Civil Specification

DAMODAR VALLEY CORPORATION
ELECTRICITY DEPARTMENT
DVC TOWERS, VIP ROAD
KOLKATA – 700054
(CIVIL SPECIFICATION FOR SUPPLY OF MATERIALS)

SPECIFICATION FOR SUPPLY OF ASSORTED TOWER MEMBERS &
SWITCHYARD STUCTURE
A. SCOPE OF SUPPLY
A.01 Fabrication, galvanization and supply of steel structural members for all types of
complete set of
 220/132/33 KV Switchyard Structure such as CT, PT, LA, CB, BPI, Isolator,
Tandem Isolator
 220/132 KV Assorted tower Member, if any.
 Gantry Trusses,
 Other Tower parts (i.e. Pack Washers, Hangers, Extension Links, U-Bolts, MS
clamp plates, Shackles for conductor & ground wire etc.), if any.
 Foundation bolts, MS angle post & Struts for fixing chain-link fencing , Barbed
wire, insert, clamps & miscellaneous structure etc
 Bolts and Nuts, spring washers, Step-bolts etc.
and delivery F.O.R. destination.
A.02 Preparation of Bill of Materials on the basis of detailed Structural / assembly drawings.
Assembly drawings will be supplied by DVC to the successful tenderer.
B. TRANSMISSION TOWERS/SWITCHYARD STRUCTURE

B.01 GENERAL DESCRIPTION
The towers/Switchyard structure are fully galvanized lattice steel structures using bolted
connections capable to be used as self supporting structures and designed to carry the
line conductors with necessary insulators, earth wires and all fittings under all loading
conditions.
All the towers has been designed as per IS: 802-1995 to suit conductor temperature of
85oC for AAAC 61/3.31 and AAAC 37/3.15.
A list of steel sections to be used for tower fabrication is indicated at the end.
B.02 TYPE OF TOWERS (OPTIONAL):

The towers shall be classified as given below:
a) A – 20 Type Tangent Towers
b) S – 150 Type Angle and Section Towers
c) B – 300 Type Angle and Section Towers
d) C – 600 Type Angle and Dead-end Towers with/without Auxiliary X-arms
e) D – 900 Type Deviation and Dead-end Towers
f) Line Xing Towers
g) Special Towers
B.03 TOWER EXTENSIONS
The above towers are designed so as to be suitable for extension at the base without
reducing the specific factor of safety in any manner. The extension leg will have butt
joints with normal towers. Such extension shall be needed where ground clearances are
found to be inadequate or for power line / railway / river-crossing etc. The foundations of
towers are so designed as to be suitable for towers with or without extensions.
Civil Specification for Supply

B.04 STUB-SETTING TEMPLATES
Stub-setting templates for towers with extensions are of adjustable type. The stub-setting
templates shall not be galvanized.
C DEVELOPMENT OF DRAWING / BOM
C.01 GENERAL
The relevant drawings for all the towers and their extensions/Switchyard structure which
shall be furnished to the Contractor by DVC shall include Structural / assembly drawings
with required fabrication details, Muff-boxes in duplicate.
The contractor should prepare their own bill of materials on the basis of Structural /
assembly / erection drawings of various types of towers and extension portion/
switchyard structure to be supplied by DVC to the successful tenderer. The types of steel
sections to be used for different types of towers / extensions are indicated in ‘Structural
Steel Requirement
C.02 DESIGN & DRAWINGS

The Structural / assembly drawings with required fabrication details for all the towers
and their extensions/ switchyard structure shall be given to the Contractor in TWO
copies. The tower/ switchyard structure members can be directly fabricated from the
Structural / assembly drawings. However, if the contractor is required to prepare the
shop fabrication drawings in addition to the Structural / assembly drawings with required
fabrication details, they have to prepare the same without any additional financial
implication to DVC.
Before taking up the mass fabrication, the Contractor shall arrange for one number
proto-assembly for each type of towers and extensions/ switchyard structure which shall
be inspected by DVC Engineer. Decision regarding preparation of Proto Assembly is at
the sole discretion of DVC Engineer.
C.03 SHOP DRAWINGS
Preparation of Shop drawings, containing complete information necessary for fabrication

of the component parts of the structures may be prepared, if required, without any
additional financial implication to DVC. These drawings should clearly indicate the
member sizes, length and marks, hole positions, gauge lines, bend lines, edge
distances, amount of chipping, notching etc.
For Gusset, separate individual item wise templates shall be made to facilitate fabrication
as well as inspection. In case of members to be bent, shop drawings should indicate the
provisions for variation in length. At the fabrication stage, care should be taken to see
that the degree of bend given in any member is such that neither flange width nor
thickness shall vary beyond permissible limits for the section.
Items requiring steep bends can be cut and welded as per approved welding procedure.
C.04 BILL OF MATERIALS

Bill of material for each type of tower/ switchyard structure should be prepared
separately. This should indicate grade of steel, mark numbers, sections sizes, member
lengths, their unit & calculated weights, number of bolts, nut and washers and their sizes,
total quantities required and structural drawing numbers.
No reduction in weight due to drilling, punching of bolt holes, skew cuts, chipping,
notching, chamfering etc., should be made while computing calculated weights of the
members. All steel sections used should have dimensions as per IS: 808.
D. BOLTS, NUTS AND WASHERS:
All tower members/ switchyard structure shall be joined together with Bolts and nuts. All
hexagonal bolts and nuts shall conform to IS-12427. They shall have hexagonal head
and nuts, the heads being forged out of the solid, truly concentric, and square with the
shank, which must be perfectly straight. All bolts and nuts shall be galvanized as per IS:
1367 (Part-13)/IS: 2629
The bolt shall be of 16/20/24 mm diameter and of property class 5.6 / 8.8 as specified in
IS: 1367 (Part-III) and matching nut of property class 5.0 / 8.0 as specified in IS: 1367
(Part-VI).
Bolts up to M16 and having length up to 10 times the diameter of the bolt should be
manufactured by cold forging and thread rolling process to obtain good and reliable
mechanical properties and effective dimensional control. The shear strength of bolts for
5.6 grade should be 310 MPa (minimum) as per IS: 12427. Bolts should be provided
with washer face in accordance with IS: 1363 (Part-I) to ensure proper bearing.
Nuts for hexagonal bolts should be double chamfered as per the requirement of IS: 1363
(Part-III.) It should be ensured by the manufacturer that nuts should not be over tapped
beyond 0.4mm oversize on effective diameter for size up to M16.
Fully threaded bolts shall not be used. The length of bolts shall be such that the
threaded portion will not extend into the place of contact of the members.
All bolts shall be threaded to take the full depth of the nuts and threaded for enough to
permit firm gripping of the members, but not further. It shall be ensured that the threaded
portion of each bolt protrudes not less than 3mm and not more than 8mm when fully
tightened. All nuts shall fit tight to the point where the shank of the bolt connects to the
head. Only approved vendor make bolts & nuts shall be used.
Flat and tapered washers shall be provided wherever necessary. All pack washers shall
be made of steel conforming to IS: 2062 Gr. A. (latest). The plain washers & heavy
washers shall conform to IS: 2016 & IS: 6610 (latest) respectively. Spring washers shall
be provided for insertion under all nuts. These washers shall be steel electro-galvanized,
positive lock type and 3.5mm in thickness for 16mm dia bolt and 4.5mm for 24mm bolt.
To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect

aggregate thickness of members more than three (3) times its diameter. Bolts at the
joints shall be so staggered such that nuts may be tightened with spanners without
fouling. It may be necessary to tack weld bolts & nuts upto bottom cross-arm level as a
precaution against theft & sabotage.
Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take care of
losses during erection. No payment shall be admissible for these extra supplies.
E. DETAIL OF FABRICATION
The fabrication of towers/ switchyard structure shall be in conformity with the following:

Except where hereinafter modified, details of fabrication shall conform to IS: 802 (Part-
II).The tower structures shall be accurately fabricated to connect together easily at site
without any undue strain on the bolts.
No angle member shall have the two leg flanges brought together by closing the angle.
The diameter of the hole shall be equal to the diameter of bolt plus 1.5mm. All parts shall
be accessible for inspection and cleaning. Drain holes shall be provided at all points
where pockets of depression are likely to hold water.
All identical parts shall be made strictly inter-changeable. All steel sections before any
work is done on them, shall be carefully leveled, straightened and made true to detailed
drawings by methods which will not injure the materials so that when assembled, the
adjacent matching surfaces are in close contact throughout. No rough edges shall be
permitted in the entire structure.
F. OPERATIONS IN FABRICATION
F.01 GENERAL
Workmanship & finish shall correspond to the best modern transmission line practice. All
similar parts shall be made interchangeable. All steel sections before any work is done
on them shall be carefully leveled, straightened and made true by methods which shall
not injure the material so that when assembled the adjacent surface are in close contact
throughout. No rough edges shall be permitted any where throughout the work.
F.02 STRAIGHTENING:
All material should be reasonably straight and, if necessary, before being worked, be
straightened and/or flattened by pressure and be free from twists. Straightening should
not damage the material. Adjacent surfaces of the parts when assembled should be in
close contact throughout keeping in view the tolerances specified. Machines used for
straightening are:-
(1) For angle sections upto 110x110x10mm – Roller Straightening Machine;
(2) For higher sections – Beam bending machine and Hydraulic Press.
F.03 CUTTING:
Cutting may be effected by shearing, cropping, flame cutting or sawing. The surfaces so
cut should be clean, smooth and reasonably square and free from any distortion.
F.04 BENDING:
Mild steel angles sections (IS:2062-Grade A) up to 75x75mm (thickness upto 6mm) shall
be bent cold upto and including bend angles of 10 degree; angles above 75x75mm
(thickness upto 6mm) and upto and including 100x100mm (thickness upto 8mm) may
also be bent cold upto the bend angle of 5 degree. All other angle sections not covered
above should be bent hot. All plates upto 12mm thickness should be bent cold up to
bend angle of 15 degree. Greater bends and/or other thicknesses should be bent hot.
F.05 PUNCHING & DRILLING:
Transmission line towers/switchyard structure demand accurate drilling or punching of

holes with high standard of workmanship and finish. Before any cutting work is started,
all steel sections shall be carefully straightened and trued by pressure and not by
hammering. They shall again be trued after being punched and drilled. Holes for bolts

shall be drilled or punched with a jig but drilled holes shall be preferred. The punching
may be adopted for thickness up to 16mm. For thicker sections, drilling should be done.
Tolerances regarding punch holes are as follows:-
a) Holes must be perfectly circular and no tolerances in this respect are
permissible.
b) The maximum allowable difference in diameter of the holes on the two sides of
plates or angle is 0.8mm. I.e. the allowable taper in a punched holes should not
exceed 0.8mm on diameter.
c) Holes must be square with the plates or angles and have their walls parallel.
All burns left by drills or punch shall be removed completely. When the tower members
are in position the holes shall be truly opposite to each other. Drilling or reaming to
enlarge holes shall not be permitted.
The edge security and bolt gauges should be maintained in all cases.
F.06 MARKING OF MEMBERS:
Each individual tower member/ switchyard structure shall carry a stamped mark
(number) assigned to in the approved drawings. These stamping shall be done by a
metal die of 16 mm size before galvanizing and on optimum depth so as to clearly legible
after galvanizing. Further more, the mark No. should be stenciled in indelible ink on each
tower member after galvanizing.
Erection Mark shall be AA-BB-C-DDD
AA = Contractor’s Mark-α-Numeric (Maximum 4)
BB = DVC’s code assigned to the Contractors- Alphabet
C = Tower Type Alphabet.
DDD = Number mark to be assigned by Contractor - Numerical.
Erection mark for high tensile steel members shall be prefixed by the letter “H”
F.07 SHOP ERECTION / PROTO-TYPE TOWER ASSEMBLY, IF ANY:
Before starting mass fabrication, one each of the different types of tower complete with
maximum extensions, cross arms and stubs or part thereof/ switchyard structure shall be
assembled horizontally in the shop to check the assembly, details and fabrication
defects, if any, so that any modifications necessary in approved drawing can be
incorporated and a fresh assembly presented to the Corporation’s Engineer or Inspector
for inspection and approval. Mass fabrication shall only start after receipt of final
approval of the check assembly and after successful completion of the tower/ switchyard
structure testing as applicable. The prices quoted for the tower/ switchyard structure
shall include all modifications to be carried out in the fabrication and assembly as a result
of check assembly and tower testing, as applicable.
The contractor shall give, at least two weeks notice to the Corporation for him to arrange
for his Engineer or Inspector to check the assembly.
F.08 TOWER/ SWITCHYARD STRUCTURE FINISH:
Contractor shall quote rates for supply of fully galvanized towers including extensions,
stubs, switchyard structure etc. All bolts and nuts, washers, step bolts and attachments

like hangers, shackles, earth wire, binding clamp, M.S. strip and pipe for earthling shall
also be fully galvanized.
G. TOLERANCE
G.01 TOLERANCE IN HOLES:
Holes for bolting should be cylindrical. The diameter of hole is equal to diameter of bolt +
1.5mm for bolts up to 20mm in diameters. For 24 mm dia bolts, the clearance between
bolt shank and hole is 2.0 mm. While deciding the diameter of the hole whether drilled or
punched, care should be taken in making allowance for thickness of galvanizing coat on
bolts as well as in the holes and for the tolerances in bolt shank diameter. It has been
observed after series of measurements on bolt shanks that their diameter varies up to
0.3 mm above the nominal diameter. Thus, the final diameter of the holes to be
punched/drilled at Black stage will be 1.5mm + bolt diameter + 0.3 mm for bolts up to
20mm in diameter. For 24 mm diameter bolts, the final diameter of the hole at Black
stage will be equal to bolt diameter + 2.0 mm + 0.4 mm.
Blocking of miss-punched/excess holes:

Miss-punch or excess holes not more than one on any one cross-sectional area should
be blocked by proper welding technique by qualified welders. Total number of such
blockings by welding may be limited to three holes in a member. No new holes should
be permitted overlapping the plugged hole. The welding must be of proper quality and
specification to ensure that strength of the welded member shall be not less than that of
the normal member.
G.02 TOLERANCE IN FABRICATION:
(a) On straightness (camber) – 0.4% of the length of sections of sizes up to 100x100mm.

- 0.2% of the length of sections of sizes over 100x100mm.
(b) The maximum allowable difference in diameter of the holes on the two sides of plate
or angle shall be 0.8mm; i.e., the allowable taper in a punched hole shall not exceed
0.8mm on diameter.
(c) On overall length of angle members : ± 2mm
(d) On consecutive holes : ± 1 mm
(e) On first hole to last hole in member : ± 2 mm
(f) On gauge distances : ± 1mm
(g) On specified hole diameters on the punch side : ± 0.3 mm / -0.0 mm
(In black) or where drilled
The fabrication tolerances in general shall conform to IS: 7215. In case of deviation
beyond prescribed tolerance, the assembly of the members may be made as per
Structural Drawings and if the overall dimensions of the structure are within limits, such
items can be accepted. For leg member joint holes, a manufactured cleat may be taken
at random and placed over the member. The bolt should pass at right-angle to the
surface of member. For corner cuts, notches, flanged cuts etc., a tolerance of ± 2.0
mm is allowed.
H TOWER ACCESSORIES (OPTIONAL):
H.01 Anti climbing Device:

Barbed wire type anti climbing device shall be provided and installed by the Contractor
for all towers. The barbed wire shall conform to IS-278 (size designation A1). The barbed
wires shall be given chromating dip as per procedure laid down in IS: 1340.
H.02 Danger, Number, Circuit and Phase plates:

Danger Plates, Number plates, circuit plates (for double circuit line only) and phase
plates shall be provided and installed by the Contractor.
a) Each tower shall be fitted with a danger plate, number plate and two sets of
phase plates for double circuit tower. Circuit plates shall also be provided on all
the Double Circuit towers.
b) The letters, figures and the conventional skull and bones of danger plates shall
conform to IS-2551 and shall be in a signal red on the front of the plate.
c) The corners of the danger, number and circuit plates shall be rounded off to
remove sharp edges.
d) The letters of number and circuit plates shall be red enameled with white
enameled background
I. INSPECTION
General
All standard tests, including quality control tests, in accordance with appropriate
Standard, shall be carried out unless otherwise specified.
a) The Contractor shall keep DVC informed in advance about the time of starting
and of the progress of manufacture and fabrication of various tower parts/ switchyard
structure at various stages, so that arrangements could be made for inspection.
b) The acceptance of any part of items shall in no way relieve the Contractor of
any part of his responsibility for meeting all the requirements of the Specification.
DVC representative shall have free access at all reasonable times to those parts of the
Contractor’s works which are concerned with the fabrication of the DVC’s material for
satisfying himself that the fabrication is being done in accordance with the provisions of
the Specification. Unless specified otherwise, inspection shall be made at the place of
manufacture prior to dispatch and shall be concluded so as not to interfere unnecessarily
with the operation of the work.
If any member of the structure is found not to comply with the supplied or approved
design, it shall be liable to rejection. No member once rejected shall be resubmitted for
inspection, except in cases where the DVC’s authorized representative considers that
the defects can be rectified. Defect which may appear during fabrication shall be made
good with the consent of, and according to the procedure proposed by the Contractor
and approved by DVC.
All gauges and templates necessary to satisfy DVC’s authorized representative shall be
supplied by the contractor. The specified grade and quality of steel shall be used by the
Contractor. To ascertain the quality of steel used, the inspector may at his discretion get
the material tested at an approved laboratory. In general, all measurements are done
with steel winding tapes in accordance with IS: 1270
For inspection of galvanized material, the manufacturer should provide galvanized
coupons enabling the Inspector to carry out tests on the coupons. The coupons should
be taken from the batches corresponding to the fabricated material under inspection.
However, galvanizing test will also be carried out on samples drawn from the finished
material.
J. STRUCTURAL STEELWORK

J.01 MATERIAL
a) STEEL:
IS Steel Sections of tested quality of conformity with IS: 2062 (Grade Designation
E 250 - Fe410 W & Grade Designation E 350 - Fe490) or / and IS: 8500 grade 490
(Designated Y.S. 350 MPa) are to be used in towers, extensions and stub setting
templates.
The chequered plates shall conform to IS: 3502-1994.
The material shall be of tested quality, recent manufacture & free from scales, slag
intrusions, pitting, flake, rusts etc. Steel sections produced by main producers like
SAIL / IISCO / TISCO / RINL shall be used in general. However, steel sections
from the DVC approved re-rollers may also be used.
Procurement of all steel materials required for fabrication of towers, such as

angles, plates, rounds etc. shall be arranged by the contractor himself at his cost.
The rate quoted for supply of towers shall include the cost of steel.
b) ZINC:
The Contractor shall arrange for procurement of Zinc required for galvanizing the
structure by himself. The rate of fabrication shall be inclusive of the cost of Zinc
and galvanization.
The Zinc required for galvanizing shall be of quality Zn 99.99 and shall conform to
IS: 209 latest.
c) BOLTS & NUTS:

All Bolts & Nuts shall conform to IS: 6639 (latest) & IS: 12427 (latest). The step
bolts should conform to IS: 10238 (latest). The bolts shall be of property class 5.6 /
8.8 as specified in IS: 1367 (Pt.-III)(latest) & nuts shall be of property class 5.0 /
8.0 as specified in IS : 1367 (Pt.-VI)(latest).. All bolts & nuts shall be galvanized &
tested in accordance with IS : 2633 (latest) & shall have hexagonal heads & nuts,
the heads being forged out of the solid, truly concentric & square with the shank
which must be perfectly straight. Fully threaded bolts shall not be used. The length
of bolts shall be such that the threaded portion will not extend into the plane of
contact of the member. Diameter of bolt shall be 16 / 20 / 24 mm. unless noted
otherwise.
d) WASHERS:
All pack washers shall be made of steel conforming to IS: 2062 (Grade
Designation E 250 - Fe410 W). The plain washers & heavy washers shall conform
to IS: 2016 & IS: 6610 (latest ) respectively.
Spring washers shall be steel electro galvanized, positive lock type and 3.5mm in
thickness for 16mm dia bolt and 4.5mm for 24mm bolt. It shall conform to IS: 3063
(latest). Spring washers shall be Electro-galvanized in accordance with Service
Condition IV of IS: 1573 (latest).
.
Contractor shall supply 2.5% extra of all sizes of bolts, nuts and washers to take
care of losses during erection. No payment shall be admissible for these extra
supplies.
e) STEP BOLTS & LADDERS:

Each tower/ switchyard structure as per requirement shall be provided with step
bolts conforming to IS: 10238 of not less than 16mm diameter and 175mm long,
spaced not more than 450mm apart and extending from 2.5 meters above the
ground level to the top of the tower. For double circuit tower, the step bolts may be
fixed on two diagonally opposite legs up to top of the towers if shown in the
drawing.

Each step bolt shall be provided with two nuts on one end to fasten the bolt
securely to the tower and button head at the other end to prevent the feet from
slipping away. The step bolts shall be capable of withstanding a vertical load not
less than 1.5 KN.
For special towers, where the height of the super structure exceeds 50 meters,
ladders along with protection rings as per DVC approved design shall be provided
in continuation of the step bolts on one face of the tower from 30 meters above
ground level to the top of the special structure. From 2.5m to 30m height of super
structure step bolts shall be provided. Suitable platform using 6mm thick
perforated chequered plates along with suitable railing for access from step bolts
to the ladder and from the ladder to each cross-arm tip and the ground wire
support shall also to be provided. The platform shall be fixed on tower by using
counter-sunk bolts.
J.02 PROCUREMENT OF RAW MATERIALS
The contractor must state in his tender the name of the manufacturers from whom he
proposes to procure the materials. The contractor shall not obtain without written
permission of the Corporation any material for the purpose of this contract from
manufacturers other than those stated in the tender and approved by the purchaser.
All raw materials required for fabrication, galvanizing etc and for complete execution of
work shall be stocked in adequate quantities by the contractor to ensure that the
progress of work is not hampered.
While designing the towers/ switchyard structure, rationalized steel sections has been
used. During execution of the project, if any particular section is not available, the same
shall be substituted by higher section at no extra cost to DVC and the same shall be
borne by the Contractor. However, design approval for such substitution shall be
obtained from DVC before any substitution.
K. TESTING OF MATERIALS:
K.01 STRUCTURAL STEEL:
Original copies of the test certificates of steel should be sent to the office of the Director
(Technical), DVC Towers, VIP Road, Kolkata – 700 054. Steel collected should be
properly stacked to avoid corrosion and kept for physical verification of the Corporation’s
Engineer. Contractor shall offer all assistance in regard to the Corporation’s inspection
and proper care shall be taken so that steel collected for Corporation’s work is not mixed
up with the steel for other agencies works. Samples from fabricated and / or raw steel for
each type should be tested if required by the Corporation at Govt. Test house or any
DVC approved Testing Laboratory free of cost to the Corporation. Such samples will be
collected by the authorized representative of the Corporation. Test should be made in
accordance with provisions of concerned ISS (latest).
The various testing to be performed are as follows:

1. Material Specification as per IS-2062 (Grade Designation E 250 - Fe410 W & Grade
Designation E 350 - Fe490) and tolerances as per IS-1852.
2. Sampling shall be as per IS-2500.
3. Physical properties: i) Verification of Mill Test Certificate.
ii) Actual Test Certificate from Laboratory.
4. Dimensional and visual inspection shall be in accordance to IS-808 and IS-1852.
5. Chemical Property in accordance to IS-2062 (Grade-A)
K.02 BOLTS AND NUTS

Producer’s routine test certificates for bolts, nuts, washers etc. as laid down in relevant
ISI code approved by the Corporation, shall be submitted by the contractor. In addition,
minimum ten numbers of random sample tests for bolts and nuts for proto-type test tower
and bulk supply shall be performed by the contractor either in Governmental Test House
or any approved Test Laboratory, free of cost to the Corporation. Sample bolts and nuts
will be collected by the Engineer or its authorized agent.
The various Testing to be performed are as follows:
1. Materials Specification: IS-6639 / IS-1363 / IS-1367(Part – III)
2. Sampling shall be as per IS-1367(Part – XVII)
3. Visual Inspection.
4. Dimensional Checking for Bolts & Nuts in accordance to IS-6639 and IS-1363
respectively.
5. Physical Test: i) Bolts – To property class 5.6 / 8.8 as per IS-1367(Part – III)
ii) Nuts – To property class 5.0 / 8.0 as per IS-1367(Part – VI)
6. Galvanizing Test in accordance to IS-1367(Part – XIII)
K.03 SPRING WASHERS
Producer’s routine test for spring washers shall be submitted by the contractor. In
addition minimum ten numbers of random sample tests shall be performed by the
contractor as directed by the Corporation. Sample spring washers will be collected by the
Engineer or its authorized agent.
The various Testing to be performed are as follows:

1. Materials Specification: IS-3063.
2. Sampling shall be as per IS-1367(Part – XVII)
3. Visual Inspection.
4. Dimensional Checking.
5. Permanent Set Test.
6. Twist Test.
7. Hardness Test.
8. Galvanizing Test in accordance to IS-1573 Service condition – IV.
K.04 GALVANIZING
Fabricated Tower Parts, Switchyard Structure & Stubs
The tower parts, switchyard structure, stubs and pack washers shall be hot dip
galvanized .The galvanization shall be done as per requirements of IS 4759 after all
fabrication work is completed. The contractor shall also take guidelines from the
recommended practices for hot dip galvanizing laid down in IS 2629 while deciding and
implementing galvanizing procedure. The mandatory requirements however, are
specified herein.
The zinc coating shall be adherent, reasonably uniform, smooth, continuous and free
from imperfections such as black/ bare spots, ash rust strains, bulky white deposits / wet
storage strains and blisters.
The surface preparation for fabricated tower parts and stubs for hot dip galvanizing shall
be carried out as indicated herein below:
(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,

wherever required, shall be carried out in accordance with clause 4.1 of IS 2629-
1985.After degreasing the article shall be thoroughly rinsed. However, if acidic
degreasers are used rinsing is not required.

(ii) Pickling: Pickling shall be done using either hydrochloric or sulphuric acid as
recommended at clause 4.3 of IS 2629 -1985. The actual concentration of the
acids and the time duration of immersion shall be determined by the Contractor
depending on the nature of material to be pickled. Suitable inhibitors also shall
be used with the acids to avoid over pickling. The acid concentration, inhibitors
used, and maximum allowable iron content shall form part of plant standard to
be formulated and submitted to Purchaser along with Quality Assurance
Program.
(iii) Rinsing: After pickling, the material shall be rinsed, preferably in running water
to remove acid traces, iron particles or any other impurities from the surface.
Two rinse tanks are preferable, with water cascading from the second tank to the
first to ensure thorough cleaning. Wherever single tank is employed, the water
shall be periodically changed to avoid acid contamination, and removal of other
residue from the tank.
(iv) Fluxing: The rinsed article shall be dipped in a solution of Zinc ammonium
chloride. The concentration and temperature of the flux solution shall be
standardized by the contractor depending on the article to be galvanized and
individual circumstances. These shall form part of plant standard to be
formulated and submitted to Purchaser along with Quality Assurance Program.
The specific gravity of the flux solution shall be periodically monitored and
controlled by adding required quantity of flux crystals to compensate for drag-out
losses. Free acid content of the flux solution also shall be periodically checked
and when it is more than two (2) grams of free acid per litre of the solution, it
shall be neutralized. Alternatively, ph value should be monitored periodically and
maintained between 5.0 to 5.5.
(v) Drying: When dry galvanizing is adopted the article shall be thoroughly dried
after fluxing. For the purpose of drying, the contractor may use hot plate, air
oven or any other proven method ensuring complete drying of the article after
fluxing and prior to dipping in the molten zinc bath. The drying process shall be
such that the article shall not attain a temperature at which the flux shall get
decomposed. The article thus dried shall be galvanized before the flux coating
picks up moisture from the atmosphere or the flux layer gets damaged or
removed from the surface. The drying procedure, time duration, temperature
limits, time lag between fluxing, drying, galvanizing etc shall form part of plant
standard to be formulated and submitted to Purchaser along with Quality
Assurance Program.
(vi) Quality of Zinc: Any one or combination of the grades of zinc specified in IS 209
or IS 13229 or other comparable international standard shall be used for
galvanizing. The contractor shall declare the grade(s) of zinc proposed to be
used by them for galvanizing. The molten metal in the zinc bath shall contain
minimum 99.99% zinc by mass. It shall be periodically measured and recorded.
Zinc aluminum alloy shall be added as per IS 2629.
(vii) Dipping Process: The temperature of the galvanizing bath shall be continuously
monitored and controlled. The working temperature of the galvanizing bath shall
be maintained at 450 +/ - 10 degree C .The article should be immersed in the
bath as rapidly as possible without compromising on safety aspects. The
galvanizing bath temperature, immersion angle & time, time duration of
immersion, rate of withdrawal etc shall be monitored and controlled depending
upon the size , shape, thickness and chemical composition of the article such
that the mass of zinc coating and its uniformity meets the specified
requirements and the galvanized surface is free from imperfections and
galvanizing defects.

