Ranchi Municipal Corporation,

Jharkhand State

Tender Document For

Development of Sewerage Collection System and Drainage

System for Zone I, Constructing, Erecting, Testing and
Commissioning of Sewage Treatment Plant based on Modern
technology at Kishanpur, Construction, Erection, Testing and
Commissioning of Sewage pumping station at Kanke reservoir,
Providing, Lowering, Laying, Jointing and Testing Rising Main DI
pipe line for RANCHI City Under JNNURM

For Prequalified & Shortlisted Bidders

Volume - II of V
(Specifications)

RANCHI Municipal Corporation, RANCHI

RANCHI - 834001 Jharkhand, India
Phone No : 0651-2203469
Email: [email protected]
Fax No: 0651-2211777

JUNE - 2014

Page 1 of 263
 INDEX

NAME OF WORK: - Development of Sewerage Collection System and Drainage System for Zone I,
Constructing, Erecting, Testing and Commissioning of Sewage Treatment Plant based on Modern
technology at Kishanpur, Construction, Erection, Testing and Commissioning of Sewage pumping station
at Kanke reservoir, Providing, Lowering, Laying, Jointing and Testing Rising Main DI pipe line for
RANCHI City Under JNNURM

Sr. No Brief Description of Contents

1 SCOPE OF WORK

2 CIVIL SPECIFICATIONS

3 MECHANICAL SPECIFICATIONS

4 ELECTRICAL SPECIFICATIONS

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 PREAMBLE

The “Volume II : Scope of Work” are to be read for the purpose of pricing in conjunction with "Volume-I :
Conditions of Contract" of the Tender Documents containing instructions to Tenderer and General
Conditions of Contract; “Volume II : Civil Specifications”, “Volume II : Mechanical Specifications”, “Volume
II : Electrical Specifications”, “Volume II : Operation and Maintenance”, Volume II : Quality Control and
Quality Assurance” and “Volume-V : “Financial Bid” of this tender.
The prices quoted in the “Volume V:”Financial Bid” shall be all inclusive value for the work described
including all costs and expenses which may be required in and for the execution of the work described
together with all general risks, liabilities and obligations set forth or implied in the document on which the
tender is based.
All works shall be carried out strictly as per detailed specifications whether actually specified or not. If not
specified, work shall be carried out as per directions of Owner/Engineer-in-charge.
The total amount entered in the Volume V: Financial Bid document shall be entered both in figures and
words.
Specifications of items of work are described for each item of Volume V: Financial Bid shall read this in
conjunction with other technical specifications and specific technical requirements and quote accordingly.
The tenderer can ask for clarifications, if any, by giving their queries in writing on or before pre bid
meeting. Verbal queries shall not be considered.

Abbreviations used in the Volume II : Scope of Work have the meanings shown below:

mm Millimetre CI Cast Iron

cm Centimetre GI Galvanized Iron

m Metre GSW Glazed Stone Ware

km Kilometre BBCC Burnt Brick Cement Concrete

sq.m Square Metre RCC Reinforced Cement Concrete

cum. Cubic Metre PCC Plain Cement Concrete

M.T. Metric Ton wt Weight

SWG Standard Wire Gauge kg Kilogram

R.M. Running Metre I.D. Internal Diameter

nos. Numbers C.M. Cement Mortar

MS Mild Steel IS Indian Standards

M.D Metre Depth of Manhole SS Stainless Steel

OHT Overhead tank SW Storm water

STP Sewage Treatment Plant PS Intermediate/terminal Pumping Station

NP Non Pressure DWC Double Wall Corrugated

High Density Polyethylene Pipe

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1 GENERAL TECHNICAL REQUIREMENTS
The Contractor should ensure technical feasibility of their tender offer, after inspecting the sites at
all STPs. PS, and sewerage collection network in Ranchi City. The tenderer shall be required to
execute every such items of work which is considered necessary for satisfactory completion and
commissioning of all the works mentioned under scope of work , even though such items are not
explicitly specified in the tender documents.

All the works mentioned under the scope are to be designed and executed as per tender civil /
electrical / mechanical/instrumentation technical specifications and requirements and after
obtaining approval from the engineer-in-charge.

1.1 Time Limit

Time of construction, erection and testing of the project as mentioned in the scope of work shall be
24 calendar months (inclusive of monsoon period) from the date of issue of work order. After 24
months there shall be start up and commissioning and performance run of 3 months followed by
Operation and Maintenance for 5 Years.

1.2 Submission During Execution Of The Project

The Contractor can take up the works of site clearance, dozing, grading and other mobilization
works with the permission of the Engineer after award of the Contract. However, before taking up
the construction, contractor shall be responsible for preparing , Vetting and submitting for checking
and obtaining approval at his cost of the following by the RMC / their authorised representative.

1. A leveling / contour plan gradation plan of the site.

2. Subsoil testing and investigations to be carried out by the contractor through a reputed
and specialist firm approved by Engineer and recommendations regarding the safe
allowable bearing capacity for the foundations of various structures of the sewage
treatment plants, pumping stations ,connected buildings and Sewerage collection network
area.
3. Collection system hydraulic re-design report, data and calculations if any are to be done
on the basis of design parameters mentioned in the latest CPHEEO Manual on Sewage
Treatment of Ministry of Urban Development, Govt. of India.
4. Process design, Process and instrumentation drawing and sizing of various units on the
basis of criteria and specification mentioned in this document.
5. Hydraulic head loss design calculations are to be done on the basis of design parameters
mentioned in the latest CPHEEO Manual on Sewage Treatment of Ministry of Urban
Development, Govt. of India.
6. Layout plan of entire site showing the location of Sewage Treatment Plant and sewage
pumping stations on the basis of process/sizing design indicating sizes of various units,
channels, Sluice, Non-return valves, pipes, roads, Drainage, pumping station, switchgear
and control room, transformer yard, compound wall etc. within the area of the site,. This
drawing shall shows all treatment plant units, buildings / sheds, channels interconnecting
piping, roads, pathways, storm water drains etc. The minimum distance between the two
structures shall not be less than 3.0 m.
7. Hydraulic flow diagram shall be prepared on the basis of Hydraulic head loss calculations,
indicating top water levels of each unit, from inlet channel to chlorine mixing chamber, side
water depths, bed levels, invert levels, top of wall of each unit including all details of each
units.
8. General arrangement drawings for each unit, buildings showing and finished ground levels
based on the levels given herein after, necessary provision for civil/structural works and
electrical/mechanical works separately.
9. Civil structural design calculations, reinforcement drawings and drawings for bar bending
schedule etc. are to be submitted. Structural design for all liquid retaining structures or
structures in contact with sewage shall be done in accordance with the provisions made in

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 I.S. code 3370 (part I to part IV) as Uncracked Section and other structures/building on the
basis of IS 456-2000 (latest revision) unless otherwise stipulated in civil specification
hereafter. M 30 grade of concrete shall be used for all liquid retaining structures and M 20
grade concrete for other structures. The plain cement concrete shall be nominal mix 1:2:4.
Minimum thickness of PCC shall be 150 mm for water retaining structures and 100 mm for
other structures.
10. Architecture drawings for all buildings, pumping station etc. An architect approved by RMC
shall approve these drawings. Necessary charges for such approval shall be borne by
contractor.
11. Design details for electrical and mechanical equipment, machinery including technical
details of pipes, centrifuge, chlorinators, valves, gates and other drawings including single
line diagrams etc. as per specifications mentioned in Mechanical specifications and
Electrical Specifications.
12. Schedule for designs, drawings and execution, Bar Charts-CPM-Pert network for stage
wise construction activities of sewage treatment plants, Pumping stations, disposal system
and Sewerage collection network .
13. Contractor shall be responsible for liasoning and getting clearances from all concerned
authorities at his own cost and should submit the clearances obtained to RMC for their
records. Contractor shall obtain consent from the Jharkhand State Pollution Control Board
(SPCB) as per statute. Clearances shall also be obtained from Authorities of National &
State Highways, Railways and other departments / agencies to expedite the project
implementation, however RMC shall facilitate the contractor thru their deputed
Engineer/consultant.
14. The contractor should get the layout of electrical substation and general electrical layout
from Electrical Inspector and also get the final inspection done for realising new
connection at his own cost.
15. The contractor shall submit details of their environmental policy to carry out the Works with
due consideration for the protection of the environment as required by the Contract. The
environment policy shall be specific to the contract and address the major environmental
hazards associated with construction of the Works. It shall include details of the
organizational framework and the designation of the engineer to take overall responsibility
and to manage the environmental control facilities on a day-to-day basis.
16. The contractor shall submit their Health & Safety policy in sufficient details to demonstrate
the adequacy of the contractor to carry out the Works with due consideration for health
and safety of his workforce and all people in the vicinity of the Works. It shall be shall be
specific to the contract and address the major risks associated with construction of the
Works. It shall also include details of the organizational framework and the designation of
the engineer to take overall responsibility and to manage health and safety on a day-to-
day basis.
17. The contactor should submit the quality control and quality assurance documents for all
the works in the project. The document should be approved from the Engineer-in-Charge
before start of the execution.
18. During the course of construction and its completion, the contractor shall submit the
following drawings/documents for Civil, Mechanical and Electrical/ Instrumentation works.
• Revised drawings and design according to requirements of the Engineer.
• Six sets of final and approved drawings and design duly bound.
• Six sets of manual of operation and maintenance of the STP plants, Pumping Stations
and collection network.

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1.3 Equivalency Of Standards And Codes
Wherever reference is made in the Contract to specific standards and codes to be met by the
goods and materials to be furnished, and work performed or tested, the provisions of the latest
current edition or revision of the relevant standards and codes in effect shall apply, unless
otherwise stated in the Contract. Where such standards and codes are national or related to a
particular country or region, other authoritative standards which ensure an equal or higher quality
than the standards and codes specified will be acceptable subject to the Engineer's prior review
and written approval. Differences between the standards specified and the proposed alternative
standards must be fully described in writing by the contractor and submitted to the Engineer at
least 28 days prior to the date when the Contractor desires the Engineer's approval. In the event
the Engineer determines that such proposed deviations do not ensure equal or higher quality, the
Contractor shall comply with the standards specified in the Bid Documents.

1.4 Sign Board

The Contractor at his own cost, shall provide sign boards at approved locations, in English and
Hindi at the site of the Works of approved size and design which provides (i) the name of the
Project, (ii) the name and addresses of the Employer, the Contractor and the Consultant; (iii) the
name and short description of the Project, (iv) the amount of the Contract Price; and (v) the
starting and completion dates. Contractor shall take care of signboard and redo it in case of loss,
damage, theft etc., as desired by the Engineer-in-Charge.

1.5 Quality Assurance Programme/Sample Tests

The Contractor shall be responsible to develop a quality control program and to provide all
necessary materials, apparatus, instruments, equipment, facilities and qualified staff for sampling,
testing and quality control of the materials and the works under the Contractor. Without limiting the
generality of the foregoing, the Contractor shall either (i) establish a testing laboratory at the site of
Works which shall be adequately equipped and staffed to carry out all sampling and testing in
accordance with the requirement set out in the tender document specifications and provide all field
equipment and apparatus as necessary to conduct all specified in-situ tests and/or any Tests on
Completion, or (ii) arrange for routine sampling, testing and reporting, as required, through a
certified independent testing laboratory acceptable to the Engineer-in-Charge. The Contractor shall
obtain the approval of the Engineer-in-Charge for the quality control programme developed by him
and incorporate any modifications suggested by the Engineer-in-Charge at no extra cost.

All costs of such sampling, testing and reporting of test results will be borne by the Contractor, and
the Contractor shall include sufficient provisions in his tendered rates to allow for independent
sampling and laboratory testing under the direction of the Engineer in-Charge. The Contractor
shall furnish certified copies of all test reports to the Engineer in-Charge within 3 days of
completion of the specified tests.

The Contractor shall, within 14 days after the date of the issue of Letter of Acceptance, submit to
the Engineer-in-Charge for his consent a detailed description of the arrangements for conducting
the quality control programme during execution of the Work, including details of his testing
laboratory, equipment, staff and general procedures. If following submission, or at any time during
the progress of Works, it appears to the Engineer-in-Charge that the Contractor's quality control
programme is not adequate to ensure the quality of the Works, the Contractor shall produce a
revised programme, as desired by the Engineer-in-Charge, which will be adequate to ensure
satisfactory quality control. In case of the contractor will fail to ensure quality control program the
action deem fit will be taken against the contractor. RMC shall carry out supervision and quality
control and monitoring the progress of works.

1.6 Protection Of Utilities

The Contractor is required to carefully examine the location of the Works and their alignments and
to make special enquiries with all authorities concerning all utility lines such as water supply,
sewers, gas pipe, telephone (underground and/or overhead) lines, electric cable (underground
and/or overhead) etc., and to determine and verify to his own satisfaction the character, sizes,
position and lengths of such utilities from authentic records. The Contractor shall be wholly
responsible for the protection and/or facilitating relocation of such utilities as may be required and
shall not make any claim for extra work or extra time that may be required to protect or facilitate
relocating such utilities. If any major shifting or realignment of water supply, sewers, gas pipes,
electric and telephone lines is necessary due to their interference with the proposed Works, the
same may be done by the contractor. The cost of such relocations will be borne by the contractor.

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1.7 Dismantling Of The Existing Units
The existing structures at the site if any shall be demolished as directed by engineer-in-charge.
Cost of the demolishing shall be included in the quoted price.

The scheme for demolishing shall be got approved from the Engineer-in-Charge before starting of
the work. This however will not absolve the contractor from the responsibility of proper and safe
demolition.

Necessary dropping, shoring and under pinning shall be provided for the safety of the adjoining
work or property, which is to be left intact, before dismantling and demolishing is taken up and the
work shall be carried out in such a way that no damages is caused to the adjoining property.

Wherever required, temporary enclosures or partitions shall also be provided. Necessary

precautions shall be taken to keep the dust nuisance down as and where necessary.

Dismantling shall be commenced in a systematic manner. All materials which are likely to be
damaged by dropping from a height or demolishing roof, masonry etc. shall be carefully dismantled
first. The dismantled articles shall be properly stacked as directed.

All material obtained from demolition shall be property of RMC unless otherwise specified and
shall be kept in safe custody until handed over to Engineer-in-Charge.

Any serviceable materials obtained during dismantling or demolishing shall be separated out and
stacked properly as directed with all lead and lift. All unserviceable material, debris etc shall be
stacked as directed by Engineer-in-Charge. Disposal of the demolished material shall be done by
contractor within RMC limit as directed by engineer-in charge at no extra cost.

On completion of work, the site shall be cleared of all debris rubbish and cleaned as directed.

1.8 Inspection
Bidders to note that various items to be procured / executed under this contract are subject to
inspection by RMC or their authorised representatives at manufacturers premises. Cost of
inspection shall be borne by contractor.

1.9 Ready Mix Concrete

The contractor can use RMC concrete for construction of treatment plant units & Pumping
Stations.

Ready mix concrete prepared and transported will be as per IS 4926 of 1976 or the latest I.S.
Code.

No dry mix shall be brought on site and water added thereat.

Ready mix concrete will be brought to the site from R.M.C. plant only by transit mixers (agitators).

Every transit mixer will carry delivery ticket, mentioning the minimum following details:- Name of
Manufactures and Depot

- Serial No. Ticket.

- Date

- Truck No.

- Name of contractor to whom the R.M.C. is being supplied

- Location of contract

- Grade of concrete

- Specified workability

- Cement content and grade of cement

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 - Time of loading

- Quality of concrete

When the truck arrives on site, the drum should always be speeded to about 10 to 15 rev/min, for
at least 3 minutes, to make sure the concrete is thoroughly mixed and uniform, before discharge.

Testing of Ready Mixed Concrete:- The sampling and testing requirements for ready mixed
concrete are the same as those for site mixed concrete. As regards testing of workability, there is
bit of problem because the standard requirement is that the sample should be made up of at least
four portions taken at intervals from the complete discharge. This obviously involves discharging
all the concrete, by which time, it is too late, for the workability, before discharge. The following
procedure is one that has been accepted by many contractors, suppliers and clients, and
recommended. After making sure that the concrete has been uniformly mixed, take a sample from
the first 0.5 cum. Of concrete discharged, and do a slump (or compacting factor) test on the
sample. If the result complies with specified requirements, then the load should be accepted. If the
results are beyond limits, a further sample should be taken from the second 0.5 cum. of the
discharged, if this is satisfactory, the load should be accepted, if not, the concrete should be
rejected, as the same is not as per the specified range. The specified slump is 50mm. While
carrying out above tests, it may vary by ± 10 mm as per IS4926: 1976. cubes shall be cast at the
plant as well as at the site, where the concrete is placed as per cube testing frequency mentioned
in IS code

A random sampling procedure shall be adopted to ensure that each concrete batch shall have a
reasonable chance of being tested, that is, the sampling should be spread over the entire period of
concreting and over all mixing units.

The minimum frequency of sampling of concrete of each grade shall be in accordance with the
following:

Quantity of Concrete in the Work No. of Samples

(M3)

1-5 1

6-15 2

16-30 3

31-50 4

51 and above 4 plus one additional for each additional

50 cum. or part thereof.

• The admixture used shall conform to IS 9103-1979 reaffirmed on 1990 or ASTM C-494 of 92

All taxes/duties etc. will be borne by the contractors and not by RMC. No extra payment will be
made for the use of admixtures.

It will be the sole right of the Administration to allow or disallow the use of ready mixed concrete in
specified works based on the site situation, number of works, distance of plant from the site of
work, etc.

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2 SCOPE OF WORK
2.1 Brief Scope Of Work
The scope of work under this Contract includes the design and construction of all Works for the
sewerage system as described in subsequent paragraphs, sufficient to collect and treat expected
flows of raw water in all zones, and other works listed herein or any other works necessary to
achieve the above objective and complete the system as per the specifications and Employer’s
Requirements. The Estimated Project is exclusive of Operations and Maintenance cost and
Bidders are required to quote annual O&M cost for 5 Years separately.

The electric power required during construction of STPs, SPS and collection system shall be
arranged by contractor. RMC will not pay any electricity charges incurred during construction
phase of project. The connection at take-off structures with necessary equipment (such as
insulators, ACSR, hardware, clamps and connectors etc.) shall be in the scope of Contractor.

Generally the following activities shall be carried out for each component of this Contract, but shall
not be limited to:

The scope of work shall include but not limited to the following:

(i) Vetting of Design, if required redesign, Planning & Construction of Sewer Network,
Manholes, property connections (House Sewer Connection) and all the ancillary structures.
(ii) Designing, Planning & Construction of Intermediate Sewage Pumping Station and all the
ancillary structures.
(iii) Designing, Planning & Construction of Sewage Pumping Main and all the ancillary
structures.
(iv) Designing, Planning & Construction of civil engineering works for all the units and all the
ancillary structures.
(v) Designing, Planning Supply, erection, testing & commissioning of all the mechanical
equipment.
(vi) Designing, Planning Supply, erection, testing & commissioning of all the electrical &
instrumentation equipment.
(vii) Designing, Planning Supply, erection, testing & commissioning of all the piping, valves and
specials etc.
(viii) Demolishing the existing structures, if any, on the site.
(ix) Construction of civil engineering works for all the units plus all the ancillary
structures as detailed in Volume II: Civil Specifications.
(x) Supply, erection testing & commissioning of all the mechanical equipment as
detailed in Volume II: Mechanical Specifications.
(xi) Supply, erection testing & commissioning of all the Electrical & Instrumentation equipment
as detailed in Volume II: Electrical Specifications.
Supply, erection testing & commissioning of all the interconnecting piping & valves as
(i) Detailed in Volume II: Civil Specifications.
(ii) Providing walkways, platforms and RCC staircase of minimum 1.2 m width
(iii) All water retaining structures shall be form finished.
(iv) All reinforcement steel shall be Fe 415 TMT grade only
(v) Swelling Gasket in paste form (Masterflex or equivalent) shall be used in all construction
joints in concrete structure to avoid leakage
(vi) Details with valve and pipe arrangement (min 200 mm dia) to all treatment plant units. All
drains shall be connected to the final treated sewage line.

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(vii) Hydraulic testing of all the water retaining structures and sewerage network.
(viii) Third party inspection.
(ix) Submission of as built drawings
(x) Removal of defects in laying & jointing of all sewers, fittings and manholes after testing and
during defect notice period.
(xi) Operation & Maintenance of Sewerage Network, Sewage Treatment Plant & Terminal
Sewage Pumping Station for start-up/stabilization for a period of Three months or complete
stabilization of the Plant process whichever is longer.
(xii) Supply of all spares required during performance run and during 3 months of O & M period.
(xiii) Zinc rich epoxy painting in two coats from inside for all shall water retaining structures.
(xiv) Water proof acrylic painting in two coats of approved shade to all units from outside up to
0.5 m below ground level.
(xv) Oil painting with anti-corrosive treatment to railing and all MS, CI and GIworks. Subsoil
testing and investigation for water table and safe allowable bearing capacity to be carried out
by the contractor through a reputed and specialist firm approved by Engineer-in-Charge.
Based on soil investigation the contractor shall prepare structural design and drawings.
(xvi) Bidders are advised to visit STP/ SPS and city area before quoting for the proposed Work.
(xvii) Any other items of work which have not been specifically mentioned in the specifications but
are necessary for construction of the plant as per good engineering practice and safety
norms and operation and guaranteed performance of the entire plant shall be deemed to be
included within the scope of work of this specifications and shall be provided by the
contractor without any extra cost to the employer.
(xviii) Operation & Maintenance of the Plant for a period of 60 months after stabilization of Plant
process.
(xix) During Operation and Maintenance period electricity charges for electric energy supplied
through Jharkhand electricity Board grid shall be borne by the RMC to the extent of average
guaranteed energy consumption quoted by the agency. If actual energy consumption
exceeds average guaranteed energy consumption, the charges for the excess energy
consumption shall be borne by the agency. Electric energy consumption from JEB grid shall
be charged as per bill raised by JEB, however electric energy consumption from genset (as
per energy meter to be installed by agency) shall be charged as per rate fixed by EIC in
writing.
(xx) Defect liability for a period of twelve months after the completion & commissioning of works.
(xxi) Supply of equipment drawings, Technical specification/Catalogue.
(xxii) Supply of as built drawings after completion
(xxiii) Manufacturer manual for Operation & Maintenance of the equipment supplied.
Technical Bid shall consist of following documents duly filled & signed by the bidder.
(i) Notice inviting tender, instruction to bidders, forms of agreement & clauses.
(ii) Scope of work for capital works.
(iii) Scope of work for operation & maintenance.
(iv) Process calculations including pipe size calculation.
(v) Layout plan.
(vi) Hydraulic diagram and P&I diagram
(vii) A copy of the power of attorney in the name of the person signing the tender.

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 (viii) Deviations, if any, from the bid document.
(ix) Memorandum of understanding or agreement with the technology provider.
(x) Copy of one unpriced bid format as per tender duly signed, stamped and accepted
confirming that no other condition is mentioned in the sealed price envelope.
(xi) Technology provider shall provide detailed documents indicating the features of process /
process design criteria and operational philosophy. This must be supported by diagrams /
photographs/video clips etc.
Notes:

1. The bidder's proposal must clearly specify the following information:

• Proposed area for the entire STP & pumping stations including Blower Room, MCC,
PLC, Toilet, centrifuge shed, chlorination room, tonnershed, sludge storage platform etc.
• Technical data such as no. of items, technical specifications, capacity and make of all
the supply items including electrical & mechanical works, instrumentation ,pipes, valves
and gates.
2. The following schedules duly filled in are to be submitted.

Electrical drive list

Pipeline schedule

Field instrumentation

Chemical requirement

1. Net present value of power consumption

Net present value of the average guaranteed power consumption indicated in the Price Bid shall
be worked out on the basis of following parameters:
• Rate per KWh of energy consumption = Rs 4.50 per KWh

• Period of capitalisation =15 years

• Rate of interest / rate of return = 10%

Example:
Average guaranteed power consumption = A kWh per day
Energy charges = Rs 4.50 per kWh
Annual Energy charges = 4.50 x 365 xA = Rs 1642.50 A
Net present value factor = 7.6061
Net present value of power consumption = 7.6061 x 1642.50 A
= Rs12493A
Note: In case actual energy consumption exceeds the average guaranteed energy
consumption, the charges for the excess energy consumption shall be borne by the
contractor. These shall be deducted by the Department out of his running bills. Cycle for
calculating excess energy consumption shall be bill to bill basis issued by the Electricity
Department.

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A. Investigations, Surveys and Submissions
Setting up fully equipped/staffed field offices to carry out the required surveys and
investigations and preparing the necessary designs and drawings at the very start of the
Contract. The design offices shall interact with the Employer’s staff/ Engineer to ensure team
work for early submission and approval of the design and drawings required.
Carrying out necessary topographical survey/sub soil investigations for sewage collection
system, treatment plant, pumping stations and outfall sewers in consultation with the
Employer’s Representative so as to verify and check the data provided in the document.
Carrying out required subsoil investigations for design of foundations including the tests for
determination of safe load. Carrying out various other subsoil investigations such as the type
of soil, the strata, and the level of ground water, optimum moisture content, soil resistivity and
chemical composition, bearing capacity, etc., as may be required.
Carrying out required raw sewage quality analysis.
Preparation of system designs where required (e.g. sewage collection system, sewage
treatment plant, pumping stations, surge protection system, power supply system, automation,
local SCADA systems for monitoring and control, communications etc.) for approval of the
Employer’s Representative. Contractor can provide his own Concept of SCADA system and
may give his financial offer accordingly subject to approval by employer. The alternate
proposal shall be included in the offer.
Planning, design and preparation of the working drawings for the proposed Works. Preparation
and submission of the L-sections, layout plans and cross sections and conceptual drawings
etc. and all other drawings at appropriate scale and details for planning and construction of all
components of the project.
Submission of documents (designs, drawings, data sheets, etc.) and samples required
according to the Contract for approval by the Employer’s Representative of all design and
drawings, material to be used, equipment specifications, etc., prior to construction.
Preparation and submission of General Arrangement Drawing (GAD) and Architectural
Elevation drawings of all structures proposed to be constructed for approval.
Preparation of the structural design and drawings (including reinforcement detailing) for all the
RCC Works taking into consideration the functional reliability and structural safety of the
buildings.
Preparation and submission of all detailed working drawings on the basis of conceptual
designs and plans approved by the Employer’s Representative.

B. Works
Setting up of suitably equipped/manned field offices for supervision of the works for the
Contractor’s staff and the Employer’s Representative and Engineers.
Development of suitable storage spaces for construction material and equipment to be
received for the works.
Identification of suitable quarries/sources for construction material and get them approved
from the Employer’s Representative.
Setting up, and staffing with qualified engineers/ technicians, of suitable laboratories for
following the Quality Assurance Program.
Setting up of suitable labor camps with all water and sanitation arrangements and other
facilities required under the relevant Labor laws.
Implementation of all the environmental and relevant social mitigation measures as required.

Page 12 of 263
 Making arrangements for equipment and material required for maintaining safety of the sites
and the workmen on site (helmets, boots, jackets, safety belts, gloves, scaffolding, barricading,
etc.)
Submission of initial work program and updating the same every month for approval by the
Employer’s Representative.
Site clearance and leveling of site. Layout of the works as per the approved drawings.
Disposal of surplus soils as directed by Employer’s Representative, construction of civil
components of all the units, and maintaining the construction site in orderly manner.
Carrying out tests on materials received and finished works and maintaining complete records
and registers required on site.
Manufacturing, shop testing, pre-dispatch inspection, packaging, transportation to site,
providing transit insurance, storage, handling at site, installation, sectional testing, pre-
commissioning testing, trial runs and commissioning of all components of the system including
the pipes, fittings, hydraulic, mechanical, electrical, electro-mechanical and instrumentation
equipment.
Providing spares, tools and tackles.
Remedying the defects during the Contract period
Site Clearance and tidying up and restoration of the premises after completion of the Works
Submission of 'As Built' drawings and Operation and Maintenance Manuals

C. Operation and Maintenance, Preventive Maintenance and Repair of Complete System

for 5 Years.

D. Training of the RMC Staff on all Aspects of Operation and Maintenance of the Full
System.

E. Handing Over of the Full System at the End of the O&M Period to RMC.
2.2 System Components
The project contemplates execution and satisfactory commissioning of Underground Sewerage
Scheme to Ranchi Municipal Corporation and the major components of the system are :
2.2.1 Collection & conveyance System
Vetting of Desig , If required redsigning , Providing, Laying, Jointing, Testing and Commissioning
of sewage collection network covering entire municipal limit with RCC NP-2, NP-3 & NP-4 /DI-
k9/DWC PE pipes having diameters ranging from 150 mm to 1400 mm with ancillary structures like
brick masonry and RCC manholes, ventilating shafts etc.
Contractor should follow following criteria/norms while designing sewage collection system.
General
This system design shall be essentially based on design criteria based on present practice as spelt
in the manual on sewerage and sewage treatment published by CPHEEO, manuals and codes of
other nations, studies reported in literature and papers in journals etc. Where possible, changes
may be suggested to evolve a more efficient design to effect economy in cost, within the
constraints of an acceptable performance level for individual components and without comprising
engineering.
Design Year
The design year shall be considered for the wastewater system is 2046 i.e. 30 years from the year
2016.
Design Flow

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The design flow shall be based on the wastewater expected to be generated in the year 2046 and
would include wastes from domestic use in residential, commercial and institutional areas and non
domestic use in industrial areas and infiltration.
Avg. dry weather flow [Q avg.] per manhole = {Population [ P ] X Sewerage Flow (Water Supply
[lpcd] X Expected Sewer 80 % as per CPHEEO manual page No. 39 point 3.2.4)} + Infiltration 5%
of flow.
Per Capita Wastewater Flow
For the purpose of design the wastewater generated shall be estimated considering population
and water supply rate as 135 lpcd and it is assumed as 80% of the water supply to reach the
sewers, i.e. 108 lpcd
Rate of Infiltration
The infiltration allowance may be considered as 5%
Peak Factor
The peak factors to be considered for design of sewers range between 2 to 3 as per the
recommendations of CPHEEO manual based on contributory population. The peak factors shall be
applied to the projected population for the design year considering an average per capita
wastewater flow based on allocation.
As pipes deteriorate with age, a roughness coefficient shall be assumed for the design period
assuming fair condition in sewers as per CPHEEO Manual.
Design of Collection System
Manning's formula may be adopted for the design of sewers.
2/3 1/2
vf = 1/n R S given that Where
vf = Velocity when pipe flows full in mps.
A = Cross sectional area of pipe in sqm.
n = Manning's roughness coefficient when pipe flows full
R = Hydraulic radius.
S = Slope of energy gradient

Design Aspects
Sewers are to be designed to carry estimated peak flows generated in the year 2045 and to run
partially full at all flows. The pipes designed to flow at depths where the maximum permissible
depth of flow in sewers for established velocity criteria shall be tabulated. From considerations of
ventilation in wastewater flow, sewers shall be designed to flow partially full at ultimate peak flow.
To ensure that deposition of suspended solids does not take place, minimum self-cleansing
velocities to be attained once in a day need to be considered in the design of sewers. The
minimum partial velocities during peak flow suggested are 0.8 m/s and the maximum velocity 3.0
m/s. This velocity is adequate to keep a wide range of particles encountered in the wastewater
system in suspension.
Pipe Material for Collection System.
DWC-PE pipe ranging in the diameter 150 mm up to 1000 mm and Reinforced Cement Concrete
(R.C.C.) pipes, with rubber gasket at joints for diameter ranging from 1200 mm to 1400 mm are
proposed for sewers as those are proven.
Other Aspects
Minimum size of sewers
The minimum size of sewers may be adopted is 150 mm diameter for analysis and identification of
proposed sewers under this study, along the major rods.
Minimum depth of cover
The minimum depth of cover on sewers shall be as 1.0 meters.
Recommended Maximum Depth of Flow in Pipes
All sewers shall be designed to flow 0.8 full at ultimate peak flow.

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 Type of bedding
Type of bedding for various pipes (first class bedding, concrete cradle etc.) depends on the depth
at which the sewer is laid, type of pipes used, load due to backfill and super imposed load.
Accordingly, suitable bedding A Class, B Class and C Class for pipes shall be provided.
Appurtenances
Manholes
Manholes will be provided at all junctions, change of sewer size, gradient and alignment. The
maximum C/C distance between manholes shall be 30 m on a straight run.
The manhole frame and cover shall Brick Masonry type. As per IS 12542 (Part I) 1988 and Part II
1991, the clear opening of manholes shall be( 1.) 560 mm as per IS 4111. (2).The bottom slab of
manhole shall be of reinforced concrete, wherever required, depending on site conditions.
Flushing Arrangements
Flushing arrangements shall be provided to extreme upstream manholes of the systems wherever
required .sudden enlargement depends upon the ratio of diameters.
Each individual case needs to be studied form various aspects such as operation of pumps, the
specified limits, availability of land required for duplicating the main in future, etc.
2.3 STPs & Pumping Stations and Raw sewage pumping Mains
Since the scheme is based on decentralized waste water system, the Sewage Treatment Plants
proposed are modernized with advance technology of Treatment plants because of scarcity of land
in the city. There is one STP proposed having treatment capacity 37 Mld.
The Scope for STPs is detailed below of this document
The details of Pumping stations and pump house with valve chamber is given below .The scope
includes designing, providing, construction and O&M for 5 years of sewerage pumping stations
and STPs.
.
2.4 Flow Measurements
Electromagnetic/ultrasonic Flow meters with GSM capability to measure the inflow to the system
and flow from STP to be provided .
2.5 Miscellaneous Works at STP
2.5.1 Data acquisition and control system, Construction of Security Guard Rooms, Meter Rooms,
Compound walls, at STPs and SPS. etc.
2.5.2 Computer, Plotters, GPS etc.
The municipal corporation is in the process of implementing sewerage scheme and this shall
require considerable establishment for implementation & further operations & maintenance of the
scheme. A provision towards equipment purchase like computers, scanners, plotters etc have
been made.
2.5.3 Communication strategy, public awareness campaign for water tariff rationalization
and judicious use of water assets
The treated water is supposed to be reused by industries and housing societies which requires an
effective communication program & awareness campaign.
2.5.4 Shifting of Existing Utilities
Since the collection and conveyance pipelines are required to be laid on main roads which shall
require shifting of existing utilities like telephone cables, electric cables , water pipelines etc.
All design procedure shall be as per CPHEEO manual with relevant IS codes.
2.6 Proposed Sewage Treatment Plant
Bidders can quote for any treatment schemes which they think is most cost effective in terms of
capital and operation cost as defined in tender.
Tenderer can suggest different technology for STP considering cost optimisation and site suitability
of the treatment technology and outlet parameters. There shall be only one suggested technology
for STP. Following are the details of treatment plant.

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2.6.1 Inlet Raw Sewage Quality (For all two treatment technologies)
Inlet Raw water characteristics are indicated in the following table.

Sr. No. Parameters Unit Raw Sewage Design Values

Characteristics

1 pH - 5.5 to 9 7 to 8

2 Total Suspended Solids mg/l 150 - 250 250

3 BOD5 at 20 0C mg/l 100 - 250 250

4 Oil & Grease mg/l 10- 30 30

5 COD mg/l 250 - 400 400

6 Faecal Coliform MPN/100 ml > 1 x 107

7 Total Kjeldahl Nitrogen (as mg/l 20 - 55 45

N)

8 Ammonia Nitrogen (as N) mg/l 4-10 10

9 Total Phosphorus (as PO4) mg/l 5 5

2.6.2 Outlet Treated Sewage Quality (For all two treatment technologies)
The treated effluent parameters should conform to the following discharge standards:

Sr. No. Parameters Unit Discharge

Standards

1 pH - 6 to 8

2 Total Suspended Solids mg/l <5

3 BOD5 at 20 0C mg/l <5

4 Oil & Grease mg/l <10

5 COD mg/l <100

6 Faecal Coliform MPN/100 ml <1000

7 Ammonical Nitrogen mg/l <5

8 Nitrate Nitrogen mg/l <10

9 Total Phosphorous mg/l <2

2.6.3 Operation and Maintenance

The proposed treatment plant shall be operated and maintained by the contractor for a period of
60 months as per the scope of work mentioned in the tender document.

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2.6.4 Plant Utilities
Fire Extinguishers
The portable fire extinguishers with ISI mark of approved make shall be provided at the MEP room,
chlorine house and centrifuge house.
Each building shall be provided with following portable fire extinguishers

• Dry chemical powder type fire extinguishers of 3.2 kg capacity - 6 cylinders

• Buckets filled with dry clean sand - 6 Nos
All buildings shall be provided with manual fire alarm system connected with main control panel.
The alarm system shall be with pillboxes and hooters. The layout of the fire alarm system shall be
in accordance with the relevant ISI.
2.7 Miscellaneous Works common for all STP’s
2.7.1 Storm Water Drainage
Storm water drains adjacent to the proposed approach road shall be sized for a rainfall intensity of
50 mm/hr, allowing for 100% runoff. Drains adjacent to roads/pathways shall be in RCC in situ
type. The Drains shall be covered with CI/RCC gratings.
The storm water drainage system shall be designed and connected to cater for the run-off from the
plot and structures, and discharged into the city drainage network nearby storm drain or nallah.
2.7.2 Pathways
Paved pedestrian (Pathways) access ways shall be constructed to provide a network of logical
routes inter-linking entire plant areas and road network. Minimum width of pathways shall be 2 m.
Pathways shall be in coloured and glossy interlocking blocks. Damage to any existing roads, on
account of their use by the Contractor shall be made good to the satisfaction of the RMC.
Hardstanding areas in coloured and glossy interlocking blocks shall be provided to permit the
parking of vehicles involved in the delivery of consumables from blocking site roadways during
unloading or loading. The road system shall be designed such that vehicles involved in the delivery
of consumables can follow a continuous route through the works and out again.
The work of approach road and storm water drainage shall be carried out as per approved layout
during execution of the contract.
2.7.3 Road Works
The roads width constructed in STP shall have min width of 5.0 m. Roads to be constructed by one
layers of soling 230 mm thick ,one layer of 80 mm trap metal of 200 mm thick, one layer of 40 mm
trap metal of 200 mm thick including supplying and spreading of stone dust, watering compaction
and 75 mm thick bituminous bound macadam with cold emulsion and bituminous macadam of 50
mm thick with bitumen of S-65 grade and 25 mm thick asphalt concrete with S-35 grade of bitumen
including compaction by vibratory roller of all layers and providing and applying tack coat of 50 Kg /
100 m2 on black top surface and bitumen contained of 250 Kg / 100 m2 for B.B.M. surface and
disposal of surplus clay / soil and side of the road fixed with kerbstone etc., complete. Pipeline
trenches of various diameter of pipes etc., complete
2.7.4 Fire Extinguishers
The portable fire extinguishers with ISI mark of approved make shall be provided at the MEP room.
Each building shall be provided with following portable fire extinguishers
Dry chemical powder type fire extinguishers of 3.2 kg capacity - 6 cylinders
Buckets filled with dry clean sand – 6 Nos
All buildings shall be provided with manual fire alarm system connected with main control panel.
The alarm system shall be with pillboxes and hooters. The layout of the fire alarm system shall be
in accordance with the relevant ISI.
2.7.5 Landscaping
Landscaping involves beautification of Sewage Treatment Plant site by cultivating Lands, Plants
and Trees of environmental value and suitably modifying the appearance of STP site. It shall add
scenic value to the STP site and to obtain maximum visual impact. Contractor has to develop
proper landscaping in the STP site.

