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TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATIONS-MATERIALS

GENERAL :

a. All materials to be used in the execution of Civil & structural works shall be governed by the requirements of this specification.

b. Whenever any reference to IS codes is made, the same shall be taken as the latest revision (with all amendments issued thereto) as on the date of submission of the bid.

c. Apart from the IS codes mentioned in particular in various clauses of this specification, for a specific work under consideration all other relevant codes regarding quality, testing and/or inspection procedures shall be applicable. Reference to some of the codes in the various clauses of this specification does not limit or restrict the scope of applicability of other referred or relevant codes.

d. In case of any variation/contradiction in provisions between IS codes and this specification, the provisions given in this specification shall be followed with the approval of the Engineer In Charge/consultant/architect.

e. All materials shall be of standard quality and shall be procured from renowned sources/manufacturers approved by the Architect/Consultant. It shall be the responsibility of the contractor, to get all materials approved prior to procurement and placement of order.

f. Quality and acceptability of materials not covered under this specification shall be governed by the relevant IS codes. In case IS code is not available for the particular material, other codes e.g. BS or DIN or ASTM shall be considered. The decision of the Engineer In Charge/ consultant/ architect in this regard shall be final and binding on the contractor.

g. Whenever asked for, the contractor shall submit representative samples of materials to be client for inspection and approval. Approval of any sample does not necessarily exempt the contractor from submitting necessary test reports for the approved material, as per the specification / relevant IS codes.

h. The contractor shall submit manufacturer’s test reports on quality and suitability of any material procured from them and their recommendation on storage, application, workmanship etc. for the intended use. Submission of manufacturer’s test reports does not restrict the client/consultant from asking for fresh test results from an approved laboratory of the actual material supplied from any approved manufacturer/source at any stage of execution of work.

i. All costs relating to or arising out of carrying out the tests and submission of test reports and or samples to the client/consultant for approval during the entire tenure of the work shall be borne by the contractor and included in the quoted rates.

Signature of the Bidder and Seal 5001

j. Materials for approval shall be separately stored and marked, as directed by the client/consultant and shall not be used in the works till these are approved. The contractor at his own cost shall immediately remove all rejected materials from the site.

1.0.0 CEMENT

1.1.0 SUPPLY :

Cement used shall be one of the following with prior approval of the Engineer In Charge/ consultant / architect.

Grade 43 Ordinary Portland Cement conforming to IS:8112.Grade 53 Ordinary Portland Cement conforming to IS:12269.

Portland Slag Cement conforming to IS:455. Portland Pozzolana Cement conforming to IS:1489.

Cement to be used shall be of the best quality from reputed brands like ACC/ Birla/ Gujrat Ambuja/ L&T or any other equivalent as approved by the Client / consultant.

Unless otherwise specified ordinary Portland cement of 43 grade conforming to IS:8112 shall be used for all concrete works.

Where specified, special cement like Sulphate resisting Portland cement (conforming to IS:8042-E), Coloured cement shall be used.

Rapid hardening cement shall have strength in one day equal to that of OPC in 3 days. It shall be used for products like Hume pipe, tiles, sleepers, poles, pre stressed and precast members. It shall also be used for foundation, bridges, culverts, causeways, etc. where quick construction activity is required however with prior permission of the consultant/architect. Test certificates showing that the cement complies with the specifications must be submitted to the consultant.

Sulphate resistant cement should possess low heat of hydration, more compressive strength at 3, 7 and 28 days than OPC. It should be capable of withstanding attack of aggressive substances like sulphate of sodium, magnesium, calcium, etc. which damage concrete structures. It shall be used with prior approval for structures in or near sea water, where the soil conditions are aggressive, where repeated cycles of drying and wetting occur and also for structures exposed to sulphate attack like industrial drains, sewage pipes, foundations, bridges, dams, tunnels. Test certificates showing that the cement complies with the specifications must be submitted to the consultant.

Coloured cement shall be white or grey Portland cement mixed with pigment as specified in the item of work. It shall comply with physical


requirements of IS:269/8112 and pigments shall be inorganic oxide pigments either natural or synthetic in origin complying with the requirements of B.S.:1014. The pigments used for coloured cements shall be of approved quality and its quantity shall not exceed 10% of cement used in the mix. The mixture of pigment and cement shall be properly ground to have a uniform colour and shade. The pigments shall have such properties as to provide durability under exposure to sunlight and weather. The pigment shall have the property such that it is neither affected by the cement nor detrimental to it.

In case more than one type of cement is used in any work, a record shall be kept showing the location and type of cement used. Each type of cement shall preferably be obtained from one constant source throughout the contract. Cement of different types shall not be mixed with one another. Different brands of cement or the same brand of cement from different sources shall not be used without prior notification or approval by client.

The cement shall be supplied to the site in original sealed bags, which shall be labeled with the weight, name of manufacturer, date of manufacture, brand and type. Cement received in torn bags shall not be used. Bags of cement that vary in weight by more than 3% shall not be accepted.

The contractor shall maintain a daily record of cement received and consumed in an approved form and a copy shall be submitted to the engineer-in-charge once a week.

1.2.0Storage :

1.2.1 Cement bags shall be stored dry, leak proof, moisture proof and well-ventilated godowns built at the cost of the contractor. Cement of different types shall be stored in separate godowns or separate compartments of a godown.

The floor of the godown shall be raised and shall consist of wooden planks resting on the base prepared with dry bricks laid on edges. Stacking of cement bags shall have a clearance 150 to 200 mm above the floor and 450 mm from the wall.

Cement shall be stored in stacks, which are not higher than 10 bags to avoid lumping due to pressure and in such a manner as to permit easy access for inspection and identification.

The bags shall be kept close together in rows of two bags to reduce circulation of air as much as possible. The bags shall be arranged in header and stretcher fashion so as to lessen the danger of topping.


1.2.5 ‘First in’, ‘First out’ rules shall be applied while removing the bags for use.

1.2.6 Cement stored during monsoons or for an unusually long period, shall be completely enclosed in polythene sheet which shall cover the top of the stack. The contractor shall ensure that the polythene sheet is not damaged at any time during use. Storage under tarpaulins shall not be permitted.

1.27 No stored cement bag shall be used after three months from the date of manufacture. Generally, stacking and storing of cement shall be in accordance with Clause 3.2 of IS:4082.

1.3.0Quality of cement.

1.3.1 The manufacturer shall satisfy himself that the cement conforms to the relevant Indian standards and if required, shall furnish a certificate to this effect to the purchaser or his representative within ten days of the dispatch of the cement.

1.3.2 The contractor shall be fully responsible for the quality of cement brought to work site. In case the contractor has any doubt regarding the quality of cement brought to work site, it is up to him to have it tested at his own expense and make sure that the cement is of acceptable quality.

1.4.0Testing :

14.1 The contractor shall submit test certificates furnished by the manufacturer to client/consult. Where the client/consultant is not convinced about the quality of cement, he can ask the contractor to have the cement tested or he can take samples in the presence of contractor from cement bags stored at work site and forward them to government approved laboratory for testing. Expenses towards such tests shall be borne by the contractor.

1.5.0Sampling :

1.5.1 For one lot of 50 tonnes of cement, 2% of bags shall be picked out at random, from which one sample of 15 kg shall be taken.

1.5.2 Samples for testing may be taken by the purchaser or his representative within one week of delivery and all tests shall be commenced within one week of sampling.

15.3 When it is not possible to test the samples within one week, the samples shall be backed and stored in airtight containers till testing.

causes for rejection :


1.6.1 Cement not conforming to relevant specification shall be rejected by the client/consultant. the contractor, at his own expense shall immediately remove rejected cement from the work site.

1.6.2 damaged or reclaimed or partly set cement will not be permitted to be used and shall be removed from the site.

1.6.3 the minimum requirements for any type of cement to be considered as acceptable are tabulated in table-A

TABLE A : PHYSICAL REQUIREMENTS FOR CEMENT.

Type of cement OPC 33Grade

OPC 43 Grade

OPC 53 Grade

PPC PSC

Code NO. IS:269 IS:8112

IS 12269

IS 1489 IS 455

Fineness by Blaine’s method (sq.m/kg),min.

225 225 225 300 225

Setting time (mins) Initial(More than)Fianl (Less than)

30600

30600

30600

30600

30600

Loss on ignition (Max %) 5 5 4 5 4Insoluble Residue (Max %)

4 2 2 {0.96X +4}X=% of Pozzolana

2.5

Soundness (Max)Lechatelier (mm)Autoclave (%)

100.8

10 0.8

100.8

100.8

100.8

Compressive Strength *(Min) (N/sq.mm)7 days28 days

2233

3343

3753

2231

22--

Compressive strength test shall be carried out on 70.70x70.70x70.70 mm mortar cubes made from cement and sand (conforming to IS 650) mixed in the proportion of 1:3.0

2.0.0AGGREGATES

Aggregates for concrete shall be procured from approved sources conforming to the specifications of IS:383 and shall be chemically inert, clean, strong, durable, with limited porosity and free from deleterious materials which cause corrosion of reinforcement or may impair the strength and durability of concrete. Aggregates shall not contain water-


soluble sulphur trioxide in excess of 0.1%. The chloride ion content of fine and coarse aggregate shall not exceed .06% and 0.02% respectively by mass of dry aggregate. If either aggregate exceeds these limits the material may still be considered acceptable by the engineer provided that the total chloride ion concentration derived from the aggregate is not grater than 0.35% by mass of the cement in the mix.

All aggregates shall comply with IS:2386 and IS:383 in respect of impurities and additionally with the following :

Absorption6% maximum by weight for ordinary construction and 2% maximum for water proof construction.

Salt 1% maximum (equivalent anhydrous calcium percentage by weight of cement)

c) Shell8% maximum by weight

d) Carbonates 10% maximum by weight.

Unless otherwise specified, fine aggregate shall be imply natural river sand for the purpose of reinforced concrete work.

2.1.0FINE AGGREGATE :

2.1.1GENERAL REQUIREMENTS :

a. The maximum size of the sand particles shall be 4.75 mm and down graded.

b. The sand shall be free from adherent coatings and shall not contain harmful materials such as iron pyrites, coal, mica, slit, clay, alkali, sea shell, organic impurities, loam, etc..

c. The maximum quantity of deleterious materials shall not exceed 5 percent and the limits specified in table 1 of IS:383 when tested in accordance with IS:2386 (Part-2).

d. Aggregates, which are chemically reactive with alkalis of cement, shall not be used, as it will induce cracking of concrete.

e. Slit and dust present in natural sand shall be limited to 8% by weight. In case it is more than 8%, it shall be washed at site with clean water. Presence of mica shall not be more than 1% by weight.

2.1.2Grading :


Fine aggregate with a fineness modulus value less than ‘2’ shall not be used for reinforced concrete work. The natural sand used for RCC work shall have a grading conforming to one of the three grading zones given in the following table (Table B). Fine aggregate conforming to grade IV as per IS:383 shall not be used for RCC works.

For coarse sand the grading of sand as determined by the method prescribed in IS : 2386 Part I shall be within the limits of grading III given in Table B.

Stone dust shall be obtained by crushing hard stone and the grading shall be as determined by the method prescribed in IS:2386 Part I & II. It shall be within the limits of grading zone III. The fineness modulus of stone dust shall not be less than 1.8. It shall not contain more than 8% of silt as determined by field test with measured cylinder. The silt content is found out by keeping a sample of stone dust without drying in 200 mm measuring cylinder. The quantity of the sample shall be such that it fills the cylinder upto 10mm mark. Then clean water shall be added upto 150 mm mark. The mixture shall be stirred vigorously and the contents allowed to settle for 3 hours. The height of slit visible as settled layer above the stone dust shall be expressed as percentage of the height of the stone dust below. The stone dust containing more than 8% of silt shall be washed so as to bring down the content within the allowable limit.

When grading falls outside the limits of any particular grading zone of sieves, other than 600 micron IS sieve, by a total amount not exceeding 5%, it shall be regarded as falling within that grading zone.

TABLE B: GRADING OF FINE AGGREGATE (AS PER IS :383)

IS Sieve Designation

Percentage by weight passing IS SieveGrading Zone I

Grading Zone II

Grading Zone II

Grading zone IV

10 mm 100 100 100 1004.75 mm 90-100 90-100 90-100 95-1002.36 mm 60-95 75-100 85-100 95-1001.18 mm 30-70 55-90 75-100 90-100600 micron 15-34 35-59 60-79 80-100300 micron 5-20 8-30 12-40 15-50


150 micron 0-10 0-10 0-10 0-15

2.1.3Sampling and testing :

a. Fine aggregate shall be subjected to inspection and testing.b. The method of sampling for test shall be in accordance with IS:2430.c. Samples of fine aggregates for testing shall be collected from

transportation units or stack or stockpiles. Each sample shall be packed separately and dispatched to the testing laboratory.

d. Packing and marking of samples shall be done in accordance with clause 6.0 of IS:2430.

e. The contractor shall furnish test results of samples as may be required by the client/consultant.

f. Testing shall be carried out in accordance with IS:2386 (Parts-1 to 8).

2.1.4Storage :

a. Aggregate shall be stored on a hard surface or a well designed platform of concrete, timber, metal or any other approved material so as to prevent the mixture of clay, dust, vegetable and other foreign matter.

b. Storing and stacking of fine aggregate shall be done in accordance with clause 3.5 of IS:4082.

c. While stacking, the aggregate shall not form pyramids resulting in segregation of different size particles. The stacks shall be regular.

d. Unless otherwise specified or necessitated by site conditions, stacking of fine aggregate shall be sufficiently away from that of coarse aggregate.

Coarse aggregate shall mean aggregate of which not less than 95% by weight is retained on 4.75 mm mesh IS test sieve of IS:2430 and shall conform to IS:383.

2.2.0COARSE AGGREGATE :

2.2.1General Requirements :

Coarse aggregates shall be machine-crushed stone of black trap or equivalent black hard stone and shall be hard, strong, dense, durable, clean or procured from quarries approved by the client/consultant. Generally coarse aggregate shall be cubical in shape and not flake or elongated.

Aggregates shall be free from injurious amounts of disintegrated pieces, reactive silica, alkali, harmful salt, organic matters and other deleterious materials. Coarse aggregates to be used for reinforced cement concrete


work shall not contain any material liable to attack the steel reinforcement.

The maximum quantity of deleterious materials shall not exceed 5 percent of the weight of coarse aggregate and the limits specified in Table I of IS:383 when tested in accordance with IS:2386 (Part-2).

The amount of fine particles occurring in the free state or as loose adherent shall not exceed 1% when determined by laboratory sedimentation tests as per IS:2386.

In selecting the aggregates the Contractor shall satisfy and ensure that the source is suitable for regular supply and a watch shall be maintained that the particle shape and grading remain reasonably uniform throughout the progress of work.

The contractor shall arrange to supply coarse aggregates in single size, for each nominal size, conforming to the grading given in Table 2 of IS:383. The single sizes shall be combined in suitable proportion to get desired overall grading of aggregates. The client/consultant at his discretion, may allow the use of “Graded Aggregate” of nominal size, to conform to the grading specified in Table 2 of IS:383.

2.2.2Maximum Size :

The maximum size of aggregates shall not be great than one quarter of the maximum thickness of the member so as to surround all reinforcement. For heavily reinforced concrete members, the nominal size of aggregate shall be 5 mm less than the minimum clear distance between the reinforcement main bar or 5 mm less than the minimum cover to the reinforcement whichever is smaller.

In reinforced concrete work, unless otherwise specified, nominal maximum size of coarse aggregate shall be 20 mm and down.

2.2.3Storage :

a. Generally, storage of coarse aggregate shall conform to clause 3.5 of IS:4082. Aggregates shall be stored at site on a hard and dry patch of ground, preferably leveled and rolled.

b. Aggregates of various sizes shall be stored in separate stockpiles with height not exceeding 1m to prevent coning or segregation. A bottom layer of coarse aggregate 100 mm deep shall be undisturbed while removing the material for use.

c. If the aggregates are stored at site for a long time, it shall be sieved before use, to remove dust, if directed by the consultant.


3.0.0STEEL REINFORCEMENT:

3.1.0Supply :

Steel reinforcement for concrete shall be round/ribbed bars, unless otherwise specified and shall comply with he following grades.

High strength deformed steel bars conforming to IS:1786. If specified, tested quality high yield strength deformed corrosion resistant steel (CRS) bars from TATA (TISCON-50CRS) or SAIL (HCR-REBARS Gr.M) conforming to IS:1786 for mechanical properties with improved corrosion resistance and bond strength shall be used.

All steel shall be procured from original procedures. No re-rolled steel shall be incorporated in the work. Only new steel shall be delivered to the site and shall be free of mill scale, loose rust, grease oil, paint or any other deleterious materials which reduce or destroys bond.

3.2.0Measurement of Reinforcement :

Measurement relating to nominal mass, dimensions and tolerances of various types steel shall conform to relevant IS codes.

Reinforcement shall be measured in lengths of bar as actually placed in position on standard weight basis, no allowance being made in the weight for rolling margin. Wastage, chairs and binding wire shall not be measured. Authorized overlaps and splices shall only be measured. Rate quoted shall include the cost of welding if specified.3.3.0Testing :

Test certificates from manufacturer, mill certificates and certificates of origin shall be submitted for each consignment. Additional tests if required shall be done as recommended by the cilent/consultant at the contractor’s own cost. An accredited laboratory shall carry out testing. Any reinforcement so sampled and tested which fails to comply with the specifications shall be rejected and the whole batch shall be removed from the site immediately. The contractor shall have no claim for bars mutilated in obtaining test samples.

3.4.0Sampling

Sampling shall be done in accordance with relevant IS codes. For every 40 tonnes of steel at least one test shall be done.

CRS reinforcing bars shall conform to the physical properties of IS:1786. In addition when tested for corrosion resistance as per the standard ASTM method such as salt spray test (B.117.90), Potential Dynamic Polarization measurement test (G.5.78), Atmospheric Corrosion test


(G.50.76) and Sulphur-di-oxide chamber test (G.87.84) shall exhibit corrosion resistance index of minimum 1.5.CRS (deformed) bars should either be butt or lap welded as per recommended practice of IS:9417. For best results basic coated electrodes containing copper and/or nickel shall be used.

The chemistry of CRS should be as given below :

Carbon -0.15% maxSulphur(S) -0.05% maxPhosphorus (P) -0.12% maxS+P -0.17 % maxSilicon -0.45 % maxCorrosionResistant elements -1.5 % max

3.5.0Binding Wire :

The reinforcement shall be securely bound wherever bars intersect or wherever required with 16 or 18 gauge (1.63 mm or 1.22 mm) annealed steel wire conforming to IS:280.

3.6.0Mechanical splices :

Mechanical connections for splicing reinforcement bars in congested locations shall be used only with the approval of consultant/Engineer-in-charge. Patented couplers as manufactured by Usha Martin Industries Ltd. (CCL bar grips) and BBR India Ltd.(BBR SWIF) shall be used wherever mentioned in the drawings. The couplers shall be attached to the reinforcement bars by forging, hydraulic pressing or screw couplers in special circumstances may be permitted. All operations relating to reinforcement coupling shall be done using supplier’s patented machine / equipment and in the presence of the supplier’s representative. The contractor shall submit relevant trade literature, mil certificates, certificate of origin and letters of approval for each proposed application. A sample of each type of mechanical coupler shall be submitted for testing and approval prior to the use of any coupler in the works.

3.7.0Welding electrodes :

Electrodes used for welding of steel bars shall be ordinary mild steel grade 2 electrodes conforming to IS:814 and shall be the best quality and approved by the Engineer-in-charge. The work shall be carried out as strictly as per IS:2751 and IS:9417.

3.8.0Causes of Rejection :


Steel reinforcement, not conforming to relevant specification, shall be rejected by the client/consultant. Every bar shall be inspected before assembling on the work and defective, brittle or burnt bar shall be rejected. Cracked ends of bars shall be discarded. The contractor at his own expense shall immediately remove rejected steel from the work site.

3.9.0 Storage :

Steel reinforcement shall be handled and stored in a manner that bending or distortion of the bars is avoided and corrosion of steel is prevented. They shall be stored in such a manner that they are not in direct contact with the ground (at least 150 mm clear above ground). In case of long storage, a coat of cement wash shall be given to the reinforcing steel to prevent any scaling or rusting. Any reinforcement, which is certified as corroded by the Engineer-in-charge, shall either be immediately withdrawn from site or stand blasted and coated with cement slurry. No extra payment shall be made for sand blasting and cement coating. Bars of different classifications and size shall be stored separately. Generally, storage of reinforcements shall be in accordance with clause 3.7 of IS:4032.

4.0.0WATER :

Water used for various works shall conform to IS:456.


Water used for both mixing and curing of concrete/brickwork/plaster as well as for washing aggregate shall be potable and free from injurious amounts of deleterious materials like alkalis, acids, oils salts, sugar, organic materials, vegetable growth or other substances which are likely to affect the strength or durability of concrete and other construction materials. Before starting any concreting/brickwork/ plaster work and wherever the source of water changes, the water shall be tested for its acceptability for use in concrete etc. by the methods given in IS:3025. No water shall be used until tested and found satisfactory and cost of all such tests shall be borne by the contractor.

Hard and bitter water shall generally be found unsuitable for curing mortar and concrete.

Water for use in mixing with cement shall neither be hotter than 25°C nor colder than 5 °C at the time of mixing.

Whenever temperature controlled concrete is specified, the contractor may establish an ice making plant of required capacity at site.


Water used for curing shall not produce any objectionable stain or unsightly deposit on the surface. It shall be free of elements that significantly affect the hydration reaction. Presence of tannic acid or iron compounds in water is objectionable.

Acceptance Criteria :

Water to be used, shall satisfy the following :

4.2.1 To neutralize 200 ml sample of water, using phenolpthylene as an indicator, it should be require more than 2 ml of 0.1 normal NaOH.

To neutralize 200 ml sample of water, using methyl orange as an indicator, it should not require more than 10 ml of 0.1 normal HCL

4.2.3 It should not contain solids by weight in excess of the following :

Organic 200 mg/litreInorganic 3000 mg/litreSulphates 500 mg/litreChlorides 1000mg/litre for RC work and

2000 mg/litre for other worksSuspended Matter 2000 mg/litre

The pH value of water shall be between 6 and 8.

If required by the Engineer-in-charge it shall be tested by comparison with distilled water. Comparison shall be made by means of standard cement tests for soundness, time of setting and mortar strength as specified in IS:269. Any indication of change in time of setting by 30 minutes or more or decrease of more than 10% in strength of mortar prepared with water sample when compared with the results obtained with mortar prepared with distilled water shall be sufficient cause for rejection of water under test.

4.3.0Sample for Testing :

The sample of water taken for testing shall represent the water proposed to be used, with due account being paid to seasonal variation. The samples shall not receive any treatment before testing other than that envisaged in the regular supply of water proposed for use. The sample shall be stored in a clean container. Test shall be carried out only once for one particular source.

Testing shall be done as per IS:3025 (Relevant parts).

4.4.0Storage :


Storage of water shall generally conform to IS:4082, whenever water is to be stored for construction purposes. Water storage tanks shall be covered to the satisfaction of the Engineer-in-charge to prevent contamination.

5.0.0ADMIXTURES

Admixtures shall be used in concrete, mortar plaster etc. as specified in the schedule of items and/or drawing only after the product is approved by the client/consultant. The contractor is bound to furnish all such information like dosage, method of application, chloride content, etc. required to decide on the suitability of the admixture. All required tests should be carried out at the instructions of the client at no extra cost.

Use of admixture being a specialized job, shall be carried out strictly as per manufacturer’s recommendations.


Admixtures used shall conform to the following relevant IS codes and shall be purchased from reputed manufacturers as approved by client/consultant. In reinforced concrete, the chloride ion of any admixture used shall not exceed 2% by weight of the admixture as determined in accordance with IS:6925 and the total chloride ion in all admixtures used in concrete mi shall not exceed 0.83% by weight of cement. The addition of calcium chloride to concrete containing embedded metal will not be permitted under any circumstances.

Accelerating Admixtures conforming to IS:9103 & 2645. It shall be in liquid state with a specific gravity of 1.3 and complying with ASTM C-494 type E. It shall accelerate the setting and hardening of the concrete mix thereby achieving high early ago strength. It shall be from CICO or equivalent and used at the rate instructed by the manufacturer. It should be compatible with all types of cement.

Retarding Admixtures conforming to IS:9103. It shall be in liquid state with a specific gravity of 1.22 and complying with ASTM C-494 type B&D, CRD-C87 type B & D, BS:5075 part 1. It shall be added to the concrete mix during the mixing process along with water and aggregates. No extension of normal mixing time is necessary. It shall delay the initial and final setting time. It shall help to spread the heat of hydration over a longer period of time. It shall give a highly workable concrete with a low W/C ratio. It shall be from CICO, Feb Roffe or equivalent and be used at the rate instructed by the manufacturer, with cement, depending on the amount of acceleration of hardening required. It should be compatible with all types of cement.


Air-entraining Admixtures conforming to IS:9103.

Water-reducing admixtures conforming to IS:9103. Only naphthalene based water-reducing admixture/plasticizers shall be permitted.

Integral waterproofing admixtures conforming to IS:2645. It shall be from Feb Roffe’s Roff Hyseal, Roff Hyproof, Algiproof or equivalent. It shall be used as an excellent cement admixture in all types of concrete/ plaster mortars, pointing mortars, masonry works, guniting works and pressure grouting works. It shall improve resistance of the surface to weathering and chemical attacks. It shall be no-toxic so as to use for waterproofing in water tanks, reservoirs, tanks, etc..

5.2.0Product information :

5.2.1 The contractor shall further provide the following information concerning each admixture to the client/consultant.

a. Optimum dosage and detrimental effects of under-dosage and over-dosage.

b. Chemical names of the main ingredients in the admixture.c. The chloride ion content expressed as percentage by weight of

admixture.d. Whether or not the admixture leads to entrapment of air when used in

the manufacturer’s recommended dosage and if so, to what extent.

