storage facilities Containers /
monitoring, monitoring by storage uncontrolled of cylinders and drums
records of Fire Warden. All facilities, left open. Poor (full and empty)
monitoring by material returned materials signage. No lying around site.
subcontractor to store at the end controlled. extinguishers Excessive
of the day or after Adequate near point of quantities on site.
Operator use. signage. use. No suitable storage
provided with Extinguishers facilities.
cutting goggle , Empty and full near to point of No ventilation. No job based
body apron and cylinder stored use. Good training
other appropriate separately stored ventilation No record of
PPE’s in secured upright specific permit No Non return
position and Record of hose to work valves fitted on gas
fastened with lead test cutting torch
chain Availability of
Hose clip and Fire extinguisher No records of
Gas cylinder clamp provided and fire watcher checking cylinder
stored in a well expiry date and
ventilated Calibrated cylinders discarded
location double pressure if found not valid
gauges fitted
Adequate facility and operable No availability of
available for Wheel barrow for
storage of Flash back transportation of
cylinder with arresters fitted cylinders from store
adequate safety on cylinder to work site
measures and valve
availability of
MSDS SOP is available
for loading and
unloading of
filled and empty
cylinder at site
6.6 Daily recorded

Requirements inspection. Fire Regular Maintained clear No Fire Major obstructions.
drills carried out inspection carried and well signed. excavation plan No signage, No
at planned out with evidence Included in emergency lighting.
intervals and of inspection. induction.
recorded. No Emergency plan
Review of drills Nearest fire Mock drill
recorded. brigade phone completed
Reporting of fire numbers
accident to displayed
Employer
6.7 Fire Adequate no of Intimation of ER approved the Non No
Fighting trained persons vacancy to ER firefighting Professionally Firefighting
Personal personal qualified personnel available
at site
6.8 Diesel All Diesel fuel Transported They stored Drums of Diesel drums
/Petrol Storage storage tanks
bunded vertically on end with diesel shall on site not in
chained on a the lid/cap rolled along good
trolley uppermost the ground. condition.
Plastic barrel
used for the
transport of
Diesel/petrol
GSAF 06
Stored more
than legal
requirements
6.9 Relevant Daily recorded Regular Fully and clearly Some displayed. None displayed.
statutory signs inspection. inspections displayed.
carried out. Included in
Reviewed with induction.
the Fire Plan.

GSAF 06
7. PPE
6 Points
7.1 Induction Spares available All persons are An occasional Numerous

Helmets records confirm for short term wearing safety operative is not operatives,
that a visitors. Risk helmets (or other wearing a safety subcontractors and
satisfactory assessment form of helmet. management are not
helmet or other available to approved wearing safety
headwear is support other headwear if Helmet not to IS helmets. No safety
brought to site. headwear. applicable) or BS standard Helmet Colour with
Records logo as per CMRL
maintained for Inadequate OHS&E
site issue supply of safety Requirements.
helmet for use of
staff , workers
and authorised
visitor’s to the
site
An occasional
7.2 Induction All visitors wear All persons are operative Numerous
Footwear records confirm safety footwear wearing including operatives,
that satisfactory unless risk satisfactory subcontractors is subcontractors &
safety footwear assessment safety footwear. not wearing management are not
is brought to site. identifies safe to safety footwear. wearing safety
do so. Inadequate footwear.
supply of safety
shoe for use of
staff , workers
and authorised
visitor’s to the
site
Induction
7.3 records confirm Spares available All persons are An occasional Numerous
Hi Viz that satisfactory for short term wearing Hi-vis operative is not operatives,
Hi-viz clothing visitors. Issued clothing to BS wearing Hi-viz subcontractors and
is brought to site. on site when not EN Standard. clothing. management are not
Records provided or wearing Hi-viz
maintained for found to be clothing.
site visitors. unsuitable.
7.4 Available for Good condition Suitable type Not as per Not enforced to use
issue standard
Eye Protection
Hearing issue standard
Protection
Respiratory issue standard
Protection
7.7 Available for Good condition Correct type for Not as per Not enforced to use
Protective issue operation standard
Gloves
7.8 Available for Warning signs Good condition Not as per Not enforced to use
Fall protection issue displayed standard
7.9 Available for Colour and In good 10% PPEs for Not enforced to use
issue company logo condition visitors not
available in site
office

GSAF 06
PPE for
Visitors
7.10 External Agency Spares available All persons are An occasional Work at height PPE
Safety Belt training wearing Full workers working not inspected or
conducted and body safety at height is not tested e.g as per IS
records harness with wearing Full standards
maintained double lanyard body safety
to BS /IS/EN harness with No fall arrest
Standard. double lanyard equipment (Safety
harness fall arrestor
)Checked by
competent person

GSAF 06
8. COSHH (Control of Substance Hazardous to Health)

6 Points
8.1 Manufacturers Good clear filing All substances Poorly Not included with
File hazard data system available identified in the maintained file. Hazard Log & Risk
maintenance (MSDS) from & corresponds to Hazard Log & Incomplete or Register. File has
Assessment supplier included Hazard & Risk Risk register. difficult to not been developed
Briefings in the Register. Name File maintained identify adequately. No
assessment. of competent Suitable substances, etc. assessments carried
Co-ordinator assessment Occasional out.
Proof that displayed or in carried out. assessment
operatives fully named in Competent carried out. No assessment
understand induction. person briefings carried
briefing content designated as Poorly kept or out.
(i.e. signed Records coordinator. incomplete
assessment for obtained from records of
questionnaire) subcontractor of Good clear briefings, unable
assessment records available to read names,
briefings. of briefings etc.
carried out to
operatives.
Persons briefed
identified.

GSAF 06
9. Plant (X 2)
6 Points
9.1 Every item of Plans available Suitable No records of Poorly maintained
Planning plant is subject for siting of equipment for equipment equipment on site.
to planned plant including the task as per issued to
maintenance and ground RA/MS. operatives. Poor condition of
inspection. All conditions i.e. Competent equipment & plant.
such test & underground operator No checks on
inspections are services, etc. Plant certificate condition of
recorded. displayed. equipment.
Daily user Weekly
inspection Sheet Inspection Sheet No maintenance
signed by signed by records
competent competent
person. person.
9.2 Lifting
Appliances and Chart showing Up to date and Up to date. All Incomplete No records, or
Lifting Gear test expiry or schedule of plant weekly records or some difficult to find
Register other scheme for competent checklists fully items expired/ paperwork.
displaying status authorised users completed out of date.
of items. displayed. within inspection
schedule.
Daily
monitoring/ pre
use records.
9.3 Plant and
machinery Maintenance Up to date, Fully complete Not fully None existing, no
inspection and/or hire status shows remedial including complete (i.e. risk assessments.
records on site, action taken, subcontractor subcontractor
equipment all some equipment equipment. Use records missing. No pre inspection
risk assessed. specific risk considered in records of plant and
assessments. task risk machinery
assessments.
Vehicle drivers Vehicle with Vehicles leaving Few of medical Vehicle drivers not
9.4Vehicle having valid and reverse horn site carrying load fitness done for having valid and
Control current licence under control of covered at site operators current licence and
and all legal banksman with securely Vehicles are No legal documents
documents sheet before overloaded No wheels washed
available at site leaving the site Insufficient fire bay
wheels washed extinguisher and
bay in All drivers over First aid box No construction
operational and 21. Complete equipment
maintained records available Few construction operations
of trained equipment operators and
operators. operations banksman are
Competence operators and trained
checks done e.g. banksman are
by assessment trained
9.5Piling and Every item of Plans available Suitable No emergency Operators using
Grab plant is subject for siting of equipment for procedure for plant without 3RD
operations to planned plant including the task as per collapse of piles party test and
maintenance and ground RA/MS. No Employer thorough
inspection. All conditions i.e. Competent examination
such test & underground operator /Engineer certificate or
inspections are services, etc. Plant certificate approval for the certificate expired.
recorded. displayed. bentonite slurry
and its
GSAF 06
Daily user Weekly subsequent Poorly maintained

inspection Sheet Inspection Sheet disposal equipment on site.
signed by signed by
competent competent No banks man Poor condition of
person person. equipment & plant.
Excavated piles
etc left
unattended Piling rigs not
tested as per ER
No records of CMRL OHS&E
equipment Requirements.
issued to
operatives. Piling rig used for
lifting other than
No checks on piling operation
condition of
equipment. Specific method
statement for piling
No maintenance and No No not
records received from
Employer
/Engineer
9.6 Records show Records collated All drivers over Incompatible Operators driving
Competent the operators into easy read 21. Complete cross-referencing plant without third
Personnel certification and sections i.e. records available of operator training certificate.
date of expiry. dumper of trained certification with Drivers not aware
operators, operators. on site records. of hazards.
MEWP Competence Associated with
operators, crane checks done e.g. No records equipment.
operators, etc. by assessment available. No lifting
Supervisor , No
Few of lifting slinger , No riggers
operations are trained
operators and
lifting
Supervisor ,
slinger , riggers
are trained
9.7 Banks man in Barriers erected Working No segregation No banks man in
On Site Traffic attendance at all Specific access equipment is of working plant attendance during
Management times with for pedestrians segregated with Free access to plant movements or
working plant. marked. crush zone crush zone. operations,
Banksman identified. All Vehicles
controls Continual movements reversing with
pedestrian monitoring in under control of no Banksman
movements place Banksman
9.8 Inspection Operatives All guards are in Guards loosely Guards missing
Guarding records of each report faults and place as per the fitted or from machinery,
Arrangements particular piece damage to site manufacturer’s makeshift guards visible signs of
of plant or management information i.e. with incorrect tampering of
equipment are who take action. no in running fittings. guards, untrained
available in site nips, guards in operatives. Plant
records. Written evidence place on bench Working / Risk poorly maintained.
required saws, piling, soil areas not
investigation barriered off
machinery etc. around
machinery.
9.9
Vehicle Checks Management Daily pre-use Vehicle registers Registers not Vehicle registers
monitor checks completed completed not maintained.
weekly.

GSAF 06
checklists/ act on completed by weekly (hit and

reports. operators. miss)
9.10
Date of File available Test and 3 monthly test Operators using
Lifting certification with sections i.e. thorough certificates not plant without 3RD
Operation expiry displayed dumpers, examination available for party test and
(Lifting on chart within MEWP, cranes, certificates are cranes to thorough
Appliances and site office. etc. All sections available on site BS7121. examination
Lifting of plant All relevant certificate or
Equipment) checklists plant checklists Only load test certificate expired.
completed and fully completed undertaken for
faults rectified. cranes. Cranes not tested as
per CMRL OHS&E
No instruction Requirements.
Manual
Crane age more
No calibration than the required
certificate for IS standards and No
monitoring special assessment
equipment as per test conducted
the manufacture No ASLI,No Load
radius indicator, No
No checks of motion limit
lifting equipment devices, No over
on site by Crane load cut-off device
Co-ordinator. ,No level Indicator ,
Faults recorded Cut off device , No
but not actioned anemometer , No
within a machine guarding ,
reasonable time No safe working
load charts .
9.11 Team briefings List of Inspections show No Plant operators

Safe Use carried out with authorised that plant is communication driving too fast.
management and drivers and being used between teams Seat belts not used
operators as a operators kept up safely. Rules are doing different by operator. No
proactive role to date. Record being observed work within stop blocks near
rather than of equipment by operators. same area. excavations.
reactive. Record issued to and Reckless operation,
of briefings, used by Daily checks not i.e. digging in close
meetings, etc. authorised showing faults. proximity to
persons. Banksman not workers.
present.
9.12 Date of expiry File with All lifting gear No checks of No lifting gear
Lifting Gear displayed of sections related thoroughly lifting gear on thoroughly
lifting equipment to lifting gear. examined every site by lifting examined every six
examination on six months supervisor and months (certificate).
chart. Storage facilities (certificate). All plant in charge. Badly worn slings
available for equipment on site. Badly
Records of equipment stamped with ID Faults recorded stretched chains on
inspections Number and or but not actioned site, etc. Wrong
available Weekly colour coded within a lifting gear used for
inspections reasonable time lifting.
completed Daily user check
9.13 Assessed Suitably Specified in risk Some specified, None specified

Suitability and regularly, documented, assessment and suitability not applicable standard
Specific PPE monitored, topic specified in utilised on site. assessed for missing.
for tools box assessment. environment.
talks.
Reliance on PPE
rather than

GSAF 06
permanent
protection e.g.
edge protection
Subcontractors Records of Permits issued Lifting Permit Lifting Permit

9.14 Permits provide records monitoring for all activities Permits issued issued for all lifting
of monitoring Lifting Permit including Sub- with incomplete work activities.
Lifting Permit maintained by contractors. All sections. No
issued daily. plant Manager. Lifting Permit monitoring of
Permits signed compliance of
Lifting off and with end Lifting Permit
supervisor, plant of shift carried out.
Manager records inspections.
inspections
daily.
9.15 Daily inspections No unauthorized All operators No Drainage No Plan of layout
Batching Plant / recorded riding on plant medically system
and Casting fit/over 18 No Barrication
Yard No Welfare
amenities No Plan for vehicle
moving area
9.16 maintained in Audible warning Fitness No Load chart of No Automatic safe
Safety Devices accordance with devices fitted certificate the vehicle load indicator
manufacturer’s
instructions Over load Limit Manufacturer No Calibration No Anemometer
switch installed details for ASLI and
Anemometer No Proxy sensor for
Reverse horn Marking of safe Automatic safe the Gantry
working load load indicator
Outrigger provided or not No digital load
extension alarm Overload alarm in working indicator
condition
Over hoist alarm
Separate main Electrode holder No checks of Welding machine

9.17 Welding Operator power switch , properly insulted welding leads & not in good order
Machine provided with ground and facility return cable free No job based
face shield, body connection and provided for from defect operator training
apron and other protection shed storage of
appropriate for weather welding No record of No Double earthing
PPE’’s electrode buds specific permit to welding machine
Presence of to work
voltmeter and No separate earth
ammeter on the Availability of connection from
machine and Fire extinguisher work piece to
functional and fire watcher transformer and
supply to welding
machine
From rated
RCCB/ELCB
Corrective Audit Report Conducted at Not Plant Not Performed once
9.18 Monthly actions taken will be sent to least 7 days prior Manager in a month
Plant and ER to Monthly accompanied
Equipment OSHE this audit
Safety Audit Committee
meeting
10 Excavations (X2)
[An Exceptional [Exceeding the [In Need of CONFORMANC
Standard] Norm] Improvement] E

GSAF 06
10 Points 8 Points [In line with 0 Points [Unsatisfactory]

OSHE -10 Points
Procedures]
6 Points
Works ready to
10.1 Planning Training/briefing Inspection All necessary start and not all Works are ready to
of safe system of requirements equipment on site equipment is on commence
work carried out specified with before works site/in place. however the
before works necessary commence. RA/MS is not on
commence. supervision Poor access into site and not been
appointed to RA/MS in place the excavation. reviewed by ER.
Records ensure & reviewed. Using
maintained of compliance with makeshift Surveys not carried
such briefings safe system of Team briefings ladders or no out
work, e.g. carried out & ladder.
inspection recorded. No permit to
required every dig in place
shift. (2 per day) where new
excavation
planned
10.2Excavations
Register Daily monitoring Up to date and Up to date and Up to date and Not up to date, or
records per shift. records in place record of defects signed but with shift inspections
to demonstrate and corrective outstanding missed.
preventative actions actions.
actions. maintained.
10.3 Information from Plans developed Correct cable (and Cable No cable avoidance
Provision of service providers to ensure certificate) avoidance tool tool on site.
Service Locators available to comprehensive avoidance tool on available, no Untrained operators
identify line of coverage of area. site. Operators calibration using equipment.
service. trained in its use. certificate on
file.
10.4 Task training Operatives Existing Plans Permit to work Safe system of
Underground carried out briefed. All available on site. not in place. work RA/MS not
Service before works experienced Permit to work in Supervisors / available or not
identification commence operative’s use. Operatives not completed. Not
(proactive) and supervision. complying with submitted to ER for
recorded. Safe system of safe system of notice of no
work followed work MS/RA objection
10.5 Regularly Sketch included Physical barrier in Inadequate No barriers in

Edge Protection monitored and in method place/ used and edge protection place.
recorded. statement. suitable. e.g. only soft
when fixed is
required
10.6 Regularly Sketch included In place as per Incorrect Works not carried
Shoring monitored and in Method approved Risk support out in accordance
recorded. Statement. Assessments or equipment on with the approved
Maintenance/ Operatives Method site to carry out safe system.
inspection briefed in safe Statements the tasks or
records available. system of work. including good equipment not No safe angle of
access. on site. incline sufficient to
prevent collapse
10.7 Regularly Operatives Trained Operatives not Works not carried
Competent monitored and briefed in system operatives Works familiar with out in according
Workface recorded. Re- of work. Records carried out in the approved with the approved
briefing of of briefing and accordance with MS/RA. safe system.
changes. training available. the MS/RA
10.8 Safe Working Design No Temporary

Procedures assessment work procedure
GSAF 06
Temporary established and Temp works Design findings not

Work communicated to coordinator Assessment in incorporated No design
Assessment supervising staff. designated place. RA/MS into RA/MS assessment
Records available incorporates
recommendations
of design
assessment
10.9 Recorded RA/MS reviewed RA/MS in place Verbal No RA/MS

Safe Working inspections as per as work and followed. procedure only.
Procedure schedule. progresses,
records Unsafe acts &
maintained. conditions on
site.
10.10
Excavation Records Permits contents Permit in place Permit in place None in place,
Work Permit maintained, communicated to issued for not fully unsafe
regular operative, sign off relevant completed and acts/conditions.
monitoring and procedure in operatives, fully signed off.
recorded place. completed. No specific
inspection of permit to work
permits
10.11 Corrective Audit Report will Conducted at Not Station Not Performed
actions taken be sent to ER least 7 days prior Manager once in a month
Monthly to Monthly accompanied
Excavation OSHE this audit
Safety Audit Committee
meeting
11. Electrics(*x2)
CONFORMANCE

GSAF 06
[An Exceptional [Exceeding the [In line with [In Need of [Unsatisfactory]
Standard] Norm] OSHE Improvement] -10 Points
10 Points 8 Points Procedures] 0 Points
6 Points
11.1 Site Electrical Maintenance Designed, Poor condition, Distribution not to

Power single line layout schedule installed frayed. No standard IP65 IEEE
Assessment drawing available and commissioned, record of 17TH Edition.
available. followed to tested, inspections.
monitor maintained by No double earthing
All faults condition of competent Loose cables on
detected & electrical person. the ground. No inspection Tag
actions taken distribution on
site. No ER approval No earth
Name and for execution of measurement
contact person the job register
posted on main
distribution No Load
board calculation for
power requirement
Warning signs in Proper earth ELCB or RCCB/ All cables enter No IP 65

11.2 appropriate connection and GFCI fitted box without
Condition of position earth pit glands
site distribution
panel
11.3 Monitor All works RA/MS Overhead lines Not included within
Overhead Lines compliance carried out to completed identified Hazard Risk Logs
Identified daily. Code of Practice. agreed by local however poor Not goal-posted.
electricity maintenance of No contract made
Maintenance authority. goalposts, with local
schedule to Signs and barriers, etc. electricity
monitor defects barriers in company. Machines
in control prominent No briefings to running under
measures. position. plant operators unidentified
Briefings to overhead lines.
plant operators
All portable
11.4 Good clear use Rechargeable electrical Incomplete No records.
Storage and Use of registers. tools used appliance register.
of Power Tools Schedule of preferentially. permanently No procedures in
inspection numbers No inspection place for issue and
periods Authorised users including sub- records of daily, authorised use.
displayed. identified. contractor weekly and
Evidence of Register of tools monthly or Poor inspection reg
equipment being Manufacturer on site. Secure inspection of condition of tools.
in good order, data used to storage. power tools
clearly assist in training. Inspection of carried out by
identifiable and competent Non-qualified
being used Equipment in person & person
correctly by good condition. Authorised issue
trained, and return.
authorised
person. Task Use of 110v
assessment (preferable).
sheets confirms
condition check Inspection,
before use. maintenance and
defect
withdrawal
schemes.
GSAF 06
Trained used,
VWF, noise and
PPE managed.
11.5 All equipment’s All cables fitted Colour coding of Are all plugs,
Plugs, Sockets All equipments connected with with IP 65 Plugs plugs and sockets and outlets
and Outlets free from defects plugs sockets IP 65 type
11.6
Competent Training records Competent Competent Untrained person Untrained persons
Persons on site of person identified person C licence carrying out carrying out
competent on site notice appointed for inspections. electrical tests.
persons. board. inspections and
tests etc.
Including Sub
contractor
activity
11.7 Records Permits contents Permit in place Permit in place None in place,
Work Permit maintained, communicated to issued for not fully unsafe
regular operative, sign relevant completed and acts/conditions.
monitoring and off procedure in operatives, fully signed off.
recorded place. completed.
inspection of
permits
11.8 Register Light fittings Periodical Insufficient Poor illumination
illumination available for installed & lay cleaning and illumination level
illumination and out plan ,pole replacement of level at site
regular update number light fittings
displayed and /lamps
sufficient Pole height
illumination maintained as
maintained at per legal
site requirements
Colour coding Correct storage Cable joints Cables lying on Not all cables free
11.9 when not in use made by IP 65 the ground / from damage
Cables connectors water
Single line & GFCI provided Employer’s No Name posted No Site electricity
Schematic Approval for on Main covered in the
11.10 diagram execution Distribution OSHE Plan
Work on site submitted Board
11.11 Earth resistance Earth pipe free Pouring 5 litre No Wet Not as per standard
Earth Pit in the limit from corrosion water per days condition
11.12 Corrective Audit Report Conducted at Not Electrical Not Performed once
Monthly actions taken will be sent to least 7 days prior Manager in a month
Electrical ER to Monthly accompanied
Safety Audit OSHE this audit
Committee
meeting
11.13
Electrical Daily monitoring Up to date and Up to date and Up to date and Not up to date, or
Register records per shift. records in place record of defects signed but with shift inspections
to demonstrate and corrective outstanding missed.
preventative actions actions.
actions. maintained.
11.14 Use of ‘Lock Work Permit Records of No maintenance Not maintenance
LOTO Out and Tag System maintenance properly maintained
Out’ (LOTO) kept
12. Work at Height (X2)
[An [Exceeding the [In line with OSHE [In Need of CONFORMANCE
Exceptional Norm] Procedures] Improvement] [Unsatisfactory]
Standard] 8 Points 6 Points 0 Points -10 Points
GSAF 06
10 Points
12.1 Evidence of Tower scaffolds, Suitably protected Stepladders or No procedure

Planning preplanning MEWP in use in working platform ladders are in available (with
carried out of place of (minimum 600mm use where notice) No RA
future high-risk stepladders/ladders fully boarded) has tower scaffolds showing hazards or
activities by and shown on RA. been provided. or MEWP risk of operatives
site Monitoring in place would be more falling.
management to ensure Scaffolders handover suitable.
team including compliance with certificate on site. Operatives working
subcontractors safe system of work. No monitoring without protection
before work for compliance in place.
commences. Risk assessments with safe
Access to justify use of system of No training records
ladders stepladders etc. work. on working at
controlled by height and use of
site safety harness
management.
Policy
displayed or
included in
CSHP.
12.2
Scaffolding Daily Up to date and Up to date and record Up to date and Not up to date
Register monitoring records in place to of defects and signed but with inspections missed.
records. demonstrate corrective actions outstanding
preventative actions. maintained. actions
12.3 Written record Ladders show ID Base is firm, level. Ladder secured Ladders too short,
Ladder of inspection, mark. Written Clear of excavations at only one ladders unsecured,
Access defects, etc. record on Set at 1-4, Lashed at point. Damaged ladders,
produced by inspection, defects, two stiles. Poor access to
subcontractors etc. Clear access onto Obstructions at ladder, Access onto
before work ladder and minimum base, Incorrect platform is poor
commences. Self-closing safety 1m above platform ladder tie used,
gate used on access landing Ladder set at No ladder register
platform. wrong angle.
12.4 Well Scaff-tag system in All components Scaffold No Handover

Scaffolding maintained place at prominent correct and in place. inspection not Certificate.
General scaffold locations and at all in date or not Operatives working
access points to the Inspections all in completed off incomplete
Red Scaff-tag scaffold. date with register platforms.
in use and completed. Scaffold not No competent
enforced by Inspections and protected from scaffolders.
supervisors handover completed Handover certificate vehicle strike Poor Standard of
Action taken, upon adaption. signed by competent erection; Bamboo
monitoring. person with working Supporting or wood in use,
load stated. concrete pump boards and rails
pipe-work missing, no access,
without not plumb, missing
vibration and bracing, damaged
load equipment in use or
assessment not to standard.
undertaken. Not erected to
design (where
No pre-load applicable)
check( where
applicable)
12.5 Pre-Use checks Register of Erected correctly Platforms used No RA carried out
Scaffold undertaken equipment but not showing hazards or
access daily and maintained. All inspections assembled risk of operatives
completed record of correctly such falling.
GSAF 06
Towers and inspection Scaff-tag in use inspection, defects, as missing

Platforms recorded etc. maintained. bracing. Erected by
Platforms used unqualified persons
wherever practicable Damaged
(in preference to equipment in Base to height
ladders) use width not correct
causing instability
No pre use
inspection. Operatives working
without edge
Operatives protection in place.
making
adaption when
not qualified
12.6 Written record Registers show All in place and Poorly recorded Areas of edge
Edge of inspection, records of secure, i.e. double register i.e. not protection
Protection defects inspections of guardrail in place. A showing defects missing.
and Toe- produced components i.e. main guard rail at or edge Operatives
boards weekly by checking for least 1 meter above protection working on
subcontractor defects. the edge , toe board missing, but no incomplete
and before work at least 200 mm high persons working platform. Toe-
commences. and intermediate on platforms. boards missing
guard rail no gap
more than 470 mm
12.7 Advanced Training records Scaffolds erected by Cross Untrained

Competent scaffolder is held for persons trained scaffolders. referencing of scaffolders erecting
Persons the supervisor erecting scaffolding scaffolders scaffold without
on site. under supervision Certification of all names do not trained supervisor
(trainees) training records on match with present. No training
site match scaffolder training records records available in
on site. in site records. site records.
12.8 Induction talks, Registers show Operatives Operatives Operatives using

Other tool box talks records of complying with the using the ladders or steps,
Precautions, and other inspections of approved Risk equipment when the RA states
Ladders, briefings with components i.e. Assessment/Method incorrectly, MEWPs will be
Stepladders, subcontract checking for defects. Statement for work at over reaching, used
MEWPs management height over-stretching.
on the safe No competency
system of work certificate of
prior to works MEWP & Scaffold
commencing. erection supervisor
12.9 Daily Full assessment, Assessment Assessment None completed.

Temporary monitoring controls completed. Controls completed not No pre-load check.
work recorded tool communicated, reasonable. Erected covering all the Not following
Assessment box talks. inspection records. as per design. Pre- issues. design
load check completed No ER Notice
Fully recorded
12.10 and monitored Fully recorded at Completed as per None recorded, None completed
Recorded at regular regular intervals. legal requirement and visual unsafe
Inspections intervals, topic OSHE Volume 1 & 2 inspection only acts/conditions.
for tool box not comply
talks. with volume 1
& 2.
12.11

GSAF 06
Work Permit Records Permits contents Permit in place Permit in place None in place,
maintained, communicated to issued for relevant not fully unsafe
regular operative, sign off operatives, fully completed and acts/conditions.
monitoring and procedure in place. completed. signed off.
recorded
inspection of
permits
12.12 Maintenance Testing Adequate number to Not Good Not approved type
Safety Net issue construction
Corrective Audit Report will be Conducted at least 7 Not station Not Performed once
12.13 actions taken sent to ER days prior to Manager in a month
Monthly Monthly OSHE accompanied
Safety Audit Committee meeting this audit
for working
at Height
13. Floor Openings

6 Points
13.1

GSAF 06
Planning Planned works Briefing with Suitable and Inadequate No Risk

include fixing of operatives on the sufficient risk Risk Assessment carried
manufacturers safe system of assessment and Assessment, out showing
cover in place work before method does not physical barriers or
when work is works commence. available with incorporate the risk of operatives
completed. Records Notice from controls as falling into hole.
Discussed in maintained ER. specified in the Design assessment
toolbox talks and design does not
inductions. Controls assessment incorporate falls
incorporate from height
design Inspections not
assessment carried out or
results recorded.
13.2 Daily monitoring Daily inspections Physical Guardrail in Pallets used as

Provision of recorded. carried out, protection has place but covers, ply sheeting
Protection recorded and been provided insufficient i.e. used as covers,
Sub-contractors action taken i.e. two only one pieces of ply used
supervision immediately guardrails, toe- guardrail and as covers, scaffold
management where deficiency boards, signs toeboard in boards provided but
include found. fixed hole place, poor unsecured, no
inspection in their cover and signage supports, openings
weekly report. Operatives barriers, covers displayed. Rail left open.
briefed on early are load does not take
reporting where bearing. weight of a fall
fault noticed
13.3 Safety signs Signs clearly Adequate Incomplete or No signs in place.

Relevant monitored daily visible and warning unclear signage
Signage and recorded. comprehensive. signage in place in place.
Changed as work Regularly before works
progresses. monitored until start.
opening
permanently
closed.
13.4 Work Records Permits contents Permit in place Permit in place None in place,
Permit maintained, communicated to issued for not fully unsafe
Procedure regular operative, sign relevant completed and acts/conditions.
monitoring and off procedure in operatives, signed off.
recorded place. fully
inspection of completed.
permits
14. Tunnelling operation (X2)

6 Points
14.1 Works planned Team briefing A detailed Little planning

Planning and sketch with all procedure and gone into
GSAF 06
displayed where members of site suitable and producing a safe No procedure in

works activity is management and sufficient Risk system of work, place including
in operation and subcontract Assessment has emergency actions.
access points, supervision on been carried out Equipment
clipped to the safe system inadequate for No Risk
permit to work. of work before Team briefings task. Assessment carried
work commence. carried out out showing
Proof of before works Detector tot hazards and risk to
understanding commence. calibrated operatives.
maintained. Permit to work.
Only few
Monthly inspection
inspection and carried out
weekly
inspection
carried out
14.2 Warning Proper control A chart listing The emergency Only few No Proper control
Signs, Notice of ingress and the names of services in the Notices to warn of ingress and
board and Tally egress of persons working event of an persons against egress of persons to
Board persons to and in the tunnel and underground fire unauthorised and from tunnel
from tunnel their location of or other entry displayed under construction
under work shall be emergency at points of entry in the worksite
construction in displayed at the identified and to the tunnel
the worksite main entrance to the name and No tally board
the tunnel and be contacts
tally board regularly displayed at site No Accurately
updated indicate the number
Accurately and location of
indicate the persons
number and underground at all
location of times
persons
underground at
all times
pre-employment Examinations in Clinical Few of staff of No pre-employment
14.3 Industrial health screening place not fully examinations by tunnelling pre- health screening
Health and done and completed and an occupational employment done and No
Welfare provision of signed off. health specialist health screening provision of cold
cold water for HAV done water drinking and
drinking and syndrome done No sub-contractor
sub-contractor records
records
No records of
checking employee
working under the
influence of
alcohol/drugs
No mosquito
breeding due to
water retain on site
and records of
fogging done at site
14.4 Subcontractors Back up monitor On site before Poorly Untrained operative

Gas detection and site on site. Records works maintained monitoring air
Equipment management of monitoring commence. Air condition of supply. Faulty
include carried out monitoring monitor. Unable equipment on site.
inspection in before works carried out every to read or poor Battery low, no
four hours by audible sound of

GSAF 06
their weekly commence and competent monitor. No equipment on site,

report. after. person. calibration. no monitoring.
Calibration Gas monitoring
certificate on displayed
site.
14.5 Subcontractor Site On site before Poorly No rescue

Self-Rescue and site management works maintained equipment on site
Equipment management include commence as condition of and works in
include inspection in per the safe rescue progress.
inspection in their daily system of work. equipment.
their weekly routine. Certificate on No Notices
tour. site. regarding the
Trained in their proper use of self
Rescue use. Records of Good Quality rescuers are posted
equipment, full such training required near the storage
breathing must be kept for &regular area
apparatus inspection by the maintenance
(SCBA), Employer
Maintained and All persons
readily available /Engineer underground
in an immediate
emergency. Notices access to a self-
regarding the rescuer
proper use of
self rescuers are
posted near the
storage area
14.6 Subcontractors Site supervisor Site supervisor Engineers, All or some

Training trained. Site trained. Rescue trained and managers and members of the
inductions, team available experienced top supervisors team untrained.
Specific man. untrained in No sub-contractor
Confined Space Visitors to confined space training
Training underground working.
conducted projects
before any conducted
person starts induction
work in tunnel training and
accompanied by
an experienced
member of the
project staff
when on site
14.7
Work Permit Records Permits contents Permit in place Permit in place None in place,
maintained, communicated issued for not fully unsafe
regular to operative, relevant completed and acts/conditions.
monitoring and sign off operatives, fully signed off.
recorded procedure in completed.
inspection of place.
permits
14.8 Quality of No Dry and wet-
Air Subcontractors Records of On site before Poorly bulb temperature
and site monitoring works maintained instrument at
management carried out commence. Air condition of Site.
include before works monitoring monitor. Unable
inspection in commence and carried out to read. No Not maintained a
their weekly after. before agreed calibration. record of the air
report. system of work quality, the
in place by location, date, time,
competent substances and
person. amount monitored.

GSAF 06
Calibration
certificate on
site.
14.9 Quality of Emergency The emergency Emergency Only limited No Emergency
illumination and luminaires lights also be luminaires Luminaries not luminaires
Emergency regularly sited at : installed along placed at
Lighting checked Fire and first aid the tunnels standard height Emergency
points, Escape intervals of not and Walkways luminaires not
routes, more than 50 m and tracks installed along the
Emergency sufficient lux not tunnels and
exits, Tunnel Emergency maintained at intervals more than
access points, luminaires walkway level 50 m
Electrical identification and general
substations, mark and Working areas
Control and register
communication maintained
points, Locations
where particular
hazards exist.
14.10 Means of The effective Communication Only limited No Means of
Communication communication communication systems Telephone communication
Systems such as at the following identification placed not at such as telephone
telephone are locations mark and standard height are not provided at
provided at working register and Walkways intervals of hundred
intervals of chamber at the maintained and tracks metres along the
hundred metres face of an sufficient lux not tunnel
along the tunnel excavation, First Displayed at site maintained at
aid points , with contact walkway level No alarms and
Alarms and Escape routes , numbers and general warning signals not
warning signals Emergency Working areas audible
audible exits ,Tunnel
access points ,
Electrical
substations ,
Control and
communication
points, interior
of each chamber
of a man-lock ,
location
conspicuous a
lock attendant's
station, shaft top
and those
working in the
shaft
14.11 Fire Hydrant Outlet fire Extinguisher Pressure for the The water No Hydrant Outlet
Extinguishers, not exceeding fitted every 15 operation and supply not or exceeding 50 M
Fire Mains & 50 M distance M regularly tested, sufficient in distance
Hose properly volume and
Connections Clearly marked , Mock drill maintained and pressure No clearly marked
readily conducted every register and not readily
accessible and month maintained accessible.
regularly
checked Smoking
prohibited below
ground and only
permitted in
designated area
on the surface
and away from
combustible

GSAF 06
materials
identified
14.12 Walkway regularly Water not A walkway Elevated No elevated

checked and accumulate at or provided within walkway walkway
hand rail marked above walkway a minimum clear provided without
with reflective level at any space of 2000 suitable
sticker point mm high and guard rails and
visible at night 900 mm wide, toe boards
and register with a walking
maintained surface not less
than 430 mm
wide
Every item of Daily user The lights Daily not carried Track not properly
14.13 Track and plant is subject inspection Sheet automatically out functional supported
Locomotives to planned signed by show white in brake check
maintenance and competent the direction of drivers Designated person
inspection. All person. travel and red to not available for
such test & the rear of the No records of maintenance of the
inspections are Locomotive locomotive equipment track
recorded. drivers when a travel issued to
authorized in direction is operatives. Poorly maintained
A safe system of writing by the selected. equipment on site.
work adopted site management Suitable No checks on
with adequate after their party equipment for condition of Poor condition of
refuge space, a training, testing the task as per equipment. equipment & plant.
nominated and the issue of RA/MS.
lookout, and a “Authorized Competent No maintenance No CCTV on
flashing warning certificate operator records Locomotives
lights being available Plant certificate
placed at either displayed.
end of the Regular testing Weekly
section of track of Locomotive Inspection Sheet
emissions signed by
competent
person.
Every item of . No records of Poorly maintained
14.14 plant is subject Daily user Weekly equipment equipment on site.
Rolling Stock to planned inspection Sheet Inspection Sheet issued to
maintenance and signed by signed by operatives. Poor condition of
inspection. All competent competent equipment & plant.
such test & person. person. No checks on
inspections are condition of No man riding cars
recorded. Personnel equipment. at site
transported man-
Purpose-built riding cars No maintenance
skips and records
materials bogies
attached as near
the locomotive
as possible with
a safety chain in
addition to the
coupling
The man-lock at Daily user Standard Incomplete No man-lock
14.15 Man lock tunnelling work inspection Sheet operating records and No attendant station is
and Medical is not used for signed by procedure in permits provided with a
Lock any purpose competent place and all are first-aid box at a
other than person. aware and construction site of
compression or records of No checks on tunnelling work
Decompression training condition of
maintained

GSAF 06
of building equipment. No Medical not

workers certificate situated near to the
man lock
No maintenance
records
Only limited
staff trained on
man lock and
medical lock
14.16 Emergency drill The emergency Emergency drills Mock drill not All site personnel
Emergency conducted on services in the including conducted for all not made familiar
Under Ground regular basis event of an evacuation emergency and with the site
Drills both day and underground fire should be held at mock drill plan emergency
night including or other regular intervals procedures
subcontractor emergency to familiarize all
participated identified and personnel with
the name and the practical
contacts work
displayed at site
14.17 Helmet stickers First aid points Named and Not identified. None on site.
Medical Staff worn. clearly displayed, good Doctor, Male
Additional first designated. Fully cover Safety, Nurse and No
aiders on site. equipped First aid box full time cover
Ambulance with available in each both day and
driver available work site with night shift. Fully
at site in all trained personal trained. In each
working hours including site office and
and emergency Manager , work location to
life support Engineer and attending
equipment Supervisor emergencies
attached in Stretchers
Ambulance (complete with
blankets)
suitable for the
An eye wash
confined space
station located
of a tunnel
near the mixing
provided and
plan and easy
maintained.
assessable
location in side
tunnel and near
the first aid
room
14.18 Emergency exit Free from Staircase made No Guardrail for No Proper staircase
Access and defects of sound staircase and lift
Egress material
Records of daily Transformer Double Portable tools No Flame proof
14.19 inspection/ used in with insulation / more than 24 V electrical
Electrical monitoring from compressed air earthing equipment
Equipment site designated condition of
persons are portable
available and equipment
actioned.
14.20 it 6m away Access within Laboratory test Quality is not Quantity is not
Drinking Water from toilets and 200m from done good sufficient
urinals worksite
Helmet stickers First aid points Named and Not identified. None on site.
14.21 worn. clearly displayed, good No full time
First Aid Additional first designated. Fully cover Safety, cover both day
Provision aiders on site. equipped First aid box and night shift.
available in each Fully trained. In
GSAF 06
Ambulance with work site with each site office No records of first
driver available trained personal and work aid boxes
at site in all location to inspection
working hours attending
and emergency emergencies No records of first
life support aid training
equipment
attached in
Ambulance No enough
qualified /trained
first aiders are
available at each
site each shift
No first Aid room

/Ambulance room
at site
No tie with nearest

hospital
No qualified doctor
available in each
shift in site
Ear muffs/plugs
14.22 Regular review Information on Sources not provided to None recorded in
of sensitive Limit/exposure identified, Workmen and Hazard & Risk Log
Noise receptors. levels held on assessments staff .No or Aspect Impact
site. completed employees assessment
training and
frequency of
training not
identified.
Sources
documented,
assessments not
completed
14.23 Available for Good condition Suitable type Not as per No eye Wash
Eye Wash issue standard Station
Station
14.24
House Keeping Records of daily No waste All waste debris Waste/debris No attempt of
inspection/ materials left in is removed from moved to housekeeping
monitoring from work area at the work areas and areas/stored in control. Loose
site designated end of the day. left clean and one area for materials causing
persons are Regular tidy. removal, trip and fire hazards
available and inspections. however it in areas.
actioned. Job allocation remains a
Periodicity of and time hazard. No No Housekeeping
housekeeping allocation Member list plan
No Dry and wet-
14.25 Subcontractors Records of On site before Poorly bulb temperature
and site monitoring works maintained instrument at
Temperature management carried out commence. condition of Site.
Monitoring include before works Temperature monitor. Unable
inspection in commence and monitoring to read. No
their weekly after. carried out calibration.
report. before agreed
system of work
in place by
competent
person.

GSAF 06
Calibration
certificate on
site.
14.26 Corrective Audit Report Conducted at Not Tunnel Not Performed once
Monthly Safety actions taken will be sent to least 7 days prior Manager in a month
Tunnel Audit ER to Monthly accompanied
OSHE this audit
Committee
meeting
15. Site Management & Supervision

[An [Exceeding the [In line with OSHE [In Need of CONFORMANCE
Exceptional Norm] Procedures] Improvement] [Unsatisfactory]
Standard] 8 Points 6 Points 0 Points -10 Points
10 Points
15.1 All Relief supervisory Site Manager Sub-contractors No supervision on

Resources management staff available as available at all supervisors only. site
staff are direct required. times Duty hours Key duty holders
employees. Duties hours not always NOTE:
An assessment including travel Key duty holders available.
of the time (to camps) are available at all Operatives THIS WILL
supervisory within the times. working RESULT IN AN
resources maximums working excessive shifts IMMEDIATE
necessary has times. Good shift rotation (12 Hours STOP WORK
been carried Maximum) (SCORE-20)
out and

GSAF 06
findings
implemented.
15.2 Regular Regular monitoring Site inspection of Irregular No site auditing.

Monitoring Monitoring by by Project Manager. the plant and monitoring, not Not submitted
senior Own KPI’s equipment following report on or before
management. established. inspection .Plant schedule. No 7th of each month to
Monitoring and Equipment , procedure Employer
Equipment Electrical site mentioned in
calibrated as per monitoring SOP for /Engineer
manufactures exercises on a daily inspection ,
requirements and and weekly basis testing and
test certificate maintenance
available at site
Monthly OSHE inspection OSHE committee
15.3 internal OSHE report meeting minutes Monthly OSHE Chief Safety
OH&S audit score report not Manager Daily
Submittal to report submitted before report not submitted
Employer 7th of Every to ER
Month
Safety Agenda cover
15.4 Awareness Safety budget Monthly inspection only limited No record of Safety
OH&S programme for discussed reviewed carried out by points and Committee
Committee workers and updated Chairman of Safety accidents statics Meetings or site
conducted on Meetings held Committee and is discussed and safety meetings.
monthly. more frequently i.e. records of Meetings held Safety Committee,
Awards to weekly. Reports inspection carried monthly site meetings held
subcontractors from Safety reps, by committee including infrequently, no
or individuals Sub-contractors members .Minutes actions/timescale action/ timescales
on safe working safety adviser issued within 2 s. Safety reps noted on the
practices. Near reports available days to the identified and minutes. No
miss reporting and shown action members. understand their subcontractor and
scheme. Near taken. Some Minutes posted on duties. .No work force
misses recorded posters displayed. all sites within Information attended meeting
at the Meetings work force area in discussed at the
and action both Hindi/Marathi Meeting
taken. Health and English distributed to site
and Safety .Lockable site operatives and
posters suggestion box displayed at site
displayed on posted as per notice board.
walls, CMRL OHS&E
Newsletters. Requirements.
Booklets etc
vided at
induction
All audit points Management Limited audit Audit not No External
15.5 complied and involved in audit observation conducted each OH&S Audit
External briefed to complied .No quarter. Quarterly conducted
OH&S Management management or report not
Audit staff review report Audit conducted submitted to
Quarterly .Follow up audit
not carried out Employer
within 28 days /Engineer Within
7days of audit
completed
Management The Management Report submitted to The contractor No formal
reviews Review Report Employer not submitted Management
15.6 undertaken Recommendations Management Review
Management annually implemented /Engineer Review Report to
Review Employer
/Engineer
within 7 days

GSAF 06
after meeting
completed
15.7 Near misses and Contractor reports Detailed Preliminary No information to
Incident minor accidents accidents , investigation report accident report Employer
Reporting also investigated incidents and within 48 hours of not submitted to
and dangerous investigation /Engineer via
Employer SMS for accident ,
communicated occurrences to completed
by Safety alert governing bodies submitted to /Engineer first aid injury , near
as per statutory Engineer within 24 hours miss , dangerous
Records obligations occurrence
available on Record available
investigation All near misses for accident No System
recommendation incidents and statistics effectively available for
implemented at accidents reported utilized to avoid classification and
site to avoid and investigated similar analysing the near
recurrence of Accident statistics incidents/accidents miss incidents and
incidents and maintained and accidents occurred
accidents updated Root cause analysis at site
done for all No accidents and
Availability of incidents and incidents notified to
RCA/CAPA on accidents 7 Employer
accident investigation /Engineer
/incident records maintained
Management’s worker rewarded All the There is no There No safety
15.8 participation subcontractors incentive promotional
Safety towards this included in schemes used programme
Promotion promotion
All NCR raised Contractor’s Corrective action Few NCR action No action on
15.9 by the Third Raised internal and preventative taken and No Employer
Employer party .The NCR as per their identified as per evidence of
contractor Quality CMRL OHS&E compliance /Engineer NCR
/Engineer submitted action Management Requirements.
Non- plan with time System
conformance scale within two
Report weeks to be
closed
16. Traffic Management (*x2)

6 Points
16.1 Safety of
Traffic Records of All persons Traffic Inadequate No control over
meetings and or wearing high management traffic vehicles entering
information sent visibility Competent management site, no segregation
to suppliers, etc. clothing, good person system in place, of pedestrians /
Plan displayed clear signage, designated. instructions not vehicles, mud on
showing one way/turn Clear provided to roads.
designated circle, instructions operatives
traffic routes for displayed. PPE, delivery drivers / No Traffic Devices
delivery vehicles Banksman signs in place. suppliers, such as cones
/ public where clearly identified Arrangements to ,drums , delineators
appropriate on signage and eliminate , traffic cylinders ,
PPE. Discussed reversing. traffic signs and
with police, barricades not
local authority, available

GSAF 06
etc where
appropriate. No records of
regular monitoring
No retro reflective
strips shapes and
size & reflective
strips placed at an
angle at bottom
16.2 Information Public safety Information Signs/notices None provided,

Public regularly notices sited in clearly erected, poorly located
Information reviewed as advance of all contact information
work progresses. critical areas and information, minimal.
Public liaison phase changes. duration of
officer appointed works etc.
Effective
16.3Safety of Daily monitoring An appointed segregation of Untidy public Pedestrian barriers
Public is recorded. team/ designated pedestrian from access, poor missing/fallen over.
person in place vehicles, signage, poorly Dirty footpath and
Road markings to monitor barriers, work constructed uneven floors.
where public access areas. Good access-ways.
appropriate. daily. Evidence clear signage.
of monitoring. Clean footpaths.
Drawings Barricade Traffic An attempt to No Traffic
16.4 Traffic available on manager Management segregate other Management Plan
Management display around assigned. Daily Plan in place road users or in place,
the site and in & weekly with no pedestrians has Road user and or
site offices inspections objection from been made but pedestrians
showing traffic undertaken with the ER. without adequate movement is
routes and traffic remedial actions planning. uncontrolled.
management stated and Plan measures Barriers not
scheme. rectified. implemented on maintained. Incorrect or no
Information Site fencing site e.g. Road Entry, exit tapers signage No barrier
issued to washed and Signage erected, not correctly set lighting. Openings
suppliers repainted Barriers with full or Maintained. in barriers with no
regarding annually lighting. Inadequate security
restricted Banksman in signage
delivery times attendance, Insufficient No as per agreed
e.g. schools Entry/exit tapers warning signs schemes of local
Inspection correctly displayed at traffic police and
conducted both installed. distance before Metropolitan and
day and night commencement other authorities
shift of work No traffic controller
Rules provided Insufficient No approval from
for in the traffic signs , Employer
railways manual barriers ,cones
followed and lighting /Engineer for the
site perimeter
fencing
16.5 Highway Areas inspected Areas undergo Roads and Reasonable but Not carried out,
Cleanliness daily, records regular recorded pavements infrequent, no hazardous
maintained inspections reasonable. programme for, conditions
Programme or poor cleaning.
established for
regular cleaning.

GSAF 06
All visitors All visitors Site plan in No clear No controls in

16.6 Visitor signed off site accompanied at place, directions place, visitors
Safety upon leaving. all times by a information displayed for uncontrolled.
member of the displayed, visitors Only No Visitors
site personal induction some inductions approvals from
attendance carried out. Employer
recorded. Visitor Entry register not
register well consistently /Engineer
used. All used. Not all
wearing PPE. wearing PPE.
Records Permits contents Permit in place
16.7 maintained, communicated issued for Permit in place None in place,
Work Permit regular to operative, relevant not fully unsafe
monitoring and sign off operatives, fully completed and acts/conditions.
recorded procedure in completed. signed off.
inspection of place.
permits
16.8 Relevant Monitored daily Good, clear and Good in most
Site Signage and upgraded concise in all areas, Poor display in Not displayed at all.
where necessary. areas. Regular maintained in critical areas.
Evidence inspections. good condition.
provided of daily
review and
updates
16.9 Barricade Areas inspected Areas undergo Barricade Reasonable but No cleaning of
Board daily, records regular recorded Boards and infrequent, no barricade
maintained. inspections painting programme for,
Programme reasonable. or poor cleaning. No flashers and
Daily monitoring established for rope light fixed on
of Barrier is regular cleaning. Barrier is in Signs of barricade boards
documented. place and is attempted access. and No inspection
Records of Securable gates stable. No gaps Wrong type
reviews of any (if necessary) an in hoarding. barrier used, No barricade
modifications access points in Good clear poorly designed. Manager
kept. place, clear signage. Temp /Supervisor
signage, painted, Works appointed
well maintained, consulted.
inspected Barriers unstable in
regularly. places. Poorly
erected, poorly
maintained, gaps in
hoarding.
16.10 Corrective Audit Report Conducted at Not Station Not Performed once
Monthly traffic actions taken will be sent to least 7 days prior Manager in a month
Safety Audit Employer to Monthly accompanied this
OSHE audit
Committee
meeting

GSAF 06
17. Noise
6 Points
Ear muffs/plugs
17.1 Regular review Information on Sources not provided to None recorded in
Identification of of sensitive Limit/exposure identified, Workmen and Hazard & Risk Log
Sources receptors. levels held on assessments staff .No or Aspect Impact
site. completed employees assessment
training and
frequency of
training not
identified.
Sources
documented,
assessments not
completed
17.2
GSAF 06
Provision of Maintenance and DBA frequently Equipment Identified in Not identified in

Silenced test certificates checked. Noise silenced to Hazard & risk Hazard & Risk
Equipment maintained for monitoring acceptable levels log but not logs. Not provided
machinery equipment implemented in areas where
available and Machine throughout. noise levels are
calibrated provided with Some provided exceeded and near
acoustic material but do not cover sensitive receptors.
and display of all risks
signage’s control Machines
been generating
implemented to excessive noise
reduce noise available work site
exposure below
the permissible
limit
17.3 Monitoring
Noise levels Frequent checks, Noise levels Equipment on No base line
from equipment records monitored site, Irregular monitoring
checked and maintained. calibration checks made no conducted as per
recorded daily records on site. calibration monitoring plan
records None carried out
18. Occupational Health

6 Points
18.1 Records signed List of All equipment Basic register Not maintained
HAV’s Register off daily, usage competent recorded, usage requires
monitored, operatives time/Trigger updating not all
equipment well attached. Tool times recorded equipment on
maintained. box talks Operatives register
completed checked for
signs and
symptoms
18.2
Malaria , OCC health, Procedure Procedures in Minimal None procedures
Dengue , exposure established place. information, available
Silicosis, Skin controlled information information mentioned in
Cancer , HIV monitored and displayed, provided fully policy No information
AIDS , recorded controls assessed provided in both
Leptospirosis , implements, dust Hindi/Marathi
GSAF 06
Tetanus and Comprehensive suspension in Educational Minimum dress, and English

Hepatitis information, place. Tool box programme part of site rules,
Information contact numbers talks completed. scheduled and information
provided, implemented. provided
controls Liaison person
monitored with nominated
records
18.3 Frequency of Confidential Conducted by Not Covered all Not All worker
Medical medical test report for all qualified person testes as per under gone
Examination maintained workers standard
18.4 Medical Adequate Floor area Non Availability No Construction
Occupational emergency equipment minimum 15 m2 nurse medical officer &
Health Centre equipment’s with two rooms qualification
18.5 Register for first- First-aider & his First-aid room No Sufficient Not Equipped with
First -Aid aid qualification facility numbers all items as per
standard
18.6 Record of all Equipped with Maintained in No Availability Non Equipped with
Ambulance van cases of accident standard good repair and numbers all items as per
and Room & sickness facilities standard
18.7 Workers HIV / AIDS Management Smoking at Employee working
Alcohol and participation / awareness participated public worksites under the influence
Drugs co-operation training provided awareness Smoking at of alcohol / drugs
training public worksites
18.8 Appropriate PPE Disposal of Approved Not Approval No Method
Radiation radioactive Method from Employer statement
substance statement
18.9 Regular Posters No waters No Periodic Water retain on the
Mosquito inspection and interval site
Breeding report
submission to
the Employer
18.10 Control plan Report Vibration limits Monitoring method
Vibration maintenance
Frequency of
monitoring
19 Training & Induction

6 Points
19.1 Audit/inspection Records of Involvement of Enough No training
Management training. retraining senior infrastructural programme is
Competency Competency whenever new management facilities with prepared in
formally hazards personnel in Audi-visual consultation with
assessed introduced. safety and health support are department heads
Knowledge of training and available
SMS training records No formal
(project, site and management / No
Availability of
corporate supervisory training
Monthly training
arrangements) schedule and
No induction./No
Matrix. Records
JV ID card with
of training
authority sign and
submitted to GC
validity
as per approved
training
implementation
plan

GSAF 06
19.2 Additional Skilled in the Skills training Only some have None attended
Supervisor training needs area supervising completed, attended the supervisors course
Training identified inductions supervisors
specific to role. completed, all course No induction./No
Competency recorded on site. JV ID card with
formally cards held, Fire authority sign and
assessed training , First validity
Aiders
19.3 Additional Fire training and Defensive driver Only some have None trained
Driver /Plant training needs first aid training training all attended safety
Operator identified completed for recorded on site. training. Persons No induction./No
Training specific to role. specific Operatives undertaking
individuals received formal tasks or role for JV ID card with
Competency authority sign and
formally training in role which no formal
needs. training has been validity
assessed
given
19.4 Programme of Programme Programme Only some No training
Training additional Regularly maintained for Training procedure or
Programme training needs reviewed and induction, safety programme programme
maintained. updated. skills and completed
Implementation Implementation competency. No training plan for
schedule standard Health HIV workmen and staff
attainment monitored and AIDS.
reported monthly reported on. Equipment
training for No monthly
training training schedule
Document presentation operatives,
Worker trained and matrix.
system covers site rules ,
established for hazard in Fire fighting No Records of
safety and health communication training as per
training and other special Involvement of training
safety rules senior implementation
specific to the management plan
project personnel in
requirements safety and health
training
19.5 Specific All competency Competency Person Formal No formal training
Training Records assessment undertaking qualification certificates held for
Competency maintained on carried out by skilled role have certificates only high risk roles e.g.
Certificate site. Records contractor prior competency held for some scaffolding,
match task to working. certificates and skilled Banksman, Lifting
undertakings Records of formal training applications Supervisor ,
assessment e.g. welders, slingers, plant
maintained slinger signallers operator and crane
and refresher operators
training
conducted at
least every three
months
19.6 Toolbox Topics pre- Regular T.B.T’s T.B.T’s held but T.B.T’s planned No T.B.T’s held or
Talks selected programmed tend to be but none carried planned.
attendance sheets proactive and reactive, no out
completed and records programme
signed off by maintained
attendees, topics
debated
19.7 Attendance syllabus project
Follow Up Workers records kept related Not take place No follow up
Training participation after six months training organized
towards training

GSAF 06
Topics pre- Regular Important days Important days Important days for
19.8 selected Important days for creating for creating creating OHS&E
Important Days attendance sheets for creating OHS&E OHS&E awareness held or
observed completed and OHS&E awareness held awareness planned.
signed off by awareness but tend to be planned but none
attendees, topics programmed reactive, no carried out
debated proactive and programme
records
maintained
New Visitor to All workforce Records of all Limited No induction
19.9 site , induction, and Management inductions induction training as per
ID card and staff with maintained training CMRL CMRL OHS&E
OH&S communicated to OHS&E Requirements. No
Induction
OH&S
Employer induction Hank Requirements JV ID card with
Training and limited
/Engineer book provided authority sign and
number of validity
workforce and No work men , staff
management training assessment
staff with records
OHS&E
induction Hank
book provided
EMERGENCY RESPONSE PLAN CONTENTS

Contractor
Name
Project Name
1 Project Highlights
i. Title of the content
ii. Contractor Number
iii. Brief scope of work
iv. Location map/ key plan
v. Period of the project
2 Reference Publications
3 Terms & Definitions

4 Design & Planning
5 Legal & Other requirements
6 Declaring of the Emergency situation
7 Roles, responsibility, accountability and authority
8 Information System to concern service & persons
9 Emergency organization during silent working hours
10 Emergency Control Room Diagram
11 Media Centre & Media Centre Diagram
12 Evacuation Map have not been included to be inserted
13 Cyclone preparedness
14 Evacuation Routes and off site assembly area Diagram
15 Conducting Hazard Analysis
16 Procedure to be followed during non-working hours

Emergency Evacuation Procedure
• In case of fire
• In case of collapse of building
• In case of shed or structure
• In case of Gas leakage
• In case of Liquid spill control
• In case of injury
17
• In case of Strom
• In case of riots or civil disturbances procedures
• In case Bomb threat
• In case of terrorist attack
• In case of land slide
• In case of floods
• In case of Earth quake and other natural calamities
18 Site Emergency Team
List of Trained personnel of fire fighting and other emergency
19
situation

20 Details of Emergency response kits at project site
21 Collapse & Settlement Emergency process
22 Rescue provisions from tunnels
23 Inundation Procedure
24 Piling Preparedness
Site Emergency response layout
• Site layout indicating site address & site telephone number
• Fire point locations
• Fire muster /Meeting point
• Fire escape routes
25 • Location of site office & welfare
• Site showing locations of structures, roads, parking area, natural features,
onsite warning devices, firefighting or other emergency equipment, major
utility systems, and other features deemed essential for emergency purposes.
• legend showing all symbolic and numerical representations used for
labelling features, or label features on the map

HEALTH PLAN CONTENTS

Contractor Name
Project Name
4 Health Policy
7 Health Hazards in construction- Chemical, Biological & Physical
8 Conduct an Assessment
9 Method of monitoring airborne hazards

Site Implementation Procedure - Prevent or minimise exposure –Hand and
10 arm vibration syndrome, silicosis, skin cancer, HIV AIDS, Leptospirosis,
tetanus & Hepatitis
11 Maintenance of control measure
12 Recording and Reviewing the Assessment
13 Health Surveillance /Exposure Monitoring - Keeping records, Monitoring

Assessment Briefing, Information, Instruction, awareness And Training For
14
Employees
15 First Aid/Spillage/Disposal Procedure
16 Communication

17 Non -Compliance /Corrective action & records
18 Review & Audit

GSAF 08
GSAF 09

ON SITE TRAFFIC MANAGEMENT PLAN CONTENTS
Contractor
Name
Project Name
4 Design & Planning
5 Legal & Other requirements (Relevant legislation, Guidelines & standards)
6 Purpose, objective & Performance goals

Structure & Responsibilities (General (Site Structure reporting chart)), Role and
7
Responsibilities for all staff
8 Concerns of local community and stake holders, limiting traffic movements
Existing road infrastructure & construction interface -Road network, Access
control, site speed limit, transport of materials, plant and equipment to site
9 existing traffic control, road dilapidation surveys, Works boundary plan,
Assignment of construction traffic, Roads & Intersection operation & Closures &
Public areas.
10 Interface between on-site and off-site road movements
11 Interface with public

Traffic Controls & Mitigation measures- project site offices, project site access
12
points, Heavy vehicle traffic routes, site office, light vehicle & parking.
Setup of traffic management controls & signage - Construction signage placement
13
plan

14 Traffic Control plan
15 Construction deliveries /project deliveries procedures
16 Environmental Impact on the area Dust Management
17 Accident & Emergencies
18 On Site Parking
19 Community
20 Monitoring and management of the traffic management plan
21 Training awareness & competence
22 Risk Assessment
23 Review & Audit
24 Pedestrian route checklist
25 Vehicle movement checklist
GSAF 10

CONSTRUCTION PHASE OCCUPATIONAL HEALTH & SAFETY PLAN

CONTENTS
Contractor
Name
Project Name
1 Application of this plan
2 Purpose of this Plan
3 Scope
6 OH&S Management and system requirements
7 Contractor OH&S policy
8 Drugs & Alcohol Policy Statement
Planning and Implementation
Interface Management
9 Management of Change
Procurement
Sub-contractor Selection
Construction Management Process Overview
10 OH&S Objectives and programme(s)
Legal and other requirement
11 Legal and other requirement
International Standards, Guidelines & ISO Certifications

Implementation and operation
Contractor’s OHS&E Organization
Resources, roles, responsibility, accountability and authority
Roles & Responsibilities
General duties of the contractor and others
12 General duties of persons employed
Contractors and sub-contractors responsibilities
Duties of the OH&S Persons
Powers of OH&S persons
Competence, training and awareness
OHS&E personnel NONO from the Employer/Engineer
13 Method Statement
14 Lift Plan
15 Hazard identification, risk assessment and determining controls
Hazard identification, risk assessment and determining controls
Hazard Log & Risk Register
Risk Assessment
COSHH Assessment
Design Risk Assessment
Risk assessment production and submittal
16 Designer’s Role
17 ID card and First day at work, OH&S Orientation training
Safety Training and Safety Promotion
Occupational health and safety training
Induction training
18 Refresher Training
Specific Training
Tool box talks
Occupational Safety Promotion
OH&S communication
Occupational Health and safety signage
19 Communication, Participation and consultation
Contractor’s site OHS&E committees
Sub contractor awards

Documentation
Management system procedure
Management System
Management System procedures
Corporate Operating Procedures
Standard Operating Procedures
Standard Operating Procedures Safety
20 Standard Operating Procedures Environmental
Standard Forms Safety
Standard Forms Environmental
Control of documents
Operational control
Operational procedures
Document Control
Control of Records
Filing System
Performance measurement and monitoring
21 Surveillance Exercise’s
Site Safety Inspections
Plant & Equipment Inspection
Request for Inspection
Evaluation of compliance
Reporting of accidents and Dangerous Occurrence
Contractor responsibility
Reportable accidents
22
Dangerous occurrences
Reporting of fire by the contractor
Reporting to Employer/Engineer
Accident investigation
23 General
Recommended actions in incident investigation
Accident Statistics
Collection of accident statistics
24
Calculation of man-days lost –construction accident statistics
Calculation of accident frequency rate (AFR)
Nonconformity, corrective action and preventive action
25
Control of records

OH&S Audit
MARS Audit
ISO Certification Audit
26 Engineer Audit
External Quarterly OH&S Audit
Period of Quarterly Audit
Areas of competence of audit team
27 Management review
Physical Fitness of Workforce
Medical Facilities
Medical Examination
28 Medical Staff
HIV/AIDS prevention control
Prevention of Mosquito breeding
Alcohol and drugs
Noise
Ventilation
Radiation
Welfare measures for workers
Latrine and urinal accommodation
Moving sites
Canteen
29 Drinking water
Living Space
Toilet/Washing Facilities
Food Preparation/Cooking Area
Lighting and ventilation
Evacuation
Evacuation procedure
First Aid/Emergency
Hazardous area
Fire safety and fire fighting
Mechanical and electrical safety
House keeping
Transportation
Pest Control
Camp/ Accommodation Supervisor
Working at height
General
30 Use of scaffolds
Use of ladders
Safety harnesses/Fall Arresters

Excavations
General requirements on excavation work
Duties of engineer on excavation
31
Access and egress from excavation
Undermining nearby structures
Avoiding underground services
Lifting Operations
Lifting appliances
32
Crane safety Equipment
Lifting gear
Working in confined space
General
33
The hazards
Entry procedure
Site Electricity
34
General
Design considerations
Cables
Maintenance
Lighting
Illumination
Electrical power circuits
Installation of electric wiring and power lines
Residual current circuit breakers and overcurrent protective devices
Prohibition on use of fuse
Industrial plug and socket outlet
Distribution board and socket out assembly
Electrical installations and equipment used underground or in confined space.
Monthly Electrical Safety Audit
Welding, gouging and cutting

Oxy-fuel gas processes
Arc Cutting, gouging and welding processes
Compressed gases storage
35
Handling of compressed gas cylinders
Regulators
Hoses
Training and instruction
Machinery
Machinery Fencing
Maintenance
36
Air receivers
Woodworking machines
Abrasive wheels

37 Plant and equipment operations
Personal Protective Equipment
Head protection
Eye protection
Whole body protection
38
Respiratory protection
High –visibility clothing
Hearing protection
Self-Rescuers
First Aid provisions and procedures
First aid bases
First Aid boxes
First aid facilities
39
First Aid rooms
First aid Training
Stretchers
Ambulance van
Blasting Operation
40 Authorisation for blasting
Risk assessment and method statements
Demolition
General duty of the contractor
Preparation of demolition
Protection of adjacent structures
41 Removal of load bearing structures
Demolition of walls, partitions, etc.
Access to floor
Barricades, catch platforms and warning signs
Mechanical method of demolition
False work /Formwork
General Requirements
Supports and shores
Appointment of formwork supervisor
42
Duties of formwork supervisor
Concrete work
Dismantling
Steel Reinforcement
Reshoring
Piling and Diaphragm walls
Stability of adjacent structures
Inspection
43
Pile driver not in use
Pile testing
Footing
44 Work adjacent to live Railways
45 Work adjacent to live roadways
Fire prevention, protection and fighting system
46 Fire Fighting equipment
Storage of flammable liquids
Construction Machinery
Safe worthiness certificate
Reverse Horns
General Operating procedure
Strength and stability
47 Capacity chart
Through examination and inspection
Handling of suspend load
Prohibition on riding in loads
Cranes or machinery at rest
Operators of employee’s lift
Traffic Management
Legal permission
Regulatory signs
Warning signs
Delineators
48 Traffic Cones and cylinders
Drums
Barricades
Yow away vehicle
Cleaning of roads
Spoil Removal
House Keeping
Accumulation of debris
49 Method of removal of debris, etc.
Floor opening for removal of debris
Debris collection area
50 Over Head protection
51 Slipping, Tripping, Cutting, Drowning and Falling Hazards
52 Launching Operation
53 Manual Lifting
54 Hand Tools and Power Tools
55 Dangerous and Harmful Environment
56 Corrosive substances

57 Batching Plant and Casting Yard
58 Radiation
59 Smoking
60 Mobile Phones, Radios and Audio Equipment’s
61 Dust ,Gases, fumes
62 Vehicular Traffic
Explosives
Handling of explosives
Smoking, open lights etc.
Opening Packages
Deepening holes
Size of holes
63 Removing cartridge wrappers
Loading and other operations
Loading and tamping
Work of firing of any blast
Warning and retreat
Return to blast area
Misfires
Operations during Thunderstorm
64 Floor Openings
65 Evaluation , selection and control of subcontractors
66 CCTV
Site Security
Hoardings
Personnel access
67
Vehicular access
Site patrols
Security Guards
Flooding
68
Flooding Evacuation and Rescue procedure

Work permit system
Implementation of permit to work
No high risk construction work without permit to work
Application for permit to work
Evaluation of permit to work
69 Issue of permit to work
Posting of permit to work and supervisor’s duty
Monitoring of work
Duty to report incompatible work
Revocation of permit to work
70 Visitor’s to site
71 Grievance and Disciplinary
72 Compressed Gases
73 Heavy Plant operations
74 Site Perimeter Hoarding
75 OH&S Submittals to the Employer/Engineer

Appendix
Emergency Preparedness Flow Chart, Emergency Evacuation Plan layout with
76 Emergency Contact Number
GSAF 11
SITE FIRE PLAN CONTENTS

Contractor
Name
Project Name
4 Design & Planning

On site Implementation procedures
• Site set up
• Site induction
• Means of Escape/Re direction of means, Escape through construction site
• Inspection, test & drills
7
• Emergency Evacuation procedure in case of fire, Hot work
• Site Security
• Flammable liquids & LPG Electricity
• Waste Material Temporary Covering materials
• Plant, Relevant statutory Signs
Fire & Smoke in Tunnels
• Storage of materials
• Combustible materials
• Flammable liquids
• Compressed Gases
8
• Handheld Blow pipes
• Lighting Fixtures
• Welding & Cutting
• Electric Arc Welding & Cutting
• Fires involving electrical equipment
Fire precautions in Tunnels
9 • Routine testing and maintenance of fire protection equipment
• Vulnerable items and locations
Emergency Team to include SCBA use, Training & awareness
10

Fire-fighting and rescue
• Emergency control facilities
• Alarm procedures
11 • Lighting
• Smoke control
• Rescue facilities
• Self-rescuers
12 TBM Firefighting facilities
13 Fire Drills, Training & awareness
14 Communication /Relevant Statutory Signs
16 Fire Risk Assessment
17 Review & Audit

Site Fire plan Layout
• Site layout indicating site address & site telephone number
• Fire point locations
18
• Fire muster /Meeting point
• Fire escape routes
• Location of site office & welfare
GSAF 12
Traffic Management Plan Contents
Contractor
Name
Project Name


2. TERMINOLOGY AND CONCEPTS
2.1 FUNDAMENTAL DEFINITIONS
2.1.1 Proponent
2.1.2 Traffic Manager
2.1.3 Traffic Control Supervisor
2.1.4 Traffic Engineer
2.1.5 Traffic Management Strategy
2.1.6 Traffic Management Plan
6
2.1.7 Authorization
2.1.8 Approval
2.2 TRAFFIC MANAGEMENT SUB PLANS
2.2.1 Traffic Control Plan
2.2.2 Public Information Plan
2.2.3 Incident Plans
2.2.4 Implementation Plan
3. TRAFFIC MANAGEMENT OVERVIEW

3.1 A CLEAR CONSISTENT PROCESS
3.2 DEVELOPING A STRATEGY - A PRACTICAL APPROACH
7 3.2.1 Identify the Type of Traffic Control Required
3.2.2 Identify Likelihood of Traffic Delays
3.2.3 Assess Risks and Special Conditions
3.2.4 Identify the Traffic Management Strategy
4. RISK ASSESSMENT
8
4.1 RISK ASSESSMENT GUIDELINES

5. DEVELOPING TRAFFIC MANAGEMENT STRATEGIES
DEVELOP A TRAFFIC MANAGEMENT STRATEGY (STEP BY STEP)
5.1 CATEGORY 1 - BASIC TRAFFIC MANAGEMENT STRATEGY.
9 5.2 CATEGORY 2 - BASIC TRAFFIC MANAGEMENT STRATEGY.
6. DEVELOPING TRAFFIC MANAGEMENT PLANS

6.1 CATEGORY 1 - TRAFFIC MANAGEMENT PLAN REQUIREMENTS.
10 6.3 CATEGORY 3 - TRAFFIC MANAGEMENT PLAN REQUIREMENTS
6.6 DEVELOP A TRAFFIC MANAGEMENT PLAN (STEP BY STEP)
PART 3 - IMPLEMENTING STRATEGIES AND

EVALUATING PLANS
7. POLICIES
7.1 NOTIFICATION
7.2 PLAN UPDATES AND MODIFICATIONS
7.3PROPONENT COMPLIANCE WITH TMP
TABLE OF CONTENTS
11 TRAFFIC MANAGEMENT GUIDELINES FOR WORK ON ROADWAYS
7.4 MINIMUM ACCEPTABLE PLAN DOCUMENTATION

7.4.1 Traffic Control Plan – Category 1
7.4.4 Traffic Control Plan – Category 4 and 5
7.8 TRAFFIC VOLUME DATA

8. TYPICAL SPECIAL PROVISIONS
8.1 TRAFFIC MANAGEMENT PLAN REQUIREMENTS
8.1.1 Risk Assessment
8.2 TRAFFIC MANAGEMENT PLAN REVIEW AND APPROVAL
8.3 PROPONENT'S TRAFFIC MANAGER
8.4 TRAFFIC MANAGEMENT SUB PLAN SUBMISSION
8.5 TRAFFIC CONTROL PLANS
8.5.1 Acceptance of Traffic Control Plans
8.5.2 Traffic Engineer
8.5.3 Proponent's Traffic Control Supervisor
8.5.4 Traffic Control Schedule
8.5.5 Provision of Services
8.5.6 Documentation
8.5.7 Permitted Work Days
8.5.8 Lane Closure/Reduction Windows
8.5.9 Permissible Delays
12 8.5.10 Obstruction of Traffic
8.5.11 Traffic Control Devices
8.5.12 Construction Detours
8.5.13 Temporary Lighting
8.5.14 Barrier Requirements
8.5.15 Drop-offs
8.5.16 Accommodation of Pedestrians and Cyclists
8.5.17 Temporary Pavement Markings
8.5.18 Use of Pilot Cars
8.5.19 Completed Sections of New Roadway
8.6 PUBLIC INFORMATION PLAN
8.7 INCIDENT MANAGEMENT PLAN
8.8 IMPLEMENTATION PLAN
8.9 SNOW AND ICE CONTROL
8.10 PROJECT INFORMATION SIGNING
8.11 LOCATION AND STORAGE OF MATERIALS AND EQUIPMENT.
8.12 STANDARD ACCOUNTABILITY MEASURES
13 TRAFFIC MANAGEMENT GUIDELINES FOR WORK ON ROADWAYS
9. EVALUATING A TRAFFIC MANAGEMENT PLAN
9.1 OVERVIEW
9.2 TMP EVALUATION PROCEDURE
14
9.2.1 Simplified TMP Evaluation Procedure (Suitable for Category 1 and 2 only)
9.2.2 Full TMP Evaluation Procedure – All Categories
APPENDIX A - TRAFFIC MANAGEMENT PLAN REVIEW AND

ASSESSMENT
APPENDIX B - TRAFFIC CONTROL PLANNING AND ASSESSMENT
15
APPENDIX C - LANE CLOSURE REQUEST/PERMIT FORM
APPENDIX D - ALTERNATE AUTHORIZATION FORMS
APPENDIX E - EXAMPLE PROJECT SPECIAL PROVISIONS
17 Review & Audit
GSAF 13

Training Implementation Plan contents
Contractor Name
Project Name
Sl. No
01 Introduction
02 Purpose
03 Project Description
04 Scope of work
05 Management Commitment
06 General Training Prerequisites
07 Training and Accountability
08 Training Approach
8.1 Training Requirements
8.2 Roles and Responsibilities
8.3 Techniques and Tools
8.4 Training Prerequisites
8.5 Training for revised Standard Operating Procedures
8.6 Schedule
8.7 Training Periods
8.8 Training Instructors and Agencies
9.0 Types of Training
9.1 New Employee Orientation
9.2 On the Job Training
9.3 Contract Workers
9.4 Experienced Workers
9.5 All workers
9.6 Safety Induction Trainings
10 Evaluation
10.1 Metrics
10.2 Strategy
11 Incentives, Recognition and Reward
Annexure-A Training Matrix
Annexure-B Internal Training Monitoring plan (for 6 month)
Annexure-C External Training Monitoring plan (for 6 month)

GSAF 14
MONTHLY OH&S REPORT CONTENTS

SI.No
Description
1 Executive Summary
2 Monthly man-hour details as specified in the Contract requirements
3 Reportable accidents, and First Aid Cases (Dangerous occurrences) and Lost work days
4 Accident /Incident by categories
5 Accident frequency Rate & Severity & Incidence Rate
6 Reportable accident /Incident Log
7 Incident investigation, Non-conformity, Corrective actions and preventive actions, Lessons
learnt
8 Daily Tool Box tack Topic Schedule
9 Safety Theme of the Month

10 Status of implementation of CMRL policy objectives & Aims.
11 Status of compliance of TBOCWR 2006
Status of Compliance of GC report (Weekly inspection, NCR and CSR), Observation of
12 CMRL staff & Legal inspector (e.g. Labour welfare inspector, TBOCWR Inspector etc.)
13 Status of Contractor Internal NCR to Employer/ER NCR (5:1)
14 Safety promotions activities.
15 Safety inspection and follow up actions ( Inspection by contractor’s safety supervisory
staff)
16 Safety walk conducted by Contractors’ Project Manager in the month
17 Contractor’s site safety committees
18 Status of NONO of Hazard identification and risk assessment
19 Status of NONO of Method statement and Lift Plan
20 Notice of no objection status of safety staff from the Employer/ER and Organization Chart
Day , Night including casting Yard and Tunneling operation
21 Status of Permit to work issued
22 Emergency preparedness plans and team and organization chart
23 OSH Communication activities under taken in the month indicating the number of posters
displayed and balance availability in stock.
24 Industrial health and Labour Colony Inspection and follow up actions
25 Records of Gas (Carbon monoxide, Carbon dioxide, Nitrogen oxides, Methane, Hydrogen
sulfide, Sulfur dioxide, Propane Butane Acetylene, Ammonia, Volatile organic compounds,
Organic solvents, Oxygen deficiency, Oxygen enrichment, Petrol/Diesel vapour, Ozone,
Radon), Noise, Vibration, Lux Meter, Ventilation Monitoring Details (in terms of m3/sec,
m3/min)
26 Records of visitor to site
27 ISO 45001 OH&S management systems certifications
28 Status of Update of Management system procedures ,Operational control procedures
,Construction phase health and safety plan, Emergency Plan , Fire plan , Health Plan and
Tunnel Plan
29 Monthly Training Plan (Management Staff , Specific Training and Worker)
30 Details of OH&S training conducted internally and External Agency in the month
31 External Quarterly Audit training plan(Management Staff , Specific Training and Worker)
32 External Quarterly OH&S Audit plan
33 Management review update
34 OSH internal audit details like MARS, Labour Colony, Traffic Management, Plant and
Equipment, Excavation, Working at Height, , Confined Space , Tunneling Operations,
Electrical audit etc.
35 PPE details: Quantity purchased, issued to the workmen and stock available.
36 Details on IP 44 panel boards, lighting poles, welding and cutting equipment’s, Ladders,
Hoists, tools & tackles.
37 Housekeeping
38 Barricade maintenance details
39 No of critical excavations
40 Status of Mock Drill
41 OH&S Activities Planned for next month

GSAF 15
Minimum No. of OH&S Posters
Sl. OHS&E Poster Minimum No. of Posters / Signage / Video

No Title No. of up to Up to up to up to up to More 500
concepts 100 200 300 400 500 Contract
in each Crore Crore Crore Crore Crore value
title Contract Contract Contract Contract Contract
value value value value value
1. Safety Culture 5 Each 10 Each 50 Each 75 Each 100 Each 125 Each 150
2. Daily Safety Oath 1 Tamil , Each 100 Each 200 Each 500
1 English Each 750 Each 1000 Each 1250
&1 Hindi
3. Mandatory PPE
Usage
a) Signages to 2 types of Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
display the sizes
messages like made up
PPE ZONE, NO of metal
PPE ZONE, sheet to be
HARD HAT mounted
AREA etc. at
different
locations
b) Helmet 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
c) Shoe 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
d) Goggles & Ear 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Protection
e) Full Body 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Harness
f) Hi-Vi Jacket 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
4. Emergency 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Management Plan
5. Working at 10 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Heights
a) Ladder, Stairway, 5 types of Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Scaffold – sizes
Signages to made up
display the of metal
messages like sheet to be
SAFE, UNSAFE, mounted
FIT FOR USE, at
AVOID USE etc. different
locations
6. Site Electricity 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
7. Crane Safety 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
8. Slings 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
9. Rigging 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Procedures
10. Excavation 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
11. Occupational 10 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Health
(Mosquito
Control,
HIV/AIDS
awareness, Dust
Control, Noise
Control, No
Smoking/Spitting,
etc.)
12. First – Aid 3 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
13. Labour Welfare 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Measures
(Payment of
Minimum Wages,
Avoidance of
Child labour,
Signing in the
Muster Roll, In
case of accidents-
what to do? Etc
14. Importance of 1 25 50 75 100 125 200
“Safety
Handbook”
15. Traffic Safety 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
(Speed limit, safe
crossing and
working within
barricaded area
etc.)
16. Environmental 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Monitoring
(Spillage of
Muck, hazardous
material,
Improper
drainage, water
spray for dust
containment etc.)
17. Video in Hindi on 1 - - - 1 1 1
PPE usage – 15
minutes duration

18 High Risk 5 Each 25 Each 50 Each 75 Each 100 Each 125 Each 200
Specific activity
Do’s and Don’t
Note 1: Items mentioned under 17 is video. Items under 3 (a) and 5 (a) are metal signage
boards and all other items are posters.
Table No.: 2 – Size of Posters / Signages
Sl.No Item Size

1. Posters – Standard 1.5 meter x 1.5 Meter Vinyl 4 Colour
Printing
2. Posters – Special (Wherever required) 17”x22” card laminated FA Poster
3. Posters - Mega size (Wherever required) 2 meter X 2 meter Flex FA Poster
4. First-Aid Booklet 6”x4”
5. Safety Handbook 6”x4”
6. Signages Small: 0.5 Meter x 0.5 Meter
Big : 01 Meter x 01 Meter
7. Road Traffic Sign Boards Strictly as per Indian Road Congress (IRC)
specifications
Reflective Stickers
Size :900mm x 900mm (Diameter of
Circle/Rectangular /Triangular)
Table No.: 3 – Safety Signage Colour (as per IS 9457)
Sl.No Type of signage Colour

1 Mandatory Blue
2 Danger Yellow
3 Prohibitory Red
4 Safe conditions Green
GSAF 16
ID Card Format
(85 mm x 55mm)
Front side of ID Card:
Section VI- A, Volume – 2, Safety Manual. CMRL2-78

Project December 2021
Company Logo Name & Address of Main / Sub /
Labour contractor
Name:
GSAF 17
Backside of ID Card:
Employee Address: ________________________________

_______________________________________________
_______________________________________________
_______________________________________________
1 This card is the property of “XX“ (Main / Sub / Labour

Contractor) and must be returned on demand and on transfer /
cancellation of employment.
CHENNAI
Main METRO
contractors’ RAIL LTD.
Address
GSAF No :
DAYS TO BE OBSERVED FOR CREATING OSH&E AWARENESS

GSAF 17
1st Monday to Road Safety Week (Subjected to confirmation from Ministry of Road
Sunday of Transport, Govt. of India every year.)
January
4th February World Cancer Day
16th February Kyoto Protocol Day
March Red Cross Month
4th March National Safety Day
22nd March World Water Day
7th April World Health Day
14th April Fire Safety Day
April 18 to 22 Earth Week
20th April Noise Awareness Day
22nd April Earth Day
28th April ILO World Day for Safety and Health at Work Day
May 1 to 7 Emergency Preparedness Week
5th June World Environmental Day
12th June World Day against Child Labours
9th July Occupational Health Day
9th Sep World First Aid Day
17th October World Trauma Day
1st December World AIDS Day
GSAF 18
MINIMUM LIGHTING REQUIREMENTS
Luminance – Ix
S.N. Facility or Function
(Im/ft2)

Administrative areas (offices, drafting and meeting rooms,
1. 540 (50)
etc.)
Construction areas
- general indoor
- general outdoor 55 (5)
2.
- tunnel and general underground work areas 33 (3)
(minimum 110 lux required at tunnel and shaft 55 (5)
heading during drilling, mucking and scaling)
Access ways
3. - exit ways, walkways, ladders, stairs 110 (10)
Maintenance / Operating areas / shops
- vehicle maintenance shop
- carpentry shop
325 (30)
- outdoors field maintenance area 110 (10)
55 (5)
4. - refueling area, outdoors 55 (5)
- shops, fine details work 540 (50)
325 (30)
- shops, medium detail work 325 (30)
- welding shop
5. Mechanical/electrical equipment rooms 110 (10)

6. Hoists, Elevators, freight and passenger 215 (20)
Warehouses and storage rooms/area
- indoor stockroom, active/bulk storage
110 (10)
7. - indoor rack storage 270 (25)
- outdoor storage 33 (3)
8. Health Centers and First aid stations and infirmaries 325 (30)
9. Toilets, wash and dressing rooms 110 (10)
10. Work areas – general (not listed above) 325 (30)
11. Parking areas 33 (3)
12. Visitor areas 215 (20)
13. Laboratories 540 (50)

Labour Camps GSAF 19
PORTA CABINS EMERGENCY PREPARDNESS BEDS, COOLING AND

AND RESPONSE PROCEDURE LOCKER FACILITY
• Ensure that the flammable storage • Provide appropriate security • Locate the DG sets away from
is kept away from the residential personnel to prevent unauthorized the flammable storage area.
zones. entry in to the camp area. • Enclosed type of DG sets will
• Display emergency contact • Maintain register to keep a track on be ideal to avoid unnecessary
numbers clearly and prominently. the head count of persons present in noise.
• Display & communicate to workers the camp at any given time. • Provide proper floor and
the MSDS and action to be taken in • Control the traffic movement & bunding if required to take care
case of an emergency. provide enough parking spaces for of spillage.
vehicles.
GARBAGE COLLECTION & SEPTIC TANK WASHING FACILITY
DISPOSAL
• Provide appropriate bins for • Provision of enclosed type of septic • Provide adequate clothes
collecting garbage. tank is mandatory. washing facilities.
• Dispose off the garbage on regular • Dispose off the sewage regularly. • Provide appropriate clothes
basis. • Do not allow the septic tank to drying facility.
• Carry out pest control in this area. overflow. • Ensure that proper drainage
Keep the surrounding clean & tidy. system is provided &
maintained.
KITCHEN FACILITY DINNING AREA SHOPPING
• Provide proper kitchen facility for • Provide shaded dining area with • Provision of shopping facility
cooking food. tables & chairs for eating food. will be added advantage.
• Take necessary Fire safety • Ensure that proper lighting and • Household items may be sold at
precautions in this area. ventilation is provided in this area. this out let.
• Always maintain good • Provide adequate numbers of insect • Do check for expiry dates of
housekeeping in this area. killers in this area. food & other items being sold.
• Always maintain good • Maintain good housekeeping in
housekeeping. this area.
• Obtain necessary license/
permission for shops.
FIRST AID RECREATION AREA REST ROOMS
• Provide First aid facility round the • Provide recreation facilities for the • Provide well shaded rest rooms.
clock. workers with TV & Audio • Provide sufficient numbers of
• Maintain stock of medicines as per arrangement. chairs and tables for workers.
the TBOCWR 2006. • Adequate air conditioners to be • Keep the area clean.
• Provide full time designated first provided for better ventilation.
aider or male nurse as the case may • Maintain good housekeeping in this
be. area.

Accident Investigation & Reporting – GSAF 20
PROCEED TO THE LOCATION CALL AMBULANCE / INFORM RELEVANT

OF ACCIDENT FIRE BRIGADE PEOPLE
• Immediately proceed to the • Do not panic. • Inform relevant Project

location of an accident as soon as • Call the concerned emergency /Construction Manager.
you receive the information / call. services if accident is serious. • Inform relevant OHS&E
• Assess the situation. Manager / Engineer.
• Find out the type of emergency. • Ensure that all the reportable
• Check out if anyone is injured. Police - 100 accidents / diseases as described
• If minor injury provide first aid. Ambulance - 108 under TBOCWR 2006 are
Fire - 101 reported to Employer /ER
COLLECT EVIDENCE &

CORDON OFF THE AREA REPORT TO EHS
INVESTIGATE
• Cordon off the accident area by • Collect evidence before it is moved • Report the accident to
using PVC tape & cones. or altered. Employer/ER, as per the Form
• Do not allow unauthorized access. • Take necessary photographs. No: 8A within 12 hours of the
• Ensure that the scene of the • Speak to eyewitnesses and collect accident.
accident is not disturbed until full facts. • Do not hide any accident or
investigation has been completed. • Note down the time and other details information.
as necessary. • Follow the contact no and email
• Report facts to ensure rumours & id of OHS&E for emergency
false information are not spread. reporting

First Aid Room / Facilities – GSAF 21
DISPLAY EMERGENCY FIRST AID BOX /

APPOINT FIRST AIDER
CONTACT NO’S CUPBOARD
• Appoint one full time first aider • Telephone numbers of hospitals or • First aid box shall be placed in a
• Appoint male nurse. ambulances and police shall be clearly identified and readily
displayed at conspicuous places. accessible location.
• Display name & contact no of the • It should contain a sufficient
first aider at the site office & other quantity of suitable first-aid
prominent places. materials.
• Emergency contact no of OHS&E • Ensure that the contents of the
also displayed at conspicuous places first-aid box or cupboard are
protected from dampness and
dust.
FIRST AID ROOM ACCIDENT REGISTER FIRST AID FACILITY
• Provide suitable staff & equipped • Provide and maintain Accident • Contents of the first-aid box /
first-aid room. Register to record all the first aid cupboard shall be as per
• Dispose off the expired medicines cases. Schedule III mentioned
in an environmentally friendly • Keep track of the number of man TBOCWR 2006
way. days lost through work related • First-aid facilities shall meet the
accidents. requirements specified in
TBOCWR2006

Personal Protective Equipment – GSAF 22
RESPONSIBILITY FOR ISSUE PPE TO BE USED AS LAST

PPE’S SHALL CONFIRM TO
OF PPE’S RESORT
• It is the responsibility of the main • Adequate control measures shall be PPE shall confirm to following
contractor to provide protective taken by contractors to protect
clothing including coverall and workers against the hazards. • Head Protection
other PPE required for different • Contractor shall not wholly rely on • Eye & Face Protection
operations. the PPE’s. • Hearing protection
• Contractor shall bear the cost of • Risk Assessment undertaken to • Protective clothing
issuing coverall and PPE’s. identify type of PPE required. • Hand protection
• Foot protection
• Safety belt, life line & lanyard
• Respiratory protection
ALTERATION / RESPONSIBILITY OF ITS

MAINTENANCE
MODIFICATION USE
• It is the responsibility of workers to • Personal protective equipment shall • It is the responsibility of line
maintain the PPE in good usable not be altered or modified. management to implement the
condition. • Do not use PPE that is damaged or effective use of PPE issued to
• However damaged PPE shall be worn out. workers.
replaced immediately by the • It must be replaced. • Workers must follow the
contractor . instruction they are given with
regard to using & maintaining
PPE.

Storage of LPG Cylinders – GSAF 23
LOCATION SHED FOR LPG CYLINDERS SECURITY
• LPG cylinders shall be stored away • Store LPG cylinders in a well- • Storage shed shall be kept under
from combustible materials. ventilated shed, made up of non- lock and key.
• Cylinders shall be stored at ground combustible material. • Key shall be readily available
level and be readily accessible. • It should be protected from extreme all the time.
• Do not store close to occupied weather / shelter provided. • Do not allow unauthorized
building. • LPG cylinders shall be stored at least access by providing a fence 2.5
• Follow Gas Cylinder Rules for 3 meters’ away from other cylinders meters’ high.
better practice. like oxygen, chlorine, ammonia. • Keep the cylinder valve closed
• Always store or keep LPG cylinders if not in use.
in vertical position.
EMERGENCY PROCEDURES DISPLAY NOTICES MAINTENANCE
• Develop a written procedure to • Display notices such as, “LPG – • Maintain all the installations by
deal with emergencies that may Highly Flammable”, “NO trained LPG fitters.
arise. SMOKING” or “NO NAKED • Pipe lines / hoses if any shall be
• Provide appropriate fire FLAME”. tested for safe working /
extinguishers as per TBOCWR • Display notices in languages that are leakages.
2006 understood by the workforce. .
• Maintain all fire-fighting
equipment in good working
condition as per TBOCWR 2006
• Ensure Personnel are trained to
deal with any emergency that may
arise.

Storage of Flammable Liquids – GSAF 24
LOCATION &
CONTAINERS & TANK BUNDING & FLOORING
STORAGE SHED
• Use containers and portable tanks • Do not store flammables near exits, • Provide concrete floor for the
made of material suitable for stairways or in passages used by flammable storage area.
storage of flammable liquids. people. • Proper bunding to be provided
• Always store flammable liquids in • Keep the store under lock and key. to contain any leakage.
a closed vessel. • Structure should be fire resistant. • Drums must be stored in a
• Keep minimum 1.5 metres space bunded area too.
between two portable tanks as per • Capacity of the bund should be
Petroleum Rules 1.5 times the storage capacity.
• Keep the area free from weeds,
debris & other combustible
materials.
FIRE SAFETY PRECAUTIONS DISPLAY NOTICES & MSDS MAINTENANCE
• Provide appropriate fire • Display notices such as, “Flammable • Maintain all the installations by
extinguishers as prescribed as per Liquid”, “NO SMOKING” or “NO trained & experienced fitters.
TBOCWR 2006 NAKED FLAME”. • Pipe lines / hoses if any shall be
• Maintain all fire-fighting • Communicate & Display Material tested for safe working / leakage
equipment in good working Safety Data Sheet (MSDS). on a regular basis.
condition. • Display notices in languages that are
• Install flame proof electrical understood by the workforce.
fittings in the area.

Manual Lifting – GSAF 25
KEEP THE BACK

ASSESS THE LOAD POSITION YOURSELF
STRAIGHT
• Assess the load to be lifted. • Come closer to the load to be lifted. • Bend your knees.
• Do not lift more than individual’s • Avoid over reaching or stretching. • Keep your back straight (but not
capacity. • Position your feet properly in the vertical).
• Avoid lifting if you are medically direction of load to be moved. • Keep chin tucked into the body.
unfit or sick.
• Wherever possible make use of
mechanical lifting aids.
CORRECT GRIP LIFTING CARRYING LOAD
• Take a firm grip by using the palms • If lifting from ground make • Make sure you can see where
of the hands and roots of fingers. maximum use of legs. you are going.
• Take care of the sharp edges. • Lift the load smoothly. • Avoid twisting the body, move
• Use appropriate PPE such as • Avoid giving jerk. your feet instead.
gloves, safety shoes etc. • Never lift the load using your back. • Keep control of the load.
• Keep your back straight at all
times.
• Take care that your fingers are
not trapped below the load.
• Check & remove tripping
hazards if any.
• Ensure adequate lighting levels
are maintained.

Permit to Work (PTW) – GSAF 26
PTW REQUIREMENT & VALIDITY OF

CANCELLATION OF PTW
RESPONSIBILITY OF ISSUE PERMIT TO WORK
• PTW is required for hazardous • PTW is valid only for the day on • Work Permit can be cancelled if
activities like, which it is issued. the work is being carried out in
• Hot Works. • It can be renewed provided the work an unsafe manner.
• Confined space entry. is continued by same group of • Cancelled work permit shall not
• Cartridge operated tools workers & at the same location. be reopened.
• Excavation • PTW must be signed by the area • New PTW to be obtained to
• Responsibility for ensuring a PTW supervisor. continue the stopped work.
is issued lies with the Main • Explain hazards involved &
Contractor. precautions to be taken to the
• Comply with all the safety workers concerned.
regulations as applicable for • Display PTW & safety notices in the
different type of works. area where work is carried out.
• Activity for which PTW is issued
must have Risk Assessment done.
•
CLOSING OF PTW TRAINING PPE
• PTW shall be closed only after • Workers associated with hazardous • It is the responsibility of main
work is completed in all respect. works shall be trained prior to contractor to ensure that
• Proper housekeeping shall be starting the work. appropriate PPE is issued before
maintained during and after • Records of toolbox talk given shall starting the work.
completion of work. be maintained. • Supervisor must ensure that
• Keep the record of issued PTW for • Everyone involved must understand PPE is worn by the workers at
at least six months. PTW requirements. all times.
• Ensure fire watch for at least 1
hour after completion of hot work.

Excavation – GSAF 27
PRIOR TO EXCAVATION BARRICADE THE AREA DISPLAY NOTICES
• Identify the presence of • Adequately barricade the area to be • Display adequate warning
underground installations & take excavated. notices in languages understood
necessary safety precautions. • Do not stack any material near the by the workers.
• Obtain NOC from service edge of any excavation, shaft, pit or • Provide flashing amber lights if
authorities opening in the ground. excavation is left open
• Ensure that Risk Assessment is • No load or plant or equipment shall overnight & there is a risk of
done for excavations & necessary be placed near excavation to prevent vehicles passing by.
safety precautions taken. collapse. • No unauthorized access to be
• Employ cable avoidance tool • Provide sufficient lighting for safe permitted.
(CAT) prior to excavating. operations.
PPE & FRESH AIR SAFE ACCESS & EGRESS SHORING & DEWATERING
• Personal protective clothing & • Provide ladder or steps for safe • If the depth of vertical cut
equipment shall be provided to the access & egress. exceeds 1.0m provide shoring.
employees & be worn. • Evacuation plans & procedures must • Provide shoring if there is a
• Contractor shall provide be made known to employees. possibility of fall or
instruments to test the atmosphere • An emergency hoisting facility shall dislodgement of earth, rock or
for oxygen deficiency in any be readily available at shafts other material.
excavation. • The angle of repose & design of
• Provide adequate ventilation where the supporting system shall be
there is insufficient movement of based on depth of cut, soil,
air. loading, system of dewatering,
• Ensure that minimum of 19.5% & vibrations, traffic etc.
maximum of 23.5% oxygen level • Ensure that surface water does
by volume is maintained in the air. not enter the excavated areas &
• Do not allow any person to enter if / or water shall not be allowed
the air is suspected to be poisonous to accumulate in an excavation.
or asphyxiating.

Hand Tools – GSAF 28
SELECT RIGHT TOOL USE THE TOOL CORRECTLY / QUALITY OF TOOL /
FOR THE JOB USE OF PPE UNSAFE TOOL
• Always select right tool for the job. • Always use hand tools in accordance • Ensure that good quality tools
• Supervisors have a responsibility to with the manufacturer’s instructions. are selected, procured & issued
ensure correct tools are available. • Managers and supervisors must to labourers.
• Use tools for their designed provide training in the use of tools • Unsafe hand tools should be
purpose only. where necessary. removed from site.
• Do not modify tools in any way. • Use appropriate PPE as detailed in (e.g. Mushroom headed chisel)
manufacturers’ instructions. • Broken or damaged tools should
• It is the responsibility of main be disposed of.
contractor to provide PPE. • Register to be maintained for
issuance of PPE.
STORAGE OF TOOLS & CARTRIDGE OPERATED
POWER OPERATED TOOLS
MAINTENANCE TOOLS
• Provide suitable cabinet for storage • Select & use tools operating at 110V • No person shall use cartridge
of tools & identify them. where possible. operated tools unless he has
• Return all tools to their proper • Ensure that the guards are fitted to been trained & is experienced in
store after use. all moving parts. the operation.
• Protect the tools by keeping them • Make employees aware of the • Make employees aware of
away from extreme weather. hazards & manufacturers operating hazards & manufacturers
• Maintain hand tools in good instructions. operating instructions.
working condition, inspect them • Do not carry tools by holding the • Shall be fitted with guards if
regularly for defects. electric cables. there is potential hazard of
• Where a specific tool is not available flying pins & splinters.
at 110V then 240V must be used • Main contractor to adopt written
only with 30mA RCD. procedure to control the issue,
use, storage & maintenance of
cartridge tools.

Arc Welding & Cutting – GSAF 29
WELDING MACHINE & WELDING ROD, HOLDER,

HOT WORK PERMIT
CONNECTIONS CABLE & EARTHING
• Select the correct welding machine • Obtain Hot work Permit from the • Do not bend the welding rod &
depending upon the type of metal area supervisor & to be closed daily. flux should be intact.
to be welded. • Cordon off the area & display PTW • Ensure that the holder is
• Ensure that connection is done by where welding work is carried out. properly insulated.
certified electrician. • Welding operations shall be shielded • Welding cable should be
• Keep the welding machine away by non-combustible or flameproof completely insulated, flexible &
from the source of heat. screens to protect people working in capable of handling the
• Ensure that the cables are not the close vicinity from ultra violet maximum current requirements
causing a tripping hazard. rays. of the work.
• Do not overload the welding • Welding or cutting work shall be • Pipe lines containing gases or
machine. performed away from the flammable flammable liquids or electrical
• Switch off the power supply to the goods storage. conduits shall not be used as a
machine when not in use. • Flammable containers shall be ground return.
drained, washed, dried thoroughly &
purged with inert gas.
FIRE FIGHTING EQUIPMENT

FUME EXTRACTION SYSTEM TRAINING & FIRE WATCH
& PPE
• Provide appropriate fire-fighting • Provide adequate mechanical fume • Contactors shall instruct
equipment as prescribed as per extraction & / or forced ventilation employees in the safe means of
TBOCWR 2006 whenever work is not carried out in arc welding and cutting.
• Workers shall be protected by the open air. • Provide fire watch for at least an
suitable eye, face, hand, body, foot hour after completion of
& respiratory protective welding or cutting work.
equipment.

Gas Welding & Cutting – GSAF 30
FLASH BACK ARRESTOR,

LOCATION OF WORK
HOT WORK PERMIT HOSE PIPES & PRESSURE
& TROLLEY
GAUGES
• Keep the flammable storage away • Obtain Hot work Permit from the • Ensure that Flash back arrestors
from the gas welding & cutting area supervisor & to be closed daily. are provided on both the
operation. • Cordon off the area & display the cylinders.
• Keep & store the gas cylinders permit where welding & cutting • Hose pipes must be connected
away from the source of heat. work is carried out. with proper clamps.
• Always keep the gas cylinders • Operations shall be shielded by non- • Maintain pressure gauges in
vertical in a trolley & tied with combustible or flameproof screens to working condition.
chain. protect people working in the close • Torch should be kept free from
• Do not lift gas trolley with crane. vicinity. molten metal slag.
• Flammable containers shall be
drained, washed, dried thoroughly &
purged with inert gas.
FIRE FIGHTING EQUIPMENT
STORING GAS CYLINDERS TRAINING & FIRE WATCH
& USE OF PPE
• Provide appropriate fire-fighting • Provide adequate mechanical fume • Contactors shall instruct
equipment as prescribed as per extraction & / or forced ventilation employees in the safe means of
TBOCWR 2006 whenever work is not carried out in arc welding and cutting.
• Workers shall be protected by the open air. • Provide fire watch for at least an
suitable eye, face, hand, body, foot • Gas cylinders shall be stored in a hour after completion of
& respiratory protective well-ventilated shed made up of non- welding or cutting work.
equipment. flammable material.
• Keep the valve caps in place.

Bench Grinders – GSAF 31
DETAILS OF MACHINE GURADING REST BRACKETS
• RPM to be displayed on the • Ensure that the guard is fixed to the • Rest bracket should be properly
machine. machine. secured & must be adjustable.
• Emergency stop button must be • Guard must be replaced after • Keep the rest bracket in
located on the machine. carrying out any maintenance work horizontal position.
• Keep the area around machine if any.
clear of all materials. • Cover the abrasive wheels after work
• Keep the machine switched off is completed.
when not in use.
ABRASIVE WHEELS SAFETY NOTICES / PPE TRAINING & USE
• Select the correct wheel for the job • Display safety notices in the • Provide appropriate training to
to be grinded. languages easily understood by the the workers.
• Ensure that the safe peripheral operators. • Do not apply excessive pressure
speed of the wheel is not exceeded. • Display names of the operators on to the wheels.
• Abrasive wheels shall be mounted, authorized to operate the machine. • Never grind on sides of the
balanced & dressed by trained and • It is the responsibility of the wheel.
experienced person. contractor to provide appropriate • Do not try to stop the rotating
• Ensure that wheels are mounted PPE like face shield or safety wheel by hand.
using washers / blotters. goggles. • Any person mounting,
• Do not use wheels that have been • Area supervisors will ensure that the balancing or dressing an
dropped or cracked. It should give operator uses the issued PPE. abrasive wheel must be trained
clear ringing sound. & appointed in writing.
• Worn out wheels must be replaced
immediately.

Circular Saw – GSAF 32
RIVING KNIFE & PUSH

DETAILS OF MACHINE GURADING
STICK
• Machine shall be positioned such • Ensure that the crown guard is fixed • Ensure that Riving knife is fitted
that there is no obstruction to to the machine. & is in place while machine is
operator & others. • Guard the fly wheel & belt located being operated.
• Always keep the machine switched below the machine. • Maintain appropriate distance
off when not in use. • Guard must be of adequate strength between the circular blade &
• Emergency stop control must be & of good construction. riving knife as prescribed in the
provided on the machine & should • Guard should not create any danger manufacturers operating
be easily accessible. to the operator while using. manual.
• Keep the space around the machine • Guard must not be bypassed or • Make use of Push stick when
clean & free from any obstructions. removed. there is a danger of hand
• It will be ideal if saw dust • Disciplinary procedure in place to coming in to contact with the
extraction system is provided if deal with any safety violation. revolving blade (danger zone).
used inside a building. • Ensure adequate lighting
arrangements have been made.
TRAINING &
SAFETY NOTICES / PPE USE & MAINTENANCE
AUTHORISATION
• Display names of the operators • Display safety notices in the • Do not apply excessive pressure
authorized to use the machine. language easily understood by the on the blades.
• Do not try to stop the rotating blade operators. • Circular saws are for straight
by hand. • It is the responsibility of the edge cutting never try to cut in
• Cutting work should be carried out contractor to provide appropriate curves.
under the supervision of a trained PPE like face shield, safety goggles • Maintain machine in good
& experienced person. & respiratory protection. working condition.
• All circular saw operators must be • Area supervisors will ensure that the • No adjustments shall be made
trained & competent and operator uses the issued PPE. while the machine is in motion.
authorized to use the machine. • Regular monitoring of airborne • Ensure that the guard is replaced
particles must be carried out & if back immediately after the
hardwoods are machined a full maintenance work is completed.
assessment must be undertaken. • Blades with broken teeth should
be replaced immediately.
Electricity at Site – GSAF 33

DESIGN & LOCATION PROTECTION SAFETY MEASURES
• Design & installation of temporary • Mechanically protected cable such as • Provide necessary protective
electrical power systems must be SWA must be used where any cables devices such as Earth Leakage
carried out by a competent above 110V are run across site. Circuit Breaker (ELCB) in the
electrical C licence. • Tools shall be disconnected before circuit to avoid risk of shock,
• Circuit breakers must be any adjustments are made or fire or burns.
appropriate for the circuits they are attachment changed. • Where cranes or excavators etc.
protecting. • All distribution boards must be kept are in operation or scaffolding is
• Cables and connections must meet under lock and key. being erected near overhead
the standard requirements & • Distribution board must be covered cables install warning barriers to
adequate steps must be taken to to protect from weather. keep persons & plant clear.
prevent cable damage in • Always use industrial sockets for • Ensure that supply cables for
construction area. joining & connecting cables. fixed plants shall be routed clear
• Inspect all cable regularly & ensure of construction work & are
any damage is repaired / replaced by protected against traffic
a competent electrician. movement & water.
• Make use of reduced voltage of
110V where tools are available.
• Ensure that RCD with 30mA
trip fitted on all 220-240V tools.
• Never insert loose wires of a
tool cord into a socket.
AUTHORISATION / SAFETY NOTICES TRAINING / LOCK OUT &

CERTIFICATION & USE OF PPE TAG OUT
• Ensure that all electrical work at • Display sign board on work area for • Provide necessary training to all
site is executed by qualified & safety awareness. electricians and workers
authorized competent person. • Display danger sign & voltage concerned.
• Contact numbers of Electrical C details on all electrical panels / • Conduct a tool box talk on safe
licence Competent shall be distribution boards used at site. use of electricity on site
displayed prominently & all the • The main contractor shall ensure that • Use lockout & tag out
electrical connections shall be necessary PPE is worn by the procedures when working on
checked and approved through electricians to prevent electrical electric circuits coupled with
them. shock or burns. permit to work systems.
• All hand tools used by electricians • Only instigator can remove lock
shall be insulated & in good out or tags from electric
condition. sources.
• No live working to be carried
out.
• All circuits must be isolated
before work commences.
Air Receivers – GSAF 34

PRESSURE GAUGE
POSITIONING DRAIN PIPE & VALVE
& SAFETY VALVE
• Air receivers shall be placed away • Ensure that adequate drain pipe & • Every air receiver shall be
from the combustible materials & valve is installed at the lowest point equipped with a pressure gauge
sources of heat. of every air receiver to remove & safety valve.
• Air receivers must never be buried accumulated oil and water. • Ensure that the safety valve is
underground or located in an • Adequate automatic traps may be tested frequently in accordance
inaccessible place. installed in addition to drain valves. with the manufacturer’s manual.
• Air receivers shall be placed with • Completely drain the air receiver by
sufficient clearance to allow a opening drain valve at such intervals
complete external inspection. as to prevent the accumulation of
excessive amount of liquid.
TESTING & CERTIFICATION GUARDING HOSE CONNECTION & USE
• Ensure that proper guards are • Air lines shall be connected

provided to all the moving parts like using proper clamps.
• Every pressure vessel shall be
fly wheel & belt. • Air lines should be of good
examined by a competent person as
• Replace the guard immediately after approved quality.
per TBOCWR 2006
completing maintenance work. • Never use compressed air for
• Testing frequency shall be once in
• Undertake regular inspections to cleaning of clothes or body
6 months.
check the guarding of the machine. parts.
• It shall be examined by visual
• Whip checks must be provided
examination & hydrostatic or
to all connections in a
pneumatic test.
compressed air line.

Confined Space Entry – GSAF 35
RISK ASSESSMENT TESTING & MONITORING COMMUNICATION
& ENTRY PERMIT OF ATMOSPHERE & USE OF PPE
• Ensure that Risk Assessment (RA) • Establish testing of atmosphere prior • Ensure that there is an agreed
is done and precautions are taken to entry where identified in the risk means of communication
accordingly. assessment. between those in the confined
• Confined space entry permit to be • Also carry out ongoing monitoring space & the person(s) appointed
obtained before entering & of the atmosphere whilst work is as the look out.
carrying out work in a confined being carried out. • Use PPE as prescribed in the
space. • Isolation & lock off procedure must Risk Assessment.
• Main contractor must ensure that be followed to prevent gases, liquids • Escape set breathing apparatus
the permit to work procedures & or other free flowing materials to be provided where there is a
working procedures are regularly entering the confined space. risk of a hazardous atmosphere
checked & audited. • Flameproof electrical equipment developing.
• Confined space shall be certified shall be used in case of possible • All persons entering a confined
by a competent person based on the flammable gas atmosphere. space must wear safety
test carried out by himself. harnesses to facilitate rescue in
an emergency situation.
SAFE ACCESS / EGRESS TRAINING, SUPERVISION & VENTILATION &
& DISPLAY OF NOTICES EMERGENCY PROCEDURE AIR QUALITY
• Provide adequate trained supervision • Provide good ventilation in the

• Ensure that safe access & egress
for the confined space working. confined space to prevent stale
are provided into and out of the
confined space. • Maintain a tally of people with air & ensure that the air quality
name, number & time of entry & exit remains breathable.
• Display appropriate warning signs
from the confined space for any • Remove any residue that may be
& notices in languages that are
emergency purposes. present & may give rise to risk
easily understood by the work
• Establish & communicate an to workers working in confined
force.
emergency procedure to deal with spaces.
• Before using open flames in a
rescue or recovery of any workers • In case of an excessive
confined space, combustible gases
who become injured or dehydrated. temperature reduce the time of
or liquids must be removed if
• Practice the evacuation drills on working shifts and give frequent
present.
regular basis. breaks.
• Manholes used for access should
• Make arrangements to ensure
be rectangular, oval or circular in
that workers do not become
shape & be not less than
dehydrated whilst working in
450mmX407mm or 457mm
excessive temperatures.
diameter.
Scaffolding – GSAF 36

SELECT THE INSPECT THE MATERIAL TRAINING TO
TYPE OF SCAFFOLD & GROUND CONDITIONS SCAFFOLDERS
• Check, for what purpose scaffold is • Scaffold material including fixtures • Select & engage experienced
required. shall be of adequate strength & free scaffolders for the job.
• Select the correct type of scaffold from any defects, corrosion and • They should possess a
for the job. bends. professional training certificate
• Scaffold should take the load of • Ground should be levelled & by OHS&E approved third party
man, material and equipment to be compacted properly. agency.
used. • Do not erect scaffold on loose soil. • Work should be carried out
• Scaffold extended over the height under the supervision of
of 6m must be designed by a competent person (scaffold
competent scaffold designer. supervisor).
• Take into account the weather • Impart tool box talk to the
condition too. labourers.
BARRICADE THE AREA & BASE PLATES & FULLY BOARDED
DISPLAY NOTICES ALL THE FIXTURES WORK PLATFORMS
• Barricade the area where scaffold • Provide base plates below all the • Work platform shall be fully
has to be erected or dismantled. uprights or standards. boarded not less than 200mm
• Display adequate cautionary • Ensure that all the ledgers, transoms wide & 38mm thick.
notices and signs. & cross bracings are used and • Secured properly.
• Do not allow any unauthorized tightened / clamped properly. • Width of the platform shall not
access. • Ties to be provided in accordance be less than 60 cm when used
with design. for persons only & shall be 80
cm) when used for man and
materials.
• Width of gangway shall be 43
cm for passage of persons only
and 60 cm if used for passage of
material.

Mobile Scaffold – GSAF 37
WORK PLATFORM &

SELECTION & ERRECTION WHEELS & OUTRIGGERS
ACCESS / EGRESS
• Ensure that the mobile scaffold is • Provide full planking. • Provide wheels as per the
of good construction, sound • Use internal ladder with protected manufacturer’s instruction
material & adequate strength. opening. manual.
• Take into consideration the type of • Ensure that the guardrails and toe • Ensure that all the castors are
work, height & weather conditions. boards are in place on all open sides. capable of being locked & in
• Place the mobile scaffold on level • Ensure that access & egress ladder is good condition.
& firm ground. properly secured to the scaffold. • Keep all the castors locked
• Keep the scaffold loads to • Do not exceed the scaffold’s when work is performed from
minimum (including tools & working load. the scaffold.
equipment). • Tagging system must be strictly • Unlock it while moving.
• Do not use partly erected or followed for using mobile scaffolds. • Provide outriggers if required as
dismantled scaffold. per the manufacturer’s
• Carry out risk assessment & take instruction manual
the necessary safety precautions.
TRAINING & PPE USE & SUPERVISION HEIGHT & WIDTH RATIO
• Ensure that only authorized people • Never move the scaffold when • Ensure that the maximum height
are allowed to assemble, use and someone is on the scaffold. to shortest width ratio of the
dismantle mobile scaffolds. • Provide adequate supervision by mobile scaffold does not exceed
• Wear appropriate personal deputing an experienced person. 3.5:1 for indoor works and 3:1
protective equipment as suggested • Never use mobile scaffold during for outdoor works.
by the manufacturer or identified in high winds. • Never climb the outside of any
the risk assessment. • Take adequate safety precautions mobile scaffold tower which
• Any scaffold must be erected by where overhead electric cables are can overturn even a correctly
persons trained through OHS&E running. erected tower.
approved third party. • Carry out weekly inspections of the
scaffold.

Working at Height – GSAF 38
RISK ASSESSMENT /
SAFE WORK PRACTICES TRAINING
PERMIT TO WORK
• Ensure that Risk Assessment (RA) • Ensure that proper safety • Working at height shall be
& Method Statement have been arrangements have been made for carried out by experienced &
completed prior to carrying out the working at height. trained workers.
work at height. • Ensure all the control measures • Record of induction training &
• Hazards involved and safety identified in the Risk Assessment tool box talks shall be
precautions to be taken shall be (RA) are implemented at site & safe maintained.
communicated to workers involved work practices are followed. • If new person is appointed, they
in working at height. • Provide life line where proper shall carry out work under the
• In special cases ensure that permit platform cannot be provided. supervision of an experienced
to work is obtained prior to starting • Cordon off the area where work at worker.
the work at height. height is carried out & provide • Medically unfit persons must
• Follow hierarchy of controls for warning signs. not be engaged to work at
mitigation of risk. height.
• Training in use of safety harness
should be given to workers.
USE OF EQUIPMENT &

USE PPE & DISPLAY NOTICES EMERGENCY ARRANGEMENTS
TESTING
• It is a responsibility of the main • Risk Assessment must detail • Equipment such as hydraulic
contractor to issue required PPE to emergency procedures including lifters or scissor lifts should be
all the workers. rescue of any person suspended by utilized where there is a space
• If proper working platforms cannot their safety harness within 10 constraint.
be provided, use full body harness minutes. • Equipment like temporary
having attachment of fall arresting • Display names & contact numbers of suspended working platform
device. the persons to be contacted in case of (cradle) shall be tested through
• Display notices in languages easily an emergency. OHS&E approved third party.
understood by workers.

Mobile Cranes – GSAF 39
POSITIONING OF CRANE &

SELECTION OF CRANE
TESTING & CERTIFICATION
RIGGING
• Select the right crane for the load • Lifting equipment must be tested • Ground must be leveled &
to be lifted. every 6 months through OHS&E compacted & shall be stable for
• Crane must be of good mechanical approved third party. positioning of crane.
construction of sound material, • Lifting must be done under the • Ensure that the crane does not
adequate strength & free from any supervision of appointed person with possess any hazard to other
defect. relevant experience. workers & moving traffic.
• Risk assessments (RA) must be • Crane operator, signaller / rigger • Outriggers must be used with
carried out for all mechanical must have competency certificate pads below.
lifting. issued by an OHS&E approved third • Make use of safe & tested
• Method of lifting as per the RA party. lifting tackle marked with SWL
must be communicated to all those • Carry out weekly service inspection on it.
involved. of crane which must be recorded in a • Lifting tackle must not be
• Detail of crane capacities at various register. altered, lengthened or repaired.
radiuses must be displayed • Ensure that all operators, signaller / • Do not position the crane
prominently. rigger are medically fit & have good unsafely near excavated pit or
• Cranes over 1 ton capacity must be eye sight. trench.
fitted with SLI/ASLI. • Lifting tackle must be free from
• Provide proper access & egress to any defects.
operator’s cabin.
• Ensure that limit

Tower Cranes – GSAF 40
CLIMBING FRAMES &

COMMUNICATION TRAINING & PPE
EMERGENCY
• Provide effective means of • All operators, signallers, slingers to • Climbing frame used in the
communication between the crane be trained & certified by OHS&E tower crane must be tested &
operators & signallers, slingers. approved third party. certified by a competent third
• When there is no clear line of sight • Use PPE as identified in RA & as party engineer.
between operators & signallers and recommended in the manufacturer’s • Emergency procedure to be in
when tower crane is erected the operation manual. place in case of any emergency.
operators cab, provide radio • Lifting equipment must be tested • Display emergency contact
communication. every 6 months & also after any numbers.
• Crane must be of good mechanical modification (i.e. jumping) through • Ensure that all the limit switches
construction, sound material, and OHS&E approved third party. are in working condition.
adequate strength and free from • Carry out weekly service inspection • Method of lifting as per the risk
any defect. of the crane which must be recorded assessment must be
• Risk Assessments (RA) must be in a register. communicated to all those
carried out for all mechanical • Ensure that all operators are involved.
lifting. medically fit & have good eye sight. • Lifting operations must be
• Detail of crane capacities at various • Lifting must be done under the planned, supervised, monitored
radiuses must be displayed supervision of appointed person with & reviewed.
prominently. relevant experience. • Ensure that people involved in
• Cranes over 1 ton capacity must be any lifting operation are
fitted with SLI/ASLI. competent to carry out their
• Provide proper access & egress to work safely.
operator’s cabin. • Lifting accessories must be safe
• Wherever possible ensure cranes & thoroughly examined by a
are positioned to avoid collision competent person every 6
• Position the crane such that it does months.
not possess any hazard to others. • Lifting tackle must not be
• Where it is possible for 2 or more altered or repaired.
cranes can collide, anti-collision • Lifting tackle must be free from
devices must be installed. any defects.
• Ensure that the highest crane is • Ensure that SWL is marked on
fitted with anemometer & kept in the tested slings.
good working condition. • Cordon of the area & display
• Do not operate the crane in high adequate safety notices.
winds refer crane manual.
Safe Use of Ladders – GSAF 41

SELECTION OF LADDER FOOTING / TRAINING USE OF LADDER
• The ladder must extend at least • The ladder must be set on a firm • Risk assessment must be
1metre above the landing place, level footing (not bricks). prepared before carrying out
unless another suitable hand hold is • Do not over load step ladders. any works from ladders or step
provided. • Do not use any metal ladder while ladders.
• Do not use homemade ladders. carrying out electrical works. • Ensure that 3 point contact is
• Metal ladders must have rubber • Long ladder shall be carried by two made all the time while
shoes fixed to its base all the time. persons. climbing or descending a ladder.
• Rung of the ladder must be flat. • Keep the front end of the portable • Ensure that the ladder is used by
• Ensure that the ladder is of ladder 2 metres above the ground only one person at a time
adequate strength and sound level when carried by single person. • The ladder must be set at the
construction. • Person involved in using portable correct angle, approximately
ladder must be given training. 750 with the horizontal.
(1H:4V)
• All ladders used for access must
be securely fixed in place.
• Do not try to stretch too far on
sides whilst standing on the
ladder.
STACKING &
STEP & EXTENSION LADDER INSPECTION & TAGGING
MAINTENANCE
• If working from a ladder or step • Ladder must be inspected by a

• After completion of the works
ladder top 3 rungs must not be competent person at the start of each
ladders should be returned to the
used. shift.
store for maintenance / thorough
• Always ensure extension ladders • Use an inspection tagging system for inspection.
and step ladders are locked ladders.
• Ideally ladders should be stored
securely to prevent collapse. • Defective ladders must be removed off the floor to maintain safe
• Overlapping of two extension from use. access.
ladders shall be done in accordance • Use PPE as per site rules or as per • Ladders with missing rung/s
with the Manufacturers Manual. risk assessment. must not be allowed to use.

GSAF 043
Fire Extinguishers – GSAF 42
TYPES OF FIRE
LOCATION SELECTION & USE
EXTINGUISHER
• Compressive risk assessment (RA) • Install firefighting equipment / • Select the correct fire
must be undertaken for site, labour extinguishers in the area where fire extinguisher depending on the
camp & office fire risks. hazard is present. type of fire.
• Risk assessment must identify • Maintain location plan of fire • Use PASS method to extinguish
sources of fire & detail adequate extinguishers installed. small fire.
control measures. • Access to all available fire • (P – Pull, A-Aim, S - Squeeze,
• Key findings of the assessment extinguishers shall be maintained at S- Swipe)
must be briefed out during the site all times. • Do not use carbon-tetrachloride
& office induction. • Portable fire extinguishers must be fire extinguishers which are
• Inspection checklist should be provided on each floor. prohibited.
prepared to ensure risk assessment • In multi-story buildings, at least one • Only trained personnel should
requirements are complied with fire extinguisher shall be located be allowed to use fire
adjacent to the staircase on each extinguisher to extinguish fires.
level. • Workers must be instructed not
• Travel distance to the nearest fire to take risks when tackling fire.
extinguisher should be within 15m
radius
STACKING &
MAINTENANCE INSPECTION & TAGGING
MAINTENANCE
• Fire extinguisher type, capacity & • Carry out weekly inspection of fire • The main contractor shall
number based upon hazard extinguishers and maintain records. provide adequate firefighting
occupancy as per TBOCWR 2006 • Carry out annual service of fire training to all employees.
• Check the pressure and contents of extinguishers & maintain records. • Maintain a list of people trained
your extinguisher recommended by • Ensure that the tag is present on all in firefighting.
the manufacturer. the fire extinguishers with the date of • Basic fire safety arrangements
• Fire extinguishers must be servicing done. must be included as part of the
maintained in good usable • Do hydraulic testing of fire site & office induction.
condition as per TBOCWR 2006 extinguishers as prescribed as per • Appoint adequate numbers of
• Examine fire extinguishers for any TBOCWR 2006 Fire Fighters at the site.
physical damage, corrosion or • Display names of Fire Fighters,
leakage, defective equipment must preferably near the fire
be replaced immediately. extinguishers.

GSAF 043
Access & Housekeeping – GSAF 43
REQUIREMENTS &
PRECAUTIONS TO BE TAKEN ACCESS REQUIREMENTS
RESPONSIBILITY
• It is the responsibility of the main • Set up designated pedestrian • Undertake risk assessments for
contractor to provide safe access walkways wherever possible. specific access needs taking into
and maintain site housekeeping. • Display clear signage indicating account numbers of workers.
• As part of safe access the main crossing points and directions. • The main contractor must
contractor must consider lighting • Install crash decks over access routes ensure emergency escape can be
requirements that provide access into a building made safely and quickly.
• All access routes must be wide under construction. • Once access is provided
enough to allow people to move • Fix electrical leads up off the ground workers must use the approved
around safely. to reduce trip hazards. access route and not take
• Good housekeeping is the regular • Stairs and passageways must be kept shortcuts.
removal of waste material and clear of rubbish and materials
management of material storage
areas.
INDUCTION & TOOLBOX
WASTE MANAGEMENT MAINTENANCE
TALK
• All workers must be briefed during • Waste must be managed. • Good access and housekeeping
the induction on the importance of • Unmanaged site will quickly become require good management
keeping the site clean and tidy. unproductive through rubbish • Regular monitoring of access
• Regular tool box talks must be accumulation. routes must be carried out.
given to workers as a reminder. • Supervisors must implement a ‘clean • The supervisor or manager of
as you go’ policy. each area must be made
• Special arrangements must be in accountable for maintaining
place for hazardous substances. access and housekeeping.
• Food waste must be collected and
disposed off separately.

Hoists (Man & Material) – GSAF 44
CONSTRUCTION /
ANCHORING WITH MAIN TEST CERTIFICATES SAFETY NOTICES / RULES
STRUCTURE
• Hoist shall be of sound • Test the hoist shall be tested through • Display safety notices /
construction & adequate strength. approved third party as per the Tamil instructions & emergency
• Use the hoist for the purpose of Nadu BOCWR 2006 at an interval of contact numbers in languages
which it is designed (for man or every three months easily understood by the
material). • Retest the hoist when relocated, operators.
• Tie the hoist mast to the permanent modified or extended up to the • Follow safety instructions in
structure at locations recommended higher floors. case of an emergency
by the manufacturer. • Display SWL & maximum number • Defective hoists shall not be
• Provide complete railing on the of persons allowed in the hoist cage. used and ‘DO NOT USE’ board
sides of the floor when cage is • Also display the operator’s training shall be displayed until defect is
stopped on that floor. certificate. rectified.
• Do not overload the cage (either with • Barricade the area around the
persons or materials). hoist at the ground level to
prevent unauthorized access and
crushing injuries.
EMERGENCY STOP BUTTON / FLOOR GATE /
TRAINING / USE OF PPES
LIMIT SWITCHES MAINTENANCE
• Provide & maintain upper and • Always employ competent & trained • Provide gate on each landing
lower level limit switches. operators for operating the hoist. floor or wherever the hoist is
• Make sure that the hoist cage • Impart tool-box talk to all users of made to stop.
cannot be moved or operated the hoist & maintain records. • Inspect every hoist weekly &
unless the hoist gate is closed. • Provide & make sure that people keep records of maintenance.
• Provide emergency stop button in wear adequate personal protective • Ensure that the gap between the
the hoist cage. equipment at all times. floor and the hoist cage is
• Provide appropriate type of fire closed adequately.
extinguisher in the cage. • Provide safe access – egress to
the hoist all the time.

Material Loading Platform – GSAF 45
DESIGN & CONSTRUCTION POSITIONING / LOADING TEST / CERTIFICATION
• It is the responsibility of the main • The location of loading platforms • Material loading platform shall
contractor to provide & maintain should be decided by the main be tested through approved third
loading platforms. contractor. party as per the Tamil Nadu
• The loading platform design must • Locate loading platforms so that they BOCWR 2006 at an interval of
be approved by a 3rd party do not create a snag hazard for the every three months.
competent person site tower cranes. • Loading platforms must also be
• Suitable edge protection must be • Load material such that it does not tested whenever modified or
provided to the edges where exceed the guardrail height. relocated.
persons and/or materials can fall. • Loading activity shall be performed • Clearly display safe working
• Any loading platform gates must in the presence of competent banks load at each loading platform.
provide ridged edge protection. man.
NOTICES / RULES TRAINING / INSPECTIONS RISK ASSESSMENT
• The area under the loading • All workers involved in the use and • A risk assessment must be
platform shall be barricaded loading of loading platforms must be undertaken for the design,
appropriately. instructed on the agreed safe system installation, use and removal of
• Display adequate warning signs & of work. loading platforms.
notices for the safe use of • A competent person must undertake • A method statement must be
platforms. a formal documented inspection of prepared covering the procedure
• All notices and warning signs must every loading platform at least for the safe use of the loading
be in a language understood by the weekly. platform.
workforce.

Site Transportation – GSAF 46
IDENTIFY THE AREA WRITTEN PROCEDURE TOOLBOX TALK
• Specific area for the pick-up and • A written procedure must be • Procedure must be
drop-off point must be identified established for the movement of communicated to all site
with relative proximity to the areas employees on the pick-up / operatives.
of work. dropdown area. • Operators must be delegated of
• Proper barriers to hold the line for • This procedure must be posted in their task and responsibility as
maintaining the queue. different languages and well as their role in site
• Area must be free from dust and communicated to all staff. implementation.
other obstacles. • Disciplinary action must be taken • Bus drivers should undergo
against the violating drivers. specific training as per rules &
regulations.
PEDESTRIAN & VEHICLE MONITORING &

SIGNAGE
SEGREGATION SUPERVISION
• Pedestrian route must be provided • Display clear directional signage • Supervision must be in place at
and separated to avoid mishap leading to the identified point. time of pick up & drop off.
involving workers crossing the • Mandatory and Informatory signs • It is the responsibility of
roads from different directions. must be displayed to enhance employer to provide safe
• Additional precautions must be awareness of the implemented transportation for all employees
taken and flash lights / flag man procedure. to and from each work station
required to be placed during foggy • “T” junctions and invisible areas and accommodation.
/ adverse weather. must have appropriate control • Adequate no of buses must be
measures to avoid collision. provided to meet legal capacity
requirements.
• Vehicles must be maintained in
good condition.

GSAF 47
Contractor Surveillance Report
Serial: GCC/NNN/NNN/0000
Internal on Contractor: Name of Originator:
External on Subcontractor: Mr. XX

Contractor Name: Date Exercise Undertaken:
XX DD/MM/YYYY
Subcontractor Name: Location:
XX XX
Subject: XX

1. General
XX
2. Purpose
a) XX
b) YY
3. Progress (if required)
a) XX
b) YY
c) ZZ
4. Surveillance Attendance
RE Team Contractor
A N Other (Designation) A. Boss (Designation - Contractor)
A Other (Designation) B. Boss (Designation - Contractor)
5. Summary of the Surveillance
a) The Surveillance was carries to verify the Contractors compliance etc
b) The following Observations were made

OBS-1: XX
OBS-2: YY
OBS-3: ZZ
Note: Observation is a statement of fact made during the Surveillance Exercise and
substantiated by objective evidence.
6. Comments & Conclusion

The Surveillance Exercise was carried out etc .
Reported by: Reviewed By:
Signature: Signature:
Date: Date:
Distribution: RE, DPD, Copy to Contractor under covering letter File No: XX.XX.XX

GSAF 48
Chennai Metro Rail Project

Non-Conformance Report (NCR)
Contractor Name: Contract No:

Package/Section: Chainage:
Date: Time: NCR Serial:
Subject:
Location:
(a) Description of the Non-conformance
Attachments:
(b) Drawing / Spec Ref:
Issued by Received by (for Contractor)
Name: Designation: Name: Designation:
Signature: Date: Signature: Date:
(c) Contractor’s Proposed Corrective Action
Statement of proposed Corrective Action, signed and dated by Contractor Project Manager / Designer:
USE AS IS - Work can proceed
REWORK - Rew ork to make it conform/acceptable for use

To incorporate in as-built draw ing To incorporate Designer comments.
REJECT - Scrap. Reasons noted below
Comments:
(d) Contractor’s Proposed Action to Prevent Recurrence
Attachments:
Issued by (for Contractor): Received by:
Name: Designation: Name: Designation:
Signature: Date: Signature: Date:
Contractor’s Proposed Corrective Action Acceptable Yes No

Comments:

Contractor Name: Contract No:
Package/Section: Chainage:
Date: Time: NCR Serial:
(e) NCR Closed out: Yes No
Name: Designation:
Signature: Date:
Project Name: Contract No.:

Contractor: Sub-contractor:
Subject: SI No.:
Discipline: Date:
Location: Chainage:
Description:
Note – This form is to be used for instructions which have no time or cost impact. If the contractor considers that this instruction has time
and cost implications he shall notify EMPLOYER in writing not later than 2 working days from the date of this site instruction or prior to
commencement of work whichever is earlier.
Attachments:
References:
Drawing:
Contract Documents:
Other Correspondence:
Issue to Contractor:
Contractor’s written response
Yes No
required:
Issued by: Signature: Date: Time:
Name:
Designation:
Received By (for Contractor): Signature: Date: Time:
Name:
Designation:
Action by Contractor:
Name: Designation: Signature: Date:
Close out by EMPLOYER:
This Site Instruction(s) has been carried out: Yes No

GSAF 49
Further Action / Comments: Site Instruction (SI)
Name: Designation:
Signature: Date:
Copied to:
Employer's Representative Document Control Contractor Site Representative
GSAF 50
Emergency Action & Notification

Contractor Employers Representative
Process Contact
Incident Resident Engineer

Occurrence
Mob:
Mob:
Alarm Raised Mob:
Chief Safety Expert

Call Emergency
Services
Contractors Site Manager /

Engineer / Incident Controller
Take charge of situation &

Employers Representative
confirm Alarm call to the
Emergency services
Inform Employers
Representative of Incident
Note: When unable to contact

the RE the next progressive CMRL
level name must be contacted.
CGM
Mob:
MD Mob:

REQUEST FOR INSPECTION (RFI)
Price Centre: Contract No: Contractor:
RFI No: Date:
Location
Price Centre –NA
Scope:-
Inspection Description:
Na na
Contractor’s Q/A or Senior Engineer Comments: Contractor Quality Manager Signature:

\’’
Date of Inspection:
Safety Precautions Taken : Yes No Contractor OHS&E Manager Signature:

Contractor’s Safety /Quality checklist (Attachment Contractor’s ref No)
Objection : Notice of No Objection/with comments (Yes/ No)

Reasons:-
Contractor Engineer Signature: GC Engineer Signature:

Dated:- Dated
Comments / Recommendations of Resident Engineer after site measurement record:
RE Comments:
Site Inspector Comments:
Objection Notice of No Objection

Reason:- R E Signature
Date & Time:
GSAF 51

GSAF 52
Minimum Requirements Of OHS&E Monitoring and Audio-Visual Equipment’s
Sl.No OSHE monitoring and Audio- OSHE monitoring and Audio-Visual

Visual Equipment details equipment required for
Contract
1. Portable hand held Digital Sound 5
Level Meter (SLM)
2. Portable hand held Digital Lux 5
Meter
3. Alcohol meter 3
4. Laptop Computer with standard 1
configuration including multi media
facilities
5. Colour Printer 1
6. Computer projector with screen 1
7. Overhead projector 1
8. Portable loudspeaker (for tool-box 5
talk and emergency purpose)
9. Gas Monitoring Equipment 5
10. Communication facility like mobile For all supervisors and managers/engineers
phone, walky-talky etc working in OHS&E
11. Accident investigation Kit 2
containing the following:
a) Chalk piece for marking
b) Measuring tape for measuring
• Flexible tape – 2m length
• Metal Foot long scale and
• Metal tape – 30m
c) Equipment tags
d) Multipurpose Flash light
e) Barrier tape of 20m length
f) Accident investigation Forms and
checklists
g) Enough Paper for witness recording
and other noting
h) Emergency Phone Numbers list

TENDER NO. CP06/UG06/RT01

PART 2
SECTION VI
APPENDIX – 20
OCCUPATIONAL, SAFETY, HEALTH AND
ENVIRONMENT
VOLUME 3
ENVIRONMENTAL MANAGEMENT
ARRANGEMENTS
DECMEBER 2021
OHS&E – Volume 3
Environmental Management

METRO RAIL PROJECT – PHASE - 2
OCCUPATIONAL, SAFETY, HEALTH AND

ENVIRONMENT
VOLUME 3 – ENVIRONMENTAL
MANAGEMENT ARRANGEMENTS

OHS&E – Volume 3
1. STATEMENT OF INTENT
Chennai Metro Rail Limited firmly believes in a “development which meets the needs of the present
without compromising the ability of future generations to meet their own needs”. This commitment
towards sustainable development is manifested clearly in our corporate culture, even as we continue
to build a world-class metro.
CMRL intends to incorporate ISO 14001 standards in its construction. This commitment entails
aggressive employment of methods and strategies during construction that maximize energy
efficiency, use cleaner technologies, reuse and or recycle materials and similar other efforts that help
to prevent and reduce environmental degradation.
It is the intent of CMRL to demonstrate continual improvement in its Environmental Management
system during the execution of the project.
This manual represents the minimum standards that Chennai Metro Rail Limited will accept on
matters of Environment. It lays down the guidance for environmental protection measures to be
adopted as part of mitigation strategy for overcoming adverse environmental impacts during
construction. It suggests environmental friendly construction practices that the Contractors are
encouraged to adopt in order to contain various types of pollutants that may be generated due to
construction activities.
Chennai Metro Rail Limited actively supports the efforts and initiatives that are instigated by the
Contractors and sub-contractors in their efforts for achieving good standards of Environment on the
project. The Corporation will use its best endeavours to ensure that all of the Contractors employed
on the Project achieve these Standards.
Managing Director
CMRL
OHS&E – Volume 3
2. ENVIRONMENTAL POLICY
Chennai Metro Rail Limited is committed to promoting sustainable development in transportation
sector and continuously improving its operations and business in a responsible way. We have created
an Environmental Management Framework setting objectives and targets, which are incorporated in
an Environmental Management System (EMS) that complies with ISO 14001:2015.
This will be achieved by:
❖ Implementing Environmental Management Systems which identify, control and wherever
possible, minimise the negative impacts on the environment arising from our activity or
operations.
❖ Compliance with all relevant environmental legislation, regulations, codes of practice and other
requirements in which we operate.
❖ Minimize Waste through a commitment of Refuse, Reduce, Reuse, Recycle and Rethink where
feasible.
❖ Commitment to the continual improvement of our EMS.
❖ Continue efforts to reduce operational waste, conserve water and energy, maximize recycling,
adopt responsible paper management practices and increase the purchase of sustainable products.
❖ Raising environmental awareness to our staff and encourage their participation in
environmental action and train them where required.
❖ Monitoring the environmental performance on an annual basis, improve where necessary.
❖ Implementing effective communication with contractors and stakeholders on environmental
issues.
❖ Make this policy available to all staff, contractors, and all interested parties/stakeholders.
Date: March 2018

Place: Chennai Managing Director
OHS&E – Volume 3
Table of Contents
1. Introduction 6
2. Purpose and Scope 8
3. Objective 9
4. Definitions and Abbreviations 10
5. Legal and Other Requirements 11
6. Responsibilities 14
7. Site Environment Plan 15
8. Contractor’s Method Statement 16
9. Environmental Performance Reviews 17
10. Environmental Friendly Construction Practices 18
11. Housekeeping 32
12. Landscape, Greenery and Aesthetics 34
13. Energy Management 37
14. Traffic Management 38
15. Archaeological and Historic Resources 39
16. Environmental Monitoring - General 40
17. Air Monitoring 42
18. Noise Monitoring 44
19. Environmental Preparedness and Response 49
20. Environmental Site Inspection 50
21. Environmental Committee Meetings 51
22. Environmental Audits 52
23. Training 54
24. Reporting System 55
25. Complaint Response Process 56
26. Completion of the EMA Programme 57
Appendix I Site Environmental Plan (SEP) Outline 58
Appendix II Weekly Environmental Inspection Checklist 60
Appendix III Details on Fly Ash 67
Appendix IV Environmental Audit Criteria 69
OHS&E – Volume 3
1. Introduction
Significant success has been made in India in developing and enforcing environmental
regulations in many areas. However, there still remain a number of areas that have not yet
seen the promulgation of Environmental Standards and Regulations. Many of these areas
have a high potential for adverse environmental impact if allowed to go unregulated. As the
CMRL undertakes to build this Metro system it shall institute and enforce adequate
environmental standards to provide for the protection of the people and the environment.
In response, the Contractor shall comply with all applicable Indian laws and regulations to
mitigate the adverse environmental impacts from the construction activities. Based on the
Employer’s Environmental Impact Assessment (EIA) report the Contractor shall conduct an
analysis of the environmental Impacts, and implement suitable measures to mitigate the
adverse impacts so as to comply with all the Environmental Standards & Regulations. All
appropriate categories/areas, such as air quality, noise, water quality, vibration etc. are to be
considered in the environmental analysis. The Contractor will have to undertake
Environmental Monitoring and Audit during construction to measure the environmental
impacts. Should the impact measurements exceed the respective limits set forth in EIA
Report, the Contractor shall be required to review and implement effective measures so as to
ensure that the impact of the construction works will not exceed the respective limits set forth
in the EIA report.
The Contractor shall be responsible for the total compliance of the Environmental Protection
safeguards as elaborated in this Environmental Management Arrangements.
1.1 The ‘Environmental Management Arrangements’ (EMA) document forms an essential part of
the overall Environmental Protection System employed by CMRL for the construction of the
Chennai Metro Rail Project – Phase 2.
1.2 The EMA has been prepared to facilitate construction progress while ensuring fulfilment of
environmental commitments. It provides systematic procedures for monitoring and
minimizing environmental impacts that may arise from the construction activities.
1.3 The EMA will apply to all construction works of the Chennai Metro Rail Project carried out
by the Contractors and Sub-contractors.
1.4 The primary reason for adopting the EMA approach is to make the Contractor aware of his
environmental responsibilities and to ensure his commitment to achieving the specified
standards.
1.5 The CMRL EMA is meant to be a living document that will be updated as design and
construction progresses and when further environmental issues are identified.
1.6 Periodic reviews of the plan and procedures will be performed to ensure continual
improvement of the Plan’s adequacy and it will be expanded and updated during the project
duration.
1.7 Because the work potentially involves build contracts, this EMA is intended to be flexible and
tailored to match highly variable construction activities and locations throughout the project.
1.8 The EMA is set out as follows:
 Section 2 highlights the purpose and scope
 Section 3 outlines the objective, which will form a basis for Environmental Management
System (EMS)
OHS&E – Volume 3
 Section 4 lists the definitions and abbreviation of terms used
 Section 5 lists the applicable legal and other requirements.
 Section 6 sets out the responsibilities for application of the procedures
 Section 7 provides guidance to the Contractor for preparation of his contract specific Site
Environmental Plan
 Section 8 commits the Contractor’s Method Statement to incorporate environmental
issues during execution of works
 Section 9 focuses on the Environmental Performance Review of Contractor’s activities
through Environmental Audits
 Section 10 details measures to contain Air, Water, and Noise Pollution and management
of waste through Environmental Friendly Construction Practices
 Section 11 specifies good Housekeeping measures
 Section 12 is on Landscape, Greenery and Aesthetics
 Section 13 suggests measures to conserve energy through effective Energy Management
 Section 14 deals with Traffic Management
 Section 15 focuses on requirements that the Contractor shall have to meet in case
Archaeological and Historic Resources are encountered
 Section 16 on Environmental Monitoring - lists the relevant monitoring equipment,
compliance criteria and monitoring programme to be undertaken by the Contractor during
construction
 Section 17 details requirements for impact monitoring for air quality including Air
Monitoring and Control Plan
 Section 18 details requirements for impact monitoring for noise including Noise
Monitoring and Control Plan
 Section 19 provides guidance to Spill Management Plan
 Section 20 describes the Environmental Site Inspection process to be implemented by the
Contractor
 Section 21 details requirements on Environmental Committee Meeting.
 Section 22 details the Environmental Audits, which the Employer’s Representative may
undertake as part of environmental performance review
 Section 23 deals with Environmental Training requirements.
 Section 24 details the Reporting requirements as related to submission of Contractor’s
Monthly Environmental Management Report under this EMA
 Section 25 sets out the Complaint response process and finally,
 Section 26 mentions the requirements of Completion of the EMA programme
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2.1 Purpose & Scope

2.2 The purpose of this Environmental Management Arrangements is to make the Contractors
aware of the environmental concerns of CMRL, and to establish guidelines for the application
of environmental controls during the construction of the project.
2.2 The Environmental Management Arrangements is intended to translate into practice, three
important principles of CMRL’s mandate, which the construction activities should not:
 Inconvenience or endanger public
 Create a permanent visual eyesore
 Result in unmitigated ecological or environmental degradation
2.3 The EMA is intended to guide and assist the Contractors in exploring all reasonable and
feasible means for reducing construction related environmental impacts as they prepare and
produce contract-specific Aspect / Impact Assessments and Site Environmental Plans.
2.4 The EMA stipulates environmental controls that in lieu of alternative controls specified by the
Contractor must be applied.
2.5 Environmental controls adopted by the individual contractors as an alternative to the measures
identified herein must be as protective of the environment.
2.6 The scope of the EMA is to establish procedures to:
 Supervise Contractor’s compliance with defined environmental control criteria by
carrying out reviews of monitored impact data
 Oversee the procedure for identification of mitigation measures, their design and
implementation
 Carry out environmental monitoring emissions during construction through an impact
monitoring programme
 Undertake additional ad hoc monitoring if required, to address specific instances
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2. Objective
3.1 The various components included in the EMA along with the Employer’s Representative
requirements on Environment will form the basis of an Environmental Management System
to be implemented by CMRL, which will enable it to manage the environmental challenges
and resolve environmental issues posed during construction of Chennai Metro Rail project.
3.2 The main objectives are to:
 Provide database from which environmental impacts of the project can be determined.
 Provide timely indication if any environmental control measure fails to achieve desired
results.
 Monitor effectiveness of environmental mitigation measures
 Initiate remedial action if unacceptable impacts arise.
 Determine contractor’s compliance with statutory and legal requirements.
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3. Definitions & Abbreviations

4.1 Air Monitoring and Control Plan is abbreviated as AMCP.
4.2 Auditor: Person with the competence to conduct an audit.
4.3 A – Weighted Noise levels in Decibels (referenced to 20 micro-Pascal) as measured with A -
weighting network of standard sound level meter, abbreviated dB(A).
4.4 Central Pollution Control Board, is abbreviated as CPCB.
4.5 Continual improvement: Recurring process or enhancing the environmental management
system in order to achieve improvements in overall environmental performance consistent
with the organization’s environmental policy.
4.6 Corrective action: Action to eliminate the cause of a detected nonconformity.
4.7 Decibel is measure on a logarithmic scale of the magnitude of a particular quantity (such as
sound pressure, sound power) with respect to a standardized reference quantity.
4.8 Document: Information and its supporting medium.
4.9 Energy Equivalent Level (Leq) is the level of a steady noise which has the same energy as
the fluctuating noise level integrated over the period of measurement. Lmax is the maximum
Noise Level during the period of measurement. L10 and L90 are the are the percentile
exceeding levels of sound which are exceeded 10% and 90% of the time of measurement.
4.10 Environmental Pollutant means any solid, liquid or gaseous substance present in such
concentration as may be or tend to be injurious to environment.
4.11 Environmental Pollution means the presence in the environment of any environmental
pollutant.
4.12 Environment: Surroundings in which an organization operates, including air, water, land,
natural resources, flora, fauna, humans, and their interrelation.
4.13 Environmental Aspect: Element of an organization’s activities or products or services that
can interact with the environment.
4.14 Environmental Impact: Any change to the environment whether adverse or beneficial,
wholly or partially resulting from an organization’s environmental aspects.
4.15 Environmental Management Manual is abbreviated as EMM.
4.16 Environmental Management System: Part of an organization’s management system used to
develop and implement its environmental policy and manage its environmental aspects.
4.17 Environmental Objective: Overall environmental goal, consistent with the environmental
policy that an organization sets itself to achieve.
4.18 Environmental Performance: Measurable results of an organization’s management of its
environment aspects.
4.19 Environmental Policy: Overall intentions and direction of an organization related to its
environmental performance as formally expressed by top management, under signature.
4.20 Environmental Target: Detailed performance requirement applicable to the organization or
parts thereof, that arises from the environmental objectives and that needs to be set and met in
order to achieve those objectives.
4.21 Interested Party: Person or group concerned with or affected by the environmental
performance of an organization.
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4.22 Internal audit: Systematic, independent and documented process for obtaining audit
evaluating it objectively to determine the extent to which the environmental management
system audit criteria set by the organization are fulfilled.
4.23 Ministry of Environment, Forest & Climate Change, Government of India is abbreviated
as MoEF&CC.
4.24 Monitoring is the use of direct or indirect reading field instrumentation to provide
information regarding the levels of pollutants released during construction.
4.25 Noise is any unwanted sound disturbance of the environment around the area of construction
operations.
4.26 Noise Monitoring and Control Plan is abbreviated as NMCP.
4.27 Nonconformity: Non-fulfilment of a requirement.
4.28 Nuisance is annoyance, which results from any construction activity that affects the material
comfort and quality of life of the inhabitants of the area surrounding the construction site.
4.29 Organization: Company, corporation, firm, enterprise, authority or institution, or part or
combination thereof, whether incorporated or not, public or private, that has its own functions
and administration. It also includes the Contractor executing the CMRL contract of Chennai
Metro.
4.30 Preventive Action: Action to eliminate the cause of a potential nonconformity.
4.31 Prevention of pollution: Use processes, practices, techniques, materials, products, services or
energy to avoid, reduce or control the creation, emission or discharge of any type of pollutant
or waste, in order to reduce adverse environmental impacts.
4.32 Procedure: Specified way to carry out an activity or a process.
4.33 Record: Document stating results achieved or providing evidence of activities performed.
4.34 Respirable Particulate Matter is abbreviated as RPM and is particulate matter with size less
than 10 µm and is measured in µg/m3(microgram per cubic meter)
4.35 Suspended Particulate Matter is abbreviated as SPM and measured in µg/m3(microgram per
cubic meter)
4.36 Site Environmental Plan is abbreviated a SEP. A document prepared by the Contractor that
contains detailed procedures on implementing the Employer’s Representative requirements on
Environment.
4.37 Tamil Nadu Pollution Control Board is abbreviated as TNPCB.
4.38 Usage factor: Expressed as the percent of time that the equipment is operated at full power
while on site.
4.39 Waste is unwanted surplus substance arising from the application of all construction
operations and any substance or articles, which is required to be disposed.
4. Legal and other requirements

5.1 Contractor shall comply with all legal obligations and the requirements of Chennai Metro Rail
Limited as contained herein.
5.2 Indian Statutory Requirements
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The Contractor shall abide by all national, state and local bye-laws. It is the duty of the
Contractor to ensure that all sub-Contractors appointed also comply with their legal
obligations as listed below but not limited to:
i. The Environment Protection Act, 1986, amended 1991
ii. The Environment (Protection) Rules, 1986
iii. The Water (Prevention and Control of Pollution) Act, 1974
iv. The Water (Prevention and Control of Pollution) Cess Act, 1977 ,
v. The Air (Prevention and Control of Pollution) Act, 1981, amended 1987
vi. The Air (Prevention and Control of Pollution) Rules, 1982
vii. The Noise Pollution (Regulation and Control) Rules, 2000 as amended by
(Amendment) Rules, 2017
viii. The Hazardous and Other Wastes (Management and Trans boundary Movement)
Amendment, Rules, 2019
ix. The Municipal Solid Waste (Management & Handling) Rules, 2016
x. The Bio-medical Waste Management Rules, 2016
xi. The Plastic Waste Management (Amendment) Rules, 2018
xii. The E- Waste (Management) Amendment Rules, 2018
xiii. The Construction and Demolition (C&D) Waste Management Rules, 2016
xiv. The Batteries (Management and Handling) Rules, 2001
xv. The Manufacture, Storage and import of Hazardous Chemical Rules, 1989.
xvi. The Ozone Depleting Substances (Regulation and Control) Rules, 2000
xvii. The Ancient Monuments and Archaeological Sites and Remains (amendment and
validation) Act, 2010
xviii. The Wetlands (Conservation and Management) Rules, 2017
xix. The Wildlife (Protection) Act, 1972, amended 2002
xx. The Forest (Conservation) Act, 1980, amended 1988
xxi. The Coastal Regulation Zone Notification, 2011 and 2019
xxii. EIA Notification, 2006 and its amendments.
xxiii. The Tamil Nadu Water (Prevention and Control of Pollution) Rules, 1983 amended
May 2009
xxiv. The Tamil Nadu Air (Prevention and Control of Pollution) Rules, 1983 amended May
2009
xxv. Tamil Nadu Forest Act, 1882
5.2 International Standards, Framework, Guidelines & ISO Certifications
5.2.1 If the requirements stated in this document are in conflict or inconsistent with the
requirements of applicable laws the more stringent requirements shall apply.
5.2.2 The works shall be undertaken in accordance with the applicable international
guidelines, standards and specifications on Environment Management and every
Contractor shall actively pursue the achievement of:
• ISO 14001-2015: Environmental Management Systems
5.2.3 The process of international certification to ISO 14001-2015 standard shall
commence immediately after the award of Contract through appointment of ISO
accrediting body for obtaining the certification. Should this not be undertaken by the
Contractor within 3 months of the Contract award, the Employer’s Representative
shall appoint at the Contractor’s cost.
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5.2.4 Should the Contractor already posses such certification, the scope of the CMRL
project must be included on the Contractor’s certification within 1 year of Contract
commencement and proof of such attainment demonstrated to Chennai Metro Rail
Limited.
5.2.5 The contractor shall comply the other legal obligations as listed below:
i. Safeguard Policy Statement (SPS) June 2009 of Asian Development Bank

(ADB)
ii. Environmental and Social Framework (ESF) of Asian Infrastructure
Investment Bank (AIIB) February 2019
iii. New Development Bank Environment and Social Framework, March 2016.
iv. Guidelines for Environmental and Social Considerations of Japan
International Cooperation Agency (JICA), April 2010.
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5. Responsibilities
6.1 The Contractor shall set up an environmental team to execute the environmental
requirements.
6.2 The duties of the Contractor’s Environmental Team will include (but not limited to):
• To monitor the various environmental parameters as required by the EMA
• To inspect, investigate and audit the work methodology with respect to environmental
mitigation and control
• To anticipate environmental issues before they arise and plan for their mitigation
• To audit and prepare audit reports, weekly/monthly reports on site environmental conditions
for submission to the Employer’s Representative.
6.3 Reporting to the Employer’s Representative, the Contractor shall
• Work within the scope of contract and other tender condition.
• Operate and strictly adhere to the requirements of his contract specific-SEP
• Undertake any corrective actions as instructed by his Environmental Manager
6.4 To lead his Environmental team, the Contractor shall deploy an Environment Manager who
shall be responsible for environmental control, environmental monitoring, and record keeping
and be available to the Employer’s Representative for resolution of environmental issues.
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6. Site Environmental Plan

7.1 To effectively implement monitoring, mitigation and remedial requirements, an appropriate
contractual and supervisory framework needs to be established.
7.2 The basis of framework within which implementation will be managed is through the
preparation of contract-specific Site Environmental Plan by the Contractor. The Employer’s
Representative will audit this contract-specific plan and advise the necessary remedial actions
required through contractual means.
7.3 The Site Environmental Plan shall provide details of the means by which the Contractor (and
all subcontractors working for the Contractor) will implement the recommended mitigation
measures and achieve the environmental performance standards defined both in Indian
environmental legislation and in the Employer’s Representative’s requirements.
7.4 Based on Site Environmental Plan outline given in this document, as Appendix – I,
Contractor shall prepare a Site Environmental Plan for submission as part of the tender
process.
7.5 The outline Environmental Plan shall demonstrate the determination and commitment of
Contractor’s organisation towards environment and indicate how the environmental
performance requirements laid out in the Employer’s Representative’s requirements will be
met and, where appropriate exceeded.
7.6 Within 28 days of the date of Notice to commence, the Contractor shall submit a draft
contract – specific Site Environmental Plan for notice of no objection of the Employer’s
Representative and a final version prior to the commencement of the works.
7.7 The contract-specific Site Environmental Plan will contain description of all procedures
developed to control environmental pollution. Elements of the plan must address the
management of pollution, the monitoring programme, and the reporting requirements.
7.8 The Site Specific Environmental Plan shall contain an Aspect Impact register together with
outline proposals/procedure for mitigating negative impacts.
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7. Contractor’s Method Statement