(viii) Post Treatment: The article shall be quenched in water. The quench water is to
be changed / drained periodically to prevent corrosive salts from accumulating in
it. If water quenching is not done then necessary cooling arrangements should
be made. The galvanized articles shall be dipped in chromating solution
containing sodium dichromate and sulphuric acid or chromic acid base additive
at a predetermined concentration and kept at room temperature to retard white
rust attack. The temperature of the chromate solution shall not exceed 65
degree C. The articles shall not be stacked immediately after quenching and
dichromating. It shall be ensured that the articles are dry before any further
handling operation.
(ix) Storing, Packing and Handling: In order to prevent white rust formation
sufficient care should be exercised while storing handling and transporting
galvanized products. The articles shall be stored in an adequately ventilated
area. The articles shall be stored with spacers in between them and kept at an
inclination to facilitate easy drainage of any water collected on the articles.
Similar care is to be taken while transporting and storing the articles at site.
The Contractor shall prepare a detailed galvanizing procedure including Flow Chart with
control parameters and all plant standards as required above and submit to DVC for
approval as part of Quality Assurance Plan.
The various testing to be performed on the finished galvanized materials:

1. Visual Inspection in accordance to IS-2629.
2. Uniformity of coating (Preece Test) as per IS-2633
3. Magnetic Gauge Test (Elcometer).
4. Stripping Test.
5. Adhesion of coating as per IS-2629.
Contractor shall perform routine test at least three samples from each Batch of
production and record the result in separate registered book. Engineer or its authorized
agent will be present at the time of test. Contractor should submit regularly the result of
all the tests performed to the Corporation for approval.
Fasteners:
For fasteners, the galvanizing shall conform to IS-1367(Part-13). The galvanizing shall
be done with centrifuging arrangement after all mechanical operations are completed.
The nuts, may however be tapped (threaded) or rerun after galvanizing and the threads
oiled .The threads of bolts & nuts shall have a neat fit and shall be such that they can be
turned with finger throughout the length of the threads of bolts and they shall be capable
of developing full strength of bolts. Spring washers shall be electro galvanized as per
Grade-IV of IS-1573.
K.05 OPTIONAL TESTS
DVC may like to send samples of smelter drawn from the galvanizing bath to the
National Test House, Kolkata or similar Test Laboratories for Chemical analysis as per
samples drawn in accordance to IS: 209, in which case the contractor shall furnish the
samples to the Corporation as desired by the latter. The cost of one such test shall be
borne by the contractor and that of any additional test by the Corporation.
L. CALCULATION OF WEIGHT FOR PAYMENT

The weight of tower/ switchyard structure shall mean the weight of tower calculated by
using the black sectional (i.e. un-galvanized) weights of all steel members of the sizes
indicated in the Structural / assembly / fabrication drawings and bill of materials without
taking into consideration the reduction in weight due to drilling of bolt holes, notches,
skew cuts, chamfering, etc. or increase in weight due to galvanizing, but taking into
consideration the weight of Pack Washers, Extension Links, Gusset Plates, Strain Plates
& Other Accessories (D-shackles, hangers, U-Bolts etc.). The weight of stub and cleats
also shall be calculated in similar manner.
The weight of Bolts & Nuts including weight of spring washers and step bolts per tower
shall be calculated from the bolt schedule applicable to each type of towers and body
extensions as approved by DVC.
The contractor is permitted to get inspected and supply upto 2.5% extra fasteners to take
care of losses during erection. No payment shall be admissible for these extra supplies.
M. PACKING
The material shall be boxed or bundled for transport in the following manner:
a) Angle shall be packed in bundles securely wrapped four times around at each end
and over 900 mm with No. 9 SWG gauge wire with ends twisted tightly. Gross
weight of any bundle shall not exceed approximately 450 Kg and length of any
individual members 6000 mm.
b) Cleat angles, brackets, fillet plates and similar small loose pieces shall be tested
and bolted together in multiples, and securely wired together through holes
wrapped round at least four times with No. 9 SWG steel wire and ends twisted
tightly. Gross weight of each bundle shall not exceed approximately 70 Kg.
c) The correct numbers of bolts, nuts and washers plus2.5% extra for each tower
shall constitute a packing unit and shall be dispatched packed in crates or wooden
boxes strong enough to withstand the normal vigorous transit and handling. The
various sizes of bolts, nuts and washers shall be kept in separate bags in side the
main container. Each container shall carry a list of the bolts contained therein
printed in water-proof ink resistant to moisture. The weight of each container shall
not exceed 70 Kg.
N. MARKING OF PACKAGES
Each bundle or package shall have the following details marked on it.
a) The name, designation and address of the Consignee.

b) Ultimate destination as required by the Corporation.
c) The relevant marks and number of tower members or reference of bolts, nuts and
small component like gusset plates, various attachments etc. for easy
identification.
The marking shall be stenciled in indelible ink on the top member of the bundle of towers
steel and on wooden boxes or gunny bags containing smaller components.
Details dispatch instructions shall be asked for by the contractor from the Corporation 4
weeks ahead of the Schedule date of dispatch.
Corporation shall, in no case, be responsible for loss of any package or bundle during
transit. It shall be the responsibility of the contractor to replace the lost items free of cost.
O. STANDARDS

The design, manufacturing, fabrication, galvanizing, testing, erection procedure and
materials used for manufacture and erection of towers, design and construction of
foundations shall conform to the following Indian Standards (IS) which shall mean latest
revisions, with amendments/changes adopted and published, unless specifically stated
otherwise in the Specification. In the event of supply of material conforming to Standards
other than specified, the Bidder shall confirm in his bid that these Standards are
equivalent to those specified. In case of award, salient features of comparison between
the Standards proposed by the Bidder and those specified in this document will be
provided by the Contractor to establish their equivalence.
1. IS:209-1992 Specification for Zinc
2. IS:278-1991 Galvanized Steel Barbed wire
3. IS:800-1991 Code of Practice for General Building Construction in Steel.
4(a) IS:802(Part-1) Code of Practice for General Building Construction in Steel
in Overhead Transmission line Towers :
Sec 1-1995 Section 1 : Materials and loads
Sec 2-1992 Section 2 : Permissible stresses
4(b) IS:802-1990 Code of practice for use of structural steel in Overhead
(Part 2) Transmission Line :
Fabrication, Galvanizing, Inspection and Packing
4(c) IS:802-1990 Code of practice for use of structural steel in Overhead
(Part 3) Transmission Line Towers Testing.
5. IS:808-1991 Dimensions for Hot Rolled Steel Beam, Column, Channel
and Angle Sections
6. IS:875-1992 Code of practice for Design Loads (other than Earthquake)
in Building and Structures.
7. IS:1363-1990 IS: 1363-1990 Hexagon Nuts (size range M5 to M36)
8. IS:1367-1992 Technical Supply Conditions for Threaded Steel / Fasteners.
9. IS:1573-1991 Electro – Plated Coatings of zinc on iron and Steel
10 IS:1852-1993 Rolling and Cutting Tolerance of Hot Rolled Steel Products.
11. IS:2016-1992 Plain Washers ISO/R887

12 IS:2062-1992 Steel for general structural purposes.
13 IS:2074-1992 Ready Mixed Paint. Air Drying, Red Oxide, Zinc Chrome,
Priming Specification
14 IS:2551-1990 Danger Notice Plates
15. IS:2629-1990 Recommended Practice for Hot Dip Galvanizing of iron and
Steel.
16. IS:2633-1992 Method of Testing Uniformity of Coating of Zinc Coated
Articles
17. IS:3757-1992 High Strength Structural Bolts
18. IS:4759-1990 Specification for Hot Zinc coatings on structural steel and
other Allied products.
19. IS:5369-1991 General Requirements for plain Washers.
20. IS:5613-1993 Installation and Maintenance of Overhead Power line.
Section 1 : Design part 2
Section 2 : Installation and Maintenance.
21. IS:6610-1991 Specification for Heavy Washer for Steel Structures.
22. IS:6623-1992 High Strength Structural Nuts.
23 IS:6639-1990 Hexagon Bolts for Steel Structure.
24. IS:10238-1989 Step Bolts for Steel Structures.
25. IS:12427-1988 Bolts for Transmission Line Towers.
26. Indian Electricity Rules.
27 Publication No. Regulation for Electrical Crossing of Railway Tracks.
19(N)/700
P. STRUCTURAL STEEL REQUIREMENT SCHEDULE AS PER APPROVED DRAWING:

P.01 The various Mild Steel (Grade E250-Fe410W) sections to be used for fabrication of 220
KV D/C & Q/C transmission towers are given below:
Sl. No. Section size Sl. No. Section size
1 ISA 45 x 30 x 4 28 ISA 100 x 100 x 10

2 ISA 45 x 30 x 5 29 ISA 110 x 110 x 8
3 ISA 45 x 45 x 4 30 ISA 110 x 110 x 10
4 ISA 45 x 45 x 5 31 ISA 110 x 110 x 12
5 ISA 50 x 50 x 4 32 ISA 120 x 120 x 10
6 ISA 50 x 50 x 5 33 ISA 130 x 130 x 8
7 ISA 50 x 50 x 6 34 ISA 130 x 130 x 9
8 ISA 55 x 55 x 4 35 ISA 130 x 130 x 10
9 ISA 55 x 55 x 5 36 ISA 130 x 130 x 11
10 ISA 60 x 60 x 4 37 ISA 130 x 130 x 12
11 ISA 60 x 60 x 5 38 ISA 150 x 150 x 10
12 ISA 60 x 60 x 6 39 ISA 150 x 150 x 12
13 ISA 65 x 65 x 4 40 ISA 150 x 150 x 16
14 ISA 65 x 65 x 5 41 ISA 150 x 150 x 20
15 ISA 65 x 65 x 6 42 ISA 200 x 200 x 16
16 ISA 70 x 70 x 5 43 ISA 200 x 200 x 20
17 ISA 70 x 70 x 6 44 CHQ PLATE 6
18 ISA 75 x 75 x 5 45 PLATE 2MM
19 ISA 75 x 75 x 6 46 PLATE 3MM
20 ISA 75 x 75 x 8 47 PLATE 4MM
21 ISA 80 x 80 x 6 48 PLATE 5MM
22 ISA 80 x 80 x 8 49 PLATE 6MM
23 ISA 90 x 90 x 6 50 PLATE 8MM
24 ISA 90 x 90 x 8 51 PLATE 10MM
25 ISA 100 x 100 x 6 52 PLATE 12MM
26 ISA 100 x 100 x 7 53 PLATE 16MM
27 ISA 100 x 100 x 8
P.02 The various High Tension Steel (Grade E350-Fe490) sections to be used for fabrication
of 220 KV Q/C transmission towers are given below:
1 ISA 65 x 65 x 5 14 ISA 150 x 150 x 15

2 ISA 75 x 75 x 6 15 ISA 150 x 150 x 16
3 ISA 75 x 75 x 8 16 ISA 180 x 180 x 15
4 ISA 80 x 80 x 6 17 ISA 200 x 200 x 16
5 ISA 90 x 90 x 7 18 ISA 200 x 200 x 18
6 ISA 100 x 100 x 8 19 ISA 200 x 200 x 20
7 ISA 100 x 100 x 10 20 ISA 200 x 200 x 25
8 ISA 110 x 110 x 8 21 PLATE 6MM
9 ISA 110 x 110 x 10 22 PLATE 8MM
10 ISA 120 x 120 x 10 23 PLATE 10MM
11 ISA 130 x 130 x 10 24 PLATE 12MM
12 ISA 130 x 130 x 12 25 PLATE 16MM
13 ISA 150 x 150 x 12

P.03 The various Mild Steel (Grade E250-Fe410W) sections to be used for fabrication of 132
KV D/C transmission towers are given below:
1 ISA 45 x 30 x 5 21 ISA 100 x 100 x 10

2 ISA 45 x 45 x 4 22 ISA 110 x 110 x 8
3 ISA 45 x 45 x 5 23 ISA 110 x 110 x 10
4 ISA 50 x 50 x 5 24 ISA 130 x 130 x 10
5 ISA 50 x 50 x 6 25 ISA 130 x 130 x 12
6 ISA 55 x 55 x 5 26 ISA 150 x 150 x 12
7 ISA 60 x 60 x 5 27 ISA 150 x 150 x 16
8 ISA 65 x 65 x 5 28 ISA 150 x 150 x 20
9 ISA 65 x 65 x 6 29 PLATE 2MM
10 ISA 70 x 70 x 5 30 PLATE 5MM
11 ISA 75 x 75 x 5 31 PLATE 6MM
12 ISA 75 x 75 x 6 32 PLATE 8MM
13 ISA 80 x 80 x 6 33 PLATE 10MM
14 ISA 80 x 80 x 8 34 PLATE 12MM
15 ISA 90 x 90 x 6 35 PLATE 16MM
16 ISA 90 x 90 x 7 36 PLATE 20MM
17 ISA 90 x 90 x 8 37 PLATE 25MM
18 ISA 100 x 100 x 6 38 PLATE 32MM
19 ISA 100 x 100 x 7
20 ISA 100 x 100 x 8
APPROVED VENDOR LIST
STRUCTURAL STEEL Materials
A) MS (Grade E250-Fe410W) / HT (Grade E350-Fe490) Angle Section
Main Producers
a) SAIL
b) IISCO
c) TISCO
d) RINL
Names of Re-rollers
Sl. Vendors Name Address Approval For Type of

No. Steel
1. SANVIJAY ROLLING AND B-202, MIDC, BUTIBORI ANGLE SECTION MS / HT
ENGINEERING LTD Nagpur-441108 UPTO 200X200X25
MM
2. SANVIJAY RE-ROLLING Unit No.H-1, F-16, MIDC ANGLE SECTION MS
AND ENGINEERING PVT. HINGNA, Nagpur. UPTO 130x130x12
LTD MM

3. SANVIJAY STEEL B-202, Butibori, MIDC, ANGLE SECTION MS / HT
(ABHISHEK STEEL) HINGNA, Nagpour- UPTO
441108 130x130x12 MM
4. PRAKASH ISPAT UDYOG F-11 & 12, MIDC, ANGLE SECTION MS / HT
HINGNA Road, Nagpur- UPTO
440016. 70x70x5 MM
5. SHILPA RE-ROLLERS PLOT NO. 1 to 4, Wanjra ANGLE SECTION MS / HT
LTD, BUTBORI Layout, Kamptee Road, UPTO
Nagpur-440044 150x150x20 MM
6. SHILPA RE-ROLLERS PLOT NO.1 to 4, Wanjra ANGLE SECTION MS / HT
LTD., KAMPTEE Layout, Kamptee Road, UPTO
Nagpur-44 110x110x16 MM
7. ORANGE CITY STEEL Kh.No.16, Old Kamptee ANGLE SECTION MS
INDUSTRIES PVT.LTD. Road, Ranala, Nagpur- UPTO
441001. 75x75x10 MM
8. HARIYANA METALS Old Motor Stand, Itwari, ANGLE SECTION MS / HT
LIMITED Nagpur-440008. FROM 90x90x6mm
UPTO
150x150x20mm
9. SHRI BAJRANG ALLOYS 512 / C, URLA ANGLE SECTON MS / HT
LIMITED INDUSTRIAL COMPLEX, UPTO 200x200x25
RAIPUR-493221. MM
10. SWASTIKA STEEL & 8/1, Nutanpara Road, ANGLE SECTION MS
ALLIED PRODUCTS Liluah, UPTO
Howrah -711204. 100x100x10 MM
11. SHREE PARASNATH RE- 3511 Part, Dr. B. C. Roy ANGLE SECTION MS
ROLLING MILLS LTD. Avenue, Durapur – UPTO
713201. 200x200x25 MM

No. Steel
12. MAHAVEER STEEL Gat No. 236/1, Pune ANGLE SECTION MS / HT
INDUSTRIES LIMITED. Solapur Road, Yawat, UPTO
Pune-412214. 100x100x12 MM
13. BHUWALKA STEEL Gut No.204, Khupri ANGLE SECTION MS / HT
INDUSTRIES LIMITED. Village, Taluka Wada, UPTO
Thane. 150x150x20 MM
14. SHRI KRISHNA ROLLING JHOTWARA INDUSTRIAL ANGLE SECTION MS / HT
MILLS LTD. AREA, JAIPUR UPTO
110x110x12 MM
15. R S INDUSTRIES LTD A-241-242, ROAD NO. ANGLE SECTION MS / HT
6AVKIA, JAIPUR - 302013 UPTO
110x110x10 MM
16. PARASURAM FORGING MIDC, HINGNA, ANGLE SECTION MS
PVT. LTD. NAGPUR UPTO
75x75x6 MM
17. MAHARASHTRA STEEL MUSARNA, BHIVANDI- ANGLE SECTION MS / HT
ROLLING & WADA ROAD, TALIKA- UPTO
ENGINEERING WORKS WADA, THANE 70x70x5 MM
18. SUNDER ROLLING MILLS B-212, MIDC Industrial ANGLE SECTION MS / HT
PVT. LTD. Area, Butibori, Nagpur- UPTO
441108 130x130x12 MM
19. PRABHU STEEL 159-160, Small Factory ANGLE SECTION MS / HT
INDUSTRIES LTD. Area, Bagadganj, UPTO 90X90X8 MM
Nagpur-440008
20. B D Castings Ltd 4,Fairlie Place ANGLE SECTION MS
(valid upto 17.05.14 only ) Kolkata-01 UPTO only
100X100X12 MM
21. Hooghly Alloy & Steels Co. 90,Stephen House, ANGLE SECTION MS
Pvt. Ltd 5th Floor UPTO only
(valid upto 17.05.14 only ) Kolkata-01 150x150x20 MM

B) MS/HT Plates
Main Producers
a) SAIL b) IISCO c) TISCO d) RINL
Re-rollers

No. Steel
1. STEEL AUTHORITY OF DANKUNI STOCKYARD, STEEL BOOMS / MS / HT
INDIA LIMITED JANAI, HOOGHLY, WEST BILLETS / ANGLES /
BENGAL PLATES
2. TATA IRON & STEEL JAMSHEDPUR, STEEL BOOMS / MS / HT
COMPANY LIMITED JHARKHAND BILLETS / ANGLES /
PLATES
3. JINDAL STEEL & POST BOX NO. 16, STEEL SLABS / MS / HT
POWER LIMITED KHARSIA ROAD, BOOMS / BILLETS
RAIGARH - 496001
4. RASHTRIYA ISPAT STEEL BOOMS / MS / HT
NIGAM LIMITED BILLETS / ANGLES /
PLATES
5. ESSAR STEEL 27 KM, SURAT HAZIRA PLATES MS / HT

LIMITED ROAD, SURAT – 394270
GUJRAT
6. LLOYDS STEEL LLOYDS NAGAR, PLATES MS / HT
WARDHA
However, the re-rollers of MS/HT angle sections & plates have to ensure the following:
i) Billets / Stabs shall be procured in line with 1S:2830 from the primary producers like
SAIL, RINL, TISCO, and JINDAL for rolling of MS and HT angle sections and plates.
ii) Material shall be rolled in line with the requirement of IS: 2062.
iii) MS angle sections shall be embossed of their own logo at regular intervals.
iv) HT angle sections shall be embossed as ‘HT’ on the rolled sections apart from their
own logo at regular intervals.
v) Any Non-embossed materials will not be accepted.
vi) Proper identifications mark and grade on the MS/HT sheets / plates.
vii) Proper correlation of test certificates with the material being supplied.
viii) Materials may be tested for Spectro Chemical Analysis including all elements for
Carbon Equivalent (CE) at NABL accredited / Govt. Laboratory in addition to
Mechanical Testing as indicated in IS: 2062.
C) B & N and Spring Washer
Sl. Item Name Vendors Name Address Approval For

No.
1. HDG BOLT AND GKW LIMITED 97, ANDUL ROAD, UPTO GRADE 8.8 / 8
NUT HOWRAH – 711 103
2. HDG BOLT AND ASP PRIVATE 7, KUMAR PARA UPTO GRADE 8.8 / 8,
NUT LIMITED ROAD, SPW,
LILUAH, STEP BOLTS (GRADE

HOWRAH – 711 204 4.6), ANTITHEFT, PW
3. HDG BOLT AND BHARAT BOJONATH LAHIRI UPTO GRADE 5.6 / 5,
NUT INDUSTRIES, LANE, SPW,
HOWRAH SANTRAGACHI, STEP BOLTS (GRADE
THROUGH THEIR P.B. NO. HOW-43, 4.6), ANTITHEFT, PW
SOLE SELLING HOWRAH – 711 104
AGENT M/s
SIMPLEX ENGG.
CO.
4. HDG BOLT AND DEEPAK 4TH FLOOR, FIRST UPTO GRADE 8.8 / 8,
NUT FASTENERS LTD. MALL, SPW,
MALL ROAD, STEP BOLTS (GRADE
LUDHIANA – 141 003 4.6), ANTITHEFT, PW
5. HDG BOLT AND NEXO INDUSTRIES 585, OVERLOCK UPTO GRADE 8.8 / 8,
NUT PVT. LTD. ROAD, SPW,
MILLERGANJ, STEP BOLTS (GRADE
LUDHIANA – 141 003 4.6), PW
6. HDG BOLT AND REMAX ( INDIA ) D-62, FOCAL POINT, UPTO GRADE 5.6 / 5,
NUT PHASE – V, SPW,
DHANDARI, STEP BOLTS (GRADE
LUDHIANA 4.6), ANTITHEFT, PW
7. HDG BOLT AND NEXO INDUSTRIES C-16, FOCAL POINT, ANTITHEFT
NUT PVT. LTD. VILL. MANAGARH,
KOHARA-
MACCHIWARA RD.
LUDHIANA
8. SPRING NAVEEN METALS 265, RAI BAHADUR
WASHERS ROAD,
KOLKATA – 700 053
-------------------------End-------------------

TECHNICAL
SPECIFICATION FOR CIVIL
WORK
Damodar Valley Corporation, SPE Section, Electricity Dept.
Tender Specification –
EDCON/EHV/BURDWAN
1
ERECTION SPECIFICATION FOR

CIVIL WORK
DAMODAR VALLEY CORPORATION

ELECTRICITY DEPARTMENT
DVC TOWERS; VIP ROAD
KOLKATA – 700054
SPECIFICATION FOR CIVIL, STRUCTURAL,
ARCHITECTURAL WORKS.
SECTION – I
GENERAL
1.00.00 INTRODUCTION
The Volume of this specification cover site survey, soil investigation, site
development works, design and construction of Civil, Structural and
Architectural works associated with substation Turnkey Package. The scope
of works covers complete Civil, Structural and Architectural Works including
supply of all materials labour, tools and plants as required for successful
execution of the turnkey package.
This section – I lists Codes and Standards to be adopted and the
principal structures of the Sub-station and briefly describes the basic
concept, requirements and features pertinent to each. Documents to be
submitted have also been brought out in this section along with the
procedure to be followed for the same.
2.00.00 CODES AND STANDARDS

Following is a general listing of Codes and Standards to be used in the
design of the substation. Specific applicable codes and standards will be
identified in System Design Descriptions/Technical Specifications as
appropriate. The latest editions/revision of following codes and standards
along with addendums/amendments, if any, shall be followed.
2.01.00 GENRAL
a) Internationally accepted design Codes and Standards where Indian
Codes are not available and which are equivalent to Indian
Standards.
b) National Building Code of India.
c) “Accepted Standards” and “Good Practice” listed in the appendix to
National Building Code of India.
d) IS-200 : Method of measurement of Building and Civil Engineering
Works.
e) IS-1256 : Code of Practice for Building Byelaws.
TS for SUB STN, SPE, DVC

2
2.01.01 Earthwork
a) IS-1498 : Classification and identification of soils for General
Engineering purposes.
b) IS-3764 : Safety Code for excavation work.
c) IS-7293 : Safety Code for working with construction machinery
2.01.02 Concrete
a) IS-269 : Ordinary and low heat Portland cement.
b) IS – 383 : Coarse and fine aggregate from natural sources for
concrete.
c) IS-432 : Mild Steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement.
d) IS -455 : Portland Slag Cement.
e) IS-456 : Code of Practice for Plain and reinforced concrete.
f) IS-460 : Test Sieves (all parts).
g) IS – 516 : Methods of test for strength of concrete.
h) IS-1199 : Methods of sampling and analysis of concrete.
i) IS-4566 : Hard drawn steel wire fabric for concrete
Reinforcement.
j) IS-1786 : High strength deformed steel bars and wires for
concrete reinforcement.
k) IS-1834 : Hot applied sealing compounds for joints in concrete.
l) IS-2386 : Methods of test for aggregates for concrete (all parts)
m) IS-2502 : Code of practice for bending and fixing of bars for
concrete reinforcement.
n) IS-3370 : Code of practice for concrete structures for storage
of liquids (all parts).
o) IS-3414 : Code of practice for design and installation of joints
in buildings.
p) IS-4948 : Welded steel wire fabrics for general use.
q) IS-6452 : High Alumina Cement for Structure use.
r) IS-7320 : Concrete slump test apparatus.
s) IS-7861 : Code of practice for extreme weather concreting (all
parts).
t) IS-8041 : Rapid Hardening Portland Cement.
2.01.03 Foundations
a) IS-1904 : Code of practice for structural safety of buildings :
Shallow foundations.
b) IS-2950 : Code of practice for design and construction of raft
foundations.
2.01.04 Loading
a) IS-875 : Code of practice for Structural safety of building
loading standards.
2.01.05 Masonry
a) IS-712 : Building limes.
b) IS-1077 : Common Burnt Clary Building Bricks.
c) IS-1127 : Recommendations for dimensions and workmanship
of natural building stones for masonry work.
d) IS-1528 : Methods of sampling and physical tests for refractory

3
materials.
e) IS-1597 : Code of practice for construction of stone masonry
(all parts).
f) IS-2212 : Code of practice for brickwork.
g) IS-2116 : Sand for masonry mortars.
h) IS-2185 : Concrete masonry units.
(all parts – Hollow and Solid concrete blocks)
i) IS-2250 : Code of practice for preparation and use of masonry
mortars.
j) IS-2572 : Code of practice for construction of hollow concrete
block masonry .
k) IS-2691 : Burnt clay facing bricks.
l) IS-3414 : Code of practice for design and installation of joints
in buildings.
m) IS-3495 : Methods of tests of burnt clay building bricks.
n) IS-4441 : Code of practice for use of Silicate type chemical
resistant mortars.
o) IS-4860 : Acid Resistant Bricks.
2.01.06 Doors, Windows and Ventilators

a) IS-399 : Classification of commercial timbers and their zonal
distribution.
b) IS-883 : Code of practice for design of structural timber in
building.
c) IS-1003 : Timber paneled and glazed shutters (all parts)
d) IS-1038 : Steel doors, windows and ventilators.
d) IS-1081 : Code of practice fox fixing and glazing of metal (steel
and aluminium) doors, windows and ventilators.
f) IS-1361 : Steel windows for industrial buildings.
g) IS-2835 : Transparent sheet glass for glazing and framing
purposes.
h) IS-1948 : Aluminium doors windows and ventilators.
i) IS-1949 : Aluminium windows for industrial building.
j) IS-2191 : Wooden flush door shutters (Cellular and hollow core
type)
k) IS-2202 : Wooden flush door shutters (solid core type)
l) IS-3103 : Code of practice for Industrial ventilation.
m) IS-3548 : Code of practice for glazing in buildings.
n) IS-3614 : Timber door, windows and ventilator frames.
p) IS-4351 : Steel door frames.
q) IS-6248 : Metal rolling shutters and rolling grills.
2.01.07 Roof and Flooring

a) IS-2204 : Code of practice for construction of reinforced
concrete shall roof.
b) IS-3201 : Criteria for the design and construction of precast
concrete trusses.
c) IS-2210 : Criteria for Design of R.C. shall structures and folded
plates.
d) IS-809 : Rubber flooring materials for general purposes.
e) IS-1196 : Bitumen mastic for flooring.

4
f) IS-1198 : Code of practice for laying, fixing and maintenance of

linoleum floors.
h) IS-1237 : Cement concrete flooring tiles.
i) IS-1443 : Code of practice for laying and finishing of cement
concrete flooring tiles.
j) IS-2114 : Code of practice for laying in situ terrazzo floor
finish.
k) IS-2571 : Code of practice for laying in situ cement concrete
flooring
l) IS-5491 : Code of practice for laying in situe granolithic
concrete floor topping.
m) IS-5766 : Code of practice for laying burnet clay brick flooring
n) IS-1197 : Code of practice for laying of rubber floors.
o) IS-2441 : Code of practice for fixing ceiling coverings.
2.01.08 Waterproofing
a) IS-1322 : Bitumen felts for waterproofing and damp proofing.
b) IS-1346 : Code of practice for waterproofing of roofs with
bitumen felts.
c) IS-1609 : Code of practice for laying damp proof treatment
using bituminous felts.
d) IS-3036 : Code of practice for laying lime concrete for a
waterproofed roof finish.
e) IS-3037 : Bitumen mastic for use in waterproofing or roofs.
f) IS-3067 : Code of practice for general design, details and
preparatory work for damp proofing and water
proofing of buildings.
g) IS-3384 : Bitumen primer for use in water proofing and damp
proofing.
h)IS-4365 : Code of practice for application of bitumen mastic for
waterproofing of roofs.
2.01.09 Soil Engineering

a) IS-1498 : Classification and identification of soil for general
engineering purpose.
b) IS-1892 : Code of practice for sub-surface investigation for
foundation.
c) IS-2131 : Method for standard penetration test for soils.
d) IS-2720 : Methods of test for soils (all parts)
2.01.10 Water Supply, Drainage and Sewerage
a) IS-404 : Lead pipes
b) IS-458 : Concrete pipes
c) IS-651 : Salt glazed stoneware pipes and fittings.
d) IS-771 : Glazed fire-clay sanitary appliances (all parts).
e) IS-774 : Flushing cisterns for water closets and urinals other than
plastic cisterns.
f) IS-783 : Code of practice for laying of concrete pipes.
g) IS-1172 : Code of basic requirements for water supply, drainage and
sanitation.
h) IS-1626 : Asbestos cement building pipes, gutters and fittings (all
parts).

5
i) IS-1742 : Code of practice for building drainage.

j) IS-2064 : Code of practice for selection, installation and
maintenance of sanitary appliances.
k) IS-2065 : Code of practice for water supply in buildings.
l) IS-2470 : Code of practice for installation of septic tanks (all parts).
m) IS-3114 : Code of practice for laying of cost Iron pipes.
n) IS-4127 : Code of practice for laying of glazed stoneware pipes.
o) IS-12251 : Code of practice for Drainage of Building Basement.
p) IS-1200 : Method of measurement : Laying of water and [Part-XVI]
sewer lines including appurtenant items.
q) IS-3486 : Cast iron spigot and socket drain pipes.
r) IS-5329 : Code of practice for sanitary pipe work above ground for
buildings.
s) IS-3076 : Low density polyethylene pipes for potable water supplies.
t) IS-1538 : Cast iron fittings for pressure pipes for water, gas and
sewage.
u) IS-1230 : Cast iron rainwater pipes and fittings.
v) IS-1729 : Sand cast iron spigot and socket soil, waste and ventilating
pipes, fittings and accessories.
w) IS-1726 : Cast iron manhole covers and frames.
aa) IS-5961 : Cast iron grating for drainage purposes.
bb) IS-5219 : “P” and “S” traps.
[Part-I]
cc) IS-772 : General requirements for enameled cast iron sanitary
appliances.
dd) IS-775 : Cast iron brackets and supports for wash basins and sinks.
ee) IS-777 : Glazed earthenware wall tiles.
ff) IS-2548 : Plastic water closet seats and covers (all parts).
gg) IS-2527 : Code of practice for fixing rainwater gutters and downpipes
for roof drainage.
2.01.11 Paving and Road work
a) IS-73 : Paving bitumen
b) IS-702 : Industrial Bitumen
c) IS-1201 : Method of testing tar and bituminous materials thru 1220.
d) Practice followed by Indian Road Congress (all parts).
2.01.12 Earthquake Resistant Design

a)IS-1893 : Criteria for earthquake resistant design of structures.
b) IS-4326 : Code of practice for earthquake resistant design and
construction of building.
2.01.13 Structural Steelwork
a) IS-800 : Code of practice for general construction in steel.
b) IS-802 : Code of practice for use of structural steel in Overhead
Transmission Line.
Part – I : Load and permissible stresses.
Part – II : Fabrication, Galvanising, Inspection and
Packing.
c) IS-808 : Rolled steel beams, channels and angle sections.
d) IS-813 : Scheme of symbols for welding.
e) IS-814 : Covered electrodes for manual metal arc welding of
carbon and carbon manganese steel.