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2.7.6 Administrative Building
The administration building shall be G + 1 structure. Each floor shall be of min 50 m2 and
maximum 200 m2 of area. Entire first floor shall be for admin block. The admin block shall
accommodate office, conference room, hall and washroom, Laboratory Room and Panel Room.
The structure will be for the sole use of the Employers representative, his staff and consultants that
shall be provided by the contractor at site. The decision regarding the area of the admin building
shall be taken by the RMC. The contractor shall provide, erect, furnish, clean, maintain and
subsequently hand over the office and associated furniture/items to the employer after the
completion of the works. Contractor shall provide luster type painting to whole admin block. The
proposed office building shall meet the following carpet requirements.
- Engineering room – 2 nos. 4 m x 5 m each with attached toilets
- Computer/SCADA/Panel room. (Total 5 tone capacity Air conditioned)
- Conference room – 1 no. x 6 m x 4 m. (Total 5 tone capacity Air conditioned)
- Record room – 1 no. 3 m x 3m
- Toilets with basins – 4 nos. 1.5 m x 2 m each
- Separate Toilet facility shall be provided for laborers comprising of the following: -
- WC–2 Nos.
- Urinals – 4 Nos.
- Bathrooms – 2 Nos.
The walls shall be 230 thick brick masonry, plastered and painted with oil bound distemper on the
inner face and snow white cement on the outer face.
Filling of conference room shall be provided with POP. Layout for interior decoration shall be as
approved by Engineer-in-charge.
RCC slab roofing with roof height of 4.5 meters from the floor painted with all bound distemper
shall be provided. The doors shall be of first quality wood and aluminium-sliding windows of
approved quality shall be provided.
Before commencing the construction of the office, the contractor shall submit to the Employers
Representative for his approval a drawing of the proposed building with all the architectural and
finishing details fully shown. The location of the office building shall be finalized after taking
approval of the Employer’s representative. The Employer’s representative’s office should be ready
in all respects within 90 days of handling over the site. The office shall be maintained throughout
the contract period with office boy, power, water and housekeeping. Power and water supply shall
be arranged by the contractor either with the available resources or from independent sources (DG
sets. bore well, etc.)
The office building shall be provided with adequate forced ventilation and exhaust fans. Flooring
for the office shall be of Ceramic tiles.
Adequate number of toilets and washbasins shall be provided separately for men & women. A
covered service water tank shall be suitable provided to cater to the water requirements of the
laboratory and office building.
Separate workshop & tool room of 5.0m x 5.0m shall be provided. It shall be provided with RCC
walking platform, cabinets to store spares & accessories. Room should be also provided lockers.
Space for keeping plant records shall be provided in the administration building. Following furniture
shall be provided in the office.
- One wooden conference table 3m x 1.5 m with twelve chairs
- Six nos. 1.5m x 0.9m tables with both side drawers
- Four nos. 1.2 m x 0.75 m table with drawers on both sides
- 2 nos. 0.9 m x 0.6 m tables with single side three drawers
- Twelve nos. chairs
- Chairs for computers
- Four nos. steel cupboards (store well or any other approved make)

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 - Two nos. filing cabinet with 4 drawers
- Vertical blinds to all windows
- Water supply, plumbing electrical complete
- Telephone with STD facility

The fittings shall include:

- 4’-0’ long tube lights in each room except in conference room and toilet (1no.per 3 sq.m.
floor area)
- 6 rube lights 4’-0” long in conference room
- 2 Nos. of 48” ceiling fan in conference room
- All rooms with 4 plug point each
- Passage 4” long tube light at every 20” distance
One number sign board of suitable size shall be provided which includes name and capacity of
treatment plant, name of employer etc as directed by engineer in charge. The whole building
should have attractive cladding externally.
The Contractor can suggest any other alternate technology other than mentioned above satisfying
the criteria provided the financial and effluent characteristics, space etc. are fulfilled.
2.7.7 Specifications of Laboratory
The Admin Building shall be provided with a laboratory in STP area for analyzing sewage samples.
The minimum floor area for laboratory shall be 25 m2. The walls shall be 230 thick brick masonry,
plastered and painted with oil bound distemper on the inner face and snowcem on the outer face.
The walls shall be painted with all bound distemper. The doors shall be of first quality wood and
aluminium sliding windows of approved quality shall be provided.
The laboratory building shall be provided with adequate forced ventilation and exhaust fans.
Flooring for the laboratory shall be of Ceramic Tiles/ mosaic tiles.
2.7.8 Laboratory Equipment
The laboratory shall be equipped with instruments, equipment, chemicals and other infrastructure
that is necessary to perform the routine analysis for the specified parameters (All electrical
instruments must be supplied with suitable stabilizer).
The Bidder to provide a list of all the equipment for the Laboratory.

2.8 Pumping Station Specification

The all Sewage Pumping Stations (intermediate) mentioned in following table shall have following
minimum units
- Terminal Manholes
- Receiving Chamber and Screen Chamber
- Raw Sewage Pump House
- Raw Sewage Pumps
- Rising Main
- EOT
- Flow Measuring Unit
- Knife Gate Valves
- Non Return Valves
- Electrical Works
- DG room
- Miscellaneous Works

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 - Operation & Maintenance
All the civil components shall be designed and constructed for ultimate stage flow (2046) and
pumping machinery shall be provided for intermediate flow (2031) of capacity mentioned table.
.
Receiving chamber and Screen Chamber
The Contractor shall have to construct an receiving Chamber followed by a Screen chamber to
receive raw sewage from the gravity sewer line. Before inlet chamber there shall be manhole at a
distance of about 15 m. The contractor shall construct this manhole (having nearly same invert
level as that of inlet chamber) and lay the gravity sewer from manhole to inlet chamber. This
gravity sewer line shall be RCC NP 4. The pipe and inlet chamber shall be designed for peak flow.
There shall be two screen channels in this chamber. The entire construction is in M 30 grade
concrete and as per IS3370 & IS 456.
The screen chamber shall have mechanical coarse screen and manual coarse screen in each
channel in series. Clear opening between the bars for coarse screen shall be 20 mm.
The screenings from manual screens shall be collected manually.
Electrically operated CI sluice gates shall be provided at the upstream and downstream of each
channel to isolate the flow. Entire super structure from inside and from outside shall be painted
with approved colour and make as directed by engineer-in-charge. All other accessories, whether
specified or not, but required for completeness shall form part of contractors scope.
There shall be overflow / by pass arrangement from inlet chamber. The by-pass and overflow
arrangement of both gravity and pumping type. The bypass and overflow arrangement shall be
provided with necessary valves and Gates.
MOC of overflow pipe shall be RCC NP3. This over flow pipe shall take the flow from SPS to
nearby water body. There shall be manholes at appropriate locations as per CPHEEO manual.
Raw Sewage Pump House
There shall be wet well and pump house above wet well. The entire structure shall be suitable to
install submersible pumps, delivery pipes, valves, EOT, Panels and all the electrical Equipments
etc. The wet well is to be constructed in RCC M 30 grade concrete as per IS 3370.
The pump house above wet well shall be in RCC framed and brick masonry structure. It shall have
proper doors, windows and rolling shutter at main entrance as per tender specifications.
Plastering and painting from inside and outside shall be carried out as per specifications. Flooring
shall be done as per civil specifications. The minimum clear height of the pump house shall be 5.0
m.
EOT of minimum 2 T capacity shall be provided in the pump house to lift the pump assembly,
valves and specials. There shall be MCC room and operator room in pump house. It shall have
proper doors, windows and rolling shutter at main entrance as per tender specifications. Plastering
and painting from inside and outside shall be carried out as per specifications. Flooring shall be
done as per civil specifications.
Arrangement of wet well and EOT shall be suitable for installation of future pumps also.
The capacity of the Wet Well should be kept such that the detention time in the Wet Well shall be
minimum 5 minutes of Peak Flow and the maximum detention time shall not exceed 30 minutes at
average flow.
Following criteria shall be considered to size the Sump:
1. That the pump of the minimum duty / capacity would run for at least 5 minutes considering
no inflow or,
2. The capacity of the Sump is to be so kept that with any combination of inflow and pumping,
the operating cycle for any pump will not be less than 5 minutes and
3. The arrangement of the submersible pumps as per Manufacturer’s data i.e. spacing
between pumps, minimum space between pump and wall etc.
4. The side water depth (live liquid depth) shall be minimum 2.5 m. In addition to the above
liquid depth, an additional depression shall be provided to ensure adequate submergence
of the pump as per the Manufacturer’s recommendations. Pumping Station should have a

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 Room adequate for installing electrical Panels. Suitable arrangement should be provided
for lifting of pumps.
5. The effective liquid volume shall be provided below the invert level of the incoming sewer
after leaving provision for a minimum of 0.5 m.
IS: 3370 and IS: 4111 (Part 4) shall be followed for the design and construction of Wet Well. The
pumps shall be submersible Raw Sewage Pumps with Centrifugal, Non-clog type design. The
speed of pump shall be less than 1500 rpm. The impeller should be of a non-clog design with
smooth passage and solid handling capability of 100 mm size. The pumps shall handle raw
sewage having specific gravity of 1.05. Plinth level: 0.5 m above HFL.
The arrangement and levels shown in the Tender drawing of SPS are indicative. Actual levels may
change marginally to suit the site conditions during executions. All other accessories, whether
specified or not, but required for completeness shall form part of contractors scope.
While designing pumping station due consideration shall be given to safety and ease of O & M.
Raw Sewage Pumps
The submersible pumps shall be provided as per tender specifications. The details of the pumps
are as follows: -

Type : Submersible non-clog, solid handling.

Max solid size : 100-mm non-compressible.
Drive : Suitable motor.
Accessories : Panel, guide rail, lifting chain, duck foot bend etc.

Ultrasonic level transmitter shall be provided in the raw sewage sump so that the pumps shall
operate as per the level of the sewage in the sump. The pumps should stop at low water level.
All the pumps shall be provided with delivery pipe along with Knife Gate valves and non return
valves at the delivery side up to common header. MOC of delivery pipe and common header pipe
inside SPS shall be CI.
All other accessories, whether specified or not, but required for completeness shall form part of
contractors scope.
Electrical Operated Trolley (EOT)
EOT is proposed in the pump house to lift pumps, valves and specials from the pump house. The
capacity of the EOT shall be 1.5 times the maximum load to be lifted.
All other accessories, whether specified or not, but required for completeness shall form part of
contractors scope.
Flow Measuring Unit
Ultrasonic/ Electromagnetic type flow measuring unit mounted on common header to measure the
total flow pumped.
Gate Valves
Gate valves are provided on the delivery side of each pump for isolation of the pumps.
No. of valves : As per requirement
Pressure rating : PN 1.6
Material of construction : Cast Iron
Non Return Valves
Non return valves are provided on the delivery side of each pump and on common header to avoid
back pressure on the pumps.
No. of valves : As per requirement
Pressure rating : PN 1.6
Material of construction : Cast Iron
Electrical Works

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 The Employer will make available power supply from their local transformer to the proposed four
pole structure. The entire pumping station will be operated on 415 V, 3-Phase, 50 c/s, 4-wire
system. The electrical system proposed for the pumping station shall include the following
components;
- 415V Switchgear.
- 415V TPN Bus Duct.
- Transformer Yard
- Motor Starters, local push button stations.
- Earthing system and Safety equipments.
- Cables and cabling system.
- Internal lighting and area lighting.
The scope of work starts from providing four pole structure and further distribution upto MEP room.
The contractor shall complete power distribution from MEP to the individual motor terminals by
providing sub panels. The cabling work shall be done by providing proper cable trays. The scope
also includes indoor /outdoor lighting system as well earthing & safety equipment.
The execution should take care of I.E. rules, Electricity Board’s requirement and other local
authorities and site condition.
DG Room
One DG set room of minimum size 4.0 m x 4.0 m shall be provided. It shall be RCC framed
structure. The inside wall shall be provided with two coats of oil bound distemper of approved
quality of colour over a coat of primer for the outside walls two coats of waterproof cement paint of
approved quality and colour shall be provided. The flooring shall be provided with minimum 20 mm
thick mosaic tiles and the make, quality and colour shall be got approved by the Engineer-in-
charge.
All other accessories, whether specified or not, but required for completeness shall form part of
contractors scope.
Valve Chamber: The construction of Valve chamber shall be of RCC in M30 Grade with provision
of required size platform for maintenance and operation of gates, valves and etc. The common
header shall be of DI pipe material with necessary provision of Mechanical joints air valves and
necessary fittings required for completion of work. The valve chamber shall be constructed with
suitable access ladder with drainage facility.

3 ERECTION, TESTING, TRIAL RUN, COMMISSIONING AND TESTS AFTER COMPLETION

The Contractor’s staff shall include adequate and competent erection engineers with proven,
suitable, previous experience on similar Contracts to supervise the erection of the Works and
sufficient skilled, semi-skilled and unskilled labor to ensure completion of Works in time. The
Contractor shall not remove any representative, erector or skilled labor from the Site without prior
approval of the Employer’s Representative.
The Contractor shall ensure that no installation or erection work shall commence until full and
unconditionally approved working drawings, signed and stamped by the Employer’s
Representative are available at Site.
The Contractor’s erection staff shall arrive on the Site on dates to be agreed by the Employer’s
Representative. Before they proceed to the Site, however, the Contractor shall first satisfy himself,
as necessary, that sufficient plant of his (or his sub-contractors) supply has arrived on Site so that
there will be no delay on this account.
The Contractor’s representative responsible for erection shall be an erection engineer who is
conversant with the erection and commissioning of the complete Works. If there are more than one
erector, one of them will be in charge and the Contractor shall inform the Employer’s
Representative in writing which erector is designated as his representative and is in charge.
Erection engineer is to report to Project Manager.
The Contractor shall be responsible for setting up and erecting the plant to the line and levels of
reference and of the positions, levels dimensions and alignment, appliances and labor in
connection there with. The checking of setting out of any line or level by Employer’s

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 Representative shall not in any way relieve the Contractor of his responsibility for the correctness
thereof.
Erection of Plant shall be phased in such a manner so as not to obstruct the work being done by
other contractors or operating staff who may be present at the time. Before commencing any
erection work, the Contractor shall check the dimension of structures where the various items of
Plants are to be installed and shall bring any deviations from the required position, lines or
dimensions to the notice of the Employer’s Representative. Plant shall be erected in a neat and
workmanlike manner on the foundations and at the locations shown on the approved drawings.
Unless otherwise directed by the Employer’s Representative, the Contractor shall adhere strictly to
the aforesaid approved drawings. If any damage is caused by the Contractor during the course of
erection to new or existing Plant or buildings or any part thereof, the Contractor shall, at no
additional cost to the Employer, make good, repair or replace the damage, promptly and effectively
as directed by the Employer’s Representative and to the Employer’s Representative satisfaction.
The Contractor shall align all equipment and holding down bolts and shall inform the Employer’s
Representative before proceeding with grouting-in the items concerned. The Contractor shall
ensure that all equipment is securely held and remains in correct alignment before, during and
after grouting-in.
The approval by the Employer’s Representative of the Contractor’s proposals for rigging and
hoisting any items of the Plant into their final positions shall not relieve the Contractor from his
responsibility for damage to completed structures, parts or members thereof or other installed
equipment. He shall at his own cost make good, repair or replace any damaged or injured items,
whether structural, electrical, architectural, or of any other description, promptly and effectively to
the satisfaction of the Employer’s Representative.
No Plant, equipment or other loads shall be moved across the floors of structures without first
covering the floors with timber of sufficient size so that applied loads will be uniformly transferred
to floor beams and girders. If it is required to reduce bending stresses and deflection, the beams
and girders shall be provided with temporary supports.
During erection of the Plant the Employer’s Representative will inspect the installation from time to
time in the presence of the Contractor’s Site representative to establish conformity with the
requirements of the Specification. Any deviations and deficiencies found or evidence of
unsatisfactory workmanship shall be corrected as instructed by the Employer’s Representative.
3.1 Levelling And Grouting Of Machinery
Contractor shall undertake, sufficiently in advance, chipping of any unevenness of concrete on
foundations, anchor bolt pockets, cut outs etc., to achieve uniform level of reference for erection.
All concrete surfaces receiving grout shall be chipped as required to ensure better bonding with
the grouting.
Contractor shall undertake the inspection of all components to be erected sufficiently in advance to
check their soundness and conformity to drawings and the inspection records shall be signed by
the Employer’s Representative as approval for undertaking the installation of the components. Any
damage, shortfalls etc. shall be made good to the satisfaction of the Employer’s Representative.
All grout for equipment shall be carried out using non-shrinkable continuous grout materials with
suitable framework of at least 12mm thickness. Surfaces to receive the grout shall be chipped and
roughened and laitance shall be removed by wire brush or blast of air. Concrete surface shall be
blown off by compressed air before commencing grouting. Grouting shall be done in one
continuous operation from one side such that grout flows in a single wave until grout reaches all
confined spaces with no air pockets and air from all confined spaces is expelled. A hydrostatic
head of 150 mm shall be maintained during grouting operations. All grouting shall be carried out in
the presence of the Employer’s Representative. All lines and levels shall be checked after grout is
set. Block outs shall be closed using cement concrete of the same grade as that of the parent
structure.
3.2 Records, Procedures And Reports
The Contractor shall maintain records pertaining to the quality of installation / erection work and
inspection, testing, compliance with all technical requirements in respect of all his works as
described in the previous paragraphs. The reporting formats shall be in the approved formats. The
Contractor shall submit such records to the Employer’s Representative after the completion of any
particular work before submitting the bill of supply / progress of work. Such report shall comprise
shop inspection reports, shop testing reports, material test reports, based on which dispatch

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 clearances are provided, and all the quality control reports of welding, erection and alignment
records.
All the above mentioned records shall be submitted in the final form duly countersigned by the
Employer’s Representative attesting conformity to specifications and his approval of installation,
and duly incorporating all the additions, alternations, and information as required by the
Employer’s Representative, on the basis of preliminary reports giving the progress of the work.
Such records notwithstanding, any records submitted earlier with bill of supply / progress, etc.,
shall be duly bound and submitted to the Employer’s Representative in six copies by the
Contractor on his notification of the mechanical completion of erection.
3.2.1 General Preparations Before Completion Of The Plant
The documents listed scope of work, civil and mechanical specifications volume should be
completed in accordance with the Contract schedule before completion of erection. The
Employer's Representative and the Contractor shall preserve and control these documents in a
safe and appropriate place on Site in order that both parties' personnel can make use of them at
anytime.

3.2.1.1 Technical Documents:

Operation and Maintenance manual

Design documents including the Contractor's design data, drawings and Specifications.

Tools and test equipment list

Spare parts list

Lubricant list

3.2.1.2 Procedures:

Mechanical testing procedure

Electrical testing procedure

Instrumentation testing procedure

Detailed pre-commissioning and commissioning procedures

Detailed Performance Test procedure

3.2.1.3 General and Coordination Documents:

Detailed organization charts for pre-commissioning and commissioning showing lines of
authorities and responsibility, and functions of all key personnel

Job description of the members of the team

Scheduled dates of assignment of each member to pre-commissioning and commissioning
organization.

Detailed schedule showing the time sequence which the Contractor anticipates to follow for
the various steps in completion of erection, pre-commissioning and commissioning of each
unit and equipment.

Regulations for safety, hygiene and discipline

Practical organization of the relationship (meetings, reports, etc.) between the Contractor and
the Employer's Representative at the phases of pre-commissioning and commissioning.

Emergency communication route.

3.2.1.4 Manpower:
Required manpower shall be provided as agreed between the Contractor and the Employer's
Representative in a Manpower Mobilization Plan, which shall include the number and qualifications
of the operator and maintenance personnel to be furnished by the Employer's Representative for
the Plant.

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3.2.2 Completion Of Erection
The completion of Plant under erection by the Contractor shall be deemed to occur if all the units
of the Plant are structurally and mechanically complete and will include, among other such
responsibilities, the following:

Plant in the Scope of the Contract has been erected, installed and grouted as per
specifications.

Installation checks are completed and approved by the Employer's Representative.

Erected Plants are totally ready for commissioning checks.
At the stage of completion of erection, the Contractor shall ensure that all the physical, aesthetic
and workmanship aspects are totally complete and the Plant is fit and sound to undergo tests on
completion and subsequent pre-commissioning checks.
Upon achieving the completion as described above, the Contractor shall, after having given 21
days advance notice of the expected date for carrying out the inspection, notify the Employer's
Representative by a written notice intimating completion of erection and notify the Employer's
Representative for inspection. The Employer's Representative shall proceed with the inspection of
such units within 24 hours of such a notice.
The Employer's Representative shall certify completion when there are no defaults in the Works or
provide the Contractor with a list of deficiencies for rectification, hereinafter referred as the "Punch
List". The Contractor shall complete the rectification work within a jointly agreed period before pre-
commissioning activities and obtain the Employer's Representative's acceptance or approval
before proceeding with the same.
The Employer's Representative may inform the Contractor that the works are accepted with the
Punch List (items which do not hamper operability, safety or maintainability) and allow the
Contractors to proceed with the pre-commissioning checks when the Contractor undertakes to
complete such outstanding works within an agreed time prior to or during the defects liability
period. Taking over shall be based on rectification of all deficiencies which are to be completed
before acceptance, as advised by the Punch List.
The erection period indicated by the Contractor would be deemed to cover all the activities up to
Completion as stipulated in previous paragraphs, notice of completion by the Contractor,
inspection by the Employer's Representative for Completion, and Contractor's rectification of all
deficiencies as noticed by the deficiency/Punch List, and acceptance by the Employer's
Representative of such rectification's, prior to Tests on Completion.
Minor defects, which in the opinion of Employer's Representative do not hamper operability or
maintainability, will not be taken into account for deciding Mechanical Completion. Such defects
shall be rectified concurrent to commissioning checks before Tests on Completion. However, the
Employer's Representative's decision in this regard is final.
The commissioning period as notified by the Contractor shall include all periods of pre-
commissioning, trial runs and tests on completion.
It is in the Contractor's interest to offer the section/units/systems, progressively under Identified
milestones within overall erection period, duly completed for rectification of any deficiencies
pointed out by the Employer's Representative and to achieve mechanical completion before
undertaking the tests on Completion within the specified erection period. The Employer's
Representative also reserves the right to withhold the cost as estimated to be equivalent to the
rectification of deficiencies pointed out to the Contractor until such a time as the deficiencies are
rectified by the Contractor to the satisfaction of the Employer's Representative.
3.2.3 Pre-Commissioning
After the completion of erection, pre-commissioning activities listed below shall be carried out to
make the Plant ready for commissioning. All instruments, materials and provisions necessary for
conducting site tests shall be provided by the Contractor at his own cost.
Upon completion of erection of each piece of equipment, facility or discrete part of the plant,
mechanical checks and tests shall be carried out according to the Contractor's checklist. The
mechanical checks and tests shall be to establish that:

The Plant is erected in accordance with the Contractor's construction drawings, pipe work
drawings, instrument diagrams, etc., issued for the Plant;

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 Materials are installedand function in accordance with the Contract; and
Applicable codes as listed in the Contract are followed for materials and workmanship.
Items such as painting, thermal insulation and final clean up which do not materially affect the
operation or safety of the Plant will be excluded. All these items shall be listed and completed after
pre-commissioning or commissioning at the discretion of the Contractor, but before acceptance.
The Contractor shall prepare and maintain at Site test forms and records, which shall include:
Description of type of test or check;
Date and times of test or check;
Identification of equipment and facilities;
Test pressure, test data and results, including remarks, if any; and
Signature of the Contractor's personnel attesting to data recorded; if any. The Contractor's
construction forces thereof shall carry out checks, tests and records.
Wherever the Employer's Representative's witnessing or attesting of the check or test is required,
the Employer's Representative's personnel shall attend such check and test. For this purpose, the
Contractor shall keep the Employer's Representative informed of a day-today test plan schedule.
The test plan schedule may be revised from time to time to reflect the actual progress of the work
and test.
Any items found incomplete or requiring repair or adjustment shall be marked as such on the test
records and reported by the Contractor to the Employer's Representative and the Contractor's
personnel in charge of the relevant construction area.
Checking procedures shall be repeated until all the items on the checklist are cleared.
A complete set of test records shall be handed over to the Employer's Representative on
completion.
The tests on the different mechanical and electrical equipment shall include but not be limited to:

3.2.3.1 Pumps, Piping and Valves

Leakage tests shall be carried out on all erected pipe work, pumps and valves immediately
after erection and where possible before being built in.

Operating tests shall be conducted on valves.

The pumps shall be tested for mechanical performance. The vibration and noise levels shall
be checked to be within the specified limits.

Pump performance tests shall be conducted for all raw water and clear water pump sets with
initial duty impellers. Each pump shall be tested at a time. For Malpura only one pump is to be
tested at a time.

To check and verify efficiency of each pump and vibration of pump.

3.2.3.2 Pump Motors

• Condition of winding insulation be tested and insulation values shall be restored to required
level by suitable heating arrangements locally.

3.2.3.3 Instrumentation Testing Requirements

(a) Tests on Cables
i. Check details are in accordance with the specification
ii. Check for physical damage
iii. Megger test between each core and armour / sheath
iv. Continuity check
v. Connections
(b) Continuity of Signal/Control/Power Supply Cables
After laying of the field signal/control/power supply cables and prior to connection up to the
control panels/instruments, the following procedures shall be adopted:

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i. The signal/control/power supply cables shall be disconnected from each termination point
in turn when the wires shall be 'rung-through' for identification and tagged.
ii. The signal/control/power supply cables shall be reconnected to the termination points and
again 'rung-through'.
(c) Loop Test
After testing and calibration of individual instruments forming the various loops, simulated
functional test of the whole loop shall be performed before pre-commissioning. The
procedure for conducting these tests shall be decided by the Employer's Representative
and results shall be recorded. During loop test, it is the Contractor's responsibility to
ensure that the calibration of instruments is intact and in order and if any instrument is
found defective in calibration, he shall recalibrate the same without any extra cost. After
the loop test is over, he shall connect back all the terminations and connections removed
for loop test.
(d) Tests on Electrical Installation
i. Check all closing, tripping, supervision and interlocking of control devices,
ii. Check operation of all alarm circuits.
(e) Test on Complete Control System
i. On completion, the functioning of the complete control system shall be tested to
demonstrate its correct operation in accordance with the Specification.
ii. For control system testing, the Contractor may provide temporary means to simulate
operating conditions, but the system will not be finally accepted until correct operation has
been demonstrated to the satisfaction of the Employer's Representative when all the Plant
is operating.
iii. The system shall be shown to operate correctly whatever the selection of duty and
standby equipments may be.
iv. Conditions to be tested shall include:
• Normal automatic operation
• Normal manual operation
• Emergency manual operation
(f) System Validation
i. The services of factory trained and field experienced instrumentation engineer(s) shall be
provided to validate each system and verify that it is operational and performing its
intended function within system tolerance. System tolerance is defined as the root-mean
square sum of the system component published specified accuracy from input to output.
ii. Each system shall be validated by simulating inputs at the first element in loop (i.e. sensor)
of 10 %, 50 % and 90 % of span, or on/off and verifying loop output devices (i.e. indicator,
alarm etc. except controllers).
iii. During system validation, provisional settings shall be made on levels, pressure, alarms
etc.
iv. Correct operation of controllers shall be verified by observing that the final control element
moves in the proper direction to correct the process variable as compared to the set point.
All logic sequences shall be verified to operate in accordance with the specifications.
v. All defects and malfunctions disclosed by tests shall be corrected immediately. New parts
and materials shall be used as required and approved and tests shall be repeated.
vi. A report certifying completion of validation of each instrument system indicating calculated
system tolerances, verification that the system meets these tolerances and any provisional
settings made to devices shall be provided. The report shall be made in the format
required by the Employer’s Representative and shall be certified by the Employer’s
Representative when he approves it.

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 (g) Final Operational Testing and Acceptance.
i. Upon completion of instrument calibration and system validation, all systems shall be
tested under process conditions.
ii. The testing shall include, but not limited to all specified operational modes, taking process
variables to their limits (simulated or process) to verify all alarms, failures, interlocks and
operational interlocks between systems and/or mechanical equipment.
iii. Any defects or malfunctions shall be immediately corrected using approved methods and
materials and the tests shall then be repeated.
iv. Upon completion of final operational testing, a report shall be submitted, indicating that the
total control system provided meets all the functional requirements specified herein. This
report shall be made in the format required by the Employer’s Representative. The
Employer’s Representative shall certify this report when he approves it and it shall
constitute final acceptance of the control system.
3.2.4 Electrical
The commissioning engineer may verify any commissioning tests / completion checks to satisfy
him that the plant is fit and sound.
The commissioning tests / completion checks to be carried out shall include, but not be limited
to, those described in subsequent paragraphs, as applicable to the individual equipment /
system.

3.2.4.1 Commissioning Tests / Completion Checks

Preliminary Checks
In general, the following checks shall be carried out on all the equipment/systems, as applicable.
a) Name plate details according to approved drawings / specifications
b) Any physical damage or defect and cleanliness
c) Tightness of all bolts, clamps and connections
d) Oil leakages and oil level
e) Condition of accessories and their completeness
f) Clearances
g) Earthing connections
h) Correctness of installation with respect to approved drawings / specifications
i) Lubrication of moving parts j) Alignment
j) Correctness and condition of connections

General tests
a) Commissioning Tests of Motor

Insulation resistance test of motor windings and cables. (PI for MV motors only)

Continuity check for power and control cables.

Winding resistance measurement in case of motors rated 55 kW and above.

Control, interlock and protection schemes.

Operation and setting of timer, in case of Star Delta starters.

Phase sequence and rotation.

No load trial run for observation of vibrations, noise and temperature of bearings etc.

On load operation, starting and running load current (also observe vibrations, noise and

temperature of bearing and winding).

Relay setting as per relay co-ordination chart

Simulation check of motor control circuit by local/ remote closing and tripping

b) Commissioning Tests of Transformer:

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 i) Test oil for dielectric strength, tan delta, acidity, resistivity and dissolved gases,
Insulation resistance test of windings,
ii) Capacitance and tan delta test of condenser type bushings, before assembly,
iii) Test the transformer for the following:

Voltage / turns ratio at all the taps.

Winding resistance at all the taps.

Short circuit impedance (at low voltage)

Magnetic balance.

Core loss at normal tap at low voltage.

IRandPI.
iv) Vector group test.
v) Phase sequence test.
vi) Test the current transformers for following:

Continuity test.

Polarity test.

Insulation resistance test.

Magnetization characteristics.

Measurement of secondary winding resistance.
vii) Line connection as per phasing diagram.
viii) Winding resistance.
ix) Insulation resistance of control wiring.
x) Buchholz relay operation (for alarm and trip).
xi) OLTC control indicating and alarm circuit.
xii) Operation test of all protective devices (electrical and mechanical) and interlocks.
xiii) Calibration of temperature indicators (oil and winding) and temperature relays.
c) Commissioning Tests of Switchboard:
i) Checks on relays.
ii) Insulation resistance test
iii) High voltage test
iv) Millivolt drop test for busbar joints
v) Checks on motors/ simulation check.
vi) Setting of relays, other alarms, tripping devices and interlocks as per scheme.
vii) Phase angle checks, measurement of magnitude and phase angle of current
transformer secondary currents and potential transformer secondary voltage.
viii) Functional checking of all power and control circuits e.g. closing, tripping, control,
interlock, supervision and alarm circuits including proper functioning of the component
equipment.
d) Commissioning Checks of Relay:
i) Check operating characteristics over the entire range by secondary injection.
ii) Check minimum pick up voltage.
iii) Check operation of electrical / mechanical targets.
iv) Relay settings.
e) Commissioning Checks of Meter:
i) Check calibration.
ii) Megger all insulated portions.
iii) Check CT and VT connection with particular reference to their polarities for relevant
meters.
f) Commissioning Test of Circuit Breaker:
i) Check control wiring for correctness of connections, continuity and IR values.
ii) Manual operation of breaker.

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 iii) Power closing / operating manually and electrically.
iv) Breaker tripping and closing time.
v) Trip free and anti pumping operation.
vi) IR Values, resistance and minimum pick up voltage.
vii) Contact resistance.
viii) Simultaneous closing and mechanical interlocks provided.
ix) Check electrical and mechanical interlocks provided.
x) Checks on spring charging motor, correct operation of limit switch and time of
charging,
xi) Checks on CTs.
xii) High voltage test,
xiii) All functional tests.
g) Commissioning Tests of Voltage Transformer:
i) Insulation resistance test.
ii) Polarity test.
iii) Ratio test on all cores.
iv) Line connections as per connection diagram.
v) Open delta test with low voltage, wherever required.
h) Commissioning Tests on Current Transformer:
i) Megger between windings, winding terminals and body.
ii) Polarity test.
iii) Ratio identification checking of all ratios on all cores by primary injection of current.
iv) Magnetization characteristics, secondary winding resistance.
v) Capacitance and tan delta test.
vi) Dielectric test of oil (wherever applicable).
h) Commissioning Checks of Cable:
i) Megger test between each core and armour / sheet.
ii) Continuity check.
iii) Connections.
iv) High voltage test for cables above 3.3kV.
i) Commissioning Checks for Battery:
i) Specific gravity test.
ii) Cell voltage test.
iii) Capacity test.
iv) Initial charging/ discharging cycle.
j) Commissioning Checks of Battery Charger:
i) Functional check of auxiliary devices, such as alarms, indicating lamps etc. and
operational checks.
ii) Insulation test of all circuits.
iii) Measurement of voltage regulation and efficiency.
iv) No load current and voltage (AC) and voltage and current (both AC and DC) at
different points.
v) Voltage at tap cell (While boost Charging)
k) Commissioning Checks of Capacitor:
i) Measurement of capacitance
ii) Capacitor loss tangent measurement (for above 1000V)
l) Commissioning Checks of Neutral Grounding Resistor:
i) High voltage test
ii) Ohmic value test

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 m) Lighting System
Commissioning tests stipulated in applicable standards and code of practice covering all lighting
system equipment
n) Earthing System
Continuity of all conductors and joints shall be checked. The Employer’s Representative may
ask for earth continuity tests, earth resistance measurements and other tests, which in his
opinion are necessary to prove that the system is in accordance with design, specification, code
of practice and electricity rules. Earth grid resistance value should be not greater than one ohm.
o) Tests for Trial run and commissioning of the 33kV Transmission System:
1. General
Before the line is energized, visual inspection of the line shall be carried out to check
that all the nuts and bolts are tight and insulators and accessories are in position. The
earth connections shall be checked to verify that these are in order.
2. Testing
Before commissioning the line, the following tests shall be carried out:
a) Conductor continuity test – The electrical resistance of the conductor shall be
measured with a Wheatstone or other suitable instrument to ensure proper electrical
connection of the line.
b) Insulation resistance test – This test may be carried out with the help of a 5kV
meggar to ascertain the insulation condition of the line.
3. The line shall be kept charged on no load at the power frequency voltage preferably for
72 hours for the purpose of full scale testing.
3.2.5 Instrumentation And Control
i) The list of tests to be carried for SAT along with test instruments to be used shall be furnished
for review by the Employer’s Representative.
ii) The testing of all the equipment and accessories shall be carried out as per latest applicable
Indian/International standards recommendations.
iii) Prior to testing, all relevant documentation and sufficient briefing about the tests shall be given
to Employer’s Representative who would witness the testing.
iv) After installation and commissioning, the Contractor shall demonstrate, by tests in the field,
compliance of the values, functionalities, quality and reliability of the complete system and its
components, both hardware and software, as specified and as per guarantees.
v) Contractor shall be fully responsible for interfacing to the equipment of Others as indicated in
the scope of works. It shall be Contractor's responsibility to ensure satisfactory functioning of
the system in conjunction with related equipment like exchanges, data equipment and other
communication equipment of the Employer’s Representative. Problems relating to such
interconnections shall be mutually resolved.
vi) After tests as above, the complete system shall be on continuous uninterrupted service with all
functionalities and interconnections without any failures or manual interventions for correction,
modification, rectification or replacements in the Contractor's system.
vii) Additional specific tests, if required, would be decided mutually.
SAT on local SCADA, UPS systems shall include the all tests covered under FAT documents
except tests such heat run test and those tests which cannot be conducted at site (such tests shall
be approved by the Employer’s Representative) in addition to integrated local SCADA, UPS
systems testing at site with all field equipments/instruments

3.2.5.1 Site Calibration

Standard calibration procedures shall be used for calibrating all field instruments. All reference
equipment, used for calibration, shall be certified from an authorized certifying agency, to be

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 arranged by the Contractor at his own cost. At the time of calibration, standard calibration norms
shall be adopted and the same will be documented for record purposes.
Calibration shall be performed in the presence of the Employer’s Representative. The
instrumentation shall be calibrated while being commissioned in order to verify that the high quality
calibration carried out during FAT is not being disturbed (No undue adjustments shall be made for
minor deviations). The Contractor will monitor and check the instrument calibration throughout the
Operation and Maintenance period.