8.1 It shall be the practice for the Contractor to prepare method Statement in advancement of
actual works, for the notice of no objection of the Employer’s Representative.
8.2 The Contractor’s Environmental Manager will be one of the signatories to the Method
Statement, after assessing and verifying the environmental impact of the prepared
construction activity and ensuring that effective control measures will be in place, timely.
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8. Environmental Performance Reviews

9.1 Environmental Performance Reviews, through an Environmental Audit Programme, may be
carried out quarterly by the Employer’s Representative to assess the effectiveness of the Site
Environmental Plan, and that the required mitigation measures are routinely implemented and
environmental standards are maintained.
9.2 The preliminary objective of the audit programme will be to assess the effectiveness of
management systems established by the Contractor to implement the environmental
mitigation measures.
9.3 The reviews by Employers Representative shall focus on the effectiveness of the implemented
measures to achieve the purpose not simply the fact that a measure has been implemented.
9.4 In such reviews, demonstrable evidence on the part of the environmental requirements will be
sought.
9.5 The Contractor shall carry out daily, environment inspection of his works and submit a
weekly report as per format for reporting is suggested as Appendix – II.
9.6 The Contractor shall ensure that his weekly/monthly environmental reports and mandating
audits are linked to respective previous submission. The Employers Representative will
ensure that this procedure is followed by the institution of a monitoring and reporting system
that provides information about the environmental performance of the construction Contractor
throughout the duration of the contract.
9.7 The Employer’s Representative will monitor Contractor’s performance of tasks specified, and
will inspect necessary records, reports and procedures as defined in this manual.
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9. Environmental Friendly Construction Practices

10.1 Containment of Air Pollution
10.1.1 During Transport of Material
(a) The Contractor shall take precautions to minimise visible particulate matter from being
deposited upon public roadways as a direct result of his operations. Precautions include
removal of particulate matter from equipment before movement to paved streets or
prompt removal of material from paved streets onto which such material has been
dropped.
(b) All construction equipment should be washed clean of visible dirt/mud before exiting the
construction sites. Any deposition of material on public streets by construction equipment
should be removed by manual sweeping, or by deploying electro – mechanical devices.
(c) The Contractor shall provide a wash pit or a wheel washing and/or vehicle cleaning
facility at the exits from work sites such as construction depots and batching plants. At
such facility, high-pressure water jets will be directed at the wheels and the body of
vehicles to remove all spoil and dirt. Water shall be pumped through an electrically
operated pump set, to hydrants attached with rubber hoses, by activation of push button
located at the hydrant, allowing for up to 10 minutes of wash time.
(d) Wheel washing facilities and/or vehicle cleaning facility will be provided with efficient
drainage, incorporating silt traps to prevent any excessive build up of water. These
facilities could include water re-circulation apparatus to minimise water consumption. At
the wheel wash facility, water, dirt, gravel etc. shall be drained into precast trench drains
with removable grated cover. This dirty water shall flow, through a piping, into solids
separator and from there to oil separator before final discharge.
(e) Where wheel-washing facility is not possible, the Contractor shall ensure manual cleaning
of wheels by wire brushes or similar suitable means.
(f) The Contractor shall ensure that Vehicles with an open load carrying shall not be used for
moving potentially dust-producing materials. Vehicles shall have properly fitting side and
tailboards. Materials having the potential to create dust shall not be loaded to a level
higher than the side and tail boards, and shall be carried in vehicles fitted with cover lids
or tarpaulin covers.
10.1.2 At Dumping Sites
(a) The Contractor shall place excavated materials in the dumping/disposal areas designated
in the drawings.
(b) The Contractor shall place material in a manner that will minimise dust production.
Material shall be stabilised each day by watering or other accepted dust suppression
techniques.
(c) The heights from which materials are dropped to 1.5 m to limit fugitive dust generation.
(d) The Contractor shall stockpile material in the designated and approved locations with
suitable slopes. Access to the site shall be regulated for entry of men, material and
machine.
(e) During dry weather, dust control methods such as water sprinkling must be used daily at
every two hours intervals especially on windy, dry days to prevent any dust from blowing
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and causing nuisance. During rains, the stockpile may be covered with tarpaulin or similar
material to prevent run off.
(f) The Contractor shall provide water sprinkling at any time that it is required for dust
control use.
(g) Sufficient equipment, water, and personnel shall be available on dumping sites at all time
to minimise dust formation and movements to prevent nuisance.
(h) Dust control activities shall continue even during work stoppages.
10.1.3 At Construction Site
(a) At each construction site, the Contractor shall provide storage facilities for dust
generating materials and shall be closed containers/bins or wind protected shelters or mat
covering or walled or any combination of the above to the satisfaction of the Employer’s
Representative. The Contractor shall spray water at construction sites as required to
suppress dust, during handling of excavation soil or debris or during demolition.
(b) Stockpiles of sand and aggregate greater than 20m3 for use in concrete manufacture shall
be enclosed on three sides, with walls extending above the stockpile and two (2) metres
beyond the front of the stockpile.
(c) Effective water sprays shall be used during the delivery and handling of all raw sand and
aggregate and other similar materials, when dust is likely to be created and to dampen all
stored materials during dry and windy weather.
(d) Areas within the Site such as construction depots and batching plants, where there is a
regular movement of vehicles shall have an approved hard surface that is kept clear of
loose surface material.
(e) Unless the Employer’s Representative has given notice otherwise, the Contractor shall
restrict all motorised vehicles on the Site to a maximum speed of 15 kilometres per hour
and confine haulage and delivery vehicles to the designated roadways inside the site.
(f) At the Batching plant the following additional conditions shall be complied with:
 The Contractor shall undertake at all times the prevention of dust nuisance as a result
of his activities.
 The Contractor shall frequently clean and water the concrete batching plant and
crushing plant sites and ancillary areas to minimise any dust emission.
(g) The Contractor shall erect hoardings as specified in Employer’s Representative
requirements – construction, securely around all construction work sites during the main
construction activity, to contain dust within the site area and also to reduce air turbulence
caused by passing traffic. The hoarding shall be safely secured to the ground to prevent
from toppling with minimum gap between the base of hoarding and ground surface.
10.1.4 During Drilling and Blasting
(a) Water spray should be used to control dust during breaking of rock/concrete.
(b) During blasting operations, appropriate precautions should be taken to minimise dust such
as the use of blast nets, canvas covers and watering.
(c) Wire mesh made of heavy-duty tyres or sand bags should be used over blast area on each
shot to prevent flying rock and reduce dust.
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(d) Blasting technique should be consistent not only with nature and quantity of rock to be
blasted but also the location of blasting.
(e) The Contractor shall give due preference to explosives with better environmental
characteristics.
(f) Vibration shall be monitored during blasting and values shall not exceed as those given in
this Environmental Management Manual
10.2 Containment of Water Pollution
(a) The Contractor shall comply with the Indian Government legislation and other State
regulations in existence in Chennai insofar as they relate to water pollution control and
monitoring.
(b) The Contractor shall provide adequate precautions to ensure that no spoil or debris of any
kind is pushed, washed, falls or deposited on land adjacent to the site perimeter.
(c) In the event of any spoil or debris from construction works being deposited on adjacent
land any silt washed down to any area, then all such spoil, debris or material and silt shall
be immediately removed and the affected land and areas restored to their natural state by
the Contractor to the satisfaction of the Employer’s Representative.
(d) At construction depots and batching plants temporary drainage works should be
maintained, removed and reinstated as necessary and all other necessary precautions
should be taken for avoidance of damage by flooding and silt.
(e) A Drainage system should be constructed during the commencement of the works, drain
off all surface water at the site into suitable drains.
(f) Sedimentation tanks or other acceptable measures, of sufficient capacity to trap silt-laden
water before discharge into the outlet drain should be provided. The system should be
flexible and be able to handle multiple inputs from a variety of sources.
(g) Temporary open storage of excavated materials meant for backfilling on site, should be
covered with tarpaulin or similar fabric during rainy season or at any time of the year
when rainstorms are likely. Washout of construction or excavated materials should be
diverted to drainage system through appropriate sediment traps.
(h) Any mud slurry from drilling, tunnelling, diaphragm wall construction or grouting etc.
shall not be discharged into the drainage system unless treatment is carried out that will
remove silt, mud particles, bentonite etc. The Contractor shall provide treatment facilities
as necessary to prevent the discharge of contaminated ground water.
(i) All water and waste products (surface runoff and wastewater) arising on the site shall be
collected and removed from the site via a suitable and designated temporary drainage and
disposed off at allocation and in a manner that will leave neither pollution nor nuisance.
(j) Bentonite slurries or other grouts used in diaphragm wall construction piling and other
concrete works should be collected in a separate slurry collection system. If reuse is not
practicable then it should be disposed off at nearest landfill site after obtaining permission
from the agency owning the landfill and under the conditions imposed by the agency
concerned.
(k) The bentonite mixing, treatment and handling system shall be established by the
Contractor giving due regard to its environmental impacts. The disposal of redundant
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bentonite shall be carefully considered whether in bulk or liquid form. The disposal
location will be advised and agreed with the relevant authorities.
(l) Due to lowering of potable water supplies in Chennai and subsequent contamination of
ground water, the Contractor is not allowed to discharge water from the site without the
notice of no objection of the Employer’s Representative. The Contractor must comply
with the requirements of the Central Ground Water Board for discharge of water arising
from dewatering. Any water obtained from dewatering systems installed in the works
must be either re-used for construction purposes and this water may subsequently be
discharged to the drainage system or, if not re-used, recharged to the ground water at
suitable aquifer levels. The Contractor must submit his proposals for notice of no
objection of Employer’s Representative, on his proposed locations of dewatering of
excavation and collection of water for either construction re-use or recharge directly to
aquifers. The Contractor’s recharge proposals must be sufficient for recharging of the
quantity of water remaining after deduction of water re-used for construction. The
Contractor will not be permitted to directly discharge, to the drainage system, unused
ground water obtaining from the excavation without obtaining notice of no objection from
the Agency controlling the system.
(m) The Contractor shall prevent soil particles and debris from entering the wells or water
discharge points by use of filters and sedimentation basins as required.
(n) The Contractor shall provide treatment facilities as necessary to prevent the discharge of
contaminated ground water.
(o) The Contractor shall at all times ensure that all existing stream courses and drains within,
and adjacent to the site are kept safe and free from any debris and any excavated materials
arising from the Works.
(p) The Contractor shall discharge wastewater arising from site offices, canteens or toilet
facilities constructed by him into sewers after obtaining prior notice of no objection of
agency controlling the system. A wastewater drainage system shall be provided by the
Contractor to drain wastewater into the sewerage system.
(q) The contractor shall take measures to prevent discharge of oil in land and water bodies.
Oil separator/interceptors shall be provided at Batching Plant and construction depot
location for vehicle maintenance to prevent the release of oils and grease into the drainage
system. These shall be cleaned on a regular basis.
(r) A Spill Prevention and Control Procedure shall be prepared to identify project
components such as storage areas, storage tanks that could allow discharge of oil grease
or hazardous materials to the drainage system or ultimately in any water body during
spillage. The volume of spill should be calculated as well as storage volume to contain
spill within the materials storage containment areas. The procedure shall include
measures to contain and mitigate transportation of oil, grease or hazardous materials to
the drainage system or any water body.
(s) The Contractor shall ensure that earth, bentonite, chemicals and concrete agitator
washings etc. are not deposited/drained in the watercourses but are suitably treated and
effluents and residue disposed off in a manner approved by local Regulatory Authorities.
(t) Perimeter channels/drains should be constructed in advance of site formation works and
earthworks. Silt removal facilities, channels and manholes should be maintained and the
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deposited silt and grit should be removed regularly, to ensure that these facilities are
functioning properly at all times.
(u) Construction works should be programmed to minimize soil excavation works in rainy
season. If excavation in soil could not be avoided in these months or at any time of year
when rains are likely, for the purpose of preventing soil erosion, temporarily exposed
slope surfaces should be covered e.g. by tarpaulin, and temporary access roads should be
protected by crushed stone or gravel, as excavation proceeds. Arrangement should always
be in place to ensure that adequate surface protection measures can be safely carried out
well before the arrival of rains.
(v) Measures should be taken to minimize the ingress of rainwater into trenches. If
excavation of trenches in wet seasons is necessary, they should be dug and backfilled in
short sections. Rainwater pumped out from trenches or foundation excavation should be
discharged into storm drains via silt removal facilities.
(w) Open stockpiles of construction materials (e.g. aggregates, sand and fill material) on sites
should be covered with tarpaulin or similar fabric during rainstorms. Measures should be
taken to prevent the washing away of construction materials, soil, silt or debris into any
drainage system.
(x) Manholes (including newly constructed ones) should always be adequately covered and
temporarily sealed so as to prevent silt, construction materials or debris from getting into
the drainage system, and to prevent storm run-off from getting into sewers. Discharge of
surface run-off into sewers must always be prevented in order not to unduly overload the
sewerage system.
(y) Groundwater pumped out of wells, etc. for the lowering of ground water level in
basement of foundation shall be discharged into storm water drains after the removal of
silt in silt removal facilities.
(z) Wastewater from Concrete Batching & Precast Concrete Casting and that generated from
the washing down of mixer trucks and drum mixers and similar equipment should
wherever practicable be recycled. The discharge of wastewater should be kept to a
minimum.
(aa) The section of construction road between the vehicle washing bay and the public road
should be paved to reduce vehicle tracking of soil and to prevent site run-off from
entering public road drains.
(bb) Surface run-off should be segregated from the concrete batching plant and casting
yard area as much as possible and diverted to the storm water drainage system. Surface
run-off contaminated by materials in a concrete batching plant or casting yard must be
treated to, within the discharge norms before disposal into storm water drains.
(cc) The effluent monitoring is carried out pursuant to and using an equipment that complies
with the relevant standards of the Central Pollution Control Board.
(dd) The contractor shall apply to the appropriate authority for installing bore wells for
water supply at site.
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10.3 Containment of Noise
(a) Construction of facilities and structures would require the use of equipment, which may
generate high noise levels and adversely affect noise sensitive receivers.
(b) In assessing the impact of construction noise and hence its containment, the nature and
level of activities that generate noise, the pathway through which noise travels, the
sensitivity of the receptor, and the period of exposure should be considered.
(c) Environmental noise is measured in decibels (dB). To better approximate the range of
sensitivity of the human ear to sounds of different frequencies, the A-weighted decibel
scale (dBA) was devised. As the human ear is less sensitive to low frequency sounds, the
A-scale de-emphasizes these frequencies by incorporating frequency weighting of the
sound signal. When the A-scale is used, the decibel levels are represented by dBA.
(d) On this scale, the range of human hearing extends from about 3 dBA to about 140 dBA. A
10-dBA increase is judged by most people as a doubling of the sound level.
(e) To the extent required to meet the noise limits the Contractor shall use reasonable efforts
to include noise reduction measures listed below to minimize construction noise emission
levels. Noise reduction measures – include, but not limited to the following:
(i) Minimize the use of impact devices, such as jackhammers, and pavement breakers.
Where possible, use concrete crushers or pavement saws for tasks such as concrete
deck removal and retaining wall demolition.
(ii) Equip noise producing equipment such as jackhammers and pavement breakers with
acoustically attenuating shields or shrouds recommended by the manufacturers
thereof, to meet relevant noise limitations.
(iii) Pneumatic impact tools and equipment used at the construction site shall have intake
and exhaust mufflers recommended by the manufacturers thereof, to meet relevant
noise limitations.
(iv) Provide mufflers or shield panelling for other equipment, including internal
combustion engines, recommended by manufacturers thereof.
(v) Employ prefabricated structures instead of assembling on-site.
(vi) Use construction equipment manufactured or modified to dampen noise and vibration
emissions, such as:
• Use electric instead of diesel-powered equipment.
• Use hydraulic tools instead of pneumatic impact tools.
(f) Maximize physical separation, as far as practicable, between noise generators and noise
receptors. Separation includes following measures:
• Provide enclosures for stationary items of equipment and barriers around
particularly noisy areas on site.
• Locating stationary equipment in such a way, so as to minimize noise and vibration
impact on community.
(g) To the extent feasible, configure the construction site in a manner that keeps noisier
equipment and activities as far as possible away from noise sensitive locations and nearby
buildings. Plant and equipment known to emit noise strongly in one direction should
where possible, be oriented in a direction away from noise sensitive receptor and reduce
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the number of plant and equipment operating in critical areas close to noise sensitive
receptors.
(h) Scheduling truck loading, unloading, and hauling operations in such a way so as to
minimize noise impact near noise sensitive locations and surrounding communities.
(i) Minimize noise intrusive impacts during most noise sensitive hours by adopting the
following.
• Plan noisier operations during times of highest ambient noise levels.
• Keep noise levels relatively uniform; avoid excessive and impulse noises.
(j) Equipment and plant are not to be kept idling when not in use.
(k) Use only well maintained plant/equipment at site, which should be serviced regularly.
(l) Maintain equipment such that parts of vehicles and loads are secure against vibrations and
rattling.
(m) Grading of surfaced irregularities on construction sites to prevent the generation of impact
noise and ground vibrations by passing vehicles.
(n) Schedule work to avoid simultaneous activities that generate high noise levels.
(o) The construction of temporary noise barriers.
(p) If back-up alarms are used on construction equipment, their noise emission level near
noise sensitive receptors such as residences, schools, hospitals and similar areas where
calmness is essential, should be regulated, especially at night time.
(q) Select truck routes for muck disposal so that noise from heavy-duty trucks will have
minimal impact on sensitive areas (e.g., residential) and submit to the Employer’s
Representative for notice of no objection:
• Conduct truck loading, unloading and hauling operations in a manner such that noise
and vibration are kept to a minimum.
• Route construction equipment and vehicles carrying soil, concrete or other materials
over streets and routes that will cause least disturbance to residents in vicinity of work.
• Avoid operating truck on streets that pass by schools during school hours.
(r) The maximum permissible sound pressure level for new generator sets (up to 1000 KVA)
run on diesel, shall be 75 dB(A) at one metre from the enclosure surface.
(s) For existing diesel generator sets, the noise from the DG set shall be controlled by
providing an acoustic enclosure or acoustic treatment of the room for DG sets. Such
acoustic enclosures/acoustically treated rooms, shall be so designed for minimum 25
dB(A) insertion loss or for meeting the ambient noise standards, whichever is on higher
side.
10.4 Containment of Waste

(a) The Contractor is required to develop, institute and maintain a Waste Management Plan
(WMP) during the construction of the project for his works, which may include:
i. Identification of disposal sites
ii. Identification of quantities to be excavated and disposed off
iii. Identification of split between waste and inert material
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iv. Identification of amounts intended to be stored temporarily on site location of
such storage.
v. Identification of intended transport means and route.
vi. Obtaining permission, where required, for disposal.
Such mechanism is intended to ensure that the designated area for the segregation and
temporary storage of reusable and recyclable materials are incorporated in the WMP. The
WMP should be prepared and submitted to Employer/Employer Representative for
NONO.
(b) The Contractor shall handle waste in a manner that ensures they are held securely without
loss or leakage thus minimizing potential for pollution. The Contractor shall maintain and
clean waste storage areas regularly.
(c) Careful design, planning and good site management can minimise waste of materials such
as concrete, mortars and cement grouts. The Contractor shall ensure regular maintenance
and cleaning of the waste storage areas.
(d) Construction activities are expected to generate a variety of waste such as:
i. General refuse
ii. Construction Waste including waste from excavated material
iii. Chemical waste and
iv. Hazardous waste
v. Biomedical waste
(e) Handling and disposal of such waste may cause environmental degradation and nuisance.
To prevent it, such waste has to be handled and disposed properly. As such,
transportation and disposal of all waste shall be strictly managed.
(f) The contractor shall make arrangements to dispose of metal scrap and other waste to
authorised vendors and make available to Employer/Employer Representative on request
and records.
(g) General Refuse
(i) Each worksite would generate general refuse including paper and food waste. There
is likely to be a concentration of such waste at batching plants on major worksite. The
storage of general refuse has the potential to give rise to negative environmental
impacts.
(ii) Burning of wastes is prohibited. The Contractor shall not burn debris or vegetation or
construction waste on the site.
(iii) Handling and disposal of general refuse should cope with the peak construction
workforce during the construction period. The refuse should be stored and
transported in accordance with good practice and disposed at licensed landfills
(iv) General refuse should be stored in enclosed bins or units and has to be separated from
construction and chemical wastes. An authorised waste collector should be employed
by the Contractor to remove general refuse from the site, on a daily basis to minimise
odour, pest and litter impacts.
(h) Construction Waste
(i) Construction Waste would mainly arise from the project construction activities and
from the demolition of existing structures where necessitated. It includes unwanted
materials generated during construction, rejected structures and materials, materials
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that have been over-ordered and materials, which have been used and discarded such
as:
• Material and equipment wrapping packaging material
• Unusable/surplus concrete/grouting mixes
• Damaged/contaminated/surplus construction materials; and
• Wood from formwork and false work.
(ii) Also, demolition of buildings and houses to accommodate station buildings and
construction depots will generate concrete rubble, plastics, metal, glass, asphalt from
surfaces, wood and refuse.
(iii) Waste from excavation would comprise soil, rubble, sand, rock, brick etc.
(iv) It is estimated that construction activities used generate 2.5mm 3 of soil, majority of
which will be used for filling purpose.
(i) Chemical Waste
(i) Chemical waste is likely to be generated by construction and maintenance activities.
For those processes, which generate chemical waste, it may be possible to find
alternatives, which generate reduced quantities or even no chemical waste, or less
dangerous types of chemical waste.
(ii) The contractor should explore the possibilities given in (i) above and produce
evidence of acceptable disposal methods (e.g., waste transfer) to the Employer’s
Representative.
(iii) Containers used for the storage of chemical waste should:
• Be suitable for the substances they are holding, resistant to corrosion, maintained in
good condition, and securely closed.
• Be of adequate capacity and
• Display a label in English and local language as to the contents, quantity and safe
method of disposal in accordance with instructions contained in MSDS.
(iv) The storage area for chemical waste should:
• Be clearly labelled and used solely for the storage of chemical waste;
• Be enclosed on at least three sides;
• Have an impermeable floor and bunding, of capacity to accommodate 110% of the
volume of the largest container or 20% by volume of the chemical waste stored in
that area, whichever is higher
• Have adequate ventilation;
• Be covered to prevent rainfall entering and
• Be arranged so that incompatible materials are adequately separated.
(v) Disposal of chemical waste should be through a licensed waste collector, duly
authorized by MoEF or State Pollution Control Board as the case may be. License of
the waste collector shall be shown to the Employer’s Representative on demand.
(vi) The Contractor should maintain an inventory of chemicals, solvents and adhesives.
He should minimise disposal of excess material, reuse when applicable and dispose of
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chemical waste properly. He should prepare a plan that identifies proper ventilation,
protected clothing and personal protective equipment.
(vii) The Contractor should have a point of contact, who will maintain the
above information and also conducts periodic inspections.
(j) Hazardous Waste
(i) If encountered or generated as a result of Contractor’s activity, then waste classified
as hazardous under the “Hazardous Waste (management, handling and trans-
boundary movement) rules, 2016” shall be disposed off in a manner in compliance
with the procedure given in the rules under the aforesaid act.
(ii) Chemicals classified as hazardous chemicals under “Manufacture, Storage and Import
of Hazardous Chemical Rules, 1989 of Environment (Protection) Act, 1986 shall be
disposed off in a manner in compliance with the procedure given in the rules under
the aforesaid act.
(iii) The Contractor shall identify all the hazardous waste generated as a result of his
activities. If such waste is generated then the Contractor shall apply to State Pollution
Control Board for ‘authorisation’ according to Form 1 of the Hazardous Waste
(Management & Handling) Rules and dispose the same only to currently authorised
recyclers( a list of which can be obtained from Tamil Nadu Pollution Control Board)
under intimation to the Employer’s Representative.
(iv) The Rules given in (I) above shall govern the Classification, Handling, Storage and
disposal of such Hazardous Waste.
(v) Hazardous waste would mainly arise from the maintenance of equipment. These may
include, but not be limited to, the following:
• Used engine oils, hydraulic fluids and waste fuel;
• Spent mineral oils/cleaning fluids from mechanical machinery;
• Scrap batteries or spent acid/alkali; and
• Spent solvents/solutions, some of which may be derived, from equipment cleaning
activities.
(iv) For disposal of waste requiring special attention and hazardous waste the contractor
shall enter into agreement with authorised agencies dealing with the same.
(v) The hazardous waste shall be stored on an impermeable surface with containment
bunding to retain leaks, spills and ruptures.
(vi) Waste oil and chemical containers shall be delivered to the Contractor’s Storage yard.
The Contractor is responsible for the correct storage and handling of waste oil/waste
chemical containers for such a time until they are transported to the chosen disposal
area or waste oil containers.
(vii) All waste collection containers shall be of appropriate size with a
closed lid. Each container will be clearly labelled both with a colour code system and
labelled in local language and English. Original labels of empty containers should be
completely covered and the contents of the type of waste stored in the used containers
clearly indicated.
(k) Bio medical waste
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i. The contractor shall not mix Biomedical Waste & General Waste. Storage time
of waste should be as less as possible so that waste storage, transportation and
disposal is done within 48 hours.
ii. All bags or containers containing segregated bio-medical waste shall be labelled (
including bar code) as per Bio Medical Waste Rules before disposal.
iii. The contactor shall ensure Adequate number of colour coded bins/containersor
bags should beavailable at the point of generation of bio-medicalwaste
iv. The contactor shall ensure Posters/ placards for bio-medicalwaste segregation
should be installed at the point of generation.
v. General waste should not be collected at the same time or in the same trolley in
which bio-medical waste is collected.
vi. Disposal of biomedical waste should be through a licensed waste collector, duly
authorized by MoEF&CC or Tamil Nadu Pollution Control Board as the case
may be. License of the waste collector shall be shown to the Employer’s
Representative on demand.
vii. Bio-medical waste collected by the staff, should be provided with PPEs.
viii. The contractor must ensure that there is no secondary handling of the waste
(l) Storage and Segregation of Waste
(i) Disposal and collection points should be established around all construction work
sites. The waste containers should be of at least 50L/100L
(ii) Outside the storage area, the Contractor shall place a ‘display board’, which will
display quantity and nature of hazardous waste, on date. Hazardous Waste needs to be
stored in a secure place.
(iii) It shall be the responsibility of the Contractor to ensure that hazardous wastes are
stored, based on the composition, in a manner suitable for handling, storage and
transport. The labelling and packaging is required to be easily visible and be able to
withstand physical conditions and climatic factors.
(iv) The contractor shall enter into a contract with a licensed organisation to collect waste
from Construction depots, Labour Colony etc. and dispose it at their landfill as per
existing norms.
(iv) The Contractor is responsible for the separation of construction and demolition
material into re-usable and non-reusable materials, and transfer of these materials to
low lying areas or landfills, depending on the type of material and the percentage of
inert material.
(v) Segregation of Waste should be done on site. All construction
waste including debris should be sorted on site into inert and
non-inert components as given in Table - I. Different areas of the
worksites should be designated for such segregation and storage
wherever site conditions permit.
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Table –1
Storage of Waste
Waste Container Colour Code Sign
Landfill / Biodegradable Green Waste
Recyclable Blue Paper & Plastic
Burning / Combustible Red Burning
Scrap Metal Brown Metal
(vi) On-site measures promoting proper segregation and disposal of construction waste
should be implemented e.g. provide separate containers for inert (rubber, sand, stone
etc.) and non-inert (wood, organics etc.) wastes. The inert waste should be used on
site before disposed of at filling area and the non-inert waste should be sorted for re-
use or recycling before being transported to landfills.
(vii) Non-inert materials such as wood, glass and plastic are acceptable for disposal to a
landfill as a last resort if these can no longer be reused or recycled.
(viii) Inert materials such as excavated materials comprising soil, rubble, sand, rock, brick
and concrete should be separated and broken down to size suitable for subsequent
filling in low lying areas, if it is determined that such material can no longer be
reused at the site itself.
(h) Reuse and Recycle
(i) If some good quality reusable topsoil is expected from site clearance works it shall
be locally stockpiled and used later in final landscaping works, thus saving on costs
for such works and transportation and environmental impacts of disposal.
(ii) The design of framework should maximise use of wooden panels so that high reuse
levels can be achieved. Alternatives such as steel framework should be considered to
increase the potential for reuse.
(iii) The Contractor should recycle as much of the construction waste as possible on-site.
(iv) Excavated materials are usually inert such as soil and rock, and can normally be
reused on site or in public filling areas. The excavated material may have to be
temporarily stockpiled on-site for subsequent re-use.
(v) Steel and other metals should be recovered from the construction waste and recycled
as far as practical. If possible, scrap steel mills can use steel bars.
(k) Transportation of Waste
(i) The transportation of construction spoil shall be allowed only to officially designated
dumpsites after obtaining necessary permission from appropriate authority.
(ii) The Contractor shall approach only Authorised Recyclers of Hazardous Waste for
disposal of Hazardous Waste, under intimation to the Employer
(iii) A procedure to facilitate tracking of loads should be developed to prevent illegal
disposal of waste. This procedure should include, inter alia, the name of driver,
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vehicle registration number, type and quantity of waste, place and time of origin,
place of disposal and route of haulage.
(iv) In orders to avoid dust or odour impacts, vehicles leaving a site carrying excavate
should have their load covered. Vehicles should be routed as far as possible to avoid
sensitive receivers in the area.
(v) Contractors who produce significant quantities of scrap are obliged to enter into
agreement with authorised dealers of scrap for its disposal. Copies of such
agreements shall be shown to the Employer’s Representative on request.
(vi) The Contractor shall submit all Environment related documents and records
pertaining to monitoring and trend analysis on key parameters as listed below but not
limited to: consumption/ efficient use of resources such as energy, water, material
such as demonstrated continual improvement in the implementation of Environmental
Management System. Failure to do so the Employer/Employer representative shall
impose appropriate penalty as per Volume 1 of OHS&E Employer Requirements.
(l) Training
(i) The Contractor’s Environmental Department is responsible for training of workers
and personnel involved in generation of waste.
(ii) The Contractor shall provide training for workers about the concepts of site
cleanliness and appropriate waste management procedure, including waste separation,
reduction, reuse and recycling. Failure to do so would result in poorly separated
waste, resulting in difficulties in treating the waste correctly and/or a bad market for
reuse /recycling.
(iii) The awareness will be created through briefings and toolbox talks. The
personnel/workers should be trained in waste classification and separation. The
training should include:
• Biodegradable waste
• Combustible waste
• Hazardous waste
• Minimisation of waste
(iv) Separation awareness training shall be given to employees responsible for the
separation of the waste and information regarding waste separation shall be posted at
appropriate locations around the site.
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10. Housekeeping
11.1 The Contractor shall constitute a special group of housekeeping personnel in charge of each
work section. Site Engineer of each section or work areas shall be responsible for
housekeeping at their respective sites.
11.2 Each section of work site shall maintain the site reasonably clean, keep free from obstruction
and properly store any construction equipment, tools, and materials. Any wreckage, rubbish
shall be temporarily stored in wreckage and rubbish bins. These wreckage and rubbish bins
shall be cleaned at frequent intervals. Special housekeeping group will ensure daily cleaning
work at the site and its surrounding areas.
11.3 General Housekeeping shall be carried out and ensured at all times at work sites, Labour
Camps, Stores and Offices.
11.4 Full height fence, barriers etc. will be installed at the site in order to preserve the surrounding
area from excavated soil, rubbish etc which may cause inconvenience to public.
11.5 The Contractor will ensure that all sub-contractors maintain the site reasonably clean through
the sub-contract’s provision related to housekeeping.
11.6 The Contractor’s designated department through daily pre-work meeting (tool box talk),
safety meeting etc. will impart the necessary introduction and education to labour on
housekeeping. Other staff such as supervisors and engineers working at the site will also be
educated on the necessity of good housekeeping.
11.7 Every individual would be responsible for housekeeping in his area i.e.
• At Work Site: All workers should clean their work place after completion of their job.
Supervisor should ensure good housekeeping of their respective work area through their
workers. Section Managers shall ensure housekeeping in their area through their
supervisors. Contractor’s designate department will monitor this activity through section
manager as well as site supervisor.
• At Labour Camp: All workers should be responsible to maintain good housekeeping and
hygienic condition in their respective rooms/dormitories. The Contractor should ensure the
availability of dustbins at required place and regular cleaning of rooms, kitchens, toilet
blocks and dustbins. Safe disposal of all waste materials should also be ensured.
Arrangement for regular fumigation should be made by the contractor.
• At Store: Proper access and stacking shall be ensured at the Stores. A list will display daily
stock of materials. All work material should be stored in clearly marked containers or at
designated storage area.
• At Office: Everyone is responsible to maintain housekeeping of their work station. Disposal
of waste materials (i.e. stationary, cigarette butts, tea bags etc.) must be in dustbin only.
11.8 Avoidance of Nuisance
(a) The Contractor shall take all precautions to avoid any nuisance arising from his
operations. This shall be accomplished, wherever possible by suppression of nuisance at
source rather than abatement of the nuisance once generated.
(b) Following site clearing and before construction, the Contractor shall remove all trash,
debris and other weeds.
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(c) The Contractor shall ensure that the work place is free of trash, garbage, debris and
weeds.
(d) The Contractor shall provide at site, metal or heavy-duty plastic ‘Refuse Containers’ with
tight fitting lids for disposal of all garbage or trash associated with food.
(e) To keep the area free of litter and garbage, specific locations shall be designated for
consuming food and snacks to prevent random disposal of waste. All waste shall be
deposited in the refuse containers. Suitable all weather signage shall be prominently
displayed for compliance of these requirements.
(f) The refuse containers shall be kept upright with their lids shut. These containers shall be
emptied at least once daily by the Contractor to maintain site sanitation. There shall be
different containers for bio-degradable/recyclable and hazardous (flammable) wastes.
(g) All plants/equipment/machinery shall be well maintained by regular servicing and kept
free from oil/grease dripping. Drip pans of suitable size shall be used to collect oil
leakages and spills. The area shall be cleaned after completion of maintenance/repair and
generated waste disposed off in approved manner.
(h) The contractor shall make available Material Supply Data Sheet (MSDS) for
material/chemicals/substances used, for which these are available to the Employer’s
Representative when requested.
(i) Such material/chemicals/substances used shall be treated, handled, stored, transported and
disposed off, by the contractor, in a manner specified in the MSDS.
11.9 Prevention of Mosquito Breeding
(a) Measures shall be taken to prevent mosquito breeding at site. The measures to be taken
shall include, but not limited to, the following:
(i) Construction run of shall not be allowed to stagnate at work sites specially at
construction depots and batching plant locations, by executing and efficient drainage
system and/ or levelling off low lying areas;
(ii) Empty cans, oil drums, packing and other receptacles which may retain water shall be
deposited at a central collection point and shall be removed from the Site regularly;
(iii) Still waters shall be treated at least once every week with oil in order to prevent
mosquito breeding;
(iv) Contractor’s Equipment and other items on the Site, which may retain water, shall be
stored, covered or treated in such a manner that water could not be retained.
Posters in both local language and English which draw attention to the dangers of permitting
mosquito breeding shall be displayed prominently on the site.
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11. Landscape, Greenery and Aesthetics

12.1 As far as is reasonably practicable, the Contractor shall maintain ecological balance by
preventing deforestation and defacing of natural landscape. In respect of ecological balance,
the Contractor shall observe the following instructions.
12.2 The Contractor shall, so conduct his construction operations, as to prevent any avoidable
destruction, scarring or defacing of natural surroundings in the vicinity of work.
12.3 Where destruction, scarring, damage or defacing may occur as a result of operations relating
to Permanent or Temporary works, the same shall be repaired, replanted or otherwise
corrected at Contractor’s expense. All work areas shall be smoothened and graded in a
manner to conform to natural appearance of the landscape as directed by the Employer.
12.4 The Contractor should be able to demonstrate evidence that the landscape and aesthetics
quality during construction have been considered and appropriate actions have seen taken to
mitigate negative impacts due to construction.
12.5 The construction of metro system will have negative but temporary impacts on the landscape
and aesthetics due to loss of amenities and tress. Large-scale construction activity will impact
negatively on roadside areas and residential communities immediately adjacent to the
construction sites.
12.6 However, transplanting, replanting of trees and additional landscape treatment is likely to
result in long-term beneficial impacts. Some such species are given in
Table –2 for guidance.
Table – 2
Recommended species for Plantation and Landscaping
Sl. No. Botanical Name Common Name
A TREES
1. Azadirachta indica Neem
2. Mangifera indica Mango
3. Madhuca indica Illuppai
4. Tamarindus indica Tamarind
5. Dipterocarpus indicus Ennei
Sl. No. Botanical Name Common Name

B PALMS
1. Corypha umbraculifera Talipot
2. Borassus flabellifer Palm
3. Cycas circinalis Queen Sago
4. Phoenix sylvestris Date Palm
5. Phoenix pusilla Ceylon Date Palm
C GROUND COVER
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1. Jatropha curcas Jatropha

2. Tecoma stans Tecoma
3. Murraya paniculata Murraya
4. Sphagneticola trilobata Wedelia
5. Sansevieria trifasciata Snake Plant
12.7 Light used for construction lighting can illuminate adjacent areas in undesired ways. Such
lighting and glare shall be prevented from striking adjacent areas, where feasible, through
directional shielding.
12.8 The other measures include but not limited to:
(a) Erection of decorative screen hoarding prominently displaying the logo of Chennai Metro
Rail Limited.
(b) Minimising height of temporary buildings.
(c) Careful positioning of construction equipment.
(d) Eliminating the possibility of stockpiles of material from being visible to public.
(e) Strategically placing hi visibility site markings at construction sites indicating facilities,
offices and stores.
(f) Adequate and properly managed parking of vehicles at construction depots and batching
plants.
12.9 Consent for height of stacks of Diesel Engines with rating more than 250 kV shall be obtained
by the Contractor from statutory Government agency. Where the calculated height of stack is
obtrusive and does not blend with the neighbourhood, the contractor will provide either
alternative sucrose of power or provide a solution that is acceptable to the Employer’s
Representative. This may include but not limited to providing appropriate cladding for the
stack.
12.10 Tree Felling
(a) The contractor shall identify the number of trees that are required to be felled as a result if
construction of works and facilities related to CMRL work and inform to the Employer.
(b) All trees and shrubs, which are not specifically required to be cleared or removed for
construction purposes, shall be preserved and shall be protected from any damage that
may be caused by Contractor’s construction operations and equipment. The Contractor
shall not fell, remove or dispose of any tree or forest produce in any land handed over to
him for the construction of works and facilities related to CMRL except with the previous
permission obtained from the Forest Department.
(c) The Employer shall arrange permission from the forest department for trees to be felled or
transplanted. The Employer will permit the removal of trees or shrubs only after prior
approval.
(d) Special care shall be exercised where trees or shrubs are exposed to injuries by
construction equipment, blasting, excavating, dumping, chemical damage or other
operation and the contractor shall adequately protect such trees by used of protective
barriers or other methods approved by the CMRL Environment Specialist.
(e) Trees shall not be used for anchorage.
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12. Energy Management

13.1 By using energy efficiently, the same services can be delivered with less energy, which helps
protect the environment by preventing pollution.
13.2 Measures to conserve energy include but not limited to the following:
a. Use of energy efficient motors and pumps
b. Use of energy efficient lighting, which uses energy efficient luminaries
c. Adequate and uniform illumination level at construction sites suitable for the task
d. Proper size and length of cables and wires to match the rating of equipment
e. Use of energy efficient air conditioners
13.3 By using energy efficiently, the same services can be delivered with less energy, which helps
protect the environment by preventing pollution.
13.4 The Contractor should optimize the use of tools and plants and equipment to perform tasks
with correct power. Optimizing cable sizes and joints can control voltage drops.
13.5 The Contractor should use energy efficient pumps (at least 80% efficiency) and motors (95%
efficiency or more). The efficiency should be measured during installation and also
periodically.
13.6 The Contractor should use Diesel Generating sets that have specific fuel consumption of at
least 3.5 units per litre of diesel. The Contractor should rigorously follow the maintenance
regime of his DG sets.
13.7 The Contractor should maximize the use of energy efficient luminaries such as LED’s, metal
halide lamps and similar and ensure optimum illumination levels to save energy. The
Contractor shall make provision of Earth Leakage Circuit Breakers (ELCBS) to prevent loss of
excessive earth currents which are unsafe.
13.8 The Contractor should plan in advance and select locations to receive and store material such
that these are at the least distance from place of use. Such an approach will result in less
energy being consumed since optimum energy will be expended for transport of material.
13.9 The Contractor should plan works in a manner as to avoid reworking especially during
meeting the interface requirements of systems contractor.
13.10 The Contractor shall design site offices maximum daylight and minimum heat gain. The
rooms shall be well insulated to enhance the efficiency of air conditioners and the use of solar
films on windows may be used where feasible
13.11 The Contractor shall use and maintain equipment so as to conserve energy and shall be able to
produce demonstrable evidence of the same upon Employer/Employer’s Representative
request.
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13. Traffic Management

14.1 Traffic Management for the project includes public roadways and sidewalks and the
maintenance of access to residence, business and public services throughout the construction
area. Traffic delays and reduction in roadways capacity are anticipated during aspects of the
construction of the metro rail.
14.2 Even though vehicular, pedestrian and surface transit traffic will be impacted at a few
locations, the contractor should minimize such impacts through the development of Traffic
Management Plans, which will be submitted in advance to the Employer’s Representative for
his notice of no objection. These plans will provide specific guidance on traffic management
for various portions of construction zones and staging.
14.3 The types of mitigation measures to be implemented by the Contractors will be on a site-
specific basis and will include
• Signage and barriers for protecting and guiding pedestrians
• Detour signs placed at strategic locations
• Relocation of bus stops at construction sites
• Provision of sidewalks of least 2m where feasible
• Physical separation between construction zone and sidewalks of concrete barriers or wood
fencing or mesh fencing
13.4 Wherever heavy equipment like cranes or dozers have to be moved on public roads and the
normal moving dimensions are infringed, these shall be moved under advice to traffic police, and
with adequate precautions and at low speed.
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14. Archaeological and Historic Resources

15.1 During the construction period, Archaeological or Historic resources may potentially be
affected by direct or indirect construction activity. If any such structures are likely to be
affected, special measures to be initiated with the notice of no objection of the Employer’s
Representative.
15.2 The Contractor shall consult the Archaeological Survey of India (ASI) and other parties, on
the advice of the Employer / Employer’s Representative, to identify and assess construction
effects and seeks ways to avoid, minimize or mitigate adverse effects on such monuments.
15.3 Adverse effects may include reasonably foreseeable effects caused by the construction that
may occur later in time, be father removed in distance or those that alter, howsoever
temporarily, the significance of the structure.
15.4 Prior to the initiation of construction Employer’s Representative intends to review a resource
protection plan for historic structures where it appears that they may be affected by the
project. This plan will be developed by the Contractor in consultation with The
Archaeological Survey of India (ASI).
15.5 The plan will identify the sensitive resources as well as specify the construction monitoring
requirements. These requirements may include ground vibration monitoring and recording
any components inadvertently subjected to impact.
15.6 If the project is likely to affect a previously unidentified historic property, work in that area
shall cease until actions that will take into account the effect of the undertaking on the
property can be implemented. .The Contractor shall consult the Employer’s Representative
before proceeding further in such an event.
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15. Environmental Monitoring - General

16.1 The Contractor’s Environmental Team shall carry out the monitoring of environmental
impacts during construction. Representative sensitive receivers in the vicinity of the works
shall be monitored for noise, water and air quality impacts.
16.2 For carrying out impact monitoring for noise and air, equipment shall be provided, operated
and maintained by the Contractor. The equipment shall be kept in a good state of repair in
accordance with the manufacturer’s recommendations and maintained in proper working
order with sufficient spare equipment available in the event of breakdown to maintain the
planned monitoring programme.
16.3 The calibration of monitoring instruments and their respective calibrators shall be carried out
in accordance with the manufacturer’s requirement to ensure they perform to the same level
of accuracy as stated in the manufacturer’s specifications.
16.4 PM2.5 levels shall be measured by following the standard high volume sampling method as set
out in High Volume Method for Suspended Particulate, BIS: 5182-1981.) PM10 shall be
measured in accordance with BIS 5182 Part 23.
16.5 24-hour average PM2.5 concentration shall be measured by drawing air through a High
Volume Sampler (HVS) fitted with pre-weighted Glass Fibre filter paper at an average flow
rate not less than 1.1 m3 per minute. Similarly for PM10, Respirable dust sampler, fitted with
pre-weighted Glass Fibre and an average flow rate of not less than 1.1 m3/minute shall be
used. The duration of monitoring of PM10 shall be 24 hrs.
16.6 The minimum requirements to the specifications of sound level meter are given in IS: 9779-
1981.
16.7 The Contractor’s monitoring programme is summarised in Table –3.
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Table –3
Summary of Contractor’s Environmental Monitoring Programme (Tentative)
Parameter Noise Air
Sampling Day Time (6 AM – 10PM) PM2.5 PM10
Lmax, Leq, L10, L90 24 hours 24 hours
Night Time (10PM – 6AM)

Lmax, Leq, L10, L90
Frequency at Once a week (when noise- Two 24 hours Two 24 hours
each location generating activities are samples every week. sample every week
underway.
Locations To be determined, by the To be determined by To be determined
and number Contractor and approved by the the Contractor and by the Contractor
Employer’s Representative based approved by the and approved by
on noise sensitive receptors, but ’Employer's the Employer’s
at least at all metro station sites, Representative, Representative,
Batching Plant and sensitive sites based on air based on air
such as school, hospital sensitive receptors, sensitive receptors,
archaeological sites etc. but at least all metro but at least all
station sites, metro station sites,
Batching Plant and Batching Plant and
sensitive location sensitive location
like school hospital like school
archaeological site hospital
etc. are to be archaeological site
monitored etc. are to be
monitored
Duration of During Civil Construction During Civil Construction
Monitoring by
Contractor
The above indicated Contractor’s Environmental Monitoring Programme is mandatory and any
additional monitoring, with respect to additional environmental attributes (like surface water &
ground water, soil etc.), additional locations, frequency, parameters etc., as directed by the
Employer’s representative, will have to be undertaken by the Contractor.
OHS&E – Volume 3
16. Air Monitoring

17.1 Construction activities that will generate dust impacts include excavation, material handling
and stockpiling, vehicular movement, and wind erosion of unpaved work areas.
17.2 The impact of fugitive dust on ambient air pollution depends on the quantity generated, as
well as the drift potential of the dust particles injected into the atmosphere. Large dust
particles will settle out near the source and smaller particles are likely to undergo dispersal
over greater distance from the sources and impeded setting. PM10 and PM2.5 levels will be
monitored to evaluate the dust impact during the construction phase of the Project.
17.3 The Air Quality Monitoring and Control Plan (AMCP) in contract-specific Site
Environmental Plan prepared by the Contractor shall establish procedures to monitor impact
air quality and measures to control air pollution including dust suppression due to
construction activities at work sites. This plan shall contain description of activities that will
cause degradation in air quality, environmental procedures to manage pollutants, monitoring
programme record keeping and reporting.
17.4 The Employer’s Representative shall monitor Contractor’s performance of tasks specified and
will inspect necessary records, reports and procedures related to the control of air quality
given in AMCP.
17.5 Information gathered during the AMCP will be catalogued and maintained by the Contractor
and shall be available for review by the Employer’s Representative.
17.6 The exact location of the air monitoring stations located near air sensitive receptors adjoining
the construction sites, such as residences, schools, and hospitals and placement of monitoring
equipment shall be agreed with the Employer’s Representative prior to commencement of air
monitoring programme.
17.7 Impact monitoring during the course of the Works shall be carried out at the monitoring
stations for two days (continuous twenty-four hours) every fifteen days and where there is a
perceived air quality problem.
17.8 The Contractor should construct suitable fence, lockable gate, 220V AC power point and
suitable access at each air monitoring station. Monitoring stations should be free from local
obstructions or sheltering.
17.9 Should impact monitoring record dust levels which are:
 Indicative of a deteriorating situation such that closer monitoring is reasonably indicated,
or
 When in the opinion of the Employer’s Representative additional measurements are
required in view of deteriorating air quality;
Then, the Employer’s Representative may require the Contractor to increase the frequency of
impact monitoring at any one or more of the monitoring stations until the results indicate an
improving and acceptable level of air quality.
17.10 The Contractor shall keep records of air quality monitoring (including location, date, time).
The Contractor shall submit a copy of monitoring results to the Employer’s Representative.
The results should represent a statistical evaluation of data by calculating maximum,
minimum, mean, for valuation of trends, and comparison with emission standards.
17.11 The National Ambient Air Quality Standards given in Air (Prevention and Control of
Pollution) Act, 1981 may be referred by the Contractor for Limit Levels of PM10 and PM2.5 in
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ambient air which may be followed in estimating the pollution level caused by Contractor’s
activities.
17.12 Where the Employer’s Representative determines that the recorded PM10 level is significantly
greater than the Limit levels, the Employer’s Representative may direct the Contractor to take
effective remedial measures including, but not limited to, reviewing dust sources and
modifying working procedures.
17.13 Where the recorded baseline levels exceed the ambient air quality standards, then at such
locations the limit level is the recorded base line. Contractor shall take all effective remedial
measures to contain the levels to their baseline value as a result of his activities.
17.14 The Contractor should inform Employer’s Representative of all steps taken to investigate
cause of non-conformance and immediate action taken to avoid further occurrences through
written reports and proposals for action.
17.15 The Contractor shall take all necessary precautions to minimise fugitive emission’s from
operations Involving excavation, grading and clearing of land and disposal of waste. He shall
not allow emissions of fugitive dust from any transport, handling, construction or storage
activity to remain visible in atmosphere beyond the property line of emission source of any
prolonged period of time without notification to the Employer/Employer’s Representative.
OHS&E – Volume 3
17. Noise Monitoring

18.1 The activities which are expected to cause noise during the construction include noise from
construction equipment, construction activities such as portal construction, earthwork
excavation, concreting, removal of spoil, movement of construction vehicles and delivery
vehicles travelling to and from the construction and disposal sites etc.
18.2 The level of impact of these noise sources depends upon the noise characteristics of the
equipment and activities involved the construction schedule, and the distance from noise
sensitive receptors.
18.3 The Noise Monitoring and Control Plan (NMCP) in contract specific site Environmental
Management Plan prepared by the Contractor shall establish procedures to monitor
construction noise and determine when to apply measures to control noise pollution due to
construction activities at works site.
18.4 The NMCP will provide site description, define acceptable noise monitoring equipment,
provide monitoring locations and operating procedures for noise equipment and indicate
reports and record keeping on noise monitoring data.
18.5 The NMCP will provide guidance for construction activity. It shall also address noise
performance criteria used in the selection of construction equipment. In defining the
requirements of the NMCP, available measures for noise control, such as, the use of
equipment with special exhaust silencers or enclosures, and the construction of temporary
enclosures or noise barriers around specific construction site activity areas shall be
considered.
18.6 The NMCP will be reviewed on a regular basis and updated as necessary to assure current
construction activities are addressed.
18.7 The Employer’s Representative shall monitor Contractor’s performance of tasks specified,
and will inspect necessary records, report and procedures related to the control of noise.
18.8 Noise monitoring shall be carried out at noise sensitive receptor locations within 200 feet of
the construction site once each week and after a change in construction activity. Construction
noise measurements shall coincide with daytime and night-time periods of maximum noise
generating construction activities.
18.9 The appropriate parameter for measuring construction noise impacts shall be the equivalent
A-weighted sound pressure level (Leq) measured in decibels (dB). The two statistical sound
levels L10 and L90; the level exceeded for 10 and 90 percent of the time respectively, shall also
be recorded during monitoring. The L90 may be considered as the ambient level into which
the L10 as average peak level intrudes. The Lmax, Leq, L10 and L90 values will be reported in the
noise measurement form along with allowable noise limit. The duration of monitoring shall
be on hourly basis for 24hours.
18.10 In no case shall the Contractor expose the public to construction noise levels exceeding 90
dBA(slow) or to impulsive noise levels with a peak sound pressure level exceeding 140 dB as
measured on an impulse sound level meter.
18.11 Limit for construction noise is based on the existing ambient noise levels in areas adjoining
the construction sites. If the measured noise levels exceed the noise limits, the noise levels
shall be reduced by appropriate abatement measures.
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18.12 The noise levels emanating from any source during construction, shall not exceed 10 dB(A)
or more above existing ambient pre-construction noise levels when measured at a point
outside the premises of the location of source. The same may be varied from time to time by
and at the sole discretion of the Employer’s Representative.
18.13 The construction activities shall be limited to levels measured at a distance of 200 feet from
the construction limits or at the nearest affected building, whichever is closer, as given in
Table - 4.
Table- 4
Allowable construction noise
LAND USE MAXIMUM NOISE LEVELS – Leq dB (A)
Day Time Night Time
Residential
75 65
At all Times
Commercial
85
Industrial 90
17.14 The ground borne noise levels within building structures due to tunnel boring machine and
any other underground and tunnelling construction activities shall not cause interior noise
levels to exceed the levels given below as measured in the inside of the affected noise
sensitive structure:
Residential: Lmax 55 dB(A)
Commercial: Lmax 60 dB(A)
18.14 At the surface of the construction site during night time hours, the Contractor shall use only
equipment that operating under full load meets the noise limits specified in Table-5, if a
sensitive receptor would be affected.
Table - 5
Noise emission limits for construction equipment measured at 50 feet from construction
equipment*
Equipment Category Lmax Level dB(A)
Backhoe 80
Bar Bender 75
Chain Saw 81
Compactor 80
Compressor 80
Concrete Mixer 85
Concrete Pump 82
Crane 85
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Equipment Category Lmax Level dB(A)
Dozer 85
Front End Loader 80
Generator 82
Gradall 85
Grader 85
Paver 85
Pneumatic Tools 85
Scraper 85
Tractor 84
18.15 The adjustments for close in equipment noise measurement shall be made in accordance with
Table - 6.
Table – 6
Adjustments for close in equipment noise measurements
(Measurement Values to be subtracted from Measured Sound)
Level to Estimate Sound Level at 50 Feet
Distance (Feet)
dB(A)
19-21 8
22-23 7
24-26 6
27-29 5
30-33 4
34-37 3
38-42 2
43-47 1
48-50 0
18.16 Should the impact monitoring record noise levels which are:
• indicative of a deteriorating situation such that closer monitoring is reasonably indicated, or
• when in the opinion of the Employer’s Representative additional measurements are required
in view of deteriorating noise environment,
then, the Employer’s Representative may require the Contractor to increase the frequency of
impact monitoring at any one or more of the monitoring stations until the results indicate an
improving and acceptable level of noise.
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18.17 The Contractor shall inform the Employer’s Representative of all steps taken to investigate
cause of non-conformance and immediate action taken to avoid further occurrences through
written reports and proposals for action.
18.18The Contractor shall submit a copy of monitoring results. The results should represent a
statistical evaluation of data for evaluation of trends and comparison with noise emission
standards.
18.19Where the Employer’s Representative determines that the recorded Noise level is significantly
greater than the acceptable levels, the Employer’s Representative may direct the Contractor to
take effective remedial measures including, but not limited to, reviewing noise sources and
modifying working procedures.
18.20Protection against the effects of occupational noise exposure should be provided when the sound
levels exceed those shown in Table No. 6 below when measured on the A-scale of a standard
sound level meter at slow response.
18.21When employees are subjected to sound levels exceeding those listed in the Table No. 7 feasible
administrative or engineering controls should be utilized.
18.22If such controls fail to reduce sound levels within the levels of the table, personal protective
equipment shall be provide and used to reduce sound levels within the levels of the table.
Table – 7
Permissible Noise Exposures
Sound level
Duration per day, Hours
(slow Response)
8 90
6 92
4 95
3 97
2 100
1½ 102
1 105
½ 110
¼ or less 115
18.23 When the daily noise exposure is composed of two or more periods of noise exposure of
different levels, their combined effect should be considered, rather than the individual effect
of each. Exposure to different levels for various periods of time shall be computed according
to the formula as given below.
Fe = (T1/L1) +(T2/T2) +…+(Tn/Ln) where,
Fe= the equivalent nose exposure factor.
T= the period of noise exposure at any essentially constant level.
L= the duration of the permissible noise exposure at the constant
level (from Table)
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If the value of f exceeds unity (1) the exposure exceeds permissible levels.
18.24 A sample computation showing an application of the above formula is as follows. An
employee is exposed at these levels of these periods:
11 dB(A) 1/4 hour.
100 dB(A) 1/2 hour.
90 dB(A) 1/2 hours.
Then,
Fe = 0.500 +0.25 +0.188
Fe = 0.938
Since the value of Fe does not exceed unity, the exposure is within permissible limits.
18.25 The vibration level limits at work sites adjacent to the alignment shall conform to permit
values of peak particle velocity as give in Table No. 8.
Table 8
Permitted Values of PPV
Sl. No. Condition of Structure Max. PPV in mm/sec
1. Most structures in “good condition” 25
2. Most structures in “fair condition” 12
3. Most structures in “poor condition” 5
4. Water supply structures 5
5. Heritage structures/bridge structures 5
18.26 When Diesel Generator (DG) Sets are used for operation of equipment and machinery, then
Ministry of Environment and Forest notification dated 12th July 2004, issued under The
Environment (Protection) Second Amendment Rules, 2004, on noise limits shall apply.
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18. Emergency Preparedness and Response

19.1 Spill Management Plan
19.1.1 The Contractor shall prepare a project specific Spill Management Plan and submit to
the Employer’s Representative for notice of no objection. The Spill Management Plan
shall be submitted within 4 weeks of contract Commencement.
19.1.2 The plan must include emergency response arrangements to be implemented if a spill
occurs.
19.1.3 The Contractor shall ensure that all persons including sub-Contractors on site are
aware of the spill management plan in the event of a spillage. Awareness training
shall commence at induction and thereafter through refresher training such as toolbox
talks and mock drills. Records of refresher training and mock drills shall be
maintained.
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19. Environmental Site Inspection

20.1 Site inspection shall be undertaken by the Contractor’s staff to inspect the construction
activities in order to ensure that appropriate environmental protection and pollution control
measures are properly followed and implemented. The frequency of site inspection shall be at
least once a week.
20.2 The Contractor shall prepare an ‘Environmental Inspection and Action Reporting System’,
submit to the Employer’s Representative for notice of no objection and make amendments as
suggested. It shall contain a contract specific comprehensive Environment Inspection
checklist as requirement of Site Environmental Plan.
20.3 The area of inspection shall not be limited to environmental compliance within the site but
areas outside the site which are likely to be affected, directly or indirectly by activities at site.
20.4 Results of inspection shall be discussed with Employer’s Representative and his
recommendations on better environmental protection shall be notified to the Contractor for
taking immediate action and rapid resolution of identified non-compliance.
20.5 If significant environmental problems are identified or if there is an environmental complaint
or as a part of investigation work, then the Employer’s Representative shall also carry out Ad
hoc site inspection which shall be attended by Contractor’s Representative.
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20. Environmental Committee Meetings

21.1 The Contractor shall establish a Environment Committee within 4 weeks of commencement
that shall be chaired by the Contractor’s Project Director.
21.2 The Contractor shall notify the Employer’s Representative of the establishment of the
Committee together with the committee members’ names and designation. The Contractor’s
Environment Manager, Safety Manager’s, Plant & procurement Manager and Human
Resources Manager shall form the minimum committee members. Site based personal shall
be represented within the Committee by the attendance of Site Manager(s) and the Workforce
OHS&E Representative.
21.3 The Employer’s Representative shall be invited to attend the Contractor’s Environment
Committee meetings.
21.4 The Contractor’s OHS&E Committee shall meet on a monthly basis throughout the duration
of the Contract.
21.5 The Committee shall review the previous month’s performance, to include, inspections and
audits undertaken, environmental impacts and any concerns or complaints that have been
raised. Short term objectives and targets for improvement shall be set for completion by the
next scheduled Committee meeting.
21.6 Minutes of the Committee meeting shall be issued within 2 days and promulgated to all
members including the Employer’s Representative. The minutes of meeting shall also be
posted on all sites within the workforce area. The minutes intended for site communication
shall be in both Tamil and English.
21.7 The Workforce OHS&E Representative shall be made a member of the OHS&E Committee
and attend all meetings.
OHS&E – Volume 3
21. Environmental Audits

22.1 As indicated earlier in this EMA, the Employer’s Representative may undertake regular audits
at monthly intervals, of the Contractor’s onsite practices and procedures as a means of
assessing the on-going performance of the Contractor.
22.2 A checklist of environmental requirements was prepared (Refer Appendix IV) and amended if
necessary, throughout the construction phase to focus on areas of frequent non-compliance
and to reflect the potential impacts associated with specific activities within the construction
programme
22.3 The criteria against which the review will be undertaken will be derived from (but not be
limited to):
(a) The approaches, procedures and commitments given by the Contractor in the ‘Site
Environmental Plan’
(b) The clauses contained within the Employer’s Representative’s Requirement on
Environment.
(c) The allocation of responsibility for fulfilling environmental requirements and the
effective lines of communication with regard to environmental issues;
(d) Compliance with procedures established to enable and effective response to
environmental incident or non-compliance;
(e) The extent and accuracy of record-keeping related to environmental performance
indicators;
(f) The effectiveness of ensuring high levels of awareness with regard to environmental
requirements; and
(g) The effectiveness of environmental management activities, including the speed and
effectiveness of responses to complaints.
22.4 The likely protocol will include (but not limited), the auditing of the following activities:
• The allocation of responsibility for fulfilling environmental requirements and effectiveness
of lines of communication.
• Compliance with procedures established to enable effective response to environmental
issues.
• The extent and accuracy of record keeping related to environment.
• The effectiveness of staff training ensuring high levels of awareness with regard to
environmental requirements.
• The speed and effectiveness of responses to complaints.
22.5 The criteria against which the audits will be undertaken shall be derived from the clauses
within the Employer’s Representatives Requirements contract-specific Site Environmental
Plan and previous site inspection results.
22.6 Nonconformity, corrective action and preventive action
a) The Contractor shall conform to their internal procedures regarding nonconformity,
corrective action and preventive action. The Contractor shall be audited by the
Employer’s Representative for compliance with internal procedures.
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b) Major and Minor non-conformances shall be raised by the Employer’s Representative as
per the Employer’s Quality Management requirements and the OHS&E Audit criteria as
defined within OHS&E Volume 2.
c) Open non-conformances shall be reflected in the Contractor’s Monthly Audit Report and
are subject to verification by the Employer’s Representative as detailed in OHS&E
Volume 2. Failure to successfully take corrective action and close out non-conformances
will impact negatively on the Contractor’s total quarterly audit score.
d) Where non-conformances have been raised by an External Auditor against the ISO 14001
Standard, the Contractor shall produce and submit for review within 2 weeks, an action
plan of how and within what timescale shall the non-conformance(s) be closed-out.
OHS&E – Volume 3
22. Training
23.1 The Contractor shall assess the training requirements for all the employees, plan and initiate a
training program to fulfil the training needs assessment. The assessment of training needs
shall incorporate all levels of staff including Sub-Contractor’s against an individual’s role,
responsibility, ability, language skill and risk
23.2 The Contractor shall produce a ‘Training Implementation Plan’ to incorporate the findings of
the needs assessment.
23.3 Records of all training conducted shall be maintained and made available for inspection by
the Employer’s Representative upon request.
23.4 Should the Contractor fail to provide the training identified within the Contractor’s
assessment, implementation plan and the Employer’s Representative’s Training matrix within
the agreed timescales, this shall be reflected in the potential scores awarded within the
monthly audit report.
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23. Reporting System

24.1 Reporting under the Environmental Management System will contain results of monitoring
and inspection programmes.
24.2 In Site Environmental Plan, the Contractor shall prepare and submit monthly Environmental
Management Reports in accordance with Employer’s Representatives Requirements.
24.3 The monthly report shall include (but not limited to) the following:
• Executive Summary
• Brief mention of construction activities
• Tree Felling, Transplanting and Compensatory Planation Details
• Monitoring results under AMCP, and NMCP
• Interpretation of monitoring results, significance and influencing factors
• Graphical representation of monitored results over past four reporting periods.
• Details on Fly ash consumption as given in Appendix-III.
• Raw material consumption details such as electricity, diesel, water
• Generation of scrap during the month and sold to authorised recyclers
• Generation of other type of waste and sold to respected authorised buyers.
• Measures to control spills
• Action taken on recommendation under site inspection programme or specific directions.
• Training Details
• Weekly Inspection Records
• Summary of complaints, results of investigations and follow-up action
• Environmental Initiatives
• Future key issues.
OHS&E – Volume 3
24. Complaint Response Process

25.1 Enquiries, complaints and requests for information can be expected from a wide range of
individuals and organisations both private and government. The majority of complaints is
likely to be received by CMRL, although the site offices are also likely to be contacted.
25.2 The objective of complaint process is to ensure that public and agency complaints are
addressed and resolved consistently and expeditiously.
25.3 The Contractor’s Project Manager will be notified immediately on receipt of complaint that
may relate to environmental impacts. The Project Manager will immediately inform the
25.4 Field investigation should determine whether the complaint has merit, and if so action should
be taken to address the impact.
25.5 The outcome of the investigation and the action taken shall be documented on a complaint
Performa prepared by the Contractor and submitted for notice by the Employer’s
Representative in advance of the works.
25.6 Where possible, a formal response to each complaint received shall be prepared by the
Contractor within seven days in order to notify the concerned person(s) that action has been
taken.
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25. Completion of the EMA Programme

26.1 The construction of Chennai Metro will be undertaken as a series of individual construction
contracts with necessarily different construction programme and completion dates.
26.2 The Employer’s Representative shall maintain an overview of the ‘impact causing potential’
of each site, monitoring parameter or contract with a view to maintaining the most cost
effective use of the environmental resources dedicated to the Project.
26.3 For release of final bill the contractor shall ensure
(i) Closure of all environment related non-conformance reports
(ii) Compensatory plantation reports
(iii) Submittal of all environment related documents and records pertaining to monitoring and
trend analysis on key parameters such as but not limited to consumption/efficient use of
resources such as energy, water, material such as cement, fly ash, iron and steel,
recycle/reuse of waste etc that shall demonstrate continual improvement in the
implementation of Environmental Management System
OHS&E – Volume 3
Appendix –I SITE ENVIRONMENTAL PLAN OUTLINE
Sl. NO. SITE ENVIRONMENTAL PLAN OUTLINE
1 GENERAL
(i) The Environmental Policy of the Contractor is clearly defined in the Site Environmental
Plan, which, inter-alia, commits the Contractor to follow national and state environmental
legislation and regulations.
(ii) The Contractor is committed to CMRL’s Environmental Management System and shall
provide desired manpower and financial resources for its success
(iii) The person responsible for day-to-day environmental matters is identified and vested with
authority to execute the Site Environmental Plan.
(iv) Procedure is available for Contractor’s system of enforcing good environmental practices of
its Sub-contractor.
(v) The Site Environmental Plan contains procedures for screening material used in the
contract, for their environmental friendliness.
2 ENVIRONMENTAL FRIENDLY CONSTRUCTION PRACTICES
(i) The Site Environmental Plan must contain specific procedures for achieving environmental
performance requirements as given in the Employer’s Representative’s requirement on
Environment and CMRL Environmental Management Manual.
(ii) Procedures for carrying out Aspect/Impact analysis of contractor’s proposed works and
their affect on environment.
(iii) Procedures for setting up Objectives and Targets commensurate with Employer’s
Representative's requirement on Environment and CMRL Environmental Management
Manual and how these shall be met.
(iv) Procedures for formulating Environmental Management Plans and Operational Control
Procedures to meet contractual requirements.
(v) Procedures for offering environmental training and methods for promoting environmental
awareness amongst his employees.
(vi) The SEP must contain details on Air Monitoring and Control Plan which details Mitigation
measures / Corrective Action / Preventive Action and Monitoring Schedule.
(vii) The SEP must contain details on Noise Monitoring and Control Plan which details Mitigation
measures / Corrective Action / Preventive Action and Monitoring Schedule.
(viii) The SEP must contain procedures on prevention and control of water pollution from
sanitary surface runoff and process wastewater.
(ix) The SEP must contain details on procedures for Storage, handling and disposal of waste
including, municipal, construction, chemical and hazardous wastes.
(x) The SEP must contain procedures for reuse/recycle of waste, selling to authorised recyclers
and records thereof.
(xi) The SEP must contain procedures for preservation of landscape disturbed due to
construction, housekeeping and traffic management as required under the contract.
(xii) The SEP must contain procedures for dealing with unforeseen environmental situations
under Environmental Emergency.
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Sl. No. SITE ENVIRONMENTAL PLAN OUTLINE
3 MONITORING, AUDITS AND RECORDS
(i) The Contractor keeps records of monitoring and the SEP contains provision for reporting
results of environmental monitoring in a manner as specified in the contract.
(ii) The Contractor carries out weekly inspection under the ‘Environmental Inspection and
Action Reporting System’ through Environmental Inspection checklist and submits to the
(iii) The SEP contains procedures for mandatory audits by the contractor as given in the
contract.
(iv) The SEP contains provisions for submitting monthly Environmental Quality Management
reports.
(v) The SEP contains procedures for recording environmental complaints and response process.
OHS&E – Volume 3
Appendix – II Weekly Environmental Inspection Checklist
SUMMARY SHEET
1. Major issues of non-conformity in the past week are:

Issue Reason
(i) Air (Specify)
(ii) Water (Specify)
(iii) Noise (Specify)
(iv) Waste (Specify)
(v) Storage (Specify)
(vi) Housekeeping (Specify)
(vii) Roads (Specify)
2. Over the last week have been able to implement environmental management requirements as
per contract
Yes No if not yes reasons are

(i)
(ii)
(iii)
3. Following issues have not been resolved for more than past two weeks
(i)
(ii)
(iii)
4. Support/Clarification from Employer’s Representative required in the following:
(i)
(ii)
(iii)
5. Complaints received in the past week.
(i) From Action Taken Reasons for Delay
(ii) Public
(iii) Client
(iv) Statutory Agency
Auditor: Project Manager
Contract Number: Contractor:

OHS&E – Volume 3
Environmental Manager Project Director Document No.:
Weekly Environmental Inspection
Report No.: Inspection Date: Inspected by :
Inspection Area:
Participants:
SL. ACTION
ITEM OBSERVATION REMARKS
NO. By Date By whom
1.0 AIR
POLLUTION
1.1 Dust  Site Satisfactory
(approach roads,  Site Dusty
adjacent roads,  Sprinkling carried out as
working area, required
cement handling
etc.)  Excavate removal within 2
days
1.2 Generators  Satisfactory
 Maintenance regime
followed
 Black smoke
 Leaking oil
 Drip Pans not available
1.3 Vehicles  Satisfactory
 PUC certificate available
 Black smoke
 Wheel Washed /Cleaned
 Leaking oil
 Side of vehicle clear of mud
 Material transported in
closed manner
1.4 Air Monitoring  Carried out as per contract
 Results reported as per
contract
 Remedial measures in place
where required
SL. ITEM OBSERVATION REMARKS ACTION
OHS&E – Volume 3
NO. By Date By whom
2.0 WATER
POLLUTION
2.1 Site Drains  Drainage system functional
 No Contamination
 Not blocked by debris/
garbage
 No indications of Oil
spilled in drains
 Storage of chemical waste
not nearby
2.1 Site Drains  storage of refuse/ excavate

muck not near the drains
2.2 Adjacent Drains  Not damaged

 No signs of pouring
bentonite
 No signs of pouring
Chemicals
 Signs of discharging Silt/
debris
2.3 Separator Tanks Tank not full of silt

 Tank regularly emptied
3.0 NOISE
POLLUTION
3.1 Noise control  All powered mechanical
measures equipments are sound
reduced
 Acoustic / enclosures
constructed in areas of
excessive noise
 Equipment located and
directed away from
noise receptors
3.2 Generators  Effective

provided with  Not effective
acoustic  Not provide
enclosures
SL. ACTION
ITEM OBSERVATION REMARKS
NO. By Date By whom
OHS&E – Volume 3
3.3 Noise Monitoring  Carried out as per
contract
 Not exceeded baseline
values
 Remedial measures in
place
 Results evaluated
statistically for inclusion
in Monthly report
4.0 WASTE
MANAGEMENT
4.1 Waste Identified  Chemical Flammable
Corrosive Construction
related/ oil/ Filters/
Batteries
 Hazardous
 Other (Specify)
4.2 Storage  Adequate number and

Containers & properly place
Bins  Proper quality
 Emptied regularly
 Labelling proper
 No spillage on container
surface noticed
4.2 Storage  Pollutants (e.g. waste

Containers & chemical), not dumped
Bins in
bins
 Recyclable (e.g. metal)
not
dumped in garbage bins
4.3 Oil Waste  Drip pans available

 No oil stains on ground
 Spill absorption material
available
 Waste oil poured in to
designated waste drums
 Used oil filters not
dumped
in garbage bins
SL. ITEM OBSERVATION REMARKS ACTION

OHS&E – Volume 3
NO. By Date By whom
4.4 Excavate/Muck  Storage satisfactory/
properly secured
 Dumping in authorized
areas
 No interference with
nearby drainage
5.0 STORAGE
5.1 Diesel Storage  Extensive diesel spillage
on ground not visible
 Drip pans used when
pumping diesel
 Pipes / connectors/
pumps not leaking
 Not located close to
storm water drains
 transfer arrangement
satisfactory
6. AESTHETICS &
CLEANLINESS
6.1 Housekeeping &  Designated storage area
Hygiene for materials
 Scraps/brickbats/rubbish
scattered at site
 Proper space for
handling
waste
 Area Clean and dry
 Stagnant water treated
weekly
 Proper stacking of
drums
 Barricades are clean, in
line, firmly secured and
proper earthling
 Water not allowed to
accumulate in work area
for any reason
7.0 ROADS
OHS&E – Volume 3
7.1 Access Roads  Satisfactory Maintenance
 In urgent need of
Maintenance
7.2 Public Roads used  Satisfactory maintenance

by Contractor  Repair not carried out
OHS&E – Volume 3
WEEKLY ENVIRONMENTAL AUDIT

AUDIT No. : WEEK ENDING :
PROGRESS IN THE LAST WEEK:
PLANNING /GOALS FOR THE NEXT WEEK:
Environmental Manager Project Director Document No.:

OHS&E – Volume 3
APPENDIX - III - DETAILS ON FLY ASH
The Employer’s Representative shall give his consent to the civil Contractor for using Fly
Ash in concrete or brick works. The Contractor shall record all relevant details on the
consumption of Fly Ash from the data of initial consumption to date of final use.
The details on Fly Ash consumption shall be reported on a monthly basis in the Contractor’s
monthly Environmental Management Report required to be submitted to the Employer’s
Representative.
The details on Fly Ash shall be reported in groups and sub groups as noted below: -
F1 Data required from the Concrete Production Contractor
F1.1 Concrete Production
• Daily records of concrete production
• Mix Design
F1.2 Material consumption from Daily production Records:
• Cement delivery records
• Fly ash delivery records
F1.3 Transportation Cement
• Load capacity of cement delivery vehicles (tons)
• Distance of batching plants to cement plant (km)
• Fuel consumption of delivery vehicles (km/l)
F1.4 Transportation (Fly Ash)
• Load capacity of fly ash delivery vehicles (tons)
• Distance of batching plants to fly ash source (km)
• Fuel consumption of delivery vehicles (km/l)
F2 Data required from Cement Manufacturer (to be obtained by the contractor and
submitted to the Employer’s Representative, on a monthly basis)
F2.1 Process Emission from daily production records
• Quantity of calcareous raw material (limestone etc.) consumed
• % of CaO in raw material
• % of MgO in raw material
• % of CaO in clinker
• % of MgO in clinker
• Quantity of clinker produced
F2.2 Kiln fuel emissions from Monthly Consumption Records
• Quantity of each type of fuel used in the kiln
• CO2 Emission factor (tons CO2/MJ) and specific heat for each fuel type (MJ/Kg)
or % carbon and density (if liquid) for each fuel type
F2.3 Non- Kiln Fuel emission from Monthly consumption records
• Quantity and specific uses for each type of non-kiln fuel used
OHS&E – Volume 3
• CO2 emissions factor (tons CO2/MJ) and specific heat for each fuel (MJ/kg)
or % carbon and density (if liquid) for each fuel type
F2.4 Emission from Electricity consumption in clinker production from Monthly electricity
consumption records
• Electricity consumption of equipment related to cement production (kWh)
• Grid electricity supplier
• Quantity of electricity drawn from grid
• Quantity of electricity self-generated
• Fuel consumption of generating plant
• Waste heat capture from kiln
F2.5 Additives from daily production records
• Quantities of all additives blended with clinker at cement plant
F2.6 Cement Delivery
Monthly records of cement delivery to batching plants

PHASE-II PROJECT”
PART 2
SECTION VI
APPENDIX-20
ENVIRONMENTAL
VOLUME 4 - TUNNELLING MANUAL
DECEMBER 2021
Table of Contents
Part-I-OH& S Management
1.0 Scope
4.0 Chennai metro rail OHS&E objectives
5.0 Normative Referances
6.0 Terms and definitions
7.0 OHS&E Management System Requirements
8.0 CMRL OHS&E Policy Statement of intent
9.0 Legal and other requirements
10.0 Objective and programme’s
11.0 Implememntation and Operation
12.0 Compentence ,Training and Awareness
13.0 ID card and First Day at Work, OH&S Training
14.0 OHS&E Training
15.0 Hazard identification, risk assessment and determining controls
16.0 Risk Register and Hazard Log determining controls
17.0 Method Statement
18.0 Lift Plan
19.0 Risk assessment
20.0 Communication
21.0 Documentation
22.0 Emergency Preparedness and Response
23.0 Incident Investigation ,Non conformity , Corrective action and
Preventive Action
24.0 Audit
Part-II:Safety
25.0 Investigation and Information Gathering

26.0 Safety requirements in all stages of construction
27.0 Permanent Support
28.0 Dealing with Water
29.0 Tunnelling boring machines and road headers
30.0 Inundation
31.0 Methane
32.0 House Keeping
33.0 Work at height
34.0 Slipping, tripping, cutting, drowning and falling hazards
35.0 Lifting Appliances and Gear
37.0 Machine and general area guarding
38.0 Electrical
39.0 Electricity
40.0 Diesel Engines
Section VI- A, Volume – 4, 4-1 December 2021

OHS&E – Tunnelling Manual
41.0 Hydraulic Plant

43.0 Work Permit System
44.0 PPE’s-Personnel Protective Equipment
45.0 Shaft and Hoist
46.0 Rail Haulage
47.0 Flooding
48.0 Illumination
49.0 Ventilation
50.0 Under Ground communication
51.0 Noise and Vibration
52.0 Transport and loading
53.0 Tunnel Plant
54.0 Maintenance and Repair
55.0 Radiation
56.0 Fire and Smoke
57.0 Fire Prevention, protection, fighting system and Rescue
58.0 Access
59.0 Blasting Operations
60.0 Drilling
61.0 Compressed air works
62.0 Pressure Vessels
63.0 Use of Explosives
64.0 Monitoring of the tunnel atmosphere
65.0 Rolling Stock Track
66.0 Pathways
67.0 Visitor’s to site
Part-III: Occupational Health and Welfare
68.0 Medical Facilities

69.0 Welfare measures for workers
70.0 Permissible exposure Limits
71.0 Dust
72.0 Protection against dust
73.0 Gaseous contamination
74.0 Emission from power units
75.0 Heat
Appendix
Appendix 1: An Example of the identification Badge
Appendix 2: Detail of Monitoring
Appendix 3: Permissible exposure limit
Appendix 4: Quality of compressed air in working chamber
Appendix 5: Lock attendant's register
Appendix 6: Compression procedure
Appendix 7: Compressed air worker's transfer record
Appendix 8: Compressed Air Worker's Medical Record
Appendix 9: Compressed Air Illness Notification Form

Appendix 10: Compressed Air Workers Individual Record

Appendix 11: Pressure and Conversion
Appendix 12: Monthly Tunnel Checklist
Appendix 13: Construction / Installation Phase Occupational Health & Safety Tunnel Plan

PART – I: OH&S MANAGEMENT
1. Scope
1.1 This document defines the principal requirements of the Employer on Occupational Health and
Safety (OH&S) associated with the contractor / sub-contractor and any other agency, to be
practiced at any Chennai Metro Rail Limited (CMRL) Tunnelling in construction sites.
2.1 This document applies to all aspects of the contractor’s scope of work, including all aspects
conducted by sub-contractors and all other agencies on their behalf. There shall be no activity
associated to the contract, which is exempted from the purview of this document.
3.1 The objective of this manual is to ensure that adequate precautions are taken to avoid accidents,
occupational illness and harmful effects on the environment during tunnelling in construction
operations.
This document:
a) Describes the OH&S interfaces between the Employer, Engineer and the Contractor.
b) Details the processes by which the contractor shall manage OH&S issues while carrying out
the works under the contract and;
c) Describes by reference, the practices, procedures and requirements pertaining to the Chennai
Metro Rail Project.
3.2 These requirements shall be read together with the Volume 1 Employer’s OHS&E requirements,
Volume 2 OH&S Manual, BS 6164:2011 Code of practice for health and safety in tunnelling in the
construction industry and IS 4756/1978; Safety code for tunnelling work.
4.0 Chennai Metro Rail OHS&E Objectives

4.1 Chennai Metro Rail Limited has identified five principle objectives for attainment during the project.
These long term objectives shall be supported with quarterly, short and medium term objectives to
enable structured advancement in overall performance. Our Short and medium term objectives
also aims to facilitate effective monitoring and measurement to identify where a directional change
may be necessary. Our Long term objectives are:
1. To eliminate or minimize the unwanted effects of hazards and risks to personnel, members
of the public and other stakeholders who may be exposed to the undertakings associated
with the construction of the Chennai Metro Rail project
2. Establish an effective and robust OHS&E management system that will enable Contractors
to achieve international recognition and registration to the ISO 45001:2018 Series.
3. Actively contribute to Contractors development through support, encouragement,
determination in control and transfer of knowledge and skills in order to make the move from
traditional compliance driven management through to risk managed processes.

4. To simplify the risk concept, to ensure a sensible approach to risk management and simplify
hazard awareness training through adoption of the ALARP (As low as reasonably
practicable) principles.
5. To practice ‘Best Practice’ within the construction industry - Establishing a work environment
that conforms to international Occupational health & safety standards and make
recommendation to improve effectiveness of regulations both nationally and locally.
5.0 Normative references
The following normative documents contain provisions which, through reference in this text,
constitute provisions of this British Standard 6164:2011. For dated references, subsequent
amendments to, or revisions of, any of these publications do not apply. For undated references,
the latest edition of the publication referred to applies.
Applicability
The standards that are referenced include the British, European and Indian Standards. In all cases
during the CMRL Project the more stringent standard shall apply. Where an Indian Standard meet
the requirements of the British and or European standard use shall be accepted.
BS EN 12336:2005+A1:2008 Tunnelling machines — Shield machines, thrust boring machines,

auger boring machines, lining erection equipment — Safety requirements
BS 449-2, Specification for the use of structural steel in building — Part 2: Metric units.
BS 476-4, Fire tests on building materials and structures — Part 4: Non-combustibility test for
materials.
BS 476-20, Fire tests on building materials and structures — Part 20: Method for determination of
the fire resistance of elements of construction (general principles).
BS 476-21, Fire tests on building materials and structures — Part 21: Methods for determination
of the fire resistance of loadbearing elements of construction.
BS 476-22, Fire tests on building materials and structures — Part 22: Methods for determination
of the fire resistance of non-loadbearing elements of construction.
BS 638-4, Arc welding power sources, equipment and accessories — Part 4: Specification for
welding cables.
BS 638-5 & BS EN 60974-5:2002 Arc welding power sources, equipment and accessories — Part
5: Specification for accessories.DD CLC/TS 62081:2002 Arc welding power sources, equipment
and accessories — Part 7: Specification for safety requirements for installation and use.
BSEN 131-2-1993, & BSEN 131-1-2007 Specification for portable timber ladders, steps, trestles
and lightweight stagings.
BS EN 529:2005 Guide to implementing an effective respiratory protective device programme.
BS 4293, Specification for residual current-operated circuit-breakers.
BS 4363, Specification for distribution assemblies for reduced low voltage electricity supplies for
construction and building sites.
BS 4592-1-2006 & BS 4592-0-2006 Industrial type flooring, walkways and stair treads — Part 1:
Specification for open bar gratings.
BS 4727-1: Group 01:1983, Glossary of electrotechnical, power, telecommunication,electronics,
lighting and colour terms — Part 1: Terms common to power, telecommunications and electronics
—Group 01: Fundamental terminology.
BS 5045 (all parts), Transportable gas containers.

BS 5306-1-2006, Fire extinguishing installations and equipment on premises — Part 1: Hydrant

systems, hose reels and foam inlets.
BS 5306-3-2003, Fire extinguishing installations and equipment on premises — Part 3:
Maintenance of portable fire extinguishers — Code of practice.
BS 5306-8-2000, Fire extinguishing installations and equipment on premises — Part 8: Selection
and installation of portable fire extinguishers — Code of practice.
BS 8500-1:2002, BS 8500-2:2002 and BS EN 206-1:2000.Concrete.
BS EN ISO 14122 parts 1, 2 and 3:2001, Stairs, ladders and walkways — Code of practice for the
design of industrial type stairs, permanent ladders and walkways. Superseded by
BS 5607-1998, Code of practice for the safe use of explosives in the construction industry.
BS 5911-1:2002 & BS EN 1916-2002-2008 Specification for reinforced jacking pipes with flexible
joints. Superseded by
BS 5930, Code of practice for site investigations. Partially superseded by BS EN ISO 14688-
1:2002, BS EN ISO 14688-2:2004, BS EN ISO 14689-1:2003, BS EN ISO 22476-2:2005 and
BS EN ISO 22476-3:2005
BS 5950 (all parts), Structural use of steelwork in building partially superseded by BS EN 1090-
2:2008
BS 6100-2.1:1992, BS 6100-2.2.1:1992, BS 6100-2.2.2:1999, BS 6100-2.2.3:1990 and BS
6100-2.3:1992. Glossary of building and civil engineering
BS 6387:1994, Specification for performance requirements for cables required to maintain circuit
integrity under fire conditions.PD CLC/TR 50426:2004; Guide to prevention of inadvertent
initiation of electro-explosive devices by radio-frequency radiation.
BS 6708:1998, Flexible cables for use at mines and quarries.
BS 6724-1997 & A3-2008 Specification for 600/1 000 V and 1 900/3 300 V armoured electric
cables having thermosetting insulation and low emission of smoke and corrosive gases when
affected by fire.
BS 7121-1:2006, Code of practice for safe use of cranes — Part 1: General.
BS 7375-1996, Code of practice for distribution of electricity on construction and building sites.
BS 7430:1998, Code of practice for earthing.
BS 7671:2008, Requirements for electrical installations — IEE Wiring Regulations —
Seventeenth edition.
BS EN 60836:2005, Specifications for silicone liquids for electrical purposes.
BS 7835-2007, Specification for armoured cables with extruded cross-linked polyethylene or
ethylene propylene rubber insulation for rated voltages from 3.8/6.6 kV up to 19/33 kV having
low emission of smoke and corrosive gases when affected by fire.
BS 7863, Recommendations for colour coding to indicate the extinguishing media contained in
portable fire extinguishers.
BS EN 3-1 (all parts), Portable fire extinguishers.
BS EN ISO 20345-2004Safety, protective and occupational footwear for professional use —
Part 1: Requirements and test methods.
BS EN ISO 20345-2004Safety, protective and occupational footwear for professional use —
Part 2: Additional requirements and test methods.
BS EN ISO 20345-2004, Safety footwear for professional use — Part 1: Specification.
BS EN ISO 20345-2004Safety footwear for professional use — Part 2: Additional specifications.
BS EN 397-1995, Specification for industrial safety helmets.
BS EN ISO 13850-2008 Safety of machinery — Emergency stop equipment, functional aspects
— Principles for design.

BS EN 981- 1997 Safety of machinery — Auditory danger signals — General requirements,

design and testing.
BS EN 471-2003 & A1-2007, Specification for high-visibility warning clothing.
BS EN 559:2003, Gas welding equipment — Rubber hoses for welding, cutting and allied
processes.
BS EN 730:2002, Gas welding equipment — Equipment used in gas welding, cutting and allied
processes, safety devices for fuel gases and oxygen or compressed air — General
specifications, requirements and tests.
BS EN 791-1996, Drill rigs — Safety.
BS EN 815:1996, Safety of unshielded tunnel boring machines and rodless shaft boring
machines for rock.
BS EN 996-1995 +A3:2009, Piling equipment — Safety requirements.
BS EN 1679-1:1998, Reciprocating internal combustion engines — Safety — Part 1:
Compression ignition engines.
BS EN 1800:2006, Transportable gas cylinders — Acetylene cylinders — Basic requirements
and definitions.
BS EN 12862:2000, Transportable gas cylinders — Specification for the design and construction
of refillable transportable welded aluminium alloy gas cylinders.
BS EN 60079-0:2006 Electrical apparatus for potentially explosive atmospheres — General
requirements.
BS EN 60079-1:2007 Electrical apparatus for potentially explosive atmospheres — Flameproof
enclosures “d”.
BS EN 60079-7:2003 Electrical apparatus for potentially explosive atmospheres — Increased
safety “e”.
BS EN 60079-11:2007Electrical apparatus for potentially explosive atmospheres — Intrinsic
safety “i”.
BS EN 61779-1:2000 Electrical apparatus for the detection and measurement of combustible
gases — General requirements and test methods.
gases — Performance requirements for Group I apparatus indicating up to 5 % (V/V) methane
in air.
gases — Performance requirements for Group I apparatus indicating up to 100 % (V/V) methane
in air.
gases — Performance requirements for Group II apparatus indicating up to 100 % lower
explosive limit.
BS EN 50104:2002, Electrical apparatus for the detection and measurement of oxygen —
Performance requirements and test methods.
BS EN 50266 (all parts), Common test methods for cables under fire conditions — Test for
vertical flame spread of vertically-mounted bunched wires or cables.
BS EN 61241-0:2006 & BS EN 61241-1:2004 Electrical apparatus for use in the presence of
combustible dust — Electrical apparatus protected by enclosures — Part 1-1: Construction and
testing.
BS EN 61241-14:2004, BS EN 61241-17:2005 Electrical apparatus for use in the presence of
combustible dust — Electrical apparatus protected by enclosures — Part 1-2: Selection,
installation and maintenance.
BS EN 60034-1:2004 Rotating electrical machines — Part 1: Rating and Protection.

BS EN 60034-5:2001 Rotating electrical machines — Part 5: Degrees of protection provided by

the integral design of rotating electrical machines (IP code) — Classification.
BS EN 60076-1 1997, Power transformers — Part 1: General.
BS EN 60079-14:2008, Electrical apparatus for explosive gas atmospheres — Part 14: Electrical
installations in hazardous areas (other than mines).
BS EN 60204-1-2006, Safety of machinery — Electrical equipment of machines — Part 1:
General requirements.
BS EN 60309-1-1999, Plugs, socket-outlets and couplers for industrial purposes — Part 1:
General requirements.
BS EN 60529:1992, Specification for degrees of protection provided by enclosures (IP code).
BS EN 61008-1:2004, Specification for residual current operated circuit-breakers without
integral overcurrent protection for household and similar uses (RCCBs) — Part 1: General rules.
BS EN 61008-2-1:1995, Specification for residual current operated circuit-breakers without
integral overcurrent protection for household and similar uses (RCCBs) — Part 2-1: Applicability
of the general rules to RCCBs functionally independent of line voltage.
BS EN 61099:1992, Specification for unused synthetic organic esters for electrical purposes.
BS EN ISO 2503:1998 Gas welding equipment — Pressure regulators for gas cylinders used in
welding, cutting and allied processes up to 300 bar.
BS EN ISO 5172:2006, Manual blowpipes for welding, cutting and heating — Specification and
tests. CP 3010, Code of practice for safe use of cranes (mobile cranes, tower cranes and derrick
cranes).
ISO 9000:2005, Quality management systems — Fundamentals and vocabulary
ISO 9001:2015, Quality management systems — Requirements
ISO 14001:2015, Environmental management systems — Requirements with guidance
ISO 19011:2002, Guidelines for quality and/or environmental management systems auditing
OHSAS 18001:2007, Occupational health and safety management systems Requirements
OHSAS 18002, Occupational health and safety management systems – Guidelines for the
implementation of BS OHSAS 18001
ISO 45001:2018 specifies requirements for an occupational health and safety (OH&S)
management system and gives guidance for its use, to enable organizations to provide safe and
healthy workplaces by preventing work-related injury and ill health, as well as by proactively
improving its OH&S performance.
PAS 99, Specification of common management system requirements as a framework for
integration
International Labour Organization:2001, Guidelines on occupational health and safety
management systems — ILO-OSH 2001
Health & Safety Guidance (HSG) Health and Safety Executive Publications United Kingdom
Occupational Safety and Health Administration(OSHA) publications USA
IS 5878-1: Code of Practice for Construction of Tunnels
IS 5878-2-2: Code of Practice for Construction of Tunnels
Indian Standards
IS: 4081- Safety code for blasting and related drilling operations
IS: 7569- Safety code for handling and storage of building materials
IS: 7293- Safety code for working with construction machinery
IS: 4130- Safety code for demolition of buildings
IS: 8989- Safety code for erection of concrete framed structures

IS: 7205- Safety code for erection on structural steel work

IS: 3764- Safety code for excavation work
IS: 5121- Safety code for piling and other deep foundations
IS: 1905- Structural safety of buildings: Masonry Walls
IS: 2750- Steel scaffolding
IS: 4756- Safety code for tunneling work
IS: 4138- Safety code for working in compressed air
IS:10291- Safety code for dress divers in civil engineering works
IS: 275- Steel scaffoldings
IS: 4014 Steel tubular scaffolding, code of practice for
(Part 1)- Definitions and materials
(Part 2)- Safety regulations for scaffolding
IS: 3696 Scaffolds and ladders, safety code for
(Part 1)- Scaffolds
(Part2)-Ladders
Welding and Gas cutting:
IS: 3016- Fire precautions in welding and cutting operations code of practice
IS: 818-Safety and health requirements in electric and gas welding cutting
IS: 11006- Flash back arrestor (flame arrestor)
Work Environment
IS: 7194 Noise-exposure during work for hearing conservation purposes, assessment
IS: 3483 Noise reduction in industrial buildings, code of practice
IS: 6665 Industrial lighting, code of practice
IS: 3103 Industrial ventilation, code of practice
Electrical Installations
IS: 5572 Classification on hazardous areas (other than mines) for electrical installations
IS: 5571 Guide for selection of electrical equipment for hazardous areas
IS: 3043 Code of practice for earthling
IS: 5216-(Part 1) Recommendations on safety procedures, Practices in electrical work
IS: 7689- Guide for control of undesirable state electricity (first revision)
IS: 5780- Intrinsically safe electrical apparatus and circuits
IS: 6539- Intrinsically safe magnet telephones for use in hazardous atmospheres
SP 31 Treatment for electrical shock
IS: 4770 Rubber gloves for electrical purposes
IS: 5424 Rubber mat for electrical purposes
Fire Protection:
IS: 5896-Firefighting appliances, code of practice for selection, operation and maintenance
IS: 2190- Selection, installation and maintenance of first-aid fire extinguishers – Code of practice
IS: 6382- Code of practice for design and installation of fixed carbon dioxide fire extinguishing
system
IS: 12835 (Part 1) - Design and installation of fixed carbon dioxide fire extinguishers system –
Code of practice: Low expansion foam
IS: 2189- Code of practice for selection, installation and maintenance of automatic fire detection
and alarm system
IS: 2175- Heat sensitive fire detectors for use in automatic fire alarm system

IS: 10548- Plans for fire control and lifesaving equipment – symbols
IS: 12349- Fire Protection Safety signs
IS: 12407- Graphic symbols for fire protection plan
IS: 8241- Method of marking for identifying electrical equipment for explosive gas atmospheres
IS: 8945- Electrical measuring instruments for explosive gas atmospheres
IS: 3016- Code of practice for fire precautions in welding & cutting operations
Personnel Protective Equipment:
IS: 5983- Eye protectors

IS: 4770- Rubber gloves for electrical purposes
IS: 6994- Industrial safety gloves
IS 15071- Chemical Protective Clothing – Specification
IS: 4501- Aprons, rubberized, acid and alkali resistant (first revision)
IS: 6519- Code of practice for selection, care and repair of safety footwear
IS 5557-Specification – safety rubber boots
IS 10667- Guide for selection for industrial safety equipment for protection of foot and leg
IS: 8318-Colour identification marking for air purifying canisters and cartridges
IS: 9623-Recommendations for the selection, use and maintenance of respiratory protective
devices
IS: 8522-Respirators, chemical cartridge
IS: 8523-Respirators, canister type (gas masks)
IS: 9473-Filter type particulate matter respirators
IS: 11057-Specification for industrial safety nets
IS: 3521-Industrial Safety belts and harnesses – Specification
IS: 8519- Safety equipment, industrial, for body protection, guide for selection of
IS: 8520-Safety equipment for eye, face and ear protection, industrial, guide for selection
IS: 8940-Safety equipment for eye and face protection, industrial, code of practice for
maintenance and care of
IS: 899 -Code of practice for maintenance and care of industrial safety clothing
IS: 8807- Safety equipment for protection of arms and hands, industrial, guide for selection
IS: 1179-Eye and face protection during welding, equipment
Machinery & Tools
IS: 4138- Working in compressed air

IS: 1991- Abrasive wheels, safety code for use, care and protections
IS: 4691- Rotating electrical machinery, degrees of protection provided by enclosure
IS: 8235- Safety procedures in hand operated hand tools, guide for
IS: 1991- Safety requirements for the use, care and protection of abrasive grinding wheels –
IS: 9474- Principles of mechanical guarding of machinery
IS: 11461- Code of practice for compressors safety
Material Handling:
IS: 6511-Cranes, lifting appliances and related excavator equipment, range of preferred safe
working loads
IS: 1860 –Lift Wire ropes, guide for inspection of
IS: 6305 -Safety code for powered industrial trucks Part 1: Application, operation and
maintenance
IS: 7155 Conveyor safety, code of practice for (Part 1 to 8)
IS: 8218 –Safety code for plant railways (Part 1 & 2)
IS: 8216- Lift wire ropes, guide for inspection
IS: 13367- Code of practice – Safe use of cranes
IS: 7155-Code of recommended practice for conveyor safety Part 1 to 8

6.0 Terms and definitions

6.1 Acceptable risk. Risk that has been reduced to a level that can be tolerated by the organization
having regard to its legal obligations and its own OHS&E policy
6.2 Accident. Incident giving rise to injury, ill health or fatality
6.3 ALARP (As low as reasonably practicable) principles.
6.4 Audit. Systematic, independent and documented process for obtaining “audit evidence” and
evaluating it objectively to determine the extent to which “audit criteria” are fulfilled
6.5 BOCWA. Building and Other Construction Workers (Regular Employment and Conditions of
Service) Act, 1996
6.6 BOCWR. Building and Other Construction Workers (Regulation of Employment and Conditions
of Service) Central Rules, 1998
6.7 Chief Safety Expert. An officer appointed by CMRL/ Engineer who is the overall responsible for
monitoring all OH&S functions prescribed in this document.
6.8 CMRL. Chennai Metro Rail Limited
6.9 Competent person. Person with the appropriate combination of skill, knowledge, qualifications
and experience
6.10 Continual improvement. Recurring process of enhancing the OHS&E management system in
order to achieve improvements in overall OHS&E performance consistent with the organization’s
OHS&E policy
6.11 Corrective action. Action to eliminate the cause of a detected nonconformity or other
undesirable situation
6.12 Design Risk Assessments. Used to record the actions of designers when reducing risks in
construction and for future repairs and maintenance issues.
6.13 Hazard. Source, situation, or act with a potential for harm in terms of human injury or ill health,
or a combination of these
6.14 Hazard identification. Process of recognizing that a hazard exists and defining its
characteristics
6.15 Health surveillance. Monitoring health of employees to detect signs or symptoms of
work‑related ill health so that steps can be taken to eliminate, or reduce the probability of, further
harm
6.16 Ill health. Identifiable, adverse physical or mental condition arising from and/or made worse by
a work activity and/or work-related situation
6.17 Incident. Work-related event(s) in which an injury or ill health (regardless of severity) or fatality
occurred, or could have occurred. An accident is an incident which has given rise to injury, ill
health or fatality.
6.18 Interested party. Person or group, inside or outside the workplace, concerned with or affected
by the OHS&E performance of an organization
6.19 Nonconformity. Non-fulfilment of a requirement; A nonconformity can be any deviation from:
relevant work standards, practices, procedures, legal requirements, etc. or OHS&E management
system requirements.
6.20 OHS&E management system. Part of an organization’s management system used to develop
and implement its OHS&E policy and manage its OHS&E risks. A management system is a set
of interrelated elements used to establish policy and objectives and to achieve those objectives.
A management system includes organizational structure, planning activities (including for
example, risk assessment and the setting of objectives), responsibilities, practices, procedures,
processes and resources.
6.21 OHS&E objective. OHS&E goal, in terms of OHS&E performance that an organization sets itself
to achieve.
6.22 OHS&E performance. Measurable results of an organization’s management of its OHS&E risks

6.23 OHS&E policy. Overall intentions and direction of an organization related to its OHS&E
performance as formally expressed by top management
6.24 Preventive action. Action to eliminate the cause of a potential nonconformity (6.19) or other
undesirable potential situation
6.25 Procedure. Specified way to carry out an activity or a process
6.26 Record. Document stating results achieved or providing evidence of activities performed
6.27 Risk. Combination of the likelihood of an occurrence of a hazardous event or exposure(s) and
the severity of injury or ill health that can be caused by the event or exposure(s)
6.28 Risk assessment. Process of evaluating the risk(s) arising from a hazard(s), taking into account
the adequacy of any existing controls, and deciding whether or not the risk(s) is acceptable
6.29 Risk control. Selection and application of suitable measures to reduce risk
6.30 Shall. Indicates a mandatory requirement within this document
6.31 Stakeholders. Those with a vested interest in an organization’s achievements that includes, but
is not limited to, internal and “outsourced” employees, customers, suppliers, partners,
employees, distributors, investors, insurers, shareholders, owners, government and regulators.
6.32 Status review. Formal evaluation of the OHS&E management system
6.33 Top management. Person or group of people who direct and control an organization at the
highest level
6.34 Worker representative. Representative of employee occupational health and safety
6.35 High Risk –A hazardous condition may cause frequency accidents which may result in
catastrophic equipment losses or buildings, severe injury, illness, disablement or possible fatality.
6.36 Medium Risk-A hazardous condition resulting in injury /illness requiring absence from work or
equipment damage.
6.37 Low Risk-A hazardous condition is unlikely to cause accidents, minor injury, and even fit
does, result in only negligible damage.
7.0 OSH&E management system requirements

7.1 General requirement
7.1.1 The Contractor shall define and document the scope of its Occupational Health, Safety and
Environmental (OHS&E) management system to meet legal requirements and the requirements
of Chennai Metro Rail Limited as stated within this document.
7.1.2 The Contractor’s OHS&E management system shall determine how the organisation shall
document, implement, maintain and continually improve upon performance in accordance with
the requirements of the International ISO45001:2018 Standard to which the Employer is
committed.

8.0 CMRL OHS&E Policy Statement of Intent

Chennai Metro Rail Limited consider that Occupational health, safety and environmental is of
equal importance in comparison to any other aspect of business management and as such is
committed to promoting high standards of Occupational health, safety and environmental and
welfare on all of their sites and premises. To achieve this Chennai Metro Rail shall:
• Constantly work towards improving the safety culture at all levels.
• Ensure compliance with all relevant legal duties in respect of health and safety at work
legislation.
• Provide adequate resources for planning and controlling working conditions and safe
systems of work.
• Work with our Contractors and suppliers to improve their safety performance, by
measuring and monitoring their performance.
Responsibilities and performance requirements for Occupational health, safety and
environmental are available on the Chennai Metro Rail Limited website. In summary: -
• All Contractors, employees, sub-Contractors, consultants, suppliers and visitors have
aduty to play an active role in achieving our objectives through compliance with their
legal obligations and this Safety Policy.
• Participation and consultation are vital aspects of this Policy and to the achievement of
our objectives. Contractors and Staff are encouraged and expected to:
• Discuss Occupational health, safety and environmental and welfare matters with their
managers, and company Occupational health, safety and environmental Representatives
who will offer or obtain further expert advice,
where necessary.
• Co-operate at all times; contribute good ideas and improvements; report defects and short
falls.
The correction of any breach of statutory provision or Chennai Metro Rail Limited requirements
on Occupational health, safety and environmental shall take priority. Should appropriate action
not be taken to meet the required standards, this will be taken seriously and may lead to
disciplinary action being taken.
This Policy Statement shall be displayed prominently on all Chennai Metro Rail Limited sites and
offices and will be kept under review to ensure its relevance.
____________________
Managing Director
Chennai Metro Rail Limited November 2019

9.0 Legal and other requirements

9.1 Contractor shall comply with all legal obligations and the requirements of Chennai Metro Rail
Limited as contained herein.
9.2 Indian statutory requirements
The Contractor shall abide by all national, state and local bye-laws. It is the duty of the Contractor
to ensure that all sub-Contractors appointed also comply with their legal obligations as listed
below but not limited to:
i.Indian Electricity Act 2003 and Rules 1956
ii.Tamil Nadu Building and other construction Workers (regulations of Employment and
conditions of service) Rules ,2006.
iii.National Building Code, 2005
iv.Factories Act, 1948,
v.The Tamil Nadu Factories Rules, 1950
vi.Motor Vehicles Act as amended in 1994, The Central Motor Vehicles Rules, 1989.
vii. Indian Road Congress Code IRC: SP: 55-2001 ‘Guidelines on Safety in Road
Construction Zones.
viii.The Petroleum Act, 1934 and Rules 1976
ix.Gas Cylinder Rules, 2003
x.Indian Explosives Act. 1884, along with the Explosives Substance Act 1908 and the
explosives Rules 1983
xi.The (Indian) Boilers Act, 1923
xii.The Public Liability Insurance Act 1991 and Rules 1991
xiii.Minimum Wages Act, 1948 and Rules 1950
xiv.Contract Labour Act, 1970 and Rules 1971
xv.Child Labour (Prohibitions & Regulations) Act, 1986 and Rules 1950
xvi.Environment Protection Act, 1986 and Rules 1986
xvii.Air (Prevention and control of Pollution) Act, 1981
xviii.Water (Prevention and Control of Pollution) Act, 1974
xix.The Noise Pollution (Regulation & Control) Rules, 2000
xx.Notification on Control of Noise from Diesel Generator (DG) sets, 2002
xxi.Recycled Plastic Usage Rules, 1998
xxii.Notification, Central Ground Water Board, Act January 1997
xxiii.Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
xxiv.The Hazardous Waste (Management & Handling) Rules, 1989
xxv.Hazardous Waste Management Rules 1989 (as amended in 1999)
xxvi.Batteries (Management and Handling) Rules
xxvii.Fly ash utilization notification, Sept 1999 as amended in August 2003
xxviii.Workman Compensation Act, 1923 along with allied Rules
xxix.The Mines Act 1952
9.3 International Standards, Guidelines & ISO Certifications

9.3.1 If the requirements stated in this document are in conflict or inconsistent with the requirements
of applicable laws or the Employer’s Requirements for the CMRL project, the more stringent
requirements shall apply.
9.3.2 The works shall be undertaken in accordance with the applicable international guidelines,
standards and specifications on OHS&E and every Contractor shall actively pursue the
achievement of:
• ISO 45001:2018 Occupational health and safety (OH&S) management system
• ISO 14001:2015 Environmental management systems
9.3.3 The process of international certification to ISO 45001:2018 and ISO 14001:2015 standard shall
commence immediately after the award of Contract through appointment of ISO accrediting body
for obtaining the certification. Should this not be undertaken by the Contractor within 3 months
of the Contract award, the Employer / Engineer shall appoint at the Contractor’s cost.
9.3.4 Should the Contractor already posses such certification, the scope of the CMRL project must be
included on the Contractor’s certification within 1 year of Contract commencement and proof of
such attainment demonstrated to Chennai Metro Rail Limited.
10.0 Objectives and programme(s)
10.1 The Contractor shall maintain procedures to establish detailed OHS&E objectives and
performance criteria. Such objectives and performance criteria shall be developed to incorporate
the Chennai Metro Rail policy and strategic OHS&E objectives. The Contractor’s objectives shall
be quantified, wherever practicable, and identified with defined timescales. The Contractor is
required to submit for notice of no objection their procedure and objectives.
11.0 Implementation and operation

11.1 Resources, roles, responsibility, accountability and authority
11.1.1The Contractor shall detail within the Construction Occupational Health, Safety and
Environmental Plan the planned roles and resources allocated for the CMRL project. In addition
to the staffing arrangements the Contractor shall prescribe the responsibilities specific to role,
accountability and the authority under which they operate.
11.1.2 OHS&E resources shall be provided by the Contractor as per table 1(Mandatory Contractor
OHS&E Management resource requirement) of the Contract value mentioned in Volume 1 of
OHS&E Employer’s Requirements.
Note 1: Qualified Senior OHS&E Manager with Tunnelling Experience as per table 2 of Volume
1 Employer’s Requirements OHS&E Personnel Qualifications & Experience to be deployed at
each worksite at each shift.
Note 2: Qualified Junior OHS&E Manager as per table 2 of Volume 1 Employer’s Requirements
OHS&E Personnel Qualifications & Experience to be deployed at each worksite at each shift.
Note 3: Qualified Safety Steward as per table 2 of Volume 1 Employer’s Requirements OHS&E
Personnel Qualifications & Experience to be deployed at each worksite at each shift.
Note 4: Qualified Junior OHS&E (Electrical) Manager as per table 2 of Volume 1 Employer’s
Requirements OHS&E Personnel Qualifications & Experience to be deployed at each worksite
at each shift.
Note 5: Senior OHS&E (Traffic) Engineer Post and Barricade Manager Posts are applicable to
contracts where the work has to be executed either below or over the right-of-way like Viaduct,
UG Station, UG Tunnel Contracts wherein erection and maintenance of barricades are
paramount important.

Note 6: One Barricade Manager supported by required supervisors and workmen at each
Note 7: One Housekeeping Manager supported by required supervisors and workmen at each
Note 8: Qualified Male Nurse as per table 2 of Volume 1 Employer’s Requirements OHS&E
Personnel Qualifications & Experience to be deployed at each worksite at each shift.
Note 9: The Chief OHS&E Manager (Safety Manager)-Key Staff shall be a professional and
experienced manager with at least fifteen (15) years’ experience in the construction of
underground metro rail Projects with at least 10 year’s direct relevant experience in administering
of OHS&E of tunnel boring machine (TBM) and UG stations of similar scope in professional
experience in OHS&E in international projects , preferably in TBM’s tunnel background .The
Chief OHS&E Manager should have minimum five years’ experience in similar position of similar
works .
Note 10: All the OHS&E personal shall be in the payroll of the main contractor
Note 11: No contractor shall engage OHS&E manpower from any outsourcing agencies in which
case the effectiveness would be lost. All OHS&E manpower shall be on the payroll of the main
contractor only and not on the payroll of any subcontractor or outsourcing manpower agencies
etc. This condition does not apply to positions like traffic marshals who are engaged almost on
a daily requirement basis.
Note 12 Environmental support staff shall be Govt. recognized PG Degree / Degree in
Environmental Engineering / Environment Science with minimum of two years of experience of
similar scope of work.
Note 13: The conduct and functioning of the contractor OHS&E personnel shall be monitored
by the Employer / Engineer. Any default or deficiency shall attract penalty as per Employer’s
OHS&E requirements.
11.2 Responsibility
11.2.1 The Project Director or Project Manager of the Contractor is responsible and accountable for
compliance with the conditions and clauses within this document.
11.2.2The Project Director or Project Manager is responsible to ensure that the necessary resources
are allocated and made available to meet the requirements as laid out within this document and
other referenced materials to include Legal Requirements (9.2).
11.2.3 For all works carried out by the Contractor and appointed sub-Contractor’s, the responsibility for
ensuring OHS&E resources remains with the main Contractor. Activities undertaken by the
Contractor’s Sub-Contractors shall be monitored by the Contractor at all times to ensure
compliance with agreed safe systems of working.
11.2.4 All Contractor’s OHS&E personnel shall report to the Chief OHS&E Manager who shall report
directly to the Project Director or Project Manager or Corporate Safety manager of the
Contractor’s organisation. This shall be reflected in the Contractor’s organisation charts within
the OHS&E plan and Quality Management Plan.
11.2.5The Employer / Engineer shall monitor adherence to the provisions of Table 1 of Employer’s
OHS&E requirements. Where deviation is evident this shall be recorded as a non-conformance.
11.2.6The Contractor shall provide all OHS&E personnel with such facilities, equipment and
information that are necessary to enable them to dispatch their duties effectively.
11.2.7 The Contractor’s OHS&E Managers are responsible for ensuring that reports on the performance
of the OHS&E management system are presented to top management for review and used as
a basis for improvement of the OHS&E management system.
11.2.8 The Contractor’s OHS&E Managers are responsible for independently monitoring the operations

of the Contractor, where deficiencies are identified they are responsible to report their findings
immediately to the Site Engineer in charge who then must take action as directed.
11.3 Accountability
11.3.1 In cases where the Contractor fails to provide the minimum required manpower as illustrated in
Table 1 of Employer’s OHS&E requirements, or fails to fill vacancies created within 30 days, the
same may be provided by the Employer / Engineer at the Contractor’s cost. Any administrative
expenses involved in providing the same for example, vacancy advertisements or recruitment
consultant charges, shall also be at the cost of Contractor.
11.3.2 No OHS&E personnel shall be permitted to do any work which is unconnected to, inconsistent
with or detrimental to the performance of the OHS&E duties.
11.3.3 Supervisors must ensure that the employees under their direct supervision are working
incompliance with the approved safe systems of working.
11.4 Authority
11.4.1 The Contractor’s Safety Managers, Senior OHS&E Manager and Junior OHS&E Manager
authority shall be stated within the Construction Occupational Health and Safety Tunnel Plan
and the authority level must be communicated to all Contractor’s Staff including sub-Contractors.
11.4.2 The Contractor’s Safety Managers, Senior OHS&E Manager and Junior OHS&E Manager shall
have the authority as assigned by the Project Director or Project Manager to suspend works
where deviation from an approved method of working occurs that presents a risk of injury,
equipment or property damage.
11.4.3 The Engineer shall have the right to stop the work at his/her sole discretion, if in his opinion the
work is being carried out in such a way that a risk of injury, property and or equipment damage
may exist. The Contractor shall not proceed with the work until remedial works have been
complied with under the direction and satisfaction of the Employer. Should the Contractor continue
to work without implementing the Engineers instruction, clause 12.2 shall be applied to the
individual responsible for the decision to proceed.
11.4.4 The Contractor shall not be entitled to any damages or compensation for stoppage of work, due
to safety reasons. T he period of such stoppages of work shall not be taken as an extension
of time for completion of the facilities and will not be the ground for waiver of levy of liquidated
damages.
11.4.5 The contractor shall submit Daily Dairy report (FSAF 029-Volume 2 of OH&S Manual) with the
target date for the completion of the observation to the Employer / Engineer including any
subcontractor activity of both shift. This reporting shall be the primary duty of the Chief OHS&E
Manager of the contractor and reporting shall be through email. The report should be submitted
at the end of the day of shift. If the information is not received or delay in submission of report.
Penalty shall be levied as per relevant clause.
12.0 Competence, training and awareness
12.1 The Contractor shall ensure that the recruitment, selection and placement processes shall be in
place to ensure that personnel are qualified, competent, and physically fit for assigned tasks. The
Contractor shall produce a procedure that shall be made available to the Employer / Engineer for
notice of no objection as per Clause 21.1.1 of this document. The procedure shall define the
processes in place to ensure competence.
12.2 Whereby any person employed thereon, who in the opinion of the Employer / Engineer,
misconducts himself or is incompetent or negligent or fails to conform with any particular
provisions with regard to occupational health , safety or environment which is set out in the
Contractor’s OHS&E Plan or a requirement of the Contract, or persists in any conduct which is
prejudicial to safety or health, shall be removed from site immediately, and such persons shall
not be employed again upon the Works. The decision of the Employer / Engineer in this regard
shall be final.
12.3 Contractor OHS&E Personnel-Notice of No Objection from the Employer / Engineer

12.3.1 The name, educational qualifications and work experience for all OHS&E persons intended for
a Contractor’s OHS&E role shall be submitted to the to the Employer/Engineer in the format
prescribed (FSAF 31-Volume 2 of OH& S Manual) for notice prior to employment. Only upon
notice of no objection by the Employer /Engineer shall OHS&E personnel be authorised to work
on a CMRL site.
12.3.2The Original certificate of degree, mark sheet, course completed certificate and work experience
shall be maintained by the Contractor and be made available for inspection and upon request
shall be submitted to the Employer/Engineer prior to employment.
12.3.3Age Limit: Contractor’s OHS&E persons shall not be exceeding 55 years on the date of
submission of proposal.
12.3.4The conduct and functioning of the contractor OHS&E personnel shall be monitored by the
Employer / Engineer. Any default or deficiency shall attract penalty as per details given under
penalty clause of Volume 1 of Employer’s OHS&E requirements.
12.3.5The Contractor OHS&E personnel permitted to work only specific contract package as per the
NONO issued by the Employer / Engineer.
12.3.6Only approved by the Govt of India Degree from recognized university /Diploma in Safety
Engineering from State board of Technical Education and Equivalent International Degree
in Safety engineering shall be considered as the valid qualification.
12.3.7The Project Director or Project Manager shall certify that the OHS&E staff, original certificate of
educational qualifications and work experiences are verified by him and found competent prior
to the submittal to the Employer.
12.3.8The minimum Employer’s requirements of such facilities / equipment’s to be provided for OSHE
personnel are given in the GSAF-53 of Volume 2 of OH&S Manual.
12.3.9The Contractor shall appoint the required OHS&E personnel in accordance with the qualifications
and experience as listed in Table 2 of Volume 1 of Employer’s OHS&E requirements.
13.0 ID Card and first Day at work, OHS&E Orientation Training
13.1 The Contractor shall ensure that all personnel working at the site receive an induction OHS&E
training explaining the nature of the work, the hazards that may be encountered during the site
work and the particular hazards attached to their own function within the operation.
13.2 All personnel shall be issued a photo identity card of size 85mm x 55mm duly signed by the
authorized representative of the contractor before they are engaged for any work as per the
format given in the CMRL OH&S Manual.
13.3 Contractor shall also issue a personnel OH&S handbook in a language known to the workers,
which provides information on OH&S and emergency procedures that all personnel working on
contract are required to know and the need to follow. Contractor shall ensure that this is
distributed and its content introduced to all personnel working at the site.
14.0 OSH&E TRAINING
14.1 The Contractor shall assess the training requirements for all the employees, plan and initiate a
training program to fulfil the training needs assessment. The assessment of training needs shall
incorporate all levels of staff including Sub-Contractor’s against an individual’s role,
responsibility, ability, language skill and risk.
14.2 The Contractor shall produce a ‘Training Implementation Plan’ to incorporate the findings of the

needs assessment.
14.3 The training needs assessment together with Implementation Plan shall be submitted to the
Employer / Engineer for notice of no objection within 4 weeks of commencement. The Employer
/ Engineer shall evaluate the assessment and plan against the base line training matrix contained
within OH&S manual Volume 2.
14.4 Records of all training conducted shall be maintained and made available for inspection by the
Employer / Engineer upon request.
14.5 Should the Contractor fail to provide the training identified within the Contractor’s assessment,
implementation plan and the Employer / Engineer Training matrix within the agreed timescales,
this shall be reflected in the potential scores awarded within the monthly audit report.
14.6 Specific training with regard to the provisions of the Construction Safety Plan, and associated
operational and system procedures shall be conducted by the Contractor for all persons with
supervision responsibilities. Records of training including duration shall be maintained.
14.7 Contractors and sub-contractors are responsible for providing OHS&E training through CMRL
approved agency shall conduct training as per the training Implementation Plan to all Staff and
workers and for retention of records of such activities for inspection by the Employer / Engineer
14.8 The Profile of the External OHS&E Agency (Training, Inspection and Testing) ISO certifications,
course details, the name, educational qualifications and training experience for of the trainers
are to be submitted to the Employer/Engineer a minimum 28 days before prior to appointment
of the agency. Only upon notice of no objection by the Employer /Engineer shall be authorised
to deliver OH&S services on CMRL sites.
14.9 The behaviour of people at all levels of the contractor is critical for OSHE performance.
14.10 The contractor shall organise quality OSHE training to engage Managers, supervisors and other
personnel in behavioural change and improve safety performance.
14.11The Contractor shall analyse the training requirements for all the employees and initiate a training
program to demonstrate that all persons employed, including subcontractors, are suitably
qualified, competent and fit. This must include:
i) Detailed Job descriptions for all personnel, to include their specific OH&S
responsibilities.
ii) Specification of qualifications, competency and training requirements for all

personnel
iii) Assessment and recording of training needs for all personnel, including
subcontractors’ employees in the workforce, vendor representatives and site visitors
iv) A system for assessing new hirers e.g. previous training

v) A means of confirming that the system is effective
vi) A matrix and schedule of training requirements, covering general, task– specific and
OH&S -related training, showing the training frequency and interval between
refresher courses
vii) Timely, competent delivery of training courses
14.12The contractor shall arrange behavioural-based training programmes for all the executives to
identify, recognise and eliminate unsafe act and unsafe conditions.
14.13The refresher-training programme for all employees shall be conducted once in every six months.

14.14Toolbox talks/task briefings shall be carried out daily by the contractor and correspond to the
works activities/tasks being undertaken.
14.15On-Site practical skill development training on height safety including scaffold safety, crane
safety, welding safety, electrical safety, traffic safety for marshals shall also be conducted to all
foremen/ workmen who were associated to the concerned jobs.
14.16Daily Safety Oath shall be taken by every employee including workman without fail.
14.17All vehicle drivers shall be trained on defensive driving. All vehicle drivers shall also undergo
refresher training on defensive driving once in six months.
14.18In case of failure on the part of the contractor to provide the above-mentioned training programs
to all employees in time, the same shall be provided by the Employer / Engineer through
accredited agencies if required by formulating a common scheme to all contractors. It is
mandatory for the contractors to participate in the common scheme. Any administrative
expenses and training fee towards the same shall be at the cost of the contractor.
15.0 Hazard identification, risk assessment and determining controls
15.1 The Contractor shall submit a procedure detailing the process in place for the identification of
Hazards and Risks and the determination of control measures including the relevant standards
as per clause 21.1.1.
15.2 Management of Change
15.2.1All temporary and permanent changes to organisational, personnel, systems, procedures,
equipment, products, materials or substances shall be evaluated by the Contractor and managed
to ensure that occupational health, safety and environmental risks arising from these changes
remain at an acceptable level. Changes made by the Contractor are subject to submittal and
notice of no objection by the Employer / Engineer prior to adopting change.
16.0 Risk Register & Hazard Log
16.1 The Contractor’s Construction Occupational Health and safety Plan shall contain a detailed ‘Risk
Register’ and ‘Hazard Log’ specific to the project. The register and log shall be assessed against
the CMRL OH&S manual Volume 2.
16.2 The Hazard Log shall identify future method statement, risk assessment and operational
procedures pertaining to specific equipment and operations in relation risk and local
environmental constraints. Construction phase OHS&E Plans shall not be accepted without a
fully completed Hazard Log and Risk Register.
17.0 Method Statements

17.1 Method statements are to be submitted to the Employer / Engineer a minimum of 28 days prior
to task commencement to ensure sufficient time is available for review and notice of no objection.
17.2 Method statements shall contain the information requirements as prescript within the CMRL
OH&S manual Volume 2.
17.3 Method statements shall incorporate the control measures within the process methodology as
identified within the risk assessment.
17.4 A copy of the relevant method statement for the activity being undertaken shall be available on
site for reference by all site management and supervisors.
18.0 Lift Plan

18.1 Lift Plan are to be submitted to the Employer / Engineer a minimum of 28 days prior to task
commencement to ensure sufficient time is available for review and notice of no objection.
18.2 Lift Plan shall contain the information requirements as prescript within the CMRL OH&S manual
Volume 2
19.0 Risk Assessment
19.1 Risk assessments shall contain as a minimum, the information as specified within the CMRL
OH&S manual Volume 2. The Contractor may choose to use their own format however the risk
tolerances, probability and consequences must be included.
19.2 Risk assessments shall be produced and submitted to the Employer / Engineer a minimum of
28 days prior to task commencement for notice of no objection. Risk assessments may be
submitted independently or as part of a Method Statement.
19.3 Generic risk assessments other than routine activities of low risk shall not be accepted by the
Employer / Engineer.
19.4 Risk assessments shall be regularly reviewed to ensure they remain suitable and sufficient. Risk
assessment reviews shall be undertaken where an incident has occurred and when a change in
location may introduce additional risks from construction activities.
19.5 Substances hazardous to health shall be subject to assessment by the Contractor. Where
Hazardous substances are identified for use within a process the assessment and determining
controls shall be included within the relative method statement.
19.6 Designer’s primary role includes to minimise the risk to Occupational health and safety of those
who are going to construct, maintain, clean, repair, dismantle or demolish the structures and
anyone else like adjoining road users/general public, who may be affected by the work.
19.7 When considering health and safety in designer’s work, they shall be expected to do what is
reasonable at the time the design is prepared. It may be possible for hazards, which cannot be
addressed at the feasibility stage to be looked at during detailed design. In deciding what is
reasonably practicable, the risk to health and safety produced by a feature of the design has to
be weighed against the cost of excluding the feature. The overall design process does not need
to be dominated by a concern to avoid all risks during the construction phase and maintenance.
However, a judgement has to be made by weighing up one consideration against another so the
cost is counted not just in financial terms, but also those of fitness for purpose, aesthetics,
buildability or environmental impact. By applying these principles, it may be possible to make
decisions at the design stage, which will avoid or reduce risks during construction work. In many
cases, the large number of design considerations will allow a number of equally valid design
solutions. What is important is the approach to the solutions of design problems. This should
involve a proper exercise of judgement, which takes account of occupational health and safety
issues.
19.8 Designers shall need, so far as reasonably practicable, to avoid or reduce risks by applying a
series of steps known as the hierarchy of risk control or principles of prevention and protection.
The steps to be adopted shall include the following:
i) Consider if the hazard can be prevented from arising so that the risk can be avoided
(e.g. alter the design to avoid the risk);
ii) If this cannot be achieved, the risk should be combated at source (eg, ensure the
design details of items to be lifted include attachment points for lifting);
iii) Failing this, priority should be given to measures to control the risk that will collectively
protect all people;

iv) Only as a last resort should measures to control risk by means of personal protection
be assumed (E.g. use of safety harnesses).
19.9 In case of situations were the designers have carried out the design work and concluded that
there are risks, which were not reasonably practicable to avoid, detailed information shall be given
about the occupational health and safety risks, which remain. This information needs to be
included within the design assessment to alert others to the risks, which they cannot reasonably
be expected to know. This is essential for the parties who have to use the design information.
19.10 If the designers’ basic design assumptions affect occupational health or safety, or occupational
health and safety risks are not obvious from the standard design document, the designer shall
provide additional information. The information shall include a broad indication of the
assumptions about the precautions for dealing with the risks. The information will need to be
conveyed in a clear manner; it shall be included on drawings, in written specifications or outline
method statements. The level of detail to be recorded will be determined by the nature of the
hazards involved and the associated level of risk. Job Specific Risk assessment shall be
submitted to the Employer /Engineer a minimum of 28 days prior to task commencement for
notice of no objection. (Example-Manual Handling, PPE and Fire)
19.11 Design Risk Assessment
19.11.1 Design Risk Assessments shall be submitted to the Employer / Engineer for granting of no
objection. Design risk assessments shall accompany all drawing submittals for operations
involving;
• Temporary works,
• Heavy lifting equipment.
19.11.2 Drawings shall not be accepted by the Employer / Engineer
without an accompanying design risk assessment.
19.12 Employer’s / Engineer approval

19.12.1Every structure like scaffold, Temporary work (shoring system), earth retaining structures etc.
shall have its design calculations included in the method statements in addition to occupational
health and safety risks. The Employer / Engineer approved proof check consultants as applicable
as per the contract conditions shall approve all these designs and issue a ‘No Objection for Use’.
19.12.2 Any non-standard structures like trestles made up of re-bars or structures which are very old,
corroded, repaired for many times etc. for which no design calculations can be made accurately
from any national standards, shall not be allowed to be used at sites even for short duration.
19.12.3If any of the above mentioned clauses are not adhered penalty shall be imposed depending
upon the gravity of the unsafe act and or condition.
20.0 Communication, participation and consultation
20.1 Communication
20.1.1The Contractor shall produce a ‘High Quality’ quarterly newsletter on a rotational basis with other
Contractors. Rotation shall be announced within the Employer / Engineer OHS&E Committee
meetings.
20.1.2All Contractors including the Employer / Engineer shall provide input into the rotational
Contractor for the newsletter content such as details of accidents, incidents and near misses
together with any lessons learned; specific safety initiatives; internal competitions and workforce
awards etc.

20.1.3The Employer / Engineer shall be issued the draft newsletter for review prior to the Contractor’s
publishing.
20.1.4The OHS&E Newsletters shall publicise all Contractors OHS&E performances over the previous
3 months in relation to OHS&E Audits and shall form the basis for the Employer / Engineer
Awards programme. Results of audits shall be provided by the Employer / Engineer for inclusion.
20.1.5The quarterly newsletters shall be issued to all interested parties and be promulgated at site
level. Where language barriers exists the contents of the newsletters shall be communicated by
the Workforce Representative to ensure understanding.
20.1.6At site level the Contractor shall erect pertinent awareness signage and posters. Posters shall
be changed on a monthly basis to maintain impact.
20.1.7Poster campaigns shall be discussed and agreed at the Employer / Engineer Committee Meeting
to maintain a consistent improvement programme across all CMRL Sites.
20.1.8Informational posters, banners etc. shall be provided in Hindi, Tamil and English.
20.1.9Visitor information signage shall be posted at site entrances detailing where to report and contact
information. Note: visitors shall be accompanied at all times by site security where office
locations require walking through operational areas.
20.2 Public Liaison
20.2.1Public informational signage and Contractor contact information shall be posted externally to the
site.
20.2.2The Contractor shall appoint an individual as a Public liaison Officer to communicate directly with
members of the public regarding forthcoming operations, what to expect, noise expectancy,
duration of operations etc.
20.3 Participation and consultation
20.3.1The Contractor shall establish a Safety Committee within 4 weeks of commencement that shall
be chaired by the Contractor’s Project Director or Project Manager.
20.3.2 The Contractor shall notify the Employer /Engineer of the establishment of the Committee
together with the committee members’ names and designation. The Contractor’s Chief Safety
Manager, Senior Safety Manager, Plant & procurement Manager and Human Resources
Manager shall form the minimum committee members. Site based personal shall be represented
within the Committee by the attendance of Site Manager(s) and the Workforce OHS&E
Representative
20.3.3 The Employer / Engineer shall be invited to attend the Contractor’s Safety Committee meetings.
20.3.4 The Contractor’s OHS&E Committee shall meet on a monthly basis throughout the duration of
the Contract.
20.3.5 The Terms of Reference for the Contractor’s OHS&E Committee shall be as follows;
i) To establish company safety policies and practices

ii) To monitor the adequacy of the contractor’s site OHS&E plan and ensure its
implementation
iii) To review OHS&E training
iv) To review the contractor’s monthly OHS&E report.
v) To identify probable causes of accident and unsafe practices in building or other
construction work and to suggest remedial measures.
vi) To stimulate interest of Employer/Engineer and building workers in safety by
organizing safety week, safety competitions, talks and film-shows on safety,
preparing posters or taking similar other measures as and when required or as
necessary.
vii) To tour round the construction site with a view to check unsafe practices and detect
unsafe conditions and to recommend remedial measures for their rectifications

including first-aid medical and welfare facilities.

viii) Committee team members should perform a site inspection before every committee
meetings and to monitor OHS&E inspection reports.
ix) To bring to the notice of the Employer /Engineer the hazards associated with use,
handling and maintenance of the equipment used during the course of building and
other construction work.
x) To suggest measures for improving welfare amenities in the construction site and
other miscellaneous aspect of Occupational Health Safety and welfare in building or
other construction work.
xi) To look into the health hazards associated with handling different types of explosives,
chemicals and other construction materials and to suggest remedial measures
including personal protective equipment.
xii) To review the last safety committee meeting minutes and to take action against
persons/sub-contractors for non-compliance if any.
20.3.6 The inspection shall review progress regarding the achievement of short term targets. The
Committee shall produce a report stating progress made together with any corrective actions
required and issue to the Employer / Engineer within 7 days following the Inspection.
20.3.7 Minutes of the Committee meeting shall be issued within 2 days and promulgated to all members
including the Employer / Engineer. The minutes of meeting shall also be posted on all sites within
the workforce area. The minutes intended for site communication shall be in both Tamil and
English.
20.4Employer/Engineer OHS&E Committee
20.4.1 A occupational Health, safety and Environmental Committee shall be established by the
Employer / Engineer and shall sit every month throughout the project period. All Contractors shall
be required to attend the monthly meetings who shall be represented by their Project director or
Project Manager, Corporate Safety Manager and Chief Safety Manager.
20.4.2The Committee shall review previous performances project wide and set short and medium term
objectives and targets for achievement within the next reporting period.
20.4.3The Employer / Engineer reserves the right to call an Emergency Meeting of the Committee
members in the event of a serious incident that requires immediate change to the operational
methods of working.
20.4.4 Minutes of the Employer / Engineer OHS&E Committee shall be promulgated to all Contractor’s
within 3 days.
20.5 Workforce Representation
20.5.1 All workers shall have access to a Workforce OHS&E Representative who is responsible to
communicate directly with the labour force with regard to occupational health and safety. The
representative’s name and contact number shall be posted on all sites externally to the site office.
20.5.2 The Workforce OHS&E Representative shall be made a member of the OHS&E Committee
(FSAF 025 of OH&S Manual -Volume 2) and attend all meetings.
20.5.3The OHS&E Representative shall meet the labour force on a monthly basis to discuss health,
welfare, safety initiatives and or concerns the workforce may have. Minutes (FSAF 026 of OH&S
Manual -Volume 2) are to be produced by the Representative and issued formally within 2 days
after the meeting date to the Contractor’s Project Director or Project Manager and Employer
/Engineer.
20.5.4 A lockable site suggestion box to which only the workforce OHS&E Representative shall have
access shall be installed on all sites and within any labour accommodation camps. The
suggestion box shall be located independent from any offices, in a public area and protected from
bad weather. The OHS&E Representative shall inform the workforce that the purpose of the

suggestion box is to provide a means of participation, communicating ideas and initiatives and
also for raising concerns without fear of reprisal.
20.5.5 The contents of all suggestion boxes shall be collected and collated on a weekly basis. Where
concerns or complaints regarding the standards of occupational health, safety or welfare have
been reported these shall be immediately reported to the Chief OHS&E Manager and Project
Director or Project Manager who shall investigate the concern(s). Records of such investigations
and resultant outcomes shall be maintained.
20.5.6 Ideas, suggestions and concerns raised by the workforce during the OHS&E representative’s on
site monthly meetings shall form an agenda item within the Contractor’s OHS&E Committee
meeting.
20.5.7 Where an idea or specific suggestion is subsequently adopted for use by the Contractor’s OHS&E
Committee, the individual shall receive an OHS&E award as determined by the Contractor.
20.5.8 Where Employee awards are issued this shall be notified to the Employer / Engineer to ensure
inclusion within the Quarterly Newsletter.
20.6 Contractor Awards
20.7 The Employer / Engineer shall recognize the effort, participation and commitment demonstrated
by the Contractor by nominating awards. The award type shall be at the discretion of the
Employer .
21.0 Documentation
21.1 Management System procedures
21.1.1 The Contractor is required to submit for notice of no objection, the organisation’s top tier
Management System Procedures as listed in Table 3 that shall be adopted for use on the CMRL
project.
21.1.2 System procedures shall be submitted to the Employer / Engineer within 4 weeks of
commencement.
21.1.3 Construction works shall not commence until such time as a notice of no objection has been
received; applicable to all management system procedures as listed in Table 3. Should the
Contractor commence operations on site without notice, the Employer / Engineer shall award a
‘Zero’ audit score for every month of non-compliance with this clause.
21.1.4 The Employer / Engineer shall evaluate the suitability of the Contractor’s system procedures
against the ISO 45001:2018 and ISO 14001:2015 standards.
21.1.5 The submitted procedures shall be individually identified with a unique reference and detail in
sequence the scope, purpose, referenced material and procedure processes.
21.1.6 Where such procedures as listed in Table 3 exist within other areas of the Contractor’s
organisational management systems such as quality management, these shall not be subject to
replication if the procedure makes specific reference to Occupational Health, Safety and
Environmental control.
21.1.7 Compliance standards against the Contractor’s management system procedures shall be subject
to audit by the Employer / Engineer.
Table 3 OHS&E Management System Procedures
Hazard identification, Communication,
Environmental Impact Objectives and
risk assessment and participation &
Aspect Assessment programme(s)
determining controls consultation
Training, awareness Implementation and Accident & Incident

Legal requirements
and competence operation Investigation

Monitoring & Emergency

Documentation Change control
Measurement Preparedness
Procurement Record keeping Audit Management review
21.2 Control of documents

21.2.1 All plans, procedures and method statements shall be controlled and subject to review and formal
approval by the Contractor’s Project Director or project manager prior to issue to the Employer /
Engineer.
21.2.2 All documents subject to review by the Employer /Engineer shall be signed by the Contractor’s
Construction Manager, Safety Manager and Project Director and issued formally.
21.2.3 Documents shall be issued as per the Employer / Engineer requirements regarding Quality
Management.
21.2.4 OHS&E Documents shall be issued, maintained, traceable and available for retrieval pursuant to
the Contractor’s ISO accredited Quality Management System.
21.3 Operational control
21.3.1Operational control shall be maintained through the implementation of the provisions stated within
the Contractor’s site specific Construction Occupational Health Safety and Environmental Plans,
the contents of which are outlined in OH&S Volumes 2 and Tunnelling Volume 4 to which the
Contractor shall comply.
21.4 Construction Phase Safety Plan
21.4.1 The Contractor shall produce a Contract Specific Construction Safety Tunnel Plan and submit
to the Employer / Engineer within 28 days of commencement.
21.4.2 The Construction Safety Tunnel Plan shall contain the informational requirements as per the
CSTP contents as prescript within the CMRL OH&S manual Volume 2, Safety Plan contents.
21.4.3 The CHSP shall be assessed by the Employer / Engineer against the provisions as stated within
OH&S manual Volume 2. Where deficiencies exist to an extent where an objection is raised,
construction activities shall be suspended until such time as the deficiencies are subject to
corrective action, re-submittal and notice of no objection by the Employer / Engineer.
21.4.4 Delays incurred as a result of the Contractor failing to achieve a ‘No objection’ status from failing
to submit within the specified timescale or non-compliance with OH&S manual Volume 2 shall
be entirely at the Contractor’s risk and cost.
21.4.5 The Contractor shall undertake a monthly review of the Contract Specific Construction Safety
Tunnel Plan. The review shall be recorded and the Employer / Engineer notified of any updates.
21.4.6The Contractor shall produce a Contract Specific Fire Evacuation plan and submit to the
Employer / Engineer within 28 days of commencement.
21.4.7The Contractor shall produce a Contract Specific Construction contingency plan and submit to
the Employer / Engineer within 28 days of commencement.
21.4.8The Contractor shall produce a Contract Specific Traffic Management Plan and submit to the
Employer / Engineer within 28 days of commencement.
21.4.9The Contractor shall produce a Contract Specific Disaster Management Plan and submit
to the Employer / Engineer within 28 days of commencement.
21.4.10The Contractor shall produce a Contract Specific Construction Health Plan and submit to the
21.4.11The Contractor shall, from time to time and as necessary are required by the
Employer/Engineer to produce supplements to the OH&S Plan such that it is at all times a
detailed, comprehensive and contemporaneous statement by the Contractor of his site safety,
industrial health and environment obligations, responsibilities, policies and procedures relating
to work on Site. Any and all submissions of supplements to the OH&S Plan shall be made to the

Employer /Engineer in accordance with the agreed procedures.

21.4.12If at any time the OH&S plan is, in the Employer /Engineer opinion, insufficient or requires
revision or modification to ensure the security of the Works and the safety of all workmen upon
and visitors to the Site, the Employer/Engineer may instruct the Contractor to revise the OH&S
plan and the Contractor shall within 7 days submit the revised plan to the Employer/Engineer for
review.
21.4.13Any omissions, inconsistencies and errors in the OH&S Plan or the Employer /Engineer
acceptance or rejection of the OH&S Plan and/or supplements thereto shall be without prejudice
to the Contractor's obligations with respect to site safety, industrial health and environment and
shall not excuse any failure by the contractor to adopt proper and recognised safety practices
throughout the execution of the Work.
21.4.14The Contractor shall adhere to the OH&S Plan and shall ensure, as far as practically possible,
that all sub-contractors of all tiers require that contracting parties each have a copy of the Site
OH&S Plan and comply with its provisions
21.4.15The Contractor shall produce a Contract Specific transportation Plan and Risk assessment and
submit to the Employer /Engineer within 28 days of commencement.
21.5Operational procedures
21.5.1 The Contractor shall identify within the Hazard Log and Risk Register the operational control
procedures that shall be applicable for the CMRL project under their individual scope of works.
21.5.2 Operational procedures shall be submitted for review to the Employer / Engineer for notice of no
objection together with the Construction Site Safety Plan within 4 weeks of commencement.
21.5.3 The operational procedures shall be evaluated by the Employer / Engineer against the
requirements stated within OH&S manual Volume 2, international safety standards such as the
International Labour Organisation, European Norms and British Standards where an equivalent
Indian Standard does not exist.
21.5.4 Construction works shall not commence until such time as a notice of no objection has been
received; applicable to all operational procedures as identified within Table 4 and the
Contractor’s Hazard Log & Risk Register. Should the Contractor commence operations on site
without notice, the Employer / Engineer shall award a ‘Zero’ audit score for every month of non-
compliance with this clause.
21.5.5 The submitted procedures shall be individually identified with a unique reference and detail in
sequence the scope, purpose, referenced material and procedure processes.
21.5.6 In the event that the Contractor is unable to comply with the 28 day timeframe for submittal of
the minimum operational procedures as detailed within Table 4, the Contractor shall assign an
individual identification reference for the outstanding procedure within the Construction Health,
Safety Plan together with the statement ‘Under process’. The ‘Under Process’ procedure shall
be required to be submitted for notice of no objection a minimum of 28 days prior to
commencement of any activity that involves the application of the procedure.
Table 4 Operational Procedures
Lifting Operations & Occupational Health Emergency Medical

Plant & Equipment
Lifting Equipment provisions Facilities & First Aid
Personal Protective Permit to Work Site Electricity & Welding & Cutting
Equipment Systems Distribution operations
Incident Investigation Traffic Management Working at Height Hazardous

Substances
Site Security Fire Safety Manual Handling Site Set-up
Welfare
Abrasive Wheels Public Interface Noise and Vibration
Arrangements
21.5.7 The Contractor shall adopt the following colour code scheme across all CMRL Sites to ensure
efficient recognition of relevant personnel.
Safety Helmet
Designation
Colour with Logo
White CMRL Staff and Engineer
Violet Contractor’s Engineers & Supervisors
Blue Sub-Contractor’s Engineers & Supervisors
Red All Electricians
Green Safety personnel
Orange Security Guards & Traffic Marshals
Yellow General Workforce
White (With Visitors

VISITOR Sticker)
21.5.8The PPE and safety appliances provided by the contractor shall be of the standard as
prescribed by Bureau of Indian Standards (BIS). The contractor shall obtain prior approval
by the Employer / Engineer before procurement of PPE and safety appliances.
21.5.9The contractor shall at all-time maintain a minimum of 10% spare PPE and safety
appliance stock. Stocks are to be recorded and made available for the Employer / Engineer upon
request. Failing to do so shall invite appropriate penalty as per the provisions of the contract.
22.0 Emergency preparedness and response
22.1 Emergency Response Plan
22.1.1 The Contractor shall prepare a project specific Emergency Plan and submit to the Employer /
Engineer for notice of no objection. The Emergency Plan shall be submitted within 4 weeks of
contract Commencement.
22.1.2 The plan must identify the potential for emergencies and the provisions for responding to such
emergencies, particular to their environment and location. The Emergency planning
arrangements shall be assessed as per the provisions in OH&S manual Volume 2 for suitability.
22.1.3 The Contractor shall ensure that all persons including sub-Contractors on site are aware of the
emergency procedure to follow in the event of an emergency. Awareness training shall
commence at induction and thereafter through refresher training such as toolbox talks and
monthly emergency drills. Records of refresher training and emergency drills shall be
maintained.
22.1.4 Site signage shall be erected and detail the emergency process to follow and include emergency
telephone numbers, fire, ambulance, police, nearest hospital etc.
22.1.5 Arrangements shall be made by the Contractor for casualty evacuation and emergency medical
treatment. The Contractor shall enter into an agreement with a hospital to provide ambulance
services. Alternatively, the Contractor shall provide a fully equipped ambulance on-site that shall

be manned by a paramedic. This provision shall be subject to the Employer / Engineer audit.
22.2 Checking
22.2.1 Performance measurement and monitoring
22.2.2 The Contractor shall submit a Monthly OHS&E Report no later than 7th of each month to the
Employer / Engineer. The Report shall contain the minimum information specified within OH&S
manual Volume 2. The report shall contain text, tables and colour photographs.
22.2.3 Site Inspection
22.2.4 Independent of the plant and equipment inspection, testing and maintenance regimes that shall
be stated within the Contractor’s Plant and Equipment Procedures, the Contractor shall carry out
site monitoring exercises on a daily and weekly basis.
22.2.5 The Contractor shall ensure that all monitoring equipment is calibrated as per the manufactures
requirements. The Employer / Engineer shall be provided with test certificates for such equipment
22.2.6 Site Engineers shall be required to participate in daily internal OHS&E tunnel inspections to
facilitate prompt communication and rectification of minor deviations. Records of such inspections
and rectification needs shall be maintained at site level and made available for review by the
Employer / Engineer other interested parties.
22.2.7 No loose electrical connections or tapped joints shall be allowed anywhere in the work site, office
area, stores and other areas. Penalty as per relevant clause shall be put in case of observation
of any tapped joints.
22.2.8 Formal site inspection reports shall be produced on a weekly basis by the Contractor’s OHS&E
personnel for each site and submitted to the Project Director or project manager and copied to
the Contractor’s corporate safety manager. The corporate Safety Manager shall conduct site
inspection on monthly basis and report shall be submitted to the Employer / Engineer.
22.2.9 The Contractor may choose inspection format of his/her choice, however format shall contain the
minimum information as provided within FSAF-028 –OH&S manual Volume 2 regarding weekly
inspection form.
22.2.10The Contractor’s OHS&E Personnel shall be accompanied during a formal site inspection by the
Site Manager responsible for the particular site. The resulting inspection report shall be signed
by both the Site Manager and the OHS&E Manager.
22.2.11The Engineer shall formally inspect and report the Contractor’s site conditions against the
compliance criteria set within the Contractor’s operational procedures and the Engineer
requirements on a weekly basis. These inspections shall include batching plant and associated
yards.
22.2.12The Contractor shall undertake specific inspections at the Employer/Employer’s
Representative’s request where concerns have been raised regarding the suitability of
control measures and or plant or equipment condition as per the IS 13367-1 (1992), IS
14475-1(1997), ISO 12482-1:1995. The special assessment shall be carried out later
than the following number of years after manufacture for:
-All other cranes: 20 years. Such inspections shall be carried out with immediate effect.
22.2.13The Profile of the External Inspection agency, ISO certifications, the name, educational
qualifications and experience in the field of testing and the certificate issued by Govt of Tamil
Nadu for testing are to be submitted to the Employer/Engineer a minimum 28 days before prior

to appointment of the agency. Only upon notice of no objection by the Employer /Engineer shall
be authorised to deliver OHS&E services on CMRL sites.
22.2.14The First Generation Hydra crane shall not be strictly used in the CMRL projects.
22.2.15The Second Generation Hydra crane shall not be used for any lifting and lowering operation.
Second Generation Hydra can be used for the material handling as per the manufacture manual.
22.2.16The Piling rig shall not be used as lifting equipment.
22.2.17Water logging or bentonite spillage on roads shall not be allowed. If bentonite spillage is
penalised as per Table -6 of Employer’s Requirements OHS&E Volume 1.
22.2.18The contractor shall submit an electrical single line diagram, schematic diagram and the details
of the equipment for all temporary electrical installation. These diagrams together with the
temporary electrical equipment shall be submitted to the Employer / Engineer for necessary
approval. Failure to do so shall invite penalty as per relevant clause.
22.2.19The Contractor shall implement a surveillance CCTV system in Administrative areas,
Construction areas (general indoor, general outdoor, tunnel and general underground work
areas, mucking and scaling), Maintenance / Operating areas, Mechanical/electrical equipment
rooms, Warehouses and storage rooms/area, Casting yard, Labour Colony, Health Centres and
First aid stations and infirmaries, Parking areas, Visitor areas and Laboratories , with cameras
strategically positioned at high-risk areas for purpose of monitoring site conditions and deterring
unsafe work practices. The number and location of cameras deployed shall be subjected to the
acceptance of the Employer /Engineer. The number and location of cameras installation shall be
subjected to the acceptance of the Employer /Engineer. The contractor shall submit the CCTV
installation and monitoring plan to Employer /Engineer.
22.2.20Request for inspection form all High risk activity shall be verified by the Chief OHS&E Manager
before submitting to the Employer / Engineer.
22.2.21Failure to do any of the above shall attract penalty from the Employer / Engineer as per relevant
clause of Volume 1 of ER OHS&E requirement.
22.2.22 The information submitted by the Contractor within the OHS&E Monthly Progress Report together
with the Engineers Reports shall be evaluated against the Employer’s compliance requirements
and OHS&E objectives.
22.2.23Inspection reports shall be evaluated against the Legal Requirements (9.0) to which the
Contractor is bound to comply.
22.2.24 The Contractor’s OHS&E Committee shall formally evaluate reports and results of accidents and
or injury on a monthly basis. The results of this evaluation such as identified changes to safe
systems of working’ shall be included with the Committee minutes
22.2.25 The Engineer shall evaluate ‘Accident Injury Rates’ and ‘Frequency Rates’ per individual
Contractor and as a project to determine performance against the international rates. The
international rates used to benchmark performance shall be promulgated to all Contractor’s and
other interested parties.
22.2.26 A Project Monthly Progress Report shall be produced by the Engineer. Evaluation results shall
be included within the relevant sections for Health Safety & the Environment.
22.2.27 The Contractor’s External OHS&E Audits shall be evaluated by the Engineer against the internal
Standards ISO 45001:2018 and ISO 14001:2015.
23.0 Incident investigation, nonconformity, corrective action and preventive action
23.1 Incident investigation
23.1.2 The Contractor shall undertake accident investigation for all fatal accidents, major injuries and
dangerous occurrences as defined within the Employer’s Project OH&S Vol 2.
23.1.3 In the event of a fatality, major injury or dangerous occurrence, the Contractor shall not disturb

the accident scene or remove equipment beyond that required to make the area safe and/or for
the treatment and/or removal of casualty(s) to hospital.
23.1.4 Should the Employer / Engineer find an accident scene disturbed beyond that reasonably
expected with making an area safe, this shall be subject to thorough investigation by the
23.1.5 The Employer / Engineer shall be informed immediately via Short Message Service or Email of
all fatalities, major injuries or dangerous occurrences. Any delay in reporting to the Employer /
Engineer may be subject to disciplinary action.
23.1.6 The Contractor is responsible to report accidents, incidents and dangerous occurrences to the
relevant governing bodies as per their statutory obligations. The Contractor shall maintain
responsibility for ensuring sub-Contractor’s under their direct control also comply with this
requirement.
23.1.7 A preliminary accident notification report shall be issued to the Employer / Engineer for all fatal
and major injuries and or dangerous occurrences within 24 hours as per OH&S manual Volume
2. This shall be followed by the detailed investigation report shall be issued to the Employer /
Engineer within 72 hours.
23.1.8 Any wilful delay in verbal or written reporting to the Employer /Engineer shall be penalised as
per relevant clause.
23.1.9 Near misses and minor accidents should also be investigated by the Contractor as soon as
possible as they are signals that there are inadequacies in the safety management system.
23.1.10 In case of fatal accidents, major injuries or dangerous occurrences the Employer / Engineer
shall conduct an independent investigation. The Contractor and his staff shall extend the
necessary co-operation.
23.1.11All persons summoned by the Employer / Engineer in connection to witnesses and statement
recording shall obey the instructions without delay. Any wilful suppression of information by any
person shall be removed from the site immediately and / or punishable as per relevant penalty
clause
23.2 Nonconformity, corrective action and preventive action
23.2.1 The Contractor shall conform to their internal procedures regarding nonconformity, corrective
action and preventive action. The Contractor shall be audited by the Employer / Engineer for
compliance with internal procedures.
23.2.2 Major and Minor non-conformances shall be raised by the Employer / Engineer as per the
Employer / Engineer Quality Management requirements and the OHS&E Audit criteria as defined
within OH&S manual Volume 2.
23.2.3 Open non-conformances shall be reflected in the Contractor’s Monthly Audit Report and are
subject to verification by the Employer / Engineer as detailed in OH&S manual Volume 2. Failure
to successfully take corrective action and close out non-conformances will impact negatively on
the Contractor’s total quarterly audit score.
23.2.4Where non-conformances have been raised by an External Auditor against the ISO 45001:2018
or ISO 14001 Standard, the Contractor shall produce and submit for review within 2 weeks, an
action plan of how and within what timescale shall the non-conformance(s) be closed-out.
23.2.5 Where the corrective action and preventive action identifies new or changed hazards or the need
for new or changed controls, the proposed actions shall be taken through the risk assessment
process. The associated method statement and risk assessment shall be amended and re-
submitted to the Employer / Engineer for notice of no objection.
23.2.6 A change in work methodology shall be communicated to the workforce. Evidence of such
communications shall be made available for inspection by the Employer / Engineer. The
Employer / Engineer shall also make random enquiries at site level to establish workforce
awareness.