6
f) IS-816 : Code of practice for use of metal arc welding for general
construction in mild steel.
g) IS-817 : Code of practice for training and testing of metal arc
welders.
h) IS-818 : Code of practice for safety and health requirements in
electric and gas welding and cutting operation.
i) IS-819 : Code of practice for Resistance spot welding for light
assemblies in Mild Steel.
j) IS-919 : Recommendations for limits and fits for engineering
k) IS-1200 : Method of measurement of steelwork and ironwork.
[Part – VIII]
l) IS-1239 : Mild steel tubes, tubular and other wrought steel fittings (all
parts).
m) IS-1363 : Black hexagonal bolts, nuts and locknuts (dia. 6 to 39 mm)
and black hexagon screws (dia. 6 to 24 mm) [all parts].
n) IS-1364 : Precision and semi-precision hexagon bolts, screws, nuts
and locknuts (dia. Range 6 to 39 mm) [all parts]
o) IS-1365 : Slotted counter sunk head screws (dia range 1.6 to 20
mm)
p) IS-1367 : Technical supply conditions for threaded steel fasteners.
q) IS-1443 : Code of practice for laying and finishing of cement
concrete flooring tiles.
r) IS-1608 : Method for tensile testing of steel products .
s) IS-1730 : Dimensions for steel plate, sheet and strip for structural
and general engineering purpose.
t) IS-1731 : Dimensions for steel flats for structural and general
engineering purposes.
u) IS-1852 : Rolling and cutting tolerances for hot rolled steel products.
v) IS-1977 : Structural steel (Ordinary quality)
aa) IS-2016 : Plain Washers.
bb) IS-2062 : Steel for General structural purposes.
cc) IS-2074 : Ready mixed paint, air drying, red oxide zinc-chrome,
priming.
dd) IS-2633 : Methods of testing uniformity of coating of zinc coated
articles.
ee) IS-3757 : High strength structural bolts.
ff) IS-4000 : High strength bolts in steel structures.
gg) IS-4759 : Hot dip zinc coatings on structural steel and other allied
products.
hh) IS-7215 : Tolerances for fabrication of steel structures.
ii) IS-7318 : Approval tests for welders when welding procedure
[Part – I] approval is not required.
jj) AWSD1.1 Structural Welding Code.
2.01.14 Painting
a) IS-348 : Specification for French Polish
b) IS-427 : Specification for Distemper, dry colour as required.
c) IS-428 : Specification for Distemper, oil emulsion, colour as
required.
d) IS-1477 : Code of practice for painting of ferrous metal in buildings.
[I & II]
e) IS-2338 : Code of practice for finishing of wood and wood based

7
[I & II) materials.

f) IS-2339 : Specification for Aluminium Paints for general purposes in
dual containers.
g) IS-2395 : Code of practice for painting concrete, masonry and
plaster surface.
h) IS-2932 : Specification for enamel, synthetic, exterior – a)
undercoating, b) finishing.
h) IS-2933 : Specification for enamel, exterior – a) undercoating, b)
finishing.
i) IS-5410 : Specification for cement paint.
2.01.15 Environmental Protection:

Charter on Corporate Responsibility for Environmental Protection (CREP)
published in Gazette of India dated 27.08.2003.
3.00.00 SCOPE OF CIVIL WORKS

The scope of civil work comprises all necessary investigations
survey/foundations, building, superstructures and infrastructure required for
the complete operating power station.
The work under this Section consists of Civil, Structural and Architectural
works, but not limited to items mentioned below.
- Area Grading, leveling & dressing.
- Soil investigation
- Demolition and site clearance including tree cutting
- Plant Boundary Wall as per Plot Plan
- Temporary fencing between facilities of existing units & proposed
area.
- In Substation Road connecting the road network of the existing
Substation (as marked in Plot Plan) and access road from adjacent
Public Road/Highway outside Boundary.
- Drainage network (as marked in Plot Plan) and terminating the same
up to the out fall location identified in the Plot Plan.
- Transformer yard including transformer foundations, Fire walls, Rail
track etc.
- Electrical Grounding mat
- Cable/pipe racks.
- 220 KV Substation structures & foundations, switchyard control buildings
& GIS Hall.
- All other civil items not covered above but required for completion and
proper functioning of the plant shall from part of the scope.
- Architectural finishing including flooring, paving, Side cladding with or
sheeting brick masonry, walls, plastering, painting, false ceiling doors &
windows, plumbing, roof treatment etc. for GIS hall buildings.
The scope shall also in include setting up by the Contractor a complete testing laboratory in
the field to carry out all relevant tests required for the civil works for the project.
Water will be supplied by the Owner free of charge at a mutually agreed single point within
the battery limit of existing plant & the Bidder shall arrange distribution of the same beyond
the above point at their own cost.
A list of Civil-Field Quality Assurance Laboratory Apparatus is enclosed in Annexure

8
– II of the Section.
The Bidder shall visit the site and assess the involvement of demolition and site clearance,
if required, within the area to construct the project & accordingly the costs is to be
considered in his offer.
The work shall have to be carried out both below and above the ground level. The work
shall be executed accordance to the relevant Indian Standard Code, and in its absence the
work shall be executed according to the best prevailing local Public Work Department
(PWD) practices or to the recommendations of relevant American and British Standards or
to the instructions of the Owner’s Engineer. This shall prevail in respect of civil works for
which no specification has been prescribed in this section.
The work shall be carried out according to the design/drawings to be developed by the
Contractor and approved by the Owner/Owner’s authorized Consultant. For all building
structures, foundations etc., necessary terraced layout and details are to be developed by
the Contractor keeping in view the statutory & functional requirement of the plant & facilities
and providing enough space & access for operation, use and maintenance.
The land will be given to the Contractor by the Owner as is where basis. All site
investigations, surveys, grading and levelling and other additional works shall be carried
out by the Contractor.
The layout and levels of all structures shall be made by the Contractor at his own cost from
the general grid of the plot and the nearest GSI bench mark or other acceptable bench
mark of Govt. Dept. The Contractor shall be solely responsible for the correctness of the
layout and levels.
All necessary statutory clearances shall be obtained by the Bidder prior to execution of
work under scope of this specification.
All the quality standard, tolerances, welding standards and other technical requirements
shall be strictly adhered to by the Contractor.
3.0.01 INSTRUCTIONS TO BIDDERS
3.0.02 Bidder are requested to go through the bid documents carefully. In case
of any contradiction/conflicts in various clauses given here in, the same
shall be brought to the notice of the owner clause wise. Owner’s decision
shall be binding on bidder and shall have no implication to Owner.
Deviations from bid document if any shall be furnished by bidder clause

wise clearly.
3.0.03 List of equipment to be deployed by the Bidder and his associates is to

be furnished to the Owner.
3.0.04 Time being essence of contract, Bidder shall submit L-1, L-2 & L-3
schedule for engineering design and construction for each
building/structure.
3.0.05 A detailed note on quality plan for construction activity proposed to be

adopted for assuring quality of civil works to be furnished.
3.0.06 List of all sub contractors that the bidder proposes to employ, in case the
contract is awarded to him, indicating their addresses with telephone
number, experience on similar jobs, name, qualification and experience
of persons who shall be involved in the project etc. on behalf of the
Bidder shall be submitted to Owner for specific approval. Only Sub

9
contractors approved by the Owner shall be engaged by the Bidder on

the job.
3.0.07 A quality control laboratory shall be established at site along with a list of
necessary testing equipments shall be furnished to the Owner for
approval.
3.0.08 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 or his representative and shall comply strictly
with the tests prescribed hereinafter or, where tests are not laid down in
this specification, with the requirements of the latest issue of the
relevant Indian, American, British, German Standards or other Standards
approved by the Engineer.
3.0.09 Samples of all materials proposed to be used in the works shall be

approved by the Engineer/Owner.
3.0.10 The work shall be carried out by competent personnel skilled in their
various trades.
3.0.11 Before commencing the works, the contractor shall ascertain the
locations and nature of all existing underground services and shall take
every possible precaution against any damage occurring to them or
interference therewith, during the execution of the works.
3.1.01 Inspection of Site by Bidder
Bidder shall inspect the site, examine and obtain all information required
and satisfy himself regarding matters and things such as access to site,
site conditions, communications, transport, right of way, type and
number of equipment and facilities required for the work, availability of
local labour, materials and their rates, local working conditions, weather,
subsoil conditions, natural drainage etc. All required dismantling/re-
construction including strengthening if required/re-erection of existing
facilities is under bidder’s scope. No extra claim on any account shall be
entertained by Owner. Ignorance of the site conditions shall not be
accepted by the Owner as basis for any claim for compensation or
extension of time.
Submission of a bid by the Bidder shall be construed as evidence that
such an examination was made and any claims / disputes later in regards
his quotation shall not be entertained or considered by the Owner.
The Bidder shall organize his own arrangement to transport his

equipment, men and material so as to match the construction schedule.
3.1.02 Construction and Erection Methodology
The Contractor shall execute all works at site as per approved

construction and erection methodology based on the detail given herein:

10
 Construction and erection activities shall generally be mechanized.

 The Contractor shall prepare detailed construction and erection
methodology scheme, which shall be compatible to the requirements.
 All excavation and backfilling works shall preferably be done using
excavators, loaders, dumpers, dozers, poclains, JCB’S excavator,
rock breakers, vibro compactors, vibratory rollers, vibro rollers,
sprinklers, water tankers, etc. Manual excavation can be done only
on isolated places, with specific prior approval of the Owner.
 De-watering wherever required shall be done using the combination
of electrical and standby diesel pumps. Wherever necessary, well-
point de-watering system shall generally be deployed. Sludge pumps
and high head pumps, wherever required, shall be used.
 For controlled rock blasting (if applicable) specialist agency, equipped
with sensors to assess the impact of the blast on the adjoining
existing structures, shall be employed. Pneumatic wagon drills with
compressors shall be deployed for controlled blasting.
 All concreting shall be done using Individual mixers / centralized

batching plant, transit mixers, concrete pumps and electrical hoists.
 The structural steel shall generally be fabricated and erected frame
wise and bay wise and temporary bracings strengthening of
members during erection shall be provided.
 All fabrication and erection activities of structural steel shall
generally be carried out using automatic submerged arc welding
machines, MIG welding machines, welding generators, pug cutting
machines, cutting torches, pillar drill machines, gantry cranes,
crawler mounted heavy cranes and other equipment like heavy
plate bending machines, shearing machines, lathe, milling machines,
grinders, etc.
 Fabricated structure shall preferably be transported from the pre-
assembly / fabrication yard to the erection site by trolley moving on
rails.
 Fabrication and erection of all structural steel works shall be done
with the help of cranes only. Use of derricks shall not be preferred.
Gantry cranes / truck mounted / cranes / crawler cranes shall be
used in pre-assembly yard / fabrication yard. Heavy crane having
lifting capacity and boom length matching with the heaviest part to
be lifted shall be used for the erection work, in combinations of
other cranes. For erection of heavy members simultaneous use of
two cranes may be required. Columns and roof trusses shall be
erected in single piece, unless specified otherwise.
 Blast cleaning of the steel surfaces shall be done in a suitable
enclosure, so as not to cause any damage / pollution to the
adjoining areas. Painting shall generally be done using airless spray
guns. Handling of the structures shall be done in a mechanised way.
 Modular units of scaffolding and shuttering shall be used.
 All grouts shall be non-shrink type as per BOQ.
 All finishing items including roofing / cladding / sheeting, etc, shall
be installed / fixed in position, using appropriate modern mechanical
tools and deploying expert technicians. Manual punching, etc, shall
not be permitted.
 Electrical power winches, electrically operated heavy duty hoists

11
and tyre mounted mobile tower crane, for lifting of construction

materials shall be deployed.
 Cleaning of surfaces wherever required, shall be done by compressed
air using heavy duty compressors.
 Stone / tile / marble / granite cutting and polishing machines shall
be deployed for flooring works.
 Breaking of concrete, wherever required, shall be done by using
jack hammers, diamond cutter as per requirement.
 Road work be done using powers, rollers and premix plant.
 Field laboratory shall be provided with all latest equipment for
aggregates, concrete, etc. For testing of structural steel works,
ultrasonic testing machines, radiographic testing machines, dye
penetration test equipment, etc, shall be deployed as specified in
Quality Assurance requirements. Help of specialist agencies shall be
taken for ultra-sonic/radiographic and other specialized testing.
 Other materials like cables, slings, heating ovens, pre-heating
arrangement, materials for making platforms and platform supports,
etc, shall be mobilized as per the requirement.
 All persons working at site shall be provided with necessary
safety equipment such as gloves, goggles, safety belts, safety
helmets, reflective jacket etc.
 All safety aspects shall be duly considered for each
construction/erection activity. Contactor shall prepare a activity wise
detailed safety plan for the approval from Owner, considering risk
involved & its safety measure for all types of activities to be taken
place during project etc.
 Contractor shall also ensure the availability of adequate medical
facilities at site as per approved plan.
 Only the persons who are trained in the respective trade shall be
employed for executing that particular type of work.
 All layouts and levels shall be taken using digitised theodolite
and level i.e. Total workstation.
 The Contractor shall mobilise all plants, equipment & machineries
required for successful completion of the work. Any additional
plants, equipment and machinery required for the timely completion
of the works but not listed in the Appendix – B shall also be
deployed by the Contractor, as directed by the Owner
*******************************************************************************************************
4.0.00A. Substation
Substation structures comprise of all towers, gantries, lighting towers, lightning
towers/masts, chain link fencing with gates, equipment supports and other structure – all of
galvanized steel and with bolted type joints. Foundations for above structures will be
reinforced cement concrete. Cable trenches with precast RCC covers of removable type,
sump pits, oil pits, cable tray supports, grounding etc. will be constructed in Switchyard
areas. Foundations for jacking transformers, oil drainage piping etc. will also be provided.
Baffle walls shall be arranged based on layout of transformers and statutory requirement.
Additional protection for buried cables need be provided under road/railway track in form of
RCC/galvanized iron pipes/RCC box culvert.
Lighting towers shall be provided with a structural steel ladder from its base up to the top of
tower. The ladder shall be provided with protection guards in the form of rings. Platform
(having a maximum spacing of 10 meters) with protection hand-railing shall be provided at

12
suitable heights for mounting of lighting fixtures.
4.0.00: Roads
Main access to the Sub-station shall be from adjacent Public Road/Highway. All substation
service roads 4 M/6 M wide, water bound macadam with bituminous topping on prepared
sub grade for heavy vehicles, providing access to all truck sized building doors and all
structures requiring maintenance by vehicles. Water bound macadam with bituminous
topping will be provided at areas requiring parking areas shall be done after completion of
substation construction.
Substation roads under scope of this package shall be connected to the existing roads of
the substation for smooth movement of internal traffic.
Peripheral road around Boundary wall (Inside), are also within the scope of this contract.
All Roads shall be designed in accordance with the provision of the latest edition of the
relevant I.R.C. codes of practice.
The subgrade shall be prepared with well compacted selected soil/earth. Subbase shall be
225 mm thick (consolidated thickness) grannular subbase with crushed stone (grading-1),
morum and sand. Seal coat shall be 25 mm thick. The wearing coarse shall be 75 mm thick
bitumen concrete binder course with 25 mm open graded premix carpet, laid on 225 mm
thick (compacted thickness) water bound macadam course.
4.0.00C Transformer Areas and Switchyard
Oil cooled equipment, such as transformers, will be located within concrete
basins filled with gravel. The individual basins will be connected by pipeline
to a separate chamber/oil pit for collection and further reclamation of oil
through oil water separators, if necessary, Drains will be adequate to
remove full discharge from deluge system used for fire control. Transformer
Yard will be paved with reinforced cement concrete. Switchyard area shall
be filled with 75 mm thick concrete P.C.C (M10).
4.0.00D Drainage System
Yard drainage system shall be designed in two parts:
i) Main Drains
ii) Auxiliary Drains
Main drains, Metro drains shall be designed as a network covering plant
area within the battery-limit of this specification. This plant area drainage
has to be terminated at the outfall location shown in the Plot Plan. Attempts
will be made to convert construction drains into main drain as far as
practicable. Auxiliary/Branch drains shall cover individual grades to terrains,
collect storm water and other non-contaminated discharge from plant
buildings and then be connected to Main drain at suitable locations. The
invert of the in-plant peripheral drains shall be kept such that water can be
discharged by gravity to the main/trunk drain under all condition. RCC pipe
culverts/box culverts will carry drainage under interrupting roads and railway
tracks. Effluent drains shall completely be separated from storm water
drainage and not within the Scope of this contract. Suitably designed
underground storm water RCC piping on the basis of design loads specified
elsewhere in this specification shall be limited to required areas where
surface drainage ways are not desirable or practicable from other functional

13
point of view. Class of RCC pipes shall be decided by Bidder as per design
requirement. For pipe drains, concrete pipes of minimum grade – Class NP2
will be used. However, for road concrete pipes of Class NP3 will be used
R.C.C. Manholes will be provided at maximum 30 m intervals along the
length, at connection points and every change of alignment, gradient or
diameter of pipeline. The drains shall generally be of open type RCC
rectangular construction with RCC pre-cast cover. R.C.C. (M-20) perforated
precast cover of minimum thickness 75mm with provision of openable G.I.
grating cover at about 4.0 m interval. Thickness of G.I. grating over drain
shall be 40 m and 32 mm for inside building and outside area (without
vehicular movement and equipment load) respectively. The storm water
drainage shall also cater for discharge of treated waste water. The drainage
system shall be designed for precipitation intensity of 75 mm per hour
(maximum hourly intensity of rainfall).
Surface drains will normally have a slope of 1 IN 1000 along longitudinal
direction and RCC pipes to have such slops such as to have effective
discharge. RCC or masonry structures will be provided at drops/falls to
prevent scouring. Minimum self-cleansing velocity should be adopted as 0.8
m/sec.
4.0.00E. Sanitary Sewerage System:
For sewage treatment, adequate number of septic tanks will be installed and
the effluent shall be discharged Soak Pit.
5.0.00 A DOCUMENT SUBMISSION
Design and Construction documents pertaining to all Civil. Structural and
Architectural works that will be required to be submitted to Owner/Owner’s
Consultant/Review Consultant for their approval have been brought out
under following clauses. Approval of these documents by the
Owner/Consultant shall not relieve the Contractor of his responsibility for
any errors and fulfillment of Contract requirements.
5.0.00B. Design Document:
Design Document shall comprise Electrical assignment Drawings, design
data, design assumptions & references, detailed structural analysis
(including computer output, if any) & design calculations and design
drawings.
Design calculations and drawings shall be submitted and reviewed only after
approval of corresponding Electrical/System general arrangement drawings.
The contractor shall submit approved GA drawings along with three (3)
copies of design documents (except design drawings) and eight (8) copies
of design drawings for comments/ approval of the Owner/Consultants.
Soft/electronic copy of 2D and 3D analysis file and drawing shall be
submitted with first submission. Contractor shall submit three (3) copies of
design calculation and twelve (12) copies of the drawing with one soft copy
in CD each to the Owner and consultant for distribution.
5.0.00C. Construction Document
Based on approved design drawing, detailed drawings for construction will
be prepared by the Contractor. For reinforced concrete structures and
foundations detailed bar bending schedules in approved format shall

14
accompany each detailed drawing. For structural steel work the Contractor
will prepare detailed fabrication drawing along with bill of materials.
Six (6) copies each of selected or all detailed drawings/fabrication drawings
as decided by Engineer for all structures along with bar bending
schedule/bill of materials need be furnished to Owner/Consultants for their
review and approval.
5.0.00D. As Built Drawings:
“As-built” drawings shall be prepared by the Contractor after completion of
construction/erection incorporating all the changes, if any, done on
Engineer'’ instruction/approval. After completion of construction, Contractor
shall submit eight (8) copies of the all drawings, irrespective of any changes
during construction, market “As Built” with one soft copy in CD each to the
Owner.
6.0.00 LAYOUT
Before starting the work, the Contractor shall carry out the setting out of
foundation and structures and provided levels, with reference to general
existing grid and bench mark. If the Contractor uses the grid, bench mark
and reference pillar made by other Contractors, he shall co-ordinate with the
Contractor and shall satisfy himself of the accuracy of the reference marks.
If he is required to set out the foundation afresh, he shall do so
independently with reference to the one existing grid and bench mark which
has been followed by other agency at the instruction of the Engineer. In
case any discrepancy be found, it shall be immediately brought to the notice
of the Engineer for any rectification/modification necessary. No complaint
shall be entertained at a later stage. The Contractor shall accurately set out
the position for holding down bolts and inserts.
If required, in the option of the Engineer, he shall construct and maintain
pillars for grid, references and bench marks and maintain them till the
completion of the construction. He shall also help the Engineer with
instruments, materials and labours for checking the detailed layouts and
levels. The Contractor shall be solely responsible for the correctness of the
layout and levels, and Engineer’s approval shall not be deemed to imply any
warranty in carrying out the works correctly. The Tenderers shall take into
account the cost of these in quoting their price.
7.0.00 WORKMANSHIP
Workmanship shall be of the best possible quality and all work shall be
carried out by skilled workmen except for those which normally require
unskilled persons. Welding shall be done by experienced and certified
welders in proper sequence using necessary jigs and fixtures. Fabrication
shall be done in shops having proper equipment for accurate edge – lanning
and milling of column shaft ends, base plate surfaces etc. and shaping and
dimensioning of anchor bolt assembly, inserts and other misc. items. In
addition to the requirement specified above, if the bye-laws of the local
Govt. Municipal or other authorities require the employment of licensed or
registered workmen for various trades, the Contractor shall arrange to have
the work done by such registered or licensed personnel. In case of
manufactured materials, the Contractor shall have, with no additional cost to
the Owner, the services of the supervisors of the manufacturers to ensure

15
that the work is being done according to the manufacturer’s specifications.

8.0.00 TEMPORARY WORK
All scaffoldings, staging, temporary bracing and other necessary temporary
work required for proper execution of the Contract shall be provided by the
Contractor at his own cost and inclusive of all materials, labour, supervision
and other facilities.
The layout and details of such Temporary work shall have the prior approval
of the Engineer but the Contractor shall be responsible for proper strength
and safety of the same. All Temporary work shall be so constructed as not
to interfere with any permanent work shall be so constructed as not to
interfere with any permanent work or with the work by other agencies. If it is
necessary to remove any of the temporary work at any time to facilitate
execution of the work or with the work of other agencies such removal and
re-erection, if required, shall be carried out by the Contractor at the direction
of the Engineer without any delay and any extra cost on this account shall
be borne by the Contractor.
9.0.00 SEQUENCE OF WORK AND PROGRESS REPORT

The sequence in which the work s are to be carried out shall be as approved
by the Engineer in accordance with the construction method accepted by
the Engineer and to be followed by the Contractor. A Programme of work is
to be submitted for the Engineer’s review and approval and this has to be
periodically updated and modified as per actual to enable timely completion.
The Contractor shall regularly submit to the Engineer progress reports for
periods of working as specified by the Engineer showing upto date progress
on all important items of work.
10.0.00 DESIGN CONSIDERATION FOR:
Generally most of the Structure are standard & only those structure
which is not available with owner are need to be designed by contractor and
prior approval of the same is to taken from owner before execution.
a) Switchyard Structures
Gantry structures consist of open web towers connected by girders. These
shall be made of structural steel conforming to IS : 2062 Grade and duly
galvanized conforming to IS : 2629. All joints shall be bolted connections. All
bolts shall be 16 mm dia conforming to IS : 12427 of property class 5.6
conforming to IS : 1367 (Part 6) : 1980. Nuts shall conform to I.S. 1363 (Part
3) : 1992 of property class 5. But splice is used for splicing the main
members and splice shall be located away from the node point. IS : 802
“Code of practice for use of structural steel in overhead transmission line
towers” shall be followed for design of structural supports & IS : 875 (Part –
II) shall be followed for wind force calculation. Height & type of towers shall
be established based on electrical requirements.
Switchyard structures shall be designed for the worst combination following
loads :

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1) Dead loads (load of wires/conductors, insulator, electrical equipment’s and

structural members),
2) Live loads.
3) Wind load on bus bars, shield, wires, insulator strings, electrical equipment,
structural members etc as per IS : 802.
4) Seismic loads.
5) Temperature load.
6) Loads due to deviation of conductor (gantries shall be checked for + 30 deg.
deviation in horizontal plane and + 20 degree deviation in vertical plane).
7) Loads due to unbalanced tension in conductor/wire.
8) Torsional load due to unbalanced and horizontal forces.
9) Erection loads.
10) Short circuit forces including snap in case of bundled conductors, etc.
Note :
i) The occurrence of earthquake and maximum wind pressure is unlikely to
take place at the same time. The structure shall be designed for either of the
two. However, temperature stresses can be ignored, as these towers are
freestanding structure in open space.
ii) Direction of wind shall be assumed such as to produce maximum stresses
in any member for the combination of wind load with conductor tensions.
The wind acting perpendicular and parallel to bus conductor and shield wire
shall be considered separately.
iii) The conductor tension shall be assumed as acting on only one side of the
gantry for the analysis and design of switchyard gantries.
iv) The distance between terminal and dead end gantry shall be taken as 200
meter.
Factor of safety:
The factor of safety for the design of members shall be considered as 2.0 for
normal condition and broken wire condition, 1.5 for combined short circuit and
broken wire condition. Foundation shall be designed for a factor of safety of 2.2 for
normal and broken wire condition and 1.65 for combined short circuit and broken
wire condition.
b) Design consideration for Equipment support:
The supporting structure for B.P.I., LA, CVT & Isolator equipment’s shall be
comprised of GI (ERW) pipe of grade YST : 210 or of higher grade conforming to IS
: 1161 & shall be designed as per IS : 806 “Code of Practice for use of steel tubes
in general building construction”.

17
The supporting structure for CT & Wave Trap equipment shall be comprised of
lattice structural steel conforming to IS 2062 and shall be designed as per IS : 802.
c) Special design consideration for lighting Mast:
Diagonal wind condition shall be considered for lightning masts. Provision of IS :
875 (Part – III) – 1987 shall apply for inclined wind condition. Lightning mass shall
be provided with minimum two nos. of platforms (with 1 at top level) and an internal
ladder for climbing purpose up to platform at top level. Top of platform shall have
grating, railing and two guard plates.
The fabrication and erection of the switchyard works shall be carried out generally
in accordance with IS : 802 and IS : 800. All materials shall be completely shop
fabricated and galvanised.
All steel work used in construction of gantry structure should be galvanized and
minimum section thickness should not be less than 4 mm. Weight of zinc coating
shall be at least 0.610 kg/m2 and foundation bolts shall have heavier zinc coating at
least 0.80 kg/m2.
d) CONTROL ROOM BUILDING & GIS Hall:
This building shall be RCC framed with brick cladding, as per drawing. The roof
shall be flat with gentle slope of about 1:100 in one direction. Heavy material store
area will be RCC slab over RCC frame beam structure. Light material store and
office area will be RCC flat roof supported an RCC beams.
Design considerations and loading considerations for R.C.C. switchyard control
room building shall be considered as specified elsewhere in the specification.
Roof 1.5 KN/M2 for accessible roofs
0.75 KN/M2 for in-accessible roofs
RCC-Floor 5 KN/M2 for offices
10 KN/M2 (min.) For equipment floors or
Actual requirement,
if higher than 10 kN/sqm based
on equipment component eight
and layout plans.
Stairs & balconies 5 KN/M2
Toilet Rooms 5 KN/M2
Chequered plate floor 5KN/M2
Walkways 5 KN/M2
RCC or Structural roof additional 50kg/m2 dust load shall be
considered.
Any additional load coming in the structure shall be calculated as per IS: 875 -
1987.
Footings shall be so proportioned to as to minimize the differential settlement.
1.1.0 Roof drainage
Roof drainage system shall be provided for quick and efficient draining of
rainwater from roof to avoid seepage and damage to roof. The runoff
gradient for the roof shall not be less than 1 in 100. Roof drainage system
shall consist of roof drain heads, rainwater down take pipes and fixtures.
Roof drains shall conduct water to storm drains through down take pipes. All

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down comers shall be covered with poly carbonate sheets of thickness

minimum 3mm.
1.1.1 Storm Water drainage
The area drainage shall be done through brick drain arrangement as per
drawing complete with all necessary hume pipes and finally connected with
the existing Plant drains at suitable locations.
1.2.0 Waterproofing
1.2.1 Roof water proofing
As per General civil works specification
1.3.0 Anti termite treatment
Pre-constructional anti termite treatment shall be given to all vulnerable

areas susceptible to termite attack and shall include column pits, wall
trenches, foundations, filing bellow the floors etc. as per IS:6313 and as per
the general specifications.
1.4.0 Plinth Protection
PCC of nominal mix of grade M20, 100mm thick laid over well compacted
soil shall be provided as plinth protection around all buildings, to a width of
1200mm or the distance between the brick wall to the garland drain. PCC
shall be provided over 75 thick BFS (brick flat soling) and BFS over 150
thick stone soling.
1.5.0 Grouting
1.5.1 Steel Grating
Grating units shall be of electroforged galvanized steel. Grating shall have a

rectangular pattern and pressure locked assembly. Size of bearing bars &
cross bars shall be 40mm x 5mm and 25mm x 3mm respectively. Spacing
of main bars shall not exceed 30mm and that of cross bars shall 100mm.
Grating units shall be provided with all necessary clips, bolts and lock
washers etc. complete with paint.
1.6.0 False ceiling and under deck insulation
1.6.1 All air conditioned areas shall be provided with the suspended false ceiling
system. Under deck insulation system shall be provided on the underside of
the roof/floor slab of the air-conditioned areas based on the functional
requirement.
6.20.2 Aluminum false ceiling system shall comprise of 84 mm wide 12.5 mm deep

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closed type plain panels of approved color, roll formed out of 0.5 mm thick
corrosion resistant aluminum alloy AA 5050 fixed on roll formed carriers.
Additional hangers and height adjustment clips shall be provided for return
air grills, supply air diffusers, light fixtures, AC ducts etc. the installation of
false ceiling shall be carried out by the specialist agency and shall be strictly
as per manufacturer’s instructions.
6.20.3 Laminated cement bonded false ceiling system shall consist of 600x600x12
mm with one coat of primer and two or more coats of acrylic emulsion paint.
The suspension system shall consist of 6 mm diameter galvanized steel
rods suspended from ceiling supporting aluminum grid of 38x25x1.5 mm
and crosstie of 25x25x1.5 mm and aluminum angle of 25x251.5 mm.
6.20.5 Contractor shall prepare a layout of the false ceiling system incorporating
light fixtures, supply air diffuser, return air grills, fire detectors, fire protection
sprinklers etc. such that the ceiling looks aesthetically pleasing. Work shall
commence only after the Owner approves the layout.
6.20.6 Under deck insulation shall be as detailed in the technical specifications.
6.22 SPECIAL REQUIREMENTS FOR CORROSION PROTECTION
6.22.1 General
In case, aggressive soil conditions are revealed in detailed soil investigations

and whenever structures are likely to be exposed to corrosive environment due
to storage of chemicals or due to any other reasons, special measures shall be
required to be taken care of work as given below.
6.22.3 For Steel Structures
All anchor bolts shall have a concrete cover of at least 100 mm.
6.22.4 Corrosion Protection
a) Steel Structure
i) All steel members of buildings and structures shall be provided

with suitable protective coating. The minimum maintenance
free life of protective coating shall be ten years (expected life,
long range 10 to 20 years as per BS 5493). Exterior of the
structure shall be considered as exposed to non-polluted inland
atmosphere condition & interior of the structure shall be
considered as normally dry condition. Minimum 75 micron DFT
of organics zinc silicate primer shall be applied over shot blast
cleaned surface to near white metal conforming to Sa2 ½
finish) on all exterior and interior surfaces.
Intermediate coat which shall be applied for all interior and
exterior surfaces shall consist of epoxy based TIO2 or MIO of
minimum 75 micron DFT.
Interior surfaces (considered with normally dry condition) shall

20
be finished with (minimum 75 micron DFT) chlorinated rubber

paint of approved shade.
All Exterior and Interior surfaces (considered as exposed to

non-polluted inland atmosphere condition) shall be finished with
(minimum 70 micron DFT) epoxy based paint, which shall be
further finished with top coat of (minimum 30 micron DFT)
polyurethane of approved shade.
All paints shall be of high built constitution.
ii) All mild steel parts coming in contact with water or water vapour
shall be hot dip galvanized. The minimum coating of zinc shall
be 610 gm/sq.m. for galvanized structures and shall comply
with IS:4759 and other relevant codes. Galvanizing shall be
checked and tested in accordance with IS: 2629.
The galvanizing shall be followed by the application of an

etching primer and dipping in black bitumen in accordance with
BS: 3416, unless otherwise specified.
6.23 Statutory Requirements
6.23.1 All the applicable statutory rules pertaining to Indian factories act Factory
rules of state government, Fire safety rules of LPA, Water act of pollution control
boards, explosives act etc. and stipulations of other relevant statutory authorities shall
be taken into consideration at the time of construction.
6.23.2 Provisions of safety, health and welfare according to Factories act shall be
complied with construction stage.
6.25 Foundation System
The requirements for the foundation systems to be adopted are as given in

subsequent clauses.
6.25.1 General Requirements:
a. No major foundations shall rest on the filled up ground/soil, in

general.
b. It shall be ensured that all foundations of a particular structure /

building / equipment shall rest on one bearing stratum.
c. In case of encountering rock, for identifying the sub-strata for

founding purposes, the Bidder shall take prior approval of the owner.
6.30 Fabrication
The fabrication shall be done as per fabrication drawing.

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Welding
a) Welding of structural steel shall be done by an electric arc proves

and shall conform generally to relevant acceptable standards viz.
IS:816, IS:9595, IS:814, IS:2014, IS:4354 and Indian standard hand
Book for metal arc welding, and other standards, codes of practice
internationally accepted. For welding of any particular type of joint,
Bidder shall give appropriate tests as described in any of the Indian
Standards – IS:817, IS:7307 and international standards as relevant.
b) Submerged arc-welding shall be used for welding longitudinal fillet

welds (connecting flange with web) and longitudinal/transverse butt
joints for fabrication of columns, framing beams and crane girders
and all other built-up members, unless manual arc welding is
specifically approved by the Engineer. Necessary jigs and fixtures
and rotation of structures shall be so arranged that vertically down-
hand position of welding becomes possible. ‘Open-Arc-Welding’
process employing coated electrodes shall be employed for
fabrication of other welded connections and field welding.
c) Wherever welding is done for assembling the components of

structures, the job shall so positioned that down hand welding is
possible.
d) Any structural joint shall be welded only by those welders who are
qualified for all welding procedures and positions in such type of joint
that is welded.
e) All records for entire welding operations such as welders

identification marks, the joints welded by the each welder , the
welding procedures adopted, welding machine employed, pre and
post heating done and any non destructive test done and stress
relieving/heat treatment performed on such joints shall be accessible
to the Engineer for scrutiny.
f) In a fabrication of plated columns/beams and built up members all

shop splices in each component part shall be done before such
component part is welded to other parts of the member. Wherever
weld reinforcement interferes with proper fitting between
components to be assembled by welding, these welds shall be
ground flush prior to assembly.
g) The members to be jointed by fillet welding shall be brought and held

as close together as possible and in no event shall be separated
locally by more than 3mm. If the local separation is 1.5mm or
greater, the fillet weld size shall be increased by the amount of
separation.
Edge preparation for welding as per weld joint detail shall be prepared either
by machines or by automatic gas cutting. All edges cut by flame shall be

22
ground before they area welded.
6.31 Structural Steel Vendor
Structural steel shall be procured from main steel producers like SAIL,
TISCO, IISO, RINL, JINDAL Steels etc. in case of non availability of some of
the sections with main producers the name of such re-rollers will have to be
cleared by corporate quality assurance of Employer for which details such
as BIS approval, Main steel producer’s approval, past experience for
production of sections of specified materials, details of machines plants
testing facilities etc. confirmation that the process control and manufacturing
of steel sections by re-rollers shall be same as that of main steel producers,
that billets for re-rolling will be sourced from main steel producers only shall
be furnished with regards to re-roller.
6.31.1 List of Vendor’s is enclosed in Annex - B
6.32 Electrodes
a) The electrodes used for welding shall be of suitable type and size
depending upon specification of the parent materials, the method of
welding, the position of welding and quality of welds desired e.g.
normal penetration welds or deep penetration welds. However, only
low hydrogen electrodes shall be used.
b) All low hydrogen electrodes shall be baked and stored before use as
per manufacturer recommendation. The electrodes shall be rebaked
at 2500C – 3000C for one hour and later on cooled in the same over
to 1000C. It shall be transferred to and holding oven maintained at
600C – 700C. The electrodes shall be drawn from this over for use.
c) Where coated electrodes are used they shall meet the requirements
of IS:814 and relevant ASME-Sec. Covering shall be heavy to
withstand normal conditions of handling and storage.
d) Only those electrodes which give radiographic quality welds shall be

used for welds which are subjected to radiographic testing.
e) Where bare electrodes are used, these shall correspond to

specification of the parent material. The type of flux-wire
combination for submerged arc welding shall conform to the
requirements of F-60 Class of AWSA-5-17-69 and IS:3613. The
electrodes shall be stored properly and the flux shall be baked
before use in an oven in accordance with the manufacturer’s
requirements as stipulated.
f) Specific approval of the Engineer shall be taken by Bidder for the

various electrodes proposed to be used on the work before any
welding is started.
6.33 Preheating inter-pass temperature and post weld heat treatment.