3.2.5.2 Instrumentation Installation and Pre-Commissioning Checks

a) Check the exact location of the instrument with reference to the pipe and instrumentation
diagram and/or the General Arrangement drawing.
b) Check that tag plate with tag no. and description is provided for each instrument.
c) Check the model No. and instrument type with reference to the technical specification
requirements.
d) Check all mounting and fixing arrangements and required accessories such as isolation valve,
nuts and bolts, siphon etc.
e) Check that the instrument installation is as per the installation drawing.
f) Check the cable type, connections for power supply as well as signal cables.
g) Check that cable shields for the instruments are properly terminated.
h) For the flow meters, check that the flow rate and totalized flow reading on the various displays
match.
i) Check that the earthing is as per manufacturer’s recommendation.
j) Check that there are no leakages.
k) For the level switches check that the level electrodes are connected to the correct level control
units.
l) For the temperature scanners, check that the communication port of temperature scanner is
properly configured and interfaced with the PLC system. Also check that the alarm and trip
signals for various channels of temperature scanner are properly configured.
m) Check the loop continuity for every circuit. While this is being done, the power supply to the
instrument shall be cut-off.
n) Calibration checks of the instruments shall be carried out to ensure integrity with the
manufacturer’s factory test reports. (No undue adjustments shall be made for minor deviations
o) After switching on the instrument/system, it shall be monitored hourly and the data obtained
shall be recorded and compared with the reference norms to ascertain whether any
recalibration is required. If recalibration is required it shall be carried out using standard
reference equipment/instruments at no extra cost.

3.2.5.3 Instrumentation Commissioning

a. Each control loop and interlock shall be tested independently, in manual mode first and then in
auto mode from the PLC and local SCADA system. The operation shall be checked for
conformity with the approved logic in both modes. All pump control ON/OFF shall be checked
in manual mode first.
b. Annunciation system shall be checked as performance testing by simulating the condition and
by passing in actual mode and then individual loop will be checked for annunciation system.
All motorized valves shall be checked in manual mode first, from controls on the control
panel, and feed-back from the field for valve on/off shall be checked on the panel.

3.2.5.4 Programmable Logic Control (PLC)

a. The PLC system and software shall be loaded by the representative of the PLC manufacturer.

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 b. Testing, commissioning and stabilization of the software shall be carried out by the authorized
representative of the PLC manufacturer. The following checks shall be carried out:

All indicators and indicating controllers will be put in manual mode after independent
checking.

Check that the PLC is properly configured and installed as per the approved drawings.

Check that the PLC wiring is as per approved drawing.

Check that the cables terminating in the PLC are properly dressed.

Check that the PLC is earthed as per manufacturer's recommendations.

Check that the PLC on-line battery is functioning properly.

Check that the PLC is correctly time synchronized with the local SCADA system

Check that the signals and events are getting correctly time stamped.

Check the PLC response when input signal is out of range.

Check that the correct ladder program is loaded in the PLC.

Check the PLC ladder program by simulating various normal and abnormal conditions.

Check that the data sheets and drawings are updated to reflect the as-built status.

All analogue inputs shall be connected to the PLC system first. All digital inputs shall be
checked at terminals before connecting to the I/O card of PLC system. PLC system shall
be installed and checked first, before connecting any control signals/cables. Software shall
be loaded in the PLC first, before connecting I/O cards with signal cables. After complete
checking of the system in manual mode, system shall be put in Auto mode.
c) The PLC system manufacturer/supplier shall provide assistance/commissioning support at the
time of commissioning, to be arranged and coordinated by the Contractor. Details regarding
commissioning shall be provided prior to commissioning and any required modifications or
changes shall be advised in advance.

3.2.5.5 Control Panel

a. Check name plate details of every piece of associated equipment for conformity with the
specifications.
b. Check the tightness of all bolts, clamps, connecting terminals.
c. Check for physical damage.
d. Check cleanliness
e. Check switch development
f. Each wire shall be traced by continuity tests and it should be confirmed that wiring is as per
the relevant drawings. All interconnections between panels/equipment shall be checked
g. Megger test on all wires,
h. Check on meters
i. Check that the primary devices are set as per the system requirements.
j. Checks on the control circuit for the functional requirements
k. Check that the control panel front fascia layout is as per approved drawings.
l. Check that the panel and all the panel equipment (viz. panel indicators, alarm annunciators,
etc.) are connected to the proper earth,
m. Check that spare cutouts on the control panel are blanked,
n. Check that the panel indicator tag plates reflect the tag no. and the correct service
description,
o. Check whether the panel meters are fixed properly in their cutouts,

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 p. Check that the instruments are identified inside the panel,
q. Check that the panel meter instrument ranges are as per approved data sheets,
r. Check that panel meters are provided with password protection facility,
s. Check that the alarm inscription details are as per approved drawings.
t. Check that the MCBs are identified by their function.
u. Check that safety guards are provided for power supply terminals.
v. Check the cables terminating in the control panel are properly dressed.
w. Check that proper node addresses are given to the panel meters/ scanners connected on
the communication bus.
x. Check that the communication bus is terminated properly.
y. Check working of alarm annunciator by simulating alarm conditions.
z. Check that the panel meter readings match with other displays.
aa. Check that the no. of decimal places and unit of measurement are same for all the displays.
bb. Check that the data sheets and drawings are updated to reflect the as-built status.

3.2.5.6 Tests for Local SCADA

SAT on local SCADA systems shall include all the tests covered under FAT documents except
tests which cannot be conducted at site (such tests shall be approved by the Employer’s
Representative) in addition to integrated local SCADA, communication system and UPS systems
testing at site with all field equipment/instruments.

3.2.5.7 Tests for UPS

SAT on UPS systems shall include the all tests covered under FAT documents except tests which
cannot be conducted at site (such tests shall be approved by the Employer’s Representative) in
addition to integrated local SCADA, UPS systems testing at site with all field
equipments/instruments.

3.2.5.8 Tests for EPABX System

SAT on EPABX systems shall include the all tests covered under FAT documents except tests
which cannot be conducted at site (such tests shall be approved by the Employer’s
Representative) in addition to integrated trunks and VHF communication systems testing at site
with all telephone instruments

3.2.5.9 Tests for VHF Communication System

SAT on VHF communication systems shall include the all tests covered under FAT documents
except tests which cannot be conducted at site (such tests shall be approved by the Employer’s
Representative) in addition to integrated with EPABX system at site with all handheld mobile sets.
Site acceptance test shall include check of the antenna in use, and include the following four main
characteristics of interest:
i) Type of antenna
ii) Height of the antenna
iii) Direction of main lobe
iv) Gain of the antenna

The radio base stations shall be confirmed as being located at the address as shown on the
license. Contractor shall resolve such matters before proceeding with the station inspection. If a
radio base station has moved a short distance so that the coverage area is little changed, the
licensee should be informed, to regularize the licensing position, rather than closing the station
down.

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3.2.6 Commissioning
After the completion of pre-commissioning activities the final checks and preparations necessary
for start-up of the plant shall be carried out. The Contractor shall submit to the Employer’s
Representative a written Notice of Mechanical Completion, which shall include:
1.Identity part of the Plant considered mechanically complete.
2.Copies of all relevant completed test reports.
3.Date on which the completion of the tests was achieved.
4.Check list.
5.Request for issuance of a Mechanical Completion Certificate in respect of that part.
6.Within fourteen (14) days from the date of receipt of the Contractor's written Notice, the
Employer's Representative shall:
• In the case of acceptance, issue a Mechanical Completion Certificate.
• In the case of objection, submit a rejection statement setting forth-remaining items to
be completed or defects or deficiencies to be corrected before Mechanical Completion
status can be accepted. When the Employer's Representative rejects the Contractor's
Notice the Contractor shall take any necessary action to complete or correct the items
marked and give the Employer's Representative a second Notice of Mechanical
Completion.
7. After the issuance by the Employer's Representative of a Mechanical Completion
Certificate, commissioning activities listed below shall be carried out to enable the start
up and operation of the Plant. Procedures are described as below:
A) Commissioning procedure shall be carried out in a methodical sequence as follows
• Warming up
• Start-up
• Initial running
• Operability adjustment
• Stable operation
• Final adjustment
8. At all stages of commissioning sequence, the Plant shall be operated at optimum Plant
conditions. To ensure this, the Contractor may make minor adjustment to the conditions
indicated in the Operation and Maintenance Manual as necessary.
9. The Contractor shall check the operating conditions of the Plant by constantly monitoring
operating data.
10. The Contractor shall specify for each discrete part of the Plant the operational data to be
recorded and the manner in which the data is to be taken.
11. The Employer's Representative on the forms to be mutually agreed shall record all the
operating data. The Employer's Representative shall make a copy of the operating log and
analytical data from initial operation through to the completion of Performance Test
available to the Contractor for evaluation.
12. The Contractor shall carry out commissioning tests in the presence of the Employer's
Representative. The evaluation of test results and decision passed by the Employer's
Representative regarding the test results will be final and binding on the Contractor. Any
additional tests or repetition of tests to establish satisfactory operation of any equipment
shall be carried out by the Contractor, if so desired by the Employer's Representative, at no
extra cost.
13. All checks and tests shall be as per the Manufacturer's drawing manuals, relevant codes of
installation and as per commissioning checklists.
14. Among other commissioning tests, the following shall be carried out at site after completion
of installation. Contractor shall ensure to use calibrated test equipment having valid
calibration test certificates from standard laboratories traceable to National Standards /
International Standards. All tests to be carried out in the presence of Employer's
Representative.

3.2.6.1 Commissioning Tests

Following commissioning tests are to be carried out on all the equipment/systems, as applicable.

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 • Insulation resistance measurement of equipment, accessories, cabling/wiring etc.
• Dielectric tests on equipment, accessories, cabling/ wires etc.
• Phase sequence and polarity
• Voltage and current ratios
• Vector group
• Resistance measurement of winding, contacts etc.
• Continuity tests
• Calibration of indicators, meters, relays, etc.
• Control and interlock checks
• Settings of equipment and accessories
• Checking of accuracy/error
• Checking of operating characteristics, pick-up voltages and currents, etc.
• Operational and functional tests on equipment, accessories, control schemes,
alarm/trip/indication circuits, etc.
• Measurement of guaranteed/approved design values including lighting levels, earth resistance
measurement, etc.
• Complete commissioning checks of the system
3.2.7 Safety Procedure And Practice
Following safety procedure and practice should be provided by the Contractor in the
switchboard room/ substation as per latest edition of I.S. 5216.
a) Rubber matting in front of HV, MV and LV switchboard and other panels in
switchboard room
b) Shock treatment chart in switchboard / electrical equipment room
c) Caution/Danger Board on -
• HV, MV and LV switchboard and other LV panels
• Lighting distribution board
• Transformer yard.

d) Sand bucket in switchboard / electrical equipment room/ transformer yard

e) Fire extinguisher in switchboard/ electrical equipment room
f) One set of hand gloves in switchboard room
g) First aid box in switchboard / electrical equipment room

3.2.7.1 Fire Safety

The requirement of hand appliance in switchboard room, electrical equipment room shall be as per
the latest edition of Fire Protection Manual by Regional Tariff Committee.

3.2.7.2 Contractor's Licence

The Contractor shall obtain the necessary Licence/ Authorization from the Licensing Board of the
locality/ State for carrying out the installation work. The persons deputed by the Contractor should
also hold valid permits issued/ recognized by the Licensing Board of the locality/ State in which the
work is to be done.
The electrical installation work shall be carried out by licensed electricians only and approved by
appropriate authorities. It is the responsibility of Contractor to get approval of complete system
from the appropriate authority.
3.2.8 Pipeline Works

3.2.8.1 Test on Pipe Line

The sectional testing of MS pipeline shall be done as per the provisions set out in the mechanical
specification along with the laying of pipelines. The tested pipeline will be joined by gap pieces to

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 complete the total physical completion of works. The maximum length for sectional testing in case
of MS pipeline shall be as specified in Subsection 3 except for cases where, according to the
Employer's Representative, the criteria cannot be met due to specific Site conditions.
The laid pipeline will be joined with respective manifold through valves. Just before the
commissioning the complete transmission main will be checked for:
i. All the motorized valves in the system will be inspected for proper lubrication, manual and
electrical operation.
ii. All air valves shall be inspected for proper fitting and operation of isolating valves.
iii. All flange joints/ expansion joints/ couplings will be checked for tightness of all bolts, clamps,
etc.
iv. The entire transmission system shall be checked for proper soil cover/ backfilling/ thrust and
anchor blocking, etc.
v. The structures will be checked for any constructional defects.
vi. The valve chambers and their surroundings will be checked for its cleanliness,
vii. The rectifiers, batteries, battery chargers at all CP stations will be checked for their functioning
along with pipe to soil potentials (PSP) at every test lead point for proper soil potential. All CP
stations, test stations to be monitored regularly during the commissioning and trial run period
and data related to PSP, individual anode current, energy consumption, battery performance,
etc., to be incorporated in the log-book.
viii. Surge protection system shall be checked for the proper functioning.

3.2.8.2 Leakage Test

The entire pipeline shall be subjected to a hydraulic test as follows, to the required test pressure as
per IS: 5822.
If a drop in pressure occurs, the quantity of water added in order to reestablish the test pressure
should be carefully measured. This should not exceed 0.1 liter/ mm of pipe diameter per kilometer
of pipeline per 24 hours for each 30 m head of pressure applied.
All the joints, valves, fittings which are not tested during sectional testing shall be physically
checked for leakages and leakages repaired if found.
The Contractor shall provide and maintain all requisite facilities, instruments, for the field testing of
the material. All pipes, specials, valves and civil works shall be replaced by the Contractor free of
cost if damaged during testing.

3.2.8.3 Surge Protection Test

The effectiveness of the surge protection system shall be checked as follows,
• Install pressure gauges at the pressure gauge points such as immediately after pumps, at
summits, at valleys, at critical points, etc.
• Run all the pumps at a time at least for one hour and then shut off all the pumps at a time.
• Record the pressure gauge readings before and after shut off.
• Inspect working of the various equipment of the surge protection system.
The pressure gauge readings at any point should show the pressure increase less than as
specified for design of surge protection system given in Subsection 6. Vacuum pressure of-3.0 m
(minus three meters) is allowed in the system. No leakages should occur other than the places
observed above in the leakage test. The surge protection system shall work smoothly without any
visual distress, failing which the Contractor shall take necessary measures to improve/correct
/replace the surge protection system.

3.2.8.4 Cathodic Protection System Test

The effectiveness of the cathodic protection system shall be checked by monitoring the current
requirements at all the Cathodic Protection (CP) Stations, If the current requirement is more than

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 that stipulated in the Subsection 4, then the corrective steps shall be taken to bring the current
requirement within specified limit.

3.2.8.5 Hydraulic Tests

All equipment subject to water pressure including castings, pressure vessels, pumps, pipes,
fittings, and valves, shall be hydraulically tested to the pressure specified or in accordance with the
applicable standard. Hydraulic test facility shall be made available at the manufacturer's works.
Any of the hydraulically tested items shall be subject to the Employer's Representative inspector's
random item proof re-test and notice of testing dates shall be submitted to the Employer's
Representative.

3.2.8.6 Site Testing

The Contractor shall arrange for the full site testing of all items of equipment and shall include
provision of:
a. All skilled and qualified operating and test staff for the testing of all equipment;
b. Provision and disposal of all services, lubricants, and fuels other than electricity;
c. All measuring and testing instruments to demonstrate equipment operates to the fulfillment of
the works test;

3.2.8.7 All Loading Weights for the Load Testing of all Lifting Equipment
The Contractor shall carry out all the tests to the satisfaction of the Employer's Representative.
The Contractor shall be responsible for coordinating the programme of site testing of all items and
to ensure that all parties concerned are present during any tests to obligate their responsibilities.

3.2.8.8 Documentation
Set of documents shall be prepared and maintained by the Contractor and one set of the latest
revised documents shall always be kept at site. The following documents shall be prepared by the
Contractor:
• All latest approved L-sections and alignment drawings.
• All up-to-date as built drawings.
• Data sheets for instrument specification and selection
• List of electrical equipment along with data sheet/ literature
• Erection/ Instruction manual of electrical equipment
• Commissioning manual of electrical equipment
• Instrument Schedule
• Electrical cable schedule and inter-connection diagram
• Instrumentation schedule
• Instrumentation cable schedule
• Loop drawings for instruments in the field and control panel
• Instrument test and calibration report
• Instrument installation drawings
• As built drawings and G.A. Drawings for equipment and instrument installation
The Contractor shall keep on site two sets of the latest revised Operation, Maintenance and
Calibration manuals for all field instruments and sub systems, annunciation system, data loggers,
indicating controllers and PLC system etc.
3.2.9 Tests for Water tightness of Water-retaining structures & sewerage Network
Water retaining structures for water supply purposes shall satisfy the following tests for water
tightness, before external finishes are applied (if any). The water for testing shall fill the first 1.25
meters and may be filled as quickly as supply permits. Between this and top water level, the rate of
filling shall not exceed a steady rate of 300 mm per 24 hours unless otherwise directed. After filling
to top water level no further water shall be introduced for 7 days. After expiry of seven days and
after the filling, the level of the surface of the water shall be recorded. The level of water shall be
recorded again at subsequent intervals of 24 hours over a period of seven days and the structure

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shall satisfy the test if at the end of this week no leakage is apparent and or the water level does
not drop more than 40 mm over the period of 7 days. The Employer's Representative shall decide
on the actual permissible nature of this drop in surface level, taking into account whether the tanks
are open or closed and the corresponding effect it has on evaporation losses. Foregoing visible
leakages and sweating will not be accepted.
If the structure does not satisfy the condition of test and the daily drop in water level is decreasing
the period of test may be extended for a further seven days and the if specified limit is then
reached the structure may be considered as satisfactory.
Following satisfactory completion of the tests the Contractor shall empty the structures and
dispose of satisfactorily the contents. He shall clean and disinfect the structures and any
equipment therein of all deposits left by the testing.

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4 START UP AND PERFORMANCE RUN
This section is valid for Sewage treatment process
4.1 Test On Completion
4.1.1 General
Prior to the commencement of Tests for STP & SPS on Completion the Contractor shall submit for
approval the following:

Site Acceptance Test Documents

As-Built Drawings

Operation & Maintenance Manuals
Tests on Completion shall not be commenced until the aforementioned documents are approved.
The initial charges necessary for Tests on Completion shall be provided by the Contractor.
Electricity required for Tests on Completion will be provided by RMC free of charge for a period not
exceeding 30 days. In case the test on completion period exceeds 30 days, the cost of power till
start of performance run shall be borne by contractor.
The cost of any consumables and chemicals required for the Tests on Completion shall be borne
by the Contractor.
4.1.2 Dry Test Requirements

4.1.2.1 General
As a minimum requirement, the following dry tests shall be carried out as a general requirement:

• a general inspection to check for correct assembly and quality of workmanship,

• a check on adequacy and security of Plant fixing arrangements

a general check to ensure that all covers, access ladders, water-proofing, guard railings etc.
are in place,

a check on damp proofing, rust proofing and vermin proofing and particularly the sealing of
aperture between building structure , chambers, etc. and the outside.

4.1.2.2 Civil and Building Works

As a minimum requirement the following dry tests shall be carried out on the civil engineering and
building works:
Check for the presence of foreign bodies in pipe work and structures.

4.1.2.3 Mechanical Works

As a minimum requirement the following dry tests shall be carried out on the mechanical systems:
Carry out preliminary running checks as far is permitted by circumstances in order to ensure
smooth operation of Plant.
4.1.3 Electrical Works
As a minimum requirement the following dry tests shall be carried out on the electrical systems:

Check phasing and polarity

Carry out point to point check on all cables;

Check on security of cable terminations

Check on completeness and adequacy of earthing systems;

Check setting on protection relays, sizes of fuses and motor overload settings;

Carry out checks on cabling systems in accordance with the requirements of the relevant
standards;

Check operation of main circuit breakers by secondary injection methods;

Check rotational direction of plant;

Check instrument loop integrity, functionality and calibration;

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Check operation of standby generator installation and mains/generator changeover

procedures; a 4 hrs load test (using the normal load of the Works) shall be carried out on the
generator when the load is available;

Check plant functionality

Check functionality of the central MMI and its power supply;
4.1.4 Process Plant Item / Equipment
All process plant items/equipment shall be tested to ensure they meet the Employer's
Requirements for quality of workmanship, construction and performance.
4.1.5 Hydraulic Wet Test Requirement
Hydraulic wet tests shall be carried out on completion of dry tests.
Potable water shall be used for hydraulic wet tests. The purposes of the tests is to prove as far as
is practical the hydraulic performance of the Works. In order to demonstrate this the Contractor
shall ensure that each part of the Works is hydraulically loaded to its maximum rated load
throughout for a period of at least seven days at twenty-four hours intervals.
In order to ensure a sufficient supply of potable water to carry out these tests the Contractor shall
provide facilities for the disposal off site in an approved manner.

In order to remove doubt the following tests inter alia shall be carried out.

Pressure testing of all piped systems laid direct in ground in accordance with the relevant
standards;

Fill all structures and check for leaks as per IS:3370;

Running of all pumped systems in order to check for

Correct functionality

Absence of leaks

Correct running temperatures

Smoothness of running and the absence of undue vibration or stress;

Check drive running currents

Carry out calibration of instruments where appropriate

Carry out valving, diversion etc. to fully hydraulically load each process element (or where
there is a requirement to withstand an over load), overload each process element;

Demonstrate correct functionality of electrical, control and instrumentation systems.
The Contractor shall simulate where practical the conditions that will prevail when operating as a
process in order to demonstrate the correct functionality of process control loop etc.
During these tests a check on the performance of Plant shall be made, as far as site facilities will
allow, to compare its site performance with the factory test data and to identify and constraints on
performance due to site conditions.
4.1.6 Process Wet Test
On approval by the RMC the Contractor shall carry out process wet tests.
Raw water shall be used as the primary feed stock for process wet tests. These tests shall be
carried out to demonstrate the process performance of the Works. In order to demonstrate this, the
Contractor shall ensure that each part of the Works is located to its rated throughput (including a
period of overload if required in order to demonstrate compliance with the Employer's
Requirements) for continuous stable operating period of not less than 48 hours.
The Contractor shall provide facilities for the disposal off site in an approved manner.
The following tests inter alia shall be carried out;

Check and rectify leakage on civil structures, pumps and pipework;

Running of all pumped systems in order to check for;

Correct functionality,

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Absence of leaks,

Correct running temperatures,

Smoothness of running and the absence of undue vibration or stress,

Check drive running currents where the solution pumped is different from that pumped during
hydraulic wet tests;

Carry out calibration of instruments;

Carry out valving, diversion etc to fully hydraulically load each process element (or where
there is a requirement to withstand an over load), overload each process element;

Demonstrate correct functionality of electrical, control and instrumentation systems not
checked during dry or hydraulic wet tests or which may have changed as a result of the
different operating conditions now prevailing.
On completion of process wet test on the various parts of the works the Contractor shall run the
plant as a whole in order to demonstrate the full functionality and performance of the Works at
various throughput rates for a continuous period of not less than 7 days. In this period power
utilised by the contractor shall be compared with the guaranteed power consumption given by the
contractor. This shall be considered as completion of Test on Completion' and shall be certified by
RMC.
4.2 Performance Run After Start Up
4.2.1 General
On successful completion of Test on Completion' i.e. Start up and commissioning, certified by
RMC, Contractor should start the performance run of the plant for 3 months.
The Contractor is to carryout Operation & Maintenance (O&M) of the whole plant including civil
works for 3 (three) months under performance run. RMC shall monitor the operation and
maintenance by the Contractor.
During performance run period, the Contractor shall provide following as minimum for round the
clock operation.
Staff
Plant in charge One
Chemist: : One
Operators : One for each shift
Maintenance unit Helpers : One fitter, One electrician :
Watchmen : One for each shift
Chemicals and consumables : As required
Spares: As required for replacement during performance run period. The spares used from the
spare supplied under the contract shall be replaced by the Contractor.
RMC shall supply power and water during Performance Run period free of cost. All other material
such as chemicals, consumables, lubricants, tools & plants, spares etc shall be provided by the
contractor. The contractor, if required, shall provide activated sludge or any other material for the
stabilisation of the plant.
The Contractor shall provide operators for various units/plants for three shifts and other
staff/supporting personnel in general shift.
The Contractor shall submit a weekly report to the Employer, about the operation and maintenance
indicating the manpower, electric power, chemicals and other consumables consumed and also
problems faced and rectified.
During this period, the Contractor shall ensure that the design treated sewage quality standards
are met in accordance with the specification within the rate of power and chemical consumption as
committed by the Contractor. The raw and treated sewage analysis pH, SS, BOD and oil & grease
shall be carried out on daily basis from the day of commissioning at a reputed laboratory as
approved by Engineer-in-Charge. 90% of the treated sewage samples should fall within prescribed

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 limits of the treated sewage. The sampling location for raw sewage shall be at raw sewage sump
and that of treated sewage shall be at outlet of chlorine contact tank.
The analysis of sewage for the above parameters at different locations such as outlet of secondary
clarifier shall also be carried out on weekly basis. The Contractor shall take immediate steps to
correct the operation of the plant to meet the guaranteed performance. The charges for analysis at
the laboratory are to be borne by the Contractor.
The Contractor’s responsibility includes the safety and security of the works/plants during the
course of performance run of three month.
The Contractor shall provide the key personnel for performance run with the minimum qualification
and experience as given below.
Sr. Category Qualification and Experience
1. Plant in Graduate in Engineering/Technology (Civil/
Environmental Charge Engineering) having5 years of
experience in O & M/Maintenance of water /wastewater
treatment plant.
2. Plant Operator Diploma in Engineering/Technology (Civil/
Environmental/Chemical Engineering) having 3 years
of experience in Operation/ Commissioning of
water/wastewater treatment plants.
3. Chemist Graduate in Environmental Science/ Chemistry having 5
years of experience in sampling/ analysis in
water/wastewater treatment plants.
4. Electrician Filter / Diploma in respective field with 5 years of experience in
erection, commissioning and O&M of M&E equipment in
water/ wastewater treatment plants.
4.3 Performance run Certificate
The conditions for issuance of a Performance Run Certificate as detailed in the Conditions of
Contract shall comprise:
1. The completion of the three months operation and maintenance under performance rum of
the treatment plant to the satisfaction of RMC.
2. 90% of the treated sewage samples fall within the prescribed limits of the treated sewage
as mentioned in the tender document.
3. The O & M Manuals have been updated following three month’s operational experience
and approved by RMC.
4. All defects identified during the three months operation of the works have been rectified
RMC shall issue a Completion Certificate for “Performance Run of Plant” after successful
completion of Performance Run of plant for 90 consecutive days by Contractor to the satisfaction
of RMC.
4.4 Payment Schedule For Stp & Sps
The contractor can submit a tentative payment schedule normally prevailing and the same can be
mutually discussed with the client for approval within one month of award of the work.

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5 OPERATION AND MAINTENANCE
5.1 General
The contractor has to maintain sewage collection system along with pumping stations and STPS
as per specification mentioned in Operation and Maintenance volume.
The contractor is to operate, maintain and monitor STP 5 years after successfully completing
performance run. The scope of work is given below but not limited to the following. This may
include other incidental items of work connected with the regular operation & maintenance of the
treatment plant as decided by Engineer-in-Charge from time to time.
1. The contractor shall ensure proper running of the plant to give the desired effluent standards
i.e. BOD less than 5 mg/l, TSS less than 10 mg/l, COD less than 100 mg/l, Amonical Nitrogen
less 5 mg/l, total Phosperus less than 2 mg/l, Oil & Grease less than 10 mg/l. The contractor
shall also be responsible for overall maintenance of the plant i.e. civil, electrical, and
mechanical system. The contractor shall also be responsible for all repairs of
equipment/machinery.
2. The contractor shall monitor the quality of raw and treated sewage. The contractor shall
intimate and take adequate action to ensure smooth and satisfactory running of the plant. The
raw and treated sewage analysis for pH, SS, BOD and oil & grease shall be carried out on
weekly basis during O & M period at a reputed laboratory as approved by Engineer-in-Charge.
3. The contractor shall prepare and implement an effective plant maintenance programme in
consultation with Engineer-in-Charge (E&M). It shall be absolutely contractor’s responsibility to
look after all sorts of maintenance whether preventive or break down. The contractor shall
maintain the operational activity record as prescribed in this volume.
4. The contractor shall be responsible for keeping updated record of documents including
History-Card for equipment and maintaining every day logbook relating to running of
machinery, consumption of energy, and other consumables etc. and various analysis
performed. In addition to above the contractor shall maintain the operation and maintenance
data for the following.

Daily status record of STP

Daily flow record

Daily analysis record

Operation records of mechanical screens

Operation record of grit channel

Operation record of Surface aerators

Operation record of Secondary clarifier

Operation record of Return sludge pumps

Operation record of chlorination system

Record of quantity of sludge generation

Operation record of Centrifuge unit

Performance data of Aeration tank.

Performance data of Chlorination system through SCADA report

Performance data of Electricity consumption through SCADA report

Any other allied works required by EIC during O&M.
5. The Contractor shall submit a monthly report to RMC, about the operation and maintenance
indicating the manpower, electric power, chemicals and other consumables consumed,
problems faced and rectified along with various analysis performed for raw and treated
sewage.
6. The contractor shall be responsible to carry out day to day as well as periodic maintenance
necessary to ensure smooth and efficient performance/running of all equipment/instruments

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 installed at the Sewage Treatment Plant. The contractor shall hand over the machinery & site
to the employer after expiry of the contract period in good running condition.
7. The contractor shall maintain all treatment plant and pumping station units and other civil
structures in the STP premises including boundary wall in sturdy manner to complete its
natural / designed life. He should paint all MS / CI / GI structures at least once in a year to
prevent rusting as and where required and as directed by EIC.
8. The contractor shall also be responsible for proper upkeep of administrative block, Staff
quarter of the Sewage Treatment Plant.
9. He shall be responsible for proper maintenance of all the pumps and allied items including
mechanical screens, gates, Aerators, sludge pumps, chlorinator etc.
10. He shall be responsible for timely removal and safe disposal of the dried sludge including
transportation, loading and unloading etc. He should get approval for the location of the
disposal of the dried sludge from RMC.
11. He shall be responsible for maintenance of streetlight, poles & fixtures also.
12. 10. The sewerage system in the STP premises, roads and pathways provided at the sewage
treatment plant shall be maintained properly.
13. Round the Clock watch and ward of the entire premises including plants/machinery etc. will
also be the responsibility of the contractor.
14. The entire STP premises including Administration building will be kept neat and clean.
15. The records maintained by the contractors shall be produced periodically to the Engineer-in-
charge for proper monitoring as desired by him.
16. Operation & maintenance of boundary wall of STP, Landscaping and Forestation done in the
Sewage Treatment Plant premises etc. shall be carried out.
5.2 General Terms and Conditions
1. During O & M period the contractor is to keep their staff engaged continuously without any
break for Operation, Maintenance and Monitoring of STP.
2. The contractor will supply all consumable and reagents. The contractor will employ its own
staff for testing purpose. However the employer will be at liberty to get random sampling &
testing done on its own or from any other agency, to the entire satisfaction of Engineer-in-
charge. In case of testing from other agency, charges will be borne by RMC
3. Contractor’s labourers and supervisors shall have to normally observe office timings of general
shift.
4. Plant and equipment covered under this contract shall be totally attended to by the contractor
including any “Trouble Shooting” to ensure smooth and trouble free operation.
5. For effective maintenance of STP, the contractor shall employ sufficient staff with proper
qualification. For his guidance the pattern and no. of minimum staff to be engaged is described
in this chapter.
6. The maintenance period shall be 5 years from the date of completion of successful
performance run of sewage treatment plant and the contract for subsequent stages of 5 years
for operation and maintenance shall be given on the performance of 1st years.
7. The contractor shall take operational measures that there shall be no flooding of STP area.
8. The contractor shall abide by all central/state govt. /Semi govt. /Local Bodies rules regulations,
pertaining to this contract, without any extra cost.
9. In the event of any damage/loss of life/theft of property, due to negligence on the part of
contractor, the contractor shall be solely responsible and liable for compensation and
damages, regarding negligence and the decision of Engineer-in-charge shall be final.
10. The contractor should maintain all kinds of securities in the premises round the clock for that
he should arrange manpower to prevent theft, robberies and malpractice. No unknown person
shall be allowed to enter the STP premises except municipal staff, officials and elected
representatives of the RMC body without permission. Educational study visits of the students
are permissible only on written permission from EIC.

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 11. The site will be open for inspection by the designated officers/official of RMC at all times
during the contract period.
12. The contractor should observe all safety rules and regulations corresponding to electricity,
factory act, bio-chem. process fire and as per building codes. Any accident causing by over
sighting the rules, the contractor at his own cost and risk shall handle the related cases.
Insurance of the entire staff at site is compulsory under insurance policy drawn from Govt. of
Jharkhand. The copy of the cover note should be submitted to RMC.
5.3 Financial Terms and Conditions
During the operation and maintenance period Electricity charges will be borne by the employer.
The electricity charges will be paid directly to JSEB.by RMC on actual basis as per electricity bill
raised by the JSEB. All other consumables, materials and required staff for Operation &
Maintenance will be provided by contractor.
The operation & Maintenance cost approved by the Employer shall be payable on monthly basis
on completion of every month on submission of bill by the contractor. The contractor shall maintain
the attendance record of the staff employed by him, which can be checked by the employer any
time. The contractor will also submit copy of all the data sheets every month for evaluation.
The Sludge available from Sewage Treatment Plant shall be property of the contractor and
suitable credit for the same shall be considered by the contractor while offering his price bid. The
wastewater will not be sold by the Contractor. However, employer is at liberty to do so, and retain
the proceedings, if any.
All sorts of Tool & Plant, required for proper operation & Maintenance of the plant, shall be
arranged by the contractor at his own cost.
5.4 Deployment of Staff During Operation and Maintenance Period
The Contractor shall arrange at his cost the staff required (as per Volume III) during the Operation
and Maintenance period of 5 years. The Lump sum tender cost shall also include all expenditure
likely to incur for repairs/replacement of any items executed in the tender during this period.
The Contractor should submit detailed information regarding the staff likely to be deployed by him
during O&M period of 5 years.
5.5 Taking over
The plant will be taken over on satisfactory completion of the operation and maintenance of the
contract for 5 years provided that,

The plant/equipment are in running condition

The result of the treated sewage quality during O & M of the plant is within the limits specified
for 90% of time.

All treatment plant units including interconnecting piping, hand railings, ladders, staircases,
buildings, various tanks, machines, panel etc are neatly painted.

All records of operation and maintenance during the 5 years period are handed over to RMC in
proper condition.

The O&M manuals have been updated following 5 years operational experience and approved
by RMC.
In case taking over is delayed on account of Contractor's failure, the O&M period will be extended
further till it meets the above requirement without any extra cost to RMC.

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6 BID DRAWINGS
6.1 Bid Drawings
The bid drawings provided for bidding purposes are listed below and are enclosed in this Volume.
1. Key Plan
2. Collection Network for all zones
3. Standard Drawings

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7 DATA SHEETS
7.1 Process Design
The Tenderer shall provide following documents / drawings in details along with the Tender
documents:
1. Process design of all units
2. Hydraulic design and head loss calculations for all the units, pipes, etc.
3. Schematic, mass balance and hydraulic flow diagram
4. Layout Plan and Process & Instrumentation Diagram
5. Single Line Diagram
6. Mechanical equipment data sheets as mechanical specifications of this document
7. Electrical system design, rating, etc. for all the power cables earthing system and
instrumentation systems as per electrical specifications of this document
8. Instrumentation & Automation System design, rating, etc. as per Instrumentation
Specifications of this document
7.2 ELECTRICAL POWER CONSUMPTION
Bidders to give the power consumption of the proposed STP as per following format :
7.2.1 Load List for the plant (100 % flow)
Sr. Equipments, Rating Quantity No of hrs kW Power
No. Buildings, area (kW) of consumed / consumed per
lighting, yard operation absorbed at day in kWH
lighting rated duty
conditions by
a single unit
Description W S

Guaranteed
power Consumed

7.2.2 Load List (fkoWr Hth)e plant (50 % flow)

Sr. Equipments, Rating Quantity No of hrs kW Power

No. Buildings, area (kW) of consumed / consumed per
lighting, yard operation absorbed at day in kWH
lighting rated duty

Page 48 of 263
 Description W S conditions by

a single unit

Guaranteed
power Consumed

(kWH) “We confirm that that we have included all process equipment required to operate the plant
and this shall be sum total of maximum power consumed by the STP for its operation for treating
raw sewage to get the desired treated sewage parameters as given in the addendum. RMC
reserves the right to use higher figure for power consumptions for bid evaluation in case of any
discrepancy.
The list of equipment and the power consumption is final and guaranteed.”
The above table along with the guarantee mentioned above shall be submitted on the letter of the
bidder.