23.2.7 The following table indicates the risk rating for the non-compliance of the requirements (unsafe
acts/unsafe conditions).
Risk Topic Deductible amount
High Explosive Handling and Blasting , Any specific high risk activity
Plant & Machinery(Examination non-conformance (unsafe
certificate of Gantry crane, rope act/unsafe condition) shall
suspended powered platform, be immediately complied by
tractor mounted drilling rig ,No legal taking corrective action by as
documents, Erection/lifting mast, low as reasonably
wire rope/web sling/dog practicable and specific high
clamp/chain pulley, rope pulley , air risk activity non-
compressor, Electrical trolley OTE conformance work shall be
duct installation ),
suspended until the
Equipment(Guarding arrangements
, Excavations(Shoring, edge, corrective actioned.
material stored on the edge of the
excavation protection) , Electrics ,
Work at Height(Edge protection, fall
protection measures , Ladder , life
line , working platform, safe
access/egress, double layer net,
provision of safety net, leading edge
protection ) , Floor Opening ,
Confined Space ,Tunnelling
Operations(Emergency lighting
,Emergency preparedness and
response, emergency rescue
basket ,emergency stop system in
conveyors, Locomotive movement
Quality of compressed air in working
chamber, hyperbaric, Emergency
Equipment, vibration,radation,fire
and smoke ,compressed air works,
pressure vessels,) ,Public Interface
, Traffic Management (Work area
perimeter hoardings, public
protection from site operations,
Height barrier, Storage of material in
public area , Vehicular Traffic)
,Lifting operations , Demolition ,
False Work/Form Work , Piling and
Diaphragm Walls , Work adjacent to
live railways , Over Head Protection
, Site Transport , HT Line ,TBM and
Launching Operation ,Material

Falling Hazards ,Building

demolition, Diesel storage
licence(statutory
documents),Tandem Lifting ,High
risk activity method statement
approval and implementation ,lift
Plan for high risk activity, harmful
substances, Incident reporting and
investigation . work adjacent to live
railways, work adjacent to live
roadways, launching operation,
barricade / cover to voids, trench,
bored holes and open edges of
structure, flooding, site security.
Medium Working at height (Harness, guard Rs 10,000/-per specific
rails and toe board), Tunnelling activity NCR
(Gas monitoring, Poor Illumination,
means of communication,
temperature, transport and loading,
ventilation, response to emergency
(Tally board), Quality of air,
emergency lighting, Muck pit design
calculation, CCTV Emergency
Under Ground Drills,), Site security,
Welfare (Drainage arrangements,
Rest Room, Toilet, washing
Facilities, bathing facility, canteen.
eating area ,fan, and light at rest
room, cooking facility ,drinking
water) ,Medical Facilities , Site
Tidiness , Fire precautions(Labour
camp) , PPE, House Keeping(Poor
housekeeping , Poor storage of
material , Muck disposal, poor
stacking, slush not disposed, waste
debris not removed , water logging ,
water stagnation) ,Gases , Fumes
Etc. , Training /Induction , Reporting
of accidents and investigation ,
Sleeping at workplace,
Electrical(Trailing cable-Trip Hazard
Poor distribution board),Slippery
Floor,Denailing, reporting of
accident ,corrective and preventive
action, Traffic management

(Pedestrian walkway, barrier

lighting),Highway cleanness,
provision of silence equipment’s ,
Power tool and condition of
equipment’s ,Plant , equipment and
machinery (Back hoe loader , tyre
condition, driving licence, material
hoist opening concrete bucket,
insurance certificate , safety sensor
, ASLI, anemometer , safety
devices, banksman ASLI
calibration, dumpers ),Access and
egress, Disposal of waste, debris
,Fire( arc welding, gas cutting set
,hot work ,First aid facility, wheel
washing facility, Mandatory
contractor OHS&E management
resource, medical examination,
Monthly audit report, Drilling
machine, power tools , Manual
Lifting and Carring of excessive
weight, Dangerous and harmful
environment, Corrosive
Substances, smoking , mobile
phones ,radio’s and audio
equipment.
Low Specific activity standard operating Rs 5000/-per specific activity
procedure , Working at height NCR
(Scaffolding inspection, competent
person, , Notice Display, COSHH
,Occupational health Risk ,OHS&E
Register’s , OHS&E Documentation
, Noise , Waste , Site OHS&E
Committees , Mobile phones , Radio
, Audio Equipment , Dust and
CCTV, Signage’s(Emergency Exit,
Warning , cautionary and
information),Safety induction,
Specific activity safe work
procedure ,risk assessment ,RASI
permit ,public liaison signage,IRC
Signage’s, PPE Examination
certification, provision of skips and
maintenance,ISO certification
audit,compentency training ,control

of dust ,control of noise,COSHH,

Display of OHS&E policy and poster
, CEIG Approval Site illumination
,permits system, Ambulance,
External OHS&E Training as per the
Training Implementation plan ,
Quarterly External OHS&E audit,
first aid resources, ID card and First
Day at Work, OH&S Training,
Labour licence,BOCW registration,
contract labour licence, legal
register, Name board display in
crane boom,OHS&E Hand book
,personal protective equipment
,Vehicle operator check, Inspection
of Plant , Equipment and machinery
by the contractor plant manager,
Eye Wash Station, visitor to site
.Tunnelling(ID Card ,lock
attendance register, medical
records), OH&S Submittal to the
Employer, Monthly OH&S Report.
23.2.8 Non conformity compliance will be reviewed on periodical monthly basis and penalty clause
imposing in the tender for Non-compliance of NCR for a) Medium Risk and b) Low risk as per
below Table-5
Table-5
S.No Risk Days from the notice Deductible amount

of the event within
which the work
should have are
commenced duly
mitigating the risk
A Medium i)The contractor Fore item i) No deduction
complied the specific ii)Closure of the specific activity
activity NCR (unsafe NCR Rs 7500/- per will be refunded
act/unsafe condition) and
≤24hours. Rs 2500/- will be a permanent
ii) The contractor deduction for each specific NCR.
complied the specific iii)Rs10,000 will be a permanent
activity NCR (unsafe deduction for each specific NCR.
7days

iii) The contractor

failure to comply the
specific activity NCR
(unsafe act/unsafe
condition) within the
stipulated time period
of 7days
B Low i)The contractor Fore item i) No deduction
complied the specific iii) Closure of the specific activity
activity NCR (unsafe NCR Rs 4000/- per will be refunded
act/unsafe condition) and
≤24hours. Rs 1000/- will be a permanent
ii) The contractor deduction for each specific NCR.
complied the specific iii)Rs 5000 will be a permanent
activity NCR (unsafe deduction for each specific NCR.
7days
iii) The contractor
failure to comply the
specific activity NCR
(unsafe act/unsafe
condition) within the
stipulated time period
of 7days
23.2.9 The High Risk Non –compliance (Unsafe act/Unsafe condition) shall be suspended the specific
work activity immediately. The Contractor shall not proceed with the work until remedial works
have been complied with under the direction and satisfaction of the Employer/Engineer.
Request for inspection with the evidence of compliance shall be submitted to the Employer/
Engineer for the verification
23.2.10 The Contractor shall not be entitled to any damages or compensation for stoppage of work, due
to safety reasons. The period of such stoppages of work shall not be taken as an extension of
time for completion of the facilities and will not be the ground for waiver of levy of liquidated
damages.
23.2.11 Any non-conformance of unsafe act should be treated as disciplinary action towards the person
and department in charge and as well as recommended for tacking refreshment training on the
specific task.
23.2.12 Closure of Non - conformance will be verified by the submission of photograph evidence or
physical verification on satisfaction of the Employer/Engineer.
23.3 Control of records
23.1 The Contractor shall maintain all OHS&E records in accordance with the Contactors ISO 9001
:2015 Quality Management System.
23.2 Records shall be made available to the Employer / Engineer upon request for the purpose of
incident investigation and management review.
24.0 Audit

24.1.1 Monthly Audit Report (MAR)

24.1.2 The Contractor shall undertake an internal monthly audit using the process and audit report form
(MAR) as prescribed within OH&S Manual Volume 2.
24.1.3 The Contractor shall submit the completed audit report no later than the 7 th of each month within
the Contractor’s monthly OHS&E Report. Failure to submit the monthly audit report within the
stipulated timescale shall result in the Employer / Engineer awarding a ‘Zero’ score for the month.
24.1.4 The audit scores awarded internally by the Contractor shall be subject to review and verification
by the Employer / Engineer . The Employer / Engineer shall substantiate the awarded scores
through making comparison with the results of a physical site inspection against the model audit
scores criteria as provided within OH&S Manual Volume 2.
24.1.5 The Employer / Engineer shall formally verify that the Contractor’s self-awarded scores comply
with the audit scoring system and scoring criteria as defined within OH&S Manual Volume 2.
Where discrepancy exists the Employer / Engineer shall provide supporting evidence
(Photographic) and instruct the Contractor to amend the initial awarded score. Following
adjustment, the monthly audit report shall be re-submitted to the Employer / Engineer within 3
days.
24.1.6 The Contractor shall be required to achieve a minimum 65% overall audit score on a monthly
basis .
24.1.7 If non-payment of the lump sum item in preliminaries occurs as a result of failing to achieve the
required 65% over a single quarterly reporting period, the Employer/Engineer may reinstate the
lump sum item at his discretion should the contractor achieve above 65% for the following six
(6) consecutive monthly OHS&E audits equating to two (2) quarterly reporting periods. This
repayment shall not occur if the quarterly aggregate of Monthly audit scores is less than 50%.
24.1.8 In the event the Contractor fails to achieve a minimum of 65% on a monthly audit, an action plan
shall be submitted together with the audit results detailing the actions that shall be taken within
timescales.
24.1.9 Monthly audits shall be conducted prior to the sitting of the Contractor’s Safety Committee and
shall form part of the agenda.
24.1.10 Contractor Recognizing
24.1.11 The Employer/Employer’s shall recognize the effort if the contractor achieves above 75% for the
following three (3) consecutive monthly OHS&E audits of one quarterly reporting periods. Only
for the preceding three (3) months deducted amount of OHS&E NCR will be refunded.
24.2 Monthly Tunnel Inspection Checklist
24.2.1A team comprising of contractor’s Chief OHS&E Manager and Construction Manager (Tunnel)
shall conduct a monthly tunnel inspection and submit the report to Employer / Engineer. The
details of the pre-designed monthly tunnel inspection format are given in the OH&S manual
(FSAF 28) and Appendix 12 of OH&S Volume 4
24.3 External OHS&E Audit
24.3.1The Profile of the External OHS&E Audit agency, the name, educational qualifications and
experience for of the auditors are to be submitted to the Employer/Engineer a minimum 28 days
before prior to appointment of the agency. Only upon notice of no objection by the Employer
/Engineer shall be authorised to conduct audit on CMRL sites.
24.3.2The External OHS&E Audit template shall be submitted to the to the Employer/Engineer in the
format prescribed (FSAF 32-Volume 2 of OH& S Manual) a minimum 28 days before prior to
conducting of the audit. Only upon notice of no objection by the Employer /Engineer shall be
authorised to conduct audit on CMRL sites.
24.3.3 The Contractor is required to conduct external audits by ISO accredited 3 rd party agency as per
the Indian Standards, ISO 45001 :2018 & ISO 14001:2015 international standards on a quarterly
basis throughout the Contract period.

24.3.4 External audit and follow up audit reports shall be submitted to the Engineer for review within 7
days of audit completion.
24.3.5 Should the Contractor fail to undertake external audits within the 3 month period the Engineer
shall appoint an ISO accredited 3rd party agency to conduct the audit at the Contractor’s cost.
24.3.6 Where ‘Major’ non-conformances with international standards are identified, a follow-up external
audit shall be carried out within 28 days for closing out of the non-conformance(s). Follow-up
audits shall continue on a 28-day rotation until such time as Major non-conformances are closed
to the satisfaction of the 3rd Party ISO accredited auditor.
24.3.7 In case of non-conformity of items identified by auditor, the Employer /Engineer shall take
necessary steps including stoppage of work and or imposing of any penalty to ensure
satisfactory execution.
24.4 Management review
24.4.1 Management Reviews shall be undertaken annually by the Employer / Engineer in compliance
with ISO 9001:2015.
24.4.2 The Management Review Report shall make recommendations for improvement.
24.4.3 The Contractor shall carry out a formal Management Review on an annual basis as a minimum.
The Management Review may form part of the review under the organisations Quality
Management System.
24.4.4 The Contractor shall submit Management Review Report to the Employer / Engineer within 7
days after meeting completion together with the organisations new objectives.
24.5 External OHS&E Agency
24.5.1The Contractor’s External OHS&E Agency thereon, who in the opinion of the Employer /
Engineer, incompetent or negligent or fails to conform with any particular provisions with regard
to OHS&E or the requirement of the contract or legal requirement, or persists in any conduct
which is prejudicial to OHS&E, shall be removed from site immediately, and such external
OHS&E agency shall not be employed again upon the Works. The decision of the Employer
/ Engineer in this regard shall be final.
24.5.6 Penalty
24.5.6.1CMRL has built an image of safety conscious organisation meticulously over a period of nine
years. Any reportable accident (fatality / injury) results in loss of life and/or property damage.
These accidents not only result in loss of life but also damage the reputation of CMRL. Most of
the accidents are avoidable and caused preliminary due to contractors’ negligence. Hence CMRL
shall recover the cost of damages from the contractors for every reportable incident (fatality /
injury).
24.5.6.2In addition every CMRL work site is exposed to public scrutiny as the work is executed just on
the right-of-way. Any unsafe act / unsafe condition observed by public further damages our
reputation. Because of the non-voluntary compliance of contractors to the Employer’s OHS&E
requirements or Employer’s direct instructions and project OH&S manual, CMRL has been forced
to establish safety-enforcing organisation. The cost of established such organisation is to be
recovered from contractors for all observed safety violations at sites.
24.5.6.3The table-6 of Employer’s Requirements OHS&E Volume -1 indicates the Occupational Health,
Safety and Environment violation (unsafe act / unsafe condition) and charges to be recovered
from contractors.

PART-II Safety
25 Investigation and information gathering
25.1 General
25.1.1The safety of tunnelling works can depend critically on adequate pre-construction investigation
of the ground and site, and proper interpretation of the information obtained. All reasonably
accessible information relevant to the construction of a tunnel shall be obtained and studied
before the work starts. Project-specific studies are essential before tunnel construction can
proceed, and should continue during the construction stage. There should be the fullest
practicable disclosure of all relevant information, or gaps in the information, to those responsible
for design, for planning, and for construction. It is important that the ground information is relevant
to, and as complete as practicable for, the needs of the design processes. It is therefore desirable
that the designer, taking advice from others as appropriate, should establish the requirements
for, and have technical control of, data acquisition for the site and ground investigation
programme. This may include on-site design involvement during the site investigation contracts.
25.2 Preliminary studies

25.2.1Topography
25.2.1.1Ordnance Survey maps, aerial photographs and plans normally provide detail for the
preliminary studies and for the basic siting of the works. Aerial photographs are held by the
Ordnance Survey, local authorities and air survey companies. Comparison of recent and earlier
aerial photographs can give important information on the masking of earlier features. In tidal
waters and coastal areas.
25.2.2Geology
25.2.2.1Published maps, both solid and drift editions, provide the essential background information to
tunnel siting and construction. Other useful material includes soil maps, a grid-references list of
available borehole/well logs, contaminated-land maps and land utilization maps.
Geomorphological studies can also be of benefit, particularly in the vicinity of tunnel portals to be
formed in natural slopes.
25.2.3Hydrology
25.2.3.1Tide tables are of great importance for work at or near sea level. Discharge rates for rivers
should be ascertained. All appropriate records and predictions should be fully examined for their
relevance to particular locations. Advice from those with local knowledge can be invaluable.
25.2.4Existing structures, services and old workings
25.2.4.1Knowledge of all structures, buildings and earthworks within any possible zone of influence of
the tunnel construction shall be sought and studied to include the possibility of ground
contamination from previous industrial works. Plans of buildings and other structures must be
examined both from the point of view of ground support required within and adjacent to the tunnel
and of danger and damage to existing structures from settlement or vibration.
25.2.4.2A search should be made for records of any wells, culverts, boreholes, borrow pits, and any old
mine workings in the area. These records can also provide information on water table levels.
Enquiries should be made as to whether there are any records of the occurrence of methane or
other gases.
25.2.4.3Forms of structural support to existing buildings and structures, such as piles or temporary or
permanent ground anchors, should be fully investigated, as they can pose hazards to the

tunnelling operations and are themselves liable to be detrimentally affected by tunnelling works.
The actual location of these services should be verified. Drawings should not be relied upon, as
they might be insufficiently accurate.
25.2.5Weather
25.2.5.1The influence of local weather conditions on tunnel construction should be taken into account,
e.g. patterns of rainfall and barometric pressure changes and the likelihood of electrical storms.
Rainfall data from the Meteorological Office should be obtained for comparison with periods of
observation in groundwater conditions.
25.3 Project-specific studies
25.3.1General
25.3.1.1All site investigations should be carried out in accordance with BS 5930 & Partially superseded
by BS EN ISO 14688-1:2002, BS EN ISO 14688-2:2004, BS EN ISO 14689-1:2003, BS EN ISO
22476-2:2005 and BS EN ISO 22476-3:2005.
25.3.2 Boreholes
25.3.2.1Boreholes (vertical, horizontal and inclined) should be sited to provide information specific to
the tunnel to be constructed. Data from boreholes supplement the geological and hydrogeological
information obtained from maps and other records. The boreholes should be located close to the
line of the proposed tunnel, but not so close as to intersect it, unless for some specific reason
that must be clearly stated in the method statement. A borehole too close to, or intersecting, a
tunnel or shaft can constitute a serious hazard if water is present, and particularly when
compressed-air tunnelling methods are employed. The siting of a borehole where a shaft is to be
sunk makes correlation possible between the borehole data and the actual ground encountered.
If a borehole intersects an aquifer it should be sealed at the appropriate location.
25.3.2.2All boreholes should be properly filled and capped using concrete plugs.
25.3.2.3There is a risk in assuming continuity of strata between boreholes. It is important that some
boreholes are taken to a depth well below the intended tunnel invert, and that these boreholes
are adequately sampled and recorded to enable geological structures and hazards adjacent to
the proposed tunnel excavation to be determined. Samples of rock, subsoil and groundwater
must be properly identified, labelled, and photographed where necessary, and stored for further
examination if required. Expert supervision of the drilling operations and of sampling is essential
to maximize the usefulness and quality of the information recovered.
25.3.2.4Consideration should be given to the use of the most appropriate methods for obtaining
undisturbed samples of soil by, for example, rotary coring and thin wall sampling tubes, in order
to provide the best information on soil structure, stress/strain behaviour and anisotropy.
25.3.3Information logging
25.3.3.1The following techniques shall be considered for information logging:

a) Stratigraphic logging, by an experienced geologist;
b) Borehole logging, using appropriate techniques for the ground conditions;
c) Impression packer tests to determine joint orientation;
d) Permeability tests over specified zones, preferably using a double packer;
e) Standard penetration test or window sampling;
f) Pressure-meter tests (self-boring or dilatometer);
g) Various types of disturbed/undisturbed samples;
h) Installation of piezometers;
i) Down-/up-/cross-hole seismic measurements.

25.3.3.2For stratigraphic logging, it may be advantageous to sink a hole with continuous

sampling/coring adjacent to holes from which samples/cores have been obtained for testing or
where in-situ tests have been performed. Cores should be retained for inspection by tunnel
designers and contractors.
25.3.3.3Appropriate techniques for borehole logging include natural gamma, gamma back-scatter,
sonar, resistivity and calliper methods. Detailed scan line logging and macro- and micro-fossil
identification can provide valuable supplementary information. Valuable additional information
can be obtained from local exposures of strata or from large diameter auger boring in which the
strata can be examined in situ, or from test pits or shafts. Precautions should be taken against
loose ground, water, gases and other hazards when boreholes and pits are being inspected. An
appropriate laboratory testing programme shall be followed to aid the determination of safe
alternatives in respect of excavation, ground support and spoil disposal.
25.3.4Geophysical investigation
25.3.4.1The geophysical methods most readily applicable to tunnel conditions are seismic, electrical
ground resistivity, ground radar and micro-gravity surveys. These methods should not be used
on their own, but as an adjunct to borehole and other information. In particular, they can trace
well-defined boundaries between underground strata and thereby provide a more comprehensive
picture and identify anomalies, which can then be examined further by, for example, additional
boreholes.
25.3.4.2In urban areas the use of geophysical methods may not be appropriate because of the
interference from existing services and structures. Radar and micro-gravity have been used
successfully to identify swallow holes and similar features. For a subaqueous tunnel, a marine
seismic survey can be of assistance in charting the riverbed, determining bedrock surface and
discovering buried channels. The survey can help to decide locations for site investigation
boreholes.
25.3.5 Topography and surface survey
25.3.5.1An accurate site survey shall be made for the purposes of setting out and tunnel construction.
This survey must define accurately the relationship of the tunnel to all existing structures and
other features that could be affected. An aerial survey can provide valuable additional
information, particularly for a major tunnelling project. Reference points, related to Ordnance
Survey reference points, for the coordinate grid system of the survey should be established and
preserved, as should benchmarks for levelling. The stability of all reference points should be
checked and referenced. Existing surface features such as manholes and valve covers should
be identified and recorded, as these help to locate existing sewers and other buried services.
25.3.6 Underground survey
25.3.6.1In addition to the surface topography, any underground structures must be accurately related
to the proposed tunnel alignment. The accuracy of the available survey information should be
taken into account. The structures that should be surveyed include:
— existing basements and foundations;

— existing headings, tunnels and underground workings;
— main sewers;
— underground services of any kind.
Any ground or rock anchor cables that can be located must be accurately surveyed. plans of
basements and foundations shall, if possible, be verified by actual survey. If any existing structure
or service intersects or is very close to the proposed tunnel, any special hazards that could result

should be carefully examined and appropriate precautions defined within a specific method
statement.
25.3.7 Structural survey
25.3.7.1All buildings and structures that could be affected by the tunnel construction must be surveyed
to determine their condition prior to, during, and after the proposed tunnelling operations.
25.3.8 Groundwater tests
25.3.8.1Where the response of the groundwater regime to pumping or other methods of creating a
differential hydraulic head could be important to the stability of the proposed tunnel or shaft,
consideration must be given to carrying out pumping tests in boreholes sunk specifically for the
purpose. Where water levels in the area are variable or could be affected by tunnelling
operations, observation wells to observe and record any variations of levels are desirable. They
may be needed prior to and during tunnelling work. Water levels in boreholes must be recorded,
and any perched water tables or artesian supplies should be identified if at all possible.
25.3.8.2In water-bearing ground, permeability tests in boreholes can contribute valuable information.
Where tidal variations could be critical, as in the case of compressed-air working, tide gauges
should be provided. In special circumstances, other water tests should be made for salinity,
acidity or pollution and/or the presence of chemicals or dissolved gases of natural or artificial
origin.
25.3.9 Gas
25.3.9.1Ground conditions should be considered very carefully to ascertain the risk arising from gas
(e.g. methane etc.) and other pollutants being present or entering the ground that is to be opened.
Depending on the level of risk, tests should be carried out to ascertain the mode of its occurrence
and the risk that it could present during the construction and the use of the works. This applies
in particular to tunnelling work in or adjacent to:
— landfill sites;
— refuse tips;
— permeable strata where air has been introduced by previous compressed-air workings;
and
— areas where the lowering of the water table has caused deoxygenation.
25.3.10 Blasting trials
25.3.10.1Where a tunnel is to be driven through rock using explosives, and in proximity to a vibration-
sensitive structure or building, it may be appropriate to carry out blasting trials to determine the
acceptable vibration parameters of the site, and the safe level of charging.
25.4 Ground investigation during construction
25.4.1 General
25.4.1.1It is necessary to continue ground investigation during the construction stage, and this can be
part of the probing operation. It can be important to check the water pressures (in hard rock) or
the porewater pressure (in soft ground). The latter is important where sprayed concrete
temporary support is employed.
25.4.2 Probing ahead
25.4.2.1Probing ahead of the tunnel face can provide valuable additional information and can improve
the overall quality of the data concerning the ground ahead of the tunnel construction. For large
or difficult tunnels, a pilot tunnel (usually located within the cross-section of the intended tunnel)
may be the appropriate method, and will provide information on the nature and behaviour of the

ground in advance of the main tunnel. This will indicate any need for any possible special
construction, ground treatment or ground support. Probing from the face as it is being advanced
should be possible in all tunnels. The extent to which it is actually employed depends on the likely
hazards. This work must be programmed to minimize interruptions to progress.
25.4.2.2In extremely bad ground conditions, probing ahead in all directions may be necessary,
combined with ground treatment. In extensive investigations of this kind, care should be taken,
when drilling, to avoid penetrating any suspected aquifers above or below the tunnel construction
25.4.3 Special investigations
25.4.3.1Special investigations may be appropriate if any of the following hazards are anticipated:
— geological faults, fissures or discontinuities;
— cavities or artificial obstructions;
— significant changes in the groundwater patterns;
— loss of safe overhead ground cover;
— the occurrence of hazardous gases and/or liquids
26.0 Safety requirements in all stages of construction
26.1 Overall construction planning.

26.1.1The contractor should ensure that suitable and sufficient tunneling equipment for the type of work
to be done, is provided and is operated and maintained in accordance with manufacturer’s
instructions.
26.1.2The contractor should reduce risk to workers underground through elimination or control of
hazardous materials and processes. Only where such risks cannot be reduced to acceptable
levels should personal protective equipment be provided in accordance with local statutory
requirements.
26.1.3The contractor should provide appropriate safety signs in accordance with ISO 3864:2002.
26.1.4The contractor should provide adequate training facilities and courses relevant to the construction
methods to be used.
26.1.5The contractor should provide adequate area lighting to ensure a safe environment.
26.1.6A system for accounting for site personnel in an emergency shall be implemented and rigorously
enforced. The system must accurately indicate the number and location of persons underground
at all times. This information is essential to the emergency services in the event of an
underground fire or other emergency. If the works have a single entrance/exit, a simple tally
board can be adequate. For works with multiple entrances/exits, a more sophisticated system is
necessary. Whichever system is used, it must be supervised and monitored, and all persons
using the system must be instructed in its correct use.
26.1.7If the tunnelling operations form part of a multiple-contractor project, then the tally system
used must be uniform across the entire extent of the underground works, and shall be built
into the contract and safety case. The system must allow persons to be accounted for across
the entire project work sites, irrespective of the entrance or exit by which they enter or leave.
26.2Portal development
26.2.1The work site should be fenced to control entry to the site.
26.2.2The contractor should ensure that the portal area is stable, and that surface water is adequately
diverted from the portal area.

26.2.3Adequate rock fall protection methods should be deployed such as barriers, canopies, check
fences, to prevent rock falling on the work site.
26.2.4Adequate resources for dewatering the face should be available.
26.3 Shaft construction Etc.,

26.3.1A protective barrier should be erected around the shaft top to prevent falls of men or materials
into the shaft. The barrier should also prevent surface water draining into the shaft.
26.3.2Man-access to the shaft bottom should be by stair tower, hoist or man riding skip. An alternative
means of access should always be available for use in an emergency when hoists or man-riding
skips are used.
26.3.3Materials transport should be separated from personnel transport by a substantial barrier.
Materials transport is covered in detail in.
26.3.4Daily during shaft sinking operations, the whole shaft shall be carefully examined for loose
material which shall be removed. The bottom of the shaft shall be free of fallen rock. The shaft to
be cleaned after each shift of work.
26.3.5All services including ventilation, lighting and communications should be securely attached to the
shaft wall. They should be adequately protected from damage.
26.3.6Platforms of raise boing equipment should be properly guarded to prevent falls of men or
materials.
26.3.7Bulkheads and air decks in shafts subject to compressed air working should be designed and
constructed to withstand all loads on them from the least favorable combination of air pressure/no
air pressure and kentledge /no kentledge, Variations in loading due to fluctuating water levels
should also be considered.
26.3.8When spoil is removed through a vertical lock, a protective system should be fitted to prevent
damage to the lock due to over winding.
26.3.9Appropriate temporary support should be provided to the shaft lining as the tunnel opening is
being formed through the shaft and for as long as necessary thereafter. Appropriate measures
should be taken to prevent water entering the shaft and to drain the shaft.
26.3.10Daily housekeeping shall be carried out after each shift of work in the shaft.
26.4 Tunnel excavation
26.4.1Safety signs should be provided in accordance with local statutory requirements.
26.4.2Equipment and material for primary ground support should be available on site, e.g. rock bolts,
arches, shotcreting.
26.4.3Adequate dewatering equipment must be available when required.
26.4.4 The contractor shall assign a Competent Person to perform all air monitoring required to
determine proper ventilation and quantitative measurement of potentially hazardous gases. The
atmosphere in all underground areas shall be tested quantitatively by the contractor for toxic
gases, dust, vapour, mist, and fumes as often as necessary to ensure that prescribed limits
given at 26.4.6 below are met. Quantitative tests for methane shall also be performed in order
to determine whether an operation is potentially hazardous. For every test carried out the
contractor shall maintain a record of the air quality the location, date, time, substances and
amount monitored. These records shall be made available to the Employer / Engineer on
demand.
26.4.5 The ventilation system shall be adequate to maintain circulation of air in all parts of tunnels and
shafts and following conditions shall be taken care of:
26.4.6 Air shall be considered unfit for workmen to breathe if it contains any of the following:
(a) Less than 19.5% oxygen by volume.
(b) More than 0.005% carbon dioxide by volume.

(c) More than 0.01% carbon monoxide by volume.

(d) More than 0.001% hydrogen sulphide by volume.
(e) More than 0.005% oxides of nitrogen.
(f) More than 0.5% of methane at any place in the tunnel.
(g) More than 0.0002% of aldehyde.
(h) Any other poisonous gas in harmful amounts.
In addition to the requirements given above, 2 m3 of fresh air per minute shall be furnished for each
brake horsepower of diesel engine used in the tunnel.
26.4.7 The Contractor will ensure the supply of fresh air to all underground work areas in sufficient
amount to prevent any harmful accumulation of dust, vapour or gases. The fresh air supplied
in such tunnel is not less than six cubic metre per minute for each building worker employed
underground in such tunnel, and the free air-flow movement inside such tunnel is not less than
nine metres per minute.
26.4.8 No inflammable materials or oil and grease shall be stored inside or near the tunnels or shafts
and all combustible rubbish from the tunnel or shaft shall be promptly removed. A regular
analysis of the gases inside the tunnel should be done with advance of the tunnel.
26.4.9 Tools made of light alloys (such as Al and Mg) are not to be used inside the tunnel. They may
cause sparks.
26.4.10 Regular checking of gas (referred at 26.4.6) at the faces shall be done before each shift. This
should be carried out using a multi gas detector.
26.4.11 Motive power other than electric, shall not be used without prior authorisation from the
Employer/ Engineer. No petrol engines shall be used underground. Diesel locomotives shall
not be used in Underground.
26.4.12All electrical installations must be suitable for the underground environment and must conform
to local statutory requirements or should be in accordance with the recommendations of this
document. A back-up power supply should be installed within the tunnel in case of power loss to
critical equipment such as pumps, fire lighting systems etc.,
26.4.13Compressed are installations must be properly designed, installed and maintained.
26.4.14Adequate supplies of water for construction work should be provided. Special provision for
drinking water should be made and such supplies should be regularly tested for contaminants
and thereafter treated as necessary to purify it.
26.4.15Proper washing and toilet facilities should be provided for all underground workers.
26.4.16Probing ahead of working faces should be undertaken according to the risk assessment to
identify potential hazards such as water, gas, unstable ground conditions, etc.
26.4.17Adequate fire detecting, warning and flighting equipment properly maintained, should be
provided.
27.0 Permanent Support
27.1 General
27.1.1In designing the tunnel lining, matters taken into account should include the information available
and the investigations. Alternative vertical and horizontal tunnel alignments may have to be
considered. The support system specified must be designed for ground loadings and hydrostatic
pressure and for external and internal special loading arising from such factors as adjacent

foundations, piles, water pressures and traffic loads. Temporary loading can arise from the
transfer of shield jacking loads or the application of compressed air.
27.1.2Handling requirements must be assessed as part of the design process, so that structural
elements can be set in place without damage.
27.2 In-situ linings
27.2.1In-situ linings generally take the form of a concrete lining that is either placed behind formwork or
sprayed on to the internal surface of the tunnel. Adherence to good practice in the production,
placing and compaction of concrete will increase its durability and reduce maintenance and the
risks associated with such work. Concrete should be specified, produced, transported and tested
in accordance with BS 8500-1:2002, BS 8500-2:2002 and BS EN 206-1:2000.
27.2.2Formwork is usually constructed so that it can be moved along the tunnel and reused.
Accordingly, it should be made as light and as easy to handle as possible, but its strength and
rigidity should be adequate for loads imposed both by the wet concrete and by handling
procedures. Formwork design shall be supported by calculation by the contractor.
27.2.3The equipment employed for depositing concrete behind formwork can include a concrete pump
or placer. Placers often discharge the material at high velocity. The discharge nozzle should
therefore be properly secured and guarded, and any joints in the supply pipes secured to prevent
the pipes from flailing about if a joint burst during concreting. No person shall be permitted to
work in the immediate vicinity of a high-velocity discharge pipe or hose.
27.2.4With sprayed concrete, the hazardous area is more extensive, since no formwork is provided. To
reduce exposure to hazardous materials, remote spraying techniques must be considered. Arch
ribs with lagging, or other systems, may be employed as part of the permanent in-situ lining. If
so, they will generally be built in, possibly with additional ribs or reinforcement, as appropriate.
The building in of untreated softwood timber should generally be avoided and shall be subject to
notice of no objection from the Employer / Engineer prior to use.
27.3 Prefabricated Linings
27.4 General
27.4.1Prefabricated linings are most commonly used for circular tunnels and are sometimes used for
oval or other cross-sections. This type of lining can be considered under three general categories:
27.4.2Bolted or other structurally rigid systems that are self-supporting and outside which grout or other
material has to be injected to complete the support system;
27.4.3Expanded systems that are forced against the ground by circumferential thrust, thus applying
immediate support to the ground;
27.5 Segments
27.5.1Segments shall be provided with sufficient holes or attachments to allow for safe handling at all
stages. Quick-release attachments, such as segment lifting “fingers”, shall be employed only where
their design prevents the accidental displacement of the load. Pneumatic (vacuum) lifting may be
considered as an alternative that saves the need to provide holes and concentrated loading points.
27.5.2Any problems arising from the lifting, transportation, handling and erection of the units must be
anticipated before manufacture to ensure adequate lifting and handling facilities are provided.

27.5.3Segments should be stacked, preferably on level ground, so that they are stable and will not be
damaged. Segment stacks on the surface shall be arranged so as not to impose additional loading
on tunnel excavations or overload the ground on which they rest. Stacks of segments shall be
designed, located and constructed to facilitate safe handling.
27.6 Transportation and Erection
27.6.1 An approved safe slinging method shall be used to transfer segments from the surface to the pit
bottom. Within the tunnel, segments are normally transported on a bogie. A positive means of
attachment or a specially shaped bogie shall be provided so that loads cannot shift during transit.
Segment transfer and erection systems shall be provided as determined within the risk assessment
wherever practicable, but the handling arrangements at the face almost inevitably involve some
manual handling, at least in guiding the units into position. There are various types of segment
erector, which can be mounted either on the shield or on a towed staging.
27.6.2 The choice of system shall be determined by the design of the lining to be erected and the space
available for segment erection. In a small diameter tunnel where segments could need manual
handling, pipe jacking shall be considered. In all cases, it is essential that the procedure for the
handling and erection of segments be carefully planned and that the erection personnel be properly
trained to keep clear of danger points, and that others be kept away from the working area.
27.6.3 The designated operator of an erector or erection winch shall be situated where there is a clear
view of the whole operation, so that it can immediately be halted, if necessary.
27.6.4 Alternatively, the erector operator may be provided with alternative control points, control panels
on wander leads or radio control of the erector. If a clear view is not obtainable, the use of CCTV
may be necessary. The erection personnel shall be properly equipped with appropriate hand tools
for handling segments, and with an adequate supply of timber or steel wedges and packings if
required.
27.6.5 Shove ram thrust (nip) must not be relied upon as the sole means of supporting segments,
particularly when upper segments are in place but the ring is not complete. All segments should
be positively supported. Where manual assistance is necessary, erection gantries should be
constructed to provide a safe place of work and means of access.
27.6.6 Because lining erection is a potentially hazardous operation, great care should be exercised in
the design and manufacture of segment lifting and erecting equipment.
27.6.7 Mechanical segment-feed devices should be designed to prevent inadvertent discharge of

segments into the building area.
NOTE: PREN 12336 specifies requirements for segment erectors, including vacuum lifting devices.
27.7 Jacking Pipes
27.7.1 Concrete jacking pipes must at least conform to BS 5911-1:2002 & BS EN 1916-2002-2008, but
shall be designed to meet more onerous requirements for superimposed loads where necessary.
Standard pipes shall be designed to enable the jacking forces to be transmitted along the pipeline
without damaging the joints. The joints shall be designed to produce the flexibility necessary for
installing the pipeline and for accommodating any future ground movement. The joint shall also
provide a high degree of water-tightness. Any minor leaks may be sealed by caulking or other
approved methods. Pipes conforming to BS 5911-1:2002 & BS EN 1916-2002-2008 are
produced in a range of lengths, diameters and joint profiles. Where thrust loadings require,
special jacking pipes with additional reinforcement or detailing shall be used immediately behind
the shield and at any intermediate jacking station.

27.7.2 Square and rectangular precast concrete units for jacking are normally purpose-made. Design
loads must include those arising from handling and placing the units. Lifting points must be
provided.
27.8 Grouting Behind the Lining
27.8.1 The proper support of a bolted lining is essential for structural competence. It is also essential
for full and uniform contact between the lining and the ground to be achieved. In cases where the
ground is liable to move quickly, and the avoidance of settlement is important, quick-gelling grout
should be injected as soon as practicable under sufficient pressure to fill all voids. The speed of
providing support can be increased by filling the void with either pea gravel or a similar material.
When tunnelling through stiff cohesive materials or weakly cemented sands, or when settlement
is of no importance, as determined by the design assessment of the contractor, injection may be
deferred until several rings have been erected, and these can then be grouted in a single operation.
27.8.2 Thick grouts, which can contain cement, cement admixtures, flash admixtures or bentonite
admixtures, should be injected through the lining under pressure, using either a grout pan or a
grout pump and filling the space from the bottom upwards. The injection pressure shall determine
through design assessment and will depend on the following:
— The viscosity of the grout;
— The permeability of the ground;
— The depth of overburden;
— The presence of underground structures or services;
— The need to prevent contamination of machine tail seals.
27.8.3 Leaks can occur when grout is freshly mixed and under pressure, especially at the point of
injection. The gun used should be such that a positive attachment is made to the lining, e.g. a
threaded connection or an expanding rubber sleeve. Under certain conditions, two-part grouting
can be effective, pea gravel being injected as the shield is shoved, in order to provide immediate
support, and the voids in the gravel later being injected with cement or similar grout when
convenient.
27.8.4 Most grouting mixtures contain hazardous materials, which can affect the skin and eyes. Some
grouting mixtures present a hazard to the environment. Substitution of less hazardous materials
must be considered from the outset and identified within the Hazardous Substances Assessment.
Appropriate training, provision, wearing of appropriate protective clothing, eye protection and when
necessary respiratory protection, is essential.
27.9 Construction of Openings
27.9.1 Where an opening leading out of a tunnel is required, and this opening is greater than half the
diameter of the main tunnel, the complete tunnel shall be constructed first and the opening formed
subsequently.
27.9.2 Temporary struts and framing adequate to carry the whole of the estimated load (including the
load in rings forming the jambs to the opening) shall first be designed and fixed in place. Extensive
experience of this type of work is necessary, both for its design and for its execution. It is essential
to make complete and even contact between the temporary members and the permanent work. All
struts shall be tightened very securely with hardwood or steel wedges and packings. The tunnel
designer shall facilitate the formation of openings by specifying opening sets or soft keys.

27.10 Monitoring of Loads and Deformation
27.10.1Throughout the construction stage of a tunnel and in situations where movement or settlement
is particularly sensitive, frequent inspection of the finished lining by an approved engineer is
essential. Completed linings should be checked for any settlement and change of shape.
27.10.2 Cracks shall be kept under close observation, their details recorded and the cause of the
cracking determined. Monitoring of ground movement around the tunnel, load build-up on the lining
and changes in groundwater levels can help in the early identification of problems. Leakage of
water or fine soil shall be noted, loose bolts and grout plugs and empty grout holes marked and
noted.
27.10.3 Settlement at the surface and near the foundations of adjacent structures or buildings can
seriously affect their safety, and possibly the safety of the tunnel. Where new tunnels or
foundations are being constructed close to existing tunnels or other underground structures, the
existing structures must be regularly inspected and any movement monitored. Records of such
inspections shall be maintained by the contractor and made available for inspection by the
27.10.4 Some settlement above tunnel excavation is almost inevitable where the tunnel is in soft ground
and at limited depth, but can usually be reduced by special design methods and techniques.
Differential settlement between different parts of the same structure or building can cause the most
serious problem.
27.10.5 Routine checks of any structures affected shall comprise photographs, inspection and recording
of cracks and defects before, during and after tunnelling, with accurate surveying based on
reference points outside any zone of movement. In special cases where structures are particularly
sensitive to settlement, more elaborate monitoring may be necessary, using inclinometers and
strain gauges within boreholes or piles. Where compensation grouting is being used, it may be
necessary to monitor the tunnel to ascertain whether the grouting has imposed additional load on
it.
28.0 Dealing with Water

28.1.1If water is anticipated, exploratory probing or drilling ahead of the face should be carried out to
confirm the quantity, the quality and the pressure. Blowout preventers shall be used during drilling
according to the risk assessment.
28.1.2If ground water is encountered, and the ground requires sealing, this should be done ahead of
the excavated face.
28.1.3Measures shall put in place for the evacuation of workers in case sudden flooding.
28.1.4Water should be removed from the working area either by open drains or by pumps and pipes.
Intermediate holding tanks and pumping stations should be set up where water has to be pumped
over large distances.
28.1.5If open drains are used they should be on the opposite side of the tunnel to the pedestrian
walkway.
28.1.6Sumps are hazards for persons walking in the tunnel and should be guarded and readily visible
to avoid injuries to workers falling into them.
28.1.7To avoid flooding, especially in downward sloping tunnels, pumps with adequate reserve capacity
should be provided and so arranged that it flooding occurs they will not be put out of action.

28.1.8Where the stability of the tunnel face or the tunnel itself is endangered by the presence of water,
the tunneling method shall be chosen accordingly.
28.1.9If water from the tunnel is to be used for drinking or spraying purposes it should be regularly
tested for contaminants and treated as appropriate.
28.1.10Where water from the tunnel is discharged it may require treatment (settling ponds, etc) to avoid
pollution of surface water.
28.1.11Groundwater lowering may have a detrimental effect on surface structures and gas and water
pipelines.
28.1.12Where groundwater is lowered during construction adequate standby capacity should be
available to prevent interruption of this process.
29.0 Tunnelling Boring Machines and Road Headers
29.1 General
29.1.1Tunneling machinery should comply with national standards.
29.1.2Machines working in rock should have an efficient dust suppression and extraction system.
Equipment shall be properly maintained.
29.1.3They should have a ventilation system which should provide sufficient fresh air for personnel and
for cooling the work environment.
29.1.4Adequate flows of fresh air shall be provided at all work places and can be achieved by a forced
feed system, an exhaust ventilation system or a combination of exhaust and forced feed systems.
29.1.5The end of the ventilation system shall extend as far through the machine towards the face or
forward bulkhead as necessary.
29.1.6Recirculation of contaminated air shall be avoided by ensuring sufficient overlap of exhaust and
force feed ducting and the use of dust filters.
29.1.7Dust hoods should be fitted to known dust sources (such as conveyor transfer points).
29.1.8Where excavating in rock, where levels of airborne dust can be high in certain rocks and
unacceptable for health reasons, dust suppression should be provided. Atmospheric dust may
be invisible; high dust concentrations can reduce visibility. Additionally some dusts such as coal
can be potentially explosive. Even with dust suppression, it may be necessary to wear dust
protection masks.
29.2 Tunnel Boring Machines
29.2.1Machines should be provided with a means of safe access to and sufficient working space at all
points where maintenance is required.
29.2.2There should be a safe system of work for changing cutters and other maintenance work.

29.2.3There should be a safe means of access to the face which may include an airlock system, and
adequate working space at the face to work safely.
29.2.4Machines should be fitted with a lock-out system to prevent accidental starting during
maintenance.
29.2.5Machines shall be so designed to allow for the installation of tunnel support systems immediately
behind the cutting head and to allow for drilling of exploratory and grout holes ahead of the face.
29.2.6Safe mechanical systems for erecting tunnel segmental linings shall be devised.
29.2.7In the design of the machine, fire risk should be assessed and the machine designed to minimize
the fire risks. Low flammability hydraulic fluids and lubricants should be used. The amount of
flammable materials on the machine should be minimized.
29.2.8Suitable smoke and gas monitoring and alarm systems should be incorporated.
29.2.9Fire suppression systems should be fixed manually operated systems supplemented by portable
extinguishers as necessary. All workers should be trained in the use of portable fire extinguishers.
For electrical requirements.
29.2.10An atmospheric monitoring system should be provided which will shut down all non-explosion
protected electrical and mechanical equipment on the TBM automatically in the event of an
unsafe atmosphere being detected.
29.2.11All safety critical electrical equipment should be explosion protected.
29.3 Road Headers

29.3.1Exhaust ducts and efficient dedusting systems should be installed to extract the dust. Preferably
dry type dedusting systems should be used.
29.3.2The exhaust ducts and the dedusting system shall be designed in accordance with the rock
characteristics (e.g. quartz content) and the tunnel surface to be dedusted.
29.3.3Exhaust ducts shall be so installed that the exhaust air is always extracted from the tunnel face.
29.3.4During operation workers shall not be in the area ahead or adjacent of the machine.
30.0 Inundation
30.1 Precautions
30.1.1In compressed-air tunnelling, an increased risk of inundation arises, if air escaping through the
ground erodes a channel of increasing area through which there could ultimately be a
catastrophic loss of air pressure. Precautions should include:
30.1.2use of the minimum practicable air pressure;
30.1.3constant inspection for air leaks at the face and surface;
30.1.4Sealing off any leaks, using bentonite, cement grout, plastic sheeting, bags or other means of
choking the airflow.
30.1.5Specific boxing-up and inspection procedures, preferably by remote means, must be

implemented at weekends and other stoppages. Special care should be taken with TBMs that
use compressed air in small compartments at the face.

30.2 Escape
30.2.1In compressed-air working, escape routes must be carefully planned to give access to airlocks.
30.2.2In small-diameter tunnels, consideration shall also be given to the use of airlocks at a higher level,
accessed by ladders in trunking, which afford a better place of safety than airlocks at tunnel level.
The provision of airtight steel curtains in the top half of a descending tunnel at appropriate
intervals should be considered. In the event of flooding, these can retain pockets of air within
which persons can remain until lost air pressure is restored, or rescue effected. However, the
size of the tunnel rolling stock can severely limit the size of such curtains.
31.0 Methane
31.1 General
31.1.1Equipment for monitoring the presence of methane must be available on site at all times. All
machinery and equipment used shall be designed to minimize the danger of sparks and high
temperatures. Both mechanical and electrical equipment may have to be explosion-protected this
is to be identified in the Risk Assessment.
31.1.2Where methane is found to be present, it should normally be dispersed by dilution using forced
ventilation. Extraction ventilation may be preferred where excessive quantities of dust have to be
removed.
31.2 Occurrence
31.2.1The presence of methane can be influenced by groundwater movements. The gas can travel
laterally for considerable distances along joints and fissures or through porous rock.
Accumulations of gas can occur under lakes and waters if trapped by overlying impermeable
strata. In urban areas the gas can occur in refuse dumps, under landfill, in sewers or sewage
sludge, or by leakage from gas mains. Methane can also enter excavations from biological
sources, e.g. by migration from landfill disposal sites, and from microbiological decay of organic
material such as could be present in silt or sludge in drains, sewers and culverts.
31.2.2.Methane can appear in an excavation as a steady infiltration, a heavy emission or in a sudden

influx when a pocket of gas under pressure is penetrated, e.g. in faulted ground. Methane
infiltration can also be influenced by changes in tunnel atmospheric pressure due to fluctuations
in barometric pressure or by the use of extraction ventilation systems. Methane dissolved in
groundwater can enter tunnel works and the gas can subsequently be released into the tunnel
atmosphere. Methane layers can form in the crown of the tunnel and can migrate from the source
of entry to a point some distance away, especially up an incline, and this can occur against the
normal flow of ventilation. Thus, an explosion can be caused some distance from the source of
entry of the methane, when mixing subsequently takes place.
31.2.3Methane can occur with carbon dioxide and other gases that can affect its density, resulting in
mixtures that are neutrally buoyant or even denser than air. Thus, layers can form at the base of
excavations and migrate down inclines. The methane layers can be dispersed by various
methods of turbulent mixing, e.g. by high-velocity airflow in the tunnel or by directing a flow of air
to the crown of the tunnel by means of local air movement devices.
31.3 Explosion Characteristics
31.3.1The danger from methane is that it is potentially explosive when mixed with air. The lower and
upper explosive limits (LEL and UEL) are approximately 5 % and 15 % by volume respectively

(see also BS EN 1127-1). The density of pure methane is approximately 0.6 times that of air and
consequently it tends to accumulate at the tunnel crown, forming persistent layers if undisturbed.
When thoroughly mixed with air, it does not again separate and can therefore be safely handled in
a ventilation system if adequately diluted.
31.4 Detection and Monitoring
31.4.1Where the presence of methane at any concentration is foreseeable, the air in the tunnel must
be continuously monitored using fixed monitoring equipment, supplemented by the use of
portable monitoring equipment. The detection system shall be coupled to an alarm system in the
tunnel to indicate when predetermined alarm levels are exceeded. On activation of the alarm,
emergency procedures must be implemented. BS EN 50057 should be consulted for advice on
the choice and use of monitoring equipment. The presence of methane or any potentially
explosive gas shall be reported to the tunnel designer and the client as soon as it is detected.
When the presence of any potentially explosive gas is indicated, the nature and source of the
gas should be determined, and the intensity of the inflow should be specifically measured.
Effective and regular maintenance and calibration of the gas-detection equipment is essential.
31.4.2 Monitoring should be carried out using fixed monitoring equipment in the pit bottom, along the
crown of the tunnel, on excavation machinery at the tunnel face and in extraction ventilation
ducts. This shall be supplemented by monitoring, possibly using portable equipment, at the
following locations:
— Along the invert;
— In the general body of the air within the tunnel;
— At low-level points such as sumps and pits;
— Where methane layering is suspected;
— In voids above crown level;
— Upwind of tunnel machinery, electrical switchgear and transformers.
31.4.3Data on current methane concentrations, obtained from the monitoring system, must always be
available to site managers on the surface and at the tunnel face. Written, printed or electronic
records should be kept showing the following:
— Calibration of the equipment;
— The results of routine monitoring;
— Abnormally high concentrations of methane;
— Atmospheric pressure;
— Position of sampling;
— Time of day;
— Date;
— Air quantity flowing at each sampling point.

31.4.4Atmospheric monitoring equipment used for detecting methane shall conform to BS EN 50054,
and to BS EN 50055 or BS EN 50056. Equipment conforming to BS EN 50055 is intended for
use only in the range 0 % to 5 % methane by volume (100 % LEL).
31.5 Danger Levels
31.5.1If concentrations of methane cannot be kept consistently below 0.25 % by volume (5 % LEL) in
the general body of the air, all mechanical and electrical equipment in use in the tunnel must be
explosion-protected. In particular it is essential that equipment deemed essential for safety,
including lighting, emergency lighting, communications equipment and fire detection, alarm and
extinguishing systems, be of an explosion-protected type so that it can remain operational at all
times.
31.5.2If concentrations of methane cannot be kept consistently below 0.5 % by volume (10 % LEL) in
the general body of the air, no explosives, cutting and welding equipment, abrasive disc cutters
and non-explosion-protected locomotives shall be used, and non-explosion-protected
mechanical and electrical equipment shall be shut down or disconnected.
31.5.3 Whenever a methane concentration of 1.25 % by volume (25 % LEL) or above is measured,
either in the tunnel or in an extraction ventilation duct, persons other than those essential for the
safety of others shall be withdrawn from all parts of the tunnel, and all non-essential explosion-
protected mechanical and electrical equipment must be disconnected until the concentration has
been reduced to below 1 % (20 % LEL). Persons essential for safety shall only remain in the
tunnel if the lighting, emergency lighting, communications equipment and fire detection, alarm
and extinguishing systems are of an explosion-protected type.
31.5.4If the methane concentration exceeds 2 % (40 % LEL), all persons must be withdrawn from all
parts of the tunnel and electrical power isolated by means of switchgear at the surface, apart
from the power supply to atmospheric monitoring equipment, which shall be left in operation.
Such equipment must be intrinsically safe in accordance with BS EN 50020
31.6 Sources of Ignition
31.6.1 Any flame or hot spot, or any spark or electric arc can ignite a potentially explosive gas mixture.
Hot spots can be generated by friction in machinery (including braking), by overloaded or
inadequately cooled electric cables or lamps, by faulty earthing and current leakage to earth, or
by metal cutting and grinding. Sparks can be produced by violent contact between metals and
rock. Cutting machines and similar equipment should therefore be operated at low speeds and
be cooled with water sprays or jets. Aluminium and other light metallic alloys can produce intense
sparks when struck by other metals or rock. These alloys should be completely excluded from
use in a tunnel where the presence of methane is foreseeable (see BS EN 60079-14:1997).
31.6.2 Electric arcs arise in making and breaking contact in a live circuit and from loose contacts. It is
because of such arcing that explosion-protected equipment should be used when operating in
any atmosphere known to contain methane at a concentration above the limits in 12.5. Electric
sparks can be generated by static electric charges that build up on insulating materials subject
to friction, such as rubber belting, nylon and other non-metallic materials. Static charges are also
produced, for example, when compressed air is used for the pneumatic handling of dry materials
(see BS 5958-1).
31.7 Explosion Protection
31.7.1The use of electrical apparatus/equipment and systems (both explosion-protected and non-
explosion-protected) under conditions where a hazard could arise from the presence of a

potentially explosive atmosphere, e.g. due to the presence of methane, shall only be permitted
after a full assessment of the risks involved. BS EN 60079-10 and BS EN 60079-14 give
recommendations for the selection, installation and maintenance of electrical apparatus in
potentially explosive atmospheres for applications other than mining.
31.7.2Where explosion-protected equipment is being used, all switchgear, cables and joints associated
with the equipment but not part of it, shall also be appropriately explosion-protected.
31.7.3When explosives are being used where the presence of methane is possible, specialist advice
must be obtained and a full assessment made.
32.0 House keeping
32.1.1Housekeeping is the act of keeping the working environment cleared of all unnecessary waste,
thereby providing a first-line of defence against accidents and injuries. Tunnel all unnecessary
waste to be cleared at the end of each shift.
32.1.2Contractor shall understand and accept that improper housekeeping is a primary hazard in any
construction site and ensure that a high degree of housekeeping is always maintained.
32.1.3Housekeeping is the responsibility of all site personnel, and line management commitment shall
be demonstrated by the continued efforts of supervising staff towards this activity. Violation may
result in suspension of the activity.
32.1.4General Housekeeping shall be carried out by the contractor and ensured at all times at the Work
Site, Tunnel, Construction Depot, Batching Plant, Labour Camp, Stores, Offices and
toilets/urinals. Towards this the Contractor shall constitute a special group of housekeeping
personnel. This group shall ensure daily cleaning at work sites and surrounding areas and
maintain a register for inspection at the Employer / Engineer request
32.1.5Adequate time shall be assigned to ensure that good housekeeping is maintained. This shall be
carried out by the housekeeping team. All combustible refuse should be removed from a tunnel
as frequently as practicable.
32.1.6The contractor shall be responsible to provide segregated containers for disposal of debris at
required places and regular cleaning of the same.
32.1.7Full height fence, barriers, barricades etc. shall be erected around the site in order to prevent
the surrounding area from excavated soil, rubbish etc, which may cause inconvenience to and
endanger the public. The barricade especially those exposed to public shall be aesthetically
maintained by regular cleaning and painting as directed by the Employer / Engineer. These shall
be maintained in one line and level.
32.1.8The structure dimension of the barricade, material and composition, its colour scheme, CMRL
logo and other details shall be in accordance with specifications laid down in tender document
or approved drawing.
32.1.9All stairways, passageways and gangways shall be maintained without any blockages or
obstructions. All emergency exits passageways, exits fire doors, break-glass alarm points,
firefighting equipment, first aid stations, and other emergency stations shall be kept clean,
unobstructed and in good working order.

32.1.10Lumber with protruding nails shall be either bent or removed and properly stacked. Un-packed
wooden strips shall be safely stored and disposed.
32.1.11All surplus earth and debris are removed/disposed off from the working areas to officially
designated dumpsites. Trucks carrying sand, earth and any pulverized materials etc. in order to
avoid dust or odour impact shall be covered while moving. The tyres of the trucks leaving the
site shall be cleaned with water, wherever the possibility of spillage on carriageways meant for
regular road traffic exists.
32.1.12No parking of trucks/trolleys, cranes and trailers etc. shall be allowed on roads, which may
obstruct the traffic movement.
32.1.13Roads shall be kept clear and materials like: pipes, steel, sand boulders, concrete, chips and
brick etc.
32.1.14Wheel washing facilities shall be available on the sites for washing down the spoil removal
trucks and the concrete delivery vehicles
32.1.15Proper and safe stacking of material are of paramount importance at yards, stores and such
locations where material would be unloaded for future use. The storage area shall be well laid
out with easy access and material stored / stacked in an orderly and safe manner.
32.1.16Flammable chemicals / compressed gas cylinders shall be safely stored.
32.1.17Unused/surplus cables, steel items and steel scrap lying scattered at different places within the
working areas shall be removed to predetermined locations(s).
32.1.18All wooden scrap, empty wooden cable drums and other combustible packing materials, shall
be removed from work place to identified location(s).
32.1.19Empty cement bags and other packaging material shall be properly stacked and removed.
32.1.20The Contractor shall ensure that all his sub-contractors maintain the site reasonably clean
through provisions related to housekeeping.
33.0 Work at Height
33.1 Organisation and planning

33.1.1The contractor shall ensure that work at height is;
i) Properly planned for any emergencies and rescue
ii) Appropriately supervised; and
iii) Carried out in a manner which is practicable.
33.1.2The contractor shall ensure that work at height is carried out only when the weather conditions
do not jeopardise the health or safety of persons involved in the work.
33.2 Competence

33.2.1The contractor shall ensure that no person engages in any activity in relation to work at height
unless he/she is competent to do so or as defined by suitable knowledge, training and
experience.
33.3 Avoidance of risks from work at height
33.3.1The contractor shall ensure that work is not carried out at height where it is reasonably
practicable to carry out the work safely otherwise than at height.
33.3.2Where work is carried out at height, the contractor shall take suitable and sufficient measures as
given below to prevent, so far as is reasonably practicable, any person falling a distance liable
to cause personal injury.
(a) Ensuring that the work is carried out
(i) From an existing place of work; or
(ii) (in the case of obtaining access or egress) using an existing means, complying to the
requirements where it is reasonably practicable to carry it out safely and under appropriate
ergonomic conditions; and
(b) Where it is not reasonably practicable for the work to be carried out in accordance with sub-
paragraph (a), his providing sufficient work equipment for preventing, so far as is reasonably
practicable, a fall occurring.
33.3.3Where the measures taken do not eliminate the risk of a fall occurring, every contractor shall;
(a) So far as is reasonably practicable, provide sufficient work equipment to minimise;
(i)The distance and consequences; or
(ii)Where it is not reasonably practicable to minimise the distance, the consequences, of a
fall; and
(b) Without prejudice to the generality, provide such additional training and instruction or take
other additional suitable and sufficient measures to prevent, so far as is reasonably practicable,
any person falling a distance liable to cause personal injury.
33.4 Selection of ‘work equipment’ for work at height
(1)The contractor, in selecting work equipment for use in work at height, shall
a) Give collective protection measures priority over personal protection measures; and
b) Take account of
i)The working conditions and the risks to the safety of persons at the place where the work
equipment is to be used;
ii)In the case of work equipment for access and egress, the distance to be negotiated;
iii)The distance and consequences of a potential fall;
iv)The duration and frequency of use;
v)The need for easy and timely evacuation and rescue in an emergency; and
vi) Any additional risk posed by the use, installation or removal of that work equipment or
by evacuation and rescue from it;
(2)The contractor shall select work equipment for work at height which:
a) Has characteristics including dimensions which:

(i) Are appropriate to the nature of the work to be performed and the foreseeable
loadings; and
(ii) Allow passage without risk; and
34.0 Slipping, Tripping, Cutting, Drowning and Falling Hazards
i) All places should be free from dust, debris or similar materials.

ii) Sharp projections or any protruding nails or similar objects shall be suitably guarded
or shall even be avoided to make the place safe to work.
iii) Contractor shall not allow workmen to work or use platforms,
scaffolds/passageways or any walkways, which has water, or oil or similar substances
spilt and has a slipping hazard, unless it is cleaned off or covered off or sanded or saw
dusted or make it safe with any suitable material.
iv) When workers are exposed to areas where fall into water is possible, the contractor
shall provide suitable and adequate equipment for saving the workers from drowning and
rescuing from such hazard. If the Employer / Engineer considers,
the contractor shall provide well-equipped boat or launch, manned with trained personnel
at the work place.
v) Open side or opening where worker, equipment, vehicle or lifting appliance may fall at
a building or outside shall be guarded suitably except in places of free access by reasons
of nature of work.
vi) Suitable safety net shall be provided at places of material / man falling is possible in
accordance with national standards
35.0 Lifting Appliances and Gear
35.1.1Lifting appliances means a crane, Piling Rig, hoist machinery, derrick, winch, gin pole, sheer
legs, jack, hoist drum, slewing machinery, slewing bearing fasteners, luffing machinery sheaves,
pulley blocks, hooks or other equipment used for lifting materials, objects or building workers
and lifting gears means ropes, chain slings, shackles, hooks, lifting lugs, wire ropes, lifting
eyebolts and eye-nuts and other accessories of a lifting appliance.
35.1.2No machine shall be selected to do any lifting on a specific job until a suitable lift plan relative to
lift type is produced incorporating the size and characteristics against:
i) The weights, dimensions and lift radii of the heaviest and largest loads
ii) The maximum lift height, the maximum lift radius and the weight of the loads that must
be handled at each
iii) The number and frequency of lifts to be made
iv) How long the crane will be required on site?
v) The type of lifting to be done for example, is precision placement of loads important?
vi) The type of carrier required and axle loads
vii) Whether loads will have to be walked or carried
viii) Whether loads will have to be suspended for lengthy periods

ix) The site conditions, including the ground where the machine will be set up, access roads
and ramps it must travel, space for erection and any obstacles that might impede access
or operation
35.1.3The contractor shall ensure that a valid certificate of fitness is available for all lifting appliances.
35.1.4A copy of fitness certificate issued by an approved body, operators’ photo, manufacturer’s load
chart and competency certificate must be either kept in the operator cabin or pasted on the
visible surface of the lifting appliances but not on windows where visibility of the operator may
be restricted.
35.1.5All lifting appliances and loose gears shall be clearly marked for its safe working load and
identification by stamping or other suitable means.
35.1.6The contractor shall also maintain a register containing a system of identification of all ancillary
lifting equipment, its date of purchase, safe working load, competent person date of examination
etc.
35.2 Test and periodical examination of Lifting Appliances and Ancillary Lifting Equipment
35.2.1All lifting appliances including all parts and gears thereof, whether fixed or movable shall be
thoroughly tested and examined by a competent person once at least in every three months or
after it has undergone any alterations or repairs liable to affect its strength or stability. Within the
validity, if the lifting appliances are shifted to a new site, re-examination by the same competent
person for ensuring its safety shall also be done.
35.2.2Contractors can utilise the services of any competent person as defined in BOCW Act, 1996 or
Factories Act, 1948, approved by corresponding act approving authority with the Notice of no
objection from the Employer / Engineer.
35.2.3 All alarms and signals like automatic safe load indicators (ASLI), boom angle indicators, boom
extension indicators, over lift boom alarm, swing alarm, hydraulic safety valves, mechanical
radius indicators, load moment indicators etc. shall be examined weekly by the operator. All
devices shall be maintained in good working condition.
35.3 Automatic safe load indicators

35.3.1Every lifting appliances and gears like cranes, hydras etc, if so constructed that the safe working
load may be varied by raising or lowering of the jib or otherwise shall be attached with an
automatic indicator of safe working loads approved by Bureau of Indian standards/ International
certifying bodies which gives a warning to the operator and arrests further movements of the
lifting parts.
35.4 Qualification of operator of lifting appliances and of signaller etc
35.4.1The contractor shall not employ any person to drive or operate a lifting machine-like crane, hydra,
Piling Rig etc whether driven by mechanical power or otherwise or to give signals to work as a
operator of a rigger or derricks unless he
i)Is above twenty-one years of age and possesses a valid heavy transport vehicle driving licence
as per Motor Vehicle Act and Rules.
ii)Is competent and reliable

iii)Possesses the knowledge of the inherent risks involved in the operation of lifting appliances
by undergoing a formal training at any institution of national importance acceptable to Employer
/ Engineer
iv)Is medically examined periodically as specified in schedule VII of BOCW Rules.
35.5 General requirements of appliances
35.5.1Out-of level
35.5.2One of the most severe effects of being out-of fit level is that side loads develop in the boom.
Because of side loads all mobile cranes lose capacity rapidly as the degree of out-of-level
increases and therefore;
35.5.3Boom
i) The boom elements of the crane must be in perfect condition at all times. No boom section
with a bent lattice member shall be allowed
ii) All welds shall be crack and corrosion free
iii) No member of the boom shall be bent
iv) All telescopic boom shall be free from cracks, rust, flaking or cracked paint etc
35.5.4The sweep area (work area) of the construction machinery shall be always free from
obstructions.
35.5.5 All hydraulic piping and fittings shall be maintained leak proof.
35.5.6 The operator cab shall posses good and safe:
i) structure, windows and windshield wipers

ii) Drivers chair and foot rest
iii)Control handles
iv)Cab instrumentation
v)Telecommunication
vi) Cab out fitting
vii) wind indicator with an adjustable set point shall be in a position representative for the wind
on the crane. The indicator shall give continuous information regarding constant speeds and
gusts.
35.6 Mandatory rigging requirements
35.6.1Rigging shall be done under experienced and qualified rigger only.
35.6.2The primary requirement in rigging shall be to assess the weight of load before attempting any
lift.
35.6.3All hooks shall be fitted with Master Rings having certificate of fitness from the competent person,
so that the hooks are subjected to balanced vertical loading only.
35.6.4Only four legged slings shall be allowed which includes master link (ring), intermediate master
link (ring) if necessary, chain / wire rope sling, sling hook or other terminal fitting.

35.6.5Hand spliced slings shall not be used at site for any lifting purpose.
35.6.6No load shall be slewed over public areas without stopping the pedestrians and road traffic first.
35.6.7Requirements of outriggers
i) All outriggers shall be fully extended and at all tyres are clear of the ground
ii) Heavy duty blocking having large bearing area shall be required
35.6.8All loads shall have tag-lines attached in order to ensure that the load can be controlled at all
times.
35.6.9No close working to any live overhead power line is permitted without the operation of a strict
Permit to Work.
35.6.10Minimum lighting is to be ensured at all lifting operations.
35.6.11Failure to do any of the above shall attract penalty from the Employer / Employer’s
Representative as per relevant clause.
36.1 Construction machineries may include dumpers and dump trucks, lift trucks and telescopic
handlers piling rigs, vibro hammers, rail welding equipments, mobile elevating work platforms,
cranes, tipper lorries, lorry loaders, skip wagons, 360° excavators, 180° backhoe loaders,
crawler tractors, scrapers, graders, loading shovels, trenchers, side booms, pavers, planers,
chippers, road rollers, locomotives, tankers and bowsers, trailers, hydraulic and mechanical
breakers etc.
36.2 Safe worthiness certificate
36.2.1All construction equipment shall be in sound mechanical working condition and certified by either
competent person under Factories Act or manufacturers’ warranty in case of brand new
equipment or authorized persons / firms approved by Employer / Engineer before induction to
any site.
36.2.2 Every such certificate shall have the date of purchase, main overhauling undertaken in the past,
any accident to the equipment, visual examination details, critical components safety check, list
of safety devices and its working condition, manufacturer's maintenance checklist, past projects
wherein the equipment’s were used etc. as its minimum content.
36.3 Reverse Horns
36.3.1All Vehicles shall be fitted with audible reverse alarms/camera and maintained in good working
condition. Reversing shall be done only when there is adequate rear view visibility or under the
directions of a banksman.
36.4 General operating procedures

i)Drivers entering site shall be instructed to follow the safe system of work adopted on site. These
shall be verbal instructions or, preferably, written instructions showing the relevant site rules, the
site layout, delivery areas, speed limits, etc.
ii)No passengers shall be carried, unless specific seating has been provided in accordance with
the manufacturer’s recommendations.
iii)Working on gradients beyond the equipments capability shall not be permitted.
iv)Prevention of dumper and dump truck accidents should be managed by providing wheel stops
at a sufficient distance from the edges of excavations, spoil heaps, pits, etc.
v)The manufacturer’s recommended bucket size must not be exceeded in excavators.
vi)If excavators operating on a gradient which cannot be avoided, it must be ensured that the
working cycle is slowed down, that the bucket is not extended too far in the downhill direction,
and that travel is undertaken with extreme caution. A large excavator must never be permitted
to travel in a confined area, or around people without a banksman to guide the driver, who should
have the excavator attachment close in to the machine, with the bucket just clear of the ground.
On wheeled excavators, it is essential that the tyres are in good condition and correctly inflated.
If stabilizing devices are fitted, they should be employed when the machine is excavating.
vii)When the front shovel of the 1800 backhoe loaders is being employed, the backhoe attachment
shall be in its “travel” position, with the safety locking device in place.
viii)When operating the backhoe in poor ground conditions, the stabilisers tend to sink into the
surface of the ground, reducing stability. Therefore, frequent checks shall be made for the stability
of the machine. The loading shovel should always be lowered to the ground to stabilise the
machine when the backhoe is employed.
ix)The netting operation of the skip wagons should be carried out prior to lifting the skip to reduce
the risks of working on the rear platform.
x)If a tractor dozer is employed on clearing scrub or felling trees, it shall be provided with adequate
driver protection from rollover and falling objects.
xi)When two or more scrapers are working on the same job, a minimum distance of at least 25m
shall be kept between them.
NOTE: All wood working machines shall be fitted with suitable guards and devices such as top
guard, riving knife, push-stick, guards for drive belts and chains, and emergency stop switch
easily accessible by the operator.
36.5 Penalty
36.5.1If any of the above clauses are not adhered, penalty shall be imposed as per relevant clause
depending upon the gravity of the unsafe act and or condition.
37.0 Machine and general area guarding

37.1 The contractor shall ensure at the construction site all motors, cogwheels, chains and friction
gearing, flywheels, shafting, dangerous and moving parts of machinery are securely fenced or
legged. The fencing of dangerous part of machinery must not be removed while such machinery
is in motion or in use.
38.0 Electrical
38.1 General
38.1.1All electrical equipment and installations shall be so constructed, installed, maintained, protected
and used as to prevent danger. Electrical equipment and its installation should be in compliance
with relevant national, CEN, CENELEC and ISO standards, and national regulations.
38.1.2Electrical equipment in the tunnel is exposed to mechanical damage and a range of adverse
environmental factors including temperature, pressure, humidity, dust, the effects of blasting and
potentially explosive gases. It shall be appropriately protected from such exposure. Protection
against ingress of dust and moisture shall be to a minimum of IP 65.
38.1.3Electrical installations should be inspected and tested by a competent person after

commissioning or, modification and thereafter at regular intervals thereafter and the results of the
inspection or test should be recorded.
38.1.4Only persons who are competent should be responsible for the operation and maintenance of
electrical installations.
38.1.5Where there are no national guidelines for assessing competence, the following criteria shall be
used.
• appropriate level of knowledge of electrical engineering principles;

• experience of electrical installation work;
• understanding of the installation to be worked on and practical experience of that work;
• understanding the hazards which can arise during the work and the precautions to be
observed;
• ability to recognize at all times whether it is safe to continue working.
38.1.6All the relevant technical documentation concerning the installations and the electrical equipment
on site should be available on site.
38.1.7To prevent accidents caused by people switching on electrical equipment while others are
working it, switches should be locked out with a lock-out device and a padlock. The padlock keys
should be under control of the person doing the work.
38.1.8Site specific guidelines should be prepared covering the operation and maintenance for electrical
equipment and be made available to the appropriate persons working in the tunnel. These
persons should also know the steps to take in the event of electric power outage as well as the
relevant safety precautions.
38.1.9The guidelines should include:
• details of the competent person(s) responsible for electrical equipment;

• description of electric equipment and personal safety precautions;
• recommended working techniques and the necessary personal skills;
• potential risk identification;
• inspection periods;

• details of periodic inspections of electric equipment, maintenance strategy and

maintenance intervals.
• procedures to prevent potential electric energy failures including the provision of back-
up supplies.
• outline accident plans for dangerous exposures such as fire, absence air ventilation,
failures of dewatering pumps, lighting etc.,
38.1.10Steps should be taken to restrict the effect of electrical energy on the surrounding construction
work and installation is including.
•Protective zones and recommended stand-off distances from existing plant, overhead
lines and cables within the high voltage distribution work;
• Prevention of premature detonation of explosives by using non electric detonators
when necessary (e.g. with effects of stray earth currents, electrostatic discharges and
atmospheric electric energy);
38.1.11Recommendations for placing and laying of firing wires.
• Standby power should be provided, from an independent mains circuit by diesel

generators, where a power failure could endanger lives e.g. compressed air work,
failure of dewatering pumps, failure of ventilation fans or fire-fighting pumps etc.
• Electrical installations should be so planned that safety critical circuits are not broken
when other circuits are disconnected or fail.
38.1.12Power supply cables should be fire-retardant and should produce low smoke and fumes
(especially halogen gases) when involved in a fire.
38.1.13All power cables should be subjected to an earth continuity test at 3-monthly intervals and
immediately after any alterations, extensions or damage to the cable concerned
38.1.14Details of all tests carried out should be recorded, including date of test, voltages recorded etc
39.0 Electricity
39.1.1Designs of electric equipment must be compliant with the environment and site where the
equipment is operated, especially with respect to electric current accidents and potentially
explosive atmosphere.
39.1.2The main causes of electric current accidents are:
• accidental contact with live parts;

• defective equipment or installations
• fault in a protective conductor in the circuit or equipment;
• other undesired effects of electric current.
39.1.3All installations should be protected against overload and short-circuit by automatic disconnection
from the supply. Continuity of earth protection should be ensured.
39.1.4The circuits for portable equipment, accessories and lighting should comply with Clause 16 of EN
60204 – 1 : 1997 with the addition of the following measures to mitigate the problems associated
with electrical equipment in a tunnel environment. These should include the use of a residual
current protective device with a fault current rating of a maximum of 30 MA or the use of a 110
volt centre earth tap supply. Control circuits should comply with Clause 9 of EN 602204-1:1997,
with the addition for handheld pendant controls, that they should operate at control voltages not
exceeding 24 volts. Low voltage supplies are those from 50 V AC to 1000 V AC. High voltage
supplies are those above 1000 V AC.

39.1.5Underground electric equipment should be located in such a manner that is protected against
mechanical damage but remains readily accessible to operating and maintenance personnel.
39.1.6A competent electrical engineer shall produce a written scheme for the methods and frequency
of inspection and maintenance requirements.
39.1.7Regular visual inspection should be undertaken to check that
i)Electric installations and cabling are not damaged or misused;
ii)Functionality of protection against accidental contract are in place (earth leakage circuit
breaker, residual current circuit breakers, protective grounding systems, enclosure, etc.);
iii)There is sufficient working space around the electric equipment.
iv)The underground lighting including emergency lighting works properly.
v)Electric equipment which is unintentionally disconnected, should not be repowered until the
relevant cause has been identified and any defect repaired.
39.1 Cables:
39.1.1Cables for use underground should be selected and installed in accordance with Indian Electricity
Act 2003 and Rules 1956. They should be appropriately sized for the expected duty.
39.1.2 Where cables are buried, markers should be installed to clearly show the position of cables.
39.1.3The voltage drop between the point of supply and any electric installation should not be greater
than 10% of the nominal voltage. If the cable length makes the voltage drop greater it is necessary
to alter the electric power transmission parameters, for example by transformation to a higher
voltage.
39.1.4High voltage cables are used in tunneling and such cables must be properly supported and
protected against mechanical damage and abrasion. Care should be taken when laying out
cables to avoid introducing twists in the cables which could damage the insulation internally.
Protection against fire damage should also be considered.
39.1.5 Cables should be insulated with materials that will not emit toxic gases or smoke when they burn.
39.1.6 Joints and connections should be suitable for the tunnel environment. Normal cable joints not
permitted. Industrial Plug and Top to be used.
39.1.7No loose cable shall be running on ground.
39.2 Substations and Switchgear

39.2.1Substations, distribution boards, cables, switches and circuit breakers should be dimensioned to
accept the currents and voltages that might foresee ably occur at the particular site during various
operational states.
39.2.2Only competent persons should enter a substation.

39.2.3Electric substations and switchgear should be, equipped by safety plates and inscriptions, and
fixed fire extinguishing systems.
39.2.4Oil filled circuit breakers, switchgear and transformers should not be used underground to
minimize fire load. Vacuum and air switches are to be preferred.
39.2.5Switchgear and distribution boards should be protected against damage. installation and
distribution boards should have sufficient clear working space to allow for operation and
maintenance. Switchgear and control cabinets on TBMs should not open on to walkways.
39.2.6Portable hand-held tools and apparatus should be double-insulated or should be used in

conjunction with residual current circuit breakers with the rates residual current not exceeding 30
mA.
39.2.7Effective means should be provided for every high voltage circuit to prevent danger arising from
earth leakage currents.
39.2.8Earth-fault protection can be used in an isolated system. Any fault current should by signaled in
case the trip fails to disconnect the power automatically.
39.2.9Every circuit or cable should be clearly marked at regular intervals with a unique reference which
allows its function and route to be identified from the operating manuals for the installation.
39.3 Electrical Installations

39.4 Earthing
39.4.1The earthing bonding system must meet the earthing wire mechanical strength requirements and
accidental contact protection conditions and be accessible to visual inspection with the exception
of structure earthing.
39.4.2All neutral parts of any electric circuit which require earth protection and all conductive structures
in the tunnel (pipelines, rails, etc.) should be adequately earth bonded, Continuity of earthing
should be checked periodically.
39.4.3It is advisable that earth leakage protection be provided to the following standards:
• Voltage of or above 1000 V – leakage current not exceeding 5 A or 15% of maximum

earth fault current.
• Higher than distribution nominal low voltage leakage current not exceeding 750 MA
• Distribution nominal low voltage – leakage current or core balance current not
exceeding 300 mA for extensive electricity distribution lines, portable equipment and
fixed lighting.
• Residual current not exceeding 30 mA for portable hand tools and apparatuses.
39.5 Transformers
39.5.1Transformer enclosures and switch rooms containing exposed conductors should be locked
when the equipment is live unless access for operating purposes is required. The keys should
be held by an authorized person.
39.5.2Preferably only transformers with air-cooling or non-flammable coolants should be used

underground.

39.5.3Enclosure of the transformer and its location should take into account local operating and
environment conditions.
39.5.4Safe means of access and adequate working space should be provided for inspection,
maintenance and emergency purposes.
39.5.5Suitable fire extinguishers should be provided at all transformer locations. Fire extinguishers
should be mounted externally and their locations indicated with relevant safety symbols.
39.5.6Appropriate safety signs should be provided adjacent to all electrical installations.
39.5.7They should be a means of isolation on the primary side of any transformer unit which should
preferably be by an integral isolator and for high voltages should be of the air-break or vacuum
contractor.
39.5.9Any external tap change selector should be securely locked in the selected position.
40.0 Diesel Engine
40.1 Diesel engines weather for haulage or other mobile equipment or stationery plant should not be
used unless adequate provision has been made for ventilation.
41.0 Hydraulic Plant
41.1.1Hydraulic oil whose Flash point exits working temperatures likely to be encountered should be
used underground
41.1.2Only high temperature hose and coupling should be used and the lines should be properly
protected
41.1.3 Hydraulic lines working at temperatures exceeding 70°Celsius should be protected by insulation
or other screening against accidental human contact.
42.1 General
42.1.1The contractor is wholly responsible for the safe condition of tools and equipment used by his
employees and that of his sub-contractors.
42.1.2Use of damaged hand tools shall be avoided and the contractor shall ensure all his hand tools
used at his worksite are safe to work with or stored and shall also train his employees (including
his sub-contractors) in their correct use.
42.1.3All hand tools and power tools shall be duly inspected before use for signs of damage.
42.1.4All hand tools and power tools shall have sufficient grip and the design specification on par with
national/international standards on anthropometrics.
42.2 Hand tools
42.2.1Hand tools shall include saws, chisels, axes and hatches, hammers, hand planes, screw drivers,
crow bars, nail pullers, scaffolders podge etc.
42.2.2The contractor shall ensure that,

i) For crosscutting of hardwood, saws with larger teeth points (no. of points per inch) shall be
preferred to avoid the saw jumping out of the work piece.
ii)Mushroom headed chisels shall not be used in the worksite where the fragments of the
head may cause injury.
iii)Unless hatchet has a striking face, it shall not be used as a hammer.
iv)Only knives of retractable blades shall be used in the worksite.
v)No screwdrivers shall be used for scraping, chiselling or punching holes.
vi)A pilot hole shall always be driven before driving a screw.
vii)Appropriate PPE shall be issued to the workforce as dictated by the equipment and
manufacturers recommendations.
42.3 Power tools
42.3.1Power tools include drills, planes, routers, saws, jackhammers, grinders, sprayers, chipping
hammers, air nozzles and drills.
42.3.2The contractor shall ensure that
i) Electric tools are properly grounded or / and double insulated.
ii)GFCIs/ RCCBs shall be used with all portable electric tool operated especially outdoors or in
wet condition.
iii)Before making any adjustments or changing attachments, the tool shall be disconnected
from the power source.
iv)All drills shall have suitable attachments respective of the operations and powerful for ease
of operation.
v)Tools shall be specifically designed for that work that shall be undertaken.
vi)Workers shall not stand on the top of the ladder to drill holes in walls / ceilings.
vii)Electric plane shall not be operated with loose clothing.
viii)Safety guards used on right angle head or vertical portable grinders must
cover a minimum of 1800 of the wheel and the spindle / wheel specifications shall be checked.
ix)All power tools / hand tools shall have guards at their nip points.
x) safety chain shall be used in case of wood working machines and the saw shall run at high
rpm when cutting to “kickback”.
xi)Leather aprons and gloves shall be used as an additional personal protection auxiliary to
withstand kickback.
xii)Push sticks shall be provided and properly used.
xiii) Air pressures are to be set at a suitable level for air actuated tool or equipment being used.
Before changing or adjusting pneumatic tools, air pressure shall be turned off.
xiv) Only trained employees shall use explosive actuated tools and the tool must also be
unloaded when not in use.
xv) Usage of such explosive actuated tools shall be avoided in case of places where
explosive/flammable vapours or gases may be present.

xvi) Explosive actuated tools and their explosives shall be stored separately and be taken out
and loaded only before the time of immediate use.
xvii) Misfired cartridges of explosive actuated tools must be placed in a container of water and
be removed safely from the project.
xviii) No worker shall point any power operated / hand tool to any other person especially during
loading / unloading.
43.0 Work Permit System
43.1.1The Contractor shall develop a Work Permit System for areas as identified within the risk register
and hazard log.
43.1.2A permit is needed when construction work can only be carried out if normal safeguards are
dropped or when new hazards are introduced by the work. Examples of high-risk activities
include but are not limited to:
i)Entry into confined spaces
ii)Work in close proximity to overhead power lines and telecommunication cables.
iii)Hot works.
iv)Breaking ground / To dig
v)Work with heavy moving machinery.
vi)Working on electrical equipment
vii)Work with radioactive isotopes.
viii)Heavy lifting operations and lifting operations closer to live power line
43.1.3The permit-to-work system should be fully documented, laying down:
i)How the system works;
ii)The jobs it is to be used for;
iii)The responsibilities and training of those involved; and
iv)How to check its operation;
43.1.4A Work Permit authorisation form shall be completed with the maximum duration period not
exceeding 12 hours.
43.1.5A copy of each Permit-To-Work shall be displayed, during its validity, in a conspicuous location
in close proximity to the actual works location to which it applies
44.0 PPE’s -Personnel Protective Equipment
44.1 General
44.1.1PPE’s serves as an additional measure to ensure safety where it is not possible to improve the
environment by engineering means, e.g. reduce noise to an acceptable level to obviate use of (ear)
hearing
44.1.2Personnel Protective Equipment should be provided, e.g. hard hats, high visibility overalls,
adequate foot protection, hearing protection, eye protection, respiratory protection.
44.1.3Means of identifying and accounting for personnel in an emergency situation.

44.2 Items of equipment to be provided:

44.2.1Hard hats for head protection should be issued to every person entering the works and the
wearing of hard hats should be mad compulsory.
44.2.2During shotcreting operations eye protection should be worn.
44.2.3Where noise levels exceed the threshold limits and levels cannot be reduced then hearing
protection should be used, e.g. ear muffs or ear plugs.
44.2.4Under all conditions where dust levels are high or where specified by local statutory requirements,
appropriate respiratory protective equipment should be used, e.g. during shotcreting operations.
44.2.5All underground workers should be provided with safety boots of acceptable quality. Such boots
should be suitable for both dry and wet conditions.
44.2.6Hand protection in the form of gloves should be provided where the type of work requires some
form of protection. A general-purpose type of glove may be adequate for most types of work but
special conditions would require special gloves, e.g. special gloves required for welding
operations.
44.2.7High visibility clothing including waterproof clothing, should be provided and used by all workers
underground.
44.2.8Cap lamps should be issued to all persons entering the underground works except where
adequate lighting and emergency lighting systems are installed. The minimum operating time
should be 12 hours.
44.2.9Recharging facilities should be provided.

44.2.10A register of each cap lamp issued should be kept in which the condition of lamps is recorded.
44.2.11DGMS approved 60 minutes self-rescuers should be issued to each worker underground. They
should always be carried by the worker or in close proximity to his working place.
44.2.12Where necessary, double Lanyard safety harnesses with shock absorber should be provided
and used for persons working unprotected at height.
45.0 Shafts and Hoist
45.1.1Shafts should be properly lined all openings at the top of shafts or other openings to ethanol must
be above the highest possible water level surrounding protective blanks must be constructed and
maintained at a safe level and protected against being watched
45.1.2Shafts of small diameter which workers are required to enter should be provided with steel casing
concrete pipe symbol showing or other material of adequate strength to support surrounding
Earth
45.1.3The casing and bracing should be provided for the full death of the shaft or at least 1.52 m (5 ft)
into solid rock and should extend at least 300 mm (1 ft) above ground level or to a sufficient
height to prevent flood water from entering
45.1.4For any shaft over 20 m (65 ft) deep, a hoist should be used for the transport of men and
materials. Reinforced concrete wraps or beams spanning any sensitive area should be provided
if the ground distance is locally inadequate

46.0 Rail Haulage
46.1.1A Minimum lateral clearance of 500 mm (20”) Should be maintained between any part of vehicle
and any fixture or equipment after allowing for through and swing.
46.1.2The overhead clearance for locomotive drivers should not be less than 1.1m (43") about the seat
where the driver 6 and not less than 2m (6.5ft) about the food plate where the driver stands.
46.1.3To provide protection for men on foot or those working adjacent to the track I level platforms or
Timber recesses should be provided at suitable points
47.0 Flooding
47.1.1Where the driving of more than one channel takes place from a shaft that should be provision for
the installation of watertight bulkhead doors. (Strict procedures to be adopted to prevent trapping
of men in isolated sections).
47.1.2Areas where there is potential inundation, especially in the case of a descending tunnel, there
should be provision for air tight steel curtains in the top half of the tunnel at appropriate intervals
to ensure the retention of pockets of air within which men can survive until last air pressure is
restored or men rescued.
47.1.3The following are the minimum requirement of Emergency Equipment shall be available at site.
S.No Equipment & Minimum qty

1. Motor Trolleys – 2 No.
2. Dip Lorry – 1 No.
3. Re-railing vehicle and Re-railing Equipment – 1 Set
4. Gas cutting equipment – 1 No.
5. Search Lights – 2 No.
6. Track continuity Jumpers – 2 No.
7. Fire Extinguishers – 3 No.
8. Hand Signals / Flags – 1 No.
9. Crank handle key, Clamps and Pad locks – 1 No.
10. First Aid Kits – 1 No. per station
11. Stretchers – 1 No. per station
12. Wheel Chair – 2 No. per station
13. Pick Axe - 2 No,
14. Self Contained Breathing Equipment – 2 No.
15. Inflatable tents – 1 No.
16. Collapsible lighting tower – 1 No.
17. Inflatable Air Bags – 2 No.
18. Automatic Spring loader – 1 No.
19. Track measuring gauges – 1 No.
20. Augmented First Aid Boxes – 2 No.
21. Wrist bands – As required
22. High visibility vests – As required
23. High Power torches – 2 No.
24. Nylon slings of 40 T capacity – 1 Set
25. Video Cameras – 1 No.
26. Tetra Sets, as required
27 Pumps
25HP -03 Nos
10HP -05 Nos
05 HP -05 Nos

03HP -05 Nos
48.0 Illumination
48.1 General
48.1.1The methods of lighting and levels of illumination in all parts of the tunnel and works should meet
the requirements of Clause 20.7 of OH&S Manual Volume-2.
48.1.2All working areas should be constantly illuminated throughout their length to an intensity of
110(10) lux(Im/ft2) at floor level.
48.1.3Adequate fixed lighting should be provided at all established stations, working faces, landing and
loading places and other similar places in vertical and inclined shafts, tunnels and underground
workings, and at night at all places on surfaces where work is being carried out.
48.1.4 Where static machinery is used, the area should be illuminated so that the external moving parts
of such machinery are clearly visible.
48.1.5When work is taking place under potentially explosive atmosphenic conditions, only an explosion
protected light or lamp, approved by the appropriate Authority, shall be permitted underground.
48.1.6Emergency lighting system should be provided.
49.0 Ventilation
49.1 General
49.1.1A purpose-built forcing, exhausting or circulation ventilation system should be employed,
depending on the contaminants which have to be rendered harmless.
49.1.2The concentration of oxygen, dust, toxic or potentially explosive fumes or harmful gases in the
tunnel atmosphere should be routinely monitored and steps taken as necessary to ensure
contaminant levels do not exceed those laid down by national legislation or guidance. Where a
specific work activity known to generate significant contamination, such as welding, is being
carried out, local monitoring should be undertaken.
49.1.3As a guide, the quantity of air supplied or extracted from the face should be such that the average
flow in the full cross section of the tunnel or shaft should be between Minimum fresh air supply
of 0.3 m3/min per person and additional supply of at least 3 cub. m /min per working kilowatt.
49.1.4The fresh air supplied in such tunnel is not less than six cubic metres per minute for each building
worker employed underground in such tunnel and the free air-flow movement inside such tunnel
is not less than nine metres per minute.
49.1.5The Contractor shall maintain a record of the air quality, the location, date, time, substances and
amount monitored.
49.1.6Ventilation air entering a tunnel should be free from dust, smoke or other impurity.
49.1.7The level of oxygen in the confined space is within the range of 19.5% to 23.5% by volume
49.1.8Gas monitoring shall be conducted by a competent confined space assessor to certify that the
confined space is safe for workers to enter and thereafter at every four-hour intervals
49.1.9the levels of toxic substances in the atmosphere of the confined space do not exceed the
permissible exposure levels as specified in Table 6 of BS 6414 :2011

49.1.10The wet globe bulb temperature should not exceed 270C. Ventilation can be used as a means
of removing excess heat from the workings.
49.1.11To minimize dust generation, wet drilling techniques should be used in a tunnel in preference to
drilling machines fitted with appropriate dust collection equipment. Other machines and
processes creating dust should be fitted with appropriate dust suppression and collection
equipment.
49.1.12Diesel-driven internal combustion machines should be fitted with particulate filters. These
machines should be kept in good order and should not be left idling in the tunnel.
49.1.13In a tunnel with risk of potentially explosive atmosphere, safety critical equipment such as
firefighting equipment, pumping equipment, ventilation equipment, communications and
atmospheric monitoring equipment should be explosion protected as necessary so that it remains
operation even when potentially explosive gases are present.
49.2 Control of Contamination
49.2.1The air in tunnels should be continuously tested for oxygen concentration and the presence of
toxic gases. Tests for dust levels should be conducted at regular intervals whilst work in progress.
49.2.2Dust levels in working areas should be maintained within national limiting values of acceptable
dust concentrations. In the absence of national limits those from another country should be
adopted.
49.2.3Dates, locations, conditions and results of tests should be recorded in a register.
49.3 Oxygen Deficiency
49.3.1Accidents have occurred when workers have entered unventilated tunnels and been overcome
by lack of oxygen in the air.
49.3.2If the old workings still have forced ventilation equipment, it is essential to adequately ventilate
the works and test the return air flow before entering. No one should enter the works without
being equipped with both CO and CO2 detectors and also an oxygen monitor.
49.3.3During freezing operations where liquid nitrogen is being used, it is essential to continuously
monitor the oxygen concentration in the air as the fracturing of freezing pipe can increase the
nitrogen content of the air and result in oxygen deficiency.
49.4 Explosive Atmospheres
49.4.1Checks using electronic atmospheric monitoring equipment should always be made to ensure
that methane or other potentially explosive gas (e.g. Hydrogen) is not present in the ground to
be traversed. Tests for potentially explosive gas should be specifically carried out before
changing a face and after blasting.
49.4.2Where water (in which gas such as methane can be dissolved) or gas is expected, and probe
boreholes have been drilled, tests should be carried out to identify and quantify any gas emission
from the probe holes.
49.4.3It is strongly recommended that ventilation should be used to maintain the concentration of
methane or other explosive gas below 10% of the lower explosive limit.
49.4.4If potentially explosive gas is detected further precautions including the use of explosion protected
equipment, the use of special explosives, specific training for operators and supervisors etc
should be considered.

49.4.5In potentially explosive atmospheric conditions, water cooled engines should be preferred
because of lower surface temperatures then encountered in air cooled engines.
50.0 Underground Communication Systems
50.1 General
50.1.1Good communication throughout the works is necessary for safety and is an aid to efficiency.
50.1.2The system adopted should be chosen having regard to the size, length and complexity of the
tunnel works; the number and distribution of personnel in the works; the method of construction
to be used; the potential hazards in the tunnel; the noise level in the tunnel; the requirements of
the emergency services and the client’s requirements for the post–construction phase.
50.1.3An alternative power source should be available for the communication systems.
50.1.4Communication equipment should be well maintained and regularly tested.
50.1.5Communication cables should be adequately protected from fire and mechanical damage and
should not be located adjacent to power lines.
50.1.6Equipment should be protected against water and dust ingress to IP 65 where possible.
50.1.7Where potentially explosive atmosphere may occur, communications equipment should be
explosion protected.
50.1.8Direction to the nearest communication set should be clearly signposted. They should be sited
as near as possible to the working area, at regular intervals not exceeding 100m along tunnels,
in workshops, in the site office, and at the tops and bottoms of shafts, where compressed air
working is being carried out, additional sets will be required to link the locks and plant installation
to the site network. There should be a link to the public telephone network for emergency use.
50.1.9Communications seats should have acoustic covers or earphones should be used. Large flashing
lights are often preferable to a bell as a call sign.
50.1.10The effective communication should also be at the following locations working chamber at the face of an
excavation, first aid points, Escape routes, Emergency exits, Tunnel access points, Electrical substations,
Control and communication points, interior of each chamber of a man-lock, location conspicuous a lock
attendant's station, shaft top and those working in the shaft.
50.1.11Emergency lighting should be provided at Fire and first aid points, Escape routes, Emergency
exits, Tunnel access points, Electrical substations, Control and communication points, Locations
where particular hazards exist.
50.1.12Users of communication systems should not be exposed to traffic or other hazards.
50.1.13A pre-arranged emergency signal system should be developed (tapping on rails or pipes) for
use in emergencies.
50.1.14Any signal system adopted, whether sound or visual, shall be clearly displayed adjacent to all
telephone sets.
50.1.15 Radio systems, developed for underground work and utilising leaky feeder technology, may be
considered instead of, or in addition to other systems.
50.1.16Emergency luminaires should be installed along the tunnels intervals of not more than 50 m
50.1.17The condition of the emergency luminaires should be regularly checked

51.0 Noise and vibration

51.1 General
51.1.1 Noise can contribute to hazards in construction by:
a) Immediate effects on hearing, e.g. temporary shift of individuals’ hearing threshold, tinnitus;
b) Failure to hear some sounds because of hearing damage;
c) Causing poor intelligibility of speech;
d) Impairing communication and the perception of warning alarms and signals;
e) Distracting persons from safe systems of work.
51.1.2The effects of noise are intensified in tunnels because the confined space increases the
reverberant sound field that can be developed by noisy plant and equipment, tools or processes.
51.1.3 This is especially problematic if persons have to work close to, or use, noisy tools, e.g. pneumatic
picks producing a sound pressure level of 110 dB(A) to 115 dB(A). The Noise Pollution
(Regulation & Control) Rules, 2000 or BS 5228-1:2009 gives guidance on how noise arising from
worksites affects site personnel and others living and working in the neighbourhood. It contains
information on noise emission from tools, plant and equipment that could be useful at the planning
stage in reducing noise and procedures for the control of noise. BS 5228-2:2009 gives guidance
covering the control of noise and vibration, and BS 5228-1 gives recommendations for controlling
noise and vibration that apply specifically to piling operations.
51.1.4The minimum height of stack to be provided with each generator set can be worked out using the
following. formula: H = h+0.2x ÖKVA. H = Total height of stack in metre. h = Height of the building
in metres where the generator set is installed.
51.1.5DG shall be silent type with acoustic enclosure
51.2 Noise emission and exposure
51.2.1The imposed duty of care will depend upon which of the action levels have been exceeded, i.e.
the 85 dB(A) First Action Level (FAL) or the 90 dB(A) Second Action Level (SAL). The Employer
/ Engineer has an obligation to undertake noise assessment and to keep records that must be
reported as per the OH&S Conditions of Contract. There is also a Peak Action Level (PAL) which
is a peak sound pressure level of 200 Pa [140 dB(C)].
51.2.2A competently executed noise assessment should provide sufficient information to enable the
production of a hierarchically prioritized engineering measures to control noise at source, or to
select correct hearing protection as an interim measure to reducing exposure to below the SAL.
The health and safety plan must specify means of minimizing noise emissions by incorporating
low noise tools and processes at the outset, as it may be impossible to install them later. In
situations where there is no reasonably practicable means of controlling noise at source, e.g. by
the use of measures such as silencers or damped picks, operators and bystanders, depending
upon their level of exposure or by request, shall be supplied with personal hearing protection as
an interim means of reducing the level of noise. This must reduce the noise to below that
associated with the SAL.
51.3 Tunnel face
51.3.1All machines and tools should be selected on the basis of risk assessment to be of low noise
emission and operator exposure. In some instances, there is insufficient space to reduce the
level of noise emission by confinement and/or containment retrospectively, emphasizing the need
for selecting low-noise construction methods and tools at the outset.
51.4 Access routes

51.4.1Access to, and egress from, tunnel workstations shall be (where possible) along clearly
designated and marked low-noise routes. Hearing protection must be worn when passing through
noisy areas resulting from activities in the constructed tunnel. These areas shall, wherever
reasonably practicable, be demarcated as Hearing Protection Zones. Journeys along the tunnel
in a man-riding car should neither be excluded from noise assessment nor preclude the use of
hearing protection.
51.5 Noise sources
51.5.1The principal sources of noise in a tunnel vary according to the method of working and the stage
in the cycle of operations. They include machines, tools, ventilation equipment and air leaks.
Other sources of noise that should be investigated with a view to reduction at source, or by
acoustic screening, include high-pressure compressed air, airlock discharge pipes, pumps,
materials handling, conveyors, hoists, winches, diesel plant, diesel locomotives, concrete pumps
and placers and compressors. In hand-excavated tunnelling, pneumatic tools are the principal
source of noise. Silenced tools, including the use of acoustically damped moil points or spades,
must be considered.
51.5.2In rock tunnels, drilling and spoil removal all generate noise, each with its own characteristics.
Blasting produces peak sound pressures that can exceed the PAL (Station Construction).
Measurements of peak sound pressure should be used to indicate whether withdrawing persons
from the face, and/or the use of hearing protection, will reduce exposure to below the PAL.
51.5.3 Noise from tunnelling machines can arise from three sources.
a) On TBMs, the ground-breaking operation does not always produce high levels of noise and
the machine operation is often the dominant source of noise. Noise reduction measures, such
as the enclosure of noisy components including pumps and motors, vibration isolation to reduce
structure-radiated noise, and damping of large radiating surfaces, shall be incorporated into the
TBM.
b) On hard-rock TBMs, ground breaking produces significant levels of noise. Consideration
must therefore be given either to vibration isolation to minimize transmission through, and noise
radiation from, the framework, or to the use of an acoustically deadened steel framework (where
possible), or both. Where space on the machine permits, a ventilated noise refuge for the
operator shall be incorporated into the design of the machine.
c) On part-face cutting machines, e.g. cutter boom, backacter or other mechanical excavator
shields excavation is across the face by means of a smaller cutting element which cannot
normally be enclosed to reduce the cutting noise. Even if the machine has a noise refuge/control
cabin, face workers may still need to use hearing protection and shall be subject to assessment
by the contractor.
51.6Noise reduction
51.6.1Noise shall where practicable and in the light of modern technology be controlled by using plant
and equipment that has been designed to eliminate or reduce the noise at source. This must form
part of the initial planning strategy of the project and in purchasing specifications. This pre-
emptive approach minimizes the costly operation of retrospectively designing and fitting noise
controls when work is in progress. A noise assessment must be undertaken in order to:
a) Confirm the adequacy of the noise and vibration controls;
b) Identify residual noise sources that significantly contribute to personal noise exposure; and
c) Identify a coherent management strategy for remedial engineering noise control measures.
51.6.2Equipment shall undergo regular maintenance checks, and noisy defective parts must be
replaced or repaired.
51.7 Communications

51.7.1Noisy environments require a safe system of communication. Frequency characteristics and the
level of workplace noise can make communication difficult, e.g. by interfering with speech
intelligibility and by masking warning alarms. A communication system can include visual signals,
radio hand-sets and hard-wired components. Hand or light signals for routine
directions/instructions in noisy environments should be systematized. Where this could prove
ineffective or there is any uncertainty about being clearly heard over a high level of noise in the
workplace, arrangements shall be made to suspend operations temporarily from time to time so
that necessary directions/instructions can be clearly and fully received.
51.7.2Consideration should be given to the use of communications head-set/hearing protection

combinations, which allow conversation in noisy areas without temptation to remove hearing
protection. The effectiveness of audible alarms and warning signals must be assessed using BS
EN 981- 1997. These alarms and signals should be audible when hearing protection has to be
worn. Current communication systems can readily accommodate large numbers of prearranged
visually displayed messages from a relatively simple transmitter using low-energy circuits, that
are either intrinsically safe or energy restricted. Where there is a risk of ignition, the use of fibre
optic circuits must be considered.
51.8 Vibration
51.8.1 Exposure to whole-body or hand–arm vibration resulting from the use and/or operation of tools,
plant and machinery can give rise to a significant risk to health.
51.9 Vibration emission and vibration exposure
51.9.1Attention is drawn that the contractor shall be required to submit to the Employer / Engineer
machinery emission data when the level of vibration reaches 0.5 m/s2 for whole-body and 2.5
m/s2 for hand–arm vibration. The level of emission is ascertained using harmonized British
Standard BS EN (“C” standard) Vibration Test Code(s) appropriate to the equipment being
assessed. Use of the test code(s) provides prospective purchasers/users with standardized
information to assist when attempting to make a low vibration purchase. However, the level of
vibration produced by the test rig can be lower than that measured under “in-use” conditions, as
the test code(s) are somewhat artificial when compared with actual use. Therefore, using the
information for the purpose of assessing exposure could underestimate the level of risk.
51.10 Whole-body vibration exposure
51.10.1Exposure to whole-body vibration (WBV) can be unpleasant and can give rise to discomfort or
annoyance, or result in impaired performance, e.g. degraded vision. It can also present a more
serious health risk, e.g. tissue damage or deleterious physiological change. Any part of the body
can be injured by exposure to a sufficient magnitude of vibration. The parts of the body most
likely to be injured during exposure to WBV will depend on the distribution of motion/energy within
the body, and this will depend upon the vibration frequency, axis of motion and body-coupling to
the vibrating source.
51.10.2BS 6841 recommends methods for quantifying vibration exposure and gives guidance on
repeated shocks in relation to human health, interference with activities, discomfort, the
probability of vibration perception and the incidence of motion sickness. The contractor shall
assess the risks associated with WBV and stipulate their intended control measures.
51.11 Level of hand–arm vibration exposure
51.11.1Vibration is transmitted to the hands and arms of persons when operating vibrating tools or
vibrating machinery, and/or operating in vibrating workplaces. Persons who regularly use tools
with a high level of vibration, resulting in a high level of exposure, can suffer from several kinds
of injury to the hand/arm, e.g. finger blanching, numbness and tingling sensations, and carpal

tunnel injury, which are collectively known as hand–arm vibration syndrome (HAVS). Included
in HAVS is the injury referred to as vibration white-finger (VWF), which is a painful and
reportable injury.
51.11.2In order to identify the possible risk of VWF injury, vibration risk assessment is required. CMRL
requires the provision of appropriate health surveillance when risk assessment identifies a
particular risk, e.g. VWF injury. Evidence of such monitoring shall be provided to the Employer
/ Engineer.
51.11.3The following publications give vital information for assessing vibration exposure and designing
a system of health surveillance:
a) HSG 88 (Hand–arm vibration);

b) HSG 61 (Health surveillance at work).
51.11.4Actions may be required where assessment identifies a specific risk, actions may include job
rotation, purchase, inspection and maintenance of low-vibration tools, etc. to reduce the risk of
VWF.
52.1.1The use of railborne plant must be planned and safe operating procedures agreed with the
Employer / Engineer. Factors affecting the choice of system are:
— Gradients;
— Length of main haul;
— Rate of muck removal;
— Clearances;
— Total mass of trains;
— Whether passing points are required;
— Size and availability of haulage system.
52.1.2Arisk assessment must be carried out for all rail operations. It shall be the responsibility of site
management to give instructions on the maximum loads that can be hauled and the maximum
speeds that are allowed on the tunnel gradient(s). Locomotive drivers must be authorized in
writing by the site management after their training, testing and the issue of a “training certificate”.
52.1.3The braking performance of the haulage system (whether locomotive, rope or manpower) will
determine the mass of train or skip which can be transported safely. The recommended
retardation for steel-tyred locomotives should be 2 % g (0.196 m/s2). Where this cannot be
achieved, the absolute minimum service braking effort should be 16 % of locomotive weight.
When hauling up a gradient, a locomotive shall never be used to haul a load greater than that
which it is capable of safely braking when travelling down that gradient, without recourse to
engine braking. It must be possible to stop a train within the range of its driver’s vision under the
worst conditions. This distance shall not exceed 60 m.
52.1.4The correct locomotive for any application must be selected by careful calculation for which there
are established formulae available from manufacturers. Manufacturers or plant hire companies
shall be consulted for advice. Preference must be given to trains with full or partial air brakes,

which are inherently safer than trains that rely on braking by the locomotive only. In particular,
the conditions for starting uphill and for braking shall be analysed. The adhesion between rail and
wheel can vary from 25 % in good dry conditions to 15 % or worse in bad conditions caused by
muck spillage or oil. Steep or long gradients can require extra measures to prevent accidents.
Where wagons do not have individual braking and are down gradient relative to the locomotive,
they shall have secondary couplings or safety chains. Locomotives fitted with power brakes that
are not fail-safe shall have a secondary manual system.
52.1.5There is a risk of train runaway if the driver exceeds the permitted speed, or train loading, for a
given locomotive on a given gradient. Where the consequences of over-speeding, identified by
the risk assessment, would be serious (collision or derailment), automatic warning equipment
must be fitted. Automatic over-speed brakes shall be considered for the steepest gradients.
Where a train is required to operate on steep gradients (2 % or steeper, and more than 50 m
long), the braking efficiency must be checked by full safe testing as the tunnel progresses.
Appropriately qualified and experienced engineers should be given specific responsibilities for
the continued safe operation of a railway system. These include:
— The selection and training of drivers;

— The enforcement of site safety procedures;
— Regular auditing of maintenance procedures for both track and rolling stock;
— Specifying and checking the haulage system relative to loads, distances and gradients.
52.2 Clearances
52.2.1A space of not less than 500 mm must be provided for trains and persons to pass safely both in
the tunnel and around machinery this shall be extended to 600mm where a crush hazard exists
from slewing plant. Any exceptions to this, for instance at foot level, shall be designed to minimize
risk.
52.2.2Methods of working shall be adopted that will prevent persons being in hazardous areas during
train operations, e.g. a ban on walking or working in the tunnel, restricting access around
machinery, and providing man-riding cars and suitable access routes. In many cases, pedestrian
access to the face along the track is not safe. Track maintenance must not be attempted during
train operation without the adoption of a safe system of work which includes adequate refuge
space, a nominated lookout, and flashing warning lights being placed at either end of the section
of track affected.
52.3Propelling
52.3.1Propelling (or breasting) trains (where a locomotive pushes a train from the rear) creates
problems of visibility for the driver and creates additional risks to persons in the tunnel. The train
shall be equipped with a warning light on the lead vehicle. The train must be propelled only where
the driver can see the track ahead of the train or where the train is under the control of a
banksman who is in a safe position.
52.3.2Trains being propelled into the backup equipment on a TBM shall be under a controlled signalling
system and persons must be kept off the tracks when the train is moving. Where trains remain
marshalled for production, CCTV can be used to allow the driver a good view ahead. Visibility
from the driver’s cab should be sufficient to avoid the need for the driver to lean out of the
locomotive and risk striking obstructions within the tunnel. Where locomotives are attached to
both ends of a train, a system of work must be adopted to ensure that the train is controlled from
the lead locomotive only. The driver shall move off only after checking that all persons are clear,
or safely aboard.
52.4 Locomotives

52.4.1Any self-propelled railborne vehicle shall be classed as a locomotive. NOTE prEN 1889-27)
specifies requirements for locomotives, including:
a) design to facilitate handling (lifting points);

b) battery containers;
c) lighting;
d) fuel systems;
e) audible warning;
f) control devices;
g) brake system;
h) fire protection;
i) speedometer.
52.4.2An exception from the need for a speedometer may be made for locomotives under 1.5 tonnes
mass which operate in small tunnels and will not accommodate more than the basic minimum of
equipment. It is a requirement to provide suitable protection for locomotive drivers, to guard
against injury caused by accidental contact with static objects in the tunnel or other rolling stock.
The design of cab or other enclosure must allow reasonable freedom of movement for the driver.
Visibility shall be adequate for safe driving of the train. Locomotives used in smaller tunnels (less
than 2.5 m diameter) should be constructed to allow clearance for personnel, and to leave room
to manoeuvre a stretcher past an immobilized locomotive.
52.4.3A daily functional brake check must be carried out by the regular drivers, supplemented by brake
testing in accordance with a maintenance programme at a frequency determined by project-
specific duties and hazards. Locomotives must be checked and, if required, serviced at least
weekly when in use. This should follow manufacturer’s service schedules, and the work must be
logged and records maintained by the contractor.
52.5 Fuelling
52.5.1The storage and handling of diesel fuel can give rise to fire hazards. A design of locomotive must
be chosen in which the fuel tank is located as far as reasonably possible from hot engine
components, and where the tank is below the fuel pump (to prevent spillage in the event of leaking
pipework). The quantity of stored fuel must be kept to a minimum, which shall be taken to be one
day’s supply.
52.5.2All fuel connections must be in good quality robust pipework. Where high-pressure fuel leaks can
spray onto a hot exhaust system, baffles must be fitted.
52.5.3Fuelling operations shall, wherever possible, be outside the tunnel, but where underground
fuelling points are unavoidable, particular attention must be paid to local drainage and the
provision of fire extinguishers in the vicinity that are appropriate for the type of fuel being used.
No welding, cutting or any other hot work shall be carried out within 10 m of the fuelling point or
at any height vertically above the fuelling point.
52.5.4The area in which fuelling operations are carried out shall be designed to facilitate the
containment and removal of spilt fuel and should be kept clear of combustible waste. The fuel
store must be constructed from materials that are non-combustible when tested in accordance
with BS 476-4, and any waste material such as rag and paper must be removed promptly. All
tanks shall be bunded. The fuelling plant should be used only by designated persons. At least
one person per shift shall be designated to be responsible for the fuelling area and to monitor its
safe use.

52.6 Battery locomotives
52.6.1An area shall be designated for the safe charging of batteries that is well ventilated (to disperse
the hydrogen given off during charging) and that is near a supply of clean water (to wash off spilt
acid). BS 6133 gives guidance on minimum local ventilation requirements. It is necessary to lift
the lids on battery boxes where the design allows accumulation of hydrogen within the box. It is
essential that the correct type of charger be used for each battery to eliminate heating and
possible explosion of cells. Defective chargers must be repaired by an electrician as soon as a
fault is evident.
52.6.2Diesel, Cylinder storage shall not be permitted within 10 m of the charging point and lighting must
be intrinsically safe.
52.6.3Battery locomotives must be fully isolated by disconnecting the main battery plug when left
unattended. This will prevent battery overheating and gassing caused by any double earth fault
on the locomotive.
52.7 Potentially explosive atmospheres
NOTE prEN 1889-2 specifies requirements for locomotives for use in atmospheres containing
potentially explosive gases (e.g. methane, or hydrocarbon fumes). Further guidance can be
obtained from BS EN 60079-10 and BS EN 60079-14:2008. Where the risk is low, it can be
adequate to rely on monitors detecting low levels of potentially explosive gases in order to stop
locomotive operations before 5 % of the LEL of the gas is reached.
52.8 Rolling stock
52.8.1Muck skips are usually designed for either tipping or hoisting. When skips are hoisted they should
be regarded as a piece of lifting equipment and designed and used accordingly. Periodic
examination and testing shall take place as for lifting tackle. When skips are tipped, provision
must be made to lock them during travelling.
52.8.2Purpose-built skips and materials bogies must incorporate restraint of the intended load to
prevent, for example, a box or stack of segments from sliding off and fouling walkways. The
design of the vehicle should be inherently stable when loaded, even on poor track and with rough
handling.
52.8.3Certain high-capacity cars have flight bar conveyor mechanisms to discharge the muck at one
end at a controlled rate. Where these types of cars are used, special attention shall be given to
the manufacturer’s recommendations concerning track laying, layout of curves and loading
across overlap points to minimize the potential for derailment.
52.8.4Personnel can be transported if purpose-built man-riding cars are used. These shall be attached
as near the locomotive as possible with a safety chain in addition to the coupling. A man-riding
car must be constructed with proper seats, side bars and a crash cage. It shall be constructed to
withstand derailment with minimum injury to passengers. It is recommended that the largest
practical wheel size be used with a suspension system on man-riding cars.
52.9 Couplings and buffers
52.9.1The use of unauthorized, temporary coupling arrangements can give rise to a high risk of runaway
vehicles. It is essential that only couplings adequate for the maximum load and type of skip be
used. Spare couplings must be available and makeshift devices such as bonds, ropes, segment
bolts or breaker steels shall not be used. The correct type of coupling to be used will depend
upon the combination of vehicles involved but can either be a rigid bar with pin type connections,
or a loose link coupling working in tension only. The loose link type must allow safe propelling of
a train without uncoupling or jamming. It is important that the links cannot jump off skip towing

pins. Where “dog bone” solid link couplings with long slotted holes are used instead of the classic
three-link coupling, they must be free-fitting to avoid jamming.
52.9.2Couplings must be designed to accept the maximum snatch load on start up or during braking.
Adequate allowance shall be made for wear due to prolonged use. By using link type couplings
constructed to conform to lifting gear regulations it is possible to select ready-made safe designs.
52.9.3Rigid bar type couplings shall be used for vehicles with large overthrow to avoid buffering
problems when propelling round curves or on uneven track. Manufacturers’ recommendations
must be followed.
52.9.4When propelling with link type couplings, buffers or buffing beams must be matched on adjacent
vehicles so that the heights are the same and the overthrow (distance from the nearest axle) is
similar. Failure to match can result in jamming and side thrust on curves, possibly leading to
derailment. Secondary couplings or safety chains shall be used between the locomotive and un-
braked vehicles running downgrade of the locomotive on inclines where runaways could occur.
52.9.5All couplings shall be inspected at a frequency determined by project-specific duties and hazards
to detect excessive wear, bending, or overloading. Damaged couplings must be destroyed.
52.10 Track
52.10.1Track should be properly supported and secured against displacement in the tunnel. Rails shall
be of adequate section, laid to gauge on an even surface and jointed with bolted fishplates, or by
other equivalent means. The following list gives an indication of suitable rail section to use with
sleeper spacing not exceeding 900 mm:
— 9.92 kg/m (20 lb/yard) — 1.5 tonnes axle load;

— 17.36 kg/m (35 lb/yard) — 3.0 tonnes axle load;
— 24.80 kg/m (50 lb/yard) — 4.5 tonnes axle load.
52.10.2For heavier loads the rail manufacturer must be consulted.

52.10.3Flush fitting, tapered-edge fishplates with four bolts shall be used for a tight, smooth joint. The
rail ends shall be saw cut and fishplate holes drilled. Due to the specification of the rail steel, any
cutting or welding of rail can cause minute shrinkage cracks which spread if stressed, eventually
leading to fracture. For this reason cutting and welding must be avoided, and cold sawing, drilling
and clamp-type connections shall be used instead. If hot work is to be carried out, the rail must
be preheated and cooled under controlled conditions.
52.10.4Poor track laying can lead to gauge spread, slack joints, and violent slewing. In unlined tunnels
the track can suffer from sinking and rolling. These problems can be avoided by provision of
suitable base materials to allow safe laying and maintenance of the track. A designated person
must assigned by the contractor for maintenance of the track.
52.10.5To avoid derailments, turnouts and crossings shall be laid on a sound base to accurate gauge
and maintained with adequate guide rails and close fitting switch blades. The radii must allow the
largest vehicle to pass without flange jamming and jumping. Sidings for the storage of unbraked
skips shall be constructed on the level. Scotches should also be utilised to prevent accidental
movement.
52.11 Winch haulage
52.11.1Where the gradient is such that winch haulage has to be used, special precautions are to be
defined and taken to anchor the winches securely, to control the ropes and to check the brake
operation of the winch. The vehicles and rail tracks shall be fitted with devices such as automatic
brakes, catch points, and Manchester gates to arrest runaway vehicles.
52.12 Rubber-tyred vehicles

52.12.1Procedures are to established to protect persons from moving vehicles by separation wherever
reasonably practicable. In larger tunnels, rubber-tyred vehicles can be used to transport
materials. Larger clearances are necessary between the vehicles and persons, equipment, or
the side of the tunnel than for rail vehicles.
52.12.2Reversing or turning vehicles present particular risks to pedestrians. Vehicles must not be
operated on steep gradients without a careful assessment of ground conditions and the capability
of the vehicles. Planning of operations shall include consultation with the suppliers.
52.12.3Vehicles shall not be employed on gradients steeper than 12.5 % unless specified as suitable
for that purpose.
52.12.3Level loading areas shall be provided and discharging must be on level ground with kerbs to
“spot” the wheels and a stop barrier where a drop occurs. Each vehicle shall be provided with the
following equipment:
(a) An audible warning device;

(b) Two white front headlights visible at 60 m;
(c) Two red rear lights visible at 60 m;
(d) A braking system, preferably fail-safe, when the design allows which can
be operated instantaneously by the driver;
(e) A parking brake capable of holding the vehicle fully loaded on the steepest
slope likely to be encountered;
(f) Sprays or jets for cleaning windscreens if fitted.
52.12.4Vehicles must be fitted with visual and/or audible reversing warning systems. Each vehicle driver
shall have received suitable training and should carry a valid certificate for that vehicle. A safe
system of work underground must be prepared, approved by the Employer / Engineer and
adherence to this shall be the responsibility of the contractor. The procedures must encompass
training and clear marking and notices underground. When several vehicles are in use, the
regulation of movements shall be the duty of supervisory personnel underground, each of whom
must be in charge of a particular section. Measures must also be taken to minimize the pollution
of the working environment.
52.13Belt conveyors
52.13.1Belt conveyors can be used to reduce traffic movements in tunnels, but a conveyor in a confined
area such as a tunnel is potentially hazardous to persons working alongside. If belt conveyors
are used, measures must be taken to minimize the risk to persons working in the vicinity. All
chains, sprockets, gears and in-running nips shall be fully guarded. It is particularly important that
pinch points between the conveyor belt and the drum are securely guarded; these occur at each
loading and discharge point and at any tensioning device that is fitted. BS 5667:1998 (all parts)
specifies requirements and BS 7300 provides guidance on applicable safety standards. Idlers on
the underside of the conveyor shall be guarded if they are accessible to persons walking past the
conveyor.
52.13.2Pull cords shall be provided on either side, throughout the length of the conveyor. Alternatively,
emergency stop buttons must be provided at suitably close intervals along accessible lengths of
the conveyor belt.
52.13.3Starting of the conveyor must only be possible from a single position, normally the main
operator’s position, but this may be on the instructions of the conveyor operator. An audible signal
must be given and a safe interval allowed to elapse before start-up.

52.13.4Fire prevention measures shall be taken, especially at all drive, transfer and tail-end locations.
Ventilation of electric motors shall be maintained and motors shall be protected against spillage.
Fire-resistant belting shall be used wherever practicable. Suitable fire extinguishers must be
located nearby.
52.13.5The conveyor must have sufficiently high sides to prevent spoil spilling over. Not only will
spillage result in an untidy workplace, but large pieces loaded on to the conveyor can strike and
injure operators or damage machinery. Oversize material shall be prevented by means of a gating
device from travelling up conveyors. Inclined conveyors, other than short lengths, shall be fitted
with anti-runback devices to prevent the belt running backwards in the event of a power failure.
52.13.6Man-riding shall not be permitted on a conveyor. On some TBMs access to the cutter head is
only possible along the conveyor. This must be done only in accordance with the manufacturer’s
instructions. When dry spoil is being handled and dust presents a problem, effective dust control
measures shall be taken.
52.13.7The safe use of conveyors depends largely upon thorough inspection (at least once each
working shift) and maintenance. Worn or damaged parts must be replaced as soon as is
practicable. The build-up of spoil on belts and rollers shall be controlled as this will result in
spillage and motor overloading. Maintenance such as greasing bearings, adjusting belt
positioning, cleaning belts, etc., or repair work must not be undertaken while the conveyor is in
motion. A lock-out switch must be used on such occasions.
52.14 Slurry pumping
52.14.1Slurry pumping for tunnelling purposes generally comprises the use of fluid mixed with the
material excavated by a tunnelling shield which is pumped out of the tunnel. The slurry system
shall either be a recirculating system or a system pumping from the shield face to a discharge
point either in the tunnel or outside the tunnel. As a minimum, the system should comprise:
— A mixer which will mix the components of the slurry;
— An injection device to inject the slurry into the face of the tunnelling machine;
— A discharge pump to pump the slurry from the machine; and
— pipe work to deliver the slurry to the point of discharge.
52.14.2In addition, there may be a charge line, intermediate pumps and a separation plant. All power
supply to mixing and slurry plant is subject to normal safety requirements for remotely operated
mechanical plant.
52.15 The mixing system
52.15.1 NOTE Attention is drawn to control of substances hazardous to health when handling bentonite
and any other caustic chemical additives.
52.15.2Slurry is generally water mixed with bentonite and other additive materials. Storage and handling
advice supplied with the materials must be followed. Appropriate training of personnel is essential
for those likely to come into contact with slurry. An eye wash station must be located near the
mixing plant, and facilities provided for washing and changing of clothing. Mixing systems must
be established in order to avoid any manual contact with moving parts. If there is any possibility
of splashing, tanks should have covers. Any spillage must be cleaned up to avoid contaminating
working areas.
52.16 The slurry pumping system
52.16.1In slurry systems pumping pressures can be high and connections between pipework and
pumps can be subject to some movement. Where high pressures exist, warning signs shall be
displayed providing sufficient data about the pressures to guide safe working practice. Advice

should be sought from the equipment supplier on what pressure will be generated in use and
whether this will require special attention.
52.16.2Where pumps are in confined spaces or in spaces where entry of personnel is forbidden, special
procedures for the isolation of the power supply must be in place. Signs shall be posted to identify
isolation points. For any maintenance work, a “permit to work” system must be enforced with a
suitable isolation and lock-off procedure to immobilize plant before maintenance work
commences.
52.16.3Where power cables to the pump have to be regularly connected and disconnected for the
purpose of pipe installation or segment installation, the cables shall be supported so that
connections cannot become contaminated by any fluids within the tunnel or access shafts. There
must be a clear system indicating when lines can be disconnected and reconnected such that no
live cable is accidentally handled. A monitoring system shall be used on power plugs and
couplers to isolate the system in the case of an accidental disconnection.
52.17 The piping network

52.17.1The slurry pipework must be of heavy-duty construction to withstand the pressures and abrasion
caused by the spoil carried in the slurry. Where supported on the tunnel wall or in the shaft,
carrying brackets shall be strong enough to allow for alignment problems causing some brackets
to carry double the predicted load. Anchorage must be designed to resist surge loading as valves
are opened and closed, particularly adjacent to bends. Where telescopic pipes are used adjacent
to a TBM, the design must allow for surge reaction forces. Where flexible hoses are used, they
must be of a suitable design to resist the pressures and shall be positioned or guarded so as to
cause no injury if there is a burst.
52.17.2All slurry pipework shall be regularly inspected to ascertain its suitability and condition for use.
Special attention must be paid to pipe connections. All valves and multiple pipework installations,
such as bypass systems, must have suitably designed supports. Where pipework is extended or
pipes are opened for the purposes of pipe jacking installation, there must be a system in use to
minimize spillage of the pipe contents, as this can lead to slipping accidents and untidy and
contaminated facilities.
52.17.3Valves shall be installed at regular intervals in advancing pipework. For larger pipes, it is
sometimes possible to insert inflatable stops through pipe sockets. Designated personnel must
release any pressure from the pipeline before joints are disconnected.
52.18 Operating procedures
52.18.1TBMs with man-entry facilities to a normally flooded slurry chamber will require extensive
procedures to ensure safety for personnel, These procedures shall be developed by the
contractor and submitted to the Employer / Engineer for notice of no objection. It is usual to
employ compressed air to maintain face support. The following safety precautions must be
employed.
a) No person should enter alone.

b) Communications are essential and a plug-in type intercom is suggested.
c) Air quality should be monitored.
d) There should be a recognized method for removing injured persons from the front of
the machine and airlocks should be able to accommodate a stretcher.
e) During work on the TBM, a constant watch should be kept to detect deterioration of the
face.
f) If conditions appear unfavourable, the crew should be withdrawn and the chamber
reflooded. Simultaneous maintenance should not be carried out on the rest of the
system.

52.18.2The slurry plant, pumping system and TBM must be kept in a state of readiness in order to be
able to excavate one cycle so that tunnelling forward into good ground can quickly recommence.
52.18.3High pressure on the face of a TBM during driving can result in high pressures at the rear of the
shield. This can affect the installation of segments and can present hazards to segment-handling
personnel. There shall be a procedure to identify when such difficulties occur so that suitable
reduction of the slurry pressure on the face of the machine can be carried out.
52.18.4During the launch of a shield from a shaft, it is possible that high slurry pressure will cause
discharge into the shaft. It is essential to manage any leakages and contain any pressures so as
not to cause a loss of ground and slurry into the shaft or the separation system, with the attendant
risks to persons and the security of the works.
52.19 Slurry separation
52.19.1Slurry separation can be carried out by the use of settlement tanks, separation plant or lagoons.
Tanks must be secured safely with adequate foundations and support. Where there is any risk
of falls into a tank, the tank must be protected with grating. Where separation plant is employed,
in addition to the protection of tank facilities, all moving parts must be guarded. An isolator shall
be installed to enable a qualified operator to shut down the plant.
52.19.2As with any fluid handling, matters can go wrong quickly, and emergency procedures must be
established in advance. All maintenance and adjustments shall be carried out in accordance with
manufacturer’s instructions. Where lagoons are employed, there must be adequate fencing,
determined by risk assessment, and warning signs identifying the depth of the lagoon and the
nature of the contents.
52.19.3Removal of slurry from a site must be managed with due recognition of the nature of the
contents. Slurry must be pumped into suitable tanks and tankered off site to a licensee with waste
transfer notes maintained by the contractor. The contractor and their suppliers are subject to
auditing by the Employer / Engineer
52.20 Tipping and disposal
52.20.1The disposal of excavated materials off site is subject to local and national waste disposal
legislation.
52.20.2The location of any on-site tip or disposal area must be carefully chosen and due consideration
given to engineering requirements for tip siting and formation, e.g. method of construction,
drainage and compaction. It should not be positioned to surcharge future tunnel excavations
unless it can be established that the soil or rock is able to withstand these additional loads. In
tipping areas, reasonably level and properly maintained roadways should be provided using
ballast or hard-core, as necessary, to allow proper traction and stability of haulage and tipping
vehicles. If tipping is to be carried out down a slope, a robust “stop” should be provided to prevent
any overrun of the haulage vehicle.
52.20.3Dust control measures shall be put in place during the tipping and storing of rock and spoil to
minimize risks to health and the environment.
52.20.4It is often necessary to provide facilities for cleaning wheels, etc., before the vehicles go on to
the public highway. The legal requirements for this are generally the subject of local by-laws. A
further hazard with pumped slurry storage is the possibility of flooding. The flood protection at
each shaft must be well above any possible slurry lagoon level.


52.21.1Track maintenance should not be attempted during train operations. A safe system of work
should be adopted which includes adequate refuge space, a nominated lookout, and flashing
warning lights being placed at either end of the section of track affected.
52.21.2Locomotive drivers should be made aware of the work in progress.
52.21.3Locomotive drivers should be authorized in writing by the site management after their training,
testing and the issue of a “Authorized certificate”.
53.0 Tunnel plant
53.1 General
53.1.1Due to the confined space in a tunnel, there is a greater likelihood of hazards occurring. Safety
aspects specific to tunnelling. Before attempting any work on powered machinery, it must be
isolated. This will apply equally to electrical and mechanical plant, and suitable instruction and
training must be given, backed up by notices on the machinery advising on the steps to be taken.
The use of burning and welding equipment in a tunnel shall be minimized and cylinders, etc.
should be transported in equipment specially designed for that purpose.
53.2 Pneumatic plant
53.2.1Flexible hoses are a hazard if they fail in use due to the violent whiplash effect caused by
escaping air. They must be protected and routed clear of possible impact or cutting damage. It is
good practice to rate the hose at a higher pressure than anticipated working pressure to allow a
reasonable margin for abuse and attrition. Typically, 10 bar hose is used in 7 bar applications.
The hose end fasteners must either be banded by a trained person or secured with correctly
matched bolted clamps. It is important to be aware that several different outside diameters are
available for a given internal diameter of hose, and different clamps will apply. Where hoses are
25 mm internal diameter or larger, whip restraint wire loops must be attached at each end. All
hoses shall be regularly inspected at least weekly for damage or deterioration and must be
discarded if there is evidence of damage from oil (a swelling and softening of the rubber material),
blistering, chafing, or cuts.
53.2.2Air-driven machinery, whether percussive hand tools, air motors, or reciprocating pumps, can be
unacceptably noisy if used un-silenced. The level of noise produced by un-silenced motors
prevents effective communication and is a hazard. Silencers must be fitted, of a type not prone
to “freezing up” due to excessive restriction. The exhaust air shall be directed away from the
operator. If the air supply is very wet, water traps should be used in the air line feeding the plant
to minimize exhaust mist.
53.3 Hydraulically operated plant
53.3.1Fire on hydraulic power packs and hydrostatic systems can burn fiercely and be extremely difficult
to extinguish with hand-held appliances. The following precautions shall all be taken as far as
practicable.
a) Fire-resistant or low flammability fluids should be used in the system where possible.
If mineral oils are essential, these should have a minimum flash point of 250 ºC.
b) Effective oil coolers should be incorporated to maintain temperatures below 70 ºC.
Temperature switches should automatically shut down overheated circuits.

c) Fixed fire extinguishing systems should be installed covering major systems such as
oil storage tanks, pumps, motors, etc.
d) Water curtains or other smoke suppression systems should be fitted. Circuit designers
should consider the most appropriate type of pipework for an installation. Compression
fittings on rigid pipes can suffer from loosening caused by circuit hammer and vibration,
while flexible hoses are prone to chafing if not adequately secured.
e) Pipe runs should be routed to minimize the possibility of oil sprays reaching hot objects.
53.3.2Hydraulic systems should be regularly maintained, at a frequency determined by project-specific
duties and hazards, to prevent leaks and removal of damaged pipework. Hoses should be
pressure-rated to allow for transient pressure spikes in use.
53.3.3Motors used on segment erectors must be fitted with fail-safe brakes to hold loads in event of
power failure or leakage. All hydraulic cylinders supporting loads that could cause injury if
released shall be fitted with load holding valves. prEN 12336 gives requirements for vacuum pad
systems on erectors. Face and forepole cylinders should be able to relieve hydraulic pressure
automatically during shield shoving to avoid overpressure in the cylinders.
53.4 Internal combustion engines
53.5 Diesel engines
53.5.1Engines of more than 37 kW rated output shall conform to BS EN 1679-1:1998. This is to prevent
the emission of exhaust gases that will cause excessive levels of particulates in the tunnel (i.e.
more than 500 ppm9) CO, CO2, 750 ppm NO and NO2, 200 ppm hydrocarbons), and to ensure
that the engines are constructed not to be a fire hazard. Ventilating air must be sufficient to dilute
toxic gases to safe levels, and reduce smoke and odours to acceptable levels.
53.5.2To avoid local concentrations of dangerous levels of fumes, some form of exhaust conditioning
must be used. This can take the form of a fume diluter or catalytic converter. Advice on correct
matching shall be sought from the suppliers of any conditioning device. Diesel particulate filters
can be incorporated, but the duty cycles on locomotives can cause fouling up. Engines for
underground use must be “clean burn” types, producing minimum fume emissions, with a virtually
clear output. Black or brown smoke indicates un-burnt fuel caused by over-fuelling and poor
combustion, whilst white smoke indicates an engine in need of attention. Blue smoke caused by
lubricating oil consumption indicates a worn engine. In addition, adequate provision must be
made for ventilation and for the storage and handling of fuel. Explosion-protected equipment shall
be used whenever there is danger of the presence of explosive gases e.g. methane.
53.6 Siting of engines
53.6.1Internal combustion engines at the surface must be sited so that exhaust fumes cannot enter the
ventilation system or compressed-air intakes, or enter the tunnel by any shaft or other opening.
53.7Concreting plant
53.7.1 Pressure concreting pipes must be installed and maintained to pump manufacturers’ guidelines.
It must be remembered that these pipes can move with the pump strokes and that reaction forces
are generated at every bend. Furthermore, the full pipeline will be heavy and must be supported,
particularly in shafts. Wear on bends and reducers can cause complete failure under pressure
and these areas should be checked regularly and records maintained.
53.7.2 When “blowing out”, the cleaning ball or sponge can exit with considerable velocity and should
be caught in a basket at the end. Once the ball leaves the pipe, a reaction “kick” from the escaping

air can dislodge the pipeline, particularly at flexible hoses or bends. As an alternative to
pneumatic blowing out of pumping lines, the system can be cleaned by washing out with water.
The pipework used with the concreting plant should be correctly matched to the performance of
the pump and its condition regularly checked. Incorrect pipe and couplings could rupture in use.
Procedures shall be approved in advance for dealing with blocked pipelines as this will entail
splitting and blowing out the line section by section.
53.8 Water drainage pumps
53.8.1Reliability of the drainage system, and adequacy of pumps, is critical for the safety of personnel
where flooding could occur. A risk assessment shall be carried out and a system designed to
eliminate the flood risk as far as reasonably possible. Consideration must be given to duplicate
pumps and pipework, and to good accessibility of pumps for regular servicing or changing over.
Submersible pumps should be suspended so that they can be progressively lifted clear of silt in
the pump sump. Pump performance must be checked regularly to detect wear or blockage.
Pipework in tunnels is prone to progressive silting up in use. A second pump line could be used
to allow cleaning of the blocked pipes.
53.9 Drilling and piling rigs
53.9.1Drilling and piling rigs used in any operation associated with tunnel construction should conform
CHAPTER XXIII of TBOCWR 2006 or BS EN 791:1996 and BS EN 996-1995 +A3:2009
respectively. All other drilling and piling “in-hole” equipment should conform to the appropriate
International, European or national standard.
53.9.2The operation of drilling or piling rigs and their ancillary equipment should be carried out in
accordance with established safe working practices and OH&S Conditions of Contract. Drilling
and piling rigs must be maintained in accordance with the instructions in the manufacturer’s
handbook.
53.10 Specific recommendations for drill rigs
53.10.1The rig and in-hole equipment selected for a specific operation must be suitable for its intended
use. Consideration must be given to site, operational and environmental conditions. Some drilling
operations require access to the area around the rotating drill string. The operator must therefore
be particularly careful in controlling the drill, when persons are working near the drill string.
53.10.2Machine ratings must be compatible with anticipated drilling conditions to prevent overloading
of a machine. The drill rig shall be set up so that it forms a stable, safe drilling platform to reduce
the risk of slipping or falling and so that all parts of the equipment are secure. Any limitations on
ambient temperature for which the rig is designed should also be adhered to.
53.11 Grouting equipment
53.11.1Grout mixers employing rotating paddles must be designed so that any dangerous parts are
either out of reach, or guarded. Before the removal of the guard, the power source must be
isolated under a permit to work system e.g. lock-out. Grout pumps used for either transferring
bulk grout or injecting at the point of use should be matched to the method of work. The potential
pressure of some piston pumps is very high (66 bars) whereas air-operated diaphragm pumps
will produce modest pressures (6 bars). It is essential that pressures be monitored and all hoses,
pipe fittings and injection nozzles (grout guns) be matched to the maximum pressure rating of
the pump and inspected regularly for damage and wear. High-pressure grout blow-outs can
cause serious injuries. Where transfer distances are great, an effective means of communication
shall be in place between the source and the point of delivery.

53.11.2The compressed-air displacement grout pan is a pressure vessel and is therefore a potentially
dangerous piece of equipment, and must only be operated only by a person who has been
instructed in its use. Opening of the lid under pressure must not be possible. All grouting
equipment should be regularly inspected and maintained and any grout build-up removed. Whip
checks should be provided for both the feed air and the grout transfer hoses. Potential hazards
arising from grouting equipment include the following:
a) bursting of the grout feed hose through damage, inadequate maintenance or improper
connection, or solidification of the grout. Cleaning and maintenance to a high standard is
therefore essential;
b) blow-out at the point of injection where a screw connection or other pressure retaining
device should have been provided;
c) back-flow of grout after injection. A stop valve may be necessary to retain the grout until it
has set;
d) damage to lining or to surface installations due to excessive pressure.
54.0 Maintenance and repair
54.1 Inspection and assessment
54.1.1Detailed inspection and recording of the tunnel lining details should be carried out at planned
regular intervals. A formal reporting procedure must be established with appropriate checklists to
enable correlations with subsequent inspections. Before each inspection, reference should be
made to the records of any previous inspection and behaviour, copies of which should be retained
and available on site. Points which are likely to require attention are:
— Degradation and spalling of the lining material or exposed rock faces;

— Deformation and cracking;
— Location and quantity of ingress of water and solids;
— Chemical and thermal effects.
54.1.2In certain tunnels where the presence of gases poses a danger, a scheme must be drawn up for
the regular assessment of the gases. Those areas of the tunnel lining that have deteriorated the
most should undergo more detailed inspection and monitoring. In addition to normal inspection
procedures, specialized techniques that can be employed include:
a) CCTV inspection;
b) Installation of monitoring studs for the accurate measurement of deformation;
c) Strain gauges;
d) Profiling, e.g. photogrammetry; laser measurement techniques;
e) Water sampling;
f) Geophysical, e.g. ground penetrating radar, thermography.
54.2 Preparation for repair
54.3 Site investigation
54.3.1It is important to carry out a site investigation to identify the ground conditions (if this is not already
known) and the extent of the voids or defects behind or within the tunnel lining. The location and
delineation of voids behind the tunnel lining is vital and will need to be determined. Trial holes
could be required to establish, for instance, the general integrity of the tunnel lining in the area of

the proposed work, whether a structural invert is present or to establish the groundwater regime
behind the lining.
54.4 Design
54.4.1The design of the existing structure should be assessed for any changes in the ground or tunnel
lining since it was built. The engineering properties of the ground or of the structure itself could
have changed as a result of the action which has prompted repair (e.g. water leakage, solids
transport, general weathering effects); and this could have affected the structural behaviour and
load-bearing capacity of the ground/structure complex. The work to be carried out can itself
impose local or widespread loading on the structure (e.g. grouting pressures). Even minor
intrusions, such as drilling for grouting, can affect structural behaviour. Major intrusions, e.g. for
partial reconstruction, will have greater effect. The design assumptions made and the limitations
on working must be clearly stated in the health and safety plan, so that the contractor is fully
aware of the dangers and able to design appropriate temporary works and emergency
procedures.
54.5 Preparation of a safe system of work
54.5.1Detailed method statements, developed from the aspects and impacts associated with the task
must be prepared for the tunnelling work. Statutory authorities and other bodies should be
consulted as appropriate and their consent obtained if necessary. Method statements are to be
submitted to the Employer / Engineer for review, notice of no objection and or no objection.
54.6 On-site procedures prior to repair documents to be held on site
54.6.1The principal contractor must ensure that site-based representatives of all parties to the contract
have access to the following documents:
a) Health and safety plan and method statements with access to the health and safety
file;
b) Relevant “as built” drawings;
c) Details of the latest condition survey;
d) The site investigation report;
e) “Permit to work” forms as appropriate;
f) Relevant parts of any by-laws, wayleave stipulations, etc.;
g) Other reports, drawings, etc. located during the historical research.
54.7Emergency procedures
54.7.1Before repair work commences, a site meeting of all relevant parties must be held to discuss
emergency procedures. Further meetings shall be held as necessary during the course of the
work.
54.8 Ventilation and testing for gases
54.8.1The procedures for ventilation during construction are equally applicable to repair works. Gases,
particularly methane, can fill voids behind tunnel lining or enter the tunnel dissolved in
groundwater.
54.9 Work in shafts
54.10 Lifting operations

54.10.1Cranes can be used for raising or lowering inspection cages but must not be used for supporting
working platforms. Particular care shall be taken to prevent sudden crane movements.
54.11Environment
54.11.1Following the completion of work carried out within a shaft, but before re-entry, the environment
within the shaft and within the tunnel at the bottom of the shaft must be checked to ensure that it
is still safe and the check recorded. It should be noted that closing a shaft can result in a changed
environment within the tunnel and therefore due regard must be given to ventilation, atmospheric
pressure effects, means of escape, etc. This can also result in a shaft becoming a confined
space. Build-up of water and debris on the temporary cover, decking or working platform must
be controlled.
54.12 Access control
54.12.1Toe boards and hand rails shall be installed to control access to the top of the shaft and to
prevent materials or debris falling on to persons working in the shaft. For work of limited duration
within the shaft, access to the tunnel at the bottom of the shaft must be isolated. For work of
longer duration or where necessitated by the nature of the work being undertaken, it may be
necessary to install a temporary cover, decking or working platform within the shaft. This will
generally protect the area within the tunnel at the bottom of the shaft. Rope access techniques
can be used for access within shafts, where appropriate however this can only be carried out by
specialists in rope access.
54.13 Working platforms
54.13.1Any working platform must have a substantial roof with a trap door. This will give protection
against wet conditions and any stones falling down the shaft. The working platform shall be
secured to the shaft wall during use and the maximum platform loading clearly displayed.
Platform suspension systems must be designed to withstand the heaviest loading to which it is
envisaged that the platform will be subjected. A secondary escape facility from the platform shall
be provided. A means of communication with the working platform or inspection cage must be in
place at all times. Communication should be both oral and visual wherever possible. Unless
working from a properly guarded fixed working platform, suitable individual safety harnesses
must be utilised.
54.14 Temporary works
54.14.1Before work on site commences, the contractor should submit to the Employer / Engineer for
notice of no objection all details of temporary works, including proposed methods of working.
54.15 Record of work
54.15.1All work carried out should be recorded in the OH&S file so that it can be available for future
inspection and repair work.
55.0 Radiation
55.1.1The use of radioactive substances and radiating apparatus shall comply with the Govt. regulatory
requirements.
55.1.2Operations involving ionising radiation shall only be carried out after having been reviewed
without objection by the Employer / Engineer and shall be carried out in accordance with a
method statement.

55.1.3Each area containing irradiated apparatus shall have warning notices and barriers, as required
by the Regulations, conspicuously posted at or near the area.
55.1.4Radioactive substances will be stored, used or disposed shall be strictly in accordance with the
Govt. regulatory requirements.
55.1.5The contractor shall ensure that all site personnel and members of the public are not exposed to
radiation.
56.0 Fire and smoke
56.1 Storage of materials
56.2 General
56.2.1Effective fire prevention depends on the elimination or control of materials likely to ignite or assist
in the development of fire. In the confined space of a tunnel, strict precautions are essential. The
amount of combustible material (e.g. timber, straw, paper, rubber), flammable liquid (e.g. oils,
chemical solvents and primers, paraffin) and compressed gas in a tunnel should be kept to a
minimum. Any materials not required imminently (generally those not needed during the working
shift), shall be removed to a surface storage area, except items such as emergency face timbers
and, in some cases, straw needed for safety purposes. Smoking and the carriage of smoking
materials constitute a fire hazard, and shall be prohibited below ground and only permitted in
designated areas on the surface away from combustible materials.
56.3 Combustible materials
56.3.1Combustible materials stored in a tunnel must have suitable fire-fighting equipment

conspicuously located nearby (see Table 5 and Table 6). Storage areas for combustible materials
shall have well-placed notices warning of the fire risk. Whenever practicable, the storage areas
shall be isolated from the general working area. They must not be in, or in the vicinity of, any
shaft or tunnel opening, or on any escape route, and be protected by some form of construction
that has a fire-resistance period of not less than 30 min when tested in accordance with BS 476-
20, BS 476-21 and BS 476-22. Surface structures and buildings at, or close to, any shaft or tunnel
opening should be constructed from non-combustible materials wherever practicable.
Table 5 — Provision of fire extinguishing equipment
Location of fire Extinguishing medium

Water (jet) Water Foam Inert gas Powder
(spray)
Tunnel — general F P P P
TBM — general P P P
TBM — hydraulics F F
TBM — electrics F F
Diesel plant F F
Battery locomotives F F
Fuel store P P

Battery charging P
Compressed-air workings F F P
Timber headings, break-outs, F P
etc.
F = Fixed
P = Portable
Table 6 — Portable fire extinguishing equipment
Class of materials involved Extinguishing medium

Fires involving solid usually of an organic nature, Water extinguisher
in which combustion normally takes place with
the formation of glowing embers
Fires involving liquids or liquefiable solids Foam extinguisher, CO2, dry powder
Fires involving gases Water spray to cool cylinder, foam to extinguish
any fire when valve has been closed
Fires involving metals Dry powder, dry sand Electrical equipment (if
live)
Electrical equipment (if live) Inert gas, dry powder, dry sand
56.3.2In any place where the use of timber would introduce a special hazard, whether by reason of the
location’s vulnerability, or because the consequences of fire are particularly serious, steel should
be substituted if possible. If straw is stored for emergency stuffing at the face, it should preferably
be kept in bales in a damp condition and stored in a metal container. However, it is strongly
recommended that straw not be used. Substitutes such as rockwool should be used wherever
possible.
56.4 Flammable liquids
56.4.1Flammable liquids shall always be contained in tightly sealed and properly labelled metal
containers, which should be stored in a cupboard or bin that is fire-resistant when tested in
accordance with BS 476-20, BS 476-21 and BS 476-22, such a bin or cupboard must be locked
when materials are not in use. Such liquids shall be stored apart from other combustible materials
and at safe distances from areas of high activity, electrical installations and explosive magazines.
Not more than one day’s supply of such liquids shall be kept in a tunnel.
56.4.2Drip pans/bunds must be provided to catch any leakage from containers.

56.5 Compressed gases
56.5.1 Below ground, cylinders containing oxygen must be segregated from cylinders of flammable gas
(e.g. acetylene, propane and butane), except when in use. Under no circumstances shall oxygen
cylinders be allowed to come into contact with any form of grease. All cylinders of compressed
gases must be kept away from flammable liquids and combustible materials. The cylinders should
be of the smallest size practicable for the operation to be undertaken, and shall remain
underground only for the period of the operation.
56.5.2 All cylinder valves, including the screw thread into the neck of the cylinder, shall be regularly
checked for leaks. Any cylinders found to be leaking must be removed to open air immediately.
Gas cylinders are liable to damage from mechanical impact, which could cause leakage from
valves or cylinder rupture, leading to explosion. Cylinders should therefore be protected by
suitable containers during handling, storage and use, and protected against any risk of impact by

falling or being struck by other plant or equipment. Cylinder valves and a fire extinguisher should
be immediately available.
56.6 Handheld blowpipes
56.6.1Handheld blowpipes must conform to BS EN ISO 5172 and shall be fitted with non-return valves
at both gas inlets, and with flame arrestors with cut-off valves at the gas supply outlets. All safety
devices must conform to BS EN 730. Hoses shall conform to BS EN 559, and pressure regulators
to BS EN ISO 2503. Transportable acetylene containers must conform to BS EN 1800.
Containers for other fuel gases shall conform to BS EN 12862 or the appropriate standard in the
BS 5045 series.
56.7 Lighting fixtures
56.7.1Any lighting fixtures in storage areas for combustible materials or flammable liquids shall be
constructed, located and maintained so that combustible materials cannot be ignited by the heat
that the fixtures produce.
56.8 Accumulation of refuse
56.8.1All combustible refuse shall be removed from a tunnel as frequently as practicable, at least once
per shift, to prevent the build-up of a fire hazard however It is preferable that such material be
removed in the normal process of working. Combustible refuse must not be deposited close to
any other combustible materials. Any combustible refuse that cannot be removed shall be stored
in metal bins with close-fitting lids, and away from naked lights and other fire hazards and ignition
sources. These refuse storage areas should have suitable fire-fighting equipment nearby.
56.9 Welding and cutting (burning)
56.10 General
56.10.1Whenever possible, such work should be undertaken at the surface or cold processes should
be adopted. In pressurized workings, the risk of fire is significantly increased, as all combustible
materials ignite more easily and burn more fiercely, making fire-fighting more difficult.
56.10.2In tunnels where explosive gases are present, hot work shall be prohibited. If there is potential
for these gases to be present, thorough atmospheric monitoring must be carried out before work
commences and continued throughout the work period. In the event of an explosive atmosphere
being detected, all hot work must cease immediately.
56.10.3A “permit to work” system shall apply to any underground welding or cutting. This should specify
the conditions for storage, transport and use of equipment, and the fire precautions. The “permit
to work” system must also cover the return of the equipment
56.10.4To surface storage. “Permits to work” shall have specific dates, as an open-ended-permits are
not considered acceptable. No work shall be carried out on fuel or oil tanks until they have been
purged and certified gas-free.
56.10.5On completion of the operation, the area shall be inspected to check that nothing is smouldering.
A fire-watcher with fire hose or extinguisher shall be in attendance during the operation and for
at least 1 h after its completion.
56.10.6No person carrying out welding or cutting shall be allowed to work alone, as they could fail to
notice a fire developing or be unable to extinguish it successfully. However, all unnecessary

personnel shall be excluded from the work area. Fumes are generated by many welding and
cutting operations, and so good ventilation is important. When worked, galvanized steel produces
toxic fumes that must not be inhaled. Local exhaust ventilation, airlines and air movers are
particularly effective in dispersing local concentrations of fumes.
56.11 Electric arc welding and cutting
56.11.1Petrol-driven generator sets shall not be permitted underground. Electrically-powered

transformer or rotary converter sets must be used as the power supplies for the generation of
electric arcs. If diesel sets are used, adequate ventilation is essential, and additional fire
precautions must be taken and proper arrangements made for the storage and handling of fuel .
Carbon electrodes may be used for arc-air gouging provided that there is adequate ventilation.
Arc welding plant, equipment, accessories and installations should conform to BS 638-4, BS 638-
5 and BS 638-7.
56.12 Fires involving electrical equipment
56.12.1The special hazard of fumes and smoke from burning PVC or similar cables must be taken into
account. Because of the restricted space in tunnels and the usually very damp conditions, it is
particularly important that arrangements for isolating defective cables or equipment be carefully
planned so that persons are not exposed to the hazards of electric shock and electrocution.
56.12.2The network of cables must be planned so that essential fire-fighting resources, including
pumps, lighting and ventilation, are not cut off in the process of isolating overheated equipment,
and so that signals and communications are maintained. Electrical fittings in areas where gas
cylinders are stored shall be protected so that they do not present a possible ignition source.
57.0 Fire precautions, Protection, Fighting System and Rescue.
57.1 General
57.1.1The advice and that of the local fire service shall be sought before the quantity, type and position
of fire protection equipment is decided. In addition to fire-fighting to save life, account must be
taken of the consequences of fire damage to the tunnel structure and the hazards associated
with any remedial work required.
57.2 Fire mains and hose connections
57.2.1A fire main conforming to BS 5306-1 / relevant IS, providing water for fire-fighting, shall be made
available throughout the tunnel, with hydrant outlets at intervals not exceeding 50 m. Such outlets
must be clearly marked and be readily accessible. The water supply shall be sufficient in volume
and pressure for the operation of fire hoses, water sprays or other fire-fighting equipment, and
the advice of the fire service must be sought. Equipment shall be located strategically in
accordance with the progress of the tunnel, and must be regularly tested and properly
maintained.
57.3 Fire extinguishing systems
57.3.1 All TBMs shall have fixed fire extinguishing systems (Refer clause No :56.3.1)
57.3.2 Portable fire extinguishers conforming to BS 7863 or IS 2190: 1979 Code of Practice for the
selection, installation and maintenance of portable fire extinguishers and to the appropriate
part(s) of BS EN 3-1 shall be provided. They shall be selected and installed in accordance with
BS 5306-8-2000 and maintained in accordance with BS 5306-3-2003. They must be sited so that
they are readily accessible by personnel. The effects of the extinguishing medium on the tunnel
atmosphere must also be taken into account in the selection process. Table 5 and Table 6
indicate suitable extinguishing media for a range of fire locations. BS 5306-1-2006 gives guidance

on the selection of appropriate systems. Recommendations concerning the application of fixed

or portable installations are given in Table 5.
57.3.3Distance of travel to Fire extinguisher not exceeding 15 M
57.4 Routine testing and maintenance of fire protection equipment
57.4.1All equipment should be maintained in good working order, and this should be verified by routine
testing in accordance with the manufacturer’s instructions. Records of such testing and
inspection shall be made available to the Employer / Engineer upon request.
57.5 Vulnerable items and locations
57.5.1Certain items and locations are particularly vulnerable to fire, whether by reason of high
flammability, or because a fire would be especially difficult to extinguish, or because the
consequences of a fire could be catastrophic. These items and locations should be identified,
assessed and protected. They include:
a) Timber in headings and face;

b) Stores or accumulations of:
— Timber and scrap timber;
— Paper cement bags;
— Straw;
— Oily rags and hemp;
— Flammable liquids and gases;
c) Conveyor belts;
d) Cables and wiring;
e) Electrical installations, including transformers and switchgear;
f) Hydraulic (oil) systems;
g) Flame cutting and welding areas;
h) All areas of compressed-air working;
i) All methane-bearing strata;
j) Storage areas for explosives;
k) Shafts and all openings to the tunnel;
l) Coal seams liable to spontaneous combustion.
57.6 Escape routes
57.6.1All escape routes underground shall be clearly signed. Blind headings must be marked as such.
Consideration shall be given to the provision of places of relative safety/refuges, where
appropriate however the suitability and location is subject to a full risk assessment and notice of
no objection from the Employer / Engineer.
57.7 Fire-fighting and rescue
57.7.1In addition to the hazard of fire, rescue of persons injured by falls and other accidents should be
considered; this is especially important in the case of a tunnelling machine that uses compressed
air in the cutter-head chamber. Lock-keepers and workers should be trained in the routine for
rescuing a person injured in the working chamber (the cutter-head chamber). They should also
be familiar with the manufacturer’s instructions for operation of the airlock(s) on the machine.
NOTE When there is a loss of pressure in the cutter-head chamber there could be a problem in
closing the door from there to the airlock in order to recompress the persons in the airlock.
57.7.2When a shaft is to be sunk using a vertical airlock, the method of removing an injured person
from the working chamber should be given consideration. The normal way to enter such an
airlock from the chamber is by climbing a ladder through a hatch and into a small chamber in

which it is only convenient to stand. An alternative means of egress for an injured person should
therefore be provided.
NOTE The most common way is to provide a man-riding cage that can be lowered through a
muck lock, into which the injured person can be lowered in a special emergency sling. The man-
riding cage can be covered with a hood or mesh so that no part of the person being rescued can
be trapped in the guides and doors. Access to the airlock should be tested to verify that it is
adequate for persons wearing breathing apparatus.
57.8 Fire services and operational capacity
57.8.1During the planning stages of construction the cooperation of the fire service should be sought in
making arrangements for fire-fighting and rescue and for summoning of the fire service.
57.8.2An assessment must be carried out during the planning stage of the tunnel project, in consultation
with the fire service, to establish their operational capacity including pre-determined attendance
times and to establish details of any additional facilities and equipment required for operations
beyond that capacity. A practical test of the plan shall be carried out in liaison with the fire
services.
57.8.3Because of the extended distances that occur in tunnel construction, special arrangements and
facilities may be necessary to assist fire services in dealing with incidents occurring in tunnels
during the construction stage. Fire service operational capacity in tunnels is based on the
principle that fire service personnel are able to take equipment to the scene of an incident, deal
with the incident and return to ground level safely. Equipment and other issues that should be
considered include some or all of the following:
a) provision of a suitable control room and/or a bridgehead location(s) from which
resources and operations can be controlled close to the incident;
b) underground transportation of personnel and equipment to the incident or bridgehead;
c) lighting, communications, ventilation, and smoke control;
d) fixed installations, e.g. water mains, fire suppression systems, fire-fighting hose;
e) portable fire-fighting equipment;
f) provision of extended-duration breathing apparatus;
g) training, and site familiarization for fire service personnel.
57.8.4 Following an assessment of operational capacity, the fire service may be unable to provide an
assurance that their personnel will be able to deal with all incidents within the tunnel. In this event,
the fire service must be asked to formally notify the contractor and give details of their reduced
operational capacity for the particular tunnel or stage of the tunnel construction. Thereafter, the
contractor should make their own arrangements for fire-fighting and rescue. The results of this
assessment must be issued to the Employer / Engineer who will verify that the contractor has
taken the appropriate measures as advised by the fire service.
57.9 Emergency control facilities
57.10 Control rooms
57.10.1An emergency control room shall be provided, from which the senior officers of the emergency
services can control their response to an incident. Such a room shall be equipped with ex-
directory telephone lines, site radio communications and drawings showing the up-to-date layout
of the underground workings.