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a) Mild steel plates conforming to IS:2062 and thicker than 20mm, may
require preheating of the parent plate prior to welding as mentioned
in Table-I. However, higher preheat and interpass temperatures
required due to joint restraint etc. and will be followed as per
approved welding procedure. In welding materials of unequal
thickness, the thicker part shall be for this purpose.
b) Base metal shall be preheated, not withstanding provisions of

IS:9595, to the temperature given in Table-1 prior to welding or tack
welding. Preheating shall bring the surface of the base metal to the
specified preheat temperature and this temperature shall be
maintained as minimum temperature while welding is in progress.
TABLE-1
Minimum Preheat and inter pass temperature for welding

Thickness of thicker part at point Welding using low hydrogen
of welding electrodes or submerged arc
welding.
Upto and including 20mm : None
Over 20mm and upto and : 200C
including 60mm
Over 40mm and upto and : 660C
including 63mm
Over 63mm : 1100C
c) Preheating may be applied by external flame which is non-

carbonizing like LPG, by electric resistance or electric induction
process such that uniform heating of the surface extending upto a
distance of four times the thickness of the plate on either side of the
welding joint is obtained.
d) Thermo-chalk, thermo-couple or other approved methods, shall be

used for measuring the plate temperature.
e) All butt welds with plates thicker than 50mm and all site butts weld of
main framing beam shall require post weld heat treatment as per
procedure given in AWS D-1.1. Post heating shall be done upto 600
deg C and rate of application shall be 20 deg. C per hour. The post
heat temperature shall be maintained for 60 minutes per 2.5cm
thickness. For maintaining slow and uniform cooling, asbestos pads
shall be used for covering the heated areas.
6.34 Sequence of Welding
a) The sequence of welding shall be carefully chosen to ensure that the

components assembled by welding are free from distortion and large
residual stresses are not developed. The distortion should be
effectively controlled either by a counter effect or by a counter
distortion. The direction of welding should be away from the point of

24
restraint and towards the point of maximum freedom.
b) Each case shall be carefully studied before finally following a

particular sequence of welding.
c) Butt weld in flange plates and/or web plates shall be completed

before the flanges and webs are welded together.
d) The beam and column stiffeners shall preferably be welded to the

webs before the web and flanges are assembled unless the web and
flanges to the beam or column are assembled by automatic welding
process.
e) All welds shall be finished full and made with correct number or runs,
the weld being kept free from slag and other inclusions, all adhering
slag being removed.
f) Current shall be appropriate for the type of electrode used. To

ensure complete fusion, the weaving procedure should go proper
and rate of arc advancement should not be so rapid as to leave the
edges unmelted.
g) Pudding shall be sufficient to enable the gases to escape from the

molten metal before it solidifies.
h) Non-uniform heating and cooling should be avoided to ensure that

excessive stresses are not locked up resulting ultimately in cracks.
i) The ends of butt welds shall have full throat thickness. This shall be
obtained on all main butt welds by the use of run off and run on
pieces adequately secured on either side of main plates. The width
of these pieces shall be removed by grinding or by other approval
means and the ends and surface of the welds shall be smoothly
finished. Where the abutting parts are thinner than 20mm the
extension pieces may be omitted but the end be welded to provide
the ends with the required reinforcement.
j) The fusion faces shall be carefully aligned. Angle shrinkage shall be

controlled by presetting. Correct gap and alignment shall be
maintained during the welding operation.
k) All main butt welds shall have complete penetration and back
surface of the weld being gouged out clean before first run of the
weld is given from the back. All butt welds will be radiographically or
ultrasonically tested as per relevant IS:Codes and standard practice.
l) Intermittent welds shall be permitted only when shown in the design

drawings.
m) The welding shrinkage shall be minimized by adopting the correct

welding procedure and method. In long and slender member extra

25
length should be provided at the time of fabrication for shrinkage.
6.35 Testing of Welders
All the welders to be employed for the job shall have to qualify the
appropriate tests laid down in IS:817 and IS:1181 and ASME IX/AWS D1.1.
All the necessary arrangements required for the testing of welders are to be
provided by the Bidder.
6.36 Inspection of Welds
a) Visual Inspection
100 percent of the welds shall be inspected visually for external

defects. Dimensions of welds shall be checked. The lengths and
size of weld shall be as per fabrication drawings. It may be slightly
oversized but should not be undersized. The profile of welds is
affected by the position of the joint but it should be uniform. The
welds should have regular height and width of beads. The height
and spacing of ripples shall be uniform. The joints in the welds run
shall as far as possible be smooth and should not show any humps
or craters in the weld surface. Welds shall be free from unfilled
craters on the surface, under-cuts, stages on the surface and visible
cracks. Such inspection shall be done after cleaning the weld
surface with steel wire brushes and chisel to remove the spatter
metal, scales, slag, etc., if external defects mentioned above are
noticed, there is every possibility of internal defects and further
radiographic/ultrasonic examination shall be undertaken.
b) Production Test Plate
Test plates shall be incorporated on either side of at least one main

butt welds of each flange plate and web plate of every main frame
columns and crane girder. The weld shall be continuous over the
test plate. The test plate extensions of the main plates and shall be
fixed so that metal lies in the same direction as that of the main
plate. Test plates shall be prepared and tested in accordance with
the accepted Standards, in the presence of the Engineer or his
authorized representative. Should any of these tests fail, further
radiographic examination are additional to those contemplated under
inspection and testing.
c) Non-destructive and special testing
Radiographic/ultrasonic or other non-destructive examination shall

be carried out. All tests of welds shall be carried out by the Bidder at
his own cost. The cordoning of radiation zone, while Radiography
testing is going on, shall be done.
In case of failure of any of the tests, re-testing of the joints shall also
be carried out after rectification is done.

26
d) Rectification of defective welding work
Wherever defects like improper penetration, extensive presence of

blow holes, undercuts, cracking, slag inclusion, etc., are noticed by
visual inspection/other tests, the welds, in such location shall be
removed by gouging process. The joints shall be prepared again by
cleaning the burrs and residual matters with wire brushes and
grinding, if necessary, and rewelded. The gouging shall as far as
possible be done using gouging electrodes.
6.37 Inspection and Testing
a) Fillet Welds
i) All fillet welds shall be checked for size and visual defects.
ii) Macrotch examination on production test coupons for main

fillet weld with minimum one joint per built up beam, column
and crane girder, etc.
iii) 25% weld length of tension members of crane girder shall be

subjected to dye-penetration test.
iv) On all other welds, dye-penetration test on 5% of weld length

with minimum 300mm at each location shall be carried out.
b) Butt Welds
i) 100% visual examination.
ii) Dye penetration test on all butt welds after back gouging shall
be carried out.
iii) Mechanical testing of production test coupons – minimum

one joint/built up beam, column and crane girder. The
engineer may reduce the frequency of the test, after getting
consistently satisfactory results of initial 10 tests.
iv) 100% radiography test on butt welds of tension flange

(bottom flange) of crane girder and bunker supporting
girders. All other butt welds shall be subjected to
radiography test on 10% of weld length of each joint.
c) Dimensional Tolerance and Acceptance Criteria of Welds
i) Every first and further every 10th set of identical structure

shall be checked for control assembly at shop before
erection.

27
ii) All structures, components/members shall be checked for

dimensional tolerance during fabrication and erection as per
IS:7215 and IS:12843 respectively.
iii) Dry firm thickness after painting shall be checked by using

elchometer.
iv) Acceptance criteria of NDTs on welds shall be as per AWS

D-1.1 (Dynamically loaded structures – Tension welds).
6.38 Correction of Defective welds
Correction of defective welds shall be carried out without damaging the

parent metal. When a crack in the weld is removed magnetic particles
inspection or any other equally positive means shall be used to ensure that
the whole of the crack and material up to 25mm beyond each end of the
crack has been removed.
6.39 Erection of Structures
All erection work shall be done with the help of cranes, use derrick is not
envisaged.
Erection Marks
a) Erection marks in accordance with fabrication drawing shall be

clearly painted on the fabricated steelwork. Each piece shall be
marked in at least on two places. Each piece shall also have its
weight marked thereon.
b) The centre lines of all columns, elevations and girder bearings shall
be marked on the sections to ensure proper alignment and assembly
of the pieces at site.
Erection Scheme
a) The erection scheme for the erection of all major structures shall be
furnished. The erectability of the structure shall be checked by the
Bidder before commencement of fabrication work to avoid future
modification. The erection scheme shall indicate the approximate
weight of the structural members, position of lifting hook, crane boom
length, crane capacity at different boom length and at different boom
inclination, etc., Bidder shall take up the erection work only after he
has obtained the approval of the erection scheme from the Engineer.
b) The erection scheme shall also give details of the method of

handling, transport, hoisting, including false work/staging, temporary,
bracing, guying, temporary strengthening, etc., It will also give the
complete details of the number and capacity of the various erection
equipment that will be used such as cranes, winches, etc., along with
disposition at the time of erection of columns, trusses, etc.

28
c) The erection of columns, trusses, trestles, portals, etc., shall be

carried out in one single piece as far as practicable. No column shall
be fabricated and erected in more than 3 pieces. The inside
sheeting runners and roof sheeting purlins may be erected
individually. When erection joints are provided in columns, their
location shall generally be just above a floor level.
i) Following connections shall be provided during erection:
1. Welded Connection
a) Connection of secondary beam to main beam

b) Connection of bracing to column
c) Connection of bracing to longitudinal tie beam
d) Connection of longitudinal tie beam to column
e) Connection of spandrel beam to column
f) Connection of other secondary structures
2. HSFG Connection
a) Splicing of column / transverse frame beam /
longitudinal tie beam
b) Connection of frame beam to column
c) Connection of crane girder to column
d) Connection between crane girders
e) Other major Connection
3. Bearing type connexions (HT Bolt of Grade 8.8)
a) All removable type connexions
7.34 Paving and Grade slab
Reinforced concrete paving/Grade slab in general, wherever required shall

be minimum 150mm thick slab with 8mm bars at top & bottom at 200c/c
each laid over compacted stone aggregate 60-40 mm down, 200mm thick
and compacted sub-grade as per specification. Expansion/Contraction
joints. Construction joints shall be provided as required and approved.
Thickness of PCC below the RCC slab shall not be less than 100mm.
50 mm thick metallic hardner finish shall be provided over the RCC slab.
7.35.6 Holding down Bolts and Shear Key
All structural steel column base shall be connected to RCC pedestals

with holding down bolts. The bolts assembly shall be made of Mild
Steel bar with anchor plates. Anchor plates shall be fillet welded to
bolts with 8mm (minimum) weld.
7.35.7 Non-Shrinking Grout for Column & Equipment Foundation Bases
7.35.7.1 Special grout shall be provided in strict accordance with the manufacturer’s

29
instructions/specifications. Conbextra GP-1 / Pidigrout 10M having minimum

28 days crushing strength of 450 kg/cm2 for foundations where concrete grade
M25 or higher is provided.
7.35.7.2 Forms and shims used to obtain adequate clearance shall not be removed and
the anchor bolts shall not be tightened for at least three days after placing the
grout. After the removal of forms and shims, area occupied by shims shall be
filled and the area between the base and edge of the foundation shall be
finished smooth to allow drainage away from the base. Attachment of
interconnecting piping of machinery and complete load transfer of machinery
shall not be done before the bolts are tightened. During this period, grouting
work shall be properly cured using rags/gunny bags.
7.35.7.5 Pre-mixed non-shrinking grout shall be used all as per manufacturer’s

instructions and without any additional materials/admixtures such as cement,
sand and aggregates etc.
7.35.8 Painting
Primer paint shall be applied after proper surface preparation as per

requirement specified under corrosion protection.
7.37 Galvanising
Purity of Zinc to be used for galvanising shall be 99.9 % as per IS : 209 ( latest
edition ).
The weight of the zinc coating shall be at least 610 Gms./m2 unless noted
otherwise.
All burrs and irregular edges of the structural steel members to be galvanised
shall be ground smooth before galvanising.
9.0 Structural Material specification
9.1 General
All construction shall be carried out based on approved final construction and
fabrication drawings. Execution shall be done as per all the relevant Indian
Standards and good engineering practices. Quality control, testing and
acceptance shall be on the basis of approved Quality Assurance Plan
(QAP).For stacking and storage of construction material at site IS: 4082 shall
be followed.
The contractor shall submit and obtain Owner’s approval of the detailed
QAP for workmanship, materials, testing and approval, for each item of
civil and structural work, prior to executing the works.
List of vendor for cement, structural steel, electrodes, reinforcement etc shall
be as per enclosed list (annexure).
9.2 Cement

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Fly ash based Portland Pozzolona cement having a minimum grade of 43 and
also conforming to IS: 1489 (Part-1) or ordinary Portland cement shall be used
for all areas. The type of cement shall be as approved by Owner.
9.3 Concrete Grade.
The following minimum grades of concrete shall be adopted for only CRB &
GIS Hall type of structures noted against each.
S. Class Grade of Minimum Maximum

No. concrete cement free water
content content
(kgs/cum)
1. Plain concrete used for lean M 10 - -
concrete and screed
concrete,
2. PCC for mass filling M 7.5 - -
3. a) Reinforcement concrete M25 365 0.5
For structural work in
foundation &
superstructure, cable
pipe, & drain trenches.
3. Precast Concrete Works M25 365 0.5
4. Pavement around buildings M20 325 0.55
5. Grade Slabs M25 365 0.5
In case required from mix design consideration, bidder may use higher cement
content at no extra cost to owner.
9.4 Reinforcement Steel
Reinforcement bars shall be thermo mechanical treated ( TMT) bars of

grade Fe500D conforming to IS:1786 . For grade, Fe500 elongation
requirement shall be same as for Fe415 for its ductile behavior (i.e. Fe 500 D).
Mild steel bars shall conform to grade-1 of IS: 432 (Part- 1) or grade A of IS:
2062. Welded wire fabric shall conform to IS: 1566.
List of vendors for procurement is Annexed in Annex – ‘B’
9.4.1 Clear cover to reinforcement shall be as per IS 456.
9.5 Structural Steel
Structural steel (including embedded steel) shall be straight, sound, free from
twists, cracks, flaw, laminations and all other defects. .

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Mild Steel shall conform to Grade-A of IS: 2062 for rolled steel members or
plates up to 20 mm thickness. For plates above 20 mm thickness and welded
construction steel conforming to Grade-B (killed and normalized) of IS: 2062
shall be used. Plates 40mm and thickness shall be normalized and
ultrasonically tested. Medium & High tensile grade steel can also be used with
proper precaution for welding and preheating.
For crane girders Grade C (IS-2062) steel shall be used.
Chequered plate shall conform to IS: 3502 of grade-A of IS: 2062 and
minimum thickness of chequered plate for floorings, covers etc shall be 6 mm
(on plane)
Hollow (square and rectangular) steel sections shall be hot formed conforming
to IS: 4923 and Pipes shall conform to IS: 116 of grade of steel Yst 240.
List of structural steel vendors enclosed in Annex – B.
9.5.1 Welding electrodes
Low hydrogen type electrodes shall conform to IS 814 and shall be

EB5426H3JX type. All electrodes, flux, wire etc. shall be as per separate
vendor list. Or any other equivalent manufacturer approved by the owner.
Low hydrogen electrodes as approved by the owner will be used in the

following cases
a) For welding of all important joints such as butt joint in columns (Flange or
web), Butt joint in main frame beams (flange or web), etc.
b) For welding steel having thickness more than 20mm.
In case of fillet weld between two components, thickness of thicker part will be
considered as the limit for (b) above.
The bare electrodes for submerged arc welding shall be as follows

Fillerware: AWS-A-5.17-EH14
Flux will be agglomerated type of classification AWS-A-5.17-F7A2EH14.

* All RCC column of the GIS building should be bolted connection
between crane girder to column corbel part as per drawing &
connection between crane girders shall be bolted.
* All moment connection in GIS building if required should be bolted
connection.
* Other steel structure shall be bolted/welded.
List of welding electrodes is enclosed in Annex – ‘B’
9.6 Masonry

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10.0 BUILDINGS AND FACILITIES
Following structures / buildings / areas / facilities are to be included scope of

work. Although most of the systems are covered here but any other system
(Civil, Structural and Architectural) required for successful completion of the
Package shall form a part of this contract and shall be deemed to be included.
10.1.1 Sewage & Waste Water Drainage System
Separate septic tanks shall be provided at suitable locations for each

building complex for substation area sanitary sewage disposal. Effluent
from the septic tank shall be connected to a soak pit arrangement.
Jointing of laid pipes shall be so planned as to avoid completely any

movement or strain to the joints already made. If any joint is suspected to be
damaged it shall be opened out and re done. .
All joints between pipes, pipes and fittings and manholes shall be gas-tight
when above ground and water tight when underground. The Sewer line
shall be tested for above, as per applicable IS code.
Manhole shall be provided with standard C.I covers. The cover shall be
close fittings so as to prevent gases from coming out. Suitable heavy-duty
covers shall be used where necessary.
13.13 Earthing Mat
40 mm Dia MS Rods as earthling mat, placed at a distance of 1.0M away

and at depths between 0.60M and 1.00M or as per Earthling mat drawings
shall be supplied and laid all around the periphery of buildings & also
beneath the GIS Hall in case of GIS building, structures, and outdoor
equipment, as per the approved drawings. Risers shall be laid up to a height
of 300 mm above the local Ground level, at each of the columns of the
buildings on outside of the buildings, and minimum 2 (Two) numbers for
structures and outdoor equipment or also within GIS hall as per Earthling
mat drawings.
13.14 Excavation Details
17.15.0 Storm Water Drainage System
All effluent drainage shall be through buried concrete pipes unless otherwise
specifically required and all storm water drainage shall generally be through
open drains. Open storm water drains shall be provided on both sides of
the roads and shall be designed to drain the road surface as well as all the
free and covered areas, etc.

33
Open brick rectangular section shall be provided for all drains.
All artillery drains and the drains along the periphery of building shall also
have perforated precast RCC covers of minimum 75mm thickness.
All drain inside the building shall have minimum 40 mm thick grating covers.
In areas where heavy equipment/ Vehicular loads would be coming, precast
RCC covers shall be provided in place of steel grating.
Invert of the drains shall be decided in such a way that the water can easily
be discharged to the natural water bodies above the high flood level.
For pipe drains, concrete pipes of class NP3 (minimum) shall be used. For
road and rail crossings concrete pipes of class NP3 with concrete
encasement shall be used. The pipes shall be laid as per IS:783. In this
case open catch water drain shall be provided on the other side or road and
connected to pipe drain through RCC manholes. RCC manholes shall be
provided at every change of alignment, gradient and diameter of pipeline.
The invert of the in-plant and plant peripheral drains shall be kept such that
water can be discharged by gravity to the main/trunk drains under all
conditions.
19.0 ARCHITECTURE AND ALLIED WORKS
19.1 General Architectural Concepts
19.1.1 Walls and Cladding:
The function of all exterior walls is to provide enclosures for buildings. The
exterior enclosure protects the enclosed system and personnel from
adverse weather conditions and allows for a controlled interior
environment.
19.1.2 Brickwork
The exterior brickwork walls shall generally consist of non-load bearing

type construction. For walls heights exceeding 3.0 m required
reinforcement shall be provided to meet the applicable building codes
and standards. Bricks of minimum 50 kg/ sq cm crushing strength shall be
provided. Brick work shall be carried out in cement sand mortars 1:6 or
higher cement content. Cement sand mortar shall conform to IS: 2250. All
external wall shall be one brick thick. However, internal partition walls shall
generally be with half brick thick. Brick work shall be provided with
plastering on both faces.
19.1.3 Plastering
All exterior and interior brick work walls shall be provided with plaster on
both faces. 12 mm and 20 mm thick plaster shall be provided on the even

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and rough faces respectively. Minimum cement sand mix of 1:6 shall be
used for plaster. Plastering shall conform to IS: 1661. Ceiling plaster shall
be 6 mm thick with cement sand mix of 1:3.
Wherever required for the painting on interior surfaces, minimum 2mm thick
Plaster of Paris shall also be applied to give even and smooth surface.
At the junction of RCC and Masonry work, galvanized chicken wire mesh
conforming to IS: 3150 shall be provided.
Provision of suitable groove and drip course shall be provided as per the
requirement.
19.3.5 RCC Roof Decking
RCC slab of minimum 120 mm clear thickness in excess of trough depth

shall be provided. Water proofing treatment as per drawing shall be provided
over RCC roof.
19.3.7 Windows and Ventilators
Aluminium section used for windows, ventilators and partitions shall be

made of extruded anodised and electro colour p o w d e r dyed
aluminium, which is resistant to the corrosive environment. Ventilation
sections shall be compatible with the frames providing a weather-tight seal
of neoprene gasket.
All extruded aluminium sections shall be made of heavy gauge considering

cyclonic wind load etc of approved make.
Corrosion protection of the aluminium including bi-metallic corrosion

protection, particularly with steel member shall also be provided.
Glazing of windows shall be done with minimum 5.5 mm thick float glass
of best quality for windows located in ground floor and at accessible floors.
All windows shall be glazed and fully flashed and sealed for weather-
tightness. The entire building enclosure shall be completely weather-tight
and air tight. All window hardware shall be substantially made, smoothly
finished, accurately fitted, and smooth in operation.
Windows shall close tightly without binding. Operators shall operate freely
and smoothly, adjusted to close tolerances for positive closing of windows
with a minimum of play in operator linkages. All ground floor windows
shall be lockable and shall be provided with security grills.
All ground floor windows shall be lockable and provided with security grill.
All ground floor ventilators shall be provided with security grills.
All windows & ventilators (all heights) in store building shall be provided with
MS security grills.

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19.3.8 Louvers
Ventilation openings shall be provided with drainable formed gutter type

storm-proof blade louvers complete with bird screens. Operating damper
blades shall be provided behind the fixed louvers to allow closing of the
openings. On long expanses of louvers, a continuous blade concealed
support system shall be provided. Louvers shall be fabricated from
extruded aluminium, steel, or other tried and proven material which is
resistant to the corrosive environment and shall be provided with a poly-
vinylidene fluoride finish.
19.3.9 Doors
For the office area, air conditioned areas, entrance lobby of buildings,
aluminium doors frame shall be of extruded anodised and electro colour
p o w d e r dyed aluminium of minimum 3 mm thickness of best quality and
workmanship of approved make. Glazing of fully glazed doors and
partitions shall be done with 5.5 mm thick float glass of best quality.
All doors of toilet areas shall be aluminium frame work with 12mm thick pre-
laminated particle board panels (MDF exterior grade).
Doors shall have a glazed vision panel when required by door function.
Glazing shall consist of tempered safety glass or wired glass.
Doors located on the ground floor of buildings shall swing out. Doors at
other levels shall swing in or as required to meet egress requirements.
Heavy duty hardware shall be used. All outside doors shall be provided
with door closers. Locks shall be provided on interior and exterior doors
as required by the Owner.
Fire doors shall conform to hollow metal door requirements and shall be
provided with fillers adequate to meet the required fire rating (Min 2 hours).
The door, frame, and hardware shall bear a certification label for the class
of opening and rating. Doors for fire exits shall be secured with panic
bars. Fire doors shall conform to IS-3614 (Part I & II).
For equipment and vehicular access, vertical lift type rolling shutters with
weather seals and wind locks shall be provided. Components shall be
formed from galvanized steel, factory primed and field painted. Doors at
high traffic areas shall be motor-operated. Doors shall be manually
operated where access is infrequent. Rolling shutters shall conform to
IS: 6248. For a very large access opening, suitable double leaf hollow
metal sliding type of doors can also be provided.
19.3.15 Flat Roof Drainage
Roof slab shall be of adequate thickness and laid to proper slope for
easy drainage of rain water. Wherever required screed concrete shall be
provided to maintain the adequate slope of about 1 in 100. Adequate
numbers of PVC rain water pipes of adequate size shall be fitted at

36
designated locations as per IS code. Suitable parapets/handrails shall be

provided. Roof drain shall be designed as per IS: 13592 medium class up
to 150mm size. For higher diameter pipe galvanized ERW steel pipe shall
be used. Rain water down comer pipe shall be or concealed using
aluminum coated panels.
19.4 Interior Architecture
Interior architectural systems shall conform to the following general

design criteria. All normally occupied areas shall be provided with finish.
19.4.1 Partitions
Interior walls shall be constructed of masonry or made of powder coated

aluminum frame provided with 5.5 mm thick clear glass or pre-
laminated board depending upon the location of partition.
Interior walls shall be constructed of concrete block/brick

masonry, structurally designed and reinforced, where other interior walls
shall not provide durability. Plaster finish shall be applied to brick
masonry walls followed by paint in approved colour.
19.4.2 Ceilings
False ceiling shall be provided for all air-conditioned areas and other
areas where required from functional requirement & as per General civil
works specification.
19.4.3 Floor Finish
Total thickness of floor finish (including under bed of Cement Mortar or

PCC and top finish) shall be 50 mm. Height of matching skirting shall be
minimum 150 mm and height of dado shall be minimum 2200mm for toilets
and up to bottom of false ceiling for other area if required.
In general following type of floor finish shall be adopted for different

area as per functional requirement.
(a) Vitrified Ceramic Tiles with or without mirror polish
 This shall be homogeneous and compact throughout the entire body

and fully vitrified. The minimum compressive strength and modulus of
the tile shall be 700 kg per sq.cm and 300 kg per sq. respectively and
MOH hardness not less than 6 (unpolished).
 Following sizes of the tiles shall generally be provided based on the

area of application.
- 400mm x 400mm x 8mm (nominal)
- 600mm x 600mm x 8mm (nominal)

37
(b) Heavy duty cement concrete tiles Size of the tiles shall be 300mm x
300mm x 25mm and conforming to IS: 1237. Top wearing coat shall
be made of white cement mixed with pigment and abrasion resistant
carborundum / quartz stone chips of different colours. Tile shall be
laid as per IS: 1443.
(c) Cement concrete flooring with metallic or non-metallic hardener

topping
This shall consist of 12mm thick metallic hardner topping with OPC. In case
of non metallic hardner finish, readymix non metallic hard granules shall be
spread directly over concrete base at a rate of 5kg per square meter.
(d) Cement concrete flooring with neat cement finish Ordinary grey
cement finish shall be applied over green concrete at the rate of 2.5
kg/sq.m and finished smooth.
(e) Cement concrete flooring with epoxy resin finish: This shall be laid with
acid, alkali and oil resistant high build, solvent free, self smoothing,
seamless epoxy resin floor finish. Total Dry Film Thickness (DFT) of the
coating (excluding primer) shall be minimum 300 micron.
(f) Interlocking Concrete Paver Block : this shall be provided as per

IRC: SP:63
(g) Granite Stone flooring Pre polished Granite stone of minimum 18mm
thickness shall be provided and nominal size of a single slab shall not be
less than 0.4 sq.m.
(h) Marble Stone flooring
Rajnagar Marble of 18mm thickness shall be plain white marble with coarse
grain predominantly showing mica particles giving reflection in bright light.
19.4.4 Painting for Masonry Works
(i) Water proof Cement Based Paint
On all external surfaces exposed to outdoor conditions which does not

require aesthetically special treatment, water-proof cement base paint
conforming to IS: 5410 shall be applied.
(ii) Oil Bound Distemper
Oil Bound Distemper shall conform to IS: 428. The primer shall be
cement primer or distemper primer. Only sufficient quantity of distemper
required for a day’s work shall be prepared.
(iii) Acrylic Emulsion Paint
Acrylic Emulsion Paint shall be water based acrylic copolymer emulsion

38
with rutile titanium dioxide and other selected pigment and fungicide
conforming to IS: 5411 (Part-I)
(iv) Chemical Resistant Paint
Chlorinated Rubber Paint shall be made from natural rubber and

chlorine. Suitable colour pigment shall be added for finishing coat. For
primer, chlorinated rubber zinc phosphate shall be used. Titanium dioxide /
micaceous iron oxide shall be used for intermediate coat.
(v) White Wash
In unimportant area like portion above False Ceiling etc., white wash shall
be applied as per IS: 6278.
19.4.5 Painting for Structural Steel
Type and details of paint shall be as mentioned under corrosion protection

requirements. Properties of the paint shall conform to BS: 5493.In addition
final coat shall be UV resistant particularly for outdoor application.
19.4.6 Water Supply, Sanitation and Plumbing
Roof water tank of adequate capacity depending on the number of users

and 8 hours requirement shall be provided for each building. Polyethylene
water storage tank conforming to IS: 12701 shall be used. The tank shall
be complete with all fittings including float valve, stop cock etc.
Galvanised MS pipe of medium class conforming to IS: 1239 shall be

used for internal piping works for potable water supply.
Sand C.I. pipes with lead joints conforming to IS: 1729 shall be used for
sanitary works above ground level
Each toilet block shall have the following minimum facilities. Unless
specified all the fittings shall be of chromium plated brass (fancy type).
(a) One set of WC (Indian type) Orissa pattern as per IS: 2556 (Part-
3) and 1 no. bibcock with all fittings including flushing arrangement of
appropriate capacity and type.
(b) One set of WC western type as per IS: 2556 (part 2) with toilet
Paper roll holder and bibcock and all fittings including, flushing
system of appropriate capacity and type.
(c) Minimum two sets of urinal with all fittings with photo voltic control
flushing system as per IS: 2556 (Part-6, Sec.1).
(d) One sets of wash basin (oval shape) with all fittings as per IS: 2556
to be fixed on concrete platform finished with 12 mm thick polished
granite stone.

39
(e) Bathroom mirror (5.5 mm thick float glass) with beveled edges
Including all fittings.
(f) One sets of stainless steel towel rail (600 x 20mm).
(g) One sets of stainless steel liquid soap holder cum dispenser.
(h) Janitor room.
(i) Provision for installation of water cooler.
All sanitary fittings and plumbing fixtures shall be of the best quality and
make, and shall be subject to Owner’s approval. All water supply fittings in
toilets, kitchen etc viz., bib cocks, pillar cocks, P-traps, towel rail, shower
rose, gratings etc., shall be of best quality chromium plated brass of
approved make.
Table A: Interior Finishing Schedule
Sl. Description CELLING Walls Flooring Door, Window & Ventilation

No. of Area (Interior)
1 GIS Hall As per Windows/ ventilator shall be of
Manufacture powder coated aluminum with
design 5.5mm thick glazing. All doors
shall be flush door shutters
made of pre-laminated particle
board with powder coated
aluminum frame.
2 Control Room False celling Plastic emulsion Vitrified tiles -do-
Paint
3 Relay Room False celling Plastic emulsion -do- -do-
Paint
4 Carrier Room False celling Plastic emulsion -do- -do-
Paint
5 Conference False celling Plastic emulsion -do- -do-
room & office Paint
6 Engineer False celling Plastic emulsion -do- -do-
Room Paint
7 Toilets DADO glazed tile -do- -do-
2100mm high &
Plastic emulsion
Paint
8 Cable White Washing Artificial Steel door 45mm thick double

Spreading Hall Grey Patent sheet 18 gauge MS steel suitably
stone reinforced and filled with mineral
wool. Windows/ventilator shall
be of powder coated aluminum
with 4mm glazing.