Where two or more admixtures are proposed to be used in any one mix, the manufacturer’s written confirmation of their compatibility.

There would be no increase in risk of corrosion of the reinfo4rcement or other embodiments as a result of using the admixture.

5.3.0Sampling :

5.3.1 Sampling for testing shall be done in accordance with clause 4.1 of IS:9103 for liquid admixtures and clause 4.2 of IS:9103 for non-liquid admixtures.

5.3.2 samples shall be packed in moisture-proof airtight containers.

5.3.3 Sampling of integral waterproofing compound shall be done as given in IS:2645.

5.4.0 Testing :

For checking the physical properties of any admixture, tests shall be carried out as detailed in clause 3 of IS:9103. Results shall conform to the requirements given in Table 1 of IS:9103.


For air entraining admixture, tests shall be carried out as agreed to between the client/consultant. And the manufacturer. Except where resistance to freezing and thawing and to disruptive action of de-icing salts is necessary, the air content of freshly mixed concrete in accordance with the pressure method given in IS:1199 shall not be more than 2% higher than that of the corresponding control mix and in any case not more than 3% of the test mix.

For integral waterproofing compound, tests shall be carried out as per methods given in IS:2645.

Uniformity tests on the admixture are essential to compare qualitatively the composition of different samples taken from batch to batch or from the same batch at different times.

All tests relating to concrete and admixture shall be conducted periodically at an independent laboratory and compared with the data given by the manufacturer.

5.5.0Storage :

5.5.1 Admixtures shall be stored in moisture-proof, airtight containers.

5.5.2 Storage shall in general conform to IS:4082.

6.0.0FORMWORK

6.1 General requirements :

6.1.1 Shuttering for concrete work below ground level shall be of wrought formwork and that for concrete work in superstructure shall be of fine formwork.

6.1.2 Formwork shall be of Marine Plywood, timber, steel and fibre glass of suitable thickness capable of resisting damage to the contact faces under normal conditions of erecting forms, fixing steel and placing concrete. For designated areas prominently in public view the choice of material shall be decided by the Engineer-in-charge.

Where timber is used, it shall be of best quality, first class hardwood, well-seasoned, of medium grain and free from sap, shekes, worm holes, wraps or other surface defects of all kinds. It shall be wooden parking of 30mm minimum thickness with or without steel lining. The timber used shall not be so dry as to absorb water from concrete and swell or bulge nor so green or wet as to shrink after erection. The timber shall be properly swan and planned on the sides and surface coming in contact with concrete. Wooden formwork with metal sheet lining or steel plates


stiffened by steel angles shall be permitted. The surface of timber shuttering that would come in contact with concrete shall be wetted and coated with soap solution before concreting is done. Alternatively coat of raw linseed oil or oil of approved manufacture may be applied in place of soap solution.

Where plywood is used, it shall be of best quality, resin bonded and waterproof. Formwork shall be minimum 12mm thick shuttering quality plywood conforming to IS:4990 and of make approved by the Engineer-in-charge. Suitable stiffeners and walers shall be provided depending on the shuttering design. It shall be stable and not liable to scrap when exposed to sun and rain or wetted during concreting.

Where steel framework is used, it shall be made out of appropriate gauge steel sheets with proper framework to ensure perfect surfaces. It shall be made of 3 mm thick black sheets stiffened with angle iron frame. The surface that would come in contact with concrete shall be thoroughly cleaned and either soap solution or raw li8nseed oil shall be applied..

Fibre glass formwork shall be of approved quality and standard.

6.1.3 The forms shall be true to dimensions and sizes. The props used on the work shall be of such type, which can afford finer adjustments for levels, etc. and ensure fully stability.

6.1.4 Wherever applicable, selection of suitable timber for formwork shall be made based on the following relevant standards :

a) Specification for ballies for general purposes as IS:3337. Specification for plywood for concrete shuttering work as per IS:4990.

7.0.0STRUCTURAL STEEL :

All material shall be new and shall conform to their respective specifications. The use of equivalent or higher grade or alternative materials will be considered only in very special cases subject to the approval of Client/Consultant.

7.1.0General requirements :

All structural steel sections shall conform to IS:2062 unless otherwise specified and shall be clearly rolled to proper dimensions and weight subject to permissible tolerances as per IS:1852.

The finished materials shall be reasonably free from cracks, surface flaws, laminations rough are imperfect edges and all other harm full defects and shall have a smooth finish. The material shall be free from


loose mill scale, rust pits or other defects affecting the strength and durability.

Structural steel work shall be painted by applying two coats of Zinc Phosphate primer conforming to relevant IS and 2 coats of synthetic enamel paint (Conforming to IS:2933) or aluminum paint (conforming to IS:2339). However, steel shall be galvanized, if so required by the Client/Consultant.

Normal hexagonal nuts and bolts shall conform to IS:3138-1966. High strength structural bolts shall conform to IS:3757. Countersunk bolts shall conform to either IS:8352 or IS:8353 depending on the type of bolt. Black bolts, nuts and screws shall be in accordance with IS:1363 for Black hexagonal with nuts of 6 to 39mm and black hexagon screw of 6 to 24mm and IS:1364 and IS:1367 for other sizes.

Hot rolled rivet bars shall conform to IS:1148 and high tensile steel rivet bars for structural purposes shall conform to IS:1149.

Welding electrodes shall conform to IS:814 and approval of welding procedure shall be as per IS:823.

Node connectors for space frame shall be Octagonal or Spherical in shape. It shall a minimum tensile strength as specified in the Bills of Quantities. Minimum elongation shall be 7% and hardness 170-240 BHN. The nodes machined out of solid bars shall conform to IS:2062 and the casing shall be as per IS:1030.

The following variety of steel shall be used for structural purposes :

ST-42S: It shall be used for all types of structures (rivetted and bolted) including those subjected to dynamic loading and where fatigue, wide fluctuations of stresses, reversal of stresses and great restraint are involved. It shall be suitable for welded structures provided that the thickness of the material does not exceed 20mm.

ST-42W : Fusion welding quality steel, conforming to IS:2062 shall be used for structures subject to dynamic loading where welding is employed for fabrication and where fatigue, wide fluctuation of stresses, reversal of stresses and great restraints are involved.

Structural steel tubes (ERW) used for building construction shall be hot finished tubes conforming to IS:1161/IS:1239/IS:806. tubes shall be designated by their nominal bore and shall be classified as light, medium and heavy as per IS:1161. tubes of thickness lower than light tubes shall not be permitted.


Unless mentioned otherwise, fusion welding quality steel ST-42w shall be used for all the structural steel works and tubes shall be YST 21 conforming to IS:806.

The chemical and mechanical properties for structural steel shall be as stated below :

CHEMICAL COMPOSITION OF STEEL

Steel designation

Maximum percentage

Carbon Sulphur Phosphorous ST-42W 0.23 0.06 0.06ST-42S 0.25/0.28 0.06 0.06ST-42O 0.07

MECHANICAL PROPERTIES OF STEEL

Steel Type

Class of Steel Product

Nominal thickness / dia mm

Tensile strength kg/mm2

Yield stress min. kg/mm2

% elongation

ST-42-W (Fusion welding quality &ST-42-S (Standard quality)

Plate sections (For example, angles, tees, beams, channels etc..) And flats

Below 6 mm only bend test shall be required. 6 mm and upto 20 mm Over 20 upto 40 mm Over 40 mm

42 to 54

42 to 54

42 to 54

26

24

23

23

23

23

Bars (round, square and Hexagonal)

Below 10 only bend test shall be required.Over 10 mm upto 20 mmOver 20 mm

42 to 54

42 to 54

26

24

23

23ST-42-O (Ordinary quality)

Plate sections (for example angles, tees, beams, channels, etc.)

Below 6 only bend test shall be required.

6mm and above 42 to 54 26 23


and flats

Bars (round, square and Hexagonal)

Below 10mm only bend test shall be required.10 mm and above

42 to 54 26 23

7.2.0Test certificate :

7.2.1 When the steel is supplied by the Contractor, test certificate of the manufacturer shall be obtained according to IS:2062 and other relevant Indian Standards. Notwithstanding the manufacturer’s certificates, the Consultant/architect may ask for testing of material in approved test laboratory. The test results shall satisfy the requirements of the relevant Indian Standards. Whenever quality certificates are missing or incomplete or where material quality differs from standard specifications, the Contractor shall conduct all appropriate tests as directed by the consultant/architect at his own cost. Materials for which test certificates are not available or for which test results do not comply with relevant IS standard shall not be used.

7.3.0Storage :

Storage of structural steel shall be as per IS:4082. Steel materials supplied by contractor shall be marked for identification and each lot shall be accompanied by manufacturer’s quality certificate, conforming to chemical and mechanical characteristics as per relevant IS codes. All steel furnished by suppliers shall be checked, sorted out, straightened and arranged by grade and quantities in stores.

Welding wire and electrodes shall be stored separately by qualities and lots inside a dry and enclosed room in compliance with IS:816 and as directed by Engineer-in-charge. Each lot of electrode, bolts nuts, etc. shall be accompanied by manufacturer’s test certificate.

8.0.0AC SHEET & ACCESSORIES


8.1.1 The asbestos cement sheets used for roofing and cladding shall be plain, corrugated or semi-corrugated sheets from Everest or approved make conforming to IS:459.


8.1.2 It shall be manufactured by reinforcing Asbestos to cement in such a manner that every fibre is coated with fine particles of cement to ensure maximum strength. It shall be alkali resistant and anti-corrosive. It should not break during transportation, handling, laying and shall be non-inflammable non-organic. It shall be resistant having high tensile strength and high slenderness ratio.

8.1.3 The minimum nominal thickness of sheets shall be 6 mm, having covering efficiency of about 90% and weight 1518kg/sqm. The permissible bending stress s shall be 130 kg/sqm.

8.1.4 The accessories shall be same thickness that of AC sheets. They shall be suitable for the type of sheet and location. They shall be from approved manufacture and free from any defect.

8.1.5 All fixing accessories shall conform to IS:730 and IS:1626. The diameter of the bolts shall not be less than 8mm. The J-bolts shall be at least 90mm longer at lap points of sheets and 75mm longer at other points than the depth required to hook the bolt to the purlin. The galvanized iron washers shall be 25mm in diameter and 1.6mm thick. The bitumen washer shall be 35mm in diameter and 1.5 mm thick.

8.1.6 Bridges shall be of type specified in the schedule such as “one piece plain angular”, “plain wing adjustable”, “Serrated adjustable”,. “Close fitting adjustable” or “North light two pieces” adjustable and appropriate for the corrugated sheets used. “Plain wing angular” type of ridges can be used only if the slope of the roof is between 26 and 30 degrees. Ridges, hip section and other accessories shall be of the same manufacture as that of sheets used for the roof unless otherwise permitted by the Client/Consultant.

8.1.7 The sheets shall have rectangular shape, corrugations true and regular, edges straight and clean, smooth surface on exposed side and free from cracks and visible defects, holes, deformation, chipped edges or otherwise damage.

8.1.8 All the AC sheets shall be painted with 3 coats of lime wash on the underside unless otherwise specified.

8.1.9 Water absorption shall not exceed 28 percent of dry weight.

8.2.0Testing :

Testing of asbestos cement products shall be done in accordance with the methods prescribed in IS:5913.

8.3.0Storage :


Storage of AC sheets and accessories shall in general conform to IS:4082.

The materials shall be handled and stored in the manner as not to damage the same. AC sheets shall be stacked on a firm and leveled ground, laid on wooden battens according to the approved stacking methods and/or instructions of the manufacturer. They shall be protected from damage and when they are to be stacked for a longer period, they shall be stored under cover.

9.0.0GALVANISED IRON SHEET

Galvanized iron sheets shall be from TATA or equivalent as approved by Engineer-in-charge.


9.1.1 G.I. Sheets used for roofing and cladding shall generally conform tot he requirements prescribed in IS:277 and shall be of the best quality duly approved by the Client/Consultant.

9.1.2 : The base metal for galvanized sheets and coils shall be hot or cold rolled mild steel conforming to IS:513. The sheets shall be free from cracks, spilt edges, twist, surface flaws, etc.. They shall be clean, bright and smooth. The galvanizing shall be uninjured and in perfect condition. The sheets shall show no signs of rust or white powdery deposits on the surface. The corrugation shall be uniform in depth and pitch and parallel to the sides.

9.1.3 Minimum thickness of GI sheets to be used for roofing shall be 0.63 mm thick (24gauge) unless noted otherwise in the drawings or in the schedule of items.

9.1.4 Unless otherwise mentioned in the schedule, the necessary accessories like flashing, ridging, capping, gable end corner piece, barge boards etc. shall be made out of 20 gauge (1mm minimum) galvanized sheets.

9.1.5 All fixing accessories shall conform to the requirements specified in IS:730.

9.2.0Testing :

9.2.1 Testing shall be done in accordance with he provisions prescribed in IS:277.

9.3.0Storage


9..3.1Storage of GI sheets and accessories shall in general conform to IS:4082.

10.0.0 COLOUR COATED METTALIC SHEET AND ACCESSORIES

11.1.0 General requirements

10.1.1 Colour coated sheets shall be made out of cold or hot rolled MS sheets conforming to IS:513 galvanized as per IS:277 and shall be of the best quality.

10.1.2 Colour coating requirements shall be in accordance with relevant indian or foreign standards ensuring a perfect and integral chemical bond between the base metal and the polymer coat.

10.1.3 The sheets shall be free from cracks, twist, surface flaws, spilt edges and any other defects which could impair the strength and quality of the material.

10.1.4 The profile of the sheets shall be uniform, smooth, regular and true to shape.

10.1.5 The colour shades shall be consistent and free from visible defects.

10.1.6 Unless mentioned otherwise all necessary accessories shall be duly approved by the Client/Consultant.

10.2.0 Sampling :

10.2.1 Representative samples of the product shall be kept in the office of the client for periodic checks by Client/Consultant on compliance of quality of material actually used for the work.

10.3.0 Storage :

11.3.1 Storage of colour coated sheets and accessories shall in general conform to IS:4082 and as per manufacturer’s specifications.

11.0.0 STONES

11.1.0 STONES FOR MASONRY :

11.1.1 General requirements :

Generally, the stone to be used shall conform to the requirements of IS:1597 (Part-1) and shall be of specified variety such as Granite, Trap


stone, Quartz, sandstone or any other type locally available good hard stones.

Stones used shall be strong, sound durable, dense, compact, close grained, homogeneous, fire resistant and fee from cracks, flaws or defects, segregation, seams, weathered portions and other structural defects or imperfections tending to affect their soundness and strength and shall be procured from quarries approved by the consultant.

Stones used shall be small enough to be lifted and placed by hand. The length of stone shall not exceed three times the height and the breadth on the base shall not be grater than 3/4” of the thickness of wall not less than 150mm. The height of stone may be upto 300mm.

Stones shall be free from rounded, worn or weathered surfaces or skin or coating which prevents the adherence of mortars.

Stones to be used as headers, quoins, copings, etc. shall comply with the requirements of facing and hearting as may be relevant.

Stones shall be non-porous and when tested in accordance with IS:1124 shall show less than 5% water absorption of its dry weight when soaked in water for 24 hours.

Dressed and worked stones shall strictly follow the recommended dimensions given in Table 1 of : IS:1127 depending on the purpose of work.

For specific use (i.e exposure to chemical fume, fire hazard etc.) type of stone shall strictly conform to the recommendations of Table 2 of IS:1597 (Part 1) or as directed by the Client/Consultant.

11.1.2 Quoin Stone or Corner Stone :

For random rubble masonry (uncoursed and brought to course), quoin stone shall not be less than 0.03 m3 in volume.

For squared rubble (coursed) masonry, the height of the quoin shall be same as the course height and shall not be less than 450mm in any direction.

11.1.3 Hearting and Backing Stone :

For random rubble masonry (uncoursed and brought to course) the hearting or interior filling of a war face shall consist of rubble stones not less than 150 mm in any direction, carefully laid, hammered down to proper position.


For squared rubble (coursed) masonry the hearting or the interior filling of the wall shall consist of flat bedded stone, carefully laid on their proper beds in mortar.

11.1.4 Through stone or Bond Stone :

One through stone shall be provided for every half a square metre of facing, evenly distributed in a staggered pattern.

They shall have about 0.03 sqm in face area and shall have a tailing for the full width of the masonry when the width of masonry is 600 mm or less.

If the masonry wall is over 600 mm thick, a line of headers overlapping each other by at least 150mm shall be laid right through the wall from the face to the back.

The length of the interior headers shall not be less than 450mm and their average cross sectional area shall not be less than 0.025 sqm.

Bond stone shall be distinctly marked on its face during construction for subsequent verification.

11.1.5 Sampling :

Sampling of stones including quoins and headers to be used in the work shall be got approved by the Client/Consultant before the work is started and such samples shall be maintained in the site engineer’s office for any subsequent inspection.

11.1.6 Testing :

For compressive strength, test pieces shall be made from selected samples in cubical or cylindrical shape. The diameter or lateral dimension of a test sample shall not be less than 50mm and the ratio of height to diameter or height to lateral dimension shall be 1:2. Compressive strength and transverse strength test (if required) on stone samples shall be carried out in the manner specified in IS:1121.

Water absorption test shall be carried out, if directed by the consultant, as per IS:1124.

Tests for durability and weathering shall be done, if directed by the consultant, as per IS:1126 and IS:1125 respectively.

The working of stones to the required sizes and their dressing shal be carried out as per IS:1127 and IS:1129.


12.0.0 KOTA/SHAHABAD/CUDDAPAH/ GRANITE STONE :

Kotah/Shahabad/Cuddapah/Granite stone blocks / slabs/tiles to be used for flooring, stairs, dados, skirtings, linings, veenering etc. shall conform to the requirements specified in the schedule of items.


The natural stone slabs shall be procured from selected quality/stock as specified in schedule of items.

These shall be hard, sound, dense and of homogeneous texture and free form cracks, decay, weathering, soft veins and flaws.

They shall be hard and machine-cut of requisite thickness along planes parallel to the natural bed of stone and shall be of uniform size and colour as required.

The exposed surface of stone slabs shall be machine polished to a smooth, even and true plane and the edges shall be chiseled to half its depth, true and square to ensure uniform width of joint.

12.1.2 Marking :

Each type of stone blocks, slabs and tiles supplied at site shall bear the manufacturer’s identification marks or initials.

12.1.3 Sampling and Testing :

a. Samples shall be selected and tested separately for each lot for determining its conformity or otherwise to the requirements of the specification.

b. The number of blocks/slabs/tiles to be selected for sampling shall depend upon the size of the lot and shall be in accordance with Table-2, IS:1130.

c. Contractor shall procure a certificate from the supplier stating that the blocks, slabs and tiles supplied, comply with the relevant Indian Standards and shall submit it to Client/Consultant.

d. Tests shall be carried out as per methods described in IS:1124 and IS:1122, as applicable.

12.1.4 Causes for rejection :

Stone slabs not conforming to the size, colour, texture and other criteria mentioned above shall be rejected by the Client/Consultant

13.0.0 BRICKS


13.1.0 BRICKS FOR MASONRY :


a. Bricks for masonry in foundations, walls and other locations shall be hand or machine moulded and made from suitable soil and kiln burnt. They shall have regular and uniform size and colour, sharp straight and right angled edges and deep cherry red and copper colour, uniformity well burnt throughout but not over-burnt. They shall have smooth rectangular faces with parallel sides and sharp corners. Generally, they shall conform to IS:1077.

b. They shall be free from cracks, flaws and nodules of free lime.c. They shall be moulded with a frog of 100 x40mm and 10mm to 20mm

deep on one of its flat sides.

d) They shall give a clear metallic ringing sound when struck by a mallet and shall not break when dropped on the ground on their flat face in a saturated condition from a height of 600 mm.

e) They shall show a fine-grained, uniform, homogeneous and dense texture on fracture and shall be free from lumps of lime, lamination, cracks, air holes, soluble salts causing efflorescence or any other defect which may impair their strength, durability, appearance and usefulness for the purpose intended. They shall not have any part under-burnt.

f) The size of the conventional bricks shall be 225 x 110 x 75 mm. Only bricks of one standard size shall be used in one work unless specially permitted by the Client / Consultant. The following tolerances are permitted in the standard conventional size adopted on the particular work.

Length plus or minus 3.0 mmBreath plus or minus 1.5 mm Depth plus or minus 1.5 mm

The size of the modular bricks shall be 190 x 90 x 90 mm or 190 x 40 mm.

g) The crushing strength of the brick to be used in all types of works shall not be less than 50 kg/sq.cm unless otherwise specified when tested according to IS:3495 (Part-1).

h) After immersion in cold water for 24 hours, absorption by weight shall not exceed 15 percent of the dry weight of the brick when tested according to IS:3495 (Part-2).


i) Efflorescence in bricks shall be within limits prescribed in (Not more than 10% of the exposed area of the brick shall be covered with a thin deposit of salts) IS:3495 (Part-3).

13.1.2 First Class Bricks for Exposed Brick work:

First class bricks are those, which strictly conform to the standard size of modular bricks and such that ten layers of brick laid in mortar shall form masonry of 1 m height. These bricks shall be manufactured from good quality plastic earth, which is free from saline deposits. They shall have straight edges and even surfaces. When immersed in water for an hour they shall not absorb water more than 1/6th of their weight. On drying they shall not show any sign of efflorescence.

13.1.3 Calcium Silicate Bricks:

These bricks shall be machine moulded and made form good quality and clean siliceous sand, lime and flash (maximum content upto 30% in raw material composition). They shall have smooth rectangular faces with sharp corners and shall be uniform in size, colour and shape. The size of bricks shall be 228 x 110 x 73 mm or as approved by the Architect / Consultant. The compressive strength of bricks shall be minimum 150 kg/m2 and the bricks shall have very high strength to weight ratio. The bricks shall have very good resistant capacity to atmospheric conditions, optimum building properties in relation to heat insulation, sound insulation, absorption of water and fire protection. Calcium silicate products shall conform to the appropriate IS Standards and there shall be no change in civil application techniques while using it in the place of traditional clay bricks.

13.1.4. Glass Brick works:

It shall be from imperial or equivalent as approved by Architect / Consultant. It shall be free from any defects like cracks, air bubbles, uneven surface, breaks etc.. During handling and laying its edges shall not be easily damaged. All edges and corners of all faces shall be sharp and well shaped. It shall be of size and colour as specified in the B.O.O. of approved by Architect / Consultant. The glass bricks shall be uniform size with a tolerance of + 2 mm. Sports of colour other than that of bricks shall not be allowed. The weight of each brick shall be about 2.75 kg. The transmission of direct light through brick shall not be less than 40%. The glass bricks shall have good thermal insulation. It shall be sound proof and vibration absorber having adequate compressive strength. If bricks with groove or projections are used, the groove or projections shall be uniform and regular in size and shape.


13.1.5 Storage of Bricks:

A) Brick shall not be dumped at site. They shall be stacked in regular tiers of height not exceeding 1.5m.

B) Bricks of different types and classifications shall be stacked separately. Generally, stacking of bricks shall conform to IS:4082.

13.1.6 Handling:

Bricks shall be unloaded by hand and carefully stacked. These shall not be thrown to the ground to avoid any damage.

13.1.7 Sampling and Inspection:

Representative samples shall be submitted by the Contractor and approved samples shall be retained by the Client / Consultant for comparison and future reference.

All bricks shall be inspected at site and shall be subjected to the approval of the Consultant who may reject such consignments as are considered by him to be inferior to the quality specified.

The contractor shall provide all labour and plant required for the inspection and conduct of such tests as shall be required by the Consultant without additional charges.

Efflorescence test shall be carried out for a sample of 20 bricks from a stock of 20,000 bricks. Water absorption test shall be done for 32 bricks out of a stock of 35,000 bricks. Compressive strength test shall be done on 50 bricks from a stock of 1,00,000 bricks.

13.1.8 Storage:

Same as that of ‘Coarse aggregate’.

14.0.0 SAND

14.1.0 SAND FOR MASONRY MORTAR:

14.1.1 General Requirements:

A) All the requirements, except particle size grading stated in the section ‘Fine aggregates’ shall apply to this sand also. The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of any of these.


B) The particle size grading of sand in mortar for unreinforced masonry work shall be within limits specified below, as per IS:2116.

I.S Sieve Designation IS:460 (Part-1)

Percentage by weight Passing I.S Sieve

4.75 mm 1002.36 mm 90-1001.18 mm 70-100600 micron 40-100300 micron 5-70150 micron 0-15

C) Clay, fine silt & fine dust in natural sand, crushed gravel or stone sand shall not be exceed 5% by mass when determined in accordance with IS:2386 (Part-2).

14.1.2 Sampling and Testing:

A) The method of sampling shall be in accordance with IS:2430.

Any test which the Client / Consultant finds it necessary to be done on sand shall be carried out in accordance with relevant parts of IS:2386. If further confirmation as to the satisfactory nature of the material is required, compressive strength test on cement mortar cube (1:6) shall be carried out in accordance with IS:2250 using the supplied material in place of standard sand and the strength value so obtained shall be compared with that of another mortar cube made with a sand of acceptable and comparable quality.

Storage:

Same as that of ‘Fine Aggregate’.

14.2.0 SAND FOR PLASTER:

14.2.1 General Requirements:

A) Sand used for external, internal wall surfaces and ceiling plaster shall conform to IS:1542 and shall be procured from approved sources.

B) Unless otherwise specified, sand for plaster shall imply natural river sand.

C) The sand shall be hard, strong, dense, durable, clean and free from veins, adherent coatings and shall not contain deleterious materials such as iron pyrites, coal, lignite, mica, silt, clay, alkali,


sea shell, organic impurities, loam or any other harmful materials in such quantities so as to adversely affect the strength or durability of plaster.