57.10.2Where practicable, an emergency control room should be provided at the top of each shaft or
other point of access. If this is not possible, an up-to-date weatherproof drawing showing the
depths of shafts, layout of tunnels and location of fire-fighting equipment shall be displayed at
these locations. It must also give details of where and how to notify the fire service.
57.10.3On multiple-contractor projects, or once multiple access points or exits are established, control
rooms must be interlinked. In larger tunnels, and where requested by the fire service, a “leaky
feeder” communication system compatible with the fire service’s radio system shall be provided
for use underground.
57.10.4Full particulars of the ventilation system in use, including details of all fans and ducts, and of
any apertures and doors, shall be kept available for use by the fire service officers or other
responsible persons. A suitably qualified member of the contractor’s staff must also be made
available to the fire service to operate the ventilation system should this be necessary. Details of
all “permits to work” relating to the use of hot cutting/burning equipment must be available to the
fire service and in the emergency control room as this will provide and indication of works being
undertaken and the likelihood of hazardous/explosive substances that may be in the vicinity of
the incident/fire.
57.11 Bridgeheads
57.11.1A forward control point, or “bridgehead”, shall be provided in situations where it may be
necessary for breathing apparatus or other operations to be started up at a distance from the
original point(s) of entry to a hazardous area, whilst remaining in a safe-air environment.
57.12 Raising the alarm
57.12.1Adequate arrangements shall be made for raising the alarm and calling the fire service in the
event of a fire underground. The fire alarm system shall be extended and modified as the
tunnelling work proceeds. The alarm should be clearly perceptible to all persons in the workings,
and to key personnel above ground. Warning arrangements can include any or a combination of
the following, as appropriate:
— Vocal warnings;
— Telephone communications;
— Hand-operated or electrically-operated bells or sirens;
— Special flashing lights;
— Flashing of the main lighting circuits.
57.12.2 The locations of the fire alarm devices shall take into account the layout of the working areas
underground, the adverse nature of the working conditions (especially high noise levels) and the
transient nature of the working locations. Where single alarm systems are used, wiring must
conform to BS 6387:1994, meeting a minimum category rating of AWZ [i.e. the lowest
performance category for resistance to fire (A), resistance to fire with water (W), and the highest
performance category for resistance to fire with mechanical shock (Z)].
57.12.3 A separate and distinct signal to order the total evacuation of the workings must be provided.
The fire alarm systems should be regularly tested and properly maintained. Records of such test
shall be regularly inspected by the Employer / Engineer.

57.12.4The locations of the alarm devices should take into account the layout of the working areas
underground, the adverse nature of the working conditions (especially high noise levels) and
the transient nature of the working locations
57.13 Alarm procedures
57.14 Consultation and planning
57.14.1Specific procedures should be prearranged for each site. The contractor shall consult the fire
service for advice on fire and evacuation procedures. Planning must cover matters such as
arrangements for fire-fighting, rescue and evacuation, and the management controls necessary
to affect this. Protocols for calling the fire service shall include instructions to switchboard/security
staff on how emergency calls are to be made, and the information that is to be passed to the fire
service control.
57.15 Action at point of discovery of fire or smoke
57.15.1All personnel should be given the following set of instructions to follow on the spot when there
is a fire or suspicion of fire in a tunnel or underground working.
a) Raise the alarm in the tunnel and attack the fire only if it is safe to do so.
b) Report the fire, stating the following;
— Where the fire is;
— What is on fire;
— Whether evacuation is in progress.
57.16 Action on receiving the alarm
57.16.1The person on site receiving the alarm must immediately undertake the following:
a) Summon the fire service, giving a precise rendezvous point, and arrange for a
responsible person to meet them on arrival;
b) Inform the senior site manager or emergency coordinator and the Employer / Engineer.
57.17 Site training
57.17.1All underground personnel shall receive training in the care and use of fire-fighting equipment.
All site personnel shall be made familiar with the fire emergency procedures prescribed. Fire drills
must be held to familiarize all personnel with the practical working of the systems.
57.18 Access
57.18.1Access to the site, and the provision of, and access to, hard standing for fire appliances and
ambulances is of vital importance and must be included in the site emergency procedures,
following consultation with the local fire service and ambulance services. Access to the shaft and
workings must be available for the emergency services at all times. The surface of any walkways
in the tunnel shall be maintained in a safe condition so that they can be used safely by fire-
fighters, even in conditions of nil visibility.
57.19 Lighting
57.19.1Emergency lighting shall be provided and maintained at all times, particularly at fire points,
escape routes, emergency exits and tunnel access points.
57.20 Smoke control

57.20.1Smoke is a major danger in fire, as it can cause asphyxiation. It can interfere with visibility,
resulting in disorientation and possibly panic. The hazard can be reduced by using the ventilation
system to the best advantage. The problem shall be studied in advance in liaison with the fire
service. The aim should be to configure the airflow so that it clears the heat and smoke without
spreading the fire.
57.20.2Valved discharge points can be provided at intervals on an air line along a tunnel to provide air
for persons trapped by fire and smoke. Self-rescuers and breathing apparatus must also be
provided, as these are necessary in severe conditions of smoke. The use of a water spray curtain
at the outbye end of a TBM will significantly control the spread of smoke from a fire on the
machine.
57.21 Rescue facilities
57.21.1First aid equipment, including stretchers, shall be available. Rescue equipment, including full
breathing apparatus (SCBA/CCBA), shall be provided and maintained so that it is readily
available in an emergency. All rescue equipment must be stored in containers designed to
provide protection from adverse conditions likely to be encountered in the workings. In many
tunnels, a dedicated rescue skip or train will be necessary for quick response by a site rescue
team and/or emergency services, the provision of such equipment shall be determined through
risk assessment.
57.22 Self-rescuers
57.22.1All persons underground should have immediate access to a self-rescuer which provides the
user with a supply of oxygen for at least 60min whilst walking. Where such oxygen supplies are
likely to be needed for longer periods, stockpiles of additional rescuers shall be provided at
intervals, e.g. in long tunnels. Self-rescuers should normally be worn on a belt by persons
underground, but may be stored in racks that are immediately accessible for use in an
emergency. Where alternative escape routes are available, racks of self-rescuers shall be
provided for each escape route. If self-rescuers are stored on racks, there must be a maintenance
and inspection system to check that a sufficient number are always available and that they are
always in full working order.
57.22.2The highest standard of cleanliness must be maintained in situations where oxygen is used.
Specialist advice should be sought on how this is best achieved. For guidance on the use of self-
rescuers in compressed air.
58.0 Access
58.1 Walkways
58.1.1Pedestrian access is generally provided by walkways. Every tunnel shall have a safe pedestrian
route from face to pit bottom and then by stair tower to the surface. In shafts and tunnels where
man-riding is carried out, a walkway may be required only for maintenance access or for
emergency evacuation.
58.1.2The pedestrian route shall be clearly marked. A walkway shall provide a minimum clear space of
2000 mm high and 900 mm wide with a walking surface not less than 430 mm wide. Where a
walkway is adjacent to a traffic route, precautions must be taken to safeguard any persons using
it during the passage of vehicles, unless the simultaneous passage of pedestrians and vehicles
is prevented.
58.1.3Extra clearances must be allowed for side-throw, end-throw and sway of vehicles and for the
contingency of derailment. Where continuous clearance with the recommended minimum

dimensions is not practicable, refuges must be provided at intervals related to the curvature and
gradient of the tunnel and to traffic speed.
58.1.4The visibility of both vehicle drivers and pedestrians can be adversely affected by dust or humidity
in the atmosphere. Such refuges shall be clearly illuminated and may comprise:
a) Recesses constructed outside the general line of excavation;
b) Robust barriers between the safe position and the haulage route;
c) Stages raised clear of any possible hazard.
58.1.5Refuges must also be provided where there is no space for a segregated pedestrian walkway
and man-riding is not in use. In addition, a safe system of work shall be implemented to protect
persons who are required to be in the tunnel from the danger of tunnel transport. The walkway
surface must be maintained in good condition and shall incorporate adequate grip and be free
from slipping, tripping or falling hazards such as irregularities, sudden changes in level, loose
boards, obstructions, etc. It could be required by the emergency services in conditions of nil
visibility.
58.1.6Elevated walkways from which a fall of 1.5 m or more is possible shall be furnished with suitable
guard rails and toe boards. Hand rails or similar shall be provided on inclined walkways. All
stairways shall be provided with guard rails and toe boards. Water should not be allowed to stand
or accumulate at or above walkway level at any point. Any accidental spillage of muck or other
material on a walkway must be cleared away promptly.
58.1.7It is important to provide adequate lighting along a walkway, not only to assist pedestrians, but
also to allow haulage drivers to see pedestrians clearly. The lights should be located so that they
are not obscured by passing vehicles. In unlit tunnels, where only occasional access is required
for inspection and maintenance, refuges shall be identified by reflective material. As necessary,
reflective signs indicating escape routes shall also be posted. Persons entering unlit tunnels must
be equipped with a suitable hand/cap lamp and appropriate means of communication.
58.1.8Access on foot shall not be permitted in a tunnel whilst a winch haulage is in operation, unless
there is adequate protection to the walkway.
58.2 Access for maintenance
58.2.1Where access in tunnels is required for maintenance/minor repair purposes only, the risk
assessment should make provision for this. Any safe system of work devised should address:
a) Minimum dimensions for access, which are set out in prEN 12336 .
b) Adequate ventilation;
c) Gas monitors and self-rescue sets;
d) Rescue procedures, with due allowance made for limited access and any reduced
number of Personnel on site;
e) The type of breathing apparatus and stretcher available;
f) The need for at least two persons in any one location.
58.3 Working at height in tunnels and shafts
58.3.1Where work at height is required in tunnels and shafts, the system used must be fit for purpose.
For work such as the installation of bolts in tunnel linings or mesh in sprayed concrete linings,
mechanical access equipment shall normally be used. Fixed ladders and access platforms or
permanently installed moveable platforms shall be provided where work at height is regularly
required at the same location, e.g. to place and tighten tunnel lining bolts on TBMs. For short
duration work at height, ladders are acceptable provided that they can be properly grounded and

secured. Mobile access towers shall not normally be used for work at height, given the rigours of
the tunnel environment.
59.0 Blasting Operations

59.1 General
59.1.1The Contractor shall design and implement his blasting techniques so as to minimise dust, noise,
vibration generation and prevention fly rock.
59.1.2Blasting technique should be consistent not only with nature and quaintly of rock to be blasted
but also the location of blasting.
59.2 Authorisation for Blasting
59.2.1The Contractor shall ensure that all blasting operations will only be permitted following
consultations with the relevant authorities and subsequent issuing of the permission to blast
permits. The Employer / Engineer must also give his consent in writing before any blasting
operations take place.
59.2.2All blasting shall be conducted under the direct supervision of a Licensed Shotfirer.
59.3 Risk Assessment and Method Statements
59.3.1The Contractor shall produce a detailed hazard and risk assessment and an in depth
method statement for amongst others the following elements:
(a) Type of explosives to be used.

(b) Anticipated effects of vibration on nearby structures.
(c) Blasting patterns.
(d) Delivery of the explosives.
(e) Transportation and storage of explosives on site.
(f) Drilling and charging of holes.
(g) Warning sirens.
(h) Measurement of Vibration
(i) Provision of sentries.
(j) Use of blast screens.
(k) ALL CLEAR.
(l) Ventilation following blasting.
(m) Atmosphere monitoring.
(n) Procedure for miss-fires.
60.0 Drilling
60.1 Drilling General
60.1.1Appropriate precautions should be taken before drilling commences including barring and scaling
the tunnel face and crown adjacent to the face, clearing the face and examining it and the muck
pile for misfires. These should be dealt with in accordance with appropriate regulations.
60.1.2Mark round on tunnel face with material which can easily be seen and not removed, e.g. paint.
Avoid drilling into existing sockets.
60.1.3Accurate marking, drilling and loading of the round will minimise shattering of surrounding rock.
61.0 Compressed air works

61.1 General Measures
61.1.1Identification badges Should be given to all employees, indicating that the wearer is a
compressed air Worker. A permanent record should be kept of all identification badges issued.
The badge which should be worn at all times off the job as well as on the job should contain the
following information;
i) Employees name
ii) Address of medical lock; and
iii) The telephone number of the appointed medical practitioner.
61.1.2 It should also contain instructions that in case of sudden illness or emergency of unknown or
doubtful cause the wearer should be rushed to the medical lock.
61.1.3 When no lock attendant is inside a man lock or working chamber the arrangements should be
such as to enable any person employed in compressed air inside the man lock or working
Chamber to control the door of the man lock or warning chamber in order to leave or enter the
working chamber in the case of emergency.
61.1.4 No person should consume alcohol whilst he is employed in compressed air.
61.1.5 No person under the influence of alcohol should undergo compression in any lock other than
India medical lock.
61.1.6 No person should smoke whilst he is employed in compressed air.
61.1.7 No person should wilfully
i) Obstruct; or
ii) Delay; or
iii) Refuse to follow any instruction given by a lock attendant or medical lock attendant in the
course of his duties.

61.2.1To be able to enter a compressed air environment the worker must present proof of hyperbaric
medical fitness.
61.2.2Personnel shall, except under exceptional circumstances, not be younger than 18.
61.2.3A comprehensive medical examination prior to entering a compressed air environment for the
first time is required along with an annual comprehensive medical examination and periodic
medical checks thereafter.
61.2.4 Workers suffering from the following ailments should not enter a compressed air environment.
a) chronic infection of the nasal ducts (sinusitis)
b) chronic ostitis, perforated eardrum, permanent obstruction of the Eustachian tube
c) chronic lung infection (bronchitis, asthma, tuberculosis, etc.)
d) heart infections
e) epilepsy
f) serious loss of hearing and sight

g) diabetes
h) psychiatric deviations
i) alcoholism
j) ulcers
k) hernia
l) anaemia
m) chronic kidney infections
n) some skin infections.
61.2.5 The medical examination and checks should be undertaken by a doctor competent in hyperbaric
medicine. The doctor should advise on the content of the examinations but as a minimum, the
following examinations but as a minimum, the following examinations should be made:
a) electrocardiogram including one under physical stress – annually.
b) ear, nose and throat – annually.
c) spirometry (functioning of the kings) – annually.
d) blood tests – complete blood count- annually.
e) pressure test in decompression tank or room.
f) lung and long bone x-rays (at the doctor’s discretion)
61.3 Competent persons for a supply plant
61.3.1The contractor should appoint your suitably qualified or experienced person to be in charge of
the art supply plant at a construction site.
61.3.2A person appointed at all times be: -
i) In charge of the plant; and
ii) In attendance at the construction site when any person is employed in compressed air at the
construction site
iii) There should be also an experienced, competent and reliable person on duty at the, air control
valves as a gauge tender who will regulate the pressure in the working areas
61.4 Air-Supply Plant
61.4.1The air supply plant for the production and supply of compressed air to any man lock working
chamber and medical lock should be of suitable design.
61.4.2The air intakes for all air compressors should be located as far as practicable at a place where
fumes exhaust gases and other air contaminants will be at a minimum. Gauges indicating the
pressure in the working chamber should be installed in the compressor building the lock attendant
station and at the contractors site office
61.5 Low Air Compressor
61.5.1The Low air compressor plant should be of sufficient capacity to ensure that the work is carried
out safely

61.5.2Air compressor units should have at least two independent and separate sources of power supply
and each should be capable of operating the entire low air plant and its ancillary systems
61.5.3Switching from one independent source of power supply to the other should be done periodically
to ensure the workability of the apparatus in an emergency.
61.5.4The air mains supplying the working chamber and airlocks should be properly protected and
where failure could result in danger to the workings should be duplicated.
61.6 Man Locks
61.6.1Every man-lock should be of adequate internal dimensions and capacity for the purposes for
which it is used
61.6.2Every man-lock should have an independent supply of fresh air which can be used for ventilation
61.6.3 Every man-lock should be provided with suitable equipment including –
i) Valves are taps controlling the flow of air into and from the man-lock so as to enable careful
compression and accurate decompression to be carried out;
ii) A clock or clocks so positioned that the lock attendant and any person in the man-lock can
readily ascertain the time;
iii) Pressure Gauges which will readily indicate –
a) To the Lock attendant the pressure in the Man-lock and in each working chamber to
which the man-lock affords direct or indirect access;
b) To persons in the man-lock the pressure in the Man-lock; and
61.6.4A notice which can be easily read and understood by the workers, indicating,
i) The precautions to be taken by persons during the compression and decompression and after
decompression;
ii) The maximum number of persons who may normally be accommodate man-lock.
iii) Should be fixed in each man-lock.
iv) All furniture and equipment in a man-lock Should be incombustible or of fireproof material
v) When the pressure in a working chamber exceeds 1 bar, the man-lock should be used solely
for the Compression and decompression of persons.
vi) No person should be employed in compressed air unless – He has had previous experience
of such work; or If he has not had such experience, He is accompanied by a person experienced
in such work.
61.7 Compression and decompression
61.7.1Compression of all persons in the man-lock should be carried out according to the compression
procedures
61.7.2Decompression of all persons to normal conditions should be in accordance with their.

decompression procedure and should be carried out under supervision of the appointment
medical practitioner

61.7.3Where a person in man-lock collapses or is taken ill during decompression, the lock attendant in-
charge should raise the pressure in the working chamber and should report the matter
immediately to the medical lock attendant on duty the lock attendant should then follow the
instruction of the medical lock attendant or the appointed medical practitioner on duty
61.8 Medical Locks
61.8.1Where persons are employed in compressed air in a working chamber, a suitably constructed
medical lock should be provided and maintained.
61.8.2Where more than 10 persons so employed medical lock should be provided.
61.8.3Every medical lock should be situated as near as possible to the Man-lock.
61.8.4Every medical lock should –
i)Have not less than 1.8 m clear headroom at its height point;
ii)Have 2 compartments so that it can be entered while under pressure.
iii)How efficient means of verbal communication and means of giving nonverbal signals between
persons inside and outside the medical lock and between persons in compartments of the
medical lock;
iv)Have one or more Windows through which any person in either compartment of the medical
lock can be observed from the outside;
v)Be adequately ventilated;
vi)Be protected from the weather and the sun;
vii)Have adequate lighting.
61.8.5Every medical lock should be provided with suitable equipment including: -
i)A pressure recording gauge which should be accurate within 0.05 bar;
ii)If a circular recording chart is used it should rotate at a speed of not less than once in 4 hours;
iii)a couch not less than 1.8 metres length.
61.8.6Medical lock should not be used for any purpose other than a therapeutic purpose, but it may be
used:
i) For training and testing of persons without previous experience of compressed air work; or
II) In case of emergency.
iii) A medical lock should at all times be kept ready for immediate use.
iv) External lighting should be used however if internal wiring is necessary then such wiring
should be of mineral insulated copper cable protected by stainless steel tubing complying with
British Standard 6207 or equivalent standards.
v) All spark or arc-creating devices such as switches, standard light bulbs, and standard electrical
outlets should not be used within a medical lock.
vi) A medical lock is an air receiver. It should be tested and registered by department of
occupational safety and health.

vii) A Medical lock should be capable of withstanding a pressure of not less than 100 Kn/m 2 above
the maximum pressure used or likely to be used in the chamber at any time.
61.9 Man-lock and medical lock
61.9.1Every man-lock or medical lock should be under the charge of a lock attendant or medical lock
attendant respectively.
61.9.2That should be not less than 3 man-lock or medical lock attendants available for duty in respect
of each man-lock or medical lock attendant respectively.
61.9.3No man-lock or medical lock attendant should be on duty for more than 12 hours in any 1 shift.
61.9.4All man lock and medical lock attendance should:
i) Be medically fit;
ii) Be willing to go into compressed air at any working pressure;
iii) Be trained in first aid; and
iv) Have completed a suitable training course designed to familiarise them with the problems
associated with compression decompression and compressed air illness and with the keeping
of records
61.9.5The Man-lock attendant should attend the man-lock or in a working chamber to which the man-
lock affords direct or indirect access.
61.9.6The medical lock attendant should attend the medical lock: -
i)Whilst any person is employed in compressed air at a pressure exceeding 1 bar.
ii)Whilst any person is being treated in the medical lock; and
iii)For 24 hours after the last man-lock decompression from a pressure exceeding 1 bar has
taken place.
61.9.7 A medical lock attendant should when on duty have immediate access to all records of precious
and other relevant information regarding conditions in the man-lock and working chamber.
61.10 Duties of man-lock attendants
61.10.1The Lock attendant in charge of a man-lock should: -
i)Control the compression of all persons in the man-lock
ii)Carry out the compression of all such persons according to the compression procedure
iii)Control the decompression of all persons who have been employed in compressed air; and;
iv)When a person has been employed in compressed air at a pressure exceeding 1 bar carry
out the decompression of the person according to year decompression procedure set up
appointed medical practitioner.
61.10.2Where any person is employed in compressed air in a working chamber the lock attendant in
charge should: -
i) Record in the lock attendant's register and any man-lock decompression chart and give them
to the medical practitioner.

ii) Keep in his custody the lock attendant's register and any man-lock decompression chart and
give them to the medical practitioner.
61.10.3 The contractor should ensure that the lock attendant in charge of a man- lock complies with
British Standard 6207 or equivalent standards.
61.11 Appointment of Medical Practitioners
61.11.1Where any construction work in compressed air is carried out, the contractor should appoint a
medical practitioner to supervise all medical matters which may arise in connection with the
construction work.
61.11.2The appointed medical practitioner should be: -
i) Suitably qualified and conversant with the problems associated with work in compressed air
and the medical aspects of such work;
ii) Conversant with the provisions of these guidelines.
iii) Medically fit;
iv) Willing go in to compressed ait at any working pressure; and
v) On call at all times when construction work in compressed air is in progress.
61.11.3The appointed medical practitioner should: -
i) Examine medically persons for fitness for employment in compressed air;
ii) Supervise medical lock attendants;
iii) Treat compressed air lines and other conditions; and
iv) Supervise the keeping of: -
v) All compressed air workers medical information, including the Compressed Air Workers
Medical Records.
vi) The compressed air workers’ Compressed Air Illness Notification Form.
vi) The compressed air workers’ individual records and
vii) Ensure that all the above records are readily available for submission to the Employer /
Engineer when required.
61.12 Medical Supervision and Certification
61.12.1No person should be employed in compressed air unless he has been examined by an
appointed medical practitioner and certified by hi, to be fit for such employment.
61.12.2 In the case of a person who: -
a) Is a new starter, the examination for certification of fitness should be carried out not more
than 3 days prior to work in the compressed air;

b) Is not a new starter and who continues to be employed in compressed air at a working
pressure not exceeding 1 bar, the examination for certification of fitness should be carried
out not less than once in every 3 months;
c) Is not a new starter and who continues to be employed in compressed air at a working
pressure exceeding 1 bar, the examination for certification of fitness should be carried out
not less than once in every 4 weeks.
61.12.3A person who is required to be employed in compressed air and who is suffering from a cold in
the head, chest infection, sore throat or earache should report the matter to the appointed medical
practitioner should recommend to the Chief Safety Manager whether he is fit to work or not.
61.12.4Any person suffering from a cold in the head, chest infection, sore throat, earache or any other
illness or injury necessitating absence from work for more than 3 consecutive days should be re-
examined by an appointed medical practitioner and certified by him to be fir for employment in
compressed air before he resumes such employment.
61.13 Radiographic Examinations
61.13.1Every person employed in compressed air at a pressure exceeding 1 bar should undergo a
radiographic examination of his major joints within 4 weeks after starting such employment,
unless the person has such an examination during the 12 months immediately preceding such
employment.
61.13.2Every person who continues to be employed in compressed air at a pressure exceeding 1 bar
should undergo such an examination at intervals of about but not more than 12 months.
61.13.3These radiographic examinations should be arranged by the appointed medical practitioner

should enter the particulars of such radiographic examinations in the Compressed Air Worker’s
Medical Record
61.13.4Every person employed a proposed to be employed in compressed air should submit himself
for the necessary medical examinations.
61.14 Working chambers:

61.14.1All parts of the working chamber should be so designed that they can withstand the specified
pressure. The effects of this pressure on the surrounding ground should be considered.
61.14.2The electrical installations should be unaffected by pressure and be waterproof, dustproof and
explosion protected.
61.14.2An emergency power system via fire hardened cables should be provided to power safety critical
equipment. In the event of power failure, the emergency lighting should switch on automatically.
The power source for the automatic emergency lighting system should be above ground.
61.14.4At the working face there should be adequate fixed lighting.
61.14.5The air temperature in the workings should be maintained between 150C and 300C
61.16 Bulkheads and Air Locks
61.16.1All Bulkheads and air-tight diaphragms retaining compressed air within a tunnel or shaft should
be capable of carrying the full thrust of the compressed air at its maximum pressure.
61.16.2If the bulkhead is across a tunnel, its anchorage into the tunnel walls should be fully adequate
to support the total load and any air lock or other sealed aperture should be properly anchored
into the bulkhead.

61.16.3Tests should be conducted on airlocks at working pressure before being put to use
61.16.4Bulkheads should be tested in situ at working pressure
61.16.5If the diaphragm takes the form of a horizontal air deck across a shaft, it should anchor sufficient
mass to resist the thrusts by gravitational force alone and should not rely on the tensile strength
of cast iron or concrete
61.16.6The deck should be designed to take all the dead loads when the shaft is under pressure.
61.16.7Air lock Construction should conform with the following: -
i) Should have adequate strength to with stand any air pressure internal or external to which
the structure may be subjected in use and in an emergency.
ii) Lock doors are to be of Steel
iii) Should be of adequate dimensions for the full number of men likely to use the lock at any
time.
iv) Anchorage of the lock against the thrusts imposed by air pressures on the ends of the lock
should be designed to carry all loads safely.
v) Air tightness for the lock itself and satisfactory devices should be provided for ceiling the
doors even at low pressures the inner walls of the locks should be suitably treated to eliminate
the escape of air; and
vi) Incombustible materials to be used as extensively as possible
61.17 Firefighting equipment:

61.17.1Water jets and sprays should be the principal means of extinguishing a fire in compressed air.
61.17.2As normally pressurized fire extinguishers cannot be relied on to function effectively under
pressure, hyperbaric extinguishers should be provided.
61.17.3Breathing apparatus for use in smoke and fumes should only be employed by those trained in
its use. Only self-contained compressed air breathing apparatus, (of the type that does not have
an air cushion seal to the mask) should be used. The effects of working in a pressurized
environment on the duration of the apparatus should be taken into account.
61.17.4Firefighting in compressed air calls for special training and a site fire squad should be
designated and trained for firefighting. Firefighting should only be attempted to save life.
61.17.5Methane gas in coal seams can occur at high pressures and could form an explosive mixture
with the compressed air in the working chamber. Any possibility of the presence of methane
therefore calls for careful study, detection, assessment and additional safety precautions.
61.18 Geological Controls
61.18.1During the construction of the works the geological data must be continuously compared with
what is actually encountered. If necessary the construction methods may have to be adapted to
suit changing conditions.
61.18.2Allowance should be made for variations in ground water level due to the tides, the presence of
water under pressure etc.
61.18.3To minimize risk from working in compressed air, the lowest possible air pressure should be
used at all times. To this end it can be beneficial to initially lower the groundwater level. The effect

of this on the surrounding ground should be thoroughly investigated. The compressors should be
able to counteract the full water pressure in an emergency.
61.18.4In day the pressure of pre-consolidated layers could cause large distortions. By adjusting the
air pressure the distortions can be limited but not eliminated and grouting may by necessary.
61.18.5In highly porous ground (e.g. coarse sand) air loss can make it impossible to achieve the
required working pressure. Air loss can be reduced by covering the face in an impermeable
material such as plastic sheeting or day by injection grouting.
61.18.6Materials used for injection grouting should not give off toxic gases.
61.18.7Consideration should be given to the possible presence of obstacles like boulders or obstacles
near the surface around which compressed air can escape (e.g. old sewers, shafts, boreholes
etc.)
61.18.8The importance of sufficient ground cover above the works to prevent ‘‘blow-up’’ should be
considered.
61.19 Control of The Air in the Working Chamber and the Lock
61.19.1The air in which the workers are working should be as clean as possible.
61.19.2In the working chamber and especially at the face the air quality should be constantly monitored
and additional ventilation air supplied as necessary. Allowance should be made for the fact that
the air could be contaminated by the nature of the ground (lignite oxidising materials, grouting
materials, presence of methane, etc.) and by the equipment being used (e.g. oil mist from
pneumatic tools).
61.19.3Monitoring instruments should clearly indicate the buildup of dangerous contaminants in the air
(O2, CO, CO2, SO2, NOX, CH4). The ventilation system must allow for the size of the working
chamber and the lock and also for the various contaminating factors.
61.20 Precautions to be taken after Work
61.20.1Hose working under pressure should be instructed in the risks associated with such work.
61.20.2Decompression illness can occur anytime during the first few hours after leaving the lock. During
this period a worker should be able to easily contact the medical lock attendant on site and to
reach a treatment chamber.
61.20.3The worker should not participate during the first few hours in diving, flying, mountaineering or
any strenuous sport or exercise.
61.20.4Following treatment for decompression illness, the doctor should examine the worker and certify
the period out of compressed air which is required before returning to compressed air working.
In principle this should be at least 12 hours.
61.21 Maintenance of Records
61.21.1The contractor should maintain a register of all persons employed in compressed air. Such a
register should include the following particulars of the person’s:
i) Name
ii) Identity card or work permit number
iii) Date of birth
iv) Nationality

v) Home address and
vi) Occupation
vii) The contractor should make available a copy of all medical records of that particular person
employed in compressed air on termination of is employment.
62.0 Pressure Vessels (Air Receivers)

62.1.1Pressure vessels should be constructed and inspected in accordance with national statutory
requirements.
62.1.2Pressure vessels should be kept clean and free from mineral oil or other inflammable material
which could ignite under working
62.1.3Pressure vessels should be maintained in a safe working condition at all times.
62.1.4Daily maintenance should include draining of any liquid which may have collected in the receiver,
for this purpose a suitable drain controlled by a valve should be provided at the lowest part of the
receiver.
62.1.5Every pressure vessel should be inspected and tested before being commissioned and thereafter
inspected at regular intervals of not more than five years.
62.1.6They should be hydraulically pressure tested at regular intervals of not more than two years.
62.1.7Every pressure vessel should have a plate securely fixed to it in a conspicuous place bearing
the following particulars:
a) Name of manufacturer
b) Manufacturing number
c) Country of origin
d) Year of manufacture
e) Maximum safe working pressure and temperature
f) Capacity
g) Date of last inspection and test
62.1.8Pressure vessels should not be modified on site.
62.1.9Every pressure vessel should be provided with at least one reliable pressure gauge on which the
maximum safe working gauge pressure shall be clearly marked with a red line.
62.1.10Every pressure vessels should be provided with at least one over-pressure relief valve capable
of passing the maximum inflow of air to the vessel.
62.1.11To prevent tampering with such valves, they should be kept locked, sealed or otherwise
rendered inaccessible to any unauthorized person.
62.1.12Every pressure vessel should be provided with a shut-off valve at the outlet into the mains.
62.2 Air Lines
62.2.1Air lines should be manufactured to a recognized national standard and rated for the expected
working pressure.
62.2.2Only pipes and fittings in good condition should be used.

62.2.3Quick coupling metal pipes (including flanged pipes) may be used for the main supply.
62.2.4Reinforced polyethylene or rubber hoses may be used for smaller diameters (less than 200 mm)
or for low pressures (up to 7 bar).
62.2.5Reinforced polyethylene or rubber hoses should be fitted with sturdy couplings.
62.2.6Restraints should be fitted across joints in flexible air lines to prevent danger in the event of
unexpected disconnection.
62.2.7The air line should not be disconnected unless the supply has been cut off and pressure has
been reduced to zero.
62.2.8Air supply lines should be adequately supported both above ground and in shafts and tunnels.
They should be protected from mechanical damage.
62.2.9Shut-off valves should be installed in all main supply air lines at regular intervals depending on
size of airline but a maximum spacing of 500 m is advisable.
62.2.10Shut-off valves should be fitted at the entrance to the works and near the end of the supply line
to close off air supply in case of damage.
62.2.11Discharge valves should be fitted in air lines to reduce air pressure in the air lines when
equipment is shut down.
62.2.12Air lines and their fittings should be maintained in good condition and leaks should be repaired
promptly both to reduce air loss and control noise emission. A drain should be fitted to an airline
to enable moisture present in the air line, to be drained off regularly before entering the
equipment.
62.2.13Filters should be installed in the air line near equipment to prevent solids entering the equipment.
63.0 Use of Explosives
63.1 General
63.1.1Only competent shot firers should be authorised to handle and use explosives. They should be
aware of local regulations, if any, and manufacturers recommendations.
63.1.2At change of shifts the shot firer should fully inform his relief of the state of the work at the face.
63.2 Explosives
63.2.1Explosives and detonators not required for immediate use should not be stored in the tunnel.
63.2.2Only water resistant explosives should be used in tunnelling.
63.2.3Under freezing conditions only explosives not susceptible to the cold should be used. In order to
ensure adequate transmission of the detonation, cartridge diameter must be more than 30 mm
and the space between explosives and surrounding material should be as small as possible.
63.2.4The destruction of old or damaged explosives is a hazardous operation and should be done in
accordance with accepted safe practice.
63.2.5Explosives should in all cases, be used in accordance with local or other appropriate regulations.
63.3 Detonators
63.3.1Various types of initiation systems are available and selection should be made with local
conditions in mind. Detonators should be stored and transported separately from explosives.
63.4 Firing Sets – Firing Lines

63.4.1The initiator should match the detonators used.

63.4.2Initiators should be adequately maintained.
63.4.3Electrical firing lines should be installed on opposite sides of tunnel from power lines or other
conductors such as water lines.
63.4.4All electrical firing lines should be kept short-circuited when not in use.
63.5 Blasting
63.5.1A blasting plan should be drawn up before any blasting is undertaken.
63.5.2All blasting should be carried out in accordance with the plan.
63.6 Transport of Explosives
63.6.1Detonators and other explosives should be transported separately and should be stored apart
until used.
63.6.2Only sufficient explosives for immediate use should be transported to the working face.
63.6.3Explosives should be transported in containers and / or vehicles specially designed for the
purpose. Such containers and/or vehicles should be dearly marked to distinguish them from other
vehicles.
63.6.4A responsible person should always accompany the explosives during transport.
63.7 Charging of the round
63.7.1Charging should not be undertaken until all drilling in that area has been completed.
63.7.2In the event of the threat of thunderstorms, charging with electric detonators should be stopped
immediately and the working face evacuated. Non-electric detonators should be used in that
case.
63.7.3Charging and blasting should be done by authorised persons.
63.7.4Electric detonators shall only be used where stray currents can be excluded.
63.8 Precautions before blasting
63.8.1Before proceeding with continuity testing of the firing circuit, care should be taken to remove all
persons from the danger zone and guards should be placed to prevent access to the danger
zone. Persons in working areas adjacent to the blasting site should be warned of pending blasting
operations.
63.8.2Guards must remain at their posts until they have received definite instructions to leave.
63.8.3Consideration should be given to the use of non-electric system or electronic (micro-chip) blasting
systems.
63.9 Protection against fly rock
63.9.1People should be removed from the blasting area to a safe place where they will be protected
from projectiles or flying rock.
63.10 Testing the firing circuit
63.10.1Testing the electric firing circuit for continuity is necessary in order to prevent misfires. Testing
consists of measuring the circuit resistance with an ohmmeter of an approved type.

63.10.2Testing should be done from the firing point and if any fault is detected it should be rectified
before the blast.
63.11 Precautions after Blasting
63.11.1Adequate ventilation should be provided and atmospheric monitoring carried out to ensure the
removal of all hazardous gases before re-entry.
63.11.2The shot firer and assistant should check the face and make safe before allowing work to
proceed.
63.11.3Before mucking operations the responsible person shall check to ensure that safety precautions
have been carried out.
63.11.3Vehicles used for the transport of explosives or detonators should be regularly inspected and
maintained to check that they do not present any risk to the materials carried.
64.0 Monitoring of the tunnel atmosphere
64.1 General
64.1.1A summary of the most commonly encountered atmospheric contaminants and their properties
is given below. This should be used as a guide when controlling the risks from these hazards.
64.1.3Monitoring for oxygen concentration should be carried out routinely by the use of electronic
atmospheric monitoring equipment. Where the presence of gaseous contaminants is
foreseeable, continuous monitoring by electronic equipment should likewise be carried out.
64.1.4At range of gases including methane, hydrogen sulfide and radon dissolved in ground water may
enter the tunnel.
64.1.5Ventilation should be used to dilute contaminants and to prevent the build up of an irrespirable
atmosphere.
64.2 Summary of The Most Commonly Encountered Atmospheric Contaminants
Gas Hazard Principal sources

Carbon monoxide Toxic and potentially Internal combustion engines and
explosive explosives
Carbon dioxide Asphyxiant Occurs naturally, explosives, welding and
internal combustion engines.
Nitrogen monoxide Toxic Internal combustion engines, explosives
Nitrogen dioxide Toxic and welding
Ammonia Toxic and potentially Explosives
explosive
Hydrogen sulphide Toxic and potentially Occurs naturally and may occur where
explosive sewage is present
Sulphur dioxide Toxic Occurs naturally
Methane Potentially explosive (and Groundwater, decay of organic matter,
asphyxiant) urban domestic gas supplies,
Carboniferous rocks
Propane Potentially explosive (and Leakage from compressed gas cylinders
Butane asphyxiant) Do
Acetylene

Oxygen deficiency Asphyxiant Natural/induced

Oxygen enrichment Increased fire risk Leaks from cylinders
Petrol/diesel vapour Potentially explosive Spillage
Ozone Toxic Welding
Radon Radioactive Ground
65.0 Rolling stock
65.1.1 Muck skips are usually designed for either tipping or hoisting. When skips are hoisted they should
be regarded as a piece of lifting equipment and designed and used accordingly. Periodic
examination and testing shall take place as for lifting tackle. When skips are tipped, provision
must be made to lock them during travelling.
65.1.2Purpose-built skips and materials bogies must incorporate restraint of the intended load to
prevent, for example, a box or stack of segments from sliding off and fouling walkways. The
design of the vehicle should be inherently stable when loaded, even on poor track and with rough
handling.
65.1.3Certain high-capacity cars have flight bar conveyor mechanisms to discharge the muck at one
end at a controlled rate. Where these types of cars are used, special attention shall be given to
the manufacturer’s recommendations concerning track laying, layout of curves and loading
across overlap points to minimize the potential for derailment.
65.1.4Personnel can be transported if purpose-built man-riding cars are used. These shall be attached
as near the locomotive as possible with a safety chain in addition to the coupling. A man-riding
car must be constructed with proper seats, side bars and a crash cage. It shall be constructed to
withstand derailment with minimum injury to passengers. It is recommended that the largest
practical wheel size be used with a suspension system on man-riding cars.
65.2 Transportation of material
65.2.1Cars carrying pipe and rail shall be properly loaded for safe passage through the tunnel. The
load shall be kept within the side limits for the car. Loads projecting over the sides are dangerous
to men working in the tunnel. If wide’ loads are transported, a special care shall be ensured in
the operation of the train with ample warning to the workmen along the track to ensure a safe
journey.
65.3 Transport of Employees

65.3.1No one shall be allowed to ride on front steps of a loco or on a coupling. None other than trainmen
shall ride the dump cars in going to and from work at change of shift or at any other time. A safe
and smooth walkway system shall be provided for pedestrians
65.4 Roles and Competencies
65.5 The Locomotive Driver shall:
65.5.1Be responsible for ensuring that all loads are properly secured before a loco movement is
commenced
65.5.2Be responsible for ensuring that identified defects are entered in the Daily Loco Checklist.

65.5.3Have received a minimum of 04 hours familiarisation training in accordance with local

arrangements and have been assessed as competent.
65.5.4Successfully complete third party approved training.
65.5.5Attend local Tunnel Induction training.
65.5.6Be appointed as a Locomotive Driver in writing by site management; records of this are to be
held on site in accordance with BS6164:2011
65.5.7Be fully briefed and conversant with all relevant local procedures.
65.5.8Be aware of track walking procedures, persons walking on the track, persons working on the
track, track possessions etc.
65.5.9Check points are fully and correctly engaged before entering any crossings.
65.5.10Ensure that when propelling (breasting) the train into the tunnel, this is carried out in accordance
with BS 6164: 2011– the driver must have sufficient visibility of the track ahead to be able to stop
within his field of view.
65.5.11Be trained in the use of derailers, wheel blockers, Manchester gates etc.
65.5.12Be trained in the use of communications systems and all relevant procedures and protocols.
65.5.13Be trained in the use of fire extinguishers and relevant firefighting equipment.
65.5.14The training will be supported by refresher training and any other briefings as deemed
appropriate by Employer / Engineer.
65.6 Operations Board Controller (OBC)
65.6.1The Operations Board Controller shall:
65.6.2Have been assessed as competent to carry out all activities associated with the role.
65.6.3Be responsible for maintaining a record of all hazardous materials contained in each load so that
appropriate information is available should an emergency arise.
65.6.4Have experience of a similar role.
65.6.5Successfully complete Third party training.
65.6.6Attend local Tunnel Induction training and be trained in the requirements of this Best Practice
Guide.
65.6.8The contractor will ensure that there is adequate cover for this post at all times.
65.6.9The contractor will ensure that there are local instructions in place which cover key issues
including:
• Use of the Operations Board

• What information is recorded
• How and where information is recorded
• Priority assignment on California crossings

65.6.10 Note: Where there is a permanent single line running arrangement (i.e. only one train on the
track at any given time), it will not be necessary to engage an OBC, but ONLY if the contractor
has put in place adequate arrangements to protect the train and those working in the tunnel.
65.7 Flagman
65.7.1Where a flagman is engaged (e.g. at a California crossing) they shall:
65.7.2Receive a minimum of 4 hours familiarisation training.
65.7.4Successfully complete Third party training.
65.7.7Be trained in the application of this Best Practice Guide. This training will be supported by
refresher training and any other briefings as deemed appropriate by local management.
65.8 Back-up operator / slinger
65.8.1The Back-Up Operator shall:
65.8.2Have experience of working within and on a TBM.
65.8.3Have receive a minimum of 4 hours familiarisation training.
65.8.5Have Successfully Complete Third party training.
65.8.8Carry out all duties as defined in local working instructions.
65.8.9Operate the Manchester gate as and when required.
65.8.10Supervise the ingress / egress of personnel movements into and from the stationary man rider.
65.9 Pre-use Checks
65.10 Locomotives and rolling stock
65.10.1Locomotives and rolling stock scheduled for use will be inspected by the driver at the start of
each day to ensure that it is fit for service and capable of delivering safe operation. This inspection
will include a brake functionality test (as required by BS 6164:2011).
65.10.2The Daily Loco Checklist (DLC) remains on the locomotive; any defects or issues identified by
the driver are to be logged at the first available opportunity prior to use.
65.10.3Unserviceable safety critical equipment must be removed from use as soon as a defect is
identified.
65.10.4The DLC is to be checked daily by the locomotive fitters who will:
i) Review entries

ii) Carry out and record any necessary repairs
iii) Schedule or carry out routine maintenance as appropriate.
iv) Report recorded defects to the OBC.
v) Complete a record of all work carried out on the locomotive.
vi) The driver will test on board communications and confirm both the locomotive and
communications are operational with the OBC prior to receiving instructions at the start of each
shift.
65.11 Train-borne plant
65.11.1The following items are to be checked by fitters at predetermined periods:
i) The engine compartment fire suppression system.
ii) The hydrostatic transmission and retarder.
iii) Pneumatic wheel brakes.
Iv) In addition, couplers and chains (for the rolling stock) are to be checked by drivers before
each movement.
v) Should any of the above items be found to be defective during checking, the loco fitter should
be consulted and appropriate remedial action taken.
65.12 Training and briefing
65.12.1The following are to be applied:
i) Locomotive drivers must have received familiarisation training on the locomotive they are
driving and have been assessed as competent to drive.
ii) All personnel on site are to be briefed in the communication procedure so that they are aware
of actions to take in the event of an emergency.
65.13 Locomotive driver aids
65.13.1The following checks are to be carried out by the loco driver at the beginning of each shift:
i)CCTV system is functionally tested and camera lens wiped clean.
ii)Functional brake test.
iii)Test that lights are operational and showing correct direction of travel
iv)Communication system is functionally tested
v)Locomotive Electronic Control is tested
vi)Horns tested
vii)Note: The locomotive should not be used if any of these systems are defective.
viii)Rail Movement Control Centres (RMCCs)
ix)Where RMCCs are in use, the following will apply:

x)Where the RMCC is equipped with CCTV cameras they are to be tested and confirmed to be
working correctly by the OBC at the beginning of each shift
xi)The communication system in the RMCC is tested and confirmed to be working correctly by
the OBC at the beginning of each shift
65.14 Communications and signalling equipment
65.14.1The following will be applied for communications and signalling equipment:
i)The tunnel radio system is to be functionally tested by the OBC at the start of each shift
ii)The CCTV system (where installed) is to be functionally tested by the OBC at the start of each
shift
iii)Signs are to be installed establishing the maximum speed (e.g. California crossings)
iv) “Trains have priority” signs are to be installed at all level crossings
v)Cameras are to be installed, tested, certified and working at both ends of all crossings
vi)The following horn blasts are to be used in the tunnels to designate the imminent action of a
loco:
3 blasts Moving outbye
2 blasts Moving inbye
1 long blast Stopped
65.14.2A continuous blast is to be given when the driver identifies personnel ahead in the tunnel who
have not acknowledged and moved out of the way of the train.
65.15 Vehicle Movement Safety
65.16 General
65.16.1The OBC will be located within a clearly defined area and will be in overall charge of all train
movements between the yard / loco stabling area and TBM
65.16.2The Back-Up operator will be in control of all train movements within the TBM for segment
movements, train unloading movements and personnel movements
65.16.3Where flagmen are used, they will direct all trains as required and always under the control of
the OBC and yard staff to ensure safety
65.16.4In addition to being appropriately trained and certificated, locomotive drivers will have read the
operations manual for the locomotive they are operating.
65.16.5Passengers are not permitted in the locomotive cab at any time EXCEPT When the driver is
under training and the passenger is the instructor
65.16.6Apart from walking along approved safe walking routes, personnel transport into the tunnel will
be by man rider only. Travelling on any other part of the train is prohibited

65.16.7Carrying work equipment or materials in the man rider is prohibited EXCEPT for surveying
equipment
65.16.8Pedestrians are not allowed into tunnels unless carrying out surveys, track inspections,
maintenance etc. In such cases, access is only permitted under the control of the OBC and with
an appropriate Permit to Work in place
65.16.9Pedestrians are only permitted to cross the track on marked safe walking routes
65.16.10All tools and materials are to be kept clear of the track at all times UNLESS work is being
carried out on the track. All such work will be carried out under (and in accordance with the
requirements of) a Permit to Work issued by the OBC
65.16.11The tunnel will be equipped with a communication system allowing radio communication
between the loco operator and other tunnel personnel
65.16.12Where local noise restrictions exist, alternative arrangements will be put in place for noise
restricted times
65.16.13The loco driver will comply with the traffic lights which are controlled by the appointed Back-
Up Operator
65.16.14Parked trains or trailers will be individually air braked and wheel scotches placed under wheels
of uncoupled rolling stock. Scotches may be of wooden or metal construction. Dog chains (or
similar) are not permitted
65.16.15Brakes and scotches / rail clamps are to be applied on static uncoupled trailers to prevent them
running away
65.16.16The loco driver will be responsible for carrying out checks of the loco to ensure that it is fit for
service. Checks are to be carried out in accordance with the mechanical and operational manual
checklists provided by the loco manufacturer
65.16.17The loco driver will be responsible for carrying out checks to ensure that there is adequate
clearance along the route for the train to travel safely without risk of colliding with obstructions;
adherence to gauge limits must be ensured
65.16.18Tampering with couplings is forbidden
65.16.19Prior to inbye movements, both the loco driver and the yardman will check train loads to ensure
they are secure
65.16.20Engines should be switched o• when not required to reduce unnecessary fuel consumption
and emissions
65.17 Tunnel movements
65.17.1The following are to be applied for all tunnel movements:
65.17.2The maximum train speed within the tunnels is to be displayed on signposts at appropriate
locations; this speed limit is an absolute and is not to be exceeded at any time
65.17.3The maximum speed for traversing a California crossing will be 5km/h; warning notices are to
be placed 60m either side of the crossing instructing loco drivers to slow down

65.17.4Movement direction lamps at the front and rear of the train are to be illuminated at all times to
indicate the direction of travel. The lights should show white at the front of the train in the direction
of travel and red at the rear when a travel direction is selected
65.17.5When passing personnel in the tunnel the train driver will sound the horn to advise of his
approach; the personnel concerned are to wave a hand to acknowledge that they are aware of
the approaching train
65.17.6Walking in the tunnels is not encouraged. However, it is acknowledged that teams are required
to work in the tunnels at certain times. When doing so they will protect their working area with
advanced warning lights which may be obtained from the OBC; these warning lights are to be
placed 60m either side of the work area. Such works may only be carried out under a controlled
Permit to Work (PTW) in accordance with local arrangements
65.17.7PTWs will be held by the OBC who is responsible for briefing all relevant personnel on the
content of the PTW including the nature of the work and number of personnel in the work group
65.17.8Loco drivers are to be continuously advised of all PTWs that are introduced / signed of during a
shift
65.17.9PTWs are only signed on when the work is complete, the site has been made safe and all
members of the working group are accounted for. A PTW may be passed to a subsequent
working group, but the names of all outgoing and incoming personnel must be recorded in
accordance with the local PTW procedure
65.17.10There will be intermediate stop points (crossings and booster locations) where workers will be
able to alight, but always within the confines of the PTW and under the control of the OBC
65.17.11All derailments must be reported for appropriate investigation, identification of trends and
implementation of corrective actions. Should a derailment occur, local procedures for re-railing
are to be followed
65.17.12 No work is permitted to start in the tunnels until a Permit to Work is in place.
65.18 Uncoupling trailers
65.18.1The following actions are to be taken when uncoupling wagons and trailers:
i) Apply parking brakes and put scotches / chocks in place before uncoupling; no unbraked
vehicles should be allowed in the tunnels
ii) Install the scotch / chock on the downhill side of the trailer; if ‘downhill’ is not clear (or if the
vehicle is on level ground), clamps should be applied at both back and front
iii) Verify that brakes are still on
iv) Disconnect lighting, CCTV and telephone cables
v) Disconnect hydraulic brake lines ensuring that all supplies are isolated as per the operational
instructions for the vehicle
vi) Check again that the brake is applied and that scotches / chocks are firmly in place
vii) Disconnect the safety chain and then uncouple the vehicle
viii) The vehicle may now be left

65.19 Coupling trailers
65.19.1The following actions are to be taken when coupling / uncoupling wagons and trailers:
i)Where Manchester gates have been installed, they must be kept closed until the fully coupled
train is ready to move into the tunnel
ii)Ensure scotches / chocks are in place before commencing coupling
iii)Connect vehicles using couplers and secure the safety chain. Safety chains must be loose
enough to allow the trailers to travel round bends in the tunnel but not so long that they are able
to touch the track
iv)Connect the hydraulic brake lines. Care must be taken to ensure that connections are clean
and seated properly with no leaks. Visual / audible checks are to be carried out. Hydraulic pipes
must not touch the track
v)Connect lighting, CCTV and telephone cables
vi)Once all the above connections have been completed the scotches/chocks may be removed
and the vehicle can then be moved
NOTE: Vehicles should not be moved until the driver has confirmed that the train is fully functional
65.20 Trains entering the TBM backup
65.21The following rules are to be applied for all trains entering the TBM backup:
i) The train must signal its arrival by sounding the horn in accordance with local procedures and
stop in front of the Manchester gate
ii) No train movements are to take place at the rear of the TBM until the Back-Up operator on the
TBM has confirmed to the loco driver that:
iii) All personnel are clear of the track
iv) No personnel are attempting to board or disembark from the man rider
vi) When the Manchester gate is open the free access will be indicated with a green light
indicating permission to move in bye. The Manchester gate opens only through hand operation
controlled by the appointed Back-Up Operator
vii) The locations for stopping the train will be marked on the gantries and indicated by a switch
of the traffic light to red. Entry to the rear of the TBM must be at creeping speed
viii) One long blast on the loco horn will be used to indicate that the loco has stopped moving and
brakes have been applied. Personnel entering or leaving the man rider will only do so when given
the all clear by the appointed Back-Up Operator
ix) Once the train is unloaded it will leave out bye the TBM backup at creeping speed once a blue
light is displayed
x) The Appointed Back-Up Operator will check before permitting movement of the man rider that
no personnel are attempting to board the train before it departs
xi) Once the operation is complete, the loco will not be permitted to move of until the appointed
Back- Up Operator has indicated to the loco driver that no personnel are attempting to board or
disembark from the man rider

xii) Immediately prior to moving of the loco driver will sound three blasts of the loco horn to
indicate that the loco is moving out bye
65.22 Track inspections and maintenance
65.22.1Track inspection and maintenance activities will be completed by a dedicated track maintenance
team on a scheduled basis (additional works will be carried out as necessary). This work will be
compliant with the following
65.22.2Local processes will be in place to detail routine maintenance, planned preventive maintenance,
breakdown repair protocols and re-railing procedures
65.22.3Local processes should include information on when train movements are to be stopped for
emergency maintenance (e.g. submerged track, build up of grease in points etc.)
65.22.4The Designated Person / Persons undertaking track maintenance must be known /

communicated to drivers and other tunnel personnel
65.22.5All track maintenance and inspection activities must be carried out under a Permit to Work
issued by the OBC
65.22.6Any track defects are to be reported to the OBC as soon as they are identified, by whoever
identifies them
65.22.7In order to avoid derailments, the track will be inspected visually during the routine maintenance
shift. Bolts will be retightened as necessary
65.22.8In order to avoid derailments, the track will be inspected visually during the routine maintenance
shift. Bolts will be retightened as necessary
65.22.9In the event of a derailment, any affected track must be fully inspected and appropriate remedial
action taken where necessary
65.22.10Spillage of materials that may affect safe train operation will be reported to the OBC who will
make arrangements with the Tunnel Superintendents for the spillage to be cleared as soon as
practical
65.22.11Track geometry will be checked (gauge and rail inclination). Special attention is to be paid to
track at the portals and sections with very small radius (<40-50m) in order to avoid derailments
65.22.12Checks are to be carried out on the different geometrical parameters of the California crossings
in order to avoid derailments
65.22.13Following any change to the track, gauge is to be checked and movements only permitted
when confirmation is given that gauge is correct
65.22.14Personnel working on the railway will wear the appropriate PPE and will operate under a Permit
to Work in accordance with the local procedure
65.22.15The invert is to be kept clear of hazards as far as reasonably practicable; the underside of the
rails must be visible above any muck in the invert
65.23 Loading and unloading (TBM)
65.23.1The loco driver must make sure that a competent person supervises the loading/unloading of
the loco. This includes ensuring that the load is:

i) Correctly loaded
ii) Secured to prevent movement
iii) Within the maximum load limit for the vehicle
iv) Within the maximum gauge limit for the track
v) The loco driver must sign the loading note and train log book to certify the load as being
correct and safe to travel.
65.24 Loco and train maintenance
65.24.1The locomotives and trailers are to be checked and maintained according to the manufacturer’s
operation manual
65.24.2Maintenance is only to be carried out by competent personnel appointed in accordance with the
requirements of BS 6164: 2011
65.24.3A record is to be maintained of all maintenance and repairs carried out on the loco and trailers
65.24.4Where a defect has been identified that makes the loco / train unfit for safe use, it is not to be
used until appropriate remedial action has been taken
65.24.5Maintenance and repairs are only to be carried out in designated areas. It is forbidden to carry
out any maintenance / repair activities outside the designated areas EXCEPT when the train has
failed in the tunnel and must be repaired before it can be moved
65.24.6The design of cab or driver-containment enclosure should allow reasonable freedom of

movement for the driver.
65.24.7CCTV can be used to allow the driver a good view ahead.
65.24.8 Visibility should be adequate for safe driving of the train.
65.24.9The lights should automatically show white in the direction of travel and red to the rear of the
locomotive when a travel direction is selected.
65.24.10A daily functional brake check should be carried out by the regular drivers
65.25 Use of new plant
65.25.1The Tunnel Manager must approve any new plant that is to be used in the tunnel
65.25.2All plant must be recorded on the asset register and regularly checked and maintained in
accordance with manufacturers recommendations
65.25.3Maintenance records are to be kept for the new piece of plant, along with records for all other
plant currently in use
65.26 Refuelling
65.26.1Refuelling will be at a dedicated and segregated area as far from the works area as practicable
65.26.2The refuelling point will be in open air; fuel will be obtained using a hose and trigger nozzle from
a tank located on the surface
65.26.3The trigger is to be locked on when not in use

65.26.4Bulk spill containment, fire extinguisher and oil binder will be in place as close to the fuelling
point as practicable
65.26.5Leaving the nozzle unattended while refuelling is underway is prohibited in all circumstances; if
it is necessary to leave the refuelling point the nozzle must be removed and replaced in its’
retainer on the pump
65.27 Communications protocols
65.27.1OBCs are to have overall responsibility for management of communications. In all cases:
65.27.2Instructions issued by the OBC are to be followed UNLESS it is believed that the instruction
may present a risk
65.27.3Instructions issued by the OBC take precedence over all other instructions relating to the railway
UNLESS it is believed that the instruction may present a risk
65.27.4All communications relating to incidents (including near misses) are to be recorded by the OBC
65.27.5When communicating alphanumeric, the phonetic alphabet is to be used at all times.
65.28 Emergencies
65.28.1Emergency response procedures are to be followed.
65.29 Tunnel vehicle maintenance
65.30 General
65.30.1All rail vehicles are required to be maintained in accordance with a maintenance plan.
65.30.2The organisation responsible for management of the construction railway must obtain the
maintenance documentation which details vehicle maintenance activities from the vehicle
manufacturer. Maintenance activities include all activities necessary such as inspections,
monitoring, tests, measurements, repairs, replacements and adjustments.
65.30.3Maintenance activities are split into:
65.30.4Preventive maintenance; scheduled and controlled
65.30.5Corrective maintenance (repair)
65.30.6Maintenance documentation should include the following:
i)Component hierarchy and functional description. The hierarchy should list all the items
belonging to the vehicle and use an appropriate number of discrete levels; the lowest level shall
be a replaceable unit
ii)Schematic circuit diagrams, connection diagrams, wiring diagrams, pneumatic schematics

and lubrication diagrams
65.30.7The maintenance plan.
65.30.8This is the structured set of tasks that include the activities, procedures, means and the working
time required to carry out the maintenance task
65.30.9It contains a description of the maintenance activities which include the following:

i)Disassembly / assembly drawings & instructions necessary for correct assembly / disassembly
of replaceable parts
ii)Maintenance criteria
iii)Checks and tests
iv)Tools and materials required to undertake the task
v)Consumables required to undertake the task
vi)Personal protective safety provision and equipment
vii)Necessary tests and procedures to be undertaken after each maintenance operation before
re-entry in to service of rolling stock
viii)Checks on lifting / jacking point
ix)Troubleshooting (fault diagnosis) manuals or facilities for all reasonably foreseeable

situations. This includes functional and schematic diagrams of the systems or IT-based fault-
finding systems
65.31 Maintenance plans – General
65.32 Relevant to all vehicles
65.32.1Vehicle maintenance activities are only to be carried out by appropriately qualified personnel.
65.32.2The maintenance plan shall detail all maintenance activities to be undertaken on the applicable
type of rail vehicle
65.32.3The maintenance plan should include all maintenance activities that must be carried out to
ensure that the rail vehicle(s) continue to conform to the safe limits defined by the vehicle
manufacturer
65.32.4The maintenance plan shall, as a minimum, include the following:
i)Maintenance requirements including the safety conditions to ensure the rail vehicle can be
safely worked on for each task
ii)A maintenance schedule which defines the periodicity at which each item shall be actioned
iii)An inspection programme for regular inspection of the vehicle to confirm that it is safe to
continue in service
iv)Definitions of the appropriate actions to be taken to ensure that all systems and equipment
continue to operate safely over the full range of environmental conditions, particularly in snow,
flood, freezing or abnormal heat
v)Technical instructions that define actions required to ensure that a vehicle can be hauled
safely when inoperative (e.g. the adjustment, isolation, removal or addition of some components
or the imposition of a restrictive maximum speed to travel
vi)The minimum engineering maintenance facilities that are necessary for the maintenance to
be carried out (e.g. pits, major equipment, covered work areas)
vii)The minimum level of competencies required for the staff carrying out the specified
maintenance tasks

viii)Each rail vehicle shall be maintained so that the prescribed tolerances for all components
and assemblies are not exceeded throughout the life of the vehicle
65.33 Maintenance Plans – Specific
65.34 Relevant to all vehicles
65.34.1The maintenance plan shall, as a minimum, set out the requirements for the following items of
the wheelset and constituent parts:
i) Relative movement of wheels, axles, tyres and axle mounted equipment
ii) Cracks and fractures
iii) Dimensions affecting running safety:
iv) Minimum wheel diameter
v) Tolerance between diameters of wheels on the same axle
vi) Back to back dimensions
vii) Flange and tread profile
viii) Wheel tread surface damage
ix) Wheel flat limits
65.35Brakes
65.35.1The maintenance plan should detail that the components of rail vehicle brake systems are
maintained at appropriate periods
65.35.2Maintenance activities and periods must be designed to ensure that the brake systems function
correctly and safely between maintenance activities
65.35.3Functional tests of the brake systems should be carried out to ensure that they are operating
correctly. This should take into account the environment in which the vehicle is being used
65.36.4The functional brake tests should show that the systems respond to graduated brake application
demands, up to and including an emergency stop
65.35.5Brake cylinder pressures should be checked to confirm that pressure increases in proportion to
the controller movement
65.35.6Appropriate functional brake tests should be undertaken whenever components of the brake
system are replaced and reconnected or following component repair, renewal or disconnection
65.35.7If a fault in a brake system or component is revealed by either the maintenance or functional
brake tests, details of appropriate remedial action should be available in the maintenance plan
65.35.8The maintenance plan shall, as a minimum, set out the requirements for (where fitted):
65.35.9Brake disc integrity, condition and dimensions
65.35.10Brake pad and brake block integrity and dimensions
65.35.11Brake rigging (pins, bushes and associated equipment)

65.35.12Integrity of operating devices, reservoirs, hoses, cocks, pipework, safety loops and associated
equipment
65.36 Rail vehicle structure
65.36.1Vehicles shall be maintained so that the body and running gear remain structurally sound and
safe
65.36.2Vehicles shall be maintained so that the connections between the body and running gear remain
structurally sound and safe
65.36.3Prescribed tolerances must be checked and maintained – this includes all components,
assemblies and systems
65.37 Speed indicating equipment
65.37.1The maintenance plan must include a method for testing speed indicating equipment – this must
include acceptable tolerances. If readings are outside this tolerance, the speed indicating
equipment must be corrected before the vehicle re-enters service
65.37.2The speedometer test shall cover the whole range of the speed indicating equipment. The test,
shall cover:
i) The accuracy of readings
ii) Intermittent or jerky operations
iii) Clarity and cleanliness of indicators and correct operation of associated lighting
iv) The integrity of connections and components that cannot be included in the equipment test
v) As a minimum, speedometer and speed control system testing shall be undertaken in the
following circumstances:
vi) When a wheelset has been replaced
vii) When a wheelset has been re-profiled
viii) When the speed indicating equipment, speed control system or their components have
been disturbed, adjusted, repaired or replaced
ix) When there has been a report of a malfunction of the speed indicating equipment or speed
control system
x) When there has been a report questioning the accuracy of the speed indicating equipment
or speed control system
xi) Following an allegation of exceeding the speed limit
65.38 Train-borne signalling and communications equipment
65.38.1All signalling and communications equipment shall be managed to ensure that its integrity and
performance remains compliant with its specification
65.38.2The maintenance requirements for each item of train-borne signalling and communication
equipment shall be developed to control the risks which would arise from failure of any part the
system

65.38.3The maintenance requirements for train-borne signalling and communication equipment shall
be documented
65.38.4Maintenance requirements shall form part of the rail vehicle maintenance plan for the vehicle
65.38.5The procedures to ensure configuration control of any software and hardware shall also be
documented in the maintenance plan
65.39 Headlights
65.39.1The maintenance plan shall set out a method for testing the functionality and alignment of the
headlights
65.39.2Testing of the headlights shall be carried out at a periodicity to reflect the use and working
environment of the vehicle
65.39.3Other equipment
65.39.4Consideration shall be given to the following during the production of the maintenance plan. The
list is not exhaustive or necessarily representative of all types of vehicles used on construction
railways.
• Buffers:
• Heights
• Integrity and condition
• Greasing
• Draw gear:
• Dimensions
• Rubber condition
• Operation
• Primary and secondary suspension:
• Spring integrity, rules for changing
• Linkage wear, dimensional limits
• Suspension settlement
• Damper integrity
• Suspension tube bearings:
• Condition, integrity and security of components and installation
• Bearing float
65.39.5Traction and auxiliary generators, alternators, other electrical machines and electrical
equipment cases:
• Integrity and security

• Earthing condition and integrity
• Presence, condition and cleaning of all safety labelling
• Cleaning:
• Ventilation ducts
• Bogies and underframe equipment
• Front end and windscreens
• Final drives / transmissions:
• Security to body or bogie frame

• Condition checks of safety critical items

• Lubrication
• Safety loops
• Presence and security of balance weights, where fitted
• Internal combustion engines:
• Security and condition of mountings
• Checks for leakage of fluids
• Integrity of shaft couplings
• Engine safety systems (for example, overspeed, crankcase explosion)
• Emissions (compliant with specification)
• Power systems (including associated protection systems):
• Integrity and security
• Earthing condition and integrity
• Presence, condition and cleaning of all safety labelling
• Hydraulic and pneumatic systems:
• Condition and integrity of hoses, pipework, valves, etc
• Fire protection systems:
• Currency of certification
• Lighting Systems
• Emergency Facilities:
• Emergency lighting capacity
• Other emergency and safety equipment provided
65.40 Tunnel Track maintenance
65.41 Roles and Competencies
65.42 General
65.42.1This Section defines the general duties and competence requirements of personnel with a role
in maintaining track, crossovers and associated equipment on the construction railway. It should
be referred to when clarification is required on specific responsibilities.
65.42.2The role titles used below may not necessarily correspond with job titles in the Contractors’
organisation, however the Contractor will be expected to demonstrate that the responsibilities
listed below have been discharged by a competent person with sufficient knowledge and
experience.
65.43Mechanical Superintendent
65.43.1 The Mechanical Superintendent (or equivalent) shall:
• Be responsible for ensuring that a track maintenance programme is in place

covering all tunnel railways track, California crossings, sleepers, fishplates and
associated components
• Ensure that all track and associated equipment is inspected on a regular basis and
to a pre-determined frequency.
• Ensure that a forward-looking programme is in place covering the inspection and
maintenance of track and associated components
• Successfully complete Third-party training.
• Attend Tunnel Induction training and the Contractor’s Track Maintenance
Procedures

65.44Track Inspector
65.44.1The Track Inspector shall:
• Be responsible for carrying out inspection and maintenance of track, California

crossings, sleepers, fishplates and associated components to the standards
prescribed in the contractors’ track maintenance procedures
• Have received training and hold the necessary competence in the inspection and
maintenance of track
• Be responsible for maintaining a record of all track inspections
• Successfully complete third-party training
• Attend Tunnel Induction training and the Contractor’s Track Maintenance
Procedures
Note: Tracks laid in the TBM are to be inspected immediately after installation. This can be
carried out by an inspector or by any suitably qualified member of the track gang.
65.45Operations Board Controller (OBC)
65.45.1The Operations Board Controller (OBC) shall:
• Provide protection for track inspectors whilst undertaking track maintenance and
inspection activities
• Communicate with all locomotive drivers when track inspectors are working in the
tunnel
• Arrange the safe system of work so the location of track inspectors working in the
tunnel is known
Note: The Contractor shall ensure that there is continuous cover for this post at all times. Where there
is a permanent single line running arrangement (i.e. only one train on the track at a given time),
it will not be necessary to engage an OBC, but only if the contractor has put in place adequate
arrangements to protect the train and those working in the tunnel through a permit to work
system.
65.46 Tunnel Tracks Work Permit
65.47Arranging the Track Works Permit
65.47.1Before any track inspection or maintenance work is carried out, the Track Inspector (or other
person undertaking work on or about the track) shall report to the OBC to arrange for a Permit to
Work – the Tunnel Track Works Permit - to be issued. The OBC will raise the Tunnel Track Works
Permit which will specify, as a minimum:
• The location of the works to be carried out

• The names and details of persons undertaking the track inspection and
maintenance works
• The means of communication between the Track Inspector and the OBC during
the works
• The duration of the work to be carried out
• The nature of the work and any requirements for train movements to be suspended
or restricted (for example a temporary speed restriction during or after the works)
• The time at which the permit will be closed

65.48 Issuing the Tunnel Track Works Permit
65.48.1The OBC will sign the Tunnel Track Works Permit and the permit will then be approved by the
Mechanical Superintendent, Tunnel Superintendent or other nominated person named in the
contractor’s procedure.
65.48.2A permit to work must be issued when entry to the tunnel is required to carry out track inspection
or maintenance duties, irrespective of whether train movements are taking place or not.
65.49 Cancelling the Tunnel Track Works Permit
65.49.1Upon completion of the works, the Track Inspector will notify the OBC that:
a) All personnel are clear of the track and are in a position of safety
b) All tools and equipment have been removed from the track
c) The track is safe for normal operations to be resumed, unless operating restrictions (for
example a speed limit) need to remain in place
65.50 Tunnel Track Maintenance Works
65.51 Track Inspection Programme
65.51.1The Mechanical Superintendent will develop a forward-looking programme of track inspections

covering a 12 month period
65.51.2The Tunnel Track Inspection Programme will detail the sections of track to be inspected on a
particular track patrol, identified by segment ring number
65.51.3The Tunnel Track Inspection Programme will also define any components, for example
California Crossings, which require specialised inspections other than a normal visual check
65.51.4Additional visual track inspections shall be undertaken following any reported rough ride,
derailment or track defect observed by the loco drivers
65.51.5The Track Inspection Programme shall ensure that every section of track is inspected at least
once every week.
65.51.6The track inspection will be undertaken on foot under adequate lighting conditions. Where 2 or
more lines exist on a stretch of track, each line shall be walked separately
65.51.7The track inspection will include a visual examination of the condition of the track and
identification of any rail defects, pitting, track spread or rail buckles
65.51.8At regular intervals defined in the contractor’s track maintenance procedure, the track gauge
will be measured and recorded using a calibrated track gauge. Where the gauge is outside the
prescribed tolerance of 900mm +/- 25mm, the OBC shall be notified immediately
65.51.9Any significant defects in the track, for example broken rail, track spread, buckled rail shall be
reported to the OBC and train movements suspended until repairs have taken place or the
Mechanical Superintendent has confirmed that it is safe for passage of trains
65.51.10Track inspections shall be recorded on a proforma defined in the contractor’s track

maintenance procedure
65.52 Track Bed

65.52.1The track inspection shall include a visual examination of the sleepers & track bed, which will
take place as part of the track inspection, including:
a) Loose or missing Pandrol clips, or other rail to sleeper fixture

b) Broken or damaged sleepers
c) Loose or damaged “anchors” which connect the sleepers to the concrete segments
d) Build-up of oil, waste material, or excessive water on or around the track bed
65.53 Fishplates and bolts
65.53.1The track inspection shall include a visual examination of the fishplates and fishplate bolts,
which will take place as part of the track inspection, for:
a) Loose or missing fishplate bolts

b) Broken or cracked fishplates
c) Condition of the grease between the fishplate, the fishplate bolts and rails
65.53.2Where “dry joints” are detected, the fishplate bolts will be loosened, grease will be applied to
the rail edges of the fishplate and bolts, then the bolts shall be re-tightened using a torque
spanner to the setting prescribed in the contractor’s track maintenance procedure.
65.54 California Crossings
65.54.1California Crossings represent a higher risk of derailment than plain line track and therefore an
enhanced inspection regime shall be adopted.
65.54.2The frequency of inspections of California Crossings and associated switches shall be at least
twice weekly. Inspections shall be undertaken by the Track Inspector and recorded on the
contractor’s record of track inspection
65.54.3Inspections of California Crossings shall additionally be undertaken following any report of rough
ride, derailment or other malfunction reported to the OBC.
65.54.4Inspections of the California Crossing shall include:
65.54.5A visual check of the crossing, including the switch blades, for signs of damage, corrosion, wear
and obstructions in the switch blades
65.54.6A check of the movement of the switch blades from normal to reverse positions and back
65.54.7Application of mineral or bearing grease to the moving parts of the switch blades
65.54.8A visual check of the mechanical parts of the California Crossing, to include the tie rods,
stabilisers, section connections, point levers and spring mechanisms
65.54.9In the case of a post-derailment inspection, the Track Inspector shall observe train movements
in both directions over the crossing to check the operation
65.55 Records of Track Inspections
65.55.1A bespoke record of track inspections and maintenance shall be kept for every track inspection.
The completion of the record of track inspection shall be defined in the contractor’s track
inspection procedures
a) The record of track inspection shall include the following information, as a minimum:
b) The date and time of the track inspection
c) The name and signature of the Track Inspector

d) The section of track patrolled – identified by segment ring numbers

e) The line patrolled, where more than one exists
f) Nature of any defects identified
g) Any work that was identified from the inspection that could not be completed at the time
h) Overall remarks on the condition of the track and any potential defects which could
arise before the next scheduled inspection
66.0 Pathways
66.1 Tunnels the walk ways shall be placed to the side of track as per the BS 6164:2011
66.2 Tunnels, shelter places for workmen shall be provided at suitable intervals during hauling
operations.
66.3 Elevated walkways from which a fall is possible should be provided with suitable
guard rails and toe boards
66.4 A walkway should be provided within a minimum clear space of 2000 mm high and 900 mm wide,
with a walking surface not less than 430 mm wide.
66.5 Water should not be allowed to stand or accumulate at or above walkway level at any point
67.0 Visitors to site
67.1 No visitor is allowed to enter the site without the permission of the Employer / Engineer . All
authorised visitors must report to the site office. The Contractor shall provide a visitor’s helmet
(White helmet with visitor sticker) and other PPE such as Safety Shoes, reflective jacket,
respiratory protection etc. as per requirement of the site.
67.1.1 All Visitors shall be accompanied at all times by a responsible member of the site personnel.
67.1.2 The contractor shall be fully responsible for all visitors’ safety and health within the site.

Part-III: Occupational Health and Welfare
68.0 Medical Facilities
68.1 Every effort should be made to provide a healthy environment for workmen. Personal protection
should be regarded as the last line of defence, e.g. respiration and ear protectors.
68.2 Physical Fitness of Workmen
68.2.1The contractor shall ensure that his employees/workmen subject themselves to such medical
examination as required under the law or under the contract provision and keep a record of the
same.
68.2.2The contractor shall not permit any employee/workmen to enter the work area under the
influence of alcohol or any drugs.
68.3.1The contractor shall arrange a medical examination of all his employees including his sub-
contractor employees employed as drivers, operators of lifting appliances and transport
equipment before employing, after illness or injury, if it appears that the illness or injury might
have affected his fitness and, thereafter, once in every two years up to the age of 40 and once in
a year, thereafter.
i)The Contractor shall maintain the confidential records of medical examination or the physician
authorised by the Employer / Engineer.
ii)No building or other construction worker shall be charged for the medical examination. The
costs of such examinations are borne by contractor.
iii)The medical examination shall include Full medical and occupational history.
a)Clinical examination with particular reference to

i)General Physique;
ii)Vision: - Total visual performance using standard orthorator like Titmus Vision Tester
should be estimated and suitability for placement ascertained in accordance with the
prescribed job standards.
iii)Hearing: - Persons with normal must be able to hear a forced whisper at twenty-four
feet. Persons using hearing aids must be able to hear a warning shout under noisy working
conditions.
iv)Breathing: - Peak flow rate using standard peak flow meter and the average peak flow

rate determined out of these readings of the test performed. The results recorded at pre-
placement medical examination could be used as a standard for the same individual at the
same altitude for reference during subsequent examination.
v)Upper Limbs: - Adequate arm function and grip
vi)Spine: - Adequately flexible for the job concerned.
vii)Lower Limbs: - Adequate leg and foot flexibility.
viii)General: - Mental alertness and stability with good eye, hand and foot coordination.
ix)Any other tests which the examining doctor considers necessary.
NOTE: If the contractor fails to initiate and continue medical examinations as stated previously,
the Employer / Engineer has the right to appoint a medical examiner through an agency and
deduct the cost and overhead charges against the contractor.
68.4 Occupational Health Centre

68.4.1The contractor shall ensure the provision of a site occupational health centre. This may be mobile
or static however, both must be maintained in good order and complete with facilities as per the
scale laid down in Schedule X of BOCWR. A construction medical officer appointed in an
occupational health centre possesses the qualification as laid down in Schedule XI of BOCWR.
68.5 Ambulance van and room
68.5.1The contractor shall ensure the availability of an ambulance at site. First Aid room shall be
constructed as per the local laws.
68.6 First-aid boxes
68.6.1The contractor shall ensure a minimum of one First-aid box for every 100 workers is provided
and maintained for providing First-aid. Every First-aid box is distinctly marked “First-aid” and is
equipped with the articles specified in Schedule III of BOCWR.
68.7 HIV/ AIDS prevention and control
68.7.1The contractor shall appoint agency for the effective implementation of HIV/AIDS prevention and
control.
68.8 Prevention of mosquito breeding

68.8.1Measures shall be taken to prevent breeding at site. The measures to be taken shall include:
i)Empty cans, oil drums, packing and other receptacles, which may retain water shall be
deposited at a central collection point and shall be removed from the site regularly.
ii)Still waters shall be treated at least once every week in order to prevent mosquito breeding.
iii)Contractor’s equipment and other items on the site, which may retain water, shall be stored,
covered or treated in such a manner that water could not be retained.
iv)Water storage tanks shall be provided.
v)Posters in Hindi, Tamil and English, which draw attention to the dangers of permitting mosquito
breeding, shall be displayed prominently on the site.
vi)The contractor at periodic intervals shall arrange to prevent mosquito breeding by fumigation
/ spraying of insecticides. Most effective insecticides shall include SOLFAC WP 10 or Baytex,
The Ideal Larvicide etc.
68.9 Alcohol and drugs
68.9.1The contractor shall ensure at all times that no employee is working under the influence of alcohol
/ drugs which are punishable under Govt. regulations.
68.9.2Smoking at public worksites by any employee is also prohibited.
69.0 Welfare Measures for workers
69.1 Latrine and Urinal Accommodation

69.1.1The contractor shall provide one latrine seat for every 20 workers up to 100 workers and
thereafter one for every additional 50 workers. In addition, one urinal accommodation shall be
provided for every 100 workers. Latrine and urinals shall be provided as per Section 33 of
BOCWA and maintained as per Rule 243 of BOCWR and shall also comply with the
requirements of public health authorities.
69.1.2When women are employed, separate latrine and urinals accommodation shall be provided on
the same scale as mentioned above.
69.1.3Latrine and urinals shall be provided and maintained shall also comply with the requirements of
public health authorities.
69.1.4In case of mobile e.g. track laying, the zone of work is constantly moving at elevated level or at
underground level. In such cases mobile toilets with proper facility to drain the sullage shall be
provided at reasonably accessible distance.
69.1.5Should the contractor fail to provide the required number of urinals and latrines or fail to maintain
it as per the requirements of Public Health laws, the Employer / Engineer shall have the right to
provide/maintain through renowned external agencies at the cost of the contractor.
69.2 Canteen:

69.2.1The contractor shall provide an adequate canteen and the charges for food stuffs shall be based
on ‘no profit no loss’ basis. The price list of all items shall be conspicuously displayed in such
canteen.
69.3 Serving of tea and snacks at the workplace:
69.3.1The building or other construction work where a workplace is situated at a distance of more than
200 m from the canteen, the contractor shall make suitable arrangement for serving tea and light
refreshments to their employees.
69.4 Drinking water
69.4.1The contractor shall make in every worksite, effective arrangements to provide sufficient supply
of wholesome drinking water with minimum quantity of 5 litres per workman per day. Quality of
the drinking water shall conform to the requirements of national standards on Public Health.
69.4.2Due care shall be taken to ensure drinking water facilities are easily accessible to the workforce
and within a distance of 200m from the place of work.
69.4.3All such points shall be legible marked “Drinking Water” in a language understood by a majority
of the workforce. Drinking water points are not to be located within six metres of any washing
places, urinals or latrines.
69.5 Labour Accommodation
69.5.1The contractor shall provide free of charge and as near as possible to the workplace, temporary
living accommodation for all workers. All provided accommodation shall conform to the
provisions made under Section 34 of BOCWA. These accommodations shall have cooking
place, bathing, washing and lavatory facilities.
70.0 Permissible exposure limits
70.1.1The Exposure to air Borne contaminants of an employee working in your tunnel or shaft should
not exceed the exposure limit.
70.1.2Employees should be removed from any area in which there is an airborne contaminant at a
concentration which exceeds the exposure limit for that contaminant.
70.1.3Portable instruments should be provided to test the atmosphere quantitatively for carbon
monoxide hydrogen sulphide Nitrogen dioxide flammable or toxic gases dust or other toxic
contaminants that occur in the Tunnel or shaft. Tests should be conducted before each shift and
once in every shift or more frequently you are necessary to ensure that the required quality of air
is maintained a record of all tests should be maintained and be kept available for inspection.
71.0 Dust
71.1.1The amount of dust generated should be minimized. All dusts are harmful and exposure should
be kept within national limits.
71.1.2The main consequences from dust exposure are pneumoconiosis and silicosis. The latter can
occur after long exposure, where there is considerable quartz content in the airborne dust.
71.1.3In its mildest form dust exposure annoys by making sensitive parts of the respiratory tract very
uncomfortable. In addition, dust reduces visibility and enters the respiratory tract.
71.1.4Exposure to some dusts e.g. cement, can cause dermatitis.
72.0 Protection Against Dust
72.1.1West flushing (preferred) or dust extraction should be used during drilling.

72.1.2The working face, tunnel walls and muck pile should be watered for at least 15 minutes after
every blast and before mucking operations begin. The muck pile should also be watered during
mucking operations.
72.1.3Dust extraction units or water sprays should be placed at sources of dust emission such as on
tunnel boring machines, conveyor transfer points, shotcrete mixing units et.,
72.1.4If the above measures are unsuccessful at controlling airborne dust concentrations, additional
ventilation should be provided.
72.1.5Dust masks for individual protection should only be necessary to use in exceptional cases and
for short duration work at that.
73.0 Gaseous Contamination
73.1.1Toxic gases are generated through the use of explosives, diesel engines, from ground
contamination or, more rarely, from natural sources.
73.1.2Sufficient ventilation should be provided prevent the buildup of a toxic or potentially explosive
atmosphere in the tunnel.
71.1.3Gases from blasting operations are basically oxides of nitrogen, ammonia and oxides of carbon.
Therefore, it is necessary to provide powerful ventilation in order to reduce the re-entry time to a
minimum. The characteristics of the fume emitted should be considered in the selection of the
explosives.
74.0 Emissions from Power Units
74.1.1Petrol driven internal combustion engines shall not be used underground because of their large
emissions of CO (10% of exhaust gas) and the fire and explosion hazard.
74.1.2Only low emission or “clean burn” diesel engines or electrically driven or battery operated motors
should be used.
74.1.3Engines should be properly adjusted and maintained to operate efficiently under prevailing
conditions in order to reduce toxic exhaust emissions to the absolute minimum.
74.1.4Engines should be effectively silenced so as to achieve a noise level not exceeding LAeq 85
Db(A) as measured in the open, at a distance of 1 m.
74.1.5Exhaust systems should be fitted with an efficient catalytic converter and particulate filter.
74.1.6Direct injection air cooled engines are preferred for reason of better exhaust emission
characteristics.
74.1.7Efficient air intake cleaners should be provided.
74.1.8 Idling of diesel engines should be kept to a minimum.
74.1.9 Storage of diesel fuel underground should be prohibited.
74.1.10All vehicles underground, should have efficient fixed extinguishing systems.
74.1.11Atmospheric monitoring in the vicinity of any engine should be carried out at least once per
month, with the engine running a full load and when idling.
74.1.12Exhaust gas analyses should be taken at least once every three months under full load and
idling conditions.
75.0 Heat

75.1.1Cooling the tunnel atmosphere should be undertaken when the temperature routinely exceeds
27*C.
75.1.2Cooling may consist of increasing the ventilation flow and / or installing cooling equipment.

Appendix 1
An Example of the Identification Badge
Colour : YELLOW
Size : 35 mm x 40 mm
Material : Plastics (or hard board) with lamination and 5 mm hole for string.
FRONT
Compressed Air Worker

Name:
In case of sudden illness or emergency of
unknown or doubtful cause, the wearer of
this badge should be rushed to
MEDICAL LOCK
XXXXXXXXXXXXXXXXXXXXXXX
(……………Site Address…………………)
Tel: XX-XXXXXXXXXX
XXXXXXXXXX
REVERSE
Compressed Air Worker

Name:
In case of sudden illness or emergency of
unknown or doubtful cause, the wearer of
this badge should be rushed to
MEDICAL LOCK
XXXXXXXXXXXXXXXXXXXXXXX
(……………Site Address…………………)
Tel: XX-XXXXXXXXXX
XXXXXXXXXX

Appendix 2
Detail of monitoring
1. AIR MONITORING
(a) Particulars of person in charge of air monitoring (attach curriculum vitae)
(i) Name:
(ii) Qualifications:
(ii) Experience in conducting air monitoring
(b) Air Contaminant to be monitored:
No Name of Contaminant Method of Sampling Method of Sampling
1 Hydrogen Sulphide
2 Carbon Monoxide
3 Carbon Dioxide
4 Oil Mist
5 Other toxic impurities

e.g. dust and fumes

MAN AND MEDICAL LOCKS AND APPOINTED DOCTOR
1. LOCKS
(a) Details of Locks
Type of Lock Number of Locks Dimensions
Man-Lock(s) ………….mØ x ………….Length
Medical-Lock(s) ………….mØ x ………….Length
2. LOCK ATTENDANTS
(i) Details of Man-Lock Attendants
Name of the man-lock

attendant
Training background
Experience in handling
man-locks
(ii) Details of Medical-Lock Attendants
Name of the medical-lock

attendant
Details of training
Details of experience in
handling man-locks

3. MAXIMUM WORKING PRESSURE
Maximum working pressure for the following locks: -
i) Man-lock …………………kpa
ii) Medical-lock …………………kpa
iii) Working chamber …………………kpa
4. APPOINTMENT MEDICAL PRACTIONER(S):
(a) Name:
(b) Address of Practice:
(c) Qualifications:
(d) Training and experience in compressed air illness problems:

Appendix 3
Permissible exposure limit
SUBSTANCE
(GAS, VAPOUR, FUME AND PPM b Mg/m3c

MIST)
Acrylamide - 0.3
Ammonia 25 17
Asphalt fumes - 5
Benzene 10 32
Butane 800 1900
Calcium hydroxide 5
-
Calcium oxide 2
-
Carbon dioxide 9000
5000
Carbon monoxide 29
25
Carbon tetrachloride 31
5
Chloride 0.5 1.5
Coal tar pitch 0.2
-
Gasoline 300 890
Hydrogen cyanide 5d
4.7
Hydrogen sulphide 14
10
Lead - 0.15
LPG (Liquified Petroleum Gas 1800
1000
31
Nitric oxide
25
Nitrogen dioxide 506
3
Nitro-glycerine 0.46
0.05
Ozone 0.1 0.2
Phosgene 0.4
0.1
Sodium hydroxide 2
-
Sulphur dioxide 5.2
2
Sulphuric acid 1
-
0.5
Trinitrotoluene (TNT) -
Welding fumes 5
-

Zinc chloride fume
Zinc oxide fume
DUST (OTHER THAN MINERAL

DUST)
Asbestos Amosite 1 fibre/ml
Chrysotile or other forms 1 fibre/ml
Fluorides 2.5 mg/m3
MINERAL DUST
Cement
Nuisance particulates 10 mg/m3
(e.g.calcium carbonate
gypsum)
Total dust 10 mg/m3
Respirable dust 10 mg/m3
Note:
• Permissible Exposure Limits refer to the time weighted average concentrations of

airborne chemical substance for an 8-hour workday, to which workers can be
repeatedly exposed without adverse health effects.
• Parts of vapour or gas per million parts of contaminated air by volume at 25°C and
760 mm Hg pressure.
• Approximate milligrams of substance per cubic metre of air.
• Capital letter C denotes ceiling limit which is the concentration that should not be
exceeded even instantaneously.

Appendix 4
Quality Of Compressed Air In Working Chamber
Man-Lock And Medical Lock
Carbon monoxide not more than 10 parts per million
Carbon dioxide not more than 500 parts per million
Oil not more than 1 mg/m3
Odour and cleanliness As far as is practicable, the air should be free from all odour and
contamination by dust, dirt, and metallic particles and should not
contain any other toxic substance

Appendix 5
Lock Attendant's Register

Date: ____________________________________
Dry Bulb Temperature: ______________________
Wet Bulb Temperature: _____________________
Construction Site: ____________________________________
Name of the Lock Attendant: ___________________________
Name NRIC/Work Date & Time of Maximum Time in

of Permit Last Compression Working Working Decompression
Worker Number Decompression Pressure Chamber
Times of Time Time

Working Decompression
entry into Hour Min decompression decompression
Pressure time
working commenced finished
chamber
The time recorded on this Form must be taken from the clock provided for the use of the man-lock attendant. Record all times as a.m or p.m

Appendix 6
Compression Procedure
1. Every employee going under air pressure for the first time should be instructed on the
precautions to take during compression.
2. During the compression of employees, the pressure should not be increased to more than
0.2 bar within the first minute. The pressure should be held at 0.2 bar and again at 0.5
bar sufficiently long to determine if any employees are experiencing discomfort.
3. After the first minute the pressure should be raised uniformly and at a rate not to exceed
0.7 bar per minute.
4. If any employee complains of discomfort, the pressure should be held to determine if the
symptoms are relieved. If, after 5 minutes the discomfort does not disappear, the man-
Iock attendant should gradually reduce the pressure until the employee signals that the
discomfort has ceased. If he does not indicate that the discomfort has disappeared, the
man-Iock attendant should reduce the pressure to atmospheric and the employee should
be released from the lock and required to report to the medical lock attendant.

Appendix 7
Compressed Air Worker's Transfer Record
Name of the Lock Attendant: _____________________________________ No: __________________________________
Date Lock No. or Description

Total Lock
When When Pressure decompression Attendant's
leaving Hour Mins Hours Mins Hours Mins time in minutes Signature
Entering
(if different)
This record is to be retained by the person to whom it is issued. Entries are to be made by the man-lock attendant who shall also make the necessary
entries in the Lock Attendant's Register (Appendix 4)

Appendix 8
Compressed Air Worker's Medical Record
This Form should be completed by the appointed medical practitioner in respect of a

compressed air worker within 8 weeks after starting to be employed in compressed air work.
Name of Worker: Date of Birth: Sex:
Residential Address:
Name & Address of Employer:
Contact No:
Date Employed:
Previous Compressed Air Experience:
Employer Dates Maximum Working Any Radiographic

(From/To) Pressure Compressed Air examination
illness (Type I/II) results and
dates

(1) MEDICAL HISTORY
Ever declared unfit for employment in compressed air? YES / NO
Currently on any drugs or medication? YES / NO
Operations: _________________________________________
Injuries: ____________________________________________
Bronchitis Yes/No Asthma Yes/No Hay fever Yes/No
Sinusitis Yes/No Ear trouble Yes/No Tuberculosis Yes/No
Hernia Yes/No Fits Yes/No Yes/No

Psychiatric
disorders
Heart trouble Yes/No Hypertension Yes/No
Yes/No Yes/No Diabetes Yes/No
Peptic ulcer problem Bone/joint
disease
(2) MEDICAL EXAMINATION
Height (Standing without shoes): ___________________________
Weight (In light clothing without using beam or lever scale): ___________________________
Body Fat: _________________%
Heart: ____________________ Pulse: _________________ Blood Pressure: _____________
Lungs: ___________________ Joints: ________________________
Ears: ____________________ Nose: __________________ Sinuses: ________________

Abdomen: _______________________ Nervous System:

___________________________
Hb: ____________________________ PBF:

_____________________________________
ECG (If indicated):

_________________________________________________________________
Sickle cell trait (If indicated):

_________________________________________________________
(3) RADIOGRAPHIC EXAMINATION
Chest X-ray: Date of Examination:

________________________
Normal / Abnormal *
If Abnormal, attach a copy of report
Skeletal X-ray: (Including shoulder, hip Date of Examination:

________________________
and knee joints)
Normal / Abnormal *
If Abnormal, attach a copy of report
(4) TEST IN LOCK:

____________________________________________________________

(5) Fit for Employment in compressed air : YES/NO
REMARKS:
_____________________________________________________________
_____________________________________________________________
____________________________
Doctor’s name & Signature
(6) ADD ANY FURTHER DETAILS OR EXAMINATION RESULTS WITH DATES:
Date Examination (given details)

Remarks
* Delete if not applicable.
Appendix 9
Compressed air illness notification form

Name of contractor: _________________________ Date Employed:
___________________
Full Name of the Worker: ____________________ No: ______________
Occupation: _______________________________ Activity:

Manual/Supervisory/Sedentary
Maximum Working Pressure:

__________________________________________________
If multiple exposure, how many ?

_______________________________________________
Total exposure time:

_________________________________________________________
Was decompressed according to approved tablets ? YES/NO
New Starter: YES/NO
“Cold” Infection: Head or Chest YES/NO
Onset of symptoms after decompression: ___________Minutes/hour

(Date:_____________)
TYPE I (BENDS)
Site of pain:
________________________________________________________________
Any signs of symptoms other than pain (skin motting or irrigation): 1
________________________________________________________________________
__
TYPE II (If Yes, tick in the appropriate box for details)

Neurosurgical:
Appendix 10

Compressed Air Workers Individual Record
Part I : General
This form should be completed by the appointed medical practitioner in respect of a compressed
air worker.
Period under consideration: ________________________ to

_______________________________
Name of the worker: _______________________NRIC/Work Permit No:

______________________
Name and Address of the contractor:

___________________________________________________
___________________________________________________
___________________________________________________
Date employed: ________________________ Date left employment:

________________________
(If applicable)
Shift Worker: YES/NO *
Part II : Summary
Compressed Air Work Record during month considered:
Maximum Working Pressure:

_________________________________________________________
Total number of decompressions from:

_________________________________________________
Number of direct (conventional) decompression from:
(a) WP < 1.9 bars : _________________________

(b) WP > 1.9 bars : _________________________

* Delete if not applicable
WP : Working Pressure
TREATMENT
Time Commenced: ________________________ Time Completed:

_____________________
Pressure or Relief: _________________________ Highest Pressure used:

________________
Method of Decompression: __________________ Number of Decompressions:

____________

Residual symptoms:
________________________________________________________________
Fit for employment in compressed air again: YES/NO
Evidence of recurrence after leaving medical centre: YES/NO
_____________________________
Signature of the notifying Doctor
For decompressions resulting in compressed air illness symptoms, give the following details :
Number of
Maximum Working Symptoms Type I /
Date Therepautic
Pressure Type II
Compressions
Required
Type III : Detailed Records
Name of the Worker : ___________________________________________________________
Permit : ____________________________________________________________
Maximum Compressed Air Illness

Length of Symptom Not
Date Working
Shift Type I Type II Treated
Pressure

Appendix 11
Pressure and conversion
1. All pressure quoted in this guidebook are gauge pressure.
2. T h e c o n v e r s i o n f a c t o r s a r e :
1 bar = 105 N/m2 1 bar = 14.5 psi
1m = 3.281 ft 1 ft = 0.3048 m
1 mm = 0.03937 1 in = 25.4 mm

Appendix 12
Monthly Tunnel Checklist
1) Pre – Tunnelling Works:

SI. Item Compliance Reference Remarks Photo Evidence
No Status Code BS
6164 / Clause
1 Whether the following method
statements have been approved by
the Employer / Engineer and the
comments / control measures
required are in place and duly
verified for
Initial drive
Main drive
Cutter head intervention
Instrumentation and monitoring
Compensatory grouting / secondary
grouting
Post tunnelling defects like cracks,
damage, leakages etc.
2. Whether designer confirmation for
the extent of TBM advance for the
initial drive has been taken and the
record available for verification.
3. Whether the facility provided for
first aid and ambulance is
acceptable to Employer / Engineer.
4. Do necessary measures have been
taken to prevent shaft against
flooding and adequate pumping
facility is made available in the
shaft.
5. The action plan for emergency

evacuation and rescue operation is
satisfactory and the flow chart with
contact numbers for emergency
has been submitted and acceptable
to Employer / Engineer.
6. Proposal for firefighting has been
submitted and acceptable to
7. Provision is made for firefighting
equipment is sufficient.
8. Emergency lighting is provided
along the tunnel with battery
backup.
9. Does the secondary power back up
for TBM are available and adequate
to runs the essential circuit in case
of accidental failure of main power
supply.
10. Whether the ground treatment at
break-in and break-out portions has
been completed.

11. Whether existing building survey
along the Tunnel alignment has
been completed.
12. Does any form of structural support
for the buildings and structures in
the zone of influence are required
along the alignment.
13. Whether any supporting of
buildings as per damage
assessment has been carried out at
site.
14. Whether all the study and survey
for locating underground services
which may affect the tunnel has
been undertaken and found
satisfactory.
15. Whether all the bore wells within
the influence zone has been
identified and plugged to the
satisfaction of Employer / Engineer.
16. Whether sufficient numbers of
boreholes for GIR have been taken
along the alignment and for
sufficient depth.
17. Whether rainfall data of previous
years is available for guidance.
18. Whether ground water has been
tested for salinity and other harmful
chemicals and gases.
19. Whether the facility provided for

cold water supply in the shaft is
adequate for the workers.
20. Whether face pressure calculations
have been submitted and
21. Has a gas monitoring system has
been established by the following
systems?
a) fixed system
b) portable system
22. Records for calibration of gas
detection equipment are available.
23. Is entry into the tunnel controlled by
tally board and which prevents non-
inducted person entering the
tunnel.
24. Has pre-employment health
screening for workers has been
completed and list submitted to
25. Is there evidence of the
competency of supervisors and
operators, verified and found
acceptable by Employer / Engineer.
26. Is the competency of electrician
verified and acceptable to Employer
/ Engineer.

27. Whether the organisation chart for
the work has been submitted and
persons are interviewed for their
basic knowledge and
communication skills.
28. Has an assessment of the
hazardous nature of chemicals and
conditioners has been undertaken
and found acceptable to Employer /
Engineer.
29. Is the working visibility for the
erector operator safe for working
30. Is the manlock is insulated against
fire and the arrangement
acceptable.
31. Has the testing of the compressed
air installation been completed and
32. Whether following special hazards
in compressed air working has
been addressed and necessary
actions are in place.
a) Restriction of hot work.
b) Usage of small cylinders for
burning equipment.
33. Is there a permit to work system for
welding and cutting which is
34. Does the hydraulic oil being used
for TBM operation conform to low
flammability category.
35. Are there sign boards indicting
prohibition of petrol driven
equipment displayed in the shaft /
tunnel.
36. Is the network of cables properly
arranged and is it possible to
isolate them in case of fire so that
most essential services can be run.
37. Is equipment provided for working
hand held tools and lighting run on
low voltage supplies. (110 volts)
38. Are the earthing arrangements
satisfactory?
39. Have escape routes have been
established and signed for clarity.
40. Whether third party testing of

EPDM / hydrophilic gaskets have
been completed and found
satisfactory.
41. Whether approval for annulus grout

material / operational grout mix
plant is confirmed by Employer /
Engineer.

42. Has the SAT has been completed
and confirmed by Employer /
Engineer.
43. Whether sufficient number of

relevant segments of
Type-1 & 2 which are more than 28
days old are available to start the
work.
44. Have the facilities for the ventilation
system been installed and
commissioned to the satisfaction of
Employer / Engineer
45. Are the necessary methods for

control of Loco movement with
signals and switches established?
46. Whether the tunnel guidance

system has been commissioned.
47. Have the crew required for

intervention has been Identified and
verified that they possess sufficient
training to effectively deal with
intervention. Are the declared
medically fit?
48. Whether the scheme for muck

removal and disposal has been
submitted and acceptable to
Employer / Engineer
49. Whether the status of reaction

frame and tunnel eye seal is
satisfactory for operation.
50. Has access and egress to the shaft

been safely erected and properly
identified with alternative route for
an emergency.
51. Have risk assessments and control

measures been developed and are
they adequate to manage the
hazards identified.
52. Whether a agreed procedure for

precautionary measures that need
to be taken to keep the TBM face
active during long idling of TBM to
avoid the possible surface
settlement have been documented
and acceptable to Employer /
Engineer.
53. Checks for LOCO Operation:

a) Has braking test of the Loco is
done.
b) Are automatic over speed brakes
required and duly incorporated.
c) Have warning lights been
installed on the lead vehicle.
d) Is there a format for daily
functional brake check been
established?
e) are tracks are properly supported
and secured against displacement.
54. Checks for Belt Conveyor:
a) Is the belt conveyor system fully
guarded.
b) Have belt weighing equipment
been fitted to the conveyors.
c) Is the starting of the conveyor
possible only from a single
controlled position.
d) Is the belt conveyor system fire
resistant.
e) are emergency stop buttons
provided at suitable close intervals
along accessible length.
f) Is there provision of an audible
start-up alarm installed and
operational.
g) Is there provision of anti-runback
devices for inclined conveyer,
installed and operational.
2) During Tunnelling Works:
SI. Item Compliance Reference Remarks Photo Evidence

No Status Code BS
6164 / Clause
55. Provision for CCTV camera has
been made.
56. Whether the shift details for staff
working in the tunnel acceptable.
57. Has the means of site
communications been addressed
Engineer.
58. Is an alert method in case of
Emergencies been put into place
Engineer
59. Has provision for Whole Body
protection been made for hot
work.
60. Are there sufficient number of Self
Rescuer available which should
last for at least 60 minutes?
61. Are there sufficient first aid
facilities including stretchers
available within working area.

62. Is there Provision for dedicated
skip, train or vehicle available for
transporting injured persons.
63. Are there arrangements to provide
adequate lighting levels, is it
acceptable to Employer / Engineer
64. Whether the facility for excavation
volume assessment is in place
Engineer
65. Whether the means for
containment in case of settlement
has been addressed and found
66. Whether the methods for
compensation / secondary
grouting is submitted and
67. Whether required procedure for
clearing Inundation of Tunnel has
been addressed and acceptable to
Employer / Engineer
68. Is the Storage of Combustible
materials well demarcated with
display board.
69. Is there provision for Smoke
control in the Tunnel.
70. Whether onsite procedures for
renovation and repair are
established and acceptable to

APPENDIX 13
CONSTRUCTION / INSTALLATION PHASE OCCUPATIONAL HEALTH & SAFETY

TUNNEL PLAN
Contractor Name
Project Name
1 Application of this document
2 Purpose of this document
3 Scope
4 Referance Publications
6 OH&S Management System Requirements
7 General Requirements
8 Contractor OH&S policy

9 Drug & Alcohol Policy Statement
Interface Management
Management of Change
10
Procurement
Sub-contractor Selection
Construction Management Process Overview
11 OH&S Objectives and programme(s)

Legal and other requirement
12 Legal and other requirement
International Standards, Guidelines & ISO Certifications
Implementation and operation
Contractor’s OHS&E Organization
Resources, roles, responsibility, accountability and authority
Roles & Responsibilities
General duties of the contractor and others
13 General duties of persons employed
Contractors and sub-contractors responsibilities
Duties of the OH&S Persons
Powers of OH&S persons
Competence, training and awareness
OHS&E personnel NONO from the Employer/Engineer
14 Method Statement

15 Lift Plan

16
Risk Assessment
COSHH Assessment
Design Risk Assessment
Risk assessment production and submittal
17 Designer’s Role
18 ID card and First day at work, OH&S Orientation training
Safety Training and Safety Promotion
Occupational health and safety training
Induction training
19
Refresher Training
Specific Training
Tool box talks
Occupational Safety Promotion
OH&S communication
Occupational Health and safety signage
20 Communication, Participation and consultation
Contractor’s site OHS&E committees
Sub contractor awards

Documentation
Management system procedure
Management System
Management System procedures
Corporate Operating Procedures
Standard Operating Procedures
Standard Operating Procedures Safety
Standard Operating Procedures Environmental
21
Standard Forms Safety
Standard Forms Environmental
Control of documents
Operational control
Operational procedures
Document Control
Control of Records
Filing System
22 Surveillance Exercise’s
Site Safety Inspections
Plant & Equipment Inspection
Request for Inspection
23
Evaluation of compliance

Reporting of accidents and Dangerous Occurrence
Contractor responsibility
24 Reportable accidents
Dangerous occurrences
Reporting of fire by the contractor
Reporting to Employer/Engineer
Accident investigation
25 General
Recommended actions in incident investigation
Accident Statistics
Collection of accident statistics

26
Calculation of man-days lost –construction accident statistics
Calculation of accident frequency rate (AFR)

Nonconformity, corrective action and preventive action
27
Control of records
OH&S Audit
MARS Audit
ISO Certification Audit
28 Engineer Audit
External Quarterly OH&S Audit
Period of Quarterly Audit
Areas of competence of audit team
29 Management review
Physical Fitness of Workforce
Medical Facilities
Medical Examination

30
Medical Staff
HIV/AIDS prevention control
Prevention of Mosquito breeding
Alcohol and drugs
Noise

Ventilation
Radiation
Welfare measures for workers
Latrine and urinal accommodation
Moving sites
Canteen
Drinking water
• Living Space
• Toilet/Washing Facilities
31 • Food Preparation/Cooking Area
• Lighting and ventilation
• Evacuation
• Evacuation procedure
• First Aid/Emergency
• Hazardous area
• Fire safety and fire fighting
• Mechanical and electrical safety
• House keeping
• Transportation
• Pest Control
• Camp/ Accommodation Supervisor
Working at height
General
32 Use of scaffolds
Use of ladders
Safety harnesses/Fall Arresters

Excavations
General requirements on excavation work
Duties of engineer on excavation

33
Access and egress from excavation
Undermining nearby structures

Avoiding underground services
Lifting Operations
Lifting appliances
34
Crane safety Equipment
Lifting gear
Site Electricity
General
Design considerations
Cables
Maintenance
35 Lighting
Illumination
Electrical power circuits
Installation of electric wiring and power lines
Residual current circuit breakers and overcurrent protective devices
Prohibition on use of fuse
Industrial plug and socket outlet
Distribution board and socket out assembly
Electrical installations and equipment used underground or in confined space.
Monthly Electrical Safety Audit
Welding, gouging and cutting
Oxy-fuel gas processes
Arc Cutting, gouging and welding processes

36
Compressed gases storage
Handling of compressed gas cylinders
Regulators
Hoses
Training and instruction
Machinery
Machinery Fencing
Maintenance
37
Air receivers
Woodworking machines
Abrasive wheels
Plant and equipment operations
Test and periodical examination

38
Automatic safe load indicators

Personal Protective Equipment
Head protection
Eye protection
Whole body protection

39
Respiratory protection
High –visibility clothing
Hearing protection
Self-Rescuers
First Aid provisions and procedures
First aid bases
First Aid boxes
First aid facilities
40
First Aid rooms
First aid Training
Stretchers
Ambulance van
Blasting Operation
41 Authorisation for blasting
Risk assessment and method statements

Demolition
Preparation of demolition
Protection of adjacent structures
Removal of load bearing structures

42
Demolition of walls, partitions, etc.
Access to floor
Barricades, catch platforms and warning signs
Mechanical method of demolition
False work /Formwork

General Requirements
Supports and shores
Appointment of formwork supervisor
43
Duties of formwork supervisor
Concrete work
Dismantling
Steel Reinforcement
Reshoring
Piling and Diaphragm walls
44

Stability of adjacent structures
Inspection
Pile driver not in use
Pile testing
Footing
45 Work adjacent to live Railways

46 Work adjacent to live roadways
Traffic Management
Legal permission
Regulatory signs
Warning signs
Delineators
47 Traffic Cones and cylinders
Drums
Barricades
Yow away vehicle
Cleaning of roads
Spoil Removal
House Keeping
Accumulation of debris
48 Method of removal of debris, etc.
Floor opening for removal of debris
Debris collection area
Over Head protection

49
Slipping, Tripping, Cutting, Drowning and Falling Hazards
50
Manual Lifting
51
Hand Tools and Power Tools
52
Dangerous and Harmful Environment
53
Corrosive substances
54
Batching Plant and Casting Yard

55

Radiation
56
Smoking
57
Mobile Phones, Radios and Audio Equipment’s
58
Dust ,Gases, fumes
59
Vehicular Traffic
60
Explosives
Handling of explosives
Smoking, open lights etc.
Opening Packages
Deepening holes
Size of holes
61 Removing cartridge wrappers
Loading and other operations
Loading and tamping
Work of firing of any blast
Warning and retreat
Return to blast area
Misfires
Operations during Thunderstorm
62 Floor Openings
63 Evaluation , selection and control of subcontractors
64 CCTV
Site Security
Hoardings
Personnel access
65
Vehicular access
Site patrols
Security Guards
Flooding
66
Flooding Evacuation and Rescue procedure

Work permit system
Implementation of permit to work
No high risk construction work without permit to work
Application for permit to work
Evaluation of permit to work
67
Issue of permit to work
Posting of permit to work and supervisor’s duty
Monitoring of work
Duty to report incompatible work
Revocation of permit to work
68 Grievance and Disciplinary
69 Heavy Plant operations
70 Site Perimeter Hoarding
71 Emergency Preparedness and Response
Warning Notice
72 • Access /Egress Plan & Control of personnel, Staff & Workmen, Check in
/Check out
73 Investigation and information gathering
74 Excavation and ground support
75 Bored Tunnels
76 Gassy Operations
Tunnel plant
77
• Erector Safety , Cutter Head safety
78 Instrumentation Monitoring
79 Safety requirements in all stages of construction
80 Ground support
81 Permanent Support
82 Dealing with Water
83 Tunnelling boring machines and road headers

Inundation
Precautions
84
Escape
Methane
General
Occurrence
Explosion Characteristics
85 Detection and monitoring
Danger Levels
Sources of ignition
Explosion Protection
86 Diesel Engines
87 Hydraulic Plant

88 Shaft and Hoist
89 Rail Haulage
90 Flooding
91 Illumination
Ventilation
General
Control of contamination
92
Oxygen Deficiency
Explosive atmospheres
93 Under Ground communication

Noise and Vibration
Tunnel face
Access routes
Noise sources
Noise reduction
Communications
94
Vibration
Level of vibration
Whole body vibration exposure
Level of hand arm vibration exposure
Transport and loading

Rail Haulage
Clearance
Propelling
Locomotives
Fuelling
Battery locomotives
Potentially explosive atmosphere
95 Rolling stock
Couplings and buffers
Track
Winch haulage
Rubber Tyred vehicles
Belt conveyors
Slurry pumping
Mixing system
Tipping and disposal
Tunnel Plant
Pneumatic Plant
Hydraulically operated plant
Internal combustion engines
96 Diesel engines
Siting of engines
Concerting plant
Water drainage pumps
Fire Prevention, protection, fighting system and Rescue

Fire Mains and hose connections
Fire extinguishing system
97
Routine testing and maintenance of fire protection equipment
Vulnerable items and locations
Escape routes

Fire Fighting’s and rescue
Fire services and operational capacity
Fire Fighting equipment
Emergency control facilities
Bridge heads
Raising the alarm
Alarm procedure
Site training
Lighting
Smoke control
Rescue facilities
Self Rescuers
Accounting personnel
Storage of flammable liquids
Access
Walkways
98
Access maintenance
Gradients
Drilling
Compressed Air Environment
General duty of contractor
Safe system of work
Warning Notice
Use of bulkhead
Plant and equipment
Supply of air
Power Source
Temperature and humidity
Means of communications
Appointment of competent person for compressed air works
Identification badges
99 Conditions for persons working in compressed air environment
Condition for multiple entries in compressed air environment
Prohibition on consumption of alcohol and smoking
Man-Locks
Compression and decompression procedure and use of man lock
Medical Locks
Attendance at man lock
Attendance at medical lock
Appointment of medical practitioner
Resting facilities and First Aid Room
Maintenance of records
Training of personnel
100 Monitoring of the tunnel atmosphere

Tunnel Track Maintenance
Roles and competencies
101 Tunnel track work permit
Tunnel track inspection and maintenance
102 Pathways
103 Permissible exposure Limits
104 Dust
105 Protection against dust

106 Gaseous contamination
107 Emission from power units
108 Heat
109 Visitor’s to site

110 OH&S Submittals to the Employer/Engineer
Appendix
Emergency Preparedness Flow Chart, Emergency Evacuation Plan layout with
111 Emergency Contact Number
General instruction for Entry into tunnel including visitor induction & Tunnel Visitor
pass Tally board

Environment Audit Measurement Criteria
Page 1 of 9
1. Waste
ACTIVITY EXCELLENT GOOD AVERAGE FAIL IMMEDIATE
[An Exceptional [Exceeding the [In line with [In Need of ACTION
Standard] Norm] Environment Improvement] [Unsatisfactory
10 Points 8 Points Procedures] 0 Points ]
6 Points -10 Points
1.1 Daily recorded Well signed Safety sited, Provided but None provided,
Provision of inspection of and regularly good access, position hazardous
Skips area. inspected. skip in good compromised sighting
Area around condition. safety, lack of
skip tidy, signs. Open
maintained topped skip.
1.2 Out-sourcing of Instructions Formal Identified in Not identified
Instructions waste displayed on procedure in Hazard & Risk in Hazard &
on waste management notice board. place, Logs, Risk Logs
disposal Segregation disposal procedure not No procedure,
points for instructions implemented hazardous
hazardous included. with poor site waste
waste clearly Procedures control Waste not
signed. followed segregated.
1.3 Carrier provides Regular Waste carrier Different Not formally

Use of Reg. regular reports collection with appointed carriers used appointed, AD-
Waste of no excessive procedures with, no formal HOC system
Carrier handling/disposa waste builds in place. procedure in
l performance at up on site. place.
transfer station.
1.4 Records of, Transfer notes Transfer Some Non existent
Use of Waste quantities retained and notes raised, completed not
Transfer maintained filed. and signed all retained
Notes off
1.5 All recycling Contractor sets Procedures Procedures and Recycling
Recycling opportunities recycling established opportunities opportunities
Materials identified and objectives and and need enforcing not identified
procedure in targets in a recycling
place for percentage active.
objective format
achievement.
1.6 All waste Comprehensiv Waste Plan Plan only partly No plan or not
Waste monitored and e plan, waste established implemented, implemented
Management plan regularly streams and not all waste
Plan & reviewed. identified, implemented considered.
Policy Corporate policy impact register , waste
also displayed in place. management
and out-sourced,
implemented. records
maintained.
1.7 Full procedures, Staff inducted, Included in Partial No
Waste staff trained records management implementation arrangements
records kept, policy, , records not
Page 2 of 9
Minimisatio waste monitored. maintained. Procedures completed in place

n in place.
1.8 Regular review Procedures in Special Special waste Not identified,
Identificatio of arrangements. place. Records waste identified, not no
n of Staff briefed/tool maintained and segregated properly stored arrangements
Special box talk. transfer notes and labelled prior to in place, not
Wastes raised. for disposal disposal segregated.
by licensed
carrier
2. Noise
[An [Exceeding the [In line with [In Need of ACTION
10 Points 6 Points
2.1 Regular review Information on Sources Sources None recorded
Identification of sensitive Limit/exposure identified, documented, in Hazard &
of Sources receptors. levels held on assessments assessments Risk Log or
site. completed not completed Aspect Impact
assessment
2.2 Maintenance dBA Equipment Identified in Not identified
Provision of and test frequently silenced to Hazard & risk in Hazard &
Silenced certificates checked. Noise acceptable log but not Risk logs. Not
Equipment maintained for monitoring levels implemented provided in
machinery equipment throughout. areas where
available and Some noise levels are
calibrated provided but exceeded and
do not cover near sensitive
all risks receptors
2.3 Noise Noise levels Frequent Noise levels Equipment on None carried
Monitoring from checks, monitored site, Irregular out
equipment records calibration checks made
checked and maintained. records on no calibration
recorded daily site. records
2.4 Stack Frequent Stack Irregular Damaged/non- None carried
Monitoring checks, records monitored checks. No standard out
maintained. calibrated standard equipment
monitoring procedure. used.
equipment
used.
Page 3 of 9
3. Air
10 Points 6 Points
3.1 Frequent Air quality Air Quality Irregular None carried
Monitoring checks, records monitored at monitored checks. out
maintained. Sensitive and calibrated Damaged/non-
Mitigation Residential monitoring standard
measures are areas. equipment equipment
in place. used. used.
3.2 Mitigation Regular review APC measures APC measures Identified, not None recorded
Measures of implemented implemented. implemented. in Aspect
arrangements. and monitored Impact Register
Staff frequently.
briefed/tool
box talk.
Dust Control
Plan at place
3.3 Relative Frequent Mitigation Monitored, Irregular None carried
Humidity checks, records measures are calibrated checks. out
maintained. in place. monitoring Damaged/non-
equipment standard
used. equipment
used.
3.4 Velocity Frequent Mitigation Monitored, Irregular None carried
Monitoring checks, records measures are calibrated checks. out
maintained. in place. monitoring Damaged/non-
equipment standard
used. equipment
used.
3.5 Frequent Mitigation Monitored, Irregular None carried
Temperature checks, records measures are calibrated checks. out
Monitoring maintained. in place. monitoring Damaged/non-
equipment standard
used. equipment
used.
Page 4 of 9
4. Land
[An [Exceeding [In line with [In Need of ACTION
Exceptional the Norm] OSHE Improvement] [Unsatisfactory]
10 Points 6 Points
4.1 Excavated Dumped in Dumped Stored at site Irregular Soil/Muck not
Soil/Muck designated within 48 and secured disposal and disposed.
areas and hours after properly. soil/muck not
transfer notes excavation. secured
retained. properly.
4.1 Muck Records of, Transfer notes Transfer notes Some Non existent
Disposal – quantities retained and raised, and completed not
Transfer Notes maintained filed. signed off all retained
4.3 Land Regular review Spill clean-up Drip trays Spillage on Spillage on
contamination of equipment available. ground. Drip ground. Used
arrangements. readily trays not used. oil drums/ oil
Staff available. filters found
briefed/tool scattered at site.
box talk.
4.4 Regular review Side of Wheel Manual Non-existent of
Transportation of vehicles clear washing cleaning of Wheel Wash
of Muck arrangements. from mud. facilities vehicle tyres. Facilities
Staff available.
briefed/tool Materials
box talk. transported in
Dust Control a closed
Plan at place manner.
Page 5 of 9
5. Tree Cutting, Tree Transplantation and Compensatory

Plantation
ACTIVITY EXCELLEN GOOD AVERAGE FAIL IMMEDIATE
T [Exceeding the [In line with [In Need of ACTION
[An Norm] OSHE Improvemen [Unsatisfactory]
Exceptional 8 Points Procedures] t] -10 Points
Standard] 6 Points 0 Points
10 Points
5.1 Method Regular MS Available Completed MS on site MS not
Statement for review of on site. as per but not completed.
Tree Cutting MS. Schedule of Environment suitable and
& Tree operative al Impact sufficient for
Transplantatio briefings Aspect task. Notice
n identified. Register. of no
Suitable and objection not
sufficient for obtained
tasks. Notice from ER.
of no
objection
received
from ER
5.2 Approvals Vegetation Weekly Approval - Tree
for Tree study in work inspections obtained cutting/transplanti
cutting and area done records from ng done without
Transplantatio maintained. ES/CMRL approval.
n
5.3 Storage & Weekly Regular update Fire wood Improper Disposed without
Disposal of disposal of Stack logs wood stacking of approval from
Fire Wood records Register proper fire ES/CMRL
maintained. stacking logs/wood
done
5.4 Excess Quarterly Compensator Compensator Compensatory
Compensatory compensatory inspection y planting y planting planting not done
Plantings plantation reports on done as per done but not
done. planting and the up to the
survival status. requirement/ requirement.
standard/
norms
5.5 Landscape Weekly Regular review Landscape Work carried No landscape
Works inspections of plan/ design out without plan/ design
records implementation implemented Landscaping
maintained.. s. at site. plan/design
approval.
Page 6 of 9
6. Environment Documentation
10 Points 6 Points
6.1 All aspects and All impacts Environment Plan only No plan or not
Environment impacts are identified, Management partly implemented
Plan monitored and mitigation Plan implemented,
plan regularly measures established not all
reviewed. implemented. aspect impact impacts
Corporate register in considered.
policy also place.
displayed and
implemented.
6.2 Daily Up to date, Up to date Information Not up to date,
Environment inspections shows with good poorly or inspections
Inspections records mitigation clear recorded. missed.
maintained. measures/action information.
taken. Well
documented
and dates of
remedial
action
required, as/
when.
6.3 Display of Posters Additional Displayed on Not in Not displayed,
Environmental displayed on Posters office notice prominent or incomplete.
Policy/ Environmental displayed board/all position
Awareness impacts (on - i.e. mess boxes (hidden
Posters going work room, site entry completed.. away)
activities) and point of
work
7. Storage of Hazardous Materials

[An Exceptional [Exceeding [In line with [In Need of ACTION
Standard] the Norm] OSHE Procedures] Improvement] [Unsatisfactory]
10 Points 8 Points 6 Points 0 Points -10 Points
7.1 Storage Proper signage’s Properly Stored as per the Spillage on Improper
and labels are stored. standard/regulation the ground. storage of
Page 7 of 9
present on all Quantity No Hazardous

waste containers. and last identification Waste
date of of storage Materials
disposal materials.
displayed at
storage
area.
7.2 Handler provides Regular Authorised Waste Different Hazardous
Authorised regular reports of collection Handlers carrier handlers used waste disposed
Handlers handling/disposal with no appointed with, no to unauthorised
performance. excessive procedures/ formal handlers.
waste agreements in procedure/
builds up place. agreement in
on site. place.
8. Water
[An [Exceeding [In line with [In Need of ACTION
Exceptional the Norm] OSHE Improvement] [Unsatisfactory]
10 Points 6 Points
8.1 Testing Water level Frequent Water Irregular testing None carried
recorded. checks, Testing done out
reports and report on
maintained. site.
8.2 Daily Onsite Out-sourcing Discharge into No treatment
Treatment inspections treatment of waste other water facilities
Facility records facilities water bodies/sewer/storm available
maintained. available. water line without
approval
8.3 Reuse of Full Staff Included in Partial No
Water procedures, inducted, management implementation, arrangements in
staff trained records policy, records not place
records kept, maintained. Procedures completed
procedure in place.
monitored.
9. Training
ACTIVITY EXCELLEN GOOD AVERAGE FAIL IMMEDIAT
T [Exceeding [In line with [In Need of E ACTION
[An the Norm] OSHE Improvement] [Unsatisfactor
Exceptional 8 Points Procedures] 0 Points y]
Standard] 6 Points -10 Points
10 Points
9.1 Audit/inspecti Knowledge of Induction done Limited No formal
Management on training. project, site environmental/ management
Page 8 of 9
Competency Competency and corporate waste or supervisory

formally arrangements. management training.
assessed. training No induction
9.2 Training Programme of Programme Programme Training No training
Programme additional regularly maintained for programme nit procedure or
training needs reviewed and induction, up to date or not programme.
maintained. updated. waste implemented.
Implementatio Implementatio management,
n schedule n standard environmental
attainment monitored and awareness and
reported reported on. management .
monthly.
Page 9 of 9
Monthly Environment Audit
Date of Inspection:
ENVIRONMENT TOTAL %

Project Manager: Environment Manager :
Site Conditions:
Points will be objectively awarded by Environmental Personnel based upon site Environmental conditions.
Scoring will be as follows: Excellent (E) = 10, Good (G) = 8, Average (A) = 6, Fail (F) = 0, Non-Compliance (NC) = -10.
All non-compliance within the heavy bordered areas will receive an Action Notice at the required level.
All Suspended Operations Notices will be referred to the Project Manager, who will visit site within 24 hours to carry out further environment inspections.
Any non applicable topic and the corresponding “possible score” will not be marked and the score will be calculated by recognising the relevant possible score as
being 100% and the actual score as a percentage of this.
1 Waste E G A F NC Actions
1.1 Provision of Skips
1.2 Instructions on Waste Disposal
1.3 Registered Waste Carrier
1.4 Retention of Waste Transfer Notes
1.5 Recycling Materials
1.6 Waste Management Plan & Policy
1.7 Waste Minimisation
1.8 Identification of Special Wastes
SUB TOTAL POSSIBLE 80
2 Noise E G A F NC Actions
2.1 Identification of Sources
2.2 Provision of Silenced Equipment
2.3 Noise Monitoring
2.4 Stack Monitoring
3 Air E G A F NC Actions
3.1 Monitoring
3.2 Mitigation Measures
3.3 Relative Humidity
3.4 Velocity Monitoring
3.5 Temperature Monitoring
4 Land E G A F NC Actions
4.1 Excavated Soil/Muck
4.2 Muck Disposal - Transfer Notes
4.3 Land Contamination
4.4 Transportation of Muck
4 Tree Cutting/Transplantation Approvals

E G A F NC Actions
5.1 MS for Tree Cutting/Transplantation
5.2 Approvals for Tree Cutting
5.3 Storage & Disposal of Fire Woods
5.4 Compensatory Plantings
5.5 Landscape Works
6 Environment Documentation E G A F NC Actions

6.1 Environment Plan
6.2 Environmental Inspections
6.3 Environmental Awareness
Rev 01 01/07/19 Monthly Environment Audit Pafe 1 of 3
7 Storage of HAZMAT E G A F NC Actions

7.1 Storage
7.2 Authorised Handlers
8 Water E G A F NC Actions
8.1 Testing
8.2 Treatment Facility
8.3 Reuse of Water
9 Training E G A F NC Actions
9.1 Management Competency
9.2 Training Programme
OVERALL TOTAL POSSIBLE 360
Environment Score % 0.00
Comments:
Environment Manager Mr. xxxxxxxxxxxxxxxxx Signed

(Print Name) --------------------------------------------------------------------
Project Manager Mr. xxxxxxxxxxxxxxxxx Signed

(Print name) --------------------------------------------------------------------
Rev 01 01/07/19 Monthly Environment Audit Pafe 2 of 3

Site Environment Compliance Audit Toolkit
Totals Sheet
Date of Inspection:
Contractor:GDCL.
Project Name:ADC-03CMRL.
Project Manager:Mr.R. K. Singh
Safety Manager: Mr.D.Pattabi Raman
SCORE
18 WASTE 66
19 NOISE 30
TOTAL % 87%
Rev 11 23/01/04 Appendix 4 - b. Environment Audit Score Sheet.xls Totals


PART-2
SECTION VII
EMPLOYERS REQUIREMENT
OUTLINE CONSTRUCTION SPECIFICATIONS
SUB SECTION - 1
CIVIL & STRUCTURAL WORKS
DECEMBER 2021
Chennai Metro Rail Project - Phase 2, Corridor 5 Part-2 Section VII
TABLE OF CONTENTS
SECTION
1 GENERAL ............................................................................................................................. 4
1.1 INTRODUCTION ......................................................................................................................... 4
1.2 STRUCTURAL WORK ................................................................................................................. 7
1.3 APPLICABLE CODES, STANDARDS & PUBLICATIONS ............................................................... 8
2 EXCAVATION ................................................................................................................... 16
2.1 PRELIMINARIES ....................................................................................................................... 16
2.2 FILL ........................................................................................................................................ 20
2.3 TESTS ...................................................................................................................................... 23
3 ROADWORK ...................................................................................................................... 24
3.1 CONTROL OF TRAFFIC ............................................................................................................. 24
3.2 GRANULAR SUBBASE (NON-BITUMINOUS) .......................................................................... 27
3.3 WET MIX MACADAM SUB-BASE/BASE ................................................................................... 29
3.4 BITUMINOUS MATERIAL .......................................................................................................... 32
3.5 PRIME COAT ........................................................................................................................... 33
3.6 TACK COAT ............................................................................................................................ 34
3.7 DENSE BITUMINOUS MACADAM ............................................................................................. 34
3.8 BITUMINOUS CONCRETE ......................................................................................................... 38
3.9 BITUMINOUS MACADAM ......................................................................................................... 43
3.10 CONTROL OF TRAFFIC ............................................................................................................. 49
3.11 OPEN-GRADED PRE-MIX CARPET ........................................................................................... 49
3.12 SEAL COAT ............................................................................................................................. 50
4 PILING AND DIAPHRAGM WALLING .......................................................................... 51
4.1 GENERAL ................................................................................................................................ 51
4.2 CONCRETE PILES..................................................................................................................... 54
4.3 PRECAST CONCRETE PILES ..................................................................................................... 54
4.4 CAST-IN-PLACE PILES ............................................................................................................. 55
4.5 PILE TESTING .......................................................................................................................... 58
4.6 DIAPHRAGM WALLING............................................................................................................ 62
5 STRUCTURAL CONCRETE: PLAIN, REINFORCED AND PRESTRESSED .............. 70
5.1 CONCRETE MATERIALS........................................................................................................... 70
5.2 CONCRETE WORKMANSHIP ..................................................................................................... 80
5.3 PRECAST CONCRETE ............................................................................................................. 100
APPENDIX A ............................................................................................................................ 105
6 FORMWORK ................................................................................................................... 108
6.1 GENERAL .............................................................................................................................. 108
6.2 MATERIALS ........................................................................................................................... 108
6.3 DESIGN & DRAWINGS ........................................................................................................... 108
6.4 FORMWORK FOR EXPOSED CONCRETE SURFACES................................................................. 109
6.5 FORMWORK FOR SLOPED SURFACES ..................................................................................... 110
6.6 FORMWORK FOR CURVED SURFACES .................................................................................... 110
Section VII – Outline Construction Specification December 2021

SS1-1
Sub-Section-1-Civil & Structural Works
6.7 ERECTION OF FORMWORK..................................................................................................... 110

6.8 CONCRETE FINISHES ............................................................................................................. 112
6.9 AGE OF CONCRETE AT REMOVAL OF FORMWORK ................................................................. 114
6.10 STRIPPING OF FORMWORK .................................................................................................... 114
6.11 REUSE OF FORMS .................................................................................................................. 114
6.12 FORMWORK FOR PRECAST / PRESTRESSED CONCRETE .......................................................... 115
6.13 SPECIAL ARCHITECTURAL FINISHES ..................................................................................... 115
APPENDIX B ............................................................................................................................ 116
7 PRESTRESSED MEMBERS ............................................................................................ 117
7.1 PRE-STRESSING TENDONS ..................................................................................................... 117
7.2 PRE-CAST CONSTRUCTION .................................................................................................... 119
7.3 STRESSING TENDONS ............................................................................................................ 119
7.4 TESTING BY CONTRACTOR .................................................................................................... 120
7.5 PRE-TENSIONING ................................................................................................................... 121
7.6 POST-TENSIONING ................................................................................................................. 121
7.7 PRE-STRESSING TENDONS - PROTECTION AND BOND ............................................................ 123
7.8 DUCTS FOR BONDED TENDONS ............................................................................................. 124
7.9 DUCTS FOR UNBONDED TENDONS ........................................................................................ 126
7.10 PRE-STRESSING TENDONS - TRIAL CONSTRUCTION-UNBONDED TENDONS ........................... 127
7.11 PRE-STRESSING TENDONS - TEMPORARY TENDONS .............................................................. 127
7.12 PREPARATION FOR CASTING ................................................................................................. 127
8 STRUCTURAL STEELWORK ........................................................................................ 131
8.1 GENERAL .............................................................................................................................. 131
8.2 MATERIAL PROPERTIES......................................................................................................... 131
8.3 TESTING ................................................................................................................................ 131
8.4 FABRICATION ........................................................................................................................ 132
8.5 DETAILING OF CONNECTIONS ............................................................................................... 133
8.6 SUBMISSIONS ........................................................................................................................ 133
8.7 WELDING .............................................................................................................................. 134
8.8 ELECTRODES ......................................................................................................................... 134
8.9 WELDERS .............................................................................................................................. 134
8.10 TESTING ................................................................................................................................ 134
8.11 SITE WELDING ...................................................................................................................... 134
8.12 ERECTION OF STEELWORK .................................................................................................... 134
8.13 TOLERANCES ........................................................................................................................ 136
8.14 BOLTED CONNECTIONS ......................................................................................................... 136
8.15 TRANSPORTATION AND STORAGE ......................................................................................... 136
8.16 DAMAGED MATERIAL ........................................................................................................... 136
8.17 GALVANISING ....................................................................................................................... 136
8.18 PREPARATION OF STEELWORK FOR PROTECTIVE TREATMENT .............................................. 137
8.19 PAINTING GENERALLY .......................................................................................................... 137
8.20 APPLICATION OF PROTECTIVE LAYERS ................................................................................. 138
8.21 PROTECTION OF BOLTS ETC. ................................................................................................. 138
8.22 HIGH STRENGTH FRICTION GRIP CONNECTIONS ................................................................... 138
8.23 PROTECTIVE TREATMENT ..................................................................................................... 138
8.24 PAINTWORK EXECUTED ON SITE ........................................................................................... 138
8.25 EARTHING AND BONDING SYSTEM ....................................................................................... 139
SS1-2
9 CUT AND COVER CONSTRUCTION ............................................................................ 139

9.1 GENERAL .............................................................................................................................. 139
9.2 WATERPROOFING .................................................................................................................. 139
10 TUNNEL AND SHAFT EXCAVATION IN ROCK ......................................................... 152
10.1 EXCAVATION METHOD ......................................................................................................... 152
10.2 BLASTING ............................................................................................................................. 152

SS1-3
CIVIL & STRUCTURAL WORKS

1 GENERAL
1.1 INTRODUCTION
1.1.1 Scope
These specifications contained herein shall be read in conjunction with other contract
documents.
The Outline Construction Technical Specifications as follow are based on latest edition of
“Specifications for Road and Bridge works” of Ministry of Road Transport & Highways
(MORTH) as published by Indian Roads Congress, Indian Railway Standards and
CPWD/TNPWD specifications – latest editions with correction slips & amendments up to
date to the extent they are applicable to the works covered under scope of works. However,
the provisions of MORTH specifications take precedence over CPWD/TNPWD
specifications. Further the specifications contained herein will supersede the provisions of the
MORTH & CPWD/TNPWD specifications to the extent of their applicability.
The Indian and International Standards as scheduled below have been used as base for the
specifications. The Contractor shall be responsible for detailing in his specifications
submitted to the Employer’s Representative, on which his materials and workmanship will
be based. These shall be of similar or higher standard than those listed below. The Contractor
is required to notice in the first instance the Indian Standards and base the specifications on
Indian Standards to the extent that they are applicable.
Alternative or additional codes and standards proposed by the Contractor shall be
internationally recognised codes and shall be equivalent to or better than, Indian Standards
issued by the Bureau of Indian Standards or any other Indian professional body or
organisation, subject to being, in the opinion of the Employer’s Representative, suitable for
incorporation or reference into the specifications. The specifications have been divided into
different sections / sub-heads for convenience only. They do not restrict any cross-references.
The Contractor shall take into account inter-relations between various parts of works/trades.
No claim shall be entertained on the basis of compartmental interpretations.
1.1.2 References
The following are the references to the standard code of practice.
References to standard code of practice
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASTM American Society for Testing Materials
BS British Standard
CPWD Central Public Works Department
DIN Deutsches Institut für Normung e.v.
IRC Indian Road Congress
IRCEM Institution de Retraite Complementarie des Employes de
Particular

SS1-4
References to standard code of practice

IRS Indian Railway Standards
IS Indian Standards
JIS Japanese Industrial Standard

MORTH Ministry of Road transport and Highway
TNPWD TamilNadu Public Works Department
UIC International Union of Railways
The detailed list of Standards referred to is mentioned in Section 1.3.
1.1.3 Storing of Materials at sites
All materials used in the works shall be stored on racks, supports, in bins, silos, godowns,
under cover etc as appropriate to prevent deterioration or damage from any cause whatsoever
to the entire satisfaction of the Employer’s Representative.
The storage of materials shall be in accordance with IS 4082 “Recommendation on stacking
and storage or construction materials on site” and as per IS 7969 “Safety code for handling
and storage of building materials”.
The materials shall be stored in a proper manner at places at site agreed by the Employer’s
Representative. Should the place, where material is stored by the Contractor, be required by
the Employer for any other purpose, the Contractor shall forthwith remove the material from
that place at his own cost and clear the place for the use of the Employer within the time as
communicated by the Employer’s Representative and at no extra cost to the Employer.
1.1.4 Materials
All materials shall be of best quality and shall conform to manufacturer’s specification.
Wherever, no specific code of practice of IRS/IRC/BIS is applicable, the decision of
Employer’s Representative shall be final and binding.
1.1.5 Workmanship
(i) All works shall be true to level, plumb and square and the corners, edges and rises in all
cases shall be unbroken and neat.
(ii) Any work not to the satisfaction of the Employer or his Representative will be rejected
and at the same shall be rectified or removed and replaced with work of the required
standard of workmanship by the Contractor at no extra cost.
1.1.6 Load testing on completed structures
1.1.7 During the period of construction or within the defect liability period, the Employer’s
Representative may at his discretion order the load testing of any completed structure or
any part thereof if he has reasonable doubts about the adequacy of the strength of such
structure for any of the following reasons.
i. Results of compressive strength on concrete test cubes falling below the specified
strength.
ii. Premature removal of formwork.
iii. Inadequate curing of concrete.
SS1-5
iv. Overloading during the construction of the structure or part thereof.

v. Carrying out concreting of any portion without the prior notice to the Employer’s
Representative.
vi. Honey combed or damaged concrete which will affect the stability of the structure
to carry the design load, more so in important or critical areas of the structure.
vii. Any other circumstances attributable to the Contractor which may result in the
structure or any part thereof being of less than the strength or performance
required under the Contract.
1.1.8 All the loading tests shall be carried out by the Contractor in accordance with the agreed
methods and Standards. Such tests shall be carried out only after expiry of minimum 28
days or such longer period. The structure shall be subjected to a superimposed load equal
to the specified superimposed load assumed in the design. This load shall be maintained
for a period of 24 hours before removal. During the test, struts strong enough to take the
whole load shall be placed in position leaving a gap under the members. The deflection
due to the superimposed load shall be recorded by sufficient number of agreed
deflectometers capable of reading to an accuracy of 0.02 millimetres and suitably located
under the structure.
The structure shall be deemed to have passed the test if the maximum deflection at the
end of 24 hours of loading does not exceed the deflection given by the following
expressions:
D = 0.001 L2/25 T, where,
D = max deflection due to imposed load only
L = span of the member under load test (the shorter span in case of slabs). The span is
the distance between centres of the supports or the clear distance between the supports
plus the depth of the member, whichever is smaller. In case of cantilever, this shall be
taken as twice the distance from the support to the end and deflection shall be adjusted
for movement of the support.
T = depth of member.
If within 24 hours of the removal of the superimposed load, the structure does not
recover at least 75% of the deflection under the superimposed load, the test loading
shall be repeated after a lapse of 72 hours. If the recovery after the second test is less
than 80% of the maximum deflection shown during the second test, the structure shall
be considered to have failed to pass the test and shall be deemed to be unacceptable.

SS1-6
1.1.9 In such cases the portion of the work concerned shall be taken down or cut out and
reconstructed to comply with the specifications. Other remedial measures may be taken to
make the structure secure at the discretion of the Employer’s Representative. However,
such remedial measures shall be carried out to the complete satisfaction of the Employer’s
Representative.
1.1.10 All costs involved in carrying out the tests defined in Section 1.1.1.7 above, (including
load and integrity test for piles) and other incidental expense thereto shall be borne by the
Contractor regardless of the result of the tests. In case of failure the Contractor shall take
down or cut out and reconstruct the defective work or shall take the remedial measures, as
instructed, at his own cost.
1.1.11 If the load testing is instructed on any grounds other than mentioned Section 1.1.1.7 above,
then the cost of the same shall be reimbursed if the test results are found to be satisfactory.
1.1.12 In addition to the above load tests, non-destructive tests on various elements (except on
piles) such as core test and ultrasonic pulse velocity test shall be carried out by the
Contractor at his own expense. Such tests shall be carried out by an agency agreed with
the Employer’s Representative and. The acceptance criteria for these tests shall be as
specified by the testing agency or good Engineering practice subject to the notice of the
1.2 STRUCTURAL WORK
1.2.1 Unless otherwise specified, only controlled concrete with design mix and weigh batching
is to be used for the work.
1.2.2 Minimum cement content for various grades/- elements of concrete as specified, is purely
from durability point of view. Larger content of cement shall be provided if demanded by
mix design or as per the requirement of relevant codes.
1.2.3 Mix design using smaller aggregates of 10 millimetres and below shall also be done in
advance for the use at the junctions, where reinforcement is congested.
1.2.4 Procedure of mixing the admixtures shall be strictly as per the manufacturer’s
recommendations.
1.2.5 All the water tanks and other liquid retaining concrete structures shall undergo hydro-
testing.
1.2.6 Special benches shall be provided at site for stacking reinforcement bars of different sizes.
1.2.7 Formwork for beams of Reinforced Cement Concrete works shall be designed in such a
way that the formwork of the adjacent slabs can be removed without disturbing the
props/supports to the beams.
1.2.8 Wherever there are tension/suspended concrete members which are suspended from upper
level structural members, the shuttering/scaffolding of such members at lower level shall
be kept in place until such time as the upper level supporting members have achieved the
required minimum strength.
1.2.9 The Contractor shall incorporate seismic considerations of anchoring and isolation in the
design and detailing of the finishes. The element to be anchored shall have its motion
suitably restrained and isolated so as not to be affected by the deformations/vibrations of
the building during Construction.
1.2.10 Formwork shall be provided for full height at all locations. Special precautions for such
tall formwork shall be taken to ensure its safety and stability.

SS1-7
1.3 APPLICABLE CODES, STANDARDS & PUBLICATIONS

The important Codes, Standards and Publications to Contract are listed here under:
A General
IS:875 (Part 3) Code of practice for design loads (other than earthquake) for buildings and
structures
IS:1322 Bitumen felts for water proofing and damp-proofing
IS:1893 Criteria for earthquake resistant design of structures
IS:2572 Code of Practice for construction of hollow concrete block masonry
IS:2974(Part 1) Code of Practice for Design & Construction of machine Foundation
IS:3414 IS:3764 Code of practice for design and installation of joints in buildings Excavation
Work- Code of Safety
IS:6408 (Parts 1,2) Recommendations for modular co-ordination in building industry
– tolerances
IS:10958 General check list of functions of joints in building
IS:11817 Classification of joints in buildings for accommodation of dimensional
deviations during construction
IS:11818 Method of test for laboratory determination of air permeability of joints in
buildings
IS:12440 Precast concrete stone masonry blocks
CPWD Specifications 1996.
BS:476 (Part 7) Method for classification of the surface spread of flame of products
BS:476 (Part 20) Method of determination of the fire resistance of elements of construction
(general principles)
BS:476 (Part 22) Methods for determination of the fire resistance of non-load bearing elements of
construction
BS:5215 Specification for one-part gun grade polysulphide-based sealants
BS:5606 Guide to accuracy in building
BS:6093 Code of practice for the design of joints and jointing in building construction
BS:8200 Code of practice for the design of non-load bearing external vertical enclosure of
building
ASTM C 332 Specification for light weight aggregate for insulating concrete
SP 7 National Building Code of India
SP 23 (S&T) Handbook on Concrete Mixes
B Bitumen
IS:702 Industrial Bitumen
IS:3384 Specification for bitumen primer for use in waterproofing and damp-proofing
C Building Construction Practices

SS1-8
IS:1838 Parts I and II. Specifications for preformed fillers for expansion joint in concrete pavements
and structures.
IS:1946 Code of Practice for use of fixing devices in walls, ceilings, and floors of solid
construction.
IS:6509 Code of Practice for installation of joints in concrete pavements.
IS:11134 Code of Practice for setting out of buildings.
IS:11433 Parts I and II. Specifications for one-part Gun grade polysulphide based joint
sealant.
IS:12200 Code of Practice for provision of water stops at transverse contraction joints in
masonry and concrete dams
D Cement
IS:269 33 grade ordinary Portland cement
IS:455 Portland Slag Cement
IS:650 Specification for standard sand for testing cement.
IS:1489 (Part 1) Portland pozzolana cement: Fly ash based
IS:1489 (Part 2) Portland pozzolana cement: Calcined clay based
IS:3535 Method of Sampling Hydraulic Cements
IS:4031 (Parts 1 to 13) Methods of physical tests for hydraulic cement.
IS:4032 Method of chemical analysis of hydraulic cement.
IS:6925 Methods of test for determination of water-soluble chlorides in concrete

admixtures.
IS:8042 White Portland Cement
IS:8112 Specification for 43 grade ordinary Portland cement.
IS:12269 Specification for 53 grade ordinary Portland cement.
IS:12330 Specification for sulphate resistant Portland cement.
E Concrete
IS:456 Code of practice for plain and reinforced concrete.
IS:457 Code of practice for general construction of plain and reinforced concrete for
dams and other massive structures.
IS:460 (Parts I to II) Specification for Test Sieves
IS:516 Methods of test for strength of concrete.
IS:1199 Methods of sampling & analysis of concrete.
IS:1200 Method of measurement of building and civil Engineering

SS1-9
IS:1343 Code of practice for prestressed concrete
IS:1607 Method of Test Sieving
IS:2386 Parts I-VIII. Methods of tests for aggregates for concrete.
IS:2430 Methods of Sampling of Aggregates of Concrete
IS:2438 Specification for roller pan mixer
IS:2514 Specification for concrete vibrating tables
IS:2571 Code of practice for laying in-situ cement concrete flooring
IS:2645 Specifications for integral cement water proofing compounds
IS:2722 Specifications for portable swing batchers for concrete (double bucket type)
IS:2770 Methods of testing bond in reinforced concrete part I pull out test
IS:3025 Methods of sampling and test (physical and chemical) for water & wastewater
IS:3370 Code of practice for concrete structures for storage of liquids
IS:3935. Code of practice for composite construction
IS:4326 Code of practice for earthquake resistant construction of building
IS:6925. Methods of test for determination of water-soluble chlorides in concrete

Admixtures
IS:7242 Specifications for concrete spreaders
IS:7251 Specifications for concrete finishers
IS:7861 Parts I & II. Code of practice for extreme weather concreting.
IS:7969 Safety code for handling and storage of building materials
IS:8989 Safety code for erection of concrete framed structures
IS:8142 Methods of test for determining setting time of concrete by penetration

resistance
IS:9103 Specifications for admixtures for concrete
IS:9013 Method of making, curing and determining compressive strengths of accelerated

cured concrete test specimens
IS:9284 Method of test for abrasion resistance of concrete
IS:10262 Recommended guidelines for concrete mix design.
MORTH Specifications for Road and Bridge Works, Ministry of Road Transport and
Highways (Roads Wing)
IRS Concrete Bridge Code

SS1-10
Standard Specifications and Code of Practice for Road Bridges Section III –
IRC 21-2000 Cement Concrete (Plain & Reinforced) (First Revision)
IRC:18-2000 Design criteria for Prestressed Concrete Road Bridges (Post – Tensioned
Concrete)
ASTM - C – 94 Ready Mix Concrete
IS 4926:2003 Ready Mixed Concrete – Code of Practice
ASTM – C - 1240 Specifications for Silica Fume for use in Hydraulic Cement and
Mortar
F Construction Plant and Machinery
IS:1791 Specification for batch type concrete mixers.
IS:2505 General requirements for concrete vibrators: Immersion type.
IS:2506 General requirements for screed board concrete vibrators.
IS:3366 Specification for pan vibrators.
IS:3558 Code of Practice for use of immersion vibrators for consolidating concrete.
IS:4656 Specifications for form vibrators for concrete.
IS:4925 Specification for concrete batching and mixing plant.
IS:11993 Code of Practice for use of screed board concrete vibrators.
G Formwork
IS:4990 Specifications for plywood for concrete shuttering work.
IRC:87 Guidelines for the design and erection of false work for road
bridges.
IS:806 Code of practice for use of steel tubes in general building construction.
IS:1161 Specification of steel tubes for structural purposes.
IS:1239 Specification for mild steel tubes. Tubulars and other wrought steel fittings.
H Gypsum and Gypsum Board
IS:2095 Gypsum plaster boards
IS:2542 (Part 1/Sec 1 to Methods of test for gypsum plaster, concrete and products: plaster and concrete
12)
IS:2542 (Part 2/Sec 1 to Methods of test for gypsum plaster, concrete and products: Gypsum products
8)
IS:2547 (Part 1) Gypsum building plaster: Excluding premixed lightweight plaster
IS:2547 (Part 2) Gypsum building plaster: Premixed lightweight plaster
I Handling and Storage

SS1-11
IS:4082 Recommendation of Stacking and Storage of construction materials
IS:8348 Code of practice for stacking and packing of stone slabs for transportation
J Instruments for Testing Cement and Concrete
IS:5513 Specification for vicat apparatus.
IS:5514 Specification for apparatus used in Le-Chaterlier test.
IS:5515 Specification for compaction factor apparatus.
IS:7320 Specification for concrete slump test apparatus.
IS:7325 Specification for apparatus to determine constituents of fresh concrete.
IS:10080 Specification for vibration machine.
IS:10086 Specification for moulds for use in tests of cement and concrete.
IS:10510 Specification for vee-bee consistometer.
K Joint Fillers
IS:1838 (Part 1) Preformed fillers for expansion joint in concrete pavements and structures (non-
extruding and resilient type): Bitumen impregnated fibre
L Paints and Coatings
IS:102 Ready mixed paint, brushing, red lead, non-setting, priming
IS:109 Ready mixed paint, brushing, priming, plaster, to Indian Standard Colour No.
361 and 631 white and off white.
IS:347 Varnish, shellac, for general purpose.
IS:2074 Ready mixed paint, air drying, red oxide-zinc chrome, priming
BS:6496 Specification for powder organic coatings for application and stoving to
aluminium alloy extrusions, sheet and preformed sections for external
architectural purposes, and for the finish on aluminium alloy extrusions, sheet
and preformed sections coated with powder organic coatings
BS: EN:10152 Specification for electrolytically zinc coated cold rolled steel flat products.
Technical delivery conditions
ASTM A 164-71 Specification for electrodeposited coatings of zinc on steel
M Pigment for Cement
BS:1014 Specification for pigments for Portland cement and Portland cement products
N Reinforcement & Structural Steel
IS:280 Mild steel wire for general Engineering purposes
IS:432 Part I. Mild steel and medium tensile steel bars. Part II Hard drawn steel wire.

SS1-12
IS:814 Parts I & II. Electrodes for metal arc welding of structural steel.
IS:815 Classification coding of covered electrodes for metal arc welding of structural
steels
IS:816 Code of Practice for use of metal arc welding for general construction in mild
steel.
IS:1566 (Part I) Specifications for hard-drawn steel wire fabric for concrete
reinforcement.
IS:1786 Specification for high strength deformed steel bars and wires for concrete
reinforcement.
IS:2502 Code of Practice for bending and fixing of bars for concrete reinforcement.
IS:2629 Recommended practice for hot-dip galvanising of iron and steel.
IS:2751 Code of Practice for welding of mild steel plain and deformed bars for reinforced
concrete construction.
IS:4759 Hot-dip zinc coating on structural steel and other allied products.
IS:5525 Recommendations for detailing of reinforcement in reinforced concrete works
IS:9417 Recommendations for welding cold-worked steel bars for reinforced concrete
construction.
IS:14268 Uncoated stress relieved low relaxation steel class 2 for Pre- stressed concrete
IS:226 Structural steel (Standard Quality)
IS:800 Code of practice for use of structural steel in general building construction.
IS:813 Scheme of symbols for welding.
IS:814 Covered electrodes for metal arc welding of structural steel. (Part I & Part II)
IS:816 Code of practice for use of metal arc welding for general construction in mild
steel.
IS:822 Code of practice for inspection of welds.
IS:961 Structural steel (High Tensile)
IS:1024 Code of practice for use of welding in bridges and structures subject to dynamic
loading.
IS:1161 Steel tubes for structural purposes.
IS:1182 Recommended practice for radiographic examination of fusion welded butt

joints in steel plates.
IS:2062 Structural steel (Fusion welding quality)
IS:3757 Specification for high tensile friction grip bolts.
IS:5624 Specification for foundation bolts.
IS:3600 Code of practice for testing of fusion welded (Part I) joints and weld metal in
steel.

SS1-13
IS:4923 Hollow steel sections for structural use.
IS:6227 Code of practice for use of metal arc welding in tubular structure.
IS:801 Code of practice for use of cold formed light gauge steel structural members in
general building construction.
IS:811 Specifications for cold formed light gauge structural steel sections.
IS:8500 Structural Steel Micro alloyed (Medium and high strength qualities)
IS:8910 General requirements of supply of weldable structural steel Recommendations
IS:9595 for metal arc welding of carbon & carbon- Manganese steels
IS:7205 Safety Code for erection of Structural Steel Works
O Aggregates
IS:383 Coarse and fine aggregates from natural sources for concrete.
P Scaffolding
IS:2750 Specification for steel scaffoldings
IS:3696 (Part 1) Safety Code of scaffolds and ladders: Scaffolds
IS:3696 (Part 2) Safety Code of scaffolds and ladders: Ladders
IS:4014 (Part 1) Code of practice for steel tubular scaffolding: Definition and materials
IS:4014 (Part 2) Code of practice for steel tubular scaffolding: Safety regulations for scaffolding
IRC:87 Guidelines for the design and erection of falsework for road bridges
Q Sealants
IS:10959 Glossary of terms for sealants for building purposes
IS:11433 (Part 1) One-part grade polysulphide base joint sealant: General requirements
IS:11433 (Part 2) One-part grade polysulphide base joint sealant: Methods of test
IS:13055 Methods of sampling and test for anaerobic adhesives and sealants
BS:5889 Specification for one-part gun grade silicone-based sealants.
R Wood
IS:303 Plywood for General Purposes
IS:848 Synthetic resin adhesives for plywood (phenolic and amino plastic)
IS:1141 Seasoning of Timber - Code of Practice
IS:1328 Veneered decorative plywood
IS:1659 Block Boards
IS:2046 Decorative thermosetting synthetic resin bonded laminated sheets

SS1-14
IS:2202 (Part 1) Wooden flush door shutters (solid core type): Plywood face panels
IS:2202 (Part 2) Wooden flush door shutters (solid core (type): Particle face panels and hardboard
face panels
S Bearings
IRC:83 Part-II Standard specifications and code of practice for road bridges Elastomeric
Bearings
IRC:83 Part-III Standard specifications and code of practice for road bridges Pot Bearings
T UPVC Pipe for Drainage
IS 4985 Unplasticized PVC Pipes for portable water supplies
U Piling
IS :2911 PART-I Bored Cast in-situ Concrete Piles
Design and construction of pile foundations - Code of practice : Part 4 Load test
IS 2911 Part 4
on piles
IS 14893 Non-destructive integrity testing of piles (NDT) - Guidelines
Standard Specifications and Code of Practice for Road Bridges, Section VII-
IRC:78
Foundations and Substructures
V Diaphragm Walls
IS 9556 Code of practice for design and construction of diaphragm walls
KODEN Testing
IS 13311 Part 1 Ultrasonic Pulse Velocity Test
W Indian Railway Standards
IRS- Bridge Rules for loading (Ministry of Railways)
IRS- Code of practice for steel bridges.