Page 49 of 263
7.2.3 Transformer Sizing

Particulars Value Unit Formula

=
Total working load as per list kW A
furnished
load list
Loading of all motors = % B

Total running load = kW C= A x B /100

Efficiency = % D

Operating corrected power = E

factor (0.98)

Total kVA drawn from the = kVA F= Cx100/ (DxE)

system

Add lighting load of the plant = kVA G

Total load on the transformer = kVA H= F+G

Add allowance as = % (I)

contingency

Total max. load on = kVA J= H x (1+I/100)

transformer
Considering the operating = % K
loading of
transformer

Minimum transformer = kVA L= (J x 100) /K

capacity required

Selected Transformer Size = kVA

7.2.4 Power Transformer

Power Transformer
Sr. Item Unit Description Remarks/
make
A General

(i) Application/Designation
(ii) Manufacturer
(iii) Quantity

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Power Transformer
Sr. Item Unit Description Remarks/
make
(iv) Installation Indoor / Outdoor

B Ratings
(i) Rating kVA
(ii) No. Load voltage :
- LV Winding kV
- LV Winding kV
(iii) Quantity supplied Nos.
(iv) Rated Frequency Hz
(v) Rated Percentage Impedance at 75°C

C Winding Connections
(i) HV
LV
Vector Group
Application/Direction of Power Flow
(ii)

Cooling Method

D Transformer Protection provided -

Buchholz relay, winding & oil temp.
indicators, OLTC, surge relay, PRD,
MOG

E System Data
(i) System Voltages
- HV Nominal/Highest kV
- LV Nominal/Highest kV
(ii) Fault Levels
- HV System MVA
- LV System MVA
(iii) System neutral earthing
- HV system
- LV system

(iv) Efficiency at 75°C at unity PF %

at full load
(v) Full load regulation at 75°C

F Losses

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Power Transformer
Sr. Item Unit Description Remarks/
make
(i) No load loss on principal tap at 100% kW
rated voltage & frequency subject to
+10% tolerance as per IS
(ii) Load loss on principal tap & rated current kW
at 75°C winding temp. (guaranteed
subject to +10% tolerance as per IS &
excluding copper losses)

G Winding Insulation Whether fully

insulated/material of Insulation

H Guaranteed maximum temperature rise

over 40°C
(i) Ref. Ambient Temp. °C
(ii) Temp. rise of oil by Thermometer °C

(iii) Temp. rise of winding by Resistance °C

I Tappings
(i) Tapping on winding
(ii) Whether on load/off Load
(iii) Total Tapping Range
(iv) Step
(v) Capacity full/reduced
(vi) On HV/LV Winding
(vii) If on load taps specify details of OLTC
gear
- Manual/Automatic
- Remote/Local Control
- Voltage class of OLTC
- Current rating of OLTC

J Terminal Bushings
(i) Rated Voltage Class kV
(ii) Minimum clearance in air
- Phase to phase mm
- Phase to ground mm
(iii) Minimum creepage distances (Total) Mm

(iv) One minute power frequency withstand

dry & wet

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Power Transformer
Sr. Item Unit Description Remarks/
make
(v) 1.2/50 impulse withstand

K Terminal Connections
(i) HV winding
(ii) LV winding
(iii) Mounting
(iv) Class of Insulation
(v) Busbar size in secondary
(vi) LV wdg neutral end
(vii) Disconnecting chamber /cable box

L Magnetizing current at rated voltage &

frequency
(i) When excited from LV side
(ii) When excited from LV side at 110% rated
voltage

M Maximum Flux Density

(i) At rated voltage
(ii) At 110% rated voltage

N Current Density
(i) HV
(ii) LV

O Miscellaneous
(i) Final painting Color shade as per IS:5

P Weight
(i) Core & windings kg
(ii) Oil kg
(iii) Tank, coolers & fittings kg
(iv) Total kg
(v) Un tanking weight kg

Q Dimensions
(i) Width mm
(ii) Height mm
(iii) Depth mm

R Details of Fittings & Accessories

(a) Inspection Cover

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Power Transformer
Sr. Item Unit Description Remarks/
make
(b) Rating Plate
(c) Terminal marking plate
(d) Two earthing terminals
(e) Lifting lugs
(f) Drain valve
(g) Dehydrating breather
(h) Oil level prismatic
(i) Thermometer pocket
(j) Oil filling hole with cover
(k) Conservator
(l) Air release plug
(m) Jacking pads
(n) Filter valves
(o) Weatherproof marshalling box with
internal connecting Cabling
(p) Cable box air insulated on HV Side with
disconnecting chambers with suitable
lugs & Glands
(q) Winding temp. indicator with Mercury
switches for alarm and trip
(r) Oil temperature indicator with mercury
switches for alarm and trip

(s) Magnetic oil level gauge with mercury

switch for Alarm Dial Size of magnetic oil
level Gauge
(t) Pressure relief valve with alarm contacts

(u) Buchholz Relay with Alarm and Trip

contacts
(v) Neutral CT - 2 Nos. Mounted on Tank
/L.V Bus Box

(w) Wheels
Flat/flanged
Unidirectional/Bidirectional
Quantity
Gauge

Page 54 of 263
7.3 Performance Guarantee
The Tenderer shall provide requirement of electrical energy and chemical usage for the qualities of
raw sewage and effluent standards to be met as detailed in Volume II.
Note: The values provided in this schedule will be used to determine a typical annual running cost
for the Works. These costs shall be used in calculations of NPV for the bid.
7.3.1 Functional Guarantees
The Tenderer Guarantee the performance of the Plant namely 37 MLD capacity STP in the
performance and in O & M period as per following format:
7.3.2 Plant Effluent
The characteristics of treated sewage achieved is guaranteed to be
o
1. BOD5 20 C, mg/l :
2. Suspended Solids, mg/l :
3. pH :
7.3.3 Electrical Energy Usage per Unit Volume of Treated Sewage
The energy usage for the Plants during the Performance and O & M period is guaranteed to be
not more than__________kWh per m3 of treated sewage
The energy costs detailed above shall be for the whole plant.
7.3.4 Chlorine usage per Unit of Treated Sewage
The consumption of chlorine during Performance and O & M period is guaranteed to be not
more than__________kg per m3 of treated sewage.
7.4 Miscellaneous Information
The Tenderer shall provide other supporting data, which he considers necessary to complete his
proposal.

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 VOLUME II
CIVIL SPECIFICATIONS

Page 56 of 263
 PREAMBLE

1.0 The “Volume II: Civil Specifications” are to be read for the purpose of pricing in conjunction with
"Volume-I: Conditions of Contract" of the Tender Documents containing instructions to
Tenderer and General Conditions of Contract; “Volume II: Scope of Work” under this tender;
“Volume II: Mechanical Specifications”, “Volume II: Electrical Specifications”, “Volume IIE:
Automation and control panel specification”,and “Volume-V: Financial Bid” of this tender.
2.0 The prices quoted in the Volume V: Financial Bid shall be all inclusive value for the work
described including all costs and expenses which may be required in and for the execution of the
work described together with all general risks, liabilities and obligations set forth or implied in the
document on which the tender is based.
3.0 All works shall be carried out strictly as per detailed specifications whether actually specified or
not. If not specified work shall be carried out as per directions of Owner/Engineer In
Charge.
4.0 The total amount entered in the Volume V: Financial Bid shall be entered both in figures and
words.
5.0 Specifications of items of work described for each item shall read this in conjunction with other
technical specifications and specific technical requirements and quote accordingly.
6.0 No separate payment whatsoever shall be made for dewatering if required to be done during
excavation, laying of PCC and RCC, laying and jointing of pipes, construction of manholes,
testing and backfilling etc. and Contractor should quote accordingly.
7.0 If the Tenderer needs any clarification, they shall obtain the same in writing from Owner/Engineer.
No notice will be taken of any verbal discussions in such matters.
8.0 Abbreviations used in this Volume II: Civil Specification document have the meanings shown
below:

mm Millimetre CI Cast Iron

cm Centimetre GI Galvanized Iron
m Metre GSW Glazed Stone Ware
km Kilometre BBCC Burnt Brick Cement Concrete
sq.m Square Metre RCC Reinforced Cement Concrete
cum. Cubic Metre PCC Plain Cement Concrete
M.T. Metric Ton wt Weight
SWG Standard Wire Gauge kg Kilogram
R.M. Running Metre I.D. Internal Diameter
nos. Numbers C.M. Cement Mortar
MS Mild Steel IS Indian Standards
M.D Metre Depth of Manhole SS Stainless Steel
HDPE High Density Polyethylene DWC Double Wall Corrugated

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 1. GENERAL
1.1. SPECIFICATION DRAWINGS

The Contractor will have to submit detailed design as well as General Arrangement drawings as
well as structural drawings to the Engineer-in-Charge and obtain prior approval to start the
construction, erection and commissioning of civil, electrical and mechanical components of the
treatment plant, Pumping stations.

For the Sewer collection networks, the drawings shall be provided by the Engineer and the same
to be vetted by the contractor and if required redesign and take approval of the Engineer/client
before start of the work.

Work shall be carried out by Contractor exactly in accordance with the Drawings marked as
RELEASED FOR CONSTRUCTION and approved by Engineer-in-Charge and as per the
instructions of the Engineer-in-Charge in writing.
1.2. GEO-TECHNICAL STUDIES
The bidders are free to visit and inspect the sites till the submission date for the purpose of
quoting and estimation. The Contractor shall carry out geo-technical studies at their cost at the
site and with prior permission of Engineer-in-Charge, from RMC approved soil consultant and the
report should be furnished to the RMC/Consultant and should approved by RMC/Consultant prior
to start of structural design & drawings. RMC accepts no responsibility, whatsoever for inferences
drawn from this data and the Contractor is to satisfy RMC on his own responsibility as to the
extent to which this information represents the conditions to be encountered.
1.3. MATERIALS
The term “Materials” shall mean all materials, goods and articles of every kind whether raw,
processed or manufactured and equipment and plant of every kind to be supplied by the
Contractor for incorporation in the works.

Except as may be otherwise specified for particular parts of the Works the provision of clauses in
“materials and workmanship” shall apply to materials and workmanship for any part of the works.
All materials shall be new and of the kinds and qualities described in the Contract and shall be
approved by the Engineer in- charge.

Materials shall be transported, handled and stored in such a manner as to prevent deterioration,
damage or contamination failing which such damaged materials will be rejected and shall not be
used on any part of the Works under this contract.

1.3.1. Samples and Tests of Materials

1. The Contractor should submit test certificates of the materials at the time of material
unloading on the site.
2. The Contractor shall submit samples of such materials as may be required by the Engineer-
in-Charge and shall carry out the specified tests directed by the Engineer- in-Charge at the
site, at the supplier’s premises and at a laboratory approved by the Engineer-in-Charge.
3. The Contractor should give Engineer-in-Charge seven days notice in writing about the date
on which any of the materials will be ready for testing or inspection at the supplier's
premises or at a laboratory as approved by the Engineer-in-Charge. The Engineer shall
attend the test at the appointed place within 7 days of the said date on which the materials
are expected to be ready for testing or inspection accordingly, failing to which the test may
proceed in his absence unless instructed by Engineer-in-Charge to carry out such a test on
a mutually agreed upon date in his presence. The Contractor shall in any case submit to the
Engineer-in-Charge within seven days of every test such number of certified copies (not
exceeding six) of the test readings as the Engineer-in-Charge in charge may require.
4. Approval by the Engineer-in-Charge as to the placing of orders for materials or as to
samples or tests shall not prejudice any of the Engineer-in-Charge's powers under the
contract particularly as to the provisions under the conditions of contract.
5. The provisions of this clause shall also apply to materials supplied under any nominated

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 sub-contract.
6. In any case the Contractor shall not use any material without prior testing and clearance by
the Engineer-in-Charge. In case such material is used, this will be liable for rejection either
partly or fully.
7. If required rejected material shall be marked and stockpiled separately; and such rejected
material shall be taken out within a week from construction site. The cost of the material
testing at the supplier premises and as on the site shall be borne by the Contractor and
without prior testing and clearance of the Engineer-in-Charge, the materials should not be
used for the work.
1.4. LIST OF IMPORTANT INDIAN STANDARDS
The following list includes various Indian Standards which are IMPORTANT and are referred to in
the general specifications and used in construction works. These standards are to be strictly
adhered to unless otherwise is applicable in the relevant context. These standards are to be
followed both in respect of materials and construction of civil engineering works included in the
tenders.

Though the list of Indian Standards includes the year of Publication of the standard, it may not in
all cases be the latest. It is obligatory that only the latest edition of the standard is referred to and
followed, along with all amendments and revisions issued with respect to the standard under
consideration. This list is not exhaustive but contains only the standards that are very frequently
used on the construction works. If a standard exists for a particular item of material or equipment
or code of practice the same shall be followed whether the same is included in this list,
specifications, other parts of the tender documents or not. Some Indian Standards are referred to
in the specifications/ drawings/ other parts of the tender documents and they are supplementing
this list if they do not find a place in the list.

Page 59 of 263
 Table 1: List of IS
Sr.No IS Code No. / Year Title
1 153-1950 Ready mixed paint, spraying, stoving, lead free, for general purposes

2 171-1985 Cotton and cotton regenerated cellulosic fibre blended grey yarn

3 2062-1984 Specification for Structural Steel (Fusion Welding Quality)

4 269-1976 Ordinary and low heat Portland cement
5 383-1970 Coarse and fine aggregates from natural sources for concrete
6 432(part1)-1982 Mild steel and medium tensile steel bars
7 455-1976 Portland slag cement
8 456 Code of practice for plain and reinforced cement concrete
9 458-1971 Concrete pipes
10 516-1959 Methods of test for strength of concrete
11 651-1981 Salt-glazed stoneware pipes and fittings
12 783-1985 Code of practice for laying of concrete pipes
13 784-1978 Pre-stressed concrete pipes
14 800-1984 Code of practice for general construction in steel
15 816-1969 Code of practice for use of metal arc welding for general
construction in mild steel
16 1038-1983 Steel-doors, windows and ventilators
17 1077-1986 Common burnt clay building bricks
18 1199-1959 Methods of sampling and analysis of concrete
19 1200 (part1-26) Method of measurement of building and civil engineering works
20 1363 (part 1-3) Hexagon head bolts, screws and nuts of product grade C
21 1367 Technical supply conditions for threaded steel fasteners
22 1477 (part 1-2) Code of practice for painting of ferrous metals in buildings
23 1542-1977 Sand of plaster
24 1726 (part 1,2 & 4) Cast iron manhole covers and frames
25 1786-1985 High strength deformed steel bars and wires for concrete
reinforcement
26 2074-1979 Ready mixed paint, air drying red oxide zinc chrome priming
27 2116-1980 Sand for masonry mortars
28 2212-1962 Code of practice for brickwork

29 2250-1981 Code of practice for preparation and use of masonry mortars

30 2339-1963 Aluminum paint for general purpose in dual container
31 2386 (part I-VIII) Methods of tests for aggregate for concrete
32 2502-1963 Code of practice for bending and fixing of bars for reinforced
concrete
33 2720(partIV,VIII) Methods of test for soil

34 3006-1979 Chemically resistant glazed stoneware pipes and fittings

35 3370 (part I-IV) Code of practice for concrete structures for the storage of liquids

36 3696 Safety code for scaffolds and ladders

37 3764-1966 (part 1-2) Safety code for excavation work

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38 4082-1977 Recommendations on stacking and storage of construction
materials at site
39 4111 (part 1-4) Code of practice for ancillary structures in sewerage systems

40 4127-1983 Code of practice for laying of glazed stone ware pipes

41 6248-1979 Metal rolling shutters and rolling grills
42 6909-1973 Super sulphated cement
43 7293-1974 Safety code for working with construction machinery
44 7969-1975 Safety code for handling and storage of building materials
45 Code National Building Code of India
46 4014 Code of practice for steel tubular scaffolding.
47 5121 Code of practice for deep foundation
48 2911-1980 Part III & IV Code of practice for design and construction of pile foundation
49 3764 Safety code for excavation work
50 4082 Recommendations on stocking & storage material at site
51 7293 Safety code of working with construction machinery
52 3114 Code of practice for laying CI pipes
53 5822 Code of practice for laying of welded steel for pipes
54 7364 Plastic pipe work for potable water supply (part I-III)
55 21138 ISO Code for HDPE pipes
56 7634 HDPE pipe laying
57 IS 16098-2 DWC pipes

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 2. SPECIFIC CIVIL REQUIREMENTS

2.1. DESIGN SUBMISSIONS

The Contractor shall submit complete detailed design calculations of foundations and
superstructure together with general arrangement drawings and explanatory sketches to the
RMC. Separate calculations for foundations or superstructures submitted independent of each
other should be deemed to be incomplete and will not be accepted by the RMC.

The design considerations described herewith establish the minimum basic requirements of plain
and reinforcement concrete structures, masonry structures and structural steel works. However,
any particular structure shall be designed for the satisfactory performance of the functions for
which the same is being constructed. The Contractor shall also take care to check the stability of
structure partly constructed to comply with design loads.
2.2. DESIGN STANDARDS

All designs shall be based on the latest International or Indian Standard (IS) Specifications or
Codes of Practice. The design standards adopted shall follow the best modern engineering
practice in the field based on any other international standard or specialist literature subject to
such standard reference or extract of such literature in the English language being supplied to
and approved by the RMC. In case of any variation or contradiction between the provision of the
IS Standards or Code and the specifications given with the submitted tender document, the
provision given in the Specification shall The following minimum loads shall be considered in
design of structures.
2.3. DESIGN LOADINGS

All building and structures shall be designed to resist the worst combination of the following
loads/stresses under test and working conditions these include dead load, live load, wind load,
seismic load, stresses due to temperature changes, shrinkage and creep in materials, dynamic
loads and uplift pressure.
2.3.1. Dead Load

This shall comprise all permanent construction including walls, floors, roofs, partitions, stairways,
fixed service equipment and other items of machinery. In estimating the loads of process
equipment all fixtures and attached piping shall be included, but excluding contents shall be
considered. The following minimum loads shall be considered in design of structures:

Sr. Parameter Load

(i) Weight of water 10.0 kN/cu.m

(ii) Weight of soil (irrespective of strata available at site and type of 20.0 kN/cu.m
soil used for filling etc) However, for checking stability against
uplift, actual weight of soil as determined by field test
shall be considered
(iii) Weight of plain concrete 24.0 kN/cu.m
(iv) Weight of reinforced concrete 25.0 kN/cu.m
(v) Weight of brickwork (exclusive of plaster) 22.0 kN/cu.m per mm
thickness of
brickwork
Sr. Parameter Load
Weight of plaster to masonry surface 18.0 kN/cu.m per mm
(vi) thickness

Page 62 of 263
 Weight of granolithic terrazzo finish or rendering screed, etc 24.0 kN/cu.m per mm
(vii) thickness
(viii) Weight of sand (filter media) 24.0 kN/cu.m

2.3.2. Live Load

Live loads shall be in general as per IS 875. However, the following minimum loads shall
be considered in the design of structures.
Sr.No. Location Live Loads
1 Office, Conference Hall 400 kg/sq.m
2 Floor supporting Pumping Machinery 1,000 kg/sq.m
3 Storage 750 kg/sq.m
4 Platform, Staircase, Corridors, Walkways 500 kg/sq.m
5 Administration Building - Hall, Toilet 200 kg/sq.m
6 Laboratory 400 kg/sq.m
7 Roof Slab 150 kg/sq.m
In the absence of any suitable provisions for live loads in IS Codes or as given above for any
particular type of floor or structure, assumptions made must receive the approval of the RMC
prior to starting the design work. Apart from the specified live loads or any other loads due to
material stored any other equipment load or possible overloading during maintenance or
erection/construction or during project life period shall be considered and shall be partial or full
whichever causes the most critical condition.

2.3.3. Wind Load

Wind loads shall be as per IS:875

2.3.4. Earthquake Load

This shall be computed as per IS:1893 considering in Zone-III.

2.3.5. Dynamic Load

Dynamic loads due to working of plant items such as pumps, blowers, compressors, switch
gears, travelling cranes, etc shall be considered in the design of structures.

2.3.6. Other Loads

In addition to earth pressure and water pressure etc., the surcharge of 1 Ton/sq.m shall be taken
into account in the design for channels, tanks, pit, sludge settler, etc.

2.4. JOINTS
Movement joints such as expansion joints, complete contraction joints, partial contraction joints
and sliding joints shall be designed to suit the structure as per relevant IS code provisions.
Expansion joints of suitable gap at intervals not more than 30 m shall be provided in walls, floors
and roof slabs of Liquid Retaining Structures.

Construction joints shall be provided at right angles to the general direction of the member. The
locations of construction joints shall be decided on convenience of construction. To avoid
segregation of concrete in walls, horizontal construction joints are normally to be provided at every
2 m height, PVC waterstops of suitable type and
approved make, minimum 230 mm width, 6 m thick shall be used for walls and base slabs.

2.5. DESIGN CONDITIONS FOR UNDERGROUND OR PARTLY UNDERGROUND

LIQUID RETAINING STRUCTURES

All underground or partly underground liquid containing structures shall be designed for the
following conditions:
1. Liquid depth up to full height of wall : no relief due to soil pressure from outside to be
considered.

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 2. Structure empty (i.e. empty of liquid, any material, etc) full earth pressure including
saturated condition and surcharge pressure wherever applicable to be considered.
3. Partition wall between dry sump and wet sump to be designed for full liquid depth up to full
height of wall
4. Partition wall between two compartments to be designed as one compartment empty and
other compartment full
5. Structures shall be designed for uplift in empty conditions with the water table indicated in
the geotechnical report or high flood level, whichever is maximum. No reduction factor for
the uplift force shall be considered.
6. The dead weight of the empty structures should provide a safety factor of not less than 1.2
against uplift pressures during construction and in service.
7. Wall shall be designed under operating conditions to resist earthquake forces from earth
pressure mobilisation and dynamic water loads;
8. Underground or partially underground structures shall be checked against stresses
developed due to any combination of full and empty compartments with appropriate
ground/uplift pressures from below to base slab
9. The walls and base slabs shall be designed for saturated earth/water pressure
corresponding to high flood level.

2.6. FOUNDATION
1. The minimum depth of foundations for all structures, equipment’s building sand
frame foundations and load bearing walls shall be as per IS:1094.
2. The earthfill above virgin ground level till formation level shall be taken as a surcharge load
and shall be added in the loads coming on foundations appropriately
3. Maximum safe bearing capacity of soil strata shall be taken as indicated in geotechnical
reports.
4. Care shall be taken to avoid the foundations of adjacent buildings or structure foundations,
either existing or not within the scope of this Contract. Suitable adjustments in depth,
location and sizes may have to be made depending on site conditions. No extra claims for
such adjustments shall be accepted by the Employer.
5. Special attention is drawn to danger of uplift being caused by the ground water table
6. Plinth level of all structures/top of tanks shall be atleast 500 mm above high flood level.
2.7. DESIGN REQUIREMENTS

The following are the design requirements for all reinforced or plain concrete structures:
1. All blinding and levelling concrete shall be minimum 100 mm thick in concrete grade M15
for Building & minimum 150 mm thick for Water Retaining Structure.
2. All structural reinforced concrete shall be with a maximum 40 mm aggregate size for
footings and base slabs and with a maximum 20 mm aggregate size for all the Water
Retaining Structures & other structural members.
3. All liquid retaining structures shall be designed as per IS:3370 as Uncracked Section.
The minimum grade of concrete shall be M 30.
4. All new liquid retaining structures shall be form finished.
5. For all old liquid retaining structures inside finish shall be provided in CM 1:3 smooth
cement plaster 20 mm thick and outside finish shall be 20 mm thick sand face plaster CM
1:3. Snowcem shall also be applied for finishing the outer surfaces.
6. Minimum Cement Content shall be 320 kg/cu.m for M 30 for liquid retaining structures.
7. The maximum free water cement ratio shall not exceed 0.42 for all liquid retaining
structures.
8. The amount of reinforcement in each of the two directions at right angles within each
surface zone should not be less than the minimum specified as IS:3370 or IS:456
which ever is applicable for the type of structure.
9. Use of pressure relief valves to reduce uplift pressure due to ground water table shall not be

Page 64 of 263
 allowed.
10. All pipes and ducts laid below the structural plinth and road works shall be surrounded
with concrete of grade M15.
The following minimum thickness shall be used for different reinforced concrete members
irrespective of design thickness.

Sr. Civil Member Width (mm)

(i) Walls for liquid retaining structures 200
(ii) Bottom slabs for liquid retaining structures 200
(iii) Wall foundation for wall of liquid retaining structures 250
(iv) Walls of Launders 150
(v) Base slab of Launders 150
(vi) Roof slabs/Domes for liquid retaining structures 125
(vii) Floor slabs including roof slabs, walkways canopy slabs 125

(viii) Walls of cables/pipe trenches, underground pits, etc 125

(ix) Column footings - Edge Thickness 200
(x) Column footings - at Face of Column 300
(xi) Parapets, chajja 100
(xii) Precast trench cover 75
(xiii) Beam 230 (width) and 300
(depth)

2.8. MINIMUM COVER TO MAIN REINFORCEMENT

Sr. Member Details Cover

(mm)
1 Slab Free Face 20
Face in contact with earth 30
2 Beam Top/Bottom 40
Side 30
Face in contact with earth 40
3 Column and pedestal Super Structure 40
Face in contact with earth 40
4 Retaining wall, Basement & Pit wall Face in contact with earth 30
Free face 30
5 Liquid Retaining Structure Face in contact with liquid 40
Face in contact with earth 40
Free face 40
6 Foundation Bottom 60
Top 60
Sides 50

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2.9. MINIMUM BAR DIAMETER

Sr. Member Diameter

(mm)
1 Major Foundation 10
2 Block Foundation - Main Bars 10
3 Block Foundation - Tie Bars 8
4 Minor Foundation (Local Foundation etc.) 8
5 Column, Pedestal - Main Bars 12
6 Column, Pedestal – Ties 8
7 Beam - Main Bars 12
8 Beam - Anchor Bars 10
9 Beam – Stirrups 8
10 Slab - Main Bars 8
11 Slab - Distribution Bars 8
12 Wall - Main Bars 8
13 Wall - Distribution Bars 8
14 Minor elements such as chajjas, Lintel Beams etc. 8

2.10. BAR SPACING

The bar spacing shall be as per design and conform to IS: 456 - 2000.
Sr.No. Member Minimum (mm) Maximum (mm)
(i) Foundations 125 200
(ii) Slabs 100 250
(iii) Stirrups for Beams 100 250
(iv) Ties for Columns, Pedestals 100 250
(v) Walls 100 250
* Bar spacing shall be provided in multiple of 25 mm.
2.11. MATERIALS General
2.11.1. The term “ materials” shall mean all materials, goods and articles of every kind whether raw,
processed or manufactured and equipment and plant of every kind to be supplied by the Contractor
for incorporation in the Works.

Expect as may be otherwise specified for particular parts of the works the provision of clauses in
“Materials and Workmanship” shall apply to materials and workmanship for any part of the works.

All materials shall be new and of the kinds and qualities described in the Contract and shall be at
least equal to approved samples.
As soon as practicable after receiving the order to commence the works, the Contractor shall
inform the RMC of the names of the suppliers from whom he proposes to obtain any materials but
he shall not place any order without the approval of the RMC which may be withheld until samples
have been submitted and satisfactorily tested. The Contractor shall thereafter keep the RMC
informed of orders for and delivery dates of all materials.

Materials shall be transported handled and stored in such a manner as to prevent deterioration
damage or contamination failing which such damaged materials will be rejected and shall not be
used on any part of the Works under this contract.

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2.11.2. Cement
The Cement shall be Ordinary Portland Cement grade-43 / 53, confirming to the relevant BIS
codes and approved by the RMC. Manufacturers Test Certificate shall have to be furnished.

2.11.3. Reinforcement Steel

Reinforcement Steel shall confirm to BIS Specification 432-1966 (with up to date revision) and
B.I.S. Specification 1786-1985 (with up to date revision). All reinforcement steel shall be Fe 415
TMT grade with preferable make of TATA Tiscon/RINL/SAIL or approved by Engineer In charge
will be permitted.

2.11.4. Minimum Cement Content

The minimum cement content for each grade of concrete shall be as per table below.

Sr. Grade of Concrete Minimum Cement Content in Concrete

(kg/cum of finished Concrete)

(i) M 20 280
(ii) M 25 300
(iii) M 30 320
(iv) M 35 350

2.12. SAMPLES AND TESTS OF MATERIALS

The Contractor shall submit samples of such materials as may be required by the RMC and shall
carry out the specified tests directed by the RMC at the site and at the Site at the supplier’s
premises or at the laboratory approved by the RMC. All testing charges shall be borne by the
contractor.
Samples shall be submitted and tests carried out sufficiently early to enable further samples to be
submitted and tested if required by the RMC.

The Contractor shall give the RMC seven days’ notice in writing of the date on which any of the
materials will be ready for testing or inspection at the supplier’s premises or at a laboratory
approved by the RMC. The RMC shall attend the test at the appointed place within seven days of
the said date on which the materials are expected to be ready for testing or inspection according to
the Contractor, failing which the test may proceed in his absence unless instructed by the RMC to
carry out such a test on a mutually agreed date in his presence. The Contractor shall in any case
submit to RMC within seven days of every test such number of certified copies (not exceeding six)
of the test results as the RMC may require.
Approval by the RMC as to the placing of orders for materials or as to samples or tests shall not
prejudice any of the RMC powers under the Contract.

The provisions of this clause shall also apply to materials supplied under any nominated sub-
contract.

2.13. ORIENTATION

The works shall be laid out within the confines of the site in order to be compatible with the
existing infrastructure facilities, inlet and outlet pipe work /channels and nearby water bodies.
Underground services requiring being relocated in order to accommodate the proposed site layout
shall be relocated by the Contractor to alignments approved by the Employers Representative.

2.14. ROADWAYS, PATHWAYS & HARDSTANDINGS

A comprehensive network of roadways shall be provided around the treatment plant to link in with

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 the existing approach road and permit access to the plant for necessary maintenance, delivery of
consumables and personnel access. All roads shall be of Water Bound Macadam (WBM) with BM +
AC of 4 m wide. Vehicular access shall be provided for all Plant structures and buildings. All roads
shall be provided with drainage and shall be constructed to prevent standing water.

Paved pedestrian access ways shall be constructed to provide a network of logical routes inter-
linking plant areas. Damage to any existing roads, on account of their use by the Contractor shall
be made good to the satisfaction of the RMC.

Hard standing areas shall be provided to permit the parking of vehicles involved in the delivery of
consumables from blocking site roadways during unloading or loading. The road system shall be
designed such that vehicles involved in the delivery of consumables can follow a continuous route
through the works and out again.
2.15. SITE DRAINAGE

The Contractor shall provide a site drainage system. The system shall comprise of the following:
• Storm Water Drainage
• Foul Drainage

2.15.1. Storm Water Drainage

Storm water drains adjacent to the existing and proposed roads (under this Contract) shall be
sized for a rainfall intensity of 50 mm/hr, allowing for 100% runoff. Drains adjacent to roads shall
be in stone/brick masonry (1:5) of appropriate thickness topped with 75 mm thick M10 concrete
and internally flush pointed plastered in cement mortar (1:4) mm thick.
The storm water drainage system shall be designed to cater for the run-off from the existing plot
areas and structures, if necessary.

2.15.2. Foul Drainage

The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be conveyed to the nearby sewer manhole.
2.16. CABLES AND PIPEWORK TRENCHES

Cables and pipe work trenches shall generally be constructed in reinforced concrete. However,
500mm x 500mm size or small trenches, not on fill may be constructed in 350 mm thick brick
masonry (1:4). The trenches will be plastered internally with cement mortar (1:4) and externally in
cement mortar (1:3).

Trenches within the buildings or Plant areas shall be covered with Gl chequered plates, suitably
painted and that outside the buildings shall be covered with M20
premoulded /branded precast RCC covers. The trenches shall be suitably sloped to drain
rainwater.

Layout of trenches outside the buildings shall allow space for construction of future trenches where
necessary with due consideration for planning for future developments. This aspect shall be
brought to the notice of the RMC while planning the works.
2.17. PIPES AND DUCTS

RCC ducts for drainage shall have adequate cover while laid under roads. Access shafts, where
required shall not be of size less than not less than 600 mm x 1000 mm.

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 All drains (except storm water drains adjacent to roads) shall be covered and designed structurally
for appropriate loads.

2.18. SOIL DATA & GROUND WATER TABLE

The contractor shall visit the site and should carry soil investigation and confirm the data at his own
cost.
2.19. BUILDINGS AND STRUCTURES

All the building and structure works shall generally comply with the following Employer’s
Requirements unless otherwise specified elsewhere:
1. All building works shall be reinforced concrete framework with concrete floors and roofs.
2. All internal partition walls except for toilet shall be in 230 mm thick brick masonry built in
cement mortar 1:5 with transomes and mullions as in (2) above. Toilet partition walls
shall be in 115 mm thick brick masonry built in cement mortar 1:4 and shall have
transomes and mullions similar to (2) above and shall form panels not exceeding 1200
mm x 1200 mm in size.
3. Toilet floor slab shall be filled with brick bat cobs (broken bricks in lime) and provided
with waterproofing as per the specifications of an approved specialist waterproofing
company.
4. The finished floor level in toilet areas shall be 25 mm below general finished floor level
elsewhere in the building.
5. The toilet facilities shall be provided in Administration-cum-Laboratory building
separately for men and women which include at least :
i) 2 Nos. Toilet (1 no. for men and 1 no. for women) with white porcelain Orissa pan
minimum 580 mm long with flushing cistern of 10 litres capacity.
ii) 2 Nos. wash basins (1 no. for men and 1 no. for women) of size 510 mm x 400 mm in
white porcelain with inlet, outlet and overflow arrangements.
iii) 2 Nos. mirrors (1 no. for men and 1 no. for women) of size 400 mm x 600 mm wall
mounted type fitted over wash basins.
iv) 2 Nos. plastic liquid soap bottles (1 no. for men and 1 no. for women)
v) 2 Nos. chromium plated brass towel rails (1 no. for mean and 1 no. For women)
minimum 750 mm long.
vi) All stopcocks, valves and pillar cocks shall be heavy-duty chromium plated brass.
vii) All fittings such as “P” or “S” traps, floor traps, pipes, downtake pipes etc.
viii) The sewage from toilet blocks shall be led to the nearest RMC sewerage network
sewer line.
6. All staircase shall have 25 mm thick chequered mosaic tiles for treads and 25 mm thick
plain mosaic tiles of approved shade for risers set in cement mortar or lime mortar to
give an overall thickness of 50 mm.
7. All floor cut-outs and cable ducts, etc. shall be covered with precast concrete covers in
outdoors areas and mild steel chequered plates of 6 mm thickness in indoor areas. All
uncovered openings shall be protected with galvanised MS hand railing.
8. All staircases shall be provided with Stainless Steel hand railing for protection.
9. For the entire finished roof surface shall have adequate slope to drain quickly the rainwater
to rainwater down take inlet points.
10. For roofing drainage, CI rainwater down takes with CI bell mouth and MS grating at top
shall be provided. For roof areas up to 40 sq.m. minimum two nos. 100 mm diameter down
take pipes shall be provided. For every additional area of 40 sq.m. or part thereof, at least
one no. 100 mm diameter down take pipe shall be provided.
11. Top surfaces of chajjas and canopies shall be made waterproof by providing a screed layer
of adequate slope or application of an approved roof membrane and sloped to drain the
rainwater.
12. All doors, windows, rolling shutters shall have lintels above. Chaija protection to lintels on

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 external walls shall be such as to prevent the rainwater splashing into the building. The
minimum width of chajja for doors, windows, and rolling shutter shall be 750 mm, 600 mm,
and 900 mm respectively.
13. All windows and ventilators shall have 25 mm thick Tandoor/Kota stone stills bedded in
cement mortar (1:3)
14. All concrete channels and ducts use for conveying liquid shall have inside width not be less
than 500 mm. All open channels shall be provided with hand railings. Also all such
channels, which are more than 1000 mm above finished plot level, shall be provided
with walkways for access.
15. Kerbs to be provided below the hand railing on the catwalks/pathways should be as per
relevant sections of Factor Act.
16. Wherever equipment and machinery are to be moved for inspection, servicing, replacement
etc., suitable movable gantry of minimum capacity of 2 tons or more as required shall be
provided with monorail and operating equipment.
17. The design of buildings shall reflect the climatic conditions existing on site. Process
buildings shall be as far as is possible permit the entry of natural light.
18. The Laboratory, Chlorine House and office building shall be provided with a sink with two
drinking water taps of 20 mm size with adequate inlet and outlet connections.
19. The sidewalls of buildings shall, except those used for storage and handling of Chlorine gas
comprise at least 15% ventilation areas. Ventilated brickwork or louvres shall not be used
where the ingress of driven rain could affect plant or stored materials.
20. All walkways, staircase, platforms etc, shall be minimum 1200 mm wide and will be
provided with hand railing on one or both sides as required.
21. The floor shall generally be made of 150mm thick concrete slab on grade with 230 mm
thick rubble soling and polyethylene sheet. The grade slab shall be provided with TOR 8
mm reinforcement Bars at 200 mm c/c bothways.
22. All hardware fittings and fixtures for doors, windows and louvers (e.g. Hinges, bolts, locks,
latches, stay doorstops, door closers, floor springs) shall be heavy type matching to the
size and weight of the door/window/ventilator shutters. These shall operate easily without
hindrance secure properly without jamming; require nominal maintenance durable under
prevailing site/weather conditions.
23. Suitable steps and/or ramp with overhead RCC Canopy shall be provided as per
requirement, at the entrances of the buildings.
24. 1,000 mm wide Plinth Protection (Apron) shall be provided all around the Building/Sheds.

2.20. ANTICORROSIVE TREATMENT

All the water retaining RCC structures shall be given anticorrosive treatment. The wall from inside
shall be coated with polymer anticorrosive paint. It shall be elastomeric (450% elongation),
thermoplastic, fire retardant. The coating skin shall have tensile strength of 18 to 21 kg/cm2. It
shall be antifungal and antibacterial. The polymer paint shall be of Meta-chem or equivalent make
as approved by Engineer-in-charge.

2.21. PRESSURE GROUTING

2.21.1. Products
All components used for grouting repair system are to be from one of the approved makes of
polymers. All components are to be of the same make. No components of different makes can
be used in conjunction with each other. Only be MC Bauchemie product shall be used.

The product shall only be from the approved list of companies.

Proper care is to be taken when using the material to maintain the required consistency and purity.

Only polymer latexes based on Styrene butadiene (SBR), acrylics, polyvinyl acetate or expoxies

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 can be used. The latex should have solid to a maximum of 50% and minimum of 40%. The
physical chemical and structural properties of the material used are to be submitted and specific
approval to be seek for the material/system, to be used.