D) Presence of clay, fine silt and fine dust in sand shall not be more than 4$ by weight as stated in clause 3.0 or IS:1542. Organic impurities shall also be within limits as per Table 1.0 or IS:383.

14.2.2 Grading

A) The grading of sand for internal wall and ceiling plaster shall be within limits specified in the following Table of IS:1542.

REQUIREMENTS OF GRADING FOR SANDS FOR INTERNAL WALL AND CEILING PLASTERPercentage By Weight Passing IS SieveIS Sieve Designation (As per IS:460)

Class-A Class-B

240

120

603015

{ 98-100 for under coats{ 100 for finishing coats{ 80-95 for under coats{ 95-100 for finishing coats 30-85 5-50 0-10

98-100 for under coats100 for finishing coats80-100 for under coats95-100 for finishing coats30-955-650-15

B) The grading of sand for external plaster coat and renderings shall be within the limits specified in Table B.

REQUIREMENTS FOR GRADING FOR SAND FOR EXTERNAL PLASTERING AND RENDERINGS.Percentage By Weight Passing IS SieveIS Sieve Designation(As per IS:460)

Class-A Class-B

480 100 100240 90-100 90-100120 70-100 70-10060 40-85 40-9530 5-50 10-65


15 0-10 0-15

Class A sand shall be used generally for plaster work but where they are not available, Class B sand may be used after getting the approval from Client / Consultant.

Deviation of about 5% from the specified limits in the grading for fractions passing IS Sieve 120 and 60 only may be allowed subject to agreement between the Client / Consultant and the supplier. Any other deviation shall be left to the discretion of the Client / Consultant.

14.2.3 Sampling and Testing:

Same as that for masonry mortar.

14.2.4 Storage:

Same as that of ‘Fine aggregate’.

15.0.0 MATERIALS FOR FILLING

15.1.0 SAND

15.1.1 Sand used for filling shall be clean river sand hard, gritty, dry and coarse, free from earth, silt organic matter, clay and other deleterious materials.

15.2.0 MURRUM

15.2.1 QUALITY OF MURRUM:

The murrum shall be naturally occurring material formed by disintegration of rock. It shall be free from vegetarian, rubbish or material of organic origin and scales deleterious to concrete and reinforced concrete.

Pieces of hard rock which do not get crushed under the roller shall not exceed 50mm size.

15.2.2 FILLING:

Filling shall be done in 20cm thick layers and every layer shall be power rolled with 8/10 ton roller so as to achieve maximum compaction and till such time that no further movement is observed under the wheels of the roller.


After filling is completed the modified Procter density shall be 92% with OMC.

Before start of work the contractor shall supply the samples of murrum from each quarry to cover the variations expected in the supply. The samples shall be tested for the following in a recognized laboratory in accordance with IS:2720 for the following.

Silt and clay content.Moisture-content and dry density relationship at modified Procter density.

Moisture Control: Water shall be always sprayed and not poured. Ponding shall never be allowed. In wet weather the work may have to be suspended. Care shall be taken to see that moisture is uniformly spread throughout the layer and where necessary mixing with harrows and rakes shall be done.

Measurements: Measurements shall be of the cubic contents of the completed filing and shall be determined by taking level of testing ground and after final layer for each type of filing. All dimensions are for compacted thickness.

15.2.3 CINDER :

Cinder is well burnt furnace residue which has been fused or centered into lumps of varying sizes. Cinder aggregates shall be well burnt furnace residue obtained from furnace using coal fuel only. It shall be sound clean and free from clay, dirt ash or other deleterious materials.

16.0.0 STEEL AND ALUMINIUM JOINERY

16.1.0 STEEL JOINERY :


Steel windows, ventilators and fixed lights shall conform generally to the provisions prescribed in IS:1033 and IS:1361 and also dimensionally to the details shown on the drawing. Rolled steel sections for the fabrication of steel joinery and material to be used in the manufacture of the sections shall conform to the requirements specified in IS:7452.18.1.2 Pressed steel door frames :

a. Steel doorframes shall be manufactured from commercial mild steel sheet of 1.25 mm thickness, conforming to IS:226 and 4351.

b. Steel doorframes shall be made true to profile and dimensions as specified in IS:4351 or as per drawings.


c. Each doorframe shall be consist of hinge jamb, lock jamb, head and , if required, angle threshold. The whole shall be welded or rigidly fixed together by mechanical means. Where no angle threshold is required, temporary base tie shall be screwed to the feet of frames in order to form a rigid unit.

d. Base ties shall be of pressed mild steel 1.25 mm thick adjustable to suit floor thickness of 25,30,35 or 40 mm and removable, or alternatively, thresholds of mild steel angle of section 50x25 mm, minimum, shall be provided for external door fram3es.

e. Fixing lugs shall have a head made of 25 wide x 1.6mm thick steel strip of specified length and a split end tall 40 mm wide x 1 mm thick and 200 long. There shall be a minimum of three lugs to each jamb.

f. Hinges shall be made of 2.5mm thick mild steel with a zinc coated removable pin of 6 mm diameter (conforming to IS:1341)

g. Mortor guards shall be provided as specified and these shall be welded to the frame at the head of the frame for double shutter doors to make provision for bolts.

h. There shall be an adjustable lock strike plate of steel, complete with mortar guard, to make provision for locks or latches complying with the relevant Indian Standards. Lock-strike plates shall be of galvanized mild steel and fixed at 75cm to 90cm from finished floor level.

i. For side-hung door there shall not be less than three buffers of rubber or other suitable material inserted in holes in the rebate and one shall be located on the centre line of the lock-strike plate lock-strike plate. For double-shutter doors there shall be two buffers of rubber or similar suitable material inserted in holes in the rebate in the lock jamb only at the head and spaced 15cm at either side of the centre line of the door.

16.1.2 Steel windows & ventilators :

a. Steel windows, and ventilators shall be manufactured from ordinary quality structural steel conforming to IS:1977. In case of composite units consisting of a combination of two or more units of windows and ventilators different units shall be coupled by using coupling sections made from MS sheet 3.15mm thick as per IS:1038. The weight of various rolled steel sections used for the manufacture of windows and ventilators shall be as per those specified in IS:1038 unless otherwise specified.

b. Frames shall show no wrap or inferior workmanship. All open able windows shall be designed to open outside with glazing on the outside of the frames unless mentioned otherwise. The hinges for side-hung shutters shall be of projecting non-friction type and for top hung plain type unless specified. Hinge pins and washers shall be of galvanized steel or aluminum alloy of suitable thickness. Weather bars shall be fitted to fabricated coupling section wherever required.


c. Steel ventilators with fixed louvers shall comprise of 16 gauge pressed steel guides spaced at 50mmc/c for receiving glass louvers 4mm thick. MS pressed steel louvers shall be fabricated out of 16 gauge sheet bent to ‘Z’ shape and shall be tack welded to frames.

16.1.2 Sliding Doors :

a. Unless otherwise mentioned, all the sliding doors shall be top hung, with coburn track and with galvanized corrugated sheeting of thickness 24 gauge (0.63mm) on the outer face. At the bottom a guide angle shall be provided with the frame of the door and a channel shall be anchored in the floor concrete. The framing angles for the doorframe shall be as per the detailed drawings. The doors shall be provided with an eyepiece of 16mm diameter.

b. The sliding door shall be in one leaf. The doors shall be hung from the top by supporting wheels fitted in steel hangers of substantial design, extending at least 400 mm down the door unless designed with a double strap in which case they need not extend more than 300 mm. Hangers shall be riveted to the door and if the door exceeds 1.5m in width not less than three hangers each with a wheel shall be fitted. Supporting wheels and pins shall be of steel and wheels of low friction type shall be used. The rail upon which the supporting wheels run shall be a flat bar of steel at least 75x50x8 mm in section or an angle at least 65x65x8mm in section on which a steel runner bar 16x16mm in section is fixed by rivets at 225 mm centres to carry grooved supporting wheels.

16.1.4 Rolling Shutters :

a. Rolling shutters shall in general conform to IS:6248 and shall be fabricated out of mild steel laths having interlocking curls at both edges with 12mm minimum depth of corrugation for resisting manual pressure and normal wind pressure. The laths shall be fabricated out of cold rolled steel strips. Conforming to IS:4030. Each lath section shall be continuous single piece without any welded joint. The water shielding surface shall be kept on the side exposed to atmosphere. When interlocked the roling centres of the laths shall be a 75mm centres minimum. Each alternate lath section shall be fitted with malleable cast iron (conforming to IS:2108) or mild steel clips securely riveted at either end and thus preventing their lateral movement and wearing of their edges against the guide channels. The clips shall be so designed so as to fit the contour of the lath sections.

b. The shutter shall be provided with bottom lock plate fabricated out of 3.15mm thick mild steel sheet reinforced by an angle iron stiffener of not less than 35x35x5 mm size at the bottom and MS flat at the top. It shall be interlocked with the bottom lath so as to have a firm contact against the sill while the shutter is in closed position. The lock plate


shall be fitted with necessary sliding bolts and pulling handles usable from both interior and exterior sides of the plate.

c. The guide channels shall be either of rolled section or one piece pressed construction and shall be of thickness not less than 3.15 mm. The depth and width of guides shall be such that there is sufficient clearance between the curtain and the inner surface of guides to ensure not only free movement of curtain but holding it firmly at the ends upto a maximum wind pressure of 200kg/sqm and preventing it from rattling as well. The minimum depth of channel shall be 65mm for widths upto 3.50 m and 75mm for widths more than 3.50 metres. Width of guide channel shall be 25mm for lath sections with depth of corrugation 12mm. The guide channel shall have minimum 3 numbers of MS holdfasts and the maximum spacing shall however, not exceed 750mm. Provision of MS stopper at the maximum height shall be made on the guide channels.

d. Bracket plates shall be of hexagonal, square or circular contour and shall have a U-shaped cast iron or mild steel clamp welded to it at the centre. The bracket plate shall be made out of 3.15 mm thick mild steel plate and size shall conform to the requirements in IS> the plate shall be held in position rigidly by means of suitable foundation bolts and in the case of push and pull type shutter, extra tying to the guide channel by means of a square bar not less than 20mm size shall be provided.

e. The suspension shaft of the roller shall be made of heavy duty steel pipe conforming to IS:1161 and shall be of adequate diameter to have minimum deflection with suitable flange coupling. The pipes of the shaft that are clamped to the brackets shall be fitted with rotatable cast iron pulleys to which the curtain is attached. The pulleys and the pipe shaft shall be connected by means of pre-tensioned helical springs, flat or coil type conforming to grade2 of IS:4454 hardened and tempered.

f. Ball bearings provided for rolling shutters shall be two-row self-aligning type with special cast iron castings at the extreme pulleys at either end. The pulleys shall be interconnected with a cage formed out of mild steel flats of at least 32 x 6mm and spaced at 15cm.

g. The hood cover shall be made of 0.9 mm thick MS sheets with necessary stiffeners and framework. The cover shall be of hexagonal, square or circular contour depending on the bracket plate contour. This shall be supported at regular intervals to prevent sagging.

h. Unless otherwise specified for overall area of rolling shutters upto 10 square metres, pull and push type hand operated shutters with ball bearings shall be provided. For areas more than 10 sq.m and upto 35 sq.m mechanically operated gear type will ball bearings shall be provided. A pulling hook shall be provided for each of the rolling shutters. The pulling hook shall consist of 12mm diameter rod with a hook at one end and a ring at the other end of adequate length.

i. Power operating shutter shall be suitable for 3 phase, 50 cycle, 400 volt Ac power supply and shall be either floor or wall mounted unit.


The motor shall be of sufficient capacity to move the shutter in either direction at a speed of 0.3m/sec. In addition to the gear motor, each standard power unit shall include a magnetic brake, reversing starter with built-in overload protection, a geared limit switch and one push button station located inside the building. It is desirable that the bottom bar of motor operated doors shall be provided with a sensitive edge, electrically connected stop the travel of the door on meeting an obstruction. Operating chains shall be tested quality, heavily galvanized and with all ends rounded to assure smooth operation and hand protection. Reduction gears shall be of high strength grey cast iron, machine moulded from machine cut pattern. These shall be operable from a push button station conveniently located beside the door. One emergency hand chain/crank operation shall also be provided for use in case of failure of the electrical system.

16.1.5 Supply : All doors frames, windows and ventilators shall be dispatched with the opening parts suitably secured to preserve alignment when fixing and glazing.

Fixing lugs, couplings, fittings and all hardware shall be dispatched separately.

Composite windows shall be dispatched uncoupled.

16.2.0 Aluminum Joinery

16.2.1.General requirements :

a. Anodized aluminum joinery shall conform to the requirements specified in IS:1948 and 1949 and shall be of Hindalco, Indal or equivalent reputed make with size and design as per relevant drawings. The average thickness of anodic coat shall not be less than 20 microns (IS:7088) and shall be matt finished.

b. Aluminum doors, windows, ventilators shall be made of aluminum alloy conforming to IS:733 and sections shall generally conform to IS:1948. Coupling members forming composite sections shall be of extruded aluminum alloy section. All frames shall have corners machine-jointed to a true right angle. For side hung shutters, hinges shall normally be of projecting type made of aluminum alloy and riveted/machine-jointed to frame and shall have stainless steel/aluminum alloy pins. Irrespective of the hinges being anodized or not, the aluminum alloy pins shall be anodized to a minimum film thickness of 25 microns and shall be sealed with oil or wax. Handles, peg stays shall be of approved heavy-duty quality aluminum or its alloy conforming to IS specifications.


c. The doorframe and shutters shall be single action or double action as indicated in the drawing with hydraulic door closer in the floor. The doors shall be provided with anodized aluminum door handles for full width of door inside and outside. The door frame shall be provided with approved anchors spaced not more than 900 mm centres.

d. Before erecting, frames coming into contact with concrete, masonry, plaster or dissimilar metals, shall be coated with a thick layer of clear transparent lacquer based on methacrylates or cellulose bytyrate, which is compatible with zinc chromate to protect the surface from wet cement during installation. This lacquer coating shall be removed after installation is completed. Before handing over, the aluminum work shall be washed with mild solution of non-alkali soap and water.

Gaskets to be used shall be made of neoprene/EDPM of approved make and shall be approved by the Client/Consultant before fixing in position. The sealant shall be of approved make and shall be duly approved before application. Aluminum doors, windows and ventilators after fixing in position shall be watertight and airtight.

Aluminum material used shall be specially anodized for protection against corrosion in marine environment in approved shade. The anodic coating shall conform to IS:1868 and shall be of AC25 grade with minimum thickness of 20 microns when measured as per IS:660/2 and density shall be at least 32MG/sqm. The anodic coating shall be double sealed or alternatively sealed with steam and shall be of minimum thickness of 50 microns. The anodic coating shall be tested in a laboratory by Eddy current method as per IS:6012 for thickness. Sulphuric acid shall be used as the electrolyte for the anodic process.

Wherever specified, polyester grade machine applied power coating of minimum thickness 20 microns shall be provided and such coating shall be of approved shade.

16.2.2 Supply :

Same as for steel joinery.

16.2.3 Unloading and Stacking :

The fabricated frames shall be transported, unloaded, stacked and handled in a careful manner. They shall be stacked on edge on level bearers and supported evenly. Ail precautions shall be taken to ensure that the frames are not damaged or distorted in any manner. As decided by the Client/Consultant, the damaged or distorted frames shall be replaced and made good at the expense of the contractor. Generally, storage of doors and frames shall conform to IS:4082.


16.2.4 Sampling :

Sampling and criteria for conformity for steel/aluminum doors, windows, ventilators and fixed lights shall be as prescribed in the respective Indian Standards.

17.0.0 Hardware for joinery works


a. Fittings shall be of MS, brass, aluminum or as specified. These shall be smooth and free from sharp edges, corners, flaws and other defects. Screw holes shall be countersunk to suit the head of specified wood screws. All hinge pins shall be of steel and their riveted heads shall be well formed.

b. MS fittings shall be finished bright or black enameled or copper oxidized or painted as specified. Brass fittings shall be finished bright (brass), oxidized or chromium plated (electroplated) an aluminum fittings shall be finished bright or anodized or as specified. Fittings shall be approved by the Client/Consultant before fixing. Screws used for fittings shall be of the same metal as that of the fittings. However, anodized cadmium / chromium plated brass screws of approved quality shall be used for fixing aluminum fittings. In case of renewal works, the new fittings shall as far as possible, match with he existing ones. Screws shall be driven home with screw driver and not hammered in.

17.2.0 Hinges

17.2.1 Butt Hinges :

These shall be mild steel but Hinges (medium), brass butt Hinges (light/ordinary), brass butt Hinge (heavy), brass oxidized butt V (light/ordinary), brass oxidized butt V (heavy), extruded aluminum alloy butt V or as specified. Brass and MS butt Hinges shall generally conform to IS:205 and IS:1341 respectively.

17.2.2 Parliament Hinges :

These shall be mild steel or cast brass or as specified and shall generally conform to IS:362.

17.2.3 Spring Hinges :

These shall be made of MS or brass casing with steel spring and shall conform generally to IS:453. Hinges shall work smoothly and hold the door shutters truly vertical in closed position. The size of spring Hinge shall be taken as length of its plate.


17.2.4 Piano Hinges :

These shall conform to IS:3818 and shall be made of mild steel, brass, or aluminum alloy sheets. Mild steel Hinges shall be finished with anticorrosive treatment or plating of brass or nickel as specified. Piano hinges shall be fixed for the full height of cupboard shutters.

17.2.5 Tee Hinges :

These shall be made of MS sheets and finished bright. They shall conform to IS:206.

19.3.0 Sliding Door Bolts :

These shall be of aluminum and conform to IS:2681. They shall be capable of smooth sliding action. Alternative materials may be adopted on the approval of the Client/Consultant for specific locations.

17.4.0 Door latch :

This shall be mild steel, brass or as specified and shall be capable of smooth sliding action.

19.5.0 Tower Bolts :

Tower bolts may be of one of the following types :

Brass barrel tower bolt with cast brass barrel and rolled or drawn brass bolt.

Brass barrel tower bolt with brass sheet barrel and rolled or drawn brass bolt.

Anodized aluminum barrel tower bolt with barrel and bolt of extruded sections of aluminum alloy (10/12mm dia shoot).

MS tower bolt with barrel.

These shall generally conform to IS:204 Parts 1&2) steel spring and ball shall be provided between the bolt and the barrel.

17.6.0 Door handles :

These shall be cast brass or MS or aluminum of specified size and of the shape and pattern as approved by Client/Consultant. These shall generally conform to IS;208. The size of the handle shall be determined by the inside grip of the handle. Door handles shall be of 100 mm size


and window handles of 75 mm size unless otherwise specified. These shall be fixed with 25mm long screws.

17.7.0 Mortice Lock :

Mortice lock with latch and pair of lever handles shall have steel casing and brass bolts and shall be right or left handed as shown in the drawing or as directed by the Client/Consultant. It shall be of the approved quality and shall conform to IS;2209. The shape and pattern shall be approved by the Client/Consultant. The size of the lock shall be determined by its length. The lock for single leaf door shall have plain face and that for double leaf door shall have a rebated face. Lever handles with springs shall be mounted on plates and shall weigh not less than 0.5 kg per pair. These shall be of brass, finished bright chromium plated or oxidized.

17.8.0 Floor door stopper :

This shall be made of cast brass or anodized aluminum and shall have a rubber cushion. The type and pattern sill be as approved by the Client/Consultant.

17.9.0 Hooks and Eyes :

These shall be of hard drawn brass or steel and shall generally conform to IS:207.

17.10.0 Casement Window Fasteners :

These shall be made of cast brass, anodized aluminum or chromium plated steel. Casement fasteners for single leaf window shutter shall be left or right handed as specified. These shall not weigh less than 0.20 kg per fastener.

17.11.0 Casement Stays :

These shall be made of cast brass, anodized aluminum or chromium plated steel. The stay shall be made from channel section and shall not weigh less than that indicated below :

200 mm --- 0.24 kg each250mm --- 0.28 kg each300 mm --- 0.33 kg each

The shape and pattern of stays shall be approved by the Client/Consultant.


These shall be made of cast brass, anodized aluminum or C.P. Steel. The shape and pattern shall be approved by the Client/Consultant. It shall not weigh less than 0.20 kg each.

17.12.0 Fan /Light Pivots :

These shall be made of cast brass or C.P. Steel and shall generally conform to IS:1837. The base and socket plate shall be made from minimum 3.15 mm thick brass or CP steel plate and projected pivot shall not be less than 12 mm in diameter and 12 mm in length, cast in single pieces with the base plate.

17.13.0 Fan light catch :

These shall be made of cast brass or CP steel and shall generally conform to IS:364. Steel springs of the catch shall be 0.90mm dia 6 coils 12 mm internal diameter and 20 mm long. The pattern and the shape of the catch shall be as approved by the Client/Consultant.

17.14.0 Chain with hook for fan light :

This shall be made of hard drawn brass or cast brass or CP steel welded or twisted as specified and shall generally conform to IS:3828. One end of the chain shall be provided with an eye and the other end with staple. The minimum thickness of plates shall be 2.24 mm and the chain shall be 300 mm long made from minimum 4 mm hard drawn wire.

17.15.0 Hasp and staple :

Hasp and staple (safety type) shall be made of cast brass or CP steel or aluminum and generally conform to IS:363. The hinge pin which in all cases shall be of mild steel, shall be firm and its riveted head well formed. The movement of the hasp shall be free, easy and square and shall not have any play or shake. The hasp shall fit the staple correctly. The size shall be determined by the length of the bigger leaf of the hasp.

17.16.0 Cupboard lock :

These shall be made of cast brass conforming to IS;729 and shall be of approved make. The lock shall be easy in working having duplicate keys.

17.17.0 Hydraulic door closer :

These shall conform to IS:3564 and be of brand approved by the Client/Consultant for both left and right hand openings.


Hardware and fixtures shall be as specified in the drawings or schedule of quantities. All hardware and fixtures shall be able to withstand repeated use. Door closer shall be suitable for doors weighing 61-80 kg. Unless otherwise stated. Each closer shall be guaranteed against manufacturing defect for one year and any defect found within this period shall be rectified or the closer replaced free of charge. Concealed door closers shall be either floor mounted or trans mounted, suitable for installation with metal doors. It shall conform to the performance requirements and endurance test stated in IS;3564.

18.0.0 Glazing :


18.1.1 The glass used for glazing works shall be of the best quality transparent and free from blisters, specks, bubbles, stones, scratches, veins, air holes and other defects also as to give a clear visibil8ity through the glass.

18.1.2 All glass shall be procured from a reputed manufacturer and duly approved by Client/Consultant. The glass supplied at site shall conform to the requirements indicated in the schedule of items and the following Indian Standards listed below :

a. Sheet glass of selected quality as per IS:2835.b. Wired and wired-figured glass as per IS:5437.

18.2.0 Sheet glass :

General :

Sheet glass is a flat transparent glass made by blowing or drawing and it shall be, to the extent possible, colourless as judged by the un-aided eye except when viewed edgewise showing a light blue to green tint.

Unless otherwise specified sheet glass shall weigh 7.5 kg/sqm for panes upto 600x600 mm. For panes larger than 600x600mm and upto 800x800 mm glass weighting not less than 8.7 kg/sqm shall be sued. For bigger panes upto 900x900 mm glass weighting not less than 11.25 kg/sqm shall be used.

Sheet glass shall be patent flattened glass of best quality and for glazing and framing purposes shall conform to IS:1761.

18.2.2 Testing :


Tests for waviness, warpage, lines, etc. shall be done as per Appendix - A of IS:2835 and test for thickness shall be done as per Appendix-B of IS:2835.

Any glass, found to suffer from defects beyond allowable limits (as per Table-2, IS;2835) shall be rejected.

18.2.3 Sampling :

Representative samples of the material shall be drawn and adjudged for conformity with this specification as prescribed in Appendix C, IS;2835.

18.2.4 Packing and marking :

Sheet glass shall be packed as agreed to between the purchaser and the supplier. The packages shall be marked with ISI certification mark. Packages shall also be marked with name and quality of the material, nominal thickness and cut size, name of the manufacturer, as per clause 6.0 of IS;2835.

18.3.0 Wired glass and wire-figured glass :

18.3.1 Wire glass apart from serving as a rigid glazing material helps in providing reasonable protection against spreading of fire across.

18.3.2 The wire mesh used in the wired glass or wired figured glass should be made of steel wire 0.46 to 0.56 mm in diameter. The pattern of mesh shall be square or diamond with wired welded or hexagonal with wires twisted. The wire mesh shall be embedded completely in the glass sheet at least 1mm from the surface and shall not be exposed at any place. Wire mesh shall not contain more than 3 broken wires per square metre of glass.

18.3.3 Sampling and testing :

Tests for flame-proofness, thickness, etc. and sampling shall be in accordance with the methods prescribed in IS:5437.

18.4.0 Plate glass :

Plate glass shall be polished patent flat glass of best quality. It shall have both he surfaces ground flat and parallel and polished to obtain clear undisturbed vision and reflection. The plate glass shall be of thickness mentioned in the item or as shown in detailed drawings or as specified. In absence of any specified thickness, the thickness of plate glass to be supplied shall be 6 mm and a tolerance for 0.2 mm shall be admissible.

18.5.0 Obscured glass :


This type of glass transmit light so that vision is partially or almost completely obscured. Glass shall be plain rolled, figure, ribbed or fluted or frosted glass as may be specified.

18.6.0 Putty :

The material shall be a homogenous paste and shall be free from dust, grit and other visible impurities and shall conform tot he specifications prescribed in IS;419.

Putty may be prepared by mixing one part of white lead with three parts of finely powdered chalk or then adding boiled linseed oil to the mixture to form a stiff paste and adding varnish to the paste at the rate of 1 litre to varnish to 18 kg of paste.