40
9 Store Room White Ironite

Washing
10 Record Room Colour washing
11 Maintenance Colour washing Ironite

Room
12 Misc Panel Plastic emulsion Mosaic tiles
Room Paint
13 Laboratory Plastic emulsion Mosaic tiles
Paint
14 Battery Room Acid Proof Paint Acid proof Steel door 45mm thick double
tiles sheet 18 gauge MS steel suitably
reinforced and filled with mineral
wool. Windows/ventilator shall
be of powder coated aluminum
with 4mm glazing.
15 Stair Plastic emulsion
Paint
16 Other Location Plastic emulsion Cast-in-situ

Paint mosaic
Note:
1. The colour and pattern of finish shall be as finalized by the Owner.
2. All materials shall be of reputed and established brand approved by the Owner.
3. All the finishing work shall be carried out as per manufacturer specifications
and of approved colour.
Annexure – ‘B’
LIST OF VENDORS
1.0 Approved vendor list for cement, structural steel, reinforcement steel and
welding electrodes.
A. Structural Steel and Reinforcement Steel

SAIL, JINDAL Steel, TISCO, IISCO, RINL.
B. Cement (for both PSC and OPC)

Grasim, Birla, Ambuja, Ultra tech, Lafarge, ACC, Century, Jaypee,

41
C. Welding electrodes conforming to E7018.
S.No Classification Brand Name Manufacturer Remarks

1. E7018 Supra Theme D & H Secheron Basic coated low
Electrodes (P) Ltd. hydrogen
electrodes for
welding of thick
sections and
structural steels.
Minimum tensile
strength 50.6
Kg/mm2.
ESAB 36H ESAB India Ltd.
MOdi 7018 Modi Arc Electrodes
Co.
Superarc Voltarc Electrodes Pvt.
Ltd.
Supabase-7018 Ador Welding Ltd.
Ultimate-18 Honavar Electrodes
Pvt. Ltd
SUPER-LH D & H welding
electrodes (I) Ltd.
WA-7018 Weld Alloy Products
Ltd Noida
BASICOTE-6 Fusion Engineering
products Ltd.,
Jamshedpur
GRICON GREEN Gee Ltd., Thane
ULTRA-7018 Maruti Weld Ltd.,
Gurgaon
12.00.00 GEOTECHNICAL INVESTIGATION AND FOUNDATION SYSTEM.

The Contractor shall carry out detailed geotechnical investigation in all work
areas under his scope for establishing the sub-soil conditions and to decide
type of foundations for the structures envisaged, construction methods, any
special requirements/treatment called for/remedial measures for sub-
soil/foundation etc. for soft-soils, aggressive sub-soils & water, expansive /
swelling soils etc. prior to commencement of detailed design / drawings.
Contractor shall obtain the approval for the field and laboratory testing
scheme proposed by him from the Owner before undertaking the
geotechnical investigation work.
Field test shall include but not be limited to the following:
Boreholes, Standard Penetration Test (SPT), collection of disturbed and
Undisturbed soil samples (UDS), Trial Pits (TP), Plate load test (PLT),
Dynamic Cone Penetration Test (DCPT), Pressure meter tests (PMT),
Seismic Refraction Test (SRT), Electrical Resistivity Tests (ERT) and
collection of water samples etc.
Scheme of Soil Investigation

The diameter of borehole shall be minimum 150 mm in soil and 76 mm in

42
rock. The diameter of UDS sampler shall be 90 mm minimum. Drilling in

rock shall be done by means of hydraulic feed equipment using double tube
core barrel with diamond bid attachment.
Filed investigations shall be done as indicated in Annexure – 1 SPT shall be

carried out in all types of soil deposits and in all rock formations with RQD<
20% within a borehole. This test shall be conducted at every 3.0m m interval
or at change of strata, upto the final depth. Number of blows shall be
recorded for every 15 cm of penetration upto 45 cm or 100 blows whichever
occurs earlier. UDS shall be collected at every 3.0 m interval or at change of
strata upto depth of borehole. Depth for DCPT shall be upto refusal (for
DCPT, refusal shall be considered, when the blow count exceeds 150 for
300 mm penetration). Depth of PLT shall be at proposed founding level for
shallow foundations only.
Laboratory tests shall be carried out on disturbed and undisturbed soil

samples for Grain Size Analysis. Hydrometer Analysis, Atterberg Limits,
Trixial Shear Tests (UU & CD), Natural Moisture Content, Specific Gravity
and Bulk Unit Weight, Consolidation Tests, Unconfined Compression Test,
Free swell Index, Shrinkage Limit6, Swell Pressure Test, Proctor tests,
Chemical Analysis test on soil and water sample to determine the
carbonates, sulphates, chlorides, nitrates, pH, organic matter and any other
chemicals harmful to concrete and reinforcement/steel.
On completion of all field & laboratory work, contractor shall submit a
Geotechnical investigation report for Owner’s approval. The Geotechnical
investigation report shall contain geological information of the region,
procedure adopted for investigation, field & laboratory observations/data /
records, analysis of results & recommendations on type of foundation for
different type of structures envisaged for all areas of work.
Recommendations on treatment for soil, foundation, based on subsoil
characteristics, soft soils, aggressive chemicals, expansive soils etc.
The report shall also contain recommendations on type of foundations to be
adopted for various structures, duly considering the sub soil characteristics,
water table, total/differential settlement permissible for structures and
equipments, minimum depth and width of foundation with supporting
calculations and design of piles in terms of safe capacity, length, diameter
termination criteria etc.
13.00.00 Foundation System

i) General Requirements:
a) Contractor can either provide open foundations (isolated footing/raft) or pile
foundations depending upon the results of the geotechnical investigations to
be carried out by him.
b) All foundations shall be designed in accordance with provisions of the

relevant parts of the latest revisions of Indian Standards.
c) No major foundation shall rest in the filled up ground/soil.
d) A combination of open and pile foundations shall not be permitted under the
same structure.

43
e) Foundation shall be designed for worst combination of loads as described

elsewhere in the specification.
ii) Open Foundations
In case open foundations are adopted following shall be adhered to:
a) Minimum width of foundation shall be 1.0 m.
b) Minimum depth of foundation shall be 1.0 m below NGL.
c) Permissible settlement of foundations.
The total permissible settlement and differential settlement shall be
governed by IS : 1904 and IS : 13063 and from functional requirements,
whichever is more stringent. However, total settlement shall be restricted to
the following:
i) All foundations including pipe supports, isolated/strip/continuous) for

widths upto 6.0 m – 40mm
ii) Footings with width greater than 6.0 mm (raft) – 75 mm
iii) Footings resting on weathered rock – 12 mm.
GENERAL CIVIL WORKS

A. MATERIALS :
A.01 Cement:
Cement shall be ordinary cement conforming to IS : 269 / IS : 455. Cement shall be
kept in clean dry, moisture-proof covered stores. It shall be adequately protected
from condensation, rising damp and atmospheric moisture. Sufficient cement shall
be stored at all times to ensure continuity of work Not more than ten bags shall be
stacked in any tier. Should at any time Engineer-in-charge have reason to consider
any cement defective, then irrespective of its origin and / or manufacturer’s test
certificates, such cement shall be tested immediately at DVC’s laboratory or a
National Laboratory, and until the results of such tests are found satisfactory it shall
not be used in any work. The Contractor shall not be entitled to any claim of any
nature on this account.
A.02 Fine Aggregates:

Fine aggregates (Sand) shall be clean, sharp coarse, gritty to the touch and free
from elongated and flaky particles with a fineness modulus between 2.8 and 3.2 It
shall be clear and free from any mixture of clay, dust, vegetable matter, mica, shale,
loam, salts and organic matter, or other impurities, which may be considered by the
Engineer-in-Charge as harmful. Sand containing clay shall be thoroughly washed
by the contractor at his own expenses before use. It shall be used in cement
concrete work. Fine sand shall be clean, gritty to the touch, free from admixture of
clay, loam, salt, organic matter or other impurities and shall pass through sieve
No.16. Unless otherwise specified fine sand may be used for sand filling and for
mixing with cement for mortar and plaster. It shall not be used for cement concrete
work in floors, pavements, reinforced brickwork etc.
A.03 Course Aggregates:

Coarse aggregates, whether crushed stone or washed and graded gravel shall

44
conform to sieve analysis presented in Table-II of IS : 383. Stone aggregate shall

consist of good, hard and broken stone of the gauge specified and approximately
cubicle in shape. It shall be free from dirt, clay, heaves or any organic matter of
admixture of soft or decayed stone. Different sizes shall be stacked sufficiently
apart or separated with approved wooden bulk heads. Should at any time the
Engineer-in-Charge have reasons to consider any aggregate defective or of poor
quality, then irrespective of any previous approval or tests, samples of such
materials shall be immediately tested and until the result of such tests prove the
materials to be satisfactory, it shall not be used in any work. The contractor shall
not be entitled to any claim of any nature on this account.
The gravel must be hard and durable, free from clay, moorum, dirt, leaves or any
organic matters or admixture of soft or any other foreign materials. The gravel must
be uniformly graded and exhaustively and thoroughly washed. The gravel must be
approved by the Engineer-in-Charge.
A.04 Bricks:
Bricks shall be of Class Designation 5 / 2nd class & of uniform standard size. No
dimension shall vary more than + 4 mm. Bricks shall be made from selected good
earth, free from gravel, saline deposits, other harmful materials well plugged and
hand moulded or machine moulded and thoroughly burnt without incipient
vitrification to a uniform deep red or copper colour. They shall be regular, uniform in
shape and size with a sharp sides and parallel faces and free from flaws, cracks,
stones, modules of lime and other objectionable blemishes and shall emit a clear
ringing sound when struck. No brick shall absorb more than fifteen (15) per cent of
its weight of moisture when immersed in water for twenty four (24) hours. All bricks
shall bear a legible stamp on one face. These shall be stacked in 2 rows
horizontally and endwise, 50 in each row and 10 bricks high, thus making 1000
bricks in each stack. All bricks shall be subject to inspection and approval and
samples shall be submitted before ordering out. The materials supplied shall
conform to the approved samples and may be subject to tests as required by the
Engineer-in-Charge.
A.05 Water:
Water shall be clean, transparent, tasteless and free from organic or deleterious
matter in solution or suspension in quantities which may impair the strength or
durability of the concrete & brick work. Contractor shall provide his own
arrangements and at his own cost for distribution, store, filtration and / or treatment,
as necessary of the required quantity of water. The water should be reasonably
clear and of turbidity limit 2000 ppm.
A.06 Glass:
Glasses of superior approved quality to be used for door, windows and ventilators
shall be of patent, flattened sheets, reinforced and / or clear as specified. Unless
otherwise specified glass shall weigh 7.5 Kg. per Sqm upto a size of 600 x 600 mm
and 10 Kg. per Sqm. for larger sizes. All glass panes and panels shall be free from
flaws, specks, bubbles wavy surface and shall have uniform thickness and
Refractive Index, straight edges, square corner.
A.07 Down Rainwater Pipe:

Down rainwater pipe shall be of best quality cast iron/ PVC, 100/75 mm in dia.

45
Unless otherwise specified, running from roof to 150 mm above ground. The joints
shall be made with cement mortar. The outlet from the roof shall be through a piece
of the same pipe fitted and laid in 1 : 3 cement mortar in a hole under the blocking
course over its full width and slope 1 in 5. Rate shall include Caps or tees, bends,
shoes, painting, carriage and fixing.
A.08 Reinforcement:
All reinforcement shall be of tested quality strictly in conformity with the relevant
Indian Standards and the purchaser shall check and ensure that appropriate test
certificates of materials are available to his satisfaction. Otherwise, necessary tests
shall be made by the Contractor at his own cost to ensure that the quality and
physical properties of the materials used conform to the specification. No
complaints or claims shall be entertained on this account.
All reinforcement materials, before its final use, shall be free from loose mill scales,
loose rust, oily or bituminous coating or injurious adherents. Pitted and otherwise
defective rods shall not be used.
Re- rolled steel bars shall not be used without the prior approval.
The Contractor shall check, ensure and procure in time, as necessary, the
reinforcement materials required for the continuous scheduled progress of the work
till completion.
All reinforcement steel shall be suitably stacked and stored by the Contractor to
protect it from damage by corrosion, and to prevent distortion of section in long
lengths.
A.09 Timber :
Where allowed, timber formwork shall be used. Approved timber used for form work
shall be well seasoned and reasonably free from sap, lose knots, fungal growth,
decay, box heart, borer holes, splits and cracks. Timber with dry-rot or otherwise
defective, shall not be used. Bamboos shall not be used for props or cross beams,
which shall be built in approved timber or slab.
Waterproof, marine quality plywood of appropriate thickness and approved and
approved manufacturer shall be used where plywood is allowed for formwork.
A.10 Mortar:
Unless otherwise specified or directed, the mortar shall consist of one (1) part
cement and four (4) parts sand by volume for all brickwork, inclusive of 127 mm
partition. It shall be mixed dry and then wetted to stiff but workable paste. The
mortar shall be used within thirty (30) minutes of mixing. Mixing of mortar shall be
done on a platform of approved type.
A.11 Structural Steelwork:

a) Steel:
All structural steel shall conform to IS : 2062 Grade A (latest) & shall be of tested
quality, recent manufacture & free from mill scales, slag intrusions, laminations,
pittings, flake rusts etc.
b) Zinc:
The Zinc required for galvanising shall be of quality Zn 99.95 & shall conform to
0IS : 209 (latest).

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c) Bolts & Nuts:

All M.S. Bolts & Nuts shall conform to IS : 6639 (latest) & IS :12427 (latest). The
step bolts should conform to IS : 10238 (latest). The bolts shall be of property class
5.6 as specified in IS : 1367 (Pt.-3)-1979 & nuts shall be of property class 5 as
specified in IS : 1367 (Pt.-6)-1980. All bolts & nuts shall be galvanized & tested in
accordance with IS : 2633 (latest) & shall have hexagonal heads & nuts, the heads
being forged out of the solid, truly concentric & square with the shank which must
be perfectly straight. Fully threaded bolts shall not be used. The length of bolts shall
be such that the threaded portion will not extend into the plane of contact of the
member. The threaded portion of each bolt shall project through the nut at least 6
mm when fully tightened. All nuts shall fit hand tight to the point where the shank of
the bolt connects to the head. M/s. GKW / TATA /ASP / BI make bolts & nuts shall
be used. Diameter of bolt shall be 16 mm.
d) Washers:
All pack washers shall be made of steel conforming to IS : 2062 Gr. A. (latest). The
plain washers & heavy washers shall conform to IS : 2016 & IS : 6610 (latest)
respectively. 3 mm square section spring washers of positive lock type shall be
used with all bolts & nuts & shall conform to IS : 3063 (latest) and shall be
electrogalvanised in accordance with service conditions 3 of IS : 1573 (latest)
B. EARTHWORK IN EXCAVATION & FILLING :
B.01 Preparation of Site and Foundation:

All rubbish, brush-wood, trees etc. shall be cleared 50 m. away from the site. All
roots to be grubbed 1 m. below ground level and holes filled with earth well
rammed. Waste materials from the clearing operations shall be burnt or removed
and satisfactorily disposed of in order to avoid unsightly appearance, unless
otherwise stated.
Lining Out
Preparatory to lining out, foundation plan to be prepared by the Engineer-in-Charge,
pegs, strings, flange, pillars and labour required for setting outwork or construction
lines or benchmark as may be required, shall be approved by the Contractor and no
extra rate will be payable to the contractor.
B.02 Excavation for Foundation :

Trenches for foundation, footing, pits, drain etc. shall be taken out to the full width of
lowest course of footing and to exact length and depth as shown in drawing or as
may be directed by the Engineer-in-Charge, if required. The sides shall be left
plumb where nature of soil admits, but they must be stepped back or shored up
carefully where they show a tendency to fall in. No excavated materials shall be
deposited within 2.0 m. of edge of foundation or twice the maximum depth of
foundation whichever is more. In case excavation is done wider or deeper than the
size & depth of foundation / trenches / drain as shown in the drawing, the
Contractor shall fill up extra width or depth at his own expense with concrete, or
sand watered and rammed as the Engineer-in-Charge may direct. Bottom of
foundation trenches shall be dressed level both longitudinally and transversely and
on completion shall be watered and well rammed. If any soft places come to sight

47
on inspection or by ramming they shall be dug out or dealt with as ordered before
putting concrete. The foundation trenches shall be inspected and passed by the
Engineer-in-Charge before any concrete or masonry work is commenced and the
Contractor shall hold and order to the effect.
Measurement of excavation: - Provision of all around excavation of 150 mm beyond

the outer dimension of footing for excavation depth up to any level below GL will be
kept. This shall be applicable for all kind of soil and rock. Excavation for sloping or
stepping the site shall not be paid for. Any additional excavation beyond this limit
shall be at the risk and cost of the agency and shall not be measured for payment
purpose.
Contractor's rate for the item shall include:

a) Lifting and removing excavated materials, surplus earth upto a lead
of 150m.
b) Provision of drain as required to prevent water accumulating round
foundation in the event of rain.
c) All shoring, sheeting and strutting required.
d) Pumping out of bailing out water.
e) Removal of loose stones or brickbats met with during course of
excavation.
f) Watering and ramming foundation bed.
B.03 Earth / Sand filling and filling of Embankment:

a) For filing up of low lying areas and for construction of embankment, good excavated
soil free from vegetation and organic matter, stones, brick bats etc. shall be
used. All filling in earth shall be laid in layers not exceeding 150 mm thick and
rammed, tamped, rolled, watered and thoroughly compacted to consolidate
properly.
b) For all backfilling with sand, clean approved river sand will be used, free from
foreign matter and impurities. The sand fill shall be fully saturated with water and
well vibrated mechanically to achieve full compaction. After compaction, water shall
be drained out through weep holes or otherwise in an approved manner.
c) Prior to filling of low lying area or before commencement of embankment
construction, the area shall be cleared of all vegetation growth and the original
surface shall be stripped to required depth of 150 mm. The stripped surface shall be
ploughed / harrowed and well moistened before depositing new material on it.
d) No bush, roots, sod or other perishable or unsuitable materials shall be placed in

the fill / embankment. The suitability of each part of the foundation for placing
embankment materials thereon, and of all materials for use in the embankment
construction will be determined by the engineer. It is the duty of the contractor to
deliver such specimens of materials to be taken from the borrow pits and the
embankment fills, as directed by the Engineer or his representatives to the
laboratory.
e) The cost of taking and transporting the materials for testing to the laboratory is to be
included in the unit rates for excavation. The actual cost of making the tests is to be
borne by DVC. Similar procedure will have to be followed for compaction control

48
tests.
f) The material shall be spread uniformly in layers not exceeding 150 mm after
compaction in depth before compaction, with optimum moisture as established by
laboratory test. The layers shall be deposited in an approximately horizontal
position with slight slopes.
g) If any equipment is used which is not capable of spreading materials in layers not
exceeding 150 mm after compaction in depth, blade graders or other similar
approved levelling devices must be used. The fill / embankment shall be compacted
as evenly and densely as possible (not less than 95% of Standard Proctor density)
by routing the hauling equipment over the layers already in place, distributing such
layer over the entire length and width of the previously placed material. Compacting
machinery such as roller shall be used for compacting the earth fill.
h) The material in each layer, while being compacted by rolling, shall contain within
practicable limits the optimum amount of water for compacting purposes, and this
optimum water content shall be uniformly distributed throughout the layer. The
application of water to materials for this purpose shall be done at the site of
excavation as far as practicable and shall be supplemented as required by
sprinkling on the fill / embankment. Harrowing or other working of the material may
be required to produce the required uniformity of water content. In case of
excessive moisture content, the material should be allowed to lie until the excessive
moisture has evaporated or drained out before the layer is rolled. In view of the
danger of over rolling the impervious core or blanket, if any, heavy hauling
equipment should be spread out over the wide area. Rolling or the passage of
heavy equipment on material with relatively high water content tends to cause local
shear failure.
i) Each layer of material shall be compacted by passing the specific roller over the
entire surface. The exact number of passes required shall be determined by the
Engineer.
j) When any mechanical equipment used for spreading and compaction becomes
inoperative or suffers a break down, all other mechanical equipment used for
placing and spreading materials should cease operations until the equipment used
for compaction is again in operation.
k) For embankment construction, embankment shall initially be raised to a level 600

mm below the final level. Superfluous materials on its slopes shall be removed and
placed on embankment to raise it to the desired top level and the slopes trimmed to
specified slopes. The contractor shall ensure that the finished slopes are neatly
trimmed and fully compacted.
l) Contractor shall include in his rate for construction of embankments, stripping of top
soil, clearing jungles, bushes etc. and any other process to get the good earth in the
borrow area also. No borrow area shall be made without the Engineer’s approval.
m) Compaction control tests for construction of embankment:

2 Nos. dry density test of compacted layer to be conducted for every 300.0 Cum. of
compacted earth work or part for every layer compacted and degree of compaction

49
attained determined
C. CONCRETE:
C.01 Code of Practice:

All concrete work shall fully comply with the latest edition of Indian Standard
Specification IS : 456, "Code of Practice for Plain and Reinforced Concrete".
C.02 Vibration:
Approved mechanical vibration for all structural and reinforced concrete shall be
mandatory. Immersion type vibrators (65 mm and / or 75 mm dia and 500 mm to
600 mm long) with a minimum vibration of 8000 revolutions / minute shall be used.
Use of pneumatic and / or electrical vibrators are mandatory.
C.03 Cement Concrete in Foundation (Mass Concrete):

a) i) Materials will be as per specification.
ii) Concrete to conform to IS : 456 and it shall be of Nominal Mix.
b) i) Consistency shall be frequently measured by carrying out slump test.

Minimum quantity of water for required workability shall be used .
ii) Proportioning and mixing shall be as specified in the Reinforced
Concrete (C.04)
c) Mixing cement concrete - Machine Mixing:

Right proportion of materials shall be loaded in mixing drum and sufficient water
added in accordance with the water-cement ratio desired. It shall be kept rotating
for 1/2 to 2 minutes till all materials are mixed thoroughly and then the concrete
shall be discharged in one operation over a level platform and thereafter turned
over once before being conveyed.
d) Hand Mixing:
Hand mixing shall be done on a watertight brick platform (at least 4m x 2.5m) with
strips fastened along 3 sides to prevent materials being washed or shoveled off
during mixing. Where hand mixing is allowed, cement and sand shall first be mixed
dry thoroughly by turning over backward and forward several times. This dry mortar
shall then be spread over the top of premeasured stack of dry aggregate. The
whole shall then be thoroughly incorporated by turning over backward and forward
at least 5 times to ensure a thorough mix. To this, water should be added from a
can fitted with a gradual and the whole stack turned over and over again till every
ballast is sufficiently coated with mortar. No excess water should be used. The
whole operation shall not be taken more than 15 minutes. If moist sand is used
allowance for bulking shall be made.
Unless otherwise mentioned in the schedule, the mixing of concrete should be done
by the machine to be approved by the Engineer-in-Charge. No hand mixing
concrete will be allowed unless specially permitted by the Engineer-in-Charge. In
case of such hand mixing being permitted, 10% extra cement on this account will
be added at Contractors expense.
e) Depositing the Concrete:

Before depositing the concrete, debris shall be removed from the space to be

50
occupied by the concrete. The concrete must be used while fresh. It shall be laid
(not thrown) in layers not exceeding 150 mm in thickness and shall be well and
quickly rammed with 6 kg iron rammer until mortar creams to the surface. Square
rammers must be used for consolidation of the edges. In laying consecutive layers,
lower course shall be well watered and made rough before upper layer is laid.
The time from starting of mixing to ramming in final position shall not take more
than 30 minutes.
Re-tampering of concrete which are partially set is absolutely prohibited. Suitable
planks and gangway shall be proved to prevent traffic over the surface of the work.
Concrete shall be cured keeping it wet for 15 days. The period, method of curing
and method of protecting concrete during curing are subject to approval of
Engineer-in-Charge.
The rate shall include in addition to provision of materials, mixing, placing curing
and finishing of concrete and contrivances for curing, if any.
Holes for passage of water wherever necessary and holes for uprights of door
frame, are to be provided during construction by the Contractor within the rates.
C.04 Reinforced Concrete:

All reinforced concrete will be either with M-15, M-20 or M-25 concrete. Nominal
Mix proportion 1:2:4, 1:1.5:3 & 1:1:2 by volume shall be taken as equivalent to M-
15, M-20 and M-25 respectively. Characteristic compressive strength of 15 cm cube
at 28 days for M-15, M-20 and M-25 mix is 15 N / Sq.mm, 20 N / Sq.mm and 25 N /
Sq.mm respectively.
Cement:
Cement conforming to I.S. : 269 or IS : 455 shall be supplied by the contractor.
Water:
Water shall be arranged by the Contractor at his own expenses, its quality should
conform to specification.
Reinforcement:
Steel reinforcement shall comply with the requirements of the latest edition of IS :
432 or IS : 1786 (latest). All steel shall be of tested quality. If demanded by DVC the
contractor shall submit the manufacturer’s test certificate for steel. All bars shall be
free from grease, oil, dirt, scale, loose rust, and bituminous materials.
All bars shall be thoroughly cleaned before being fabricated. Pitted and defective
rods shall not be used.
All bars shall be rigidly hold in position before concreting as per requirements of the
latest edition of IS : 2502. No welding of rod shall be allowed. Laying of
Reinforcement bars shall be in accordance with relevant I. S. specifications unless
otherwise specified. Lap lengths shall not be less than the minimum values
specified in the relevant codes of practice. The laps shall be staggered. Dowel bars
shall be provided wherever required or as directed by the Engineer or as shown in
the approved drawings. Special attention shall be given to proper and adequate
reinforcement where the section of the concrete member changes.
The horizontal distance between parallel reinforcement bars in row shall not be less
than the greatest of the following :
a) The larger diameter if the diameter be unequal.
b) Diameter, if the diameters are equal.
c) 6 mm. more than the nominal maximum size of coarse aggregate.
The vertical distance between two rows of reinforcement bars shall be not less than
12 mm unless they are cross reinforced or lapped. Reinforcement bars shall be

51
bent by machine or other approved means. All the bars gradually and correctly bent
to shape shall be used and the bends and shapes shall comply strictly to the
dimensions in the approved drawing. No reinforcement shall be bent when in
position in the work without approval whether or not this is partially embedded in
concrete. Reinforcement shall be accurately fixed and maintained in position by
approved means. Bars intended to be in contact at crossings shall be securely
bound together at all such points by annealed galvanised Iron wire of approved
gauge. Placing of reinforcement shall be completed well in advance of concreting.
In case reinforcement bars are in coil form, straightening of the same shall be done
by the contractor.
Shuttering and formwork:

The formwork shall conform to the shape, lines and dimensions shown in the
approved drawings. It shall be constructed as to remain sufficiently rigid during
placing and vibration of concrete and to prevent bulging of formwork. It shall also be
strong enough to withstand the weight of men and materials and scaffolding hung
therefrom. The formwork and joints shall also be sufficiently tight to prevent loss of
liquid from the concrete. Leaking joints shall be caulked. The formwork shall be
such as to ensure a fairly smooth finish free from honeycombs, air bubbles, fins,
bulges, depressions prominent grain marks of wood etc. The finish expected would
be equivalent to that which would have been obtained had plywood or steel lines
shuttering been used. Timber, if used for shuttering shall be well seasoned, free
from sap, shaked, loose knots and work holes. Faces coming in contact with
concrete shall be free from adhering grout, plaster, paint, projecting nails, splits or
other defects. Connections shall be so constructed as to permit easy removal of
shuttering and shall be either screwed, bolted, clamped, wired or otherwise secured
so as to be strong enough to retain the correct shape during consolidation.
Necessary provision shall be made for fixing anchor bolts, sleeves, or any other
devices as shown in the approved drawings or as directed by the Engineer.
Shuttering shall be provided for the top faces of the sloping work and anchored to
prevent floatation where the slope exceeds 1 (vertical) : 2.5 (Horizontal).
Care shall be taken to see that the formwork is perfectly cleared and two coats of
approved mould oil / any other approved materials applied before placing concrete.
Such coating shall be insoluble in water, non-staining and non-injurious to the
concrete. It shall not become flaky or be removed by rain or wash water. Care shall
also be taken to prevent contact of the mould oil with the reinforcement. Bolts
crossing through water retaining members for the purpose of securing and aligning
the formwork shall not be used unless effective precautions are taken to ensure
water tightness after removal. Any steel left in the structure shall be adequately
protected against corrosion. Formwork shall not be struck before the expiry of the
following period :
a) Walls, columns and vertical sides of beams - 48 hours
b) Slabs (props left under) - 7 days
c) Slabs - removal of props - 14 days
d) Beam soffits - 21 days.
Striking of forms:
Shuttering shall be removed without shock or vibration by gently releasing the
wedges. The contractor shall record on the drawings or elsewhere, as approved,
the date on which concrete is placed in each part of the work and the date of
removal of shuttering. The consequences arising during the removal of the

52
shuttering shall be contractor’s entire responsibility.
Re-use of forms:
Before re-use all forms shall be thoroughly cleaned as specified earlier and may be
re-used with the approval of the Engineer. The contractor shall, however, equip
themselves with sufficient shuttering and formwork to continue with the work
uninterruptedly.
Concrete proportioning:
In proportioning concrete, the quantity of both cement and aggregate shall be
determined preferably by mass. Water shall either be measured by volume in
calibrated tanks or weighed. The proportions of nominal mix concrete shall be in
accordance with Table 3 of IS : 456. The amount of water to be added shall be
adjusted to compensate for any observed variations in moisture content. In the
absence of exact data, the amount of surface water may be estimated as per
values given in Table 4 of IS : 456. Incase uniformity in the materials used for
concrete making has been established over a period of time, the proportioning may
be done, with the permission and approval of Engineer-in-Charge by volume
batching and periodic checks shall be made on mass volume relationships of the
materials. In volume batching, if the fine aggregate is moist due allowance shall be
made for bulking in accordance with IS : 2386 (Part III). Concrete shall be mixed in
mechanically operated batch mixers. Water shall not be admitted into the drum of
the mixer until all ingredients constituting the batch are in the drum and mixed dry
for one minute. Each batch shall be mixed until the concrete is uniform in colour
and for a period of not less than two minutes after all the materials and water are in
the drum. Partly set or excessively wet and re-tampered concrete shall not be used.
Such concrete shall be immediately removed from the site. Each time the work
stops, the mixer shall be cleaned out and when commencing the mix again, the first
batch shall have 10% additional cement to allow for adhesion to the drum.
In exceptional circumstances such as mechanical breakdown of mixer, work in
remote areas or when the quantity of concrete work is very small, hand mixing can
be done, with the approval of Engineer-in-Charge, subject to adding 10% extra
cement at the cost of Contractor.
Concrete shall be handled from the place of mixing to the place of final deposits
rapidly as practicable by methods which will prevent segregation or loss of
ingredients. It shall be deposited as nearly as practicable in its final position to avoid
re-handling or flowing. Mixing and distributing equipment shall be kept free from set
concrete. Before proceeding to place concrete, the shuttering shall be realigned, if
necessary, and water and rubbish removed therefrom by approved means. No
concrete shall be placed until the forms and reinforcements are approved by the
Engineer. The interval between addition of water to the dry batch and the
completion of placing of concrete shall not exceed 30 minutes. The concrete shall
be placed in the final position and shall not be disturbed thereafter. Concrete shall
be placed in the shuttering by means approved by the Engineer and shall not be
dropped from a height or handled in a manner which will cause segregation.
Special care shall be taken in this respect while recommencing the work at a
construction joint. Accumulation of set concrete on the reinforcements and
shuttering shall be avoided. After the concrete has been placed it shall be
compacted by approved mechanical vibration and thoroughly worked round the
reinforcements into the correct form and shape. Vibrators must be operated by
experienced men and over-vibration shall not be permitted. Some hand tampling of
concrete may be necessary and the same shall be done if so found necessary or if

53
directed by the Engineer. Care must be taken to ensure that the reinforcements and
formwork are not displaced or disturbed during placing of concrete. No concrete
shall be placed in wet weather. Concrete that has been washed away by rains shall
be entirely removed, if there has been any sign of cement and sand having been
washed away from the concrete mixture. Suitable precautions shall be taken to
protect fresh concrete against rains before leaving the work unattended.
Accumulation of water on freshly laid concrete surface shall not be permitted. Any
leakage of cement grout through the shuttering or elsewhere during the concreting
shall be immediately caulked properly by coir mastic or any other approved
materials. Concrete shall be placed continuously until completion of the part of work
between construction joints. This shall be strictly followed in the case of water
retaining structures. If stopping of concreting become unavoidable at any other
section a construction joint shall be made where the work is discontinued as
specified. Concrete which is in the process of setting shall not be disturbed or
shaken. Slots, openings or holes shall be provided for bolts, sleeves, anchors,
fastening etc. embedded in concrete as shown in the approved drawings or as
directed by the Engineer. These shall be provided in the proper places as shown in
the approved drawings and any deviation therefrom shall be set right by the
contractor at his own expense.
C.05 Construction Joints:

The Contractor shall provide all required construction joints as shown in the
Engineer’s drawings or as directed by the Engineer prior to commencing any
specified work. Such joints shall be located and constructed to least impair the
structural strength. Unless otherwise specified or approved the construction joints
shall be located as follows :
Columns : 75 mm below the lowest soffit of the beams supported by it.