2.21.2. Surface Inspection and Preparation

All surfaces to be treated are to be exposed to the base level with removal of all claddings,
plasters, facaders, waterproof layers etc. The surface is to be examined for surface cracks,
crevices and spalls and honey combing.
Concrete surface to which treatment is to be applied shall be freshly exposed parent concrete free
of loose and unsound materials. Prepare surfaces by mechanical abrasion unless prohibited by
environmental limitations in which case acid etching may be used.
Mechanical abrasion - Use sandblasting or scarifying or water blasting or other approved means.
ACID ETCHING - Etch surface with a commercial grade (22 deg. Baume) of
hydrochloric acid diluted at a ratio of 10:90 to 20:80. After this application, scrub surface with a
stiff bristled broom, or similar implement. Immediately after foaming action of acid has subsided,
flush surface with water jets until all residue is removed.
Repeat procedure until laitance is completely removed. Wash such areas with water at least three
times and allow to air dry prior to further treatment. This method of cleaning is to be used only in
exceptional cases and under normal cases permission will not be given for use of this method.
Inspection of concrete surfaces prior to mortar application.
Inspect all concrete surfaces prior to application of mortar to ensure that requirements of this
Article are met.
Surfaces shall be free of any deleterious materials such as laitance, curing compounds, dust, dirt
and oil. Materials resulting, from surface preparation specified shall be removed.
All concrete surfaces shall be dry as defined in tender below unless a water insensitive coating is
used. Surface temperature shall be at least 40F to permit wetting of concrete surface by polymer
coating.
Valuate moisture content for concrete by determining if moisture will collect at surfaces.
This may be accomplished by taping a 4 x 4ft polyethylene sheet of concrete surface. If moisture
colelcts on underside of polyethylene sheet before polymer would cure, then all concrete to dry
sufficiently. Drying of the surfaces can be accomplished by either heating the surfaces by blow
lamps or by use of sawdust, sand or any other means so that the surface is bone-dry.
2.21.3. Identification of Methods of Grouting

2.21.3.1. For All Surfaces having Cracks / Crevices:

Locate the cracks by either surface inspection or by scrubbing the surface. In case the cracks are
not visible to naked eye use compressed air to clear marks. Having identified the cracks use light
chisel or mechanical/electrical saw to clear the crack upto the depth of the crack. In case widening
of the crack is necessary to reach the depth of the crack it is advisable to do so at this juncture.
After cleaning/widening the crack use compressed air/water jet to clean the opened crack surface.
Ensure that the surface is dried in case water jet is used.
A method of grouting thorough rows of grout nipple is to be adopted for all such cases.

2.21.4. Grouting for Honey Combed Surfaces

For surface, which exhibits honeycombed concrete, the surface has to maintained in its dry state
and a method of grouting through triangular grout nipples is to be adopted. The opposite side to
the grouting surface has to be sealed for flowing grout by either impervious cement plaster or by
use of proper sealant as specified in the material to be used for grouting.

2.21.5. Size and Spacing of Nipples

To determine the size of nipples use a standard caliper or a metric scale and measure the width of

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the opened crack. The size of the nipple to be fixed within the crack has got to be minimum half
the surface width of the crack measured above, but should not exceed s15 mm in dia.

The nipples to be used should be of metal with one end tapered and thickness should be sufficient
to withstand 5 m head of water. The spacing for the crack depends inversely to the width of the
crack and will not exceed more than 300 mm c/c and will not be less than 125 mm c/c. The
member of nipples along the crack will always be a less than two rows of nipples that needs to be
fixed parallel to the crack at the same distance as the nipples spacing in the crack so as to form
equilateral triangle with the apexes in the crack.

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 3. EARTHWORK AND EXCAVATION
3.1 RELAVENT IS CODE

IS: 1200 : Method of Measurement for Building Works

IS: 3764 : Safety code for Excavation Work

IS: 3385 : Code of practice for measurement of civil engineering works

IS: 2720 : Part II - Determination of Moisture Content

: Part VII - Determination of Moisture content dry density relation using light
compaction
: Part VIM - Determination of Moisture Content Dry Density using heavy
compaction
: Part XXVIII - Determination of Dry Density of soils, in place, by the sand
replacement method
: Part XXIX - Determination of Dry Density of soils, in place, by the core cutter
method.

3.2 EXCAVATION

3.2.1 Definitions

The following terms shall have the meanings hereby assigned to them:
• Top Soil means any surface material, including turf, suitable for use in soiling areas to be
grassed or cultivated.
• Excavation means excavation in open cut (excluding trench excavation) down to levels
required as per approved Drawings or otherwise as being the general levels after
completion of excavation.

3.2.2 Site Clearance

All area of the Site, marked in the Specification Drawings shall be cleared to the extent required by
the Engineer-in-Charge of all buildings, walls, gates, fence and other structure and obstructions of
all bushes, hedges, trees, stumps, roots and other vegetation except for trees marked for
preservation. Material so cleared shall so far as suitable be preserved and stacked will be the
property of RMC for further use but shall otherwise be burnt to ash or disposed off the Site as
directed by the Engineer-in-Charge. Before starting the work the site shall be cleared of
1. All shrubs, grass, and other vegetation including large and small bushes, all stumps, removal
of roots, cutting and disposal of small trees up to 300 mm girth etc.
2. All the tress having girth above 300 mm. (the girth shall be measured at a height of 1.5 m
above the ground level) by felling, logging, fashioning of timber and billeting of all branches,
trunks etc. including removal of all roots etc. complete as directed.
3. All serviceable reclaimed material shall be stacked separately at the site shown by the
Engineer In Charge near the site of excavation and/or transported as directed by Engineer In
Charge. All the existing utilities passing through or along the plant and station site has be
shifted by contractor before commencing of works. All the Liaoning work and expenditure
required to shift utility shall be done by contractor.
4. After the tree is cut and roots taken out the potholes formed shall be filled with good earth in
250mm layers and consolidated unless directed by the Engineer in Charge otherwise. The
trees shall be cut in suitable piece as instructed by the Engineer In Charge

3.2.3. General Excavation

1. General excavation means excavation in all types of soild like dry soil, wet soil, murum,

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 boulders, hard strata, rock of any type at different depth and lift required for structures and
from borrow areas, and shall not include trench excavation. General excavation may also
include miscellaneous isolated lengths of trenches beneath or adjacent to other structures,
trial pits along the structural layout or otherwise.
2. The ground shall be excavated by such methods and to such dimensions and depths as shall
allow for the proper construction of the works and safety of personnel and equipment used on
excavation. Slopes required for stable formation of sides shall be provided.
3. The excavation in earth, murum, boulders, soft and hard rock shall be carried out to the
correct levels required and specified and no tolerance, plus or minus, shall be permitted.
However, if any depressions/Loose pockets are formed due to removal of boulders, they shall
be made good by filling with 1:5:10 concrete up to the bottom layer of the footing/raft.
4. Payment for all types of excavation shall be made by detailed measurement supported by
ground levels recorded prior to and after completion of excavation, subject to the limit for
payment indicated by the slopes of excavation indicated in the specification drawing. Any
additional excavation will be at the Contractor’s expense, unless specifically approved by the
Engineer-in-Charge. Measurement for excavation shall be done all as per dimensions of
P.C.C. given in design drawings & specifications. For concrete foundations same shall be paid
on least dimensions at bottom and Contractor shall cover any extra excavation required for
workspace, supports etc while quoting.
5. As far as possible excavation should be done by means of mechanical equipment. The
bidder should quote accordingly and nothing extra will be paid for mechanical excavation and
deployment of extra staff.
6. It will be the responsibility of the Contractor to obtain prior permissions from the competent
authority to use blasting device, if at all to be resorted to and the license are to be obtained for
the same.
7. The chance of blasting required shall be well decided with the expert, to avoid any damage to
the surrounding property. However for any such damage to the surrounding property or public
or additional excavation shall be the Contractor's responsibility and the risks what so ever
arising from the same will have to be borne by the Contractor.

3.2.4. Lift and Lead

Lead for deposition of the excavated materials should be as per mentioned in the relevant Clause
for the purpose of measurement of lead, the area to be excavated or filled or area in which
excavated material is to be deposited /disposed off shall be divided into suitable blocks and for
each of the blocks, the distance between centrelines shall be taken as the lead which shall be
measured by the shortest straight line route on plan and not the actual route taken by Contractor.
No extra compensation is admissible on the grounds that the lead including that for borrowed
material had to be transported over marshy or kaccha land route.

3.2.5. Excavation in Hard Rock

Excavation in hard rock may be done either by blasting or chiseling or by mechanical means
depending upon the site conditions. When excavation has reached within 300 mm of the required
formation level, further excavation shall be carried out carefully either by blasting (if as directed by
the Engineer-in-Charge) or chiseling. Where blasting is resorted to, small charges shall be used to
minimize occurrence of heavy over-cuts. The Contractor shall make every effort to carry out the
excavation to correct formation level as far as practicable. In order to minimize the over break and
loosening of materials at the finished surfaces, final cutting for the last 450 mm to 600 mm in rock
shall be carried out by controlled blasting and trimming with the help of pneumatic or other power
tools. Unless otherwise specified, the over break shall not exceed 75 mm. The over breakage of
75 mm shall not be measured for payment and therefore the Contractor while quoting his rates for
rock excavation has to take this into account. Deduction of 40% or higher percentage as may be
decided by the Engineer-in-Charge shall be made to allow for the voids. Stacks shall not be of

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 width greater than 1.5 m wide or of height less than one meter
1. Blasting shall be carried out by the licensed person only if permitted by the Engineer-in-
charge for which contractor shall obtain the required permission from police commissioner.
2. The Contractor shall provide a method statement and shall comply fully with the requirements
of this clause, or any direction, order, requirement or instruction given by the police
department or any other relevant authorities as required by the law.
3. Contractor shall submit Blasting plan to the Engineer-in-charge and take approval for the
same on daily basis
4. Contractor shall plan the blasting activities in well advance and convey same to the Project
In-charge so as to co-ordinate with all the work groups at site.
5. If blasting is not permitted then contractor shall excavate the rock by manual methods or by
mechanical mean like needle breaker, poclain, rock splitter etc without any extra cost.

This includes rock, which is easily excavated by blasting, but due to close proximity of structures
or any other reason that the Engineer-in-Charge may consider, will have to be excavated by
chiseling.

Hard rock excavation means excavation in all types of rock at any depth or lead required as per
design and drawings. The contractor shall ascertain the level and type of rock by inspecting site,
trial pits or trial bore at his cost before quoting the tender.

It should be noted that this clause does not override the Contractor's obligation to satisfy the
requirement of the relevant authorities but sets out the extent to which the engineer in charge will
exercise his control in approving the Contractor's use of explosive to ensure that explosive are
always used in a safe manner. It is the Contractor's sole responsibility to ensure that his method of
blasting is safe, that all statutory and imposed limitation are adhered to, and to obtain a permit to
use explosive from the relevant authorities and to comply with the condition of issue of the permit.

The Contractor shall be solely responsible for obtaining the necessary licenses for the
procurement, possession, transport, storage and handling of explosive and for ensuring the
validity of such licenses at all times. Before starting work, the Contractor shall satisfy the engineer
that all the requirement permits are in order and that this category of work is adequately covered in
the policies of insurance.

Explosives shall be used in the quantities and manner recommended by the

manufacturers. All necessary precautions shall be taken to preserve the materials below in the
soundest possible condition and also beyond the lines of all excavations.

Blasting by means of drill holes, tunnels or any other similar method shall be the responsibility
of the Contractor.

The Contractor shall take all necessary precautions during blasting operations to ensure that no
injure is caused to persons or damage to property or to the finished works. Shots shall be properly
loaded and capped and only appropriate charges shall be used in each hole.

3.2.5.1. Storage and Transport

Proper building or magazine, with separate compartment for detonators in suitable positions for
the storage of explosive in the manner and quantities to be approved, shall be provided.
Separate vehicles or vessels for detonators shall also be used for the transportation of explosives.
The prevention of any unauthorised issue or improper use of any explosive brought on to the site
shall be the responsibility of the Contractor and only experienced licensed short firers shall be
employed to handle the explosive for the purpose of the work the relevant security regulations
dealing with the storage, handling and transport of explosives shall be complied with.

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3.2.5.2. Safety

The Contractor shall provide an approved system of warning and preparing the general public and
all site personnel of an impending blast by both audible & visual means and shall ensure that the
blasting area is cleared of all personnel immediately prior to blasting. This system shall comply
with all statutory requirements. The Contractor's attention I drawn to the need to devise adequate
system for warning and clearing the public from specified areas during blasting operations and to
prevent persons entering the blasting area.

When blasting is near to the proximity of existing public and private thoroughfares, traffic is to be
stopped just prior to firing. The operation is to be carried out I close cooperation with the police
department and in such a way as to cause minimum traffic delay.

All operations involving explosives shall be suspended on the approach of a thunderstorm

and shall not be resumed until the storm has clearly passed. Blasting screens shall be erected to
conform with the permit conditions. Public roads, private roads and property adjacent to the site
and services within the site area shall be protected by rock fall fences which will be subjected to
the engineer's approval.

The Contractor shall take all necessary precautions to avoid damage to permanent and temporary
works already completed. In all cases, delay blasting techniques will be mandatory with the
quantity of explosives restricted to ensure that the peak particle velocity generated does not
exceed the peak particle velocity of each component of the safe limits of the nearest structure
subject to vibration damage. All operations shall stop when these limits are exceeded until reports
are made available to the engineer that no damage has occurred and will not occur or corrective
action has been taken to lower the vibration. The sound level limit in areas where site personnel or
public can access during blasting operation must not exceed 110 dB.

The Contractor may not be permitted to use explosives in areas of the site immediately adjacent to
pylon positions. Particular limitations may apply in such areas depending on the Contractor's
proposed method of working and a detailed method statement will therefore be required from the
Contractor. The method statement shall cover the methods of excavation and protection systems
proposed, all of which shall be subjected to the approval of the relevant authorities and the
Engineer.

In all such cases particular attention should be paid to the requirements stated above and effects
on these structures and installations shall be closely monitored and the quantities of explosives
limited accordingly.

Drilling rigs for shot hole shall be of the hydraulic type fitted with efficient silencers and with means
of dust separation.

The Contractor may report to any of the following methods to excavate rock by chiseling:
• Wedging by means of crowbars, pick axes or pneumatic drills
• Heating and quenching
• Controlled blasting with a small charge just sufficient to make a crack in rock which will be
subsequently removed by wedging
• No extra payment shall be made for removal of rock by chiseling and controlled blasting.

3.2.6. Excess excavation to be made good

The Contractor, at his own expense, shall, if directed, remove from the Site all excess material
resulting from excess excavation and shall make good the same with such kind of fill material or in

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 such class of concrete as may be reasonably required by the Engineer-in-Charge having regard to
the circumstances.

3.2.7. Supporting Excavations

1. The Contractor shall properly support the sides and ends of all excavations to prevent any fall
or run from any portion of the ground outside the excavation and to prevent settlement or
damage to structures adjacent to the excavation. Any excavation necessary to provide space
for such support or other working space shall be carried out. If, for any reason, any portion of
the bottoms, sides or ends of any excavations shall give way, the Contractor shall at his own
expense take all necessary remedial measures including the extra necessary excavation and
removal of excess material.
2. Where the Contractor proposes and is permitted by the Engineer-in-Charge to perform
excavations with sloping faces (other than sloping excavations shown on the Drawings or
required as permanent features of the Works) and without shoring, the excavated faces shall
be to stable slopes and heights.

3.2.8. Trimming Excavations

1. When excavating to specified or required levels for the foundation of any structure or to
specified or required limits for the face of any structure required to abut undisturbed ground,
the Contractor shall not excavate the last 150 mm until immediately before commencing the
constructional work, except where the Engineer-in-Charge shall permit otherwise. After
getting the permission for the commencement of the construction, if the Contractor delays on
any account & the formation level gets damaged he will have to do further excavation upto
150mm or as per Engineer-in-Charge's instructions at his own account.
2. Before commencement of any constructional work all shattered and loose materials shall be
removed from the excavations by hand so as to ensure that the work rests on a solid and
perfectly clean foundation or abuts against solid ground.
3.2.9. Inspection by the Engineer-in-Charge

1. When the specified levels or limits of excavation are reached the Engineer-in-Charge will
inspect the ground exposed, and if he considers that any part of the ground is by its nature
unsuitable he may direct the Contractor to excavate further. Such further excavation shall be
refilled to the specified levels or limits with concrete, selected excavated material or selected
imported material as directed by the Engineer-in-Charge.
2. Should the material forming the bottom of any excavation, while acceptable to the
Engineer-in-Charge at the time of his inspection, subsequently become unacceptable to him
due to exposure to weather conditions or due to flooding or have puddles, soft or loss during
the progress of the works, the Contractor shall remove such damaged, softened or loosened
material and excavate without any extra cost.

3.2.10. Disposing Excavated Material

All excavated material shall remain the property of the Employer. The Contractor shall ensure that
no excavated material which is suitable for and is required for re-use in the Works is transported
unless so ordered by the Engineer-in-Charge.

3.2.11. Back-Filling General Site Grading and Sand Filling

3.2.11.1. Fill Material

1. All fill material whether such material is brought from outside borrow areas or excavation
within the site, will be subject to Engineer-in-Charge’s approval after carrying required tests at
Contractor’s Soil testing laboratory. Notwithstanding any approval given to the fill material or

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 borrow areas from which fill material is proposed to be brought, the Engineer-in-Charge
reserves the right to reject such material which does not meet the specification requirements
or unsuitable for the purpose for which it is intended.
2. Roads, of a temporary nature, required to be constructed for access and for movement of
men, materials, equipment, transport vehicles, vehicles carrying fill material, etc. to or over
borrow areas and or to or over areas on which fill has to be deposited shall be constructed by
the Contractor. Such access roads shall be maintained in good condition during all seasons
to ensure completion of the work according to the time schedule. No separate payment shall
be made for such items of work.

3.2.11.2. Backfilling

1. Excavated material used as back filling to excavations or completed structures shall be free
from rubbish, vegetation, clods and lumps and shall be approved by the Engineer-in-Charge.
The approved materials shall be placed in layers, not exceeding 150 mm in depth before
compaction and shall be compacted with watering, consolidating and ramming. The
maximum boulder size shall be of 150 mm for filling material
2. Soft material shall not be used as back filling around structures in rock. The Contractor shall
backfill such excess excavation with concrete; rubble, stone or rock fills as directed by the
Engineer-in-Charge. Filling other than concrete shall be placed in layers not exceeding 150
mm in thickness, shall be thoroughly compacted and have adequate fined content to fill the
voids.
3. Should the material being placed as back filling, while acceptable at time of selection,
become unacceptable to the Engineer-in-Charge due to exposure to weather conditions or
due to flooding or have become puddles, soft or segregated during the progress of the
works, the Contractor shall remove such damaged, softened or segregated material and
replace it with fresh approved material at his expense.
4. The Contractor shall while placing the back filling make due allowance for any settlement
that may occur before the end of the Defects Liability Period, remove any excess material or
make up any deficiency by back filling to the specified levels. As a rule material to be back
filled shall be stacked temporarily at a suitable place.
5. General Site Grading: Site grading shall be carried out as directed by the Engineer-in-
Charge. Excavation shall be carried out as specified in the specification. Filling and
compaction shall be carried out as specified under (6) of this Clause unless otherwise
indicated below.
6. The approved material shall be placed in layers not exceeding 150 mm in depth before
compaction and shall be compacted to 90% of Proctor Density with water contain at OMC.
7. The Contractor shall protect the earth fill from being washed away by rain or damaged in any
other way. Should any slip occur, the Contractor shall remove the affected materials and
make good the slip without any extra cost.
8. The fill shall be carried out to such dimensions and levels as directed by the Engineer-in-
Charge, after the compaction.
9. Sand filling below Plinth and other places
Back filling shall be carried out with sand at places as directed by the Engineer-in-Charge.
The sand used shall be clean, medium grained and free from impurities. The filled-in-sand
shall be kept flooded with water for 24 hours to ensure maximum consolidation. Any
temporary work required to contain sand under flooded conditions shall be to the
Contractor’s account. The surface of the Consolidated sand shall be dressed to the required
level or slope. Construction of floors or other structures on sand fill shall not be started until
the Engineer-in-Charge has inspected and approved the fill.
Where specified in the schedule of works, compaction of the plinth fill shall be carried out by
means of 12 tonne rollers smooth wheeled, sheep foot or wobbly wheeled rollers.
A smaller weight roller may be used only if permitted by Engineer-in-Charge. As rolling

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 proceeds water sprinkling shall be done to assist consolidation. Water shall not be sprinkled
in case of sandy fill.
The thickness of each unconsolidated fill layer can in this case upto 300 mm. Engineering-
Charge will determine the thickness of layers in which fill has to be consolidated depending
on the fill material and equipment used. Rolling shall commence from outer edge and
progress towards the centre and continue until compaction is to the satisfaction of the
Engineer-in-Charge, but in no case less than 10 passes of the roller will be accepted for each
layer. The compacted surface shall be properly shaped, trimmed and consolidated to an
even and uniform gradient. All soft spots shall be excavated and filled and consolidated. At
some locations / areas it may not be possible to use rollers because of space restrictions
etc. Contractor shall then be permitted to use pneumatic tampers, rammers etc and he shall
ensure proper compaction.
3.2.12. Fill Density

The compaction, only where so called for, in the schedule of quantities /items shall comply with
the specified (proctor/modified proctor) density at moisture content differing not more than
4 percent from optimum moisture content. Contractor shall demonstrate adequately at his cost, by
field and laboratory tests that the specified density had been obtained.

3.2.13. Local Rules and Regulations

1. The Contractor shall familiarize himself with the local rules and regulations governing the
excavation, quarrying operations, etc. and the work shall be carried out strictly in accordance
with rules and regulations, if any. Whenever a quarry is required to be opened in connection
with the execution of work covered under this Contract, the Contractor shall investigate that it
shall yield stones and other materials such as sand, murum, soil etc. of approved quality and
shall satisfy himself as to the availability in desired quantity. He shall supply necessary
quantity of sand, stone, metal aggregate etc. to the Engineer-in-Charge for carrying out tests
as desired by the Engineer-in-Charge and well in advance of its use so as to carry out tests
and to get approval. The cost of opening and operating the quarry & royalties and ant other
charges shall be borne entirely by the Contractor. 2. The Contractor shall obtain necessary
permission from the concerned authorities before opening the quarry. In case of quarries in
private land on payment of whatever charges as may be due to the owner.
3.3. DEWATERING

a. All excavations shall be kept free of water. Grading in the vicinity of excavations shall be
controlled to prevent surface water running into excavated areas. The Contractor shall remove
by pumping or other means approved by Engineer-in-Charge any water inclusive of rain water
and sub-soil water accumulated in excavation and keep all excavations de-watered until the
foundation work is completed and back filled. Sumps made for dewatering must be kept clear
of the excavations/trenches required for further work. Method of pumping shall be approved by
Engineer-in-Charge; but in any case, the pumping arrangement shall be such that there shall
be no movement of sub-soil or blowing in due to differential head of water during pumping.
Pumping arrangements shall be adequate to ensure no delays in construction.
b. When there is a continuous inflow of water and quantum of water to be handled is considered
in the opinion of Engineer-in-Charge, as large, well point system: Single-stage or Multi-stage
shall be adopted. Contractor shall submit to the Engineer-in-Charge his scheme of well
pointing system including stages, the spacing, number and diameter of well points, headers
etc. and the number, capacity and location of pumps for approval.
c. The rates for excavation are inclusive of dewatering by any means and no extra payment is
allowed for excavation in wet condition.

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3.4. TIMBER SHORING

The Timber Shoring shall be as per 3764-1966 safety code for excavation work and the cost &
payment is inclusive in other items like supply of Pipes/ Excavation/Bedding / Backfilling/Testing of
pipes etc and shall not be paid separately.

a. Close timbering shall be done by completely covering the sides of the trenches and pits
generally with short, upright members called ‘polling boards’. The boards shall generally be
placed in position vertically side by side without any gap on each side of the Excavation and
shall be secured by horizontal walings of strong wood at maximum 1.2 m spacing and
suitably strutted. If the soil is very soft and loose, the boards shall be placed horizontally
against each side of the excavation and supported by vertical walings, which in turn shall be
suitably strutted. The lowest boards supporting the sides shall be taken into the ground and
no portion of the vertical side of the trench or pit shall remain exposed, so as to render the
earth liable to slip out.

b. The shoring material shall not be sizes less than those specified below unless steel sheet
piling is used or unless otherwise approved by the Engineer-in-Charge in writing:
• Planks - 5 cm x 25 cm
• Waling pieces - 10 cm x 20 cm
• Struts - 15 cm x 20 cm

c. Timber shoring shall be ‘close’ or ‘open’ type, depending on the nature of soil and the depth
of pit or trench. The type of timbering shall be as approved by Engineer-in-Charge. It shall
be the responsibility of the Contractor to take all necessary steps to prevent the sides of
excavations, trenches, pits, etc., from collapsing.

d. Timber shoring may be required to keep the sides of excavations vertical to ensure safety of
adjoining structures or to limit the slope of excavations, or due to space restrictions or for
other reasons. Such shoring shall be carried out, except in an emergency, only under
instructions from the Engineer-in-Charge.

e. The withdrawal of the timber shall be done very carefully to prevent the collapse of the pit or
trench. It shall be started at one end and proceeded systematically to the other end. Concrete
or masonry shall not be damaged during the removal of the timber. No claim shall be
entertained for any timber, which cannot be retrieved.

f. In the case of open timbering, the entire surface of the side of trench or pit is not required to
be covered. The vertical boards of minimum 25 cm X 5 cm sections shall be spaced
sufficiently apart to leave unsupported strips of maximum 50 cm average width. The detailed
arrangement, sizes of the timber and the spacing shall be subject to the approval of the
Engineer-in-Charge. In all other respects, the specification for close timbering shall apply to
open timbering.

g. In case of large pits and open excavations, where shoring is required for securing safety of
adjoining structures or for any other reasons and where the planking across sides of
excavations/pits cannot be strutted against, suitable inclined struts supported on the
excavated bed shall be provided. Load from such struts shall be suitably distributed on the
bed to ensure no yielding of the strut.

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 4. CONCRETE AND ALLIED WORKS
4.1. GENERAL
a. 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.
b. The Engineer-in-Charge 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-in-Charge’s approval obtained, prior to starting of concrete work. However, this
shall not relieve the Contractor with any of his responsibilities and all the materials, which do
not conform to the specifications, will be rejected.

c. The minimum wall thickness for all RCC wall shall be 225 mm thick.

d. The liquid retaining structures will be in M 30 grade.

e. The Contractor will maintain all registers and formats for quantity qualitative and quantitative
measures of all concrete works on daily basis of steel consumed and concreting done
updated on daily basis.

f. As per site conditions, if required, contractor may use ready mix concrete of approved mix
design from approved ready mix plant without any extra cost.

4.2. APPLICABLE CODES

The following specifications, standards and codes, including all official amendments/revisions and
other specifications & codes referred to therein to therein, should be considered a part of this
specification. In all cases the latest issue /edition/revision shall apply. In case of discrepancy
between this specification and those referred to herein this bid document, this specification shall
govern.

MATERIALS
1. IS:269 - Specification for 33 grade ordinary Portland cement
2. IS:455 - Specification for Portland slag cement.
3. IS:1489 - Specification for Portlandpozzolana cement.
4. IS:8112 - Specification for 43grade ordinary Portland cement.
5. IS:12330 - Specification for sulphate resisting Portland cement.
6. IS:383 - Specification for coarse and fine aggregates from natural sources
for concrete
7. IS:432 - Specification for mild steel and medium tensile steel (Parts-I & II)
bars and harddrawn steel wires for concrete reinforcement.
8. IS:1786 - Specification for high strength deformed steel bars and wires for
concrete reinforcement.
9. IS:1566 - Specification for harddrawn steel wire fabric for (Part-I) concrete
reinforcement.
10. IS:9103 - Specification for admixtures for concrete.
11. IS:2645 - Specification for integral cement waterproofing compounds.
12. IS:4990 - Specification for plywood for concrete shuttering work.

MATERIAL TESTING
1. IS:4021 - Methods of physical tests for hydraulic cement. (Parts-1 to 13)
2. IS:4032 - Method of chemical analysis of hydraulic cement.
3. IS:650 - Specification for standard sand for testing of cement.

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 4. IS:2430 - Methods for sampling of aggregates for concrete
5. IS:2386 - Methods of test for aggregates for concrete. (parts-I to VIII)
6. IS:3025 - Methods of sampling and test (physical and chemical) water
used in industry

MATERIALS STORAGE

1. IS: 4082 - Recommendations on stacking and storing of construction materials at

site

CONCRETE MIX DESIGN

1. IS: 10262 - Recommended guidelines for concrete mix design.
2. SP: 23 - Handbook on Concrete Mixes. (S & T)

CONCRETE TESTING
1. IS: 1199 - Method of sampling and analysis of concrete.
2. IS:516 - Method of test for strength of concrete
3. IS: 9013 - Method of making, curing and determining compressive strength of
accelerated cured concrete test specimens.
4. IS: 8142 - Method of test for determining setting time of concrete by penetration
resistance.
5. IS: 9284 - Method of test for abrasion resistance of concrete.
6. IS: 2770 - Methods of testing bond in reinforced concrete.

EQUIPMENT
1. IS: 1791 - Specification for batch type concrete mixers.
2. IS: 2438 - Specification for roller pan mixer.
3. IS: 4925 - Specification for concrete batching and mixing plant.
4. IS: 5892 - Specification for concrete transit mixer and agitator.
5. IS: 7242 - Specification for concrete spreaders.
6. IS: 2505 - General Requirements for concrete vibrators: Immersion type.
7. IS: 2506 - General Requirements for screed board concrete vibrators.
8. IS: 2514 - Specification for concrete vibrating tables.
9. IS: 3366 - Specification for pan vibrators.
10. IS: 4656 - Specification for form vibrators for concrete.
11. IS: 11993 - Code of practice for use of screed board concrete vibrators.
12. IS: 7251 - Specification for concrete finishers.
13. IS: 2722 - Specification for portable swing weigh batchers for concrete (single and
double bucket type).
14. IS: 2750 - Specification for steel scaffoldings.

CODES OF PRACTICE
1. IS: 456 - Code of practice for plain and reinforced concrete.
2. IS: 457 - Code of practice for general construction of plain and reinforced concrete
for dams and other massive structures.
3. IS:3370 - Code of practice for concrete structures for storage of liquids.(parts-I to
IV)
4. IS: 3935 - Code of practice for composite construction.

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5. IS: 2204 - Code of practice for construction of reinforced concrete shell roof.
6. IS: 2210 - Criteria for the design of reinforced concrete shell structures and folded
plates.

7. IS: 2502 - Code of practice for bending and fixing of bars for concrete
reinforcement.
8. IS: 5525 - Recommendation for detailing of reinforcement in reinforced concrete
works.
9. IS: 2751 - Code of practice for welding of mild steel plain and deformed bars used
for reinforced concrete construction.
10. IS: 9417 - Specification for welding cold worked bars for reinforced concrete
construction.
11. IS: 3558 - Code of practice for use of immersion vibrators for consolidating
concrete.
12. IS: 3414 - Code of practice for design and installation of joints in building.
13. IS: 4326 - Code of practice for earthquake resistant construction of building.
14. IS:4014 - Code of practice for steel tubular scaffolding.(parts-I & II)
15. IS: 2571 - Code of practice for laying insitu cement concrete flooring.
16. IS: 7861 - Code of practice for extreme weather concreting.
Part-I: Recommended practice for hot weather concreting.
Part-II: Recommended practice for cold weather concreting.
17. IS: 13920 - Ductile Detailing of Reinforced Concrete Structure subjected to 1993
seismic forces.
18. SP-16 - Design Aids for Reinforcement Concrete to IS:4561978 (S&T) 1980
19. SP-24 - Explanatory Handbook on IS:4561978
20. SP-34 - Handbook on Concrete Reinforcement and Detailing (S&T) 1987

CONSTRUCTION SAFETY
1. IS:3696 - Safety code for scaffolds and ladders.(Parts-I & II)
2. IS:7969 - Safety code for handling and storage of building materials
3. IS: 8989 - Safety code for erection of concrete framed structures.

MEASUREMENT
1. IS: 1200 - Method of measurement of building and engineering works.
2. IS: 3385 - Code of practice for measurement of civil engineering works.

4.3. MATERIALS FOR STANDARD CONCRETE

a. The ingredients to be used in the manufacture of concrete shall consist solely of Ordinary
Portland Cement or Sulphate Resistant Cement of approved make clean sand, natural
coarse aggregate, clean water, and admixtures.
b. Cement
1. The Contractor will have to make own arrangements for procuring cement and steel.
Cement remaining in bulk storage at the mill, prior to shipment for more than 6 months
or cement in bags in local storage in the hands of vendor for more than 3 months after
completion of tests may be retested before use and may be rejected if it fails to
conform to any of the requirement of IS 269-1976.
2. The Contractor will have to make his own arrangements for transport from supplier
godown and storage of adequate quantity of cement. Contractor will construct cement

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 godown at site as per RMC rules. Cement in bulk may be stored in bins or silos, in
batches of 10x10, which will provide complete protection from dampness,
contamination and minimize caking and false set. Cement bags shall be stored in a dry
enclosed shed (storage under tarpaulins will not be permitted), well away from the
outer walls and insulated from the floor to avoid contact with moisture from the 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. The
storage bins and storage arrangement shall be approved by the Engineer-in-Charge.
Consignments of cement shall be stored as received and shall be consumed in the
order of their delivery. Stacking of cement shall be done as per IS and in such a way
that first come cement shall be used first.
3. Cement held in storage for a period of ninety (90) days or longer shall be tested.
Should at any time the Engineer-in-Charge 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 the Contractor’s cost at an
approved laboratory and until the results of such tests are found satisfactory, it shall not
be used in any work. Testing certificates for each batch of cement should be submitted
by the Contractor to the Engineer-in-Charge, before starting the concreting work. The
Contractor shall not be entitled to any claim of any nature on this account.
4. Aggregates
i) General
“Aggregate” in general designates both fine and coarse inert materials used in the
manufacture of concrete (Vide BIS 456 & BIS 383) and confirming to tests as per BIS
2386 (Part I to VI)
“Coarse Aggregate” is aggregate most of which is retained when passed through on
4.75 mm BIS sieve.
All fine and coarse aggregates proposed for use in the works shall be subject to the
RMC Quality Control Department approval and after specific materials have been
accepted, the source of supply of such materials shall not be changed without prior
approval of the RMC Quality Control Department. Aggregates shall consist of natural
sands, stone (crushed or uncrushed) and gravel from a source known to produce
satisfactory aggregate for concrete and shall be chemically inert, non-flaky, strong,
hard, durable against weathering, of limited porosity and free from deleterious
materials that may cause corrosion of the reinforcement or may impair the strength
and or durability of concrete. The grading of aggregates shall be such as to produce
a dense concrete of specified strength and consistency that will work readily into
position without segregation and shall be based on the “mix design” and preliminary
tests on concrete specified later.
ii) Sampling and testing
Samples of the aggregates for mixed design and determination of suitability shall be
taken under the supervision of the Engineer-in-Charge and delivered to the
laboratory, well in advance of the scheduled placing of concrete. Records of tests,
which have been made on proposed aggregates and on concrete made from this
source of aggregates, shall be furnished to Engineer-in-Charge in advance of the
work, for use in determining aggregate suitability. The costs of all such tests,
sampling etc. shall be borne by the Contractor.
iii) Storage of aggregates
All coarse and fine aggregates shall be stacked separately in stock piles in the
material yard near the work site in bins properly constructed to avoid inter mixing of

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 different aggregates. Contamination with foreign material and earth during storage
and while heaping the materials shall be avoided. The aggregates must be of
specified quality not only at the time of receiving at site but more so at the time of
loading into mixer. Rakers shall be piled in layers not exceeding 1.20 m in height to
prevent coning or segregation. Each layer shall cover the entire area of stockpile
before succeeding layers are started. Aggregates that have become segregated shall
be rejected.
iv) Specific Gravity
Aggregates having a specific gravity below 2.4 (saturated surface dry basis) shall not
be used.
4.4. FINE AGGREGATE
a) Fine aggregate shall consist of natural or crushed sand conforming to BIS 383 confirming
to tests as per BIS 2386 part I to VI. The sand shall be clean, sharp, hard, strong and
durable and shall be free from dust, vegetable substances, adherent coating, clay, alkali,
organic matter, mica, salt, or other deleterious substances, which can be injurious to the
setting qualities/strength/durability of concrete.
b) Screening and Washing: Sand shall be prepared for use by such screening or washing, or
both, as necessary, to remove all objectionable foreign matter while separating the sand
grains to the required size fraction.
c) Foreign Material limitations : The percentage deleterious substances in sand delivered to
the mixer shall not exceed the following:

Table 2: Foreign Material Limitations in Fine Aggregate

Sr. Foreign material Percentage by weight
Uncrushed Crushed
1 Material finer than 75 micron BIS sieve 3 15
2 Shale 1 -
3 Coal & Lignite 1 1
4 Clay Lumps - 1
Total 5 17
d) Gradation: Unless otherwise directed or approved by the Engineer-in-Charge, the grading
of sand shall be within the limits indicated hereunder:

Table 3: Grading of Sand for Fine Aggregate

BIS: Sieve Grading Grading Grading Grading
Designation Zone I Zone II Zone III Zone IV
10 mm 100 100 100 100
4.75 mm 99-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns May-20 Aug-30 Dec-40 15-50
150 microns 0-10 0-10 0-10 0-15

Where the grading falls outside the limits of any particular grading zone of sieves, other than 600
microns IS sieve, by total amount not exceeding 5%, it shall be regarded as falling within that
grading zone. This tolerance shall not be applied to percentage passing the 600 micron IS sieve
or to percentage passing any other sieve on the coarser limit of grading zone I or the finer limit of
grading zone IV. Fine aggregates conforming to grading zone IV shall be used. Mix designs and
preliminary tests shall show its suitability for producing concrete of specified strength and

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 workability. e) Fineness Modulus The sand shall have a fineness modulus of not less than 2.0 or
more
than 3.5. The fineness modulus is determined by adding the cumulative percentages
retained on the following IS sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 microns and
150 microns) and dividing the sum by 100.