19.0.0 Tiles :

19.1.0 Terrazzo Tiles :

Terrazzo tiles shall generally conform to the standards prescribed in IS:1237 in all respects.


a. All tiles to be used shall be heavy duty flooring tiles only, conforming to clause 3 of IS:1237.

b. Tiles shall be manufactured from cement, natural aggregate and colouring pigment (where require) as specified in clause 4 of IS:1237, under hydraulic pressure not less than 140 kg/sqcm and shall be given the first grinding with machine before delivery to site.

c. Manufacturing process of tiles shall conform to the requirement given in clause 5 of IS;1237.

d. Unless otherwise stated, the size of terrazzo flooring tiles shall be as follows :

Length (mm) Breadth (mm) Thickness (mm)200250300

200250300

202225

However, special shapes and sizes of tiles can be asked for by the client. In such as case, the manufacturer/supplier shall ensure to supply the tiles only in the specified shape and size.

e. Tolerances on length or breadth of tiles shall be +/- 1 mm. In addition, the difference in length of side between the longest side and shorter side in the sample shall not exceed 1mm. Tolerance on thickness


shall be +/- 5 mm. In addition, the difference in thickness between the thickest and the thinnest tile in the sample shall not exceed 3 mm.

f. The minimum thickness of wearing layer for the various classes of terrazzo flooring tiles shall be as specified in Table 1 to IS:1237. Unless otherwise specified, the tiles shall be supplied with initial grinding and grouting of the wearing layer.

g. The wearing layer of the tiles shall be free from projections, depressions, cracks, holes, cavities and other blemishes.

19.1.2 Physical requirements :

The tests on tiles to check physical requirements shall not be carried out earlier than 28 days from the date of manufacture.

a. Client can ask for any physical test to verify the acceptability of the tiles. All physical tests shall be carried out as per Appendix A to F of IS:1237 as applicable, depending on the tests to be done.

b. On testing, the physical requirements shall conform to the acceptability limits specified in clause 11 of IS:1237. Tiles, failing to meet acceptability criteria, shall be rejected.

19.1.3 Sampling :

Sampling and inspection shall be carried out as per clause 14 of IS;1237.

19.1.4 Marking :

All tiles shall be legibly marked on the back with the name of the manufacturer or his trade mark. Heavy duty tiles shall be marked ‘H’

19.2.0 Ceramic Tiles :

Ceramic tiles to be used for flooring and dadoing shall conform to IS:13712. These shall be procured from approved manufacturers and a few approved samples shall be submitted to Client/Consultant/architect for future reference.


The tiles shall be of vitreous ware and shall be free from deleterious, substances. The finished tile, when fractured shall appear fine grained in texture, dense and homogeneous. The tiles shall be sound, true to shape , flat, free from flaws and other manufacturing defects affecting their utility.


Glazed ceramic tiles : Glazed ceramic tiles shall be highly pressed, single fired, red body, top glazed white or coloured, plain or with designs. The body glazed ceramic tiles should consists of high grade clay and minerals and well pressed in hydraulic presses and glaze should be a combination of different minerals. The top surface shall be glazed with stable gloss/semi-gloss/matt finish of uniform colour and texture. The edges and under side of the tiles shall be free from glaze and shall have ribs or indentations so that these may adhere properly to the surface below.

Floor tiles : These tiles should have high strength, good resistance to wear and tear, low water absorption and sufficient anti-skid properties and all shall conform to IS: 13755. Based on the properties of the glaze and hardness, floor tiles are categorized abrasion resistant-wise as group II to V. According to the intensity of foot traffic the tile group shall be selected and used.

Wall tiles : These tiles shall be single fast fired having medium water absorption and high strength characteristics. These tiles shall have high glaze and better adhesion to wall and shall conform to IS:13753. Wall tiles shall be glossy/semi-glossy, matt glaze finish, white or coloured, plain or printed special printed and premium printed.

Vitrified ceramic unpolished/polished tiles : These tiles are of different shades having monolithic body that is pressed in very high tonnage press and fired to high temperature. The tiles shall be homogeneous and compact through out the entire body with very high strength, low porosity and extreme surface hardness, high resistance to abrasion by chemicals and shall conform to IS:4457. The tiles shall be with smooth surface or textured anti-skid finish surface. Polished vitrified ceramic floor tiles shall be homogeneous heavy and tough with highly reflective polished surface but non-slippery.

19.2.2 Sampling & Testing :

Sampling shall be done as per IS:13711 and testing shall be done as per IS:13630. Samples of each type/design/finish/print/size/colour of tiles shall be submitted well in advance to the Architect/consultant for approval at the contractor’s cost. The consultant/architect shall retain approved sample. Tiles shall be procured from a single approved source who can provide products of consistent quality and physical properties.

19.2.3 Storage :

The tiles shall be delivered in original containers with seals unbroken. Adequate precaution shall be taken to prevent accidental damage to tiles while unloading and these shall be stored under cover in manner approved by the Engineer-in-charge.


19.2.4 Acceptance criteria :

Acceptance criteria shall be as per IS:13711.

19.3.0 Anti-skid tiles :


The tiles shall be free from any flaw, fissure, crack or any other manufacturing defect that may adversely affect their utility. They shall be flat, square, true to shape and sound.

Finish shall be mat finish.

Compressive strength shall not be less than 70 N/mm2.

Maximum permissible water absorption shall be 2 percent.

Maximum permissible average wear shall be 2mm. However, for an individual specimen this value shall be 2.5 mm.

Tiles meant for dadoing purposes shall not be used for flooring.

19.3.2 Sampling and testing :

Same as that of ‘Ceramic tiles’.

19.3.3 Acceptance criteria :

Same as that of ‘Ceramic tiles’.

19.4.0 Acid Resistant tiles :


The tiles shall be of vitreous ware and shall be free form deleterious, substances. The finished tile, when fractured shall appear fine grained in texture, dense and homogeneous. The tiles shall be sound, true to shape, flat free from flaws and other manufacturing defects affecting their utility.

Size of ceramic unglazed vitreous acid resistant tiles shall be as follows :

i. 100 x 100 (or) 98.5 x 98.5mmii. 150 x 150 (or) 148.5 x 148.5mmiii. 200 x 200 (or) 198.5 x 198.5mm


Half tiles for use as full tiles, if manufactured, shall have dimensions that shall be such as to make the half tiles, when jointed together, match with the dimension of a full tile.

Thickness shall be 25,20,12 & 10mm.

Depth of the grooves on the underside of tiles shall not exceed 3mm.

Tolerance in length, width and thickness of tiles shall be +/-2.5 percent.

Half tiles for use as full tiles, if manufactured, shall have dimensions that shall be such as to make the half tiles, when jointed together match with the dimension of a full tile.

Tolerances in length width and thickness of the tiles shall be +/- 2.5 percent. Other requirements shall be in accordance with Table-1 of IS:4457.

20.0.0 Paints

20.1.0 Enamel paint :


Paint and enamel shall be of approved quality. Colour for enamels shall conform to IS:5. These shall always meet the requirements (colour and space) of the client/consultant/architect.

These shall be purchased from reputed manufacturers only as directed by the client/consultant.

Under no circumstances the paint shall be diluted with linseed oil or any other material before application. The method of application shall be as prescribed by the manufactures.

Paint shall not show excessive setting in freshly can and shall easily be mixed with paddle to a smooth homogeneous state.

While brushing, the paint shall be easily brushable possess good levelling properties with no running or sagging tendencies.

The paint shall dry to a smooth uniform finish free from roughness, unevenness and other imperfections.

20.1.2 Primer :

Primers shall be Zinc Phosphate


20.1.3 Packing and Marking :

Packing and marking of packages of paints, enamels & primers shall be in accordance with IS:5661.

20.1.4 Sampling :

Representative samples of the material shall be drawn as prescribed under 3 of IS:101 whenever directed by the Client/Consultant.

20.1.5 Storage :

Paints of all types shall be stored in a cool dry place, preferably in a godown specifically made for the purpose. In general, storage of paints shall be in accordance with IS:4082.

20.2.0 Plastic emulsion paint :

Plastic emulsion paint for interior and exterior use shall conform to IS:5411 (Parts-1 &2) respectively.


a. The emulsion paint and primers in general shall be of approved quality, colour, shade and brand as directed by the Client/Consultant.

b. The material shall consist of pigments with suitable extenders in suitable proportions, in a medium consisting of any stable synthetic polymer emulsion in water, with suitable other ingredients as may be necessary to produce a material so as to satisfy the requirements of this standard.

c. The paint, for interior use, shall meet the requirements of IS:5411 (Part-1), on testing. The paint for exterior use shall comply with he requirements of IS:5411 (Part-2).

d. Any special requirement, if agreed to between the supplier and the Client/Consultant, shall have to be complied with.

20.2.2 Packing and marking :

Unless otherwise specified, the material shall be packed in metal containers lacquered inside with a suitable chemical resistant material.

Each container shall be marked in a manner as specified in clause 4 of IS:5411 (Part-1).

20.2.3 Sampling :

Representative samples of the material shall be drawn as prescribed under 3 of IS:101 whenever directed by the Client/Consultant.


20.2.4 Testing :

a. Tests shall be conducted according to the methods prescribed in IS:101, Appendices A to E of IS:5411 (Part-1) and Appendices A to F of IS:5411 (Part-2), as applicable.

b. Unless otherwise specified, pure chemicals and distilled water (conforming to IS:1070) shall be employed in tests.

20.2.5 Storage :

Paints shall be delivered in sealed containers. They shall be stored in accordance with the provisions of IS:4082.

20.3.0 Cement paint :


Cement paint shall conform tot he requirements laid down in IS:5410.

The material shall be in powder form, free from lumps.

When mixed with required volume of water, it shall be suitable for use on porous surface of masonry, concrete, stucco, common brick and rough plaster work, except gypsum plaster.

20.3.2 Scaffolding :

Wherever scaffolding is necessary, it shall be erected in such a way that as far as possible no part of scaffolding shall rest against the surface to be white or colour washed.

A property secured and well tied suspended platform may also be used for whitewashing and colour washing.

Where ladders are used, pieces of old gunny bags shall be tied at top and bottom to prevent scratches to the walls and floors.

For whitewashing of ceilings, proper stage scaffolding may be erected, where necessary.

20.4.0 White wash, colour wash :

White washign and colour washing on concrete, masonry and plaster surfaces in buildings shall conform to IS:6278.

20.4.1 Materials :


Following materials are used to prepare whitewash and colour wash.

Lime used for whitewashing shall be freshly burnt fat line (also classified as class ‘C’ lime) conforming to IS:712. It shall be white in colour.

Water shall be clear, free from all organic and suspended impurities. Water shall meet the requirements mentioned in the clause 4.3 of IS:456. Potable water is generally considered suitable for this purpose.

Colour wash shall be done with mineral colours not affected by lime added to white wash. No colour wash shall be done until a sample of the colour wash to the required shade or tint has been approved by the architect/consultant. The colour shall be of even shade over the whole surface. If it is blotchy or otherwise badly applied, it shall be redone by the contractor at his own cost.

Gum or glue.

Sodium chloride to be used shall conform to IS:253 or grade II of IS:797.

Ultramarine Blue or Indigo shall conform to IS:55.

Pigments :

i. Yellow and red ochre - The ochre’s shall conform to IS:44. The solid lump shall be crushed to powder.

ii. Blue vitriol - Fresh crystals of hydrous copper sulphate (blue vitriol) shall conform to IS:261 and shall be grounded to fine powder.

20.4.2 Scaffolding : Same as for ‘Cement Part)

20.5.0 Distemper :

20.5.1 Dry distemper :

The powdered / dry distemper shall be approved colour and of approved brand and shall conform to the requirements prescribed in IS:427 & 428. The shade shall be got approved from the architect/.consultant before application. The dry distemper of approved brand and colour shall be stirred slowly in clean water using 6 decilitres (0.6 litres) of water per kg of distemper or as specified by the manufacturer. Warm water shall be used. It shall be allowed to stand for at least 30 minutes (or if practicable over night) before use. The mixture shall be well stirred before and during use to maintain an even consistency. Distemper shall not be mixed in larger quantity than is actually required for one day’s work.

20.5.2 Oil bound distemper :


The specifications and condition for this shall be the same as that applicable for dry distemper, except that oil bound distemper of approved make, shade and colour shall be used after applying priming coat of petrifying liquid or other primer as may be recommended by the manufacturer / supplier. It shall conform to IS:428.

20.5.3 Scaffolding :

Same as for ‘Cement Paint’.

20.6.0 Heritage wall finish :

It shall be from Bakelite Hylam Ltd or equivalent as approved by the architect/consultant. It shall conform to International Standards.

It shall be two-component finish. It shall be easily applicable using trowels and no special tools and training shall be required for application. The single coat application thickness shall be 1.52mm of colour and texture as approved by the architect. It shall be weather and fade resistant water and damp resistant, durable, highly washable. It shall be acid and alkali resistant, high abrasion resistant, non-toxic and shall be capable to take any shade. It can be applied on wide variety of surface like cement mortar, plywood, plaster board, AC sheet, gypsum plaster or any other absorbent material to get homogenous layer.

It shall be incombustible and flexible. It shall be good fire resistant, anti-fungal, good impact resistant having adhesion strength more than 8kg/sqcm. There shall not be any development of hairline cracks and no peeling off shall occur after the maximum drying time of 4 hours and during period of 2 days.

20.7.0 Acrylic emulsion paint :

It shall be water based acrylic co-polymer emulsion with rutile titanium-di-oxide and other selected pigment and fungicide. It shall exhibit excellent adhesion to plaster and cement surface and shall resist deterioration by alkalis salts. The paint film shall allow the moisture in the wall to escape without peeling or blistering the paint. After it is dried, the paint should be able to withstand washing with mild soap and water without any deterioration in colour or without showing flaking, blistering or peeling.

21.1.0 False ceiling :


21.1.1 The ceiling boards shall conform to the requirements specified in the schedule of items or in the drawings. They shall be


strong and with uniform texture without cracks, holes or any other defects.

21.1.2 Galvanized steel grid system :

Main runner-Hot dipped galvanized steel, T shaped of 24x38mm size and thickness 0.33mm cross runner - Hot dipped galvanized steel, T shaped of 24x30mm size, thickness 0.25mm. 1200 mm long and 24x25mm size, thickness 0.25mm, 600 mm long. Perimeter section shall be same material as runners. Sections shall be 22x22mm size with thickness of 0.45 mm. Exposed areas of all metallic members shall be powder coated to a thickness of 25 micron.

21.1.3 Gypsum Board Tiles with Seamless Joints :

The above shall be of the best quality from India Gypsum or equivalent as approve by the architect. It shall be formed by enclosing and bonding together a core of set gypsum plaster by two sheets of heavy paper. It shall offer high standard of safety, thermal efficiency and aesthetics. It shall be heavy weight, offer good fire resistance. It shall be a non-resonant material, rendering sound insulation. It shall be strong, durable and dimensionally stable. It shall offer a smooth surface which can be painted, tiled or wall-papered. It shall block this passage of heat and shall retard the spread of fire. It shall reduce upto 60 db of sound.

Gypsum boards shall conform to IS:2095-1982 & IS:2542-1981.

It shall be resistant to delamination due to moisture and cyclic changes in weather and humidity.

The density shall be 288 kg/cum and the weight shall vary from 8-12.8kg/sqm depending on the thickness. It shall be available in thickness of 9.5, 12.5 and 15mm.

Standard sizes are 610x610mm, 1220x1220mm and 1220x610mm.

21.1.4 Steel false ceiling :

21.1.5 Panels shall be of cold rolled steel, galvanized as per IS:277 coil coated as per JIS 3312. Panels shall be 150 wide and 17mm deep. They shall be roll-formed out of 0.5mm TCT coil coated galvanized steel. They shall be degreased, pretreated and coil coated on one side in manufacturer’s standard shades. The rear of the panels shall be given a coat of primer and a wash coat, while the finished side will be given a coat of primer and a finish colour coat in polyester paint for a minimum dry film thickness of 20 microns. Panels shall be factory cut to lengths up to 5m to suit site dimensions.


21.1.6 Panel Stringers shall be 34.5 mm wide and 48 mm deep with cutouts to hold panels in a module of 150mm. They shall be roll-formed out of 0.6mm thick galvanized steel strip cut to a standard length of 5m. Stringers shall be stove enameled black.

21.1.7 Stringers shall be suspended form the roof/truss by galvanized steel wire rod hangers and suspension clips. Hangers shall be fixed to roof by J hooks and nylon inserts or using 18g annealed GI wire.

21.1.8 Edge profiles shall be L shaped, roll formed out of 0.65mm aluminum strip/0.6 mm galvanized steel strip with powder coating in standard colours.

21.2.0 Testing :

21.2.1 Tests shall be carried out in accordance with the provisions of relevant standards and as directed by the client/consultant.

22.0.0 Miscellaneous materials :

22.1.0 Performed fuller board for joints :

22.1.1 Performed filler board shall be “SHALITED” or equivalent conforming to IS:1838 and should consist of a fibre board impregnated with bituminous materials to render it durable and waterproof. It should be compressible and possess a high degree of resilience. It shall withstand a dampen minor vibrations.

22.1.2 The filler should permit free movement of the concrete members in expansion and contraction and should provide waterproof seal and resist entry of any foreign material. The filler should be resilient and non-extrudible.

22.2.0 Poly sulphide sealant :

22.2.1 Poly sulphide sealants shall be of approved make and shall comply with all the requirements prescribed in IS:12118.

22.2.2 It shall be a two-component poly sulphide rubber joint sealant based on low molecular weight polymer. It should not contain chlorides or other corrosive substances.

22.2.3 The modulus of elasticity of the sealant shall not be less than 0.16 Mpa +/-10% at 100% elongation, the shore “A’ hardness shall be 22+/-3 @ 25°C. The operating temperature range shall be -25°C to 80°C. The permanent dynamic movement capability shall be +/-25%. The tensile strength shall not be less than 0.4Mpa.


22.2.4 It shall possess properties like 550% elongation at break, non-toxicity when fully cured, no staining, shrinkage less than 1%. The trafficable strength shall be achieved within 24 hrs and full at 7 days (at 25°C & 250% RH).

TECHNICAL SPECIFICATION FOR WORKMANSHIP

EARTHWORK:

SETTING OUT AND MAKING PROFILE:

Masonry pillars will be erected at suitable points. These bench mark shall be connected to standard bench mark. In addition to these pillar center line pillars shall also be erected by the Contractor and footing positions shall be marked with the help of these pillars. The necessary profile shall be set out. The level shall be taken at a interval as directed by IEC.The levels shall be recorded in field books and plotted on plan before starting the excavation.

EXCAVATION FOR FOUNDATION:

The cutting shall be done to minimum depths as per drawings and as advised by EIC. Any excess excavation carried out by the Contractor without proper permission from EIC shall not be paid and the excess depth shall be made good by the Contractor by PCC 1:4:8 at contractor’s own cost.

BACKFILLING:

In case water is encountered during the excavation for foundation, or flooding of pits due to any other reasons the contractor shall arrange for dewatering the same at his own cost.

EXCAVATION IN HARD ROCK:CUTTING Where hard rock is met, generally excavation by chiselling and wedging shall be carried out. Excavation by blasting shall be done only after obtaining written approval from Engg.-in-Charge/Architects. In case of excavation by blasting all the provisions of explosive rules 1940 (Corrected upto date) shall be complied with storing, transportation and handling of explosive materials. The blasting operation shall be carried out under the supervision of a responsible authorised agent of the contractor. Blasting work shall not be carried out within 200 metres of an existing structure unless otherwise permitted by the Engg.-in-Charge / Architects.


MEASUREMENTWhere ordinary rock and hard rock is mixed, the measurement of the excavation shall be carried out by stacking both the types of excavated rock separately. The net quantity of rock shall be arrived at by applying reduction of 50% for looseness in stack. If the sum of net quantity of two kinds of rock exceeds the total quantity of excavated material, then the quantity of each type of rock shall be in the ratio of net quantities in stack measurements of the two types of rocks.

SPECIFICATIONS FOR MOORRUM FILLING

QUALITY OF MURRUM:

The murrum shall be naturally occurring material formed by disintegration of rock. It shall be free from vegetarian, rubbish or material of organic origin and scales deleterious to concrete and reinforced concrete.

Pieces of hard rock which do not get crushed under the roller shall not exceed 50mm size.

FILLING:

Filling shall be done in 20cm thick layers and every layer shall be power rolled with 8/10 ton roller so as to achieve maximum compaction and till such time that no further movement is observed under the wheels of the roller.

After filling is completed the modified Procter density shall be 92% with OMC.

Before start of work the contractor shall supply the samples of murrum from each quarry to cover the variations expected in the supply. The samples shall be tested for the following in a recognized laboratory in accordance with IS:2720 for the following.

Silt and clay content.Moisture-content and dry density relationship at modified Procter density.

Moisture Control: Water shall be always sprayed and not poured. Ponding shall never be allowed. In wet weather the work may have to be suspended. Care shall be taken to see that moisture is uniformly spread throughout the layer and where necessary mixing with harrows and rakes shall be done.

Measurements:


Measurements shall be of the cubic contents of the completed filing and shall be determined by taking level of testing ground and after final layer for each type of filing. All dimensions are for compacted thickness.

BRICK MASONRY

SOAKING OF BRICKS:

Bricks required for masonry shall be thoroughly soaked in clean water for at least one hour.

LAYING:

Bricks shall be laid in English bond unless otherwise specified. Half or cut bricks shall not be used except where necessary to complete the bond. Closure in such cases shall be cut to the required size and used near the end of the wall.

The walls shall be taken up truly plumb. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. Vertical joints in alternate course shall come directly one over the other. The thickness of the brick courses shall be kept uniform.

All hold fasts of doors, windows, etc. which are required to be built in walls shall be embedded in cement mortar or in cement concrete as specified in their correct position as the work proceeds.

JOINTS:

Bricks shall so laid that all joints are full of mortar. The thickness of joints shall not exceed one cm for brickwork of any class designation. All face joints shall be raked to a minimum depth of 10mm by a raking tool during the progress of work where the mortar is still green so as to provide proper key for the plaster or pointing to be done. Where plastering or pointing is not required to be done the joints shall be struck flush and finished at the time of laying.

The face of brickwork shall be cleaned on the same day on which brickwork is laid.

CURING:

Brickwork shall be protected from rain by suitable covering when mortar is green. Masonry work shall be kept constantly moist on all faces for a minimum period of seven days by spraying water.

ANTI TERMITE TREATMENT :-


SCOPEThe scope of job is to form a chemically treated soil barrier to prevent growth of nests or colonies of the sub terrainian termites.

MATERIALS :The following chemical (as specified) in water emulsion shall be used :

Chemicals Concentration (by weight) Chloropyrifos 1.0%

PRE-CONSTRUCTION CHEMICAL TREATMENT :

Hand operated pressure pumps shall be used for uniform spraying and proper check shall be maintained to ensure that specified quantity of chemical is used for the required area.

TIME OF APPLICATION

Anti-termite treatment shall start in foundation trenches and pits before laying the leveling course of PCC. The PCC shall be done only after the chemical emulsion has been observed by the soil and surface is quite dry. Treatment should not be carried out when it is raining or the soil is wet. The treated soil barriers shall not be disturbed after they are formed and if by chance, they are disturbed, the same shall be made good before laying the PCC.

PROCEDURE :

Treatment of Column Pits, Wall Trenches and Basement Excavation :-The bottom surface and sides (upto 300mm) shall be treated with chemical at the rate of 5 litres/sq.MThe portion of the column foundations and the retaining walls coming in contact with the backfill, the structure shall be treated at the rate of 15 litres/sq.M of the vertical surface. If water is used for ramming the earth fill then treatment shall be carried out after the ramming operation is completed by spreading the earth at 150mm close to the structure surface and spraying the required quantity of chemical. For RCC framed


structures using 1:2:4 or richer concrete the treatment shall start from a depth of 500 mm below ground level and there is no need to start the treatment from the bottom of excavation for columns and plinth beams. The earth from 500mm below the ground level and above shall be treated as described in previous paragraph. However, for RCC frame structure, there shall be no chemical treatment for column foundations. Treatment of top Surface of Plinth Filling :-The top surface of filled earth within plinth walls shall be treated with chemical emulsion at the rate of 5 litres/sq. M before the sub grade of floor is laid. Holes upto 50-70mm deep at 150mm centres shall be made to facilitate saturation of the soil with chemical emulsion.Treatment of Junction of Wall and Floor :-To achieve continuity of vertical chemical barrier on inner wall surfaces, small channels of 30 x 30mm shall be made at all the junctions before laying the subgrade and rod holes shall be made upto ground level at 150mm centres and chemical emulsion shall be poured at 15 litres/sq. M of the vertical surface.Treatment of soil along external perimeter of Buildings :-After the building is complete, rod holes shall be made along external perimeter at 150 mm centres and 300mm deep and these holes shall be filled with chemical emulsion at 5 litres/running metre of perimeter.

RECORD OF CHEMICAL USED :A detail record of quantity of chemical used for each operation shall be kept at site duly approved by Engg.-in-Charge/Architects.

GUARANTEE The contractor shall give a guarantee of 10 years for effective anti-termite treatment barrier.

MEASUREMENT :The measurement shall be made in square metres on the basis of the plinth area of the building at plinth level only for all operations described above . Nothing extra shall be measured.

REINFORCED CEMENT CONCRETE:

SCOPE:


This specification covers the general requirements for concrete to be used on jobs using on-site production facilities including requirements in regard to the quality, handling, storage of ingredients, proportioning, batching, mixing and testing of concrete and also requirements in regard to the quality, storage, bending and fixingof reinforcement. This also covers the transportation of concrete from the mixer to the place of final deposit and the placing, curing, protecting, repairing and finishing of concrete.