Beams : No joint as far as possible, but if unavoidable, the joint shall be at
midspan and shall be vertical joint with a rebate at mid-depth.
Slabs : Parallel to the principal reinforcement, but if this is not possible,
then at mid-span.
Before depositing fresh concrete at a construction joint the hardened surface shall
be well scrubbed with steel wire brushes and thoroughly cleaned by compressed air
and then thoroughly wetted. Excess water shall be removed. A 13 mm thick layer of
cement and sand grout of same ratio as the cement and sand the concrete mix
shall then be applied to the wetted surface and the fresh concrete shall be
thoroughly worked against this prepared face before the grout sets.
Where the concrete has not fully hardened all lattance shall be removed by
scrubbing the wet surface with wire or bristle brushes, care being taken to avoid
dislodgement of particles of aggregate. The surface shall be thoroughly wetted and
all free water removed. The surface shall then be coated with neat cement grout.
The first layer of concrete to be placed on this surface shall not exceed 150 mm in
thickness and shall be well rammed against old work, particular attention being paid
to corners and close spots.
The above works of construction joints are deemed to be included in the items of
concrete works and no separate payment shall be made for the same.
However, when required, suitable dowels shall be provided at the construction
joints for which payment shall be made as per reinforcement steel bar item.

54
C.06 Finish:
Exposed concrete surface shall be smooth and free from blemishes. While concrete
is still green, i.e., just after the removal of shuttering the surface of concrete shall be
carefully gone over and any hole, honey comb etc. noticed shall be filled with
cement mortar 1 : 1 unless otherwise directed by the Engineer-in-Charge. Newly
placed concrete shall be protected from rain, sun or wind. The immature concrete
shall be protected from damage by debris, excessive loading, vibration, abrasion,
deleterious substances and other materials that may impair the strength and / or
durability of concrete by approved means.
C.07 Protection and Curing:

All newly placed concrete shall be adequately protected from harmful atmospheric
effects, shock and detrimental vibrations. Adequate steps shall be taken to prevent
floating or flooding.
Vertical faces of concrete shall be adequately covered with a layer of absorbent
Hessian or equal, which shall be kept thoroughly and continuously wet for at least
ten (10) days following the date of placement. Exposed flat and horizontal faces
(e.g. top of mat or slabs) shall be made to retain adequate quantity (50 mm) of
standing water by ponding. The standing water shall be maintained constantly for a
least ten (10) days following the date of placement.
C.08 Precast Concrete:

The Contractor shall furnish and install required covers for cable trenches and
ducts, surface water drains, trenches, inspection chambers and holes. The precast
covers shall be manufactured unwrapped, true to shapes and forms, properly cured
etc. in accordance with the Engineer’s drawings. All joints shall snugly fit together
for the full length.
All planks shall be of removable type, with at least two (2) collapsible galvanised
M.S. lifting hooks and shall bear at each support at least 50 mm. Necessary
openings in coves shall be provided, as required. Anti-slip treatment shall be given
to the finished surfaces, wherever required. All surfaces exposed to atmosphere,
except for cover of water drains shall be plastered and jointly grouted with 1:3
cement mortar unless otherwise directed or specified.
The concrete shall be M-15, M-20 or M-25 as specified in the dwg. Materials also
shall conform to specification as stated except that coarse aggregate shall be of
size specified in the drawings or as per Engineer’s directions. The Engineer may
take specimens for testing to ensure the quality or work. Cost of such specimens
and tests shall be borne by the Contractor.
C.09 Encasement of Structural Steel:

Structural steel work as shown in the drawings or as directed, shall be encased in
concrete or brickwork. Before encasing, the portion of steel to be encased shall be
thoroughly cleaned with wire brush to remove loose scales, rust, paints etc.
C.10 Grouting:
The contractor shall grout base plates of steel structures as per drawings. Unless
otherwise specified on the drawings or directed, grout not exceeding 25 mm
nominal thickness shall consist of one part cement, one part metallic aggregate
(such as Embeco or approved equivalent) and one part fine aggregate by weight,
thoroughly mixed with with water just sufficient to make the mix suitable for the

55
required application. The water-cement ratio shall in no case exceed 0.50.

However, if greater flowability is required at any particular location, the water-
cement in the mix may be increased keeping the water cement ratio 0.50.
Aluminium powder of unpolished variety shall be added to the grouting mix at the
rate of one teaspoonful to a bag of cement as and when directed. The Aluminium
powder shall be thoroughly mixed with cement to ensure its uniform distribution in
the mix. For grout of over 25 mm nominal thickness, the mix shall consist of one
part cement, one part metallic grouting aggregate and one and half parts course
aggregate (10 mm maximum size) by weight. Ready mix grout like SHRINKKOMP,
CONBEXTRA GP2, SIKA GROUT 214 or approved equivalent may also be used.
Before placing of grout, the concrete surface shall be thoroughly cleaned of loose
materials by means of compressed air jet and wetted to facilitate the flow of grout.
Form work, where necessary, shall be placed around the area to be grouted and
suitably braced to prevent slipping during grouting operations.
The grout shall be laced by whatever means that is most practicable. The grout
may be done by ramming, by pressure grouting, by gravity, by pumping or by
pouring in place. Any method used shall first be got approved.
The grout shall be thoroughly compacted and all air pockets eliminated. Whenever
practicable, grout shall be poured from one end or side only to avoid excessive air
entrapment. After sufficient set has been attained, the shuttering shall be removed
and the excess grout shall then be trimmed away. Every precaution shall be taken
to prevent surface temperature variation for a period of 7 days after placing of grout.
Immediately after the final finishing is completed and the grout is hardened
sufficiently, the surface shall be thoroughly wetted and be kept wet for a minimum
of 7 days.
The grout thickness shown in the drawings will be nominal and actual amount will
depend on the actual finished height of the concrete foundation. No extra payment
will be paid for this reason.
D. ROOF TREATMENT :
Water-proofing treatment over R.C.C. Roof:
1:2:4 plain cement concrete (with 1/2” to 1/4” stone aggregate) with an average
thickness of 60 mm maintaining a slope of about 50 mm from mid portion to the
side of the roof (85 to 35 mm). The roof is then be treated with 6 coats diluted
solution of Sodium Silicate followed by 2 coats cement slurry wash (mixed with
small quantity of Cow-dung) as per direction of Engineer-in-Charge or as specified
in the item. Sodium Silicate of approved quality suitable for waterproofing purpose
is to be used.
Alternate Item
Providing and laying integral cement based water proofing treatment including
preparation of surface as required for treatment of roofs, balconies, terraces etc
consisting of following operations:
a) Applying a slurry coat of neat cement using 2.75 kg/sqm of cement admixed with
water proofing compound conforming to IS. 2645 and approved by Engineer-in-
charge over the RCC slab including adjoining walls upto 300 mm height including
cleaning the surface before treatment.
b) Plane cement concrete 1: 5: 10 (1 Cement: 5 fine sand:10 burnt brick) admixed
with water proofing compound conforming to IS : 2645 and approved by Engineer-
in-charge over 20 mm thick layer of cement mortar of mix 1:5 (1 cement :5 coarse

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sand ) admixed with water proofing compound conforming to IS : 2645 and

approved by Engineer-in-charge to required slope and treating similarly the
adjoining walls upto 300 mm height including rounding of junctions of walls and
slabs
c) After two days of proper curing applying a second coat of cement slurry using
2.75 kg/ sqm of cement admixed jointless cement mortar of mix 1:4 (1 cement :4
coarse sand) admixed with water proofing compound conforming to IS : 2645 and
approved by Engineer-in-charge including laying glass fibre cloth of approved
quality in top layer of plaster and finally finishing the surface with trowel with neat
cement slurry and making pattern of 300x300 mm square 3 mm deep.
d) The whole terrace so finished shall be flooded with water for a minimum period
of two weeks for curing and for final test. All above operations to be done in order
and as directed and specified by the Engineerin- Charge : With average thickness
of 120 mm and minimum thickness at
khurra as 65 mm.
E. BRICKWORK :
E.01 Cement Brickwork :

a) Brick, sand and cement shall conform to specification. Unless otherwise specified
brick work shall be of 2nd class bricks of approved quality laid in mortar. Work shall
be strictly as per drawings. Bricks shall be soaked in water for at least 6 hours.
Bricklined tanks of sufficient size, to admit this being done, must be constructed by
the Contractor at site of work and filled up after execution of work at his own cost.
b) Cement and sand shall be measured and mixed dry, minimum quantity of water to
ensure workability shall be added and the mortar turned over and over, backward
and forward as approved by the Engineer-in-Charge. All cement mortar shall be
used up within 30 minutes of mixing.
c) The brickwork is to be of English bond with frog upwards. No more half brick shall
be used than are necessary to complete the bond.
d) In laying each course brickwork shall be truly level and in perfect bond. All bricks
being thoroughly bedded and flushed with mortar. No mortar joint shall exceed 10
mm in thickness.
The work shall be carried up regularly. The maximum height of brickwork erected in
any day shall not exceed one metre and no portion of work shall be left more than
one metre lower than another. Temporary steps left during construction shall be
raked back according to bond and not toothed so that when work is continued the
new brick will be laid over those previously laid.
No mortar joints shall exceed 10 mm thickness and shall be less than 6 mm
thickness, unless otherwise specified or approved by Engineer-in-Charge. The
Contractor shall provide planks on which the wetted bricks shall be stacked before
laid on the wall.
All brickwork shall be kept wet for at least 10 days after it is laid. The work shall be
left flooded at the end of each day’s work by making through with mortar fillets.
All the fixtures shall be built into the walls in their correct position as work proceeds,
joints of all brickwork shall be raked out while the mortar is still green to a depth of
20 mm to ensure a good key to plaster. All scaffoldings shall be provided by the
Contractor. The Contractor shall be responsible for any damage or injuries resulting
from all erected scaffolding. The Contractor’s rate for brickwork shall include cost of

57
all scaffolding, curing etc. and shall apply to all brickwork in steps, string course
over ghoondies in roof and all projections, curves etc. The measurement for
payment shall be made for the actual volume / area of work executed. Deduction
for opening shall be as per I.S. Specification.
E.02 Damp Proof Course :

This specification covers the laying of damp proof course ( D.P.C.) required to
prevent seepage of water at the plinth level of the building. It shall consist of cement
concrete mixed in the proportion 1:2:4 with 10 mm & down size graded aggregates.
The materials shall conform to the respective I.S. Code. It shall be of best quality,
fresh & thoroughly cleaned.
The D.P.C. shall be laid at plinth level of brick walls, flush with floor surface & shall
not be carried across door ways. It shall cover the full width of solid walls.
Before laying, the top surface of the wall shall be thoroughly cleared & watered. The
D.P.C. shall be laid in layers of 20 mm thickness or as the case may be, retaining
the edges by necessary shuttering & shall be well tamped & trowelled to a smooth
finish. The layer shall be cured by keeping the surface wet for 7 days and after
which it shall be allowed to dry.
After it has dried a coat of hot bitumen shall be applied over it. Bitumen shall
conform to I S : 702. It shall be heated to a temperate slightly higher than the
softening point to make it workable. It shall be applied at the rate of 1.78 kg / sq.m
to a uniform and the surface shall be blinded with clean dry sand at the rate of 0.05
cum./ sq.m.
Water proofing materials ( powder, paste or liquid ) of approved manufacture and
quality shall be added where specified, to the cement concrete in accordance with
manufacturer’s specification.
E.03 Cement Plaster:

Fine sand shall be used in plaster. The plaster shall be of thickness as specified.
But the Contractor shall allow in his price for any dubbing required due to
irregularities of brickwork. It shall be composed of 1 part of cement to 4 part of sand
unless otherwise specified.
The mix shall be thoroughly mixed and the wet plaster being used within half an
hour of being mixed. Surface to be plastered shall be wetted for 24 hours and joints
of brickwork raked out 20 mm deep before plaster is put in. Mortar which has began
to set shall not be used for plastering. Plaster in any place shall not be thinner than
specified. Plaster shall be kept wet for a period of 10 days. All internal and external
angles shall be rounded to 25 mm radius. The area of all corners, doors and
windows shall have richer mortar 1: 3 over a width of 75 mm on either side and
Contractor’s rate shall include this. The rates for plaster shall also include (a)
Plastering the surface and Corner and rounding at angles, (b) Preparing, clearing
and watering surface, (c) Watering and protecting plaster after completion, (d)
Provision, erection and removal of scaffolding.
E.04 Cement Punning (Neat Cement Finish ) :

Punning (neat cement finish) when specified shall be done as soon as the surface
of the plaster has hardened a little and shall not be delayed too long after the same.
The required quantity of cement and water shall be thoroughly mixed together into a
paste of the desired consistency. The cement paste shall then be applied to a
thickness of 1.5 mm. or as specified over the surface with a small steel trowel and

58
polished well. Punning shall in general be done from top to bottom in one operation
to eliminate joint marks.
E.05 Scaffolding:
The unit rate for all the items of work specified above shall include the cost of all
required scaffolding. All scaffolding shall be strong, right and shall have two
uprights, or be of the swinging type supported from outrigger beams at appropriate
locations to avoid the objectionable practice of leaving holes in the walls. Horizontal
and vertical diagonal bracings shall be provided. Single scaffolding shall not be
allowed for any work. Stage scaffolding, independent of the walls, shall be provided
for ceiling plaster.
All scaffolding shall be kept safe to men and materials and be fireproof as far as
possible. Records of its inspection shall be properly maintained.
F. FLOORING AND FLOOR FINISHING :
F.01 Single Brick Flat Soling in Flooring:

Second class bricks shall be used for the soling, and shall be soaked in water for at
least 6 hours before use. Before laying the soling, the bed on which it is to be laid
shall be well watered, rammed and surfaced evenly to the proper level and slope
necessary and as directed by the Engineer. On the top of this 12 mm thick layer of
fine sand shall be laid and well rammed and the surface made even. The bricks
shall be laid breaking joints using sand at the joints. The bricks shall be carefully
struck with a hammer to press against one another through the mortar so that the
joints are not more than 10 mm thick.
The excess of mortar rising through the joints shall be scrapped off. Grouting the
joints with this mortar shall not be permitted. Care shall be taken in laying with
bricks so that the entire surface shall present an even and compact appearance
Dust, dirt or earth shall not be allowed to adhere to the surface and shall be
thoroughly clean until concrete is laid on the top of it.
F.02 Cement Concrete Flooring:

If not otherwise specified the flooring shall be 75 mm cement concrete, 1:3:6 using
stone aggregate of 20 mm and down size. The work shall be carried out as per
cement concrete for foundation. The top surface shall be leveled and finished
smooth with straight edge and trowel and left clean to receive the floor finishing.
F. 03 Artificial Stone Flooring :
This shall be of 1:2:4 proportion using 13 mm down stone chips. The materials,
proportion mixing, laying, curing etc. shall be carried out as per Controlled
Reinforced Concrete (C.04). The surface of the bed concrete over which the
flooring is to be laid shall be rough and well watered. The flooring shall be laid
before the base concrete is set.
To prevent construction cracks the floor space shall be divided into squares or
rectangular panels not exceeding 4 square metres (with a maximum length of
2.5M). The exact size shall be decided by the Engineer-in-Charge. The edge of
each section into which the floor is divided shall be Aluminium dividing strips (3 mm
thick), top of which shall make exact level of the finished floor. Alternative bays shall
be worked at a time.
The concrete after laying shall be thoroughly rammed with wooden thappy and the
mortar working up to be smooth off with steel trowel and rubbed with a gumla to

59
give smooth finish. The use of additional mortar for finishing is absolutely
prohibited.
The junction of the floor with the wall of dado or skirting shall be rounded to a
uniform radius varying from 25 mm to 50 mm as directed by the Engineer-in-
Charge.
On completion the whole floor shall be kept flooded with 50mm water for 14 days. If
the whole floor is not completed in a day, the finished portions shall be kept under
water with small bunds or damped by empty gunny bags. In no circumstances,
hammering of any type shall be allowed on the finished surface.
F.04 Cast-In-Situ Mosaic Floor:

Cement:
Cement shall be as specified under concrete work. Coloured cement shall be
supplied by the Contractor.
Marble Chips:
Marble Chips shall be hard, free from flakes and 6 mm and down to 3 mm graded
size or as specified and of approved quality.
Colour:
Coloured mosaic, when required, shall be laid with approved first class quality of
coloured cement in preference to white cement mixed with colouring pigments.
Base Coat:
Monolithic base coat of cement concrete shall be finished as specified under
‘Concrete Floor’. Before commencement of mosaic work, the base coat shall be
well roughened, cleaned of all loose materials, grits and rubbish. The surface shall
be wetted well.
Mix:
a) The mosaic coat shall consist of the following proportion:
Marble chips (6 mm & down to 3 mm graded) ... 5 parts.
Marble dust ... .1 part
Cement .... 3 parts
b) The proportion of marble chips, dust and cement shall be as specified above.
Extra colouring materials shall be added to get the desired shade as necessary.
c ) The marble dust and cement or mixture of cement and colouring pigment as the
case may be shall first be intimately mixed in adequate quantities. The marble
chips shall then be added and thoroughly mixed thereafter. Water shall then be
added in quantity to give a mix of the driest workable consistency.
Sample :
Sample slabs of 600 mm x 600 mm shall be prepared for the approval of the
Engineer as regard to shade of colour and finish before commencing the mosaic
work which shall conform to the shade and finish of the approved sample.
Laying:
a) Mosaic work shall be laid (as per IS : 2114) in appropriate thickness in
square or rectangular panels of not more than 600 mm. dimension in any
direction. The panels shall be as nearly as possible squarish and shall be
accurately marked out. The laying shall be in alternate panels at a time.
b) All joints of panels shall be absolutely straight and square. Glass partition
shall be used as specified or as directed. The width of the glass partition
shall be as per the specified thickness of the floor. The thickness of the strips
shall be at least 3 mm unless otherwise specified.

60
c) The mosaic coating shall be laid on the base coat at least 24 hours after the
laying of the base coat. A coat of neat cement wash shall be applied on the
base coat before laying the mosaic coat.
d) Finished mosaic coat shall be 6 mm thick. The floor shall be kept damp by
using moist sand, after the time of laying the topping. Grinding shall not start
earlier than three days after laying.
Polishing:
The surface of the mosaic shall be polished to a highly glossy finish with power
grinders and with different grades of Carborundum stones, starting with coarse
grinding stone followed by stones of finer grades. After first cutting with coarse
stone, the surface shall be given a neat cement wash of the same colour and shade
as the mosaic before starting the next stage of polishing. Between each stage of
polishing with different grades of stones an interval of at least 4 days be allowed,
during which proper watering shall be done to cure and harden the cement. In the
final stages of polishing, oxalic acid power shall be used. Care shall be taken that
final surface is free from cracks, marks stains, blemishes and disfigurations.
F.05 Mosaic Tiles:

Precast mosaic tiles shall be of approved colour and design.
Tiles shall be of 250 mm x 250 mm or 200 mm x 200 mm size and about 20 mm
thick of which mosaic thickness shall be 6 mm thick. Special shapes shall be used
at joints of floors with walls, cornices, window sill etc.
Samples shall be submitted to the Engineer for prior approval of quality and shade.
The tiles shall be free from cracks, crazings, blemish, broken corners or edges, any
other defects and shall be uniform in colour.
Setting :
Tiles shall be well wetted before laying and shall be set on floors and walls over
cement mortar bed consisting of one part of cement and three parts of sand. Neat
cement grout of honey like consistency shall be spread over the mortar bed over
such an area at a time as would accommodate about 20 tiles. The tiles shall be
fixed in this grout one after another, each tiles being gently tapped with wooden
mallet till it is properly bedded and in level with the adjoining tile. The joint shall be
kept as close as possible and shall not exceed 1.5 mm width and in straight lines or
as directed by the Engineer. After the tiles have been laid, it shall be cleaned off
with saw dust. The day after the tiles have been fixed, the joints shall be refilled with
cement paste or grout of the same shade as the colour of the tile. The finished
floor shall be laid to level and flat and to slope as directed. The flooring shall be
allowed to remain undisturbed for at least seven days or as directed so that the
bedding sets properly. Heavy movement shall not be allowed on the floor for at
least 14 days after fixing of tiles.
Polishing :
Polishing of tiles shall be commenced only after the floor as well as the joints have
dried up, the period being at least 3 weeks after fixing of tiles. The tiles shall be
thoroughly wetted with sufficient water and rubbed down with different grades of
carborundum stones evenly and without scratching the surface. Thereafter the floor
shall be washed cleaned and again rubbed hard with felt and slightly moistened
with Oxalic acid. After polishing the floor shall again be very carefully washed,
cleaned and dried. When dried, the floor shall be covered with oil free dry saw dust

61
which may be removed only after the construction work in the area is over. While
removing saw dust, finer polish shall be done by running the floor machines fitted
with hessian bobs or felts until the floor shines.
Tile skirting, Dado work etc. :

Tile skirting or dado work where required, shall be fixed only after laying the tiles on
the floor. The portion of the wall to be tiled shall be left unplastered. Before fixing
tiles on brick walls, the wall surface shall be wetted with clean water. Thereafter it
shall be evenly covered with a coating of cement mortar (1:3) of required thickness.
Before this cushioning mortar has hardened, the back of each tile shall be coated
with a thin layer of neat cement paste and the tiles shall then be gently tapped
against the wall. The fixing shall be done from the bottom of the wall upwards. Each
tile shall be fixed as close as possible to the adjoining and any difference in the
thickness of tiles shall be evened out in the cushioning mortar or cement paste so
that all the tile faces are set in conformity with one another. Any fine open joint, if
occurs, shall be sealed up with plaster of paris which shall be coloured to match the
tiles. The vertical joint shall be staggered or kept in a line as decided by the
Engineer.
The rate for all the mosaic works shall include cost of base coat, mosaic coating,
cement mortar bed, neat cement paste, plaster of paris paste etc. for completing
the job in full as specified above.
F.06 Glazed Tiles:

Tiles :
Glazed ceramic tiles shall be ISI approved, heavy duty, industrial type of best
quality, resistant to the action of acids and alkalis. They shall be free from cracks,
crazing and other defects and blemishes and shall remain free for at least five (5)
years.The colour shall be as approved by the Engineer. All tiles shall be 150 mm x
200 mm or 300 mm x 200 mm size and 5 mm thick.
Setting:
a) Glazed tiles shall be set on the walls and floors with cement mortar
consisting of one (1) part of cement and three (3) parts of sand.
b) The base surface shall be well cleaned and the tiles shall be set butting
each other without leaving any open joints. A few open joints, if approved,
may be filled up with plaster of paris, which shall be coloured to match the
colour of the tiles.
c) Glazed tiles shall be laid in a perfectly plain and level surface or sloped.
Vertical joints in case of walls shall be staggered as directed. The faces of
the glazed tiles on walls shall be flushed or projected as required.
Polishing :
After completion, the tiled surface shall be thoroughly cleaned with lime and
finished as a highly glossy thorough clean surface.
G. STRUCTURAL STEELWORK:
G.01 Fabrication:
i) The fabrication of structures shall be in accordance with relevant clauses of IS :

62
800 & IS: 802 (Part-II) latest.

ii) All parts of the structures shall be fabricated in accordance with the shop
drawings approved by DVC.
iii) Structures shall be of bolted construction unless otherwise specified. Unless
specially demanded, welding at no point shall be permitted.
iv) Structures shall be accurately fabricated, to bolt together easily at the site
without any undue strain on the structural members or in the bolts. Otherwise,
the structure or parts of it will be rejected.
v) Structures demand accurate drilling/punching of holes with high standard of
workmanship. No bolt holes shall be more than 1.5 mm larger than the
corresponding bolt diameter. Holes shall be drilling or punched to jig, but drilled
holes shall be preferred and they must be perfectly circular and no tolerance in
this respect is permissible.
vi) All steel sections, before any cutting work is started, shall be carefully levelled,
straightened and made true by methods which shall not injure the material.
They shall again be trued up after being punched and drilled. No rough edges
shall be left. Bends, if any shall be thoroughly cold straightened without injury.
Shearing shall be neat & edges shall be planed & trimmed, as necessary.
vii) Workmanship & finish shall correspond to the best & modern practice. All
similar parts be made interchangeable. No rough edges shall be permitted any
where throughout the work. The structure shall be so fabricated that all parts
be accessible for inspection & cleaning. Drain holes shall be provided at all
points where pockets or depressions are likely to hold water.
G.02 Marking of Members :

Each individual member shall carry a stamped mark (number) assigned to it in the
approved Drawings. These stampings shall be done by a metal die before
galvanising and on optimum depth so as to be clearly legible after galvanising.
Further more, the mark No. should be stenciled in indelible ink on each member
after galvanisation.
G.03 Galvanisation:
The galvanising shall be as per IS :2633 (latest). Zinc coating over galvanised
surface of structure members and threaded fasteners shall not be less than 610
gms per sq.m. & 375 gms per sq.m. respectively. Uniformity of galvanisation shall
be determined by the Preece Test. The samples shall withstand four one minute
dips for passing the test.
Contractor should submit regularly the result of all the tests performed, to DVC for
approval. Corporation’s Engineer or their authorised representatives will witness the
tests. Hot dip Galvanizing of the structural members shall conform to IS-2629
(latest) and IS-4759 (latest) and that for bolts & other fasteners, shall conform to IS-
1367 (Part-XIII) latest. All galvanizing material shall withstand test as per IS 2633
(latest). The weight of Zn Coating shall be determined as per method stipulated in
IS-2633 (latest)
G.04 Painting:
Surface preparation is very important before actual painting is made unless
otherwise specified. All steelwork shall be given one coat of shop paint applied
thoroughly and evenly to dry surfaces which have been cleaned. Paints to be used
for shop coat of fabricated steel shall conform to IS :2074 (latest). Unless otherwise
specified two coats or red oxide paint should be provided as primer (one coat at

63
shop & the other at site after erection) before applying two coats of finish coat. The
paint should be manufactured by Berger, Jenson & Nicholson and / or Asian Paints.
All paints & primer shall be of standard quality & procured from approved
manufacturer & shall conform to the provision of relevant IS Codes. Relevant IS
Codes for various types of paints are as follows :
i) IS : 2074 : Red-oxide zinc chrome paint.

ii) IS 2932 : Synthetic enamel paint.
iii) IS : 158 : Anti-Corrosive black bituminous paint.
iv) IS : 2339 : Aluminium paint
For other specifications refer (G).
G.05 Erection :
The complete erection of the steel work is a part of a contract and the contractor
shall be responsible for determining the erection procedure as well as for providing
temporary bracing and connections and shall be liable for loss or damage resulting
from faulty erection. All materials shall be effectively protected from injury, while at
the shop/in transit, until erection complete and inspected & accepted.
The structural steel erection work shall commence only after the foundations have
been checked and passed by the Engineer. The work shall include, besides the
scope specified elsewhere in this specification, the following.
a) Straightening and repairing on ground and materials damaged in transit and
assembling, bolting, riveting or welding of all connections on ground or in
position. Straightening of erected members will not be permitted. The
structures shall be ground assembled in largest possible size which can be
erected with the equipment available.
b) Varnishing and applying the base coat of paint damaged in transit and/or site
connection and splice.
The Contractor shall erect all necessary guys and braces to ensure proper
alignment and stability until all members are permanently connected. Such
temporary guys and braces shall be maintained in place until, in the opinion of the
Engineer they can be removed without danger to the stability of the structure.
As each part of the work is erected, it shall be passed by the Engineer. This
particularly applies to accurate plumbing of all stanchions or columns, levelling,
setting, aligning and fixing of the various parts and adjusting of bearings. Free
movement shall be ensured where required for contractions and expansions.
Variations from Engineer’s drawings shall be checked, noted and reported to the
Engineer immediately. Prior to erection the Contractor shall ascertain from the
Engineer as to which parts will be inspected and passed from time to time. Such
passing will not, however, exonerate the Contractor from this responsibility for
proper erection,
The Contractor shall furnish, at his own expense, necessary staging and hoisting of
all materials or equipments required for the erection of the structure and shall
remove and take away when the work is completed. Where directed, the staging
and hoisting equipment and materials shall be non-inflammable.
All necessary cutting, punching, drilling, welding & fitting including cutting & making
good concrete and/or masonry or other adjacent work for installation of the
structural & miscellaneous steelwork shall be included. The contractor shall also

64
make necessary modifications to the existing or already staled work (by other
contractors) & make firm connections thereto of the structural & miscellaneous steel
as directed or as approved by the Engineer.
Welding work shall be performed only by qualified welders who have passed
qualification tests in accordance with the codes.
H. FINISHING ITEMS:
H.01 White Washing :

Preparation of surface :
Before whitewashing the surface of new walls, the walls shall be well cleaned of all
dust, dirt marks, greased and oily spots, if any, and of mortar drops and free from
all foreign matters. The walls shall be brushed and all paintings scraped properly.
Before laying on walls which have been once white washed, the old loose white
wash shall be first removed and minor repairs to the plaster done such as filling
holes, etc. The contract rate shall cover all the above work and no extra payment
shall be made for preparation of surface.
Preparation of materials :
The white wash shall be prepared from katni lime or shell lime, as specified, only.
The lime shall be screened through a sieve of 324 meshes to the square inch
(or 7 meshes/cm) and dissolved in a tub with a sufficient quantity of water and the
whole well mixed to give a thin creamy consistency. When thoroughly mixed, it
shall be strained through a clean coarse cloth, and clean gum or glue added to it at
the rate of 4 kg per cu.m. (4oz. per cft) of lime used. Ultramine blue in adequate
quantity shall also be added to the mixture, prepared as above to give a light blue
tint.
Application :
Each coat shall be laid on with a brush and allowed to dry before next coat is
applied. A stroke of the brush shall be given from the top downwards, another from
bottom upwards over the first stroke and similarly one stroke from the right and
another from the left over the first brush before it dries and these four stroke shall
be considered as one coat of white washing. Number of coats shall be as described
in the item of work.
Each coat shall be allowed to dry and got inspected from Engineer-in-Charge
before applying the next coat. After white washing is completed, the surface shall
present a uniform white appearance without exhibiting any patches, or hair cracks,
or streaks and the washing shall not come off when rubbed with the fingers.
The contractor shall take every precaution to prevent white wash being splashed on
the walls, floor and other surface and articles not be white washed. The Contractor
shall clean all such items to the satisfaction of the Engineer-in-Charge at his own
cost. Ladders poles, scaffolding etc. shall be shed with gunny bags to prevent
damages and scratching of the walls and the floors.
H.02 Colour Washing :

The colour washing shall be prepared and applied in accordance with the standard
specification for white washing.
The number of coats of colour washing shall be as specified in the item of work.
The surface to be coloured shall be prepared exactly as per white washing. The
wash shall be prepared by adding the required quantity of colouring matter to lime

65
wash as prepared for white washing. No blue shall be added to the lime wash in
this case. The contractor shall make a pattern of the colour for the approval of the
Engineer-in-Charge, before applying.
Only sufficient wash for the day’s work shall be prepared in the morning. The wash
shall be stirred continuously during use, to give uniform colour all over. The colour
wash shall be applied with great care so as not to leave any cut shade or brush
marks on the wall when the work is finished.
If the colour wash on drying turns out to be streaky, blotchy or powdery, or if it
comes off easily on touch or otherwise badly applied, the contractor shall redo it at
his own expenses.
Whether it is specified in the item of work or not, the surface to be colour washed
shall first be treated with coat of white wash and the contractor’s rate for colour
washing shall cover its cost
H.03 Distempering :
The type of distemper its colour, make and brand and the number of coats to be
applied shall be as specified in the item of work, or as per the direction of Engineer-
in-Charge.
Preparation of wall surface :

The surface to be distempered shall be thoroughly cleaned of dust, dirt, grease, oil
marks, cement marks, loose scales etc. and rubbed with sand paper or pumice
stones to a very smooth surface. Plaster shall present a fine polished surface and
absolutely dry before commencing distempering. Inequalities and small holes such
as nail holes and any type of depressions shall be filled up with whiting and allowed
to set hard before applying distemper. No extra payment shall be made for this
cleaning and filling etc. The surface shall be got approved by the Engineer-in-
Charge before applying any distemper.
Mixing :
Unless otherwise directed by the Engineer-in-Charge the mixing of the distemper
shall be carried out in accordance with the instructions by the manufacturer of the
distemper, being used. Approval of the Engineer-in-Charge shall be obtained in
regard to exact shade and colour before laying distemper. Only approved quality of
distemper shall be used.
Application :
Where a priming coat is to be given, it will be indicated in the item of work. The
primers shall be in accordance with the recommendation of the manufacturer.
Distemper shall not be applied on damp walls or during monsoon. Distemper shall
not be mixed in larger quantity than is actually required for a day’s work. Distemper
shall be applied by dipping the brush in the distemper mixture and stroking cross-
wised on the wall and immediately stroking perpendicularly and then stopping. The
shade shall be absolutely uniform throughout and the finished surface shall be free
from brush marks. The distemper shall be applied with stiff brushes of approved
quality and only after the first coat has thoroughly dried then another laid on, if
specified. The first coat shall always be of a lighter tint and shall be applied with
care. The brushes used shall not be allowed to rest on the bristles and after use
shall be carefully and thoroughly cleaned. Old brushes caked with dry distemper
shall not be allowed on the work.
On drying the distemper shall not come off on touch and shall not crack. In case the

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finish do not conform to these standards then additional coat/coats of distemper

shall be given to rectify the defects. If the distemper cracks, it shall be washed off
and a fresh coat/coats or washing required for rectification.
H.04 Painting:
Materials :
All paints, oils, other materials and labour for painting shall be provided by the
contractor and included in the contract rate for painting or as specified. Ready
mixed paints shall be used exactly as received from the manufacturers and without
any mixture whatsoever except without the previous approval of the Engineer-in-
Charge. Also refer (G.04)
Preparing the surface for painting :

i) For new woodwork :
The surface shall be cleared thoroughly of all dust and dirt and sand
papered. All projections such as glue or whiting spots, all tool marks and
other irregularities shall be carefully removed and smoothened off . All
heads of screws and nails are to be set 1/8” ( or 3 mm) below the surface.
ii) For new Iron and steel work :
The surface shall be thoroughly scraped, well brushed and cleaned free of
rust, scale, dirt, grease etc. When a priming coat is specified it shall be of
red lead and boiled linseed oil unless otherwise specified. Primer coats shall
be applied without any time lag after the pre-cleaning and care shall be
taken that paint is not applied to a damp surface.
Application of Paint:
No paint shall be applied until the items of painting have been passed by the
Engineer-in-Charge. Surface of all description to be painted shall be thoroughly dry
before application of paint.
Paint brush shall be of the best quality and skilled painters shall be employed on
painting, varnishing etc. Application of the paint shall be done in the manner
specified by the manufacturers of paint. The paint shall be laid on evenly and
properly by means of crossing and laying off the later in the direction of the grain for
woodwork and care shall be taken that the paint is of such consistency that it runs
easily from brush. If a skin has formed on the top of the paint, it shall be carefully
removed before paint is used.
Successive coats of colour shall be applied after the previous coats are thoroughly
dried and inspected by the Engineer-in-Charge. Each coat, except the last coat,
shall be slightly rubbed down with sandpaper or fine pumice stone and cleaned off
dust before the next coat is laid. No hair marks from the brush or clogging of paint
shall be left on the work or in the corners of panels, angles of mouldings etc.
Surface Finish:
All painting and varnishing shall be neatly finished and the final surface after
painting shall be absolutely uniform in colour and shade and free from brush marks,
and without bristles, dirt etc. sticking to the surface. The contractor shall be held
responsible for any damage done by dropping or smearing paint or varnish, where it
is not required, and shall make good the same. Superfluous patches or stains of
paint of varnish may be removed by means of methylated spirit.