IRS- Code of practice for plain, reinforced and pre-stressed concrete for
general Bridge construction.
IRS- Code of practice for the design of substructures and foundation of
bridges.
X Indian Roads Congress Standards (IRC)
IRC 5 Standard Specifications and Code of Practice for Road Bridges, Section I-
General Features of Design
IRC 6 Standard Specifications and Code of Practice for Road Bridges, Section II –
Loads and Stresses
IRC 10 Recommended Practice for Borrow pits for Road Embankments Constructed by
Manual Operation
IRC 11 Recommended practice for the design of layout of cycle tracks

SS1-15
IRC19 Standard Specifications and code of Practice for Water Bound Macadam
IRC 112 Code of Practice for Concrete Road bridges

IRC22 Standard Specifications and Code of Practice for Road Bridges, Section VI –
Composite Construction
IRC24 Standard Specifications and Code of practice for Road Bridges, Section V –
Steel Road Bridges
IRC36 Recommended Practice for the Construction of Earth Embankments for Road
Works
IRC37 Guidelines for the Design of Flexible Pavement
IRC45 Recommendations for Estimating the Resistance of Soil below the maximum
Scour Level in the Design of Well Foundations of Bridges
IRC48 Tentative Specifications for Bituminous Surface Dressing Using Pre-coated
Aggregates
IRC75 Guidelines for the Design of High Embankments
IRC78 Standard Specifications and Code of Practice for Road Bridges, Section VII
(Parts 1 and 2), Foundations and Substructure
IRC83 Standard Specifications and code of practice for Road Bridges, Section IX -
Bearings Part I & II: Bearings (Metallic and Elastomeric)
IRC87 Guidelines for the Design and Erection of False Work for Road Bridges
IRC89 Guidelines for Design and Construction of River Training and Control Works for
Road Bridges
IRC: SP11 Handbook of Quality Control for Construction of Roads and Runaways
All Indian Railway Standards
Y MORTH Specifications for Road and Bridge works (latest Revision)
Z CPWD / TNPWD Specifications (latest Revision)
“Specification for tunnelling third edition” (2010) produced by the British

Tunnelling Society and the Institution of Civil Engineers, published by
Thomas Telford Limited.
2 EXCAVATION
2.1 PRELIMINARIES
2.1.1 Site Clearances
(i) The Contractor shall clear the Site as required by demolishing all buildings, structures and
the like, and removing vegetation, debris, trees along with their roots and the like to
locations agreed with the Employer’s Representative either on or off Site
(ii) Stumps and major roots shall be grubbed up and disposed of offsite. The Contractor shall
take precautions to protect all adjacent public and private property during these operations
and shall be responsible for all and damage arising from such.

SS1-16
(iii) The Contractor shall prevent erosion of all cleared excavation and fill areas by providing
suitable protection.
(iv) The Contractor shall also prevent siltation of all areas adjacent to the Works as a result of
fines being transported from the Works by provision of suitable silt fences.
2.1.2 Topsoil Stripping
(i) Topsoil shall be removed as required and deposited in separate heaps at locations agreed
with the Employer’s Representative.
2.1.3 Removal of Unsuitable Material
(i) Unsuitable materials are defined in Section 2.2.2
(ii) The Contractor shall remove all unsuitable materials and dispose of such on or off Site.
(iii) Boulders, stones and other materials of value or usable again on the Works shall be neatly
stacked in graded heaps.
(iv) Surplus suitable materials shall be deposited in layers of appropriate thickness and well
compacted in the designated disposal site subject to the Contract requirements.
2.1.4 General Excavation
(i) Excavation shall be carried out to the lines, levels and profiles shown on the Drawings.
The work shall be carried out by the Contractor in such a way as to avoid soil erosion,
groundwater pollution, accidents in habitational or frequented places, disturbance to the
surrounding ground or structures, accident to workmen and any other untoward incident.
Particular care shall be taken to maintain stability when excavating in close proximity to
existing Works. Fencing, caution signages with red lights and other safety measures shall
be employed to avoid accidents. Where necessary, signal men shall be employed to guide
the movement of people, vehicles and equipment.
(ii) The work shall be carried out in a careful manner to ensure that the exposed surfaces are
as sound as the nature of the material permits and that no point shall protrude inside the
lines shown on the Drawings except as given notice by the Employer’s Representative. In
soft soil excavation, which is to remain open permanently, exposed faces shall be formed
accurately to the required slopes and profiles and properly protected by turfing or pitching
as given notice by Employer’s Representative.
(iii) The Contractor shall dispose of all material arising from excavations either off the site or
to noticed heaps on the Site, as required.
(iv) The Contractor shall be responsible for keeping all excavations free from water from
whatever cause arising and shall provide such pumping capacity and other measures as
may be necessary for this purpose.
(v) The Contractor shall be responsible for the safety and stability of all excavations
performed by him or under his control. In case of any slips or blows in the excavation, the
same shall be cleared by the Contractor at his own cost.

SS1-17
(vi) The Contractor shall notify the Employer’s Representative without delay of any permeable
strata, joints, faults, fissures or unusual ground conditions encountered during excavation
and any excavation instability and/or collapse.
(vii) The Contractor shall ensure that no air pollution takes place during excavation, storage
and transportation of earth by providing suitable measures such as appropriate cover and
the like.
(viii) The Contractor shall provide to the Employer’s Representative full details of the proposed
rock excavation methods for his notice. Excavation should be carried out by such
manual/mechanical means or methods, as to eliminate noise and dust up to the prescribed
limits and without using any blasting and/or any expansive chemicals. Similarly, the
Contractor shall submit his plans for methods for monitoring ground stability and vibration
adjacent to residential area.
(ix) The Contractor shall carry out ground stabilisation measures without delay before and/or
after excavation., the Contractor may request the Employer’s Representative to
accompany him when inspecting structures and excavated rock surfaces revealed after
excavation operations.
2.1.5 Excavation beyond true lines and levels
(i) If from any cause whatsoever excavations are carried out beyond their true line and level
other than as per the noticed drawings then the Contractor shall make good at his own cost
to the required line and level with the appropriate grade of filling to be contained in the
true excavation, or with concrete or other material in such a manner subject to the notice
of the Employer’s Representative.
2.1.6 Notice for Excavation
(i) When excavations have been taken out accurately to the profiles or dimensions required
for the Works, the Contractor shall inform the Employer’s Representative for his notice.
(ii) The Contractor shall carry out additional excavation to such new profiles or dimensions
as the Employer’s Representative may give notice.
2.1.7 Excavation for structures
(i) Open excavation to lay a foundation for a structure shall be carried out to the lines and
dimensions necessary to permit the proper construction of that structure.
(ii) Where a structure is to be founded on soft ground, the excavation shall be taken down until
the required suitable soil formation is exposed and prepared to the notice of the Employer’s
Representative.
(iii) In the event of excavation having been made deeper than that shown on the drawings or
as noticed by the Employer’s Representative, the extra depth shall be made up with
concrete or masonry of the foundation grade to the cost of the Contractor. Ordinary filling
shall not be used for the purpose to bring the base of foundation to required level.
(iv) Prior to any construction within that excavation the bottom of the excavation shall be re-
compacted to achieve a dense smooth and level surface longitudinally, transversely or
SS1-18
stepped. Subject to the notice of the Employer’s Representative, layers of granular fill not
exceeding 200 millimetres loose thickness shall be placed and compacted to 95%
maximum dry density.
(v) Where required, filtered under drainage pipes shall be placed within the granular fill layer
in accordance with the noticed designs
(vi) Surfaces of excavations or filling on which plain (unreinforced) or reinforced concrete will
be formed shall be prepared with a blinding layer of concrete as shown on the Drawings
or in such other manner as will provide a suitable surface at the correct lines and levels to
the notice of the Employer’s Representative.
2.1.8 Trench excavations for utilities and services
(i) Trench excavation shall be performed by the use of suitable equipment, in such manner so
as to minimise disturbance to the required finished sides and bottom of the excavation.
(ii) Trenches for pipes shall be excavated to a sufficient depth and width to enable the utility
or service and the specified joint, bedding, haunching and surrounding to be
accommodated and for all loose material placed to be compacted to the required standards.
2.1.9 Trenches
(i) The Contractor shall carry out excavation in a safe manner such that the sides of the trench
are adequately supported and stable till the completion of this work.
(ii) The Contractor shall leave a clear adequate space between the edge of the excavation and
the inner toes of the spoil banks.
(iii) Trenches shall be excavated to the lines and levels shown on the Drawings.
(iv) Trenches shall not be excavated too far in advance of pipe-laying and the like and shall be
sufficiently wide to allow proper and efficient jointing to be carried out in clean and dry
conditions. Due allowance shall be made for bedding and surrounds where these are
specified.
(v) The bottoms of all trenches shall be trimmed to grade and level and compacted before any
bedding is placed or pipes laid.
(vi) The widths of trenches crossing roads, or at other locations as directed shall be as narrow
as is practicably possible. The maximum width measured between undisturbed soil in the
trench sides shall not exceed the outside diameter of the pipe being laid plus 550
millimetres for pipes up to and including 800 millimetres in diameter and plus 750
millimetres for pipes over 800 millimetres in diameter.
(vii) Trenches for pipes carrying water under pressure shall, except where otherwise described
in the Contract, be excavated to a sufficient depth to ensure a minimum cover of 900
millimetres to the top of the pipes.
2.1.10 Road Crossings
(1) The Contractor shall provide adequate support to all excavations within and across existing
roads. Care shall be taken by the Contractor to ensure that existing roads and services are

SS1-19
not damaged by road-crossing operations. Excavations in roads shall be backfilled and

roads repaired as soon as practicable taking all safety precautions.
2.1.11 Channels
(i) Channels shall be excavated by methods which do not endanger the stability of the side-
slopes.
(ii) Existing channels, which are to be reshaped, cleared and trimmed, shall be cleared of all
weeds and growth and the beds graded to the required levels. The sides of channels shall
be trimmed to the required safe limits of slope and width.
(iii) Side-banks of channels shall be trimmed to provide a neat appearance and even surfaces.
(iv) Any channels, streams, drains or pipes conducting water to or from cultivated land shall
be diverted so as to maintain their flow before being moved or broken into. All diversions
and their subsequent reinstatement shall be carried out to the notice of the Employer’s
Representative
(v) The Contractor shall control the rates of filling and drawdown of water in channels so as
not to endanger the stability of the Works.
2.1.12 Notice for Excavations
(i) The Contractor shall seek the Employer’s Representatives notice for all excavations prior
to placing pavement layers, fill or concrete.
(ii) The Contractor shall maintain open excavations in a safe and stable condition and shall
rectify the effects of deterioration due to weather.
2.2 FILL
2.2.1 Fill General
(i) Prior to commencement of any filling either as backfill to excavations or in the formation
of embankments, the Contractor shall submit in writing to the Employer’s Representative
for ‘’Notice of No Objection’’ his proposals for carrying out the work such that the
optimum use may be made of excavated material. The proposals shall include details of
the compaction plant and methods for adjusting the moisture content of the material.
(ii) No filling shall commence until the ‘’Notice of No Objection’’ to his proposals have been
received from the Employer’s Representative.
2.2.2 Fill Material
(i) Fill material shall be obtained only from a source agreed with the Employer’s
Representative
(ii) Fill material, other than for roadworks, shall be evenly graded granular material. Material
with more than 20% passing a 75-micron sieve or more than 10% in excess of 75
millimetres size is unlikely to be suitable for use in the Works.
(iii) Before compacting the fill material, clods or hard lumps of earth over 75 millimetres in
greatest dimension shall be broken up.
(iv) The following types of material are considered unsuitable and shall not be used for filling.
SS1-20
(i) Materials from swamps, marshes or bogs.

(ii) Peat, loam, fine silt, log, stump or organic or perishable materials.
(iii) Material susceptible to spontaneous combustion.
(iv) Clay of liquid limit exceeding 80% and plasticity index exceeding 55%.
(v) Materials containing salts prone to inducing leaching in the embankment.
(vi) Any contaminated and environmentally unacceptable material.
(v) The Contractor shall carry out the following initial tests on the proposed material.
Thereafter, one set of tests shall be carried out for each 2000 cubic metres of fill, supplied
to Site or as noticed by Employer’s Representative.
(i) Wet sieve analysis
(ii) Dry density/moisture content relationship
2.2.3 Backfill - General
(1) Except around structures, excavations shall be backfilled with suitable excavated material
and/or noticed material compacted in layers of 300 millimetres maximum loose thickness
to achieve a density of at least 95% of the maximum dry density.
2.2.4 Backfill to Structures
(i) The Contractor shall not backfill around structures until the structural elements have
attained adequate strength.
(ii) The backfill material shall be selected excavated material or sand, thoroughly compacted
in layers not exceeding 200 millimetres loose thickness to achieve a density of at least 95%
of the maximum dry density
2.2.5 Preparation of Base/Foundation for Embankment
(i) Prior to placing any embankment upon any area all clearing and grubbing operations shall
have been completed in accordance with this Contract.
(ii) Where the height of embankment is 1 metre or less all sod, grass and vegetable matter
shall be removed from the ground surface and the top 150 millimetres shall be processed
as necessary and compacted to 90% of the maximum dry density.
(iii) Where new embankments are to be constructed against and on existing slopes steeper than
1 vertical to 5 horizontal continuous horizontal benches, each no greater than 500
millimetres in vertical height shall be cut into the existing slope and the embankment built
up in successive layers. Material in the existing slope which has been loosened shall be re-
compacted simultaneously with the first level of embankment material placed.
(iv) Where an embankment is to be placed against sloping ground flatter than 1 vertical to 5
horizontal the existing ground shall first be loosened to a depth no greater than 100
millimetres to ensure adequate bond between nex and existing ground

SS1-21
(v) Unless otherwise shown on the Drawings, where existing unpaved roads are to be covered
with less than 300 millimetres of fill, excluding pavement, the top of the old roadbed shall
be scarified and re-compacted with the next layer of the new embankment. The total depth
of the scarified and added material shall not exceed the permissible depth of layer.
(vi) Granular material (e.g., sand or gravel) shall be used as filling in swamps or waterlogged
ground. The Contractor shall submit details of his proposed granular fill material to the
Employer’s Representative for his notice. The Contractor shall first remove all unsuitable
material from the base of the proposed fill area and backfill with the agreed granular
material, placed and compacted in accordance with the requirements of this Contract.
Where deemed necessary the Contractor may place a geofabric “separator” fabric to
prevent “punching of the fill into the underlying soft material in accordance with
Section.2.2.6
2.2.6 Construction of Embankment
(1) General
(i) Except as otherwise required all embankments shall be constructed in layers
approximately parallel to the finished grade of the track/roadbed. During construction of
embankment, a smooth grade having an adequate crown or super elevation shall be
maintained to provide drainage. Embankments shall be constructed to the required grade
and completed embankments shall correspond to the shape of the typical sections as shown
on the Drawings.
(2) Earth Embankment
(i) Earth embankments shall be defined as those principally of material other than rock and
shall be constructed of noticed material brought from designated or other noticed sources.
(ii) Except as specified for embankment in swamps, earth embankments shall be constructed
in successive layers, for the full width of the cross-section and in such lengths as are suited
to the compaction and watering methods used.
(3) Placing in swampy or waterlogged ground
(i) Embankment in or over swamps or in water shall be placed by placing granular material
in a uniformly distributed layers of thicknesses greater than that necessary to support the
equipment while placing subsequent layers, after which the remainder of the embankment
shall be constructed in layers and compacted as specified.
(ii) Separation layers of either suitable geofabric and/or graded sand shall first be placed in
controlled layers to prevent excessive penetration and/or the development of mud-waves.
(4) Preparation of subgrade
The surface of the finished subgrade shall be neat and workmanlike and shall have the
required form, super elevation, levels, grades, and cross-section. The surface shall be
constructed to sufficient accuracy to permit the construction of subsequent layers of
material to the thickness, surface tolerance, and compaction specified.
2.2.7 Compaction of Embankments
(1) When necessary, each layer before being compacted shall be processed as required to bring
the moisture content sufficiently close to optimum to make possible its compaction to the
SS1-22
required density. The material shall be worked as to have uniform moisture content
through the entire layer.
(2) Each layer of material shall be compacted uniformly by use of adequate and appropriate
compaction equipment. The compaction shall be done in a longitudinal direction along the
embankment and shall generally being at the outer edges and progress towards the centre
in such a manner that each section receives equal amount of compaction.
(3) Hauling equipment shall be operated over the full width of each layer in so far as
practicable. There should be a minimum overlap of 150 millimetres between each run of
the rollers.
(4) Embankment or backfill compaction shall be carried out in the following way.
(i) The top 200 millimetres of the finished embankment shall be compacted to a dry density
equal to or greater than 98% of the maximum dry density.
(ii) Other embankment layers more than 200 millimetres below finished surface, or the
underside of the lowest layer of base, subbase and shoulder shall be compacted to a dry
density equal to or greater than 95% of the maximum dry density.
2.2.8 Inverted Filter
(i) An inverted filter comprising of durable coarse stone aggregates with an appropriate filter
layer or geofabric between this filter and the subgrade shall be constructed behind earth
retaining structures.
(ii) The inverted filter shall be constructed simultaneously with the filling work to the retaining
structure. Care shall be taken during placing of the filter media to ensure that it does not
cause damage to structural members or application of excessive pressure against the
retaining structure.
2.3 TESTS
2.3.1 Testing of Fill - General
(i) Classification tests as per relevant Standards to which the Employer’s Representative has
given his notice shall be carried out to ensure that true comparisons can be made between
in-situ densities, laboratory compaction densities and field trial densities so that it can be
determined that variations in properties of the fill materials are being allowed for.
(ii) Tests shall be carried out on fill to determine the degree of compaction achieved, at the
rate of one test for either each 1200 cubic metres placed or each layer whichever is the
more frequent. Compacted layers shall not be covered without notice from the Employer’s
Representative.
(iii) The density of individual compacted layers shall be determined by a method given notice
to the Employer’s Representative.
(iv) The in-situ dry density of fill shall average 95% of the maximum reached in trials. No
single result shall be less than 92% and no more than 25% of the results on any one layer
shall fall between 92% and 95%. The average shall be computed from the total number of

SS1-23
tests on any one layer where the extent of the layer is defined by the Contractor when
submitting same for inspection.
2.3.2 Materials for Topmost Layer of Fill
(i) In addition to the general requirements for fill material, the material in the topmost layer
shall not exceed the following test values.
a. Plasticity Index : 6%
b. Liquid Limit : 35%
(ii) Total fines content shall not exceed 15% and Uniformity Coefficient (Cu) shall not be less
than 4.
(iii) The laboratory California Bearing Ratio (CBR) value at 95% maximum dry density
achieved after soaking for 96 hours, shall not be less than 30%.
2.3.3 Testing of Top Layer of Fill
(i) Tests shall be carried out on the top layer of fill as shown in the following table. Tests shall
be carried out as required by the accepted test procedures.
Test Frequency of test (not less
than one test per...)
A. Laboratory tests to monitor the consistency of
the noticed material during construction:
Maximum dry density 1000 square metres

Optimum moisture content 1000 square metres
Grading 1000 square metres
Plasticity index 1000 square metres
Linear shrinkage 1000 square metres
CBR Value 2000 square metres
B. In situ tests to confirm that the required degree
of compaction is being achieved during
construction:
Dry density 250 square metres
CBR Value 1500 square metres
3 ROADWORK
3.1 CONTROL OF TRAFFIC
3.1.1 General
The Contractor shall be responsible for designing and implementing all Temporary Traffic
Management (TTM) schemes required for the execution of the Works. The Contractor shall
obtain approval from the Employer’s Representative and Relevant Authorities for the TTM
schemes.

SS1-24
All traffic impact assessment reports and TTM schemes in form of drawings provided by the
Employer are for information only.
Prior to the implementation of any works affecting road and pedestrian traffic, the Contractor
shall determine the requirements for the TTM schemes and conduct a detailed assessment of
the proposed outline TTM schemes for notice by Employer’s Representative and for approval
by Relevant Authorities. The assessment shall include:
(i) a notice of the construction sequence, programme and outline TTM schemes
submitted, and the impact on traffic;
(ii) estimates of the peak volume of construction traffic that will be generated during
each phase of construction together with plans showing the proposed routing of
construction traffic to and from the Site;
(iii) additional details of traffic management schemes, including diversion routes, that
the Contractor intends to implement for the construction of his Works;
(iv) traffic impact analyses to demonstrate the impact of construction traffic and the
Contractor’s proposed traffic management schemes on the surrounding road
network;
(v) additional field surveys and studies to establish traffic conditions where appropriate;
(vi) all such additional information as may be required for the detailed design of the
traffic management schemes;
(vii) consultation and liaison with Relevant Authorities with a view to developing a
design that causes minimal impact and is acceptable to all affected parties; and
(viii) Inversion routes’ road capacity improvement measures such as parking restrictions,
removal of road humps, overhead constraints due to wires and trees, road pavement
improvement, junction widening for ease of vehicle turning, signal timing change,
etc.
The Contractor shall also provide Employer’s Representative and the Relevant Authorities
with plans and diagrammatic representations to accompany publicity materials relating to the
approved TTM schemes.
The Contractor shall be responsible for the construction, manufacture, supply, erection,
relocation, and subsequent removal of all temporary traffic signs, directional signs, bollards,
street furniture, streetlights, roads and road markings related to the TTM schemes. All
temporary signs required for the implementation of traffic diversions and the Contractor’s
TTM schemes shall be designed in accordance the relevant Code of Practice such as the
Indian Roads Congress, Ministry of Road Transport & Highways and India Standards.
The Contractor shall note that no traffic signals, traffic signs and road markings in the public
roads shall be erected, relocated or removed unless authorized by Employer’s Representative,
Traffic Police and Relevant Authorities. Furthermore, no roads, lanes or footpaths shall be
opened or closed unless authorized by Employer’s Representative, Traffic Police and
Relevant Authorities.

SS1-25
The contractor shall protect the works related to TTM schemes from damage until such time
as the works has developed sufficient strength to carry normal traffic loads without any
damage to those works. The Contractor shall also take up the maintenance responsibilities of
the TTM schemes.
The Contractor shall be responsible for the temporary removal of all existing signs
(regulatory, warning and information type), bollards, street furniture, street lights, associated
ducting, road markings etc. that may affect the TTM schemes.
Before any existing pedestrian route is severed or diverted, the Contractor shall submit a
detailed proposal to the Employer’s Representative, for his onward submission to Relevant
Authorities for approval. The detailed proposal shall include:
(1) The width of the existing pedestrian route;
(2) Pedestrian volumes prior to diversion;
(3) The width of the diverted pedestrian route;
(4) The anticipated pedestrian volume along the diverted pedestrian route; and
(5) Proposed temporary pedestrian direction signs.
The Contractor shall ensure all existing or diverted pedestrian routes within the Site are paved,
protected, sign posted, illuminated, clean and maintained in good condition to Employer’s
Representative’s satisfaction.
The contractor shall be responsible for the relocation, installation, traffic signal time
adjustment, and traffic signal design of the traffic signals affected by the TTM schemes.
Traffic signals include related posts, cables and equipment necessary for the proper operation
of the traffic signals, traffic signs erected shall be in accordance with IRC specifications
and/or as prescribed and approved by the Chennai Traffic Police Department.
3.1.2 Reinstatement
The Contractor shall reinstate all signs, bollards, street furniture, streetlights, associated
ducting, road markings, road, etc that have been removed for the TTM. The reinstatement
works shall be of at least the original standards and to the satisfaction of the Relevant
Authorities and Employer’s Representative.
Unless agreed with Relevant Authorities and Employer’s Representative, the Contractor shall
not remove any traffic signals installed for TTM schemes and reinstate area. The
reinstatement works shall be to the original standards and to the satisfaction of the Relevant
Authorities and Employer’s Representative.
Unless agreed with Relevant Authorities and Employer’s Representative, the Contractor shall
reinstate any traffic signals removed for TTM schemes. The reinstatement works shall be to
the original standards and to the satisfaction of the Relevant Authorities and Employer’s
Representative
3.1.3 Special Events
For special public events such as festivals, and as ordered by Employer’s Representative or
Relevant Authorities, the roads or pedestrian routes being occupied by the Contractor, or
where the Contractor’s works are being carried out, may have to be opened for public use for
SS1-26
a short duration. The Contractor shall proceed with all necessary measures or modify his
works to suit this purpose. The Contractor shall note that the Relevant Authorities may
suspend the TTM schemes up to 10 days before the date of the special public events.
The Contractor shall take approval by all necessary and sufficiently adequate precautions to
protect against accidents, damages or the like that may be deemed caused by construction
equipment, tools, materials, bitumen and bituminous material, or any other construction
materials, and shall be responsible for any claims arising from such damage.
3.2 GRANULAR SUBBASE (NON-BITUMINOUS)
This work shall consist of laying and compacting well-graded material on prepared subgrade
in accordance with the requirements of these specifications or as per IRC standards, as
acceptable to Highway authorities. The material shall be laid in one or more layers according
to lines, grades and cross-sections shown on the drawings.
3.2.1 Materials
The materials to be used for the work shall be natural sand, moorum, gravel, crushed stone,
or a combination thereof, depending upon the grading specified in MORTH specifications for
Roads and Bridges. The material shall be free from organic or other deleterious constituents
and conforms to one of the three gradings given in Table 3.2.2.1 & 3.2.2.2
3.2.2 Physical requirements

The material shall have a 10 percent fines value of 50 kN or more (for sample in soaked
condition) when tested in compliance with BS: 812 (Part III). The water absorption value of
the coarse aggregate shall be determined by IS: 2386 (Part 3); if this value is greater than 2
percent, the soundness test shall be carried out on the material delivered to site as per IS: 383.
CBR Value shall be determined at the density and moisture content likely to be developed in
equilibrium conditions which shall be taken as being the density relating to a uniform air
voids content of 5 percent.
The material passing 425-micron sieve when tested in according to IS: 2720 (Part 5) shall
have liquid limit and plasticity index not more than 25 and 6 percent respectively.
Table 3.2.2.1 GRADING FOR CLOSE GRADED GRANULAR SUB-BASE

MATERIAL
IS Sieve Designation Per cent by weight passing the IS sieve
Grading I Grading II Grading III
75.0mm 100 --- ---
53mm 80-100 100 ---
26.5mm 55-90 70-100 100
9.50mm 35-65 50-80 65-95
4.75mm 25-55 40-65 50-80
2.36mm 20-40 30-65 40-65

SS1-27
0.425mm 10-25 15-25 20-35

0.075mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20
Table 3.2.2.2 GRADING FOR CLOSE GRADED GRANULAR SUB-BASE

MATERIAL
Grading I Grading II Grading III
75.0mm 100 --- ---
53mm --- 100 ---
26.5mm 55-75 50-80 100
9.50mm --- --- ---
4.75mm 10-30 15-35 25-45
2.36mm --- --- ---
0.425mm --- --- ---
0.075mm < 10 < 10 < 10
CBR Value (Minimum) 30 25 20
Note : The material passing 425 micron sieve when tested in according to IS: 2720 (Part 5)
shall have liquid limit and plasticity index not more than 25 and 6 percent respectively.
3.2.3 Strength of sub-base

It shall be ensured prior to actual execution that the material to be used in the sub- base
satisfies the requirements of CBR and other physical requirements when compacted and
finished. As per IRC-37-2001, the sub-base material should have minimum CBR of 20
percent for cumulative traffic up to 2 million standard axle (msa) and 30 percent for traffic
exceeding 2 million standard axle (msa).
3.2.4 Construction Operations
(1) Preparation of sub-grade
Immediately prior to the laying of sub-base, the sub-grade already finished or existing surface
shall be prepared by removing all vegetation and other extraneous matter, lightly sprinkled
with water if necessary and rolled with two passes of 80 to 100 KN static weight smooth-
wheeled roller. Damage to the subgrade shall be made good before subbase is laid.
(2) Spreading and compacting
The noticed sub-base material shall be spread on the prepared sub-grade by a grader of
suitable type and adequate capacity.
When the sub-base material consists of combination of materials, mixing shall be done
mechanically by the mix-in-place method.

SS1-28
The equipment used for mix-in-place construction shall be suitable equipment capable of
mixing the material to the desired degree.
Moisture contents of the loose material at the time of compaction shall be checked in
accordance with IS: 2720 (Part 7) and suitably adjusted.
Rolling procedure shall be as described under Subsection 3.7.3 (6) except stated herein.
Rolling shall be continued till the density achieved is at least 98% of the maximum dry density
for the material determined as per IS: 2720 (Part 8).
3.2.5 Control of Traffic
Control of traffic shall be as described under Sub section 3.1.
3.3 WET MIX MACADAM SUB-BASE/BASE
3.3.1 Description
This work shall consist of laying and compacting clean, crushed, graded aggregate and
granular material, premixed with water, to a dense mass on a prepared sub- base/ in
accordance with the requirements of these Specifications. The material shall be laid in one
or more layers as necessary to lines, grades and cross-sections as per the construction
drawings or as directed by the Employer’s Representative.
The thickness of a single compacted wet mix macadam layer shall not be less than 75mm.
When vibrating or other approved types of compacting equipment’s are used the
compacted depth of the single layer of the sub-base course may be increased 200mm upon
the Engineer’s Notice.
3.3.2 Materials
(1) Aggregate
Physical requirements: Coarse aggregates shall be crushed stone. If crushed
gravel/shingle is used, not less than 90 percent by weight of the gravel/shingle pieces
retained on 4.75-millimetre (mm) sieve shall have at least two fractured faces. The
aggregates shall conform to the physical requirements set forth in Table 1.3.3.1 below.
S.No. Test Test Method Requirements
1. * Los Angeles abrasion value or IS: 2386 (Part-4) 40 per cent (Max.)
* Aggregate Impact value IS: 2386 (Part-4) or IS: 30 per cent (Max.)
5640
2. Combined Flakiness and Elongation IS: 2386 (Part-1) 30percent (Max.)

indices (Total)
* Aggregate may satisfy requirements of either of the two tests.

Table 3.3.2.1 Physical requirements of Coarse Aggregates for Wet Mix Macadam for Sub-Base/Base Courses
If the water absorption value of the coarse aggregate is greater than 2%, the soundness test
shall be carried out on the material delivered to site as per IS : 2368 (Part – 5)

SS1-29
Grading requirements: The aggregates shall conform to the grading given in Table 1.3.3.2
53.00 mm 100
45.00 mm 95 to100
26.50 mm -
22.40 mm 60 to 80
11.20 mm 40 to 60
4.75 mm 25 to 40
2.36 mm 15 to 30
600.00 micron 8 to 22
75.00 micron 0 to 8
Materials finer than 425 microns shall have Plasticity Index not exceeding 6
Table 3.3.2.2 Grading requirements of Aggregates for Wet Mix Macadam
The final gradation approved within these limits shall be well graded from coarse to fine and
shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice-
versa.
3.3.3 Construction Operations

(1) Preparation of base
The surface of the subgrade/sub-base/base to receive the wet mix macadam course shall be
prepared to the specified lines and crossfall (camber) and made free of dust and other
extraneous material. Any ruts or soft yielding places shall be corrected in a noticed manner
and rolled until firm surface is obtained if necessary, by sprinkling water. Any sub-
base/base/surface irregularities, where predominant, shall be made good by providing
appropriate type of profile corrective course before sub-base/base is overlaid.
While constructing wet mix macadam, arrangements shall be made for the lateral confinement
of wet mix. This shall be done by laying materials in adjacent shoulder along with that of wet
mix macadam layer and following the sequence of operations described in the MOST
specifications.
(2) Preparation of mix

Wet Mix Macadam shall be prepared in a noticed mixing plant of suitable capacity having
provision for controlled addition of water and forced/positive mixing arrangement like
pugmill or pan type mixer of concrete batching plant. For small quantity of wet mix work,
the mixing may be done in concrete mixers.
Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part-8) after
replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4
SS1-30
mm size. While adding water, due allowance should be made for evaporation losses.
However, at the time of compaction, water in the wet mix should not vary from the optimum
value by more than agreed limits. The mixed material should be uniformly wet, and no
segregation should be permitted.
(3) Spreading of mix
Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the
prepared sub-base in required quantities. In no case should these be dumped in heaps directly
on the area where these are to be laid nor shall their hauling over a partly completed stretch
be permitted.
The mix may be spread either by a paver finisher or motor grader. For portions where
mechanical means cannot be used, manual means may be used. The motor grader shall be
capable of spreading the material uniformly all over the surface. Its blade shall have hydraulic
control suitable for initial adjustments and maintaining the same so as to achieve the specified
slope and grade.
The paver finisher shall be self-propelled, having the following features :
(i) Loading hoppers and suitable distribution mechanism
(ii) The screed shall have lamping and vibrating arrangement for initial compaction
to the layer as it is spread without rutting or otherwise marring the surface profile.
(iii) The paver shall be equipped with necessary control mechanism so as to ensure
that the finished surface is free from surface blemishes.
The surface of the aggregate shall be carefully checked with templates and all high or low
spots remedied by removing or adding aggregate as may be required. The layer may be tested
by depth blocks during construction. No segregation of larger and fine particles should
bellowed. The aggregates as spread should be of uniform gradation with no pockets of fine
materials
(4) Compaction
After the mix has been laid to the required thickness, grade and crossfall/camber the same
shall be uniformly compacted, to the full depth with suitable roller. If the thickness of single
compacted layer does not exceed 100 mm, smooth wheel roller of 80 to 100 kN static weight
may be used. For a compacted single layer up to 200 mm, the compaction shall be done with
the help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent capacity
roller. The speed of the roller shall not exceed 5 kilometres per hour (km/h).
In portions having unidirectional cross fall/super elevation, rolling shall commence from the
lower edge and progress gradually towards the upper edge. Thereafter,
roller should progress parallel to the centre line of the road, uniformly overlapping each
preceding track by at least one third width until the entire surface has been rolled. Alternate
trips of the roller shall be terminated in stops at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running forward and
backward until the edges have been firmly compacted. The roller shall then progress gradually
towards the centre parallel to the centre line of the road uniformly overlapping each of the
preceding track by at least one-third width until the entire surface has been rolled.

SS1-31
Any displacement occurring as a result of reversing of the direction of a roller or from any
other cause shall be corrected at once as specified and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be
thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of an
area without scarifying the surface to permit proper bonding of the added material shall not
be permitted.
Rolling shall be continued till the density achieved is at least 98% maximum dry density for
the material as determined by the method outlined in IS: 2720 (Part- 8).
After completion, the surface of any finished layer shall be well-closed, free from movement
under compaction equipment or any compaction planes, ridges, cracks and loose material. All
loose, segregated or otherwise defective areas shall be made good to the full thickness of the
layer and recompacted.
(5) Quality Control & Surface evenness
The finished sub-base/ base at any point shall not exceed 12mm above the planned grade or
adjusted grade with 3m straight edge applied to the surface parallel to the centerline of the
road. With the template laid transversely the maximum permissible variation from specified
profile shall be 12mm and 8mm respectively. The surface finish of construction shall
conform to the requirements of Clause 902, of MOST specification. Control on the quality
of material sand works shall be exercised by the Engineer in accordance with Section 900.
of MOST specification.
3.4 BITUMINOUS MATERIAL

3.4.1 Materials
Materials shall meet requirements of the relevant IS Codes. These shall be of the following
types.
(1) Cut back Bitumen
Cut back bitumen shall be Rapid Curing (RC), Medium Curing (MC) or Slow Curing (SC)
conforming to IS: 217.
(2) Cationic Emulsion
Bitumen emulsions of the cationic type for roads shall conform to IS: 8887. Emulsified
bitumen shall be Rapid Setting (RS), Medium Setting (MS), or Slow Setting (SS). The
physical and chemical requirements of the three types emulsions shall comply with the
requirements specified in Table 1 of IS: 8887.
(1) Paving Bitumen
Paving bitumen shall be conforming to IS: 73 and of the following two types:
Type 1 Paving bitumen from non-waxy crude to Table 1 of IS: 73.
Type 2 Paving bitumen from waxy crude to Table 2 of IS: 73.
The temperature at application of bituminous materials shall be maintained as per
manufacturer’s instructions and/or as directed by Employer’s Representative.

SS1-32
3.4.2 Methods of storage and handling

Asphaltic material shall be handled and stored with due regard for safety and in such a
way that at the time of use in the work the material conforms to the Specifications.
Following precautions shall be taken while using these materials:
a. Work with these materials shall be carried out in good weather conditions and it
shall be carried out in warm and Emulsified asphalt showing sign of separation
shall not be used.
b. During heating, no water or moisture shall be allowed to enter the boiler.
c. Heating of bitumen shall be done to the correct temperature range, as prescribed
by the manufacturer for the grade used.
d. The temperature shall be controlled with the use of a suitable thermometer, and
the material shall be drawn and used while still at such temperature as is prescribed
by manufacturer or in accordance with MORTH specifications.
e. It shall be ensured that mixing of ingredients is through and all particles of
aggregates are coated uniformly and fully.
f. Dry weather, and not in wet or extremely cold weather.
g. Emulsified asphalt shall be handled with care and not subjected to mechanical
shocks or extremes of temperature likely to cause separation of the asphalt.
3.5 PRIME COAT
3.5.1 Description
This work shall consist of the cleaning and preparing of the surface to be primed to
specified lines, grade, and cross-section, booming and clearing thoroughly and applying
bituminous material in accordance with these Specifications.
3.5.2 Materials
The choice of the primer shall depend upon the porosity characteristics of the surface to
be primed. The primer shall be Medium Curing Cutback (MC) and the particular grade to
be used for the work shall have the notice of Employer’s Representative.
Slow setting Cationic emulsion conforming to IS: 8887 may also be used. Sampling and
testing of bituminous primer shall be as per IS: 217, IS: 454 and IS: 8887.
3.5.3 Construction Methods
(1) Weather Limitations
Prime coat shall not be applied at a time when the surface is wet or when the weather is foggy,
rainy or windy.
(2) Equipment
The equipment used for the work shall include a power broom and primer material distributor
spraying it uniformly at specified rates and temperatures.
It shall be equipped with self-heating arrangement, suitable pump, adequate capacity
compressor and spraying bar with nozzles having constant volume or pressure system.

SS1-33
Spraying by manual methods may be allowed for inaccessible or small areas with the notice
of the Employer’s Representative.
(3) Cleaning Surface
Immediately prior to applying the prime coat the surface to be primed shall be swept clean
from all loose dirt and other objectionable material and shall be shaped to the required lines,
grades, cross section.
(4) Application of bituminous primer
The primer material shall be applied by means of a distributor at rates usually from 0.8 to 1.4
litres per square metre and at a temperature within the allowable range corresponding to the
material used and porosity condition of surface over which it is laid. The temperature of
primer at time of application may vary from 400C to 600C for cutback bitumen and 400C to
600C for bitumen emulsion.
Prime coat shall be allowed to penetrate for at least 48 hours to allow penetration into the
base course and aeration of volatile from the primer material, then covered with clean dry
sand or stone screening. Areas containing an excess or deficiency of priming material shall
be corrected by the addition of sand or primer
3.6 TACK COAT
3.6.1 Description
This work shall consist of furnishing and applying bituminous material to an existing road
surface or to an existing bituminous prime coat surface which has dried out or preparatory to
laying another bituminous layer over it.
3.6.2 Materials
The material for tack coat shall be a bituminous or cut back emulsion of suitable type and
grade.
a) Cleaning Surface
The whole surface on which the tack coat is to be applied shall be cleaned of dust and any
extraneous material before the start of application of tack coat by using a power broom or any
other equipment/ method.
b) Application of tack coat material
The tack coat material shall be applied uniformly by means of a distributor at controlled rates
as per MORTH specifications and at the temperature within the allowable range
corresponding to the material used It shall be done with self-propelled or towelled bitumen.
Surfaces of structures and trees adjacent to the areas being treated shall be protected in such
a way as to prevent their being spattered or marred.
3.7 DENSE BITUMINOUS MACADAM
3.7.1 Description
This work shall consist of construction in a single course of 50 to 100 mm thick base/binder
course to the following Specifications on a previously prepared base.
3.7.2 Materials
a) Bitumen
The bitumen shall be paving bitumen of suitable grade given notice by the Employer’s
Representative and conforming to IS: 73
SS1-34
b) Coarse Aggregate
The coarse aggregates shall consist of crushed stone, crushed gravel/shingle or other stones.
They shall be clean, strong, durable, of fairly cubical shape and free from disintegrated pieces,
organic or other deleterious matter and adherent coating.
Sl. Test Test Method Requirement
No.
1. Los Angles Abrasion * Value IS: 2386 (Part-4) 40 per cent Maximum
2. Aggregate Impact value * IS: 2386 (Part-4) 30 per cent Maximum
3. Flakiness and Elongation** Indices IS: 2386 (Part-1) 30 per cent Maximum
(Total)
4. Coating and Stripping of Bitumen AASHTO T 182 Minimum retained
Aggregate Mixtures coating 95 per cent
5. Soundness IS: 2386 (Part-5)
Loss with Sodium Sulphate 5 cycles 12 per cent Maximum 18
Loss of Magnesium Sulphate 5 cycles per cent Maximum
6. Water absorption IS: 2386 (Part-3) 2 per cent Maximum
* Aggregates may satisfy requirements of either of the two tests.
Table 1.3.7.1 Physical requirements of Aggregates for Dense Bituminous Macadam
c) Fine aggregates
Fine aggregates shall be the fraction passing 2.36 mm sieve and retained on 75-micron sieve,
consisting of crusher-run screening, gravel, sand or a mixture of both. These shall be clean,
hard, durable, uncoated, dry and free from any injurious, soft or flaky pieces and organic or
other deleterious substances.
d) Filler
Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement
as given notice by the Employer’s Representative.
The filler shall be graded within the following limits:
IS Sieve Per cent passing by weight
600 Micron 100
300 Micron 95 to 100
75 Micron 85 to 100
The filler shall be free from organic impurities and have a Plasticity Index not greater than 4.
The Plasticity Index requirement shall not apply if filter is cement or lime. When the coarse
aggregate is gravel, 2 per cent by mass of total aggregate of Ordinary Portland Cement (OPC)
or hydrated lime shall be added, and the percentage of fine aggregate reduced accordingly.
OPC or hydrated lime is not required when the gravel comprises limestone.
e) Aggregate gradation
The combined coarse and fine aggregates and filler (when used) shall produce a mixture to
conform to the grading set forth in Table 1.3.7.2.

SS1-35
Sieve Size Percentage passing the sieve by

weight
37.5 mm 100
26.5 mm 90 to100
13.2 mm 56 to -80
4.75 mm 29 to 59
2.36 mm 19 to 45
300 microns 5 to 17
75 microns 1 to 7
Table – 1.3.7.2 Aggregate Gradation for Dense Bituminous Macadam
The aggregate mix, as used in work, shall not vary from the low limit on one sieve to the high
limit on the adjacent sieve but shall be well graded.
(1) Weather and seasonal limitations
The work of laying shall not be taken up during rainy or foggy weather or when the base
course is damp or wet, or during dust storm or when the atmospheric temperature in shade is
10oC or less. The Engineer may order work to cease temporarily on account of adverse
weather, unsatisfactory condition of materials, equipment’s or any conditions which may
considerably affect the Work adversely.
(2) Preparation of base
The base on which Dense Bituminous Macadam is to be laid shall be prepared, shaped and
conditioned to the specified lines, grades and cross sections in accordance with MORTH
Clause 501 The surface shall be thoroughly swept clean free from dust and foreign matter
using mechanical broom and dust removed or blown off by compressed air. In portions where
mechanical means cannot reach, other noticed method shall be used. A priming coat where
needed, shall be applied in accordance with Section 3.5
(3) Tack coat
A tack coat over the base shall be applied as per Section 3.6.
(4) Preparation of mix
Dense Bituminous macadam mix shall be prepared in a hot mix plant of adequate capacity
and capable of yielding a mix of proper and uniform quality with thoroughly coated
aggregates. Before apply of mix for the work, consent for the use of mix shall be taken from
the Engineer.
Hot mix plant shall be of suitable capacity preferably of batch mix type. Total system for
crushing of stone aggregates and feeding of aggregate fractions in required proportions to
achieve the desired mix, deployed by the Contractor must be capable of meeting the overall
Specification requirements under stringent quality control.
The temperature of binder at the time of mixing shall be in the range of 150oC to 163oC and
that of the aggregate in the range of 155oC to 163oC. provided that the difference in
temperature between the binder and aggregate at no time exceeds 14oC.

SS1-36
Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all
particles of the aggregates are coated uniformly, and the discharge temperature of mix shall
be between 130oC to 160 0 C.
The mixture shall be transported from the mixing plant to the point of use in suitable tipper
vehicles. The vehicles employed for transport shall be clean and be covered in transit. Any
tipper causing excessive segregation of materials by its spring suspension or other
contributing factors or that which shows undue delay shall be removed from the work until
such conditions are corrected.
(5) Spreading
The mix transported from the hot mix plant to the site shall be spread by means of a self-
propelled paver with suitable screeds capable of spreading, tamping and finishing the mix to
specified grade, lines and cross-section. However, in restricted locations and in narrow widths
where the available equipment cannot be operated. Similarly, for smaller jobs, mechanical
paver may be used with the given notice to the Employer’s Representative.
The temperature of mix at the time of laying shall be in the range of 1200 to 160 0 C.
Mixes with a temperature of less than 1200C shall not be put into paver spreader. Longitudinal
joints and edges shall be constructed true to the delineating lines parallel to the centre line of
the road. Longitudinal and transverse joints shall be offset by at least 250 mm from those in
the lower courses and the joint on the topmost layer shall not be allowed to fall within the
wheel path. All transverse joints shall be cut vertically to the full thickness of the previously
laid mix with asphalt cutter and the surface painted with hot bitumen before placing fresh
material. Longitudinal joints shall be preferably hot joints. Cold longitudinal joints shall be
properly heated with joint heater to attain a suitable temperature of about 80 0 C laying of
adjacent material.
(6) Rolling
After spreading the mix by paver, it shall be thoroughly compacted by rolling with a set of
rollers moving at a speed not more than 5 km/h, immediately following close to the paver.
Generally, the initial or breakdown rolling shall be done with 80 to100 kN static weight
smooth-wheeled roller. The intermediate rolling shall be done with 80 to -100 kN static
weight vibratory roller or with a pneumatic tired roller of 150 to -250 kN static weight having
a tyre pressure of at least 0.7 MPa. The finish rolling shall be done with 60 to 80 kN static
weight smooth wheeled tandem roller. All the compaction operations, i.e., breakdown rolling,
and intermediate rolling can be accomplished by using vibratory tandem roller of 80 to 100
kN static weight. During initial breakdown rolling and finish rolling, no vibratory compaction
shall be resorted to. The exact pattern of rolling shall be established after trial compaction.
Any displacement occurring as a result of reversing of the direction of a roller or from any
other cause shall be corrected at once as specified and/or removed and made good. The rollers
shall not be permitted to stand on pavement which has not been fully compacted and where
temperature is still more than 70oC. Necessary precautions shall be taken to prevent dropping
of oil, grease, petrol or other foreign matter on the pavement either when the rollers are
operating or standing.
The wheels of roller shall be kept moist to prevent the mix from adhering to them. But in no
case shall fuel/lubricating oil be used for this purpose nor excessive water poured on the
wheels. Rolling shall commence longitudinally from edges and proceed towards the centre,
except that on super elevated and unidirectional cambered portions, it shall progress from the
SS1-37
lower to upper edge parallel to the centre line of the pavement. The roller shall proceed on
the fresh material with rear or fixed wheel leading so as to minimise the pushing of the mix
and each pass of the roller shall overlap the preceding one by half the width of the rear wheel.
Rolling shall be continued till the density achieved is at least 98 per cent of that of laboratory
Marshall specimen (compacted as defined in Table 500-10) and all roller marks are
eliminated. Skin patching of an area that has been rolled will not be permitted. Rolling
operations shall be completed in all respects before the temperature of the mix falls below
1000C.
3.8 BITUMINOUS CONCRETE
3.8.1 Description
This work shall consist of a surfacing of single-layer bituminous concrete of specified
thickness on previously prepared bituminous surface to the lines, grades, dimensions and
cross section as shown on Drawings. It shall be 25mm/40mm thick
3.8.2 Materials
(1) Bitumen
The bitumen shall be paving bitumen of suitable penetration grade within the range S 35 to S
90 (or A 90) to IS: 73. The actual grade of bitumen to be used shall be appropriate to the
requirements of the work and environmental conditions.
(2) Coarse aggregates
The aggregates shall satisfy the physical requirements given in Table 3. Flakiness index shall
not exceed 30% and water absorbed not more than 1%
(3) Fine aggregates
Fine aggregates shall be the fraction passing 2.36 mm sieve and retained on 75-micron sieve,
consisting of crushed run screenings, natural sand or a mixture of both. These shall be clean,
hard, durable, uncoated, dry and free from any injurious, soft or flaky pieces and organic or
other deleterious substances.
(4) Filler
Filter shall consist of finely divided mineral matter such as rock dust, hydrated lime or
cement. The filter shall be graded within following limits.
IS Sieve Per cent passing by weight
600 microns 100
300 microns 95 to 100
75 microns 85 to 100
The filter shall be free from organic impurities and have a Plasticity Index not greater than 4.
The Plasticity Index requirement shall not apply if filter is cement or lime.
When coarse aggregate is gravel, 2 per cent of mass of total aggregate of OPC or hydrated
lime shall be added, and percentage of fine aggregate reduced accordingly. OPC or lime is
not required when the gravel comprises limestone.
(5) Aggregate gradation
Mineral aggregates, including filler shall be so graded or combined as to conform to gradings
set forth in Table 1.3.8.1 below.
SS1-38
Sieve Per cent by weight passing through sieve for

Designation
25mm thick Grade 1 25 to 40mm thick Grade 2 >40mm thick Grade 1
26.5mm -- -- 100
22.4mm -- 100 75 to 100
13.2mm 100 80 to 100 --
11.2mm 90 to 100 75 to 95 50 to 85
5.6mm 60 to 80 55 to 75 20 to 40
2.8mm 40 to 55 40 to 55 5 to 20
710micron 20 to 30 20 to 30 --
300micron 15 to 25 15 to 25 -
180micron 10 to 20 10 to 20 -
90micron 5 to 11 5 to 11 0 to 5
Table 1.3.8.1
3.8.3 Mix Design

(1) Requirements of the Mix
Apart from conformity with grading and quality requirements of individual ingredients, the
mix shall also meet the requirements set forth in Table 1.3.8.2.
Sl. No. Description Requirements
1. Marshall stability (ASTM Designation: D-1559) 820 Kg
determined on Marshall specimens compacted by 75 (1800 pounds)
compaction blows on each end
2. Marshall flow Minimum 2 to 4 mm
3. Air voids in mix 3 to 5%
4. Voids in mineral aggregate (VMA) Minimum 11 to 13%
5. Voids in mineral aggregates filled by bitumen (VFB) 65 to 75%
6. Binder content, by weight of mix Minimum 4.5%

7. Water sensitivity (ASTM: D-1075) loss of Stability on Minimum 75% Retained
immersion in water at 60 deg. C strength
8. Swell Test (Asphalt Instt. MS-2, No. 2) Maximum 1.5%
Table 1.3.8.2 Requirements of Bituminous Concrete Mix
(2) Binder content

Binder content shall be so determined as to achieve the requirements of the mix set forth in
Table 1.3.8.2 above. Marshall method for arriving at binder content shall be adopted.

SS1-39
(3) Job Mix Formula

Before starting work, the Contractor shall submit the Job Mix Formula to the Employer’s
Representative for his notice. The Job Mix formula for the mixture shall fix a single
percentage of aggregate passing each required sieve size, a single percentage of asphalt to be
added to the aggregate, and a single temperature at which the mixture is to be delivered on
the road, all of which shall fall within the ranges of the composition and the temperature
limits. The formula shall give the following details.
(i) Source and location of all materials.
(ii) Proportions of all materials as described under:
Binder - as percentage by weight of total mix;
Coarse aggregate - as percentage by weight of total, and;
Fine aggregate/aggregate including mineral filler Mineral Filler.
(iii) A single definite percentage passing each sieve for the mixed aggregate.
(iv) Test results as obtained by the Contractor.
(v) Test results of physical characteristics of aggregates to be used.
(vi) Mixing temperature and compacting temperature
(4) Application of Job Mix formula and Allowable Tolerances
The Job Mix formula shall remain effective unless and until modified. As many samples of
the materials and mixtures shall be taken and tested as considered necessary, for checking on
the required uniformity of the mixture.
All mixture furnished shall conform to the Job Mix formula within the range of tolerances set
out in Table 1.3.8.3 below.
Sl. No. Description of Ingredients Permissible Variation by
Weight of Total mix in %
1. Aggregate passing 13.2mm sieve and larger +8

2. Aggregate passing 9.5mm sieve and 4.75mm sieve +7
3. Aggregate passing 2.36mm sieve & 1.18mm sieve +6

4. Aggregate passing 600 micron sieve & 300 micro +5
sieve
5. Aggregate passing 150-micron sieve +4
6. Aggregate passing 75-micron sieve +3
7. Binder + 0.3
8. Mixing Temperature (Centigrade) + 10
Table 1.3.8.3 Permissible variations from the Job mix formula
When unsatisfactory results or changed conditions make it necessary, a new Job Mix shall be
submitted for notice by the Employer’s Representative.

SS1-40
Should a change in a material be encountered or should a change in a source of material be

made, a new job Mix formula shall be submitted for notice by the Employer’s Representative
before the mixture containing the new material is delivered.
a) Weather and seasonal limitations:
The work of laying shall not be taken up during rainy or foggy weather or when the base
10oC or less.
b) Progression of Works
No works shall be performed when there is insufficient hauling, spreading or finishing
equipment, or labour to ensure progress at a rate not less than 75% of the capacity of the
mixing plant.
c) Preparation of Existing Surfaces
The surface on which the mix is to be laid shall be swept thoroughly and cleaned of all loose
dirt and other objectionable material using mechanical broom immediately before start of
work, in portions where mechanical means cannot reach.
The surface shall be prepared, shaped and conditioned to specified levels, grade and cross-
fall (camber).
d) Preparation of Mixes
A hot-mix plant of adequate capacity and capable of producing a proper and uniform quality
mix shall be used for preparing the mix.
The plant may be either a weigh batch type or volumetric proportioning continuous or drum
mix type. The plant shall have co-ordinated set of essential units capable of producing
uniform mix as per the job-mix formula.
The temperature of the binder at the time of mixing shall be in the range of 150○C to 163○C.
and of aggregates in the range of 155○C to 163○C.
Provided also that at no time shall the difference in temperature between the aggregates and
binder exceed 14○C.
The Contractor shall submit the exact temperatures and total mixing time for the notice of the
Mixing shall be thorough to ensure that a homogeneous mixture is obtained in which all
particle of mineral aggregates is coated uniformly.
e) Transportation and Delivery of Mixes
The mix shall be transported from the mixing plant to the point of use in suitable tipper
vehicles. The vehicles employed for the transport shall be clean and be covered in transit.
f) Spreading and Finishing
The mix transported from the hot mix plant to the site and shall be spread by means of a self-
propelled mechanical paver with suitable screeds capable of spreading, tamping and finishing
the mix to specified grade, elevation, and cross- section.
However, in restricted locations and narrow widths, available equipment cannot be operated,
other suitable means shall be employed subject to the notice of the Employer’s
Representative.
SS1-41
The mixture shall be laid upon a noticed surface and only when weather conditions are
considered suitable. The temperature of the mix, at the time of laying, shall be in the range of
120○C to ○C.
The prime coat and tack coat to be applied shall be as per Section 3.5 and 3.6, respectively.
Spreading, finishing and compacting of the mix shall be carried out during daylight hours
only, unless satisfactory illumination is provided by the Contractor.
g) Compaction of Mixture
Immediately after spreading of mix by paver, it shall be thoroughly and uniformly compacted
by rolling with a set of self-propelled rollers moving at a speed not more than 5 km/h,
immediately following close to the paver. Generally, with each paver, two steel wheeled
tandem rollers and one pneumatic tired roller will be required.
The initial or breakdown rolling shall be with 80 to 100 kN static weight smooth three
wheeled steel roller and finish rolling with 60 to 80 kN static weight tandem roller. The
breakdown rolling shall preferably be followed by an intermediate rolling with a smooth
wheel pneumatic roller of 100 to 250 kN static weight having a tire pressure of 7 kilograms
per square centimetre (kg/cm2) moving with a speed not more than 7 km/hr and shall be at all
times slow enough to avoid displacement of the hot mixture.
Means shall be provided for checking and adjusting the tire pressure on the job at all times.
All compaction operations, i.e., breakdown rolling can be accomplished by using vibratory
roller of 80 to 100 kN static weight. During initial (or breakdown) and finished rolling, the
vibratory shall be switched off. The joints and edges shall be rolled with an 80 to 100 kN
static weight three wheeled static roller.
No delays in rolling the paved surface shall be permitted. The breakdown roller must be right
up to the paver at all times and the intermediate pneumatic roller right up to the breakdown
roller. The compaction of the asphaltic concrete shall be controlled by temperature as follows:
Roller Temperature
Breakdown 120 C to 135 C
Pneumatic 95 C to 115 C
Finishing < 65 C
Rolling shall be continued till the density achieved is at least 98% of that of laboratory
Marshall specimen. Rolling operations shall be completed in all respects before the
temperature of the mix falls below 100○C.
h) Joints
Both longitudinal and lateral joints in successive courses shall be staggered so as not to be
one above the other.
Longitudinal joints and edges shall be constructed true to delineating lines parallel to the
centre line of the road. Longitudinal joints shall be offset by at least 150mm from those in the
lower course.
Longitudinal and transverse joints shall be made in a careful manner so that well bonded and
sealed joints are provided for the full depth of the course.

SS1-42
i) Surface Regularity
Surface shall be tested for undulations in longitudinal and cross profiles with 3 metre (m)
straight edge and crown template respectively. Crown template shall conform to the typical
cross section.
Maximum permissible undulation in longitudinal profile with 3m straight edge shall be as
8mm.
Maximum permissible variation from specified cross profile under camber template shall be
as 4mm.
Surface evenness requirements in respect of both longitudinal and cross profiles should be
simultaneously satisfied.
3.9 BITUMINOUS MACADAM
3.9.1 Description
The work shall consist of one or more applications of compacted crushed aggregates
premixed with bituminous binder (suitable grade) to a primed non-bituminous surface or
previously constructed bituminous surface and in conformity with the lines, grades,
dimensions and cross-sections as per Drawings This shall comprise of a single course of
50mm to 75mm thickness as specified in the drawings.
3.9.2 Materials
a) Bitumen
The bitumen shall be paving bitumen of suitable grade given notice by the Employer’s
Representative and conforming to IS: 73.
b) Additives
Adhesion and Ant-stripping agent shall be added to the bitumen subject to Employer’s
Representative notice at the required percentage of additive. The additive shall be thoroughly
mixed with the bituminous material in accordance with the manufacturer’s instructions.
c) Aggregates
Aggregates shall consist of clean and hard crushed stone free from dust, clay, dirt and any
other deleterious matter. The physical requirements shall be as given in Table 1.3.9.1.
Àggregates shall conform to one of the two gradings given in Table 1.3.9.2 depending on
the compacted thickness; the actual grading shall be subject to notice of the Employer’s
Representative.
Sl. No Test Test Method Requirement
(maximum)
1. * Los Angeles Abrasion value IS :2386 (Part-4) 40 %
2. * Aggregate Impact value IS :2386 (Part-4) 30 %
3. Flakiness Index and Elongation IS: 2386 30 %
Indices (Total) (Part-1)
Coating and Stripping of Bitumen AASHTO T-182 Minimum retained
4. aggregate mixtures coating 95%

SS1-43
Soundness:
(i) Loss with Sodium Sulphate 5 12 %
5. cycles
(ii) Loss with Magnesium 18 %
Sulphate 5 cycles
6. Water absorption IS: 2386(Part-3) 2%
* Aggregates may satisfy requirements for either of the two tests.
Table 1.3.9.1 Physical requirements of aggregates for bituminous macadam
Per cent by weight passing the

IS Sieve sieve
Designation Grading 1 Grading 2
45.0mm 100 -
26.5mm 75 to 100 100
22.4mm 60 to 95 75 to 100
11.2mm 30 to 55 50 to 85
5.6mm 15 to 35 20 to 40
2.8mm 5 to -20 5 to 20
90.0 micron 0 to 5 0 to 5
Table 1.3.9.2 Aggregate grading for bituminous macadam
Bitumen content for premixing shall be 4% by weight of total mix unless otherwise noticed
a) Weather and Control of Works
The work of laying shall not be undertaken during rainy or foggy weather or when the base
150C or less.
b) Cleaning and Preparation of Surfaces
Prior to the application of binder, loose dirt and other objectionable material shall be removed
from the surface to be treated by means of the power broom or blower or both. If this does
not provide a uniformly clean surface, additional sweeping shall be done by hand, using stiff
brushes or similar brooms. The areas inaccessible to the cleaning means shall be cleaned
manually. The sweeping shall extend 200mm beyond each edge of the area to be treated.
Adherent patches of objectionable material shall be removed from the surface by steel scraper
or other noticed method and the scraped area shall be washed down with water and hand
brooms.
No application of bituminous materials shall be undertaken until the surface has been cleaned.
Before application of the bituminous material any necessary preliminary patching of the
surface of the road (to fill in potholes) shall be done.

SS1-44
Tack coat and Prime coat (if required) shall conform and be applied in accordance with these
Specifications.
c) Plant and Equipment
All plant used by the Contractor for the preparation, hauling and placing of asphalt mixtures
shall be subject to the notice of the Employer’s Representative and shall minimise smoke,
dust and noxious emission and odours. These shall generally meet the following
requirements.
(i) The mixing plant shall be a batching plant and shall have adequate capacity sufficient
to supply the finisher on the road continuously when spreading the asphaltic mix at
normal speed and required thickness.
(ii) Scale for any weigh box shall be designed to be accurate to within 1% of the
maximum load required and shall be fully automatically controlled.
(iii) The Contractor shall provide and have at hand not less than ten number 25 kilograms
weights for frequent testing of all scales.
(iv) Weigh box or hopper shall include a means for accurately weighing each bin size of
aggregate in a weight box or hopper, suspended on scales, ample in size to hold a full
batch without running over.
(v) The asphaltic materials shall be stored in storage tanks designed to keep the
temperature of the asphaltic material at maximum temperature of 110 ○C The
properties of the asphaltic material kept in that storage tanks shall be in good
condition before mixing.
The plant shall be provided with a circulating system to ensure continuous circulation
between the storage tank and the mixer.
(vi) The plant shall be provided with a cold bin for feeding the aggregates. The cold bin
shall have a calibration gate and a mechanical means to insure uniform feeding of the
aggregates into the drier.
(vii) The rotary drier shall be capable of drying and heating the aggregates to the specified
temperature.
(viii) The plant shall be provided with plant screens capable of screening all aggregates to
the specified sizes.
(ix) The plant shall include at least 3 hot bins for storing the aggregates fed from the drier
after passing through the screen. Each hot bin shall be provided with an overflow
pipe to allow even distribution of material into all hot bins.
(x) The plant shall be provided with asphaltic control unit by weighing to obtain the
proper amount of asphaltic material in the mix within the tolerance specified for the
Job Mix.

SS1-45
(xi) The batch mixer shall be a noticed twin pugmill type and capable of producing a
continuous uniform mixture within the job-mix tolerances. The mixer capacity shall
not be less than 1,000-kilogram batch.
(xii) An armoured thermometer reading from 50°C to 200°C shall be fixed in the asphaltic
feed line at a suitable location near the discharge valve at the mixer unit.
The plant shall be further equipped with an electric pyrometer, or other noticed thermometric
instrument so placed at the discharge chute of the drier as to register automatically
or indicate the temperature of the heated aggregate.
(xiii) The plant shall be equipped with a dust collector.
(xiv) The plant shall be equipped with accurate positive means to govern the time of mixing
and to maintain it constant. The time of mixing shall be divided into two steps, dry
mixing and wet mixing.
For dry mixing, the aggregate from hot bins shall be mixed for a period of 5 to15 seconds.
For wet mixing, the mixing time shall begin with the start of the asphalt spray after dry
mixing. The wet mixing shall take about 30 to 45 seconds. The mixing time shall be extended
if the material obtained is not homogeneous and to the notice to the Employer’s
Representative.
d) Equipment for Hauling and Placing
(i) Trucks for hauling asphaltic mixtures shall have tight, clean, and smooth metal beds that
have been sprayed with soapy water, thinned fuel oil, or lime solution to prevent the
mixing from adhering to the beds. The amount of sprayed fluid shall however be kept to
the practical minimum. Each load shall be covered with a canvas or other suitable material
of such size as to protect the mixture from the weather. Any truck causing excessive
segregation of material by its spring suspension or other contributing factors, or that shows
oil leaks in detrimental amounts, or that causes undue delays, be removed from the work
until such conditions are corrected.
(ii) The equipment for spreading and finishing shall be mechanical, self-powered pavers,
capable of spreading and finishing the mixture true to the lines, grades, dimensions and
cross sections.
The pavers shall be equipped with hoppers and distributing screws of the reversing type
to place the mixture evenly.
The pavers shall maintain trueness of grade and confine the edges of the pavement to true
lines without the use of stationary side forms. The equipment shall include blending or
joint levelling devices for smoothing and adjusting longitudinal joints between lanes. The
assembly shall be adjustable to give the cross-section shape prescribed and shall be so
designed and operated as to place the thickness or weight per square metre of material
required.
Pavers shall be equipped with activated screeds and devices for heating the screeds to the
temperature required for the laying of the mixture without pulling or marring.

SS1-46
The term “screed” includes any cutting, crowing, or other practical action that is effective
in producing a finished surface of the evenness and texture specified, without tearing,
shoving, or gouging.
If, during construction, it is found that the spreading and finishing equipment in operation
leaves in the pavement surface tracks or indented areas or other objectionable
irregularities, the use of such equipment shall be discontinued, and other satisfactory
spreading and finishing shall be provided by the Contractor forthwith.
e) Preparation and transport of mix
Bituminous macadam mix shall be prepared in a hot mix plant either owned by the
Contractor or it may be taken from a hot mix plant, the notice shall be given on the details
of the plant to the Employer’s Representative in advance. The hot mix plant should be of
adequate capacity of batch mix type with the features as described under Section 3.9.3 or
otherwise given notice by Employer’s Representative unless some work-specific features
are required and capable of yielding a mix of proper and uniform quality with thoroughly
coated aggregates. The plant shall meet the overall requirements through stringent quality
control practices.
The mineral aggregates shall be dried and heated to a temperature between 150°C and
163°C. The Contractor shall submit for notice the exact temperature to the Employer’s
Representative. Surfaces of aggregates shall be clean and free of carbon and unburnt fuel
oil. The aggregates, immediately after heating, shall be screened into three or more
fractions and conveyed into separate bins ready for combining and mixing with asphaltic
material.
The dried mineral aggregates prepared as prescribed above, shall be combined in the plant
in the amount of each fraction of aggregate required to meet the Job Mix formula for the
particular mixture. The proper amount of asphaltic material shall be distributed over the
mineral aggregate and the whole thoroughly mixed for a period of at least 30 seconds, or
longer if necessary, to produce a homogeneous mixture in which all particles of the mineral
aggregates are coated uniformly. The total mixing time shall be regulated by a suitable
locking means.
The mixture shall when emptied from the mixer be at a temperature between 150°C and
163°C even for tolerances.
The mixture shall be transported from the mixing plant to the point of use in vehicles
conforming to the requirements of Section 3.9.3 unless otherwise given notice by the
f) Application of the Pre-mix
The application of the pre-mix shall proceed immediately after application of tack coat.
The pre-mix shall be spread immediately by means of self-propelled mechanical paver
with suitable screeds capable of spreading, tamping, and finishing the pre-mix true to lines,
levels, dimensions and cross-sections specified. Any bare or insufficiently filled areas shall
be re-treated by the mechanical spreader or covered by hand as necessary to give uniform
and complete coverage. Any aggregate spread in excess of the agreed rate shall be
scattered and evenly distributed on the road or otherwise removed and stockpiled.
The temperature of the pre-mix at the time of laying shall be in the range of 120°C or
160°C.
SS1-47
g) Rolling
After the spreading of the mix, the rolling shall be done by road roller of suitable type and
capacity. Rolling shall start as soon as possible after the material has been spread and it
shall be completed within limited time frame, and to meet this, the Contractor shall deploy
a set of rollers. Rolling shall be done with care to avoid unduly roughening of the pavement
surface. It shall commence at the edges and progress towards the centre longitudinally
except that on super- elevated and unidirectional cambered portions, it shall progress from
the lower to the upper edge parallel to the centre line of the pavement.
The speed of the rollers shall not exceed 5 km/h for steel wheeled rollers and 7 km/h for
pneumatic tired rollers and shall be at all times slow enough to avoid displacement of the
hot mixture. Any displacements occurring as a result of reversing the direction of the roller
or from any other cause shall at once be corrected with rakes and fresh mixture where
required. Care shall be exercised in rolling not to displace the line and grade of the edges.
Rolling shall progress continuously as may be necessary to obtain uniform compaction
while the mixture is in a workable condition and until all roller marks are eliminated.
Heavy equipment or rollers shall not be permitted to stand on the finished surface until it
has thoroughly cooled or set.
Any petroleum products dropped or spilled from the vehicles or equipment employed by
the Contractor upon any portion of the pavement under construction is cause for the
removal and replacement of the contaminated pavement by the Contractor.
When the roller has passed over the whole area once, any high spots or depressions which
become apparent shall be corrected by removing or adding premixed material.
Rolling shall then be continued until the entire surface has been rolled to 95 % of the
average laboratory density, and there is no crushing of aggregates. and all roller marks are
eliminated. In each pass of the roller, preceding track shall be overlapped uniformly by at
least one third the width of the roller.
The roller wheels shall be kept damp to prevent premix from adhering to the wheels and
being picked up. In no case shall fuel/ lubricating oil be used for this purpose.
Along kerbs, manholes etc., and at any other locations where proper consolidation by
rollers is not practicable, alternative means such as steel rammers shall simultaneously be
used to secure adequate consolidation.
3.9.4 Surface Control
Surface Regularity
Maximum permissible undulation in longitudinal profile with 3m straight edge shall be as
12mm.
Maximum permissible variation from specified cross profile under camber template shall
be as 8mm.
Surface evenness requirements in respect of both longitudinal and cross profiles should be
simultaneously satisfied.
Tests for conformity with the specified crown and grade shall be made immediately after
initial compaction, and variations shall be corrected by removing or adding materials as
may be necessary.
SS1-48
Rolling shall then be continued as specified. After final rolling, the smoothness of the course
shall be checked again and any irregularity of the surface exceeding the permissible limits
corrected as agreed by the Employer’s Representative, including removal and replacement.
Surface Finish
The bituminous macadam shall be covered with either the next pavement course or wearing
course, as the case may be, without any delay. If there is to be any delay, the course shall be
covered with the seal coat. The seal coat in such cases shall be considered incidental to the
work and shall not be paid separately.
3.10 CONTROL OF TRAFFIC
This shall be as described under section 3.1.
3.11 OPEN-GRADED PRE-MIX CARPET
3.11.1 Description
This work shall consist of laying and compacting an open-graded carpet generally of 20mm
thickness or as otherwise specified in a single course composed of suitable small sized
aggregates premixed with a bituminous binder on a previously prepared base to serve as a
wearing course.
3.11.2 Materials
Binder
Binder shall be a bitumen of suitable grade meeting the requirements of the work and other
environmental conditions. This shall be conforming to the requirements of IS: 73, IS: 217 and
IS: 454 or other noticed cut back bitumen as applicable.
Coarse aggregates
Coarse aggregates consist of crushed stones and shall be clean, strong, durable, and free from
organic or other deleterious materials. The aggregates shall be hydrophobic and of low
porosity. If hydrophilic aggregates are to be used, bitumen shall preferably be treated with
anti-stripping agents of noticed quality in suitable doses.
The aggregates shall meet the requirements given in Table 1.3.9.1 except that the water
absorption shall be limited to 1%. The Stone Polishing Value as measured by BS: 812-(Part-
114) shall not be less than 55.
Proportioning of Materials
They shall comprise of a mix of stone chipping 13.2mm size (passing 22.4 mm sieve and
retained on 11.2 mm size) and 11.2 mm size (passing 13.2 mm sieve and retained on 5.6 mm
sieve.)
The Contractor shall propose material proportions to the Employer’s Representative for his
notice.
Weather and Control of Work
This shall be as carried out per Section.3.9.3.
Cleaning and Preparation of Surface
This shall be as carried out per Section 3.9.3.
Tack Coat
This shall be applied as per Section.3.6.
SS1-49
Preparation and transport of Premix

The binder shall be heated to a temperature appropriate to the grade of bitumen in boilers of
suitable design avoiding local overheating and ensuring a continuous supply. The aggregates
shall be dry and suitably pre-heated to the required temperature before they are placed in a
mixer. After about 15 seconds of dry mixing, the heated binder shall be distributed over the
aggregates at the rate specified.
Mixing shall be continuous and thorough to ensure a homogeneous mixture in which all
particles are coated uniformly, and the discharge temperature shall be within the specified
range.
The mixing of binder with chippings shall be continued until the chippings are thoroughly
coated with binder. The mix shall be discharged and immediately transported from mixer to
the point of use in suitable vehicles or wheelbarrows.
The vehicles employed for transport shall be clean and the mix being transported should be
covered in transit and protected from any kind of damage.
Spreading and Rolling
Immediately after the application of tack coat, premixed material shall be spread by means of
mechanical paver finisher truly to lines, levels, dimensions and cross section as specified. The
areas not covered by the mechanical means shall be treated with manual means.
Rolling
This shall be carried out as per Section 3.9.3.
3.11.4 Control of Traffic
The requirements of Section 3.1 shall apply.
3.12 SEAL COAT
3.12.1 Description
This work shall consist of application of a seal coat for sealing the voids in a bituminous
surface laid to the specified levels, grade, and cross fall. Seal coat used shall be of pre-mix
type unless otherwise given notice by the Employer’s Representative.
3.12.2 Materials
Binder
The binder shall be bitumen of a suitable grade appropriate to the requirements of the work
and other environmental conditions and satisfying the requirements of IS: 73, 217, 454 or
other cut back as applicable.
Aggregates
The aggregates shall be sand or grit and shall consist of clean, hard, durable, dry particles and
shall be free from dust, soft or flaky/ elongated material, organic matter or other deleterious
substances.
The aggregates shall pass 2.36mm sieve and be retained on 180-micron sieve. The quantity
used for premixing shall be 0.06 cubic metres per 10 square metre area.

SS1-50

Preparation of base
The seal coat shall be applied immediately after laying of bituminous course which is required
to be sealed. Before application of seal coat materials, the surface shall be cleaned free of any
dust or other objectionable matter.
Preparation and Application of Mix
Mixers of noticed type shall be employed for mixing aggregates with suitable bituminous
binder.
The binder shall be heated in boilers of suitable design, to a temperature appropriate to the
grade of bitumen. The aggregates shall be clean, dry and suitably heated to a temperature
before the same are placed in the mixer.
Mixing of binder with aggregates to specified proportions shall be continued till the latter are
thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to the point of use and spread
uniformly on the bituminous surface to be sealed.
Rolling
As soon as sufficient length has been covered with pre-mixed material, the surface shall be
rolled with vibratory 80 to100 kN static weight smooth-wheeled steel roller, or other suitable
equipment.
The procedure for rolling shall comply with the requirements of Section 3.9.3.
Control of Traffic
Control of traffic shall comply with the requirements of Section 3.1.
4 PILING AND DIAPHRAGM WALLING
4.1 GENERAL
4.1.1 Piling plant and Methods
(i) Not less than 2 weeks before any piling work is commenced the Contractor shall submit
to the Employer’s Representative for notice full details of his proposed piling plant, and
detailed method statements for carrying out the Works. Such details shall include where
applicable a full description of the piling frame, hammer, helmet and packing, methods of
handling, pitching and supporting the piles before and during driving, the proposed driving
procedure to obtain the required penetration, or the proposed set and the method of
calculation of the specified working load of the piles and such further information as the
Employer’s Representative may require. Details of casings and concreting methods in
respect of any driven or bored cast-in-place concrete piles shall be included in the
submission.
(ii) The Contractor shall not commence any piling until the plant and methods which he
proposes to use have received a “Notice of No Objection‟ from the Employer’s
Representative but such a notice shall not relieve the Contractor from any of his obligations
and responsibilities under the Contract. If for any reason the Contractor wishes to make
any change in the plant and methods of working, he shall not make any such change

SS1-51
without having first obtained the Employer’s Representative's “Notice of No Objection‟

for such changes.
(iii) Reference shall be made to the following documents regarding matters relating to the
safety of piling works
BS8004 Code of Practice for Foundations
BS5573 Code of Practice for Safety Precautions in the Construction of Large Diameter
Boreholes for Piling and Other Purposes
IS 2911 (Part I & IV) : Design and Construction of Pile Foundation
4.1.2 Records
The Contractor shall keep complete records of all data as required by the Employer’s
Representative covering the fabrication, driving and installation of each pile and shall submit
two signed copies of these records to the Employer’s Representative not later than 24 hours
after installation of the piles.
4.1.3 Programme and Progress Report
(i) The Contractor shall inform the Employer’s Representative each day of the programme of
piling for the following day and shall give adequate notice of his intention to work outside
normal hours and at weekends.
(ii) The Contractor shall submit to the Employer’s Representative on the first day of each
week, or on such other date as the Employer’s Representative may decide, a progress
report detailing the rate of progress to that date and progress during the previous week
and/or period of all main items of piling works.
4.1.4 Setting Out
(i) The Contractor shall establish and maintain permanent datum level points, base lines and
grid lines to the notice of the Employer’s Representative and shall set out with a suitable
identifiable pin or marker the position of each pile.
(ii) The setting out of each pile shall be given notice by the Employer’s Representative at least
one day prior to commencing work on a pile and adequate notice for checking shall be
given by the Contractor.
(iii) Notwithstanding such notice, the Contractor shall be responsible for the correct and proper
setting out of the piles and for the correctness of the positions, levels, dimensions, and
alignment of the piles.
4.1.5 Tolerances
Piles
(1) Piles shall be driven or bored accurately vertical or to the specified rake and the permitted
deviation of the pile centre from the centre-point shown on the setting out plan shall not
exceed 50 millimetres measured at the working level of the piling rig, or other level given
notice to the Employer’s Representative.
(2) Deviation from specified cut-off level shall be ±25 millimetres.

SS1-52
(3) The maximum permitted deviation of the finished pile shall be 1 in 200 or 75mm whichever
is lesser from the vertical for vertical piles, and for racking 1 in 25 from the specified rake..
(4) Forcible corrections shall not be made to piles.
(5) The manufacturing tolerances for precast concrete piles shall comply with the following
requirements.
(i) The external cross-sectional dimensions shall be within 0 millimetres and +5
millimetres of the specified dimensions.
(ii) The wall thickness of hollow spun concrete piles shall be within 0 millimetres and +25
millimetres of the specified thickness.
(iii) There shall be no irregularity exceeding 6 millimetres in a 3-metre length along the face
of the pile measured using a 3-metre straight edge.
(iv) The centroid of any cross-section of the pile shall not be more than 12 millimetres from
the straight line connecting the centroids of the end faces of the piles.
(v) The centroid of any cross-section of a hollow pile shall be determined by assuming that
the pile has a solid section.
(6) The diameter of cast-in-situ piles shall be at least 98% of the specified diameter.
Pile caps
(1) Variation in dimensions shall be limited to +50 millimetres and –10 millimetres.
(2) Misplacement in plan from specified position shall be limited to 15 millimetres.
(3) Surface irregularity measured with 3 metre straight edge shall be limited to 5 millimetres.
(4) Variation of levels at the top shall not be beyond ±25 millimetres.
4.1.6 Disturbances and Noise
(1) The Contractor shall carry out the piling work in such a manner and at such times as to
minimize noise and disturbance.
(2) The Contractor shall take precautions adequate enough to avoid damage to existing utilities
and services and adjacent structures.
(3) The Contractor shall ensure that damage does not occur to any part of completed piling works
and shall submit to the Employer’s Representative for notice his proposed sequence and
timing for driving or boring piles having regard to the avoidance of damage to adjacent piles.
4.1.7 Obstructions
If during the execution of the Works the Contractor encounters obstructions in the ground, he shall
immediately notify the Employer’s Representative, accordingly, submit to him details of
proposed methods for overcoming the obstruction and proceed according to the Employer’s
Representative's notice.

SS1-53
4.2 CONCRETE PILES

4.2.1 Materials - General
(a) Requirements of concrete and reinforcement for precast and cast in-situ piles shall
comply with Section 5 of this Contract. Minimum cement content for concrete in cast-
in- place piles as per IS 2911.
(b) Precast piles shall be marked at the time of concreting with all relevant information –
e.g., date, reference number, length and the like.
4.2.2 Reinforcement
(i) The reinforcement shall be assembled before placing in the moulds and all hoops and links
shall be of uniform length firmly wired into position. Ends of helical reinforcement shall
be firmly secured. Diagonal fork spacers shall be of a noticed pattern. The cover to all bars
shall be not less than 45 millimetres but increased cover thickness may be provided where
piles are exposed to the action of harmful chemicals (as in the case of concrete in contact
with earth faces contaminated with such chemicals), acid, vapour, saline atmosphere,
sulphurous smoke (as in case of steam operated railways), etc, and such increase of cover
may be between 15 millimetres and 50 millimetres beyond 40 millimetres as may be
specified by the Contractor‟ subject to the notice of the Employer’s Representative. The
Contractor shall validate the cover requirements given in drawings to suite his construction
methodology and the requirements of DAAR
(ii) Joints in main longitudinal bars will be permitted only where each bar cannot be practically
supplied in one complete length. Where permitted, joints shall be provided at agreed
centres, designed to develop the full strength of the bar across the joint, provided with
adequate links or stirrups and staggered in position from those of adjacent longitudinal
bars.
(iii) Welding of cold worked high tensile requirement bars at joints in main longitudinal bars
will not be permitted without the agreement of the Employer’s Representative in which
case, the Contractor shall comply with the requirements of IS 9417-1989.
(iv) Welding of hot rolled high tensile steel bars shall be permitted provided the method used
for the same will not adversely affect the properties of bars.
4.3 PRECAST CONCRETE PILES
4.3.1 Formwork
(1) Formwork shall comply with Section 6 of this Contract except as specified below. The head
of each pile shall be square to the longitudinal axis. The corners of the head and pile shaft for
a distance of 300 millimetres from the head shall be chamfered 25 millimetres by 25
millimetres. The method of forming hollow cores where required shall be such that a
continuous core is formed. The use of previously cast piles as side forms will not be permitted.
Holes for toggle bolts shall be at right angles to the faces of the pile and lined with steel tubes
or other noticed material. Holes for lifting, handling and pitching shall be formed in
accordance with the agreed Drawings.

SS1-54
(2) Details of all pile shoes shall be submitted to the Employer’s Representative for notice prior
to fabrication or supply. All shoes shall be fitted to the reinforcement as shown on the agreed
Drawings.
4.3.2 Protection of Finished Piles
Protection of finished piles against aggressive soil conditions shall be provided by one of the
following methods.
(1) Using sulphate-resistant cement - ASTM or TIS Type 5 or Equivalent Indian
Standards IS 12330-1988.
(2) Increasing concrete cover to the reinforcement
4.3.3 Lengthening Concrete Piles
(1) Where it becomes necessary to lengthen a pile, the reinforcement at the head of the pile shall
be stripped of all surrounding concrete and additional reinforcement added.
(2) The length stripped shall be not less than 40 times the maximum diameter of the longitudinal
reinforcement in the case of a spliced joint or at least 300 millimetres for a butt-welded joint.
New binders of the same size and spacings as in the original pile head and additional blinders
shall be fixed in the extension and the pile extended by concreting between properly formed
and supported moulds to the required length. Prior to casting the extension, the existing
concrete surface shall be cut to sound concrete square to the pile axis and all loose particles
removed by wire brushing. This shall be followed by washing with water and preparing and
coating with a noticed epoxy bonding agent applied in accordance with the manufacturer's
recommendation. Care shall be taken to ensure that the alignment of the extended pile across
the joint is exactly maintained.
(3) Prior to carrying out any work for the lengthening of piles, the Contractor shall submit a
detailed method statement to the Employer’s Representative for his notice.
(4) After piles have been lengthened, driving shall not be resumed until the specified
characteristic strength of the added concrete has been attained. Subject to the Notice of No
Objection‟ from the Employer’s Representative in writing, the Contractor may use rapid
hardening Portland cement conforming to IS 8041–1990 for pile extensions in order to
expedite the work.
(5) Driving or redriving of concrete piles extended as described above shall not be resumed until
the notice of the Employer’s Representative has been given.
4.4 CAST-IN-PLACE PILES
4.4.1 Bored Piles
(i) The Contractor shall check and agree with the Employer’s Representative the casing
position for each pile during and immediately after placing the casing. Piles shall be
constructed in a sequence submitted in advance to the Employer’s Representative. During
boring, the Contractor shall where take soil, rock or groundwater samples and transport
them to a noticed testing laboratory or carry out in-place soil tests. A complete record of
the construction of each pile shall be kept by the Contractor and made available for
inspection by the Employer’s Representative.
SS1-55
(ii) Diameters of the piles shall not be less than the diameters specified by the Contractor’s
Designer and given notice by the Employer’s Representative. Where enlarged bases are
required, these shall be mechanically formed and concentric with the pile shaft to within a
tolerance of two per cent of the shaft diameter and shall not be smaller than the required
dimension. The sloping surface of the frustrum forming the enlargement shall make an
angle not less than 55 degrees to the horizontal. The diameters of piles shall be verified by
Koden method or other methods subject to the notice of the Employer’s Representative.
(iii) Where bentonite drilling fluid is used in boring for maintaining stability, the level of the
fluid in the excavation shall be kept at not less than 1.5 metres as per IS:2911–1979 above
the level of the external groundwater or at such other level as will ensure that the fluid
pressure is at all times in excess of pressures exerted by the soils and external groundwater.
(iv) An adequate temporary casing shall be used where required for ensuring stability of the
strata near ground level until concrete has been placed in the pile. A pile excavation shall
be backfilled without delay where a rapid loss of drilling fluid occurs and no further
excavation at the location of that pile shall be carried out until the Contractor has obtained
the Employer’s Representative's notice for the proposed remedial work.
(v) Pumping from a boring shall not be permitted unless notice is given by the Employer’s
Representative.
(vi) Where temporary casings or alternative methods for maintaining stability of a boring are
used, these shall be subject to the notice of the Employer’s Representative.
(vii) Temporary casings shall be free from distortion and of uniform cross-section throughout
each continuous length. During concreting, all temporary casings shall be free from
internal projections, encrusted concrete or other materials. For minimum standards the
length of such casing shall be as per IS:2911-1979.
(viii) Piles constructed in a stable cohesive soil without temporary casings or other forms of
support shall be bored and concreted without prolonged delay which might allow collapse
of any part of the pile boring.
(ix) On completion of boring, all loose, disturbed or remoulded soil shall be removed from the
base of the pile. Prior to placing concrete, the Contractor shall inspect each and every pile
boring and submit his pile boring inspection records for notice by the Employer’s
Representative. After each pile has been cast, any empty bore which may remain shall be
protected and carefully backfilled as soon as possible.
4.4.2 Concreting
(i) The method of placing and the workability of the concrete shall be such as to ensure that
a continuous monolithic concrete shaft of the full cross section is formed. The method of
placing shall be subject to the notice of the Employer’s Representative and shall be carried
out after inspection without such interruption as would allow the previously placed batch
to have hardened. No contamination of the concrete by spoil, liquid or other foreign matter
shall be allowed.

SS1-56
(ii) The Contractor shall take all precautions to ensure that the concrete mix and placing of the
concrete does not result in arching of concrete in a casing. Slump measured at the time of
discharge into the pile boring shall be in accordance with requirements as specified in IS
2911-1979, Part I Section 2. Internal vibrators shall not be used to compact concrete unless
the Contractor is satisfied that no segregation or arching of the concrete will result.
(iii) Where concrete is placed in dry borings, measures shall be taken to avoid segregation and
bleeding and to ensure that the concrete at the bottom of the pile is not deficient in cement.
(iv) Concrete placed under water or drilling fluid shall be by means of a tremie and shall satisfy
requirements as per IS 2911-1979, Part I Section 2.
(v) Before concreting is commenced, the Contractor shall remove any accumulation of silt or
other material at the base of the pile or boring.
(vi) The hopper and pipe of the tremie shall be clean and water-tight throughout. The pipe shall
extend to the base of the pipe or boring and a sliding plug shall be placed in the pipe to
prevent direct contact between the first charge of concrete in the tremie pipe and the water
or drilling fluid. At all times during concreting, the tremie pipe shall penetrate the
previously placed concrete and shall not be withdrawn from the concrete until completion
of concreting. A sufficient quantity of concrete within the pipe shall be maintained at all
times to ensure that the pressure within the tremie pipe always exceeds that from the water
or drilling fluid.
(vii) The internal diameter of the tremie pipe shall not be less than 200 millimetres for concrete
made with 20 millimetres aggregate, or as agreed with the Employer’s Representative.
4.4.3 Drilling Fluid
(1) Drilling fluid shall comprise bentonite complying with Specification IS:2720-1965; IS:2911-
1979, Part I Section 2 Appendix B or DFCP 4 of the Oil Companies Materials Association or
given notice by the Employer’s Representative and thoroughly mixed with clean fresh water
to form a suspension meeting the specification requirements as submitted to and given notice
(2) The Contractor shall obtain manufacturers' certificates of the bentonite powder consigned
to the Site giving properties of each consignment and shall submit them to the Employer’s
Representative prior to commencing the work and whenever required.
(3) The temperature of the water used in mixing the suspension shall not be lower than 5 ○C.
Where saline or chemically contaminated groundwater occurs, special precautions to the
notice of the Employer’s Representative shall be taken to modify the bentonite suspension
or prehydrate the bentonite in fresh water so as to make it suitable for pile construction.
(4) The type and frequency of testing drilling fluid and the method and procedure of sampling
shall be proposed by the Contractor and s u b j e c t to notice by the Employer’s Representative
prior to commencement of piling work. Such control tests on the bentonite suspension shall
be carried out during the course of the piling work.

SS1-57
(5) B e f o r e concreting a pile, the Contractor shall remove any heavily contaminated bentonite
suspension which could impair the free flow of concrete from the tremie pipe. A sample of
the bentonite suspension shall be taken from the base of the boring using a noticed slurry
sampling device and the specific gravity of the suspension should not exceed 1.20 as per
standard practice and also as per IS:2911. Consistency of the mud suspension shall be
controlled throughout the pouring as well as concreting operations in order to keep the hole
stabilized as well as to avoid concrete mixing with the thicker mud suspension.
(6) All reasonable steps shall be taken to prevent the spillage of bentonite suspension on the Site
in areas outside the immediate vicinity of boring. Discarded bentonite shall be removed from
the Site without delay and any disposal thereof shall comply with the regulations of all
appropriate relevant authorities.
4.4.4 Extracting Temporary Casing
(1) The plant and methods of extraction of temporary casing shall be subject to the notice of the
Employer’s Representative. Temporary casings for driven or bored cast-in-place piles shall
be extracted carefully while the concrete is sufficiently workable to ensure it is not disturbed
or lifted.
(2) During extraction, a sufficient quantity of concrete shall be maintained inside the casing to
overcome the pressure from external water, soil or drilling fluid and to ensure that no
reduction in section by way of necking or shearing of concrete and contamination of the pile
takes place.
(3) Concrete shall be placed continuously as the casing is extracted whilst maintaining the
required head of concrete. The pile should be formed at least 300 millimetres above the cut-
off level. Guidelines in this regard as mentioned in IS 2911, shall be followed along with
other international standard practices. No payment shall be made for laitance or scum concrete
beyond the cut-off level.
4.5 PILE TESTING
4.5.1 General
(i) Load testing of Piles shall conform to IS 2911-1985, Part IV.
4.5.2 Safety Precautions
General
(i) When preparing for conducting a pile test the Contractor shall comply with the
requirements of the various acts, orders, regulations and other statutory instruments that
are applicable to the work for the provision and maintenance of safe working conditions,
and shall in addition make such other provision as may be necessary to safeguard against
any hazards that are involved in the testing or preparations for testing.
Personnel
(i) All tests shall be carried out only under the direction and in presence of an experienced
and competent supervisor conversant with the test equipment and test procedure. All
personnel operating the test equipment shall have been trained in its use.

SS1-58
Kentledge
(i) Where kentledge is used the Contractor shall construct the foundations for the kentledge
and any cribwork, beams or other supporting structures in such a manner that there will
not be differential settlement, bending or deflection of an amount that constitutes a hazard
to safety or impairs the efficiency of the operation.
(ii) The kentledge shall be adequately bonded, tied or otherwise held together to prevent it
collapsing, or becoming unstable due to deflection of the supports.
(iii) The weight of kentledge shall be greater than the maximum test load and if the weight is
estimated from the density and volume of the constituent materials an adequate factor of
safety against error shall be allowed.
(iv) No part of the kentledge support system shall be closer to the pile centreline than a distance
of 2.5 times the shaft diameter of the pile subject to the notice of the Employer’s
Representative.
(v) The weight of the kentledge shall be transferred in manner so that:
(1) the load is transferred symmetrically around the pile head;
(2) the suitability of the kentledge is maintained at all time, and;
(3) any tendency of the kentledge to tilt or sway is minimized.
(vi) Loads shall not be allowed to be applied by supporting the kentledge directly on the pile
or pile cap.
Tension piles and ground anchors
(i) Where tension piles or ground anchors are used the Contractor shall ensure that the load
is correctly transmitted to all the tie rods or bolts.
(ii) The extension of rods by welding shall not be permitted unless it is known that the steel
will not be reduced in strength by welding.
(iii) The bond stresses of the rods in tension shall not exceed normal permissible bond stresses
for the type of steel and grade of concrete used.
Testing equipment
(i) In all cases the Contractor shall ensure that when the hydraulic jack and load measuring
device are mounted on the pile head the whole system will be stable up to the maximum
load to be applied.
(ii) Means shall be provided to enable dial gauges to be read from a position clear of the
kentledge stack or test frame in conditions where failure in any part of the system due
to overloading, buckling, loss of hydraulic pressure and so on might constitute a hazard to
personnel.
(iii) The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under
hydraulic pressure shall be capable of withstanding a test pressure of one and a half times
the maximum working pressure without leaking.

SS1-59
(iv) The maximum test load or test pressure expressed as a reading on the gauge in use shall
be displayed and all operators shall be made aware of this limit.
(v) General requirements for load test equipment shall be as follows.
(a) Load capacity not less than the maximum required load in the schedule of testing.
(b) Adequate enough to accommodate the maximum required pile movement
specified in the schedule plus the displacement of the reaction system that occurs
during load test.
(c) Fully controlled increase or decrease in test load
(d) Fully capable of sustaining the applied load as constant for specified period of
time.
4.5.3 Presentation of Results
Results to be submitted
Results shall be submitted as follows.
(i) Unless otherwise directed the Contractor shall submit a summary of the pile test results in
writing to the Employer’s Representative, within 24 hours of the completion of the test.
This summary shall include as a minimum the following information.
1. For a proof test with maintained load for each stage of loading, the period for which
the load was held, the load and the maximum settlement or uplift recorded.
2. For Constant Rate of Penetration (CRP) or Constant Rate of Uplift (CRU) test, the
maximum load reached and a graph showing applied load versus penetration
(movement) or applied load versus uplift - movement.
(ii) Complete schedule of all recorded data shall be submitted to the Employer’s
Representative as both hard and soft copy in spreadsheet (Excel) format within seven days
of the completion of the pile test.
4.5.4 Completion of a Test
Measuring equipment
On completion of a test all equipment and measuring devices shall be dismantled, checked
and either stored so that they are available for use in further tests or removed from the Site.
Kentledge
Kentledge and its supporting structure shall be removed from the test pile and stored so
that they are available for use in further tests or removed from the Site.
Ground anchors and temporary piles
On completion of a preliminary test, tension piles and ground anchors shall be cut off
below ground level, removed from the Site and the ground made good with noticed
material.
Preliminary test pile cap
(a) The pile cap, if formed in concrete, shall be broken off and the resulting material
disposed of off the Site. If the pile cap is made of steel, it shall be cut off and stored
so that it is available for use in further tests or removed from the Site.
SS1-60
(b) For preliminary test piles which are not to be incorporated into the Permanent Works,
they shall be broken down to 2 metres below ground level or as required and backfilled
to the original ground level with suitable material. For preliminary test piles which are
to be incorporated into the Permanent Works the pile head shall be made good or
extended to the cut-off level.
Test pile cap
(a) On completion of a test on a working pile, the test pile cap, if in concrete, shall be
stripped, the pile left in a state ready for incorporation in the Permanent Works and
the resulting material disposed of off the Site.
(b) If the pile cap is made of steel, it shall be cut off and stored so that it is available for
use in further tests or removed from the Site as specified.
4.5.5 High Strain Dynamic Testing of Piles
Dynamic pile testing, which mobilizes all or part of the available pile static capacity, shall
be used where specified or required and shall be subject to the notice of the Employer’s
Representative.
4.5.6 Lateral Load Tests
Lateral load tests, where required shall be carried out using temporary plant capable of
providing an unyielding reaction of at least 1.5 times the maximum lateral load to which
the pile is to be tested. Alternatively, where tension piles of the same size and type as the
permanent piles are used for providing the reaction system for vertical load tests these may
be used for the lateral load test by jacking apart. In this case the reaction piles shall be
provided with sufficient reinforcement to sustain the effects of maximum lateral load.
4.5.7 Pile Integrity Tests
General
(i) Pile integrity testing shall be used where specified or required as a method of proof-testing
a pile as work proceeds with the aim of indirectly assessing one or more of the following.
1) The structural integrity of the pile.
2) The relative shape of the pile shaft and an estimate of the physical dimensions of
the pile or both.
3) The continuity of the pile
(ii) Pile integrity testing, when specified, shall be performed on a sufficient number of piles.
(iii) All testing shall be subject to the notice of the Employer’s Representative.
Test Procedure
(1) Where integrity testing is required, the test to be adopted shall be one of the following.
(i) Sonic impact test (SIT)
(ii) Sonic vibration test (SVT)
(iii) Alternative test, as agreed / specified.

SS1-61
Supervision and recording of results

Pile tests shall be carried out under the direction of a person experienced in the supervision
of pile integrity tests who shall record all results in both hard and electronic form in
preparation for submission to the Employer’s Representative.
4.6 DIAPHRAGM WALLING
4.6.1 General
(a) The recommendations of BS 8004 ”Code of Practice for Foundation” and DIN 4126
“Cast-in-situ concrete diaphragm walls; design and construction‟ shall be followed in
so far as they are applicable to diaphragm wall construction. Similar Indian Standards
for guidance or adoption are; IS 9556, IS 4651 and IS 456. Minimum cement content
for concrete in Diaphragm wall shall be 400 kg/m3.
(b) The Contractor shall take full account of fact that in some locations the walls may be
close to existing structures and/or within a location where headroom is limited.
(c) The Contractor shall pay particular attention to safety aspects of the work, employing
barriers and covers as necessary.
4.6.2 Diaphragm Wall Equipment – Minimum Requirement
The Contractor shall mobilize the necessary plant, equipment and tools to be able to
excavate through all types of soils and rocks indicated by the ground investigations.
The trench cutter shall be used to excavate through the rock strata and shall have
following minimum requirements.
(a) The trench cutter shall have Round shank chisel cutter wheel or equivalent
(b) Minimum Torque shall be 81 kNm
(c) Speed of rotation shall be 0 to 25 rpm
(d) Delivery Rate of mud pump 450 m3/h
(e) Weight shall be 22.5 Tons to 34 Tons
(f) The Cutter Control data including basic operational data, machine operating
parameters such as actual cutter depth, penetration rate, inclination of cutter and its
deviation is captured and recorded for post construction evaluation.
4.6.3 Method Statement
(a) The Contractor shall submit a method statement giving the full details of materials,
plant and operations involved in the construction of diaphragm walls at least 4 weeks
prior to the commencement of construction of diaphragm wall. This method statement
shall include but not be limited to the following details.
(i) Dimension of walls and lengths of panels.
(ii) Design calculation, dimensions and details of guide walls.
(iii) Formation of the joints between panels, including sealing the joints and
installation of water stop.

SS1-62
(iv) Sequence of excavation and concreting of panels.

(v) Plant and equipment such as Grab, Trench Cutter and Cranes.
(vi) Methods of monitoring and checking the stability of adjacent buildings,
structures properties, pavements, railways, services, utilities road furniture and
the like, all termed EBS.
(vii) Methods of monitoring and checking the tolerances associated with the
diaphragm wall panels using KODEN.
(viii) Methods of monitoring and checking the stability of the diaphragm wall trench.
(ix) Mixing, transporting and placing equipment for the bentonite slurry.
(x) the cleaning and re-use of bentonite slurry;
(xi) Method of disposal of contaminated bentonite slurry.
(xii) Type, source, chemical and physical properties of the bentonite to be used.
(xiii) Calculations to show that the density of the bentonite and lowest head of slurry
are sufficient to maintain the stability of the trench, in the ground conditions
envisaged, to its entire length.
(xiv) Methods of protection of any adjacent structure and utilities existing close to the
trench.
(xv) Safety precaution and risk assessment.
(b) Construction of diaphragm walls shall not commence until the Contractor’s proposals
have received a “Notice of No Objection‟ from the Employer’s Representative.
(c) Unless otherwise given notice by the Employer’s Representative, the construction of
panels shall be continuous once excavation has commenced. Excavated panels or part
panels shall not be left open at night or during weekends.
4.6.4 Levels of Work
(1) Diaphragm walls shall be concreted to the levels shown on the drawings.
(2) The effective trimmed final wall levels shall normally be taken as 250 millimetres below top
of guide wall when concrete is cast-up to top of trench. If the groundwater table is high and
if required cut-off is low and the groundwater table is also at depth, concreting can be stopped
at lower level subject to the notice of Employer’s Representative.
(3) Any remaining bentonite within the trench shall be displaced off using lean mix concrete,
which shall be poured to the top of the guide walls.
4.6.5 Length of Panels
The length of the panels to be concreted shall be defined in the Contractor's method statement
and. shall be subject to a “Notice of No Objection‟ from the Employer’s Representative.

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4.6.6 Tolerances
1. Construction shall be carried out in accordance with the following normal tolerances,
unless otherwise defined by the Contractor's drawings or procedures.
a) For straight or other specified profile panels, the minimum clear distance between
the faces of the guide walls shall be the specified diaphragm wall thickness plus
25 millimetres, and the maximum distance shall be the specified diaphragm wall
thickness plus 50 millimetres. The guide walls shall be propped as necessary, to
maintain these tolerances, and the inner guide wall shall be constructed to the line
as shown on the drawings.
b) Finished face of guide wall towards the trench shall be vertical and shall have no
ridge or abrupt changes. Variation from straight line or specified profile shall not
exceed 25mm in 3m.
c) The trench face of the guide wall on the side of the trench nearest to the
subsequent main excavation shall be vertical to within 1:200. The wall face shall
not vary from a straight line or the specified profile by more than +15 millimetres
in 3 metres and shall be without ridges or abrupt irregularities.
d) The plane of the diaphragm wall face to be exposed shall be vertical to within a
tolerance of 1:200, relative to a vertical line projected from the base of the guide
wall. In addition to this tolerance, 75 millimetres shall be allowed for
protuberances resulting from irregularities in the ground excavated beyond the
general face of the wall.
e) The ends of panels shall be vertical to within a tolerance of 1:80.
f) Where recesses are to be formed by inserts in the wall, they shall be positioned
within a vertical tolerance of ±75 millimetres, a horizontal tolerance measured
along the face of the wall of ±75 millimetres, and a horizontal tolerance at right
angles to the face of the wall as constructed of ±25 millimetres measured to the
reinforcement cage.
g) The tolerance in positioning reinforcement shall be as follows.
(1) Longitudinal tolerance of cage head at the top of the guide wall and measured
along the trench: ±75 millimetres.
(2) Vertical tolerance at cage head in relation to the top of the guide wall: ±50
millimetres.
(3) Lateral tolerance of reinforcement position in the direction across the width
of the wall; ±25 millimetres
h) The tolerance in positioning couplers and starter bars for subsequent structural
connections shall be as follows.
(1) Longitudinal tolerance measured along the trench, ±75 millimetres.
(2) Vertical tolerance, ±50 millimetres.
SS1-64
(3) Lateral tolerance in the direction across the width of panel, ±25 millimetres.
i) A minimum cover to main reinforcement shall be 75 millimetres. Minimum clear
distance between reinforcement bars shall be 100 millimetres.
j) Notwithstanding the requirements of this subsection the tolerances may be
aggregated only to the extent that they do not exceed 250 millimetres.
2. If, during the general excavation, it is detected that the above-stated tolerances have
been exceeded, the Contractor shall draw up proposals for remedying or compensating
for the defects.
The Contractor shall review the method statement for all subsequent diaphragm wall
construction.
4.6.7 Access
The Contractor shall note the restricted access to portions of the Works and shall satisfy
himself that his method of excavation, positioning of equipment, spoil handling, placement
of reinforcement cages, stop ends, and concreting can be accommodated within these
restrictions.
4.6.8 Adjacent EBS
(a) The Contractor shall be responsible for any movement, distortion or damage resulting
from his work to adjacent EBS.
(b) The Contractor shall be deemed to have made do allowance in his rates and prices for
all ancillary treatment and all work necessary to ensure the stability of all EBS that
may be affected by his work.
4.6.9 Reinforcement
(a) Reinforcement shall comply with the requirements of Section 5 of the Contract.
(b) High strength deformed steel bars and wires for concrete reinforcement conforming to
IS 1786-1985 and structural steel sections conforming to IS 800- 1984 shall be used.
(c) Structural steel sections shall be inserted into the cage where openings shall be made
at subsequent stages.
(d) All reinforcement bars and other structural steel section used shall be clean and free
from loose mill scales, dust, rust, oils, grease, paint or other coatings which may reduce
the bond with concrete.
(e) Front and rear of cages shall be marked on Site to identify them during placement and
lifting points and design of lifting lugs shall not cause distortion of the cage.
(f) Distance spacers shall be of an agreed type, capable of resisting displacement during
cage placement within the trench and shall not entrap slurry during cage placement or
concreting.
(g) The reinforcement shall be adequately fixed to avoid displacement and to maintain the
minimum specified cover during concreting.

SS1-65
(h) Welding of cold work high tensile reinforcement bars shall not be permitted as a
method of splicing cage. If permitted requirements of IS: 9417 shall be adhered to.
(i) Welding of hot rolled high tensile reinforcement bars will be permitted provided that
method is used which will not adversely affect the properties of the bar.
(j) The trench shall not be left unattended after lowering of cage and concreting shall
commence immediately.
4.6.10 Concrete
(1) Concrete shall comply with the requirements of Section 5. Structural concrete shall have a
minimum cement content as per the drawings, specifications and DAAR requirements.
(2) Minimum slump of the concrete shall be 150 millimetres and the mix shall flow easily within
the tremie pipe and be designed to produce a dense impervious concrete. Such structural
concrete shall have a minimum compressive cube strength of 40 Megapascals at 28 days and
the water: cement ratio of the mix shall not exceed 0.40 or as required by the design subject
to fulfilment of the provision in DAAR (Durability Approach and Assessment Report) by
contractor.
(3) Lean mix concrete as per IS 456-2000 clauses 5 to 8 shall be used as backfill above any cut-
off level for structural concrete and be taken to the top level of the guide walls.
(4) In order to avoid cake formation and ensure the quality of diaphragm wall the cage lowering
and concreting shall be continuous activity
4.6.11 Test Cubes
(1) Samples from fresh concrete shall be taken as per IS 1199 and tested in accordance with
Section 5.2.3
(2) Test cubes shall be taken from each trial batch at 3 nos. of cubes at 7 days and 3 nos. of cubes
at 28 days. Cubes shall be marked with the wall panel numbers and shall be sub-marked
within each panel set to indicate a location within the panel.
4.6.12 Bentonite
(1) Bentonite for use in the wall support slurry shall be in accordance with the requirements of
this Contract.
(2) The Contractor shall institute a programme of regular sampling and testing to ensure that the
bentonite fluid properties are suitable for use in the Works. In this regard IS: 9556-1980 shall
be used for guidance.
4.6.13 Storage of Bentonite
(1) Bentonite shall be stored in dry cool conditions. Particular care shall be taken with bulk
storage to prevent balling of bentonite powder due to damp, or deterioration of properties due
to damp and heat.
(2) A suitable design of hopper cone and bentonite feeding device shall be adopted. IS 4082-1996
shall be used for guidance regarding stacking and storage of construction materials and
components at site.

SS1-66
4.6.14 Alternative Materials

(1) The Contractor may, subject to the requirements of the Contract, consider and adopt suitable
additional or alternative ingredients and additives for the wall support slurry to that of the
bentonite specified above. Samples and full details shall be obtained from the supplier and
manufacturer of such ingredients.
(2) Any such materials shall have no detrimental effect upon the stability of the excavation or
concreting or formed concrete immediate as well as long term.
(3) Ingredients to counteract the loss of slurry to the surrounding strata shall be deemed covered
by this Section.
4.6.15 Placing Concrete by Tremie
(1) Tremie pipes shall be clean, water-tight and with a minimum internal diameter of 200
millimetres.
(2) The tremie tube shall extend to the bottom of the trench excavation prior to concreting and
care shall be taken to ensure that all bentonite slurry is expelled from the pipe during the
initial charging operation. The tremie pipe shall be maintained with a minimum embedment
of 2 metres into the concrete to prevent the re-entry of slurry into the pipe.
(3) The Contractor shall ensure that an adequate supply of concrete to the tremie is available at
all times so that placement is continuous until completion of the panel.
(4) The number of tremie pipes per panel shall be in accordance with the method statement.
Where more than one tremie pipe is employed during concrete pouring to any one panel, the
charging of concrete into the pipes shall be arranged so that it is evenly distributed between
the pipes and so that no differential head exists at the concrete/slurry interface over the length
of the panel. This level shall be confirmed by soundings taken during the concrete pour.
4.6.16 Stop Ends
(1) Stop-ends, inserted before placement of concrete in the panel, shall be clean and have a
smooth regular surface. Any shutter release agent shall have no detrimental effect on the
finished works. Where stop-ends are inserted in sections, adequate joint connections must be
provided to ensure verticality over the whole length.
(2) Extraction of stop-ends shall be carried out at such a time and in such a manner that no damage
is caused to the concrete placed against them, or to the adjacent soil and structures.
(3) Stop-ends shall be adequately restrained to prevent movement during concreting and not be
permanently encased in the diaphragm wall
(4) Bond between the stop end and diaphragm wall concrete shall be avoided by suitable means.
The removal of stop end shall not cause undue damage to the water bar.
4.6.17 Inserts / Couplers
Inserts shall be formed at the locations shown in the Contractor's drawings and in accordance with
his method statements and procedures. Inserts/couplers shall be boxed properly to prevent from
getting dislocated.

SS1-67
4.6.18 Checking and Monitoring

The Contractor shall provide all necessary monitoring instrumentation necessary for the close and
continuous checking of the movements and distortions of adjacent ground and EBS.
4.6.19 Safety and Emergency Procedures
The Contractor shall take all necessary precautions to ensure stability of his excavations and guide
walls and shall take all necessary precautions and be responsible for the safety of personnel in the
area of operation.
The Contractor shall maintain, available for immediate use, a sufficient quantity of slurry to allow
for any sudden loss. Should the loss continue despite the addition of the slurry and the stability of
the trench be placed at risk, the Contractor shall backfill with lean mix concrete to preserve the
stability of the trench and ensure the safety of adjacent ground and EBS. The cause of the loss of
slurry shall be investigated and works shall not recommence until remedial measures have been
implemented.
4.6.20 Site Cleanliness
The Contractor shall ensure that the Site is cleared of slurry and that surplus or displaced slurry is
disposed of safely and without nuisance. All operations shall be conducted in such a manner as to
minimise any spillage of slurry over the Site or accesses thereto.
4.6.21 Obstructions
(1) An obstruction is defined as material, the excavation of which hinders normal progress and
the existence of which could not have been foreseen.
(2) Upon encountering an obstruction, the Contractor shall determine the method to be employed
in removing the obstruction and such method shall be subject to the notice of the Employer’s
Representative
4.6.22 Disposal of Spoil
(1) Spoil removed from the excavation shall be separated from the slurry employed in the
excavation process. It shall be disposed of as quickly as possible to locations subject to the
notice of the Employer’s Representative and in such a manner that spillage and annoyance be
minimised.
(2) Contaminated slurry, not suitable for re-use, shall be removed from the Site and disposed of
in accordance with cl 4.6.25 below.
4.6.23 Joints
(1) All joints shall be fitted with a water-stop covering the full height of the wall.
(2) Where concrete is cast against previously completed wall panels, the previously formed
concrete shall be cleaned so that solid substances are removed before the joint is formed.
(3) When the joint is exposed upon subsequent excavation, the Contractor shall immediately
repair any joints which permit jetting or spraying of water or within which solid foreign
substances greater than 3 millimetres separate the concrete in adjacent panels.
(4) The walls and joints formed shall satisfy the water-tightness requirements of this Contract.

SS1-68
4.6.24 Minimum Testing Requirement

Test regime for Sonic Test, KODEN tests shall be as mentioned below.
(i) Contractor shall carry out ultra sound pulse velocity test on 20 percent of total number
of diaphragm wall concrete panels. The selection of panels for testing is subjected to
approval of the Engineer.
(ii) Provision in the form of PVC pipes shall be left for all panels of first 20 percent, if the
quality is meeting the requirements pipes to be provided for 20 percent of balance panels.
The test report shall be submitted to Engineer for Notice.
4.6.25 Records
(1) The following records shall be maintained and kept for each wall panel and such records shall
be available for inspection by the Employer’s Representative.
(i) Name of work.
(ii) Panel No and reference drawing number.
(iii) Date and time of start and finish of panel excavation.
(iv) Details of any obstructions encountered; time spent, and construction method adopted
in overcoming such obstructions.
(v) Date and time of completion of cage placement.
(vi) Date and time of start and completion of panel concreting;
(vii) Length of panel and width and depth of panel from top of guide wall
(viii) Top of guide wall level and densities;
(ix) Top level of wall as cast, in relation to top of guide wall at the edges and at the centre.
(x) A log of soil type encountered from start to finish of excavation, and of slurry levels and
densities.
(xi) Volume of concrete used and time of any interruptions in concrete supply where these
exceed 15 minutes.
(xii) Volumes of normal and lean mix concrete.
(xiii) Cut-off level of concrete below top of guide wall level.
(xiv) Date, place and time of slurry control tests and results recorded.
(xv) Concrete test cubes, w/c ratio, slump markings, date and results obtained on testing.
(xvi) Details of reinforcement and cage type.
(xvii) Quantity of slurry removed from Site and spoil removed from Site recorded by date.
(xviii) A graph of theoretical and placed concrete volumes with depth.
(xix) KODEN test record

SS1-69
(xx) Sonic Logging test record

4.6.26 Disposal of Slurry
Used bentonite or contaminated slurry not suitable for re-use shall be disposed of in water-
tight containers. The Contractor may propose alternative means of disposal which shall be
subject to the notice of the Employer’s Representative.
5 STRUCTURAL CONCRETE: PLAIN, REINFORCED AND PRESTRESSED
5.1 CONCRETE MATERIALS
5.1.1 General
(1) This work shall comprise the construction of all or portions of structures with Ordinary
Portland Cement (OPC) concrete, of the required class or classes, with or without
reinforcement, with or without admixtures, constructed in accordance with the Contract and
the relevant Standards to the lines, levels, grades and dimensions shown on the Drawings.
Any proposal by the Contractor to partially substitute any cementitious materials such as fly
ash, ground granulated blast furnace slang or silica fume for Portland cement shall be
submitted for Engineer’s Notice. The Contractor shall not change the cement brand or source
of any approved cementitious material until he has obtained permission in writing from the
Engineer prior to change.
(2) Constituent materials for the concrete mix shall comply with the requirements of IS:456 or
BS EN 206-1 & BS8500 with a minimum cement content of 360 kg/m3, unless otherwise
given notice by the Employer’s Representative.
(3) Use of fly-ash, granulated blast furnace slang or silica fume is permitted only if the contractor
shall demonstrate adherence to the approved Quality Assurance procedures including sources
of fly ash, granulated blast furnace slang or silica fume, the tested and expected properties,
handling as per the relevant IS: 3812 (Part I & II) & International codes, etc., and used only
after a “no objection”” has been obtained from the Engineer.
(4) Ordinary Portland cement (OPC) of 43 grade and 53 grade conforming to IS 8112 and IS
12269 respectively shall be used. Portland pozzolana cement (PPC) conforming to IS 1489
of grades 43 & 53 can also be used. The Employer’s Representative may direct the usage of
sulphate resistant Portland cement conforming to IS 12330 for structural elements exposed to
soil having sulphates as specified under Clause 5.1.2 (1). For sulphates, chlorides and pH
contents in soil and ground water the geotechnical factual report shall be referred. In all cases
the cement shall meet the 28-day strength requirement of IS 8112-1989 or IS 12269-1987.
Portland Slag Cement (PSC) shall conform to IS: 455.
(5) All the sources of the materials shall require Engineer’s Notice of No Objection in advance
before bringing to the site. All materials for making concrete shall also require Engineer’s
Notice of No Objection. A sample of material shall be deposited in the office of the Engineer
before placing orders for the materials with suppliers. The materials brought on to the works
shall conform in every respect to their samples and specifications which shall have Notice of
No Objection.

SS1-70
(6) Fresh samples shall be deposited with the Engineer whenever type or source of any material
changes. The Contractor shall check fresh consignment of materials as it is brought on to the
works to ensure that they conform to the specifications.
(7) Testing and non-conformances affecting the standard of the concrete shall be notified to the
Employer’s Representative in-line with the Quality Assurance (QA) procedure such that
mitigation may be effected expeditiously within the critically defined timeframes.
(8) The Engineer shall have the option to have any of the materials tested to find whether they
are in accordance with specifications at the Contractor's expense. All bills vouchers and test
certificates which in the opinion of the Engineer are necessary to convince him as to the
source and quality of materials or their suitability shall be produced for his inspection when
required.
(9) Any materials which have not been found to conform to the specifications and/or without
Notice of No Objection by the Engineer shall be rejected forthwith and shall be removed from
the site by the Contractor at his own cost within the time stipulated by the Engineer. The
Engineer shall have the powers to cause the Contractors to purchase and use materials from
any particular source, as may in his opinion, are necessary for the quality execution of work
5.1.2 Cement
(1) General
a) Unless otherwise described in the contract, Ordinary Portland cement, of the grade specified
by the designer, conforming to relevant Indian standard or BS 12 or other equivalent standard
shall be used from approved manufacturing suppliers.
b) Silica Fumes may also be used as a part replacement of cement to improve durability. The
proportion of Silica Fumes shall be subject to approval of the Engineer.
c) The cement will be blended with processed fly-ash, granulated blast furnace slang or silica
fume conforming to IS specifications
d) If soil has soluble salts in excess of 0.5%, sulphate-resistant cement shall be used conforming
to IS12330 (or BS 4027), or total chloride content in cement shall in no case exceed 0.05
percent by mass of cement. Also, total sulphur content calculated as sulphuric anhydride
(SO3), shall in no case exceed 2.5%and 3.0% when tri-calcium aluminate per cent by mass is
up to 5% or greater than 5% respectively
(2) Testing
a) Cement shall be certified by the manufacturer as complying with the requirements of the
relevant Standard. The Contractor shall submit to the Employer’s Representative the
manufacturer's QA forms to demonstrate that the cement complies with relevant standards.
b) With each and every delivery of cement the Contractor shall provide manufacturer’s
certificate that the cement conforms to the relevant Indian standard. The Contractor shall
provide complete facilities at site for carrying out the following tests:
• Setting time by Vicat's apparatus as per IS: 4031 and IS: 5513
SS1-71
c) Compressive strength on cement as per IS: 4031, IS: 650, IS: 10080.
d) Before ordering cement, the Contractor shall submit relevant QA details on the proposed
supplier and methods of transport, storage and certification to the Employer’s
Representative’s for notice to proceed (HOLD POINT). It must be proven that the quantity
and quality required can be attained and maintained throughout the construction period.
e) Representative samples of the proposed cement may be required to be taken and forwarded
to an independent laboratory for analyses before the source is noticed. If cement is imported,
fresh tests as per the relevant Standards shall be conducted in a noticed laboratory.
f) Subsequent to obtaining the Employer’s Representative's notice. the Contractor shall not
change the agreed arrangements without the prior notice by the Employer’s Representative.
Each consignment of cement shall be accompanied by a certificate which shall be submitted
to the Employer’s Representative immediately on delivery, substantiating the place of
manufacture and the results of required testing carried out on the batch.
g) The Contractor may be required to sample cement and test such samples in accordance with
the relevant or equivalent Indian Standards. The Contractor shall store the cement so that
separate consignments can be identified and used in order of delivery to site (first-in, first-out
process). In no circumstances shall cement that has exceeded its „use-by‟ date be allowed as
part of the concrete mix.
h) Xx The temperature of the cement when added to the mixer shall not exceed 40° C unless
otherwise agreed by the Engineer.
i) All cement and cement extenders used in the Works shall be tested by the manufacturer or
the Contractor in a laboratory which has Engineer’s Notice of No Objection. Copies of all
test results so obtained shall be delivered to the Engineer before the cement and cement
extenders are incorporated in concrete. All cement extenders used shall comply with the
appropriate Indian standards for Fly Ash (FA) or Condensed Silica Fume (CSF) respectively
as detailed above.
j) The Contractor shall keep full records of all data relevant to the manufacture, delivery, testing
and use of all cement and cement extenders used in the Works and shall provide the Engineer
with two copies thereof.
k) If the Contractor proposes to use Ordinary Portland Cement, he shall only do so by blending
it with a noticed cement extender that has been issued Notice of No Objection by Engineer.
Blending of Ordinary cement with an extender may be done, in the batch plant, or at a
commercial blending plant.
l) Each set of tests carried out by the manufacturer or Contractor shall relate to not more than
one day's output of each cement plant and shall be made on samples taken from cement which
is subsequently delivered to the Site. Alternatively, the frequency of testing shall be one set
of tests for every 200 tonnes of cement delivered to Site from each cement plant.
m) Xx Cement and cement extenders which are older than 120 days from date of grinding shall
be retested in a laboratory which has Engineer’s Notice of No Objection at the rate of one set
SS1-72
of tests for every 200 tonnes or as otherwise directed by the Engineer and at monthly intervals
thereafter
(3) Cement Delivery and Storage
a) Cement shall be delivered in bulk or in the original manufacturer's sealed and marked bags
and shall be protected from the weather by enclosed transfer systems or other noticed
coverings. The Contractor shall provide silos to store sufficient bulk cement for continuity of
work, and cement shall be placed therein upon delivery.
b) All necessary precautions shall be taken to prevent cement dust causing a nuisance.
c) On receipt of notice from Employer’s Representative cement that has been damaged or does
not comply with the Contract requirements shall not be used in the Works and be removed
from the Site within 3 days of the Contractor's receipt of such notice.
5.1.3 Aggregate
Aggregate Sources
Prior to commencing any concrete work, the Contractor shall obtain the Employer’s
Representative's notice for the proposed types and sources of aggregate. Sampling of
aggregates shall be as per IS 2430. Aggregates from natural sources shall be in accordance
with IS: 383. The Contractor shall submit to the Engineer certificates of grading and
compliance for all consignments of aggregate for Notice of No Objection. In addition, at site
from time to time, the Contractor shall allow for carrying out such tests and for supplying test
records to the Engineer
Coarse Aggregates
a) Coarse aggregate for all classes of concrete shall conform to the requirements of IS 383. It
shall be furnished in two separate sizes; either the 20 millimetres down and or the 38
millimetres down to No. 4 as required by the Standard. The coarse aggregate shall be
crushed stone, natural gravel or a suitable combination thereof Coarse aggregate obtained
from crushed or broken stone shall be angular, hard, strong, dense, durable, clean and free
from soft, friable, thin plate, elongated or flaky pieces and any deleterious material.
b) Physical tests for suitability shall be carried out in accordance with IS 2386 or Parts I to
VIII or British equivalent standards.
c) Coarse aggregate shall be clean, free from dust and other deleterious material. For
reinforced and pre-stressed concrete aggregate shall be well- graded and durable with
nominal 20-millimetre sized stones.
d) Hand-broken stone may be used providing such complies with the Contract requirements.
e) Water absorption shall be less than 3% by weight (ASTM C 128)
Fine Aggregate
a) Fine aggregate shall conform to the requirements of IS 383 or as required to meet the design
requirements.
b) The Contractor shall provide complete facilities at site for determining grading of
aggregates by sieves as per IS: 383, IS: 460, IS: 1607, and IS: 2386.

SS1-73
c) To achieve an acceptable particle, shape the fine aggregate shall be manufactured using
crushers specially adapted (Rollobar or similar) to suit the type of material available. Stone
dust or grit from the stone quarries should not be considered as of acceptable quality.
d) It shall be free from clay, loam, earth or vegetable matter, salt or other harmful chemical
impurities. It shall be clean, sharp, strong, angular and composed of hard siliceous material.
e) The fine aggregate shall be river sand, manufactured sand of appropriate grading. Sand
dredged from sea, creeks will not be used. Sand shall be washed and screened to remove
any organic matter and clay. RMC manufactured with sand dredged from sea/creek will not
be used.
f) The grading of fine aggregate when determined as described in IS: 2386 (part I), shall be
within the grading zones I, II, III. As per IS 383: 1970 it is recommended find aggregate
confirming to grading zone IV should not be used in reinforced concrete unless test have
been made to ascertain the suitability of mixed proportion. When concrete of high strength
and durability is required fine aggregate confirming to any of the four grading zones may
be used, but the concrete mix should be properly designed.
g) The Contractor shall provide complete facilities at site for carrying out the following tests:
h) Proportion of clay, silt and fine dust by sedimentation method as per IS: 2386 part II.
i. Moisture content in fine aggregate as per IS: 2386 Part III.
ii. Bulk density / Bulkage.
iii. Specific Gravity
i) Water absorption shall be less than 3% by weight

(4) Alkali-Silica Reactivity (ASR)
(i) If aggregates contain materials which have been tested to show chemical reactivity with
alkalis found in any of the constituents of the concrete mix, or in water which will be in
contact with the finished work, then the Contractor shall take samples of these materials
every week.
(ii) The Contractor shall ensure that the concrete mix complies with the requirements of this
Contract regarding "Minimising Risk of Alkali-Silica Reaction in Concrete”,
(Section5.1.7)
(iii) The results of the Contractor's weekly ASR monitoring tests shall be submitted in writing
to the Employer’s Representative for his notice
(iv) The minerals present should be determined in accordance with ASTM C294 and C295 on
a range of samples selected to include every mineral type present in the aggregate as a
whole irrespective of the proportion of the mineral.
(v) The aggregate shall be kept clean at all times. The sand equivalent when tested in
accordance with ASTM D2419 of the fine aggregate shall be greater than 80. The sand
equivalent of the zero to 4.75 fractions of all aggregates shall be greater than 75.
SS1-74
(vi) Ethylene glycol tests shall be carried out by the Contractor. Petrographic examination shall
be carried out in accordance with ASTM or standard procedures to identify the minerals
present and in particular the percentage of clay minerals.
(5) Chloride Content
(i) The chloride content of aggregates shall be within the recommended limits stated in IS
383 or BS 882.
(ii) The chloride content of the concrete mix shall be within the recommended limit of IS 456
or BS 8110.
(iii) Chloride levels shall be determined daily in accordance with the methods described in BS
812.
(6) Sulphate Content
The total acid soluble sulphate content of the concrete mix, expressed as SO3, shall not exceed
the recommended limits in IS 456 or BS 8110.
(7) Storage
(i) All aggregates shall be stored in such a way that they shall be kept free from contact with
deleterious matter.
(ii) All aggregate shall be shaded from direct sunlight by means of a roof of sufficient height
to enable unimpeded access to plant. Spraying of aggregate stockpiles with water shall be
undertaken as necessary.
(iii) Aggregate of different sizes shall be stored separately shall be stored in masonry or
concrete-based bins or on stages to prevent intermixing, segregation and the inclusion of
dirt and foreign materials. Storage bins shall be emptied and cleaned regularly. All
aggregate hoppers shall be painted white.
(8) Blending of aggregates
In order to obtain optimum workability, individual aggregates of nominal size 40mm, 20mm,
10mm, 4.75mm and 2.36mm will be blended in such a way that the grading curve for all
aggregates will be a smooth curve from size 0.15mm to 40mm falling within the established
envelop grading curve. Contractor shall establish envelop grading curve for each grade of
concrete for given maximum size of aggregates for Notice of No Objection before finalising
the mix design.
(9) Testing
(i) Acceptance Testing
As soon as the first aggregates have been produced to stockpile the Contractor shall carry
out tests. The method of sampling shall be in accordance with IS: 2430. The amount of
material required for each test shall be as specified in the relevant method of test given
in IS: 2386 (Part I) to IS: 2386 (Part VIII). All tests shall be carried out as described in
IS: 2386 (Part I) to IS: 2386 (Part VIII).

SS1-75
If at any time a significant physical or chemical change in the nature of the coarse or fine
aggregate occurs, or a new source of aggregate is used, and the Engineer may direct that
some or all of the acceptance testing is repeated.
(ii) Routine Testing
The Contractor shall carry out routine testing of aggregates for compliance with the
Specification during the period in which concrete is being produced for the Works. The
tests set out below shall be performed on aggregates from each separate source on the
basis of one set of tests for each day on which aggregates are delivered to the concrete
batching plant provided that no set of tests shall represent more than 250 tonnes of fine
aggregate nor more than 500 tonnes of coarse aggregate, and provided also that the
aggregates are of uniform quality. If the aggregate from any source is variable, the
frequency of testing shall be as instructed by the Engineer.
5.1.4 Reinforcement
Steel for Reinforcement
(i) Only thermo-mechanically treated reinforcing bars of grade Fe 415/500 with minimum
total elongation of 14.5% conforming to IS 1786-1986 shall be supplied and used as steel
for reinforcement.
(ii) All reinforcement bars shall be procured from main steel suppliers and re- rolled steel shall
not be used under any circumstances.
(iii) All reinforcement work shall be executed in conformity with the drawings and carried
out in accordance with relevant standard specifications IS: 2502 Bending and Fixing of
bars for concrete reinforcement.
Binding/Tying Wire
Tying wire shall be finally annealed mild steel of core diameter approximately 1.25
millimetres or as specified by the Contractor.
Testing & Inspection
(i) The Contractor shall provide copies of the manufacturer's certificates of tests results
relating to the steel reinforcement to be supplied, and independent test results obtained
from a noticed laboratory in respect of samples taken from reinforcement delivered to the
Site.
(ii) Every bar shall be inspected before assembling and any defective, brittle excessive rusted
or burnt bar shall be removed. Cracked end of bars shall be cut-out.
Storage
(i) Steel reinforcement shall be stored above ground, on timber supports or on a concrete
slab, under cover and racked as necessary for protection.
(ii) Stored steel shall not be at any time in direct contract with the ground, floor, slab or racks.

SS1-76
(iii) Any reinforcement which is likely to remain in storage for long period shall be protected
from the weather as to avoid corrosion and pitting. All reinforcement which has become
corroded or pitted to the extent, which in the opinion of the Engineer will affect the
properties shall be removed from site without any delay.
5.1.5 Water
General
The Contractor shall make his own arrangements and procure fresh potable water for the
mixing and curing of concrete. Testing of such water shall be in accordance with IS 3025.
Quality
Water to be used for mixing and curing concrete and mortar shall be fresh and free from
dissolved or suspended matter which may be harmful and shall comply with the
requirements of IS 456.
Water samples from the intended source of supply shall be taken for analysis before any
concrete work is commenced, and shall be tested in accordance with BS EN1008 and
shall be submitted to Engineers Notice. The frequency of testing shall be as follows:
Potable water
no testing;
Water recovered from processes in the concrete industry (as defined in A.2.1
of BS EN1008)
test in accordance with annex A of BS EN1008;
Water from underground sources, natural surface water and industrial waste
water.
test before first use and thereafter monthly until such time that a clear insight in
the fluctuation of the water composition has been established. Thereafter a lower
frequency may be adopted;
Where potable water supply is not available the Contractor shall obtain confirmation of
quality and reliability of a proposed source from the appropriate Water Authority and
shall test the water for its chemical and other impurities before its use in the Works. Cost
of all such tests shall be borne by the Contractor.
5.1.6 Admixtures
General
(i) The Employer’s Representative’s notice shall be obtained prior to using any admixture
in any concrete mix. The minimum cement content specified shall not be reduced on
account of use of admixtures.
(ii) Admixtures shall conform to IS: 9103 or BS 5075 and BS 1014.
(iii) Admixtures containing chlorides or other potential corrosive agents shall not be used.

SS1-77
Quality
(i) If admixtures are permitted these shall be used in the correct quantities. Noticed
equipment and methods shall be used for dispensing and incorporating the admixture in
the concrete; the dispensing unit shall be designed so that the discharge of the admixture
is visible.
(ii) The concrete tests described herein shall be conducted with the admixture incorporated
to establish that specified strengths are achieved, and that densities are not reduced. If air-
entraining agents are used the density shall not be reduced by more than 5%.
(iii) Set-retarding and water-reducing admixtures shall comprise ligno-sulphonate.
(iv) Air-entraining agents shall comprise neutralized vinsol resin.
(v) The manufacturer's declared equivalent acid soluble alkali content and the dosage rate of
any admixture or pigment to be incorporated shall be included with details of all concrete
mixes
(vi) The alkali content of admixtures shall be taken into account when determining the total
equivalent alkali content of the concrete mix.
5.1.7 Minimising the Risk of Alkali-Silica Reaction (ASR) in Concrete
(i) Concrete mixes for use in the Permanent Works shall comply with the Contract. The
Contractor shall notify the Employer’s Representative of his proposals for complying
with this requirement.
(ii) The materials shall satisfy one of the following requirements.
The reactive alkali content shall not exceed a maximum value of 0.6% by mass
when defined and tested in accordance with this Contract.
The total mass of reactive alkali in the concrete mix shall not exceed 3 kg/m3 of
concrete when defined, tested and calculated in accordance with this Contract.
The aggregate shall be classed as non-reactive in accordance with this Contract.
(iii) Cementitous Material (Hydraulic and Latent Hydraulic Binders):
The term alkali refers to the alkali metals sodium and potassium expressed as their
oxides. The reactive alkali content of Portland cements shall be defined as the
percentage by mass of equivalent sodium oxide (Na2O) calculated from the
following relationship.
% equivalent Na2O = % acid soluble Na2O + 0.658 x (% acid soluble K2O)
The method used in determining the acid soluble alkali content of the materials
shall be in accordance with BS 4550: Part 2: Subsection 16.2.
The Contractor shall make available the certified average acid soluble alkali
content of Portland cements on a weekly basis.
The Contractor shall give immediate notice of any change which may increase the
certified average acid soluble alkali content above the level used in the mix design
SS1-78
for the concrete. A revised mix design for any concrete which would be affected
by the increased alkali content shall be submitted to the Engineer’s Representative
for his notice with notification of the change.
(iv) Minimising risk by use of cementitous material containing less than 0.6% of reactive
alkali.
These requirements shall be met provided the contribution of alkalier from other
source does not exceed 0.2 kg/m3.
The cementitous material shall be Ordinary Portland Cement (OPC) complying
with Indian Standards and shall have additionally a certified maximum acid
soluble alkali content not exceeding 0.6%. The Contractor shall provide on request
weekly certificates which name the source of the cement and confirm compliance
with the Contract.
Minimising risk by limiting the reactive alkali content of the concrete to 3 kg/m3.
The reactive alkali content of the concrete contributed by OPC to the concrete
shall be calculated from:
A = C x a/100
Where,
A = reactive alkali content of the concrete to the nearest 0.1 (kg/m3)
C = target mean Portland cement content of the concrete (kg/m3)
a = certified average acid soluble alkali content of OPC (%)
Where reactive alkalis in excess of 0.2 kg/m3 are contributed to the concrete from
sources other than the cementetious material, the limit of 3 kg/m3 from the
cementetious material shall be reduced by the total amount so contributed. The
reactive alkali contributed by sodium chloride contamination of aggregates shall
be calculated from:
H = 0.76 x {(NFxMF)+(NCxMC)} per 100 Kg/m3 where
H = equivalent alkali contribution made to the concrete by the sodium chloride
NF = chloride ion content of the fine aggregate as a percentage by mass of dry
aggregates and measured according to BS 812: Part 4
MF = fine aggregate content (kg/m3)
NC = chloride ion content of the coarse aggregate as a percentage by mass of
dry aggregate and measured according to BS 812: Part 4: 1976 (now in draft as
Part 117)
MC = coarse aggregate content (kg/m3).
The factor 0.76 is obtained from a consideration of the composition of seawater.
The chloride ion content of aggregate sources containing 0.01% of chloride ion
by mass or more shall be determined weekly in accordance with BS 812 or
another noticed method. When the chloride ion level is less than 0.01% it shall
be regarded as nil.

SS1-79
(v) The Contractor shall provide certificates on request confirming compliance with the
Contract which state the following.
a) The target mean cementetious material content of the concrete.
b) The names of the works manufacturing the cement.
c) A weekly report of the cement alkali determinations.
d) The certified average acid soluble alkali content of OPC.
(vi) Minimising the Risk by Using Selected Aggregates
a) Fine and coarse aggregate material shall comply with the requirements of IS 383
and/or AASHTO Standard Specifications M6 and M80 respectively) to be taken out
to conform to 512(2).
(vii) Water
a) Water for use in the manufacture of concrete shall be obtained from a public utility
supply or from a source noticed by Employer’s Representative.
b) Water shall be potable and comply with the requirement of IS 456 and or BS 3148
c) Where potable water supply is not available the Contractor shall obtain confirmation
of quality and reliability of a proposed source from the appropriate water authority test
the water for its chemical and other impurities before using. Cost of all such tests shall
be borne by the contractor.
5.2 CONCRETE WORKMANSHIP
5.2.1 Grade
(1) Mixes General
Concrete shall be provided in accordance with IS 456 or BS 5328 except where required
otherwise by this Contract.
(2) Concrete Mixes
The concrete mixes to be used in the Permanent Works shall be tabulated in the form in a
typical “Table of Concrete Mixes” as given below.
TABLE OF CONCRETE MIXES
(to be completed by the Contractor)
Description used on Drawings
Type of Mix
Type of Cement.
Type of Aggregate.
Coarse -
Fine -
Nominal Aggregate maximum size (mm)
Grade -
Minimum cement content (kg/m3)
Sampling rate (cubic metres) - 28-day normal curing

SS1-80
- 7-day normal curing

Workability - Slump (millimetres)
Compacting
Maximum free water/cement ratio
Maximum cement content (kg/m3)
Special cement
Special aggregate Coarse:
Fine:
Fine aggregate (%)
Admixtures Specified:
Prohibited:
Amount:
Air content
Temperature of Fresh concrete (°C)
Maximum:
Minimum:
Density of Concrete (kg/m3)
Maximum:
Minimum:
(3) Chlorides
The total chloride content of the concrete mix shall be in accordance with the limitations
given in IS 456 or BS 8110
(4) Sulphates
The total water-soluble sulphate content of the concrete mix shall not exceed the limitations
given in IS 456 or BS 8110.
5.2.2 Trial Mixes
(1) Laboratory Trials
a) Concrete shall be proportioned to provide an average compressive strength; namely a
specified characteristic strength plus a standard deviation factor; in accordance with
acceptance criteria given in IS: 456 or relevant British Standard.
b) Not less than 35 days before commencement of concreting, the Contractor shall carry out
trials to determine the concrete mixes which will satisfy the requirements of the Contract.
The materials and conditions used shall reflect those intended to be used for the Works. A
minimum six test cubes shall be made from each of three consecutive batches with three
cubes from each batch to be tested at 7 days and three cubes at 28 days.
c) If the average 28-day strength (being defined as the measured stress when the cube fails)
exceeds the specified characteristic strength by 20% or more, and the other requirements
of IS 456 and IS 10262 or BS 5328 are met, then the trial mix proportions may be used to
commence the Permanent Works. Otherwise further trials shall be carried out using re-
designed mixes until the minimum required strength is achieved.
d) Additional Requirements of trial mixes shall be tested to determine the following
properties of mixes proposed for initial field tests.
(i) Bleeding in accordance with ASTM C232.
SS1-81
(ii) Drying shrinkage in accordance with BS 1881.

(iii) Air content, if applicable.
(iv) Free water/cement ratio.
(v) Workability.
(vi) Wet and dry densities.
(vii) Indirect tensile strength in accordance with BS 1881 including cylinder - splitting and
beam tests.
e) If the test results obtained do not satisfy the Contract or the design requirements, the mixes
shall be re-designed.
(2) Initial field tests
Trial mixes shall be prepared under full-scale site conditions and tested in accordance
with IS 10262 or BS 1881.
Samples of concrete incorporating the reinforcing details to be used shall be cast and
examined, before hardening using hand tools, and after hardening by coring to assess
the mixes. Cores shall be 150 mm diameter by 200 mm long.
5.2.3 Quality Control
(1) Test cubes
Cubes shall be manufactured in an on-site laboratory, specially equipped for the purpose,
in controlled conditions. They shall be made, cured, stored, transported and tested in
accordance with IS 516 and BS 1881.
The cube-testing machine shall be housed in a laboratory and calibrated to BS 1610
when delivered. The machine calibration shall be verified at 3- monthly minimum
intervals by a testing authority having National Accreditation Board for Testing and
Calibration Laboratories (NABL) Certification.
(2) Cubes samples
A sample of concrete shall be taken at random on eight separate occasions during each
of the first five days of using a mix. The standard deviation shall be calculated from at
least 25 individual cube results each representing separate batches of similar concrete
produced by the same batching plant under the same supervision. The margin for the
concrete batching plant shall be 1.64 times the standard deviation.
Thereafter one sample shall be taken at random for each class of concrete from every
group of 25 batches made by each concrete batching plant, and at least one sample shall
be taken each day that concrete of a particular grade is made. Samples shall also be
taken, and two cylinders cast to determine the indirect tensile strength of the concrete at
7 days and 28 days, as specified in relevant IS code or BS 1881.
These samples shall be taken from every 100 batches, but at least once a week during
concreting operations, and shall coincide with samples taken for test cubes. The
frequency of sampling may be required to be varied.
SS1-82
In addition to the above requirements, at least one sample shall be taken from each
individual structural unit, or part of a unit, when the latter is the product of a single pour.
From each sample two cubes shall be made for testing at 28 days and one for testing at
7 days for control purposes. The 28-day Concrete Cube Strength (CCS) shall be the
mean of two cubes. The procedures shall be repeated when materials or design mixes
are changed.
The procedures shall be repeated when materials or design mixes are changed.
(3) Cube Strength Results
The results will be unacceptable if:
(i) the average strength determined from any four consecutive test cubes does not
exceed the specified CCS by 0.5 times the current margin, or;
(ii) one or more values in forty is less than 85% specified CCS, or;
(iii) three or more values in forty are less than specified CCS;
In which case any of the following actions may be instructed.
a. Change the mix.
b. Improve quality control.
c. Cut and test cores from placed concrete.
d. Load-test relevant structural units.
e. Carry out non-destructive tests on as placed concrete.
f. Cut-out and replace defective concrete.
If the range of individual cube strength made from the same sample exceeds 15% of the
mean then the method of making, curing and testing cubes shall be checked.
In the event of a result having a range exceeding 20% the Contractor shall submit his
proposals corrective action for notice by the Employer’s Representative. c) The
Contractor shall cut concrete cores from as-built locations as may be required by the
Employer’s Representative and test them to BS 1881 as modified by Concrete Society
Report TR 11. If the values, reduced by 0.69 Mega Pascal per week of age in excess of
28 days, are less than 75% CCS, the concrete shall be cut out and replaced unless
otherwise agreed with the Employer’s Representative.
(4) Concrete durability and Other tests
(a) Concrete shall be tested for drying shrinkage, water absorption and moisture
movement as directed for which 102 mm cubes and 76 mm by 76 mm prisms shall be
prepared and tested in accordance with BS 1881.
(b) The acceptance limits are as follows.
(i) Water absorption: 3% absorbed after 10 minutes;

SS1-83
(ii) 6.5% absorbed after 24 hours.

(iii) Drying shrinkage: 0.05%
(iv) Moisture movement 0.03%
(c) Cubes may be required, and trials carried out to determine stripping times for
formwork, the duration of curing and to check-testing and sampling errors. The air
content of air-entrained concrete shall be determined for each batch produced until
consistency has been achieved, when fewer batches may be tested.
(d) During concreting of the Permanent Works six 150 mm diameter by 200 mm long
cores shall be cut through horizontal reinforcement to assess plastic qualities. The
qualities shall be equal to those obtained in the initial field tests.
(e) Compaction factor, slump, or other workability tests shall be carried out as required
during concreting of Permanent Works to control workability at the batching plant at
the site of the pour. The degree of workability shall be as for the trial mixes; permitted
tolerances shall be in accordance with IS 1199 or BS 5320.
(f) Tests shall be carried out at least daily for the moisture content and weekly for
absorption value of the aggregate. The values for the aggregate at the mixer shall be
determined and changes made to the mix to compensate for variations.
(5) Concrete Durability Tests: Acceptance Criteria
Concrete
Acceptable Values References
Durability Tests
RCPT(Coulombs) <700 (28 days) ASTM C1202
ASTM C642 & BS1881-

Water Absorption 1.50%
122
0.2 to 0.3% by wt of ACI 301 & ASTM C1218,
Chloride Content
cement EN 206-1
Concrete
Acceptable Values References
Durability Tests
Sulphate Content 3% BS1881-124
Water Permeability <10mm DIN 1048 & BS EN 12390
Initial Surface
Absorption Test 0.25ml/m2/sec BS 1881- 208
(ISAT)
Concrete of permanent structures shall fulfil the above mentioned minimum values.
SS1-84
TEST FREQUENCY
The frequency on the 150mmX150mmX150mm sized cubes cast and cured in similar fashion
shall be as follows:
(i) RCPT-1 Test per 500 cum. Concrete cast; Three such test initially
(ii) Permeability - 1 Test per 500 cum (PENETRABILITTY=10mm as per DIN-1048-5
concrete cast); three such test initially.
(iii) After all the above mentioned test results are satisfactory then one test for every 200
cum of concrete cast.
(iv) Permeability of co-efficient of base slab is 5X10-13 m/sec confirming to IS 3085-
1985-R-2002; Three such test initially.
For the concreting in permanent structures like ADITS, Shafts etc., where the total concreting
is less than 1000 cum the above frequency shall be one test for 200 cum of concreting.
(6) Scheme for monitoring

(i) Monitoring shall be carried out in accordance with the relevant Standards, as
implemented under the requirements of ISO 9002.
(ii) Compliance of the concrete and associated work to required levels of performance
shall be captured in the monitoring regime.
(iii) The scheme implemented shall be subject to the notice of the Employer’s
Representative and undergo regulatory QA checks to ensure the levels of competence
in monitoring are being consistently adopted and undertaken in the Works.
5.2.4 Batching
Machinery
Batching shall be by weigh-batching machines equipped with accuracy checks for the
weighing mechanism. The machines shall be cleaned, checked and adjusted regularly. The
water supply to the concrete mixers shall have a metering system to control and record the
amount.
Accuracy of Batching
Batched materials shall be measured to the following tolerances and discharged into the mixer
without loss.
(i) Cement ± 2% of the weight of the cement in the batch.
(ii) Aggregate ± 2% of the weight of each aggregate in the batch.
(iii) Water ± 2% of the weight of water added to the batch.
(iv) Admixture ± 5% of the amount to be added to the batch.
Calibration of Measuring Equipment
(a) Measuring equipment shall be checked and calibrated at the start of preliminary
concrete tests and at weekly intervals. The necessary test weights and the like shall be
kept available on site. Scales shall be checked over their complete range by a specialist
every three months.
SS1-85
(b) A calibrated container shall be used to check the accuracy of admixtures dispensers
once each month. The results of these checks shall be notified
Mixing
Concrete constituents shall be thoroughly mixed in batches. The machines shall be capable
of discharging while running.
Ready-Mixed Concrete
a) Ready-mixed concrete shall not be used unless noticed and shall comply with the
requirements specified herein and those of IS:4826 and BS 5328.
b) The supply and use of ready-mixed concrete shall be subject to the Contractor's QA
procedures.
c) Ready-mixed concrete shall be obtained from a depot subject to the notice of the
Employer’s Representative. and transported to the Site in truck type mixers which shall
continuously agitate the concrete mix.
d) The concrete shall be placed in its final position and compacted within 2 hours of the
introduction of cement to the aggregates.
e) The ready-mixed concrete delivered to the Works shall comply with this Specification.
One cubic metre of each mix shall be supplied to Site before it is required in the Works to
allow the Contractor to carry out workability tests.
f) The supply and delivery of the ready-mixed concrete shall comply with the
recommendations of IS:4826 BS 5328
g) For plant-mixed concrete the delivery note for each batch shall state the time at which the
concrete was mixed and the weight of the constituents of each mix.
h) When truck-mixed concrete is used, water shall only be added under the Contractor’s
direct supervision either at the Site or at the central batching plant in accordance with the
standard Quality Procedures. In no circumstances shall extra water be added to the
concrete after the original mixing is complete.
i) Samples for testing shall be taken as the concrete is placed in its final position.
j) The Contractor shall arrange for the ready-mix concrete supplier to provide the facilities
stated in BS EN 206-1 & BS8500.
Records
a) Daily returns shall be provided showing the quantities of cement and the total volume
batched of each class of concrete for each section of the Works.
b) The Contractor shall submit detailed records and test results for all test cubes and
specimens taken without delay to the Employer’s Representative for his notice.
5.2.5 Control of Chlorides and Sulphates
(i) Chlorides in Concrete
a) The levels of equivalent acid-soluble chlorides as NaCl (Cl x 1.65 = NaCl) in the
constituents of concrete as stated elsewhere are indicative and are subject to the over-riding
SS1-86
limits for the mixes. The total estimated content as a percentage by weight of the cement
in the mix shall not exceed the following limits.
• For reinforced concrete
0.5% if made with Ordinary Portland Cement (OPC)
0.1% if made with Sulphate-Resistant Portland Cement (SRPC)
• For mass concrete

1.0% if made with OPC
0.2% if made with SRPC
b) The Contractor shall test the constituents of the concrete to establish these contents as
provided for elsewhere in this Contract.
c) In addition, regular tests to BS 1881: Part 6 for chloride content shall be made on the
hardened concrete. The following values are considered tolerable but shall be subject to
notice by the Employer’s Representative.
(i) For reinforced concrete made with OPC
95% of the test results less than 0.4% NaCl by weight of cement and no result greater
than 0.5% NaCl by weight of cement.
(ii) For reinforced concrete made with SRPC
(iii) For mass concrete made with OPC
95% of the test results less than 1% NaCl by weight of cement, and no result greater
(iv) For mass concrete made with SRPC
d) In the event that the SRPC used contains a proportion by weight of tri-calcium aluminate
which approaches 4% to 8%, then notice shall be sought from the Employer’s
Representative for an appropriate adjustment of the relevant chloride content limits.
(ii) Sulphates in Concrete
a) The level of acid-soluble sulphates (SO3) in the mix shall satisfy all of the following
requirements.
Coarse aggregate ≤ 0.4% by weight
Fine aggregate ≤ 0.4% by weight
Water ≤ 500 mg/l.

SS1-87
b) The total estimated sulphate content (SO3) of the mix including that present in the cement
shall not exceed 3.7% by weight of cement in the mix.
c) In addition, regular tests in accordance with BS 1881: Part 6 shall be carried out on the
hardened concrete to determine the total sulphate content, which shall not exceed 4% by
weight of cement in the mix.
(iii) Permissible Level of Chloride and Sulphates
The permissible level of chlorides and sulphates stated in this Contract shall not be considered
as mean values for the whole of the Works but shall apply to any concrete used in the Works.
(iv) Concrete for water-retaining structures shall comply with IS 3370.
5.2.6 Placing
(1) General
(a) Concrete shall be transported by means which prevent contamination (by dust, rain and
the like) segregation or loss of ingredients and shall be transported from the batching plant
and placed without delay.
(b) Concrete shall be placed in the positions and in sequences indicated on the Drawings.
Placing shall not commence until the fixing and condition of reinforcement and items to
be embedded and the condition of the containing surfaces or formwork have been noticed
by the Employer’s Representative. The Contractor shall provide the Employer’s
Representative with written notification not less than 24 hours prior to his intention to
place concrete in the Works.
(c) Concrete shall be placed directly in its final position without segregation or displacement
of the reinforcement, embedded items and formwork. Where necessary concrete may be
placed in water in accordance with the Contract requirements.
(d) Concrete shall not be dropped through a height greater than 1 meter.
(e) The method of placing shall be such as to prevent formation of cold joints, adulteration,
segregation or loss of ingredients. The thickness of horizontal layers shall not exceed
300mm.
(2) Extent of Pours
(a) The limit of individual pours and the height of lifts shall be as noticed.
(b) For walls, the length of panel placed at one time shall not exceed 6m; adjacent panels shall
not be placed within 2 days but shall be placed as soon as practicable thereafter.
Subsequent vertical lifts shall not be poured within 2 days.
(c) Floors, roofs and ground slabs shall be placed in a sequence of pours to the approval of
the Designer and the notice of the Employer’s Representative.
(d) If the use of slip-forms or paving trains is permitted, the above pour limits may be revised.
(e) The sequence of pours shall be arranged to minimise thermal and shrinkage strains.

SS1-88
(3) Placing Equipment

Concrete shall generally be placed without segregation by pumping or bottom- opening skips.
If chutes are used their slopes shall not cause segregation and spouts or baffles shall be
provided.
(4) Time for Placing
Concrete and mortar must be placed and compacted within 30 minutes of water being added
to the mix or otherwise included via damp aggregates, unless admixtures are in use. Partially
set concrete shall not be used in the Works.
(5) Compaction
(a) Concrete shall be compacted during placing by noticed internal vibrators. The
vibrators shall operate at a frequency of not less than 10,000 cycles per minute and
shall be designed for continuous operation.
(b) The performance of vibrators shall suit the working conditions and depending on the
thickness of layer to be compacted; 25 mm, 40 mm, 60 mm and 75 mm diameter
internal vibrators may be used. The radius of influence of the vibrator used shall ensure
that the concrete mass being vibrated is compacted at a speed commensurate with the
rate of supply of concrete.
(c) Special attention shall be given to the compaction of concrete behind embedded items
and in all places where high concentrations of reinforcing steel occur. The concrete
shall be compacted by use of appropriate diameter vibrator by holding the vibrator in
position until:
(i) Air bubbles cease to come to surface
(ii) Resumption of steady frequency of vibrator after the initial short period of drop
in the frequency, when the vibrator is first inserted.
(iii) The tone of the vibrated concrete becomes uniform.
(iv) Flattened, glistening surface, with coarse aggregates particles blended into it
appears on the surface.
(v) To secure even and dense surfaces free from aggregate pockets, vibration shall
be supplemented by tamping or tamping by rods in the corners of forms and
along the form surfaces while the concrete is plastic.
(vi) A sufficient number of spare vibrators shall be kept readily accessible to the
place of deposition of concrete to assure adequate vibration in case of
breakdown of those in use.
(vii) Form vibrators whenever used shall be clamped to the sides of formwork and
shall be positioned such that the efficient compaction and avoidance of surface
blemishes is ensured. The formwork must be made specially strong and against
over vibration especially where the workability of the concrete mix is high since
this will encourage segregation of the concrete.