APPLICABLE CODES AND SPECIFICATIONS;

The following specifications, standards and codes are made a part of this specifications. All standards, tentative specifications, specifications, codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions.

In case of discrepancy between this specification and those referred to herein, this specification shall govern.

APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE:

IS 269:- Specification for ordinary, rapid hardening and low heat Portland cement.

IS 8112:- Specification for high strength ordinary, Portland cement.

IS 1489 - Specification for Portland - pozzolona cement.

IS 383:- Specification for coarse and find aggregates from natural source for concrete.

IS 2386:- Methods of test for aggregates for concrete. (Part I to VIII)

IS 516:- Method of test for strength of concrete.

IS 1199:- Method of sampling and analysis of concrete.

IS 3025:- Methods of sampling and test (Physical and chemical) water used in industry.

IS 432:- Specification for mild steel and medium tensile steel (parts I & II) bars and hard drawn steel wire for concrete reinforcement.

IS 1139:- Specification for hot rolled mild steel and medium tensile steel deformed bars for concrete reinforcement.


IS 1566:- Specification for plain hard drawn steel wire fabric (Part I) for concrete reinforcement.

IS 1786:- Specification for cold twisted steel bars for concrete reinforcement.

IS 2645:- Specification for integral cement waterproofing compound.

IS 456:- Code of practice for plain and reinforced concrete.

IS 3370:- Code of practice for concrete structures for storage of liquids (Part I to IV)

IS 2502:- Code of practice for bending and fixing of bars for concrete reinforcement.

IS 2571:- Code of practice for laying in situ cement concrete flooring.

IS 3596:- Safety code for scaffolds and ladders. (Part I & II)

IS 1200:- Method of measurement of building works.

In the event that state, city or other Government bodies have requirements, more stringent than those set forth in this specification, such requirements shall be considered part of this specification and shall supersede this specification where applicable.

The quality of materials , method and control of manufacture and transportation of all concrete works irrespective of the mix , whether reinforced or otherwise, shall conform to the applicable portion of this specification.

Engineer shall have the right to inspect the source/s of material/s , the layout of operations of procurement and storage of materials, the concrete batching and mixing equipment and quality control system. Such an inspection shall be arranged and approval of Engineer-In-Charge shall be obtained prior to starting of concrete work. Concrete shall be mixed by mechanical mixer only and no hand mixing shall be allowed for RCC works.

GENERAL:

The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portions of this specification.


Engineer shall have the right to inspect the source/s of material/s, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and Engineer’s approval obtained, prior to starting of concrete work.

MATERIALS FOR STANDARD CONCRETE:The ingredients to be used in the manufacture of standard concrete shall consist solely of a standard type Portland cement, clean sand, natural coarse aggregate, clean water and admixtures, if specially called for on drawings or specifications.

CEMENT

The use of bulk cement will be permitted only with the approval of Engineer. Changing of brands or type of cement within the same structure will not be permitted.

CONTRACTOR will have to make his own arrangements for the storage of adequate quantity of cement. If supplies are arranged by owner, cement will be issued in quantities to cover work requirements of one month or less, as deemed fit by the engineer and it will be the responsibility of contractor to ensure adequate and proper storage. Cement bags shall be stored in a dry enclosed shed (storage under tarpaulin will not be permitted), well away from the outer walls and insulated from the floor to avoid contact with moisture from ground and so arranged as to provide ready access. Damaged or reclaimed or partly set cement will not be permitted to be used and shall be removed from the site. Not more than 12 bags shall be stacked in any tier. The storage arrangement shall be approved by engineer. Consignment of cement shall be stored as received and shall be consumed in the order of their receipt at site.

Cement held in storage for a period of Ninety (90) days or longer shall be tested. Should at any time Engineer have reasons to consider that any cement is defective, then irrespective of its origin, date of manufacture and/or manufacturer’s test certificate, such cement shall be tested immediately at Contractor’s cost at a national Test such tests are found satisfactory, it shall not be used in any work. Contractor shall not be entitled to any claim of any nature on this account.

CONSISTENCY:The consistency of the concrete shall be such that it flows sluggish into the forms and around the reinforcement without any segregation coarse aggregate from mortar. The slump tests are mandatory and shall be carried out at regular intervals so that the consistency concrete can be monitored.

PLACING OF CONCRETE:


Concreting shall commence only after inspection and written approval by EIC.Shuttering shall be clean and free from deposits of foreign materials and proper deshuttering agent shall be applied to the surface.Proper arrangements shall be provided for conveying the concrete the place of deposition without disturbing the reinforcement.

COMPACTION:Concrete shall be compacted immediately after placing by means of mechanical vibrators.All RCC works shall be cured for a minimum period of 14 days or more as advised by EIC.

INSPECTION AND RECTIFICATION OF DEFECTS:

Immediately on removal of forms, the RCC works shall be examined by the Engg. -in-Charge / Architects before any defects are made good.The work that has sagged or contains honey combing to an extent detrimental to the structural safety or architectural concept shall be rejected.Surface defects on a minor nature may be accepted and the same shall be rectified as follows :a) Bulges due to movement of forms, ridges at forms, ridges at form

joints shall be carefully chipped and then rubbed with a grinding stone.

b) Honeycombed and other defective areas must be chipped out, the edges being out as straight as possible and perpendicular to the surface. Shallow patches are first treated with a coat of thin grout (1 cement : 1 sand) and then filled with mortar similar to that used in concrete. Large and deep patches shall be filled up with concrete held in place by forms and shall be reinforced.

c) Holes left by bolts shall be filled carefully with mortar. Holes extending right through the concrete shall be filled with mortar with a pressure gun.

d) The same amount of care to cure the material in patches should be taken as with the whole structure.

POST TREATMENT OF SURFACE :


The surface which has to receive plaster or where it has to be joined with brick masonry walls shall be properly roughened immediately after the shuttering is removed.ACCEPTANCE CRITERIA OF CONCRETE WORK :Minimum of six sample cubes shall be taken for all concreting work (periodicity as specified in 9.6 of section III) and three cubes shall be tested after 7 days curing and balance after 28 days curing.7 Days Test :The average strength of the three specimens shall be accepted as the compressive strength of the concrete provided that the difference between maximum and minimum strength of the three cubes does not exceed 15% of average strengthIn case the 7 days strength is not satisfactory all further work structurally interlinked with the concrete represented by the samples shall be stopped till the remaining three cubes are tested for 28 days strength and are found satisfactory.

28 Days Test :The tests should generally be carried out on 28th day, but in no case, should be delayed beyond 35 days. The strength of the cubes shall be as specified in table above if they are tested on the 28th day. In case, the cubes are tested after 28 days, the minimum acceptable compressive strength shall be increased by 1.5 kg/cm2 for each day beyond 28th day.

The acceptance criteria of 28 days test shall be as follows ;a) If the average compressive strength of three cubes is more or equal

to the comp. Strength shown in table above, the concrete shall be accepted at full rates.

b) If the average comp. Strength of the three cubes is less than specified but not less than 75% of the specified strength, the concrete shall be accepted at reduced rates at the discretion of EIC. The reduced rate shall be calculated on proportionate basis, i.e. for every percent decrease in the specified strength the rate shall be reduced by the same percentage.

c) If the average compressive strength of the three cubes is less than 75% of the specified strength, EIC shall either reject the defective portion or get it dismantled along with the structurally connected


work as considered necessary at the risk and cost of the contractor. EIC may also desire to carry out additional tests on the defective work and if on the basis of these additional tests, EIC is satisfied about the structural adequacy of the concrete the concrete work may be accepted at the reduced rate as specified in b) above except, for the reduced strength below 75% for which the reduction shall be 1.5 times for every percent decrease below 75%

Example : Average compressive strength is 70% of specified strength. The rate payable shall be 75 - 1 5 (75-70) = 67.5% of tendered rate.MEASUREMENT All measurements shall be as per IS 1200

PLASTERING

PREPARATION OF SURFACE:

The following surface preparation shall be made for both single and double coat plasters. The surface shall then be thoroughly washed with water, cleaned and kept wet before plastering is commenced.

In case of concrete the surface shall be chipped by chiseling and wire brushing, cleaning the surface and erecting scaffolding it required.

CEMENT PLASTER (SINGLE COAT)

APPLICATION:

Plastering shall be started from the top and worked down towards the floor. All holes shall be properly filled in advance of the plastering as the scaffolding is being taken down. To ensure even thickness and a true surface, plaster of about 15 x 15cm shall be first applied horizontally and vertically, at 3 metres intervals over the entire surface to serve as gauges. The surfaces of these gauged areas shall be truly in the plane of the finished plaster surface. The mortar shall then be laid on the wall, between the gauges with trowel. The mortar shall be applied in a uniform manner slightly more than the specified thickness and brought to true surface by working a wooden straight edge reaching across the gauges with small upward and sideways movements at a time.

All corners, arises, angles and junctions shall be truly vertical or horizontal as the case may be and shall be carefully finished. Rounding or chamfering corners, arises, junctions, etc. where required shall be done without any extra payment. Such rounding or chamfering shall be carried out with proper templates to the sizes required.


Horizontal joints in plaster shall not occur on parapet tops and copings as these invariably lead to leakages. Good quality lime neroo shall be applied to plastered surface with steel trowel to a thickness slightly more than specified and rubbed down to give overall thickness of 12mm and polished to a perfectly smooth and even finish working from top to bottom.

Curing shall be commenced as soon as the plaster has hardened sufficiently. This shall be done by spraying water at regular intervals.

CEMENT PLASTER (TWO COAT WORK):

The plaster shall be applied in two coats as detailed below:

- Apply 12mm thick coat of CM 1:4 mixed with CICO / ACCO Proof water proofing compound mixed as per manufacturer’s specifications as 1st

cost leaving the surface rough.

When the plaster has been brought to true surface with a wooden straight edge the surface shall be left rough with 2mm deep furrows shall be made with a scratching tool to form key for the finishing coat. The surface shall be kept wet till the finishing coat is applied.

Apply 2nd coat of 8mm thick of CM 1:3 and finishing the surface by rubbing with sponge till uniform texture is obtained.

The finishing coat shall be applied after the undercoat has sufficiently set but not dried and in any case within 48 hours of laying the first coat.

Water Proofing All water proofing works to be carried out in this scope of work shall be through the following approved agencies / any other reputed approved local agency: -For Cement Based Water Proofing:

(i) Indian water Proofing Company.(ii) Leak proof - Waterproofing Corporation of India.(iii) Nina Industries.(iv) Hindustan Waterproofing.(v) Overseas Waterproofing.

Contractor will be required to submit a guarantee in respect of performance of waterproofing for 10 years on stamp-paper. In addition to this, an amount equal to 10% of cost of waterproofing items shall be retained as retention money for 2 years from the date of completion, which shall be returned only after successful completion of this period.


CEMENT PAINTING

All outside exposed surfaces of masonry and concrete shall be painted with cement paint of approved make and shade .The surface shall be thoroughly cleaned & wetted with water just before the painting commence.Cement paint shall be mixed with water as per the specification of manufacturer. Cement paint which can be used within an hour of its mixing shall be prepared

MARBLE MOSAIC TILE FLOORING :SCOPE :This covers the laying and finishing of cement concrete flooring tiles in floors, wall, staircases, etc.MATERIALS :Cement, sand, terrazzo tiles shall conform to the specifications detailed in the Materials Section.Mixing of mortar shall be done in accordance with the specification laid down under “Cement Mortars”.LAYING :Subgrade concrete or the RCC slab on which tiles are to be laid shall be cleaned, wetted and mopped. The bedding of the tiles shall be either with lime mortar 1:3 (1 lime putty : 3 sand) or cement mortar 1:3 or as specified. The average thickness of mortar shall be 30mm and thickness at any place shall not be less than 10mm.Lime mortar bedding shall be spread, tamped and corrected to proper levels and allowed to harden for a day before the tiles are laid.Over this bedding, neat grey cement slurry of honey like consistency shall be spread at the rate of 4.4 kg/sq.mt over such an area that would accommodate 20 tiles.Before laying, the tiles shall be soaked in water for at least 20 minutes and then allowed to dry for about 10 minutes. It is necessary to have tiles damp but not wet when they are laid. Tiles shall be fixed by gently tapping with a wooden mallet till they are properly bedded and in level with the adjoining tile. The joints shall be kept as thin as possible not exceeding 1.5 mm. Where full-size tiles cannot be fixed, tiles shall be cut to the required size and their edges rubbed to ensure a straight and true joint. Tiles which are fixed in the floor adjoining the wall shall enter not less than 12mm under the plaster, skirting or dado. After the tiles have


been laid, excess cement coming out through the joints upto the surface shall be immediately wiped clean.

CURING, POLISHING AND FINISHING :The day after the tiles are laid all joints shall be cleaned of the grey cement with a wire brush. The joints shall after 24 hours be filled with matching cement paste and allowed to set. The same cement slurry shall be applied to the entire surface of the tiles in a thin coat with a view to protect the surface from abrasive damage and fill the pin holes that may exist on the surface.

The floor shall then be kept wet and protected for a minimum period of seven days before starting the polishing. No one shall be allowed to walk on the floor during the first 24 hours immediately after the tiles are laid.

The surface shall thereafter be grounded evenly with machine fitted coarse grade grit block. Water shall be used profusely during grinding. It shall then be covered with a thin coat of cement mixed with colouring pigment to match the topping of the wearing surface of the tile sand second grinding shall then be carried out with machine fitted with fine grade grit blocks.

The final grinding with machine fitted with the finest grade grit blocks shall be carried out after 24 hours of completion of second grinding or before handing over the floor. The entire surface shall be finally washed with weak solution of soft soap in warm water.For small areas or where circumstances so require, hand polishing may be permitted as in the case of skirting, treads and risers of staircase, etc. by the Engg.-in-charge / Architects.

MEASUREMENT :Length and breadth dimensions shall be measured to the correct centimetre before laying skirting, dado or wall plaster and area calculated in square metres correct to two decimal places. No deduction shall be made nor extra amount paid for any opening in the floor area upto 0.5 sq.mt. No extra shall be paid for use of cut tiles nor for laying the tiles at different levels in the same room.


TILES IN SKIRTING PREPARATION OF SURFACE :The joints of masonry shall be raked out to a depth of at least 15mm. In case of concrete and plastered surfaces, the surface shall be roughened by hacking. All the surfaces receiving tiles shall be cleaned thoroughly, washed with water and kept wet before the tiling is commenced.

LAYING :12mm thick plaster of CM 1:3 or mixed as specified shall be applied and allowed to harden. The plaster shall be roughened with wire brushes making grooves of at least 2mm deep before the plaster dries. The tiles shall be soaked in water. The tiles shall be buttered with a coat of grey cement slurry and then shall tamped in position corrected to proper planes and lines with a wooden mallet. The tiles shall be set in required pattern and butt jointed with very fine joints. Top of skirting or dado shall be truly horizontal and joints truly vertical unless specified otherwise. The skirting or dado shall rest on the top of flooring. The projection of skirting from the finished wall surface shall not be more than 12mm.

POINTING AND FINISHINGJoints shall be cleaned off grey cement grout with wire brush or trowel to the depth of 2 to 3mm and all dust and loose mortar removed. Joints shall then be flush pointed with white cement added with colouring pigment if required to match the colour of the tiles. The wall shall be kept wet at least for seven days. The finished wall shall not sound hollow when tapped with a wooden mallet.

MEASUREMENTS :Length shall be measured correct to a cm. Height shall be measured correct to a cm in case of dado and 5mm in case of riser and skirting. The area shall be calculated in square metres correct to two decimal places. Length and height shall be measured along the finished face of the skirting or dado including curves where specials such as coves, internal and external angles and beads are used.

PLASTIC EMULSION PAINT :


MATERIAL :The plastic emulsion paint shall be of approved brand and manufacturer and of the required shade.APPLICATIONThe number of coats shall be as specified. The paint shall be applied with brushes or rollers. The thinning of the emulsion is to be done with water only and not turpentine. The quantity of water to be added shall be as specified by the manufacturer. The surface finish shall be flat, velvety and smooth.PRECAUTIONS :Old brushes shall not be used. Oil based Putties for filling in cracks, depressions, etc. shall not be used. Splashes if any, shall be cleaned immediately as they will be difficult to remove afterwards. Washing of the surface shall not be done within 3 to 4 week of application.Other details shall be as Detailed in Oil Bound Distemper.

ELECTRICAL INSTALLATION

Electrical installation shall be as per IS 732-1989 and IE rules.

Internal and external wiring in buildings shall be carried out in concealed PVC conduit of minimum 2 mm thickness. These PVC conduits shall be laid before canting concrete or by making chases in the brick wall and making good the wall after fixing of conduits at no extra cost.

Wiring for power and light/fan circuits shall be separate. Entire wiring shall be done by flexible PVC insulated copper conductors of specified (in the job schedule)size.

Point Wiring:

The following components are deemed to be included in point wiring.

1. Metal switch board2. Control switches 5A/15A as specified.3. PVC Channels with cover.4. Copper conductors for neutral/live earthing.5. Ceiling Roses6. All accessories required for termination.

The above components shall meet the following specific requirements.

1) Switch BoxesBody : 16 SWG CRCA sheet. Flush typeSize : Sufficient to accommodate required no.of switches.


2) Control SwitchesFans : 5 Amps SP SwitchLigths : 5 Amps SP SwitchPower Plug : 15 Amps 3 Pin Plug combined SS type.

ERECTION AND EARTHING:

The conduit of each circuit or section shall be completed before conductors are drawn in. The entire system of conduit after erection shall be tested for mechanical and electrical continuity throughout and permanently connected to the earthing conforming to the requirements by means of special approved type of earthing clamps efficiently fastened to conduit pipe in the workmanlike manner for a perfect continuity between earth wire and conduit. Gas or water pipe shall not be used as earth medium. If conduit pipes are liable to mechanical damage they shall be adequately protected. In a conduit system the pipe must be continuous when passing through walls or floors.

An insulated copper earthing wire of green colour having cross sectional area of 2.5 sq.mm. Shall be drawn in the conduit pipes alongwith the circuit wires for earthing of light fittings and pins of socket outlets.

JOIN AND LOOPING PACK:

Phase or live conductors shall be looped at the switch box and natural conductor can be looped either from the switch box or from the light fan or socket outlet.

In both systems of wiring, no bare or twist joints shall be made at intermediate points in the through run of cables, unless the length of final sui-circuit or sub-main is more than the length of the standard coil, as given by the manufacturer of the cable.

Wiring Termination:

All terminations must be mechanically and electrically sound. There should be maximum surface contact between the terminal and conductor and such contacts shall be tight since loose contact results in high resistance and over heating at the point. In case of securing a resistance conductor at a ordinary screw termination, it is preferable to loop the conductor in a clockwise direction as tightening the screw tends to close the loop rather than open it. At a pillar type terminal, the single conductor shall be bent back into itself and if two or more conductors are to be terminated, they shall be twisted together before inserting into terminals.

Identification of Wires:

The phase conductors shall be of any of the RYB colours and the neutral conductor shall be of black colour. Further the phase conductors in one line shall be of only one colour i.e. either red blue or yellow. Earthing conductor shall be green.

Testing and commissioning:


After completion of installation, tests shall be carried out and test results shall be tabulated. Following are the tests to be carried out and test certificates shall be handed over to the Engineer-in-charge for records.

Lighting Distribution Boards:

a) Insulation test between phases, phases and neutral, phase and earth with 500 V meggar.

b) Operational Test

Safety Earthing:

a) All earthing circuits shall be checked for continuity. The earth resistance of all identifiable electrical equipment shall be measured and recorded.

TECHNICAL SPECIFICATIONS - ELECTRICAL SYSTEM

1. SCOPE OF WORK

The scope of work covered by this specification shall include supply and installation of all electrical equipment and materials including testing and commissioning.

Any equipment, device and component of work not specifically mentioned in this specification but considered essential for proper design and operation shall be included by the tenderer in his offer.

The successful tenderer shall carryout the installation as per the arrangement and details shown in the construction drawings, standards and instructions given by the Engineer.

Any variation or changes to be carried out at site shall be done with the approval of the Engineer.


The scope of work shall include, but not to be limited to the supply, storing, installation, testing and commissioning of the following :

i. Electricity Board meeting arrangement to receive incoming supply, LT switch board as per specifications and drawings. LT cabling between switch boards.

ii. Motor Control Centre for Pumps / compressors.iii. Miniature Circuit Breaker Distribution Boards for lighting

distribution boards and power distribution boards, miniature breakers and earth leakage circuit breaker.

iv. 1.1 K. grade aluminum copper conductor, PVC insulated / FRLS PVC insulated and sheathed armoured / unarmoured power / control cables and cable termination accessories like glands, lugs, ferrules etc.

v. Luminaries and Lamps, Ceiling fans, Exhaust fans.vi. Switch socket boxes, junction boxes and draw boxes.vii. Switches sockets and accessories.viii. 1100 grade copper conductor, PVC insulated / FRLS PVS

insulated multi stranded wires of various colours.ix. Wiring materials and accessories.x. Earth electrode stations and earthing conductors.xi. Building Electrification, Canopy lighting, External lighting, Low

level garden lighting, power connections to all facility sign boards, compressors, dispensing pumps.

xii. Street light poles and accessories.xiii. Cable laying in trenches and backfilling for underground

cables.xiv. Miscellaneous works other than the above as stipulated in

specification and BOQ.xv. Laisoning with Electricity Board / Telephones Department to

avail power supply / Telephone connection unto the meter board / Telephone tag block. The cabling work for electrical system for availing incoming power is given as an optional item, which may be required to be executed on behalf of electricity board.

xvi. All other installation materials, hardware and consumables. xvii. All tools, tackle, ladders etc. and the contractor shall but all

testing and measuring instruments as required.xvii. Storing of material at site and watch & ward of it till handing over.

The design shall include all reasonable precautions and provisions for the safety of operation and maintenance personnel. All equipment to be supplied shall be subject to inspection by the owner/consultants. Such inspection shall however not relieve the contractor of his obligations under the contract.


The Engineer reserves the right to specify electrical materials and equipment of a particular make for the purpose of standardization and the tenderer shall agree to supply the materials of the make specified, if so required. The contractor shall be responsible for timely delivery of material at site, transport to the place of installation, storing, installation, testing and commissioning of all the equipment and the materials that are included in the scope of work. The electrical contractor executing this work shall have a valid license issued by the State Government for carrying out installation work of the voltage class involved under the direct supervision of a person holding a certificate of competence for the same voltage classes, issued of recognized by the State Government. The tenderer shall furnish with this tender the particulars of the license for carrying out the installation work against this specification. All necessary safe holding for working at various heights shall be the responsibility of the Contractor. The contractor shall be responsible for compensation in case of any accident to his workmen at site. The contractor shall fulfill and bear all statutory charges for their workmen. The tenderer shall indemnify owner/consultant of any such charges for workmen compensation. The contractor shall supply all necessary hardware and consumable required for the entire installation. ELECTRICITY SUPPLY PARTICULARS All equipment and installation covered under the scope of work shall be designed for electricity supply of the following specification : Voltage : 415V/240V -6% No. of phases : 3/1 Type of system : 3 phase, 4 wire Frequency : 50Hz + 3% Type of neutral earthing : Solidly earthed Short circuit level : Not exceeding 35 KA at 415V DRAWING The drawings enclosed with this specification are only for the guidance of the tenderer. The exact routing of conduits, cables and wires and the exact location of the equipment shall be as per construction drawings or as decided at site by the Engineer. (Any field corrections shall be shown in five (5) copies of each drawing and such as - built drawings shall be


handed over to the owner by the contractor after completion of the installation. The drawings and other documents to be submitted by the tenderer shall be in the English language and all the dimensions, weights and quantities shall be in the metric units. The contractor shall submit for the approval of the owner / consultant, drawings of switch boards/tailor made equipment etc., as required in four (4) sets before commencing the manufacture and /or supply. The equipment shall submit four sets (4) of 'as built certified drawings' after complete fabrication of the equipment. LOCAL CONDITIONS The tenderer shall visit the site, ascertain the local conditions, entry, traffic restrictions, and obstructions if any and also site conditions. Whether the tenderer visits the site or not, he is deemed to have visited the site and ascertained all the site conditions. The tenderer shall allow in his tender for an extras likely to be incurred due to site conditions. No claim will be allowed on this account under any circumstances. STANDARDS The equipment and the installation work shall generally conform to the requirements of the Indian Electricity Rules with its latest amendments and all relevant standards and code of practice of the Bureau of India Standards. However, the decision of site engineer shall be final with respect to requirements. SAFETY The tenderer shall include and take adequate precautions as per the Indian Standard codes to ensure safety for personnel and prevention of accidents at site. The tenderer shall be responsible for compensation to their workmen due to accident, if any. STATUTORY REQUIREMENTS The contractor shall obtain the approval of the State Electricity Board and Electrical Inspectorate and carryout charges as called for by the Electrical Inspector at no extra cost to the owner. He shall also obtain the drawing approvals and final safety certificate from CEIG. Only the statutory fees payable to Electricity authority shall be reimbursed by the owner on production of valid vouchers.


INSPECTION All the materials to be supplied shall be subject to inspection by the employer/consultant. Such inspection shall not however relieve the contractor of his obligations under the contract. Samples of all items materials, hardware, etc., to be used to the work shall be got approved by the Engineer-in-Charge / Consultant in advance. The brand/makes and grades of items/materials shall be as directed by the employer/consultant. TIME SCHEDULE The tenderer shall be responsible for timely procurement and delivery of the items, off-loading at site, safekeeping at site, transport to the place of installation, installation and testing of all the material that are included in his scope of work. Work shall be progressed and completed as per schedule mutually agreed upon. CO-OPERATION The contractor shall coordinate his work with those of the other agencies at the site and shall avoid any interference and interruption with the progress of the work. The contractor shall be required to carryout the installation side by side with other agencies as may be required by the other contractor from time to time. QUANTITIES The Quantities indicated in the Bill of quantities is for the guidance of the tenderer. The contractor shall supply the items based on the requirements as per Construction drawings only. 2. TECHNICAL SPECIFICATION FOR LOW VOLTAGE (415V) SWITCH GEAR / BOARD GENERAL This specification covers the Design, Manufacture, Fabrication, Testing at factory and supply, installation, testing and commissioning of 415V Switch gear incorporating MCCBS/Fuse Switches/Contactors / relays etc. The switch board and the mounted equipment shall comply with the latest edition of the following Indian Standards " IS: 4237 : General requirement for switch gear and control gear for voltage not


exceeding 1000 V.