4.5. COARSE AGGREGATE

a) Coarse aggregate for concrete, except as noted above, shall conform to IS 383 & IS 2386.
This shall consist of crushed stone and shall be clean and free from elongated, flaky or
laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali, mica,
organic matter or other deleterious matter.
b) Screening and Washing: Crushed rock shall be screened and or washed for the removal of
dirt or dust coating, if so requested by the Engineer-in-Charge.
c) Grading
i) Coarse aggregate shall be either in single size or graded, in both cases the grading
shall be within the following limits:

BIS Percentage passing for single sized Percentage Passing For

Sieve aggregate of normal size Graded Aggregate Of Normal
Size Size
(mm)
40mm 20mm 16mm 12.5mm 10mm 40mm 20mm 16mm 12.5mm
63 100 - - - - 100 - - -
40 85- 100 - - - 95- - - -
100 100
20 0-20 85- 100 - - 30-70 95- 100 -
100 100
16 - - 85- 100 - - - 90- -
100 100
12.5 - - - 85-100 100 - - - 90-100
10 0-5 0.20 0-30 0-45 85- 10-35 25-35 30-70 40-85
100
4.75 - 0-5 0-5 0-10 0-20 0-5 0-10 0-10 0-10
2.36 - - - - 0-5 - - - -

ii) The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable,
flaky and laminated pieces, mica and shale, if present, shall be only within tolerance limits
which will not affect adversely the strength and or durability of concrete. The maximum size
of coarse aggregate shall be 40 mm for M-7.5 and M-10 and 20mm for M-15 to M-30
concrete, or as directed by the Engineer-in-Charge or specified. The maximum size of coarse
th
aggregate shall be the maximum size specified above but in no case greater than 1/4 of the
minimum thickness of the member, provided that the concrete can be placed without difficulty
so as to surround all reinforcement thoroughly and fill the corners of the form. For plain
concrete the maximum size of aggregate shall be of 40 mm. For heavily reinforced concrete
members, the nominal maximum size of the aggregate shall be 5 mm less than the minimum
clear distance between the reinforcing main bars or 5 mm less than the minimum cover to
reinforcement whichever is smaller.

d) Foreign material limitations

The percentage of deleterious materials in the aggregate delivered to the mixer shall not
exceed the following:

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 Table 4 : Foreign Material Limitations in Coarse Aggregate
Sr. Foreign Material Percentage by Weight
Uncrushed Crushed

1 Material finer than 75 micron BIS Sieve 3.0 3.0

2 Coal and lignite Clay Lumps Soft 1.0 1.0
3 Fragments 1.0 1.0
4 Soft Fragments 3.0 -

Total 8.0 5.0

4.6. WATER
a) Water used for washing, mixing and curing shall be free from injurious amounts of deleterious
materials. Potable water is generally satisfactory for mixing and curing concrete. Physical and
chemical analysis of the water should be submitted to the Engineer-in-Charge, before starting
the work.
b) In case of doubt, the suitability of water for making concrete shall be ascertained by the
compressive strength and initial setting time test specified in BIS 456. The sample of water
taken for testing shall be typical of the water proposed to be used for concreting, due account
being paid to seasonal variation. The sample shall not receive any treatment before testing
other than that envisaged in the regular supply of water proposed for use in concrete. The
sample shall be stored in a clean container previously rinsed out with similar water.
c) Average 28 days compressive strength of at least three 15 cm concrete cubes prepared with
water proposed to be used shall not be less than 90% of the average strength of three similar
concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested
in accordance with the requirements of BIS 516.
d) The initial setting time of test block must be made with the appropriate test cement and the
water proposed to be used. It shall not be less than 30 minutes and shall not differ by more
than +/-30 minutes from the initial setting time of control test block prepared with the
appropriate test cement and distilled water. The test block shall be prepared and tested in
accordance with the requirements of BIS 4031.
e) Where water can be shown to contain an excess of acid, alkali, sugar or salt, Engineer-in-
Charge may refuse to permit its use. As a guide, the following concentrations represent the
maximum permissible values.
1) To neutralise 200 ml sample of water, using phenolphthalein as indicator, it should not
require more than 2 ml of 0.1 normal NaOH. The details of test shall be as given in BIS
3025.
2) To neutralise 200 ml sample of water, using methyl orange as an indicator, it should not
require more than 10 ml of 0.1 Normal HCl. The details of test shall be as given in BIS
3025.
3) Percentage of solids, when tested in accordance with the method indicated below shall
not exceed the following:
Solids Percent Method of test
Ref. to col. no in IS:3025) Organic
(organic solid = total solids minus ignited residue) 0.02 10 and 11
Inorganic 0.03 11(ignited residue)
Sulphates (as So4) 0.05 20
Alkali Chlorides (as Cl) 0.2 24
Suspended matter 0.2 12
T he pH value of water shall not generally be less than 6.

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4.7. STEEL AND ALUMINIUM MEMBERS ENCASED IN CONCRETE
Structural steel and aluminum ladders etc. to be encased in concrete shall be without paint.
Primer should be used for encasing purpose. The encasing shall be done in concrete with 10
mm, maximum size aggregate and a works cube strength not less than 150 kg/sq.cm. at 28 days
unless otherwise specified. The member shall be wrapped with galvanized aluminum wire mesh
of adequate size. The galvanized aluminum wire mesh shall be kept 20 mm from the edge or
surface of the member and shall be held in position securely. The member will have a minimum
cover of 50 mm unless otherwise indicated in the drawings. Where the clear cover is more than
75 mm, concrete with 20 mm coarse aggregate can be used.

4.7.1. Anchor Bolts, Anchors, Sleeves, Inserts,

The Contractor shall build in to concrete work all the items mentioned in Drawings or Engineer In
Charge and shall embed them partly or fully as directed and secure the same as may be
required. The materials if required to be supplied by the Contractor, shall be as specified and be
of best quality available according to relevant Indian standards of approved manufacture and to
the satisfaction of the engineer. Exposed surface of embedded materials is to be painted with one
coat of approved anti-corrosive paint and/ or bituminous paint without any extra cost to the owner.
If welding is to be done subsequently on the exposed surface of embedded material the paint
shall be cleaned off the member to a minimum length of 50 mm beyond each side of the weld
line.

Necessary templates, jigs, fixtures, supports etc. shall be used as may be required or
directed by the Engineer In Charge.

4.8. CONTROLLED CONCRETE

All concrete in the works shall be “Controlled Concrete” as defined in IS: 456 except for M-7.5
and M-10 for which normal mix concrete shall be used. Whether reinforced or otherwise, all
concrete works to be carried out under this specification shall be divided into the following
classifications:

Minimum Compressive Strength Of 15 cm cubes at 7 days and 28 days after mixing, conducted
in accordance with IS: 516. Any operation of concrete done at atmospheric temperature above 40
degree C or where the temperature of concrete at the time of placement is expected to be beyond
40 degree C may be categorize as hot weather concreting and should be confined to the
requirement of IS 7861(Part-I) 1975 and SP-23 (S&T)-1982.

2 2
Class Preliminary Test N/mm Works Test N/mm Max. Size of Aggregate
in mm
M40 33.5 50 27 40 20
M35 30 44 23.5 35 20
M30 25 38 20 30 40 or 20
M25 22 32 17 25 40 or 20
M20 17.5 26 13.5 20 40 or 20
M15 13.5 20 10 15 40 or 20
At 7 Days At 28 At 7 days At 28 As indicate in the
days days specification or as
required

Note: It shall be very clearly understood that whenever the grade of concrete such as M-
20, etc. is specified it shall be Contractor’s responsibility to ensure the minimum crushing
strength stipulated for the respective grade of concrete is obtained at works.

4.9. MIX DESIGN

4.9.1. General
i) This is essential for investigating the grading of aggregates, water-cement ratio, workability

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 and the quality of cement required to give preliminary and works cubes of the minimum
strength specified. The proportions of the mix shall be determined by weight. Adjustment
of aggregate proportions due to moisture present in the aggregate shall be made.
Determination of mix proportions shall be carried out according to “Recommended
guidelines for Concrete Mix Design” conforming to IS: 10262.
ii) Whenever there is a change either in required strength of concrete, or water-cement ratio
or workability or the source of aggregates and/or cement, preliminary tests shall be
repeated to determine the revised proportions of the mix to suit the altered conditions.
While designing proportions, over-wet mixes shall always be avoided.
iii) Mix Design may be done without changing its minimum cement content mentioned in NIT
iv) While fixing the value for water/cement ratio for preliminary mixes, assistance may be
derived from the graph (Appendix A, BIS 456 showing the relationship between the 28
day compressive strengths of concrete mixes with different water/cement ratios and the
7-day compressive strength of cement tested in accordance with IS: 269.
4.9.2. Preliminary Tests

Test specimens shall be prepared with at-least two different water/cement ratios for each class of
concrete, consistent with work ability required for the nature of the work. The materials and
proportions used in making preliminary tests shall be similar in all respects to those to be actually
employed in the works as the object of these tests is to determine the properties of cement,
aggregates and water necessary to produce concrete of required consistency and to give the
specified strength, it will be Contractor’s sole responsibility to carry out these tests and he shall
therefore furnish to Engineer-in-Charge a statement of proportions proposed to be used for the
various concrete mixes. For preliminary tests, the following procedure shall be followed.

Materials shall be brought to the room temperature and all materials shall be in a dry condition.
The quantities of water cement and aggregates for each batch shall be determined by weight to
an accuracy of 1 part in 100 parts.

Mixing concrete shall be done by hand (for small quantities, as directed by Engineer-in-Charge)
or in a small batch mixer as per IS: 516 in such a manner as to avoid loss of water. The cement
and fine aggregate shall first be mixed dry until the mixture is uniform in color. The coarse
aggregate shall then be added, mixed and water added and the whole batch mixed thoroughly for
a period of not less than two minutes until the resulting concrete is uniform in appearance. Each
batch of concrete shall be such a size as to leave about 10% excess concrete, after moulding the
desired number of test specimens.

The consistency of each batch of concrete shall be measured immediately after mixing, by the
slump test in accordance with IS: 1199. If in the slump test, care is taken to ensure that no water
or other material is lost, the material used for the slump test may be re-mixed with the remainder
of the concrete for making the specimen test cubes. The period of re-mixing shall be as short as
possible yet sufficient to produce a homogeneous mass.

The samples for compression tests of concrete shall be made as per IS: 516 on 15 cm cubes.
Each mould shall be provided with a metal base plate having a plate surface so as to support the
mould during filling without leakage. The base plate shall be preferably attached to the mould by
springs or screws. The parts of the mould when assembled shall be positively and rigidly held
together. Before placing concrete, the mould and base plate shall be cleaned and oiled. The
dimensions and internal faces of the mould shall be accurate within the following limits. Height
and distance between the opposite faces of the mould shall be of specified size +0.2 mm. The
angle between the adjacent internal faces and between internal faces and top and bottom faces
of mould shall be 90-
degree +0.5 degree. The interior faces of the mould shall be plane surfaces with a permissible
variation of 0.03 mm.

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 Concrete test cubes shall be moulded by placing fresh concrete in the mould and compacted as
specified in IS 516.

Curing shall be as specified in IS 516. The cubes shall be kept in moist air of at least 90% relative
humidity at a temperature of 27 degree C + 2 degree C for 24 hours +2 hours from the time of
adding water to the dry ingredients. Thereafter they shall be removed from the moulds and kept
immersed in clean, fresh water and kept at 27 degree C +2 degree C temperature until required
for test. Curing water shall be renewed every seven days. A record of maximum and minimum
temperatures at the place of storage of the cubes shall be maintained during the period they
remain in storage.

The strength shall be determined based on not less than five cube test specimens for each age
and each water cement ratio. All these laboratory test results shall be tabulated and furnished to
the Engineer-in-Charge. The test results shall be accepted by the Engineer-in-Charge if the
average compressive strengths of the specimens tested is not less than the compressive strength
specified for the age at which specimens are tested subject to the condition that only one out of
the five consecutive tests may give a value less than the specified strength for that age. The
Engineer-in-Charge may direct the Contractor to repeat the tests if the results are not satisfactory
and also make such changes as he considers necessary to meet the requirements specified. All
these preliminary tests shall be conducted by the Contractor at his own cost in an approved
laboratory of RMC.

4.10. PROPORTIONING, CONSISTENCY, BATCHING AND MIXING OF CONCRETE

The determination of the water cement ratio and proportion of aggregates to obtain the required
strength shall be made from preliminary tests by designing the concrete mix. Controlled concrete
shall be used on all concrete work complying with all the requirements of IS: 456. Cube tests shall
be carried out by the Contractor on the trial mixes before the actual concreting operation starts.
Based on the strength of the concrete mix sanction for the use has to be obtained from Engineer-
in-Charge.

If during the execution of the works it is found necessary to revise the mix because of the cube
tests showing lower strengths than the required one due to inconsistency of quality of material or
otherwise, The Engineer-in-Charge shall ask for fresh trial mixes to be made by the Contractor.
No claim to alter the rates of concrete work shall be entertained due to such change in mix
variations, as it is the Contractor’s responsibility to produce the concrete of the required grade.

Great care shall be exercised when mixing the actual works concrete using the proportions of the
selected trial mix. The final concrete mix shall have the same proportions and same source of
cement, fine and coarse aggregates and water as that of the approved selected mix.

A reasonable number of bags should be weighed separately to check the Net weight, where the
weight of cement is determined by accepting the manufacturer's weight per bag at the site.
Proper control of mixing water is deemed to be of paramount importance. If mixers with automatic
addition of water are used, water should be either measured by volume in calibrated buckets, tins
or weighed. All measuring equipment shall be maintained in a clean serviceable condition and
their accuracy periodically checked and certified and the Engineer-in-Charge’s approval obtained.
The Engineer-in-Charge may require the Contractor to carry out moisture content tests in both
fine and coarse aggregates. The amount of the added water shall then be adjusted to
compensate for any observed variations in the moisture contents. BIS: 2386 shall be referred to
for determination of moisture content.

No substitution in material, used on the work or alteration in the established proportions shall be
made without additional tests to show that the quality and strength of concrete are satisfactory.
No alterations shall be permitted without the prior sanction of the Engineer-in-Charge.

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4.10.1. Mixing of Concrete

The mixing of concrete shall be strictly carried out in an approved type of mechanical Concrete
mixer. The mixing equipment shall be capable of combining the aggregates. Cement and water
within the specified time into a thoroughly mixed and uniform mass, and of discharging the
mixture without segregation. The entire batch shall be discharged before recharging. Mixing
periods shall be measured from the time when all of the solid materials are in the mixing drum,
provided that all of the mixing water shall be introduced before one fourth of the mixing time has
elapsed. The mixing time in no case shall be less than two minutes. The mixer speed shall not be
less than 14 nor more than 20 revolutions per minute.

Mixing shall be continued until there is a uniform distribution of the materials and the mass is
uniform in color and consistency. Hand mixing of concrete shall not be permitted at all.

For quantities less than 1 cum of concrete, hand mixing may be permitted at the discretion of the
Engineer-in-Charge with 10% excess cement quantity.

4.10.2. Grade of Concrete

The different grades of concrete specified shall conform to the strengths as required by IS: 456-
1987.Standard deviation shall be calculated as stated in 14.5 of IS: 456-1978. The acceptable
criteria for concrete shall be as stated in clause 15 of IS: 456 -1978.The assumed standard
deviations as given in table 6 of IS: 456-1978 has to be followed and are given here under.
However, the minimum cement content shall be as per Table no. 7: Minimum Cement Content in
Concrete in this tender document.

Table 5: Grade of Concrete

Grade of Concrete Assumed Standard Deviation N/sq.mm

M 10 2.3
M 15 3.5
M 20 4.6
M 25 5.3

In order to get a quick idea of quality of concrete the optional tests are conducted as stipulated in
14.1.1 of IS: 456-1978 and the results are analyzed according to table 5 on page 41 of IS: 456-
1978.

4.10.2.1. Controlled Concrete

Controlled concrete shall be used on all concreting works except where specified otherwise the
mix proportions for all grades of concrete shall be designed to obtain strengths corresponding to
the values specified in table below for respective grades of concrete.

Table 6: Compressive Strengths at 28 days

Grade Specified Characteristic Compressive Strength at 28 days (N/sq.mm )
M15 15
M20 20
M25 25
M30 30

The maximum Water : Cement ratio for all controlled concrete works shall be as specified in IS:
456-1978 as Preliminary tests as specified in the BIS code and required by the Engineer-in-
Charge shall be carried out sufficiently ahead of the actual commencement of the work with
different grades of concrete made from representative samples of aggregates and cement

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 expected to be used on the job to ascertain the ratios by weight of cement of total quantity of fine
and coarse aggregates and the water cement ratio required to produce a concrete of specified
strength and desired workability. The minimum cement content for each grade of concrete shall
be as per table below.

Table 7: Minimum Cement Content in Concrete

Grade of Concrete Minimum Cement Content in Concrete
(kg/cum of finished Concrete)

M 20 280
M 25 300
M 30 320
M 35 350

At least 4 (four) trial batches are to be made and 7 test cubes should be taken for each batch
noting the slump on each mix. These cubes shall then be properly cured and two cubes from
each mix shall be tested in a testing laboratory approved by the Engineer-in-Charge at 7 days
and others at 28 days for obtaining the ultimate compressive strength. The test reports shall be
submitted to the Engineer in charge. The cost of mix design and testing shall be borne by the
Contractor. On the basis of the preliminary test reports for trial mix, a proportion of mix by weight
and water cement ratio will be approved by the Engineer-in-Charge, which will be expected to
give the required strength. Consistency and workability and the proportions so decided for
different grades of concrete shall be adhered to during all concreting operations. If however at
any time the Engineer-in-Charge feels that the quality of material, being used has been changed
from those used for preliminary mix design, the Contractor shall have to run similar trial mixes to
ascertain the mix proportions and consistency.

The mix once approved must not be varied without prior approval of the Engineer-in-Charge.
However should the Contractor anticipate any change in the quality of future supply of materials
than that used for preliminary mix design, he shall inform the same to the Engineer-in-Charge and
bring fresh samples sufficiently ahead to carry out fresh trial mixes. The Engineer-in-Charge shall
have access to all places and laboratory where design mix is prepared. Design mix will indicate
by means of graphs and curves etc. the extent of variation in the grading of aggregates which can
be allowed.

In designing the mix proportions of concrete, the quantity of both cement and aggregate shall be
determined by weight. All measuring equipment shall be maintained in clean and serviceable
condition and their accuracy periodically checked.

To keep the water cement ratio to the designed value, allowance shall be made for the moisture
contents in both fine and course aggregates and determination of the same shall be made as
frequently as directed by the Engineer-in-Charge. The determination of moisture contents shall be
according to IS: 2386 (Part III). Absorption of water by dry aggregates shall not be more than 5%.

4.10.2.2. Strength Requirements

Where ordinary Portland cement conforming to IS: 269 or Portland blast furnace slag cement
conforming to IS: 455 is used the compressive strength requirements for various grades of
concrete shall be as shown in table below. Where rapid hardening Portland cement is used the
28 days compressive strength requirements specified in Tablehereunder shall be met in 7 days.
The strength requirements specified in table shall apply to both controlled concrete and ordinary
concrete.

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 Strength Requirements of Concrete
Grade of Concrete Minimum Compressive Strength Concrete in
accordance with IS: 516 (in Kg/Cm2) As per IS 456-
2000 for 15 cm Cube Specimens

at 3 days at 7 days at 28 days

M 15 100 200 150
M 20 135 260 200
M 25 170 320 250
M 30 200 380 300

Other requirements of concrete strength as may be desired by the Engineer-in-Charge shall be in

accordance with Indian Standard IS: 456 (latest revision). The acceptance of strength of concrete
shall be as per clause 5.4 “Sample size and Acceptance Criteria” of IS: 456 (latest revision)
subject to stipulation and/or modifications stated elsewhere in this specification if any.

Concrete work found unacceptable shall have to be dismantled and replaced to the satisfaction of
the Engineer-in-Charge by the Contractor free of cost to the Owner. No payment will be made for
the dismantled concrete, the relevant formwork and reinforcement, embedded mixtures etc.
wasted in the dismantled portion shall be made. In the course of dismantling if any damage is
done to the embedded items or adjacent structures, the same shall also be made good free of
charge by the Contractor to the satisfaction of the Engineer in charge. If the water quantity has to
be increased in special cases, cement also has to be increased proportionately to keep the ratio
of water to cement same as adopted in trial mix design for each grade of concrete.

4.10.2.3. Workability

The workability of concrete shall be checked at frequent intervals by slump test. Where facilities
exist and if required by the Engineer-in-Charge, alternatively the compacting factor test in
accordance with IS: 1199 shall be carried out. The degree of workability necessary to allow the
concrete to be well consolidated and to be worked into the corners of form work and round the
reinforcement to give the required surface finish shall depend on the type and nature of the
structure and shall be based on experience and tests. The limits of consistency for structures are
as specified in the table below:

Table 8: Limits of Consistency

Concreting of shallow Sections with Very low 20-10 seconds Veebee time or
vibration 0.75-0.80 compacting factor

Concreting of lightly Reinforced Low 10-5 seconds or 0.80-0.85

sections With vibration compacting factor

Concreting of lightly Reinforced Medium 5-2 seconds Veebee time or 0.85-

sections Without Vibration or 0.92 compacting factor or 25-
Heavily reinforced Section with 75mm slump for 20 mm
Vibration Aggregate
Concreting of heavily Reinforced High Above 0.92 compacting factor or
sections compacting Without 75-125 mm slumps for 20 mm

4.10.3. Workmanship

All workmanship shall be according to the latest relevant standards. Before starting a pour the
Contractor shall obtain the approval of the Engineer-in-Charge and all other concerned
department including safety dept, in a “Pour Card” maintained for this purpose. He shall obtain

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 complete instructions about the material and proportion to be used, slump, workability of water
per unit of cement, number of test cubes to be taken, finishing to be done and any admixture to
be added etc.

4.11. SAMPLING AND TESTING OF CONCRETE IN THE FIELD

Sampling and Testing of Concrete shall conform to IS: 456 2000.

a) Facilities required for sampling materials and concrete including whether proof buildings to
house the facilities in the field, shall be provided by the Contractor at no extra cost. The
following equipment with operator shall be made available in serviceable conditions.

i. Concrete cube-testing machine suitable for 15 cm cubes of 100 tonnes capacity with
proving calibration ring 1 no.
ii. Cast iron cube moulds 15 cm size 24 nos.
iii. Slump cone complete with tamping rod 2 set
iv. Laboratory balance to weigh upto
5 kg with sensitivity of 10 gm 1 no.
v. BIS sieves for coarse and fine aggregates 1 set
vi. Set of measures from 5 litres to 0.1 litre 1 set
vii. Electric oven with thermostat upto 120° C 1 no.
viii. Flakiness gauge 1 no.
ix. Elongation index gauge 1 no.
x. Sedimentation pipette 1 no.
xi. Calibrated glass jar 1.0 litre capacity 2 nos.
xii. Glass flasks and metal containers As required
xiii. Chemical reagents like sodium hydroxide,
tannic acid, litmus paper etc. - As required
xiv. Laboratory balance of 2 kg capacity and
sensitivity of 1 gm - 1 no.
xv. Weighing Machine for cement bags of 6 Nos.: 2 no.
xvi. Vernier Calipers As required.
xvii. Thermometer for concrete 1 no.
b) No concrete of any kind may be placed until the field concrete testing laboratory as specified
is provided to the satisfaction of the Engineer. The Contractor shall notify the Engineer in
advance of all concrete and concrete material testing as provided in the clause to provide
the Engineer/his representative with an opportunity to witness all prescribed tests.
c) At least 12 test cubes of each class of concrete shall be made of every 50cum concrete or
part thereof or from different batches as directed by Engineer-in-Charge. Such samples shall
be drawn on each day for each type of concrete. Of each set of 12 cubes, six shall be tested
at 7 days age and six at 28 days age. The cubes must be casted from various batches to
arrive at an average strength. The laboratory test results shall be tabulated and furnished to
the Engineer. The Engineer will pass the concrete if average strength of the specimens
tested is not less than the strength specified, subject to the condition that only one out of
three consecutive tests may give a value less than the specified strength but this shall not be
less than 90% of the specified strength.
d) Consistency: Slump tests shall be carried out as often as requested by the Engineer and
invariably from the same batch of concrete from which the test cubes are made. Slump tests

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 shall be done immediately after sampling.

4.12. CONCRETE TESTS

The Engineer-in-Charge, may order tests to be carried out on cement, sand, coarse aggregate,
water in accordance with the relevant Indian standards. Tests on Cement shall include:
• Fineness test
• Test for normal consistency
• Test for setting time
• Test for soundness
• Test for tensile strength
• Test for compressive strength
• Test for heat of hydration (by experiment and by calculations) in accordance with BIS 269
• Tests on Sand shall include:
• Sieve test
• Test for organic impurities
• Decantation test for determining clay and silt content
• Specific gravity test
• Test for unit weight and bulkage factor
• Test for sieve analysis and fineness modulus
• Tests on Coarse Aggregate shall include:
• Sieve analysis
• Specific gravity and unit weight of dry, loose and rodded aggregate
• Soundness and alkali aggregate reactivity
• Petrography examination
• Deleterious materials and organic impurities
• Test for aggregate crushing value

Any or all these tests would normally be ordered to be carried out only if the Engineer feels the
materials are not obtained and shall be performed by the Contractor at a test laboratory approved
by RMC. The Contractor shall bear the charges of these optional tests.

Concrete not made to the requirements of specification in all respects may be rejected by the
Engineer-in-Charge in which case it shall be removed and reconstructed entirely at the expense
of the Contractor.

Failure to meet Specified Requirements

If from the cube test results it appears that some portion of the work has not attained the required
strength, the Engineer may order that portion of the structure be subjected to further testing of any
kind whatsoever as desired by the Engineer, including if so desired by him, full load testing of the
suspected as well as adjacent portions of the structure as specified in the contractors cost. The
engineer may also reject the work and order its demolition and reconstruction at the contractors
cost.

If the Strength of concrete in any portion of the structure is lower than the required strength, but is
considered nevertheless adequate by the Engineer So that demolition is not necessary, the
contractor shall be paid a lower rate for such lower strength concrete as determined by Engineer.

If the concrete is not able to meet the prescribed acceptance standard the effect of such
deficiency on structure shall be investigated by the contractor as directed by the Engineer. The
engineer may accept the work as sub standard work. Any additional work required by the Engineer
for such acceptance shall be carried out by the contractor at his cost. In case the concrete is not
found to be acceptable after investigation, the contractor shall remove the rejected work.

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4.12.1. Load Test on Members or Any Other Tests

i) In the event of any work being suspected of material or workmanship or both, the Engineer-
in-Charge requiring its removal and reconstruction may order, or the Contractor may request
that it should be load tested in accordance with the following provisions.
ii) The test load shall be 125% of the maximum superimposed load for which the structure was
designed. Such test load shall not be applied before 56 days after the effective hardening of
concrete. During the test, struts strong enough to take the whole load shall be placed in
position leaving a gap under the members. The test load shall be maintained for 24 hours
before removal.
iii) If within 24 hours of the removal of the load, the structure does not show a recovery of at least
75% of the maximum deflection shown during the 24 hours under load, the test loading shall
be repeated after a lapse of at least 72 hours. The structure shall be considered to have
failed to pass the test if the recovery after the second test is not at least 75% of the maximum
deflection shown during the second test. If the structure is certified as failed by the Engineer-
in-Charge, the cost of all the new construction and the load tests shall be borne by the
Contractor.
iv) Any other tests, e.g. taking out in an approved manner concrete cores, examination and tests
on such cores removed from such parts of the structure as directed by the Engineer-in-
Charge, sonic testing etc. shall be carried out by the Contractor, if so directed, at no extra
cost.

4.12.2. Unsatisfactory tests

Should the results of any test prove unsatisfactory, or the structure shows signs of weakness,
undue deflection or faulty construction, the Contractor shall remove and rebuild the member or
members involved or carry out such other remedial measures as may be required by the
Engineer-in-Charge.

4.13. ADMIXTURES

4.13.1. General

Admixtures may be used in concrete where required, only with the approval of the Engineer-in-
Charge. How ever it should be seen that, with the passage of time, neither the compressive
strength nor its durability is reduced. Calcium chloride shall not be used for accelerating set of
the cement for any concrete containing reinforcement or embedded steel parts. When calcium
chloride is permitted to be used, such as in mass concrete works, it shall be dissolved in water
and added to the mixing water in an amount not to exceed 1.5% of the weight of the cement in
each batch of concrete. When admixtures are used, the designed concrete mix shall be corrected
accordingly. Admixtures shall be used as per manufacturer’s instruction and in the manner and
with the control specified by the Engineer-in-Charge.

4.13.2. Air Entraining Agents

Neutralized Vinson resin or other approved air in the concrete mix agents shall conform to the
requirements of ASTM standard 6.260; Air Entraining Admixtures for Concrete. The
recommended total air content of the concrete is 4% + 1%. The method of measuring air content
shall be as per IS: 1199.

4.13.3. Water Reducing Admixtures

Water reducing lignosulfonate admixture may be added in quantities approved by the Engineer-
in-Charge. The admixtures shall be added in the form of a solution.

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4.13.4. Retarding Admixtures
Retarding agents may be added to the concrete mix in quantities approved by the Engineer-in-
Charge.
4.13.5. Water Proofing Agent
Water proofing agents shall conform to IS: 2645.
4.13.6. Other Admixtures
The Engineer-in-Charge may at his discretion allow the Contractor to use any other admixture in
the concrete.

4.14. PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL INSPECTION AND APPROVAL

a. Before the concrete is actually placed in position, the insides of the formwork shall be
inspected to see that they have been cleaned and oiled. Temporary openings shall be
provided to facilitate inspection, especially at bottoms of columns and wall forms, to permit
removal of sawdust, wood shavings, binding wire, dirt etc. Openings shall be placed or holes
drilled so that these materials and water can be removed easily. Such openings/holes shall
be suitably plugged later.
b. The various agencies shall be permitted ample time to install drainage and plumbing lines,
floor and trench drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames and other
miscellaneous embedment to be cast in the concrete as specified or required or as is
necessary for the proper execution of the work as specified in the drawings.
c. All embedded parts, inserts, etc. supplied by the RMC or the Contractor shall be correctly
positioned and securely held in the forms to prevent displacement during depositing and
vibrating of concrete.
d. All anchor bolts shall be positioned and kept in place with the help of properly manufactured
templates unless specifically waived in writing by the Engineer-in-Charge.
e. Slots, openings, holes, pockets etc. shall be provided in the concrete work in the position
specified in drawing or required or as directed by the Engineer-in-Charge.
f. Reinforcement and other items to be cast in concrete shall have clean surfaces that will not
impair bond.
g. Prior to concrete placement, all work shall be inspected and approved by the
Engineer-in-Charge and if found unsatisfactory, concrete shall not be poured until after all
defects have been corrected.
h. Approval by the Engineer-in-Charge of any and all materials and work as required herein
shall not relieve the Contractor from his obligation to produce finished concrete in accordance
with the requirements of the specifications.
i. Rain or wash water
No concrete shall be placed in wet weather or on a water-covered surface. Any concrete that
has been washed by heavy rains shall be entirely removed, if there is any sign of cement and
sand having been washed away from the concrete mixture. To guard against damage, which
may be caused by rains, the works shall be covered with tarpaulins immediately after the
concrete has been placed and compacted before leaving the work unattended. Any water
accumulating on the surface of the newly placed concrete shall be removed by approved
means and no further concrete shall be placed thereon until such water is removed. To avoid
flow of water over/around freshly placed concrete, suitable drains and sumps shall be
provided. During summer season, temperature of water should be maintained, as per the
criteria and for the same, icing should be done for concreting work.
j. Bonding Mortar Immediately before concrete placement begins, prepared surfaces except
formwork, which will come in contact with the concrete to be placed, shall be covered with
abonding mortar as specified.
k. The corrosive matters on the reinforcement should be removed by means of wire brush.

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 l. Laitance should be removed by means of chiseling from top concrete layer which was earlier
concreted

4.15. TRANSPORTATION
4.15.1. General
All buckets, containers or conveyors used for transporting concrete shall be mortar-tight, leak
proof irrespective of the method of transportation adopted, concrete shall be delivered with the
required consistency and plasticity without segregation or loss of slump. However, chutes shall
not be used for transport of concrete without the written permission of the Engineer-in-Charge
and concrete shall not be re-handled before placing.

4.15.2. Retempered or Contaminated Concrete

Concrete must be placed in its final position before it becomes too stiff to work. On no account,
water shall be added after the initial mixing. Concrete, which has become stiff or has been
contaminated with foreign materials shall be rejected and disposed off as directed by the
Engineer-in-Charge.

4.15.3. Avoiding Segregation

Concrete shall, in all cases, be deposited as nearly as practicable directly, in its final position and
shall not be re-handled to flow in a manner which will cause segregation, loss of materials,
displacement of reinforcement, shuttering or embedded insets, or impair its strength. For
locations where direct placement is not possible, and in narrow forms, the Contractor shall
provide suitable drop and “Elephant Trunks” to confine the movement of concrete. Special care
shall be taken when concrete is dropped from a height, especially if reinforcement is in the way,
particularly in column and the walls.

4.15.4. Placing by Manual Labour

Except when otherwise approved by the Engineer-in-Charge, concrete shall be placed in the
shuttering by shovels or other approved implements, and shall not be dropped from a height
more than 1.0 m or handled in a manner, which will cause segregation.

4.15.5. Placing by Mechanical Equipment

The following specification shall apply when placing concrete by use of mechanical equipment is
warranted considering the nature of work involved. The control of placing shall begin at the mixer
discharge. Concrete shall be discharged by a vertical drop into the middle of the bucket or hopper
and this principle of a vertical discharge of concrete shall be adhered to throughout all stages of
delivery until the concrete comes to rest in its final position.

4.15.5.1. Types of Buckets

Central-bottom-dump buckets of a type that provides for positive regulation of the amount and
rate of deposition of concrete in all dumping positions, shall be employed.

4.15.5.2. Operation of Bucket

In placing concrete in large open areas, the bucket shall be spotted directly over the position
designated and then lowered for dumping. The open bucket shall clear the concrete already in
place and the height of drop shall not exceed 1.0 m. The bucket shall be opened slowly to avoid
high vertical bounce. Dumping of buckets on the swing or in any manner, which results in
separation of ingredients or disturbance of previously placed concrete, will not be permitted.

4.15.6. Placement of Restricted Forms

Concrete placed in restricted forms by barrows, buggles, cars, short chutes or hand shoveling
shall be subject to the requirement for vertical delivery of limited height to avoid segregation and
shall be deposited as nearly as practicable in its final position.

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4.15.7. Usage of Chutes
Where it is necessary to use transfer chutes, specific approval of Engineer-in-Charge must be
obtained to type, length slopes, baffles, vertical terminals and timing of operations. These shall be
so arranged that an almost continuous flow of concrete is obtained at the discharge and without
segregation. Concrete should flow smoothly in the chute and there should not be any obstruction
to the flow. To allow for the loss of mortar against the sides of the chutes, the first mixes shall
have less coarse aggregate. During cleaning of chutes, the wastewater shall be kept clear of the
forms. Concrete shall not be permitted to fall from the end of the chutes by more than 1.0 m.
Chutes, when approved for use shall have slopes not flatter than 1 vertical, 3 horizontal and not
steeper than 1 vertical, 2 horizontal. Chutes shall be of metal or metal lines end of rounded cross
section. The slopes of all chute sections shall be approximately the same. The slopes of all chute
sections shall be approximately the same. The discharge end of the chutes shall be maintained
above the surface of the concrete in the forms.

4.15.8. Placing by Pumping/Pneumatic Placers

Concrete may be conveyed and placed by mechanically operated equipment e.g., pumps or
pneumatic placers only with the written permission of the Engineer-in-Charge at no extra cost.
The slump shall be held to the minimum necessary for conveying concrete by this method.
When pumping is adopted, before pumping of concrete is started, the pipeline shall be lubricated
with one or two batches of mortar composed of one part cement and two parts sand. Care shall
be taken to avoid stoppages in work once pumping has started.

When a pneumatic placer is used, the manufacturer’s advice on layout of the pipeline shall be
followed to avoid blockages and excessive wear. Restraint shall be provided at the discharge box
to cater for the reaction at this end. Manufacturer’s recommendations shall be followed regarding
concrete quality and all other related matters when pumping/ pneumatic placing equipment is
used. It should be noted that no extra payment is made for these items, if required and directed
by Engineer-in-Charge.

4.15.9. Concrete in Layers

Concreting, once started, shall be continuous until the pour is completed. Concrete shall be
placed in successive horizontal layers of uniform thickness ranging from 15 cm to 45 cm directed
by Engineer-in-Charge. These shall be placed as rapidly practicable to prevent the formation of
cold joints or planes of weakness between each succeeding layer within the pour. The thickness
of each layer shall be such that it can be deposited before the previous layer has stiffened. The
bucket loads or other units of deposit, shall be spotted progressively along the face of the layer
with such overlap as will facilitate spreading the layer to uniform depth and texture with a
minimum shoveling. Any tendency to segregation shall be corrected by shoveling stones into
mortar rather than mortar on to stones. Such a condition shall be corrected by redesign of mix or
other means, as directed by the Engineer-in-Charge.

4.15.10. Cover Blocks

Cover blocks of required size depending on the cover of the reinforcement as mentioned in the
drawings shall be prepared in 1:3 cement mortar with fine aggregates and minimum compressive
strength of 300 kg/sq.cm.

4.15.11. Bedding of Layers

The top surface of each pour and bedding planes shall be approximately horizontal unless
otherwise instructed. Top layer should be rough and with key for further extension of work.

4.15.12. Compaction
Concrete shall be compacted during placing with approved vibrating equipment until the concrete
has been consolidated to the maximum practicable density, as specified in the IS, is free of
pockets of coarse aggregate and fits tightly against all form surfaces, reinforcement and

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 embedded fixtures. Particular care shall be taken to ensure that all concrete placed against the
form faces and into corners of forms against hardened concrete at joints is free from voids or
cavities. The use of vibrators shall be consistent with the concrete mix and caution exercised not
to over vibrate the concrete to the point that segregation results.

4.15.12.1.Type of Vibrators

Vibrators shall conform to BIS specifications. Type of vibrator to be used shall depend on the
structures where concrete is to be placed. Shutter vibrators to be effective, shall be firmly secured
to the formwork which must be sufficiently rigid to transmit the vibration and strong enough not to
be damaged by it. Immersion vibrators in sufficient numbers and each of adequate size shall be
used to properly consolidate all concrete. Tapping or external vibrating of forms by hand tools or
immersion vibrators will not be permitted.

4.15.12.2.Use of Vibrators

The exact manner of application and the most suitable machines for the purpose must be
carefully considered and operated by experienced men. Immersion vibrators shall be inserted
vertically at points not more than 450 mm apart and withdrawn when air bubbles cease to come
to the surface. Immersion vibrators shall be withdrawn very slowly. In no case shall immersion
vibrators be used to transport concrete inside the forms. Particular attention be paid to vibration
at the top of a lift e.g. in a column or wall.