SS1-89
(6) Vibrators
(a) Vibrators shall penetrate the full depth of the layer of concrete placed and just into the
layer below and be withdrawn slowly to avoid the formation of voids.
(b) Vibration shall not be applied directly or indirectly to concrete after the initial set has
taken place, nor shall it be used to make concrete flow in formwork.
(c) The Contractor shall have a minimum of two spare vibrators available during each
concrete pour in case of mechanical breakdowns.
(7) Continuity of Placing
(a) Placing in each section of work shall be continuous between construction joints. The
Contractor shall make provision for standby equipment.
(b) If the placing of concrete is delayed due to breakdown then the Contractor shall erect
vertical stop-ends and form a construction joint or remove the concrete already placed and
restart after repair of the breakdown.
(8) Placing in Inclement Weather
(a) Placing shall not take place in the open during rain or inclement weather. If such conditions
are likely to occur the Contractor shall provide protection for the materials, plant and
formwork so that placing of concrete may proceed.
(b) If strong winds are prevalent protection from driving rain and dust shall be provided for.
(c) During storms and heavy rain periods only underground or enclosed concrete pours shall
be permitted and this shall also be subject to where there is a reasonable level of protection
to the concreting work.
(9) Placing in High or Low Temperatures
(a) The temperature of fresh concrete shall not exceed 32oC, nor drop below 5oC, nor exceed
the temperatures stated in the table of mixes. The lowest of these shall be used at the time
of placing concrete.
(b) The maximum concrete temperature after placement shall not exceed 50oC nor be 30oC
above the temperature at the time of placement, whichever is the lower.
(c) The Contractor shall comply with the document entitled "Concrete in Hot Countries"
published by the FIP congress at New Delhi 1986. The procedures the Contractor wishes
to employ in this regard shall be subject to notice by the Employer’s Representative’s.
(d) The Contractor shall supply suitable maximum and minimum temperature thermometers
and record the shade and open-air temperatures at locations where concrete is being placed.
A recommendation for cold weather concreting is provided in IS: 7861 (Part 2).
(10) Placement at Night
(a) If notice has been given for placing concrete at night or in dark interiors, adequate lighting,
ventilation and access shall be provided when mixing, transportation and placing are in
progress.

SS1-90
(11) Placement Underwater

(a) Underwater concreting shall be carried out with minimum disturbance of the water.
Running water and wave wash shall be controlled.
(b) The specified concrete grade shall be used, and the mix design shall provide for good
flowing ability.
(c) Tremie pipes, bottom-dump skips or other noticed placing equipment shall be used.
(d) Segregation shall be avoided.
(e) Placing shall commence in sections and continue to completion subject to notice by the
(f) The tremie pipe shall be buried in the concrete for at least 1.5m and the tremie pipe must
not be emptied until the pour is complete.
(g) If a bottom-dump skip is used, the contents shall be covered by canvas or similar before
lowering into the water. The doors shall be opened when the skip is resting on the bottom
with no tension in the support cable, and the skip shall be lifted gradually so that the
concrete flows out steadily.
(12) Preparation Before Placing
(a) Before placing concrete for reinforced work on the ground, the formation shall be
compacted as specified and a screed of blinding concrete shall be applied to form a surface
for construction.
(b) Before placing concrete on or against rock, masonry, brickwork or old concrete, loose
material shall be removed, and the surface washed down; water seepage shall be stopped
or channelled away from the work.
(c) For mass concrete placed against masonry or brickwork the following shall apply.
(i) The mortar joints in the face work shall have fully hardened.
(ii) The water-cement ratio of the concrete shall be increased to compensate for absorption
of moisture by the existing work.
(iii) The surface shall be soaked prior to placing.
(iv) The concrete shall be worked around ties and bond stones and into open joints.
5.2.7 Reinforcement
(i) Reinforcement General
(a) Steel rod reinforcement shall be cut, bent and fixed in accordance with IS 456 or BS 8110:
Part 1.
(b) Cold bending shall be used which does not damage the material.
(c) Bending hot at a cherry-red heat not exceeding 840oC may be noticed except for bars
dependent on cold-working for strength.
(d) Bars shall not be cooled by quenching.

SS1-91
(ii) Fixing
(a) The number, size, form and position of pieces of reinforcement shall be as shown on the
Drawings. They shall be held in position in the formwork during the placing of concrete
by use of distance pieces and spacer bars.
(b) Links shall be taut so that bars are braced, and the inside of their curved parts shall be in
contact with the bars being connected. Binding wire shall be twisted tight with pliers and
the free ends shall be bent inwards.
(c) Reinforcement shall be grit-blasted before use if instructed by the Employer’s
Representative to remove rust, oil, grease, salt and other deleterious matter, and where
pitting has occurred the causes and products thereof. Repeated blasting may be required
when the reinforcement is in position, or partially cast in. Partially set concrete adhering
to exposed bars during concreting operations shall be removed.
(d) Reinforcement temporarily projecting from the concrete at joints shall not be bent out of
position without notice of Employer’s Representative, in which event the reinforcement
shall be bent over a suitably sized former to prevent any damage or over-stressing.
(iii) Bending
All bars shall be carefully and accurately bent by approved means in accordance with IS:
2502, and relevant drawings. It shall be ensured that depth of crank is correct as per the bar
cutting and bending schedule and bent bars are not straightened for use in any manner that
will injure the material.
Prior to starting bar bending work, the Contractor shall provide drawings detailing the
reinforcement required and shall prepare bending schedules in accordance with SP 34 of BIS
and IS 5525 BS 4466 and get the Engineer’s Notice of No Objection. Laps and anchorages
shall be as stated in IS 456 or BS 5400, Part 4. Any discrepancies and inaccuracies found by
the Contractor in the Drawings shall be immediately reported to the Engineer whose
interpretation and decision there to, shall be accepted.
Except as provided in this Contract, all bars shall be bent cold and bending shall be done
slowly, a steady, even pressure being used without jerk or impact. Reinforcing bar that have
been bent shall not be re-bent in location of the original bend.
(iv) Welding
(a) Electric arc welding may be used, if noticed, for joining bars. Covered-alloy or shielded-
arc electrodes shall conform to IS 814 and/or BS 639.
(b) Workmanship shall be to IS 2251 or BS 5135.
(c) Joints shall be butt-welded with standard double-V or double-U welds.
(d) Wherever specified all lap and butt welding of bars shall be carried in accordance with IS:
2571. Only qualified welders shall be permitted to carry out such welding.
(e) For cold twisted reinforcement welding operations must be controlled to prevent a supply
of large amounts of heat larger than that can be dissipated. The extreme non twisted end
portion shall be cut off before welding. Electrodes with rutile coating should be used.

SS1-92
(f) Bars shall be free from rust at the joints to be welded.

(g) Wherever specified all lap and butt welding of bars shall be carried in accordance with IS:
2571. Only qualified welders shall be permitted to carry out such welding.
(h) For cold twisted reinforcement welding operations must be controlled to prevent a supply
of large amounts of heat larger than that can be dissipated. The extreme non twisted end
portion shall be cut off before welding. Electrodes with rutile coating should be used.
(i) Bars shall be free from rust at the joints to be welded.
(v) Cover to Reinforcement
(a) Control of the minimum thickness of concrete cover to reinforcement shall be achieved by
the use of noticed concrete or plastic spacers. Minimum cover shall be as specified in the
Contract or IS 456.
(b) If concrete spacers are used, they shall be of similar concrete grade to the main concrete
and shall have non-metallic ties. For 30 Megapascal or more concrete, the spacers shall
comply with the requirements of this Contract for water absorption.
(c) Cover blocks used also should be same mix as the concrete of member and be with
roughened faces
(vi) Lapping
As far as possible, bars of the maximum length available shall be used. Laps shown on
drawings will be based on the use by the Contractor of bars of maximum length. In case the
Contractor wishes to use shorter bars, at the locations with the Engineer’s Notice of No
Objection.
Bars having butt or lap welds shall be provided as specified in the Drawings or as per
Engineer’s Notice of No Objection.
Mechanical couplings shall be made only by the methods specified and at the positions shown
on the Drawings.
(vii) Spacing, Supporting and Cleaning
Bars may be welded by noticed electrical process which does not affect the tensile properties
of the bar. Alternatively, the bars shall be bound together with No. 16gauge, soft annealed
wire at sufficient intersections to ensure that the network of bars will retain its designed form,
and the network shall be temporarily supported so as to retain its correct position during the
process of placing and compacting the concrete. The ends of all such tying wires shall be
carefully turned into the body of the concrete and clear of the mould.
Top reinforcement shall be supported on adequate stools to ensure that the reinforcing bars
are firmly held in position during concreting.
Normal stools and supports will be detailed on the Drawings and bending schedules. The
Contractor shall provide for any additional supporting steelwork to suit his particular
arrangements.
Reinforcement shall be rigidly fixed so that no movement can occur during concrete placing.
Any fixings made to the formwork shall not be within the space to be occupied by the concrete
being placed.
SS1-93
Cover and spacer blocks required to support the reinforcement shall be as small as possible
consistent with their use and be of noticed design and material. Projecting ends of ties or clips
shall not encroach into the concrete cover.
(viii) Inspection & Testing
Every bar shall be inspected by the Contractor before assembling on the Works and any
defective, brittle, rusted or burnt bars shall be removed. Cracked ends of bars shall be cut out.
Reinforcement steel shall be fresh, free from corrosion. Corroded steel will not be
incorporated into the Work. If there are traces of corrosion, then the Contractor have to give
the following treatment to steel.
• Cleaning of steel by wire brush for removal of dust and rust.
No work shall be commenced without the Engineer’s Notice of No Objection. Manufacturer's
Certificate shall be supplied for each lot of supply.
Specimens sufficient for three Tensile Tests for each different size of bar for each
consignment delivered shall be sampled and tested by the Contractor. Batches shall be
rejected if the average results of each batch are not in accordance with the specifications and
shall be removed from Site, without delay.
All manufacturer's test certificates, batch reference labels and quality control certificates shall
be retained by the Contractor and noted against each bar mark number at the time of cutting
and bending. This information shall be submitted to the Engineer.
(ix) Coupler Specifications
Only cold-forged, parallel threaded mechanical coupler system are recommended. All
mechanical couplers shall be of Type 2 (or Class H as specified in IS-16172) and should be
simple to install and which can be confirmed by quick visual inspection to have been correctly
installed and to have achieved the required full strength connection. Any other types of
mechanical coupler systems are not permitted provided the same meet the specification
indicated in Appendix – A.
(x) Protection Coating
In order to offer adequate resistance against corrosion, reinforcement bars shall be provided
with protective coating. The Contractor shall propose a suitable method for notice of
Employer’s Representative
5.2.8 Joints
(i) Construction Joints
(a) Construction joints shall be located, and the sequence of placing arranged as noticed, to
minimise shrinkage and thermal strains in the concrete.
(b) Concrete placing shall not be interrupted except where joints occur, and shall continue
after normal hours if necessary, to achieve this.
(c) Joints shall be formed square to the work with keyways included.
(d) Before placing is resumed at a joint the set surface shall be roughened to remove laitance
and expose the aggregate; the aggregate shall not be damaged. If damaging materials have
come into contact with the surface of the joint the concrete shall be cut back and the
roughened surface cleaned by compressed air or water jets and brushed and watered
SS1-94
immediately before placing. If required, the surface shall be coated with a layer of stiff
cement grout prior to placing the new concrete.
(e) Chemical surface-retarding agents shall not be used.
(f) Construction joints shall be sealed with a noticed sealant at external and liquid-contact
faces.
(g) Construction joints in water-retaining structures shall incorporate a noticed water-stop.
(h) Construction joint of structures exposed to soil shall be provided with hydrophilic water
bars.
(ii) Expansion, Contraction and Movement Joints
(a) Expansion, contraction and other movement joints shall be incorporated in the Works as
shown on the Drawings.
(b) Where shown on the Drawings, expansion joint fillers shall be supplied and installed. Filler
material shall be stored flat on a dry surface adequately protected from rain or moisture in
such a way that the material does not deteriorate. Filler material which has been damaged
or has started to deteriorate shall not be incorporated in the works.
(c) Movement joints shall be sealed with a noticed sealant applied in strict accordance with
the manufacturer's instructions to the dimensions shown on the Drawings. The surface of
the concrete to which the sealant is to adhere shall be straight and cleaned of all filler
material, dirt, oil, grease and other matter. The sealant shall be applied by methods
recommended by the manufacturer so that the sealant is brought flush to the surface of
structure and a smooth surface is achieved. Excess material and spillage shall be properly
cleaned off and removed.
(d) Dowel bars shall be installed and cast-in across the movement joint where shown on the
Drawings. The bars shall be straight with clean cut ends of the diameters and lengths as
shown on the Drawings or in the Schedules. Cutting and cleaning of the dowel bars shall
comply with the requirements of the Contract
(e) The bars shall be firmly supported in the positions shown on the Drawings so that they
remain accurately parallel and are not displaced during the casting of the concrete in the
first part of the structure. After the concrete has hardened and the formwork removed, the
projecting ends shall be cleaned of all concrete spillage and painted with two coats of a
noticed bituminous paint and caps shall be fitted to the free ends of the bars. Dowel bar
end caps shall be of cardboard or other material, of correct diameter for the dowel bar and
of sufficient length to allow the specified movement of the two adjacent concrete
structures. They shall be manufactured expressly for this purpose by a noticed
manufacturer.
(f) The Contractor shall take care to protect the projecting ends of dowel bars from bending
or other damage prior to concreting the succeeding bay. The bituminous paint shall be
applied as soon as practicable, but end caps shall not be fitted until immediately prior to
the succeeding concreting operations.
SS1-95
(iii) Water-stops
The layout and installation of the water-stops shall be in accordance with the manufacturer's
recommendation and shall be subject to the notice of the Employer’s Representative.
(iv) Bolts, Inserts and Openings
(a) All fixing blocks, brackets, built in bolts, holes, chases, etc., shall be accurately set out and
formed and carefully sealed prior to the concrete being placed. No cutting away of concrete
for any of these items shall be done.
(b) Bolts and other inserts to be cast into the concrete shall be securely fixed to the formwork
in such a way that they are not displaced during the concreting operations, and that there
is no loss of materials from the wet concrete through holes in the formwork.
(c) Unless shown otherwise on the Drawings reinforcement shall be locally moved so that the
minimum specified cover is maintained at the locations of inserts, holes, chases, and the
like.
(d) Temporary plugs shall be removed, and the threads of cast-in bolts shall be proved to be
free and shall be greased before handing over any part of the Works.
5.2.9 Curing and Protection
Curing and Protection
(a) Concrete shall be protected from sunshine and drying winds by noticed shading and
windbreaks, and from cold, rain or running water, for a period of at least 7 days after
placing. During this period or for any extended period the following measures shall be
taken to prevent the loss of moisture and to minimise thermal stresses caused by the
difference in temperature between the surface of the concrete and the core of the concrete
mass.
(b) Horizontal surfaces
Polythene sheeting shall be placed immediately after finishing.
After final set has taken place, the polythene shall be replaced by wet Hessian covered with
polythene. The Hessian shall be kept permanently damp.
After 7 days the Hessian and polythene shall be removed, and a noticed aluminised or white
resin-based curing compound applied unless an alternative method is used. The method of
application shall be as recommended by the manufacturer.
Alternative methods of curing shall be subject to the notice of the Employer’s Representative
before use in the Works.
(c) Vertical surfaces
Polythene over wet Hessian shall be secured to the surfaces immediately after removal of the
formwork. The Hessian shall be kept permanently damp.
After 7 days the Hessian and polythene shall be removed, and a noticed aluminised or white
resin-based curing compound applied. Alternatively, the Hessian and polythene to stay for a
further 7 days.

SS1-96
Water used during curing operations shall be fresh water. Curing membranes shall be
compatible with waterproofing or other materials that may subsequently be applied to the
surface of the concrete.
In case of steam curing method, the period of curing shall be as required.
Contamination
Concrete shall be protected from contamination by sea or brackish water, oil, fuel and other
deleterious materials for a minimum period of 30 days after placing.
Insulating Formwork
Insulating formwork shall be left in place for 72 hours after placing the concrete or until the
temperature peak of the concrete is reached. The initial curing period defined above may then
be reduced in proportion subject to the notice of the Employer’s Representative
Protection of Joints
Rebates formed to receive sealant and the surfaces of construction joints shall be protected
from curing compound by wet Hessian to ensure proper curing of the joint surface and
adjacent concrete. The protection shall remain in place until the joint surface is sealed.
5.2.10 Finishes
General
(a) The finished faces of concrete shall be sound, even-coloured, even-textured and free from
defects. Arises shall have a 20mm by 20mm chamfer. Concrete faces shall not be
rendered, and defective concrete shall be cut out and replaced or made good. A fine finish
shall be provided unless otherwise detailed on the Drawings.
(b) Any concrete structure for the Platform Screen Doors shall be cast with smooth surfaces,
free of blowholes and any raised blemishes. The Contractor shall carry out timely
interfacing to ensure that appropriate finish of concrete surface is rendered to
accommodate Concessionaire’s requirements of various Architectural finishes in the
stations.
Fine Finish
Surfaces defined as having a fine finish shall be rubbed smooth by Carborundrum stone; small
holes shall be stopped with noticed mortar of the same final colour as adjacent concrete.
Concrete Surfaces without Formwork
(a) On upward-facing surfaces which do not require formwork or special finish the finish shall
be produced by proper placing and compacting operations alone.
(b) For a fair-finish screeding, this shall be carried out by sliding and tamping a screed board
running on the top edges of the formwork, or on screeding guides, to give a dense concrete
skin.
(c) For a fine finish screeding as described, the surface shall be left until the concrete has
stiffened and the film of surface moisture has disappeared. A steel or wooden float shall
then be used for a glossy or sandpaper surface as required. Working shall be the minimum
compatible with a good finish. The surface shall be protected from water drops.

SS1-97
Wire-Brushed Finish
After removal of the formwork the surface of the concrete shall be abraded by stiff wire
brushes and water to remove the cement laitance and expose the aggregate.
Bush-Hammered Finish
(a) The surface shall be abraded by Carborundrum stones to remove irregularities. Within 3
weeks, the surface shall be bush hammered to remove the cement laitance and expose the
aggregate. Noticed bush hammers shall be worked to within 12 millimetres of corners and
arises; the remaining 12 millimetres shall be hand-chiselled to match.
(b) Bush hammers shall be operated perpendicularly to the surface, and the remaining exposed
aggregates shall not be loose or fractured. The treated surface shall be washed with water
and stiffly brushed. The exposed aggregate shall be clean and free from film.
Chemical Retarders
Chemical surface retarders may be used to produce an exposed aggregate finish, and the
Contractor shall demonstrate that the durability of the concrete surface is not reduced.
Carborundum Finish
(a) Carborundum finish shall be achieved by sprinkling carborundum grit on the unset surface
and working-in by wooden float.
(b) The carborundum grit shall vary in size between BS 1.18 millimetres mesh and BS 0.6
millimetres mesh and shall be distributed from a BS 1.18mm hand-screen at the rate of
2.15 kilograms per square metre.
Specimen Panels of Concrete
(a) If required, the Contractor shall produce specimen panels of finished concrete for the
notice of the Employer’s Representative.
5.2.11 Special Concrete
(1) No-Fines Concrete
(a) The aggregate for no-fines concrete shall be coarse-graded from 10mm to 20mm. A small
percentage of fines from 10mm to 5mm may be added to improve the strength if noticed.
(b) Cement shall be mixed with the aggregate in the proportion of 1 to 8 by volume.
(c) Segregation of the cement grout shall be prevented.
(2) Granolithic Concrete
(a) Granolithic concrete shall consist of one part by weight cement to three parts of combined
coarse and fine aggregate.
(b) Granolithic concrete shall preferably be laid on top of the unset base concrete and
compacted and worked to the correct levels. The surface shall be floated with a steel float
after hardening until water sheen has disappeared. Cement or cement-sand shall not be
sprinkled onto the surface. The layer shall be 12mm to 18mm thick.
(c) If a granolithic layer is required to be placed on set concrete, the latter shall be scrabbled
and cleaned to expose the aggregate, and a noticed bonding agent applied. The layer shall
not be less than 50mm thick.
SS1-98
(d) If required, compounds shall be added or applied to give a concrete with improved dust-
proof and oil-proof qualities of any desired colouring. The compounds shall be used in
accordance with the manufacturer's instructions.
(e) Granolithic concrete paving shall be placed in panels not exceeding 3 metre square.
Contraction joints shall be provided around the perimeter of each panel.
(3) Cement - Mortar, Grout, and Rendering
(a) Cement-mortar shall consist of one-part cement and four parts fine sand by volume with
just enough water to achieve workability.
(b) Cement-lime-mortar shall consist of three parts of sand to one part of mixture comprising
one part of cement to one part of hydrated lime.
(c) Grout shall consist of cement mixed with water in designed proportions. Fine sand may be
included in noticed quantities.
(d) Rendering shall consist of three parts fine, sharp sand to one-part cement applied in two
10mm thick coats and one 5 mm thick finishing coat. The colour of the finishing coat shall
be subject to the notice of the Employer’s Representative.
(e) Acid-resistant epoxy mortar shall be obtained from a noticed manufacturer and applied in
(f) Mortar render and grout shall be used freshly mixed.
5.2.12 Protective Coatings
(1) External Sheet Tanking Membrane
(a) External protection to concrete substructures where required shall be as noticed by the
Employer’s Representative and fixed to the surface in accordance with the manufacturer's
instructions.
(b) Materials and workmanship shall be in accordance with the Contract waterproofing.
External Brush-Applied Tanking Membrane
Substructures shall be protected externally, where required with a noticed
membrane applied to the top of the blinding concrete and to the outside
surfaces of all buried concrete and continued where appropriate to 300mm
above finished ground level.
The surfaces shall be cleaned and brought to a fine finish before coating.
Each coat shall be applied at the rate specified by the manufacturer.
Coatings shall be protected by a hardboard or similar materials during
backfilling.
(c) Internal Protection to Concrete
Protection to internal concrete faces shall be provided as required.
(d) Protection of Concrete Above Ground Level

SS1-99
All exposed concrete surfaces above tanking membrane tuck-in level shall
be coated with a noticed two-coat protection level system, subsequently
over- coated with a noticed compatible two-coat smooth finish acrylic paint
system.
Sample panels of minimum area 10 square metres shall be made on
finished concrete to prove the finish quality and enable the colour to be
selected. Only those panels finally noticed may be included in the Works.
5.2.13 Tolerances
The tolerances of concrete surfaces shall be in accordance with the following.
Precast Concrete BS 8110 Members Subsection 6.2.8
Foundations and other BS 5606 in-situ buried concrete
Exposed concrete BS 5606 (including internal surfaces of sewer culverts)
Other concrete surfaces: As shown on drawings/schedule of finishes
5.3 PRECAST CONCRETE
5.3.1 Manufacture off site
(a) Casting of members shall not begin until notice has been given by Employer’s
Representative to the shop drawings, required computation, pre-stressing system (if
required) and method of manufacture.
(b) When the drawings and method of manufacture have been noticed, no changes shall be
made without the notice of the Employer’s Representative
(c) The Contractor shall inform the Employer’s Representative in advance of the date of
commencement of manufacture and casting of each type of member. Concrete
reinforcement and workmanship shall be as per IS 456.
(d) A copy of all cube test results for the precast concrete works shall be sent to the Employer’s
Representative as soon as these are available.
(e) No members to which the tests relate shall be dispatched to the Site until the tests have
been satisfactorily completed and noticed by the Employer’s Representative.
(f) All members shall be indelibly marked to show the “member mark” as described in the
Contract, the production line on which they were manufactured, the date on which the
concrete was cast and, if they are of symmetrical section, the face that will be uppermost
when the member is in its correct position in the works. The markings shall be so located
that they are not exposed to view when the member is in its permanent position.
5.3.2 Forms
The design and engineering of the forms and false work as well as their construction shall
be the responsibility of the Contractor.
All exposed surfaces of each element of the structure shall be formed with similar material
to produce similar concrete surface textures, colour, and appearance.

SS1-100
Forms shall be inspected prior to authorizing casting operations. Details shown on the
Drawings shall be built into the forms. Worn, damaged, or otherwise unacceptable forms
shall be repaired before casting of any member will be authorised.
The forms may be made either of steel or of plywood. If the Contractor elects to use
plywood forms, it shall be a high-quality plywood, 19mm minimum thickness marine
grade subject to the notice of the Employer’s Representative.
Forms shall be structurally adequate to support the members within permissible tolerances.
The form design shall incorporate the method and the necessary hardware to adjust and
maintain grade and alignment. Details of the hardware and adjustment procedure shall be
included in the required plans.
Forms shall be coated with a noticed form-release agent prior to use. Form release agents
shall be of commercial quality, of oil or other equivalent substances which permit the ready
release of forms and will not discolour the concrete. Excess form release agents shall not
be allowed to stand in puddles in the forms nor shall coating be allowed to come in contact
with reinforcing steel or hardened concrete.
Anchor devices may be cast into the concrete for later use in supporting forms, provided
the arrangement shall be to the notice of the Employer’s Representative. The use of driven
or drilled types of anchorages for fastening forms or form supports to concrete shall not
be permitted.
5.3.3 Curing
(a) The steam curing shall be at 100% relative humidity to prevent loss of moisture and to
provide moisture for proper hydration of the cement. Application of the steam shall not be
directly on the concrete. During application of the steam, the ambient air temperature shall
increase at a rate not exceeding 22 degrees Celsius per hour (oC/h) until the maximum
temperature has been reached. Curing shall comply with the requirements of the Contract.
(b) Steam curing process may be used as an alternative to water curing. The casting bed for
any unit cured with steam shall be completely enclosed to prevent steam escaping and
exclude outside atmosphere. 2 to 4 hours after placing concrete and after the concrete has
undergone initial set, the first application of steam shall be made, unless retarders are used,
in which case the waiting period before application of the steam shall be increased to from
4 to 6 hours. Water curing methods to be used from the time concrete is placed until steam
is first applied.
(c) Where the steam has been raised the maximum temperature shall be held until the concrete
has reached the desired strength. In discontinuing the steam application, the ambient air
temperature shall not decrease at a rate to exceed 22oC/h until a temperature has been
reached 10 oC above the temperature of the air to which the concrete shall be exposed. The
maximum curing temperature shall be from 60oC degrees to 67oC .
(d) If the Contractor elects to cure by any other special method, the method and its details
shall be subject to the notice by Employer’s Representative.
5.3.4 Storage
When members are stored, they shall be firmly supported only at the points specified.

SS1-101
(a) The accumulation of trapped water and deleterious matter in the units shall be prevented.
(b) Care shall be taken to avoid rust staining and efflorescence.
5.3.5 Handling and Transport
(a) Members shall be lifted or supported only at points specified or otherwise given notice by
the Employer’s Representative and shall be handled and placed without impact.
(b) The Contractor shall define the method of lifting, the type of equipment and transport to
be used, and the minimum age of the members to be handled and shall be subject to the
notice of the Employer’s Representative.
5.3.6 Assembly and Erection
(a) The method of assembly and erection described in the Contract shall be as practicable and
be strictly adhered to on site.
(b) Immediately after a unit is in position, and before the lifting equipment is removed,
temporary supports or connections between members, as necessary, shall be provided.
(c) The final structural connections shall be completed as soon as possible.
5.3.7 Forming Structural Connections
(a) No structural connections shall be made until the Employer’s Representative's notice has
been received.
(b) Unless otherwise noticed by the Employer’s Representative, the composition and water:
cement ratio of the in-situ concrete or mortar used in any connection and the packing of
joints shall be in accordance with the assembly instructions.
(c) Levelling devices shall only be released or removed subject to the notice of the Employer’s
Representative.
5.3.8 Epoxy Grout for Structural Connections (if required)
(1) Description
Epoxy shall be furnished as two components mixed together at the Site.
(2) Sampling and Testing
All tests will be conducted in accordance with the latest test methods of the American Society
for Testing and Materials, Federal Test Method Standard No. 141 or equivalent British
Standard.
(3) Packaging, Labelling and Storing
(a) Each component shall be packaged in steel containers not larger than 20 litres in volume.
When the components are to be mixed at a ratio of 2 parts A to one-part B, by volume, the
container containing component B shall be one half the volume of the container containing
component A.
(b) The containers shall have lug type crimp lids with ring seals, shall be new, not less than
0.6mm nominal thickness and shall be of such character as to resist any action by the
components.

SS1-102
(c) Each container shall be clearly labelled with the designation (Component A or B), type
(Standard or Rapid) if applicable, manufacturer's name, date of manufacture, batch number
(a batch shall consist of a single charge of all components in a mixing chamber), lot number,
all directions for use specified elsewhere and the following warning in Tamil and English:
"CAUTION” or Equivalent in Tamil
"This material will cause severe dermatitis if it is allowed to come in contact with the skin or
eyes. Use gloves and protective creams on the hands. Should this material contact the skin,
wash thoroughly with soap and water. Do not attempt to remove this material from the skin
with solvents. If any gets in the eyes, flush for 10 minutes with water and secure immediate
medical attention."
(d) Attention is directed to the characteristic of some epoxy components to crystallize or thicken
excessively prior to use when stored at temperatures below 2oC. Any material which shows
evidence of crystallization or a permanent increase in viscosity or settling of pigments which
cannot be readily re-dispersed with a paddle shall not be used.
(4) Directions for Use
(a) At the time of mixing, components A and B shall be at a temperature between 16 degrees and
29oCunless otherwise specified. Any heating of the adhesive components shall be done by
application of indirect heat. Immediately prior to mixing, each component shall be
thoroughly mixed with a paddle. Separate paddles shall be used to stir each component.
Immediately prior to use, the two components shall be thoroughly mixed together in the
specified ratios. When mixed, all adhesives shall have a uniformly grey colour without black
or white streaks. No solvent shall be added to any epoxy.
(b) After mixing, all epoxies shall be placed in the work and any overlaying or inserted be cleaned
and it shall have moisture content of not more than 0.5% when tested. The maximum size of
the aggregate shall not exceed that of material which is to be bonded to the work by the epoxy.
It shall also be placed before thickening of the epoxy has begun. Surfaces upon which epoxy
is to be placed shall be free of rust, paint, grease, asphalt, moisture and loose and deleterious
material. When epoxy is used as a binder to make epoxy concrete or grout, the two
components of epoxy shall be thoroughly mixed together before the aggregate is added and,
unless otherwise specified, the mix proportions shall consist of one part of binder to
approximately 4 parts of aggregate, by volume. Aggregate for use in epoxy concrete and grout
shall one-fourth of the thickness of the joint to be grouted. All surfaces against which epoxy
concrete and grout are to be placed shall be primed with a coat of the epoxy used just prior to
placing the grout.
(c) No more material shall be mixed than can be used within 20 minutes from the time mixing
operations are started. Pot life of the epoxy mixture shall be 45 minutes.
(5) Epoxy Grout Strength Requirements
The compressive strength of 38mm cubes of epoxy grout tested in accordance with ASTM
C39 after 10 hours of curing at 20oCshall be not less than the design strength of the pre-cast
member.

SS1-103
5.3.9 Protection
At all stages of construction, pre-cast concrete units and other concrete associated therewith
shall be properly protected to prevent damage to permanently exposed concrete surfaces,
especially arises and decorative features.

SS1-104
APPENDIX A
Coupler Specifications
The couplers shall be of standard parallel thread type. Ends of the reinforcement bars, which are
to be joined, shall be enlarged by cold forging/upsetting, threaded in such a way that root thread
diameter is not lesser than the parent bar to be joined. The coupler shall be of TYPE – II and
qualified/Certified as per UK CARES, IS code 16172:2014, ACI 318, ASME, Section III, and
Div.2, Caltrans.
Couplers installed shall be strictly in accordance with the manufacturer’s recommendations.

Couplers shall preferably be located away from high stress zones in the various structural elements
and shall be staggered.
All the couplers should be manufactured in a factory which is ISO 9001:2008 (or higher revision)
certified for “Manufacturing of Mechanical Steel Rebar Couplers & Accessories” and also be
certified for “Site Management of Threading & Processing of Rebar including Sales and
Distribution”. All the couplers shall undergo quality checks on uniformity of threads, dimensional
accuracy etc. Each coupler shall be clearly stamped indicating batch number and diameter. This
number shall be traceable to the original cast. The relevant material mill certificate shall be
submitted with supply of a particular lot. The certificate shall give salient material properties. The
coupler manufacturer shall operate at least an ISO 9000 approved quality assurance programme or
equivalent for the manufacture of couplers.
a) Threading of ends of the reinforcing bars:

This threading activity shall preferably be done at Site. The various stages involved in threading
are as given below:
i) Cutting (Rebar End Preparation):

The ends of reinforcement bars shall be cut by mechanical means to get a perfect plain and surface
perpendicular to the axis of the bar.
ii) Cold forging & threading:

After cutting the ends of the bar shall be enlarged by cold forging such that the area of cross section
after threading shall not be less than the area of cross section of the parent bar. The length of cold
forging shall be adequate for proposed thread length as per manufacturer's design. Threading shall
be done preferably on threading machine. The threads shall be square parallel type to suit the
couplers. The thread length and depth shall be as per manufacturer's design.
After threading is completed, the threaded length of the bars shall be protected by providing plastic
end caps before taking the bars out of the shop.
b) Quality control in making of threads:

Double forging of bars is not permitted. In case of improper cold forging the forged of the bar shall
be square cut and fresh cold forging shall be undertaken. 100% threading at threaded rebars shall
be checked with 'go' and “no go' gauges for the correctness of the thread profile on the rebar. A
proper record for same shall be maintained at site.
Qualification Tests:
SS1-105
The coupler shall be qualified as per IS code 16172:2014, ACI 318, ASME - Section III, and Div.2,
Caltrans and must have conducted & qualified for the following tests :
i) Static Tensile Test:

Mechanical connections shall be tested for all reinforcing rebar sizes. For each rebar size, a
minimum of three connections (3 joints + 1 Parent bar) in each load direction shall be tested in
accordance with ASTM A370 test method to meet code requirement. A tensile test on an unsliced
specimen from the same bar used for the spliced specimens shall be performed to establish actual
tensile strength. The tensile strength of an individual splice system shall not be less than the 125%
of the specified minimum yield strength (fy of rebar) of the spliced bar.
ii) Cyclic Tension and Compression Test:

Mechanical connections shall be tested in all reinforcing rebar sizes. For each rebar Outline
Construction Specifications for Civil Works size, a minimum of three connections shall be tested
for cyclic tension & compression test. Each specimen shall withstand cycles of stress variation of
the specified minimum yield strength of the reinforcing bar. The test should be carried out as per
the table mentioned below:
Table B.1 : Loading Stages and cycles per stage for cyclic load test
Stage Tension Compression Cycles
1 0.95 fy 0.5 fy 20
2 2 Ɛy 0.5 fy 4
3 5 Ɛy 0.5 fy 4
Note:
fy is specified yield strength of the reinforcing bar.
Ɛy is the strength of reinforcing bar at actual yield stress.
iii) Cyclic Tensile Test:

Mechanical connections shall be tested in all reinforcing rebar sizes. For each rebar size, a
minimum of three connections shall be tested for low cyclic tensile test. Each specimen shall
withstand 100 cycles of stress variation from 5% to 90% of the specified minimum yield strength
(fy) of the reinforcing bar. One cycle is defined as an increase from the lower load to the higher
load & return.
iv) Low Cycle Fatigue Test (for 10,000 cycles):

Fatigue test shall be conducted on splice sample from +173 Mpa to -173 Mpa for 10,000 cycles.
A sine wave form @ 0.5 Hz shall be followed for bar dia 36 mm & above and 0.35 Hz shall be
followed for bar dia less than 36 mm. Test shall be conducted confirming to IS 16172:2014 &
Caltrans specifications. Past certificates for low cycle fatigue test shall be accepted; however, these
should not be more than 3 years old.
v) High Cycle Fatigue Test (for 2,000,000 cycles):

SS1-106
In high cycle fatigue test, the test specimen is subjected to an axial tensile load which varies
cyclically according to the sinusoidal wave form of constant frequency in the elastic range, as
accordance with IS-16172. Past certificates for high cycle fatigue test shall be accepted; however
these should not be more than 3 years old.
vi) Slip test :

Slip Test Shall be performed on each diameter coupler specimen as per ASTM A 370 section 10.
Test shall be conducted confirming to IS 16172:2014 & Caltrans specifications. Total slip shall
not exceed the max value of 0.1 mm. Refer table below for more details:
Bar diameter TOTAL Slip (μ m)

8mm to 20mm 250
25mm to 28mm 350
32mm to 40mm 450
45mm 600
56mm 750
vii) Proof loading test

Every cold-forged, threaded bar end shall undergo a proof load test prior to leaving system
supplier’s workshop. Every threaded bar must be subjected to proof load testing to a minimum test
loading of 75% of the characteristic strength (theoretical fy). The system supplier shall essentially
install a proof load tester equipment within its threading workshop premises and ensure to test each
and every threaded bar. A positive indication shall be marked on the rebar to indicate that this
operation has been carried out.
INSTALLATION OF COUPLERS IN THE FIELD:

The installation of couplers in the field, for joining reinforcing bars shall be undertaken by trained
manpower and as per manufacturer's instructions. Threads of both the couplers and the bars shall
be thoroughly cleaned just before installation. Where couplers are cast-in the concrete, but
connection is not to be completed immediately, the couplers shall be internally greased and plastic
capped to a protection detail acceptable to the engineer. This cap shall be removed only when next
bar is to be attached, then the same to be cleaned before joining the next bar.
The contractor shall arrange for a suitably qualified manufacturer's representative experienced in
mechanically connecting reinforcement to be present at site before the start of work for initial
training of personnel, and also to demonstrate the equipment and techniques as necessary. The
threading workshop is to be fully supervised by the manufacturer's representative.
The contractor shall submit to the Engineer-in-Charge, for his acceptance a method statement for
mechanically connecting the reinforcement and for the installation and verification in the field.
This shall take into account any special requirements for horizontal, vertical and inclined couplers
and shall include a rectification procedure, if the connection is incorrectly made. It shall also cover
the correct methodology for handling of tools and equipment for mechanical connection on site.
The following information shall also be included:

(1) Requirements for cleanliness.
(2) Equipment for threading bars.

SS1-107
(3) Method of locking the connections on both rebars.

(4) Method of verification of final rebars alignment and coupler integrity.
Each coupler shall be visually examined prior to use to ensure the absence of rust and of any
foreign material on the inside surface. All completed couplers shall be inspected and verified in
accordance with the approved QAP. The Contractor shall ensure the acceptance of the Engineer
for a procedure for documenting the inspection of the couplers. The contractor shall retain
inspection records and shall submit copies to the Engineer-in-Charge within 7 days. The Couplers
that do not meet the acceptance shall be completely removed and the bars re-connected as required.
6 FORMWORK
6.1 GENERAL
These specifications shall be read in conjunction with the MORTH specifications and
CPWD/TNPWD specifications with correction slips/amendments up to date, and other
relevant specifications described in Section 1of this Volume
6.2 MATERIALS
Formwork shall be of timber, plywood (including marine plywood), steel or any other suitable
material capable of resisting damage to the contact faces under normal conditions of erecting
forms, fixing steel and placing concrete. The selection of materials suitable for formwork
shall be made by the Contractor based on the quality consistent with the specified finishes
and safety. The entire responsibility of planning, designing, erecting, dismantling, shifting
and safety of false work lies with the Contractor.
All formwork and formwork support (centering, props, scaffolds, ladders etc.) shall be in
structural steel only and preferably of pipes conforming to IS:806, IS:1161, IS:1239, IS:2750.
Wooden ballies shall not be permitted as props/formwork supports. All props shall be
properly braced using x & k bracings. Ladders to be used at site should have treads and shall
be fabricated from structural steel. Wooden/ bamboo/aluminium/pipe ladders shall not be
permitted.
6.2.1 Timber
Timber used for formwork shall be easily workable with nails without splitting. It shall be
stable and not liable to warp when exposed to sun and rain or wetted during concreting.
6.2.2 Plywood
Plywood used for formwork shall be minimum 12mm thick. Shuttering quality plywood
complying with IS:4990. Suitable stiffeners and walers shall be provided depending on the
shuttering design.
6.2.3 Steel
Steel formwork shall be made of minimum 4mm thick black sheets stiffened with angle iron
frame made out of M.S. angles 40mm x 6 mm supported at suitable spacing.
6.3 DESIGN & DRAWINGS
The permissible stresses in materials in all Temporary Works such as formwork, falsework,
staging, launching and the like. shall be the same as for the Permanent Works. The
Contractor’s checked and verified calculations and drawings of the same including
construction sequence (along with soft copy in CD ROM) shall be submitted to Employer’s
Representative for his notice well in advance of work.

SS1-108
All constructed Temporary Works shall be also inspected by the Design Checker and an
inspection report shall be submitted to Employer’s Representative. All Temporary Works
shall be robust, safe and constructed such a way that the concrete can be properly placed and
thoroughly compacted to obtain the required shape, position and level subject to specified
tolerances. It is the responsibility of the Contractor to obtain the results required by the
Employer’s Representative, whether or not some of the work is sub-contracted. Agreement
of the temporary works by the Employer’s Representative shall not diminish the Contractor's
responsibility for the satisfactory performance of the same, nor for the safety and co-
ordination of all operations.
The design of false work should be such as to facilitate easy and safe access to all parts for
proper inspection.
Methodology for removal of form should be planned as a part of total formwork design
process.
In case of pre-stressed concrete work, careful consideration shall be given to re- distribution
of loads due to pre-stressing.
6.4 FORMWORK FOR EXPOSED CONCRETE SURFACES
The facing formwork, unless indicated otherwise in drawings, shall generally be made with
materials not less than the thickness mentioned below for different elements of the structure:
(1) Plain slab soffit, and sides of beams, joists and ribs and side of walls, parapets, etc shall be
made with:
(a) Steel plates not less than 4mm thick of specified sizes stiffened with a suitable structural
framework and fabricated true to plane
(b) Timber planks of 20mm actual thickness and of specified surface finish, width and
reasonable length,
(c) Plywood not less than 12mm thick (IS:4990 - Specification for Plywood for Concrete
Shuttering Work) stiffened with a suitable timber framework or 3mm thick plywood with
a 20mm timber plank backing, of specified sizes stiffened with a suitable timber
framework and bracing. At joints 6mm/10mm sponge to be provided.
(2) Bottoms of beams, sides of columns shall be formed using the following materials.
(a) Steel plates not less than 5mm thick of specified sizes stiffened with a suitable structural
framework, and fabricated true to plane
(b) Timber planks of 35mm actual thickness and of specified surface finish, width and
reasonable length,
(c) Plywood not less than 12mm thick (IS:4990), of specified sizes stiffened with a suitable
timber framework.
(3) For precast segments, portals, tunnel connections and the like. suitable steel formwork shall
be used.

SS1-109
6.5 FORMWORK FOR SLOPED SURFACES

(a) Forms for sloped surfaces shall be built so that the formwork can be placed board-by-board
immediately ahead of concrete placement so as to enable ready access for placement,
vibration, inspection and finishing of the concrete.
(b) The formwork shall be built in such a way so that the boards can be removed one by one
from the bottom up as soon as the concrete has attained sufficient stiffness to prevent
sagging. Surfaces of construction joints and finished surfaces with slopes steeper than 2
horizontals:1 vertical shall be formed as required herein.
6.6 FORMWORK FOR CURVED SURFACES
(a) The Contractor shall interpolate intermediate sections as necessary and shall construct the
forms so that the curvature will be continuous between sections. Where necessary to meet
requirements for curvature, the form lumber shall be built up of laminated splices cut to
make tight, smooth form surfaces.
(b) After the forms have been constructed, all surface imperfections shall be corrected and all
surface irregularities at matching faces of form material shall be dressed to the specified
curvature.
6.7 ERECTION OF FORMWORK
The following shall apply to all formwork:
(a) Before fabricating the forms, the Contractor shall submit for the Employer’s
Representative’s notice the design of forms and the types of material to be used. (Ref. ACI
347 Formwork for Concrete or equivalent I.S. Code).
(b) All shuttering planks and plates shall be adequately backed by a sufficient number and
size of walers or framework to ensure rigidity during concreting. All shutters shall be
adequately strutted, braced and propped to prevent deflection under deadweight of
concrete and superimposed live load of workmen, materials and plant, and to withstand
pouring rate and vibration.
(c) Vertical props shall be supported on wedges or other measures shall be taken so that the
props can be gently lowered vertically during removal of the formwork. Props for an
upper level shall be placed directly over those in the level immediately below, and the
lowest props shall bear on a sufficiently strong area. Care shall be taken that all formwork
is set plumb and true to line and level or camber or better where required.
(d) Provision shall be made for adjustment of supporting struts where necessary. When
reinforcement passes through the formwork care should be taken to ensure close fitting
joints against the steel bars so as to avoid loss of fines during the compaction of concrete.
(e) If the formwork is held together by bolts, these shall be so fixed that no iron will be
exposed on surfaces against which concrete is to be laid and within the concrete cover to
the steel reinforcement. In any case wires shall not be used with exposed concrete
formwork. If the Contractor elects to use tie-bolts running through the concrete, then the
Contractor shall define the location and size of such tie-bolts and submit his proposals for

SS1-110
notice by the Employer’s Representative. The tie-bolts shall be so designed that their
removal on de- shuttering does not leave any embedment within the concrete cover to steel
reinforcement. Holes left in the concrete by these tie-bolts shall be filled by the concrete
repair material and the methodology set out in the Contractor’s noticed proposal.
(f) Provision shall be made in the shuttering for beams, columns, and walls for a port hole of
convenient size so that all extraneous materials that may be collected could be removed
just prior to concreting.
(g) Formwork shall be so arranged as to permit removal of forms without jarring the concrete.
Wedges, clamps and bolts shall be used wherever practicable instead of nails.
(h) The formwork for beams and slabs shall be so erected that forms on the sides of the beams
and the soffit of slabs can be removed without disturbing the beam bottoms or props under
beams.
(i) Surfaces of forms in contact with concrete shall be oiled with a mould oil of noticed quality
form releasing agent. The use of mould oil which results in blemishes of the surface of the
concrete including diesel, burnt oil and any other lubricating oil shall not be allowed.
Mould oil shall be applied before reinforcement has been placed and care shall be taken
that no oil comes in contact with the reinforcement while it is being placed in position.
The formwork shall be kept thoroughly wet during concreting and the whole time that is
left in place, nothing extra shall be paid to Contractor for oiling the moulds.
(j) Immediately before concreting is commenced, the formwork and other related
arrangements shall be carefully examined to ensure the following.
(1) Removal of all dirt, shavings, sawdust and other refuse by brushing, washing and
compressed air/vacuum cleaning.
(2) The tightness of joints between panels of sheathing and between these and any
hardened core.
(3) The correct location of tie bars, bracing and spacers, and especially connections
of bracing.
(4) Adequate cover blocks are in place
(5) Straightness and plumbness of the formwork
(6) Side supports/restraints for the formwork are enough and robust
(7) Construction joint (wherever applicable) is properly prepared
(8) That all wedges are secured and firm in position.
(9) That provision is made for traffic on formwork not to bear directly on reinforcing
steel.
(10)Pouring platform along with its approach from ground is robust and safe for
workers movement.

SS1-111
(11)Arrangement for vibrators for compaction of concrete

(12)Sequence of concrete pouring is well defined and is agreed upon by the
Employer’s representative and is explained to concrete pouring team
(13)The Pouring area is well lit.
(14)Curing arrangements are well planned and agreed upon by the Employer’s
Representative.
(15)The concrete protection measures in accordance with the Contract are in place.
(k) The Contractor shall ensure dimensional accuracies of the work and for the general
arrangement of propping and bracing. (IS:3696 - Safety Code of Scaffolds and Ladders,
IS:4014 Steel Tubular Scaffolding I & II). All scaffolding and staging shall be either of
steel tubes or built up section of rolled steel with adequate bracing at several levels in each
perpendicular direction connecting each prop. In addition to this diagonal bracing should
be provided in elevation ideally at 45 degrees or between 30 degrees and 60 degrees. The
Contractor shall be entirely responsible for the adequacy of propping, and for keeping the
wedges and other locking arrangements undisturbed through the de-centering period.
(IS:8989 Safety code for erection of concrete framed structures)
(l) Formwork shall be continuously watched during the process of concreting. If during
concreting any weakness develops and formwork shows any distress the work shall be
stopped, and remedial action shall be taken.
6.8 CONCRETE FINISHES
This section deals with the surface of concrete on which forms had been fixed while
concreting.
6.8.1 Formed Surface
Allowable deviation from plumb or level and from the alignment profile, grades and
dimensions shown on the drawings is defined as "tolerance" and is to be distinguished from
irregularities in finishes as described herein. Tolerances in concrete construction are specified
elsewhere.
The classes of finish and requirements for finishing of concrete surface shall be as shown on
the drawings or as hereinafter specified.
Completed concrete surface shall be tested, where necessary to determine whether surface
irregularities are within the limits specified hereinafter.
Surface irregularities are classified as "Abrupt" or "Gradual". Offsets caused by displaced or
misplaced form sheathing, or form sections or by loose knots or otherwise defective timber
form will be considered as abrupt irregularities and shall be tested by direct measurements.
All other irregularities shall be considered as gradual irregularities and will be tested by use
of template, consisting of a straight edge or the equivalent thereof for curved surfaces. The
length of the template shall be 150 cm for testing of formed surfaces and 300 cm for testing
of unformed surfaces.

SS1-112
The classes of finish for formed concrete surfaces are designated by one of the symbols F1,
F2, F3 and F4. Unless otherwise specified or indicated on drawings, these classes of finish
shall apply as follows:
Finish F1: This finish applies to surfaces where roughness is not objectionable, or surface
that will otherwise be permanently concealed. Surface treatment shall be the repair of
defective concrete, correction of surface depressions deeper than 25 mm and filling of tie rod
holes. Form sheathing will not leak mortar when concrete is vibrated. Forms may be
manufactured with a minimum of refinement.
Finish F2: This finish is required on surfaces permanently but not prominently exposed to
public view for which other finishes are not specified except F1. Forms shall be manufactured
in a workmanlike manner to the required offsets or bulges. Surface irregularities shall not
exceed 5mm for abrupt and 8mm for gradual irregularities measured with a 1.5 m template.
Finish F3: This finish is required for coarse textured concrete surfaces intended to receive
plaster, stucco or wainscoting. Surface irregularities shall not exceed 5mm for both abrupt
and gradual irregularities.
Finish F4: This finish is designated for surfaces prominently exposed to public view where
appearance is also of special importance. To meet with requirements for F4 finish, forms shall
be manufactured in a skilful, workmanlike manner, accurately to dimensions. There should
be no visible offsets, bulges or misalignment of concrete. At construction joints, the forms
shall be rightly set and securely anchored close to the joint. Abrupt and gradual irregularities
shall not exceed 3mm. Irregularities exceeding this limit shall be reduced by grinding to a
level of 1:20 ratio of height to length. Jute bag subbing or sand blasting shall not be used.
6.8.2 Unformed Surfaces
The classes of finish for unformed surfaces are designated by symbols U1, U2, U3 and U4.
Unless otherwise specified or indicated on drawings, these classes of finish shall apply as
follows:
Finish U1: This finish applies to unformed surfaces that will be concealed permanently or
otherwise where a screeded surface finish meets the functional requirements. Finish U1 is
also used as the stage of finishes for U2 and U3. Finishing operations shall consist of
sufficient levelling and screeding to produce an even uniform surface. Surface irregularities
shall not exceed 10mm.
Finish U2: This is floated finish, and used on all outdoor, unformed surfaces. Finish U2 is
also used as the second stage of finish for U3. Floating to be performed manually or
mechanically on stiffened screed surface shall be minimum to produce textured surface. If
finish U3 is to be applied, floating shall be continued till a small amount of mortar without
excess water is brought to the surfaces so as to permit effective trowelling. Surface
irregularities shall be removed
Finish U3: This is a trowelled finish and shall be used for tops of parapets, etc prominently
exposed to view. When the floated surface has hardened sufficiently, steel trowelling shall be
started. Steel trowelling on hardened, floated surface shall be performed with firm pressure
to produce a dense uniform surface free from blemishes and trowel marks and having slightly
glossy appearance. Surface irregularities shall not exceed 5mm.

SS1-113
Finish U4: This is a steel-trowelled finish, similar to finish U3, except that light surface
pitting and light trowel marks such as obtained from the use of machine trowelling will be
acceptable, provided that surface irregularities do not exceed the limits specified for finish
U3.
Unformed surfaces which are nominally level shall be sloped for drainage as shown on
drawings unless the use of other slopes or level surface is indicated on drawings. Narrow
surface such as tops of parapets, walls and kerbs shall be sloped approximately 10mm per
300mm of width. Broader surface such as roadways platform shall be sloped approximately
5mm per 300mm of width. Finishes of floor and roof slabs shall be sloped Exposed Concrete
Work
Exposed concrete surfaces shall be smooth and even, originally as stripped without any
finishing or rendering. The surface shall be rubbed with carborundum stone immediately on
striking the forms. The Contractor shall exercise special care and supervision of formwork
and concreting to ensure that the cast members are made true to their sizes, shapes and
positions and to produce the surface patterns desired. No honeycombing shall be allowed.
Honeycombed parts of the concrete including the other surface defects in the concrete shall
be removed by the Contractor as per the methods, which do not affect the strength of adjoining
concrete.
Part of defective concrete thus removed shall be re-cast using fresh concrete of same grade
or noticed quality concrete repair material depending upon the size, location, thickness of the
defective concrete and structural behaviour of the member having defective concrete at no
additional cost. Contractor shall ensure that no air bubbles are formed on the exposed surface.
Concrete pouring sequence, vibration methodology etc shall be planned to avoid air bubbles.
6.9 AGE OF CONCRETE AT REMOVAL OF FORMWORK
In accordance with CPWD/TNPWD Specifications or IS: 456. Immediately after the forms
are removed, they shall be cleaned with a jet of water and a soft brush.
6.10 STRIPPING OF FORMWORK
The work of formwork removal should be planned, and a definite scheme of operation worked
out. Formwork shall be removed carefully without jarring the concrete and curing of the
concrete shall be commenced immediately. Concrete surfaces to be exposed shall be rubbed
down with carborundum stone or bush- hammer to obtain a smooth and even finish. Where
the concrete requires plastering or other finish later the concrete surface shall be immediately
hacked lightly all overusing noticed methods. No extra payment will be due to the Contractor
for such work on concrete surfaces after removal of forms.
6.11 REUSE OF FORMS
The Contractor shall not be permitted reuse of timber facing formwork brought new on the
works for more than 5 times for exposed concrete formwork and 8 times for ordinary
formwork. 5 or 8 uses shall be permitted only if forms are properly cared for, stored and
repaired after each use. Use of different quality boards or the use of old and new boards in
the same formwork shall not be allowed. If any other type of special or proprietary formwork
is used, the number. of times they can be used shall be given a notice by the Employer’s
Representative.

SS1-114
6.12 FORMWORK FOR PRECAST / PRESTRESSED CONCRETE

The provisions in this section shall be considered supplementary to the general
provisions stated above and additional Technical Specifications for pre-cast segments.
Pre-cast concrete members and panels shall be made in accurately constructed moulds,
on a properly prepared casting bed.
The Contractor shall submit detailed drawings of formwork to the Employer’s
Representative for his notice. Finishing with cement mortar shall not be allowed.
The formwork should be so designed that it does not restrain the shrinkage movements
and possible shortening due to pre-stress of the concrete. The formwork shall be of
sturdy construction with special considerations to shutter vibrators when used. All edges
and joints of the formwork should be designed and sealed so that no cement grout can
escape and there is no wedging or keying to the concrete. The effect of curing on the
formwork should be given special consideration. Depending on care, curing, erection
and maintenance of the formwork after stripping, the following number of uses can be
made with different types of formwork.
Stripping: As soon as the pre-cast units have attained sufficient strength, the formwork
shall be stripped. The pre-cast unit shall be lifted uniformly out of the formwork without
being subjected to tilting or restraint effects.
6.13 SPECIAL ARCHITECTURAL FINISHES
Special noticed architectural finishes like grooves, logos, engravings/projections in inset and out
set as per the noticed design shall be provided by fixing monolithic rubber forms or any other
noticed material fixed on the entire surface of the formwork. The shore hardness of the rubber shall
be 600 ± 5A to ensure strength, flexibility and elasticity. The rubber shall be coldcured (preferably
polyurethane based) and fixed to the formwork under controlled conditions in shade and air
temperature not exceeding 280 0 C.
The form liners should be shrinkage free, solvent free and should be impervious to abrasion by
Concrete, resistant to concrete pressure and heat resistant up to 700oC dry heat. Formwork liner
fixation should be factory made under close tolerances and stage inspections.
If proprietary system of formwork is used, detailed information as given in Appendix B herein
shall be furnished to Employer’s Representative for his notice before use.

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APPENDIX B
6.13.1 Information to be Supplied by Manufacturers of Proprietary Systems of formwork
1. General
(a) The information which the manufacturer is required to supply shall be in such detail as to
obviate unsafe erection and use of equipment due to the intention of the manufacturer not
having been made clear or due to wrong assumptions on the part of the user.
(b) The user shall refer unusual problems of erection/assembly not in keeping with intended
use of equipment, to the manufacturer of the equipment.
2. Information Required
The manufacturers of proprietary systems shall supply the following information;
(a) Description of basic functions of equipment.
(b) List of items of equipment available, giving range of sizes, spans and such like, with
manufacturer’s identification number or other references.
(c) The basis on which safe working loads have been determined and whether the factor of
safety given applies to collapse or yield.
(d) Whether the supplier’s data are based on calculations or tests. This shall be clearly stated
as there may be wide variations between results obtained by either method.
(e) Instructions for use and maintenance, including any points which require special attention
during erection, especially where safety is concerned.
(f) Detailed dimensional information, as follows:
(i) Overall dimensions, depths and widths of members.
(ii) Line drawings including perspectives and photographs showing normal uses.
(iii) Self-weight.
(iv) Full dimensions of connections and any special positioning and supporting
arrangements.
(v) Sizes of members, including tube diameters and thicknesses of material.
(vi) Any permanent camber built into the equipment.
(vii) Sizes of holes and dimensions giving their positions.
(viii) Manner of fixing including arrangements for sealing joints.
(ix) Method of de-stripping, storing & shifting.
(g) Data relating to strength of equipment as follows:
(i) Average failure loads as determined by tests.
(ii) Recommended maximum working loads for various conditions of use.

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(iii) Working resistance moments derived from tests.

(iv) Working shear capacities derived from tests.
(v) Recommended factors of safety used in assessing recommended loads and
deflections based on test results.
(vi) Deflections under load together with recommended pre-camber and limiting
deflections.
(vii) If working loads depend on calculations, working stresses should be tested. If
deflections depend on theoretical moments of inertia or equivalent moments of inertia
rather than tests, this should be noted.
(viii) Information on the design of sway bracing against wind and other horizontal
loadings.
(ix) Allowable loading relating maximum extension of bases and/or heads.
(x) Any restrictions regarding usage of any component or full assembly with regard to
spans, heights and loading conditions.
7 PRESTRESSED MEMBERS
7.1 PRE-STRESSING TENDONS
7.1.1 Materials
(i) Steel Wire
Steel wire shall comply with BS 5896.
(ii) Cold worked high tensile alloy bar
Cold worked high tensile alloy steel bars for prestressing shall comply with the requirements
of BS 4486.
(iii) Stress-relieved seven-wire strand
Stress relieved seven-wire strand shall comply with the requirements in TIS 420, Grade 1860,
nominal diameter 12.7 millimetres or 15.2 millimetres, or have properties that are not inferior.
The characteristic breaking load shall not be less than that specified by the Contractor.
(iv) Sampling and Testing
(a) When it is proposed to use super strand complying with BS 5896 Table 6 or other than the
lowest strength 3,4,5,6 or 7 mm diameter wire complying with BS 5896 Tables 4 or 5 the
following shall apply:
(1) A sample shall be taken from each reel of material proposed for use in the Works
(2) A reel shall only be accepted if both the breaking load and the 0.1% proof load of the
sample exceeds the specified characteristic loads given in Tables 4 or 6 of B5 5896.
In the case of Table 5 this requirement shall apply to the breaking load and the load at
1% elongation.
(3) These requirements shall be additional to any other requirements of the Contract.

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(b) The Contractor shall arrange for samples of the steel intended for use in the Works to be
tested at a noticed laboratory.
7.1.2 Handling and Storage
(a) Care shall be taken to avoid mechanically damaging, work-hardening or heating pre-
stressing tendons while handling. All pre-stressing tendons shall be stored clear of the
ground and protected from the weather, from splashes from any other materials, and
from splashes from the cutting operation of an oxy-acetylene torch, or arc-welding
processes in the vicinity.
(b) In no circumstances shall pre-stressing tendons after manufacture be subjected to any
welding operation, or 'on-site' heat treatment or metallic coating such as galvanising.
This does not preclude cutting as specified in this Contract.
(c) All wires, strands or bars stressed in one operation shall be taken, where possible, from
the same parcel. Each cable shall be tagged with its number from which the coil
numbers of the steel used can be identified. Cables shall not be kinked or twisted.
Individual wires and strands for which extensions are to be measured shall be readily
identifiable at each end of the member. No strand that has become unravelled shall be
used.
7.1.3 Surface Condition
Pre-stressing tendons anchorages, blocking devices and internal and external surfaces of
ducts shall be clean and free from pitting, loose rust, loose scale and chloride
contamination at the time of incorporation in the work. If any surface cleaning is required
it shall not heat, damage or polish the surface, or coat it with oil, grease or any other
material.
7.1.4 Straightness
(a) Prestressing Wire
Unless otherwise agreed with the Employer’s Representative, low relaxation and normal
relaxation wire shall be in coils of sufficiently large diameter to ensure that wire pays off
straight.
(b) Strand
Pre-stressing strand, however manufactured, shall be in coils of sufficiently large diameter to
ensure that the strand pays off reasonably straight.
(c) Bars
Pre-stressing bars as delivered shall be straight. Bars bent in the threaded portion shall be
rejected. Any straightening of bars shall be carried out cold but at a temperature of not less
than 5oC. Any necessary heating shall be by means of steam or hot water.
(d) Reinforcement mesh or wire
Mesh or wire shall be delivered in sheets or coils. Any straightening of bars shall be carried
out cold but at a temperature of not less than 5oC. Any necessary heating shall be by means
of steam or hot water.

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(e) Cutting
All cutting of wire, strand or bar shall be carried out using either:
(i) a high-speed abrasive cutting wheel, friction saw at not less than one diameter from
the anchor or any other mechanical method noticed by the Employer’s Representative,
or
(ii) an oxy acetylene cutting flame, using excess oxygen to ensure a cutting rather than a
melting action not less than 75 millimetres from the anchor whilst the temperature of
the tendon adjacent to the anchor shall not be greater than 200oC. Care shall be taken
that neither the flame nor splashes come into contact with either the anchorage or other
tendons or reinforcement.
7.2 PRE-CAST CONSTRUCTION
Care shall be exercised in the set-up of each member. All materials to be encased within the
concrete of the member shall be properly positioned and supported. Provisions for all
projections, recesses, notches, openings, blackouts and the like shall be made in accordance
with the Drawings.
7.3 STRESSING TENDONS
7.3.1 General
(i) It shall be the obligation of the Contractor to provide a technician skilled in pre- stressing
systems to supervise or provide appropriate surveillance of the work and give the
Employer’s Representative such pertinent information as he may require for inspecting the
work. Such a representative shall be available full-time on all days during which the
stressing and grouting of tendons is in progress.
(ii) All post-tensioning steel shall be tensioned by means of hydraulic jacks so that the force
of the pre-stressing steel shall not be less than the value shown on the noticed working
drawings. The maximum temporary tensile stress (stressing stress) in pre-stressing steel
shall not exceed 80% of the specified minimum ultimate tensile strength of the pre-
stressing steel.
7.3.2 Tensioning Apparatus
The tensioning apparatus shall meet the following general requirements: -
(i) The means of attachment of the tendon to the jack or tensioning device shall be safe and
secure.
(ii) Where two or more wires or strands are stressed simultaneously, they shall be
approximately of equal length between anchorage points at the datum of load and
extension measurement. The degree of variation shall be small compared with the expected
extension.
(iii) The tensioning apparatus shall be such that a controlled total force is imposed gradually,
and not dangerous secondary stresses are induced in the tendons, anchorage or concrete.
(iv) The force in the tendons during tensioning shall be measured by direct-reading load cells
or obtained indirectly from gauges fitted in the hydraulic system to determine the pressure

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in the jacks. Facilities shall be provided for the measurement of the extension of the tendon
and of any movement of the tendon in the gripping devices. The load-measuring device
shall be calibrated to accuracy within ± 2% and checked at intervals Elongation of the
tendon shall be measured to accuracy within 2% or ±2 millimetres, whichever is the more
accurate.
(v) The tensioning equipment shall be calibrated before the tensioning operation and at
intervals of months or as noticed by the Employer’s Representative.
(vi) Any indication in the loss of strength in tendons during the tensioning operation shall be
brought to the attention of the Employer’s Representative. Any corrective measures which
may be required in procedures and/or material shall be noticed by the Employer’s
Representative.
(vii) When friction must be reduced, water-soluble oil may be used to the notice of the
Employer’s Representative. This oil may be flushed from the duct as soon as possible after
stressing is completed by use of water pressure. These ducts shall be flushed again just
prior to the grouting operations. Each time the ducts are flushed, they shall be immediately
blown dry with oil-free air.
(viii) Loss in strength of tendons may occur from wedge pull-in, bond failure tendon slippage
or concrete elastic shortening, and these shall be separately identified by methods agreed
with the Employer’s Representative. Immediate loss in strength must also be identified
from relaxation loss for the purposes of design and testing.
7.4 TESTING BY CONTRACTOR
(i) For the purpose of accurately determining the tendon elongations while stressing, the
Contractor shall bench-test two samples of each size and type of strand tendon to determine
the modulus of elasticity prior to stressing the initial tendon. The bench should be at least
6 metres long, with concrete anchorage blocks having a constant area end section of at
least four times that of the anchorage assembly area. The tendon shall be straight and
centered on the cross-sectional area of the bench.
(ii) The test procedure shall consist of stressing the tendon at an anchor assembly with the
dead end consisting of a load cell. The test specimen shall be tensioned to 80% of ultimate
in a minimum of 10 increments.
(iii) For each increment, the gauge pressure, elongation and load cell force shall be recorded.
The data shall be furnished to the Employer’s Representative. The theoretical elongations
shown on the post-tensioning working drawings shall be re-evaluated by the Contractor
using the results of the tests and corrected as necessary.
(iv) Revisions to the theoretical elongations shall be noticed to the Employer’s Representative.
Apparatus and methods used to perform the tests shall be proposed by the Contractor.
After the initial testing, five (5) more tests shall be performed. These tests shall be spaced
evenly throughout the duration of the Contract.

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7.5 PRE-TENSIONING
Where pre-tensioning methods are used, the tension shall be fully maintained by some
positive means during the period between tensioning and transfer. The transfer of stress shall
take place slowly to minimize shock. It is important to identify the different modes of stress
transfer between and ungrouted tendons and allow for the test system to behave in the
appropriate manner for each setup.
7.5.1 Straight Tendons
(i) In the long-line method of pre-tensioning, sufficient locator plates shall be distributed
throughout the length of the bed to ensure that the wires or strands are maintained in their
proper position during concreting.
(ii) Where a number of units are made in the line, they shall be free to slide in the direction of
their length and thus permit transfer of the pre-stressing force to the concrete along the
whole line for grouted tendons. In the individual mould system, the moulds shall be
sufficiently rigid to provide the reaction to the pre-stressing force without distortion. In
ungrouted tendons the locator plates must be fashioned so that load transfer is not
incorrectly carried out at these plate locations but only at the external concrete faces by
bearing.
7.5.2 Deflected Tendons
(i) Where possible the mechanisms for holding down or holding up tendons shall ensure that
the part in contact with the tendon is free to move in the line of the tendon so that frictional
losses are nullified. If, however, a system is used that develops a frictional force, this force
shall be determined by test and due allowance made as agreed with the Employer’s
Representative.
(ii) For single tendons the deflector in contact with the tendon shall have a radius of not less
than 5 times the tendon diameter for wire or 10 times the tendon diameter for a strand, and
the total angle of deflection shall not exceed 15 degrees. Where the radius is less than 5
times the diameter of the tendon and the angle of deflection exceeds 15 degrees, the loss
of strength of the tendon shall be determined by test and due allowance made.
(iii) The transfer of the pre-stressing force to the concrete shall be effected in conjunction
with the release of hold-down and hold-up forces as noticed by the Employer’s
Representative.
7.6 POST-TENSIONING
7.6.1 Arrangement of Tendons
Where wires, strands or bars in a tendon are not stressed simultaneously, the use of spacers
shall be in accordance with the recommendations of the system manufacturer.
7.6.2 Anchorages
(i) Anchorages shall be tested in accordance with the requirements of BS 4447
(ii) For each anchorage system used in the Works, the characteristic value for anchorage
efficiency shall be not less than 90%.

SS1-121
(iii) Proprietary anchorages shall be handled and used strictly in accordance with the
manufacturer's instructions and recommendations.
7.6.3 Deflected Tendons
The deflector in contact with the tendon shall, have a radius of not less than 50 times the
diameter of the tendon, and the total angle of deflection shall not exceed 15 degrees unless
otherwise agreed with the Employer’s Representative.
7.6.4 Tensioning Procedure
(i) Before tensioning, the Contractor shall demonstrate that all tendons are free to move in the
ducts unless the geometry of the ducts makes this impracticable as agreed with the
Employer’s Representative. Tensioning shall be carried out in such a manner that the stress
in the tendons increases at a gradual and steady rate.
(ii) Unless otherwise described in the Contract, concrete shall not be stressed until it has
reached at least the age at which 2 test cubes taken from it attain the specified transfer
strength. The test cubes shall be made and tested as described in BS 1881. They shall be
cured in similar conditions to the concrete to which they relate in a manner noticed by the
(iii) The Contractor shall cast sufficient cubes to demonstrate that the required strength of the
concrete at transfer has been reached.
(iv) The Contractor shall ensure that those carrying out the stressing are provided with
particulars of the required tendon loads, order of stressing and extensions. Allowance shall
be made during stressing for the friction in the jack and in the anchorage, although the
former is not necessary when using load cells.
(v) Any allowance for draw-in of the tendon during anchoring shall be noticed to the
(vi) Stressing shall continue until the required extension and tendon load are reached or are
noticed by the Employer’s Representative.
(vii) The extension shall allow for any draw-in of the tendon occurring at the non- jacking end,
but measurement shall not commence until any slack in the tendon has been taken up.
(viii) Immediately after anchoring, the forces in the pre-stressing tendons shall not exceed 70%
of their characteristic strength. During stressing the value may exceed 70% of their
characteristic strength, with notice to the Employer’s Representative, but shall not exceed
80%.
(ix) After the tendons have been anchored, the force exerted by the tensioning apparatus shall
be decreased gradually and steadily so as to avoid shock to the tendon or the anchorage.
Full records shall be kept of all tensioning operations, including the measured extensions,
pressure-gauge or load-cell readings, and the amount of draw-in at each anchorage. Copies
of these records shall be supplied to the Employer’s Representative within 24 hours of
each tensioning operation.

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(x) Unless otherwise agreed with the Employer’s Representative tendons shall not be cut less
than 3 days after grouting.
7.7 PRE-STRESSING TENDONS - PROTECTION AND BOND
(i) The pre-stressing tendons shall be protected in their permanent positions from both
mechanical damages shall be applied to all unbonded pre-stressing tendons within 28 days
of installation of the tendon in the duct. The tendon protection compound shall be applied
to the ends to avoid corrosion as described in the Contract and the following sub-clauses.
(ii) The exposed tendons at the anchorages and the anchorages themselves shall be sealed
within a closed box and protected from both mechanical damage and corrosion. Suitable
access shall be left for jacking equipment for the later removal of the strands of unbonded
tendons. The means of protection shall be designed by the pre-stressed steel supplier and
noticed by the Employer’s Representative.
(iii) A tendon protection compound shall be a micro-crystalline wax (petrolatum) base material
containing additives to enhance the corrosion inhibiting, wetting, and moisture displacing
properties, as well as the ability to form a polar bond with the tendon steel.
(iv) The compound manufacturer shall provide test data verifying that the following properties
are met for the service life of 120 years and temperature range of 0 degrees to 50oC
(1) Freedom from cracking and brittleness;
(2) Continuous self-healing film over the coated surfaces;
(3) Chemical and physical stability;
(4) Non reactivity with the surrounding and adjacent materials such as concrete,
tendons, and ducts;
(5) Moisture displacing characteristics.
(v) Additionally, it shall remain flexible to allow removal and replacement of the tendons. The
tendon protection compound and its method of installation shall be noticed by the
(vi) Provision shall be made for expansion of the tendon protection compound during the
lifetime of the structure.
(vii) Before installing the tendon, protection compound it shall be demonstrated that the ducts,
U-bend anchorage and anchorages are clean and free of water and chlorides.
(viii) The tendons, internal face of the steel u-bend anchorage, stressing anchorages and any
other metallic components of the pre-stressing system shall additionally be pre-treated
with a protection compound before delivery to site. The protection compound shall be
applied to each strand of the tendon and shall be compatible with the tendon protection
compound injected into the ducts. The protection compound shall be noticed by the

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(ix) The Contractor shall notice the Employer’s Representative on tendon protection
compound suppliers’ proposals which shall describe how the tendon protection compound
can be removed and re-injected into ducts, including buried ducts, within the permanent
works.
(x) All materials used in the pre-stressing systems shall not give off toxic fumes at
temperatures below 50oCand shall not support combustion.
7.8 DUCTS FOR BONDED TENDONS
7.8.1 Ducts
(i) Ducts for longitudinal, transverse or vertical tendons embedded into the concrete may be
of flexible, semi-rigid, or rigid galvanized, ferrous metal capable of withstanding concrete
pressures without deforming or permitting the entrance of cement paste during casting of
the member.
(ii) Ducts shall retain their shape and be capable of transferring bond stresses. The semi-rigid
duct must be rigid enough to remain straight when supported at 1200 millimetres
maximum intervals but flexible enough to allow 3600 millimetres radius curves. Flexible
duct shall be secured or supported at not more than 300 millimetres intervals.
7.8.2 Grouting of Pre-stressing Tendons
(1) General
The Contractor shall undertake grouting trials when required by the Employer’s
Representative.
(2) Materials
(i) Unless otherwise directed or agreed by the Employer’s Representative as a result of
grouting trials, the grout shall consist only of Ordinary Portland Cement.
(ii) Cement and water. The water/cement ratio shall be as low as possible consistent with the
necessary workability, and under no circumstances shall the water: cement ratio exceeds
0.45 by weight.
(iii) The grout shall not be subject to bleeding in excess of 2% after 3 hours or 4% maximum
when measured at 25oCor such other temperature as may be noticed by the Employer’s
Representative, in a covered cylinder approximately 100 millimetres diameter with a
height of grout of approximately 100 millimetres and the water shall be reabsorbed by the
grout during the 24 hours after mixing.
(iv) Admixtures may be used with the written permission of the Employer’s Representative
and shall be applied strictly in accordance with the manufacturer's instructions.
Admixtures shall not contain chloride ions in excess of 0.25 % by weight.
(v) Dry materials shall be measured by weight.
(3) Ducts
(i) Air vents shall be provided at any crests in the duct profile and elsewhere as specified.

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(ii) All ducts shall be thoroughly clean before grouting. Ducts formed without metal sheathing
shall be provided with effective drainage and, unless otherwise directed by the Employer’s
Representative, shall be flushed with water before grouting.
(iii) All surplus water shall be removed by compressed air injection.
(iv) All anchorages shall be sealed or fitted with grouting connections.
(4) Grouting Equipment
(1) The mixing equipment shall produce a grout of homogeneous consistency and shall be
capable of providing a continuous supply to the injection equipment.
(2) The injection equipment shall be capable of continuous operation with little variation of
pressure and shall include a system for recirculating the grout while actual grouting is not in
progress. Compressed air shall not be used.
(3) The equipment shall have a sensibly constant delivery pressure not exceeding 1 Megapascal.
All piping to the grout pumps shall have a minimum of bends, valves and changes in diameter.
All baffles to the pump shall be fitted with 1.18-millimetre sieve strainers. All equipment,
especially piping, shall be thoroughly washed through with clean water after every series of
operations and at the end of use for each day. The interval between washing shall not exceed
3 hours.
(4) The equipment shall be capable of maintaining pressure on completely grouted ducts and
shall be fitted with a valve that can be locked off without loss of pressure in the duct.
(5) Mixing
Water shall be added to the mixer first, then the cement. When these are thoroughly mixed,
the admixture, if any, shall be added. Mixing shall continue until a uniform consistency is
obtained. Mixing shall not be by hand.
(6) Injecting Grout
(i) Grouting shall be carried out as soon as is practicable after the tendons in them have been
stressed and anchors trimmed and the Employer’s Representative's permission to
commence has been obtained.
(ii) Injection of grout shall be continuous, and it shall be slow enough to avoid producing
segregation of the grout. The method of injecting grout shall ensure complete filling of the
ducts and complete surrounding of the steel. Grout shall be allowed to flow from the free
end of the duct until its consistency is equivalent to that of the grout injected. The opening
shall then be firmly closed. Any vents or bleed holes shall be closed in a similar manner
one after another in the direction of the flow. After an appropriate time, further injections
shall be carried out to fill any possible cavities.
(iii) The injection tubes shall then be sealed off under pressure until the grout has set.
(iv) The filled ducts shall not be subjected to shock or vibration within 1 day of grouting.
(v) Not less than 2 days after grouting, the level of grout in the injection and vent tubes shall
be inspected and made good as necessary.

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(vi) The Contractor shall keep full records of grouting including the date each duct was
grouted, the proportion of the grout and any admixtures used, the pressure, details of any
interruptions and topping up required. Copies of these records shall be supplied to the
Employer’s Representative within 3 days of grouting.
(vii) The Contractor shall provide facilities and attendance for the radiographic testing of the
grouted duct.
(7) Strength of Grout
The compressive strength of 100 millimetres cubes made of the grout shall exceed 17
Megapascals at 7 days. Cubes shall be cured in a moist atmosphere for the first 24 hours and
subsequently in water.
7.9 DUCTS FOR UNBONDED TENDONS
(i) Unless shown otherwise on the Drawings, ducts and injection tubes in the superstructure and
substructure shall be formed from high density polyethylene (HDPE) which shall incorporate
a stabilizing agent to prevent Ultraviolet Light (UVL) degradation.
(ii) The minimum wall thickness of the ducts shall be such that the ducts are capable of resisting
the pressures developed during installation of the protection compound. The ducts shall be
smooth bore.
(iii) Ducts with external diameters greater than 70 millimetres shall be transported and stored in
straight lengths without stacking. The distance between supports shall be limited to 3 metres
and the height of storage to 1.5 metres. Alternatively, ducts may be transported and stored in
coils provided that they are fixed to the designed tolerances. Damaged ducts shall not be used
in the Works.
(iv) No boring of any holes in the ducts shall be permitted once the tendons are installed.
(v) U-bend anchorages shall be formed from smooth-bore unwelded steel tubes and shall comply
with the requirements of BS 4360.
(vi) Joints between ducts, ducts and anchorages and ducts and U-bend anchorages shall be formed
by a coupling device using thermo-fusion techniques which shall provide a water-tight seal
to the ducts and shall be capable of resisting the pressure developed during installation of the
tendon protection compound. The inner surfaces of the joints shall form a smooth transition
between ducts and U- bend anchorages to allow satisfactory installation of the tendons. All
coupling devices shall be noticed by the Employer’s Representative.
(vii) Injection tubes shall be provided at the U-bend anchorages, the stressing anchorages and at
any other positions on the length of the ducts which are required to achieve satisfactory
installation of the tendon protection compound. The injection tubes at the U-bend anchorages
shall also be used as drainage points for the U-bend. The connection between the ducts and
the injection tubes shall be water-tight and capable of resisting the pressure developed during
installation of the tendon protection compound.
(viii) All injection tubes shall be sealed after use to prevent the ingress of water.

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(ix) After completion of all duct joints and before completion of the in-situ joints between pre-
cast segments and before installation of the tendons, all ducts shall be air tested to an
equivalent 100 millimetres water gauge. The test shall be performed in accordance with BS
8301 Section 5.
(x) Any ducts which do not contain tendons shall remain empty and shall be sealed at each end
to prevent the ingress of water.
7.10 PRE-STRESSING TENDONS - TRIAL CONSTRUCTION-UNBONDED TENDONS
(i) Before commencing construction of the pre-cast segments a trial shall be carried out which
shall demonstrate the satisfactory installation, removal and replacement of a pre-stressing
strand together with the proposed techniques for duct jointing, duct testing and installation
of the tendon protection compound.
(ii) The tendons shall be stressed in accordance with this Contract.
(iii) The ducts shall be filled with a tendon protection compound in accordance with this Contract
and the tendon extension and anchorage shall be protected as if they were to be included in
the permanent works.
(iv) The trial shall demonstrate that any one strand may be destressed, removed, inspected,
replaced and restressed and that no voids are created within the tendon protection compound.
(v) The trial shall also demonstrate that all of the strands in a duct may be removed and that the
tendon protection compound can be removed from the ducts and U- bend anchorage
(vi) The trial shall be undertaken using the pre-stressing system to be used in the Permanent
Works and shall be noticed by the Employer’s Representative.
7.11 PRE-STRESSING TENDONS - TEMPORARY TENDONS
(1) Temporary tendons may be re-used as temporary tendons elsewhere provided special
precautions are incorporated at the anchorages to ensure tendons are not damaged. These
precautions shall be noticed by the Employer’s Representative.
(2) The tendons shall be enclosed within a duct throughout their length.
(3) The tendons shall be pre-treated in accordance with the Contract and the protection compound
shall be applied to the outer surfaces of the tendon after each use.
(4) The maximum jacking force for the re-usable temporary tendons shall not exceed 70% of
their guaranteed minimum breaking load.
(5) After removal of the tendons the ducts shall be sealed at each end to prevent the ingress of
water.
7.12 PREPARATION FOR CASTING
(1) The Contractor shall submit for notice, in accordance with the provisions of the Employer's
Requirements, working drawings of the pre-stressing system proposed for use. For initial
notice, 3 sets of such drawings shall be submitted.

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(2) After notice, between 6 and 12 sets, shall be submitted The working drawings of the pre-
stressing system shall show complete details and be accompanied by substantiating
calculations of the method and materials the Contractor proposes to use in the pre-stressing
operations, including any additions or rearrangement of reinforcing steel from that shown on
the Drawings. Such details shall outline the method and sequence of stressing and shall
include complete specifications and details of the pre-stressing steel and anchoring devices,
working stresses, anchoring stresses, type of ducts, and all other data pertaining to the pre-
stressing operation, including the proposed arrangement of the pre-stressing steel in the
members.
(3) Working drawings shall be A1 size and each drawing and calculation sheet shall include the
job site, name of the structure as shown on the Contract Drawings and Contract name.
(4) Working drawings shall be submitted sufficiently in advance of the start of the affected work
to allow time for notice by the Employer’s Representative and correction by the Contractor
of the drawings without delaying the work. Such time shall be proportional to the complexity
of the work but in no case shall such time be less than eight (8) weeks.
(5) At the completion of each structure, one set of reproducible Mylar of the corrected original
tracing of all working drawings for said structure shall be furnished to the Employer’s
Representative. Drawings which are common to more than one structure shall be provided
for each structure. An index prepared specifically for the working drawings for each structure
containing sheet numbers and titles shall be included.
(6) Reinforcing steel shall be fabricated and placed in accordance with the Drawings and as
required herein. No reinforcing steel shall be cut and removed to permit proper alignment of
stressing ducts. Any bar that cannot be fabricated to clear the conduits shall be replaced by
additional bars with adequate lap lengths and shall be submitted to the Employer’s
Representative. In the plane of the steel parallel to the nearest surface of concrete, bars shall
not vary from plan placement by more than 12 millimetres or one-tenth (1/10) of the spacing
between bars, whichever is less.
(7) All pre-stressing steel shall be protected against physical damage and rust or other results of
corrosion at all times from manufacture to grouting or encasing in concrete. Pre-stressing
steel that has sustained physical damage at any time shall be rejected. The development of
visible rust or other results of corrosion shall be cause for rejection, Pre-stressing steel shall
be packaged in containers or shipping forms for the protection of the steel against physical
damage and corrosion during shipping and storage. A corrosion inhibitor which prevents rust
or other results of corrosion shall be placed in the package or form or shall be incorporated in
a corrosion inhibitor carrier type packaging material, may be applied directly to the steel, with
notice to the Employer’s Representative. The corrosion inhibitor shall have no deleterious
effect on the steel or concrete or bond strength of steel to concrete. Packaging or forms
damaged from any cause shall be immediately replaced or restored to original condition.
(8) The shipping package or form shall be clearly marked with a statement that the package
contains high-strength pre-stressing steel, and the care to be used in handling; and the type,

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kind and amount of corrosion inhibitor used, including the date when placed, safety orders
and instructions for use.
(9) Pre-stressing steel for post-tensioning which is installed in members prior to placing and
curing of the concrete, shall be continuously protected against rust or other corrosion, until
grouted, by means of a corrosion inhibitor placed in the ducts or applied to the steel in the
duct. The corrosion inhibitor shall conform to the requirements specified herein.
(10)When steam curing is used, pre-stressing steel for post-tensioning shall not be installed until
the steam curing is completed.
(11)All water used for flushing ducts shall contain either quick lime (calcium oxide) or slaked
lime (calcium hydroxide) in the amount of 13 grams per litre. All compressed air used to blow
out ducts shall be oil free.
(12)When acceptable pre-stressing steel for post-tensioning is installed in the ducts after
completion of concrete curing, and if stressing and grouting are completed within 10 calendar
days after the installation of the pre-stressing steel, rust which may form during said 10 days
will not be cause for rejection of the steel. Pre- stressing steel installed, tensioned and grouted
in this manner, all within 10 calendar days, will not require the use of a corrosion inhibitor in
the duct following installation of the pre-stressing steel. Pre-stressing steel installed as above
but not grouted within 10 calendar days shall be subject to all the requirements in this section
pertaining to corrosion protection and rejection because of rust.
(13)Any time acceptable pre-stressing steel for pre-tensioning is placed in the stressing bed and
is exposed to the elements for more than 36 hours prior to encasement in concrete, adequate
measures shall be taken by the Contractor, as noticed by the Employer’s Representative, to
protect said steel from contamination or corrosion.
(14)All ducts shall be located within 5 millimetres of the locations given on noticed fabrication
plans. Method and spacing of supports for ducts shall be shown on the working drawings.
After installation in the forms, the end of the ducts shall at all times be sealed to prevent entry
of water and debris. Following each pour of concrete, the Contractor will be required to
demonstrate that all empty ducts are free of water and are unobstructed and undamaged.
Immediately prior to installation of the pre-stressing steel, the Contractor shall again
demonstrate that all ducts are unobstructed and that they are free of water and debris.
(15)Where tendons are described in the Contract as deboned from the concrete, they shall be
covered with sleeves noticed by the Employer’s Representative. The ends of the sleeves shall
be taped to the tendon to prevent the ingress of grout.
(16)Concrete shall not be deposited into forms until the entire set-up of the forms, reinforcement,
ducts, and anchorage has been thoroughly inspected and checked. The Contractor shall submit
a proposal to the effect that the rate of producing and placing concrete will be sufficient to
complete the proposed pour and finishing operations within the scheduled time, that
experienced concrete finishers are available where required for finish work and all necessary
finishing tools and equipment are on hand at the site of the work and are in satisfactory
condition for use.
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(17)Concrete on sloped forms shall be placed on the lowest end or edge and worked to the higher
end or edge to avoid loss of water and compaction. Self-levelling concrete may be used where
access is limited, however vibration is still necessary.
(18)Conveying equipment shall be of a size and design that will permit the placing of concrete
within the time limits specified. Conveying equipment shall be cleaned at the end of each
operation or workday and just prior to reuse shall again be checked and cleaned of hardened
concrete and foreign materials.
(19)Belt conveyors shall be horizontal or at a slope which will not cause excessive segregation of
loss of ingredients. Concrete shall be protected against undue drying or rise in temperature.
A noticed arrangement shall be used at the discharge end to prevent aggregate segregation.
Mortar shall not be allowed to adhere to the return length of the belt. Concrete shall be
discharged into a hopper or through a baffle.
(20)The concrete shall be first placed in the web forms followed by placement at the bottom slab
and then in the top form. Any alternate sequence shall be submitted noticed to the Employer’s
Representative.
(21)For pours conducted in stages, the concrete from the first stage interfacing with the newer
pour should be clean and moistened. Older concrete surfaces should be scrabbled to allow
aggregates to be partially visible or else scarified and roughened if the first pour is fairly
recent.
(22)All concrete shall be consolidated by means of noticed vibrators together with any other
equipment necessary to perform the work as specified. Internal vibrators shall have a
minimum frequency of 8,000 vibrations per minute and sufficient amplitude to consolidate
the concrete effectively.
(23)Vibrators should be of sufficient size but not oversized for the particular pour – e.g., the
vibrators should be able to fit between reinforcement cages, rebar spacings and into corners.
Vibration time shall be controlled such that segregation is not caused by keeping the vibrator
in one place for prolonged periods. Typical diameters range from ½” to ¾” (12 to 18
millimetres) for standard pours and to be determined by trial pours prior to use on actual
works. Honeycombing from air-entrainment is also reduced by proper vibration, especially
between the reinforcement and form faces.
(24)At least two (2) stand-by vibrators in working condition shall be provided for emergency use
in case of malfunction. The use of external vibrators or vibrating forms for consolidating
concrete will be permitted and may be required when the concrete is inaccessible for adequate
consolidation. When external vibration is used, the forms shall be constructed sufficiently
rigid to resist displacement or damage. Vibrating of concrete shall be done with care and in
such a manner as to avoid displacement of reinforcing, conduits, and other items to be fixed
in place.

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8 STRUCTURAL STEELWORK
8.1 GENERAL
Workmanship and materials shall be generally in accordance with relevant Indian Standards
or where alternatively noticed by the Employer’s Representative, in accordance with BS-EN
or ASTM standards.
8.2 MATERIAL PROPERTIES
(i) Steel for rolled sections, plates and bars shall normally comply with IS 226/ IS 2062 or BS
5950, Part 2 Grade 43, or special steel as per design requirement.
(ii) Dimensional properties, tolerances and rolling margins shall comply with the relevant
Standards.
(iii) The condition of steel for fabrication shall be to IS 2062 or Swedish Standard 05 5900, Grade
C unless otherwise detailed.
(iv) Bolts and nuts shall comply with design requirement.
(v) Washers shall comply with BS 4320.
(vi) Stainless steel shall be grade 316 S31 to BS 970: Part 1, unless detailed otherwise.
8.3 TESTING
(i)The Contractor shall perform tests and submit test certificates for the materials to be used in the
work. The tests shall include the following in accordance with IS: 226/IS: 2062 or BS-EN
1993:2006 or applicable Indian Standard.
(i) Chemical analysis
(ii) Tensile tests
(iii) Bend tests
(iv) Flattening tests
(ii) The tests shall be carried out by a noticed testing authority and notice shall be given of the
intended execution of any such test. The specimens for testing shall be a random sampling of
steelwork to be used for the project.
(iii) If any sample fails a test, the consignment it represents may be rejected in part or in whole.
Alternatively, it may be possible to either:
a. retest the consignment using another sampling set or;
b. notice the criteria for acceptance of this particular consignment, should the Employer’s
Representative allow an acceptance for a particular use justified by the design
requirements
(iv) In no way do these specific qualifications provide a precedent for future acceptance of any
failed consignment.

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8.4 FABRICATION
(i) The work of fabrication shall comply with the requirements of IS: 800 or other relevant
codes of practice noticed to the Employer’s Representative, in accordance with BS-EN 1993:
2006 or ASTM. Fabrication accuracy shall be within the limits detailed in BS-EN 1993:
2006.
(ii) All parts assembled for bolting shall be in close contact over the whole surface and all
bearing stiffeners shall bear tightly at top and bottom without being drawn or caulked. The
component parts shall be so assembled that they are neither twisted not otherwise damaged
as specified cambers if any shall be provided. Drilling done during assembling shall not
distort the metal or enlarge holes. The butting surfaces at all joints shall be so cut and milled
so as to butt in close contact throughout the finished joints.
(iii) Cutting shall be done automatically. Hand flame cutting will not be permitted.
(iv) The edges and ends of all cut/sheared flange plates, web plates of plate girders, and all cover
plates, and the ends of all angles, tees, channels and other sections forming the flanges of
plate girders, shall be planed/ground.
(v) Holes for bolts shall be drilled to conform to clause 10 of IS:7215 (1974). Punching of holes
will not be permitted. All drilling shall be free from burrs. No holes shall be made by gas
cutting process.
(vi) All welding for the works shall be carried out by first class welders and shall be in
accordance with IS:816, IS:819, IS:1024, IS:1261, IS:1323 and IS:9595. The Employer’s
Representative may at his discretion order periodic tests of the welder and/or of the welds
produced by them. All such tests shall be carried out by the Contractor at his cost.
(vii) Safety requirements should conform to IS: 7205, IS: 7273 and IS: 7269 as applicable and
should conform to safety, economy and rapidity.
(viii) As much work as possible shall be welded in shops. The pieces shall be manipulated to
ensure down hand welding for all shop joints as far as possible. All parts to be welded shall
be arranged so as to fit properly on assembly. After assembly and before the general welding
is to commence the parts are to be tack welded with small fillet or butt welds as the case may
be. The tack welding must be strong enough to hold the parts together but small enough to
be covered by the general welding. The welding procedure shall be so arranged that the
distortion and shrinkage stresses are reduce to a minimum.
(ix) All joints required in structure to facilitate transport or erection shall be shown on the
drawings. The lengths of structural shall be the maximum normally available in the market
and the jointing of shorter length in order to make up lengths required shall not be permitted.
(x) Each piece of steel work shall be marked distinctly before delivery, indicating the position
and direction in which it is to be fixed. Three copies of a complete marking plan shall be
supplied to the Employer’s Representative before erection commences.
(xi) In the case of welded fabrication any distortion remaining in the member after welding
operations are completed shall be rectified by and/or at the expense of the Contractor.
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(xii) All members of trusses and lattice girders shall be straight throughout their length, unless
shown otherwise on the drawings, and shall be accurately set to the lines shown on the
drawings. Sheared edges of gussets or other members to be straightened and dressed where
necessary.
(xiii) Templates and jigs used throughout the work shall be all steel. In cases where actual
materials have been used as templates for drilling similar pieces, the Employer’s
Representative’s notice shall be obtained to use as parts of the finished structure.
(xiv) Apart from the requirements of welding specified under the above sub clauses, sections
above, the Contractor shall ensure the following requirements in the welded joints.
(xv)Strength-quality with parent metal.
(xvi) Absence of defects
(xvii) Corrosion resistance of the weld shall not be less than that of parent material in an
aggressive environment.
(xviii) No gasket or other flexible material shall be placed between the holes. The holes in parts
to be joined shall be sufficiently well aligned to permit bolts to be freely placed in position.
Driving of bolts is not permitted. The nuts shall be placed so that the identification marks
are clearly visible after tightening. Nuts and bolts shall always be tightened in a staggered
pattern and, where there are more than four bolts in any one joint, they shall be tightened
from the centre of the joint outwards.
8.5 DETAILING OF CONNECTIONS
(i) Detailing of connections shall be validated by Contractor to suite his construction
methodology to ensure that inaccessible pockets/gaps are avoided. In this respect, back-to-
back angles with spacers and similar details which would prevent full accessibility for
painting are not acceptable.
(ii) Where cope holes are required to allow completion of butt welding, they shall be of adequate
size to allow fillet welding to seal the connection, while still allowing full accessibility for
subsequent painting.
(iii) Snipping of stiffeners at the root radii of rolled members is not acceptable. Stiffeners shall
be cut to the required profile to fit closely into all such radii, and seal welded.
(iv) High-strength friction grip (HSFG) bolts shall be used only on mating surfaces as specified
herein.
(v) HSFG bolted connections, slip-bolted connections and welded connections shall not be used
interchangeably or in tandem with each other. The use of each of these types of connections
shall be separate and distinct.
8.6 SUBMISSIONS
(i) The Contractor shall submit to the Employer’s Representative two initial copies of each shop
drawing and subsequently four copies of the final shop drawings for retention by the
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(ii) The Contractor shall submit for notice details of erection procedures. The procedure should
contain details of safety precautions to be taken during erection refer IS 7205.
8.7 WELDING
(1) Metal-arc welding of steel shall be in accordance with the requirements of relevant IS, BS-
EN or ASCI standards.
(2) Run-on/run-off plates shall be used during butt welding.
(3) Fillet welds shall be continuous to form a complete seal where two members join or abut.
8.8 ELECTRODES
(1) Welding consumables shall be suitable for the type of steel and position of welding and shall
give a weld deposit with mechanical properties not less than the minimum specified in the
relevant welding standards. Hydrogen-controlled electrodes shall be used for butt welding of
steel over 25 millimetres thick.
8.9 WELDERS
Welders employed on the work shall be tested to BS 4871 and BS 4872: Part 1. Welding
shall be carried out under the supervision of a competent welding technologist and the test
pieces shall be tested to BS 4870.
8.10 TESTING
(1) The Contractor shall make radiographic examination of butt welds in accordance with Section
8 of American Petroleum Industry (API) Standard 1104 and shall carry out dye-penetrant
tests in accordance with BS 6443.
(2) Not less than 10% of the length of each butt weld shall be radiographically inspected and 10%
shall be tested using the dye-penetrant method.
(3) Not less than 10% of the length of each fillet weld shall be tested using dye penetrant testing.
The locations and lengths to be tested shall be as instructed by the Engineer.
8.11 SITE WELDING
(i) The Contractor may, subject to prior notice, use site welding as an alternative to bolted
connections.
(ii) Site-welded joints shall be inspected by radiography in accordance with Section 8 of API
Standard 1104. Initially 100% of each butt weld shall be inspected. At the notice of the
Employer’s Representative, the number of inspections may subsequently be reduced.
(iii) Finished welds shall comply with Section 6 of API Standard 1104. Defective welds shall
be cut out, remade and retested as noticed.
8.12 ERECTION OF STEELWORK
Erection of steelwork shall comply with the requirements of BS-EN 1993: 2006, Stanchions
shall be plumbed using steel packs and wedges and restrained while the spaces beneath the
baseplates are filled with a noticed non-shrink cementations grout. Packs and wedges shall
be protected by grout to a minimum thickness of 50mm.

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The Contractor shall be responsible for checking the alignment and level of foundation and
correctness of foundation bolt centres, well in advance of starting erection work, and shall be
responsible for any consequences for non-compliance thereof. Discrepancies if any shall
immediately be brought to the notice of the Employer’s Representative.
The structure should be divided into erectable modules as per the total scheme. This should
be pre-assembled in a suitable yard/platform and its matching with members of the adjacent
module checked by trial assembly before erection.
Immediately prior to erection any rust in the paint area shall be removed by power wire
brushing to a standard equivalent to SA3.
During erection the rough handling of fabricated materials such as bending, straining or
pounding with sledges shall be avoided. Any damage to the structure during transportation or
erection shall be immediately rectified by the Contractor at his own cost. The straightening
of bend edges of plates, angles and other sections shall be done by methods which will not
cause fracture.
Following the completion of the straightening, the surface of the member shall carefully be
inspected for damage before further use.
The Contractor shall be responsible for accurately positioning, levelling and plumbing of all
steelwork and placing of every part of the structure in accordance with the noticed drawings
and to the satisfaction of the Employer’s Representative. All stanchion base, beam and girder
bearings etc. shall be securely supported on suitable steel packs. All reference and datum
points shall be fixed near the work site for facilitating the erection work.
All equipment used by the Contractor shall be sufficient for the purpose and for the erection
of the steel work, in the time specified in the contract. Any lifting or erecting machinery shall
be noticed to be removed from the site if the Employer’s Representative considers such
appliances dangerous or unsuitable for their functions. The notice of the Employer’s
Representative shall not relieve the Contractor of the responsibilities for the loads to which
the erection equipment shall be called upon to carry. Adequate arrangement shall be made to
resist wind loads and lateral forces arising at the time of erection.
The Contractor is entirely responsible for the stability of the structure during erection and
shall arrange that sufficient tack bolts, braces or guy ropes are used to ensure that work will
remain rigid until final bolting, riveting or welding is completed. The Contractor shall supply
and fix, without extra charge, any temporary bracing which may be necessary.
All steelwork shall be erected in the exact position as shown on the Drawings. All vertical
members shall be truly vertical throughout and all horizontal members truly horizontal,
fabrication being such that all parts can be accurately assembled and erected. No permanent
bolting, welding or grouting shall be done until proper alignment has been obtained and
checked.
At stanchion splices and at other positions where concrete cover to the steel is liable to be
restricted, bolts will be placed with their heads on the outside of the members.

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All field assembly bolting and welding shall be executed in accordance with the requirements
for shop fabrication excepting such as manifestly apply to shop conditions only. Where steel
has been delivered painted the paint shall be removed before field welding for a distance of
at least 50mm on either side of the joints. The number of washers on permanent bolts shall
not be more than two for the nut and one for the bolt head.
8.13 TOLERANCES
The tolerances for erected steelwork shall be as shown on the Drawings. In-lieu of other
information the tolerances from BS-EN 1993:2006 shall be adopted.
8.14 BOLTED CONNECTIONS
(1) Bolts shall be threaded only over the length of shank which is outside the parts bolted
together. The bolt shall protrude by at least two complete threads and not more than four
complete threads beyond the outer face of the tightened nut.
(2) Holes shall not be distorted or enlarged by the use of drifts.
(3) High strength friction grip bolts shall be fitted in accordance with BS 4604, Part 2.
(4) Load-indicating washers shall be installed in accordance with the manufacturer's
recommendations.
8.15 TRANSPORTATION AND STORAGE
Steelwork and protective coatings shall be protected from damage during packing, handling,
transportation and storage. The Contractor shall ensure that members are not subjected to
greater stresses than those allowed in BS 5950, Part 2 during fabrication, transportation,
storage and erection.
Stored items shall not be in contact with each other and shall be clear of the ground.
8.16 DAMAGED MATERIAL
(1) Steelwork deemed to be damaged during the Contract period shall be replaced. The
Contractor shall provide notice to the Employer’s Representative for remedial work to
damaged material if repairable. The method of repair and final repaired condition shall be
obtained a notice by the Employer’s Representative.
8.17 GALVANISING
(1) Galvanising of steelwork, if required, shall be carried out after fabrication is complete.
Steelwork required to be galvanised shall be pickled in dilute hydrochloric acid, washed,
fluxed and stoved, and then coated with zinc by dipping in a bath of molten zinc. Components
shall be immersed in the bath only for the period sufficient to attain the temperature of the
bath and shall be withdrawn at a speed which ensures that a coating of 610 grams per square
metre of surface is achieved – i.e., 85 microns minimum Dry Film Thickness (DFT).
Components shall be covered evenly on all surfaces. Items shall not be galvanised in more
than one dip event due to potential warping or additional stresses that may be induced in the
metal.

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(2) Items described as heavily galvanised shall be grit or sand blasted prior to galvanising and
shall receive a minimum coating of 1000 grams per square metre of surface – ie,140 microns
minimum DFT.
(3) Lightweight gauge metalwork shall be galvanised by the hot-dip process as specified in BS
3083 or BS 2989.
(4) Contact between galvanised steel members and aluminium surfaces or between galvanised
and ungalvanized steel members shall be prevented by means of noticed insulating washers
and grommets.
(5) Galvanised steelwork shall be cleaned, degreased and etch primed before application of the
specified paint treatment.
8.18 PREPARATION OF STEELWORK FOR PROTECTIVE TREATMENT
(1) Surfaces shall be cleaned to BS 7079 before any protective treatment is commenced.
(2) Steelwork shall be degreased and shot, or grit blasted to Sa 2.5 quality standard with surface
amplitude of 50 to 75 microns to remove rust and mill scale. Dust and debris shall be removed
by vacuum cleaner, compressed air or brush. Site welds and adjacent steelwork shall be blast
cleaned and similarly prepared. Surface defects shall be removed in accordance with BS 5950.
(3) Regular mill scale detection tests shall be made using the Copper Sulphate method.
(4) Blasting operations and painting processes shall be segregated.
8.19 PAINTING GENERALLY
(i) Paint shall be applied by brushing or spraying in accordance with the manufacturer’s
instructions. When permitted, thinners shall be added to paint in strict accordance with the
manufacturer’s permitted percentages.
(ii) Brushes stored in thinners shall be worked to remove thinners before reuse.
(iii) Painting shall not be carried out when the steelwork temperature is below 4oC, above 50oC,
less than 3oC above the dew point, or when the relative humidity is above 80%.
(iv) Stripe coats shall be applied to welds and steel edges before painting.
(v) Strong paint films shall be achieved on all cleats, arises, bolt holes, bolt heads and the like.
(vi) Protective treatment, other than the site-applied coatings, shall be applied under factory
conditions in an enclosed shop. Completed coats shall be checked for continuity by a low-
voltage wet sponge holiday detector and for thickness by an Elcometer. The colour of each
coat shall be sufficiently different to permit detection of incomplete application.
(vii) If a required film thickness is specified, it shall be the minimum dry film thickness (DFT) as
measured by a noticed gauge. The gauge shall be calibrated for each coating by the use of a
shim placed on the shot blasted blank or on the underlying coat. The shim shall correspond
to the theoretical film thickness of the coating to be measured. Otherwise, a full coating shall
be applied in accordance with the rate of coverage recommended by the manufacturer,
having regard to the surface profile of the steel and the conditions of application.
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(viii) Sample plates shall be prepared for approval and shall thereafter be adopted as the standard
to be achieved in the finished work.
(ix) The Contractor shall prevent dust and dirt coming into contact with freshly painted surfaces.
(x) Before the site painting coats are applied, the surfaces shall be lightly abraded, if required
by the manufacturer's instructions, and washed with clean water to remove salt and other
impurities.
(xi) Paint shall not be applied to the embedded portions of metal items except those within 75
millimetres of the finished concrete surface.
8.20 APPLICATION OF PROTECTIVE LAYERS
Blast-cleaned surfaces shall be kept dry and shall receive the first coat within 4 hours of the
start of cleaning – i.e., 2 hours for outdoor blast-cleaning. They shall be treated in accordance
with the protective treatment schedule, except the faying surfaces for high strength friction
grip bolt connections.
8.21 PROTECTION OF BOLTS ETC.
Bolts, including high strength friction grip bolts, nuts and washers shall be hot-dip spun-
galvanised or as noticed by the Employer’s Representative. The threads of nuts may be re-
tapped as provided for in BS 729.
8.22 HIGH STRENGTH FRICTION GRIP CONNECTIONS
(i) Faying surfaces for high strength friction grip connectivity shall be blast-cleaned to Sa 2.5
quality standard, masked within two hours to exclude air and exposed just before bolting-
up. Paint and other contaminants shall not be allowed on faying surfaces.
(ii) Each consecutive coat of paint shall be stepped back from the edge of the faying surface by
15 millimetres.
8.23 PROTECTIVE TREATMENT
(i) Damaged paintwork shall be blast-cleaned if bare metal is exposed or corrosion is present.
If the first coat is intact the surface shall be prepared by power wire brushing. The prepared
surface shall be protected with a nominated full paint protection system.
(ii) Submerged steelwork shall, in addition, be coated with a compatible chlorinated rubber-
based anti-fouling paint to a DFT of 75 microns.
8.24 PAINTWORK EXECUTED ON SITE
(1) Following erection, the exposed parts of galvanised nuts, washers and bolts (except chain
fixing bolts) shall be degreased, etch-primed and painted to the specification for adjacent
steelwork. Freshly galvanised surfaces shall be abraded and washed before application of the
etch-primer.
(2) After the preceding operations, and prior to the erection of cladding, if any, the Contractor
shall apply to the superstructure steelwork the finish coat(s) as specified. Any damage to
shop-coats will be made good on site prior to application of the Site coats. If steel has been

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exposed, then the area shall be blast-cleaned primed and receive all shop-coats or Site-coats
to the required standard.
(3) Before the Site-coats are applied, the surfaces shall be lightly abraded, if required by the
manufacturer's instructions, and washed with clean water to remove salt and other impurities.
Paint shall not be applied to the embedded portions of metal items except those within 75
millimetres of the finished concrete surface.
8.25 EARTHING AND BONDING SYSTEM
Earthing and bonding system shall comply with EN-50122-1 Railway applications fixed
Installations-Part I: provisions relating to electrical safety and earthing and BS 7430 Code of
Practice for Earthing.
9 CUT AND COVER CONSTRUCTION
9.1 GENERAL
(i) Cut and cover construction shall comply with the relevant requirements of the Contract for
temporary ground support including elements to be incorporated into Permanent Works.
(ii) Temporary ground support including elements to be incorporated into the Permanent Works
are described in section 2, 4 & 5 of the Contract.
(iii) Support by bracing, ties or anchors are described in Sections 4 & 8 of the Contract.
(iv) Excavation and backfilling are described in section 2 of the Contract.
(v) Reinforced concrete construction is described in section 5 of the Contract.
(vi) Vibration recording devices shall be provided to monitor for vibrations which may cause
damage to the proposed constructions and EBS. These devices shall be installed at intervals
and locations to provide comprehensive coverage of the Works. Unless otherwise directed
by the Fire/Life Safety Committee, these devices shall record ground accelerations generated
by the Works to ensure that these accelerations do not exceed the values set by the
Employer’s Drawings or relevant Authorities or those determined by the Contractor for the
stability and safety of the Temporary and Permanent Works and adjacent EBS.
9.2 WATERPROOFING
9.2.1 General
(i) Material Requirements
Spray applied liquid polymer membranes shall be used for waterproofing of walls other than
Diaphragm walls and roof slabs of underground structures.
Fully bonded membrane waterproofing system with silica fume (also known as micro silica)
added to the concrete shall be used for the base slabs of underground structures.
(ii) Performance Requirements
The water tightness standards to be applied to all underground structures, water-retaining or
water-excluding structures shall be in accordance with the standards defined in Table 9.2.1
below.

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Table 9.2.1: Water tightness Standards
Structural Element Performance Requirements

1. External walls other than Diaphragm walls, Free from all visible leakage, seepage and
base slabs and roof slabs of underground damp patches.
structures.
2. Suspended slab over tracks, concourses, and Free from all visible leakage, seepage and
public areas, areas with sensitive electrical damp patches.
and mechanical plant and areas where
leakage would, in the opinion of the
Engineer, affect the operation of the railway,
roadway or other operations
within the structure.
3. Permanent diaphragm walls Free from all visible leakage, seepage and
damp patches except at the joint where
minor damp patches with no visible film
of water shall be permitted.
Note: Dampness shall be defined as moist to touch with no visible film of water.
(iii) Submission, Requirements, Method Statements and Working Drawings
The proposed waterproofing material shall be suitably resistant to all chemicals with which
they are likely to come into contact. The Contractor shall submit the following information
to the Engineer for his review and acceptance.
Make and composition of all waterproofing materials including ancillary items such as
primer, mastic sealant, and protection boards as recommended by the manufacturers.
(a) Test reports of not more than five years old shall be submitted to demonstrate that the
material properties without and with 6 months thermal ageing meet the requirements and
properties specified in the relevant sections of this specification. All tests shall be carried
out by a laboratory that are accredited and recognised internationally and Noticed by
Engineer to do the specified tests.
(b) Comprehensive working drawings showing, as a minimum, locations and extent of
waterproofing, details and methods for waterproofing of the Works, including details of
membranes, water stops, injection tube systems, position of joints, isometric layout of
water stops and injection tubes, details at sump pits and details at contract interfaces
etc...
(c) Manufacturer’s literature of the proposed waterproofing materials including installation
recommendations and instructions to confirm the suitability.
(d) Detailed method statements prepared in conjunction with, and endorsed by, the proposed
applicator and manufacturer of the material, describing the waterproofing system and
installation details including protective measures at all stages of the waterproofing
works.

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(e) Samples of the proposed waterproofing materials. Upon acceptance of the proposed
waterproofing system, the Contractor shall submit detailed shop drawings showing all
details and procedures to the Engineer for his acceptance prior to commencing any
waterproofing works.
(iv) Quality Assurance
The approved waterproofing materials shall be tested to verify that the material properties
without thermal ageing meet the performance requirements and properties as specified in
this section.
For waterproofing membrane installation up to 15,000m2, a complete set of tests as
specified in Table 9.2.2 and 9.2.3 shall be conducted on the samples taken from the
waterproofing membrane delivered to site. Additional sets of tests shall be conducted for
every subsequent 15,000m2.
Samples shall be taken for every 1000m3 of silica fume concrete delivered to site. A
complete set of tests as specified in Clause 9.2.6 shall be conducted on the samples. A
complete line of automated, high precision dispensing equipment with computerised
control of adding waterproofing admixture as per approved trial mix shall be introduced at
the batching plant for good quality control.
In the event that the tests show that the waterproofing materials, waterproof concrete or
silica fume concrete do not meet the performance requirements, the entire batch of
materials where the samples are taken shall be rejected and the Contractor shall submit
rectification proposal for the Engineer’s acceptance.
The Contractor shall carry out a trial application of the waterproofing materials for the
proposed waterproofing system.
Waterproofing materials shall be installed only by the manufacturer of the product or his
approved applicator.
No material shall be used beyond its manufacturer’s expiry date. Also waterproofing
material shall be stored in a cool place. The material which are subsequently exposed to
sunlight shall not be affected by atmospheric conditions or Ultra Violet Light for minimum
period of 45 days or the difference in time between laying of water proofing material and
concrete pouring whichever is higher.
(v) Waterproofing Application
(a) Waterproofing material shall be installed only by the manufacturer of the products or his
noticed applicator. The Contractor shall submit a method statement, prepared in
conjunction with the applicator and endorsed by the manufacturer of the material,
describing the details of the waterproofing works including protective measures at all
stages.
(b) No waterproofing works shall commence without the written consent of the Engineer.
(c) Application of waterproofing system shall only commence upon completion of curing
of the concrete. The Contractor shall ensure that surfaces to which waterproofing is to
be applied shall be clean, dust free and dry and shall be prepared fully in accordance
with the manufacturer’s recommendations and requirements.

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(d) All cracks on exposed surfaces of external structural members shall be effectively sealed
in accordance with Contract before applying any waterproofing system. Inside rendering
shall not be accepted as a method of making the joints water tight.
(e) Spray applied liquid polymer membrane that is applied for roof slab, a 6-mil
polyethylene separating sheet shall be laid before covering with a minimum 50mm thick
protective Grade 20 lean concrete slab.
(f) Damaged or non-compliant sections of the laid membrane shall be repaired in
accordance with the manufacturer's recommendations and as accepted by the Engineer.
(g) The primer shall be capable of conditioning the concrete to promote the adhesion of the
membrane. In confined and poorly ventilated areas solvent-based primers shall not be
used.
9.2.2 Structural Concrete Works
(1) Concrete Joints
(a) Notwithstanding the provision of waterproofing membranes, the Contractor shall construct
his concrete works so as to minimise the likelihood of water penetration. Before placing new
concrete against concrete that has already hardened, the face of the old concrete shall be
treated in accordance with Section 5 of the Contract requirements. Special attention shall be
given to the compaction and curing of concrete, particularly in areas such as at construction
joints, around waterstops, king posts and other structural penetrations.
(b) Concrete shall be cast water-tight between construction joints. All construction joints in
external slabs and walls shall be provided with an effectively continuous Hydrophilic water
stop and re-injectable grout tube. In top surface of base slab and roof slab at junction with
diaphragm walls, a 25 X 25 mm recess will be cast in the slab and subsequently filled with a
high performance water stop grout of the crystalline growth type.Should such concrete be
found to leak or to have moist patches, the affected concrete shall be rectified by injection of
resin material, breaking out and recasting, or other methods of sealing within the concrete.
Inside rendering will not be accepted as a method of making watertight.
(2) Water-stops
All water-stops used in the Works shall be of PVC material and of a type appropriate to the
location. All joints shall be made with moulded or prefabricated intersection pieces properly
jointed in accordance with the manufacturer's instructions. The water-stops shall be installed
so that they are securely held in their correct positions whilst the concrete is being placed. No
holes shall be made through any water-stop except where provided for by the manufacturer.
Water stops shall be appropriate for the type of joint where they are used. They shall have a
proven satisfactory performance when used in similar conditions.
Water stops shall be of barrier type flexible PVC/rubber for Diaphragm walls and for other
concrete members it shall be of hydrophilic water stops. All water stops shall possess a
hydrostatic resistance appropriate to the structure and joint in which they are installed.

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Hydrophilic water stops shall have a delayed swell action to prevent premature expansion
prior to concreting and shall have a volumetric increase of not less than 120%. The
hydrophilic water stop shall exhibit good consistency in swell rate during repeated wetting
and drying cycle. The water-swellable component of the hydrophilic water stop shall not leach
from the carrier matrix under any conditions.
Hydrophilic water stops shall be installed just before concreting and shall be placed as near
as possible to the face subject to hydrostatic pressure whilst conforming to the manufacturer’s
requirement of minimum edge distance. They shall be firmly fixed in place so that they cannot
be displaced during concreting.
(3) Piles and Pile caps

Where the waterproofing membrane is discontinuous to permit structural connections to piles
and pile caps, water tightness shall be achieved by use of a concrete additive or bituminous
material in accordance with the manufacturer's recommendations.
(4) Fillers and Sealants to Expansion Joints
(i) All materials used to fill expansion joints shall be such that they will accept the calculated
movements of the joints without extrusion and shall not shrink away from either surface of
the joints. Backing strips and fillers agreed with the Employer’s Representative shall be used
in accordance with the manufacturer's recommendation.
(ii) Where joints are required to be filled with polysulphide or polyurethane sealants, the
material shall comply with BS 4254 or BS 5212.
(iii) The appropriate sealant grades shall be used for horizontal and vertical joints, and the joints
shall be thoroughly cleaned and primed with the appropriate primer before applying the
sealant. The sealant shall be of a colour to match as nearly as possible the colour of the
adjoining surfaces where it is to be permanently exposed. The sealing material shall be used
and applied strictly in accordance with the manufacturer's instructions. The Contractor's
attention is drawn to the undesirability of the sealant being smeared over the adjacent
surfaces, and appropriate precautionary measures, including the use of masking tape, shall
be taken to avoid this.
(5) Injection Tube System
Injection tube system shall include tough, flexible and chemically inert tubes, connecting
tubes, junction boxes, grout, pumps and all other items required for their installation and use.
The Contractor shall provide full details of his proposed injection tube system for the
Engineer's review and acceptance.
The injection tube system shall be suitable for resinous or cementitious grout and be capable
of re-injection to seal joints.
The injection tube shall be robustly fixed in place in accordance with the manufacturer's
instructions and recommendations.
Different colours shall be used for horizontal and vertical runs to facilitate identification on
site. Tube vent ends/packers shall be colour-coded by same colours for each end of the same
tube.

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Junction boxes shall be installed in locations which are readily accessible and which do not
interfere with the use to which the structure will be put. Unless otherwise accepted by the
Engineer, they shall be set into the concrete.
The injection hose shall be tested by injecting water through them.
Upon completion of the Works, the Contractor shall submit a manual containing detailed
instructions for grouting and flushing, materials data, as-built/ record drawings showing
location of all tubes, packers and corresponding junction boxes and other information
pertinent to future maintenance.
9.2.3 Cleaning and Preparation of Surfaces
No laying shall be commenced until all rough edges and excrescencies have been removed
from the surfaces to receive the membrane. Surface depressions shall be filled in accordance
with the noticed procedures and the filling allowed to set. The surface to be waterproofed
shall be thoroughly cleaned, dried and swept, and kept clean and dry at all stages until the
work is completed.
9.2.4 Waterproofing Underground Structures
The following requirements are applicable to all underground structures built by cut and cover
methods. A complete method statement for the Works together with relevant shop drawings
and details shall be submitted to the Employer’s Representative for notice prior to application
of the system. The method statement shall include all QA/QC procedures required to ensure
the integrity of the system. Proposed manufacturers and applicators should have similar
experience on previous metro projects in India.
9.2.5 Base Slabs
(1) General
(i) Waterproofing shall consist of a fully bonded membrane system with silica fume (also
known as micro silica) in concrete applied to a blinding concrete layer, or other similar
system noticed by the Employer’s Representative.
(ii) The silica fume concrete shall meet the specified 28-day compressive strength and
maximum water penetration at 28 days of 10mm as tested in accordance with BS EN
12390-8. In addition, the silica fume concrete shall be tested in accordance with ASTM
C1240 for rapid chloride penetration and the results shall be within the ‘Very Low’
permeability range.
(iii) Silica fume concrete shall conform to the requirements given in the relevant clauses of
Sub-section 1, Section VII, Part 2 of this Contract.
(iv) Binding concrete shall be a minimum of 75 millimetres thick. Where ground conditions
are such that there would be risk of localised settlement of this blind layer during or after
subsequent construction operations, the concrete thickness shall be increased and
reinforced as necessary to avoid such localised settlement. A drainage layer shall be
provided beneath the blinding concrete where necessary to ensure that the blinding
concrete is not damaged by hydrostatic pressures prior to casting of the structural slab.

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(v) The waterproofing membrane shall be laid by the manufacturer’s applicators strictly in
accordance with the recommendations of the manufacturer and with accepted good
practice in the trade. Proper accessories such as anchor strips, pipe collars, outside and
inside corners, steel laminated plates etc. shall be used for the correct and secure
application of the waterproofing system.
(vi) When laying the membrane, no other works shall be carried out in the vicinity which may
cause personnel or equipment to intentionally or accident ally come into contact with the
membrane before it has been protected. Expanded polystyrene boards or similar shall be
used by the persons laying the membrane to avoid stepping directly on to the laid
membrane.
(vii) Membranes shall be laid such that there is a clearance of not less than 300mm beyond a
construction joint and the nearest lap of the membrane. The membrane may be laid across
changes in the plane of the concrete surface where the material is sufficiently pliable to
enable the adhesive to remain in continuous contact with the primed concrete. Where this
cannot be achieved, preformed angles or similar features shall be provided and bonded to
the concrete surface.
Where openings must be left in the membrane for structural continuity of piles, king
posts, pipes or for other items projecting below the soffit of the base slab, the membrane
shall be cut away at the junction with these protrusions or penetrations and the edges
sealed all round with a bituminous liquid membrane or approved sealant. The bituminous
liquid membrane or sealant must be proven compatible with the membrane.
(viii) Where external wall above the base slab are to be constructed in open cut, the membrane
laid beneath the base slab shall extend and turn up 300 millimetres beyond the top of the
structural slab in order that waterproofing to the wall may be lapped on to it. Blinding
concrete beneath the membrane shall extend 500 millimetres beyond the limits of the
structural slab.
(ix) Where the structural base slab will be cast against diaphragm walls, piled walls, or rock
faces, the membrane shall be turned up against the face of the wall by a minimum of 100
millimetres and then turned horizontally into a 20 millimetres by 20 millimetres chase
cut into the wall face, and sealed with a bituminous compound. The bituminous liquid
membrane or sealant must be proven compatible with the membrane. The wall surface
shall first be levelled by the application of a steel trawled mortar coat where there is any
risk that its roughness may cause the membrane to be punctured. The construction joints
shall form a sealed compartment for which general arrangement is indicated in the
drawings.
(x) Laps must be staggered and of minimum width 500mm. The membrane shall be laid on
blinding concrete complying with the requirements of Clause 1.9.2.6(d). The adhesive
side of the preformed membrane shall have its upper surface protected by a factory
applied weatherable and trafficable coating of a composition that will facilitate the
forming of a bond of the specified strength to the cured concrete.

SS1-145
(xi) The membrane shall also have sufficient strength to resist all impacts and other forces to
which it may be subject to prior to placing of the structural concrete.
(xii) Prior to construction, trial mixes are to be conducted under the supervision of the Engineer
and with the manufacturer present to confirm that the proposed mix conforms to strength,
w/c ratio, slump and other requirements. The trial mix concrete shall further have an
average water permeability coefficient when tested at 28 days of not greater than 5x10-13
m/s under 5kgf/cm2 and an average penetration depth not greater than 10mm as measured
by DIN 1048. The procedure for determination of coefficient of water permeability shall
be as described in Appendix 9.2 (A).
(i) After completion of each section of membrane, and before casting the permanent
protective slab, the waterproofing system shall be tested by ponding with minimum
150mm of water for a 48-hour period. The water level shall be topped up as necessary
over the 48-hour period. At the end of this period, the underside of the slab shall be
inspected for water leakage or dampness. Where there is any evidence of water
penetration, the Contractor shall investigate and propose rectification works to the
acceptance of the Engineer.
(ii) A preformed membrane capable of achieving full bond to the base slab shall be used. The
membrane shall meet the performance requirements given in Table 9.2.2.
Table 9.2.2: Performance Requirements for Base Slab Bonded Membrane

Membrane thickness (DIN EN ISO 2286-3) Applied on site in a single layer of
minimum 1.2mm thick
Dimensional stability Not more than 0.5% (both longitudinal and
transverse)
Tensile strength Carrier Film 25MPa
22.5MPa minimum with 6 months thermal
ageing
Elongation at break 300% minimum
240% minimum with 6 months thermal
ageing
Peel or stripping strength to concrete (ASTM 750N/mm
D903)
Resistance to hydrostatic head (DIN 16726) Water head consistent with the depth at
which the structure is seated and shall not in
any case be less than 50m water head
Puncture resistance (ASTM E154) 1000N

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Thickness, tensile strength, elongation at Properties not affected by more than 10%
break, peel or stripping strength to concrete,
resistance to hydrostatic head and puncture
resistance after storage in aqueous solution
(DIN 16726 for the storage of test specimens
in aqueous solutions. The specimens shall be
tested for the above properties in accordance
with the respective ASTM/DIN standards)
Design Life 120 years
(2) External Walls to Structures Built in Open Excavation

(i) Waterproofing shall be provided and shall conform to the requirements of this Contract.
Concrete surfaces to be waterproofed shall be prepared where necessary by grinding and
local filling with mortar having a steel towelled finish to provide a smooth surface free
from voids, loose aggregate and sharp protrusions. A brickwork protection layer shall be
provided to the membrane system to ensure that no damage is suffered to the membrane
during backfilling operations.
(ii) Where pipe penetrations are required through the wall, these shall be formed as sections of
galvanized steel pipe of the required diameter, with 36-millimetre welded flange plates
having outside diameter 300 millimetres greater than the diameter of the pipe. The
waterproofing membrane shall be fitted into the pipe penetration to maintain the integrity
of the waterproofing system as per a recommended detail which shall be proposed by the
waterproofing manufacture and noticed by the Employer’s Representative.
(3) External walls Built against Diaphragm Walls
(i) Where in-situ concrete lining walls are cast against diaphragm walls having water-bars at
panel joints, no waterproofing membrane is required at the interface between the diaphragm
and in-situ walls. At base and roof slab levels, water bar shall be provided or allowance for
caulking by grout injection.
(ii) In all cases where slabs are cast against diaphragm walls an injection grouting system shall
be provided in each diaphragm wall panel joint at the base and roof slab level, sufficient to
enable the joint to be grouted between the inner face of the diaphragm wall and the
innermost water bar across the panel joint. After completion of the base slab but before
concreting of the in- situ lining wall, if any, the base slab level grout injection shall be
carried out.
(iii) After the grout has set the groundwater level beneath the joint shall be allowed to rise to 1
meter above slab level and left for 7 days. The panel joint shall be inspected for water
leakage or dampness and if present the joint shall be re-grouted and re-tested. Grout
injection at roof slab level shall be carried out after completion of the roof slab.
(4) External Walls Built Against Pile Walls or Rock or Soil Faces
(i) Where in-situ concrete walls are cast against temporary pile walls, rock or soil faces, or any
other material, a fully bonded membrane system shall be provided. The face against which
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the in-situ wall is to be cast shall be built up by with a steel-trowelled finish, to provide a
smooth surface free from voids, loose aggregating and sharp protrusions. Where the
thickness of mortar would be excessive, concrete shall be cast as primary filler.
(ii) Material and application requirement for the waterproofing membrane shall be in
accordance with this Contract for base slabs. The membrane shall be lapped to the base slab
membrane and continued upwards to 300 millimetres above roof slab level, or to the limit
of the face against which the in-situ wall is to be cast if this is lower. In such cases suitable
provision shall be made for continuity of the membrane with the water-tightness provisions
to the wall above. Unless it is to be bonded to the structural wall the membrane shall be
protected by suitable geofabric (fleece) sheeting hung from above and left in place
(iii) Where the thickness of the infill concrete is greater than 75mm, steel mesh shall be
provided.
(iv) Where membranes are applied and bonded to infill concrete surface, the primer and the
waterproofing membrane shall be in accordance with the appropriate requirements of
Clause 9.2.1.(v) and Clause.9.2.6. In addition, a third layer of membrane shall be provided.
(v) For membrane that is bonded to the external face of the in situ structural wall, the
preformed membrane shall meet the performance requirements given in Table 9.2.5.1.
(5) Waterproofing Details at Knock-out Panel
Where an underground structure connects to an existing underground structure that has
knock-out panels or bulkheads, the Contractor shall, as a minimum, adhere to the
waterproofing requirements. In addition, the Contractor shall develop these details taking into
consideration the proposed method and sequence of construction. The detailed design shall
be carried out by the Contractor, subject to the Engineer's acceptance. The Contractor shall
also ensure that the integrity of the waterproofing system of the existing structure is not
compromised. In addition, the Contractor shall grout the interface between the new
underground structure and existing underground structure to prevent potential leakages.
9.2.6 Underground station Roof/Top Slab
(i) The spray applied liquid polymer membrane shall be suitable for use in an ambient
temperature range not greater than 40oC and the member shall be weather and UV
resistant. It shall allow diffusion of water vapour to prevent any buildup of pressure between
the membrane and substrate.
(ii) The membrane shall meet the performance requirements given in Table 9.2.6.1.
Table 9.2.3: Performance Requirements for Spray Applied Liquid Polymer Membrane

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Total membrane thickness 2.5mm minimum dry film thickness and

sprayed in a minimum of two coats of
contrasting colours, with the second coat
applied to the first coat only after the
first coat has cured. Single-coat
application may be considered for fast-
curing membranes subject to the
acceptance of the Engineer
Tensile strength (ASTM D412) 4.0MPa minimum in any of the three
orthogonal planes of the membrane
Elongation at break (ASTM D412) 130% minimum
Puncture resistance (ASTM E154) 300N minimum
Pull-off strength (ASTM D7234) 2.0MPa minimum
Static crack bridging (ASTM C836) 2mm minimum
Resistance to hydrostatic head (DIN16726) Water head consistent with the depth at
which the structure is seated and shall not
Thickness, tensile strength, elongation at
in any case be less than 50m water head
break, pull-off strength, resistance to
hydrostatic head and puncture resistance after
storage in aqueous solution (DIN16726 for
Properties not affected by more than 10%
the storage of test specimens in aqueous
solutions. The specimens shall be tested for
the above properties in accordance with the
respective ASTM/DIN standards)
Design Life 120 years
(iii) Concrete surfaces to be waterproofed shall be prepared to fine finish and shall confirm to
the requirement of this Specifications.
(iv) The cured membrane shall be chemically resistant to the effects of seawater, hydraulic
fluids, diesel fuel and diluted mineral acids etc.
(v) The substrate shall be prepared and primed in strict accordance with the manufacturer's
recommendations and requirements. The membrane shall be of a thixotropic nature and
cold applied to ensure consistent thickness is achieved over all substrate irregularities.
(vi) The materials used must be based upon resin systems that do not react with moisture
although the substrate should be dry during application. The liquid polymer membrane
shall be terminated in a chase or by a method acceptable to the Engineer.
(vii) Waterproofing membrane shall be continued 1m down the vertical side of the roof slab
where the roof is cast by bottom up construction method along with Permanent RCC walls.
(viii) All components of waterproofing system shall be provided by one manufacturer. All
materials must be supplied to site in unopened packaging, with batch numbers marked and
corresponding manufacturer's certificates of conformity and must be used within the
product's shelf life. All components of the system exposed to rain within the curing period
shall be replaced.
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(ix) Where the external wall to the structure has been constructed in open excavation, or cast
directly against diaphragm walls, piled wall and the like, the membrane protecting the roof
slab shall be extended and turned down and provided with a minimum 300 mm lap onto
the wall membrane and welded to the external water-bar across the roof slab/wall
construction joints to form the sealed compartment to complete the Contract water-
tightness requirements. After completion of each section of membrane, and before casting
the permanent protective slab, the system shall be tested by flooding for a 48-hour period.
The area to be tested shall be enclosed by sandbag or other methods of water containment
and flooded such that the whole of the membrane is covered by a minimum of 150mm of
water. The water level shall be topped up as necessary overt the 48-hour period. At the end
of this period, the underside of the slab shall be inspected for leakage or dampness. Where
there is any evidence of water penetration, the membrane shall be removed locally, and
the surface of the concrete inspected. Any visible cracking or other defects which may
permit water penetration shall be sealed by grouting, following which new waterproofing
membrane shall be laid and the waterproofing against tested by flooding.
(x) Protection to the waterproofing membrane shall be provided by 25mm thick expanded
polystyrene boards which shall be spot bonded to the membrane. A 6 mm polyethylene
separating membrane shall then be laid and covered with a protective concrete slab of lean
concrete mix of minimum 75mm thickness.
(xi) Where the external wall to the structure has been constructed in the open excavation and
is protected by a block work or in-situ wall, the protective slab to the roof shall be
continued over this wall. Where the roof slab has been cast against a diaphragm wall or
other face, the protective slab shall be provided with an up stand at the perimeter to provide
a minimum 150mm concrete protection over the turned up waterproofing membrane. This
is to ensure that the membrane termination is protected from damage or dislodging prior
to back-fill.
(xii) The membrane wet film thickness should be checked every 10m2 during application
of each layer, using a pin or comb gauge. Destructive testing to measure dry film thickness
shall be carried out on the cured membrane at every 100m2 or at every working shift,
whichever occurs sooner, and shall be made good to the satisfaction of the Engineer.
(xiii) Holiday tests or similar tests to the acceptance of the Engineer shall be carried out on the
cured membrane to identify any discontinuities in the membrane and to prove the integrity
of the membrane.
9.2.7 Diaphragm Walls
All leaks in the diaphragm walls shall be sealed. At the junctions with the base slab and
roof slab, horizontal continuous runs of re-injectable grout tubes within the slab sections
shall be installed on properly prepared surfaces to the satisfaction of the Engineer.
After completion of the base slab and roof slab, regardless whether there is any leak, the
junction with the base slab and roof slab shall be grout injected. all the junctions shall be
re-grouted if necessary.

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9.2.8 Waterproofing of Below Grade Construction Joints

(i) All below-grade construction joints shall incorporate a re-injectable hose which shall be
capable of performance in the following manner:
(a) The hose should be of a re-injectable nature and be capable of re-injection several
times over the life of the structure.
(b) Installation should be seamless and without cuts and joints when installed at multiple
bends/corners/circular paths in congested heavily reinforced concrete.
(c) The hose shall be capable of following infinite changes in direction and turn corners
with ease without impeding the path of grout injected through the hose.
(d) Valves shall be enclosed in a retaining mesh to avoid displacement of these during
pressure testing and injection.
(e) The injection resin should be of a re-sealable type made of an acrylate hydrogel,
capable of being vacuumed out of the hose with water (not flushed), before it gets.
(f) The injection resin should be of a low viscosity (<50 Centipoises) to enable maximum
penetration of very narrow fissures.
(ii) The system shall be placed in 10 to 12 metre lengths with entry port and vent ends
terminating in a junction box and shall offer the user the option of vacuuming and re-
injection should this be necessary. The junction box shall be placed in vertical elements
adjacent to the joint. Should this not be possible the junction box and its cover should be
installed flush with the floor level and should be able to tolerate vehicular traffic.
(iii) The system should be used to seal off the construction joints permanently thus providing
protection to the steel reinforcement.
(iv) Where indicated, all construction joints (vertical and horizontal) shall have the re-
injectable hose installed. The re-injectable hose system shall be injected at least once, prior
to switching off the dewatering with a vinyl ester methacrylate-based injection resin of
viscosity < 40milli Pascal (mPas).
9.2.9 Waterproofing to Surface and Partially Underground Structures
(i) Ground Slabs
Waterproofing to ground slabs shall be the same as for all underground structures defined in
this Contract
(ii) External Walls Below Ground Level
The requirements of this Contract shall apply to all external walls at greater depth than 500
millimetres below ground level
(iii) External Walls Protruding Above Ground Level
Where external walls protrude above the ground level, the waterproofing membrane shall be
terminated in a chase and at least 150mm above the adjacent ground level. Continuity of
waterproofing between the junction with above ground structure and the external walls must
also be assured.

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9.2.10 Stray current collectors

These shall be provided as per the Contract.
9.2.11 Warranty
(i) All waterproofing systems shall be warranted against all defects for a minimum period of
10 years from the date of completion of the Works.
(ii) The warranties shall cover the whole of the waterproofing systems and shall be provided
jointly and severally by the Contractor and the supplier/applicator.
APPENDIX – 9.2 (A)

Determination of Coefficient of Water Permeability
1. Specimens of 28-day cores of 100mm diameter by 50mm thick.
2. Specimens are placed between 2 metal plates and conditioned for 24 hours.
3. The test cell was filled up till overflowing to expel air.
4. The graduated tube was filled with water up to a height of about 2 metres.
5. The free end of the tube was connected to a test pressure consistent with the depth at
which the structure is seated and shall not in any case be less than 0.50MPa (50m
water head), unless otherwise specified by the Engineer.
6. The pressure was maintained throughout the test and the drop in water level in the
manometer was noted and recorded.
7. A constant rate of flow was achieved, i.e. when the difference between the highest
and lowest readings of the 4 consecutive readings taken at every 24 hours did not
exceed 3mm.
8. The coefficient of permeability is then calculated.
10 TUNNEL AND SHAFT EXCAVATION IN ROCK

10.1 EXCAVATION METHOD
The Contractor shall provide to the Employer’s Representative full details of the proposed
rock excavation methods for his “Notice of No Objection”. Similarly, the Contractor shall
submit his plans for methods for monitoring vibration adjacent to structures.
Rock Stabilisation
The Contractor shall carry out rock stabilisation measures with minimum delay after the
excavation of each round.
10.2 BLASTING
Definitions
“Controlled blasting” means that a designed drill and charging pattern has been noticed and
will incorporate one of the following techniques.
SS1-152
"Pre-splitting" means drilling a line of closely spaced parallel holes of appropriate diameter
along the excavation surface, charging the holes with an appropriate amount of explosive and
detonating these holes simultaneously, prior to the main production blast, to shear the rock
along the line of drill holes.
"Smooth blasting" means the drilling of a line of closely spaced parallel holes along the
excavation surface, with a suitable burden/spacing ratio, loading all the holes lightly with an
appropriate amount of explosive and detonating all these charges simultaneously, after the
detonation of the main production blast.
General
The Contractor shall submit for the ER’s “Notice of No Objection‟, at least 28 days before
the commencement of any excavation work, or whenever he changes his methods of blasting,
full details of his proposed methods, including the depth and spacing of holes, the amount of
explosive used per hole and the number and sequence of detonators, and sequence of
excavation and programme for the use of explosives.
Delivery and Use of Explosives
Use of explosives shall be permitted only with the “Notice of No Objection” from the
Employer’s Representative and only after the appropriate permits have been obtained. The
handling of explosives including storage, transportation and charging will be carried out in
accordance with BS 5607 – 1998, “Code of Practice for Safe use of Explosives in the
Construction Industry” and IS 10386 Part 4 1986 “Handling Storage & Transportation of
Explosives”. A local building Code Official will issue all blasting permits. The permits will
include requirements of the International Fire Code and other international standards for
explosive and blasting procedures, explosives training, blaster’s handbook and safety practise
manual. All explosives and related material shall be in conformity with the requirements of
the authority having jurisdiction and the specifications contained herewith. Blasting will not
be permitted within 25metres of any building structure without appropriate monitoring
systems and no objection from the Employer’s Representative. All blasting operations shall
be conducted under the direction of a certified blaster. Evidence of blaster certification shall
be carried by blasters or shall be on file at the ERs office during blasting operations. The
blaster shall be present at the firing of a blast at all times.
The Contractor shall submit his proposal for explosives collection and delivery for Notice of
No Objection from the ER. The risk assessment for the proposed arrangement shall be
addressed in the Blasting Assessment Report.
The Vehicle shall not carry more than 200kg of explosives at any one time or the figures as
agreed by the ER. Upon each delivery of explosives, the Vehicle shall be escorted by the
Contractor's appointed Responsible Person(s) and armed guards and as agreed by the
Relevant Authority & the ER. The explosive container shall be secured to the body of vehicle.
The vehicle carrying the explosives shall have atleast two number serviceable fire
extinguishers installed on it. The Vehicle which has been fitted out to the above requirement
is required to be presented for inspection and agreed with the Employer/ Engineer.
The contractor should ensure that only enough explosives and detonators are brought to the
Site for immediate blasting requirements. Explosives and detonators remaining unused after
each blasting operation shall be disposed of or removed from the Site. The contractor shall

SS1-153
appoint a responsible person to order an receive explosives at the site. The name of this
person(s) shall be notified to ER.
The contractor should ensure that No persons other than those authorised by the ER shall
approach within 50m of the area being prepared for blasting, i.e. during charging and firing
of the blast holes. The Contractor shall inform the ER of the names of his authorised personnel
and his method for excluding others.
The Contractor shall provide an agreed system of warning and preparing the general public
and all Site personnel of an impending blast by both audible and visual means and shall ensure
that the blasting area is cleared of all personnel immediately prior to blasting. This system
shall comply with all statutory requirements.
The limits for air-overpressure and vibration monitoring together with actions associated with
the alert, alarm and action levels shall be addressed in the Blast Assessment Report / Method
Statement for the Notice of No Objection from the Engineer.
The Contractor shall use a lightning detector on site to assess the potential risk of lightning
risk during delivery, loading and charging blast holes with explosives. The lightning detector
shall be capable of detecting thunderstorms.
The Contractor shall check for stray electric current at the blasting site prior to commencing
charging.
Blast partition doors separating the Contractor's working areas from the public and other
operational areas shall be of adequate fire protection, water tightness, weight, thickness and
density to effectively reduce the noise, water and dust transmitted from the Works and confine
the effects of the blast to acceptable levels. The effective damping mass of the partitioning
materials shall not be less than 30 kg/m2 blasting.
Blasting trials
The Contractor shall incorporate a series of blasting trials in his initial blasting operations to
substantiate his proposed methods of blasting. Details of all proposed blasting trials and
procedures shall be submitted for the ER’s “Notice of No Objection”.
A sufficient number of trials in each of the main rock types shall be carried out to substantiate
that the depth and spacing of holes, the type and amount of explosive used per hole and the
number and sequence of delays has been optimised in order to avoid as far as practicable
fracturing or otherwise damaging the ground below or beyond the excavation line or level.
The Blasting trials shall also substantiate that
a) the procedure for carrying out the blast is safe,
b) the dust and noise created by the blast are within the acceptable limits.
c) the resulting maximum peak particle velocity and maximum allowable vibration
amplitude at locations stated in the Contract, or instructed by the ER, can be
satisfactorily predicted, recorded and demonstrated to be within the prescribed limits,
and shall not adversely affect the safety and stability of adjoining structures,
installations and land, facilities and equipment; and
d) the specified tolerances for the final blasted surfaces and formations can be achieved.

SS1-154
Blasting trials shall be completed at least 7 days before the related main blasting starts.
Blasting trials for pre-splitting and other methods of controlled blasting shall be carried out
to form a face similar to the permanent works design. The blasting trials shall be carried out
on rock which has similar properties to production blast areas, and which is at least ER.
The blasting trials shall be sufficient to demonstrate the effectiveness of the Contractor's
proposed methods of blasting in all of the different areas of the blasting works.
The results of all trial blasts shall be interpreted using regression analysis method. Regression
lines together with all blasting data showing the relationship of peak particle velocity against
scaled distance shall be plotted on logarithmic scale to define the site vibration constants for
the 50%, 84% and 95% confidence levels. All subsequent main production blasting results
shall be produced on the same plot, and the plot modified and updated, as appropriate to allow
for the additional information. Separate trials are required for different blasting types and
areas.
In underground work at least one of the trial blasts shall incorporate the full cross section and
maximum round length. In surface work the minimum depth and length of each trial section
shall be 5 m and 10 m respectively. The Site for the trials shall be agreed with the Employer’s
Representative
Once the results of the trials are noticed, such results shall form the basis of whether future
controlled blasting is achieving the required standard.
If in the opinion of the ER, the methods of blasting are at any time causing excessive or
undesirable disturbance of the rock mass surrounding the excavated space, he may order the
Contractor to change his methods of blasting and/or carry out further blasting trials until the
desired results are achieved. No additional payment shall be made for any change or further
trials ordered by the Employer’s Representative or any delays resulting there from.
Notification of blasts
The Contractor shall notify the Employee’s Representative of the intention to blast at least 24
hours before that operation is carried out. The notification shall show the location of and the
intended time of each blast and the name of the licensed blaster and shift foreman responsible.
The Contractor shall distribute written notification to all organisations on Site 24 hours prior
to undertaking surface blasting. Any delay or postponement of any blasts shall be notified to
all organisations immediately.
Blast design and precautions during blasting
A blast design shall be submitted to the Employer’s Representative for “Notice of no
Objection” prior to any blasting operations. The blast design will include sketches of drill
patterns, delay times and blasting mats and shall indicate the type and amount of explosives
to be used, critical dimensions, and the location and general description of structures to be
protected, as well as an outline of design factors to be used, which protect the public and meet
the applicable air blast and ground vibration standards. The work shall be programmed so as
to minimise blasting adjacent to previously constructed sections of the Works.
Every precaution including the use of blast mats, timber boarding or other means shall be
exercised to protect the Works and persons, animals and property in the vicinity of the Site.
The Contractor shall accept responsibility for all injury or damage occasioned by any blasting
operations and shall make good such damage without any additional payment.
SS1-155
Screens and other protective covers as specified in the Method Statement shall be erected to
prevent the projection of flying fragments of material resulting from blasting.
Presplitting and other methods of controlled blasting shall be carried out in such a manner
that the rock mass is cleanly split on the required plane such that the remaining rock mass is
not shattered or loosened.
Faces formed by presplitting or other methods of controlled blasting shall not exceed 1.5m in
height in any one blasting operation or as agreed by the Engineer.
If at any time, any method of drilling and blasting does not produce a uniform final surface
profile without overbreak, all within the required tolerances, the Contractor shall undertake
further trials until a technique is established that results in an excavation profile to the
acceptable tolerances
The Contractor shall, in particular, note the requirement that he must limit to the maximum
extent practicable the spillage of material from surface excavations, whether by blasting or
other means. To this end the Contractor shall take all necessary precautions including, if
necessary, covering the rock prior to blasting with sufficient loose material to prevent the
blasted material being thrown into the adjacent areas. If the Employer’s Representatives of
the opinion that insufficient precautions are being taken to minimise the spillage of material,
he may instruct the Contractor to adopt further measures to reduce the spillage. No separate
payment will be made for any such measures required.
Blasting near structures
The Contractor shall be responsible for avoiding personal injuries and damage to adjacent
structures from fly rock by erecting barricades and/or the use of blast mats or other means
acceptable to the Employee’s Representative. Should any damage be caused by his operations
this shall be made good without any additional payment.
The unrestricted use of explosives will generally not be permitted in any part of the Works.
The amount of explosives that may be detonated shall not result in a ground vibration
sufficient to damage the nearest point of any part of the Permanent Works to the blasting Site.
In each and every case where the Contractor wishes to blast within 15 m of a structure, he
shall prepare a proposal for this blasting and submit it to the Employer’s Representative for a
„notice of no objection, No blasting work of this nature may be carried out without the Notice
of No Objection from the Employer’s Representative .
The Contractor shall prepare a photographic record of each structure within 100 meter of any
work, weather or the surface or underground , prior to any blasting taking place.
Vibrations due to blasting and Monitoring of blasts
The Contractor shall restrict the weight of explosives fired simultaneously to keep the
vibrations (measured in terms of Peak Particle Velocity,( PPV)) at structures and installations
due to blasting within the following limits:
1. Structures in “good” condition, Roads, pavements and open areas : 25 mm/sec
2. Structures in “fair” conditions :12 mm/sec
3. Structures in “poor” condition and heritage structures/bridges and
Water supply structures :5 mm/sec
SS1-156
The vibration amplitude at various structures due to blasting shall follow the following limits:
1. Structures in “good” condition, Roads, pavements and open areas : 0.2 mm
2. Structures in “fair” conditions : 0.15 mm
3. Structures in “poor” condition and heritage structures/bridges and
Water supply structures :0.1 mm
The Contractor shall submit calculations which demonstrate that the charge weights per delay
period proposed at 84% Confidence Level do not exceed the vibration limitations stated in
above to the Engineer for Notice of No Objection. No blasting operations shall be carried out
without Notice of No Objection from the Engineer.
The Contractor shall supply and operate a noticed tri-axial particle velocity meter equipped
with a permanent paper trace output, which shall be used to monitor blasting work.
The Contractor shall keep records of all blasting carried out showing the time and location of
each blast, the type and amount of explosive used, together with any other relevant data. Two
copies of these records shall be sent to the Employers Representative weekly relating to the
previous week's work.
The contractor shall make all the arrangements for installing instruments and taking
measurements both inside and outside the Site.
Measurement of vibrations generated by blasting shall be taken at locations proposed by the
Contractor in his Blasting Assessment Report, Building Damage Assessment Report and
Monitoring Proposal or as instructed by the Engineer at all times when blasting are carried
out. Records of the vibrations shall be kept by the Contractor on the Site and a copy provided
to the Engineer within 24 hours of measurement.
Vibrations due to blasting shall be measured in terms of Peak Particle Velocity (PPV) and
Vibrational Amplitude. The peak values shall be taken as the maximum resultant calculated
by vector summation of the three orthogonal components of velocity and amplitude
respectively measured as instantaneously as the resolution of the recording instrument
permits.
Measurements shall be made with seismographs of a type with Notice of No Objection from
the Engineer. The accuracy of seismographs shall be checked before blasting are carried out
and shall be calibrated at least once a year.
No blasting works shall be permitted without vibration measurements being recorded with
approved vibration monitoring equipment mounted on a geophone pad which is rigidly
bonded to form an integral part of the structure.
If a production blast results in vibration amplitudes or peak particle velocity in excess of the
specified limits, the Engineer shall be notified immediately. The Contractor shall immediately
check the fixing of monitoring equipment to confirm the reading accuracy and inspect the
integrity of affected structures to ensure no immediate danger to the public and to implement
remedial measures if necessary. No further blasting shall take place until measures to reduce
the PPV and/or amplitude are adopted with a Notice of No Objection from the Engineer.
Controlled blasting
SS1-157
Controlled blasting methods shall incorporate, but are not limited to, pre-splitting or smooth
blasting techniques, and shall make use of explosives specially manufactured for this purpose.
The Contractor shall control the alignment and depth of holes so that the actual profile as
excavated complies with the specified tolerances.
All charges shall be accurately made up and inserted into the holes at the correct spacing, and
all holes shall be correctly stemmed and connected in the correct sequence, with detonators
being correctly delayed.
The Contractor shall carry out Controlled Blasting so as to achieve a final blast surface that
exhibits a regular fracture plane between barrels without underbreak or overbreak greater than
those which have been considered in deriving the theoretical excavation line and the required
finished tunnel profile.
If at any time the methods of drilling and blasting do not produce a uniform profile within the
tolerances to achieve the required finished tunnel profile, no further blasting works shall be
permitted until the Contractor establishes a technique that results in an excavation profile to
the acceptable tolerances.
Both cartridge and bulk explosives may be used where appropriate.
In controlled blasting the type, size, decoupling and charge concentration of perimeter and
bulk charges shall be within established parameters unless otherwise proven acceptable by
Site trials.
Fully charged production holes shall be kept sufficiently clear of the final profile to prevent
damage being caused by these holes. Production holes closest to the final surface (easer holes)
shall have lighter charges to minimise damage to the final surface.
The bottom charge of a pre-split hole shall not be larger than the line charges unless otherwise
directed. The top charge of the pre-splitting hole shall be placed far enough below the collar
to avoid over breaking the final profile. All charges in a pre- split row shall be detonated
simultaneously using detonating cord.
Adequate stemming shall be used to avoid blow-outs.
Drilling
In all controlled blasting, drilling accuracy of perimeter holes is of prime importance and the
Contractor shall take particular care and make use of sight lines and guide rails in surface
work to control the alignment and depth of blast holes.
In both surface and underground works the blast pattern shall be accurately set out and holes
shall be collared within 50 mm of the required position. Holes which are over drilled shall be
fully stemmed to the required depth before charging up takes place.
The burden and spacing of holes shall be chosen to suit the explosive charge concentration
limits as determined by the Site trials. The spacing of holes for pre- split blasting is generally
required to be at closer spacing than those for smooth blasting. Perimeter holes for controlled
blasting should generally be at centres not exceeding ten times the diameter of the drill holes.
Exploration in Rock face

SS1-158
One probe hole shall be drilled ahead of every rock face for probing the ground conditions
ahead prior to the blast hole drilling. Probing ahead shall be by impact or rotary drilling
techniques and is intended to detect any ground water or potential unstable soils, which may
be treated by grouting techniques.
All blasting work for bulk excavation of tunnels and shafts shall be carried out using perimeter
drilling and blasting techniques to control the geometry of and to minimise any damage to the
theoretical excavation profile and minimise geological over break.
All charges shall be accurately made up and inserted into the holes at the correct spacing, and
all holes shall be correctly stemmed and connected in the correct sequence with detonators
being correctly delayed.
Where tunnel excavation by explosives is within 6m of the ground surface or an adjacent
opening the Contractor shall modify his blasting pattern to reduce the overbreak and to
produce the minimum amount of disturbance to the surrounding rock mass. Such Controlled
Blasting shall incorporate, but may not be limited to, pre-splitting or smooth blasting
techniques, decoupled charges and shall make use of explosives specifically manufactured
for these purposes.
Quality of excavated surface
Unless otherwise detailed on the drawings all blasting work shall be carried out using
controlled blasting techniques to minimise any damage to the final profile.
Use shall be made of noticed special explosives and/or blasting techniques which will
minimise blasting induced fractures, or disturbance, on the rock faces outside the excavation
line so preserving the rock in the soundest possible condition.
The surface after blasting shall exhibit a regular fracture plane between barrels without back
break and with half barrels visible over the major portion of the surface. The surface shall be
scaled down of all loose and hollow sounding rock to leave a solid, intact surface. Light
charges shall be used for enlarging or correcting the excavated profile and also for excavating
trenches.
Blasting Risk Assessment
The Blasting Risk Assessment and Blasting Risk Assessment Report shall be undertaken by
a qualified Engineer with the Notice of No Objection from the Engineer.
The Blasting Risk Assessment and Blasting Risk Assessment Report shall be carried out in
accordance with the procedures submitted to and agreed by the Engineer. The location and
size of the blasting trials associated with the Blasting Risk Assessment shall have a Notice of
No Objection from the Engineer.
The Blasting Risk Assessment shall evaluate the impact caused by blasting using gradual
increase in vibration levels generated by trial blasts, which shall not be exceeding the
specified values in the Contract. Planned vibration target levels generated by the trial blasts
shall be obtained by adjusting explosive charge weights at the same time taking into
consideration changes in distance, drilling pattern, confinement of the blast and rock
condition. The design of explosive charge weights shall be made from linear regression based
on previous blasting works. The predicted PPV (not exceeding the specified values in the
Contract) for each trial blast shall be made in accordance to a confidence level of 84%.