IS: 4047 : Heavy duty air break switches and fuses for voltages not exceed 1000 V

IS: 3072 : Code of practice for installation and maintenance of switchgear.

IS: 2208 : HRC CARTRIDGE FUSE LINKS - Up to 650 V

IS: 2705 : Current Transformers. Parts I, II, III

IS: 3156 : Voltage transformers

IS: 1248 : Electrical indicating instruments

IS:375 : Marking and arrangement for switch gear bus bars, main connections and

auxiliary wiring

IS: 5 : Painting

IS:8623 : Specifications for factory built assemblies of Switch gear and control gear for voltage up to and including 1000 V AC & 1200 V DC

GENERAL REQUIREMENTS:

FABRICATION AND GENERAL DETAILS :

Switch gear shall be indoor, floor mounting, free standing type enclosed in sheet steel cubicles and shall be dust, weather and vermin proof. Enclosures shall conform to IP-54 and shall be cold rolled sheet steel. Gaskets shall be used between all adjacent units and underneath all covers to render the joints effectively dust proof. Steel sheets shall not be less than 2.00 mm (14 S.W.G.) in thickness. Switch gear should be of single front type design.

Switch gear shall be extensible at both ends by the addition of vertical sections. Ends of the bus bars shall be suitably drilled for this purpose.

The switch board shall be totally enclosed, dust, weather and vermin proof. If necessary, openings for natural ventilation shall be provided. Gaskets of durable materials shall be provided for doors and other openings. Switch Boards specified for outdoor installation shall be housed in outdoor type kiosks to make it weatherproof. The switchboards shall be suitable for the ambient and site conditions


specified. Suitable hooks shall be provided for lifting the boards. These hooks when removed shall not leave any openings in the boards.

Access from the back shall be limited to bus bars and cables only for 415 V main switch board and DG panels. For all other panels, all equipment shall be mounted on the front side and shall be accessible from the from through hinged doors. Switches, ammeters, voltmeters and lamps etc. shall preferably be mounted on fixed portions.

Individual switch fuse units, MCCBs bus bar and cable entrance alleys shall be housed in separate enclosed compartments separated from each other by metallic or any other fire resistant insulating material barriers.

Barriers and automatic safety shutters shall be provided such that bus bars and other live parts are inaccessible even with breakers completely drawn out. Opening of bus bar chambers shall be possible with special tools only.

PAINTING

All metal surfaces shall be thoroughly cleaned and decreased to remove mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then cleaned to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking the finishing cost.

After preparation of the under-surface, the switch board shall be painted by powder coating method of final paint. Colour shade of final paint shall be approved by the purchaser before final painting is started. The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc. The vendor shall furnish painting procedure details alongwith the bids.

All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust corrosion. If these parts are moving elements then they shall be greased. Suitable lifting lugs shall be provided for switchboard. These lifting lugs shall not leave any opening when removed.

SWITCH BOARD COMPONENTS:

INSTRUMENT TRANSFORMERS:

Current and voltage transformers shall be cast resin insulated type, primary and secondary terminals shall be marked indelibly.


Current transformers shall generally conform to BIS:2705. They shall be mounted on the stationary part. The CT ratio and ratings shall be as indicated on the single line diagrams. For general guidance, the vendor shall note that the protective current transformers shall have an accuracy class "5P" and an accuracy limit factor greater than "10". Low reactance CTs shall be used for protection.

Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor less than 5.0. The current transformers shall be capable of withstanding the peak momentary short circuit current for 1.0 second. The neutral side of the current transformers shall normally be earthed through a link.

Wherever provided, the voltage transformers shall generally conform to BIS 3156. The voltage transformers shall be provided with primary fuses. Preferably miniature circuit breakers with auxiliary contacts shall be provided on the secondary side.

The voltage transformers shall have an accuracy class 3.0 from 50% to 110% of normal voltage and class 1.0 from 80% to 120% of normal voltage with burdens varying between 25% to 100% of the rated value at 0.8 PF lagging.

The primary of the voltage transformers shall be rated for 415 volts and the secondary for 110 volts. Unless otherwise stated, 2 single phase V-connected VTs shall be used.

MEASURING INSTRUMENTS :

AMMETERS

Ammeters shall be moving iron or moving coil type. The moving part assembly shall be with jewel bearing. The jewel bearing shall be mounted on a spring to prevent damage to pivot due to vibrations and shocks. The ammeters shall be manufactured and calibrated as per the latest edition of IS:1248. The ammeters shall be instrument transformer operated and shall be suitable for 5A secondary of instrument transformer. The scales shall be calibrated to indicate primary current unless otherwise specified. The ammeters shall be capable of carrying sustained overloads during fault conditions without damage or loss of accuracy.

VOLTMETERS

Voltmeters shall be of moving iron or moving coil type. The range for 415V, 3 phase voltmeters shall be 0 to 500V. Suitable selector switch shall be provided for each voltmeter to read voltage between any two


lines of the system. The voltmeter shall be provided with protection fuse of suitable capacity.

SWITCH AND FUSE UNITS :

The load break switches shall be heavy duty air break type and shall have quick make/break manual operating mechanism. The operating handle shall be mounted in the door of the compartment having the isolator. It shall be possible to padlock the switches in the ON & OFF position. Door interlock shall be provided so that it should not be possible to open the door with the switch in the "closed" position. Normal it shall not be possible to close the switches with the door open but for testing purposes it shall be possible to defeat this interlock. Switches shall be able to carry full load current continuously without overheating. Barriers shall be provided to prevent inter-phase arcing. The live terminals shall be shrouded to avoid accidental contact. Motor feeder switches shall be adequately rated for motor duty.

Fuses shall be HRC cartridge link types. Diazed fuses will not be acceptable.

The fuses shall be non-deteriorating type and shall have an operation indicator, which will be visible without removal of fuses from service. Fuses shall be pressure fitted type and shall have ribs on the contact blades to ensure good line contact. It must be possible to handle fuses during off-load conditions although full voltage may be available on the terminals. Fuse-pullers shall be provided.

MOULDED CASE CIRCUIT BREAKERS (MCCBs)

General

MCCBs shall be four-poles, triple poles or double poles, independent manual closing air break type. They shall be totally enclosed in a moulded casing formed from an insulating material. The construction of the casing shall be capable of withstanding the appropriate rated short circuit current and reasonably rough use without fracture or distortion. The moulded casing shall have protection not less than IP56.

MCCBs shall comply with and be type tested to IEC157-1, 157-1A, 157-1B.

All MCCBs to be used for serving pump motors, fan motors, and other motor equipment shall be of motor type and shall be capable of handling the starting currents.

All MCCBs shall be completed with dust-proof metal enclosures with all the live terminals totally enclosed.


Operation Characteristic

MCCBs shall have a thermal-magnetic tripping mechanism giving an adjustable, stable, inverse time-current characteristic. The operating characteristic shall be such that :

The time delay on overload tripping shall be inversely proportional to the over currents unto a threshold value of approximately 7 times the rated current.

There shall be no intentional time-delay on over current tripping due to short-circuit or heavy over currents exceeding the threshold value.

The overload trip setting can be adjusted on site from 60% to 100% of breaker rated current in 10% steps.

Performance Characteristic

MCCBs shall be certified, in accordance with IEC Standards and shall have the following performance characteristics :

Rated short circuit breaking capacity - not less than 25 KA for lateral sub -main installation or the prospective fault current at the point of installation whichever is greater. Short circuit current withstanding duration shall not be less than 1 second.

Shunt Trip Release

This shall operate correctly at all values of supply voltage between 70% and 120% of the nominal supply voltage under all operating conditions of the MCCB. MCCBs incorporating shunt release shall be provided with block terminals and shunt release lead cables.

All the MCCB should have front drive kits

CONTROL SWITCHES:

All control switches shall be rotary, back connected type, having a cam operated contact mechanism. Preferably phosphor bronze contacts shall be used on the control switches. They shall have pistol grip handles. Number of ways, locking system etc. shall be as stated on these switches. Ammeter selector switches shall have make generally have 4 positions for reading 3 phase currents and the neutral current. The voltmeter selector switch has to also have 4 positions. Three shall be used to measure phase to phase voltage and fourth shall be OFF position.


Remote/Trip/Off selector switch for the motor feeders shall be lockable in OFF position.

PUSH BUTTONS :

Push button colours shall be as follows :

Stop/Open/emergency - RedStart/Close - Green

INDICATING LAMPS :

Indicating lamps shall be provided with translucent covers to diffuse light, with series resistors.

PROTECTIVE RELAYS :

Wherever used, all protective relays shall be back connected, draw out type, suitable for flush mounting and fitted with dust tight covers. Alternatively, plug-in type of relays shall also be acceptable. The relay cases shall have provision for insulation of test plug at the front for "testing and calibration" using an external power supply without disconnecting the permanent wiring. It shall be possible to short the CTs through the test plugs.

AUXILIARY RELAYS/CONTACTORS :

Auxiliary relays/contactors shall generally be used for interlocking and multiplying contacts. Auxiliary contacts shall be capable of carrying the maximum estimated current. In any case, their rating must not be less than 5A for 240V AC. at a power factor between 0.3 to 0.1 and 1.5A for 24V DC (inductive load). Vendors shall note that lower voltage contactors with a series resistance will not be acceptable for 220V DC control supply.

TRIPPING RELAYS :

All tripping relays shall be lockout with hand reset contacts and shall be suitable to operate off the specified DC voltage. These relays shall have self coil-cut-off contacts and shall be provided with hand reset operation indicators. Tripping relays will be acceptable in non-draw out cases. The number of contacts shall be as shown in the schematic drawings.

INSPECTION & TESTING:

The panels shall be completely assembled, wired and tested as per IS-8623-1977 at the factory in the presence of purchaser's engineer or his authorised person.


The test shall include wiring continuity tests, insulation resistance tests, high voltage tests (2.5 KV AC for 1 min.) and functional tests to ensure operation of control scheme and individual equipment.

Manufacturer's test certificates in respect of all meters, switchgears, contactors etc. prior to inspection of Panels shall be produced to the Purchaser's engineer at vendor's works.

DRAWING & INSTRUCTION MANUALS :

Along the offer, the contractor shall submit the following documents:

General arrangements drawings of Panels (includes switch board) showing the various constructional features etc.Single line diagram.Technical leaflets for MCCB, fuse switches, lamps meters etc.Foundation plan including weight.Type test reports as per IS8623-1977 Clause 8.2.1 & 8.2.3.

After award of the contract, the manufacturer shall submit the following documents in for approval.

General arrangement drawing of Panels showing various views and foundation drawings.Arrangement of compartments.Single line diagram.Complete technical particulars of all equipment.Commissioning and maintenance instruction for all equipment.Set of re-producible for all the above drawings.

Before manufacturer of the Panels, the supplier shall have to take the approval for the design and drawings in writing. Any manufacturing done prior to approval of drawing shall be rectified in accordance with the approved drawings by the supplier at his own cost and the equipment shall be supplied within the stipulated period. Time schedule for drawing documents shall be enclosed separately.

PACKING AND TRANSPORTS :

The switch board shall be shipped to site packed in wooden crates. They shall be wrapped in polyethylene sheets before being placed in crates to prevent damage to the finish. Crates shall have skid bottoms for handling.

GUARANTEE :


The switch board shall be guaranteed for trouble free operation for a period of 12 months from the date of commissioning or 18 months from the date of arrival at site whichever is earlier. Any defects discovered during this period shall be rectified free of charge.

3.0 TECHNICAL SPECIFICATION FOR POWER & LIGHTING DISTRIBUTION BOARDS.

GENERAL

This specification covers the design, manufacture, assembly, testing at works and supply and installation of power and lighting distribution Boards, complete with all accessories for efficient and trouble-free operation.

The distribution boards shall be fabricated out of 1.6 mm thick sheet steel (RCA) and shall be totally enclosed, dust and vermin proof, dead front, with hinged door type of bolted/welded construction suitable for wall mounting.

Each dB shall have individual hinged/bolted gasket doors with a suitable locking device and shall be suitable for dusty atmospheric conditions. 3 mm thick removable gland plates shall be provided in the top and bottom of the distribution boards for cable entry.

Protective insulated cover plate shall be provided inside the panel to shroud all the live parts. Only the operating knobs of the miniature circuit breakers / ELEC. shall be projecting outside the cover plate. The incoming/outgoing ELCB/MCB terminals shall be suitably shrouded to avoid accidental contact. Each phase or way shall also be suitably shrouded with hylam plates.

The incoming and outgoing terminals shall be suitable for terminating cables as per the specific requirements.

BUSBARS

The busbars shall be air insulated and made of high conductivity, electrolytic grade copper liberally sized with high safety factor for the required rating (both short circuit and continuous current). The busbar shall be sized for the full rating of the incomer. The neutral busbar shall have adequate number of terminals for all outgoing single phase circuits. A copper earth bus of size 25x3 mm shall be provided in each DB for earthing of the power / lighting circuit and earthing of DB. The neutral busbar shall be seized equal to the phase busbar.

MINIATURE CIRCUIT BREAKERS


The Miniature Circuit Breakers (MCBs) shall be heat resistant, molded type designed, manufactured and tested as per IS8828. The MCBs shall have inverse-time tripping characteristic against over loads and instantaneous trip against short circuit. The MCBs shall be clip on type to the DIN Channel. The ON and OFF positions shall be clearly marked. The MCBs shall be suitable for operating in ambient temperature without derating. The incoming and outgoing of the MCBs shall be accessible only after opening the front door of the DB. The MCBs shall be suitable for 415 V, 3 phase, 4 wire, 50 Hz system with the fault level of 10 kA RMS symmetrical. The terminals of MCBs shall be suitable for use with eye lugs. The 4 pole, 3 pole and 2 pole MCB knobs shall be trucked with adequately strengthened tandem pin.

EARTH LEAKAGE CIRCUIT BREAKERS

Incoming of the lighting and power DB shall be provided with current operated Earth leakage circuit breakers with a sensitivity of 30mA or as specified in the drawings. The ELCB shall have Trip free mechanism and shall operate even on neutral failure.

The ELCB shall be provided with a Test Button to simulate leakage and to test the ELCB. The ELCB shall operate and switch off the circuit within 30 milli seconds in case of a fault.

The enclosures of the ELCB shall be molded from high quality insulating materials, which shall be fire retardant, anti-tracking, non-hygroscopic, impact resistant and shall withstand high temperature.

GROUNDING

The DBs shall be provided with two nos. brass earthing stud terminals with suitable nuts, washers etc. for connection to earth bus outside the DB.

PAINTING

The steel surface shall be chemically cleaned to remove scale etc. rinsed, dried and shall be finished with Epoxy paint. The shade shall be as per the specific requirement sheets.

TESTING & INSPECTION

All routine and acceptance tests as per the relevant IS shall be carried out in presence of the purchaser or his representative.

PACKING


All the equipment covered under this specification shall be packed properly in order to avoid damages during transit and during storage at site.

DRAWING & INSTRUCTION MANUALS :

Along the offer, the contractor shall submit the following documents:

General arrangements drawings of DBs showing the various constructional features etc.Single line diagram.Technical leaflets for MCB, ELCB etc.Type test reports as per IS.

After award of the contract, the manufacturer shall submit the following documents for approval.

General arrangements drawing of DBs showing various views and mounting details.Arrangement of compartments.Single line diagram.Complete technical particulars of all equipment.Commissioning and maintenance instruction for all equipment.Set of re-producible for all the above drawings.

Before manufacturer of the DBs, the supplier shall have to take the approval for the design and drawings in writing. Any manufacturing done prior to approval of drawing shall be rectified in accordance with the approved drawings by the supplier at his own cost and the equipment shall be supplied within the stipulated period. Time schedule for drawing documents shall be enclosed separately.

4. TECHNICAL SPECIFICATIONS FOR MEDIUM AND HIGH VOLTAGE CABLES AND ACCESSORIES

GENERAL :

This specification covers the requirements for design, manufacture and supply of PVC, FRLS cables for Medium and High voltage systems and cable joining/terminating accessories for high voltage / low voltage systems.

The cables shall comply with the latest edition of the following standards :

IS:1554 (PART-I) - PVC insulated (heavy duty) electric cables - working voltage unto and including 1100V


IS:7098 (PART-II) - Cross-linked polyethylene insulated PVC sheathed cables for working voltages fro-1.1kV

unto and including 33kV

IS:8130 - Conductors for insulated electric cables and flexible cords.

IS:5831 - PVC insulation and sheath of electric cables

IS:3975 - Mild steel wires, stripes and tapes for armouring of cables.

IS:2633 - Methods of testing weight, thickness and uniformity of coating on hot dipped galvanised articles.

IS:209 - Specification of zinc.

IS:3961 (PART-II) - Recommended current ratings for PVCinsulated and PVC sheathed heavy duty cables.

IS:10418 - Wooden drums for electric cables.

IEC:502 - Extruded solid dielectric insulated power cables for rated voltages from 1kV unto 30kV.

IEC:540 & 540A - Test methods for insulation and sheaths of electric cables and cords.

IS:10462 (PART-I)- Fictitious calculation method for determination of dimensions of protective coverings of elastomeric and thermoplastic insulated cables.

IS:10810 (PART 58)- Oxygen Index test.

GENERAL CONSTRUCTION :

The cables shall be suitable for laying in trays, trenches, ducts and conduits and for underground buried installation with uncontrolled backfill and possibility of flooding by water and chemicals.

Outer sheath of all PVC and XLPE cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2º C. In addition, suitable chemicals shall be added into the PVC compound of the outer sheath to protect the cable against rodent and termite attack.


Sequential marking of the length of the cable in meters shall be provided on the outer sheath at every one metre. The embossing shall be legible and indelible.

The overall diameter of the cables shall be strictly as per the values declared in the technical information furnished along with bids subject to a maximum tolerance of ± 2 mm.

PVC/Rubber end caps shall be supplied free of cost for each drum with a minimum height of eight per thousand metre length. In addition, ends of the cables shall be properly sealed with caps to avoid ingress of water during transportation and storage.

SPECIFICATION FOR PVC CABLES

Al power / control cables for use on medium voltage systems shall be heavy duty type, 1100 insulated, insulated, inner-sheathed, armoured and overall PVC sheathed as detailed below.

The conductors shall be 'stranded' for both aluminium and copper cables. Conductors of nominal area less than 25 sq. mm shall be circular only. Conductors of nominal area 25 sq.mm and above may be circular or shaped. Cables with reduced neutral conductor shall have sizes as per Tables 1 of IS 1554 (Part-I).

The core insulation shall be with PVC compound applied over the conductor by extrusion and shall conform to the requirements of type 'A' compound as per IS:5831. The thickness of insulation and the tolerance on thickness of insulation shall as per table 2 of IS:1554 Part-1. Control cables having 6 crores and above shall be identified with prominent and indelible Arabic numerals on the outer surface of the insulation. Colour of the numbers shall contrast with the colour of insulation with a spacing of maximum 50 mm between two consecutive numbers. Colour coding for cables unto 5 crores shall be as per Indian Standard.

The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC conforming to the requirements of TYPE ST1 PVC compound as per IS: 5831. The minimum thickness of inner sheath shall be as per Table 4 of IS:1554-Part-1.

Armouring for multi-core cables shall be by single round galvanised steel wires where the calculated diameter below armouring does not exceed 13 mm and by galvanised steel strips where this dimension is greater than 13 mm. Requirement and methods of tests for armour material and uniformity of galvanisation shall be as per IS-3975 and IS-2633. The dimensions of armour shall be as per table 5 of IS-1554 (Part-1). Armouring for single core cable shall be with H4 grade hard drawn aluminum round wire of 2.5 sq.mm diameter.


The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound conforming to the requirements of type ST-1 compound as per IS:5831. The minimum thickness of outer sheath shall be as per column-3 for both armoured and unarmoured cables.

SPECIFICATION FOR XLPE CABLES

The conductor shall be stranded and compacted circular for all cables.

All cables rated 1.1/ 3.8/6.6kV and above shall be provided with both conductor screening and insulation screening. The conductors shall be provided with non-metallic extruded semi conducting shielding.

The core insulation shall be with cross-linked polyethylene insulating compound applied by extrusion. It shall be free from voids and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions. It shall conform to the properties given in Table-1 of IS:7098 (Part-II).

The insulating shielding shall consist of non-metallic extruded semi-conducting compound in combination with a non-magnetic metallic screening of copper screen shall be capable of carrying the insulation shielding shall consist of non-metallic extruded semi-conducting compound in combination with a non-single line to ground fault current.

The conductor screen, XLPE insulation and insulation screen shall all be extruded in one operation by 'Triple Extrusion' process to ensure perfect bonding between the layers. The core identification shall be by coloured strips or by printed numerals.

The inner sheath shall be applied over the laid up crores by extrusion and shall conform to the requirements of type ST2 compound of IS:5831. The extruded inner sheath shall be of uniform thickness. For multicore cables, the armouring shall be by galvanised steel strips. If armouring is specified for single core cables in the data sheet, the same shall be with H grade hard drawn aluminium round wire of 2.5 sq.mm diameter.

The outer sheath of the cables shall be applied by extrusion after the armouring and shall be of PVC compound conforming to the requirements of Type of IS:5831. The thickness of outer sheath shall be as per amendment No.1 to Table 5 of IS:7098 part 2. (column 3 & 5 for both armoured and un armoured cables).

The dimensions of the insulation, inner sheath and armour materials shall be governed by values given in Tables 2, 3 and 4 (Method 'b') of IS:7098 PART-II.


SPECIFICATION FOR CABLE ACCESSORIES :

The termination and straight through jointing kits for use on the systems shall be suitable for the type of cables offered as per this specification.

The accessories shall be supplied in kit form. Each component of the kit Shall the manufacture's mark of origin.

The kit shall include all stress grading, insulating and sealing materials apart from conductor fittings and consumable items. An installation instruction sheet shall also be included in each kit.

The contents of the accessories kit including all consumables shall be suitable for storage without deterioration at a temperature of 45º with self life extending to more than 5 years.

TERMINATING KITS : The terminating kits shall be suitable for termination of the cables to an indoor switchgear or to a weatherproof transformer/motor. For outdoor terminations, weather shields/sealing ends and any other accessories required shall also form part of the kit. The terminating kits shall be one of the makes/types mentioned in the preferred makes.

JOINTING KITS : The straight through jointing kits shall be suitable for installation on overhead trays, concrete lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility of flooding by water and chemicals. These shall have protection against any mechanical damage and suitably designed to be protected against rodent and termite attack.

The cables shall be tested and examined at the manufacturer works both before and after manufacture. The manufacturer shall furnish all necessary information concerning the supply to consultant/owner's Engineer. The Engineer shall have free access to the manufacturer's works for the purpose for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any material which appears to him to be at unsuitable description or of unsatisfactory quality.

PVC & XLPE CABLES :

After completion of manufacture of cables and prior to despatch the cables shall be subject to special tests as detailed below. Consultant / owner reserves the right to witness all tests with sufficient advance notice from vendor. The test reports for all cables shall be got approved from the Engineer before despatch of the cables.


All routine tests, acceptance tests and type tests shall be carried out on cables as listed in IS:1554 Part-1.

The inner and outer sheath of XLPE cables shall be subjected to all the tests applicable for PVC cables. The test requirements for insulation and sheath of PVC cables shall be a per latest revision of IS:5831.

Following are the special tests to be performed on the cables and test results for similar type of cables shall accompany the offer.

Accelerated water absorption test for insulation as per NEMA-WC-5. (For PVC insulated cables) and as per NEMA WC-7 (for XLPE insulated cables).

Dielectric Retention Test : The dielectric strength of the cable insulation tested in accordance with NEMA WC -5 at 75 ± 1º shall not less than 50% of the original dielectric strength. (For PVC insulated cables).

Oxygen Index Test : The test shall be carried out as per ASTMD 2863 or applicable Indian standard specification.

Test for rodent and termite repulsion property : The vendors shall furnish the test details to analyse the property by chemical method.

CABLE ACCESSORIES:

Type tests should have been carried out to prove the general qualities and design of given type of termination / jointing system. The type tests shall include the following tests conforming to VDE 0278/IS specification. The type test certificates shall be submitted alongwith the offer.

1. Rated withstand AC voltage test2. Partial discharge test3. Rated withstand surge voltage test4. Continuous AC voltage test with cyclic current load (Number of

heating cycles-3)5. Partial discharge test6. Continuous AC voltage test with cyclic current load (Number of

heating cycles-60)7. Thermal short circuit test8. Continuous AC voltage test with cyclic current load9. Rated withstand surge voltage test10. D.C. voltage test11. Test under the influence of moisture12. Dynamic short circuit test

PACKING AND MARKING


Cables shall be despatched in non-returnable wooden drums of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defect. Wood preservatives shall be applied to the entire drum. Ferrous parts used shall be treated with a suitable rust preventive finish or coating to avoid rusting during transit of storage.

On the flange of the drum, necessary information such as project title, manufacturer's name, type size, voltage, drum no., cable code, BIS certification mark, gross weight etc. shall be printed. An arrow instruction to show the direction of rotation of the drum.