67
Contractor’s rate shall include all the materials and labour involved for execution of
the work as specified.
WOODWORK :
I.01 General:
The variety of timber to be used in the wood work shall be as specified in the
relevant schedule item. The Engineer-in-Charge may inspect all logs previously to
use and reject any, which he considers to be defective. The Engineer-in-Charge
may reject all timber wrought or unwrought in which he considers “Sound Knots”
are in excess to impair its strength.
All workmanship is to be of best description, neatly finished to the exact dimensions
required. If after the woodwork has been erected, undue-shrinkage or bad
workmanship is discovered, the contractor shall forth-with replace or re-fix the same
to the satisfaction of the Engineer-in-Charge.
Frames for Doors, Windows, Ventilators etc. :
The work shall be carried out as per detailed drawings or as directed by the
Engineer-in-Charge. All members of frames shall be absolutely straight and without
any intermediate joints. The joints shall be either mortised or dove-tailed as may be
directed by the Engineer-in-Charge.
The joinery shall be of perfect workmanship, tight and close fitting. Patching of
joints by wood glue, putty or other filling will not be allowed. The surface shall be
thoroughly planed and sand papered, and finished smooth.
Rivets shall be formed in the frame on the side or sides on which shutters are to be
fixed, and shall be according to the drawing. In case of swing shutters no rivets are
necessary.
Holdfasts made of M.S. Flats 1.5" x 1/8” x 1’-0” (or 40 mm x 6 mm x 30 cm.) shall
be screwed securely to the outside of the frames to fix it in position in masonry. The
end to be embedded in masonry shall be split and splayed and the end to be fixed
to the frame shall be bent truly square and provided with 3 holes for screws or bolts.
Each hold fast shall be fixed to the frame with 3 nos. of 2” (or 50 mm) screws of
3/8” (or 10 mm) dia bolts. Three holdfasts shall be fixed on each side of a door
frames one at the centre point and the other two at 12” (or 30 cm) from the top and
the bottom of the door frames. In case of window a pair on each side shall be fixed
at quarter points of the frames, while for the ventilator one holdfast shall be fixed on
each side at the centre point.
All frames shall be fixed into the masonry simultaneously with the masonry work.
No priming coat or paint or polish shall be applied before the frames are inspected
and passed by the Engineer-in-Charge.
Payment will be made on cu. foot (or cu.metre) basis on the overall measurement
of each member without making any deduction for beads, rebates, joints and
recesses. Rate for frames shall be inclusive of cost of joinery, making rebate,
beads, recesses etc. and shall be equally applicable to doors, windows and
ventilators.
I.03 Shutters For Doors, Windows & Ventilators:

The type of shutter i.e. whether flushed, panelled, glazed, venetian etc. and the
thickness of shutter will be as specified in the item of work and in the drawings. The
thickness will mean the finished thickness of the styles and rails.
All shutters shall fit squarely into the rebates of the frames in the closed position. In
the case of doors having no sill pieces a maximum gap of 1/4” (or 5 mm), between

68
the bottom of the shutter and the floor, shall be provided. The meeting style of the
shutters, having double leaves, shall be so shaped that in the closing position they
lap each other without leaving any gap. The lap shall be half the thickness of rails or
3/4” ( or 20 mm.) whichever is greater.
For particulars other than those furnished, which the contractor may require for
making shutters, he shall obtain the sketches or instructions from the Engineer-in-
Charge and the shutters manufactured accordingly. No priming coat or painting or
polishing shall be applied unless the shutters are inspected and passed by the
Engineer-in-Charge.
I.04 Panelled Shutter:

The work shall be carried out as per detailed drawing or as directed by the
Engineer-in-Charge.
Solid wood panels shall be made out of one or more pieces of timber of not less
than 5” ( or 12.5 cm) in width. In order to avoid warping, splitting, and cracking,
normally pieces not exceeding 8” (or 20 cm) in width shall be used, or as instructed
by the Engineer-in-Charge. When made from more than one piece, the pieces shall
be joined with a continuous tongued and grooved joint, together and reinforced with
metal dowels at regular intervals. Jointed pieces of timber shall belong to the same
species. The grains of the solid panels shall run along the longer dimension of the
panel.
The thickness of the panel shall be the thickness of the plain central portion
of panel. The edges of the panels shall be tapered symmetrically on both faces, or
as shown in the drawing, for insertion into style and rails. The tapered edges of the
panel shall be 1/4” (or 6 mm) thick. The central portion of the panel shall be raised
1/8” ( or 3 mm) sharp round on
both faces, or as shown in the drawing or instructed. Panels shall be framed into
grooves to the full depth of the groove which shall be 1/2” (or 13 mm) or as
specified, leaving an air space of 1/16” (or 1.6 mm) and the faces shall be closely
fitted to the side of the groove.
Styles, rails and solid panels in the shutters shall be of the same species of timber.
Assembly of the shutters shall be exactly at right angles and all members of the
shutters shall be straight without any warp or bow and shall have smooth well-
planed faces.
I.05 Glazed Shutters:

The glass shall be embedded in putty and secured to the rebates either by putty or
by wooden beads of suitable size and shape as directed by the Engineer-in-
Charge. All putty exposed to view shall be coloured to suit the paint of the shutters
and given a coat of oil paint to protect it from air. Putty shall consist of pure raw
linseed oil (and not boiled linseed oil) and best whiting, well mixed up by hand. The
whiting shall be specially dry and shall be mixed with as much linseed oils will form
it into a stiff paste. If frosted glass is used, it shall be fixed with frosted face away
from the putty.
On completion the surface of all the shutters shall be cleaned and all damaged
putty replaced. The contractor shall make god any glass broken by his workmen
whilst cleaning.
I.06 Wooden Flush Door Shutters:

Solid core flush door shutter shall be of the decorative or commercial types as
specified. The size of the door, finish etc. will be as specified in schedule of

69
quantities. The thickness of the shutter shall be as specified.
Materials :
Moisture content in timber used in the manufacture of flush door shutters shall not
be more than 12 per cent. Timber shall be free from decay and inspect attack.
Timber used shall be treated before assembly. Timber and cut-end shall be given a
protective treatment.
Commercial plywood used in flush door shutters shall conform to I.S : 303.
Construction Details :
Styles and rails shall be made of one piece or, alternatively two or more pieces
laminated together.
The face panel shall be formed by gluing under pressure on both faces of the core
either plywood or cross-bands and face veeners, as desired by the Engineer-in-
Charge.
In the case of double shutter doors, the meeting of the styles shall be rebated
3/4”(or 20
mm). Where lipping is provided, the depth of lipping at the meeting of styles shall
not be
less than 1.13” ( or 30 mm). The rebating s hall be of either splayed or square type
or of
any other type as specified by the Engineer-in-Charge.
Shutters shall be shop-prepared for taking mortice locks or latches as may be
ordered. Where the Engineer-in-Charge so desires, suitable blocks of wood shall be
provided for fixing the hardware.
Workmanship and Finish:

All the four edges of the door shutter shall be square. The shutter shall be free from
twist or warp in its plane. Both faces of the door shutter shall be sanded to smooth
even texture. If specified all surfaces of shutters, which are to be painted shall be
covered evenly by brush painting with suitable priming coat as may be directed by
the Engineer-in-Charge. All door shutters shall be flat and square.
Test :
Door shutters shall be tested for resistance of their base to immersion in water as
follows
Door shutters shall be immersed vertically to a height of 12” (or 30 cm) in water at
room temperature for 24 hours and then allowed to dry for 24 hours. The cycle shall
be repeated 8 times. There shall be no delamination at the end of the test.
LIGHT METAL WORKS:
J.01 Steeldoors, Windows and Ventilators :

All steel doors, windows and ventilators are of approved best quality & shall
conform to IS :1038 “Specification for steel doors / windows and ventilator”, IS :
1361 “Specification for steel windows for Industrial Buildings” & IS : 7452 , unless
otherwise stated. In case of doors and windows not in conformity with the above
I.S. the Contractor shall furnish the Maker’s name and details for approval by
Engineer. Best quality hot rolled mild steel sections conforming to IS : 7452 will be
used.
All fittings and fixtures shall be of superior chrome plated quality as approved by the

70
Engineer-in-Charge. Each door shall be provided with one superior quality rimlock
or mortice lock ( Godrej or equivalent ) with handles on both sides, 2 nos. 30 cm.
tower bolts & 1 (one) approved brass door closer ‘Yale’ or equivalent & necessary
lug for fixing. Each window shall be provided with :
1) Peg Stay arms

2) Handles
Each ventilator shall be provided with bronze cup pivots and spring catch closures.
For all doors, windows and ventilators, steel surface shall be thoroughly cleaned
free of rust, scale or dirt by pickling or phosphating and immediately painted with
two coats of red oxide painting conforming to IS : 102 before despatch.
a) Windows :
All windows shall be of steel section. The windows shall be provided with wire
reinforced glass of Indian manufacture at locations likely to be subjected to
vibrations. In other locations the glazings to be used shall be minimum 4 mm thick
and shall not weigh less than 10.0 Kg / Sq.m. Windows and ventilators cannot be
opened from outside.
b) Doors :
Doors shall be of steel sections, completely or partly sheeted. For
airconditioning rooms, rubber padding of approved type and quality shall be fitted
to the bottom of the door to make it absolutely airtight in closed position.
The glazings to be used shall be minimum 4 mm thick and shall not weigh less
than 10.0 Kg / Sq.m (unless otherwise specified or provided for in the drawings) .
Doors and windows of the toilets and other locations as decided by the Engineer
shall be provided with frosted glass.
Installation :
After the masonry work has been constructed, the contractor shall install the
door, window and ventilators frames in line and plum and shall firmly anchor
these to the masonry with approved steel anchors. The anchors / fixing lugs shall
be securely fixed by embedding in cement concrete blocks of 1:3:6 Mix. In some
cases the space between the masonry and frame shall be carefully filled with
cement mortar 1:2 or such other type of cement as recommended by the
manufacturer and as required. The Contractor shall ensure that variations in the
building dimensions will not cause the doors, windows or ventilators to jam or not
close properly. Work not properly anchored or out of plumb shall be rectified to
the Engineers’ satisfaction. After all the Civil works under this and other sections
have been completed, the Contractors shall carefully inspect all doors and
windows and ventilators and make necessary adjustment to ensure efficient
operation.
J.02 Aluminium Doors:

Aluminium doors shall comply with the specifications vide para J.01 except that
the materials shall be extruded sections, anodised to natural colour. Fittings shall
also be of anodised Aluminium. The Aluminium door shall be made from extruded
section of M/s. INDAL or any approved equivalent.
Special Aluminium doors for room and/or other locations shall be supplied as per
details in the Engineer’s drawings and fitted and fixed as required. These heavy

71
doors shall be fitted and fixed with superior most quality polished shoot glass of
5.5 mm minimum thickness and weighing at least 13.75 Kg / Sq.m.
J.03 Glazings:
Glazings for doors, windows and ventilators (both steel and aluminium) shall be of
patent, flattened sheets and glass, reinforced or clear as specified, of superior-most
approved quality. Unless otherwise specified glazings shall weigh not less than 10.0
Kg / Sq.m. Specifically stated polished shoot glass of superior-most quality
weighing 13.75 Kg / Sq.m shall be used. All glass panes and panels shall be free
from flaws, specks, bubbles and wavy surface and shall have a uniform refractive
index. All panels shall have properly squared corners and straight edges. Frosted
glass shall have a cast surface on one side. Defective or damaged glass shall not
be accepted.
Glass panes shall be securely fixed in position by means of putty, mastic paint and
glazing clips. Putty shall be fresh and ready mixed of superior quality. Rivets and
grooves shall be oiled and cleaned before glazing. Glazing shall commence only
after all other work in the respective portion has been completed. All glazing work
shall be watertight. When completed, all glazing shall be thoroughly cleaned with
turpentine to remove stains of paint smears, spots and other blemishes.
J.04 Rolling Shutters:

The rolling steel shutters shall be of an approved design and make. The dimension
shall be as shown in the Engineers drawings. Wicket gates shall be provided as
required.
The curtain shall be made of interlocking scrolls made of hot rolled double dipped
galvanised steel lath sections of 18 SWG tested mild steel strips at 75 mm (3 inch)
rolling centres locked with galvanised malleable clips. The bottom lath shall be
coupled to a lock plate fabricated from 3 mm thick galvanised steel plate and
securely riveted with stiffening angles. The guides shall be hot rolled mild steel
galvanised channel sections. These shall be embedded securely into concrete or
masonry face or anchored to steel stanchions with necessary lugs in an approved
manner. Latches shall be provided at both ends of the bottom bolt plate of the
curtain and provisions shall be made for locking from both sides.
Where required, wicket doors shall be provided with a safety lock, tower bolt and
handle. The hood covers shall be double-dipped hot galvanised 20 gauge steel
adequately reinforced to prevent sag. The shutters shall be machanically operated
and shall conform to I.S. 6248.
Installation :
The shutters shall be erected complete with all necessary hardware, operating
mechanisms, equipment, wiring and materials to suit the sizes of the opening.
Tests :
After the equipment has been installed, tests shall be made by the Contractor in the
presence of the Engineer to ensure efficient operation of the equipment. These
tests shall be repeated after all civil works have been completed and the contractor
shall make necessary checks and adjustment to ensure efficient operation.
J.05 Collapsible Steel Shutter :

The collapsible shutters shall be of approved manufacture and shall be fabricated
from the mild steel sections.

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These shall consist of double or single collapsible gates depending on the size of
opening. These shall consist of vertical double channels each 3/4” x 3/8”x 1/8” (or
20 mm x 10 mm x 3.0 mm) weighing 0.7 Kg. per metre at 4” (or 10.0 cm) centres
braced with flat iron diagonal, 3/4” x 3/16” ( or 20 mm x 5 mm) and top and bottom
rails of T-iron 1.5” X 1/4” (or 40 mm x 40 mm x 6.0 mm) with 1.5” ( or 40 mm)
diameter steel pulleys or ball bearings in every fourth double channels, unless
otherwise specified.
Wherever collapsible gate is not provided within the opening and is fixed along the
outer surface, T-Iron at the top may be replaced by flat iron 1.5” x 3/8” ( or 40 mm x
10.0mm) or as approved by the Engineer-in-Charge.
The collapsible gate shall be provided with necessary bolts and nuts locking
arrangement, stopper, handles. Any special fittings like spring, catches and locks,
shall be as specified in the description of the item, where so required.
The gate shall be of best quality and shall open and close smoothly and easily.
Fixing :
T-iron rails shall be fixed to the floor and to the lintel at top by means of anchor
bolts embedded in cement concrete of floor and lintel. The anchor bolts, shall be
placed approximately at 18” ( or 45 cm) centres alternatively in two flanges of the T-
iron. The bottom runner (T-iron) shall be embedded in the floor and proper groove
shall be formed along the runner for the purpose. The collapsible shutter shall be
fixed at sides by fixing the end double channels with T-iron rails and also by
holdfasts bolted to the end double channel and fixed in the masonry of the side wall
on the other side.
In case the collapsible shutter does not reach the lintel, beam or slab level then a
T-section, of approved design, may be fixed at the top embedded in masonry and
provided with necessary clamps and roller arrangement at the top. The entire
arrangement shall receive the prior approval of the Engineer-in-Charge.
All the adjoining work damaged in fixing of the gate shall be made good to match
the existing work, at Contractor’s own expense.
Painting :
All the members of the collapsible gate including T-iron shall be thoroughly cleaned
of rust, scale, dust etc. and given a priming coat of red lead before fixing them in
position.
Rates :
The rate shall include all materials including supply of the shutter, its fixing in
position in a manner as described above or as specified.
K. PLUMBING AND SANITARY WORKS :

Contractor’s rate shall include cost of the materials, fixtures, labour, supply, fitting,
fixing etc. complete involved for execution of the work as specified.
K.01 Plumbing Works :

General :
All soil pipes waste pipes, ventilating pipes, and all other pipes when above ground
shall be gas tight. All screws and drains laid below ground shall be watertight.
Laying of pipes :
The pipes shall be carefully laid to the alignment levels and gradient shown on the

73
plans and sections, care being taken that no sand earth or other matter enters the
socket of pipe while laying, the pipes shall be laid with the leading uphill, beginning
at the lower end, and shall rest on solid and even foundation for the full length of
the barrel. Socket holes shall be formed in the foundation. Each pipe shall be laid
singly, and no pipe shall be laid until the trench has been excavated to its required
depth for a distance of 20 yds. (or 20 metres) in front of the pipe to be laid.
Unless otherwise specified, the pipes shall be bedded in 1:3:6 cement concrete.
Where it is necessary to cut pipes, this shall be done with a suitable wheel type
pipe cutter so as to leave clean and square to the axis of the pipe. No extra
payment shall be made for cutting and wastage of pipes.
Joining glazed stone-ware pipes :

Tarred gasket or hemp yarn soaked in thick cement slurry shall first be placed
round the spigot of each pipe and the spigot shall then be placed well home into the
socket of the pipe previously laid.
The pipe shall then be adjusted and fixed in the correct position and the gasket
caulked tightly home so as not to fill more than 1/4 th. of the total depth of the
socket. The remaining of the socket shall then be filled with a stiff mixture of cement
mortar 1:1 or proportion as specified into the Schedule of Work or as shown on the
plans. When the socket is completely filled, a fillet of 1:1 cement mortar shall be
formed round the joint with a trowel flush with the outside of the socket and forming
an angle of 45o with the barrel of the pipe.
Water Testing :
Testing of pipes shall be done wholly at the contractor’s expenses inclusive of all
appliances and materials, provision of clean water etc.
Inspection Chambers (or pits) and Manholes :

The masonry work shall be built in the sewer trench at such place and to such level
as is shown on the contract drawings or at such place and level as may be
instructed by the Engineer-in-Charge during progress of the work. All materials and
workmanship shall comply with the relevant specification for the class of work
shown on the plans or ordered by Engineer-in-Charge.
Rungs shall be cast iron and of dimensions as specified or as instructed by
Engineer-in-Charge, and shall be built while the walls are being constructed fixed in
cement concrete 1:3:6 and shall be set staggered. The manhole covers and frames
shall conform to IS : 1726.
The reinforced concrete slab shall be in 1:2:4 cement concrete and shall be
reinforced as instructed by the Engineer-in-Charge. Concrete rate shall be inclusive
of reinforcement, unless otherwise specified. All manholes and such other
structures shall be constructed so as to be water-tight under test. C.I.manhole cover
may also be provided instead of R.C.C. manhole cover as per instruction of the
Engineer-in-Charge.
Test for Plumbing Works :

Upon completion the entire work shall be tested, care being taken that all work
which is to be encased or concealed is tested before it is finally enclosed. Pipe
system shall be tested for gas tightness and for hydraulic performance.
All water closets, urinals shall be tested after installation, as to their flushing
effectively and operating properly and noiselessly.
Testing of pipes and sanitary fittings or fixtures shall be wholly done at the
contractor’s expense inclusive of all testing appliances and materials. The mode of

74
testing for pipes and fixtures / fittings would be decided by Engineer-in-Charge.
K.02 Sanitary Fittings:

Materials :
The sanitary fittings shall comply with the specifications as given in the schedule of
work and all such fittings and appliances shall be of the best quality (Parryware,
Hindustan or Neycer) and workmanship and the contractor shall got the fitting
approved before installing in place.
Lavatory Basins :
Lavatory Basins shall be of white glazed earthenware or fireclay, as specified in the
item of work. The waste outlet shall not be less than the specified, with vulcanite
plug securely attached to the basin by means of a C.P. Chain, unless a standing
waste or other type of waste is specified. The waste fitting shall be provided with
unions for connection to lead pipes. Basins shall be fixed in manner as specified or
directed by the Engineer-in-Charge.
Sinks:
Sinks shall be of glazed fire clay and shall be fixed on cast iron plain painted
cantilevers. They shall be provided with heavy brass waste fittings with vulcanite
plugs securely attached by means of a C.P. chain. The waste fittings shall be
fitted with unions for connection to lead pipes. Over flows, when desired by the
Engineer-in-Charge, shall be accessible for cleaning purposes.
Water Closets:
Water Closets shall be of earthenware or fire clay, as specified, glazed inside and
outside, except the Indian pattern closet which shall be glazed inside and non-
glazed on outside. Unless otherwise specified, the pan and trap shall be in one
piece, the depth of seal being less than 3” (or 7.5 cm).
The European closets shall be provided with polished teak or plastic seat as
specified, and of a pattern approved by the Engineer-in-Charge. It shall be secured
to the pan with C.P. hinges and suitable rubber buffers shall be provided.
Flushing Cisterns:
Flushing Cisterns for closets shall be of vitreous china or fibre glass, of 8-10 litres
discharge capacity and as per the instruction of the Engineer-in-Charge.
K.03 Water Supply Work:

General :
The work shall be carried out at such locations and with materials as specified in
the schedule of work and in accordance with the plans supplied.
The contractor shall assume full responsibility for the correct setting out of the work
in accordance with the plans and is responsible for verifying the correctness of the
plan and bringing any discrepancy to the notice of the Engineer-in-Charge in
writing. Datum points will be fixed by the Engineer-in-Charge, but the contractor
shall be responsible for the correct setting out as regards to position, levels and
dimensions of the several works according to the drawing.
All cutting through walls, floors etc. for laying of the pipes and fittings and making
good shall be carried out by the contractor at his own expenses. Unless otherwise
specified, this will not include concealed pipe work in which case the cutting of
chase and making good will be paid separately.

75
The contractor rate shall be for complete execution of the work including supply of
all materials. The rate shall cover all contingencies of weather and soil and shall be
understood to include all charges for fencing, lighting, pumping or bailing, and
which shall not be paid separately.
All work materials, articles, workmanship supplied or carried out shall be the best of
their respective kinds and subject to the approval of the Engineer-in-Charge.
Contractor’s rate shall be inclusive of the cost of all materials, labour, fitting, fixing
etc. complete and testing as per direction of the Engineer-in-charge.
The Contractor shall supply suitable apparatus for testing and carrying out the test
at his own expense.
L. ROAD WORK:
L.01 Materials
Coarse Aggregates:
Coarse aggregates shall be either crushed / broken stone, crushed slag or
as approved by the Engineer-in-charge. The coarse aggregates shall conform to
the physical requirements as per IS:2386(Part-IV)
The coarse aggregates shall conform to one of the gradings given in Table-
01 below. For crushable type of aggregates such as brick metal, kankar and
laterite, grading shall not be regarded as very important, but the material should
generally be within the specified range.
TABLE –01
GRADING REQUIREMENTS OF COARSE AGGREGATES FOR W.B.M.
Grading No. Size range Sieve designation % by weight

passing the sieve
1 90mm to 45 mm 125 mm 100

(Suitable for sub base course of 90 mm 90 - 100
compacted layer of not less 63 mm 25 - 60
than 90 mm thickness) 45 mm 0 - 15
22.4 mm 0 - 5
Fine Aggregates
The fine aggregates shall be the fraction passing 2.8 mm sieve and retained
on 90 micron sieve. It shall consist of crusher run screenings, natural sand or a
mixture of both. These shall be clean, hard, durable, uncoated, dry and free from
injurious, soft or flaky pieces and organic or deleterious substance.
Binding Material
Binding materials to prevent ravelling of water bound macadam construction
shall consist of a fine grained material possessing plasticity index value of 4 to 6
when W.B.M. is being adopted as a sub-base/base course with bituminous
surfacing on top of it.
Bitumen straight run
A range of grades, from a very soft to a very hard consistency, can be
produced by varying the temperature and the rate of flow during distilling process.
It shall conform to IS : 73. Grades of bitumen for different uses is given in Table-02.
TABLE - 02
BITUMEN GRADES
Grade Temperature to which it
shall be heated
I For painting (surface dressing)
1.Paving bitumen from Assam Petroleum A 90 177 deg. C to 190 deg. C

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2. Paving bitumen from other sources 80/100 – S90 177 deg. C to 190 deg. C
3. Bitumen emulsion min. 50% bitumen ( Cold application)
Content :- RS grade IS:8837
II FOR PREMIX CARPETING
1. Paving asphalt 30/40 S-35 or80/100-S-90 149 deg. C to 177deg. C.
2. Bitumen Emulsion min. 60% bitumen ( Cold application)
contents RS grade IS:8837
Screenings :
Screening to fill voids in the coarse aggregate shall generally consists of the
same material as the coarse aggregate.
As far as possible screenings shall conform to the grading set-forth in Table-
03. Screenings of Type A shall be used with coarse aggregate of Grade I of Table-
01. The use of screenings may be omitted in the case of soft aggregates such as
brick metal, kankar and laterite.
TABLE-03
GRADING FOR SCREENINGS
Grading Size of screenings Sieve designation % by weight passing sieve
classification
A 13.2 mm 13.2 mm 100
11.2 mm 95 – 100
5.6 mm 15 – 35
180 microns 0 – 10
B 11.2 mm 11.2 mm 100
5.6 mm 90 – 100
180 microns 15 – 35
L.02. Supplying & Stacking of Materials

Aggregates
Stacking :
Ground where stacks are proposed to be made shall be cleared, levelled or dressed to a
uniform slope and all lumps, depressions etc. shall be removed. The aggregate shall be
stacked in convenient units of 1.0M top width, 2.2M bottom width, 0.6M
height and of length in multiples of 3.0M for new roads.
Measurements :
Length, breadth and height shall be measured correct to a cm. The total
quantity so arrived shall be reduced by 7.5% to arrive at the net quantity for
payment, in cases of aggregates.
Binder
Stacking
Binder shall be brought to the site of work in the sealed original containers.
Binder brought in damaged containers shall not be allowed. The material shall be
stacked in fenced enclosures, on one side of the roadway. The material shall be
purchased from reputed firms or their authorized dealer. All the drums brought to
site shall be serially numbered and used in the same order.
Materials shall be kept in the custody of the contractor. The empty
containers shall not be removed from the site of work, till the relevant item of work
has been completed and permission obtained from the Engineer-in-Charge. A few
drums may be removed before completion of work for heating bitumen and mixing
aggregates etc. with the permission to the Engineer-in-Charge.
Measurements:
The materials shall be recorded as per standard weights of different type of

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container as intimated by manufacturers. The material shall be weighed where

containers are found leaking.
Moorum / Stone chippings

The item of work shall specify moorum/stone chippings, as the cases may
be.
Stacking
Ground where stacks are proposed to be made, shall be dressed to a
uniform slope and all lumps, depressions etc. shall be removed. Sample of moorum
shall be got approved from the Engineer-in-Charge, before the material in bulk is
brought to site.
Moorum shall be stacked in convenient units of one cubic metre in between
aggregate stacks in each length of 100 m as per requirement. The stacks shall be
made with wooden boxes open at both ends and of 2.0x2.0x0.25 m dimensions.
These shall always be kept at site for stacking and check measurement.The stacks
shall be uniformly distributed along the road.
Measurements
Length and breadth of boxes shall be measured correct to a cm. Volume
shall be calculated in cubic metres, correct to two places of decimal.
Rate
The rate shall include the cost of all materials and labour involved in all the
operations described above.
L.03 Embankment Construction (Under Optimum Moisture