SS1-159
After each trial blast a structural inspection of structures and tunnels shall be carried out to
assess the effect of blasting induced vibration. The scope and extent of the structural
inspection shall be agreed with the Engineer. When no structural defects are reported the
subsequent trial blasting may be increased to the next higher vibration target level, which
shall not be exceeding the values specified in the Contract. Following completion of the
Blasting Risk Assessment field works a Blasting Risk Assessment Report shall be required
to be submitted to the Engineer for Notice of No Objection.
The report shall include the following minimum contents:
a) drilling and explosive loading details for each trial blast
b) delay plan for each trial blast
c) charge weight per blast hole and charge weight per delay for each trial blast
d) details of vibration monitoring instruments and geophone locations and
orientation of each trial blast
e) details of instrumentation and settlement monitoring for each blast
f) graphical record of Elapse Time against Particle Velocity and Acceleration for
each of the three orthogonal geophone directions for each trial blast for each
filtering frequency used. All records are to identify the following: date, time,
monitor, location, filtering frequency, channel number, channel maximum,
project and trial blast identification
g) full wave form of the vibration measured on structures and installations
showing; PPV, predominate frequency, displacement and acceleration;
h) maximum resultant peak values calculated by vector summation of the three
orthogonal components of velocity and amplitude for the monitoring point
closest to each trial blast at each filtering frequency used. Results to include
distance from blast and range of the dominant vibration frequency;
i) results of structural condition survey conducted following each trial blast,
and results of vibration monitoring and all other structures and buildings
Submissions
The following are a minimum contents of blasting procedures that shall be submitted to
theEngineer for Notice of No Objection:
a) Any conditions or restrictions imposed by the Relevant Authorities, including
copies of applications, licences, permits and correspondence;
b) Names, qualifications and experience of the persons responsible for the design
and supervision of blasting operation
c) The roles and responsibilities of key personnel for blasting supervision
shall be clearly defined on the Blasting Assessment Report

SS1-160
d) Location with survey control, diameter, inclination and depth of holes to be

charged with explosive;
e) Type and total mass of explosive to be used and its mass and distribution in each
hole
f) Initiation sequence, delay periods and mass of explosive per delay;
g) Burden and bench height
h) Ratio of diameter of explosive to diameter of hole
i) Ratio of explosive charge weights to both volume and weight of rock to be
removed by the proposed blast
j) Arrangements for vibration monitoring system (e.g. relevant vibration
and air overpressure monitory points) and methods of instrumentation and
monitoring the effects of blasting
k) Details of vibration monitoring systems, including manufacturers literature and
calibration certificates
l) Methods of control blasting
m) Protective measures that have been agreed by the Engineer to ensure
there is no damage to surrounding property or equipment or EBS and to
fully comply with the provisions of the Contract in this respect.
Items (a) & (b) shall be submitted at least 30 days before blasting in a particular works area
starts. Items (c) to (m) shall be submitted to the Engineer at least 48 hours beforethe relevant
blasting starts. The blasting procedures shall be reviewed as blasting continues and shall
beupdated to suit particular local conditions. When the procedures are required to be revised,
the Items (c) to (m) shall be submitted to the Engineer for Notice of No Objection at least 48
hours before blasting starts.

SS1-161

PHASE-II PROJECT”
PART-2
SECTION VII
SUB-SECTION - 2
TUNNELLING
DECMEBER 2021
TABLE OF CONTENTS
SECTION
1 INTRODUCTION ...................................................................................................................... 4
2 GENERAL .................................................................................................................................. 4
3 SURVEY...................................................................................................................................... 4
4 FIELD CONTROL AND MONITORING EQUIPMENT ..................................................... 4
4.1 SETTING OUT OF LINE LEVEL AND PROFILE................................................................................ 4
4.2 CHAINAGE MARKERS AND BENCHMARKS .................................................................................. 4
4.3 MONITORING EQUIPMENT ......................................................................................................... 4
5 MECHANIZED TUNNELING - TBM ..................................................................................... 5
5.1 GENERAL ................................................................................................................................... 5
5.2 GENERAL REQUIREMENTS OF TBM ............................................................................................. 5
5.3 PARTICULAR REQUIREMENTS FOR TBM ................................................................................... 5
5.4 ALIGNMENT CONTROL .............................................................................................................. 8
5.5 INSPECTION AND TESTING ......................................................................................................... 8
5.6 PERSONNEL AND TRAINING ...................................................................................................... 8
5.7 CONTRACTOR’S SUBMISSIONS ................................................................................................... 8
5.7.1 General..................................................................................................................................... 8
5.7.2 TBM method statement ............................................................................................................. 8
5.7.3 TBM daily monitoring and reporting ....................................................................................... 9
5.8 SEGMENTAL TUNNEL LINING ................................................................................................... 10
5.8.1 General................................................................................................................................... 10
5.8.2 Moulds for precast tunnel lining ............................................................................................ 11
5.8.3 Segment storage at site ........................................................................................................... 11
5.8.4 Trial Assembly ........................................................................................................................ 12
5.8.5 Marking of Segments .............................................................................................................. 12
5.8.6 Transporting and Storing Segments ....................................................................................... 12
5.8.7 Joints ...................................................................................................................................... 12
5.8.8 Rolled Rings ........................................................................................................................... 12
5.8.9 Bolts ....................................................................................................................................... 12
5.8.10 Plane .................................................................................................................................. 13
5.8.11 Sealing Strips and gaskets ................................................................................................. 13
5.8.12 Caulking Grooves .............................................................................................................. 13
5.8.13 Grout Valves ...................................................................................................................... 13
5.8.14 As-built Tolerances ............................................................................................................ 13
5.8.15 Non - Compliance with Tolerances .................................................................................... 14
5.8.16 Damaged Segments ............................................................................................................ 14
5.8.17 Concrete Grade.................................................................................................................. 14
5.8.18 Segment Casting Tolerances .............................................................................................. 14
5.8.19 Handling and storage ........................................................................................................ 14
5.8.20 Cracks ................................................................................................................................ 15
5.8.21 Defective concrete segments .............................................................................................. 15
5.8.22 Repair of defects ................................................................................................................ 15
5.9 MATERIALS FOR SEGMENTAL LINING – CONCRETE ................................................................. 15
5.9.1 General................................................................................................................................... 15
5.9.2 Source of Materials ................................................................................................................ 16
5.9.3 Batching plants, mixers and vibrators.................................................................................... 20
5.9.4 Mix Design ............................................................................................................................. 21
5.9.5 Tests for concrete ................................................................................................................... 21
5.9.6 Curing .................................................................................................................................... 24
SS2-1
Sub-Section-2- Tunnelling
5.10 MATERIAL FOR SEGMENTAL LINING – REINFORCEMENT ......................................................... 24

5.10.1 Storage ............................................................................................................................... 25
5.10.2 Cutting and bending........................................................................................................... 25
5.10.3 Surface condition ............................................................................................................... 25
5.10.4 Inspection & Testing .......................................................................................................... 25
5.10.5 Bar bending and Bar bending schedule ............................................................................. 25
5.10.6 Lapping & Welding ............................................................................................................ 26
5.10.7 Tying/Binding Wire ............................................................................................................ 26
5.10.8 Spacing, Supporting and Cleaning .................................................................................... 26
5.10.9 Cover ................................................................................................................................. 26
5.10.10 Welding .............................................................................................................................. 27
5.11 MATERIALS FOR SEGMENTAL LINING - ELASTOMERIC GASKETS ............................................. 27
5.12 MATERIALS FOR SEGMENTAL LINING - BOLTS AND GROMMETS ............................................. 28
5.12.1 Bolts ................................................................................................................................... 28
5.12.2 Grommets ........................................................................................................................... 28
5.12.3 Packings............................................................................................................................. 28
5.13 GROUTING .............................................................................................................................. 28
5.13.1 Primary grouting ............................................................................................................... 28
5.13.2 Proof/Secondary grouting .................................................................................................. 29
5.13.3 Contractor’s Submissions .................................................................................................. 29
5.14 TOLERANCES AND INSPECTIONS ............................................................................................. 30
5.15 ALTERNATIVE TUNNEL LINING ................................................................................................ 31
6 NATM TUNNELING ............................................................................................................... 31
6.1 EXCAVATION .......................................................................................................................... 31
6.1.1 General................................................................................................................................... 31
6.1.2 Excavation with care .............................................................................................................. 32
6.1.3 Excavation method and Equipment ........................................................................................ 32
6.1.4 Soft ground excavation ........................................................................................................... 32
6.1.5 Excavation for contractor’s convenience ............................................................................... 33
6.1.6 Disposal of excavated material .............................................................................................. 33
6.2 TUNNEL TEMPORARY SUPPORT ................................................................................................ 33
6.2.1 General................................................................................................................................... 33
6.2.2 Sprayed concrete .................................................................................................................... 33
6.2.3 Rockbolts and Dowels ............................................................................................................ 41
6.2.4 Lattice girders ........................................................................................................................ 44
6.2.5 Forepoling .............................................................................................................................. 45
6.2.6 Grouting for in-situ lining ...................................................................................................... 46
6.2.7 Water-tightness of tunnel ....................................................................................................... 47
6.3 FINAL TUNNEL SUPPORTS ........................................................................................................ 47
6.3.1 Concrete lining ....................................................................................................................... 47
6.3.2 Preparation of surfaces .......................................................................................................... 47
6.3.3 Placing of concrete ................................................................................................................ 47
6.3.4 Testing of concrete ................................................................................................................. 47
7 INVERT CONCRETE ............................................................................................................. 47
8 BACKFILLING OF SHAFTS AND ADITS .......................................................................... 48
9 DAILY RECORDS ................................................................................................................... 48
10 SAFETY AND UNDERGROUND FACILITIES .................................................................. 48
10.1 SAFETY GENERAL .................................................................................................................... 48
10.2 UNDERGROUND FACILITIES ..................................................................................................... 49
10.2.1 General .............................................................................................................................. 49
10.2.2 Telephone communications ................................................................................................ 49

SS2-2
10.2.3 Electric cables ................................................................................................................... 49

10.2.4 Ventilation.......................................................................................................................... 49
10.2.5 Lighting .............................................................................................................................. 50
10.2.6 Dewatering ........................................................................................................................ 50
10.2.7 Stand-by Generator............................................................................................................ 50
10.2.8 Noise control ...................................................................................................................... 50
10.2.9 Hot Work ............................................................................................................................ 51
10.2.10 Safety notices ..................................................................................................................... 51
10.2.11 Control of Entry ................................................................................................................. 52
10.2.12 Compressed air working in cutterhead chamber ............................................................... 52
10.2.13 Stores, Offices and Workshops .......................................................................................... 52
10.2.14 Quality of air...................................................................................................................... 52
10.2.15 Dust .................................................................................................................................... 53
10.2.16 Ventilation Quantities ........................................................................................................ 53
10.3 HAZARDOUS GAS .................................................................................................................... 54
10.3.1 General .............................................................................................................................. 54
10.3.2 Methane detection .............................................................................................................. 54
10.3.3 Ventilation Equipment ....................................................................................................... 55
10.3.4 Contractor’s Equipment .................................................................................................... 55
10.3.5 Personnel ........................................................................................................................... 55
10.3.6 Acceptable concentrations of methane .............................................................................. 55
10.3.7 Records .............................................................................................................................. 55
11 AS BUILT SURVEY OF ALIGNMENT ................................................................................ 55
11.1 OBJECTIVE .............................................................................................................................. 55
11.2 PROCEDURE ............................................................................................................................ 56

SS2-3
1 INTRODUCTION
The present section specifies the materials, methods and workmanships required for the
construction of tunnels (bored and NATM), shafts and other underground structures.
2 GENERAL
All tunnelling works shall be carried out in compliance with the government of India rules
and regulations.
3 SURVEY
Before commencement of any work, the Contractor shall prepare and submit appropriate
survey method statements relating to his proposed methods of working. Contractor shall
establish the system for underground surveying, setting out and correcting deviations from
theoretical alignment, using a laser-based system.
Reference point and targets shall be used in conjunction with lasers to ensure the accuracy of
the system and it should be easy to monitor by the Employer’s representative. Laser based
guidance systems shall have an alternative system as back-up.
In the case of tunnel boring machines, where construction is computer controlled, the
Contractor shall use software for ring selection logic, steerage logic, etc.
If at any time during the excavation for the tunnel, it is evident that the alignment for the
tunnel is outside the specified tolerances then, before proceeding further with the excavation,
the Contractor shall submit the necessary corrections to the alignment, and the Contractor
shall forthwith make the accepted corrections.
4 FIELD CONTROL AND MONITORING EQUIPMENT
4.1 SETTING OUT OF LINE LEVEL AND PROFILE
Prior to starting underground work, the Contractor shall submit to the Employer’s
Representative, proposals on the setting out the Works and for correcting any deviations.
4.2 CHAINAGE MARKERS AND BENCHMARKS
Chainage markers shall be provided in tunnels at 10m intervals. The markers shall be painted
in white durable paint. The contractor shall provide the Employer’s representative the location
and description of all survey stations, and all survey data.
4.3 MONITORING EQUIPMENT
The Contractor shall provide basic equipment for measurement of deformations along
excavation perimeters and ground surface conditions. The types of basic underground
equipment to be provided comprises the following:
⚫ levelling instruments,
⚫ wire extensometer for convergence measurement and
⚫ bore hole extensometer
The equipment shall be installed where directed by the Employer’s representative. During the
execution of excavation works, the Contractor need to procure supplementary types of
equipment as may be required for standard tunnelling methods. Measurements by all types of
equipment shall be performed by the Contractor as directed by the Employer’s representative.
Results from each measurement shall be submitted to the Employer’s representative
expeditiously.

SS2-4
5 MECHANIZED TUNNELING - TBM

5.1 GENERAL
The Contractor shall be fully responsible for the selection, design and supply of tunnel boring
machines (TBM) shields and ancillary equipment. The Contractor shall take into
consideration all geological and other relevant information available to him. He shall satisfy
himself as to the suitability of the TBM or shields which he will provide.
5.2 GENERAL REQUIREMENTS OF TBM
TBM design shall make adequate provision for the safety of the workmen and the application
of safe methods of tunnelling as per Global Standards. The TBM shall be robust with adequate
safety margins for the anticipated duty, designed and manufactured to comply with all safety
standards (BS 6164 Safety in tunnelling in the construction industry or equivalent, BS EN
16191 Tunnelling machinery - Safety requirements or equivalent). The external diameter of
the TBM or shield shall be designed to produce minimum over break and the least necessary
clearance for the proper construction of the tunnels. Design shall take into account the
horizontal and vertical alignment. Provision shall be made to limit and correct TBM roll.
Whenever possible hydraulic piping shall be of rigid metal tubing, the use of flexible hose
shall be kept to a minimum. Liquids for use with hydraulic equipment shall be non-toxic and
of low flammability. Hydraulic equipment shall be designed to operate up to twice the
working pressure but shall not exceed 500 bars.
All machines and shields shall be self-propelled, where propulsion is by means of hydraulic
shove-rams thrusting off previously constructed segmental lining. Shove ram shoes and shoe-
facings shall be designed to distribute the thrust without causing damage to the as-built lining.
Shove-ram shoe pads shall be adequately secured.
Shove-rams shall be capable of operating individually or collectively in any combination. The
shove-rams shall permit the insertion of a key closing segment, in any location.
Arrangements for extraction, transport and disposal of spoil shall be appropriate for the
material to be handled.
Segment erection systems shall be capable of lifting and placing segments safely. Lifting and
gripping systems shall be designed to handle the loads with an adequate factor of safety and
without damaging the segment and segment sealing systems. Segment erection systems shall
be capable of compressing all joint gaskets.
The erector shall be in clear view of the operator. A safety device shall be fitted to avoid
accidental release of segments during lifting, handling and placing. There shall be adequate
access to all areas of the TBM where work, including maintenance, may be carried out. A
clear means of egress in an emergency shall be provided and maintained at all times.
Minimum dimensions shall conform to the appropriate international standards. The machine
characteristics and specification shall be submitted to the Employer’s representative for notice
prior to procurement of the TBM.
5.3 PARTICULAR REQUIREMENTS FOR TBM
The cutter-head shall be capable of clockwise and anticlockwise rotation and shall only be
able to excavate the ground whilst the hydraulic rams are being actuated. The design shall
ensure that the cutter-head can be retracted back from the unexcavated ground to minimise
the risk of the cutter-head jamming and to facilitate maintenance.
The cutting tools shall incorporate wear detection systems. The cutter-head discs and/or picks
shall be able to be renewed from the rear of the cutter-head and shall be interchangeable.
SS2-5
Where boulders could occur on the tunnel face the TBM design shall permit a boulder of at
least 300 millimetres across its smallest cross-sectional dimension to be pushed through the
cutter-head. The TBM shall have the capability to handle, break up as required and remove
such boulders through the screw conveyor, slurry discharge aperture or other spoil discharge
system without special procedures. The TBM shall be designed to allow forward drilling
through the cutter-head for the purpose of probing ground conditions and to carry out ground
treatment to the face. The TBM shall be designed to enable the void behind the segments to
be grouted continuously and completely from the shield as it is propelled forward. The grout
ports shall be incorporated within the shield tail skin rather than mounted externally on it.
There shall be grout ports in each quadrant of the shield tail skin circumference, preferably
located at or close to the tunnel shoulder and knee levels. The TBM shall have the facility and
the capacity to inject grout simultaneously through at least two grout ports and through at
least one grout port in each quadrant. The TBM design shall enable the grout pipes to any
individual port to be cleaned or replaced from within the shield in the event of a blockage
without impairing the performance or preventing the use of any other grout port. At least one
grout port in each quadrant of the shield shall be operational and available for grouting at all
times during shield advancement. Grout pressure and flow rates shall be maintained at all
times whilst the shield is advancing. The shield shall incorporate automatic systems for
monitoring and controlling the volume and pressure of the grout being delivered to the tail
void. The TBM shall be equipped with the facility to generate foam conditioners and deliver
them to the face during excavation.
The TBM shall be designed for and equipped with a supplemental ground stabilisation
system. This system shall comprise regularly spaced grout ports built into the shield for
grouting the ground ahead of the tunnel face. The location and number of ports shall be
adequate for implementation of face stabilisation measures needed for access to the face in
all ground conditions. All ports shall be readily accessible and fitted with valves.
The cutter-head shall be articulated such that the cutter-head can be retracted from the
excavated face and can be turned in any plane so that it is at an angle to the main body. The
TBM shield must be capable of negotiating 200 metre curves. All closed face TBM shall be
designed to maintain pressure on the excavated ground at all times. The TBM shall be able to
at least balance the total overburden pressure (including hydrostatic pressure) and shall be
capable of varying the face pressure as the overburden pressure changes. Earth pressure
sensors shall be located at the crown, at TBM axis level and at the invert of the chamber.
All closed face TBM shall incorporate a two-compartment air-lock for man access to the
cutter-head and face. Where a screw-conveyor is used the discharge gate on the screw-
conveyor shall be fitted with an accumulator which automatically closes the gate in the event
of a power failure.
All TBM shall incorporate a system which enables the face to be closed expeditiously to avoid
any ground loss in the event that unstable ground is encountered during the drive. This shall
take the form of hydraulically operated gates on the cutter-head or a similar system to the
notice of the Employer’s representative. The Contractor shall produce operational data for
each EPBM or STBM throughout the whole tunnelling process in both hard and soft
(electronic) copy for each working shift. These shift reports shall be submitted to the
Employer’s representative within 24 hours for notice of no objection and shall provide the
following minimum information.

SS2-6
⚫ Start and finish time of the excavation stroke including all stoppages, recording the
reasons for the stoppages.
⚫ Ring number, chainage and key position.
⚫ Start and finish time of the ring build including all stoppages, recording the reasons
for the stoppages.
⚫ All delays and the reasons for those delays during the shift.
⚫ Earth pressure readings at start, middle and end of excavation stroke for cutter
chamber and screw.
⚫ Quantity of material excavated for each ring e.g. number of skips removed.
⚫ Total advance for the shift and the accumulative advance.
⚫ Number and location of any cutter bits changed.
⚫ Volume of grout injected per ring and the pressure, the accumulative volume of
grout for the shift.
⚫ Volume, type and location of soil conditioning added per ring and the accumulative
amount per shift with the concentration value.
⚫ General comments on description of the excavated material.
⚫ Quantity of tail grease consumed per ring.
⚫ Any segment damage on completed rings.
⚫ The timing and nature of any machine maintenance carried out.
The TBM shall be fitted with a data-logger which shall be linked by the Contractor to a colour
monitor display in the Employer’s representative office. Each TBM shall have its own
dedicated colour monitor. The data-logger shall display and record information in real time
and shall have the facility to store all accumulated data from the tunnel drive and to read and
display past data. As a minimum the data-logger shall record and report the following
information.
⚫ Start and finish time of the excavation stroke.

⚫ Stroke number, chainage and guidance system’s prediction of the next ten strokes
after each build.
⚫ Numbers of thrust cylinders, location and pressures used during the stroke.
⚫ Extensometer readings of thrust cylinders at the start and end of the stroke.
⚫ Articulation cylinder position at the start and the end of the excavation stroke
articulation angle.
⚫ Amount of TBM roll at start and end of the excavation stroke.
⚫ Cutting direction, speed, pressure/torque of cutter-head. Shield position and attitude
for each ring.
⚫ Earth pressure readings throughout the excavation stroke at the plenum chamber
and screw.
⚫ Volume and pressure of grout injected per stroke. Pressure shall be measured at the
point of injection.
⚫ Volume, type and location of soil conditioning added per ring and the cumulative
amount per shift with the concentration value.
⚫ Quantity of tail grease consumed per shift.
⚫ Speed and torque of screw conveyor
⚫ Rate of advance of TBM
⚫ Use of copy cutter, amount and location
⚫ Gas detector sensors readings
⚫ All data-loggers and ancillary equipment shall be fully operational at all times and
shall be maintained by the Contractor.

SS2-7
5.4 ALIGNMENT CONTROL

The Contractor shall ensure the TBM is provided with a suitable guidance and control system
capable of providing the necessary survey information such that the TBM operator is able to
accurately control the TBM and tunnel alignment to within the tolerances.
The guidance system shall have the capability to predict ahead of the face and to determine
the inclination, line, level, roll and square of the TBM. Detailed guidance information shall
be checked against the tunnel alignment control at regular intervals, as agreed with the
Employer’s representative. All information and data shall be clearly displayed in the TBM
operator’s control panel and shall also be linked to a data-logging system.
5.5 INSPECTION AND TESTING
Where a new, modified or purpose-built TBM is proposed, the Employer’s representative
shall be permitted to visit the TBM’s manufacturer’s premises for the purposes of inspection.
The Contractor shall be responsible for the quality of all materials used or present within the
TBM and must ensure that all such materials used, or present are adequate for the task they
are to perform.
The Employer’s representative shall be permitted at any stage during manufacture of the TBM
to inspect, examine and test on the manufacturer’s premises the materials, workmanship and
performance of all plant and components to be supplied under the Contract. Such inspections,
examination or testing shall not release the Contractor from any obligation under the Contract.
New and reconditioned machines shall be assembled at the manufacturer’s works on
completion of fabrication or modification and tested to demonstrate that all components
operate correctly. Test running will also be required at the site following assembly, prior to
commencement of tunnel driving.
5.6 PERSONNEL AND TRAINING
The Contractor shall ensure that all key personnel who are responsible for driving,
maintenance and controlling the TBM have received the necessary training in the duties that
they are required to perform and have appropriate experience.
The Contractor shall provide and maintain a complete list of the names of persons, and their
duties, responsible for TBM operation, who have completed the appropriate training to an
accepted standard. The details and experience of all key personnel for driving and controlling
the TBM shall be submitted to the Employer’s representative for a notice.
5.7 CONTRACTOR’S SUBMISSIONS
5.7.1 General
The Contractor shall submit his programme for the provision, inspection, testing, transport,
erection and commissioning of each and every TBM supplied for the Works, for the
Employer’s representative notice. The machine characteristics and specifications shall be
submitted to the Engineer for obtaining his Notice of No Objection prior to procurement of
TBM.
5.7.2 TBM method statement
Not less than 56 days before the Contractor intends commencing TBM excavation, he shall
submit to the Employer’s representative for notice of no objection a detailed method
statement, which shall include but not be limited to the following:
⚫ Methods of transportation and erection of the TBM.

SS2-8
⚫ Methods of commencing the tunnel drives, including details of the temporary thrust
arrangements.
⚫ Methods of determining ground conditions ahead of the face, and the methods of
treating such conditions.
⚫ Methods for dealing with water wells that may be intersected or influenced by the
excavations.
⚫ Methods of functioning with the launch, retrieval and any other shafts, including
dismantling of the TBM.
⚫ Operational details, including excavation, segment handling, ring
selection/orientation control, ring building procedures, annulus and proof-drilling,
grouting and control, alignment control, tunnel logistics, maintenance, slurry plant
operation (for STBM), effluent disposal, muck disposal, soil conditioning control
(for EPBM), interventions, changing cutters & picks.
⚫ Safety procedures, including compressed air working, cutter-head entry, cutting tool
changes, ventilation details, emergency evacuation procedures.
⚫ Details of the proposed monitoring and reporting systems. Details of key personnel
responsible for supervising, operating, maintaining and controlling the TBM.
The Contractor shall make all arrangements and provide all the labour, plant, and materials
necessary at the TBM launch sites for launching and/or receiving the TBM as appropriate.
The Contractor shall co-ordinate the delivery arrangements with the manufacturer. The
Contractor shall be responsible, under the supervision of the TBM manufacturer, for the
erection and commissioning of the TBM and all back-up equipment required to allow the
TBM to commence excavation in a fully operational condition in all respects and in
accordance with the TBM manufacturers’ recommendations.
The Contractor shall be responsible for the design and installation of the temporary TBM
launch structures and for ensuring they are satisfactory in all respects for receiving and
assembling the machine components. The shaft walls (or other structures) and surrounding
ground shall have sufficient capacity, to sustain without excessive deformation the thrust from
the TBM shove rams during the launch of the TBM.
The Contractor shall be responsible for the provision of any and all ancillary structures at the
shaft bottoms (for example fixed or moveable cradles to act as a “base” for commencing
machine erection) and for co-ordinating design and configuration of such ancillary structures
with the TBM manufacturer.
The Contractor shall provide and regularly maintain a mechanical lift at his main working
shaft that complies with all applicable safety standards for the vertical movement of people.
5.7.3 TBM daily monitoring and reporting
Information required Not less than 56 days before the commencement of TBM excavation,
the Contractor shall submit details of his proposed monitoring and reporting for the
Employer’s representative notice. The content of this submission shall include, but not be
limited to, the following:
⚫ Chainage of face at the start and end of each shift

⚫ Line and level of the tunnel rings erected during each shift, including details of any
corrections made to the plane of the rings
⚫ Survey control data
⚫ Serial numbers of the segments erected, referenced against ring numbers and tunnel
chainage

SS2-9
⚫ Details of the geological conditions encountered during each shift, including details
of any geological anomalies encountered; Operational data of the cutterhead drive,
including torque and RPM
⚫ Thrust of propulsion rams
⚫ Operational data of slurry system
⚫ Hours of operation of the TBM
⚫ Details of any operational delays, including the TBM, backup and slurry systems,
recorded in 5-minute intervals
⚫ Details of any probing undertaken
⚫ Detailed cycle times for each ring, identifying the boring and erection times
⚫ Details of any planned or unplanned maintenance carried out
⚫ List of cutting tools replaced, their position and serial numbers
⚫ List of spare parts used
⚫ Quantities and pressures used in the annulus grouting, with a reconciliation of the
amount used;
⚫ Number and classification of supervisors and workmen engaged during each shift;
⚫ Any other information that the Employer’s representative may reasonably request.
5.8 SEGMENTAL TUNNEL LINING
5.8.1 General
The segments shall be designed to ensure that the full design life is achieved. In the case of
pre-cast concrete linings special care shall be taken to ensure that corrosion of reinforcement
or other cast in metal components does not affect the durability of the segments.
Notwithstanding the requirements of the Specification the design shall assume that the tunnel
waterproofing measures will not be completely effective and therefore allowance shall be
made for the effect of groundwater on any face of a segment.
To achieve full design life of concrete lining, impermeable concrete shall be produced and
shall be tested in accordance with DIN 1048, the depth of penetration when tested according
to this standard shall be less than 10 mm. Suitable additives such as micro silica shall be used
in appropriate % by the weight of cement to ensure the protection of precast linings against
corrosion of reinforcement.
The Contractor shall be entirely responsible for the all the phases from manufacture to
installation of the precast concrete tunnel lining segments for the bored tunnel.
Casting/manufacture of segmental lining shall be carried out in pre-casting facilities used
solely for the production of precast units. The design and manufacture of the facilities and the
control of production procedures shall be undertaken by experienced specialist personnel
familiar with the manufacture of high strength, durable, dimensionally accurate precast
concrete units.
The segmental lining shall be a bolted lining built under the protection of the TBM’s tail skin.
The lining joints shall be watertight; caulking grooves and gasket recesses shall be provided
and elastomeric gaskets with appropriate configuration shall be provided to achieve the
required water tightness and design life as stipulated in the contract.
Prior to the commencement of manufacture of precast segments, the Contractor shall submit
a statement to the Employer’s representative of his proposed method of carrying out all
operations connected with the manufacture, testing and quality control and assembly of
precast segments, including:
⚫ the details of the casting yard(s) and location of manufacture, testing and storage of
segments; a programme which shall include, but not be limited to, trial mixes,
SS2-10
design and manufacture of prototype moulds, casting of prototype units,

establishment of the casting yard, design and manufacture of moulds;
⚫ general arrangements of the production lines and typical mould details;
⚫ types, sources and quality of cement, aggregate, reinforcement and water;
⚫ types and sources of any concrete admixtures proposed;
⚫ the proposed methods of compacting, curing and protecting the units;
⚫ the proposed quality assurance arrangements;
⚫ the proposed method of handling the units, transport arrangements and logistics;
⚫ details of proposed suppliers and subcontractors;
⚫ samples of all cast-in items, e.g., sleeves, lifting sockets and the like.
No work shall start until the Employer’s representative has issued a no objection statement in
writing.
5.8.2 Moulds for precast tunnel lining
Moulds for the precast concrete segments shall be strongly constructed with smooth casting
faces so that a true, sound surface of concrete is obtained. Joints shall be completely tight and
close to prevent the escape of laitance from the concrete. All chamfer and radius strips, bolt
hole formers and pockets, liners, cores, and all cast-in items shall be provided where required.
“Scratch” marks shall be inscribed at meeting faces of the moulds to assist in accurate
assembly. Loose mould components which affect the integrity of the mould shall be clearly
identified as being part of the main mould. The parts of one mould within a ring set shall not
be interchanged with another. A marking system shall be adopted to ensure compliance with
this requirement.
The design of the moulds to be used for all the pre-casting work shall receive a “notice of no
objection” from the Employer’s representative before any such moulds are manufactured.
The fabricator shall make a trial casting using the first set of moulds. The internal dimensions
of the moulds shall be measured to 0.1 mm before each trial pour. One trial unit shall be cast
from each mould. The units shall be provided with a full reinforcement cage including radial
joint reinforcement. As soon as possible after stripping from the moulds the segments shall
be checked against the dimensions shown on the drawings. During these trials, the segments
are to be cured and stored in conditions equivalent to those to be used during works
production. The segment dimension deviations shall be measured at 7, 28, and 90 days.
Concurrent records of concrete temperatures, ambient humidity and any other relevant details
shall be kept at these dates. No segment production shall be instituted until the tolerances
shown on the drawings are achieved in the trials.
5.8.3 Segment storage at site
The Contractor shall establish a system of site segment stock ordering, supply, and control
which shall eliminate the possibility of tunnel construction stoppage due to lack of material.
The Contractor shall satisfy himself that segment design takes account of the method of
delivery of the segments to the face, erection expedients, shove ram disposition, and other
features of the TBM having an impact on the segments. To this end, the Contractor shall work
closely with the TBM manufacturer to ensure lining and machine compatibility. If required,
the Contractor shall be responsible for ensuring a full ring of the lining is delivered to the
TBM manufacturer, at no additional cost to the Employer, and at an appropriate time during
the TBM manufacturing programme, to ensure compatibility with the TBM segment handling
and erection systems.
The Contractor shall, for the duration of the tunnel drive(s), maintain a stock of fully cured
(age >28 days) segments. These shall be sufficient for a minimum of 4 weeks driving at each

SS2-11
location from which the Contractor may decide to supply material at the programmed rates
of advance. During the closing stages of the tunnel drives these stocks shall be drawn down.
5.8.4 Trial Assembly
There shall be a trial assembly, before commencement of the bulk manufacture, of three rings
bolted together on a horizontal plane platform to demonstrate compliance with this
Specification of rings of each material and diameter. The rings shall be built one above the
other with the cross joints offset by half a segment as appropriate except for expanded linings.
The fully bolted bottom ring shall be bolted to the platform or otherwise secured in position
and shall be retained as a master ring until the completion of tunnel construction. From time
to time, as may be required, segments shall be built to form two rings on the master ring to
ensure that tolerances and interchange ability of the segments are maintained. Adequate
notice of the trial assembly shall be given to the Employer’s representative to enable him to
arrange inspection and checking of the assembly.
5.8.5 Marking of Segments
All tunnel segments delivered to site shall bear the indelible marks described as below. Any
segment which is delivered to site and upon which the markings cannot be read for whatever
reason, shall not be used in the works. The markings must in no way compromise any
requirement of this Specification, i.e. cover to reinforcement or waterproofing. The following
minimum information shall be included on the marking:
⚫ Internal diameter
⚫ Type of segment:
▪ ‘O’ ordinary
▪ ‘T’ top (the T shall be put near the key end of the segment)
▪ ‘K’ key segment
▪ ‘X’ special or taper
5.8.6 Transporting and Storing Segments
Segments shall be transported face up with timber spacers. When stored on site segments
shall be stacked on edge, on a prepared level base with timber packing as necessary. The
method of lifting and handling, the type of equipment and method of transport shall not
damage the segments. Segments shall not be transported to site until they have achieved the
28 days compressive cube strength.
5.8.7 Joints
The faces of joints shall be cleaned before bolting segments. Bolts shall be tightened at the
time of erection of each ring. For a shield drive the circle bolts shall be re-tightened prior to
release of the shoving jack force.
5.8.8 Rolled Rings
Rings may be rolled to facilitate the construction of openings and may also be rolled to
facilitate maintenance of the plane of the rings. Tapered rings shall be rolled as appropriate
to achieve the specified alignments and gradients of the tunnels.
5.8.9 Bolts
The length of each bolt shall allow for two washers and two grommets and for all adjustments
required in the alignment of the tunnels. When fitted in position the bolt threads shall be
exposed for at least 3 mm clear of the nut.

SS2-12
5.8.10 Plane
Errors in the plane of a ring should be kept to a minimum. When they occur, the plane of the
ring shall be adjusted by packing of maximum practicable continuous lengths of resilient,
durable material which shall have received notice of no objection from Employer’s
representative. Packing in a single joint shall not exceed 6 mm for concrete lining. The
packing shall be supplied in various thickness, as required, but not less than 2 mm, and when
in place, shall be clear of the sealing strip. In tunnel drives which utilise all tapered rings,
packing shall not exceed 3 mm per circle joint.
5.8.11 Sealing Strips and gaskets
Two Sealing strips comprising a gasket of the hydrophilic type and a gasket of the elastomeric
type shall be provided at all faces between segments to provide a seal against ingress of
ground water. Immediately prior to the erection of a gasketed segment, the gaskets shall be
checked for cleanliness and position.
5.8.12 Caulking Grooves
Caulking grooves shall be formed in segments in accordance with the design and this
Specification to ensure that caulking to circle joints and radial joints may be made effectively
continuous, the depth of caulked material in the joints being not less than 25 mm. Prior to
caulking all joints shall be inspected and thoroughly cleaned out as necessary. Any packing,
grout or other foreign material projecting into the caulking space shall be cut out by an
appropriate method. Immediately prior to caulking, the joints shall be blown out with a
compressed air jet as necessary to remove any loose debris or water.
5.8.13 Grout Valves
For linings built behind tunnelling machines, having a pressurised face system, grout holes if
provided in the linings segments shall incorporate one-way valves to prevent ground and
water loss during the grouting operation.
5.8.14 As-built Tolerances
In general, the as-built segmental lined tunnel shall conform to the tolerances noted below.
1) No ring of segmental lining will be accepted if at any point on its internal
circumference it is out of position with respect to the theoretical tunnel alignment at
the chainage of the leading edge of the ring by more than ±100mm. This tolerance is
overall and includes all shape, roll, survey, setting out, and casting errors.
2) The maximum and minimum measured diameters in any one ring shall be within 40
mm of the theoretical design diameter of the ring.
3) Lipping The lip between adjacent segments in a ring shall not exceed 5 mm and shall
not be so great as to prevent the connections between segments from being correctly
installed, nor prevent the effective functioning of gaskets, nor reduce the face-to-face
radial joint bearing area to an extent where structural efficacy will be compromised.
4) Stepping The step between adjacent rings shall not exceed 10 mm and shall not be
so great as to prevent the connection between adjacent rings from being correctly
installed, nor prevent the effective functioning of gaskets.
5) The plane of the leading face of each ring, including a taper ring, shall not depart at
any point from the plane surface by more than 6 mm.

SS2-13
6) The roll of adjacent circle joint bolt holes shall not be greater than 5 mm; the
maximum total allowable bolt hole roll of any ring is 40 mm from the relevant TBM
roll.
5.8.15 Non - Compliance with Tolerances
Where any part of the lining does not comply with the specified tolerances the Contractor
shall submit to the Employer’s representative for notice of no objection, proposals for
remedial or other measures to correct the defect or negate its effects as appropriate.
5.8.16 Damaged Segments
Any segments which are damaged or defective shall be indelibly marked and removed from
the Site and replaced by the Contractor. Such damaged or defective segments shall be
destroyed. No damaged or defective segments shall be used in the Works.
Rings which have been built and shoved and are subsequently damaged may have to be
removed and rebuilt.
5.8.17 Concrete Grade
The grade of concrete shall be at least M50.
The Contractor shall designate its grade of concrete as follows:
Concrete M 50/20.
The letter M refers to the mix.
The number 50 represents the characteristic compressive strength of 15cm cubes at 28 days
in MPa (Mega Pascal: 1 MPa: 10 kg/cm2 approximately). M50 concrete thus has a
characteristic strength of 500 kg/cm2. Other mix design will also be denoted in same way.
The number 20 represents the nominal size of the aggregate in mm.
5.8.18 Segment Casting Tolerances
The dimensions of precast concrete segments shall be within the following tolerances:
⚫ Circumferential Length ±1mm

⚫ Thickness ±3mm
⚫ Width ±1mm
⚫ Internal diameter of completed ring ±0.2% internal diameter or
6mm whichever is the greater
⚫ Bolt holes size +1mm, -0.2mm
⚫ Bolt holes position ±1mm
⚫ Width of gasket sealing groove ±1mm
⚫ Depth of gasket sealing groove +1mm, -0.5 mm
⚫ Mismatch of gasket sealing groove at corners <2mm
Steel templates fit for purpose shall be provided for the control of the production of segments
to the required tolerances.
5.8.19 Handling and storage
The precast units shall be stored under cover prior to stacking and placing in the stockpile.
The area intended for the storage of precast units should be surfaced in such a way that no
unequal settlement can occur.
To prevent deformation of slender units, they should be provided with supports at fairly close
intervals and should also be safeguarded against tilting. Lifting and handling positions should
SS2-14
conform to the requirements. In addition, location and orientation marks should be put on the
members, as and where necessary. During erection the precast units should be protected
against damage caused by local crushing and chafing effects of lifting and transport
equipment.
5.8.20 Cracks
If cracks, which in the opinion of the Employer’s representative may be detrimental to the
stability, strength and durability of the construction, develop in concrete construction, the
Contractor at his own expense shall test the structure in accordance with specified tests
requirements.
5.8.21 Defective concrete segments
Precast concrete segment which may get damaged by improper curing or during stripping
from the mould or during storage and handling or any other cause or segments which are
honeycombed or has interstices or is not homogeneous or segment which is not true to
dimensions, or the surface finish defects fall outside those required by these Specifications,
may be classed as defective concrete segment, and, if so the Contractor shall immediately
remove the defective concrete segment and shall replace it with acceptable concrete segment
of specified strength and specifications without any additional cost to the Employer. The
decision of Employer’s representative in this regard will be binding on the Contractor.
5.8.22 Repair of defects
If on stripping the precast segment moulds the concrete surface is found to be defective in
any way, the Contractor shall make no attempt to remedy such defects prior to inspection and
the receipt from Contractor Quality Department.
5.9 MATERIALS FOR SEGMENTAL LINING – CONCRETE
All the constituents of concrete viz., Cement, Aggregates (fine & coarse), Reinforcement,
Water, Admixtures along with Alkali silica reaction requirements shall also comply with the
various clauses mentioned in “Concrete” section of these specifications.
5.9.1 General
The Contractor shall establish a full-fledged most modern concrete laboratory with trained
engineers, Quality Control (QC) Manager and technicians at site/in the casting yard. Concrete
laboratory shall contain facilities for testing physical properties of cement, workability of
concrete, cube strength, permeability of concrete, sieve analysis, RCPT, aggregate tests, tests
required for mix design, chloride and sulphate tests of water and admixture, concrete
temperature, oven, accelerated tests for cement/concrete strength, flexural strength of
concrete. One room shall be airconditioned to control temperature and humidity for cement
tests.
All off-site material sampling and testing is to be at laboratories accredited by NABL
(National Accreditation Board of Testing and Calibration Laboratories) or internationally
accredited laboratory to ISO 17025: 2005. The durability requirements in terms of
environment condition, concrete cover, type and quality of material constituent, cement
content and water cement ratio, workmanship to obtain full compaction and efficient curing,
shape and size of members as mentioned in design drawings and technical specifications shall
be taken care of.
The Contractor shall submit to the Employer’s representative full details and samples of all
materials which he proposes to use for the manufacture of the precast concrete segments at
least 56 days before the commencement of manufacturing. No concrete segments shall be
placed in the Works until the Employer’s representative Notice of No Objection for all

SS2-15
materials of which it is composed. These materials shall not thereafter be altered or replaced
by other materials without informing the Employer’s representative for Notice of No
Objection.
5.9.2 Source of Materials
All the sources of the materials shall require Employer’s representative Notice of No
Objection in advance before bringing to the site. All materials for making concrete shall
require Employer’s representative Notice of No Objection. A sample of material shall be
deposited in the office of the Employer’s representative before placing orders for the materials
with suppliers. The materials brought on to the works shall conform in every respect to their
samples and specifications which have Notice of No Objection.
Fresh samples shall be deposited with Employer’s representative whenever type or source of
any material changes. The Contractor shall check fresh consignment of materials as it is
brought on to the works to ensure that they conform to the specifications.
The Employer’s representative shall have the option to have any of the materials tested to
find whether they are in accordance with specifications at the Contractor's expense. All bills
vouchers and test certificates which in the opinion of the Employer’s representative are
necessary to convince him as to the source and quality of materials or their suitability shall
be produced for his inspection when required.
Any materials which have not been found to conform to the specifications and/or without
Notice of No Objection by the Employer’s representative shall be rejected forthwith and shall
be removed from the site by the Contractor at his own cost within the time stipulated by the
Employer’s representative. The Employer’s representative shall have the powers to cause the
Contractors to purchase and use materials from any particular source, as may in his opinion,
are necessary for the quality execution of work.
Contractor shall also ensure that all constituents of exposed concrete shall be taken from same
sources to achieve a uniform colour and texture.
Cement
Cement/blended cement/cementitious material They all will mean the same thing. The cement
or cementitious material used shall be of the following types:
⚫ 43 grade Ordinary Portland Cement conforming to IS: 8112.

⚫ 53 grade Ordinary Portland Cement conforming to IS: 12269.
⚫ Portland Pozzolana Cement (PPC) as per IS: 1489 (Part-I)
⚫ Portland Slag Cement (PSC) as per IS: 455
Whenever possible all cements of each type shall be obtained from one constant source
throughout the contract, cement of different types shall not be mixed together. Different
brands of cement, or the same brand of cement from different sources, shall not be used
without Employer’s representative Notice of No Objection. Packaged cement shall be
delivered to the site in original sealed bags which shall be labelled with the weight, name of
manufacturer, brand and type. Cement received in torn bags shall not be used. Cement bags
will not be handled with hooks which allow ingress of moisture.
Material which has become hardened or lumpy or fails to comply with the Specification in
any way shall be removed from the site.
Contractor may obtain cement in bulk and store it in suitable silos of adequate capacity. Each
type of cement shall be stored in a separate silo and it shall be ensured, that cements of
different quality are not mixed up.

SS2-16
All cement shall be fresh when delivered and at ambient atmospheric temperature. In fair
faced elements, the cement used in the concrete for any complete element shall be from a
single consignment. All cement for exposed concrete shall be from the same source and
uniform in colour.
With each and every delivery of cement the Contractor shall provide manufacturer’s
certificate that the cement conforms to the relevant Indian standard. The Contractor shall
provide complete facilities at site for carrying out the following tests:
⚫ Setting time by Vicat's apparatus as per IS: 4031 and IS: 5513.
⚫ Compressive strength on cement as per IS: 4031, IS: 650, IS: 10080.
⚫ Total chloride content in cement shall in no case exceed 0.05% by mass of cement.
Also, total sulphur content calculated as sulphuric anhydride (SO3), shall in no case
exceed 2.5% and 3.0% when tri-calcium aluminate percent by mass is upto 5% or
greater than 5% respectively.
Cement and cement extenders shall be free flowing and free of lumps and shall be supplied
in the manufacturer's sealed unbroken bags or in bulk.
The temperature of the cement when added to the mixer shall not exceed 40°C unless
otherwise agreed by the Employer’s representative.
All cement and cement extenders used in the Works shall be tested by the manufacturer or
the Contractor in a laboratory which has Employers representative Notice of No Objection.
Copies of all test results so obtained shall be delivered to the Employer’s representative before
the cement and cement extenders are incorporated in concrete. All cement extenders used
shall comply with the appropriate Indian standards for Fly Ash (FA) or Condensed Silica
Fume (CSF) respectively as detailed above.
The Contractor shall keep full records of all data relevant to the manufacture, delivery, testing
and use of all cement and cement extenders used in the Works and shall provide the
Employer’s Representative with two copies thereof.
If the Contractor proposes to use Ordinary Portland Cement, he shall only do so by blending
it with a noticed cement extender that has been issued notice of no objection by Employer’s
representative. Blending of ordinary cement with an extender may be done, in the batch plant,
or at a commercial blending plant.
Each set of tests carried out by the manufacturer or Contractor shall relate to not more than
one day's output of each cement plant, and shall be made on samples taken from cement which
is subsequently delivered to the Site. Alternatively, the frequency of testing shall be one set
of tests for every 200 tonnes of cement delivered to Site from each cement plant.
Cement and cement extenders which are older than 120 days from date of grinding shall be
retested in a laboratory which has Employer’s representative Notice of No Objection at the
rate of one set of tests for every 200 tonnes or as otherwise directed by the Employer’s
representative and at monthly intervals thereafter.
Aggregates
Aggregates from natural sources shall be in accordance with IS: 383. The Contractor shall
submit to the Employer’s representative certificates of grading and compliance for all
consignments of aggregate for Notice of No Objection. In addition, at site from time to time,
the Contractor shall allow for carrying out such tests and for supplying test records to the
Employer’s representative. Aggregates shall be produced by crushing, screening, washing
and procured from sources only that have Employer’s representative Notice of No Objection.

SS2-17
5.9.2.2.1 Fine Aggregate

The Contractor shall provide complete facilities at site for determining grading of aggregates
by sieves as per IS: 383, IS: 460, IS: 1607, and IS: 2386.
Only the product of the secondary crusher will be acceptable, subject to conformity with IS:
383. To achieve an acceptable particle, shape the fine aggregate shall be manufactured using
crushers specially adapted (Rollobar or similar) to suit the type of material available. Stone
dust or grit from the stone quarries should not be considered as of acceptable quality.
It shall be free from clay, loam, earth or vegetable matter, salt or other harmful chemical
impurities. It shall be clean, sharp, strong, angular and composed of hard siliceous material.
The fine aggregate shall be river sand, manufactured sand of appropriate grading. Sand
dredged from sea; creeks shall not be used. Sand shall be washed and screened to remove any
organic matter and clay. RMC manufactured with sand dredged from sea/creek shall not be
used. Water absorption of fine aggregates shall be less than 3%.
The grading of fine aggregate when determined as described in IS: 2386 (part I), shall be
within the grading zones I, II, III. The Contractor shall provide complete facilities at site for
carrying out the following tests:
i) Proportion of clay, silt and fine dust by sedimentation method as per IS: 2386 part II.
ii) Moisture content in fine aggregate as per IS: 2386 Part III.
iii) Bulk density / Bulkage.
iv) Specific Gravity
5.9.2.2.2 Coarse Aggregate
The coarse aggregate shall be crushed stone, natural gravel or a suitable combination thereof.
Coarse aggregate obtained from crushed or broken stone shall be angular, hard, strong, dense,
durable, clean and free from soft, friable, thin plate, elongated or flaky pieces and any
deleterious material.
The grading of aggregate shall be controlled by obtaining the coarse aggregate in different
sizes and blending them in correct proportions as and when required.
All coarse aggregate shall conform to IS: 383 and tests for conformity shall be carried out as
per IS: 2386, Parts I to VIII.
The maximum size of coarse aggregate shall be such that the concrete can be placed without
difficulty so as to surround all reinforcement thoroughly and fill the corners of formwork.
Water absorption for aggregates shall be less than 3% by weight.
5.9.2.2.3 Alkali reactive materials
The aggregates shall be evaluated to identify any minerals known to have a potential to cause
alkali silica, alkali silicate, alkali carbonate or any other damaging chemical reaction between
alkalis and aggregates. The minerals present should be determined in accordance with ASTM
C294 and C295 on a range of samples selected to include every mineral type present in the
aggregate as a whole irrespective of the proportion of the mineral.
The aggregate shall be kept clean at all times. The sand equivalent when tested in accordance
with ASTM D2419 of the fine aggregate shall be greater than 80. The sand equivalent of the
zero to 4.75 fractions of all aggregates shall be greater than 75.

SS2-18
Ethylene glycol tests shall be carried out by the Contractor. Petrographic examination shall
be carried out in accordance with ASTM or standard procedures to identify the minerals
present and in particular the percentage of clay minerals.
The contractor shall ensure that the concrete mix complies with the requirements of this
contract regarding “Minimising Risk of Alkali-Silica Reaction in Concrete” provided under
section 5.1.7 of specifications on Concrete.
Chlorides
The chloride content of aggregates shall be within the recommended limits stated in IS-383
or BS 882. The chloride content of the concrete mix shall be within the recommended limit
of IS-456 or BS 8110.
Sulphates
The total acid soluble sulphate content of the concrete mix, expressed as SO3, shall not exceed
the recommended limits in IS 456 or BS 8110.
5.9.2.2.4 Blending of aggregates
In order to obtain optimum workability, individual aggregates of nominal size 40mm, 20mm,
10mm, 4.75mm and 2.36mm shall be blended in such a way that the grading curve for all
aggregates will be a smooth curve from size 0.15mm to 40mm falling within the established
envelop grading curve. Contractor shall establish envelop grading curve for each grade of
concrete for given maximum size of aggregates for Notice of No Objection before finalising
the mix design.
5.9.2.2.5 Testing of aggregates
Acceptance Testing:
As soon as the first aggregates have been produced to stockpile the Contractor shall carry out
tests. The method of sampling shall be in accordance with IS: 2430-1969. The amount of
material required for each test shall be as specified in the relevant method of test given in IS:
2386 (Part I) – 1963 to IS: 2386 (Part VIII) – 1963.
All tests shall be carried out as described in IS: 2386 (Part I) – 1963 to IS: 2386 (Part VIII) –
1963.
If at any time a significant physical or chemical change in the nature of the coarse or fine
aggregate occurs, or a new source of aggregate is used, the Employer’s representative may
direct that some or all of the acceptance testing is repeated.
Routine Testing:
The Contractor shall carry out routine testing of aggregates for compliance with the
Specification during the period in which concrete is being produced for the Works. The tests
shall be performed on aggregates from each separate source on the basis of one set of tests
for each day on which aggregates are delivered to the concrete batching plant provided that
no set of tests shall represent more than 250 tonnes of fine aggregate nor more than 500 tonnes
of coarse aggregate and provided also that the aggregates are of uniform quality. If the
aggregate from any source is variable, the frequency of testing shall be as instructed by the
Employer’s representative.
Water
The contractor shall make his own arrangements and procure fresh potable water for the
mixing and curing of concrete. Testing of such water shall be in accordance with IS 3025.
SS2-19
Water to be used for mixing and curing concrete and mortar shall be fresh and free from
dissolved or suspended matter which may be harmful and shall comply with the requirements
of IS 456.
Water samples from the intended source of supply shall be taken for analysis before any
concrete work is commenced, and shall be tested in accordance with BS EN1008 and shall be
submitted to Engineers Notice. The frequency of testing shall be as follows:
⚫ Potable water: No testing

⚫ Water recovered from processes in the concrete industry (as defined in A2.1. of BS
EN 1008): test in accordance with Annex A of BS EN 1008.
⚫ Water from underground sources, natural surface water and industrial waste water:
Test before first use and thereafter monthly until such time that a clear insight in the
fluctuation of the water composition has been established. Thereafter a lower
frequency may be adopted.
Where potable water supply is not available the Contractor shall obtain confirmation of
quality and reliability of a proposed source from the appropriate Water Authority and shall
test the water for its chemical and other impurities before its use in the Works. Cost of all
such tests shall be borne by the Contractor.
Admixtures
Chemical admixtures are not to be used until Employer’s representative Notice of No
Objection. In case their use is permitted, the type, amount and method of use of any
admixtures proposed by the Contractor shall be submitted to the Employer’s representative
for Notice of No Objection. The minimum cement content specified shall not be reduced on
account of the use of the Admixtures.
The Contractor shall further provide the following information concerning each admixture to
the Employer’s representative:
i) Normal dosage and detrimental effects if any of under dosage and over dosage.
ii) The chemical names & solid contents of the main ingredients in the admixtures.
iii) The chloride content, if any, expressed as a percentage by weight of admixture.
iv) Whether or not the admixture leads to the entrainment of air when used in the
manufacturer's recommended dosage.
v) Where two or more admixtures are proposed to be used in any one mix, the
manufacturer's written confirmation of their compatibility.
The admixtures when used shall conform to IS: 9103, ASTM C-494 or AASHTO M- 154 or
BS EN 934-2 and BS EN 480-10. The suitability of all admixtures shall be verified by trial
mixes. The addition of calcium chloride to concrete containing embedded metal will not be
permitted under any circumstances. Retarding admixtures when used shall be poly hydroxyl
compounds or as Notice of No Objection by Employer’s representative. Air-entering agents
shall comply with ASTM C-260 or AASHTO M-194 or BS 5075. Each batch / consignment
shall be tested for specific gravity & performance in concrete before their use.
5.9.3 Batching plants, mixers and vibrators
Unless otherwise specified, for all structural concreting work the Contractor shall provide
automatic weigh-batching plant of suitable capacity. The plant used shall conform to IS: 4925.
The Contractor shall provide Concrete mixers (IS: 1791 – Batch type concrete mixers, IS:
2438 – Roller Pan Mixer) and Vibrators (IS: 2505 – Concrete Vibrators Immersion Type, IS:
2506 – Screed board concrete vibrators, IS: 4656 – Form Vibrators for Concrete) supplied by
recognised manufacturers.
SS2-20
5.9.4 Mix Design

It is the complete responsibility of the Contractor to design the concrete mixes by approved
standard methods and to produce the required concrete conforming to the specifications and
the strength, durability, workability requirements as required by the specification.
Mix Design once approved must not be altered without prior Employer’s representative
Notice of No Objection. However, should the Contractor anticipate any change in quality of
future supply of materials than that used for preliminary mix design, he should inform the
Employer’s representative in advance and bring fresh samples sufficiently in advance, to
carry out fresh trial mixes. Design mix will indicate by means of graphs and curves etc., the
extent of variation in the grading of aggregates which can be allowed. Cement will mean
cement/blended cement. The S.D. and coefficient of variation shall be established for each
grade of concrete. Statistical Quality Control (SQC) graphs shall be submitted monthly.
5.9.5 Tests for concrete
Acceptability Criteria
5.9.5.1.1 Permeability test
The concrete shall be tested for permeability according to DIN 1048. Regular permeability
tests shall be carried out as per the frequency specified in relevant standard. From the batches
thus selected two concrete cylinders shall be made in accordance DIN 1048.
All cylinders shall be made, cured, stored, transported and tested in accordance with DIN-
1048 Specifications. The tests shall be carried out in the site laboratory or off-site laboratory.
The depth of penetrability of water shall be less than 10 mm when tested in accordance with
DIN 1048.
5.9.5.1.2 Rapid Chloride Penetration Test
RCPT shall be carried out as per ASTM-C-1202 under controlled conditions and by trained
technicians. The necessary equipment shall be installed at site laboratory or off-site laboratory
with Employer’s representative Notice of No Objection. The RCPT values should not exceed
700 coulombs for the concrete tested at 28 days.
Production test on materials
This Section covers tests which are to be carried out at the preproduction stage only. Regular
testing during full production shall be carried out in accordance with the Specification.
The tests have been classified in terms of the level of compliance required:
Compliance Tests Tests to prove that the concrete satisfies an existing requirement.
Preproduction Trials Tests to establish the criteria which will be used during production.
Reference Tests Tests which provide information for design or for long-term confirmation
of the more rapid tests.
The following sections list the tests and their form and gives reasons for their inclusion.
The numbers of tests and frequency of sampling are summarised in Table 1 below.
5.9.5.2.1 Compliance tests
1) On Aggregates:
i) Wet sieve analysis
ii) 10 % fines values

SS2-21
iii) Flakiness index of coarse aggregates shall not be more than 30%
iv) Aggregate chloride content : The chloride content of any aggregate used shall
not exceed 0.03% by mass expressed as chloride ion.
v) Petrography: Petrographic examination shall be carried out in accordance with ASTM
or standard procedures to identify the minerals present and in particular the percentage
of clay minerals.
The petrography tests, because of the specialist knowledge required in the analysis, shall only
be carried out at an external laboratory which has Employer’s representative Notice of No
Objection. The main purpose is to compare the structure of the aggregate as delivered to that
of samples from the quarry which was tested previously.
2) On hardened concrete:
Concrete strength - Standard cube crushing methods to establish 28-day strength and
correlation with 3-day and 7-day strength. Standard and match curing as for production
segments will be used to determine the correlation between the two.
5.9.5.2.2 Preproduction Trials
1) On aggregates:
Moisture content
2) On fresh concrete:
Veebee - To develop a target range of times and assess the controllability of workability
3) On hardened concrete:
Schmidt hammer - To calibrate for possible use as comparative NDT during production.
Weighing of samples - Cubes and cores to establish density
4) Curing trials:
Temperature monitoring - Segments and cubes shall be instrumented with thermocouples to
monitor temperatures during curing. Monitoring shall continue after demoulding to establish
the optimum type and period of curing to avoid thermal shock and rapid drying out Inspection
for cracking - For the various cooling regimes visual inspection (by wetting the concrete) for
cracking and inspection of cores taken from the segment will be made.
5) Durability tests:
Water permeability tests
5.9.5.2.3 Reference tests:
1) Design parameters:
E value test
Creep test (on a 90-day cylinder)
Thermal expansion coefficient - for use in design and monitoring of linings Drying
shrinkage/wetting expansion (on cores).
Concrete compressive strength - relationships between 28 day and 90-day cube strengths and
between cube and cylinder strengths.
SS2-22
Concrete tensile strengths - cylinder splitting tests for input to design and interpretation of
joint tests. The cylinders shall be accelerated cured in the same manner as the segments before
being put into a curing tank.
2) Durability:
Standard absorption test
Water permeability
Summary of tests
The tests required are summarised in Table 1. Unless otherwise notified, tests on concrete
shall be carried out on three trial batches.
Type of test Number of tests Sampling
Compliance tests
Wet sieve analysis 2 One representative sample
10% fines value 1 One representative sample
Flakiness 1 One representative sample
Aggregate chloride content 1 One representative sample
Petrography 1 Random sample of each size
Cement and FA - Sample every 100 tonnes
Wet concrete chlorides
1
content
3 numbers at 7 days and 3
Cube tests Every trial batch
numbers at 28 days
Pre-production tests
Moisture content 2 One representative sample
Vee Bee 1 Every trial batch
On all preproduction cubes and
Schmidt Hammer Every trial batch
segments
Density Every cube and core tested Every trial batch
Curing 2 segments, 3 cubes
Water permeability 2 One core per segment for each test
Reference tests
E- value 1 -
Creep 1 Cylinder
Thermal expansion 1 -
Drying shrinkage/wetting
1 Not less than two cores
expansion
3 numbers at 20 days and 3
28 to 90 days cubes ratio Every trial batch
numbers at 90 days

SS2-23
Type of test Number of tests Sampling

Cube to cylinder ratio 3 3 cylinders and 3 cubes per test batch
3 cylinders per test batch, random
Tensile strength 3
cube or core
Absorption 1 Random cube or core
Water permeability 2 One core per segment for each test
Table 1 Summary of tests

5.9.6 Curing
Segments shall not be demoulded until the concrete has achieved a strength of 15 MPa to
prevent damage to the segment during the demoulding process.
Secondary curing of segments is to be initiated immediately following initial stripping of the
moulds. The segments are to be maintained for 7 days at a minimum of 100 % humidity,
under cover prior to stacking and placing in the stockpile.
Curing of concrete shall be complete and continuous using potable water free from chlorides
and sulphates, water that is free of harmful amounts of deleterious materials that may attack,
stain or discolour the concrete as per IS 456.
Immediately after compaction and completion of any surface finishes the concrete shall be
protected from the evaporation of moisture by means of polythene sheet, wet Hessian or other
material kept soaked by spraying. As soon as the concrete has attained a degree of hardening
sufficient to withstand surface damage moist curing shall be implemented and maintained for
a period of at least 21 days after casting.
Method of curing and their duration shall be such that the concrete will have satisfactory
durability and strength and members will suffer a minimum distortion, be free from excessive
efflorescence and will not cause undue cracking in the works by shrinkage.
Steam curing with approved methodology can be adopted if required.
Curing compounds may be permitted with Employer’s representative notice of no objection.
However, it is required to be proved that using curing compound the concrete shall not have
less strength than concrete cured by water curing. It shall not leave any discolouration on the
structural concrete and should not be detrimental to durability of concrete.
The segments shall not be moved until the Contractor has demonstrated that the strength of
the concrete when such movement is affected, for any proposed method of lifting, will not
induce deleterious effects on the concrete, in particular the generation of cracks in the
concrete which will reduce the protection indicated by the minimum design cover.
5.10 MATERIAL FOR SEGMENTAL LINING – REINFORCEMENT
All the requirements for reinforcement shall also comply with the various clauses mentioned
under section 5.1.4 “Reinforcement” of these specifications.
Only Thermo-Mechanically Treated (TMT) reinforcing bars of grade Fe 415/500 with
minimum total elongation of 14.5% conforming to IS 1786-1986 shall be supplied and used
as steel for reinforcement Any steel specified for reinforcement shall conform in every respect
to the latest relevant Indian Standard Specifications and shall be of tested quality under the
ISI Certification Scheme.

SS2-24
All reinforcement work shall be executed in conformity with the drawings and carried out in
accordance with the relevant Indian Standard Specifications IS: 2502- Bending and Fixing of
Bars for Concrete Reinforcement.
The reinforcement steel shall be from primary producers and not re-rolled steel shall be
supplied/used under any circumstances.
5.10.1 Storage
Reinforcement shall be clearly labelled and stored on Site either in racks or on a hard-
impermeable base so that it remains straight and free from contamination.
Any reinforcement which is likely to remain in storage for a long period shall be protected
from the weather so as to avoid corrosion and pitting. All reinforcement which has become
corroded or pitted to an extent, which, in the opinion of the Employer’s representative will
affect its properties, shall be removed from site without delay.
5.10.2 Cutting and bending
No flame cutting of high-tensile steel bars shall be permitted. Except as provided for below,
all bars shall be bent cold and bending shall be done slowly, a steady, even pressure being
used without jerk or impact.
Reinforcing bars that have been bent shall not be rebent at the location of the original bend
without Employer’s representative Notice of No Objection.
5.10.3 Surface condition
Immediately before the concrete is placed around the reinforcement, the reinforcement shall
be clean, free from mud, oil, grease, paint, loose rust, loose mill scale or any other substance
that can have an adverse effect on the steel or concrete, or reduce the bond.
5.10.4 Inspection & Testing
Every bar shall be inspected by Contractor before assembling on the Works and any defective,
brittle, rusted or burnt bars shall be removed. Cracked ends of bars shall be cut out.
Reinforcement steel shall be fresh, free from corrosion. Corroded steel will not be
incorporated in work. If there are traces of corrosion, then the Contractor have to give the
following treatment to steel for which nothing extra shall be paid.
(a) Cleaning of steel by wire brush for removal of dust and rust. No work shall be commenced
without the Employer’s representative Notice of No Objection of design drawings.
Manufacturer's Certificate shall be supplied for each lot of supply.
Specimens sufficient for three Tensile Tests for each different size of bar for each
consignment delivered shall be sampled and tested by the Contractor. Batches shall be
rejected if the average results of each batch are not in accordance with the specifications and
shall be removed from Site, without delay.
All manufacturer's test certificates, batch reference labels and quality control certificates shall
be retained by the Contractor and noted against each bar mark number at the time of cutting
and bending. This information shall be copied to the Employer’s representative weekly.
5.10.5 Bar bending and Bar bending schedule
All bars will be carefully and accurately bent by approved means in accordance with IS: 2502,
and relevant drawings. It shall be ensured that depth of crank is correct as per the bar cutting
and bending schedule and bent bars are not straightened for use in any manner that will injure
the material.

SS2-25
Prior to starting bar bending work, the Contractor shall prepare bar bending schedule from
the structural drawings supplied to him and get Employer’s representative Notice of No
Objection. Any discrepancies and inaccuracies found by the Contractor in the drawings shall
be immediately reported to the Employer’s representative whose interpretation and decision
there to, shall be accepted.
5.10.6 Lapping & Welding
As far as possible, bars of the maximum length available shall be used. Laps shown on
drawings will be based on the use by the Contractor of bars of maximum length. In case the
Contractor wishes to use shorter bars, laps shall be provided at the Contractor's cost in the
manner and at the locations that the Employer’s representative Notice of No Objection. Bars
having butt or lap welds shall be provided as specified in the drawings or as Employer’s
representative Notice of No Objection.
Mechanical couplings shall be made only by the methods specified and at the positions shown
on the Drawings.
5.10.7 Tying/Binding Wire
Tying wire shall be finally annealed mild steel of core diameter approximately 1.25
millimetres or as specified by the Contractor.
5.10.8 Spacing, Supporting and Cleaning
Bars may be welded by noticed electrical process which does not affect the tensile properties
of the bar. Alternatively, the bars shall be bound together with No. 16 gauge, soft annealed
wire at sufficient intersections to ensure that the network of bars will retain its designed form,
and the network shall be temporarily supported so as to retain its correct position during the
process of placing and compacting the concrete. The ends of all such tying wires shall be
carefully turned into the body of the concrete and clear of the mould.
Top reinforcement shall be supported on adequate stools to ensure that the reinforcing bars
are firmly held in position during concreting.
Normal stools and supports will be detailed on the Drawings and bending schedules. The
Contractor shall provide for any additional supporting steelwork to suit his particular
arrangements.
Reinforcement shall be rigidly fixed so that no movement can occur during concrete placing.
Any fixings made to the formwork shall not be within the space to be occupied by the concrete
being placed.
Cover and spacer blocks required to support the reinforcement shall be as small as possible
consistent with their use and be of noticed design and material. Projecting ends of ties or clips
shall not encroach into the concrete cover.
5.10.9 Cover
The term "cover" in this context shall mean the minimum clear thickness of concrete between
the surface of the reinforcement and face of the concrete.
The minimum cover to reinforcement shall be 40 mm.
Cover blocks or spacers required for ensuring that the specified cover is obtained shall be of
a material, design and same colour, strength and material source as the surrounding concrete.
The blocks shall be formed in specially manufactured moulds and the concrete compacted on
a table vibrator, all with Notice of No Objection from Employer’s representative.
The blocks shall be cured in water for at least 7 days.

SS2-26
The Contractor shall measure the cover to all reinforcement with a cover meter as soon as the
formwork has been stripped and submit the record of this survey to the Employer’s
representative as soon as practical.
Precast concrete segments with inadequate cover shall be rejected and removed from Site
without delay.
5.10.10 Welding
Wherever specified all lap and butt welding of bars shall be carried in accordance with IS:
2571. Only qualified welders shall be permitted to carry out such welding. For cold twisted
reinforcement welding operations must be controlled to prevent a supply of large amounts of
heat larger than that can be dissipated. The extreme non-twisted end portion shall be cut off
before welding. Electrodes with rutile coating should be used.
Bars shall be free from rust at the joints to be welded.
Slag produced in welding after alternative run should be chipped and removed by brush.
Electrode should not be lighted by touching the hot bar.
Contractor shall submit welding procedure for Employer’s representative Notice of No
Objection. All tests certificates shall be made to prove the soundness of the welded connection
to the Employer’s representative.
5.11 MATERIALS FOR SEGMENTAL LINING - ELASTOMERIC GASKETS
The gasket shall be capable of providing a watertight seal under all combinations of specified
tolerances associated with manufacturing and ring erection. Gaskets shall be dense,
elastomeric synthetic rubber and shall be supplied from approved manufacturers and shall be
tested in the presence of the Employer’s representative.
The test rig shall simulate a range of conditions of displacement and joint gap, including the
worst combination to be encountered in the completed structure. In each test the water
pressure shall be increased in increments of 0.5 bar and held at each value for 5 minutes. The
final pressure shall be at least 1 bar in excess of the maximum hydrostatic pressure to which
the structure may be subjected. This pressure shall be maintained for 24 hours during which
no leakage shall occur at the gasketed faces. Tests shall be carried out at normal ambient
temperature.
Gaskets shall be manufactured to fit the groove preformed in the segment. Prototype gaskets
shall be fit-tested to assess stretch characteristics. The material from which the gaskets are to
be manufactured shall withstand any aggressive response from the ground or groundwater. In
particular the gasket material shall withstand chemical attack and biological degradation such
that the gasket functions properly for the design life of the facility.
Elastomeric gaskets shall comply with the requirements of BS 7874, BS EN 681 and BS EN
682. The material shall consist of a compound based on EPDM able to withstand the long-
term stresses and strains without detriment to the specified performance.
The gasket cross section shall be dimensioned to suit the groove as detailed in the Drawings
for the mating faces of the segmental tunnel linings. Manufacturing tolerances shall be ±1
mm for width and ±0.5 mm for thickness.
Gaskets shall be manufactured from extruded solid sections with appropriate spaces within
the section to enable the gasket to be fully compressible within the groove formed in the
concrete segments. The gasket shall still be capable of further compression when its top
surface is level with the groove.
SS2-27
The extruded section shall be joined to form a rectangular gasket that is a stretch fit into the
grooves of the segments. The corner joint shall be shot moulded and the corner pieces shall
be of different section from the extruded lengths in order that the water-tightness
characteristics described in the specification may be achieved and to avoid excessive load on
the corners of the concrete segments.
Gaskets shall be fitted into the groove cast in the segmental tunnel linings prior to erection.
The adhesive used shall be as recommended by the gasket manufacturer with a “notice of no
objection” from the Employer’s representative. The maximum leakage rate for segmental
lining shall not exceed 0.048 l/m2/day.
The Contractor shall submit to the Employer’s representative full details and samples of the
gaskets which he proposes to use at least 56 days before the commencement of
manufacturing.
5.12 MATERIALS FOR SEGMENTAL LINING - BOLTS AND GROMMETS
5.12.1 Bolts
Radial and circumferential joint bolts shall be made from steel grade 8.8 to BS 5950 and
sherardized to BS 4921. The length of each lining bolt shall allow for two washers of a type
accepted by the Engineer and for all adjustments required in the alignment of the tunnels.
When fitted in position the bolt threads shall be exposed for at least 3mm clear of the nut.
This applies even where the maximum build tolerances have all been used in the erection of
the lining.
5.12.2 Grommets
Grommets shall be plastic and to a specification that has a “notice of no objection” from the
5.12.3 Packings
Stress distribution packings for radial and circumferential joints shall be detailed and
specified and shall be cut from an approved bituminous felt fibre-based sheet or marine
hardboard to a minimum thickness of 2 mm.
Timber packings that may be required for the correction of the plane of the ring shall be
marine hardboard or plywood, sawn to shape with boltholes. They shall be treated to retard
rot and fire and shall be available in all necessary thicknesses as may be required to suit the
tapered ring.
5.13 GROUTING
5.13.1 Primary grouting
A grouting system shall be provided on the TBM which shall be designed to inject grout
continuously into the void behind the tail shield as it advances. This system shall be kept
piped up to the tail shield ports but shall have the facility for emptying the pipes and washing
them when not in use.
The system shall be capable of manual control or automatic operation linked to the advance
of the TBM. The system should have the facility for selectable volume and pressure control
and should be sized to suit the anticipated tail shield void and the annulus between the
excavated surface and the extrados of the segmental lining.
For a slurry TBM the system shall be arranged to prevent the contamination of the slurry in
the cutterhead chamber due to over injection of grout. It shall be arranged such that injection
of grout is not possible unless the slurry circulation system is operational.

SS2-28
Control and monitoring of grout injection volumes and pressures shall be possible on the
operator’s control panel and at the grouting station within the backup of the TBM and the
results shall be recorded in the data logger.
The grout shall achieve a minimum cube strength of 50 kPa before the next 'shove'
commences and a minimum 2 MPa at 28 days when measured on 100 mm cubes. Such test
shall be conducted after installation of every 120 rings. During production grout pressures
shall be continuously monitored at the point of injection using in-line pressure gauges and
shall be restricted to values not greater than 1.2 x total overburden.
The amount of grout used shall be recorded, and if the quantity falls short of that required to
fill the void, further investigation and grouting shall be carried out.
The Contractor shall undertake trials, to demonstrate compliance with the grout strength
requirements. The grout mix requires a notice of no objection from the Employer’s
representative before use.
5.13.2 Proof/Secondary grouting
Proof grouting of the segmental lining shall take place after Primary grouting and prior to any
consolidation grouting in mixed ground conditions. Proof grouting is necessary to ensure that
the void around the segmental lining is completely filled with grout and shall be carried out
wherever segmental linings are used. The proof grouting shall be carried out at a distance
back from the advancing lining section as agreed with the Employer’s representative, but in
any instance not closer than 30 m or further than 100 m from such position. The preformed
grout holes in the segments of every 5th ring are to be drilled out to 650 mm or to rock contact,
whichever is the greater, and grout injected commencing at the lowest holes to allow any air
and water to be displaced.
All the grout holes in the ring being grouted shall be drilled out prior to injection. When
interconnections occur, the holes shall be kept open until the emerging grout is of the same
consistency as the grout being injected before being closed. Injection shall continue until the
hole refuses to accept grout at the specified maximum pressure. Any leakage of grout through
the joints in the segments shall be stemmed by a proposed method.
On completion of proof grouting at any particular hole the pressure shall be maintained until
the grout has set and the grout holes shall be completely filled.
5.13.3 Contractor’s Submissions
Method Statement
Prior to commencement, the Contractor shall submit a method statement for primary grouting
and obtain the ‘Notice of No Objection’ from the Employer’s representative. The method
shall include details of the mixing plant and grout pump(s), mix design and constituents,
pumping rates and pressures, injection points, the methods of monitoring, recording and
controlling the sequence and timing of grouting, the method of preventing grout leakage, and
details of the relevant experience of the personnel and supervisors.
Grouting Pressures
The Contractor shall ensure that the grout pressures are sufficient to properly place the grout
and to fully fill the annulus but do not cause ground heave, over stress or distort the lining,
distort or damage the gaskets or damage other structures.
Grouting pressures shall not exceed 1 bar above the line pressure and the hydrostatic pressure
at the invert of the tunnel.

SS2-29
Mix
The grout shall be a mixture of Ordinary Portland Cement and water with a water/cement
ratio in the range of 0.35 to 0.5 by weight as appropriate to the circumstances. PFA, GGBS
or additives such as plasticizers or non-shrink agents excepting those containing calcium
chloride may also be proposed. Other grouts compatible with the Contractor’s tail seal system
may be proposed.
Injection
The grout shall be injected, continuously as the tunnelling machine moves forward through
pipelines embedded within the shield tail skin, by positive displacement pumping. The
Contractor shall ensure that grouting pressures used are consistent with his proposals and
shall adopt appropriate methods and procedures for controlling and monitoring the process.
The Contractor shall ensure that the tail skin seals and sealing material shall prevent grout
loss. Rings shall be restrained by the shove rams to prevent distortion or floatation, whilst
allowing the free flow of grout in the void.
Grout Plugs
Upon completion of grouting, all grout plugs shall be greased and shall be fully tightened into
the segment. Hydrophilic ‘O’ rings shall be provided at all grout plugs.
Grout Valves
For lining built behind tunnelling machines, having pressurised face system, grout holes if
provided in the linings segments shall incorporate one-way valves to prevent ground and
water loss during grouting operation.
Records
The Contractor shall record at each stage of the grouting process the quantity and type of
grout and the pressure applied at each injection point. Grouting records shall be kept in the
Contractor's offices and be available for inspection by the Employer’s representative.
Monitoring Pressures
The Contractor shall monitor proof grouting pressures and quantities to ensure that grouting
does not damage the Works or third-party utilities or structures.
Caulking
Where caulking is specified it shall be carried out after completion of primary and secondary
grouting. Caulking grooves shall be formed in segments in accordance with the design and
the specifications to ensure that caulking to circle joints and radial joints may be made
effectively and continuous, the depth of caulked material in the joints being not less than 25
mm.
Prior to caulking all joints shall be inspected and thoroughly cleaned out as necessary. Any
packing shall be cut out by an appropriate method. Immediately prior to caulking, the joints
shall be blown out with a compressed air jet to remove any loose debris.
5.14 TOLERANCES AND INSPECTIONS
The tunnel lining segments shall be cast to the dimensions shown on the drawings and within
the tolerances specified. Segments shall be cast with such accuracy and uniformity of
dimensions that all similar segments shall be interchangeable with corresponding segments
of other rings.
A comprehensive quality control and inspection procedure shall be provided by the
Contractor. The Contractor shall be responsible for the production of segments of the required
quality and accuracy and, in addition, shall carry out the inspections specified hereafter.

SS2-30
Templates, gauges and testing apparatus as required shall be provided and kept suitably
protected from damage and distortion and free from dirt and corrosion, ready for use in
checking the segments as hereafter described. The segments shall be checked for dimensional
accuracy using a noticed measuring system.
The first segment cast in any mould shall be gauged. Thereafter 5 per cent of the segments
shall be gauged. Further, the number of segments gauged shall, whenever any variation in
quality has occurred, be that required to establish the accuracy and consistency of production
as quickly as possible.
A record shall be kept of the units cast in each mould and any mould that becomes distorted
or which casts faulty units shall be withdrawn from service readjusted or repaired until proved
satisfactory. A fully detailed record of the result for each measured segment will be available
within 24 hours of the verification.
To prove the accuracy of manufacture the Contractor shall undertake a trial assembly of 3 full
rings complete with gaskets and bolts and stacked vertically on a flat surface, shall be
undertaken at no additional cost to the Employer. Should any rings fail to meet the specified
tolerances, they shall be rejected and removed from the Works and the test undertaken again
until proved satisfactory.
5.15 ALTERNATIVE TUNNEL LINING
If the Contractor intends to use an alternative form or type of tunnel lining, he shall submit
for consent comprehensive details of his proposals. Such proposals shall include details of
materials, method statement, specification and design sufficient to demonstrate compliance
with the various Employer’s Requirements. If such proposals, or any modifications to them
which may be submitted, cannot be consented to, the Contractor shall adopt the lining types
and methods specified herein as appropriate to the works.
6 NATM TUNNELING
6.1 EXCAVATION
6.1.1 General
The Contractor shall perform all NATM works in accordance with this specification or as
required by the Contract and shall conform to the dimensions shown on the drawings that
have received a notice of no objection from the Employer’s representative.
Prior to commencing any excavation for NATM works, the Contractor shall prepare and
submit appropriate designs, drawings and method statements relating to his proposed methods
of working. Such methods shall ensure that there is no damage to or deterioration of the final
surfaces of the excavations and ensure that surface settlement and distortion to underground
structures are kept to acceptable limits.
The exhaust systems of any internal combustion vehicles used underground shall be fitted
with air cleaning equipment.
The safety and security of all excavations, shall, at all times during the construction, be the
responsibility of the Contractor. The Contractor shall implement such measures, including
supporting, dewatering and consolidation, as may be necessary to fulfil this obligation. The
design of temporary works and ground supports, particularly those for locations below
residential areas, railways and highways should be verified as required under the Contractor's
Quality Plan. All inclined tunnel drives shall have runaway vehicle protection. The Contractor
shall construct the works in such a way that the settlement effects are kept within the limits
specified in relevant section on settlement in these specifications.

SS2-31
Such measures might include:
⚫ special tunnelling methods to reduce ground loss;

⚫ protection measures such as:
▪ Underpinning
▪ ground improvement
▪ compensation grouting
▪ structural jacking and supporting
▪ structural strengthening
▪ curtain walling
▪ or other supporting methods
6.1.2 Excavation with care
All necessary precautions shall be taken in order to prevent softening or deterioration of
excavation surfaces through exposure such as installation of primary support at the earliest.
The following points may also be considered appropriate in this regard:
⚫ Where necessary to ensure the safety and security of the Works, excavation for
underground Works shall be continuous by day and night. The Contractor's
procedures may allow intermissions at weekends and general holidays, providing
the Works are safe and are inspected by the Contractor at appropriate intervals.
⚫ Where open faced tunnelling is to be carried out, the Contractor shall provide
adequate means to support the face in an emergency. The support system shall be
maintained in good order at all times and it shall be stored as close to the face as
practicable. A detailed drawing of the support system shall be available close to the
tunnel face for reference.
⚫ Temporary support will be required to the face at all times during manual
excavation. The type of support provided must suit the actual and anticipated ground
conditions. The ground must be carefully trimmed in order that the supports can be
properly seated and bear fully onto the face with a minimum of wedging.
⚫ Where the excavation is to be discontinued for any period of time the face must be
supported in such a manner that ground movement is prevented.
In general, the Contractor shall at all times carry out excavation to the Works such that the
minimum of ground movement is allowed to take place.
6.1.3 Excavation method and Equipment
Rock excavation shall be performed by using modern blasting methods, road header,
excavator or breaker, expansive chemical agents etc. depending upon the ground conditions
and site constraints. Controlled blasting methods (where permitted by the Engineer) such as
“smooth blasting” shall be used to limit the over-break, prevent the shattering of the rock
surfaces, limit the vibration/noise and prevent adverse effects on the Works & EBS. Road
header shall have transverse type of cutter head and shall be capable of working in the type
of rocks likely to be encountered in the tunnel excavation.
6.1.4 Soft ground excavation
In ground which is not self-supporting, measures shall be taken to ensure that no undue loss
of ground occurs at the face, and there is no run of material from behind support or lining.
Where excavation is discontinued for any reason, the contractor shall take all necessary steps
to secure and support the excavation, to ensure that ground movement is prevented.

SS2-32
6.1.5 Excavation for contractor’s convenience

Excavations for the Contractor's own use and convenience shall conform in every respect
with this Specification. For this purpose, the Contractor shall submit detailed proposals to the
Employer’s representative. The proposals shall include the Contractor's method of backfilling
and reinstatement.
6.1.6 Disposal of excavated material
Excavated material, which is not acceptable or cannot be accommodated for use in the Works,
shall be disposed of in spoil dumps or elsewhere as approved by the regulating authorities.
Excavated material, which can be used at a later stage in the Works, shall be temporarily
stockpiled in a dumpsite as proposed by the Contractor and agreed by the same authorities.
6.2 TUNNEL TEMPORARY SUPPORT
6.2.1 General
The support by NATM principles will mainly consist of the following:
⚫ steel ribs or lattice arches and wire mesh sprayed with shotcrete to a specified
thickness
⚫ shotcrete with wire mesh or fibre and rockbolts.
⚫ a combination of the above.
The initial Support shall be monitored continually for settlements/deformations throughout
the stabilisation process. Other monitoring shall include forces in rock bolts and
stresses/strains in shotcrete lining.
The temporary support system with respect to each rock class shall be verified by the
contractor with respect to his intended construction methodology and the ground conditions
anticipated and this shall be agreed with the Employer’s representative.
After the excavation of a round, the excavated surface (including the face) of the tunnel shall
be immediately applied with a sealing layer of shotcrete of required thickness. The face
support during stoppages or lining installation shall either consist of a spoil buttress which
has to be supported by shotcrete and wire mesh or shotcrete and wire mesh with grouted rock
dowels inserted into the face.
Wherever ground conditions require a pre-support, the contractor shall provide an Umbrella
type forepoling either by installing a pipe roof or by spiling with grout pipes or bars depending
on the ground condition.
Where the water in-flow into the excavation is expected, ground treatment such as grouting
etc. shall be done by the Contractor before commencing the excavation. However, the
localised dewatering in the tunnel face can be carried out by either drainage pipes inserted
into the face or a mild vacuum system duly ensuring that it doesn’t lead to unacceptable
ground surface settlements/distortions adversely affecting the EBS.
The face support during stoppages or lining installation shall either consist of a spoil buttress
which shall be supported by shotcrete and mesh or shotcrete and mesh with grouted rock
dowels inserted into the face.
6.2.2 Sprayed concrete
General
Sprayed concrete may be applied by either a wet or dry mix process. The term "gunite" will
be used for sprayed concrete where the maximum aggregate size is less than 9.5 mm and the
term "shotcrete" where the maximum aggregate size is 9.5 mm or greater. The Contractor

SS2-33
shall have equipment available on the site for shotcrete which can also be used for gunite if
necessary.
The sprayed concrete after completion is not to be touched up, trowelled, smoothed off or
worked in any way, but left undisturbed unless otherwise specified. If considered necessary
sprayed concrete shall be applied immediately following the barring down of the excavation
and before the removal of spoil.
Sprayed concrete shall be applied to both clear and mesh reinforced faces and to the final
thickness all as specified on the Drawings. Large radius irregularities will be permitted, but
local roughness and re-entrant angles are to be covered. Where specified sprayed concrete
shall be applied in one or more layers to reach the specified total thickness.
Materials
6.2.2.2.1 Cement and water
Cement, cement extenders, and water shall comply with the requirements. Silica fume shall
be supplied in densified form and shall comply with the following requirements:
⚫ Fineness : surface area not less than 18 000 m2/kg

⚫ Particle size : average 0.2 micron, maximum 0.4 micron
⚫ Si02 content : not less than 85 %
⚫ C content : not greater than 5 %
⚫ Total alkali content : not greater than 1.5 % (when combined with
cement total alkali content not greater than 0.6 %)
6.2.2.2.2 Aggregates
Aggregates shall comply with the requirements except as regards grading requirements which
shall be as given in Table 2. The combined aggregates shall normally lie within the following
grading limits by mass.
Aggregates with gradings outside these limits will not be accepted unless the Contractor has
demonstrated in full-scale trials that a satisfactory end product can be produced with such
aggregates.
Table 2 Aggregate grading limits

6.2.2.2.3 Steel fibres
Steel fibres, where specified, shall be collated or uncollated deformed steel fibres conforming
to the requirements of ASTM A820-90.
Fibres shall be stored in dry sealed containers until ready for use and shall be free from
corrosion, oil, grease, chlorides and deleterious materials which may reduce the efficiency of

SS2-34
the mixing or spraying process, or which may reduce the bond between the fibres and the
sprayed concrete.
Fibres shall have an aspect ratio in the range of 30 to 150 for lengths of 12.7 to 63.5mm.
Tolerances shall be in accordance with ASTM A820-90.
6.2.2.2.4 Accelerators
Accelerators can be used to achieve a fast set and to get sufficient early strength development.
Only liquid accelerators shall be used. Accelerators shall be alkali-free, not be caustic or
corrosive to reinforcement and shall be of a type with a history of satisfactory long-term
performance. References shall be obtained from suppliers and submitted to the Employer’s
representative for notice of no objection.
Only alkali-free accelerators shall be used, the alkali content shall be less than 1% mass
(Na2O-equivalent, EN480-12).
The dosage rate determined by the field suitability tests shall not exceed 2% of the cement
content of the mix design by weight. The dosage of accelerator shall be kept to the minimum
required for spraying in-situ.
Automatic devices shall be used to add the accelerator.
6.2.2.2.5 Plasticisers and Retarders
Plasticisers and retarders complying with BS 5075: Part 1 may be used to reduce the quantity
of the mixing water and to improve the pumpability of the concrete. The effects and optimum
dosages of plasticizers and retarders shall be determined during the acceptance tests.
Compatibility of plasticizes with cements. Latent hydraulic binders and accelerators shall be
verified by field suitability tests. The effects and optimum dosages of plasticizers and
retarders shall be determined by the field suitability test to achieve the shotcrete properties as
required.
6.2.2.2.6 Compressed air
Compressed air used in the process shall be clean, dry, and free of oil.
Design of sprayed concrete
The grade of shotcrete shall be M30. The mix design shall be carried out by the contractor
and details submitted to the Employer’s representative for notice. The mix for shotcrete shall
be designed by field suitability tests to meet the requirements. The following factors need to
be taken into consideration.
⚫ Material and gradation curves of aggregates

⚫ Cement Content
⚫ Water-cement ratio
⚫ Plasticizer or super plasticiser type and dosage, if any
⚫ Hydration control admixture type and dosage, if any
⚫ Internal curing admixtures, if any
⚫ Accelerating admixtures
⚫ Early and final strength
⚫ Strength loss as compared to the design mix strength of the shotcrete rebound
⚫ Temperature of the mix
⚫ Establishment of target slump and slump retention of the mix for optimum
performance and placement
⚫ Other additives if any
SS2-35
6.2.2.3.1 Cement content

The cement content shall be designed to meet the strength requirements of shotcrete applied
in the field.
⚫ For the dry shotcrete process the quantity of cement shall not be less than 350 Kg/m3
of dry mix.
⚫ For the wet shotcrete process the minimum cement content shall be 400 Kg/m3.
6.2.2.3.2 Requirements of shotcrete
Early strength
The early strength of shotcrete shall confirm to the early strength class J2 according to the
figure 1 below. For explanations regarding the use of early strength classes J1, J2 and J3
Austrian guidelines for shotcrete may be referred to.
The measurement of early strength shall be done by using the penetration needle, Hilti
Shotbolt (stud-bolt) system (or equivalent) according to the Austrian Guideline for Shotcrete,
August 2006.
Further Strength Development
The 72 hours strength of the shotcrete shall be at least 12.5 N/mm2. The strength of shotcrete
after 7 days shall be 70% of the specified 28 days strength of the mix.
Figure 1 Early strength requirement of shotcrete

Final Strength
The 28 days strength of shotcrete shall confirm to the 28 days design mix strength. A
maximum factor of 0.85 (the ratio of in-situ strength to the design mix strength) shall be taken
into consideration while designing the mix to account for the side effects of in-situ installation
conditions as compared to the conditions obtainable in the field suitability tests.
Equipment
All the equipment used for batching and mixing of materials and the application of sprayed
concrete shall be of noticed design and in proper working order. The sprayed concrete gun
and ancillary equipment shall be of adequate capacity for the volumes to be applied. The
equipment shall be capable of handling and applying 13 mm maximum size of aggregate. A
stand-by gun and ancillary equipment shall be available at all times. Air for the equipment is
to be provided at the equipment at not less than the operating pressure specified by the
manufacturer.
SS2-36
Dosing of additives by hand will not be permitted. Equipment for dosing additives shall be
adjustable for various quantities and provide a uniform rate of discharge evenly mixed with
the other ingredients of the mix. The equipment shall be capable of delivering admixture to
ensure the noticed dosage ratio to an accuracy of ± 5 %.
The working area shall be well illuminated to a minimum lighting intensity of 50 lux. Cap
lamps attached to safety helmets will not be accepted as sufficient. Dust pollution shall be
minimised by means of pre-damping of materials, additional ventilation, water sprays, and
maintaining equipment in good order. Protective clothing and dust masks shall be provided
for and used by all sprayed concrete operators.
If at any time the Employer’s representative considers that the environmental conditions of
the area where sprayed concrete is being applied are likely to cause a health hazard or affect
the quality of the finished work because of excessive dust or lack of adequate ventilation or
lighting, he may order the Contractor to suspend operations on sprayed concrete work until
steps are taken to improve the conditions in the affected area. No additional payment will be
made either for the additional measures called for or for any delays resulting from such
suspension of works.
Batching
6.2.2.5.1 Dry shotcrete process
Cement and aggregates shall be batched in the proportions as designed. Batching shall be
done by weight. At the time of batching all aggregates shall have been dried or drained
sufficiently to result in a stable moisture content, which shall not exceed 7%.
Mixing of cement and aggregates shall be performed by a mechanical mixer. Shotcrete shall
not be used unless placing can be completed within a period of 90 minutes from the time of
mixing unless a hydration control admixture is used that is suitable to inhibit setting and retain
consistency for the required time period till the placing of shotcrete. The hydration control
admixture must have a notice of No objection from the engineer.
The mixing time shall be in accordance with BS 5328.
A system of delivery notes shall be maintained to record the date, the time of mixing, mix
design number, quantity, delivery point, time of delivery and completion of placing. The
delivery notes shall be available to the Engineer for inspection.
For the dry process, powder or liquid type accelerating admixtures shall be added to the dry-
mix. The powder type accelerator shall be proportioned and added just before the dry mix
enters the shotcrete machine through a mechanical device (dispenser). Periodic calibration
checks shall be performed in accordance with the procedures prescribed by the manufacturer.
Liquid type accelerator shall be delivered by a special dosage pump and added to the dry-mix
at or near the nozzle. Dosage pump and the hoses to the nozzle shall be kept in good order.
Dry-mix delivered to shotcrete machine shall have a minimum temperature of 5° C and a
maximum temperature of 32° C.
During hot weather periods the water content of the aggregates for the dry process shall be
kept above 4%, in order to avoid cement loss at the rotor of the shotcrete machine.
During transportation the dry mix shall be effectively protected against the influence of
weather.

SS2-37
6.2.2.5.2 Wet shotcrete process

Only liquid types of accelerator can be used in the wet process; these shall be added at or near
the nozzle. The delivery from the accelerator pump must be controlled to be proportional to
the output of the concrete pump. Accelerator pump calibration shall be periodically checked
in accordance with the procedures prescribed by the manufacturer. The nozzle must be such
as to ensure a homogeneous mixture of the accelerator with the wet-mix.
Shotcrete shall not be used unless placing can be completed within a period of 120 minutes
from the time of mixing unless a hydration control admixture is used that is suitable to inhibit
setting and retain consistency for the required time period till the placing of shotcrete. At high
temperatures, hydration control admixtures shall be used to ensure fresh concrete and
sufficient initial setting time.
Concrete delivered to the shotcrete machine shall have a minimum temperature of 15°C and
a maximum temperature of 32°C.
A system of delivery notes shall be maintained to record the date, the time of mixing, mix
design number, quantity, delivery point, time of delivery and completion of placing. The
delivery notes shall be available to the Engineer for inspection.
6.2.2.5.3 Other points regarding batching
Materials shall be batched by weight and cement shall not be added more than 1 hour before
the anticipated time of placing the sprayed concrete. Aged material shall be discarded.
Batching and mixing equipment shall be cleaned at least once per shift to prevent
accumulations of aged material.
The addition of steel fibres shall be at a stage in the mixing suitable for the sprayed concreting
equipment. The procedure for the addition of steel fibres shall be determined during the Site
trials. Fibres shall be added and mixed in a manner to avoid clumping and bending of the
fibres. Any fibre clumps in the mix shall be diverted and removed by means of a screen placed
over the concrete hopper. Fibres shall be uniformly distributed throughout the mortar matrix
without isolated concentrations. Fibres shall not be added to the mix at a rate faster than that
at which they can be blended with the other ingredient without forming clumps or balls.
Preparation of surfaces
Before sprayed concrete is applied, checking and correction of the excavated cross section
profile shall be carried out. The surfaces to which sprayed concrete is to be applied are to be
barred down of all large loose material and the area cleaned down of all loose and foreign
material with a mixture of water and air applied at high pressure.
Where the inflow of groundwater renders the surface too wet for the normal application of
sprayed concrete, the surface shall be treated by suitable measures to be proposed by the
contractor and agreed by the Employer’s representative. All surfaces to receive sprayed
concrete shall be moist and free of all traces of dirt, oil, rebound or other deleterious material.
Placement of shotcrete
Where sprayed concrete is to be placed over a previous layer, that layer shall be first allowed
to reach its initial set and then cleaned of all rebound or other loose material.
Rebound shall be removed immediately after finishing of each shotcrete application. In
particular at horizontal shotcrete connections and at all construction joints the rebound shall
be removed, if necessary, by pneumatic hammers, prior to further application of shotcrete.

SS2-38
The rebound material, under no circumstances shall be worked back into the construction.
The work shall be continuously kept free of rebound material.
The minimum specified layer thickness shall be controlled by depth pins attached to the rock
surface and reinforcement, or by other noticed means. Before a succeeding layer is placed the
existing work shall be checked for hollow or non-adhering areas and these shall be cut out
and replaced to the satisfaction of the Employer’s representative.
Measures to establish the thickness of shotcrete shall be set up by the Contractor and as agreed
by the Engineer. These may include visual guides installed prior to shotcreting, holes drilled
after completion of shotcreting or a full control by laser scanning.
Curing of the shotcrete shall be performed after application by water spraying or other
appropriate measures subject to the agreement of Engineer.
Sprayed concrete shall not be applied to any surface without the prior inspection and a notice
of no objection from the Employer’s representative.
Curing
The use of a sprayed surface curing compound will not be permitted. The sprayed concrete
shall be kept moist continuously for 3 days by spraying with a fine mist of water at intervals
not exceeding 4 hours.
Operators for sprayed concrete
Only trained and tested operators shall be used for sprayed concreting operations. The
Contractor shall satisfy the Employer’s representative that the personnel are capable of doing
work of a high standard prior to any sprayed concrete work being undertaken in the Works.
For this purpose, each nozzleman and back-up team shall carry out a series of trial
applications in the presence of the Employer’s representative to demonstrate their ability in
applying sprayed concrete on vertical and overhead surfaces. Test panels shall be made by
each operator. No operator shall be approved unless the 28 day crushing strengths of all tests
exceed the design requirements.
The Employer’s representative may at any time withdraw his notice of no objection of
personnel if the quality of sprayed concrete applied falls below the specified standard.
Drainage holes
Where required drainage holes shall be provided. Where sprayed concrete is applied after the
completion of the drainage holes, the drainage holes shall be extended through the sprayed
concrete with suitable formers or similar noticed method.
Pressure relief holes
Generally, one day after spraying concrete, pressure relief holes 38 mm in diameter shall be
drilled through the sprayed concrete and 100 mm minimum into the rock. In general, a spacing
of 1 hole per 4m2 shall be provided in areas where a build-up of water pressure could be
expected.
Checking applied thickness
The thickness of applied sprayed concrete shall be checked by the Contractor by means of
randomly positioned test holes. An acceptable procedure for these test holes shall be such that
on average in any 100 m² area of sprayed concrete area at least 10 test holes shall be drilled
with a percussion drill.
The basis of acceptance shall be that in any area of 100 m², the arithmetic mean thickness of
all the points checked shall be equal to or greater than the specified thickness. In addition, at
no point checked shall the thickness be less than 70 % of the specified thickness for layers
SS2-39
less than 100 mm specified thickness or 50 % for layers of 100 mm specified thickness or
more. Where the thickness is not acceptable, an additional layer of sprayed concrete to be
applied and rechecked for thickness without additional payment until the placed thickness is
acceptable.
Initial testing
For the first 50 m² of sprayed concrete applied in each shift, test panels shall be prepared and
tested. Initial testing of shotcrete shall consist of one test panel for every 10 m² of sprayed
concrete applied. The test panels shall be prepared by the nozzleman doing the work during
normal sprayed concrete operations.
The test panels shall be made by spraying into moulds 750mm x 750mm x 150mm deep with
sides splayed outwards at 45° to prevent entrapment of rebound. Panels shall be made for
each mix and position sprayed (that is overhead, vertical, or downward) by fixing the moulds
to the surface being sprayed. Panels shall be clearly marked to identify the time and date of
spraying, and the area where they were sprayed.
Testing of sprayed concrete
For acceptance and routine testing, 100 mm diameter cores of a length between 110 mm and
150 mm after the ends are cut and trimmed shall be drilled from test panels by the Contractor.
Test panels shall be sprayed for each design mix and for each position of spraying required
in the Works such as downward, vertical and overhead positions. Cores shall be cut from
these panels and 3 cores tested for each strength requirement (8 hours, 24 hours and 28 days).
The average of the 3 results tested at 8 hours, 24 hours, and 28 days age shall be not less than
the 8 hours, 24 hours, and 28 days required strengths respectively. In addition, the value of
each core tested shall be within 20 % of the average value.
Sufficient tests shall be done to prove the acceptability of the sprayed concrete to meet the
requirements with regard to:
⚫ Compressive strength at 8 hours, 24 hours and 28 days (as per the relevant
standards)
⚫ Boiled absorption (as per ASTM C 642)
⚫ Volume of permeable voids (as per ASTM C642)
⚫ Setting time: initial and final (as per the relevant standards)
For the purpose of sampling and testing sprayed concrete the Contractor shall supply all the
panel moulds and core sampling equipment. The concrete testing machine supplied by the
Contractor for testing concrete cubes shall also be suitable for testing sprayed concrete
samples.
Failure of sprayed concrete
For the purposes of routine testing the quality of the sprayed concrete will be considered
satisfactory if every test result is at least 80% of the specified strength and if at least 80 percent
of all results exceed the specified strength.
Should test samples of sprayed concrete not achieve the specified minimum strength, the
Engineer will, if he considers necessary, order that additional tests be carried out by the
Contractor to determine new mix proportions to avoid further such failures.
If the Employer’s representative considers that the low strengths of the applied sprayed
concrete may reduce the safety of the Works and persons or be detrimental to the effectiveness
of the support, he may order that the following action be taken:
SS2-40
⚫ remove the defective sprayed concrete in strips or panels in such a way that the
safety of the Works and persons is not endangered and replace with sprayed concrete
that is acceptable, which may also require the replacement of the mesh, or apply
additional thickness of sprayed concrete not exceeding the thickness originally
required.
In either case no payment will be made for the defective sprayed concrete already applied,
nor for the work involved in removing it from the areas where it has been applied, nor for any
mesh that must be replaced, including additional laps, nor for any work involved in removing
the resultant rubble from the underground Site and spoiling it in an noticed spoil dump.
Welded wire mesh reinforcement
Mesh reinforcement, where specified, shall comprise welded mesh reinforcement. Such
welded mesh reinforcement shall comply with IS 1566. The yield strength of wire mesh shall
not be less than 415 N/mm2.
The mesh shall be securely fixed at maximum centres 1m both ways, using 6 mm diameter
mild steel bar mesh pins, generally in hollows at the optimum distance from the rock face for
the application process such as to minimise rebound and prevent voids. The minimum cover
between the mesh and the exposed face of the sprayed concrete shall be 25 mm, or a greater
cover if instructed by the Employer’s representative, or shown on the Drawings. The mesh
shall be set at a nominal distance of 20 mm from the rock face. The wire mesh shall overlap
by minimum 300 mm.
Mesh reinforcement shall be retained to the rock by mesh pins as described above, and with
as many intermediate fixing pins, in accordance with the details shown on the Drawings, as
required.
6.2.3 Rockbolts and Dowels
General
For the purpose of this Specification rockbolts and dowels are defined as follows:
“Rockbolt” is a high yield deformed bar, or glass fibre reinforced resin rod, of specified
diameter and length (in rock) which is end anchored with resin grout, fully column bonded
with resin or cement grout, equipped with a faceplate, hemispherical washer and nut and
tensioned to a specified load;
“Dowel” is a high yield deformed bar, or glass fibre reinforced resin rod, of specified diameter
and length (in rock) for which the protruding portion may be either straight or bent, which is
fully grouted with either resin or cement grout. Dowels will not be fitted with accessories nor
will they be tensioned. The use of resin or cement grout shall be at the Contractor's discretion,
unless specifically detailed on the Drawings;
Rockbolts and dowels other than those specified herein shall not be used in the Works.
Materials
Rockbolts and dowels shall be manufactured from hot rolled deformed bars with a
characteristic strength of not less than 450 MPa complying with BS 4449, with the exception
of areas to be excavated by TBM where glass fibre reinforced resin rods shall be used.
Face plates, hemispherical washers and nuts for rockbolts shall be manufactured to suit the
loading requirements.
Resin grout shall be a commercially produced epoxy product in capsule form with both fast
and slow setting times as applicable especially formulated for use with rockbolts or dowels,
and transported, stored and utilised in accordance with the manufacturer's recommendations.
SS2-41
Cement grout shall be a commercially prepared product in capsule form especially produced
for use with rockbolts or dowels. The product shall not contain any material which could
corrode the rockbolts or dowels.
Alternatively, where a pumped cement grout is used for the installation of rockbolts or
dowels, the materials shall comply with the requirements of the relevant parts of this
Specification.
Manufacture of rockbolts
Rockbolts shall be manufactured from 25mm diameter high yield deformed bar. The bar
length specified shall be the required length of bar to be bonded to the rock and due extra
allowance in the cutting length shall be made for any length including the threaded portion
protruding from the rock as required for installation. One end shall be threaded for at least
150 mm with a coarse cut thread which shall not reduce the overall specified bar diameter by
more than 3 mm. The other end shall be chamfered to facilitate installation.
Face plates shall be 15 mm square, 8mm thick and dish shaped in steel to the appropriate
standard and shall have a hemispherical seating with a centralised slot to suit the dimensions
of the rockbolts.
The face plates shall be fitted with a hemispherical washer to permit seating of the face plate
at inclinations up to 30 degrees from normal to the bolt.
Manufacture of dowels
Dowels shall be manufactured from 25 mm diameter high yield deformed bar, with the
exception of areas to be excavated by TBM where glass fibre reinforced resin rods shall be
used.
Dowels shall be either straight bars or shall have the protruding end bent to facilitate the
specified connection between the rock and surrounding concrete or sprayed concrete when so
detailed on the Drawings.
Dowels for installation with resin or cement cartridges shall be threaded at one end
sufficiently for attachment of the installation equipment. The other end shall be chamfered to
facilitate installation.
Testing of rockbolts
Prior to the installation of rockbolts in the Works the Contractor shall carry out a series of
tests as agreed with the Employer’s representative to prove the capacity of the system and the
Contractor's capability to correctly install and tension the rockbolts.
The tests shall demonstrate:
⚫ number of resin cartridges required to provide the end anchorage with an applied
load equal to the bar's characteristic strength and taking into account the over-length
variation of holes.
⚫ number of resin or cement cartridges to fill the annulus around the rockbolt or dowel
over the length of the hole between the anchorage and collar of the hole.
⚫ strength of the resin grout to fully anchor the bars up to the characteristic strength
of the rockbolts.
⚫ capacity of the equipment to install the longest fully grouted rockbolts or dowels.
⚫ equipment for tensioning the bolts to the specified loads.
⚫ capability of each crew to correctly install and tension the rockbolts.
The Contractor shall undertake the tests with the equipment to be used on the Works and shall
install the test bolts in a suitable rock face in a steeply upward direction.
SS2-42
The Contractor shall provide a suitably calibrated direct tensioning jack and/or load cell of
capacities in excess of the characteristic strength of the rockbolts. Loads and bolt elongations
shall be recorded during the tests.
Installation of rockbolts
The method of installation and tensioning of bolts must receive a notice of no objection from
the Employer’s representative prior to commencement. Manufacturer's instructions for the
use of proprietary components shall be followed wherever appropriate.
Unless otherwise proven acceptable by site trials the rockbolts shall be installed in holes of
diameter from 10 mm to 15 mm greater than the maximum diameter of the rockbolt. The
holes shall not be more than 100 mm longer than the grouted length of the rockbolt unless
otherwise proven acceptable by site trials. A sufficient number of cartridges shall be used to
ensure the annulus around the rockbolt is completely filled over the full length of the hole.
End cartridges for the anchorage zone shall be of fast setting resin whilst the column shall be
filled with slow setting resin or cement cartridges. Tensioning shall be carefully controlled to
ensure that it takes place after setting of the end cartridges but prior to commencement of
setting of the column grout.
The effectiveness of the installation procedure shall be checked by testing to yield a minimum
of 1 bolt in 100 installed. Should the assemblies fail at tensions less than the characteristic
strength of the bolt, the Contractor shall investigate the cause and make such proposal for
amendment of the installation procedure as may be necessary. Tests shall continue thereafter
at a rate of 1 bolt in 50 until the Employer’s representative is satisfied that the cause of failure
has been overcome. Regular calibration of tensioning devices shall be carried out by the
Contractor in the presence of the Employer’s representative.
Installation of dowels
The method of installation of dowels shall have a Notice of No Objection from the Engineer
prior to commencement. Manufacturer's instructions for the use of proprietary components
shall be followed wherever appropriate.
Holes of diameter 10mm to 15mm greater than the maximum diameter of the dowel shall be
drilled and cleaned. The gauged amount of pumped cement grout or cartridges of resin/
cement grout shall then be inserted and the bar driven firmly into the hole. If pumped cement
grout is used, the grout shall be inserted using a tremmie pipe pushed down to the bottom of
the hole and withdrawn slowly as the grout is placed. After installation the bar shall be
vibrated for a short period to ensure the complete distribution of the grout around the full
length of the bar. Additional grout shall be added to make up any shortfall. Where required,
grouting of the hole shall be carried out in stages to allow the flow of grout into cavities, each
stage being topped up by the following stage.
Records
For each rockbolt or dowel installed the following information shall be recorded:
⚫ reference number
⚫ type of installation
⚫ name of person taking record
⚫ date of drilling and installation
⚫ length and orientation of the drill hole
⚫ length of installed rockbolt or dowel
details of any tests carried out

SS2-43
6.2.4 Lattice girders

General
This sub-section applies to the supply and installation of the lattice girders required and used
as support in underground excavations. The contractor needs to check and confirm that the
design of lattice girder suffices the construction methodology to be used by the contractor.
General requirements
Lattice Girders shall be effective as initial support immediately after excavation and shall
subsequently act as reinforcement and load distributing members for the initial shotcrete
lining. The lattice girders shall be manufactured to meet the geometrical requirements for the
excavation geometries including the construction tolerances for each rock class.
During transport, storage and handling of lattice girders, adequate measures shall be taken by
the Contractor to prevent their bending, scraping, overstressing or any other damage. The
damaged pieces shall not be used in the works.
Submissions
Shop Drawings for the fabrication of the lattice girders shall be submitted for Notice of No
Objection from the Engineer prior to the commencement of the work. The submission shall
comprise the following:
⚫ Complete fabrication details of the lattice girders.

⚫ Installation procedures and layout.
⚫ Details of joints, connections, spacers, geometry etc.
⚫ Certificates of compliance for the materials.
Materials
Each of the primary bars of a lattice girder segment shall be composed of only one piece of
high strength steel having yield strength of 500 MPa or more.
The connection elements at the end of lattice girder segments shall be constructed of angled
structural steel having yield strength of 250 MPa or more, or of welded flat steel ensuring
similar strength characteristics.
Manufacturing of lattice girders
Geometry
The lattice girders shall be fabricated to meet the minimum clearances duly taking into
account the permissible inaccuracy of placement during construction and the permissible
material tolerances.
Welding of lattice girders
Testing of materials and workmanship shall be carried out in accordance with AWS D1.4. A
third-party testing agency shall be employed by the Contractor to carry out the tests.
The manual metal-arc welding process shall be employed. The Contractor shall be responsible
for ensuring that the capacity of the welding plant and ancillary equipment is adequate for the
welding procedure to be used and for maintaining all welding plant and ancillary equipment
in good working order.
Covered electrodes complying with German Standard DIN 1913 shall be used. Electrodes
shall be selected with regard to the particular application (welding position, joint design etc).
Electrodes shall be stored in their original containers in a dry, preferably heated place,

SS2-44
adequately protected from the effects of the weather and in accordance with the
Manufacturer’s Specifications.
Surfaces to be welded shall be dry. Fusion faces and the surrounding surfaces shall be free
from heavy scale, moisture oil, paint or any other substance which might affect the quality of
the weld. Slag shall be removed from each run of weld metal before a further run is
superimposed. The most favourable welding position for each case shall be chosen.
For the cutting of the steel profiles the manual flame cutting process may be employed.
Sawing will also be permitted.
Further preparation of joint and fusion faces shall be done by grinding.
Parts to be welded shall be assembled such that the joints are easily accessible and visible to
the operator.
Slag shall be removed from all welds in order to allow visual inspection.
Welding operations shall be supervised by a suitably trained supervisor who shall have
particular production experience.
Installation of lattice girders
Lattice girder shall be installed to conform to the excavated shape. The geometry of Lattice
Girders shall take into account the permissible inaccuracy of construction and tolerances of
materials.
Lattice girders shall be erected to the lines and levels as required. The exact excavation levels
will be determined by the Contractor suiting his equipment and construction method subject
to a Notice of No Objection by the Engineer.
Lattice girders shall be secured by use of spacers as well as temporary wood blocking or other
appropriate means to maintain position during shotcreting.
Butt plates for steel girder segments and expansion unit in invert shall be provided as required.
Tight connection of all elements shall be ensured such that the static efficiency of the cross
section is maintained.
Lattice girders shall be embedded in shotcrete, in order to get contact between rock and lattice
girder by a solid shotcrete packing which shall have a minimum cover to steel of 20 mm.
The lattice girders shall be erected perpendicular to the tunnel axis.
6.2.5 Forepoling
General
Forepoling is a pre-excavation support element that may be required for tunnel excavation
works. Forepoling shall be applied in rock and soil conditions, which tend to produce
overbreak, collapses or material inflows immediately following excavation. Forepoling may
be applied locally or systematically as per the requirement for the safety of the works and to
prevent over breaking. All forepoles must be fully grouted.
Material
6.2.5.2.1 Stable bore holes
Steel pipes with a minimum outer diameter of 40 mm shall be used. Wall thicknesses of steel
pipes shall not be less than 4 mm. Dowels (spiles) consisting of deformed high yield steel
bars of grade Fe 500 with a minimum diameter of 32 mm may also be used instead of steel
pipes, where found suitable.

SS2-45
6.2.5.2.2 Unstable bore holes

Self-drilling bolts shall be used as forepoling elements where stability of the predrilled
boreholes cannot be achieved, due to the encountered ground conditions. Self-drilling bolts
shall be installed only if permitted by the Engineer and shall have a yield load of at least 200
KN. The grout used for self-drilling bolts shall be in accordance with the requirements
specified by the bolt manufacturer. Grouting shall be carried out simultaneously with drilling
to achieve a better grouting effect along the bolt.
Installation
Forepoling shall be applied as shown on the drawings that have a Notice of No Objection
from the Engineer. Forepoling elements at 300 to 500 mm centres shall be inserted into the
predrilled holes (steel pipes or dowels) at the face or drilled into the face (self-drilling bolts)
towards the unexcavated ground.
The length of forepoling elements shall be according to the design and drawings and shall be
at least 1.50 meter longer than the excavation round length.
Forepoling shall be used together with lattice girders or any other steel support system.
Grouting of forepoling pipes and dowels shall be done with cement mortar, either before or
after their insertion, as per the approved scheme.
Forepoling shall be required to be properly supported by the lattice girder/steel sets and the
shotcrete above the lattice girder/steel sets. Therefore, shotcreting of the gap between lattice
girder/steel sets and rock in the portions of forepoling shall be completed only after the
installation of forepoling.
Pipe roof
A pipe roof is a special type of long forepoling (typically 9 – 15 m). The forepoling elements
shall consist of steel pipes with a minimum outer diameter of 76 mm and a minimum yield
load of 1200 KN. The length and spacing of the pipes shall be as per the design and drawings
and as agreed by the Engineer. The pipes shall be grouted with cement mortar.
6.2.6 Grouting for in-situ lining
General
(a) All voids remaining unfilled outside the in-situ concrete permanent linings in tunnels,
including junctions, headwalls and the like, shall be grouted as specified. For this purpose,
the grout shall be injected through pipes set in the concrete, through drilled holes, or, where
appropriate, through grout holes in segmental linings or temporary supports. Drilled holes
shall not be used where there is a possibility that damage to the Permanent Works could
result, for example in puncturing of waterproofing membranes.
(b) Where grout is to be placed in voids occurring within the design thickness of linings the
grout shall have a characteristic strength equal to the required characteristic strength of the
linings.
(c) Injection points used for cavity grouting shall be provided at least one per 2.0 linear metres
of tunnel and more frequently in any areas of excessive over break. The injection points
for cavity grouting in arched roofs shall be located within 500 mm of the crown. The
injection points for grouting of shafts shall be determined to ensure complete filling of the
cavities.
(d) Grout pipes set in concrete shall be fitted with means of preventing blockage and, before
injecting grout; they shall be drilled or pricked through to provide a clear passage for grout.
Grout pipes and grout holes for grouting shall be at least 40 mm diameter.

SS2-46
(e) The grouting of the upper surface of concrete works in junctions and the like shall be
carried out through a series of grout pipes and vent pipes built into the concrete for the
purpose and extending to the highest part of the excavation. The number and locations of
pipes shall be determined to suit temporary ground supports left in place, sufficient to
ensure that cavities are completely filled.
(f) The grouting of the upper surface of concrete works shall be continued until the grout
emerging from the vent holes or adjacent grout holes is of the same consistency as the
grout being injected. No vented grout shall be re-injected.
(g) Where in situ concrete tunnel linings are backed by a waterproofing membrane or a
protective geo-textile the grouting pressure shall not exceed 2 bars.
(h) Grout and vent pipes shall not be permitted to remain within 50 mm of a finished concrete
internal surface and, when no longer required, all holes in concrete linings shall be cleaned
and filled with a polymer modified non-shrink mortar.
Equipment
Grouting equipment shall be fitted with a pressure gauge and automatic pressure release
valves capable of being preset to a specific pressure. Grout pressure is to be measured at the
point of injection with a suitable gauge.
6.2.7 Water-tightness of tunnel
Waterproofing membrane
The waterproofing membrane shall consist of an impermeable heat welded sheet of one of
the following materials:
⚫ High Density Poly Ethylene (HDPE)

⚫ Soft polyethylene chloride (PVC)
⚫ Ethylene Copolymerical Bitumen (ECB)
The membrane as supplied shall be of such dimensions and shape as will result in the
minimum on-site seam welds. The loosely laid PVC sheet shall have a minimum
thickness of 2 mm ±10%.
6.3 FINAL TUNNEL SUPPORTS
6.3.1 Concrete lining
The Contractor shall construct the final concrete linings to meet the requirements of the
specifications pertaining to concrete.
6.3.2 Preparation of surfaces
The surface against which concrete is to be placed shall be cleaned of loose material and dirt.
A waterproofing membrane shall be placed. No concreting shall take place before inspection
of the surfaces which are to receive concrete.
6.3.3 Placing of concrete
Concrete shall be placed so that the space between the form and the ground/excavated profile
is filled as completely as possible, especially any voids in the crown of arches. Not sooner
than 28 days strength obtained after placing concrete, the interface between the concrete and
the rock in the crown shall be contact grouted.
6.3.4 Testing of concrete
Testing of concrete samples shall be performed as set out in the specification pertaining to
concrete.
7 INVERT CONCRETE
The Contractor shall provide the first pour (stage) concrete including the shear connectors
required for laying the track work and also prepare the upper surface of the first stage concrete
SS2-47
to meet the requirements of Track bed design specifications duly interfacing with the
Trackwork Contractor. The minimum grade of concrete for invert concrete shall be M-30.
8 BACKFILLING OF SHAFTS AND ADITS
Temporary shafts and adits shall be completely backfilled on completion of the Works.
Backfill material shall be Grade M10 concrete covering 2m over the tunnel crown which may
be placed either wet or dry. Adits shall be backfilled in sections working from the permanent
Works.
Temporary bulkheads shall be formed at agreed intervals and the upper part of the adit
completely filled by grouting through pipes which have been installed into the adit roof. The
bulkhead shall be moved back in stages until the whole of the adit is backfilled. Shafts shall
be backfilled in layers not thicker than 250 mm, each layer being thoroughly compacted with
an appropriate power rammer. The backfill material shall be homogenous; no large pieces of
concrete or "plums" shall be used.
As far as practicable all extraneous materials such as steelwork and temporary timbers shall
be removed as the backfilling progresses. Shaft linings shall be dismantled to two metres
below finished ground level and the site reinstated with suitable granular material compacted
as specified in Earthworks. Details of temporary works left in place shall be included in the
as-built information and drawings.
9 DAILY RECORDS
The Daily Report shall be submitted by 09:00 hrs the following day and in a format agreed
by the Employer’s representative. Such a format, which may require modification from time
to time during the progress of the work, may include the required information in tabular and/or
graphical form, as appropriate for the information being presented.
In addition, wherever possible the recording of the required information should be automatic
and be available to download at any time to a computer located in the Employer’s
representative office. Any evaluation software shall be in English and be made available to
the Engineer at no extra charge to the Employer. The database shall be recorded to CD ROM
and submitted to the Employer’s representative on a weekly basis.
10 SAFETY AND UNDERGROUND FACILITIES
10.1 SAFETY GENERAL
Safety in the underground works shall be to the highest internationally recognised standards.
At an early stage of the work, the Contractor shall undertake the organisation, equipping and
training of rescue teams. These teams shall be trained in underground rescue work and the
administration of first aid.
No workmen shall be employed underground until they have shown themselves conversant
with basic safety precautions. The Contractor shall strictly enforce all safety regulations and
shall provide adequate protective clothing and safety gear for his workmen.
The Contractor shall observe all precautions to avoid accidents or injury to Workmen or the
Works and to minimise the extent and severity of any accident or injury which may occur.
Such precautions shall have due regard to the skill and training of the labour force employed
underground and shall comply with local mining or other applicable regulations.
The Contractor shall be solely responsible for day and night warning systems (visual and
sound) for machine operations and “clear off the track” warning shall be installed at the site
and preventative measures taken against accident.

SS2-48
10.2 UNDERGROUND FACILITIES

10.2.1 General
The Contractor shall submit descriptions of the installations he proposes to use for supply of
water, ventilated air, compressed air, lighting, power supply, etc., and for the disposal of
drainage and waste water, contaminated air, etc., for the Employer’s representative notice of
no objection in advance of starting underground works.
10.2.2 Telephone communications
Telephone communications shall normally be provided between the working faces, portals
and other areas where work is going on. Telephone locations shall be prominently displayed.
Telephone network should be provided for Employer’s representative office including
telephone connection to the work’s place and tunnel shafts.
10.2.3 Electric cables
All lighting and power cables installed underground shall be adequately insulated with joints
made in a noticed manner. All installation and maintenance work shall be done by qualified
personnel to a high standard. Cables shall be securely fixed above floor level with the
exception of cables needed for occasional work.
Separate circuit breaker systems shall be provided for the supply of power for equipment and
for lighting, respectively, and they shall be kept well separated from signalling and telephone
cables.
Circuits used for firing explosives shall be kept separate from all other circuits by placing
them on the opposite wall.
All electric installations shall be adequately earthed in accordance with normal practice and
local requirements and be noticed by the Employer’s representative. Installations shall
furthermore be protected by earth-fault breakers, all in accordance with modern practice and
safety standards and obtain a notice of no objection from the Employer’s representative.
10.2.4 Ventilation
The Contractor shall install, operate and maintain a forced ventilation system in the
underground works to enable the Works to be constructed in healthy, well ventilated
conditions. Dust shall be abstracted at or adjacent to the source.
To minimise the dust hazard arising from drilling operations in rock excavations, all holes
shall be wet drilled. Water sprays or atomisers shall be used to prevent dust rising including
keeping the floors of haulage ways damp.
The Contractor shall submit to the Employer’s representative for his notice of no objection a
full and detailed method statement detailing his proposed ventilation system, and where
necessary cooling system, in the tunnels. The statement shall be accompanied by supporting
calculations. The method statement shall be submitted at least 28 days before the start of any
underground excavation.
The ventilation system used during construction shall ensure that at all times a minimum
oxygen content of 20 % by volume is available in any underground works. Furthermore, the
minimum fresh air requirements given herein refer to the required ventilation conditions and
additional provision shall be made to account for any losses, e.g. due to leaks in the ducts, for
which the Contractor shall make provision in the ventilation calculations.
The Contractor shall supply and utilize a hot-wire anemometer for the purpose of measuring
air flows in the ventilation ducting.

SS2-49
Instruments to register all the various noxious gases and dust shall at all times be available at
the heading in good working order and condition. These shall be supplied and maintained by
the Contractor, throughout the duration of the underground work.
The Contractor shall be responsible for operating the ventilation system in the underground
works until all his construction work is completed.
10.2.5 Lighting
All underground areas where work is going on shall be illuminated with electric lights of
adequate strength and number to allow work, inspection, mapping and surveying to be carried
out in a proper and safe manner.
Generally, the illumination on a horizontal plane at floor level shall be not less than 10 lux.
At working faces, the illumination shall be not less than 50 lux. Hand inspection lamps and
electric battery torches shall be available at working faces at all times, together with
emergency backup light for evacuation.
10.2.6 Dewatering
The Contractor shall keep all underground areas substantially free from water by providing
drains, ditches, pipes, pumps, sumps, etc. to drain water away. The Contractor shall submit
to the Employer’s representative, details of his proposals for dealing with water from any
source prior to commencing underground work.
In the event that gravity flow cannot be satisfactorily arranged, the Contractor shall remove
the water by pumping and he shall provide, install, operate and maintain all necessary pumps,
piping and other equipment required. The Contractor shall also provide sufficient numbers of
standby pumps and generator to serve during periods of breakdown or maintenance.
Where water bearing seams, fissures or broken ground is yielding undesirably large quantities
of water, the contractor shall grout such seams, fissures or broken ground to stem the same.
The Contractor shall provide devices for measuring the quantities of water removed from
underground excavations, by pumping or by gravity as the case may be. The Contractor shall
provide certified calibration charts for all measuring devices and shall submit to the
Employer’s representative a complete record of the quantities of water disposed either by
pumping or by gravity and the times during which pumping has occurred.
The Contractor shall provide water treatment facilities for wastewater disposal that satisfies
the stated environmental standards.
10.2.7 Stand-by Generator
The Contractor shall provide Stand-by generator for emergency case, details of proposals for
this system shall be submitted to the Employer’s representative.
10.2.8 Noise control
The Contractor shall take all necessary measures to minimise the impact of noise. Such
measures shall include:
⚫ the placing of covers over and around the source of noise.

⚫ fitting adequately sized mufflers to ventilation and other equipment.
⚫ erecting screens to separate the source of noise from the rest of the working area.
⚫ the use of electrically powered plant where possible.
The Contractor shall provide a means of measuring the noise level and shall regularly
calibrate such equipment. Measurements shall be taken regularly as requested by the
Employer’s representative and a full report of readings made shall be submitted to the

SS2-50
Employer’s representative within 24 hours. If in the opinion of the Employer’s representative

noise levels are unacceptable the Contractor will take additional measures to restrict noise.
The Contractor shall provide suitable ear protectors to his entire workforce and other persons
on Site. Zones of risk shall be clearly identified with warning signs.
10.2.9 Hot Work
Welding and burning operations (hot work) within the tunnel and upon the TBM or trailing
backup system shall be kept to a minimum. Wherever possible, components shall be prepared
on the surface and consideration given to alternative methods such as bolting and sawing/disc
cutting.
In addition to the above, hot work includes specialist operations such as conveyor belt
vulcanisation procedures. Hot work may be undertaken providing the following measures are
adhered to:
⚫ The relevant permits are in place.

⚫ Only qualified personnel are permitted to perform hot work.
⚫ All gas cylinders underground shall be stored and transported within steel protective
cages.
⚫ Gas bottles shall be fitted with flashback arresters.
⚫ A designated fire watch is in place and aware of his duties.
⚫ One dry powder hand held fire extinguisher shall be available at the work location.
A fire watch shall be maintained during burning operations. The fire watch shall have a fire
extinguisher or fire hose readily available. The fire watch shall continue for a minimum of 30
minutes following the cessation of burning operations. When the maintenance teams do not
change shift at the work area then all burning operations shall cease 30 minutes before the
work area is vacated.
Whenever it is necessary to carry out hot work in a confined space, a specially assigned person
shall stand-by throughout the operation at the nearest point of entry. The stand-by person shall
be equipped to give prompt assistance in the event of an emergency.
Only one acetylene bottle and one oxygen bottle shall be permitted within the TBM and
trailing backup system at any time. Upon job completion, gas bottles shall be removed as
soon as possible.
All welding sets, cables, connectors and terminations mounted upon the TBM or trailing
backup system shall be maintained in a safe and serviceable condition. Earth returns shall be
coupled directly to the item to be welded and to an independent earth in such a manner that
the earthing path remains inside the protected work area. Pipes or vessels containing
hydrocarbons must not be used for earthing purposes. Earth leads mounted upon the trailing
backup system shall not be connected to hydraulic oil pipelines, motors, conduits, panels or
switch panels. All supplies for welding equipment must be made with noticed cables and plug
boxes, and must be controlled from a circuit which includes protection sensitive to earth
current security.
Where stationary transformers are being used, a suitable switch shall be provided close to the
equipment which allows for the isolation from the main supply.
10.2.10 Safety notices
The Contractor shall obtain, erect and maintain adequate safety notices for underground work
to satisfy statutory regulations and to the satisfaction of the Engineer.

SS2-51
10.2.11 Control of Entry

The Contractor shall establish and maintain effective systems to control access to the
underground works by all persons. A system utilising the issue and retrieval of tokens or
similar method shall be employed. The systems of control used by the Contractor shall obtain
a notice of no objection from the Employer’s representative. The Employer’s representative
reserves the right to withdraw his notice of no objection if he is not satisfied that the systems
are being applied and enforced adequately.
Where persons not normally engaged on the Works are authorised to enter the underground
works, they shall at all times be accompanied by a representative of the Contractor or
The Contractor shall also establish and maintain effective systems to control access to the
TBM cutterhead, including electrical lockout procedures and obtain a notice of no objection
from the Employer’s representative for the procedure.
10.2.12 Compressed air working in cutterhead chamber
The Contractor shall submit for the Employer’s representative notice of no objection a method
statement describing the type, capacity and arrangement of plant and medical facilities he
proposes to install with full details of his low pressure compressed air plant, standby plant,
power sources, air cleaning, air cooling plant, bulkhead and locking arrangements. The
method statement should also describe the proposed system of signalling, communications
and controls to be used in the compressed air operations.
10.2.13 Stores, Offices and Workshops
The erection of stores, offices and workshops in the underground works, excepting those
contained within the TBM backup, will not be permitted without the prior notice of no
objection from the Employer’s Representative.
10.2.14 Quality of air
When called for by the Employer’s representative, the Contractor shall collect gas samples
and send them for laboratory analysis. The concentrations shall not exceed the following
limits:
⚫ Carbon dioxide : 5,000 ppm

⚫ Carbon monoxide : 30 ppm
⚫ Nitric oxide : 25 ppm
⚫ Nitrogen dioxide : 3 ppm
⚫ Hydrogen sulphide : 10 ppm
The above values shall relate to average concentrations over an 8-hour working shift. The
maximum permissible limit at any time underground shall be the following:
⚫ Carbon dioxide : 15,000 ppm

⚫ Carbon monoxide : 100 ppm
⚫ Nitric oxide : 35 ppm
⚫ Nitrogen dioxide : 5 ppm
⚫ Hydrogen sulphide : 15 ppm
⚫ Flammable gas : 750 ppm
The Contractor shall at all times comply with both the average and the maximum
concentration levels.

SS2-52
10.2.15 Dust
The Contractor shall check at the face and elsewhere for concentrations dust at least weekly
and more regularly if necessary and when called upon to do so by the Employer’s
representative. In the case of air breathed by persons in the underground works the air shall
not contain more than the following concentrations of total respirable airborne particles of
dust (size from 5.0 to 0.2 micron):
⚫ Limit of crystalline silica content (as a % age of dust) : <1%

⚫ Limit of total respirable dust : 5 mg/m3
These values shall relate to average concentrations over an 8-hour working shift. When dust
concentrations exceed the above, all persons in the affected area shall be notified and be
required to wear respirators.
10.2.16 Ventilation Quantities
General
All equipment and ducting shall be maintained in sound working order at all times. Any
damage to ducting shall be repaired without delay. Failure by the Contractor to comply with
the above requirements or to maintain the prescribed ventilation and cooling standards will
entitle the Employer’s representative to order a temporary halt of all work within the affected
area until the specified requirements are met.
The ventilation system in each section of the Works shall ensure that the following minimum
air quantity requirements are provided at all times:
⚫ 3 m3/min for each person or worker in the underground works;

⚫ 4.8 m³/min for each operating kW power of diesel plant, or equipment working in
the underground works, based on 70 % of the installed power being in operation at
any one time;
⚫ Sufficient to maintain an average air velocity of 0.5 m/s on every cross-section in
working areas.
⚫ Notwithstanding the above, the minimum quantity of fresh air delivered at the
advancing face shall be 7 m3/s.
The ventilation, and where necessary cooling, arrangements shall be designed to ensure a
working environment such that
⚫ at any time, the mean wet bulb temperature at all workplaces in any one tunnel drive
shall not exceed 27.5°C.
⚫ Similarly, the weighted mean wet bulb temperature at all workplaces within 100 m
of the advancing face of any one tunnel drive shall not exceed 27.5°C.
To ensure compliance with the foregoing, the Contractor shall provide all necessary
equipment to measure the wet bulb temperatures at regular intervals during each working
shift or such other interval agreed with the Employer’s representative, and ensure that suitable
air coolers are available for use with the ventilation system at all times.
All above procedures shall be subject to a notice of no objection from the Employer’s
representative.
Maintenance of ventilation and cooling systems
All equipment and ducting shall be maintained in sound working order at all times. Any
damage to ducting shall be repaired without delay.

SS2-53
Failure by the Contractor to comply with the above requirements or to maintain the prescribed
ventilation and cooling standards will entitle the Employer’s representative to order a
temporary halt of all work within the affected area until the specified requirements are met.
Use of internal combustion engine
No internal combustion engine other than a diesel engine shall be used in the underground
works. Any diesel engine used in the underground works shall be provided with a means,
which shall be maintained in efficient order, of cooling exhaust gases and reducing the
concentration of toxic gases in the exhaust gases to acceptable levels and prevent emission of
flames, sparks or pollutants.
Notwithstanding the Contractor's compliance with the above requirements for ventilation, the
operation of all diesel engines in the underground works shall be discontinued and ventilation
improved or other acceptable measures taken if any of the acceptable specified limits are
exceeded.
No diesel equipment shall be allowed underground if the exhaust gases contain more than
2,000 ppm carbon monoxide or 1,000 ppm of oxides of nitrogen.
The engines of diesel-powered equipment underground shall not be kept running idle except
while being tested or during brief halts while in use. No equipment shall be refuelled
underground unless proper precautions are taken.
Modification of ventilation system
After excavation of any tunnel which will be lined, the ventilation system used for the
excavation phase may have to be modified to allow for subsequent phases. Any such
modifications, which shall be subject to a notice of no objection from the Employer’s
representative, shall be allowed for by the Contractor in his design of the ventilation systems
for the underground works. These allowances shall also include for increased localised
ventilation during concreting and grouting operations and during the time that Subcontractors
or others are carrying out welding or painting operations in the underground works. After
concreting of linings, the ventilation system shall be so operated as to maintain satisfactory
conditions for curing of the concrete.
Records
The Contractor shall record all readings and submit two copies to the Employer’s
representative on a weekly basis unless otherwise instructed.
10.3 HAZARDOUS GAS
10.3.1 General
The Contractor shall continuously monitor the underground works for the presence of
hazardous gas. Should hazardous gas be detected the level shall be controlled by dilution via
the ventilation systems.
For this purpose, the Contractor shall supply, use and keep in good order, sufficient equipment
and apparatus to comply with the requirements specified hereunder. Where the term methane
is used it shall be construed to mean any potentially explosive or hazardous gas.
10.3.2 Methane detection
The atmosphere upon the TBM and trailing backup system shall be constantly monitored for
both the ingress of methane and oxygen levels. Regular testing for methane shall be carried
out at each probe hole. Particular attention shall be paid for testing of methane when intrusive
rocks are intersected by the probe hole.

SS2-54
The Contractor shall provide a procedure and appropriate equipment to allow the safe re-entry
and recommissioning of the TBM and trailing backup system following a gas-initiated power
shutdown.
Prior to the start of any shift, the person responsible for that shift shall test the underground
works for the presence of methane and declare the area safe for excavation or otherwise.
Inspection of tunnels is to be carried out on a weekly basis.
10.3.3 Ventilation Equipment
Ventilation equipment shall be provided in accordance with section 10.2. In the case of the
tunnel boring machine, special attention shall be paid to ensuring that air is directed into areas
of the machine and back-up equipment where methane may be trapped, and if necessary
auxiliary ventilation equipment shall be provided.
10.3.4 Contractor’s Equipment
In addition to the requirements noted above the following other minimum requirements are
to be adhered to:
⚫ Sufficient calibrated hand held methanometers of a noticed type or other noticed gas
detection devices shall be provided at all times.
⚫ All equipment shall be suitably earthed.
⚫ All diesel driven plant shall be fitted with effective scrubbers to the exhaust systems.
⚫ In the case of excavation by drill and blast, no mechanical equipment shall be
brought to the face until the examination for methane has been completed.
10.3.5 Personnel
The following minimum requirements are to be adhered to:
⚫ At all times persons shall be present in the working tunnel that has passed a gas
testing course acceptable to the Employer’s representative.
⚫ Entry of unauthorised persons to the underground works shall be prevented at all
times, whether work is in progress or not.
⚫ Appropriate precautions shall be taken to prevent persons bringing into the
underground works matches, lighters and similar items and to prohibit smoking in
the underground works.
10.3.6 Acceptable concentrations of methane
Should methane be detected in any part of the underground works then all work in that part
shall immediately be halted and the Employer’s representative shall be informed without
delay. The Contractor shall then decide in conjunction with the Employer’s representative the
appropriate action to be taken. Generally, if the percentage of methane recorded is less than
10% of the lower explosive limit then work may be restarted immediately on notification to
the Employer’s representative of the occurrence. In this case monitoring for methane shall be
pursued continuously during all operations to detect any increase in the level of methane.
10.3.7 Records
The Contractor shall record all readings taken and submit two copies to the Employer’s
representative on a weekly basis.
11 AS BUILT SURVEY OF ALIGNMENT
11.1 OBJECTIVE
As soon as practicable after the completion of the bored tunnelling over specific lengths of
the tunnel as the work progresses, the Contractor shall carry out an as-built survey of the
tunnel alignment. The objectives of the survey are as follows:
SS2-55
⚫ to discover the position of every 5th ring of lining with respect to the theoretical
alignment; this includes both vertical and horizontal geometry;
⚫ to plot the positions of the rings at points around the circumference with respect to
their theoretical positions;
⚫ to assess the implications in respect for example of
▪ the need to demolish and reconstruct any ring or section of lining because of
proximity of space proofing on the thickness of internal structures and
▪ whether or not an adjustment of the alignment of internal structures (if any)
within the as-built space is achievable while preserving the essential purpose
of the tunnel;
⚫ to produce an accurate record of the position of the tunnel with respect to the city
infrastructure;
⚫ to decide any necessary action.
11.2 PROCEDURE
The Contractor shall carry out the alignment survey. He shall determine the position, with
respect to the theoretical tunnel alignment, of the leading edge of every 5th ring of tunnel
lining at not less than 8 points on the circumference. These shall be as follows:
⚫ tunnel crown;
⚫ tunnel invert;
⚫ axis left;
⚫ axis right;
⚫ 45° above axis left;
⚫ 45° above axis right;
⚫ 45° below axis left;
⚫ 45° below axis right.
The Contractor shall take all necessary actions to ensure that the zones where measurements
are required are clear of all construction-related obstructions.

SS2-56

PART-2
SECTION VII
SUB-SECTION - 3
GEOTECHNICAL, INSTRUMENTATION AND
MONITORING, EBS PROTECTION
DECMEBER 2021
TABLE OF CONTENTS
SECTION
3 GENERAL ............................................................................................................................................. 1
3.1 INTRODUCTION .................................................................................................................................... 1
3.2 GROUND AASSESMENT ........................................................................................................................ 1
3.3 INSTUMENTATION, MONITORING & REPORTING ................................................................... 7
3.4 EBS PROTECTION .............................................................................................................................. 12
Geotechnical
3 GENERAL
3.1 INTRODUCTION
3.1.1 Scope
The purpose is to establish the minimum requirements for ground investigation
instrumentation and monitoring for the geotechnical and bored tunnel works in this
Contract.
Definitions
"Geotechnical works" shall mean site investigation, ground investigation,
instrumentation and monitoring and reporting for the Works and protection to EBS
“EBS” shall mean all existing buildings, structures, services, utilities, railways, wells,
pavements, slopes, street furniture and the like.
“Bored tunnel works” shall mean all underground works that are constructed beneath
and enclosed by the ground surface.
3.1.2 EBS Protection
The Contractor shall minimise the induced loads, total deflections and differential
deflections (angular distortion) and vibrations of the ground surface and EBS above or
below the ground surface that may result from the Works. The impacts of construction
shall be so limited as to not significantly affect the operation of the EBS, road or cause
undue distress to the public.
3.2 GROUND AASSESMENT

3.2.1 General Ground Conditions
1) The Contractor shall be responsible for determining the geology, ground
conditions and hydrology for his proposed construction area.
2) The regional geology for the area of these rail alignments are generally
documented by the Geological Survey of India.
3) The Employer has carried out geotechnical investigations. Refer to Part 4 of the
tender document. The Contractor shall supplement this information to the extent
necessary to ensure that all his construction will satisfy the Employer’s
Requirements as set out in the Contract.
4) To ascertain the nature of the ground to enable the construction, the Contractor
shall fully develop a detailed geotechnical report, comprehensive method
statements for bored tunneling cut and cover works cross passage works, and
related activities. In preparing his method statements, the Contractor shall carry
out his own assessment on the adequacy of the available geotechnical information
Section VII -Outline Construction Specification December 2021

Sub-Section 3 - Geotechnical, Instrumentation SS3-1
and Monitoring, EBS protection
and shall indicate where he considers such information to be deficient having

regard to the particular works or activities to which the design or method
statement relates. The contractor shall submit the additional ground investigation
proposal to the Engineer for the Notice of No Objection.
5) The Contractor shall at his own expense conduct further soil investigations
where his method statements identify that it is necessary or prudent to do so.
This is to enable the Contractor to identify all reasonably foreseeable
circumstances which may affect the execution of the Works and to ensure that
there is no likelihood of meeting unexpected conditions of a critical nature.
6) The Contractor shall compile a list of risks expected in his Risk Register and
submit this to the Engineer along with the proposed mitigation measures to
eliminate such risks.
7) If the Contractor intends to carry out additional ground investigation
from the
surface, beyond the limits of the Works areas, he shall make his own
arrangements with landowners and occupiers for the necessary access. He shall
not assume that such access will necessarily be granted. The Engineer will
provide assistance where such additional investigation is deemed to benefit the
Works. If surface access for ground investigation is not available, or if for any
other reason there is a significant likelihood of encountering geological hazards
whose location is unknown, the Contractor shall identify in his method
statements the means by which such hazards will be identified as construction
proceeds. The Contractor shall also identify how his bored tunnel, cut-and-cover
structure and cross-passage construction activities will be modified to recognise
any deficiency in the ground information prior to construction.
3.2.2 Site Investigation Requirements

1) The intent and objectives of the additional site investigations shall be to collect
all pertinent and reliable data and information required to meet all the Contract
requirements.
2) For the above purpose, site investigation shall be considered to include, but not
be limited to, the following.
a) Compiling and reviewing pertinent existing geological data.
b) Compiling and reviewing pertinent existing geotechnical data supplied
and from the vicinity projects.
c) Compiling and reviewing pertinent existing foundation, structure,
substructure, utilities and other related data from the vicinity projects.
d) Performing a detailed field reconnaissance.
e) Performing geophysical surveys/investigations.
f) Performing ground investigations that include, but are not limited to
drilling, soil sampling, rock coring, groundwater sampling, in-situ field

installations and testing, trial pits, soil stripping, rock mapping and cored
holes in EBS, where appropriate.
g) Performing laboratory testing on soil, rock, and groundwater samples
collected from the ground investigations, including chemical testing to
identify potentially corrosive conditions and/or contamination that may
be a threat to public and durability of Works.
3) As a minimum, the site investigation programme shall consider the locations
and lateral and vertical extent of the following.
a) Major existing structures such as viaducts, bridge, flyovers,
underpass/subways s and crossing structures, underground water and
sewage treatment plants, water tunnels, bored tunnels, cut-and-cover
tunnels, portal structures, retaining structures, commercial developments,
ancillary structures and the like.
b) Earthworks such as soil and rock excavations, embankment fills, land
reclamations, areas requiring ground improvement, borrow pits and areas,
disposal areas and the like.
c) Existing adjacent structures that may be influenced by proposed
construction works i.e., structures adjacent to, above, or below
excavations or tunnels that may be affected by construction works such
as dewatering or blasting; structures deemed to have poor structural
integrity; structures containing sensitive equipment or materials,
structures with heritage/historic/cultural significance and the like.
d) Significant engineering geological features that may influence the
proposed construction works – i.e., major principal ground discontinuities
such as faults, shear zones, persistent jointing; mass wasting, old landslips
and the like.
e) Electrical earthing.
f) All EBS, particularly private water supply wells/tube wells.
4) Ground investigations (GI), shall be conducted in accordance with IS1892 and
BS 5930. The extent of such GI shall be consistent with the form, type and
extent of the proposed construction works unless otherwise agreed with the
Engineer.
5) All aspects of the work shall be conducted under the direction of qualified
geotechnical personnel. Detailed plans, technical specifications, and standard
forms, outlining the proposed staffing and reporting formats, and indicating
the types, locations, and proposed depths of ground investigations relative to
the proposed Works shall be prepared and submitted to the Engineer for
Notice prior to undertaking any such work. Any and all revisions to the site
investigation and GI programmes shall be submitted to the Engineer for
Notice.
6) Prior to any investigation in any area the Contractor shall obtain all approvals
from relevant agencies/authorities and determine the locations of any services
or utilities that may be damaged by the proposed GI. The Contractor shall
comply with the requirements of all agencies/authorities and protect any and
all utilities and services from damage that may result from his GI.
7) Additional drillholes, tests and the like shall extend a minimum depth of 5
metres below the underside of the proposed structures and preferably not
directly on the line of the tunnels. Additional GI should be carried out where
unusual features have been identified such as deep weathering of the rock, high
piezometric pressures, loss of drilling fluid or very weak ground, and the like.
8) Drill holes of dia 300mm and less made for any purpose along the alignment
shall be filled (plugged in) with grout of M25 grade, whereas the concrete grout
can be allowed for hole dia more than 300mm to the satisfaction of Engineer.
3.2.3 Investigation Methods
1) Geological studies
Geological studies shall include, but not be limited to, a review of pertinent and
existing literature, aerial photographs, and remote-sensing data; a detailed field
reconnaissance of the site; and preparation of project-specific maps and cross-
sections.
Project-specific geological plans and cross-sections shall be prepared to 1:2000
scale, for both horizontal and vertical directions. The geological plans shall be
overlain on suitable base plans which show relevant features such as survey grid,
roads, selected EBS and the like.
2) Geophysical surveys/Investigations
Geophysical surveys/investigations shall be carried out where appropriate to
provide additional site-specific information on depths and characteristics of
overburden soils and bedrock.
Geophysical (e.g., seismic refraction, reflection, Side acting shear wave, resistivity,
magnetometer, gravity, and the like) surveys/investigations may be used to obtain
subsurface information for planning other detailed GI studies, and for extending
information between other investigation positions. All such geophysical
surveys/investigations shall be calibrated by appropriate absolute GI methods such
as drilling, Cone Penetration Tests (CPT), test pits and the like.
3) Exploratory drillholes
Exploratory drilling in soil and rock, disturbed and undisturbed soil sampling, and
rock coring shall be performed according to procedures outlined in IS 1892 and BS
5930. For additional GI refer cl 3.5 below. Full-time monitoring by qualified
geotechnical personnel is required not only to direct the drilling, sampling, and
coring, but also to prepare field records for these drillholes.
4) Other ground investigation methods
Other ground investigation method to be employed shall include but are not limited
to, the following.
a) Field testing: Standard Penetration Tests (SPT), Cone Penetration Test
(CPT) with pore pressure measurement (CPTu) or with seismic cone
(CPTz) In-situ vane shear, pressuremeter, permeability, water absorption
tests, impression packer or/and discontinuity survey, acoustic borehole
imaging, in-situ density, plate load testing, point load tests, cover meter and
the likes
b) Coring through rock, earth retaining structures or man-made features
c) In-place (constant or falling head) permeability tests.
d) Packer tests for rock permeability and/or rock jointing.
e) Pumping tests.
f) Groundwater sampling for chemical testing.
g) Test pits with and without recovery of ‘disturbed’ and ‘un - disturbed’
samples.
h) Inspection pits
i) Hand augur bores
5) Groundwater
a) Standpipes and piezometers shall be installed during ground investigations to
measure current and seasonal fluctuations in groundwater levels. The GI
programme shall incorporate the details of a groundwater observation plan,
including locations and details of standpipe/piezometer installations and
frequency and duration of observations. The GI programme shall also include
chemical analysis of groundwater.
b) Where necessary, full-scale groundwater pumping tests deemed shall be
conducted to develop design parameters for construction dewatering schemes.
c) Groundwater information shall be interpreted, and recommendations for
design groundwater levels, including variation of levels that may develop
across structures during Construction and subsequent Rail Operations shall be
provided by the Contractor.
6) Environmental Testing for Soil and Groundwater Contamination
a) Areas with potential land contamination concerns or suspected historical
contamination, once identified in the assessment, shall be investigated for
contamination.
b) Soil/rock samples shall be collected at different depths using ground
investigation methods such as trial pits, auger bores or other soil/rock boring
methods. Groundwater monitoring wells shall be set up for the collection of
groundwater samples.
c) Care shall be taken to avoid cross-contamination and degradation of samples.
All samples shall be, sealed in properly labelled air-tight containers and stored
in a shaded, air- and moisture-tight store, the storage area of which shall be
maintained at constant temperature and humidity in accordance with the
standards.
d) Unless otherwise permitted all such samples shall be tested within one week of
having been obtained.
3.2.4 Laboratory Testing Methods

1) General
The Contractor shall develop a laboratory testing programme which allows for the
particular site conditions, Project/Contract requirements and the applicable design
standards, codes, regulations, and related publications as identified in these
documents and shall be submitted to the Notice of the Engineer.
2) Preparation and submission of information
All laboratory test data shall be prepared using the latest version of AGS format.
All data shall be provided in both printed and electronic file (spreadsheet)
formats. All testing shall be conducted by laboratories holding current
accreditation under International Standards Organisation/Bureau of Indian
Standards
3) Soil testing
a) Index/classification soil tests shall comprise; natural moisture content,
specific gravity, particle size distribution (with and without hydrometer
grading) Atterberg limits, bulk and dry density, dry density and moisture
content relationships, and shrink-swell limits, where applicable.
b) Strength testing shall include: single- and/or multi-stage, consolidated-
drained and consolidated-undrained (with pore pressure measurement)
triaxial tests; unconsolidated undrained triaxial tests; on “undisturbed” samples
of diameter not less than 70 millimetres: vane shear tests on re trieved
undisturbed samples.
c) Consolidation testing shall include one-dimensional, consolidation or Rowe
cell tests on undisturbed 60 to 100 millimetre diameter specimens.
d) Soil permeability tests shall include constant-head and variable-head
permeability tests performed using either a permeameter or triaxial cell.
e) Chemical tests for soil and groundwater shall include determinations of
resistivity, redox potential, acidity (pH), chloride ion content, sulphate ion
content, total sulphate content, total sulphide content, organic content, and
carbonate content and identification of other potentially corrosive conditions.
4) Rock testing
Rock testing shall include water content, porosity, density, water absorption
triaxial strength testing of discontinuities (using hoek cell or appropriate shear
box), Brazilian tensile test uniaxial compressive strength testing of intact rock
core, abrasiveness (Cerchar tests) and description of the rock (especially bound
and unbound quartz content) based on evaluation of petrographic thin sections
prepared for representative rock specimens.
5) Environmental testing
Environmental testing soil and groundwater samples shall test for potential
contaminants such as; heavy metals, volatile organics, semi-volatile organics,
pesticides, petroleum hydrocarbons, polychlorinated biphenyls, cyanide and

other chemicals of concern.
3.3 INSTUMENTATION, MONITORING & REPORTING

3.3.1 General
1) The Contractor shall instrument, monitor and report on ground and EBS
movement and distortion, groundwater level, stress and displacement in the
excavation and lateral support system, structural movement during construction
to check design predictions.
2) Monitoring shall be carried out on case-by-case, day-to-day to more frequent
basis depending upon importance of EBS and / or the risk damage to that EBS.
Special attention shall be paid to the heritage/historical buildings, sensitive
structures and water wells located along the alignment.
3) Monitoring shall begin prior to commencement of the Works to enable
instrument base-line values to be determined accurately, and shall continue until
all movements and distortions to the ground and EBS, and changes to the
groundwater table that might be attributed to the Works, as shown by the
monitoring, have effectively ceased for a period of three months.
4) The Contractor shall install a complete comprehensive instrumentation,
monitoring and reporting scheme prior to any construction to achieve the
following.
a) To establish typical background movement, distortion, groundwater
fluctuation, and noise and vibration limits for the ground, groundwater and
EBS prior to commencement of the Works.
b) Protection to all parties during and after the construction by providing early
warning of any excessive and undue movement and distortion of the
adjacent ground and EBS.
c) To provide movement and deformation information for design verification
of the Temporary and Permanent Works.
d) To ensure that the maximum allowable tolerances associated with various
structures/elements within the zone of influence of the Works are not
exceeded.
e) To confirm that groundwater drawdown outside of the excavations does not
exceed the expected fluctuation limits
5) Vibration recording devices shall be provided to monitor for vibrations which
may cause damage to the proposed constructions and EBS or undue distress to
the public. These devices shall be installed at intervals and locations to provide
comprehensive coverage of the Works. Unless otherwise directed by the Fire/Life
Safety Committee/or any other agencies/authorities, these devices shall record
ground accelerations generated by the Works to ensure that these accelerations
do not exceed the values set by the relevant Authorities or those determined by
the Contractor for the stability and safety of the Temporary and Permanent Works
and EBS.
3.3.2 Limiting Construction-Induced Vibrations at EBS.
Unless otherwise accepted by the applicable government agencies and the
Engineer, peak particle velocities at existing adjacent structures shall not exceed 5
mm/sec.
Above limit is the maximum permissible, however these limits may have to restricted
further following the Contractors EBS study if required to avoid damage to the EBS or
causing discomfort to the EBS occupants. Along the proposed alignment, other
limitations may need to be imposed at sensitive EBS, such as hospitals, school
buildings, telephone-exchange structures, special water supply structures and Heritage
structures etc. In addition working hours for such equipments causing vibrations may
have to restricted, for the convenience and comfort of the occupants of these sensitive
EBS.
3.3.3 Types of Instrumentation
1) The types and quantities of geotechnical instrumentation shall be at least
as shown on the Employer’s drawing, plus as required Instruments of rob ust nature
shall be used which are capable of giving reliable data to within the
manufacture’s tolerances over long periods of measurement.
2) The Contractor shall establish suitable temporary bench marks for the purposes of
monitoring vertical movements. Such bench marks shall be outside the zone of
influence of construction.
3) Precise levelling points shall be provided on monuments at ground level to extend
throughout the area where predicted settlement is expected to exceed 5
millimetres.
4) Precise levelling studs (road nails) shall be installed on highway and pavement
areas in array at 90 degrees to the tunnel alignment. These arrays shall extend to
the outer edges of the 5 millimetres predicted settlement contour lines. Suitable
monitoring points which cannot be readily disturbed shall be installed over
open/park areas.
5) Precise levelling shall be carried out of survey monuments and of settlement
monitoring points on EBS sufficient to determine the imposed strain. Where the
structures are subjected to protective works, electro-level beam systems shall be
employed, with a back-up system relying on the use of precise levelling pins also
installed.
6) Piezometers (vibrating wire, pneumatic, Casagrande and standpipe) are to be
provided in the ground for measuring changes in piezometric pressure at different
depths. The type of piezometer required will be determined by the anticipated
response times.
7) Inclinometers, strain gauges and extensometers in the ground and within

diaphragm walls are to be provided for measuring lateral displacements. The depth
of the instrumentation in the ground shall extend beyond the influence zone of the
tunnels with respect to ground movement and excavations and shall be fixed at
least three (3) metre below the bottom of the diaphragm wall and into a hard
stratum.
8) Extensometers are to be provided to measures convergence at tunnel openings or
at any other critical sections. Borehole extensometers shall be provided in soft
grounds to monitor heave and vertical deformations with depth.
9) Load cells shall be installed at selected struts and anchors in excavations to enable
design predictions to be verified and to monitor performance.
10) Tilt meters shall be provided on walls of adjacent structures where tilt
has been identified
as being critical.
11) Crack meters shall be installed to monitor existing cracks on applicable EBS.
12) Vibration recording devices attached to structures assessed to be critical during
the Contractor’s EBS study.
3.3.4 Monitoring and Reporting

1) The Contractor shall monitor the performance of the Works with trigger
(Alert, Alarm and Action) levels for each EBS and instrument as shown in
the Employer’s Drawings. Any changes to these trigger levels during the
Works shall be subject to the Notice of the Engineer.
2) The general definitions for the trigger (Alert, Action & Alarm) levels are given
below.
"Alert Level" shall initially be set as 0.5 times the serviceability limit movement
for the monitored element.
"Action Level" shall be set at 0.8 times the serviceability limit movement for the
monitored element.
"Alarm Level" shall initially be set at the serviceability limit movement for the
monitored element.
3) The serviceability limit movement for a monitored element shall be the lesser of:
a) calculated design value for the serviceability limit including stress and
displacement/movement for the monitored element;
b) monitored element movement/distortion which would theoretically cause
service disruption.
c) allowable structure or ground limits based on the damage assessment.

d) For utilities value of settlement/rotation those are accepted to the relevant

agencies/ authority and/ or the Engineer.
e) Ground water drawdown by one metre below the lowest recorder ground
water table
4) If any of the trigger levels are attained, the Contractor’s Response Actions shall
comprise emergency actions which could include the following and other
necessary measures.
f) On reaching an “Alert Level’ at any location, the Contractor shall
immediately
submit a written report to the Engineer, reviewing all total and
differential movements/distortions including construction records to
date. Engineer shall assess the effects of the movements/distortions on
the monitoring elements and their effect on monitored elements based
on the trend to date. Where it is considered by the Engineer that
movement trends indicate that “Action Level” may be reached during
the course of the works, the Contractor shall carry out the remedial
measures to limit further movement as per Drawings, Documents,
Specifications issued by the Engineer.
g) On reaching an ”Action Level” at any location, the Contractor shall
submit an updated report reviewing the movements including differential
movements and distortion including construction records to date. The
Contractor shall also provide a report detailing the full history of
movements and remedial measures adopted in relation to the actual
construction sequence. Engineer shall assess the effects on monitored
elements and their subsequent effect on monitored elements. In addition,
revised “Alert Level” and “Action Level” values which take into account
the implemented remedial works shall be issued by the Engineer before
work may be continued.
h) On reaching an “Alarm Level”, all work shall be suspended within 30
meters of the instrument or for affected portion of the Work. The
Contractor shall immediately implement the measures as defined in the
contingency/emergency plans to make the related part of Work safe and
control the situation. The Contractor shall provide a report detailing the
full history of movements including construction records and
interpretation of event to the Engineer. Engineer shall review the
available records and recommend additional remedial measures which
shall be implemented by the Contractor. Work may only resumed upon
Notice from the Engineer.
5) Throughout the construction period, all adjacent EBS shall be subject to regular
inspections by the Contractor’s Engineer. Signs of distress in any structures shall
be recorded and steps taken to immediately alleviate such distress.
3.3.5 Frequency of Monitoring

1) At least 21 days time shall be allowed between installation of instruments and
commencement of relevant site activities to enable a reliable set of base readings
to be established for all installed instrumentation.
2) The instruments shall be connected to data logging equipment where necessary so
that measurements can be taken on a continuous 24 hour basis. Data shall be
accessible via computers in the Engineer’s site offices. An alarm system shall be
incorporated into the computer network, with the alarm being activated if gauge
readings exceed either the agreed Alert, Action and Alarm levels.
3) Reports of monitoring results shall be submitted to the Engineer within 24 hours.
A detailed graphical presentation of historical values of monitoring shall be
submitted on a weekly basis in a format agreed with the Engineer. All
results/information shall be submitted to the Engineer weekly on virus-free digital
storage devices. The information on the storage devices must be retrievable using
Microsoft Excel software running on IBM PC or compatible systems. Where a
greater frequency of monitoring is required than on a 24-hour cycle, the Contractor
shall submit the reading taken directly at the site to the Engineer on the same day.
4) All instruments shall be suitably protected against accidental damage, vandalism
and adverse climatic conditions. Any damaged instrument shall be replaced
immediately, with a set of base readings being taken as soon after installation as
practicable.
5) The Contractor shall permanently record in both hard and soft (electronic) form
for future reference as required all readings and observations from each installed
instrument. On the Monday of each week the Contractor shall provide to the
Engineer the updated records (in both hard and soft copy) for all instruments.
These records shall show all previous readings in both numerical and graphical
form and include the location, type and trigger levels for each instrument, noting
any exceedances and any changes to the instrumentation location, type or records.
6) The Contractor shall permit access to the Works for personnel from
academic/research institutions duly noticed by the Engineer so that they can
collect relevant data for making studies on performance of various underground
construction elements. The Contractor shall make all such instrumentation data
freely available to these academic/research institutions for academic/research
purposes only.
3.3.6 Protection, Maintenance and Repair
1) The Contractor shall protect and maintain in good working condition all
monitoring instruments and devices throughout the Contract period. Any
instrument or device deemed critical to the Works that is not functioning properly
or accurately shall be replaced immediately at the Contractor’s own cost.
2) The Contractor shall ensure that all instruments and devices accessible to public
shall be protected with sturdy lockable boxes.
3.3.7 Removal
1) No instrument or device shall be demolished, abandoned, removed, disposed

of, or rendered inaccessible without the agreement of the Engineer.
2) All instruments and devices shall be removed on final acceptance of the Works.
All terminal boxes and covers shall be removed and disposed of. All boreholes
and excavations shall be completely filled and all instruments and devices attached
to EBS removed to the satisfaction of the Engineer.
3) All costs incurred in the satisfactory removal of the instruments and devices are
deemed to be included in the Contract rates and prices.
4) All read-out units and devices shall become the property of the Employer.
3.4 EBS PROTECTION
3.4.1 General
1) The Contractor shall be responsible for the control of all ground movements and
distortions and for any resulting damage to EBS. The Contractor shall investigate
all EBS that may be influenced by the Works. The Contractor’s EBS study shall
extend to at least 50 meters either side of the track alignment.
2) For operating rail tracks, maximum permissible total movement shall not be
greater than 15 millimetres or as agreed by the concern railway authority. Angular
distortion to rail tracks shall be limited to an absolute maximum of 5 millimetres
in 10 metres (1:2000) longitudinally, and 1 in 2500 transversely as measured
across any one single track set.
These requirements are in addition to any other requirements imposed by
applicable government agencies, utility companies and the Employer.
3) The Contractor shall obtain Notice from the Engineer and relevant authorities
and/or utilities companies prior to carrying out any dewatering of the ground.
Dewatering may only be carried out within contained excavations once the walls
or cut-offs which provide that containment are all in place and proven to be
effective to the satisfaction of all interested parties and the Engineer.
4) The ground water drawdown (drop of water table during dewatering/construction)
outside excavation/ adjacent to Works, shall be controlled such that water table
doesn’t get lowered by more than one (1) meter below the lowest recorded
groundwater table (lowest level recorded by Contractor prior to construction). For
ensuring this Contractor shall provide recharge well system if required.
5) The Contractor's attention is drawn to the General Conditions of Contract and
Employer's Requirements relating to repair of damage should any arise as a result
of the Contractor’s construction activities.
6) The Contractor shall take due regard of the presence of all utilities and services
within and adjacent to the Works.
7) The Contractor shall instrument and regularly monitor the ground and EBS
adjacent to all excavations to determine the rate and magnitude of any movements
and distortions.