Cables shall be supplied in drum lengths as follows :

Medium voltage power cables unto and including 6 sq.mm - 1000M

Medium voltage power cables from 10 sq.mm unto and including 300 sq.mm - 500 M

Control cables unto and including 27 crores 1000M

A tolerance of plus or minus 5% shall be permissible for each drum. However, overall tolerance on each size of cable shall be limited to ±2%. Offers with short / non-standard lengths are liable for rejection.

5. TECHNICAL SPECIFICATION FOR LIGHT FITTINGS AND ACCESSORIES GENERAL

This specification covers the design, manufacture, testing at works, inspection and delivery at site and installation of lighting fittings and their associated accessories.

The light fittings and their associated accessories such as lamps/types, reflector, housings, ballasts etc. shall comply with the latest applicable standards.

All luminaries, lamps and accessories shall be same make.

GENERAL REQUIREMENTS

Fittings shall be designed for continuous trouble-free operation under hot humid atmospheric conditions, at an ambient of 50º C, without reduction in lamp life or without deterioration of materials and internal wiring. Outdoor fittings shall be weather proof and rain proof type.


The fittings shall be designed so as to facilitate easy maintenance, including cleaning, replacement of lamps/starters etc.

Connectors between different components shall be made in such a way that they will not work loose by small vibration.

For each type of light fitting the MANUFACTURER shall supply the utilisation factor to indicate the proportion of the light emitted by the bare lamp which falls on the working plane.

The fittings shall be supplied complete with lamps.

The fittings and accessories shall be designed to have low temperature rise, the temperature rise above the ambient temperature shall be as indicated in the relevant standards.

All mercury vapour and metal halide fittings shall be complete with accessories like lamps, ballasts, power factor improvement capacitors, starters/igniters wherever applicable, etc.

Outdoor type fittings shall be provided with outdoor type control gear box the fittings shall be power factor corrected to 0.95 lagging (maximum).

Each fitting shall have a terminal block suitable for loop-in, loop-out and T-off connection. The internal wiring shall be complete by the MANUFACTURER by means of stranded copper wire and terminated on the terminal block.

All hardware used in the luminaries shall be cadmium plated.

EARTHING

Each light fitting shall be provided with an earthing terminal suitable for connection to the earthing conductor.

All metal of metal enclosed parts of the housing shall be bonded to the earthing terminal so as to ensure satisfactory earth continuity throughout the fixture.

PAINTING / FINISH

All surfaces of the fittings shall be thoroughly cleaned and degreased. The fittings shall be free from scale, rust, sharp edges and burrs.

The housing shall be stove-enamelled / epoxy stove-enamelled / vitreous enamelled or anodised as indicated under various types of fitting.


The finish of the fitting shall be such that no bright spots are produced either by direct light source or by reflection.

LIGHT FITTINGS

HPSV / HPMV / MH FLOOD LIGHT LUMINAIRE (for Canopy area / Hoardings) :

Flood light fixture suitable for HPSV / HPMV / MH lamps consists of cast aluminium alloy housing with heat dissipating fins. Heat resistant and toughened glass in front is held by a weatherproof gasket and aluminium frame assembly. It shall have anodised aluminium reflector. Re lamping facility shall be made simple without disturbing the previously set aiming. It shall be provided with galvanised MS mounting bracket which will have facility to fix the fixture in any position. It shall be provided with the protractor for angle adjustment.

HPMV / MH HIGH/MID/LOW BAY LUMINAIRE (for Canopy area / Hoardings) :

High/MID/LOW bay fixture suitable for HPSV / HPMV/MH lamps consists of reflector made out of high purity aluminium and anodised. The integral control gear shall be housed in a cast aluminium housing which will have cooling fins. It shall have a strong MS bracket with an anti vibration eyebolt.

HPSV/HPMV/METAL HALIDE STREET LIGHT LUMINAIRE (for Yard Lighting) :-

Street light fixture suitable for HPSV / HPMV lamp consists of cast aluminium housing, stove enameled grey outside and white with an anodised aluminium reflectors and highly transparent clear acrylic sheet cover with hinge and toggle fastening, neoprene gaskets and integrated prewired ballasts etc.

POST TOP LANTERN (for Landscape Lighting) :

The luminairs shall have die cast aluminium spigot complete with integral copper wound control gear, PF correction capacitor mounted in canopy, lamp holder and suitable rated lamps. The diffuser / cover shall be opal acrylic HDP in double conical shape.

LOW LEVEL GARDEN LIGHTING (BOLLARDS) (for Landscaped Lighting) :

The luminaries shall comprise of acrylic diffuser mounted on suitable MS pillar which shall house suitable control gears, starters, capacitors. The luminaries shall be suitable for GLS / PL lamps.


FLUORESCENT TUBE LIGHT FITTING WITH STOVE ENAMELLED OPEN REFLECTOR (for Sales Building) :-

Industrial type fixture suitable for 2x40W/ 1x40W fluorescent lamp consists of reflector, made from CFCA sheet steel finished in stove enamel grey outside & white inside.

ACID PROOF FLUORESCENT TUBE LIGHT (for Battery rooms) :

It shall be suitable for 2x40W / 1x40W fluorescent lamp comprises of rubber gasketed cast aluminium control gear housing with detachable cover incorporating ballasts, starters, capacitors and connector block. It shall be specially designed with rubber gasket to prevent entry of corrosive vaporous or dust.

MIRROR OPTICS FLUORESCENT TUBE LIGHT (for Sales Building) :

It shall be suitable for 2x40W / 1x40W fluorescent lamp comprises of CRCA sheet steel housing finished in stove enamel while inside and grey outside. Mirrors made of high purity anodised aluminium sheet, giving a very high light output, with wide spread light distribution.

DECORATIVE FLUORESCENT TUBE LIGHT (for Sales Building) :

It shall be suitable for 2x40W/ 1x40W fluorescent lamp comprises of sheet steel housing fabricated from CRCA sheet steel, finished in stove enamel white inside and outside. It shall consist of Acrylic diffuser which is supported by brown high impact polystyrene end plates.

CHANNEL MOUNTED FLUORESCENT TUBE LIGHT WITHOUT REFLECTOR (for DG / Compressor / Electrical rooms) :

It shall be suitable for 1x40W / 2x40W Fluorescent lamps made out of CRCA sheet steel finished in grey stove enamel. The cover plate shall be finished in white stove enamel.

100W INCANDESCENT BULK HEAD FITTING (for Peripheral of Building) :

It shall be suitable for GLS lamp unto 100W and comprises of die cast aluminium alloy body, prismatic heat resistant glass cover held with a weatherproof gasket in a MS galvanised wire guard. It shall be painted in white stove enamel inside and grey outside.

COMPACT FLUORESCENT FITTING (Sales Building) :

It shall be suitable for 9/11/18W CFL, suitable for surface mounting and recessed mounting and made of CRCA sheet steel housing, finished in


stove enamel white inside and grey outside, fitted with high purity anodised aluminium reflector and complete with control gear.

REFLECTORS

The reflectors shall be made of CRCA sheet steel/aluminium/silvered glass as indicated for above-mentioned fittings.

The thickness of steel/aluminium shall comply with relevant standards. Reflectors made of steel shall have stove enamelled/vitreous enamelled/epoxy coating finish. Aluminium used for reflectors shall be anodised/epoxy stove enamelled/mirror polished.

Reflectors shall be free from scratches or blisters and shall have a smooth and glossy surface having an optimum light reflecting co-efficient such as to ensure the overall light output specified by the manufacturer.

Reflectors shall be readily removable from the housing for cleaning and maintenance without disturbing the lamps and without the use of tools. They shall be securely fixed to the housing by means of positive fastening device of captive type.

LAMP/STARTER HOLDERS

Lamp holders shall comply with relevant standards. They shall have low contact resistance, shall be resistance to wear and shall be suitable for operation at the specified temperature without deterioration in insulation value. They shall hold the lamps in position under normal condition of shock and vibration met within normal installation and use.

Lamp holders for the fluorescent lamps shall be of the spring loaded bi-pin rotor type. Live parts of the lamp holder shall not be exposed during insertion or removal of the lamp. The lamp holder contacts shall provide adequate pressure on the lamp cap pins when in working position.

Lamp holders for incandescent, mercury vapour & metal halide lamps shall be of Edison screw (E.S) type. Starter holders for fluorescent lamps shall conform to the relevant standards. All material used in the construction of the holder shall be suitable for tropical use.

The starter holders shall be so designed that they are mechanically robust and free from any operational difficulties. They shall be capable of withstanding the shocks met within normal transit, installation and use.


BALLASTS

The ballasts shall be designed, manufactured and supplied in accordance with the relevant standards. The ballasts shall be designed to have a long service life and low power loss.

Ballasts shall be mounted using sell locking, anti vibration fixings and shall be easy to remove without demounting the fittings. They shall be in dust-tight, non-combustible enclosures.

The ballasts shall be of the inductive, heavy-duty type, filled with thermosetting, insulating, moisture repellent, polyester compound filled under vacuum. Ballasts shall be provided with tapings to set the voltage within the range specified. End connections and taps shall be brought out in a suitable terminal block, rigidly fixed to the ballast enclosure. The ballast wiring shall be of copper wire shall be free from hum. Ballasts which produce humming sound shall be replaced free of cost by the contractor.

Separate ballast for each lamp shall be provided in case of multi lamp fittings.

The ballasts for metal halide lamps shall not be constant wattage type.

STARTERS

Starters shall have bimetal electrodes and high mechanical strength. Starters shall be replaceable without disturbing the reflector or lamps and without the use of any tool. Starters shall have brass contacts and radio interference capacitor.

The starters shall generally conform to the relevant standards.

CAPACITORS

The capacitors shall have a constant value of capacitance and shall be connected across the supply of individual lamp circuits.

The capacitors shall be suitable for operation at supply voltage as specified and shall have a value of capacitance so as to correct the power factor of its corresponding lamp circuit to the extent of 0.95 lag.

The capacitors shall be hermetically sealed preferably on a metal enclosure to prevent seepage of impregnant and ingress of moisture.

LAMPS


Incandescent (GLS) lamps shall be of "clear" type unless otherwise specified.

The fluorescent lamps shall be "Cool Day Light" type unless otherwise specified and shall be provided with features to avoid blackening of lamp ends. The lamp shall have triple coil electrode with an anode ring and a triband phosphor coating.

Mercury vapour lamps shall be of high pressure, colour corrected type, with a high luminous efficiency. The discharge tube shall be made of high grade quartz.

Metal halide lamp shall be provided with internal diffuse coating and the average lumen output shall be 19000 lumen for 250W and 32000 lumens for 400W and the lamp voltage shall not exceed 100v for 250W and 128 v for 400W. The colour rendering index of the lamp shall be 93. The lamp shall be suitable for universal burning position and for use in open type luminaries.

The lamps shall be capable of withstanding small vibrations and the connections at lead in wires and filaments/electrodes shall not break under such circumstances.

Lamps/tubes shall conform to relevant standards and shall be suitable for supply voltage and frequency specified.

CEILING FANS :

The ceiling fans shall be designed, manufactured and tested as per IS:374. The fans shall have totally enclosed capacitor start and run motor suitable for operating on 240v, single phase, 50Hz AC supply system. The fan shall be of double bearing type, having 3 blades with a sweep of 1200 / 1400 mm complete with suspension rod, canopies and mounting rollers. The regulators shall be modular type electronic step less regulator suitable for mounting on modular switch boxes.

EXHAUST FANS :

The exhaust fans shall be of industrial type designed, manufactured and tested as per IS:2312 and operating on 240v, single phase, 50Hz, AC supply system. The exhaust fan shall be of ring-mounted type and shall be complete with louvers. It shall be designed for opening and closing automatically with air flow velocity. A separate bird screen made of brass wire mesh shall be provided with steel framework on the outer wall.

WIRES


PVC insulated multistranded copper wires of 1100V grade as per IS:694 and ISI Certification shall be used.

The type and size of wires to be used shall be as indicated in the BOQ & drawings.

The following colour code shall be adopted for the wiring :

Three phase wiring : Red, Yellow, Blue

Single Phase wiring : Red / Yellow / Blue

Switched phase (wire from switch to light fan, bell, : White5A socket etc.)

Neutral : Black

Earth : Green

No joint is permitted in the run of wires.

SWITCHES

Switches, manufactured in accordance with IS:3854 shall be used. Switches in areas where concealed wiring has been adopted shall be flush mounting piano/modular type unless otherwise specified.

RECEPTACLES

Only three-pin type receptacles manufactured in accordance with IS:1293 shall be used with the third terminal connected to the earth. All receptacles shall be provided with a switch mounted on the same enclosure but shall be a separate unit to facilitate replacement by part. Flush mounting type receptacles shall be used in areas where concealed wiring has been adopted and surface type shall be used in other areas.

OUTLET BOXES

Outlet boxes for sockets, switches, fixtures and fan regulators etc. shall be of minimum 16 gauge or as specified. M.S. sheet 2.5" deep. Junction/Outlet boxes shall be used in roof slab where concealed wiring has been adopted. Front cover plate shall be of sheet steel in areas where surface wiring has been adopted. For concealed wiring the front cover plate shall be of Formica or modular front plate of approved equivalent with colour to suit the walls. Outlet boxes shall be electro-galvanised after fabrication. Cover plate shall be fixed by cadmium


plated brass screw and suitable C.P. brass cup washers. Samples of these shall be approved by Engineer-in-Charge.

CONDUIT AND FITTINGS

Conduit shall be minimum 16 gauge ERW or GI or Polyethylene as specified. Generally, polyethylene conduits shall be used in concealed wiring and for surface wiring GI conduits in industrial building and ERW conduit in non-industrial building shall be used.

Care shall be taken to see that all conduit ends have no burrs and ends are neatly reamed to avoid damage to wires. All metal conduit accessories shall be only of threaded type. Pin grip or clamp type accessories are not acceptable. Samples of these shall be furnished for approval by Engineer-in-Charge at site, before installation.

The maximum number of PVC insulated wires which can be drawn in conduits of various sizes shall be as given below :

Nominal Cross sectionals area in Sqmm Sizes of Conduits

20 mm 25 mm 32 mm 40 mm

1.5 5 10 12 -2.5 5 8 12 -4.0 3 6 8 -6.0 2 5 7 -10.0 2 4 5 816.0 - 2 3 6

STREET LIGHT POLES

Lighting poles shall be fabricated as per drawings from seamless pipes of specified section, with joints, swaged together when hot and bevelled on outside edges, poles shall be coated with bituminous preservative solution, throughout on the inside surface and on the ground portion of the outside surface. Remainder of the outside surface shall be given one coat of red oxide primer and finished with two coats of aluminium paint. Each pole shall be provided with a outdoor junction box which contains terminal connectors (size and the number of terminals shall be as per the requirement) and 6A SPN MCB for local control. GI conduit shall be embedded in muff for incoming and outgoing cables. Foundation for lighting poles will be made by the electrical contractor and the cost for


the same including supply of cement and all the reconnected materials shall be deemed to have been included in the erection of pole. Lighting poles shall be numbered serially as per the direction of Engineer-in-Charge.

6. TECHNICAL SPECIFICATIONS FOR EARTHING FOR ELECTRICAL WORKS

GENERAL

The contractor shall provide the complete bonding & earthing of the neutral point of power system & non current carrying metal parts of all electrical equipments & apparatus.

Each & every piece of electrical equipments & apparatus shall be connected to the main earth bus by means of branch main connection of earth continuity conductors.

All electrical equipments, except those operating at extra low voltages shall be provided with an earth terminal.

All types of electrodes comprising an earth system shall be connected together with a continuous ring of earth conductor. After installation tests shall be made to ascertain that the earth resistance hereinafter specified is obtained. If the required resistance value cannot be obtained, a sufficient number of additional electrodes shall be installed until the resultant resistance not exceeding the specified value can be obtained.

In all cases, the electrodes shall be driven such that the zones of earthing do not overlap.

Each earth electrode shall be connected to its associated earth conductor through a linked connection. The link shall be installed as close to the earth electrodes as possible. Each earth electrodes shall be enclosed together with the link in a reinforced concrete hand hole with slab cover, which shall be set flush with the ground.

A continuous earth ring of GI flat as specified shall be provided in the electrical room and connected to the earth electrodes. The resistance between any point on each earthing system and the earth electrodes shall not exceed 1 ohm. The overall resistance between the earthing installation and the general mass of earth shall be less than 1 ohm.

The system earthing shall be carried as per IS-3043.

All non-current carrying metal parts of electrical installation shall be earthed properly. All metal conduits, trunking cables, switch gears,


distribution boards, lift fitting and all other parts made of metal shall be bounded together & connected by means of specified earthing conductor to all efficient earthing system. All earthing shall be in conformity with Indian Electricity Rules.

EARTHING CONDUCTORS :

Earthing conductors shall be of electrolytic copper / GI & shall be protected against mechanical injury or corrosion. Zinc coating shall be as per latest IS codes.

SIZING OF EARTHING CONDUCTORS:

The cross-sectional area of copper earthing conductor shall not be smaller than the largest current carrying conductor subject to an upper limit of 80 Sqmm. If the area of the largest current carrying conductor or busbars exceeds 160 Sqmm than two or more earthing conductors shall be used in parallel, to provide atleast half the cross sectional area of the current carrying conductor or busbars. All fixture outlet, boxes & junction boxes shall be earthed with multi-stranded copper wires.

All three phase switches & distribution boards unto 60 amps, rating shall be earthed with 2 nos. distinct & independent 3 mm dia GI wires. All three phase switches & distribution boards unto 100 amps. rating shall be earthed with 2 nos. distinct & independent 4 mm dia GI wires. All 200 amp & above switches shall be earthed with minimum of 2 nos. separate & independent 40 mm x 6 mm GI strip.

EARTH PIT DETAILS :

Copper / Galvanised / cast iron earth plate of 60x60x0.6 cm /1200x1200x1.2 cms in size buried in specifically prepared earth pit of 1.5 meters below ground level with 40 kg charcoal & salt with alternate layers of charcoal & salt with 90 mm dia GI pipe with funnel with funnel with wire mesh for watering & brick masonry block cover, heavy duty CI cover complete as per IS 3043 with necessary length of double GI earth wire of 6 SWG bolted with lug to plate with cadmium plated GI nut-bolts & covered in 12 mm dia GI pipe 2.5 meters long complete connected to nearest switch gears as directed & duly tested by earth tester.

Pipe electrodes shall be of 3 M long 40 mm or 100 mm dia class B GI pipe. The GI pipes shall be provided with holes at regular intervals as per IS 3043.

RESISTANCE TO EARTH

The resistance of earthing system shall not exceed 1.0 ohm.


7. TECHNICAL SPECIFICATION FOR TELEPHONE DISTRIBUTION SYSTEM

GENERAL

The telephone system shall include providing main / sub distribution frames, interconnecting cabling, tag blocks inside the buildings, interconnecting telephone wires between tag block and telephone socket outlets. The telephone socket outlet shall be modular type or as specified in the bill of quantities.

MAIN TAG BLOCK

The main / sub distribution frame shall be enclosed type made out of CRCA sheet steel of suitable thickness (2 to 3.15 mm). This shall house necessary number of terminations with tags as specified with provision for terminating incoming and outgoing cables. The terminations and the frame shall be of standard make.

The frame shall be suitable for outdoor application with IP55 protection.

This shall be mounted on suitable civil foundation with necessary GI pipe sleeves for taking incoming and outgoing cables.

Outdoor termination block, if require to be used, shall be with weather proof enclosure with locking facility housed with necessary brick and RCC foundation and excavation in soil etc. as required.

TELEPHONE CABLES

All telephone cables shall be PVC insulated, copper conductor conforming to latest IS and IEC standards. Telephone cables shall be armoured/un armoured to suit the nature of application and as indicated in the Bill of quantities.

All cable shall be run in vertical or horizontal trunking, conduits or cable trays suitably prepared for distribution and separated from electrical cabling/wiring in an appropriate manner so as to eliminate electromagnetic interference. All telephone wiring shall be run in dedicated conduits separate from power wiring. All telephone locations to be in accordance with Owners requirements.

All cables shall be identified by tags and schedule identifying each termination to be issued to the client upon completion of the cabling installation.

TELEPHONE TERMINAL BLOCKS


Telephone termination block shall be Krone make as per latest standards. The termination block should have loop in - loop out arrangements, as required.

8. INSTALLATION

The installation shall be carried out in accordance with the Indian Electricity Rules, the Codes of Practice of the Bureau of Indian Standards and other relevant regulations.

MEDIUM VOLTAGE SWITCH BOARDS

Switch Boards shall be floor mounted in the room on the pre-formed trenches constructed with top / bottom entry for cables or free standing on floor with top entry for cables.

The portion of the trenches which is not covered by the switch board shall be covered with 6 mm thick checkqered steel plates with suitable reinforcement if required.

All unused cable entries shall be closed with suitable blind plugs or plates made from 4 mm thick sheet steel bolted to the gland plates.

MCB DISTRIBUTION BOARD

MCB Distribution Board shall be fixed with bolts and nuts grouted to the wall concealed in the cupboards/niches provided or flushed / semiflushed directly into the wall.

WIRING

PVC insulated wires shall be drawn through concealed PVC conduits / open metal conduits.

The wires of a circuit shall not run through the conduits switch / socket boxes of another circuit. A common drawbox with hylam barrier separating individual circuit wires may be adopted to minimise the number of draw boxes.

Wires shall be terminated at the switch boxes with suitable crimping type tinned copper lugs.

The wiring shall be carried out by looping the phase conductors at the switch box and the neutral conductors at the lights, fans and sockets. For coping of wires in switch boxes, shrouded type multiway 10A/20A rated connectors shall be used.

CIRCUIT WIRING


The circuit wiring shall be from MCB distribution boards to first switch box and looping to the consecutive switch box in the circuit including conduits and accessories.

POINT WIRING

The following shall be deemed to be included in Light / Ceiling Fan / Exhaust fan / Call bell / 6A socket points :

a. Conduit & Conduit accessories (bends, tee, deep junction boxes, fan book boxes) from switch box t point.

b. Wiring of point from switch to point.c. Earth wiring of each point from switch to point.d. Fixing accessories such as clips, nails, screws, phil plug, rent plug etc.

as required.e. Modular range of plate type cover plate, control switch, box etc.f. Junction boxes, pull boxes etc.g. Connectors for termination of pointh. Ceiling rose / Angle holder / Battern holder for light pointsi. 6A socket outlet for Exhaust fan.j. 6A socket outlet and switch for socket points.k. Cutting and chasing the wall for conduit & boxes installation and

making good the same in original finish after installation complete as required.

The point wiring shall be classified as the following :

a. Short point - unto 3 mtrs.b. Medium point - unto 6 mtrs.c. Long point - unto 10 mtrs.

TELEPHONE WIRE

The Telephone wire shall be drawn in the conduits provider for the purpose. It shall be terminated with standard termination accessories at the end of socket pin and Telephone junction boxes.

SWITCH / SOCKET BOXES

Switch / Socket Boxes shall be concealed in the wall and the mounting height of the boxes shall be as indicated in the drawings. Generally the lighting switch box will be +1350 mm from FFL and sockets will be at 450 mm from FFL.

The switch and socket front plates shall project beyond the switch/socket box. In the case of concealed conduit wiring, the joints between the box and the surrounding plaster is covered by the cover plate. The cover


plate shall be fixed with brass cup washers and full threaded brass screws.

CEILING FANS

Concealed type fan hook boxes shall be provided for mounting of the ceiling fans.

The fan shall be fixed to the hook in such a way that the canopy covers the opening of the fan hook box. Necessary down rods and other accessories shall be included as required for complete operation.

EXHAUST FANS

Exhaust fans shall be mounted on an MS ring which shall be 100 mm to 300 mm below the ceiling level.

The boxes shall be covered with 3 mm thick hylam sheet of approved colour. In the case of concealed flush mounting, the hylam sheet shall project 6 mm beyond the box so that the joint between the box and the surrounding plaster is covered by the sheet. The hylam sheet shall be fixed to the box with brass cup washers and full threaded brass screws.

LUMINAIRES

The installation of luminaires shall be at fixed locations indicated in the drawings with necessary fixing accessories.

CABLES

The underground cable shall be laid in excavated trenches outside the building. The trenches shall be excavated to a depth of not less than 800 mm and the cables shall be laid at a depth of 750 mm.

The cables shall be laid over a 50 mm thick sand cushion at bottom and 250 mm on top of cable and shall be with bricks at either ends of trench and protected at top by slab/bricks. The gap between the cables and the bricks shall be filled with sand. Above the brick, for 150 mm the cable trench shall be filled with sand, after that for 400 mm (i.e.) unto formed ground level the cable trench shall be back filled suitably with soil.

The cable trench shall have the widths as indicated by suitably excavating in all types of soil to attain the required width.

Cable markers shall be installed at every 30 m internal along all straight lines and at bends. The cable markers shall be of cast iron and shall have a clear and legible inscription "LT CABLE".


Wherever cables are required to enter the building the cable shall be drawn through hume pipe or GI pipe. Suitable packing shall be made at both ends of the pipes. Cables inside building shall be run in cable trays.

Where cables are required to cross the roads, cables and pipes of other services the cable shall be drawn through hume pipe or GI pipe. Suitable sealing shall be made at both ends of the pipes.

Vertical runs of cables along the wall shall be laid through GI pipe of suitable diameter unto a height of 900 mm above finished floor level. The GI pipe shall be clipped to the wall with GI clamps and GI screws. The distance between the clamps shall not exceed 400 mm.

The cable laying shall be done in such a way that there is no damage/injury to the cable. Adequate care shall be taken while pulling cable from drum and while laying.

Sharp bends shall be avoided in the cable runs. The bending radius shall not be less than 12 times the diameter of the cables.

No joints shall be permitted in the runs of the cables unto a run of 500 Metres.

Where more than one cable has to be laid along the same route, the cables shall be laid horizontally touching each other and not one above the other.

The armour of the cables shall be effectively earthed at termination point through cable glands.