4.15.12.3.Melding Successive Batches

When placing concrete in layers, which are advancing horizontally as the work progresses, great
care shall be exercised to ensure adequate vibration blending and melding of the concrete
between the succeeding layers.

4.15.12.4.Penetration of Vibrators

The immersion vibrator shall penetrate the layer being placed and also penetrate the layer below
while the under layer is still plastic to ensure good bond and homogeneity between the two layers
and prevent the formation of cold joints.
4.15.12.5.Vibrating against Reinforcement/Formwork

Care shall be taken to prevent contact of immersion vibrators against reinforcement steel.
Immersion vibrators shall not be allowed to come in contact with reinforcement steel after start of
initial set. They shall also not be allowed to come in contact with forms or finished surfaces.

4.15.12.6.Use of Form Attached Vibrators

Form attached vibrators shall be used only with specific authorization of the Engineer-in-Charge.

4.15.12.7.Use of Surface Vibrators

The use of surface vibrators will not be permitted under normal conditions. However, for thin
slabs, surface vibrating by specially designed vibrators may be permitted, upon approval of
Engineer-in-Charge.

4.15.12.8.Stone Pockets And Mortar Pondages

The formation of stone pockets and mortar pondages in corners and against faces of forms shall
not be permitted. Should these occur, they shall be dug out, reformed and refilled to sufficient
depth and shape for thorough bonding, as directed by the Engineer-in-Charge.

4.15.13. Placement Interval

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 Except when placing with slip forms, each placement of concrete in multiple lift work, shall be
allowed to set for atleast 24 hours after the final set of concrete and before the start of a
subsequent placement

4.15.14. Special Provision in Placing

When placing concrete in walls with openings, in floors of integral slabs and beam construction
and other similar conditions, the placing shall stop when the concrete reaches the top of the
opening in walls or bottom horizontal surface of the slab, as the case may be. Placing shall be
resumed before the concrete in place takes initial set, but not until it has had time to settle as
determined by the Engineer-in-Charge.

4.15.15. Placing Concrete Through Reinforcing Steel

When placing concrete through reinforcing steel, care shall be taken to prevent
segregation of the coarse aggregate. Where the congestion of steel makes placing difficult, it may
be necessary to obtain Engineer in-Charge’s permission for temporarily moving the top steel
aside for proper placement & for restoring reinforcement as per drawing.
4.15.16. Bleeding
Bleeding or free water on top of concrete being deposited into the forms, shall be the cause to stop
the concrete pour and the conditions causing this defect corrected before any further Concreting
is resumed.
4.16. APPLICATION OF ARALDITE FOR BONDING OF NEW AND OLD CONCRETE
4.16.1. General
Araldite epoxy resins will be used to bond fresh concrete to concrete that is fully cured, to give a
monolithic bond capable of transmitting high stresses when traditional bonding agents such as
cement slurry cannot always be relied upon to provide good adhesion which is particularly the
case when large areas are involved.

a. The Araldite based formulation shall be applied to a suitably prepared concrete sub strata
and the fresh concrete poured as soon as possible, but always during the ‘open time’ of the
adhesive.
b. Materials used shall be of best quality like CIBA, FOSROC or ROFF and approved by the
Engineer-in-Charge.
c. Manufacturer’s instructions shall be followed in all respects.
d. No separate payment shall be paid for this item of work.

4.16.2. Formulation
ARALDITE GY250 100 Parts by weight
Hardener HY825 20 Parts by weight
Hardener HY830 20 Parts by weight
Hardener HY850 20 Parts by weight
Silica Flour 20 Parts by weight

4.16.3. Application
The application of the adhesives shall be as per manufacturer standards.

4.16.3.1. Preparation of the Substrata

To obtain good adhesion, it is necessary to have clean and sound substrata. Preparation can be
carried out using a variety of techniques including chemical treatment and mechanical methods
such as grinding, milling, abrading, planning and sand blasting. Dust and loose particles resulting
from the pretreatment should be removed by vacuum cleaning or oil-free or blast.

4.16.3.2. Mixing

The resin and hardener should be thoroughly mixed in the dry filler. The mixed, ready to use

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 adhesive should not contain lumps of unwetted filler and should be of uniform color. For a total
weight of 1 kg or less hand mixing should be sufficient. For quantities in excess of 1 kg, the use of
a mechanical mixer is recommended.

4.16.3.3. Pot life and ‘Open time’

The pot life is the period during which the ready to use ARALDITE based formulation must be
applied. After this period, the mix can no longer be worked and will have begun to set in its
container. The table below indicates the pot life at different temperatures:
Mix Temperature Pot life in minutes
25° C 90 Minutes
30° C 60 Minutes
35° C 45 Minutes
(The figures in this table are for batches less than 1 kilogram).

The ‘Open time’ is the maximum period of time allowable between application of the ARALDITE
adhesive and pouring the fresh concrete. Exceeding the ‘Open time’ would result in considerably
reduced adhesion. The adhesive should be applied to the pre-treated substrata as soon as the
components have been mixed and fresh concrete poured immediately afterwards.

Accurate knowledge of the ‘Open time’ is essential in case the work is interrupted.
Table gives the ‘Open time’ of ARALDITE based formulations as a function of substrata
temperature. In all cases, the adhesives shall be applied immediately after mixing. Any delay
between mixing and application will reduce the ‘Open time’. Fresh concrete must be poured
before the adhesive begins to gel. New to old concrete bonding is not recommended at
temperatures below 5-Degree Centigrade, as curing cannot be assured under these
circumstances.

4.16.3.4. Methods of Application

The shape and size of the concrete structure will determine the method of application used. The
ARALDITE based adhesive may be applied by hand using brushed, brooms or any other suitable
applicator.

4.16.3.5. Suitability of Fresh Concrete

Best results are obtained when the water/ cement ratio of the new concrete is low as is
practicable.

4.16.3.6. Coverage

One kilogram of the mixed ARALDITE adhesive including hardeners and filler covers an area of 2
to 3 sq.m. when applied with a stiff nylon bristle brush. However, the coverage is very much
dependent on the finish in the concrete.

4.17. HANDLING PRECAUTIONS

Epoxy resins can cause irritation of the skin in sensitive person if incorrectly handled. Certain
safety precautions must therefore be observed and those handling the resins and hardeners
should be given suitable instructions. Those working with epoxy resins should, above all, be
instructed that personal cleanliness at the place of work is essential. The resin and hardener
should not be allowed to come into direct contact with the skin. The most effective protection is
achieved by wearing rubber or polythene gloves, the latter having the advantage that they can be
replaced when dirty. They are more pleasant to wear if cotton gloves are worn underneath. Parts
of the skins, which have come into contact with the resin or hardener, should be washed with
lukewarm water and a mild soap. Special cleaning creams may be used as they have proved to

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 be highly suitable.

4.18. CONSTRUCTION JOINTS

a. A construction joint is defined as a joint in the concrete introduced for convenience in
construction at which special measures are taken to achieve subsequent continuity without
provision for further relative movement.
b. No concreting shall be started until the Engineer-in-Charge has approved the method of
placing the positions and form of the construction joints and lifts. The construction joints shall
be so located as not to impair the strength of the structure. Water stops shall be inserted as
per clause 3.20
c. Concrete placed to form the face of a construction joint shall have all Laitance removed and
the aggregate exposed prior to the placing of fresh concrete. The Laitance shall wherever
practicable be removed by spraying the concrete where it is still green. The whole of the
concrete surface forming part of the joint shall be hacked to expose the aggregate to the
1/3rd size of maximum size of aggregate. Where aggregate is damaged during hacking, it
shall be removed from the concrete face by further hacking. All loose matter shall be
removed and the exposed surface thoroughly cleaned by wire brushing, air blasting or
washing, leaving the surface clean and damp. Immediately before fresh concrete is placed, a
12 mm thick layer of sand/cement mortar mixed in the same proportions as in the concrete
shall be spread in the horizontal face of the construction joint. A drier mix shall be used for
the top lift of horizontal face of the construction joint. A drier mix shall be used for the top lift
of horizontal pours to avoid Laitance. The new concrete shall be well worked against the
prepared face before the mortar sets. Special care shall be taken to obtain thorough
compaction and to avoid segregation of the concrete along the joint plane.

4.19. MOVEMENT JOINTS

a. Movement joints are defined as all joints intended to accommodate relative movement
between adjoining parts of a structure, special provision being made where necessary for
maintaining the water tightness of the joint. The Contractor shall comply with the instructions of
manufacturers of proprietary jointing materials and shall, if required by the Engineer-in-
Charge, demonstrate that the jointing materials can be applied satisfactorily.
b. The surface of set concrete in a movement joint shall, as shown on the drawings, be painted
with two coats of bituminous paint and new concrete shall be placed against it only when the
paint is dry. Expansion joints shall be formed by a separating strip of approved preformed joint
filler.
c. Caulking grooves shall be provided. At all joints where a caulking groove is formed,
immediately prior to caulking, the groove shall be wire brushed and loose material removed
and blown out by compressed air. After the groove has dried, it shall be primed and caulked
with approved sealing compound applied in accordance with the manufacturer’s instructions.
At all caulked joints, the face of the caulking strip and a width of concrete on either side shall
be painted with two coats of paint having the same base as the sealing compound.

4.20. WATER STOPS AND JOINT FILLERS

4.20.1. Water stops
a. At all construction, contraction and expansion joints in the water retaining structures and
wherever specified or directed by the Engineer-in-Charge, water stops shall be provided. The
water stops shall be PVC type or of any other equivalent material as approved by the
Engineer-in-Charge. PVC water stops shall have a tensile strength of not less than 14 MN/m2
and elongation at break of not less than 300%. Water stops shall not be exposed to direct
sunlight for long periods. Before being concreted in water stops shall be cleaned of all foreign
materials. Wherever provided, water stops shall be placed in such a manner that they are
embedded in the adjacent sections of the panels for equal width.
b. As far as possible, jointing on site shall be confined to the making of butt joints in straight runs
of water stops and all the joints should be monolithic. Where it is agreed with the Engineer-in-

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 Charge that it is necessary to make an intersection or change of direction of any joint, other
than a butt joint in a straight run on site, a preliminary joint, intersection or change of direction
piece shall be made and submitted to such tests as the Engineer-in-Charge may require.
c. Flexible water stops shall be fully supported in the form work, free of nails and clear of
reinforcement and other fixtures. Damaged water stops shall be replaced and during
concreting care shall be taken to place the concrete so that water stops do not bend or distort
or displace,
d. The different types of water stops to be used in liquid retaining structures will be as follows:

Table 9: Types of water Stops

Sr. Type of Joint Type of water stops
1 Partial/complete Contraction joint in walls 230 mm wide, ribbed with hollow
and slabs centre bulb & 6 mm minimum
thickness
2 Expansion joints in walls and slabs 230 mm wide, ribbed with hollow
centre bulb & 9 mm minimum
thickness
3 Construction joint in raft 230 mm wide, ribbed with hollow
centre bulb & 9 mm minimum
thickness
4 Construction joint in wall 230 mm wide, ribbed with hollow
centre bulb & 6 mm minimum
thickness
5 Expansion joint raft 230 mm wide, ribbed with hollow
centre bulb & 9 mm minimum
thickness
6 Partial/complete Contraction joint in raft 230 mm wide, ribbed with hollow
centre bulb & 9 mm minimum
thickness

4.20.2. Jointing fillers

Joint fillers shall be of durable, compressible and non-extruding material.
Details of jointing material required here. Type of joint, size or width of joint and joint filler
material to be used with preferred brands if any.

4.21. SEALING COMPOUNDS

Horizontal joints shall, where used in water-retaining structures be sealed with a cold pouring
polysulphide rubber sealing compound of quality equal to, or better than serviced "Paraseal".
Horizontal joints in roofs, floors and other non-water retaining structures shall be sealed with an
approved sealant with properties equal to or better than serviced "Paraplastic 41". Vertical joints
and joints in the soffits of slabs in both water retaining as well as non-water retaining structures
shall be sealed with a trowel or gun applied polysulphide rubber sealing compound such as
serviced "Vertiseal" or equivalent. Sealing compounds shall be fully cured before water is
permitted to come in contact. At 40° C, the curing time would be approximately 7 weeks for
polysulphide compounds like CIBA, FOSROC or ROFF as approved by Engineer-in-Charge.

4.22. TOLERANCES IN CONCRETE SURFACES

• Concrete surfaces for the various classes of unformed and formed finishes specified in
various clauses shall comply with the tolerances shown in Table hereunder, except where
different tolerances are expressly required by the specification.
• In the table 'line and level' and 'dimension' shall mean the lines, levels and cross-sectional
dimensions as specified and required.

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 • Surface irregularities shall be classified as 'abrupt' or 'gradual'. Abrupt irregularities include by
shall not be limited to offsets and fins caused by displaced or misplaced formwork, loose
knots and other defects in formwork materials, and shall be tested by direct measurement.
Gradual irregularities shall be tested by means of a straight template for plane surfaces and
1.5 m long formed surfaces.

Maximum tolerance (mm)in:

Class of Line & Level Abrupt Gradual Dimension
finish Irregularity irregularity

U1 12 6 6 -
U2 6 3 3 -
U3 6 3 3 -
F1 12 6 6 6
F2 6 6 6 6
F3 3 3 3 +6-

4.23. CURING, PROTECTING, REPAIRING AND FINISHING

4.23.1. Curing
All concrete shall be kept continuously in a damp or wet condition by ponding or by covering with
a layer of sacking, canvas, hessian or similar materials and kept constantly wet for atleast seven
days from the date of placing concrete in case of OPC and 10 days in case of mineral admixture
or blended cements are used. The period of curing shall be not less than 10 days for concrete
exposed to dry and hot weather condition

4.23.2. Curing with Water

Fresh concrete shall be kept continuously wet for a minimum period of 10 days from the date of
placing of concrete, following a lapse of 12 to 14 hours after laying of concrete. The curing of
horizontal surfaces exposed to the drying winds shall however begin as soon as the concrete has
hardened. Water shall be applied to formed surfaces immediately upon removal of forms.
Quantity of water applied shall be controlled so as to prevent erosion of freshly placed concrete.

4.23.3. Continuous Spraying

Curing shall be assured by use of an ample water supply under pressure in pipes, with all
necessary appliances of hose, sprinklers and spraying devices. Continuous fine mist spraying or
sprinkling shall be used, unless otherwise specified or approved by the Engineer-in-Charge.

4.23.4. Alternate Curing Methods

Whenever in the judgement of the Engineer-in-Charge, it is necessary to omit the continuous
spray method, a covering of clean sand or other approved means such as wet gunny bags, which
will prevent loss of moisture from the concrete, may be used. No type of covering will be
approved which would stain or damage the concrete during or after the curing period. Covering
shall be kept continuously wet during curing period. For curing of concrete in sidewalks, floors,
flat roofs of other level surfaces, the ponding method of curing is preferred. The method of
containing the ponded water shall be approved by the Engineer-in-Charge. Special attention shall
be given to edges and corners of the slabs to ensure proper protection to these areas. The
ponded areas shall be kept continuously filled with water during the curing period.

4.23.5. Curing Compound

Surface coating type-curing compounds shall be used only by special permission of Engineer-in-
Charge. Curing compounds shall be liquid type white pigmented, conforming to US Bureau of
Reclamation specification. No curing compound shall be used on surfaces where future blending

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 with concrete, water of acid proof membrane or painting is specified. Curing compound shall
be used only after getting sufficient/satisfactory test results at site.

4.23.6. Curing Equipment

All equipment and materials required for curing shall be on hand and ready for use before
concrete is placed.

4.23.7. Protecting Fresh Concrete

Fresh concrete shall be protected from defacements and damage due to construction operations
by leaving forms in place for an ample period as specified in section D3 of this specification.
Newly placed concrete shall be protected by approved means such as tarpaulins from rain, sun
and winds. Steps as approved by the Engineer-in-Charge shall also be taken to protect immature
concrete from damage by debris, excessive lading, vibration, abrasion or contact with other
materials, etc. that may impair the strength and/or durability of the concrete. Workmen shall be
warned against and prevented from disturbing green concrete during its setting period. If it is
necessary that the workmen enter the area of freshly placed concrete, the Engineer-in-Charge
may require that bridges be placed over the area.
4.23.8. Repair and Replacement of Unsatisfactory Concrete
4.23.8.1. General

Immediately after the shuttering is removed, the surface of concrete shall be very carefully gone
over and all defective areas called to the attention of the Engineer-in-Charge who may permit
patching of the defective areas or also reject the concrete unit either partially or in its entirety.
Rejected concrete shall be removed and replaced by the Contractor. Holes shall be filled with
mortar composed of one part of cement to one and half parts of sand passing 2.36 mm I.S sieve
after removing any loose stones adhering to the concrete. Concrete surfaces shall be finished as
described in specifications or as directed by the Engineer-in-Charge. Superficial honey combed
surfaces and rough patches shall be similarly made good immediately after removal of shuttering,
in the presence of the Engineer-in-Charge and superficial water and air holes shall be filled in.
The mortar shall be well worked into the surface with a wooden float. Excess water shall be
avoided. Unless instructed otherwise by the Engineer-in-Charge, the surface of the exposed
concrete placed against shuttering shall be rubbed down immediately on removal of shuttering to
remove fine or other irregularities, care being taken to avoid damaging the surface. Surface
irregularities shall be removed by grinding. If reinforcement is exposed or the honeycombing
occurs at vulnerable positions e.g. ends of beams or columns, it may be necessary to cut out the
member completely or in part and reconstruct. The decision of the Engineer-in-Charge shall be
final in this regard. If only patching is necessary, the edges being cut perpendicular to the
affected surface or with a small under cut if possible. Anchors, tees or dovetail slots shall be
provided whenever necessary to attach the new concrete securely in place. An area extending
several centimeters beyond the edges and the surfaces of the prepared voids shall be saturated
with water for 24 hours immediately before the patching material is placed. For small repairs
concerned Engineer-in-Charge shall permit to repair the same and shall be repaired at his
directions. For major repairs Contractor shall submit the method of statement and on approval of
same shall carry such repairs with strict compliance to the method of statement.

4.23.8.2. Use of Epoxy

The use of epoxy for bonding fresh concrete used for repairs will be permitted upon written
approval of the Engineer-in-Charge. Epoxies shall be applied in strict accordance with the
instructions of the manufacturer.

4.23.8.3. Method of Repair

Small size holes having surface dimensions about equal to the depth of the hole, holes left after
removal of form bolts, grout insert holes and slots cut for repair of cracks shall be repaired as

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 follows.

The hole to be patched shall be roughened and thoroughly soaked with clean water until
absorption stops. A 5 mm thick layer of grout of equal parts of cement and sand shall be well
brushed into the surface to be patched, followed immediately by the patching concrete which
shall be well consolidated with a wooden float and left slightly protrude of the surrounding
surface. The concrete patch shall be built up in 10 mm thick layers, after an hour or more,
depending upon weather conditions, it shall be worked off flush with a wooden float and a smooth
finish obtained by wiping with hessian. A steel trowel shall be used for this purpose. The mix for
patching shall be of the same materials and in the same proportion as that used in the concrete
being repaired, although some reduction in the maximum size of the coarse aggregates may be
necessary and the mix shall be kept as dry as possible. Mortar filling by air pressure (gunniting)
shall be used for repair of areas too large and/or too shallow for patching with mortar. Patched
surfaces shall be given a final treatment to match the colour and texture of the surrounding
concrete. White cement shall be substituted for ordinary cement, if so directed by the Engineer-in-
Charge, to match the shade of the patch with the original concrete.

4.23.8.4. Curing of Patched Work

The patched area shall be covered immediately with an approved non-staining, watersaturated
material such as gunny bags which shall be kept continuously wet and protected against sun and
wind for a period of 24 hours. Thereafter, the patched area shall be kept wet continuously by a
fine spray, or sprinkling for not less than 10 days. All fillings shall be tightly bounded to the
concrete and shall be sound, free from shrinkage cracks after the fillings have been cured and
dried.

4.23.8.5. Approval by the Engineer-in-Charge

All materials, procedures and operations used in the repair work shall be subject to the approval
of the Engineer-in-Charge.

4.23.9. Finishing
4.23.8.6. General

The type of finish for formed concrete surfaces shall be as follows, unless varied by the
design/architectural drawings and specifications.
When the structure is in service all the surfaces shall receive no special finish, except repair of
damaged or defective concrete, removal of fine and abrupt irregularities, filling defective concrete,
filling of holes left by form ties and rods and clean up of loose or adhering debris. Surfaces which
will be exposed to the weather and which would normally be level, shall be sloped for drainage.
Unless a horizontal surface or the slope required is specified, the tops of narrow surfaces such as
stair treads, walls, curbs and parapets shall be sloped across the width approximately 1 in 30.
Broader surfaces such as walkways, and platforms shall be sloped about 1 in 50. Surfaces that
will be covered by backfill or concrete, subfloors to be covered with concrete topping, terrazzo or
quarry tiles and similar surfaces shall be smooth ascended and leveled to produce even surfaces.
Surface irregularities shall not exceed 6 mm. Surfaces which will not be covered by backfill,
concrete or tile toppings such as outside decks, floors of galleries and sumps, parapets, gutters,
side-walks, floors and slabs, shall be consolidated, screened and floated. Excess water and
laitance shall be removed before final finishing. Floating may be done with hand or power tools
and started as soon as the screened surface has attained a stiffness to permit finishing
operations and these shall be the minimum required to produce a surface uniform in texture and
free from screened marks or other imperfections. Joints and edges shall be tooled as specified or
as directed by the Engineer-in-Charge.

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4.23.8.7. Standard Finish For Exposed Concrete

Exposed concrete shall mean any concrete, other than floors or slabs, exposed to view upon
completion of the works. Unless otherwise specified, the standard finish for exposed concrete
shall be a smooth finish. A smooth finish shall be obtained with the use of lined or plywood forms
having smooth and even surfaces and edges. Panels of forms shall be of uniform size and be as
large as practicable and installed with closed joints. Upon removal of forms the joint marks shall
be smoothed off and all blemishes, protections etc., removed leaving the surfaces smooth.
4.23.8.8. Integral Cement Concrete Finish

When specified, an integral cement concrete finish of specified thickness for floors and slabs shall
be applied either monolithic or bonded, as specified or directed by the Engineer-in-Charge. The
surface shall be tested with a straight edge and any high and low spots eliminated. Floating or
trowelling of the finish shall be permitted only after all surface water has evaporated. Dry cement
or a mixture of dry cement and sand shall not be sprinkled directly on the surface of the cement
finish to absorb moisture or to stiffen the mix.

4.23.8.9. Rubbed Finish

A rubbed finish shall be provided only on exposed concrete surfaces. Upon removal of forms, all
fins and other projections on the surfaces shall be carefully removed, offsets leveled and voids
and/or damaged sections immediately saturated with water and repaired by filling with a concrete
or mortar of the same composition as was used in the surface. The surfaces shall then be
thoroughly wetted and rubbed with carborundun or other abrasive. Cement mortar may be used
in the rubbing, but the finished surfaces shall not be brush coated with either cement or grout
after rubbing. The finished surfaces shall present a uniform and smooth appearance.

4.23.8.10. Protection

All concrete shall be protected against damage until final acceptance by the Engineer-in-Charge.
4.24. HOT WEATHER REQUIREMENT
a. All Concrete work performed in hot weather shall be in accordance with IS:456, except as
herein modified.
b. Admixtures may be used only when approved by the Engineer-in-Charge.
c. Adequate provisions shall be made to lower give limit concrete temperatures by cool
ingredients, eliminating excessive mixing, preventing exposure of mixers and conveyors to
direct sunlight and the use of reflective paint on mixers, etc. The temperature of the freshly
placed concrete shall not be permitted to exceed 38 degrees centigrade.
d. Consideration shall be given to shading aggregate stockpiles from direct rays of the sun and
spraying stockpiles with water, use of cold water when available, and burying, insulating,
shading and/or painting white the pipelines and water storage tanks and conveyance.
e. In order to reduce loss of mixing water, the aggregate, wooden forms, subgrade, adjacent
concrete and other moisture absorbing surfaces shall be well wetted prior to concreting,
placement and finishing shall be done as quickly as possible.
f. Extra precautions shall be taken for the protection and curing of concrete.

Consideration shall be given to continuous water curing and protection against high
temperatures and drying hot winds for a period of at least 7 days immediately after concrete
has set and after which normal curing procedures may be resumed.

4.25. PLACING CONCRETE UNDERWATER

a) Under all ordinary conditions, all foundations shall be completely dewatered and concrete
placed in the dry. However, when concrete placement under water is necessary, all work
shall conform to IS:456 and the procedure shall be as follows:
• Method of Placement

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 Concrete shall be deposited underwater by means of tremises, or drop bottom buckets of
approved type.
• Direction, Inspection and Approval
All work requiring placement of concrete underwater shall be designed, directed and
inspected with due regard to local circumstances and purposes. All underwater concrete
shall be placed according to specifications approved by the Engineer-in-Charge.
b) Special precautions shall be taken for prevention of lifting of concrete due to uplift
pressure of subsoil water.

4.26. PRECAST CONCRETE

4.26.1. General

Precast concrete units, whether manufactured on or off site, shall comply in every way with the
provisions of the contract for in situ concrete. Wherever possible, precast units shall be
hydraulically pressed. When ready for incorporation in the works, precast units shall be
responsible for the accuracy of the level, shape of the bed or platform. A suitable serial number
and the date of casting shall be impressed or painted on each unit.

4.26.2. Striking Forms

Side shutters shall not be struck in less than 24 hours after depositing concrete and no precast
unit shall be lifted until the concrete reaches strength of at least twice the stress to which the
concrete may be subjected to at the time of lifting.

4.26.3. Precast Units

The lifting and removal of precast units shall be undertaken without causing shock, vibration or
undue bending stresses to or in the units. Before lifting and removal takes place, Contractor shall
satisfy the Engineer-in-Charge or his representative that the methods he proposes to adopt for
these operations will not over-stress or otherwise effect seriously the strength of the precast
units. The reinforced side of the units shall be distinctly marked.

4.26.4. Curing
All precast work shall be protected from the direct rays of the sun for at least 7 days after casting
and during that period each unit shall be kept constantly watered or preferably be completely
immersed in water if the size of the unit so permits.

4.27. SLOTS, OPENINGS, ETC.

4.27.1. General
Slots, openings or holes, pockets, etc., shall be provided in the concrete work in the approved
positions as per design drawings and as directed by Engineer-in-Charge and extra reinforcement
should be provided as per design requirement. Short pipes with puddle collar shall be fixed in the
side wall of suction pipes. They shall be supplied at the appropriate time during construction. Any
deviation from the approved drawings shall be made good by Contractor at his own expense,
without damaging any other work. Sleeves, bolts, inserts etc., shall also be provided in concrete
work where so required.
4.27.2. Grouting

4.27.2.1. Standard Grout

The proportions of grout shall be such as to produce a flowable mixture consistent with minimum
water content and shrinkage. The grout proportions shall be limited as follows:

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 Table 10 : Proportions for Standard Grout

Sr. Use Grout thickness Mix proportions W/c ratio

(max.)
1 Fluid Under 25 mm One part Portland cement to 0.44
one part sand

2 General 25mm & over One part Portland cement to 2 0.53

but parts of sand
less than 50mm
3 Stiff Mix 50mm & over One part Portland cement to 3 0.53

Sand shall be such as to produce a flowable grout without any tendency to segregate.
Sand for general grouting purposes, shall be graded within the following limits:
• Passing BIS 2.36 mm sieve 95 to 100%
• Passing BIS 1.18 mm sieve 65 to 95%
• Passing BIS 300 micron sieve 10 to 30%
• Passing BIS 150 micron sieve 3 to 10%

Sand for fluid grouts, shall have the fine material passing the 300 and 150 micron sieves at the
upper limits specified above. Sand, for still grouts, shall meet the usual grading specifications for
concrete laitance. Anchor bolts, anchor bolt holes and the bottoms of equipment and column
base plates shall be cleaned of all oil, grease, dirt and loose material. The use of hot, strong
caustic solution for this purpose will be permitted. Prior to grouting, the hardened concrete
surfaces to be grouted shall be saturated with water. Water in anchor boltholes shall be removed
before grouting is started. Forms around base plates shall be reasonably tight to prevent leakage
of the grout. Adequate clearance shall be provided between forms and base plate to permit grout
to be worked properly into place. Grouting, once started, shall be done quickly and continuously
to prevent segregation, bleeding and breakdown of initial set. Grout shall be worked from one
side of one end to the other to prevent entrapment of air. To distribute the grout and to ensure
more complete contact between base plate and foundation and to help release trapped air, link
chains can be used to work the grout into place. Grout throughout holes in base plates shall be by
pressure grouting. Variations in grout mixes and procedures shall be permitted if approved by the
Engineer-in-Charge.

4.27.2.2. Non-Shrinking Grout for Equipment Foundation

Non-shrinking grout shall be used for grouting of machine base plates, anchor bolts, other
anchoring devices and at locations where ordinary grouts are ineffective due to shrinkage. It shall
be composed of a type of expansive hydraulic sheeting binder and select-graded
aggregates. It shall have properties as mentioned below:

Table 11 : Proportions for Non-Shrinking Grout

Sr. Properties Values

1 Maximum grain size 6 mm
2 Water % (for 80% flow) 15.17
3 Density of hardened grout 2.27 - 2.30 gm/m1
4 Compressive strength N/mm2
Minimum 3 days 23
7 days 34
28 days 45
5 Expansion %
Free 0.1- 0.2
Restrained 0.08 - 0.12
Restrained 0.08 - 0.12

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 Mixing, batching, cleaning, preparation of surface and curing of non-shrinking grout shall be done
as per manufacturer’s instructions. Brands like FOSROC / BUILDMASTER etc or equivalent
brand as approved by Engineer-in-charge shall be used as per manufacturer specifications.

4.28 INSPECTION
a. All materials, workmanship and finished construction shall be subject to continuous
inspection and approval of the Engineer-in-Charge.
b. All materials supplied by the Contractor and all work or construction performed by the
Contractor which is rejected as not being in conformity with the specifications and
requirements, shall be immediately replaced.
c. All concrete shall be protected against damage until final acceptance by the Engineer-in-
Charge.

4.29 CLEAN-UP
a. Upon completion of the concrete work, all forms, equipment, construction tools, protective
coverings and any debris resulting from the work shall be removed from the premises.
b. All debris i.e. empty containers, scrap wood, etc., shall be removed to “dump” daily, or as
directed by the Engineer-in-Charge.
c. The finished concrete surfaces shall be left in a clean condition satisfactory to the Engineer-
in-Charge.

4.30 RECORDS OF CONCRETING

An accurate and up to date record showing times, dates, weather and temperature conditions
when various positions of all the concrete structures forming the works were concreted will be
kept by the Contractor and shall be countersigned by the Engineer-in-Charge. If the Contractor
fails to sign the Engineer-in-Charge’s record, it shall nevertheless be regarded as correct and
binding on the Contractor.

The Contractor has to submit concrete pour card in duplicate duly to be signed to the Engineer-in-
Charge for each type of concreting work. Contractor shall keep copy of it, after Engineer-in-
Charge has checked and signed the pour card.

4.31. SUPPLY OF CEMENT

Contractor shall procure / purchase the cement and shall be sacked and well maintained as
specified in the earlier sections. Contractor shall procure cement in those quantities required for
maximum one month of concreting work and more than the prescribed time limit is not allowed.
For any damage to cement RMC will not be responsible and the damaged cement will not be
used in the work.

4.32. FOUNDATION BEDDING, BONDING AND JOINTING

In no case foundation shall rest on any loose strata or loose pockets etc. even though it has
reached level shown on design drawings and referred back to design engineer / Engineer-in-
Charge
a. All surfaces upon or against which concrete will be placed shall be suitably prepared by
thoroughly cleaning, washing and dewatering, as specified or as the Engineer-in-Charge
may direct, to meet the various situations encountered in the work.
b. Soft or spongy areas shall be cleaned out and backfilled with lean concrete or clean sand
fill compacted.
c. Prior to construction of formwork for any item where soil will act as bottom form, approval
shall be obtained from the Engineer-in-Charge for the suitability of the soil.

4.33. PREPARATION OF ROCK STRATA OF FOUNDATIONS

a. To provide tight bond with rock foundations, the rock surface shall be prepared and the
following general requirements shall be observed.

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b. Concrete shall not be deposited on large sloping rock surfaces. Where required by the
Engineer-in-Charge, the rock shall be cut to form rough steps or benches to provide
roughness or a more suitable bearing surface.
c. Rock foundation stratum shall be prepared by picking, barring, wedging and similar
methods which will leave the rock in an entirely sound and unshattered condition.
d. Shortly before concrete is placed, the rock surface shall be cleaned with high pressure
water and air jet even though it may have been previously cleaned in that manner.
e. Prior to placing concrete, the rock surface shall be kept wet for a period of 2 to 4 hours
unless otherwise directed by the Engineer-in-Charge.
f. Before placing concrete on rock surfaces all water shall be removed from depressions to
permit thorough inspection and proper bonding of the concrete to the rock.

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 5. FORMWORK

5.1. FORMWORK, FIXING AND GENERAL

a) All formwork shall be constructed of waterproof plywood or preferably sheet metal. Plywood
used for form work shall be conforming to BIS:4990 i.e. Specification for plywood for
concrete shuttering works. The materials for formwork shall got approved by the Engineer-
in-Charge before starting the work. Formwork shall be firmly supported, adequately
strutted, braced and tied to withstand the placing and vibrating of concrete and the effects
of weather. The tolerance on line and level shall not exceed 3 mm and the soffits of beams
other than pre-stressed beams shall in the absence of any specified camber, be erected
with an upward camber of 6 mm for each 3 meters of span.
b) The Contractor shall be responsible for the calculations and designs for the formwork, and
if required, shall submit them to the Engineer-in-Charge for approval before construction.
On form work to external faces, which will be permanently, exposed, all horizontal and
vertical formwork joints shall be so arranged that joint lines will form a uniform pattern on
the face of the concrete. Where the Contractor proposes to make up the form work for
standard sized manufactured form work panels, the size of such panels shall be approved
by the Engineer-in-Charge before they are used in the construction of the Works. The
finished appearance of the entire elevation of the structure and adjoining structures shall be
considered when planning the pattern of joint lines caused by form work and by
construction joint to ensure continuity of horizontal and vertical lines.
c) Faces of form work in contact with concrete shall be free from adhering foreign matter,
projecting nails and the like, splits or other defects, and all form work shall be clean and
free from standing water, dirt, shavings, chippings or other foreign matter. Joints shall be
sufficiently watertight to prevent the escape of mortar or the formation of fins or other
blemishes on the face of the concrete and no bleeding should be allowed through the
joints.
d) Form work shall be provided for the top surfaces of sloping work where the slope exceeds
fifteen degrees from the horizontal (except where such top surface is specified as spaded
finish) and shall be anchored to enable the concrete to be properly compacted and to
prevent flotation, care being taken to prevent air being trapped.
e) Openings for inspection of the inside of the form work and for the removal of water used for
washing down shall be provided and so formed as to be easily closed before placing
concrete. Before placing concrete, all bolts, pipes or conduits or other fixtures which are to
be built in shall be fixed in their correct positions, and cores and other devices for forming
holes shall be held fast by fixing to the formwork or otherwise. Holes shall not be cut in any
concrete without approval of the Engineer-in-Charge.
f) All exterior angles on the finished concrete of 90 degree or less shall be given 20 mm x 20
mm chamfers unless otherwise ordered by the Engineer-in-Charge.
g) No ties or bolts or other device shall be built into the concrete for the purpose of supporting
formwork without the prior approval of the Engineer-in-Charge. The whole or part of any
such supports shall be capable of removal so that no part remaining embedded in the
concrete shall be nearer than 50 mm from the surface in the case of reinforced concrete
and 150 mm in the case of un-reinforced concrete.
h) Holes left after removal of such supports shall be neatly filled with well rammed drypack
mortar.
i) Formwork in contact with the concrete shall be treated with suitable non-staining mould oil
to prevent adherence of the concrete except where the surface is subsequently to be
rendered. Care shall be taken to prevent the oil from coming in contact with reinforcement
or with concrete at construction joints. Surface retarding agents shall be used only where
ordered by the Engineer-in-Charge.
j) No formwork shall be started or placed unless the requirement work is fully
completed and checked by Engineer-in-Charge.

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 k) Necessary cover blocks shall be provided before starting connection.

5.2. REMOVAL OF FORMWORK

a) Formwork shall be so designed as to permit any removal without resorting to hammering or
levering against the surface of the concrete.
b) The periods of time elapsing between the placing of the concrete and the striking of the
loads likely to be imposed on the concrete and shall in any case be not less than the
periods shown in Table below. Where soffit formwork is constructed in a manner during and
after such removal of a sufficient number of adequate supporting props in an undisturbed
condition, the Contractor may, with the agreement of the Engineer-in-Charge, remove the
formwork at the earlier times listed below provided that the props are left in position.
Table 12 : Period for Formwork
Position of formwork Days for striking

Walls 1
Sides of beams and columns 2
Slabs (Drops left under) 3
Props to slabs (span not exceeding 4.5m) 7
Props to slabs (span exceeding 4.5 m) 14
Beams soffits (props left under) 7
Props to beams (span not exceeding 6 m) 14
Props to beams (span exceeding 6 m) 21
Circular structures, domes ,cantilever portions etc. 21

c) Notwithstanding the foregoing, the Contractor shall be held responsible for any damage
arising from removal of formwork before the structure is capable of carrying its own weight
and any incidental loading.
d) Striking shall be done slowly with utmost care to avoid damage to projections and without
shock or vibration, by gently easing the wedges. If after removing the formwork it is found
that timber has been embedded in the concrete. It shall be removed and made good as
specified earlier.
e) Reinforced temporary openings shall be provided, as directed by the Engineer-in- Charge,
to facilitate removal of formwork which otherwise may be inaccessible.
f) The rods, clamps, form bolts, etc. which must be entirely removed from walls or similar
structures shall be loosened not sooner than 24 hours not later than 40 hours after the
concrete has been deposited. Ties, except those required to hold forms in place, may be
removed at the same time. Ties, withdrawn from walls and grade beams shall be pulled
toward the inside face. Cutting ties back from the faces of the walls and grade beams will
not be permitted.
g) For liquid retaining structures, no sleeves for through bolts shall be used nor shall through
bolts be removed as indicated above. The bolts, in this case, shall be cut at 25
mm depth or more from the surface and then the hole shall be made good by cement sand
mortar of the same proportions as the concrete just after striking the form work.