Condition)
In the case of earth work consolidated under optimum moisture conditions
each layer of earth shall be carefully moistened to give field moisture content of
about +1% to –2% of the optimum moisture content (OMC). The OMC shall be
determined according to IS:2720 (Pt. VIII) Methods of Tests for Soils. Each layer
shall then be compacted by rolling with 8 to 10 tonnes power road roller and a
sheep foot roller, if required. The required amount of water shall be added during
consolidation to keep the moisture content of the soil at the optimum as per test.
The density to be achieved for each layer of the material shall not be less than 95%
of the density obtained in the laboratory (Proctor Method).
Each compacted layer shall be tested in the field for density and accepted
before the operations for next layer are begun.
Control on compaction in the field shall be exercised through frequent
moisture content and density determinations. A systematic record of these shall be
maintained. As all times during construction the top of the embankment shall be
maintained at such cross fall as will shed water and prevent ponding.
L.04 SUB-GRADE
PREPARATION AND CONSOLIDATION
Preparation of sub-grade:
The surface of the formation for a width of sub-base, which shall be 15 cm
more on either side of base course, shall first be cut to a depth equal to the
combined depth of sub-base and surface courses below the proposed finished level
(due allowance being made for consolidation). It shall then be cleaned of all foreign
substances.
Consolidation
The sub–grade shall be consolidated with a power road roller of 8 to 12

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tonnes. The roller shall run over the sub grade till the soil is evenly and densely
consolidated and behaves as an elastic mass (the roller shall pass a minimum of 5
runs on the sub grade). All undulations in the surface that develop due to rolling
shall be made good with material or quarry spoils as the cases may be and the sub-
grade is rerolled.
Measurements
The length and width shall be measured correct to a cm. The area shall be
worked out in square metre, correct to two places of decimal.
Rate
The rate for preparation and consolidation of sub grade shall include the
cost of materials and labour involved for all the operations.
L.05 SUB BASES

Water bound macadam with stone aggregate
Stone aggregate of size 90 mm to 45 mm is used. This consists of clean crushed
coarse aggregate mechanically inter lock by rolling and voids there of filled with
screening and binding materials with the assistance of water, laid on a prepare sub-
grade, sub-base, base or existing pavement as the case may be . Water bound
macadam may be used as a sub base, base course or surfacing course.
Quantities of materials
Quantities of coarse aggregate, screening and binding material required to
be stacked for 100 mm approximate compacted thickness of W.B.M. sub-base
course for 10 sqm shall be as per Table-04.
TABLE - 04
Coarse Stone screenings Binding material

aggregates
Classification Size Net Quantity Grading/ Quantity

Range Classification &
size
Grading I 90mm to 1.21 cum to Type A 0.27 cum to 0.08 cum to
45 mm 1.28 cum 13.2mm 0.30 cum 0.10 cum
Note : Net quantity = Loose quantity measured in stacks minus 7.5%.
Spreading Aggregate
The course aggregate shall be spread uniformly and evenly upon the
prepared base in required quantities with a twisting motion to avoid segregation.
The aggregates shall be spread uniformly to proper profile. Where specified,
mechanical devices may be used to spread the aggregates uniformly. The levels
along the longitudinal direction upto which the metal shall be laid, shall be first
obtained at site to the satisfaction of Engineer-in-Charge, and these shall be
adhered to.
The surface of the aggregate spread shall be carefully trued up and all high
or low spots remedied by removing or adding aggregate.
The W.B.M. sub-base shall be constructed in layer of 100 mm compacted
thickness. No segregation of large or fine particles shall be allowed and the coarse
aggregate as spread shall be of uniform gradation with no pockets of fine material.
Rolling
Immediately following of spreading of the coarse aggregate, it shall be
compacted to the full width by rolling with three-wheel-power-roller of 8 to 10 tonnes

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capacity.
The rolling shall begin from the edges with the roller running forward and
backward and adding the screenings simultaneously until the edges have been
firmly compacted. Only slight sprinkling of water may be done during rolling, if
required.
Rolling shall not be done when the sub-grade is soft or yielding or when the
rolling causes a wave like motion in the sub-base or sub-grade. When rolling
develops irregularities that exceed 12 mm, the irregular surface shall be loosened
and then aggregate added to or removed from it as required and the area rolled
until it gives a uniform surface conforming to the desired cross-section and grade.
In no case shall the use of screenings to make up depressions be permitted.
Application of Screenings
After the coarse aggregate has been lightly rolled to the required true
surface, screenings shall be applied gradually over the surface to completely full the
interstices. Dry rolling shall be continued while the screenings are being spread so
that the jarring effect of the roller causes them to settle into the voids of the coarse
aggregates. The screenings shall be spread uniformly in successive thin layers.
The screening shall be applied at a slow rate so as to ensure filling of all void.
Rolling and brooming shall continue with the spreading of screenings. Damp and
wet screening shall not be used under any circumstances.
Sprinkling and Grouting
After spreading the screening and rolling, the surface shall be copiously
sprinkled with water, swept and rolled. Hand brooms shall be used to sweep the
wet screening into the void and to distribute them evenly. The sprinkling, sweeping
and rolling operations shall be continued and additional screenings applied where
necessary until the coarse aggregates are well bonded and firmly set for the entire
depth and until a grout has been formed of screenings and water that will fill all
voids and form a wave of grout ahead of the wheels of the roller. The quantity of
water to be used during the construction shall not be excessive so as to cause
damage to the sub-base or sub-grade.
Application of Binding Material
After the application of screenings and rolling, a suitable binding material
shall be applied at a uniform and slow rate in two or more successive thin layers.
After each application of binding material, the surface shall be copiously sprinkled
with water and the resulting slurry swept in with hand brooms to fill the voids
properly. The surface shall then be rolled by a 8-10 tonnes roller, water being
applied to the wheels in order to wash down the binding material that may get stuck
to the wheels. The spreading of binding material, sprinkling of water, sweeping with
brooms and rolling shall continue until the slurry that is formed will, after filling the
voids form a wave ahead of wheels of the moving roller.
Setting and Drying
After final compaction of the course, the road shall be allowed to cure
overnight. Next morning defective spots shall be filled with screenings or binding
material, lightly sprinkled with water, if necessary and rolled. No traffic shall be
allowed till the macadam sets.
Rectification of Defective Construction
Where the surface irregularity of the W.B.M. sub-base course exceeds the
tolerances as per CPWD or where the course is otherwise defective due to sub

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grade soil mixing with the aggregates, the layer to its full thickness shall be scarified
over the affected area, reshaped with added material or removal and replaced with
fresh materials as applicable, and recompacted. The area treated in the aforesaid
manner shall not be less than 10 sqm. In no case shall depressions be filled up with
screenings and binding materials.
Measurements
The length and breadth shall be taken to the nearest centimetre. The depth
of consolidated layer shall be computed to nearest half centimetre by taking
average of depths at the centre and at 30 cm from the left and right edges at a
cross section taken at 100 metre interval by making small pits. The consolidated
cubical contents calculated in cubic metres correct to two places of decimal. The
cubical contents for each 100 metres length should be compared with the volume of
aggregate collected less 7.5%.
Rate
The rate shall include the cost of all labour and materials involved in all the
operations described above, except cost of stone aggregate, kankar, moorum,
screenings etc. for which separate payments shall be made.
L.06 BASES :
BITUMEN MACADAM
This shall consist of construction of a single course of compacted crushed
aggregates premixed with bitumen laid immediately after application of the tack
coat. The thickness of single compacted course shall be 50mm.
Materials :
Aggregates
These shall be crushed or broken from hard stones obtained from approved
quarry. These shall be clean, strong durable of fairly cubical shape and free from
disintegrated soft, thin, elongated or laminated pieces. These shall also be free
from dirt, organic deleterious and any other foreign matter and adherent coatings.
These shall conform to the physical requirements laid down in Table - 03.
Grading
Aggregates shall conform to grading specified in Table - 5.
TABLE 05
Sieve Percentage of wt. passing the Sieve
Designation IS:460 For 50mm compacted thickness
53 mm 100
45 mm 95 – 100
26.5 mm 60 – 95
13.2 mm 15 – 35
90 microns 0–5
Bitumen :
It shall be straight run bitumen of penetration value 80/100 conforming to

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IS:73.
Weather & Seasonal limitations
Bitumen macadam shall not be laid during rainy weather or when the
surface is damp of wet or when the temperature is less than 16 deg. C under
shade.
Plant
A hot mix plant of adequate capacity and capable of producing a proper and
uniform quality mix shall be used for preparing the mix.
Temperature :
The temperature of the binder at the time of mixing shall be in the range of
150 deg. C – 177 deg. C and of aggregates in the range of 155 deg. C – 163 deg.
C. At no time, however, shall the difference in temperature between the aggregates
and the binder exceed 14 deg. C. At no time shall bitumen or aggregates be over
heated.
The hot graded aggregates and bitumen shall be measured separately and
as accurately as practicable, to the proportions in which they are to be mixed.
Mixing shall be done thoroughly so that a homogeneous mixture is obtained in
which all the particles are uniformly coated.
Transporting Mixed Materials:
The mixed materials shall be transported from mixing plant to the point of
use in clean vehicles. Every precaution shall be taken to avoid segregation of
mixed materials and to ensure that they do not become contaminated with dust or
foreign matter.
Laying :
The mix transported from the hot mix plant to the site shall be spread
without causing segregation, dragging, burning, irregularities or other surface
defects.
Rolling :
After spreading of the mix, consolidation shall be done by an approved
power driven roller or rollers weighing not less than 8/10 tonnes each. Rolling shall
start as soon as possible after the material has been spread. Rolling shall be done
with care to keep from unduly roughening of the pavement surface. Rolling shall
start longitudinally at the sides and proceed towards the centre of the pavement,
over lapping on each successive trip by at least one half the width of a rear wheel.
The speed of the roller shall be slow enough to avoid displacement of the
mixture and, any displacement occurring as a result of reversing the direction of the
roller, or from any other cause, shall at once be corrected by the use of rakes and
addition of fresh mixture where required.
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
fresh material. Rolling shall then proceed continuously with at least 10 passes of
the roller till no further compaction is possible.
Rectification :
The surface accuracy shall be checked immediately after rolling. Surface

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irregularities which fall outside the specified tolerance limits as laid in CPWD
Manual shall be rectified by removing to full depth the affected area which shall not
be less than 10 sqm and relaying with fresh materials. In no case shall depressions
be filled up with screen or binding material.
Measurements :
Before commencement of laying of bitumen macadam, levels shall be taken
jointly at 3 metre intervals both ways. Tack coat shall then be applied and bitumen
macadam shall then be laid and consolidated to required levels. Levels of the
consolidated bituminous surface shall be taken at grid points at which levels where
recorded earlier.
Quantity for payment shall be the theoretical quantity (Based on Proposed
formation levels) or the actual quantity (based on actual finished levels) whichever
is less.
Rate :
The rate shall include the cost of all materials Plant, machinery and labour
required in all operations described above including all carriages and lifts involved.
The rate also includes all cost of setting up the laboratory at site and carrying out
the quality control measures/test.
L.07 SURFACE COURSES:
The main function of surface courses are to provide a dust free wearing course over
base course such as water bound macadam or bitumen macadam. It is also
provided to protect water bound macadam by preventing removal of binder between
aggregate pieces.
TABLE - 06
Stone Chipping
Nominal Specification Quantity Bitumen Quantity
size
First coat 13.2mm 100 percent passing through IS 1.5 cum/ 1.8 kgm per sqm
22.4mm square mesh and 100sqm
retained on IS 11.2mm square
mesh
Second 11.2mm 100percent 1.0cum/ 1.1 kgm per sqm
coat passing through 13.2mm square 100sqm
mesh and retained on 5.6mm
square mesh
Tack coat of hot straight run bitumen

The rate of application of binder which shall be as specified and which shall
conform to Table – 02 shall be 0.75 kg./ sqm on W.B.M. surface on which the
premix carpet is to be laid.
Bitumen :
This shall be straight-run bitumen of penetration value 80/100 conforming to
IS:73 specifications.
Preparation of Surface

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Cleaning :
Prior to the application of bitumen, all vegetation, loose sealing compound,
foreign material shall be removed from the entire surface of the pavement with steel
wire brushes, small picks, brooms or other implements as approved by the
Engineer-in-Charge. The material so removed shall be disposed off.
Weather and seasonal limitations :

The tack coat shall not be applied nor any bitumen work done during rainy
weather or when the surface is damp or wet or when the atmospheric temperature
in the shade is 16 deg. C or below.
Application of Tack Coat:

Heating :
Bitumen shall be heated in a boiler to a temperature of 165 deg. C to 175
deg. C and maintained at that temperature.
Application of bitumen :
Hot bitumen shall be applied evenly to the clean, dry surface by means of a
pressure sprayer at 0.75 Kg/sqm on WBM surface. Even and uniform distribution of
bitumen applied longitudinally along the length of the pavement and never across it.
Measurements :
Length and breadth shall be measured correct to a cm, along and surface
of pavement. Area shall be worked out in sqm correct to two places of decimal.
Rate :
Rate shall include the cost of all materials and labour involved in all the
L.08 PREMIX CARPET WITH HOT BITUMEN

The consolidated thickness of this type of treatment shall be 2 cm or 2.5 cm
as specified. This treatment consists of applying a tack coat on the prepared base
followed immediately by spreading aggregates precoated with specified binder to
camber and consolidated.
Premix carpet shall not be laid during rainy weather or when the base
course is damp or wet or, when the atmospheric temperature in the shade is 16
deg. C or below.
Preparation of surface :
Pot holes or package and ruts in the WBM base or surface course which is
to be treated shall be prepared by removal of all loose and defective material by
cutting in rectangular patches and replacement with suitable materials. Prior to the
application of the binder, all dust, dirt, loose and foreign material etc. shall be
remove. The prepare surface shall be close to trafic and maintained fully clean till
the binder is applied. The binder shall be applied evenly, longitudinally along the
road and never across it. The edges of the binder surface shall be defined by wire
or a rope stretched in position.
Materials :
Quantities of Binder, stone chipping and grading of stone chipping shall be
as per Table - 05. Binder shall be as specified and shall conform to Table - 05.
Stone chippings shall conform to grading as per Table -06. A proper record shall

84
be kept to ensure that the daily out turn of work is correlated with the quantity of
bitumen used. Quantities of materials will be as per Table-07.
TABLE - 07
Binder hot bitumen Stone chippings

Consolidated (In cum/100sqm)
thickness of premix
carpet Carpet 13.2mm size 11.2mm size
2.5 cm (52 kg/cum of 13.2 mm size and 2.25 1.12

56 kg/cum of 11.2 mm size
Tack Coat :
The rate of application of binder for tack coat shall be as specified. The
rate will be depending upon the surface on which the premix carpet is to be laid i.e.
water bound macadam surface or existing black topped surface. Tack coat shall be
applied as described above.
Preparation of Premix :
The aggregate shall be dry and suitably heated to temperature as
directed by Engineer-in-Charge before these are placed in the mixer to facilitate
mixing with the binder. Mixers of approved type shall be employed for mixing the
aggregates with the bituminous binder. The binder shall be heated to the
temperature appropriate to the grade of bitumen approved by the Engineer-in-
Charge, in boilers of suitable design avoiding local over heating and ensuring a
continuous supply.
The aggregates shall be dry and suitably heated to a temperature as directed by
Engineer-in-Charge before these are placed in the mixer. After about 15 seconds
of dry mixing, the heated binder shall be distributed over the aggregated at the rate
specified.
The mixing of binder with chipping shall be continued until the chipping are
thoroughly coated with the binder. The mix shall be immediately transported from
the mixer to the point of use in suitable vehicles or wheelbarrows. The vehicles
employed for transport shall be cleaned and be covered over the transit if so
directed.
Spreading and Rolling :

The premixed material shall be spread on the road surface with rakes to the
required thickness and camber or distributed evenly with the help of a drag spreader,
without and undue loss of time. The camber shall be checked by means of camber boards
and inequalities evened out. As soon as sufficient length of bituminous material has been
laid,
rolling shall commence with 6 to 9 tonne power rollers, preferably of
smooth wheel tandon type, or other approved plant. Rolling shall begin as the
edges and progress towards the centre longitudinally. Except on the super-
elevated portions rolling shall progress from the lower to upper edge, parallel to the
centre line of the pavement. The consolidated thickness shall in no place be
less than the specified thickness by more than 25%.
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 materials. Rolling shall then be continued until the entire surface has
been rolled to compaction and all the roller marks eliminated. In each pass of the
roller, preceding track shall be overlapped uniformly by at least 1/3 width. The roller

85
wheels shall be kept damp to prevent the premix from adhering to the wheels and
being picked up. In no case shall fuel/lubricating oil be used for this purpose.
Rollers shall not stand on newly laid material as it may get deformed thereby.
The edges along the transverse of the carpet, laid and compacted earlier
shall be cut to their full depth so as to expose fresh surface which shall be painted
with as thin surface coast of appropriate binder before the new mix is placed
against it.
Further, the prepared finished surface shall be protected from traffic for 24
hours or such period as `may be specified by the Engineer-in-Charge.
Surface Finishing :
The surface regularity both in longitudinal and transverse directions shall be
within the tolerances specified in CPWD Manual.
Rectification:
Where the surface irregularity fall outside the specified tolerances the
contractor shall be liable to rectify it to the satisfaction of Engineer-in-Charge by
adding fresh material and recompacting to specifications where the surface is
low. Where the surface is high the full depth of the layer shall be removed and
replaced with fresh material and compacted to specifications.
Measurements :
The length and width of the finished work shall be measured correct to a cm
as long the finished surface of the road. The area shall be calculated in square
metre, correct to two places of decimal.
For record purposes, the measurement for binder and stone chipping shall
be taken before they are actually used on the work. Pre-measurements of the
materials taken for record purposes shall simply serve as guide and shall not
form the basis for payment
Rate :
The rate shall include the cost of materials and labour involved in all the
L.09 BRICK EDGING

Edging :
Trenches of specified width and depth shall first, be made along the edges
of the wearing coarse of the road to receive the bricks. The bed of trenches shall
be compacted to a firm and even surface and then the bricks shall be laid with its
length are right angle or parallel to the side of the road depending upon the width of
edging as specified in the item. The bricks shall be abutting against the wearing
course, true to line, gradient and in camber with the finished road surface at the
edge.
Finishing :
Berms and road edges shall be restored with excavated earth and
consolidated by hand packing. All surplus earth including rubbish etc. shall be
disposed off as directed by the Engineer-in-Charge.
Measurements :
Length of the finished work shall be measured in running metres along the
edges of the road correct to a cm.
Rate :

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The rate shall include the cost of materials land labour involved in all the
M. MISCELLANEOUS WORKS :
M.01 Dismantling & Demolition :
The building and other structures including switchyard structures, tower members,
rail poles, etc. to be dismantled should be brought down carefully from top to
bottom including foundations where required. Dismantling shall be commenced in a
systematic manner. All materials which are likely to be damaged by dropping from a
height or demolishing roofs, masonry etc. shall be carefully dismantled first. The
dismantled articles shall remain as DVC’s property and should be stacked as
directed by the Engineer. All unserviceable materials, rubbish etc. shall be disposed
off to a place as directed by the Engineer-in-Charge.
Measurement of all work shall be taken before dismantling and no allowance for
increase in bulk shall be allowed. Demolition of all types of brick work, cement or
lime concrete, reinforced cement concrete etc. below or above ground level shall be
measured together in cubic metre without deducting opening for doors, windows
etc. No separate measurement and payment shall be made for dismantled doors,
windows, pipes and any other wood, steel and iron work etc. Dismantling of all
types switchyard structures, tower members, rail poles, etc. below or above ground
level shall be measured together in metric tonne.
M.02 Water Proofing :

Heavy treatment with four courses for very severe conditions as per I.S. 1346 shall
be applied to the roof. This treatment shall consist of one primer coat and laying two
course of bitumen, and two layers of tarfelt alternatively and one course of pea-
sized gravel on top surface. Bitumen felts shall be Hessian / Fibre glass ( RP
TISSUE ) based self finished felt Type-3, Grade-I as per I.S : 1332 or IS : 9918 and
shall bear I.S.I. certification mark. Heavy treatment shall be done as per I S.
Preparation of roof surface before laying of water proofing treatment shall be in
accordance with IS : 1346. The roof shall be cleaned of all foreign matters and
loose particles and priming coat as specified in IS : 1346 shall be applied. Then a
coat of hot bitumen shall be applied at a rate not less than 1.22 kg / m2. Over the
surface so prepared, a layer of tarfelt shall be laid when the bitumen is still hot.
The overlaps shall be at least 100 mm. The above process shall be repeated twice
to give two layers of bitumen and two layers of tarfelt. Over the final layer of tarfelt a
coat of bitumen shall be applied similar to that over insulation. A surface finish of
pea sized rounded gravel (of size passing through 6.3 mm sieve) shall be provided
as a measure of protection of the treatment, at a rate of not less than 0.006
cu.metre per Sq.m On flashings and at drain mouths, the gravel shall be omitted
and a finish of two coats of bituminous paint provided instead.
The roofing and water proofing shall carry a guarantee for a minimum period of 25
years. In case of leakage or damages occuring during this period, the contractor
shall repair and make good the same at his own cost.
Or Roof water proofing shall be provided using high solid content liquid
applied elastomeric water proofing joint less membrane with separate
wearing course as per ASTM C-898 & ASTM C-896. Thickness of the
membrane shall be a minimum of 1.5mm. The treatment includes
application of polymerized mortar over sloped roof to achieve a smooth

87
surface and a primer coat. The roof shall be provided with precast
concrete tiles of minimum 22mm thickness over the entire area. Bidder
shall have to furnish a guarantee for material and workmanship for a
minimum period of 20 years.
M.03 Rail Fixing In Concrete :

The rail Section shall be fixed to concrete foundation or embedded in concrete true
to the alignment and levels and as per standards and direction with Contractor’s
labour, tools
and tackles etc. The rail section shall be supplied to the Contractor at free of cost
from DVC Store. Handling, transporting, cutting / shaping to suitable length &
shapes of rails shall be done by the Contractor at his cost. The Contractor shall
supply, fabricate and erect the required fixture like bolts, plates, tie rods,
separators, fish plates etc. as directed by the Engineer to fix the Rails Section in /
on concrete.
M.04 Acid & Alkali Proof Tiles :
Acid proof Tiles :
The acid and alkali proof tiles shall be of material fully resistant to the actions of
both acids and alkalis of strength of 10% and above including full concentrations.
Such tiles shall be obtained from an approved manufacturer and shall be subjected
to specimen tests before approval. The tiles shall be of different sizes as shown in
drawing or as directed. They shall be free from cracks, crazing and other defects
and blemishes. It shall conform to IS : 4457 (latest). The tiles may be of size
200x200 mm. or 150x150 mm. and the thickness shall not be less than 20 mm.
Installation :
a) The tiles shall be set on floors and walls with special mortar which shall also
be fully resistant to the actions of acids and alkalis described above.
Installation of mortar base which shall be 10 mm. thick and the tiles over the
mortar shall be done by experienced and approved personnel in strict
compliance with the manufacturer’s instructions.
b) The base surface shall be well cleaned of all dirts, loose materials etc. prior
to laying these tiles. Over the base surface a primer coat of approved
materials as required shall be applied and a 10 mm thick layer of acid and
alkali proof mortar base shall be laid and the tiles shall then be set butting
each other without leaving any open joint. A few open joints, if approved,
may be filled with the acid and alkali proof mortar. Each tile shall be
thoroughly cemented in place.
c) Vertical joints in case of walls shall be staggered. The face of the tiles on
walls shall be flushed or projected as required.
Guarantee :
The acid and alkali proof tile flooring work shall bear a guarantee for a period of five
years and any defects occuring during this period shall be rectified and made good
by the Contractor at his own cost. The area shall be closed for any movement of
traffic for a period of atleast 3 weeks till the tiles are firmly act.
Acid proof brick :

Acid proof bricks are to be silica free and capable of withstanding acid action of ten
(10) percent dilute sulphuric acid, caustic soda or other chemicals. Such bricks shall
be obtained from an approved manufacturer (Burns, Kumardhubi, Reliance or

88
equal) and shall be subjected to a specimen test before approval. Representative

sampling and testing shall be taken from the materials used. It shall conform to IS :
4860 (latest) of category class-II.
Acid Proof Cement and Mortar :

Acid proof cement shall be suitable for jointing and plastering the acid proof bricks
and shall be of an approved manufacturer. The cement and mortar shall both be
inert to the action of dilute acid and alkalis and shall not dissolve out in condensate
of high purity.
Acid Proof Plaster :

Acid proof plaster shall be applied in a manner similar to cement plaster but with
approved materials and in accordance with the instructions of the manufacturer of
acid proof cement (and mortar). It shall be at least 19 mm thick unless otherwise
specified or directed. It shall conform to IS : 4832 (Part-III) latest.
M.05 Barbed Wire Fencing :

Barbed Wire :
The barbed wire shall be of galvanised steel and it shall generally conform to IS :
278-Type-I The barbed wire shall be formed by twisting together two line wires of
nominal diameter 2.50 mm one containing the barbs. The barbs shall carry four
points and shall be formed by twisting two point wires of nominal diameter 2.24
mm.
Fixing of Barbed Wire :

The barbed wire shall be stretched and fixed in number of rows as specified.
Galvanised Turn & buckles and straining bolts shall be used at end posts.
Measurement and Rates :

Barbed wire fencing shall be measured correct to a centimetre for the finished work
in metres per line of barbed wire. Rate shall include the cost of all labour and
materials involved in all the operations including the cost of galvanised turn buckles
and straining bolts and other fixtures and excluding the cost of posts, struts,
excavation and concrete in foundation which shall be measured and paid
separately under respective items.
M.06 Chain Link Fencing : Fencing with gate shall be provided around
transformer yard, switchyard area, and other areas wherever
necessary due to security, safety, and statutory requirements as
per following specifications.
The fencing with gate (unless specified otherwise) shall comprise of

G.I. welded wire mesh fencing of minimum 4 mm diameter (including
PVC coating) of mesh size 75mmX75mm of height 2.4m above the toe
wall with a 600mm high galvanised concertina at the top, such that
total fence height of 3.0m above the toe wall is achieved. The diameter
of the steel wire for chain link fence (excluding PVC coating) shall not be
less than 2.5 mm.

89
Scope :
This specification specifies the requirements of chain link fencing for
security purposes. The height of the fence shall be approximately 2.0 m. The
material requirements shall conform to IS : 2721 (latest) for chain link fence except
for requirement which are as given below :
Materials :
Posts and Struts :
Straining posts, intermediate posts and struts shall be of Painted M.S. Angles.
Erection :
Straining posts shall be provided at all ends and corners of fences, at
changes in direction of acute variations in level and at intervals not exceeding 66
m on straight lengths of fence. Intermediate posts shall be spaced at regular
intervals not exceeding 3.0 m. Struts shall be fitted to all straining posts behind the
chain link fabric in the direction of the line of fence.
Fixing :
The chain link fencing shall be strained between each pair of straining posts
and secured to each straining post by means of a stretcher bar.
M.07 Gravel (Pebbles) Filling:

The gravel ( pebbles ) shall be clean, hard, durable, free from clay, moorum, dirt
leaves, any organic matters or admixture of soft or any other foreign materials and
shall be of standard approved quality and as suggested / approved by the
Engineer-in-Charge. The pebbles/crushed stone must be uniformity graded any
thoroughly washed.
The contractor shall prepare site surfacing to the lines and grades in accordance
with the requirements and direction of the Engineer-in-Charge. The soil of the entire
switch yard area shall be subjected sterilization / antiweed treatment before placing
the site surfacing pebbles / crushed stone fill material or strictly as per instruction /
required for soil sterilization / antiweed treatment.
Anti weed treatment shall be done as per separate approved item and shall be paid
separately.
After antiweed treatment is complete, the surface of the switchyard area shall be
maintained, suitably rolled / compacted to the lines and grades as decided by
Engineer-in-Charge. The sub grade shall be saturated with suitable water sprinkling
arrangement. The surface shall be compacted by ½ tone roller with minimum 4 to 5
passes. Compacting of the sub grade shall be continued till the soil is evenly and
densely consolidated and behaves as an elastic mass.
In area that are considered by the Engineer-in-Charge to be too congested with
foundations and structures for proper rolling of the site surfacing material by normal
rolling equipments, the material shall be compacted by hand, if necessary. Due
care shall be exercised so as not to damage any foundation structures or
equipment during rolling/compaction.
Over the prepared sub grade, 75 thick base layer of cement concrete in 1:3:6 (1
cement : 3 coarse sand : 6 graded stone aggregate 20mm nominal size) shall be
provided in the area excluding roads, drains, cable trenches as per detailed
Engineering drawing / site requirement. The area wherever foundation / structure /

90
drain / road / cable trenches / building etc. are coming, shall not have anti-weed
treatment & gravel ( pebbles ) filling. For easy drainage of water, a slope of 1:1000
is to be provided from the ridge to be nearest drain. The ridge shall be suitably
located at the centre of the area between the nearest drain. The above slope shall
be provided at the top of base layer of cement concrete (1:3:6) . A final layer of 75
mm thickness of gravel (pebbles/crushed stone) of 40 mm normal size (ungraded
size) shall be spread uniformly over cement concrete layer after curing is complete.
The work should be taken up preferably after monsoon.
M.08 Anti termite treatment

Pre-constructional anti termite treatment shall be given to all vulnerable areas
susceptible to termite attack and shall include column pits, wall trenches,
foundations, filing bellow the floors etc. as per IS:6313 and as per the general
specifications
N.B.
If any item of work is not available in the Schedule of Works of Agreement,
the item shall be derived from the similar item of CPWD, DSR-2014. This
Specification for General Civil Works shall be read along with Schedule of
Rates for Civil Works. However, in all practical purposes the description of
any item in the Schedule of Rates for Civil Works will be prevalent. For any
discrepancies regarding Specification for General Civil Work’s reference may
be made to CPWD Specification for Civil Works.
------End of Vol-----

Civil Specification

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Civil Specification

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DAMODAR VALLEY CORPORATION

(CIVIL SPECIFICATION FOR SUPPLY OF MATERIALS)

B. TRANSMISSION TOWERS/SWITCHYARD STRUCTURE

B.02 TYPE OF TOWERS (OPTIONAL):

B.03 TOWER EXTENSIONS

Civil Specification for Supply

C DEVELOPMENT OF DRAWING / BOM

C.02 DESIGN & DRAWINGS

C.03 SHOP DRAWINGS

Preparation of Shop drawings, containing complete information necessary for fabrication

C.04 BILL OF MATERIALS

Civil Specification for Supply

D. BOLTS, NUTS AND WASHERS:

To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect

Civil Specification for Supply

F.05 PUNCHING & DRILLING:

Transmission line towers/switchyard structure demand accurate drilling or punching of

Civil Specification for Supply

F.06 MARKING OF MEMBERS:

F.07 SHOP ERECTION / PROTO-TYPE TOWER ASSEMBLY, IF ANY:

F.08 TOWER/ SWITCHYARD STRUCTURE FINISH:

Civil Specification for Supply

G.01 TOLERANCE IN HOLES:

Blocking of miss-punched/excess holes:

G.02 TOLERANCE IN FABRICATION:

(a) On straightness (camber) – 0.4% of the length of sections of sizes up to 100x100mm.

H TOWER ACCESSORIES (OPTIONAL):

H.01 Anti climbing Device:

Civil Specification for Supply

Civil Specification for Supply

Procurement of all steel materials required for fabrication of towers, such as

c) BOLTS & NUTS:

e) STEP BOLTS & LADDERS:

Civil Specification for Supply

J.02 PROCUREMENT OF RAW MATERIALS

K.01 STRUCTURAL STEEL:

The various testing to be performed are as follows:

K.02 BOLTS AND NUTS

Civil Specification for Supply

K.03 SPRING WASHERS

The various Testing to be performed are as follows:

Fabricated Tower Parts, Switchyard Structure & Stubs

(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,

Civil Specification for Supply

Civil Specification for Supply

The various testing to be performed on the finished galvanized materials:

K.05 OPTIONAL TESTS

L. CALCULATION OF WEIGHT FOR PAYMENT

Civil Specification for Supply

a) The name, designation and address of the Consignee.

Civil Specification for Supply

11. IS:2016-1992 Plain Washers ISO/R887

P. STRUCTURAL STEEL REQUIREMENT SCHEDULE AS PER APPROVED DRAWING:

Civil Specification for Supply

Sl. No. Section size Sl. No. Section size

1 ISA 45 x 30 x 4 28 ISA 100 x 100 x 10

Sl. No. Section size Sl. No. Section size

1 ISA 65 x 65 x 5 14 ISA 150 x 150 x 15

Civil Specification for Supply

Sl. No. Section size Sl. No. Section size

1 ISA 45 x 30 x 5 21 ISA 100 x 100 x 10

APPROVED VENDOR LIST

STRUCTURAL STEEL Materials