Suitable phase identifiers shall be provided at the terminals.

The cables shall be laid in preformed trenches wherever required. The preformed trench shall be RCC casting on all the sides. 50x50x6 mm MS angle at required intervals shall be fixed to the casting. The preformed trench shall be covered with RCC cover which shall be capable of taking the heavy vehicular load. The wall thickness of preformed trench shall be suitable to take all type of loads.

STREET LIGHT POLES

Poles for external lighting shall be installed along the road/pathway edges as indicated in the drawing and shall be provided with cement concrete foundation below the ground level and above the ground level.

The concrete used for the foundation shall be fixed in 1:2:4 proportions with stone aggregate of 20 mm nominal size. Concreting shall be done solidly to avoid honeycombing using shuttering.


The depth and height of the concrete work shall be as per requirement of the pole heights.

STREET LIGHT LUMINAIRE

The luminaries shall be installed at the locations indicated over the poles. The lamps shall be fixed after the luminaries are installed.

TECHNICAL SPECIFICATION FOR PANEL

System :

The switch Board shall be suitable for operation on 3 phase, 4 wire, 415/433v, 50 cycles.

Standards :

The design, manufacturing of the various equipment covered by this specification shall comply with the latest edition of the relevant Indian Standard and Indian Electricity Rules and Regulations.

Construction :

The switch board shall be cubicle type and fabricated out of 16 SWG CRCA sheet steel. The base frame shall be made out of ISMC 100/ 75.

The Board shall be totally enclosed design, completely dust tight and vermin proof. Soft compressible gasket shall be provided between all metal joints, doors and covers to ensure the switch board as dust and vermin proof.

Self Threading screws shall not be used in the construction of switch boards. All hardware used shall be hot dip galvanised.

All similar materials and removal parts of switch board shall be interchangeable.


The switch board shall be provided with lifting lugs for easy lifting.

Separate cable compartment shall be provided for incoming / outgoing cable.

Busbars :

The busbars shall be made of high conductivity, electro litic copper and shall be housed in a seperate compartment.

The busbars shall have suitable and uniform cross sectional area through out the length and to carry the specified rate of current and to with stand the fault level.

The busbars shall be fully covered with heat shrinkable colour coded PVC sleeves. The inter connections shall be sleeved with colour coded PVC sleeves / insulation tapes.The busbars shall be supported on suitable, durable anti-cracking insulation support at short intervals to with stand the forces due to short circuit in the system.The minimum clearance between phases and body shall be maintained.The busbar chamber shall be adequately ventilated with wire mesh protection.Earthing :All metallic parts of the switch board other than the current carrying parts shall be connected to the earth bus of size 25 x 3 mm copper flat or suitable size.Painting :All steel work shall undergo the relevant process to obtain a perfect smooth surface and whole shall be powder coated with necessary treatment. The colour shall be simens grey.

LIST OF MAKE OF COMPONENTS FOR PANEL

1. Switch Fuse Units - L & T /HAVELS/STANDARD 2. MCC B - L & T 3. Change Over Switches - L & T /HAVELS/STANDARD


4. Cables - Unistar / CCI /Glowstar 5. Wires for interconnections - Finolex6. Capacitor - Universal / Asian7. Volt meter/Ammeter - AE8. Voltmeter/ Ammeter Switch - AE


TESTING OF MATERIALS

NOTEThe contractor shall carry out the following tests at his own cost and as directed by representatives of HPCL/Consultant. HPCL Engineer in Charge reserves his right to ask the contractor to carry out further tests on any material which is being used in the project at no extra cost.

SR NO MATERIAL LAB TESTS FIELD TESTS PERIODICITY OF TESTING

RELEVANT IS:CODES

REMARKS

1 Water Acidity, Alkalinity, PH value

Whenever there is change in source of water

IS : 10500 (specification for drinking water)

2 Cement (OPC) * Fine ness Min. 20 MT repeated for 50 MT

IS: 269 Latest for material

* Sound ness To be tested if stored for

IS: 4031 Latest for testing

* Setting time more than 3 months

*Compressive strength

3 Sand for concreting

Particle size, Percentage of deleterious material/organic impurities

Silt content , Bulking of sand

Whenever there is a change in source of supply or EIC directions

IS: 383 for material and IS: 2386 part (I) to (VIII) for testing

Silt content should not exceed 8%

4 Sand for plastering

Particle size, Percentage of deleterious material/organic impurities

Silt content Min. 500 Sq.M. of plaster / when there is change in source of supply / EIC directions

IS: 1542 for material and IS: 1727 for testing

Silt content should not exceed 5%, Sand to be sieved in seive size 4.75mm

5 Coarse aggregates (HBG)

Particle size, Crushing , Impact, Abrasion

Percentage of soft deleterious materials

Min. 45 Cu.m. and to be repeated for every 45 cum

IS: 383 - latest for material and IS: 2386 part (I) to (VIII) for testing

Visual inspection shall be done by EIC for Percentage of soft deleterious materials. In case of doubt lab test may be done.


RELEVANT IS:CODES

REMARKS


6 Bricks Compressive test Water absorption Efflorescence Dimension , Percentage of deleterious material

minimum 7500 Nos. and to be repeated for every 7500

IS: 1077 - latest for material and IS: 3495part (I) to ( III) for testing

7 Reinforcement steel

*Ultimate tensile stress

Free from defects

Min. quantity of 1.0 MT of each size

IS: 432 for mild steel

*Yield stress Tests shall be repeated

IS: 1786 for tor tor steel

*Elangation percent age

for every 10 MT

IS: 1608 for testing

Bend -rebend test

Steel shall be tested if

*Weight stored for more than one year

*Size 8 Murrum Sieve analysis &

grading , Plasticity index, CBR value

When there is change in source of supply or as directed by EIC.

IS: 2720 Part IV

Optimum Moisture content , Maximum Dry density, Field dry density with core cutter method

Minimum three samples per layer

IS: 2720 Part VII

9 Cement concrete Cube strength (7 days & 28 days)

Slump cone test

Once for minimum 5 Cum or part there of

IS: 456 latest

Cube test to be done for both 7 days & 28 days

10 Stone aggregate for WBM

los angles value, flakiness index, Aggregate impact value

Minimum for 400 sqm to be repeated for every 600sqm


RELEVANT IS:CODES

REMARKS


11 Structural steel (beam, channel, angles, flats, square bar etc.)

Ultimate tensile stress, Yield stress, Elongation percent, weight, size

free from defects

minimum 5 MT to be repeated for every 10 MT

IS: 226/2062 for material

12 Paver Blocks Compressive strength, Abrasion resistance, Flexural strength, Water absorption

3 samples for 5000 blocks, average of minimum 8 blocks per site

IS : 1237


SPECIFICTIONS FOR PAVER BLOCKS

1. Scope Of Work

The scope of work includes manufacturing, supplying and laying of precast paver blocks at various Retail outlets. The work includes:

1.1 Verification of the existing site condition and advising out project in-charge to lay suitable base course if required. Contractors are required to satisfy themselves with quality of sub-grade, sub-base course before the paver blocks are laid and suggest strengthening if required.

1.2 Clearing the site by removing all obstacles such as stones, debris etc. for laying of paver blocks.

1.3 Manufacturing of paver blocks in your plant as per requirements in technical specification enclosed.

1.4 Supplying of paver blocks at site, including handling at both ends.

1.5 Laying of paver blocks at site as per requirement in technical specification, with shortest possible time. The site being existing operating Retail Outlets, care should be taken to ensure that the operation is not closed. The job of laying may be required to be carried out during night also.

1.6 Testing of paver blocks through reputed Govt./Non Govt. Test house and submission of test results as per requirements in technical specifications. HPCL reserves the right to carryout tests at random. Cost for such tests to be borne by party.

1.7 The contractor shall guarantee that all material and components designed, fabricated, supplied and laid by him shall be free from any type of defect due to faulty material and/or workmanship/erection for a period of One year from the date of completion of work at individual sites. However, free Maintenance for two years shall be rendered by the contractor.


TECHNICAL SPECIFICATIONS

II.1. Paver Block Manufacturing Facilities

The Paver Block shall be made in factory with following minimum facilities:

11.1.1 Concrete Block making Machines:The machine should be capable of producing high quality Paver Blocks by obtaining high level of compaction by application of hydraulic compaction and also by high intensity vibration to the moulds. The machine should have automation control panel for uniformity in strength.

11.1.2 Concrete Batching & Mixing Plant: The concrete Mix Design should be followed for each batch of

materials. The concrete ingredient should be mixed in concrete Batching & Mixing plant with minimum capacity of 30 cum/hour. The plant should equipped with automatic control panel for maintaining water cement ratio from batch to batch to obtain concrete of uniform quality and strength. The plant should be equipped with adequate mechanism for mechanized loading of raw materials into mixer and conveyor or belt for transportation of concrete from mixer to concrete block making machine to maintain quality of wet cement.

11.1.3 Curing: The factory should have well designed curing area to ensure adequate

curing of paver blocks.

11.1.4 Laboratory (Desirable but not essential)The factory should have the following:(i) Compression testing machine of adequate capacity(ii) Other tools and equipment for testing raw materials and paver

blocks.(iii) (1) Systematic record of test results of various paver blocks

manufactured in the factory. (2) Concrete Mix Design for various grade of concrete used for

Making of paver blocks.

2. Raw Materials

11.2.1 CEMENT The cement used in the manufacture of high quality precast concrete paving Blocks shall be conforming to IS 12269 (53 grade ordinary Portland cement)


or IS 8112 (43 grade ordinary Portland cement). The minimum cement content

In concrete used for making paver blocks should be 380 kg/Cum.

11.2.2 AGGREGATESThe fine and coarse aggregates shall consist of naturally occurring crushed or uncrushed materials which, apart from the grading requirements comply with IS 383 -1970. The fine aggregates used shall contain a minimum of 25% natural silicon sand. Limestone aggregates shall not be used. Aggregates shall contain no more than 3% by weight of clay & shall be free from deleterious salts and contaminants.

11.2.3 WATERThe water shall be clean and free from any deleterious matter. It shall meet the requirements stipulated in IS:456-2000.

11.2.4 OTHER MATERIALSAny other materials /ingredients used in the concrete shall conform to I.S. Specifications.

3. Pavers Block Characteristics

II.3.1 The concrete pavers should have perpendicularities after release from the mould and the same should be retained until the laying.

II.3.2 The surface should be of anti skid and anti glare type.II.3.3 The paver should have uniform chamfers to facilitate easy drain of

surface run off.II.3.4 The pavers should have uniform interlocking space of 2mm to 3 to

ensure compacted sand filling after vibration on the paver surface.II.3.5 The concrete mix design should be followed for each batch of

materials separately and automatic batching plant is to be used achieve uniformity in strength and quality.

II.3.6 The pavers shall be manufactured in single layer only.II.3.7 Skilled labour should be employed for laying blocks to ensure and

level of laying, desired shape of the surface and adequate compaction of the sand in the joints.

II.3.8 The pavers shall be of cement grey colour without any pigments.II.3.9 The pavers are to be skirted all round with kerbing using solid

concrete blocks of size 100mmX200mmX400mm. The kerbing should be embedded for 100mm depth. The concrete used for kerbing shall be cured properly for 7 days minimum.


4. Paver Block Dimensions

Thickness ≥ 80 mmShape Uni regular (Uniform Shape with no

Hollow or Cracks)

Chamfer 4 mm to 6 mm along top edges

Colour Natural Cement grey colour without use of any pigment

Dimensional Tolerance (+/-) 2mm for Length & Width , (+/-)3mm Height (Thick ness)

5. Testing of Paver Blocks :

SR.No TEST SPECIFICATION (Average of Minimum Five Samples/ Site)

1 Compressive Strength Minimum 40 N/Sqmm (for 80 mm)

2 Flexural Strength Minimum 4.5 N/Sqmm

3 Abrasion Resistance Maximum 1.5

4 Water Absorption Maximum 5.80%

5 Minimum Cement Content 380 Kg/CuM

* Sampling and Testing Procedure As Per Enclosed Specifications

6. Sampling and Testing Procedures

Sample Size:

INTERNAL - Average of minimum 3 samples per 5000 Blocks

EXTERNAL – Minimum 2 Blocks per 10000 blocks. Average of Minimum 8 blocks per Site

1. Sampling For Testing Sampling for testing of paver blocks shall be done in accordance with Appendix-A.

2. Compressive Strength


Testing for compressive strength shall be undertaken in accordance with Appendix-B. The average compressive strength of the blocks tested shall be 40 N/Sq. mm.

3. Abrasion ResistanceTesting for abrasion shall be in accordance with IS 1237 (Specifications for Cement Concrete Floor Tiles) - Appendix C

4. Flexural Strength Testing for flexural shall be in accordance with IS 1237 (Specifications for Cement Concrete Floor Tiles) – Appendix D

5. Water AbsorptionTesting for water absorption shall be in accordance with IS 2185: 1979: part 1(Specifications for Concrete Masonry Units) – Appendix E

APPENDIX A


SAMPLING OF PAVER BLOCKS

1. Method of Sampling:

Before laying paver blocks, each designated section comprising note more than 50000 blocks shall be divided into ten approximately equal groups. Three blocks shall be drawn from each group.

2. Marking and Identification:

All samples shall be clearly marked at the time of sampling in such a way that the designated section of part thereof, and the consignment represented by the sample, are clearly defined.

The sample shall be dispatched to the approved test laboratory taking precaution to avoid damage to the paving in transit. Protect the paving from damage and contamination until they have been tested. The testing shall be carried as soon as possible, after the sample has been taken. As soon as practicable shall sampling. The samples shall be stored in water at 20 degree C ± 5 degree C for 24 hours prior to testing.


APPENDIX – B

Procedure for Testing of Compressive Strength of Paver Blocks

Reference: BS6717 Part-I (1993) Specification for Paving Blocks:

B.1 TESTING MACHINE: The testing machines shall be of suitable capacity for the test and capable of applying the load at the rate specified. It shall comply, as regards repeatability and accuracy with the requirements of relevant ISI specs.

B.2 PROCEDURE: The sample specimens shall be tested in wet condition after being stored for at least 24 hours in water maintained at a temperature of 20 degrees C ± 5 degrees C before the specimens are submerged in water, the necessary area shall be determined by the method described in Appendix A.

The plates of the testing machine shall be wiped clean and any loose grit or other material removed from the contact faces of the specimen. Plywood normally 4mm thick, shall be used as packing between the upper and lower faces of the specimen and the machine plates, and these boards shall be larger than the specimen by a margin of at least 5mm at all points. Fresh packing shall be used for each specimen tested. The specimen shall be placed in the machine with the wearing surface in a horizontal plane and in such a way that the axes of the specimen are aligned with those of the machine plates. The loads shall be applied without shock and increased continuously at the rate of Approximately 15 N/Sqmm per minute until no greater load can be sustained. The maximum load applied to the specimen shall be recorded.

B.3 CALCULATION OF CORRECTED STRENGTH: The compressive strength of each block specimen shall be calculated by dividing the maximum load by full cross section area and multiplying by an appropriate factors.

Thickness and Chamfer Correction Factors For compressive StrengthWork Size Thickness in mm Correction Factors

PLAIN BLOCK CHAMFERED BLOCK

60 1.00 1.0680 1.12 1.18100 1.18 1.24

B.4 COMPRESSIVE STRENGTH CALCULATION: The average corrected compressive strength for the designated block section shall be calculated.


APPENDIX C

Method for Determining of Wet Transverse Strength (Flexural Strength)

1. The pavers shall be tested wet after soaking in water for 24 hours.

2. The specimen shall be placed horizontally on two parallel steel supports, with wearing surface upwards and its sides parallel to the supports. Atleast one of the supports shall be self-adjusting.

3. The load shall be applied by means of a steel rod parallel to the supports and mid way between them.

4. Plywood padding about 3mm thick and 20mm wide shall be placed between the paver and each of the supports and between the paver and the steel rod.

5. The load shall be applied gradually and at a uniform rate.

6. The load ‘P’ which caused the breaking of the paver shall be recorded.

7. The wet transverse strength `F’ shall be calculated as follows:

F = 3PL/2BT².Where,

P – Breaking load in N,L – Span between supports in mmB – With the paver in mmT – Thickness of the paver in mm.

8. The average wet transverse strength shall be reported.


APPENDIX D

Method for Determining of Resistance to Wear (Abrasion Resistance)

The grinding path of the disc of the abrasion-testing machine shall be event strewn with 20 g. of the abrasive power. The specimen shall than be fixed in the holding device with the surface to be ground facing the disc, and loaded at the center with 300 N (30’kgf). The grinding disc shall than be pu in motion at a speed of 30 rev/min and the abrasive power is continuously fed back on to the grinding pat so that it remains uniformly distributed in a track corresponding to the width of the test piece. After every 22 revolutions, the disc shall be stopped the abraded tile power and the remainder of the abrasive power shall be removed from the disc, and fresh abrasive power in quantities of 20g applied each time. After every 22 revolutions the specimen shall be turned about the vertical axis through an angle of 90° in the clockwise direction and it should be repeated 9 times thereby giving total number of revolutions of 220. The disc, the abrasive power and the specimen shall be kept dry throughout the duration of the test. After the abrasion is over, the specimen shall be reweighed to the nearest 0.1 g. It shall be placed in the thickness measuring apparatus once again in identical manner and the reading taken with the same position and setting of the dial gauge as for the measurement before abrasion.

The wear shall be determined from the difference in readings obtained by the measuring instrument before and after the abrasion of the specimen. T value shall be checked up with the average loss in thickness of the specimen obtained by the following formula:

T = (W1 – W2) V1

W1 X A

Where,

T = Average loss in thickness in mm,W1 = Initial mass of specimen in g1

W2 = final Mass of abraded specimen g3

V1 = Initial volume of specimen in mm2

A = Surface area of the specimen in mm2


APPENDIX – E

Method for the determination of Water Absorption

1. The test specimens shall be completely immersed in water at room temperature for 24 hours.

2. The specimens shall then be weighed, while suspended by a metal wire and completely submerged in water.

3. They shall be removed from the water and allowed to drain for one minute.

4. Visible surfaces water being removed with a damp cloth, and immediately weighed.

5. Subsequent to saturation, all specimens shall be dried in a ventilated oven at 100° to 115°C for not less than 24 hours and until two successive weightings at intervals of 2 hours show an increment of loss not greater than 0.2 percent of the last previously determined mass of the specimen.

6. Calculate the absorption as follows:

Absorption, kg/m3 = A-B X 1000A-C

Absorption, percent = A-B X 100 B

Where, A = Wet mass of unit in Kg,B = Dry mass of unit in kg, andC = Suspended immersed mass of unit in kg


6. LAYING OF PAVER BLOCKS

6.1.1 PRIMING: The contractors are required to verify the existing WBM driveway surface and

ascertain the CBR Value. Accordingly the total subgrade thickness required to

achieve the desired CBR value to be advised to HPCL within seven days of receipt

of call-up. HPCL shall through regular vendors arrange to carryout such WBM,

wherever required. Before taking over the sites, the paver block laying party is

required to verify the stabilization of the surface with CBR Values.

It will be the responsibility of the paver block party to ensure that the

Manholes/Pipeline/Cable trenches /circular drainage system etc. raised to

driveway level using the requisite materials as per instruction of Engg In Charge

(EIC) of HPCL. The areas of potholes/deep depressions at the isolated locations

also have to be filled up before laying the paver blocks. No extra payments will be

made for this purpose. The area of raised manholes shall be included in the

measurement of overall area of paver blocks for the purpose of payment.

It will be the responsibility of the contractors to ensure that undulations on the paver

blocks are eliminated after the traffic is allowed on it. Proper slope for draining or

water needs to be ensured by the contractor. All necessary materials, tools,

tackles are required to be arranged by the contractor.

6.1.2 BEDDING SAND COURSE The bedding sand shall consist of a clean will graded sand passing through 4.75

mm sieve and suitable to concrete manufacture. The bedding should be from

either a single source or blended to achieve the following grading.

IS SIEVE SIZE % PASSING9.52 mm 100

4.75 mm 95-100

2.36 mm 80-100

1.18 mm 50-100


600 microns 25-60

300 microns 10-30

150 microns 5-15

75 microns 0-10

Contractor shall be responsible to ensure that single-sized, gap-graded sands or

sands containing an excessive amount of fines or plastic fines are not used. The

sand particles should preferably be sharp not used. The sand particles should

preferable be sharp not rounded, as sharp sand possess higher strength and resist

the migration of sand from under the block to less frequently areas. Even though

sharp sands are relatively more difficult to compact than rounded sands, the use of

sharp sands is preferred for the more heavily trafficked driveways.

The sand used to for laying the paver block should be free of any deleterious

soluble salts or other contaminants likely to cause efflorescence.

The sand shall be of uniform moisture content and within 4%-8% when spread and

shall be protected against rain when stockpiled prior to spreading. Saturated sand

shall not be used.

The bedding sand shall be spread loose in a uniform layer as per drawing. The

compacted uniform thickness shall be of 50mm and within ± 5 mm. Thickness

variation shall not be used to correct irregularities in the base course surface. The

spread sand shall be carefully maintained in a loose dry condition and protected

against pre-compaction both prior to and following screeding.

Any pre-compacted sand or screeded sand left overnight shall be loosened before

further laying of paving unit take place. Sand shall be slightly screeded in a loose

condition to the predetermined depth only slightly ahead of the laying of the paving

unit. Any depressions in the screeded sand exceeding 5mm shall be loosened,

raked and rescreeded before laying of paving units.


6.1.3 LAYING OF INTERLOCKING PAVING UNITS:

Paving units shall be laid in herringbone laying pattern throughout the pavement.

Once the laying pattern has been established, it shall continue without interruption

over the entire pavement surface. Cutting of blocks, the use of infill concrete or

discontinuities in laying pattern is not be permitted in other than approved locations.

Paving units shall be placed on the uncompacted screeded sand bed to the

nominated laying pattern, care being taken to maintain the specified bond

throughout the job. The first row shall be located next to an edge restraint.

Specially manufactured edge paving units are permitted or edge units may be cut

using a power say, a mechanical or hydraulic guillotine, bolster or other approved

cutting machine.

Paving units shall be placed to achieve gaps normally 2 to 3 mm wide between

adjacent paving joints. No joint shall be less than 1.56 mm nor more than 4mm.

Frequent use of string lines shall be used to check alignment. In this regard, the

“lying face” shall be checked at least every two meters as the face proceeds.

Should the face become out of alignment, it must be corrected prior to initial

compaction and before further laying job is proceeded with.

In each row, as full units shall be laid first. Closure units shall be cut and fitted

subsequently. Such closure unit shall consist of not less than 25% of a full unit.

To infill spaces between 25 mm and 50 mm wide, a concrete having 1:2:4 cement :

sand: course aggregate mix and a strength of 45 N/Sqm shall be used. Within

such mix for smaller spaces dry packed mortar shall be used.

Except where it is necessary to correct any minor variations occurring in the laying

bond, the paving units shall not be hammered into position. Where adjustment of

position is necessary care shall be taken to avoid premature compaction of the

sand bedding.


6.1.4 INITIAL COMPACTION After laying the paving units, they shall be compacted to achieve consolidation of

the consolidation of the sand bedding and brought to design levels and profiles by

not less than two (2) passes of a suitable plate compactor.

The compactor shall be a high-frequency, low amplitude mechanical plat plate

vibrator having plate area sufficient to cover a minimum of twelve paving units.

Prior to compaction all debris shall be removed from the surface.

Compaction shall proceed as closely as possible following laying and prior to any

traffic. Compaction shall not, however, be attempted within one metre of the laying

face. Compaction shall continue until lapping has been eliminated between

adjoining units. Joints shall then be filled and recompacted as described in Clause

6.1.5.

All work further than one metre from the laying face shall be left fully compacted at

the completion of each day’s laying.

Any units that are structurally damaged prior to or during compaction shall be

immediately removed and replaced.

Sufficient plate compactors shall be maintained at the paving site for both bedding

compaction and joint filling.

6.1.5 JOINT FILLING AND FINAL COMPACTION:

As soon as practical after compaction and in any case prior to the termination of

work on that day and prior to the acceptance of construction traffic, sand for joint

filling shall be spread over the pavement.


Joint sand shall pass a 2.36 mm (No.8) sieve and shall be free of soluble salts or

contaminants likely to cause efflorescence. The same shall comply with the

following grading limits:

2.36 mm 100

1.18 mm 90-100

600 microns 60-90

300 microns 30-60

150 microns 15-30

75 microns 10-20

The Contractor shall supply a sample of jointing sand to be used in the contract

prior to delivering any such material to site for incorporation into the works.

Certificates of test results issued by a recognized testing laboratory confirming that

the samples conform to the requirements of this specification shall accompany the

sample.

The jointing sand shall be broomed to fill the joints. Excess sand shall then be

removed from the pavement surface and the jointing sand shall be compacted with

not less than one (1) pass the plate vibrator and joints refilled with sand to full

depth. This procedure shall be repeated until all joints are completely filled with

sand. No traffic shall be permitted to use the pavement until all joints have been

completely filled with sand and compacted.

Both the sand and paving units shall be dry when sand is spread and broomed into

the joints to prevent premature setting of the sand.

The difference in level (lipping) between adjacent units shall not exceed 3mm with

not more than 1% on any 3 m X 3m area exceeding 2mm. A pavement which is


deformed beyond above limits after final compaction shall be taken out and

reconstructed to the satisfaction of the Engineer.

6.1.6 EDGE RESTRAINT:

Edge restraints need to be sufficiently robust to withstand override by the

anticipated traffic, to withstand thermal expansion and to prevent loss of the laying

course material from beneath the surface course. The edge restraint should

present a vertical face down to the level of the underside of the laying course.

The surface course should not be vibrated until the edge restraint, together with

any bedding of concrete launching, has gained sufficient strength. It is essential

that edge restraints are adequately secured.


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