8) Movement and distortion shall be limited such that any individual EBS shall
not suffer damage greater than "Slight" as defined in the “Damage
Classification” in Table 3.1.
9) Movement and distortion to critical structures such as hospitals, bridges,
Flyovers, underpasses/ subways, viaducts, heritage structures and
“protected” structures etc. shall be limited to “Negligible” as defined in
the “Damage Classification” Table 3.1.
3.4.2 Minimising Ground Movements
All tunnel including cross passages and cut-and-cover works shall be constructed in
such a way as to minimise ground and EBS movements and distortions by immediate
installation of support/pre-support to the ground and by cutting off of any inflow of
water into the Works. Care should be exercised to ensure that there is no over-
excavation.
Construction from the surface shall be undertaken with due regard to the settlement
associated with the particular method chosen.
3.4.3 Condition Survey
The Contractor shall determine the potential influence zones for his Works and
undertake condition surveys of all EBS within these influence zones for ensuring
compliance with the Contract provisions.
Table 3.1: Building Damage Classification
Building Damage Classification (after Burland et al, 1977 and Boscardin and Cording, 1989)
Risk Description Description of Typical Damage and Likely Approx Crack Max
Category of Degree Form of Repair for Typical Masonry Width Tensile
of Damage Building (mm) Strain %
Less than
0 Negligible Hairline cracks 0.05
Fine cracks easily treated during normal

1 Very Slight redecorations. Cracks in exterior brickwork 0.1 to 1 0.05 to
visible upon close inspection 0.075
Cracks easily filled. Redecoration probably

required. Exterior cracks visible: some
2 Slight repointing may be required for weather 1 to 5 0.075 to
tightness. Doors and windows may stick 0.15
slightly.
Cracks may require some opening up and
patching. Repointing and possibly replacement 5 to 15, a
of a small amount of exterior brickwork may be number of
3 Moderate
required. Doors and windows sticking. Utility cracks greater 0.15 to 0.3
services may be interrupted. Weather than 3
tightness often impaired.

Extensive repair involving removal and

replacement of sections of walls, especially 15 to 25 but
over doors and windows required. Windows also depends Greater
4 Severe
and door frames distorted. Floor slopes on number of than 0.3
noticeably, Walls leaning or bulging noticeably, cracks
some loss of bearing in beams.
Major repair required involving partial or Usually greater

complete reconstruction. Beams, load bearing than 24 but
5 Very Severe walls lean badly and require shoring. Windows depends on
broken by distortion. Danger of instability. number of
cracks
Notes :
1) Crack width is only one aspect of damage and should not be used on its own as its
direct measure. It is the ease of repair that is the key factor in determining the
category of damage.
2) The degree of severity given in the table only applies to standard domestic or office
buildings. For buildings with sensitive finishes the degree of severity might not
apply. Burland et al. (1977) also points out that more stringent criterion might be
necessary where initial cracks can lead to corrosion, penetration of harmful liquids
etc.
3.5 ADDITIONAL GEOTECHNICAL INVESTIGATIONS.
3.5.1 General
The additional ground investigations shall be undertaken as shown in the tender
drawings.
3.5.2 Schedule of field and laboratory tests
The frequency and extent of sampling and testing including the types of field and
laboratory tests to be performed shall be minimum as performed by the Employer and
included in the Part 4 of the tender document. The Contractor shall submit a
comprehensive ground investigation proposal including locations of drillholes,
frequency and type of sampling, frequency and types of field and laboratory tests to the
Notice of the Engineer.
3.5.3 Report
On completion of all the field and laboratory works, the contractor shall submit a draft
report containing geological information of the region, procedure adopted for
investigation, field observations, summarized test data, conclusion and
recommendations. The report shall include detailed bore logs, sub-soil sections, field
test results, laboratory observations and test results in both tabular as well as graphical
forms, practical and theoretical considerations for the interpretation of test results, the
supporting calculations for the conclusions drawn etc.

Bore logs shall report full blow count details, rock drilling intervals, recovery and RQD,
the depths at which tests are conducted and samples collected, borehole water
observations, casing depth, date of start and completion of the borehole, location details
including the reduced level of borehole location, etc. The depth shall be in a suitable
scale.
The SPT N values shall be graphically presented in the bore log.
Initially, the contractor shall submit one draft copy of the report for each part of the
alignment in his scope for the Notice of the Engineer. After review of the draft report,
the Engineer comments will be intimated to the contractor. The contractor shall address
the comments and after getting the amended report Noticed, four copies of the detailed
final report shall be submitted along with colour prints of graphs, color photographs of
core box and bore log cross section, tables etc. All the data shall also be submitted in
the editable format using Microsoft Excel software running on IBM PC or compatible
systems
Data to be Furnished
The report shall also include but not be limited to the following:
a. Plot plan showing the location and reduced levels of all field tests e.g. bore holes,
trial pits, etc. properly drawn to scale and dimensioned with reference to the
established grid lines. Geological information of the area such as geomorphology,
geological structure, lithology, stratigraphy and tectonic faults, seismicity of the
region and site, core recovery and rock quality designation etc.
b. True cross section of all individual boreholes and trial pits with reduced levels
and co-ordinates showing the classification and thickness of individual stratum,
position of ground water table, various in-situ tests conducted and samples
collected at different depths and the rock stratum if met with.
c. Set of longitudinal and transverse soil/rock profiles connecting various bore
holes in order to give a clear picture of the variation of the subsoil strata as per
IS: 6065.
d. Water level contours and rock level contours
e. Plot of standard penetration test -N values (both uncorrected and corrected) with
depth for identified areas.
f. Results of all field tests in tabular as well as in graphical forms.
g. Results of all laboratory tests summarised (i) for each sample as well as (ii) a
consolidated table giving the layer-wise soil and rock properties. All the relevant
charts, tables, graphs, figures, supporting calculations, conclusions and
photographs of representative rock cores and trial pits shall be furnished.
h. For all triaxial shear tests, stress vs strain diagrams as well as Mohr's circle
envelopes shall be furnished. If back pressure is applied for saturation, the
magnitude of the same shall be indicated. The value of modulus of elasticity -E

shall be furnished for all tests along with relevant calculations.
i. For all consolidation tests the following curves shall be furnished.
e vs log P, e vs P and Compression vs log t or square root of t (depending upon
shape of the plot for proper determination of coefficient of consolidation) The
point showing initial condition (eo, Po) of the soil shall be marked on the curves.
j. Values of compression index, coefficient of volume compressibility etc. shall be
furnished. The procedure adopted for calculating the compression index from
the field curve and settlement of soil strata shall be clearly specified. The time
required for 50% and 90% primary consolidation along with secondary
settlement if significant shall also be calculated.



PHASE-II PROJECT”
PART-2
SECTION VII
SUB-SECTION - 4
ARCHITECTURAL

SS4-1
Sub-Section-4- Architectural
TABLE OF CONTENTS
1. GENERAL 5
1.1 DESCRIPTION OF WORK SITE 5
1.2 STANDARD SPECIFICATIONS 5
1.3 SETTING OUT OF WORKS 5
1.4 MATERIALS 6
1.4.1 SOURCE OF MATERIALS 6
1.4.2 QUALITY 6
1.4.3 SAMPLING AND TESTING 6
1.4.4 DISPATCH OF MATERIALS 6
1.4.5 TEST CERTIFICATES 7
1.4.6 REJECTION 7
1.4.7 STORING OF MATERIALS AT SITE 7
1.5 WATER 7
1.5.1 WATER FROM APPROVED SOURCE 7
1.5.2 STORAGE 7
1.5.3 TESTING 7
1.6 WORKMANSHIP 8
1.7 SURVEY WORK 8
1.8 FINISHING WORK 8
1.8.1 SUB-CONTRACTOR 8
1.8.2 GUARANTEES AND BUILDING MAINTENANCE FOR FINISHES 8
1.8.3 RESPONSIBILITY FOR SHOP DRAWINGS, SAMPLES AND MOCK-UPS 8
1.8.4 CLEANING 8
1.8.5 EXPANSION BOLTS/ FASTENERS: 9
1.9 APPLICABLE CODES, STANDARDS & PUBLICATIONS 9
2. BRICK WORK 21
2.1 AUTOCLAVE AERATED CONCRETE BLOCKS 21
❖ TYPES OF WALL : SOLID 22
2.2 WORKMANSHIP GENERALLY 22
2.2.1 SITE STORAGE 22
2.2.2 CONDITIONING OF CONCRETE BLOCKS : 22
2.2.3 MORTAR GROUPS 22
2.2.4 TESTING - MORTAR STRENGTH 23
2.2.5 TESTING - CEMENT CONTENT OF MORTAR 23
2.2.6 LAYING GENERALLY 23
2.2.7 ACCURACY 23

SS4-2
2.3 LEVELLING OF SEPARATE LEAVES 24

2.4 COURSING BLOCK WORK 24
2.4.1 ADDITIONAL REQUIREMENTS FOR FACEWORK 25
3. FINISHING WORK 27
3.1 PLASTER 27
3.1.1 APPLICABLE SPECIFICATIONS 27
3.1.2 CEMENT 27
3.1.3 MEASUREMENTS 27
3.1.4 RATE 27
3.1.5 PREPARATION OF SURFACES 27
3.1.6 WORKMANSHIP –GENERAL 27
3.1.7 INTERNAL PLAIN FACE PLASTER 28
3.1.8 BACKING SCREEDS 28
3.1.9 CURING 28
4. DOORS 29
4.1 FABRICATION 29
4.1.1 FRAMES 29
4.2 REQUIREMENTS OF WELDED JOINTS 29
4.3 PRESSED STEEL DOORS 30
4.3.1 MATERIAL 30
4.3.2 CONSTRUCTION 30
4.3.3 FABRICATION 30
4.3.4 FINISH 31
4.3.5 FIXING 31
4.3.6 MEASUREMENTS 31
4.3.7 RATE 31
4.4 FIRE DOOR 31
4.4.1 GENERAL 31
4.4.2 FRAME 32
4.4.3 SILL 32
4.4.4 SHUTTERS 32
4.4.5 HINGES 32
4.5 HARDWARE/FITTINGS 32
4.5.1 DOOR CLOSER: 32
4.5.2 MORTICE LOCK 33
4.5.3 DOOR CO-ORDINATOR 33
4.5.4 TOWER BOLT 33
4.5.5 PANIC BAR/EXIT DEVICES 33
4.5.6 MAKE – INGERSOLL RAND/ DORMA/ UNION 33
4.5.7 SHOP DRAWINGS 34
4.5.8 SHOP PRIMING 34
4.5.9 PROTECTIVE COATINGS 34

SS4-3
4.5.10 POLYESTER POWDER COATING 35

4.5.11 FLUOROCARBON COATING 35
4.5.12 GENERAL 35
4.5.13 QUALITY ASSURANCE 35
4.5.14 COAT SYSTEM 35
4.5.15 COATING 35

SS4-4
1. GENERAL
1.1 Description of Work Site
The specifications for the architectural works shall be read in conjunction with other sections of these
specifications and other tender documents for this Contract, CPWD Specifications 2009 and approvals,
instructions given by the Engineer. The general requirements are described in Section 01 herein.
1.2 Standard Specifications

These Specifications contained herein shall be read in conjunction with other tender documents.
The Work shall be carried out in accordance with the "Good for Construction" drawings and designs
would be issued to the Contractor by the Engineer duly signed and stamped by him. The Contractor
shall not take cognizance of any drawings, designs, specifications, etc. not bearing Engineer's signature
and stamp. Similarly the Contractor shall not take cognizance of instructions given by any other
Authority except the instructions given by the Engineer in writing.
The work shall be executed and measured as per metric units given in the Schedule of Quantities,
drawings etc. (FPS units where indicated are for guidance only).
Absence of terms such as providing, supplying, laying, installing, fixing etc in the descriptions does not
even remotely suggest that the Contractor is absolved of such providing, supplying etc unless an explicit
stipulation is made in this contract. The Owner shall bear no costs of materials, labour, equipment,
duties, taxes, royalties etc.
The specifications may have been divided into different sections / sub-heads for convenience only. They
do not restrict any cross-references. The Contractor shall take into account inter-relations between
various parts of works/trades. No claim shall be entertained on the basis of compartmental
interpretations.
The classification of various items of works for purposes of measurements and payments shall be as per
bills of quantities (BOQ). Except where distinguished by BOQ, the rates apply to all heights, depths,
sizes, shapes and locations. They also cater for all cuts and wastes. No floor wise separation shall be
made for the rates. Likewise all heights of centering, shuttering, staging, formwork and scaffolding,
trusses and erection methods are covered by the rates including multi stage propping for heights greater
than one floor as per drawings.
1.3 Setting Out Of Works

The Contractor shall set out the Works indicated in the Conditions of Contract. The Contractor shall
provide suitable stones with flat tops and build the same in concrete for temporary benchmarks. All the
pegs for setting out the Works and fixing the levels required for the execution thereof shall, if desired
by the Engineer, likewise be built in masonry at such places and in such a manner as the Engineer may
direct. The Contractor shall carefully protect and preserve all benchmarks and other marks used in
setting out the works. The Contractor will make overall layout of complete work and get it checked from
engineer. The cost of all operations of setting out including construction of benchmarks is deemed to be
included in the quoted rates as per Bill of Quantities.

SS4-5
All the survey work except levelling work shall be carried out using total stations with one second
accuracy. The levelling work shall be carried out using Auto level.
The triangulations point given by CMRL before start of work shall be maintained during execution and
handed over back to CMRL after completion
1.4 Materials
1.4.1 Source of Materials
It shall be the responsibility of the Contractor to procure all the materials required for construction and
completion of the contract. The Contractor shall indicate in writing the source of materials well in
advance to the Engineer, after the award of the work and before commencing the work. If the material
from any source is found to be unacceptable at any time, it shall be rejected by the Engineer and the
Contractor shall forthwith remove the material immediately from the site as directed by the Engineer.
1.4.2 Quality
All materials used in the works shall be of the best quality of their respective kinds as specified herein,
obtained from sources and suppliers approved by the Engineer and shall comply strictly with the tests
prescribed hereafter, or where tests are not laid down in the specifications, with the requirements of the
latest issues of the relevant Indian Standards.
1.4.3 Sampling and Testing
All materials used in the works shall be subjected to inspection and test in addition to test certificates.
Samples of all materials proposed to be employed in the permanent works shall be submitted to the
Engineer at least 45 days in advance for approval before they are brought to the site.
Samples provided to the Engineer for their retention are to be labelled in boxes suitable for storage.
Materials or workmanship not corresponding in character and quality with approved samples will be
rejected by the Engineer.
Samples required for approval and testing must be supplied sufficiently in advance if required quality
and number to allow for testing and approval, due allowance being made for the fact that if the first
samples are rejected further samples may be required. Delay to the works arising from the late
submission of samples will not be acceptable as a reason for delay in completion of the works.
Materials shall be tested before leaving the manufacturer’s premises, quarry or resource, wherever
possible. Materials shall also be tested on the site and they may be rejected if not found suitable or in
accordance with the specification, notwithstanding the results of the tests at the manufacturer’s works
or elsewhere or test certificates or any approval given earlier.
The Contractor will bear all expenses for sampling and testing, whether at the manufacturer’s premises
at source, at site or at any testing laboratory or institution as directed by the Engineer. No extra payment
shall be made on this account.
1.4.4 Dispatch of Materials
Materials shall not be dispatched from the manufacturer’s works to the site without written authority
from the Engineer.

SS4-6
1.4.5 Test Certificates
All manufacturer’s certificates of test, proof sheets, etc showing that the materials have been tested in
accordance with the requirement of this specification and of the appropriate Indian Standard are to be
supplied free of charge on request to the Engineer.
1.4.6 Rejection
Any materials that have not been found to conform to the specifications will be rejected forthwith and
shall be removed from the site by the Contractor at his own cost within two weeks or as instructed by
the Engineer.
The Engineer shall have power to cause the Contractors to purchase and use such materials from any
particular source, as may in his opinion be necessary for the proper execution of the work
1.4.7 Storing Of Materials at Site
All materials used in the works shall be stored on racks, supports, in bins, under cover etc. as appropriate
to prevent deterioration or damage from any cause whatsoever to the entire satisfaction of the Engineer.
The storage of materials shall be in accordance with IS 4082 “Recommendation on stacking and storage
or construction materials on site” and as per IS 7969 “Safety code for handling and storage of building
materials”.
The materials shall be stored in a proper manner at places at site approved by the Engineer. Should the
place where material is stored by the Contractor be required by the Employer for any other purpose, the
Contractor shall forthwith remove the material from that place at his own cost and clear the place for
the use of the Employer.
1.5 Water
1.5.1 Water from approved source
Potable water only shall be used for the works. Contractor shall have his own source of water duly
approved by Engineer. The water shall be free from any deleterious matter in solution or in suspension
and be obtained from an approved source. The quality of water shall conform to IS 456.
1.5.2 Storage
The Contractor shall make his own arrangements for storing water, if necessary, in drums or tanks or
cisterns, to the approval of the Engineer. Care shall be exercised to see that water is not contaminated
in any way.
1.5.3 Testing
Before starting any concreting work and wherever the source of water changes, the water shall be tested
for its chemical and other impurities to ascertain its suitability for use in concrete for approval of the
Engineer. No water shall be used until tested and found satisfactory. Cost of all such Tests shall be borne
by the Contractor.

SS4-7
1.6 Workmanship
All works shall be true to level, plumb and square and the corners, edges and arises in all cases shall be
unbroken and neat.
Any work not to the satisfaction of the Engineer or his representative will be rejected and the same shall
be rectified, or removed and replaced with work of the required standard of workmanship at no extra
cost.
1.7 Survey Work

The said work involves at the very start of work taking-over of reference point from the Engineer,
establishment of control points, triangulation points, bench marks, grid layout for all the piers/column
and other structures maintaining horizontal and vertical control within the permissible limits,
incorporating changes (if any), submission of full data in the tabulation form and survey drawings
including setting and layout of various works during the progress of work.
1.8 Finishing Work

1.8.1 Sub-Contractor
Works as listed below and those dealing with proprietary materials/ products may be carried out by the
Contractor through the Sub-Contractors as may be approved by the Engineer in writing. The Sub-
Contractors must be firms of repute and long standing, having adequate experience and complete
facilities to carry out all items of work required for completion as per Specifications and expected quality
to the satisfaction of the Engineer. The Sub-Contractor must also have personnel experienced in
preparing shop drawings. All such works shall be carried out under the direct supervision of the
manufacturers of the proprietary materials/ products or their trained and accredited licensee.
1.8.2 Guarantees and Building Maintenance for Finishes
The Contractor shall guarantee and undertake to maintain and rectify the various components of the
Civil Works for their successful performance for the periods as specified below. The Contractor shall
indemnify the Engineer for a similar period against any damage to property and injury to persons on
account of any defective work or maintenance carried out by the Contractor. The format and text of the
Guarantee and the Indemnity Bond shall be as followed in PWD/CPWD or as approved by the Engineer.
a) Waterproofing for the other areas such as toilets, kitchens, chajjas etc. shall be guaranteed for 10
years. The waterproofing shall include all allied works on the slab etc. such as concrete/ mortar
screeding, if any, floor finish between which the waterproofing treatment shall be sandwiched.
1.8.3 Responsibility for Shop Drawings, Samples and Mock-Ups
Approval of shop drawings, samples and mock-ups for the various components shall not absolve the
Contractor of his responsibility of completing the work to the specifications, standards, tests for
performance and guarantees given in these documents and to a quality of finish as desired by the
Engineer.
1.8.4 Cleaning
Surfaces on which finishes are to be provided shall be cleaned with water jets or oil free compressed air
or power tools with wire brushes and detergents all as approved by the Engineer.

SS4-8
1.8.5 Expansion Bolts/ Fasteners:
a) Unless specified otherwise all expansion bolts/ fasteners shall be fabricated from stainless steel
sheet, strip or plate conforming to ASTM A 240 GR 304 or bar to ASTM A 479 GR 304 of approved
make and design. The material of the bolt shall not cause any bimetallic corrosion with the
reinforcing bars of the RCC/ brickwork or with any other fixings or doors or windows or skylights
etc.
b) For steel backings the fasteners shall be prevented from contact with other metals, which would lead
to bimetallic corrosion.
c) For block masonry backing the sleeves of the expansion bolts shall be fixed in wedge shaped pockets
having an area of 75mm × 75mm at the surface and 100mm × 100mm at the inner surface and shall
be 125mm deep. The wedge could also be as a truncated cone of 75mm dia / 100mm dia. The
dimensions shall be reviewed by the Engineer during execution of the work. The wedge shall be
filled with PCC 1:1:2 (1 Cement, 1 Sand and 2 Coarse Aggregate) mixed with non-Shrink
Compound in the proportion as recommended by the manufacturer.
d) The holes drilled for the expansion fasteners shall be cleaned of all ground material, dust, etc. before
inserting the expansion sleeves.
e) All expansion bolts fixed into soffits shall be bonded to the backing with epoxy/ polyester resin of
approved make.
f) All expansion bolt fixings shall be tightened in accordance with the recommended torque figures by
the manufacturer. Where such values are not available the Contractor shall test at least 6 samples to
determine the safe torque values. All bolts shall be tightened using torque spanner/ wrenches. All
bolts shall be checked 24 hours (minimum) after installation and retightened if necessary.
g) No walls, terraces shall be cut for making any opening after water proofing has been done without
written approval of the Engineer. Cutting of waterproofing when authorised by the Engineer in
writing shall be done very carefully so that no other portion of the waterproofing is damaged. On
completion of the work at such places, the water proofing membrane shall be made good and ensured
that the opening / cutting is made fully water proof as per specifications and details of water proofing
approved by the Engineer at no extra cost. No structural member shall be cut or chased without the
written permission of the Engineer.
Provision of grooves in plaster, drip courses etc, if directed, at junction of walls-ceilings, columns-walls,
frames-plaster and such other generally typical locations shall not be paid extra, including grooves in
concrete, masonry, stonework.
1.9 Applicable Codes, Standards & Publications

The more important Codes, Standards and Publications to Contract are listed here under:
Table 1.1 Codes, Standards & Publications
Code Description
IS: 1200 (Part 4) Methods of measurement of building and
Civil engineering works-Stone masonry
IS: 1237 Specification for cement concrete flooring
tiles
IS: 1322 Bitumen felts for water proofing and damp-
proofing

SS4-9
Code Description
IS: 2185 (Part 1) Concrete masonry units: Hollow and solid
concrete blocks
IS: 2185 (Part 2) Concrete masonry units: Hollow and solid
light weight concrete blocks
IS: 2185 (Part 3) Concrete masonry units: Autoclaved
cellular aerated concrete blocks
IS: 2572 Code of Practice for construction of hollow
concrete block masonry
IS: 3414 Code of practice for design and installation
of joints in buildings
IS: 3462 Specification for unbaked flexible PVC
flooring
IS: 5318 Code of practice for laying of flexible PVC
sheet and tile flooring
IS: 6408 (Parts 1,2) Recommendations for modular co-
ordination in building industry – tolerances
IS: 8183 Bonded mineral wool
IS:10958 General check list of functions of joints in
building
IS:11817 Classification of joints in buildings for
accommodation of dimensional deviations
during construction
IS:11818 Method of test for laboratory determination
of air permeability of joints in buildings
IS:12440 Precast concrete stone masonry blocks
CPWD Specifications 96 with up-to-date correction
slips
BS:476 (Part 7) Method for classification of the surface
spread of flame of products
BS:476 (Part 20) Method of determination of the fire
resistance of elements of construction
(general principles)
BS:476 (Part 22) Methods for determination of the fire
resistance of non-load bearing elements of
construction
BS: 1245 Specification for metal door frames (steel)
BS: 3261 Specification for unbaked flexible PVC
flooring
BS:3261:Part 1 Homogeneous flooring
BS:5215 Specification for one-part gun grade
polysulphide-based sealants

SS4-10
Code Description
BS:5606 Guide to accuracy in building
BS:5725 (Part 1) Specification for panic bolts and panic
latches mechanically operated by a
horizontal push-bar
BS:6093 Code of practice for the design of joints and
jointing in building construction
BS:8200 Code of practice for the design of non-load
bearing external vertical enclosure of
building
ASTM C 332 Specification for light weight aggregate for
insulating concrete
ASTM C 635 Specification for the manufacture,
performance and testing of metal
suspension systems for acoustical tile and
lay-in panel ceilings
SP 7 National Building Code of India
B Bitumen
IS:702 Industrial Bitumen
IS:3384 Specification for bitumen primer for use in
waterproofing and damp-proofing
C Building Construction Practices
IS: 1838 Parts I and Specifications for preformed fillers for
II. expansion joint in concrete pavements and
structures.
IS: 1946 Code of Practice for use of fixing devices
in walls, ceilings, and floors of solid
construction.
IS: 3414 Code of Practice for design and installation
of joints in buildings.
IS: 6509 Code of Practice for installation of joints in
concrete pavements.
IS: 11134 Code of Practice for setting out of
buildings.
IS: 11433 Parts I and II. Specifications for one part
Gun grade polysulphide based joint sealant.
IS: 12200 Code of Practice for provision of water
stops at transverse contraction joints in
masonry and concrete dams
D Cement
IS: 269 33 grade ordinary Portland cement
IS: 455 Portland Slag Cement

SS4-11
Code Description
IS: 650 Specification for standard sand for testing
cement.
IS: 1489 (Part 1) Portland puzzolana cement: Flyash based
IS: 1489 (Part 2) Portland puzzolana cement: Calcined clay
based
IS: 3535 Method of Sampling Hydraulic Cements
IS: 4031 (Parts 1 to 13) Methods of physical tests for
hydraulic cement.
IS: 4032 Method of chemical analysis of hydraulic
cement.
IS: 6925 Methods of test for determination of water
soluble chlorides in concrete admixtures.
IS: 8042 White Portland Cement
IS: 8112 Specification for 43 grade ordinary
Portland cement.
IS: 12269 Specification for 53 grade ordinary
Portland cement.
IS: 12330 Specification for sulphate resistant Portland
IRS: T 40 cement.
Indian Railways standard specifications for
special grade cement for use in concrete
sleepers
E Concrete
IS:456 Code of practice for plain and reinforced
concrete.
IS:1200 Method of measurement of building and
civil engineering
IS:2571 Code of practice for laying in-situ cement
concrete flooring
IS:2645 Specifications for integral cement water
proofing compounds
IS:2722 Specifications for portable swing batchers
for concrete (double bucket type)
IS:3025 Methods of sampling and test (physical and
chemical) for water & waste water
IS:3370 Code of practice for concrete structures for
storage of liquids
IS:3935. Code of practice for composite construction
IS:6925. Methods of test for determination of water
soluble chlorides in concrete Admixtures
IS:7242 Specifications for concrete spreaders

SS4-12
Code Description
IS:7251 Specifications for concrete finishers
IS:7861 Parts I & II. Code of practice for extreme
weather concreting.
IS:7969 Safety code for handling and storage of
building materials
IS:8989 Safety code for erection of concrete framed
structures
IS:8142 Methods of test for determining setting
time of concrete by penetration resistance
IS:9103 Specifications for admixtures for concrete
IS:9013 Method of making, curing and determining
compressive strengths of accelerated cured
concrete test specimens
IS:9284 Method of test for abrasion resistance of
concrete
F Construction Plant and Machinery.
IS:4656 Specifications for form vibrators for
concrete.
IS:806 Code of practice for use of steel tubes in
IS:1161 Specification of steel tubes for structural
purposes.
IS:1239 Specification for mild steel tubes, tubulars
and other wrought steel fittings.
H Gypsum and Gypsum Board
IS:2095 Gypsum plaster boards
IS:2542 (Part 1/Sec 1 Methods of test for gypsum plaster,
to 12) concrete and products: plaster and concrete
IS:2542 (Part 2/Sec 1 Methods of test for gypsum plaster,
to 8) concrete and products: Gypsum products
IS:2547 (Part 1) Gypsum building plaster: Excluding
premixed lightweight plaster
IS:2547 (Part 2) Gypsum building plaster: Premixed
lightweight plaster
I Handling and Storage
IS:4082 Recommendation of Stacking and Storage
of construction materials
IS:8348 Code of practice for stacking and packing
of stone slabs for transportation
IS:8759 Code of practice for maintenance and
preservation of stones in building

SS4-13
Code Description
J Instruments For Testing Cement and
Concrete
IS:5513 Specification for vicat apparatus.
IS:5514 Specification for apparatus used in Le-
Chaterlier test.
IS:5515 Specification for compaction factor
apparatus.
IS:7320 Specification for concrete slump test
apparatus.
IS:7325 Specification for apparatus to determine
constituents of fresh concrete.
IS:10080 Specification for vibration machine.
IS:10086 Specification for moulds for use in tests of
cement and concrete.
IS:10510 Specification for vee-bee consistometer.
K Joint Fillers
IS:1838 (Part 1) Preformed fillers for expansion joint in
concrete pavements and structures (non
extruding and resilient type): Bitumen
impregnated fibre
L Paints and Coatings
IS:102 Ready mixed paint, brushing, red lead, non-
setting, priming
IS:109 Ready mixed paint, brushing, priming,
plaster, to Indian Standard Colour No. 361
and 631 white and off white.
IS:218 Creosote and anthracene oil for use as
wood preservatives
IS:347 Varnish, shellac, for general purpose.
IS:348 French Polish
IS:2074 Ready mixed paint, air drying, red oxide-
zinc chrome, priming
IS:4833 Methods of field testing of preservatives in
wood
IS:10013 (Parts 1 to Water soluble type wood preservatives:
3)
IS:10013 (Parts 1 to (Part-1) Acid-copper-chrome preservative
3)
IS:10013 (Parts 1 to (Part-2) Copper-chrome-arsenic wood
3) preservative

SS4-14
Code Description
IS:10013 (Parts 1 to (Part-3) Copper-chrome-boron wood
3) preservative
BS:6496 Specification for powder organic coatings
for application and stoving to aluminium
alloy extrusions, sheet and preformed
sections for external architectural purposes,
and for the finish on aluminium alloy
extrusions, sheet and preformed sections
coated with powder organic coatings
BS:EN:10152 Specification for electrolytically zinc
coated cold rolled steel flat products.
Technical delivery conditions
ASTM A 164-71 Specification for electrodeposited coatings
of zinc on steel
M Pigment for Cement

BS:1014 Specification for pigments for Portland
cement and Portland cement products
N Reinforcement & Structural Steel
IS:206 Code of Practice for use of Steel Tubes in
General Building Construction
IS:210 Grey Iron Castings
IS:280 Mild steel wire for general engineering
purposes
IS:432 Part I. Mild steel and medium tensile steel
bars. Part II Hard drawn steel wire.
IS:451 Technical Supply conditions for Wood
Screws
IS:806 Code of practice for use of steel tubes in
general building construction
IS:815 Classification coding of covered electrodes
for metal arc welding of structural steels
IS:1239 Specification for mild steel tubes, tubulars
and other wrought steel fittings
IS:1363 Black hexagon bolts, nuts and lock nuts and
black hexagon screws.
IS:1365 Slotted countersunk screws.
IS:1566 (Part I) Specifications for hard-drawn steel
wire fabric for concrete reinforcement.
IS:1786 Specification for high strength deformed
steel bars and wires for concrete
reinforcement.

SS4-15
Code Description
IS:2502 Code of Practice for bending and fixing of
bars for concrete reinforcement.
IS:2629 Recommended practice for hot-dip
galvanising of iron and steel.
IS:2751 Code of Practice for welding of mild steel
plain and deformed bars for reinforced
concrete construction.
IS:4759 Hot-dip zinc coating on structural steel and
other allied products.
IS:9417 Recommendations for welding cold-
worked steel bars for reinforced concrete
construction.
IS:14268 Uncoated stress relieved low relaxation
steel class 2 for Prestressed concrete
IS:226 Structural steel (Standard Quality)
IS:800 Code of practice for use of structural steel
in general building construction.
IS:813 Scheme of symbols for welding.
IS:814 Covered electrodes for metal arc welding of
structural steel. (Part I & Part II)
IS:816 Code of practice for use of metal arc
welding for general construction in mild
steel.
IS:822 Code of practice for inspection of welds.
IS:961 Structural steel (High Tensile)
IS:1024 Code of practice for use of welding in
bridges and structures subject to dynamic
loading.
IS:1030 Carbon steel casting for General
Engineering Purposes
IS:1120 Coach Screws
IS:1367 Technical Supply Conditions for Threaded
Fasteners
IS:1161 Steel tubes for structural purposes.
IS:1182 Recommended practice for radiographic
examination of fusion welded butt joints in
steel plates.
IS:1915 Code of Practice for Steel Bridges
IS:2016 Plain Washers
IS:2062 Structural steel (Fusion welding quality)

SS4-16
Code Description
IS:3063 Single Coil Rectangular Section Sprint
Washers for Nuts, Bolts and Screws
IS:3443 Crane Rail Sections
IS:3757 Specification for high tensile friction grip
bolts.
IS:5624 Specification for foundation bolts.
IS:3600 Code of practice for testing of fusion
welded (Part I) joints and weld metal in
steel.
IS:4923 Hollow steel sections for structural use.
IS:6227 Code of practice for use of metal arc
welding in tubular structure.
IS:801 Code of practice for use of cold formed
light gauge steel structural members in
IS:811 Specifications for cold formed light gauge
structural steel sections.
IS:8500 Structural Steel Micro alloyed (Medium
and high strength qualities)
IS:8910
General requirements of supply of weldable
structural steel
IS:9595
Recommendations for metal arc welding of
carbon & carbon-Mangnese steels
O Sand
IS:383 Coarse and fine aggregates from natural
sources for concrete.
P Scaffolding
IS:2750 Specification for steel scaffoldings
IS:3696 (Part 1) Safety Code of scaffolds and ladders:
Scaffolds
IS:3696 (Part 2) Safety Code of scaffolds and ladders:
Ladders
IS:4014 (Part 1) Code of practice for steel tubular
scaffolding: Definition and materials
IS:4014 (Part 2) Code of practice for steel tubular
scaffolding: Safety regulations for
scaffolding
IRC:87
Guidelines for the design and erection of
false work for road bridges

SS4-17
Code Description
Q Sealants
IS:10959 Glossary of terms for sealants for building
purposes
IS:11433 (Part 1) One part grade polysulphide base joint
sealant: General requirements
IS:11433 (Part 2) One part grade polysulphide base joint
sealant: Methods of test
IS:13055 Methods of sampling and test for anaerobic
adhesives and sealants
BS:5889 Specification for one part gun grade
silicone-based sealants.
R Wood
IS:303 Plywood for General Purposes
IS:848 Synthetic resin adhesives for plywood
(phenolic and amino plastic)
IS:1141 Seasoning of Timber – Code of Practice
IS:1328 Veneered decorative plywood
IS:1659 Block Boards
IS:2046 Decorative thermosetting synthetic resin
bonded laminated sheets
IS:2202 (Part 1) Wooden flush door shutters (solid core
type): Plywood face panels
IS:2202 (Part 2) Wooden flush door shutters (solid core
(type): Particle face panels and hardboard
face panels
U All Indian Railway Standards
V Metal
IS:276 Austenitic manganese steel castings
IS:733 Wrought aluminium and aluminium alloy
bars, rods and sections for general
engineering purpose.
IS:737 Specifications for wrought aluminium and
aluminium alloy sheet and strip for general
engineering purpose.
IS:3614 (Part 1) Specification for fire check doors: Plate
metal covered and rolling type
IS:3614 (Part 2) Specification for metallic and non-metallic
fire check doors: Resistance test and
performance criteria
IS:7196 Hold Fasts

SS4-18
Code Description
ASME Sect 2 Part A Ferrous Material Specifications
ASTM B 221 Specification for aluminium-alloy extruded
bars, rods, wires, shapes, and tubes
BS:4873 Specification for Aluminium alloy
windows
BS:7352 Specification for strength and durability
performance of metal hinges for side
hanging applications and dimensional
requirements for template drilled hinges
BS EN:10143 Specification for continuously hot-dip
metal coated steel sheet and strip.
Tolerances on dimensions and shape
W Glazing
BS:952 (Part 1) Glass for glazing: classification
BS:952 (Part 2) Glass for glazing: Terminology for work
on glass
BS:4315 (Part 2) Methods of Test for Resistance to Air and
water penetration: Permeable walling
constructions (water penetration)
BS:5368 (Part 1) Method of testing Windows: Air
permeability test
BS:5368 (Part 2) Method of testing Windows: Water
tightness test under static pressure
BS:5368 (Part 3) Method of testing Windows: Wind
resistance tests
BS:5368 (Part 4) Method of testing Windows: Form of test
report
BS:5713 Specification for Hermetically sealed flat
double glazing units
BS:6262 Code of practice for glazing for buildings
BS:6262 (Part 4) Glazing for buildings: Code of practice for
safety, Human impact
BS:6375 (Parts 1) Performance of windows: Classification for
weather tightness (including guidance on
selection and specification)
BS:6375 (Parts 2) Performance of windows: Specification for
operation and strength characteristics
DIN:1249 (Part 12) Glass for use in building construction;
toughened glass; dimensions, working and
requirements
JIS:R 3203 Float and Polished Plate Glasses

SS4-19
Code Description
ASTM E 283 Test method for determining the rate of air
leakage through exterior windows, curtain
walls, and doors under specified pressure
differences across the specimen
ASTM E 330 Test method for structural performance of
exterior windows, curtain walls, and doors
by uniform static air pressure difference
ASTM E 331 Test method for water penetration of
exterior windows, curtain walls, and doors
by uniform static air pressure difference
X Stone and Facings/ Linings
IS:1121-(Parts 1 to Methods of test for determination of
4) strength properties of natural building
stones
IS:1121-(Parts 1 to (Part-1 Compressive strength)
4)
IS:1121-(Parts 1 to (Part-2 Transverse strength)
4)
IS:1121-(Parts 1 to (Part-3 Tensile strength)
4)
IS:1121-(Parts 1 to (Part-4 Shear strength)
4)
IS:1122 Method of test for determination of true
specific gravity of natural building stones.
IS:1123 Method of identification of natural building
stones.
IS:1124 Method of test for determination of water
absorption, apparent specific gravity and
porosity of natural building stones.
IS:1125 Method of test for determination of
weathering of natural building stones.
durability of natural building stones.
IS:1127 Recommendations for dimensions and
workmanship of natural building stones for
masonry work.
IS:1128 Specification for Limestone (Slabs and
Tiles)
IS:1129 Recommendation for dressing of natural
building stones.
IS:1130 Specification for marble (blocks, slabs and
tiles).

SS4-20
Code Description
IS:1597 (Part 2) Code of practice for construction of stone
masonry: Ashlar masonry
IS:1706 Method for determination of resistance to
wear by abrasion of natural building stones
IS:1805 Glossary of terms relating to stones,
quarrying and dressing
IS:3620 Specification for laterite stone block for
masonry
IS:3622 Specification for Sandstone (slab & tiles)
IS:4101 (Part 1) Code of practice for external facing and
veneers: stone facing
veneers: Cement concrete facing
veneers: Wall tiling and mosaics
IS:4121 Method of test for determination of water
transmission rate by capillary action
through natural building stones
IS:4122 Method of test for surface softening of
natural building stones by exposure to
acidic atmospheres
permeability of natural building stones
IS:5218 Method of test for toughness of natural
building stones
IS:8381 Recommended practice for quarrying
stones for construction purposes
IS:14223 (Part 1) Polished building stones: Granite
BS: 8298 Code of practice for design and installation
of natural stone cladding and lining
2. Brick Work
2.1 Autoclave Aerated Concrete Blocks
AAC Blocks - Shall conform to the requirements of IS: 2185(part –III) 1984 for Specifications of AAC,
IS 6041, 1985 (Reaffirmed 1990) Code of practice for construction of AAC block masonry and IS: 6441,
1072 (Part 1 to 4): Method of testing for AAC products, AAC blocks shall have a minimum compressive
strength of 3N/mm^2, the normal dry density shall be in range of 551-600 Kg/m^3. AAC blocks should
be appropriate for desired fire safety as required by Employer/Employer’s representative . Aerocon
blocks must have precise edges and shape.

SS4-21
❖ Types of Wall : Solid
External and internal load bearing walls shall be of load bearing lightweight concrete. blocks of
appropriate thickness.
In special cases where high thermal insulation is required, cavity walls having inner leaf of
lightweight concrete blocks and the outer leaf of dense concrete block may be used. Each leaf
of the cavity wall shall not be less than 100 mm thick. To ensure adequate impermeability for
the walls the exterior surface of external walls shall be plastered with composite mortar.
For General Use Blocks: To IS 2185 (Part-1) 1979

Type: Solid
Minimum average compressive strength: 3 N/mm²
Maximum thermal conductivity at N/A % moisture content to IS 2185(Part-1) 1979
Work size(s): 600 × 200 × 100mm and 600 × 200 × 200mm.
Finish: 'Fair-faced' finish
Special shapes: None
Mortar: To IS 2250 - 1981.
Mix: Group 2 as clause 105/F10
Special requirements: None
Bond: Stretcher
Joints: Flush
Features: None
2.2 Workmanship Generally

2.2.1 Site Storage
Blocks shall be unloaded one at a time and stacked in regular tiers to minimize breakage and defacement.
These shall not be dumped at site. The height of the stack shall not be more than 1.2 m. The length of
the stack shall not be more than 3.0 m, as far as possible and the width shall be of two or three blocks.
Store concrete blocks in stable stacks clear of the ground and clearly identified by type, strength, grade,
etc. Protect from adverse weather and keep clean and dry.
2.2.2 Conditioning of Concrete Blocks :

Conditioning Of Concrete Bricks/Blocks:
a) Do not use autoclaved concrete bricks/blocks when still warm from the manufacturing process.
b) Do not use autoclaved concrete bricks/blocks until at least four weeks after casting.
c) Do not wet concrete bricks or blocks before laying; use an approved water retaining admixture in
the mortar to counteract suction.
2.2.3 Mortar Groups
Mortar shall be of 1:6. Mix proportions are by volume. Use the same mortar throughout any one type of
facing work.

SS4-22
2.2.4 Testing - Mortar Strength

Have tests carried out to determine compressive strength of mortars listed below. Preliminary and site
tests to be carried out in accordance with IS:2250-1981 and the following requirements by an approved
laboratory.
A provisional sum for testing is included elsewhere. Preliminary tests: Six specimens of 25 × 25 × 100
mm prisms or 40 × 40 × 160 mm prisms or 70.7 mm cubes or 100 mm cubes to be prepared at least six
weeks before walling commences, using materials from the source(s) from which the site will be
supplied Half of the specimens to be tested at seven days and the remainder at 28 days. For retarded
mortar mixes the curing periods are to be extended to include the retardation period. For any walling
type, if the mean compressive strength of mortar at 28 days is not within the range given below then
repeat the tests using either more suitable sand or the next higher designation of mortar.
Site tests: During construction, six specimens to be prepared for every 150 m² of each walling type, or
for every storey of the building, whichever is the more frequent. Half of the specimens to be tested at
seven days and the remainder at 28 days. For retarded mortar mixes the curing periods are to be extended
to include the retardation period.
Type of specimen used for site tests to be same as that used for preliminary tests.
Mean compressive strength of mortar at 28 days to be within the following range:
Walling Preliminary Site Max. Site Tests Max.

Type Min.(N/sq m) (N/sq m) Min. (N/sq m) (N/sq m)
F10/250 3.6 5.0 2.5 5.0
2.2.5 Testing - Cement Content of Mortar

When instructed by ER, test mortar for walling type(s) F10 before use, to determine cement content.
Carry out tests using the BREMORTEST method described in Building Research Establishment
Information Paper 8/89, or other equivalent.
A provisional sum for testing is included elsewhere.
2.2.6 Laying Generally

a) Lay bricks/blocks on a full bed of mortar; do not furrow. Fill all cross joints and collar joints; do
not tip and tail.
b) Build walls in stretching half lap bond when not specified otherwise.
c) Plumb perpends of face work every third or fifth cross joint along a course and even out the
joint widths in between.
Overhand Laying: Must not be used without approval.
2.2.7 ACCURACY
Keep courses level and true to line. Accurately plumb all wall faces, angles and features.
Unless otherwise specified, build brickwork/block work within the following permissible
deviations (mm):

SS4-23
Position in plan of any point or specified fair face in relation to the nearest building grid line at the
same level: ± 10
Length (unless otherwise defined by adjacent construction):
a) Up to 5 m: ± 15
b) 5 to 10 m: ± 20
c) 10 to 20 m: ± 25
d) Over 20 m: ± 30
Height:
a) Up to 3 m: ± 15
b) 3 to 6 m: ± 20
c) Over 6 m: ± 25
Level of bed joints:
a) Up to 5 m long: ± 10
b) 5 to 10 m long: ± 15
c) Over 10 m long: ± 25
d) Straightness in any 5 m length: ± 10
Vertically:
a) In any 3 m height: ± 10
b) In o/a height of building exceeding 6 m: ± 20
Thickness:
Overall thickness of walls or width of piers (subject to the following): ± 15, Difference in thickness
of a wall or width of a pier at any two points 3 m apart: ± 10
2.3 Levelling Of Separate Leaves

• Bring both leaves of cavity walls to the same level at: Every course containing vertical twist
type ties or other rigid ties.
• Every third tie course for double triangle/butterfly ties.
• Courses in which lintels are to be bedded.
2.4 Coursing Block work

Lintel Bearings: Carefully predetermine setting out to ensure that full length masonry units occur below
lintel ends.

SS4-24
Jointing: When not specified otherwise, finish joints neatly to the specified profile(s) as the work
proceeds.
Unexposed Joints: As the work proceeds, strike off joints that will not be exposed to view in the finished
work.
Fire Stopping:
• Fill joints around joist ends built into cavity walls with mortar to seal cavities from interior of
building.
• Ensure a tight fit between brickwork and cavity barriers to prevent fire and smoke penetration.
Holes, Recesses And Chases In Block Walling - Comply with the relevant clause in section N30.
Adverse Weather: Do not use frozen materials and do not lay on frozen surfaces.
Do not lay bricks/blocks:
• In cement gauged mortars when the air temperature is at or below 3°C and falling or below 1°C
and rising (unless mortar has a temperature of 4°C when laid and walling is thoroughly
protected).
• In hydraulic lime sand mortars when the air temperature is at or below 5°C and falling or below
3°C and rising.
• In thin joint mortar glue when climatic conditions are outside the limits set by the mortar
manufacturer.
Maintain temperature of the work above freezing until mortar has fully hardened.
Protect newly erected walling from:
• Rain and snow by covering when precipitation occurs, and at all times when the work is not
proceeding.
• Drying out too rapidly in hot conditions and in drying winds.
• Rake out and replace cement gauged or hydraulic lime mortar damaged by frost. When
instructed, rebuild damaged work.
• When instructed rebuild frost damaged thin joint masonry walling.
2.4.1 Additional Requirements for Facework
The Term Facework :

Where used in this specification, applies to all brick/block walls finished fair. Where any face work is
to be painted, the only specification requirement to be waived is that relating to colour.
Reference Panels :
Prepare panel(s) as set out below and, after drying out, obtains approval of appearance before
proceeding. Construct panels in an approved location using randomly sampled bricks/blocks but
rejecting any that are damaged.
Walling type 010.
Size of panel: 1.5m × 1.5m. Including example of Cut bricks/at reveals.

SS4-25
Colour Mixing :
• Agree with manufacturer and ER methods for ensuring that the supply of facing bricks/blocks
is of a consistent, even colour range, batch to batch and within batches.
• Check each delivery for consistency of appearance with previous deliveries and with approved
samples or reference panels; do not use if variation is excessive.
• Mix units from different packs and deliveries which vary in colour to avoid patches, horizontal
stripes and racking back marks in the finished work.
Appearance :
• Select bricks/blocks with proper edges. Cut with a masonry saw where cut edges will be exposed
to view.
• Set out and lay bricks to match appearance of relevant approved reference panel(s).
• Keep courses evenly spaced using gauge rods. Set out carefully to ensure satisfactory junctions
and joints with adjoining or built-in elements and components.
• Complete each lift in one period of operation.
• Protect face work against damage and disfigurement during the course of the works, particularly
arises of openings and corners.
Ground Level
Face work to start not less than 150 mm below finished level of external paving or soil except where
shown otherwise.
Putlog Scaffolding to face work will not be permitted.
Toothed Bond
Except where a straight vertical joint is specified, new and existing face work in the same plane to be
bonded together at every course to give a continuous appearance.
Brick Sills/Cappings
Bed solidly in mortar with vertical joints completely filled. Press mortar firmly into exposed joints and
finish neatly.
Cleanlines :
• Keep face work clean during construction and thereafter until Practical Completion.
• Turn back scaffold boards at night and during heavy rain.
• If, despite precautions, mortar marks are deposited on the face of masonry units, leave to dry
then remove with a stiff brush.
• Rubbing to remove marks or stains will not be permitted.

SS4-26
3. FINISHING WORK
3.1 Plaster
3.1.1 Applicable Specifications
All work will generally be in accordance with the CPWD Specifications 2009 except as modified
hereunder and as per the additional requirements.
Grooves will be made on external /internal wall plaster complete as per architectural drawing.
3.1.2 Cement
Portland ordinary Cement conforming to IS: 1489 will be used for all plaster work. The total chloride
content of the cement will not exceed 0.05%.
3.1.3 Measurements
Plaster will be measured as per clause 13.1.9 of CPWD Specifications 2009 except that the visible
surface area will be measured and plaster bands irrespective of widths will also be measured as part of
wall plaster.
Plaster for all floor levels and all heights will be measured under the same item.
3.1.4 Rate
As per quoted rates of BOQ.
3.1.5 Preparation of Surfaces
Plastering or tiling shall not be applied on any work which may be unfinished, imperfect, and wrong or
in any other improper condition to receive such finishing.
Improper work shall not be covered up or finished against until it has been rectified and authority to
proceed has been given by the Engineer.
All joints of brickwork are to be thoroughly raked out and loose particles of mortar, etc. brushed off to
form a key for plaster.
If concrete surfaces are not sufficiently rough to provide a key, the surfaces are to be hacked or an
approved bonding agent or a dash coat comprising 1:2 cement and coarse sand dashed wet are to be
applied on to the surface to provide a key.
All surfaces to be plastered must be brushed clean and well wetted before each coat is applied.
3.1.6 Workmanship –General
All plastering works and tiling works shall be carried out in accordance with BS 5385 where not
inconsistent with this Specification.

SS4-27
Materials shall be mixed in sufficient quantities for immediate use and shall not be used after one hour
has elapsed from the addition of water. Gauges are not to be mixed with each other or old batches
retempered.
No plastering or tiling works shall be carried out in unsuitable weather conditions unless adequate
protection is arranged beforehand.
All workmanship shall be of best quality.
The plastering and tiling Contractors are required to do all making good of work specified in this trade
after all other trades.
All finishes shall be properly made good around all pipes, brackets, electrical boxes, switches, and the
like.
Where shown on the Drawings expansion joints in plastering or tiling are to be provided.
3.1.7 Internal Plain Face Plaster
Internal plain face plaster shall be applied in three coats to a total finished thickness of 20 mm.
Undercoat and floating coat shall comprise one part cement, one part lime and six parts sand by volume.
The undercoat shall be 12 mm thick rough plastering laid on evenly, straightened to rule and scratched
to form a key to receive floating coat-
The floating coat shall be 5mm thick lightly scratched to form a key to receive finishing coat.
The finishing coat shall be 3mm thick comprising gypsum plaster gauged with not more than one-quarter
volume of lime, trowelled to a smooth, hard surface with a steel trowel.
A minimum of seven days must elapse between the applications
Plasticisers may only be used with the approval of the Engineer and then shall be added in accordance
with the manufacturer's instructions.
Metal plastering accessories shall be used where shown on the Drawings and are to be fixed in
accordance with the manufacturer's printed instructions.
3.1.8 Backing Screeds
Backing screeds for tiling shall be in single coat work and to the same general specification as for
undercoat to plaster work, laid on evenly, straightened to rule and scratched to form a key for the applied
finish.
3.1.9 Curing
Each coat of all plastering work or backing screeds is to be maintained in a moist condition for a
minimum of three days after it has developed enough strength not to be damaged by water.

SS4-28
4. DOORS
Hot rolled steel sections for fabrication of steel doors, windows, ventilators and fixed lights will conform
to IS: 7452. Shapes weights and designations of hot rolled sections will be as per IS: 7452. Appendix '0'
of Chapter 10 indicates the purpose or the situation where the sections are normally used. Tolerance in
thickness of the sections will be +0.2 mm. The steel doors, windows, ventilators and composite units
will be got fabricated in workshop approved by the Chief Engineer.
The steel doors and windows will be according to the specified sizes and design. The size of doors and
windows will be calculated, so as to allow 1.25 cm clearance on all the four sides of opening to allow
for easy fitting of doors windows and ventilators into opening. The actual sizes of doors, windows and
ventilators will not vary by more than + 1.5 mm from those given in the drawing.
4.1 Fabrication
4.1.1 Frames
Both the fixed and opening frames will be made of sections which have been cut to length and mitered.
The corner of fixed and opening frames will be welded to form a solid fused welded joint conforming
to the requirements given below. All frames will be square and flat. The process of welding: adopted
will be flash butt welding or metal arc welding or any other suitable method. The section for glazing
will be tennoned and riveted into the frames and where they intersect the vertical tie will be broached
and horizontal tee threads through it, and the intersection closed by hydraulic pressure.
4.2 Requirements of welded joints

1. Visual Inspection Test
2. When two opposite corners of the frame are cut, paint removed and inspected, the joint
will conform to the following:
3. Welds will make all along the place of meeting the members and tack welding will not be
permitted.
4. Welds will properly ground.
5. Complete cross section of the corner will be checked up to see that the joint is completely
and there are no cavities visible.
6. Micro and Macro Examinations
7. From the, two opposite corners obtained for visual test, the flanges of the sections will be
cut with the help of a saw. The cut surface of the remaining portions will be polished,
etched and examined. The polished and etched faces of the weld and the base metal will,
be free from cracks and reasonably free from under cutting, overlaps, gross porosity and
entrapped slag.
8. Fillet Weld Test
9. The fillet weld in the remaining portion of the joint will be fractured by hammering. The
fractured surfaces will be free from slag inclusion porosity, crack penetration defects and
fusion defects.

SS4-29
4.3 Pressed Steel Doors

4.3.1 Material
Steel door frames will be manufactured from commercial mild steel sheet of 1.25 mm thickness,
conforming to IS: 226 and IS: 4351 of the required profile
Steel door frames with or without fan light will be made in the profiles indicated in which may be
manufactured to suit doors of either type opening inwards or outwards as directed by the Engineer-in-
Charge.
4.3.2 Construction
Each door frame will consist of hinge jamb, lock jamb, head and if required angle threshold .These will
be welded or rigidly fixed together by mechanical means. Where no angle threshold is required,
temporary base tie will be screwed to the feet of frames in order to form a rigid unit. Where so specified
base ties will be of pressed mild steel 1.25 mm thick adjustable to suit floor thickness of 35 or 40 mm
and removable, or alternatively, threshold of mild steel angle of section 50x25 mm, minimum will be
provided for external doors frames.
4.3.3 Fabrication
The pressed steel door frames will be got fabricated in an approved workshop as approved by the Chief
Engineer.
Fixing lugs
There will be three adjustable lugs with split end tail to each jamb without fan light, and
four for jamb with fan light.
The head of the fixing lug will be of one of the following lengths
95 mm long for use with profile A
120 mm long for use with profile B
160 mm long for use with profile C
The head will be made from flat steel strip 25 mm wide and not less than 1.60 mm thick.The tail of the
lugs will be 200 mm long and will be made of steel strip not less than 40 mm wide and not less than 1
mm thick.
1. Hinges
2. 100 mm mild steel butt hinges will be used. For door frames 89 cm wide and under, three hinges
will be rigidly fixed to one jamb and for frames for door above 89.0 cm wide, four hinges will
be rigidly fixed to one jamb, if it is single shutter. Where the height of door shutter exceeds 2.15
meters, one additional hinge will be provided for every 0.5 m or part thereof of the additional
height.
3. In all cases the hinges will be so fixed that the distance from the inside of the head rebate to the
top of the upper hinge is 20cm and distance from top of (upper hinge to lower hinge)is about
175 cm.
4. Hinges will be made of steel 2.5 mm thick with zinc coated removable pin of 6 mm diameter.
The space between the two leaves of the hinge when closed will be 3 mm and the leaf that is not
welded to the frame will have four counter sunk holes to take No-10 wood screws.
5. Mortar

SS4-30
6. Guards: Mortar guards as instructed by Engineer-in-Charge will be provided. These will be

welded to the frame at the head of the frame for double shutter doors to make provision for
bolts.
7. Lock-Strike Plate
8. There will be an adjustable lock-strike plate of steel complete with mortar guard to make
provision for locks or latches complying with the relevant Indian Standards. Lock-strike plates
will be of galvanized mild steel and fixed at 95 cm from the head of the frame.
9. Shock Absorbers
For side hung door there will not be less than three buffer of rubber or other suitable material inserted
in holes in the rebate and one will be located on the centre line of the lock strike plate and the other two
at least 45cm above and below the centre line of the lock strike plate. For double shutter doors, there
will be two buffers of rubber or similar suitable material inserted in holes in the rebate in the lock jamb
only at the head and spaced 15 cm at either side of the centre line of the door.
4.3.4 Finish
The surface of doorframe will be thoroughly cleaned, free of rust, mill-scale dirt, oil etc. either by
mechanical means, for example, sand or shot blasting or by chemical means such as picking. After
pretreatment of the surface one coat of approved primer I.e., red oxide zinc chrome primer conforming
to IS: 2074 and two coats of paints as directed by the Engineer-in-Charge will be applied to the exposed
surface.
4.3.5 Fixing
Frames will be fixed up right in plumb. To avoid sag or bow in width during fixing or during construction
phase, temporary struts across the width preventing sides bulging inwards may be provided. Wall will
be built solid on each side and grouted at each course to ensure solid contact with frame leaving no voids
behind the frame.
Three lugs will be provided on each jamb with spacing not more than 75 cm. The temporary struts will
not be removed till the masonry behind the frame is set. In case screwed base tie is provided, this will
be left in position till the flooring is laid when it can be removed. After pretreatment of the surface, one
coat of steel primer and two coats, of paint, as directed by the engineer-in-Charge will be applied to the
exposed surface.
4.3.6 Measurements
As per quoted rates of BOQ
4.3.7 Rate
The rate will include the cost of labour and material involved in all the operations described above
including one coat of approved steel primer but excluding two coats of paint.
4.4 Fire Door

4.4.1 General
The shutter of the door of approved make and will be so designed so as to provide the specified fire
resistance when tested as per IS:3614 (Part 2): 1992 and BS: 476 part 20 & 22 to suit the specified

SS4-31
requirement and the manufacturer must produce certificates of a recognized laboratory to the satisfaction
of the Engineer.
4.4.2 Frame
Door frames of 1.6mm thk G.I. sheet formed to double rebate profile of suitable section as per
manufacturer with heat activated in tumescent fire seal strips of size 10x4mm (for smoke sealing)
mounted in the groove in frame or EPDM gasket to act as smoke seal suitable for mounting 120 minutes
fire rated shutters. Frame to be primed with Zinc-phosphate primer and finished with Polyurethane
aliphatic grade paint or epoxy paint
4.4.3 Sill
The sill will be of 16 SWG G.I. tube (not required in escape route doors).
4.4.4 Shutters
43mm thick light weight asbestos free fire proof doors of 120min. fire rating confirming to BS: 476
Part 22, IS: 3614 Part II fabricated with 2 nos. 1.6mm thick M. S. Sheet with infill material of
Rockwool/Mineral wool/ Honeycomb paper kraft/Polyurethane foam with lock seam joints at stile
edges and internal reinforcement at top, bottom and stile edges for fire rating. The door frames and
door shutters are finished with zinc chromate primer. Shutter to be primed with Zinc-phosphate primer
and finished with Polyurethane aliphatic grade paint or epoxy paint
4.4.5 Hinges
304 grade Stainless Steel ball bearing Hinges of size 125x75x3mm Indian make minimum 4 nos. on
each door.
4.5 Hardware/Fittings
4.5.1 Door Closer:
Fire Rated Briton 121 or equivalent imported from Europe / USA having following specifications:
• Fixed Strength size 3, CE marked

• Certifier Approve CF390 – suitable for fire doors
• Strip steel arm set is pressed for increased rigidity
• Pressure Die Cast Aluminium body
• Hardened and ground steel rack and pinion mechanism for smooth and efficient operation
• High Quality hydraulic fluid with built in temperature compensation ensure reliable
operation between -15degree C to +40degree C
• Independently certified for conformity to all requirements of EN1154, tested to 5,00,000
cycles
• Independently certified for conformity to all requirements of EN1634 fire test (upto
2hours)
• Separate adjustments for both closing speed and latching speed
• Carries a manufacturer ten (10) year warranty

SS4-32
4.5.2 Mortice Lock
Make – Ingersoll Rand / Dorma / Union
Fire Rated Mortice Lock ME 60 / E-Series or equivalent imported From Europe/ USA having
following specifications:
• Lock case European Standard EN12209/DIN18251 and cylinder to EN1303
• Grade 304 stainless steel faceplate to resist fire/corrosion
• Non-handed and field reversible
• Stainless steel 22mm throw deadbolt for high security
• Lock case is in Steel
• Latch/Deadbolt/Follower in Cast Stainless Steel
• Follower suitable for 8mm spindles
4.5.3 Door Co-Ordinator
Ingersoll Rand make ‘IVES’ or equivalent Door Co-ordinator for Double Leaf door co-ordination.
4.5.4 Tower Bolt
304 grade S. S. concealed tower bolt 300mm long Indian make.
4.5.5 Panic Bar/Exit Devices
These will be of press type/ pull type panic bars either single or triple latch. Briton 376 E series or
equivalent imported from Europe/ USA having the following specifications:
• Successfully tested for Panic Application and exceeds the requirement of EN 1125
• Successfully tested for Emergency Application to the requirement of EN 179
• Carries a manufacturer 5yrs. Warranty certificate
4.5.6 Make – Ingersoll Rand/ Dorma/ Union
Seal - An heat activated in tumescent seal of size 10×4mm of approved quality and make or EPDM
gasket will be provided on all edges of door to check the spread of smoke in case of fire.
Paint - The door frame and panel will be primed and finished in polyurethane paint.
Vision panels wherever required, to be fixed with clip on window frames with screws and fasteners on
the surface, fire rated vision glass to be minimum 6mm thick fire glass with clear vision and should have
tested for Thermal Properties and Hose Steam test.

SS4-33
4.5.7 Shop Drawings
The Contractor shall be required to submit detailed shop drawings necessary for carrying out the work
and for information and approval of the Engineer. Any such approval shall in no way absolve the
Contractor from his responsibilities and obligations under the Contract.
These drawings shall be submitted for checking and approval before any manufacturing or fabrication
work is proceeded with.
Drawing submitted shall show complete and detailed particulars, which shall include the following
items: -
• Proper drawings showing full construction, support and fixing details

• Proposed methods of supporting and fixing exterior screens, and louvers.
• Complete specifications of materials and coating used, steel or Aluminium alloys from which
the sections are manufactured including chemical and mechanical properties and detailed results
of tests.
• Details of guarantees covering materials, manufactured items and fixings from manufacturers
(if obtainable) shall be provided to the Engineer.
Shop drawings are specifically required for but not limited to roller shutters, door sets, louvered walling
system, balustrades, handrails, Aluminium suspended ceiling, track canopy, track access stairs, kiosk,
footway bridge cladding and roof structure.
4.5.8 Shop Priming
All ferrous metals except galvanized, chromed, stove enamelled surfaces or stainless steel shall be
cleaned and shop primed with one shop coat of metal primer compatible with later finish coats of paint
All ferrous metals exposed to the weather or attached to the exterior of the building shall receive one
additional coat of metal primer on the concealed surfaces before their installation.
Ferrous metals shall be thoroughly cleaned of all oil, grease, rust, mill scale and other deleterious
materials by solvent cleaning and wire brushing or other approved means.
Shop priming shall be applied immediately after cleaning the metal. Priming shall be applied in dry
weather or under cover and metal surfaces including edges, joints, holes, corners, etc. shall receive
primer and all surfaces which will be concealed after assembly shall be shop primed prior to assembly.
All primers shall be used in accordance with the manufacturer's printed instructions and the use of any
thinner, adulterants, or admixtures shall be only as stated in the instructions. Priming shall be applied
uniformly and completely over the metal surfaces. No work shall be delivered to the Site until the shop-
primed coat has thoroughly dried.
Any damaged or abraded surfaces of the metal items shall have their priming touched up in the shop
and if necessary after assembly on the Site. Touching up primer shall be the same as the primer applied
in the shop.
4.5.9 Protective Coatings
Wherever dissimilar metals will be in contact or wherever galvanized or Aluminium metals will be in
contact or embedded in the concrete, cement, mortar, plaster or masonry, the contact surfaces shall be
separated by coating each contact surface prior to assembly or installation with one coat of bituminous

SS4-34
Aluminium paint which shall be in addition to the specified. shop prime or galvanizing. Those surfaces
not required to receive protective coatings shall be masked off.
4.5.10 Polyester Powder Coating
Polyester powder coating shall be of polyester powder and be applied by a specialist firm approved by
the Engineer to a minimum thickness of 70 microns.
The various colours to be coated are to be selected by the Engineer from the full BS colour range.
Before applying the powder coating, all weld slag, weld spatter, anti-spatter compounds, paints, grease,
flux, rust, burrs and sharp arises are to be removed. All defects which would show after application of
the coating are to be made good and finished smooth.
All surfaces shall be prepared in accordance with the powder manufacturer's recommendations including
de-burring, degreasing, and oven drying.
Powder coating shall be applied after fabrication of the components is complete and all fixing holes
have been drilled unless otherwise specified.
Unless otherwise specified two coats of bitumen solution or mastic impregnated tape shall be applied
before fixing to surfaces of Aluminium in contact with cement or plaster and between dissimilar metals
and alloys where contact could lead to electrolytic corrosion.
4.5.11 Fluorocarbon Coating
4.5.12 General
a) This section specifies the requirements of fluorocarbon coating for extruded Aluminium
sheets and galvanized metal sheets and extrusions.
b) Fluorocarbon coatings shall be carried out by a selected or approved applicator and shall
observe strict factory application requirements as recommended by the coating
manufacturer.
4.5.13 Quality Assurance
The Fluorocarbon coatings shall meet the performance requirements of the AAMA 605.2 - Specification
for high performance Organic Coatings on Architectural Extrusions and Panels.
4.5.14 Coat System
The Fluorocarbon coating for extruded Aluminium and Aluminium sheet shall be factory applied, oven
baked finish. The Fluorocarbon coatings cannot be field applied.
The Fluorocarbon coating system shall be applied to properly cleaned and pre-treated aluminium. The
pre-treatment shall meet ASTM D1730-67, Type B, Method 5 or Method 7_ Processing shall conform
with ASTM B-449-67 (1972) section J. Conversion coating weight shall be between 30-110 mg/sq. ft.
4.5.15 Coating
The Fluorocarbon coating (3 coat system) consist of an inhibitive Primer with dry film thickness
averaging 5 to 7 microns, top-coat (colour coat) with a minimum dry film thickness of 25 microns and

SS4-35
a clear top coating with a minimum dry film thickness of 10 to 20 microns. The total minimum dry film
thickness of the 3 coat system shall be 40 microns.

SS4-36
Chennai Metro Rail Project – Phase 2, Corridor 5 Part-2, Section VII
TENDER No. CP06/UG06/RT01 Employer’s Requirments
TECHNICAL SPECIFICATION
FOR
PLUMBING WORKS
Section VII -Outline Construction Specification SS5-1 December 2021
Sub-Section 5 -Plumbing & Earthmat

1 SCOPE OF WORK
1.1 Scope under this contract shall include preparation of the shop drawings, supply of
materials, installation, testing and handover of plumbing works indicated below as per
the drawings and specifications.
a) Embedded piping work in earth, RCC, PCC and walls
b) Pump pedestals and lifting arrangements
c) Plumbing and drainage appurtenances.
d) Puddle flanges and sleeves
e) Municipal water, storm water & waste water sewer connections approval
f) Inspection chambers & Sump.
g) Bore well and pump
2 STANDARDS, CODES AND REGULATIONS

2.1 The entire system and its basic components shall comply in all respect to the relevant
International Standards and regulations of the National Building Code of India (NBC),
and Bureau of Indian Standards.
2.2 In addition to the International Standards and NBC listed in the Technical
Specifications, the Installation shall also be governed by all applicable local codes,
regulations, standards and requirements issued by all the Local Authorities, agencies
and services providers. Given below is the list of standards to be followed at least,
note that this list is not exhaustive
IS: 8321 Glossary of terms applicable to plumbing work
IS: 554 Dimensions for pipe threads where pressure tight joints are
IS: 782 Specification for caulking load
IS: 1172 Code of Basic requirements for water supply, drainage and sanitation
IS: 2065 Code of practice for water supply in buildings
IS: 2379 Colour code for identification of pipe lines
IS: 5329 Code of practice for sanitary pipe work above ground for buildings
IS: 9668 Code of practice for provision and maintenance of water supplies and fire
fighting
IS: 9912 Coal tar based coating materials and suitable primers for protecting iron and
steel pipe lines
IS: 10446 Glossary of terms relating to water supply and sanitation
IS: 11149 Rubber Gaskets
IS: 11790 Code of practice for preparation of butt-welding ends for pipes, valves, flanges
and fittings
IS: 12183 (Part 1) Code of practice for plumbing in multistoried buildings: Part 1 water supply

IS: 5572 Code of practice for sanitary pipe work

IS: 8329 Centrifugally Cast (Spun) Ductile Iron Pressure Pipes for Water, Gas & Sewage
Specification
IS: 9523 Ductile Iron Fittings for Pressure Pipes for Water, Gas & Sewage-Specification
3 SPECIFICATIONS
3.1 Work under this contract shall be carried out strictly in accordance with specifications
attached with the tender.
3.2 Item not covered under these specifications due to any ambiguity or misprints, or
additional works, the work shall be carried out as per specifications of the latest central
public works department with latest amendments as applicable in the contract.
3.3 Works not covered under Para 2.1 and 2.2 shall be carried out as per relevant Indian
standards or codes of practice.
4 EXECUTION OF WORK
4.1 The work shall be carried out in conformity with the plumbing drawings and within the
requirements of architectural, Electrical, Structural and other specialized services
drawings.
4.2 The contractor shall cooperate with all trades and agencies working on the site. He
shall make provision for sleeves, structural openings and other requirements well in
advance to prevent hold up of progress of the construction programme.
4.3 On award of the work, contractor shall submit a programme of construction in the form
of a pert chart or bar chart for approval of the Employer. All dates and time schedule

agreed upon shall be strictly adhered to, within the stipulated time of
completion/commissioning along with the specified phasing, if any.
5 DRAWINGS
5.1 Plumbing drawings are diagrammatic but shall be followed as closely as actual
construction permits. Any deviations made shall be in conformity with the architectural
and other services drawings.
5.2 Architectural drawings shall take precedence over plumbing or other services
drawings as to all dimensions.
5.3 Contractor shall verify all dimensions at site and bring to the notice of the Employer
all discrepancies or deviations noticed. Employer’s decision shall be final.
5.4 Large size details and manufacturers dimensions for materials to be incorporated shall
take precedence over small-scale drawings.
5.5 Any drawings issued by the Employer for the works are the property of the Employer
and shall not be lent, reproduced or used on any works other than intended without
the written permission of the Employer.
5.6 SHOP DRAWINGS

5.6.1 The contractor shall submit to the Employer four copies of the shop drawings.
5.6.2 Shop drawings shall be submitted under following conditions:
a) Showing any changes in layout in the plumbing drawings.
b) Equipment layout and piping, wiring diagram.
c) Manufacturer's or contractor's fabrication drawings for any materials or equipment
supplied by him.
5.6.3 The contractor shall submit four copies catalogues, manufacturers drawings,
equipment characteristic data or performance charts as required by the Employer.
5.7 AS BUILT DRAWINGS

5.7.1 On completion of work, contractor shall submit one complete set of original tracings
and two prints of 'as built' drawings to the Employer. These drawings shall have the
following information:
a) Run of all piping & diameters on all floors and vertical stacks.
b) Ground and invert levels of all drainage pipes together with location of all
manholes and connections up to outfall.
c) Run of all water supply lines with diameters, locations, of control valves, access
panels.
d) Location of all mechanical equipment with layout and piping connections.

e) Contractor shall provide four sets of catalogues, performance data and list of
spare parts together with the name and address of the manufacturer for all
Plumbing, electrical and mechanical equipment provided by him.
f) All 'warranty cards' given by the manufacturers shall be handed over to the
Employer.
6 PUMPS FOR BORE WATER SUPPLY

6.1 Scope
6.1.1 This section shall involve that the supply, installation, testing and commissioning of
borewell pump with control panels and electrical work.
6.1.2 All installation work shall comply with the latest rules and regulations.
6.1.3 The scope of work shall include the following (list is indicative and not exhaustive):
a) pumping unit’s for bore water supply.
b) Control panel for pump control complete with circuit breakers, fuses, etc.
complete with all interconnections between pumps and panels.
c) Provision of all hold down bolts, spigots struts and the like required to be built in
during construction.
d) Provision of dry contacts to BMS indicating the status of the pumps in form of
hardware interfacing panels inside pump room and control panels of pumps.
e) All interfacing work with other trades.
f) Testing and commissioning and balancing of the Pumping system.
g) Provision of twenty-four (24) months operational maintenance and breakdown
services.
h) Provisions of operating instructions and maintenance manuals.
i) Liaison with Local Authorities to obtain all necessary certificates and approvals,
including the completion of all submission drawings, forms and payment of any
fees and charges. All the costs for all the tests required by Local Authorities shall
be included. To attend to any Authorities inspection regardless of whether this
6.2 Bore well
6.2.1 General conditions
6.2.1.1 The boring work shall be carried out in an orderly and systematic manner in
accordance with a programme prepared in consultation with the Engineer. The
contractor shall clear the site of any trees, shrubs, grass and rubbish to enable the
proper execution of the work. On successful completion of the work the contractor
shall clean the site of all surplus material, equipment and accessories, to the
satisfaction of the Engineer.
6.2.2 Requirement
6.2.2.1 The location of borewell shall be finalised in station premises by water divining
(Electric resistivity method). The total yield from each tube well shall be minimum
20,000 litres per day, with a possible continuous operation of bore well for up to

max of 10 hours per day. Bore well will be bored by a suitable method, with the
help of standard rig for 300 mm dia bore, 200mm dia casing consisting of blind and
slotted pipes and with gravel packed complete as per instruction of The Engineer.
The bore shall be carried out up to a depth instructed by The Engineer.
6.2.3 Boring
6.2.3.1 Boring shall be 300 mm dia. Plain casings pipe shall 200 mm dia UPVC pipe
confirming to IS 4985 Class III. Slotted pipes shall be 200mm dia UPVC pipe
confirming to IS 4985 Class III. The slots shall be made by machine/ blade cutting.
Well assembly shall be truly vertical. Space between boring and well assembly
shall be packed with washed pea gravel 3 to 5 mm size. The well shall be
developed by an air compressor for a period until the development is satisfactory.
6.2.4 Test data
6.2.4.1 The contractor shall provide necessary data regarding strata, yield and depression.
Yield tests shall be conducted by providing a suitable channel and V-notch and
reading taken over a period of 48 hours at intervals of 2-3 hours and in the presence
of The Engineer. The well drawdown & recovery pump tests as per Indian
standards shall be conducted for assessing the well yield. Any test done by filling
buckets, drums etc. will not be accepted as the final yield.
6.2.4.2 The contractor shall get the water tested for the quality of water by a Laboratory,
as specified by the Engineer. Tests shall be Bacteriological and physical and
chemical examinations. (Tests shall be performed after development of the well).
6.3 Bore well Pump
The pump shall be of latest standard designed to give maximum efficiency when
operated under most exacting condition at speed 1500/ 3000 rpm. The equipment
shall confirm to the following specifications as per IS 8034 – 1996.
6.3.1 PUMP BOWL
6.3.1.1 The pump bowl shall be manufactured to offer resistance to corrosion. The bowls
maybe equipped with replaceable bearing.
6.3.1.2 The bowl assembly shall bear a name plate giving the following information.
a) Name of the manufacturer or trade mark
b) Serial Number of the pumpset
c) Pump type
d) Number of stages
e) Total head
f) Capacity
g) Speed
6.3.2 IMPELLERS
6.3.2.1 The impellers shall be closed type with stainless steel material conforming to IS
6603 (SS 316). They shall be turned and accurately finished and balanced on their

own pump shaft for maximum lifting capacity without overloading the prime mover
irrespective of water level fluctuations. The impeller shall be of the enclosed type
and shall be properly balanced. Dynamic balancing is recommended. Enclosed
impellers shall be equipped with sealing rings on their hubs.
6.3.3 PUMP SHAFT
6.3.3.1 The pump shaft shall be stainless steel of ample size and stiffness to transmit
maximum power without strain or vibration. The pump shaft shall be guided by
bearings provided below and above the impeller shaft assembly. The shaft without
protecting sleeves shall have a surface finish of 0.75 micron.
6.3.4 BEARING SLEEVE
6.3.4.1 The bearing sleeve shall be of stainless steel 304 conforming to IS 6603.
6.3.5 COUPLING
6.3.5.1 A suitable coupling arrangement shall be provided in case of directly coupled
pumpsets.
6.3.6 NON-RETURN VALVE
6.3.6.1 Non return valve shall be provided above the pump discharge case. It shall be
inbuilt type with Stainless steel material conforming to IS 6603 (SS 304).
6.4 SUBMERSIBLE MOTORS
6.4.1 General
6.4.1.1 The submersible motor shall be wet type, squirrel cage induction motor suitable for
operation on 380/440 volts, 3 phase 50 Cycles AC supply and capable of
developing the required HP at a speed 1500/3000 RPM with class-F insulation.
The motor windings and the bearing bushes of the rotor shaft shall be lubricated
by pure water / oil, filled in the motor before erecting the pump set. The motor shall
confirm to IS 9283 – 1979
6.4.1.2 The motor shall be connected by means of cable glands rubber seals etc., from
inside of borewell to arrest the entry of sand and other foreign matter. The motor
shall be provided with a breathing attachment like bellows diaphragm etc., to
compensate the Volumetric variation due to changes in the temperature. The motor

shall be made of corrosion resisting materials or suitably treated materials to resist

corrosion under normal condition.
6.4.2 BEARINGS
6.4.2.1 The thrust bearing shall be of adequate size to withstand the weight of all rotating
parts as well as the imposed hydraulic thrust. These shall be lubricated suitable.
6.4.2.2 The thrust bearing housing shall be provided with a drain plug to empty the oil pure
water filled into thrust bearing housing rotor.
6.4.3 Motor rotor Shaft
6.4.3.1 The rotor shaft shall be provided with shaft protective sleeves having a surface
finish of 0.75 micron.
6.4.4 OUTPUT
6.4.4.1 The motor shall be capable of developing the Mechanical output for the required
conditions and shall have continuous normal rating to suit the maximum load when
operated at the pump speed.
6.4.5 TECHNICAL DATA
6.4.5.1 The motor HP shall be such that to safely take the load when the total head is
reduced by the rise of water level.
6.4.5.2 The H.P. of the motor offered shall have a Margin above the H.P. absorbed by the
pump set at duty point and also above the maximum BHP absorbed by the pump
set offered.

6.4.6 OVERLOAD CAPACITY

6.4.6.1 The motor shall be capable of withstanding the over load specified in the relevant
condition of BIS.
6.4.7 STARTING
6.4.7.1 The motor shall give full load torque when taking 1 to 1.5 times full load current.
6.4.7.2 The motor shall have a name plate giving the following information.
a) Induction motor
b) Name of manufacturer
c) Manufacturers number & frame reference
d) Type of enclosure
e) B.H.P
f) Rated voltage and winding connections
g) Rated output in K.W.
h) Number of phases
i) Frequency in HZ
j) Current approximate in amperes at rated output
k) Speed in revolutions per minute at rated output
6.4.8 Motor Starter Panel
6.4.8.1 The Starter Panel Power supply: 230-440V, 50 Hz + 3%, three-phase, 4 wires, in
built with single phase preventer, Indicator lamp, 3 pole MCB, Pump controller,
Conductor, current sensing for dry run protection. Control Panel shall comprise of:
a) starter with overload protection for Pump,
b) Main circuit breaker,
c) ON/OFF button,
d) Hour-meter to indicate total hours of operation,
e) Start/Stop button with lamp indicating Pump operation,
f) Indicator for auto operation,
g) Easy access for service points,
h) Thermal/magnetic protection for each appliance,
i) Single phasing protection.
j) The location of this cabinet shall be proposed according to its dimensions
and the electrical power supply distribution point. The starter enclosure must
be of IP65 rating.
k) All terminal boards and power supply cables shall be marked in accordance
with the electrical schematic diagrams.

l) The functions of the main components shall be identified by engraved labels

whose contents shall be identical to the electrical schematic diagrams
m) Control panel shall be floor/wall-mounted factory built assemblies with
necessary support fixing arrangement including foundation, frame, fixing bolt
nuts etc..
6.4.9 Installation, Commissioning and Guarantees
6.4.9.1 Installation
a) The pumps and accessories shall be installed in a true workman like manner
true to level and grade in accordance with the best current practice.
b) Vendor shall employ sufficient and proper equipments for lifting and placing of
pumping equipment, in a manner which shall not strain or cause damage to
the existing structures. If any damage is done, the same shall be made good
to the satisfaction of the Engineer without any additional cost.
c) The vendor shall submit detailed shop drawing showing sizes of all piping,
valves, etc. for approval. The work shall be started only after approval of shop
drawing
6.4.9.2 Commissioning
a) On completion of the work in all aspects, the vendor shall start up the pumps
in a manner normally done for the continuous operation for a period of not less
than 48 hours and shall rectify and adjust the pumps and equipments for
leakages and balancing the system.
b) After satisfactory commissioning of the pumps, the vendor shall conduct
performance tests to satisfy the Engineer that all pumps and equipments are
performing to the rated outputs. Any or all pumps and equipment shall be
rectified or replaced if the same is not performing in accordance with the
specifications.
6.4.9.3 Guarantees
a) On award of the work the vendor shall submit a guarantee covering the quality
and performance of all materials and installations under the contract. This
guarantee shall cover each and every material whether manufactured by the
contractor or not.
Vendor shall specify a suitable procedure to test the rated performance of the
equipment and the system and shall provide all necessary equipments,
gauges, etc. for conducting such tests.

6.4.10 Bore well Data

a) Yield required : 60 lpm for 2 hours
b) Bore : 300 mm
c) Approximate Depth : 120 m (As per Water Table at site condition)
d) Drilling : DTH cum Rotary Rig / Calyx
e) Assembly : Blind/Slotted Pipes -200mm dia upto complete
depth
f) Material : UPVC pipe confirming to IS 4985 Class III
g) Verticality : True verticality as per IS 2800 -1979.
h) Packing : Pea Gravel.
i) Developing : Till sand free discharge is obtained
j) Location of Tube well : Proposed Site
k) Water for drilling : Contractor shall make his own arrangement for
water required for drilling purposes as well as
for development of tube well.
6.4.10.1 Samples of drill cuttings shall be collected at regular depth intervals of three metres
or whenever there is a change in strata encountered. The samples shall be dried,
labeled & preserved for study and preparation of a lithological log.
6.4.10.2 The design for the bore well indicating the depth range of aquifer zones to be
tapped shall be given after a detailed study of the data collected during drilling
operations.
6.4.10.3 The annular space between the borehole and tube-well assembly shall be packed
with well graded pea gravel of good quality, durability and high sphericity.
6.4.10.4 The bore wells shall be developed with an air compressor/Over Pumping Unit till
the water becomes clear and sand free at maximum discharge. As per IS "the
development of tube-well by over pumping shall be done to 25% higher discharge
than the expected discharge from the tube-well. The final discharge shall be free
from sand with a maximum tolerance of 20 PPM of water by volume after 20
minutes of starting pump". A three metre long blank pipe with bail plug shall be
welded to the bottom of the lower most slotted pipe which will act as a receptacle
for the traces of sand that may come with the water in the initial periods of pumping
and prevent slotted pipes from getting choked.
6.4.10.5 Contractor shall conduct constant discharge pumping test for a continuous duration
of 12-16 hours of pumping. During the test, depth of water table measurements
should be made at regular time intervals, both during pumping & recovery periods.
These data are essential to draw the Specifications of pump to be installed and
evaluate the yield characteristics of the tube-well.
6.4.10.6 Contractor shall collect water samples (about 2 liters) in a double stopper sterilized
plastic container (after rinsing it thoroughly with the tube-well water) for chemical

analysis for the determination or various constituents as per the requirements of

process / drinking water standards.
6.4.10.7 Tube well shall be sealed with PCC blocks of appropriate size.
6.4.11 Control of Bore well Pump
6.4.11.1 Operation of the pump shall be carried out by the following method:
a. Automatic controls shall be operated the alarm by level switches in the
Domestic water tank.
b. Manually by means of a local start/stop push buttons on pump local motor
control panel and emergency stop switch.
c. When the water level drops to the pre-determined level, the alarm will start
thro’the low level switch (Pump will start by manually) and when the water level
reaches the high level the pump will be stopped thro’the high level switch.
6.4.12 Pump Indicator

6.4.12.1 The following audible and visible indication shall be provided at the pump local
control panel as applicable:
a. Red "overflow level" indicator with buzzer for the associated water tanks;
b. Amber "high water level" indicator;
c. Amber "low water level" indicator;
d. Amber "pump trip" indicator
e. Red" pump on" indicator
f. Green “Pump off’’ indicator
g. "Pump electrical supply healthy" indicator
h. Amber "remote/local" status indicator
6.5 Warranty period and services

6.5.1 The contractor shall ensure adequate and prompt services during warranty period,
in the form of maintenance, spares and personnel as and when required and shall
minimize the breakdown period.
6.5.2 The manufacturer shall provide a warranty period of 2 years for above pump
(Borewell Pumps).

7 PIPES & FITTINGS FOR WATER SUPPLY & DRAINAGE

SYSTEM
7.1 G.I. PIPING WORK (Concealed):
7.1.1 GENERAL: The item includes provision of G.I. pipes with G.I. fitting of specified nom.
bore and class as mentioned in the schedule including laying, fixing. The G.I. pipes
and fittings shall run on the surface of the walls or ceilings unless otherwise specified.
7.1.2 MATERIAL: The pipes and fittings shall be of M.S. galvanised as specified in the
schedule. They shall conform to IS 1239 (P-I). All the pipes and fitting shall have ISI
certification mark. The specified nominal bore of the pipe shall refer to inside
approximate bore according to the thickness corresponding to outside fixed diameter.
The pipe and fittings shall be smooth, sound, free from any imperfections and neatly
dressed. The pipe and fitting shall be able to withstand a hydrostatic test pressure of
1 MPa (10 Kg/cm2) maintained for at least 3 seconds at manufacturing works (lab
test). The table showing the dimensions and different bores of pipes are given below.
7.1.3 CHASES: Chases of size 75 mm x 75 mm shall be cut in the wall, floor, slab wherever
required or as directed by chases cutting machine. After testing the pipe line the
chases shall be filled with cement mortar 1:3 and surface made good to its original
condition.
7.1.4 LAYING: The plumbing contractor shall set the layout of the plumbing approved by
the Engineer as shall be required by the bye-laws. Pipes shall be laid in plumb and in
straight and parallel lines. No lime plaster or composition containing lime shall be
allowed to come in direct contract with the pipe, which are to be concealed as the pipe
is affected by lime.
7.1.5 FIXING: The entire pipeline shall be fixed in position as shown in the drawing or as
directed by the Engineer. All pipes and fittings, which are to be concealed, shall be
properly embedded in the wall, flooring etc. after being treated. No moulding or plaster
design or any ornamental plaster work shall be done over the walls or flooring or
ceiling where concealed pipes have been laid.
7.1.6 If the pipe is required to be cut and the end threaded, the burns of the cut end shall
be filed smooth and any obstruction in bore shall be entirely eliminated.
7.1.7 JOINTING: While fixing the pipe line the joints shall be made by applying a few turns
of hemp yarn dipped in linseed oil shall be taken over the threaded end of the pipe
and socket screwed home using the pipe wrench, pipe connected shall touch each
other and the socket covering each end about equally. The branch connection shall
not protrude in the bore of parent pipe.
7.1.8 PAINTING: All the concealed piping work shall be thoroughly painted with two coats
of anti-corrosive black bitumastic paint of approved quality shade over a coat of
approved primer before concealing and filling the mortar.
7.1.9 WRAPPING: After painting the cold water pipe line, it shall be wrapped with two layers
of hessian cloth of approved quality.
7.1.10 TESTING: The pipes and fittings after they are laid and jointed shall be tested to
hydraulic pressure of 1 MPa (10 Kg/sq.cm). The pipes shall be slowly and carefully
charged with water allowing all air to escape and avoiding all shock or water hammer.
The draw off taps and stop cocks shall then be closed and specified hydraulic

pressure shall be applied gradually, Pressure gauge must be accurate and preferably
should have been recalibrated before the test. The test pump having been stopped,
the test pressure should be maintained without loss for at least 2 (two) hours. The
pipes and fittings shall be tested in sections as the work of paying proceeds, having
the joints exposed for inspection during the testing. Pipes or fittings which are found
leaking shall be replaced and joints found leaking shall be redone, without extra
payment.
7.2 CPVC PIPES & FITTINGS
7.2.1 The pipes shall be CPVC (Chlorinated Poly Vinyl Chloride) material for hot & cold
water supply piping system with pipes as per CTs SDR -11 at a working pressure of
320 PSI at 23 deg C and 80 PSI at 82 deg.C, using solvent welded CPVC fittings i.e.
Tees, Elbows, Couples, Unions, Reducers, Brushing etc. including transition fittings
(connection between CPVC & Metal pipes / GI) i.e. Brass adapters (both Male &
Female threaded and all conforming to IS 554 with only CPVC solvent cement
conforming to IS 14182, with clamps / structural metal supports as required /directed
at site including cutting chases & fitting the same with cement concrete / cement
mortar as required, including painting of the exposed pipes with one coat of desired
shade of enamel paint.
7.2.2 All termination points for installation of faucets shall have brass termination fittings.
Pipes from 65 mm to 150 mm dia shall be Schedule 40 for CWC & Schedule 80 for
HWS / HWR.
7.2.3 Joining Pipes & Fittings
7.2.3.1 Cutting:
Pipes shall be cut either with a wheel type plastic pipe cutting or hacksaw blade and
care shall be taken to make a square cut which provides optimal bonding area within
a joint.
7.2.3.2 Deburring / Beveling:
Burrs and fittings should be removed from the outside and inside of pipe with a pocket
knife or file otherwise burrs and fittings may prevent proper contact between pipe and
fittings during assembly.
7.2.3.3 Fitting preparation:
A clean dry rag/cloth should be used to wipe dirt and moisture from the fitting sockets
and tubing end. The tubing should make contact with the socket wall 1/3 or 2/3 of the
way into the fitting socket.
7.2.3.4 Solvent Cement Application:
Only CPVC solvent cement confirming to ASTM-F493 should be used for joining pipe
with fittings. An even coat of solvent cement should be applied on the pipe end and a
thin coat inside the fitting socket, otherwise too much of cement solvent can cause
clogged water ways.
7.2.3.5 Assembly:
After applying the solvent cement on both pipe and fitting socket, pipe should be
inserted into the fitting socket within 30 seconds and rotating the pipe ¼ to ½ turn
while inserting so as to ensure even distribution of solvent cement with the joint. The

assembled system should be held for 10 seconds (approximately) in order to allow

the joint to set up.
An even bead of cement should be evident around the joint and if this bead is not
continuing remake the joint to avoid potential leaks.
a) Set & Cure times:
Solvent cement set and cure times shall be strictly adhered to as per the below
mentioned table.
b) Minimum Core prior to pressure testing at 150 PSI
Ambient Temperature Pipe Size

during
½ " - 1" 1.¼" - 2"
Core period
Above 15 deg. C 1 Hr 2 Hrs
4-15 deg.C 2 Hrs 4 Hrs
Below 4 deg C 4 Hrs 8 Hrs
Special care shall be exercised when assembling flow guard systems in extremely
low temperature (below 4°C) or extremely high temperature (above 45°C) In
extremely hot temperatures, make sure that both surfaces to be joined are till wet with
cement solvent when putting them together.
7.2.3.6 Testing
Once an installation is completed and cored as per above mentioned
recommendations, the system should be hydrostatically pressure tested at 150 psi
(10 Bar) for one hour. During pressure testing, the system should be fitted with water
and if a leak is found, the joint should be cut out and replacing the same with new one
by using couplers.
7.2.4 Transition of Flow guard CPVC to Metals
7.2.4.1 When making a transition connection to metal threads, special Brass / plastic
transition fitting (Male and female adapters) should be used. Plastic threaded
connections should not be over torqued Hard tight puts one half turn should be
adequate.
7.2.5 Threaded Sealants
7.2.5.1 Teflon tape shall be used to make threaded connections leak proof.
7.2.6 Solvent Cement
7.2.6.1 Only CPVC solvent cement conforming to ASTMF 493 should be used for joining pipe
with fittings and valves. Flow guard CPVC cement solvent have a minimum shelf life
of 1 year. Aged cement solvent will often change colour or being to thicken and
become gelatinous or jelly like and when this happens, the cement should not be
used. The cement solvent should be used within 30 days after opening the company’s

seal and tightly close the seal after using in order to avoid its freezing. The freezed
cement solvent should be discarded immediately and fresh one should be used. The
CPVC solvent cement usage should be adhered to as given in table below
Diameter of pipe in inch

2
½” ¾” 1” ¼” 1½”
(flow guard) ”
Approx. nos. of joints which 1

can be mode per litre of 7
8
solvent cement. 0
200 1500 130 100
Nos NosN Nos Nos N
o
o
s
s
7.2.7 Hangers and supports
7.2.7.1 For Horizontal runs, support should be given at 3-foot (90 cm) intervals for diameters
of one inch and below and at 4-foot (1.2m) intervals for larger sizes.
7.2.7.2 Hangers should not have rough or sharp edges which come in contact with the tubing.
7.2.7.3 Supports should be as per the below mentioned table:
Size of Pipe 21°C 49°C 71°C 82°C
Inch Ft. Ft. Ft. Ft.
½” 5.5 4.5 3.0 2.5
¾” 5.5 5.0 3.0 2.5
1” 6.0 5.5 3.5 3.0
1¼” 6.5 6.0 3.5 3.5
1½” 7.0 6.0 3.5 3.5
2” 7.0 6.5 4.0 3.5
7.3 DI (Ductile Iron) Pipes and Fittings for Waste Pumping Appliances
7.3.1 DI pipes and fittings (Class K9 for Municipal main and Class K7 for drain pipes) shall
be in accordance with IS 8329 and IS 9523. Pipes and fittings shall be procured from
reputed manufacturers and with the Services Consultant / Client / Project Manager /
Architect’s approval. The Engineer shall at all reasonable times have free access to

the place where the pipes and fittings are manufactured for the purpose of examining
and testing the pipes and fittings and for witnessing the test and manufacturing.
7.3.2 All tests specified either in this specification or in the relevant Indian Standards
specified above shall be performed by the supplier/Contractor at his own cost and in
presence of the Engineer if desired. For this, sufficient notice before testing of the
pipes and fittings shall be given to the Engineer.
7.3.3 If the test is found unsatisfactory the Engineer may reject any or all pipes and fittings
of that lot. The decision of the Services Consultant / Client / Project Manager /
Architect’s in this matter shall be final and binding on the Employer and not subject to
any arbitration or appeal.
7.3.4 The pipes and fittings shall be stripped, with all precautions necessary to avoid
warping or shrinking defects. The pipes and fittings shall be free from defects. Any
defect in pipes and fittings in the opinion of the Engineer shall be rejected and shall
be replaced by new one.
7.3.5 In the case of spigot and socket pipes and fittings the socket shall be without the
center ring.
7.3.6 In the case of flanged pipes, the flanges shall be at the right angles to the axis of the
pipe and machined on face. The bolt holes shall be drilled and located symmetrically
off the centre line. The bolthole shall be concentric with the bore and boltholes equally
spaced. The flanges shall be integrally cast with the pipes and fittings and the two
flanges of the pipe shall be correctly aligned.
7.3.7 Materials
7.3.7.1 The materials used in the manufacture of pipes and fittings shall comply with
requirements specified in IS 8329 and IS 9523.
7.3.8 Dimensions and Tolerances
7.3.8.1 The internal diameter, thickness and length of barrel, dimensions of pipes and fittings
shall be as per relevant tables of IS 8329/IS 9523 for different class of pipes and
fittings. Each pipe shall be of uniform thickness throughout its length.
7.3.8.2 The tolerances for pipes and fittings regarding dimensions, mass, ovality and
deviations from straight line in case of pipes shall be as per IS 8329/IS 9523.
7.3.9 Testing
a) Mechanical Tests
Mechanical tests shall be carried out during manufacture of pipes and fittings as
specified in IS 8329 / IS 9523. The frequency and sampling of tests for each batch
of pipes shall be in accordance with IS 8329. The test results so obtained for all
the pipes and fittings of different sizes shall be submitted to the Engineer. The
method for tensile tests and the minimum tensile strength requirement for pipes
and fittings shall be as per IS 8329/IS 9523.
b) Brinell Hardness Test
For checking the Brinell hardness, the test shall be carried out on the test ring or
bars cut from the pipes used for the ring test and tensile test in accordance with IS
1500. The test shall comply with the requirements specified in IS 1500/IS 8329.

c) Retests
If any test piece representing a lot fails in the first instance, two additional tests
shall be made on test pieces selected from two other pipes from the same lot. If
both the test results satisfy the specified requirements, the lot shall be accepted.
Should either of these additional test pieces fail to pass the test, the lot shall be
liable for rejection.
d) Hydrostatic Test
For hydrostatic test at works, the pipes and fittings shall be kept under test pressure
as specified in IS 8329 / IS 9523 for a period of minimum 15 seconds, during which
the pipes shall be struck moderately with a 700 g hammer for conformation of
satisfactory sound. They shall withstand the pressure test without showing any
leakage, sweating or other defect of any kind. The hydrostatic test shall be
conducted before surface coating and lining.
7.3.10 Joints
a) General
Jointing of DI pipes and fittings shall be done as per IS 12288 and manufacturer's
recommendations. After jointing, extraneous material, if any, shall be removed from
the inside of the pipe. Rubber sealing rings/gaskets used for jointing shall conform
to IS 638, IS 12820 and IS 5382.
b) Flanged joints
These shall be of PN 1.6 rating and shall comply with dimensions and drilling
details as specified in IS 8329. These shall have isolation gaskets between the
flanges, isolation sleeves around all bolts and isolation washers under all bolt
heads and nuts. All material shall be supplied by a reputed manufacturer and shall
be approved by the Engineer.
Each bolt should be tightened a little at a time taking care to tighten diametrically
opposite bolts alternatively.
c) Gaskets for Flanges
All gaskets used between flanges of pipes shall be of natural rubber conforming to
IS 638 of thickness 3 mm suitable for clear water conveyance and as specified by
manufacturer.
7.3.11 Coatings
a) General
Unless otherwise specified, DI pipes and fittings shall be coated with Bitumen in
accordance with relevant IS specification. All buried DI pipes and fittings shall also
have factory or site applied polythene sleeving. Coating shall not be applied to
pipe and fittings unless its surface is clean, dry and free from rust. Pipe coatings
shall be inspected at site and any damage or defective areas shall be made good
to the satisfaction of the Engineer.
b) Bitumen coating
Bitumen coating shall be of normal thickness of 75 microns unless otherwise
specified. It shall be cold applied compound complying with the requirements of

relevant Indian standards, suitable for tropical climates, factory applied in

Damaged areas of coating shall be repainted on site after removing any remaining
loose coating and wire brushing any rusted areas of pipe.
c) Polythene Sleeving
Where polythene sleeving is specified to be applied in addition to bitumen coating
above it shall comply with ISO 8180. Site applied sleeving shall be stored under
cover out of direct sunlight and its exposure to sunlight shall be kept to a minimum.
Pipes having a factory applied sleeving must be stored in the same conditions.
Joints in the sleeving shall be properly overlapped and taped in accordance with
manufacturer's instructions to provide in continuous sleeving.
d) Cement mortar lining
All pipes and fittings shall be internally lined with cement mortar in accordance with
BIS: 11906. Cement mortar lining shall be applied at the factory in conformance
with the above mentioned standards. No admixtures in the mortar shall be used
without the approval of the Engineer.
Pipe linings shall be inspected on site and any damage or defective areas shall be
made good to the satisfaction of the Engineer.
Lining shall be uniform in thickness all along the pipe. The minimum thickness of
factory applied cement mortar lining shall be 3mm for up to DN 300 mm pipes.
e) Marking
Marking shall be done as per IS 8329 and IS 9523 or any other relevant IS codes.
7.3.12 Installation
7.3.12.1 All piping shall be installed parallel to, or at right angles with, the building
walls and partitions. A pitch in the direction of flow and drain shall be not
less than 1:500. Branches from mains shall be taken in a manner to facilitate
venting and draining. Reductions in bore shall be formed eccentrically to facilitate
venting, except on vertical pipes where concentric reduction shall be used.
7.3.12.2 All piping shall be installed in such a way that all circuits can be completely
drained off and all air pockets in the water circuits shall be suitably vented.
Clearance between pipe works and equipment or machinery shall be
adequately provided to facilitate maintenance. Overhead clearance shall be at
least 600 mm over access ways, and where possible the projection of valve stems
into access ways shall be avoided. Pipe works and pumps shall be so arranged
that the removal for maintenance of the equipment can be carried out with
minimum dismantling. Provision of all pipe fittings and accessories necessary
for the efficient functioning of the various systems shall be included.
7.3.12.3 All pipes shall be installed in an appropriate manner to present a neat and
orderly appearance, using fittings for all changes of direction, and arranging pipe
run parallel or at right angles with structural members of the building, to provide

utmost head-room and to clear lights and other obstructions. In general, suspended
pipes shall be installed as closely as possible to the overhead structure.
7.4 CAST IRON SOIL QUALITY PIPING WORK:
7.4.1 GENERAL
7.4.1.1 The item includes supplying of soil quality CAST IRON pipe of specified diameter
with fittings and fixtures including laying, fixing, cutting, jointing and painting the
pipe line.
7.4.2 MATERIAL
7.4.2.1 Cast Iron soil quality pipes and fittings shall have ISI certification mark. Sand -Cast,
Cast Iron Soil quality or rain water pipes and fittings shall confirm to IS 1729 and
centrifugally cast (Spun Cast) cast iron soil quality pipe shall confirm to IS 3989.
All the pipes and fittings shall be cylindrical reasonably true with inner and outer
surfaces and nearly concentric as practicable. The outer surface of the pipe and
fitting shall be finished well, sound, free from pin hole, cracks and other
imperfections. The pipes & fittings shall be treated with solution of Dr. Angus
Smith’s solution.
Nominal weight for pipes of overall length (L) (Exclusive of ears)

Nominal Thickness
S.No 2.0 m 1.80m 1.50m 1.20m 0.90m 0.75m 0.6m 0.45 m 0.3m
Dia. of wall
kg kg kg kg kg kg kg kg Kg
2 75 mm 5 mm 18.37 16.52 13.83 11.5 8.8 7.5 6.1 4.8 3.4
3 100 mm 5 mm 24.15 21.67 18.14 15.1 11.6 9.8 8 6.3 4.5
4 150 mm 5 mm 35.66 31.92 26.7 22.6 17.3 14.7 12.1 9.5 6.9
7.4.2.2 The dimensions, weight of Sand-Cast Iron/ Ductile Iron pipes and fittings shall be
as per following table of IS 1729 – 2002 or its latest revision.
7.4.3 EXAMINING:
7.4.3.1 Before laying the pipe line, it shall be first examined for damages and cracks. No
cracked or damaged pipe and fittings shall be used in the work and they shall
remove from the site by the contractor at his own cost & charge.
7.4.4 CLEANING:
7.4.4.1 All pipes and fittings shall thoroughly cleaned with brush and washed if necessary
to remove any accumulated stone, soil or dirt inside and out side of piping material.
7.4.5 FIXING:
7.4.5.1 The pipe shall be fixed as shown in the drawing. If the holes are not left in parapet,
wall, beam, slab, floor, etc., they shall be cut and cavity surrounding the pipe made
good properly after fixing the pipe. The pipe shall be fixed with nails and M.S.

clamps having thickness not less than 3 mm, 20 mm wide or as specified in the
schedule with socket facing up.
7.4.5.2 Spacing between clamps for fixing internal piping shall be as per IS 2065 – 1983
as given below:
Horizontal
Nom. dia of pipe Vertical Runs
Runs
50 mm 2M 2M
75 & 100 mm 2.5 M 2.5 M
7.4.5.3 The pipe and fitting shall be kept 50 mm away from the wall face to facilitate
cleaning and painting etc. For rain water pipe the inlet end shall be carefully fixed
to admit water from roof and shoe shall be fixed at outlet. Cowl shall be fixed at top
end of the vent pipe.
7.4.6 LAYING:
7.4.6.1 The pipes shall be carefully laid straight to correct alignment in gradients as
indicated in the drawing or as directed by the Engineer. The socket end of the pipe
shall be uphill. All the pipes shall be used in standard length as far as possible. Cut
length shall be used only where it is necessary to make up exact length. While
joining, the spigot shall be neatly placed into the socket for full length and properly
supported. The entire length of pipe shall be evenly supported on the trench bed
through out. Care shall be taken to prevent any sand, earth or other materials from
entering into the pipes during laying. At the end of day's work the open end shall
suitably plugged.
7.4.6.2 No pipe shall be laid until the trench has been excavated to its required depth for
a distance of about 5 M in front of the pipe to be laid. No pipe shall be covered until
it has been passed by the Engineer.
7.4.7 MAKING LEAD JOINT:
7.4.7.1 The spigot shall be carefully centered in the socket by one or more laps of spun
hemp yarn twisted into ropes of uniform thickness thoroughly soaked in hot coal-
tar or bitumen and cooled before use. The joints shall be made with molten lead
and hemp yarn. The lead shall be melted rendering it thoroughly fluid and each
joint shall be filled in one pouring. The lead may project 3 mm beyond the face of
the socket against the outside of spigot, but must be flushed with the outside edge
of the socket.
7.4.7.2 After the lead has been run into the joint, the lead shall be thoroughly caulked by a
suitable caulking tool and 2 Kg hammer and the joint left neat and smooth. The

consumption of lead will be worked out on the basis of actual observation at sit.
The following table shows consumption of lead and yarn per joint.
7.4.7.3
DIAMETER OF PIPE YARN LEAD

(MM) (in kg) (in kg)
50 0 06 0 77
80 0 09 0 88
100 0 11 0 98
150 0 18 1 20
7.4.8 TESTING:
7.4.8.1 The pipe line which is laid on the ground or below the ground level, the joints shall
be tested with two meter head of water from a higher section of pipe line.
7.4.8.2 The pipe line fixed vertically on the wall shall be tested by the smoke test. The
Greasy cotton waste shall be burnt in a smoke machine consisting of bellows and

a burner. If any lead joint is found to be sweating or leaking, the contractor shall
rectify the same till water tightness is attained to the full satisfaction of the Engineer.
7.4.9 DEWATERING:
7.4.9.1 In case of underground piping, the contract rate shall include bailing or pumping
out all the water till completion of work if accumulated during the progress of work
either from seepage, springs, rain or any other cause,
7.5 HIGH DENSITY POLYETHYLENE PIPING WORK FOR WATER SUPPLY:

7.5.1 GENERAL:
7.5.1.1 The item includes supplying of HDPE pipes with fittings of specified diameter including
laying, fixing, cutting, jointing.
7.5.2 MATERIAL:
7.5.2.1 The pipes and fittings shall conform to series IV of IS 4984. HDPE pipes and fittings
shall be free from cracks, flaws and defects and shall be able to withstand a pressure
as mentioned in the schedule.
7.5.3 EXAMINING:
7.5.3.1 Before laying the pipe line, if shall be first examined for damages and cracks, No
cracked or damaged pipe and fittings shall be used in the work and they shall be
removed from the site by the contractor at his own cost and charge.
7.5.4 LAYING:
7.5.4.1 The pipes shall be carefully laid straight to the correct alignment in gradients as
indicated in the drawing. All the pipe shall be used in standard length as far as
possible. Cut length shall be used only where it is necessary to make up exact length.
7.5.4.2 The entire length of pipe shall be evenly supported on bed of the trench through out.
Care shall be taken to prevent any sand, earth or other materials from entering into
the pipes during laying. At the end of day's work the open end shall be suitably
plugged.
7.5.5 FIXING:
7.5.5.1 The pipe line shall be fixed in position as shown in the drawing or as directed by the
Engineer.
7.5.5.2 The pipe shall be fixed with G.I. clamps not less than 2 mm thick or with suitable
diameter HDPE clamps. The clamps shall be fixed into the wall with M.S. nails not
less than 40 mm long / Wooden gutties etc. chromium plated screws with wooden
gutties fixing the pipe line on internal wall surface.
7.5.6 MAKING JOINT:
7.5.6.1 The joining of pipes and fittings generally shall be done by Butt weld with heat mirror
jointing.
7.5.6.2 The pipe shall be cut to desired length, Care shall be taken that profile of cut surfaces
is not changed and the fibrous material shall be removed with scraper or knife. The
butt weld jointing shall be made with electrical heated plated at the required
temperature around 205, + or - 5 degree Centigrade. While jointing, care shall be

taken that formation of the rim at end of pipe after heating by hot plate should be
made uniform and complete on both the ends. Holding and pressing of pipe is done
manually or mechanically to give the leak proof joint.
7.5.7 DETACHABLE JOINT:
7.5.7.1 Detachable joints shall be made where pipes of different materials have to be jointed
or as specified in the schedule. The flanges are first pushed over the pipe ends and
a rim is made by heating the pipe end in a suitable device to 70-180 Centigrade and
welding pre-heated rim of the pipe.
7.5.8 DEWATERING:
7.5.8.1 In case of underground pipes, the contract rate shall include bailing or pumping out
all the water till completion of work if accumulated during the progress of work either
from seepage, springs, rain or any other cause.
7.5.9 TESTING:
7.5.9.1 Solvent welded pipe shall not be pressure tested until at least 24 hours after the last
solvent cemented joint has been done. All control valves shall be positioned open for
the duration of the test and open end closed with water tight fittings. The testing
pressure on completion of the work shall not be less than 1.5 time the working
pressure of the pipes.
7.5.9.2 Pressure shall be applied either by hand pump or power driven pump. Pressure
guages shall be correctly positioned and closely observed to ensure that at no time
are the test pressure exceeded. The systems shall be slowly and carefully filled with
water to avoid surge pressure or water hammer. Air vents shall be open at all high
points so that air may be expelled from the system during filling.
7.5.9.3 When the system has been fully charged with water and air displaced from the line
air vent shall be closed and the line initially inspected for seepage at joints and
firmness of supports under load. Pressure is reached. Without any additional
requirement of make-up-water the test pressure should not fall more than 0.02 MPa
(0.2 kg./sq.cm) at the end of one-hour test duration.
7.6 UPVC Pipes and Fittings
7.6.1 The pipes shall be round and shall be supplied in straight lengths with socketed
ends. The internal and external surfaces of pipes shall be smooth, clean, free from
groovings and other defects. The ends shall be cleanly cut and square with the axis
of the pipe. The pipes shall be designed by external diameter and shall conform to
IS:4985-1981. The pipes shall be of Class-III; 10 Kg/sq.cm pressure rating.or type
B.
7.6.2 Fittings
7.6.2.1 Fittings shall be of the same make as that of pipes, injection moulded and shall
conform to IS:14735.
7.6.3 Laying and Jointing
7.6.3.1 The pipes shall be laid and clamped to wooden plugs fixed above the surface of
the wall. Alternatively plastic clamps of suitable designs shall be preferred.
Provision shall be made for the effect of thermal movement by not gripping or

disturbing the pipe at supports between the anchors for suspended pipes. The
supports shall allow the repeated movements to take place without abrasion.
7.6.3.2 Jointing for UPVC pipes shall be made by means of solvent cement for horizontal
lines and ‘O’ rubber ring for vertical line. The type of joint shall be used as per site
conditions / direction of the Engineer. Where UPVC pipes are to be used for rain
water pipes, the pipe shall be finished with GI adopter for insertion in the RCC slab
for a water proof joint complete as directed by the Engineer.
7.6.4 Supports
7.6.4.1 UPVC pipes require supports at close intervals. Recommended support spacing
for unplasticised PVC pipes is 1400 mm for pipes 50 mm dia and above. Pipes
shall be aligned properly before fixing them on the wooden plugs with clamps. Even
if the wooden plugs are fixed using a plumb line, pipe shall also be checked for its
alignment before clamping, piping shall be properly supported on, or suspended
from clamps, hangers as specified and as required. The Contractor shall
adequately design all the brackets, saddles, anchors, clamps and hangers and be
responsible for their structural sufficiency. Pipe supports shall be primer coated
with rust preventive paint.
7.6.5 Repairs
7.6.5.1 While temporary or emergency repairs may be made to the damaged pipes,
permanent repairs shall be made by replacement of the damaged section. If any
split or chip out occur in the wall of the pipe, a short piece of pipe of sufficient length
to cover the damaged portion of the pipe is cut. The sleeve is cut longitudinally and
heated sufficiently to soften it so that it may be slipped over the damaged hard
pipe.
7.7 Salt glazed Stoneware Pipes (S.W. pipes)
7.7.1 All underground sewer lines where specified shall be Stoneware pipes of first-class
quality salt glazed and free from rough texture inside and outside and straight. All
pipes shall have the manufacturers name marked on it and shall comply with IS
651.
7.7.2 Laying and jointing of stoneware salt glazed pipes
7.7.2.1 Pipes are liable to be damaged in transit and notwithstanding tests that may have
been made before despatch each pipe shall be examined carefully on arrival at
site. Each pipe shall be rung with a wooden hammer or mallet and those that do
not ring true and clear shall be rejected. Sound pipes shall be carefully stacked to
prevent damage. All defective pipes should be segregated, marked in a
conspicuous manner and their use in the works prevented.
7.7.2.2 The pipes shall be laid with sockets leading uphill and rest on solid and even
foundations for the full length of the barrel. Socket holes shall be formed in the
foundation sufficiently deep to allow the pipe jointer room to work right round the
pipe and as short as practicable to admit the socket and allow the joint to be made.
7.7.2.3 Where pipes are not bedded on concrete the trench bottom shall be left slightly
high and carefully bottomed up as pipe laying proceeds so that the pipe barrels
rest on firm ground. If excavation has been carried too low it shall be made up with

cement concrete of the same mix as specified for pipe bedding at the Contractor's
cost and Charges.
7.7.2.4 If the bottom of the trench consists of rock or very hard ground that cannot be easily
excavated to a smooth surface, the pipes shall be laid on cement concrete bed to
ensure even bearing.
7.7.3 Jointing of pipes
7.7.3.1 Tarred gaskin shall first be wrapped round the spigot of each pipe and the spigot
shall then be placed into the socket of the pipe previously laid, the pipe shall then
be adjusted and fixed in its correct position and the gaskin caulked tightly home so
as to fill not more than one quarter of the total length of the socket.
7.7.3.2 The remainder of the socket shall be filled with stiff mix of cement mortar (1cement:
1clear sharp washed sand). When the socket is filled, a fillet should be formed
round the joint with a trowel forming an angle of 45 degrees with the barrel of the
pipe. The mortar shall be mixed as needed for immediate use and no mortar shall
be beaten up and used after it has begun to set.
7.7.3.3 After the joint has been made any extraneous materials shall be removed from
inside of the joint with a suitable scraper of "badger". The newly made joints shall
be protected until set from the sun, drying winds, rain or dust. Sacking or other
materials which can be kept damp shall be used. The joints shall be exposed and
space left all round the pipes for inspection by the Engineer. The inside of the sewer
must be left absolutely clear in bore and free from cement mortar or other
obstructions throughout its entire length and shall efficiently drain and discharge.
7.7.4 Testing
7.7.4.1 All lengths of the sewer and drain shall be fully tested for water tightness by means
of water pressure maintained for not less than 30 minutes. Testing shall be carried
out from manhole to manhole. All pipes shall be subjected to a test pressure of at
least 1.5 metre head of water. The test pressure shall, however, not exceed 6-
meter head at any point. The pipes shall be plugged preferably with standard
design plugs with rubber plugs on both ends. The upper end shall, however, be
connected to a pipe for filling with water and getting the required head.
7.7.5 Sewer lines shall be tested for straightness by:
7.7.5.1 Inserting a smooth ball 12 mm less than the internal diameter of the pipe. In the
absence of obstructions such as yarn or mortar projecting at the joints the ball
should roll down the invert of the pipe and emerge at the lower end, Means of a
mirror at one and a lamp at the other end. If the pipe line is straight the full circle of
light will be seen otherwise obstruction of deviation will be apparent.
7.7.5.2 The Contractor shall give a smoke test to the drains and sewer at his own expense
and charges, if directed by the Engineer.
7.7.5.3 A test register shall be maintained which shall be signed and dated by Contractor
7.8 Reinforced Cement Concrete pipes (R.C.C. pipes)
7.8.1 All underground storm water lines shall be S&S RCC pipes to IS 458 NP-2.class.
Pipes shall be true and straight with uniform bore, throughout. Cracked, warped
pipes shall not be used on the work. All pipes shall be tested by the manufacturer

and the Contractor shall produce, when directed a certificate to that effect from
the manufacturer.
7.8.2 Laying
7.8.2.1 R.C.C. Spun pipes shall be laid on cement concrete bed or cradles as specified
and shown on the detailed drawings. The cradles may be precast and sufficiently
cured to prevent cracks and breakage in handling. The invert of the cradles shall
be left 12 mm below the invert level of the pipe properly placed on the soil to prevent
any disturbance. The pipe shall then be placed on the bed concrete or cradles and
set for the line and gradient by means of sight rails and bonding rods etc. Cradles
or concrete bed may be omitted, if directed by the Project Manager.
7.8.3 Jointing
7.8.3.1 After setting out the pipes the socket shall be centered over the spigot and filled in
with tarred gaskin, so that sufficient space is left on either side of the collar to
receive the mortar. The space shall then be filled with cement mortar 1:2 (1 cement:
2 fine sand) and caulked by means of proper tools. All joints shall be finished at
an angle of 45 degrees to the longitudinal axis of the pipe.
7.8.4 Testing
7.8.4.1 All pipes shall be tested to a hydraulic test of 1.5 m head for atleast 30 minutes at
the highest point in the section under test. Test shall also be carried out similar to
those for stoneware pipes given above. the smoke test shall be carried out by the
Contractor, if directed by the A test register shall be maintained which shall be
signed and dated by Contractor / Project Manager.
7.9 Embedded piping work in earth, RCC, PCC and walls
7.9.1 General
7.9.1.1 The Contractor shall supply and install all embedded piping work including fittings
as shown in the drawings.
7.9.2 Pipes and fittings
7.9.2.1 Embedded pipes and fittings in concrete / block work for soil and waste applications
shall be cast iron pipes and fittings as per IS 3989. Floor traps / floor drains shall

be cast iron with SS gratings for public area and Cast iron grating for other areas
(Back house area).
7.9.2.2 Embedded pipes and fittings in blockwork for water supply applications shall be
CPVC pipes conforming to IS 15778
7.9.2.3 External earth buried sewer pipes shall be glazed stoneware conforming to IS 651
at street level.
7.9.2.4 External earth buried potable water pipes shall be DI conforming to IS 8329 at
street level.
7.9.2.5 External earth buried storm water pipes shall be RCC pipes conforming to IS 458
NP-2 Class at street level.
7.9.3 Pipeline Installation
a) Setting out
Setting out of pipes in earth, RCC, PCC and walls shall be to straight lines and the gradients/
levels as per drawing. Adequate working space for pipe layers and jointers shall be considered.
Before any permanent work may commence, the Engineer shall be invited to check the setting
out.
b) Excavation
All earth work excavation / wall chasing shall be carried out to the required lengths, width,
depths as may be necessary for the construction of the Works. Minimum trench width for pipes
up to 500 mm dia shall be 2D + 50mm where D is the outer diameter of the pipe.
Where localised areas of soft earth work material at the invert of the excavation are required
to be removed by the Engineer, backfilling of the resultant void shall be carried out using lean
concrete.
Should the Contractor’s temporary Works like earth work shoring & strutting, RCC centring,
wall chasing scaffolding fail, regardless of acceptance by the Engineer, the Contractor shall
take full responsibility for the damage and repair to his works and to any adjacent works
belonging.
c) Pipe Laying
Drainage pipe sockets shall face up the gradient during laying. The bore of the pipe cleared of
any obstruction before the next pipe is laid. All open ends of pipes shall be blanked off with
blank flanges or pipe caps. These shall be removed only immediately prior to connecting to
adjacent sections
Pipe shall be placed in the trench on its required position and check the invert elevation of the
pipe as per approved GFC drawings. After installation of pipes and fittings check for level,
alignment and straightness. The level of each pipe shall be tested. Care shall be taken that

there is no irregularity in the invert of the joints. Where it is required to shorten any pipe it shall
be cut off square and cleanly with accepted pipe-cutting machines.
Ensure external coating and internal lining are NOT damaged during installation and testing.
Any deficient or damaged lining to be repaired as per manufacturer’s recommendations.
Supports as necessary / haunch pipe support to keep in position during pouring of concrete
shall be provided.
d) Restoration Works
All drain lines passing under buildings and driveways are to be surrounded with concrete, which
shall be carried up, from the bed in a square section with a minimum of 150mm thickness over
the barrel of the pipes.
All earth, walls and RCC/ PCC concrete shall be restored/ closed and finished to the
acceptance of the Engineer.
e) Tests
All drainage pipework shall be gravity tested to a water head of 1200mm at the high for 2 hours
prior to concreting slab / backfilling earth. The flow test shall be carried after concreting/ Back
filling
All water supply pipework shall be pressure tested for 10 bar or 1.5 times working pressure
whichever is higher.
7.10 Workmanship
7.10.1 All pipes shall be cut accurately to measurements, established at the site, and shall
be worked into place without springing or forcing.
7.10.2 Piping shall be installed so that it may expand and contract freely without injury to
itself or other work. Steel and wrought-iron pipe shall be cut with pipe cutters and
threaded with sharp, clean dies. All cut sections shall be reamed to remove all burrs
and to restore the pipe to full diameter. All changes in size shall be made with
reducing fitting. Pipe bends and bushings are prohibited.
7.11 Location of Device
7.11.1 All valves, equipment, accessories, and devices shall be so located that they are
accessible for repair and replacement.
7.12 Storage and Cleaning
7.12.1 Pipes shall be delivered and stored with plugged ends. Ends shall be kept closed
with temporary covers during erection. Before any pipe is installed, it shall be
opened and pounded to remove any foreign substances, or swabbed, if necessary,
for thorough cleaning.
7.12.2 Pipes shall be stored on racks in a suitable warehouse or cover to avoid rusting. If
necessary, carbon steel pipes shall be coated with anodic rust converter or red
lead primer.
7.12.3 During the course of installation, the Contractor shall take every precaution to
prevent any debris from being left in the pipes. The Contractor shall be
responsible for any damage that may occur. Immediately after erection, exposed

threads at all fittings shall be painted with zinc-chromate paint, and after
welding each joint shall be wire-brushed and then painted with zinc-chromate paint.
7.12.4 Before start-up, all piping systems shall be thoroughly flushed with water until it
runs clear. Fixtures and equipment shall be lightly covered and protected against
damage. At the completion of the work, fixtures, materials and equipment shall be
thoroughly cleaned and delivered in a satisfactory condition.
7.13 Disinfection of Piping System and Storage Tanks
7.13.1 Before commissioning the water supply system, the contractor shall arrange to
disinfect the entire system as described in the succeeding paragraph.
7.13.2 The water storage tanks and pipes shall first be filled with water and thoroughly
flushed out. The storage tanks shall then be filled with water again and disinfecting
chemical containing chlorine added gradually while tanks are being filled to ensure
thorough mixing. Sufficient chemical shall be used to give water a dose of 50 parts
of chlorine to one million parts of water.
7.13.3 If ordinary bleaching powder is used, the proportions will be 150 gm of power to
1000 liters of water. The power shall be mixed with water in the storage tank. If a
proprietary brand of chemical is used, the proportions shall be specified by the
manufacturer. When the storage tanks is full, the supply shall be stopped and all
the taps on the distributing pipes are opened successively working progressively
away from the storage tank. Each tap shall be closed when the water discharged
begins to smell of chlorine. The storage tank shall then be filled up with water from
supply pipe and added with more disinfecting chemical in the recommended
proportions. The storage tank and pipe shall then remain charged at least for three

hours. Finally the tank and pipes shall be thoroughly flushed out before any water
is used for domestic purpose.
7.13.4 The pipework shall be throughly flushed before supply is restored.
7.14 Sterlization of Main
7.14.1 After the pipe work has been tested and approved, but before it is coupled, it shall
be sterilized with a solution of chloride of lime.
7.15 Connection to Equipment
7.15.1 Connections to coils, pumps and other equipment shall be made in such a manner
that undue strains between pipes and equipment are eliminated. Unions and /
or flanges shall be used to facilitate the removal of the equipment.
7.16 Expansion and Contraction
7.16.1 The piping systems shall be installed so that there will be no damage due to
expansion and contraction during operation.
7.16.2 Packless type expansion connectors shall be used where the expansion and
contraction of the pipe is excessive or cannot be compensated by expansion loops
or offsets.
7.17 Sleeves
7.17.1 Vertical pipes passing through floors shall be provided with sleeves of black steel
pipes. Sleeves shall be of a proper length to pass through the entire floor
construction and shall terminate 50 mm. above the finished floor level.
7.17.2 Horizontal pipes passing through walls and partitions shall be provided with full
thickness sleeves made of standard weight black steel pipes.
7.17.3 Sleeves shall be large enough to leave not less than 12.5 mm. clearances around
the pipe and covering insulation, if there is any. Sleeves shall be set in place where
the walls and partitions are built.
7.17.4 Sleeves in concrete work shall be flanged at the bottom or provided with
temporary centring caps and securely nailed or screwed to formwork before the

concrete is poured. Provide chromium-plated escutcheon, where exposed pipes

pass through walls or floors.
7.17.5 When sleeves are installed through a fire wall, the clearance between sleeves and
pipes shall be filled with fire-resistant material. The fire rating of the fire-
resistant material shall be at least equivalent to that of the fire wall.
7.17.6 When pipes pass through waterproof walls, water retaining rings with approved
type of sealant shall be applied.
7.18 Painting
7.18.1 Soil waste vent and rain water pipes in exposed location in shafts and pipe space
shall be painted with two or more coats of ready mix oil paint to give an even shade.
All dust and extraneous matter shall be removed before painting.
7.18.2 Paint shall be of approved quality and shade. Where directed by the Engineer pipes
shall be painted in accordance with approved pipe colour code.
7.18.3 Pipe in chase shall be painted with two coats of bitumen paint covered with
polythene tape and a final coat of bitumen paint. Exposed pipes shall be painted
with synthetic enamel paint after removing dust and extraneous matter.
7.19 Testing
7.19.1 Testing shall be done in accordance with IS: 1172 and IS: 5329 except as may be
modified herein under.
7.19.2 Entire drainage system shall be tested for water tightness and smoke tightness
during and after completion of the installation. No portion of the system shall remain
untested. Contractor must have adequate number of expandable rubber below
plugs, manometers smoke testing machines pipe and fitting work tests.
7.19.3 All materials obtained and used on site must have manufacturer’s hydraulic test
certificate for each batch of materials used on the site.
7.19.4 Soil and waste pipes shall be tested in sections after installation by filling up the
stack with water. All openings and connections shall be suitably plugged as
approved by the Engineer. The total head in the stack shall be 4.5 m at the highest
point of the section under test. The period of test shall be minimum for 30 minutes
or as directed by The Engineer. If any leakage is visible the defective part of the
work shall be cut and made good.
7.19.5 On completion of the work the entire installation shall be tested by smoke testing
machine. The test shall be conducted after the plumbing fixtures are installed and
all traps have water seal or by plugging the outlets with bellows plugs. Apply dense

smoke keeping the top of stack open and observe for leakages. Rectify or replace
defective sections.
7.19.6 After the installation is fully complete, it should be tested by flushing the toilets,
running at least 20% of all taps simultaneously and ensuring that the entire system
is self-draining has no leakages blockages etc rectify and replace where required.
7.19.7 A test register shall be maintained and all entries shall be signed and dated by the
Contractor and the Project Manager or his representative.
7.19.8 All pipes in wall chase or meant to be encased or buried shall be hydro tested
before the chase in plastered or the pipe encased or buried.
7.20 Shop drawings
7.20.1 The contractor has to submit the model of submersible pump that he proposes to
install. The shop drawings for electrical panel shall also be submitted for approval
before the installation.
7.21 Guarantees
7.21.1 On award of the work the vendor shall submit a guarantee covering the quality and
performance of all materials and installations under the contract. This guarantee
shall cover each and every material whether manufactured by the contractor or not.
7.21.2 Vendor shall specify a suitable procedure to test the rated performance of the
equipment and the system and shall provide all necessary equipments, gauges,
etc. for conducting such tests.

8 VALVES AND ACCESSORIES

8.1 General
8.1.1 This section shall involve that the supply, installation, testing and commissioning of
valve and accessories.
8.2 Ball Valve
8.2.1 The Ball Valve shall be made from die cast brass conforming to IS 292 LCB 1 and
tested to 12 Kg/cm2 pressure. The valve shall be internally threaded to receive pipe
connections conforming to IS 554.
8.2.2 The Ball shall be made from Stainless Steel IS 6603, X04Cr17Ni12Mo2 (SS 316), and
machined to perfect round shape and subsequently chrome plated. The seat of the
valve body- bonnet gasket and gland packing shall be of Teflon.
8.2.3 The handle shall be of chrome-plated steel with PVC jacket. The handle shall also
indicate the direction of òpen' and `closed' positions. The gap between the ball and
the Teflon packing shall be sealed to prevent water seeping up to 12 Kg / cm2
pressure.
8.2.4 The handle shall also be provided with a lug to keep the movement of the ball valve
within 90 degree. The lever shall be operated smoothly and without application of any
unnecessary force. The lock nut shall be made up of Stainless-steel conforming to IS
6603 (SS 304).
8.3 Flap valve
8.3.1 Flap valve shall be of the circular port design with offset single pivoted hinge. They
shall be of the iron body bronze mounted type and furnished with a flanged end.
8.3.2 The assembly shall consist of three parts: flap gate, body and hinge pin. The flap
gate and body shall be cast iron conforming to IS 210. The seats and hinge pin shall
be furnished of bronze. The flap gate seat ring shall be rolled into a dovetailed groove
under pressure to make one inseparable unit.
8.3.3 The body seat ring shall be threaded and screwed into place in the body. Both gate
and body seat ring faces shall be machined to a smooth finish. The valve shall be
constructed with a 10-degree offset from vertical to ensure positive closure. The
flange shall be drilled according to IS 6392.
8.4 TRAPS
8.4.1 Floor Traps
8.4.1.1 Floor traps where specified shall be siphon type full before P or S type cast iron
having a minimum 50 mm deep seal. The trap and waste pipes when buried below
ground shall be set and encased in cement concrete blocks firmly supported on firm

ground or when installed on a sunken RCC structural slab. The blocks shall be in
1:2:4 mix (1 cement : 2 coarse sand : 4 stone aggregate 20 mm nominal size).
8.4.1.2 Contractor shall provide all necessary shuttering and centering for the blocks. Size
of the block shall be 30 x 30 cms of the required depth.
8.4.2 Floor Trap Inlet / Hopper
8.4.2.1 Bathroom traps and connection shall ensure free and silent flow of discharging
water. Where specified, contractor shall provide a special type of floor inlet fitting
fabricated from GI pipe, with one, two or three inlet sockets welded on side to
connect the waste pipe. All joint between waste hopper and CI inlet socket shall be
drip seal/Lead Caulked. Inlet shall be connected to a CI “P” trap. Floor trap inlet and
the traps shall be set in cement concrete blocks where burried in floors without extra
charge. Floor trap for the shower cubicle shall suit site and as per the approval of
the Engineer. All fabricated hopper shall be hot dip galvanized.
8.4.3 Floor Trap Grating
8.4.3.1 Floor and urinal traps shall be provided with 100 – 150 mm square or round stainless
steel gratings, with frame and rim of approved design and shape or as specified in
the schedule of quantities approved by the Engineer.
8.4.4 Cleanout Plugs
8.4.4.1 Clean out plug for soil, waste or rain water pipes laid under floors shall be provided
near pipe junctions bends, tees, “Y” and on straight runs at such intervals as required
as per site conditions. Cleanout plugs shall terminate flush with the floor level. They
shall be threaded and provided with key holes for opening. Cleanout plugs shall be
cast brass suitable for the pipe dia. With screwed to a GI socket. The socket shall
be drip seal joined / Lead Caulked to the drain pipes.
8.5 Pump Pedestals & lifting arrangements.
8.5.1 The concrete plinths for pump bases, expansion vessels and accessories shall be
provided as shown in the drawing.
8.5.2 The Contractor shall design, supply, install and test the manual mono rail lifting
systems in fire domestic water pump room.
8.5.3 The lifting system shall include the chain pulley block with I-beam for the lifting of the
2 ton load The Contractor shall select the hoisting system to enable a safe installation,
maintenance and removal of the pumps subject to the approval of the Engineer.
8.5.4 All lifting system shall be tested to 1.5 times the rated load capacity in the direction of
pull appropriate to its proposed use.
8.6 Plumbing and drainage appurtenances
8.6.1 All Plumbing and drainage appurtenances like manholes, inspection chambers, catch
pits, rain water harvesting chambers, settling chambers, grease trap, gully trap, water

meter chambers, valve chambers and pump sumps shall be constructed by the Civil
Contractor including cover, frame, plastic encapsulated iron step etc. as per drawing.
8.6.2 Inspection chambers/waste sumps shall be provided with an opening fitted with an
air-tight frame and cover.
8.6.3 Recessed type covers with SS frame Grade shall be provided in public areas and the
cover shall be finished to match the floor finish.
8.6.4 Plastic encapsulated iron steps shall be provided for sumps, water tanks, manholes,
rainwater harvesting chambers and settling tanks as required.
8.6.5 A stainless screen shall be provided in each catch pit / collection pit in order to hold
the debris from flowing water. The location of this screen shall be such that
maintenance worker standing at access cover level can easily clear all debris trapped.
8.6.6 Waterproofing of manholes shall be with FRP (or) equivalent material approved by
the Engineer.
8.7 Puddle Flanges & Pipe Sleeves
8.7.1 The pipe flanges shall confirm IS 6392. All puddle flange shall be hot dip galvanised
as per IS 4736.
8.7.2 Pipes passing through external diaphragm walls and RC water tanks, shall be fitted
with a puddle flange.
8.7.3 For pipe of 80mm diameter and above, the minimum length of puddle flange shall
have twice the diameter of pipe.
8.7.4 For pipe of 80mm diameter below, the minimum length of puddle flange shall be of
150mm.
8.7.5 Where pipes pass through internal walls, floors, etc., the Contractor shall provide pipe
sleeves of diameter of next size of the service pipe as per the drawing. All sleeves
shall be the same material as the services pipe and set during construction so that
they project 20 mm beyond the finished surfaces. The gap between the pipe and its

sleeve shall be firmly packed with fire sealant / fire stopping compound to maintain
fire rating of the wall/ floor etc.
8.8 INSPECTION CHAMBER:
8.8.1 GENERAL: The item includes provision of brick masonry Inspection Chamber of
internal size as specified in the schedule.
8.8.2 CONSTRUCTION:
a) Internal dimensions and initial depth shall be as specified in the schedule or as
shown in the drawing.
b) Foundation of 1:2:4 concrete shall be 150 mm thick and shall have 150 mm
offset.
c) The concrete 1:2:4 shall be laid to necessary shapes to form the channel for the
pipe being received in the channel. It shall be of appropriate diameter and shall
be half round. The sides shall be kept sloping towards the channel.
d) Brick masonry shall be 230 mm thick in cement mortar 1:2 or as specified in the
schedule of work, making brick tapering for longitudinal wall 450 mm from top
of cover of the chamber.
e) Brick masonry shall be rendered with 20 mm thick plaster in cement mortar 1:1
or as specified in the schedule of work inside and outside surfaces in two
courses and inside surface finished smooth with neat cement punning.
8.8.3 DEWATERING: The contract rate shall include bailing or pumping out all the water if
accumulated during the progress of the work either from rain, seepage, springs or any
other cause.
8.9 EXTRA DEPTH FOR INSPECTION CHAMBER AND MANHOLE:
8.9.1 GENERAL: The item includes provision for extra depth of Inspection Chamber and
manholes of brick masonry.
8.9.2 CONSTRUCTION: Extra depth for inspection chamber and manhole shall be
constructed under the clause 8.8.2 of the Section – 8.8.
8.9.3 DEWATERING: The contract rate shall include bailing or pumping out all the water if
accumulated during the progress of the work either from rain, seepage, springs or any
other cause.
8.10 SCREENING
8.10.1 Screening shall be provided at outlet pipe of each inspection chamber in undercroft
level. It shall be stainless steel conforming to IS 6603 (SS 304) and 1.5 - 2 mm
thickness.
8.11 C.I. FRAME AND COVER FOR MANHOLES:
8.11.1 GENERAL: The item includes supply HD/EHD C.I. frame and cover as specified in
schedule including fixing and painting.
8.11.2 MATERIAL: C.I. Frame and cover shall conform to IS 1720 and shall have IS
certification mark with grade HD/EHD and the weight of frame and cover shall not be
less than as specified in the schedule.

8.11.3 FIXING: Frame shall be fixed in the cement concrete 1:2:4 for bearing course and
capping on the brick masonry wall of the chamber of manhole and finishing shall be
done in 1:2 cement plaster finished smooth with neat cement.
8.11.4 PAINTING: The frame and cover shall be painted with two coats of approved black
bitumastic anticorrosive paint over a coat of primer.
8.12 PRECAST CONCRETE FRAME AND COVER FOR MANHOLES:
8.12.1 GENERAL: The item includes supply HD/ EHD factory made precast steel fiber
reinforced concrete (SFRC) frame and cover as specified in schedule including fixing
and placing.
8.12.2 MATERIAL: The precast frame and cover shall be of steel fiber reinforced concrete
(SFRC) conforming to IS 12592 and shall be of approved make. The frame and cover
shall be of HD/ EHD grade, size and thickness as mentioned in the description of the
item. The defective Frame and cover shall be replaced by the contractor at his own
cost and charges.
8.12.3 FIXING: Frame shall be fixed in cement concrete 1:2:4 for bearing course & capping
on the top of masonry wall of chamber or manhole and finishing shall be done in 1:2
cement plaster finished smooth with neat cement.
8.13 Channel Drain Grating:
8.13.1 Grating with frame shall be Cast Iron (CI) conforming to IS 5961. It shall be located at
track area, vent shafts and pump room.
8.13.2 Grating with frame shall be Stainless steel (SS 304) conforming to IS 6603, which is
located at the entrance area.
8.14 GULLY TRAP:
8.14.1 GENERAL: The item includes provision of S.W. Gully trap with C.I. frame including
construction of Gully Trap Chamber.
8.14.2 MATERIAL: The Gully Trap shall be of salt glazed stoneware with 150 mm nominal
square inlet or as specified in the schedule with 100mm diameter outlet.
8.14.3 CONSTRUCTION:
a) Internal dimension of the Gully trap chamber shall be as specified in the schedule.
b) Foundation of 1:4:8 concrete shall be 150 mm thick and shall have 100mm offset.
c) Brick masonry shall be of 230 mm thick in cement mortar 1:6 and masonry shall
be plastered with 15mm thick plaster in 1:3 cement mortars inside and outside
surface with smooth finish.
8.14.4 C.I. FRAME AND COVER: C.I. frame and cover shall be fixed with the cement
concrete 1:2:4 at the top of Gully trap chamber, the weight of frame and cover shall

not be less than 7.5 kg. and they shall be painted with two coasts of black bitumastic
paint.
8.14.5 DEWATERING: The contract rate shall include bailing or pumping out all the water till
completion or work if accumulated during the progress of work either from seepage,
springs, rain or any other cause.
8.15 Municipal water, storm water & waste water sewer connections
8.15.1 Making connection to existing or new Municipal sewer / storm water drain including
necessary excavation and breaking the wall of municipal manhole and making good
the same with Cement mortar 1:3, finished with a floating coat of neat
cement and making drains etc. complete. Removing the excavated surplus
material. This also includes the contractor for liasoning work such as filling necessary
applications, submission of forms for approval to the municipal authorities, getting the
premises / installations inspected and approved and all other formalities
required till the sewer / storm water connection is obtained. All the expenses
incurred in this regard shall be borne by the Contractor, except for the payments to be
made for any security deposits which will be paid by employer
8.15.2 Effecting connection from Existing/ Municipal Water Supply line including necessary
excavation & making good the same including cutting, boring and tapping the Existing
line by providing and installing ferrule / Tee connections with necessary fittings as
required and making good the same. The scope of work also includes
complete services from the contractor for liasoning works such as
filing necessary applications, submission of forms for approval to the municipal
authorities, for getting the premises / installations, inspected and approved and
all other formalities required till the water connection is obtained. All the expenses
incurred in this regard shall be borne by the Contractor except for the official
payments to be made for any security deposit, which will be paid by employer.
8.15.3 Connection fees for water supply and drainage services to CMWSSB to be specified.

TECHNICAL SPECIFICATION
FOR
EARTH MAT

1. EARTHING SYSTEM
1.1 Scope:
a) Supply, installation, testing and commissioning of power earth mat, clean earth mat and
structural earthing for the Underground Metro Stations as shown in the drawings.
b) The Contractor shall carry out soil resistivity tests at actual earth mat installation area (base
slab level) coordinated with his base slab construction programme. It shall be early enough to
allow 2 weeks for the redesign of the earth mat if necessary.
c) The Soil resistivity shall use the Werner 4 pin method and the results submitted to the Engineer
for Notice of No Objection. The Contractor shall select a minimum of 2 test locations for each
station, subject to the acceptance of Engineer. Five sets of tests shall be conducted at each
location: each set at pin spacing of 2 m, 4 m, 6m, 8m and 10 m respectively.
d) The Contractor shall be responsible for preparation of the Shop drawings, As Built drawings,
delivery, installation, functional testing and handover of earthing system. Construction of earth
mat up to the risers at undercroft leveland structural earthing as shown in drawings is in the
scope of this contract.
e) After the risers in the undercroft level all the works related with earthing is not in the scope of
this contract. The Contractor shall be responsible for supplying required drawings and test
results of earthmat to interface Contractor for CEIG approval.
1.2 Standard and Reference
▪ IEEE Std 80 - IEEE Guide for Safety in AC Substation Grounding
▪ IEEE 81-Guide for Measuring Earth Resistivity, Ground Impedance and Earth Surface
Potentials of a Grounding System
▪ IS 3043 – Code of Practice for Earthing
▪ IEEE-142 -2007 Grounding of Industrial and Commercial Power Systems.
1.3 Material Description
The material of Power / clean earthmat shall consists of copper horizontal rod, copper vertical
earth electrode, earthing riser cable XLPE, exothermic welding and sleeves. While installing
ground rods, waterproofing requirements of the base slab must be taken care of. Steel
reinforcement bar shall be used for structural earthing as shown in the drawings.
The earthing configuration shall be TN-S as per IS: 3043 and earth mats shall be constructed
in accordance with IEEE 80 to limit the grid resistance, maximum attainable grid potential and
step / touch potentials within the safe limits.
1.4 Components
1.4.1 Earth Mats
Earth mat shall be constructed as per IEEE 80 and IS 3043. Copper rods shall be used for
constructing earth mat of sizes as per drawings (horizontal and vertical conductors) and at
depth of 300 mm from base slab or as shown on the drawing. Number of risers shall be brought

from earth mat up to undercroft level as shown in drawings for further connection to equipment.
The resistance of the earth mat shall not be more than 1 Ohm for power earthing and 0.5 Ohm
for clean earthing.
After the risers in the undercroft level all the works related with earthing is not in the scope
of this contract. The Contractor shall be responsible for handing over the earth risers in
undamaged condition, Shop drawings and test results of earth mat to interface Contractor.
1.4.2 Copper Electrode (vertical Electrode)
18mm diameter, 3m length copper electrode shall be used for power earth Mat and 13mm
diameter 3m length copper rod shall be used for Clean earth Mat. Copper electrodes of high
conductivity with minimum copper content of 99.9%.
The earth electrodes shall be connected to the earth rods (horizontal conductors) through
Exothermic welding.
1.4.3 Copper Rods (Horizontal Conductor)
18mm diameter copper rods shall be used as horizontal conductor for power earthmat and
13mm diameter copper rods shall be used for Clean earthmat.
High conductivity copper for earth rods shall have a minimum copper content of 99.9%.
All joints shall be through Exothermic welding.

1.4.4 RISERS
The Copper earth riser cables shall be brought from earthmat up to the undercroft level as
shown in the drawings. At each earth riser cable entry through the baseslab, a HDPE sleeve
shall be provided with required waterproofing as shown in the drawings.
Earth riser cable shall be Single core XLPE insulated flexible copper conductors, 450/750
Volts as per BS 7211.
Size of Copper riser cable shall be 1 Core x 240 Sq.mm for power earthmat and 1 core X 120
Sq.mm for clean earthmat, Colour shall be Green.
1.4.5 EXOTHERMIC WELDING
Suitable sample of moulds for each type of joints / connections shall be submitted to the
Engineer for Notice of No Objection. Exothermic welding shall comply with IEEE 837. The
resistance of the joint shall be tested on a random sample. Method statement clearly indicating
various procedures, precautions required for an effective welding shall be submitted by the
contractor for approval.
1.4.6 Artificial treatment of soil/ground ( Earth Enhancing Material )
The soil/ground resistivity immediately surrounding the earth electrodes shall be reduced by
adding sodium chloride, calcium chloride, sodium carbonate, copper sulphate, salt and soft
coke or charcoal in suitable proportions complying to IEEE 80/ IS 3043. Earth Enhancing
material shall be submitted to Engineer for Notice of No Objection

1.5 STRUCTURAL EARTHING
The steel reinforcement of the structure offers a good potential control for step and touch
potential and gives a reference for the electric power supply, telecommunication and electronic
installations of the building and could ensure the provision for subsequent installation of a
protection system against stray currents.
Civil works shall provide electrical continuity of all conductive parts of the building structures
such as concrete reinforcement through "rebar binding" as shown in Employer’s drawings.
The Contractor shall be responsible to ensure the electrical continuity of all conductive part’s
of building structures such as concrete reinforcement bars by rebar binding as shown in the
drawings.
1.6 Testing and Commissioning
Following Earth resistance values shall be measured with an approved earth megger and
recorded as per IEEE 80 / IEEE 142 / IS-3043 / IEEE 81.
(i) Each earthing mat for combined resistance value
(ii) Individual earthing electrode.
1.7 Quality Control
All Earthing & Bonding system installed shall be of industrial grade quality complying to IEEE
and shall be undertaken in accordance with the procedure’s set out in the contractors Quality
assurance and Quality management plan.
1.8 Factory Acceptance test:
Contractor shall submit test reports for copper earthing materials, cables, earth enhancement
compound, exothermic welding materials from NABL accredited laboratory.
Contractor shall submit the factory acceptance tests and procedure required for the earthing
system (copper rods, cables, exothermic weld, earth enhancing material) to the Engineer for
Notice of No Objection.

Chennai Metro Rail Limited: TENDER No. CP06/UG06/RT01

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CHENNAI METRO RAIL LIMITED

CHENNAI METRO RAIL PROJECT PHASE 2, CORRIDOR 5

“CONSTRUCTION OF UNDERGROUND STATIONS AT