5.3. FORMED SURFACES - CLASSES OF FINISH

a) Finishes to formed surfaces of concrete shall be classified as F1, F2, or F3, or such other
special finish as may be particularly specified. Where the class of finish is not specified the
concrete shall be finished to Class F1.
b) Form work for Class F3 finish shall be lined with as large panels as possible of non-staining
material with a smooth unblemished surface such as sanded plywood or hard compressed
fiber board, arranged in a uniform approved pattern and fixed to back form work by oval
nails. Unfaced wrought boarding or standard steel panels shall not be permitted.

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 c) Form work for Class F2 finish shall be faced with wrought tongued and grooved boards or
plywood or metal panels arranged in a uniform approved pattern free from defects likely to
detract from the appearance of the surface.
d) Form work for Class F1 finish shall be constructed in sheet metal. Surfaces subsequently to
be rendered, plastered or tiled shall be adequately scrabbled or hacked as soon as the
form work is removed to reduce the irregularities to not more than half the thickness of such
rendering, plastering or bedding for tiles and to provide a satisfactory key.

5.4 DEFECTS IN FORMED SURFACES

a. Workmanship in formwork and concreting shall be such that concrete shall normally require
no making good, surfaces being perfectly compacted and smooth.
b. If any blemishes are revealed after removal of formwork, the Engineer-in-Charge's decisions
concerning remedial measures shall be obtained immediately. These measures may include,
but shall not be limited to the following:
• Fins, pinhole bubbles, surface discolouration and minor defects may be rubbed down
with sacking immediately after the formwork is removed.
• Abrupt and gradual irregularities may be rubbed down with carborundun and water after
the concrete has been fully cured. These and any other defects shall be remedied by
methods approved by the Engineer-in-Charge which may include using a suitable epoxy
resin or, where necessary, cutting out to a regular dovetails shape at least 75 mm deep
and refilling with concrete over steel mesh reinforcement sprung into the dovetail.
c. The form work shall be checked by the Engineer-in-Charge before the form work starts and
form found defective shall be rejected and the same can be used after rectifying the defects
and with due approval of the Engineer-in-Charge

5.5 HOLES TO BE FILLED

1. Holes formed in concrete surfaces by form work supports or the like shall be filled with dry-
pack mortar made from one part by weight of ordinary Portland cement and one part fine
aggregate passing BIS sieve 1.18 mm. The mortar shall be mixed with only sufficient water
to make the materials stick together when being moulded in the hands.
2. The Contractor shall thoroughly clean any hole that is to be filled with dry-pack mortar and
where the surface has been damaged, the Contractor shall break out any loose, broken or
cracked concrete or aggregate. The concrete surrounding the hole shall then be thoroughly
soaked after which the surface shall be dried so as to leave a small amount of free water
on the surface. The surface shall then be dusted lightly with ordinary Portland cement by
means of a small dry brush until the whole surface that will come into contact with the dry-
pack mortar has been covered and darkened by absorption of the free water on the
surface. The surface shall then be dusted lightly with ordinary Portland cement by means of
a small dry brush until the whole surface that will come into contact with the dry-pack
mortar has been covered and darkened by absorption of the free water by the cement. Any
dry cement in the hole shall be removed.
3. The dry-pack material shall then be placed and packed in layers having a compacted
thickness not greater then 15 mm. The compaction shall be carried out by use of a
hardwood stick and a hammer and shall extend over the full area of the layer, particular
care being taken to compact the dry-pack against the sides of the hole.
After compaction, the surface of each layer shall be scratched the dry-pack fill and striking
the block several times. Steel finishing tools shall not be used and water shall not be added
to facilitate finishing.

5.6. TOLERANCES
Tolerance is a specified permissible variation from lines, grade or dimensions given in approved
drawings. No tolerance specified for horizontal or vertical building lines or footings shall be
construed to permit encroachment beyond the legal boundaries. Unless otherwise specified, the

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following tolerances will be permitted:

Tolerances for RCC Structures

i. Variation from the plumb

In the lines and surfaces of columns, piers, walls 5 mm per 2.5 m or 25 mm, whichever is less.
For exposed corner columns and other conspicuous lines
In any bay or 5 m maximum 5 mm
In 10 m or more 10 mm
ii. Variation from the level or from the grades indicated on the approved drawings
In slab soffits, ceilings, beam soffit, and in arises
In 2.5 m 5 mm
In any bay or 5 m maximum 10 mm
In 10 m or more 15 mm
For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines
In any bay or 5 m maximum 5 mm
In 10 m or more 10 mm
iii. Variation of the linear building lines from established position in plan and related
position of columns, wall and partitions
In any bay or 5 m maximum 10 mm
In 10 m or more 20 mm
iv. Variation in the sizes and locations of sleeves, openings in walls and floors Except in
the case of and for 5mm anchor bolts
v. Variation in cross sectional dimensions of columns and beams and in the thickness
of slabs and walls
Minus 5 mm
Plus 10 mm
vi. Footings
Variation in dimension in plan
Minus 5 mm
Plus 10 mm
vii. Misplacement or eccentricity 2% of footing width in the direction of misplacement but not
more than 50 mm Reduction in thickness: Minus 5% of specified thickness subject to a
maximum of 50 mm

viii. Variation in steps

In a flight of stairs
Rise 3 mm
Tread 5 mm
In consecutive steps
Rise 1.5 mm
Tread 3 mm
Tolerances in other Concrete Structures

ix. All structures

Variation of the constructed linear outlines from established position in plan
In 5 m 10 mm
In 10 m or more 15 mm
Variations of dimensions to individual structural features from established positions
In 20 m or more 25 mm
In buried construction 50 mm

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 Variation from plumb, from specified batter or from curved surfaces of all structures
In 2.5 m 10 mm
In 5 m 15 mm
In 10 m or more 25 mm
In buried construction twice the above amounts
Variation from level or grade indicated on approved drawings in slab, beams, soffits,
horizontal grooves and visible arises
In 2.5 m 5 mm
In 7.5 m or more 10 mm
In buried construction Twice the above amounts
Variation in cross-sectional dimensions of columns, beams, buttresses, piers and similar
members
Minus 5 mm
Plus 10mm
x. Footings for columns, piers, walls, buttresses and similar members Variation of dimensions
in plan
Minus 10 mm
Plus 50 mm
Misplacement or eccentricity
2% of footing width in the direction of misplacement but not more than 50 mm. Reduction in
thickness
5% of specified thickness subject to a maximum of 50 mm
xi. Tolerance in other types of structures shall generally conform to those given in Clause
2.4 of Recommended Practice for Concrete Formwork (American Concrete Institute Act
347). xii. Tolerance in fixing anchor bolts shall be as
follows:

Anchor bolts without sleeves + 5 mm

Anchor bolts with sleeves + 5 mm for bolts up to 20 mm dia above 32 mm dia

3 mm for bolts above 32 mm dia
Embedded parts + 5 mm in all directions

5.7. BRACING, STRUTS AND PROPS

a. Form work shall be braced, strutted, propped and so supported that it shall not deform under
weight and pressure of the concrete and also due to the movement of men and other
materials. Bamboo shall not be used as props or cross bearers.
b. The formwork for beams and slabs shall be so erected that the formwork on the sides of the
beams and under the soffit of slabs can be removed without disturbing the beam bottoms.
Repropping of beams shall not be done except when props have to be reinstated to take
care of construction loads anticipated to be in excess of the design load. Vertical props shall
be supported on wedges or other measures shall be taken whereby the props can be gently
lowered vertically while striking the formwork.
c. If the formwork for a column is erected for the full height of the column, one side shall be left
open and built up in sections as placing of the concrete proceeds, or windows may be left for
pouring concrete from the sides to limit the drop of concrete to 1.0 m as directed by the
Engineer-in-Charge.
Contractor shall submit the detailed design and methodology with applicable drawings if any
of Formwork system for different members for approval of Engineer-in-Charge.

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 6. REINFORCEMENT
6.1. RELEVANT IS CODES
IS:432 : Mild steel and medium tensile steel bars & hard drawn steel wire for
concrete reinforcement
IS:1786 : Cold twisted steel bars for concrete reinforcement (CTD).
IS:2502 (1963) : Code of practice for bending and fixing of bars for concrete
Reinforcement
IS:55225(1969) : Recommendations for detailing of reinforcement in RCC works
IS:2751 : C.P. for welding of MS bars used for RCC
IS:9417 : Recommendations for welding cold worked steel bars for RCC
IS:10790 : Methods of sampling of reinforced steel

6.2. GENERAL
Reinforcement shall be CTD and high strength deformed corrosion resistant (CRS) bars as per
IS:1786 - Fe415. Wire mesh or fabric shall be in accordance with IS:456. Substitution of
reinforcement will not be permitted except upon written approval from the Engineer-in-Charge.

6.3. STORAGE
a. The reinforcement shall not be kept in direct contact with the ground but stacked on top
of an arrangement of timber sleepers or the like.
b. If the reinforcing rods have to be stored for a long duration, they shall be coated with
cement wash before stacking and/or be kept under cover or stored as directed by the
Engineer-in-Charge.
c. Fabricated reinforcement shall be carefully stored to prevent damage, distortion,
corrosion and deterioration.
d. It should be seen that the reinforcement will not be exposed to direct sunlight and
preventive measures should be taken for the same.

6.4. QUALITY
All reinforcements shall be clean, free from grease, oil paint, dirt, loose mill scale, loose rust, dust
bituminous material or any other substances that will destroy or reduce the bond. All rods shall be
thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used. No
welding of rods to obtain continuity shall be allowed unless approved by the Engineer-in-Charge.
If welding is approved, the work shall be carried out as per IS:1786 - Fe415 according to the best
modern practices and as directed by the Engineer-in-Charge. In all cases of important
connections, tests shall be made to prove that the joints are of full strength of bars welded.
Special precautions, as specified by the Engineer-in-Charge, shall be taken in the welding of cold
worked reinforcing bars and bars other than mild steel.

6.5. LAPS
Laps and splices for reinforcement shall be as per IS:456-2000. Splices in adjacent bars shall be
staggered as mentioned in structural drawings and locations of all splices shall be approved by
the Engineer-in-Charge.
Also Contractor shall submit the Bar bending schedule for approval of Engineer-in-Charge and
shall follow same unless and until changed by any design changes.

6.6. BENDING
a. Reinforcement bars supplied bent or in coils, shall be straightened before they are cut to size.
Straightening of bars shall be done cold and without damaging the bars.
b. All bars shall be accurately bent according to the sizes and shapes shown on the approved
detailed working drawings/bar bending schedules. They shall be bent gradually by machine
or other approved means. Reinforcing bars shall not be straightened and re-bent in a manner
that will injure the material; bars containing cracks/splits shall be rejected. They shall be bent

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 cold, except bars of over 25 mm in diameter, which may be bent hot if specifically, approved
by the Engineer-in-Charge. Bars, which depend for their strength of cold working, shall not
be bent hot.

Bars bent hot shall not be treated beyond cherry red colour (nor exceeding 845°C) and after
bending shall be allowed to cool slowly without quenching. Bars incorrectly bent shall be used
only if the means used for straightening and re-bending be such as shall not, in the opinion of
the Engineer-in-Charge, injure the material. No reinforcement shall be bent when in position
in the work without approval, whether or not it is partially embedded in hardened concrete.
Bars having kinks or bends other than those required by design shall not be used.

6.7. FIXING
Reinforcement shall be accurately fixed by any approved means and maintained in the correct
position shown in the approved Drawings by the use of blocks, spacers and chairs, as per
IS:2502 to prevent displacement during placing and compaction of concrete. Bars intended to be
in contact at crossing points shall be securely bound together at all such points with number 16
gauge GI wire. The vertical distances required between successive layers of bars in beams or
similar members shall be maintained by the provision of mild steel spacer bars at such intervals
that the main bars do not perceptibly sag between adjacent spacer bars. No binding wire shall
protrude in cover area and shall bent inside.

6.8. COVER
Unless indicated otherwise, clear concrete cover for reinforcement (exclusive of plaster or other
decorative finish) shall be as follows:
a. At each end of a reinforcement bar, not less than 25 mm nor less than twice the diameter of
the bar whichever is greater
b. For a longitudinal reinforcing bar in a column, not less than 40 mm, nor less than the
diameter of the bar. In case of columns of minimum dimension of 20 cm or under with
reinforcing bars of 12 mm and less in diameter, a cover of 25 mm may be used.
c. For longitudinal reinforcing bars in a beam, not less than 40 mm nor less than the diameter of
the bar, whichever is greater
d. For tensile, compressive, shear or other reinforcement in a slab, or wall, not less than, 20
mm, nor less than the diameter of such reinforcement.
e. For any other reinforcement, not less than 20 mm, nor less than the diameter of such
reinforcement.
f. For footing and other principal structural members in which the concrete is poured on a layer
of lean concrete, the bottom cover shall be reduced to 60 mm.
g. For concrete surfaces exposed to the weather or the ground after removal of forms, such as
retaining walls, grade beams, footing sides and tops, etc. not less than 40 mm for bars larger
than 16 mm diameter and not less than 30 mm for bars 16 mm diameter or smaller.
h. For liquid retaining structures, the minimum cover to all steel shall be 40 mm or the diameter
of the main bar, whichever is greater.
i. The correct cover shall be maintained by cement mortar cubes or other approved means.
Reinforcement for footings, grade beams and slabs on subgrade shall be supported on
precast concrete blocks as approved by the Engineer-in-Charge. The use of pebbles or
stones shall not be permitted.
j. The 28 day crushing strength of cement mortar cubes/precast concrete cover blocks shall be
at least equal to the specified strength of concrete in which these cubes/blocks are
embedded.
k. The minimum clear distance between reinforcing bars shall be in accordance with IS:456

6.9. INSPECTION
After final erection of reinforcement, it shall be intimated to Engineer-in-Charge in writing or
through pour cards. Erected and secured reinforcement shall be inspected and approved by the

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 Engineer-in-Charge prior to placement of concrete.

6.10. WELDING OF REINFORCEMENT

a. Reinforcement which is specified to be welded shall be welded by any process which
conforms with the requirements of IS:2751 and which the Contractor can demonstrate by
bend and tensile tests will ensure that the strength of the parent metal is not reduced and
that the weld possesses a strength not less than that of the parent metal. The welding
procedure established by successful test welds shall be maintained and no deviation from
this procedure shall be permitted.
b. Welds in positions other than those shown on the approved Drawings shall not be permitted.
Tack welding to lightly secure reinforcement in place will be permitted subject to approval of
the Engineer-in-Charge.

6.11. SUPPLY OF REINFORCING BARS

Steel reinforcement, such as MS bars HYSD bars etc. required for the works shall be procured by
Contractor. The Contractor shall arrange for transport, loading, unloading and storage at the work
sites. The Contractor should plan the procurement of steel in such a way that at least required
quantity of steel of specified sizes is available at site for 3 months period.

Steel brought on site shall be stored in proper manner as approved by Engineer In Charge so as
to avoid distortion, deterioration and corrosion. The Contractor shall maintain proper register for
the steel account, showing the steel received at site, steel used, and the balance stock on site, to
the entire satisfaction of the Engineer-in-Charge.

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 7. STRUCTURAL STEEL WORK

7.1. RELEVANT IS CODES

IS:2062 : Specification for Structural Steel (Fusion Welding Quality)
IS:800 : C.P. for general construction in steel
IS:808 : R.S. beam, channel and angel sections
IS:814 : Covered electrodes for metal arc welding of structural steel
IS:1148 : Hot rolled steel rivet bars for structural purpose
IS:1363 : Black hexagon bolts, nuts, and lock nuts (dia 6 to 39mm) & black hexagon screws (dia
6 to 24mm) IS:2062 : Structural steel (fusion welding quality)
IS:3954 : Hot rolled steel channel sections for general engineering purposes
SP-6 (I - VII) : ISI Handbook for Structural Engineers
SP-40 : Handbook on structures with steel portal frames (without cranes)

7.2. GENERAL
Structural steel fabrication work shall include all types of steel structural work required for
installation of platform for operation and installation of equipment where rolled steel sections are
joined together either by bolting or riveting or welding as specified in the drawings/bill of
quantities/directed by the Engineer. It shall also include fabrication and installation of air
vessels/pressure vessels etc. Covers for ducts for electrical panels along with their seating
arrangements are also classified under this heading unless they are provided separately under a
different heading. Reaction tanks or storage vessels are also classified under this heading.

7.3. MATERIALS
The MS structural members such as MS angles, channels, flats, I sections etc. shall conform IS
2062. Structural steel that is used for fabrication shall be conforming to any of the following grades
of steel as specified to each of the works:
• IS:2062 : Specification for Structural Steel (Fusion Welding Quality)
• IS:1977-1975: Structural steel (ordinary quality)
• IS:2062-1980: Weldable Structural steel (fusion quality)
Whenever the Contractor supplies steel, he shall on demand the test certificates from the
manufacturer.
The welding rods used for fabrication shall conform to IS:814-1974 (parts I and II). The fasteners
like bolts, nuts etc., shall conform to IS:1367. Rivets shall conform to IS:1184-1982. Plain
washers shall conform to IS:2016-1967. Spring washers shall conform to IS:3063-1972.
MS rivets shall conform to IS:1148 and IS:1929-1967 bolts and nuts shall conform to IS:1363 -
1967.
If metal arc welding is to be done as per design or as ordered by the Engineer-in-Charge the
electrodes used for strength welds shall conform to IS: 814 and shall be of such shape and size
approved by the Engineer-in-Charge and shall be prevented from oxidation and shall be kept in
clean condition.
Paints used shall be of approved manufacture and shade and shall conform to the ISI standards.

7.4. FABRICATION AND ERECTION

All the shop drawings shall be prepared by the Contractor and submitted in advance of atleast 15
days to the Engineer for his approval. The drawings shall be submitted in triplicate. The
fabrication work shall not be taken in hand until the shop drawings are approved by the Engineer.
Approval of the shop drawings however shall not relieve the Contractor of his responsibility of
correct conformation to the designs and fabrications of the structure to meet the requirements of
the contract. One copy of the approval drawings shall be given to the Contractor for going ahead
with the fabrication work.

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In the shop drawings to be submitted by the Contractor, standard symbols as described in the
IS:813-1961 shall be followed.

Fabrication work shall be carried out as laid down in IS:800-1984 Code of practice for general
construction in steel.

Welding shall be carried out in accordance with the following specifications as

applicable:

IS:803 - 1976 : Code of practice for design fabrication and erection of vertical mild steel
cylindrical welded oil storage tanks.
IS: 816 - 1969 : Code of practice for use of metal and welding for general construction in mild
steel
IS:822 - 1970 : Code of practice for manual and welding of mild steel
IS:9595 - 1980 : Recommendations for metal are welding of carbon Radiographic tests are
required to be carried out as directed by the Engineer in case of pressure
vessels.
IS:818 - 1968 : Code of practice for safety and health requirements in electric and gas welding
and cutting operations
IS:3016-1982 : Code of practice for fire precautions in welding and cutting operations
IS:7205 - 1973 : Safety code for erection of structural steel work

The sections shall be fixed absolutely vertical or to the specified angle as shown in the drawings/as
desired/directed by the Engineer.
All connections like angle brackets, cleats, gusset plates, anchor bolts, bearing plates shall all be fixed as
shown in the drawings or as directed by the Engineer.
The items of work shall include supply of materials, fabrication and erection in position on site as shown
in the drawings. This shall also include all labour consist, materials and equipment required for all
fabrication, hoisting, erection, and satisfactory completion of the item of work.
The supply of materials includes all structural members like rolled sections, plates, brackets, rivets, bolts
and nuts and welds.
The steelwork shall be painted as specified in the drawings, described in the bill of quantities or as
directed by the Engineer. Unless otherwise provided for in the bill of quantities separately, the rate
quoted for the item is inclusive of all costs for painting like cost of paint, cost of labour, scaffolding etc.
Welding work shall be done generally using electric arcs welding. Where public electricity is not
available, generators shall be arranged by the Contractor shall be arranged by the Contractor himself.
Gas welding shall not be allowed to be resorted to for welding. Under special circumstances if in the
opinion of the Engineer it cannot be avoided, gas welding can be done with the prior permission of the
Engineer. However gas welding shall not be used where structural strength is the criteria for
consideration.
All arrangements shall be made by the Contractors for access for inspection by the Engineer or his
representative to the workshop where the welding work is being carried out and necessary equipment like
gauges, measuring instruments etc., shall be made available to the inspecting personnel.
Painting work shall not be started without the express approval of the Engineer and the painting shall be
started only after his inspection and approval of the works after carrying out surface preparations.
All holes shall be carefully marked. Holes shall have their axis perpendicular to the surfaces bored
through. Holes being made through two or more members shall be truly concentric.
Holes shall not be formed cutting process.
All the temporary connections of parts during assembly shall be done in the following ways. For welded
structures. Tack welding fixtures.
After welding is over, the surface on the joint should be ground and made smooth and even.

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 The welding should be so perfect so as to give required strength as taken for designed purpose
at joints in particular. The Contractor will make necessary arrangements for testing of joints as
required by Engineer in Charge.
Welded joints shall be free from defects that would impair the service performance of the
construction. All the welds shall be free from incomplete penetration, incomplete fusion, slag
inclusion, burns, un-welded creators undercuts and cracks in the welded metal, porosity etc. All
the defects shall be rectified as directed by the Engineer. Defective portions shall be removed to
the sound metal and re-welded. Rectification of the welds by caulking shall not be permitted. All
welds shall be cleaned of stag and other deposits after completion.

7.5. PAINTING
Painting shall generally comply with IS subject to addition and alterations as may be prescribed in
the special provisions for any particular item. It shall also comply with the requirements of the
manufacture’s specifications. One priming coat of red lead shall be applied immediately after
fabrication. Two coats of oil paint of approved shade shall be applied after complete erection. The
structural steel to be embedded in concrete shall not be painted.
Inspection and testing shall be carried out in conformity with IS:800.
Riveting, welding and bolting shall not be started until such time as the Engineer has personally
satisfied himself that the alignment is correct, in the vertical plumb, the camber correct with
camber packs, screwed tight, all joints and cover plates fixed tightened with service bolts and
field rivet holes coinciding. While assembling holes in different components shall be made
concentric with the use of drills before service bolts are fixed.
Welding if required shall be done as per standard practice and as approved by the Engineer-in-
Charge.
All permanent machine fitted nuts and bolts must be perfectly tight and shall be burred or
otherwise checked to prevent nuts from becoming loose. No unfitted rivet or bolt holes are to be
left in any of the structure. Structural Steel
All structural steel shall conform to IS:2062-1984. The steel shall be free the defects mentioned in
IS given above and shall have a smooth finish. The material shall be free from loose mild scale,
rust pits or other defects affecting the strength and directly.
7.5.1. General
Engineer’s approval shall be obtained before commencing the painting work. All paints and
preserves shall be of approved make and colour and their application shall conform to the
manufacture’s instructions. Where more than one undercoat is specified it shall be applied in
coats of distinctive tints. Workmanship shall conform to the requirement of IS:2395
Unless the manufacturer’s instructions state otherwise48 hours drying time shall elapse between
successive applications of any primer and 24 hours between applications of all subsequent coats.
The surface of bituminous paints shall be left at least 3 days before further handling.
No paints in any coats shall be applied until the engineer is satisfied that the surface is clean and
dry. And that any previous coat is satisfactory and has hardened adequately. When a surface has
been approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper between coats. No paint shall be applied to a
surface, which is damp, dirty or otherwise inadequately prepared.

7.5.2. Ironwork and Ungalvanised Steelwork

Structural steelwork shall be shot blasted to a "white metal" finish, and grease and oil removed
prior to painting. Priming shall immediately follow blast cleaning and no cleaned surface shall be
left unprimed for more than four hours. Only primers that chemically inhibit corrosion shall be
used. Where the iron or steelwork is not in contact with raw or treated water, the primer shall be
red lead complying with IS: 57. Where there is a possibility that the steel or ironwork may come in
contact with water, the priming treatment shall be non toxic, zinc chromate or equivalent. Where it
is anticipated that further welding will be required. an approved welding primer shall be applied to
the areas to be welded and re primed with the main primer when welding has been completed.
Primer coats shall not be less than 0.05 mm each.

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After erection, all damaged areas shall be made good, and re primed where the original coat has
spread under the primer, the affected surface shall be cleaned down to bare metal to the
satisfaction of the Engineer and then re primed.

Repainting shall be carried out as soon as possible after erection. If` it is to he exposed to
weather or condensation, it shall receive one further coal of primer.

Metalwork in intermittent or permanent contact with raw or treated water shall have two finishing
coats of an approved coal tar pitch epoxy paint such as "Epilux 5" by Berger Paints, or equivalent.
The total coating shall be minimum of 0.125 mm thick.

After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting down to
a smooth uniform surface. When the surface becomes dry, be undercoat of synthetic enamel
paint conforming-to IS:2932 of optimum thickness shall be applied by brushing with minimum of
brush marks. The coat shall be allowed to hard dry. The under coat shall then be wet rubbed
cutting down to a smooth finish, taking adequate care to ensure that at no place the undercoat is
completely removed. The surface shall then be allowed to dry.

The first finishing coat of paint shall be applied by brushing and allowed to hard dry. The gloss
from the entire surface shall then be gently removed and the surface dusted off. The second
finishing coat shall then be applied by brushing.
At least 24 hours shall elapse between the application of successive coats. Each coat shall very
slightly in shade and this shall be got approved by the Engineer.

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 8. BRICK WORK AND STONE MASONRY

These specifications deal with all types of brickwork required for buildings, manholes, drains, retaining
walls or any construction made out of bricks.

8.1. RELEVANT IS CODES

IS:1077 : Common burnt clay building bricks IS:2180 :
Heavy duty burnt clay-building bricks IS:2212 : C.P. for
brickwork
IS:3495 (I - IV) : Method of test for clay building bricks
IS:5454 : Method of sampling of clay building bricks

8.2. MATERIALS

8.2.1. Bricks

Bricks used for the construction of brick masonry shall be sound, hard, rectangular in shape and
size and well burnt of uniform deep red, cherry or copper colour and shall conform to IS:1077-
1986.

The bricks shall be brought from approved brick kilns. The bricks shall be free from cracks,
chippings flaws, stones or lumps of any kind. The bricks shall not show any signs of
efflorescence and shall be homogeneous in texture.

They should emit a clear metallic sound on being struck and shall have a minimum compressive
strength of 50 kg/sq.cm. They shall not absorb water more than specified in the Indian Standard
Specifications, of its dry weight when soaked in cold water for 24 hours.

8.2.2. Mortar

The proportion of the cement mortar used for the masonry work shall be as specified on the
various drawings for different places/types of construction, bills of quantities, specifications for
each part of the work.

Mortar should be prepared by volume using boxes of appropriate sizes on clean platform or this
sheet to avoid mixing of foreign material and maintain consistency of mortar.

Sharp coarse sand is mixed with the required quantity of cement for the preparation of the mortar.
Mortar shall be prepared in accordance with IS:2250-1981. The sand used for the masonry
mortar shall meet the requirements as specified in IS:2116-1980. Sand for masonry mortars.
Sand and cement of required proportions are mixed in small quantities in a dry state first and then
water is added to make the mortar of required the consistency suitable for the type of work it is
required as directed by the Engineer-in-Charge. No left over mortar shall be used and therefore
only that much quantity of mortar that can be consumed within 30 minutes shall be mixed in
batches.

8.3. CONSTRUCTION
The brick masonry shall be constructed as per the Indian Standard Code of Practice for Brick
Work - IS:2212-1962. The thickness of the joints shall not be thicker than those specified in of the
above Code of Practice.

The bricks shall be thoroughly soaked in water before using them on the work for at least six
hours and all the air bubbles shall come out during soaking process. The soaked bricks shall be
stacked on wooden planks/platforms so as to avoid sticking of the earth and other materials on to
the surfaces of bricks. Bricks required for construction in mud mortar or lime mortar shall not be

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 soaked. Brickwork shall be laid in English Bond unless otherwise specified. Half bricks shall not
be used except when need to complete the bond. Each course shall be perfectly straight and
horizontal. The masonry shall be true to plumb in case of vertical walls and in case of battered
construction the batter or slope shall be truly maintained. The level of the courses completed shall
be checked at every metre interval or less as required.
The bricks shall be laid frogs upwards. While laying the bricks they shall be thoroughly bedded
and flushed in mortar and well trapped into position with wooden mallets and superfluous mortar
shall be removed.
No part of the structure shall be raised more than one meter above than the rest of the work. In
case it is unavoidable the brickwork shall be raked back at an angle of not more than 45 degrees
so as to maintain a uniform and effectual bond, but raking shall not start within 60 cms from a
corner.
In cases of construction of buttresses, counterforts, returns they are built course by course
carefully bound into the main walls. At all junctions of walls the bricks at alternate courses, shall
be carried into each of the respective walls so as to thoroughly unite both the walls together. The
brickwork shall not be raised more than 14 courses per day.
All the beds and joints shall be normal to the pressures applied upon them i.e. horizontal in
vertical walls, radial in arches and at right angles to the face in battered retaining walls.
Vertical joints in alternate courses shall come directly one over the other and shall be truly
vertical. Care shall be taken to ensure that all the joints are fully filled up with mortar, well flushed
up where no pointing is proposed, neatly struck as the work proceeds. The joints in faces, which
are plastered or painted, shall be squarely raked out to a depth not less than 12 mm while the
mortar is still green. The raked joints shall be well brushed to remove the loose particles and the
surfaces shall be cleaned with a wire brush so as to remove any splashes of mortar sticking to
the surfaces during the construction.

All iron fixtures, pipes, bolts, conduits, sleeves, holdfasts etc., which are required to built into the
walls shall be embedded in cement mortar or cement concrete as shown in the
drawings/indicated in the specifications directed during the execution by the Engineerin-Charge
as the work proceeds and no holes be left for fixing them at a later date unless authorised by the
Engineer-in-Charge.

8.4. CURING
Fresh work shall be protected from rain by covering the work suitably. Masonry work as it
progresses shall be thoroughly kept wet by watering on all the faces for atleast 7 (Seven) days
after completion of the parts of the work. Proper watering cans, flexible pipes, nozzles shall be
used for the purpose. The top of the masonry work shall be kept flooded at the close of the day’s
work by constructing fillets of mortar 40 mm high all around the edges of the top course. In case
of fat lime mortar curing shall start two days after construction of masonry and shall continue for
seven days. No additional payment is admissible for curing and the rates quoted are deemed to
be inclusive of the cost of curing.

8.5. SCAFFOLDING
Double scaffolding sufficiently strong so as to withstand all loads that are likely to come upon it
and having two sets of vertical supports shall be provided. Where two sets of vertical supports are
not possible the inner end of the horizontal supporting pole shall rest in a hole provided in a
header course only. Only one header for each pole shall be left cut. Such holes, however shall
not be permitted in pillars under one meter in width or immediately near the skewbacks of arches.
Such holes shall be filled up immediately after removal of the scaffoldings. Safety Code for
Scaffolds and Ladders, IS:3696-1987 (Parts I and II) shall be followed. The cost of scaffolding is
deemed to be included in the rates quoted for brick masonry and no separate costs are payable.

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8.6. STONE MASONRY FOR RETAINING WALLS
Stone masonry in general is to be used for retaining walls as per engineer in-charge’s instructions
and as per drawings, which will be supplied during course of construction to suit site conditions.

Following Indian Standards shall be applicable:

IS:1122-1974 Method of determination of specific gravity and porosity of natural building

stones
IS:1200 Method of measurement of stone masonry.
IS:1597 Code of practice of construction of rubble stone masonry.
IS:1805 Glossary of terms relating to stone quarrying and dressing
IS:4101 Stone facing
IS:1121 Determination of strength, properties of natural building stones

8.7. UNCOURSED STONE MASONRY

Uncoursed stone masonry shall be built in layers not exceeding 450 mm in height. No stone shall
be less in breadth than 14 times its height and less in length than twice its height. Every stone
whether large or small, shall be laid in its natural bed and set flush in mortar, and the small stones
used for wedging or filling being carefully selected to fit the interstices between the large stones.
Care shall be taken to see that no dry work or hollow space is left in the masonry. The stones
shall be so arranged as to break joints at least every 80 mm and long vertical joints of joints shall
be avoided. The joints at the face shall be finished off neatly, being struck and smoothed with a
trowel while the mortar is fresh. The upper surface of the work shall be brought to a uniform level
at the height of each course. The faces of masonry walls shall be kept in perfect plumb and
where batter has to be given it shall, be uniform. The stones at all comers and junctions of walls
shall be of large sizes and hammer dressed to the correct angle.

Each stone shall be thoroughly wetted before being used in the work. The masonry shall be kept
thoroughly wet during the progress of the work, (care being taken to water it even on Sundays
and Holidays, special labour being employed if so required for this purpose) until it becomes hard.
As far as practicable, the whole of the masonry shall be raised in one uniform level and no part of
the masonry shall he allowed to rise more than 1 metre above the rest to avoid unequal
settlement. If raising one part of wall before the other becomes unavoidable the end of the raised
portion shall be racked back in steps to prevent cracks developing at the junction of the old and
new work. Care shall be taken to see that the sides of the wall are not built separately from the
hearting, the faces and internal filling being done simultaneously .The stones shall overlap and
cross each other as much as possible. No course shall be laid unless the previous course is
perfectly set. Al least one header or through stone per square metre of` wall face shall be built
into the work. The headers or through stones shall be at least 0.05 m″ in area al face and shall
have at least 0.025 m″ area at the back face. Where the thickness of the wall is more than 600
mm a series of through stones shall be laid through the work so as to form a tie from front to
back, breaking joints or overlapping each other for at least 150 mm. No stone whose length is
less than 600 mm shall be used in such work as a header.

All the through stones shall be marked inside and outside and the marks shall be retained until
ordered by the Engineer to be removed. Sufficient number of headers shall be collected on site
before commencing any masonry work. Where adequate sized through stones are not available
in required quantities, the use of pre-cast plain concrete headers in M-20 mix may be permitted at
the discretion of the Engineer. No extra payment will be made for the provision of substitute
headers in concrete

Quoins shall be 150 mm high and formed of header stones at least 300 mm long. They shall be
laid lengthwise alternately along each face and square on their beds, which shall be dressed to a

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 depth of at least 80 mm.

Weep holes 80 mm wide and 150 mm in height shall be provided in retaining walls at the rate of
one per square metre as specified or directed. They shall he pointed with 1:2 cement sand mortar
after raking the joints to a minimum depth of 25 mm.

Completed masonry shall be kept wet for a minimum period of 14 days. In wet weather newly laid
masonry shall be protected from the effects of heavy rainfall by tarpaulins or other approved
material.

8.7.1. Pointing of Uncoursed Masonry

Joints in exposed masonry faces shall be formed while the mortar is still green and shall be
finished as flush joints, weathered joints, round-recessed joints or square-recessed joints as
directed by he Engineer. Masonry which is to be rendered or plastered shall have the joints raked
out to a depth of 15 mm to form a key.

8.8. STONE PITCHING

Stone pitching: to slopes shall be carried out where specified or as directed by the Engineer.
Stone for pitching shall be obtained from an approved source and shall be hard, sound, durable,
clean and generally as specified. The minimum dimension of any stone shall be, at least equal to
the specified thickness of the pitching.
After excavation and trimming, slopes to be pitched shall be spread with a 75mm thick layer of
crusher run rock or graded coarse aggregate ranging from 75mm particle size to fines. The slope
shall then be hand packed with hard broken rock to a total thickness of 150 mm, each stone
being individually placed and rammed home, with smaller stones edged into the cracks. 50mm dia
weep-holes shall be provided where specified at intervals not exceeding two meter's in both
directions. Joints in stone pitching shall be flushed up with sand/cement mortar on completion.

8.9. RUBBLE PACKING

Rubble used for packing under floors, foundations, etc. shall be hard and durable rock, free from
veins, flaws and other defects. The quality and size of the rubble shall be subject to the approval
of the Engineer.
Rubble shall be hand packed as directed by the Engineer. They shall be laid closely in position
on the sub-grade. All interstices between the stones shall be wedged in with smaller stones of
suitable size well driven to ensure tight packing and complete filling of interstices. Such filling
shall be carried out simultaneously with the placing in position of rubble stones and shall not lag
behind. Small interstices shall be filled with hard clean sand and well watered and rammed.

8.10. CONCRETE BLOCK MASONRY

8.10.1. Materials
Masonry units of hollow and solid concrete blocks shall conform to the requirements of IS : 2185
(Part I).
Masonry units of hollow and solid light-weight concrete blocks shall conform to the requirements
of IS:2185(Part 3).
Masonry units of autoclaved cellular concrete blocks shall conform to the requirements of
IS:2l85(Part 3).
The height of the concrete masonry units shall not exceed either its length or six times its width.
The nominal dimensions of concrete block shall be as under. Length 400, 500 or 600 mm Height
100 or 200 mm
Width 100 to 300 mm in 50 mm increments
Half blocks shall be in lengths of 200, 250 or 300mm to correspond to the full-length blocks.
Actual dimensions shall be 10mm short of the nominal dimensions.

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 The maximum variation in the length of the units shall not be more than 5 mm and maximum
variation In height or width of the units shall not be more than3mm.
Concrete blocks shall be either hollow blocks with open or closed cavities or solid blocks.
Concrete blocks shall be sound, free of cracks, chipping or other defects, which impair the
strength or performance of the construction. Surface texture shall as specified. The faces of the
units shall be flat and rectangular, opposite faces shall be parallel and all arises shall be square.
The bedding surfaces shall be at right angles to the faces of the block.
The concrete mix for the hollow and solid concrete blocks/light weight concrete blocks shall not
be richer than one part of cement to six parts of combined aggregates by volume.
Concrete blocks shall be of approved manufacture, which satisfy the limitations in the values of
water absorption, drying shrinkage and moisture movement, as specified for the type of block as
per relevant IS code. Contractor shall furnish the test certificates and also supply the samples for
the approval of Engineer In Charge.

8.10.2. Workmanship
The type of the concrete block, thickness and grade based on the compressive strength for use in
load bearing and/or non-load bearing walls shall be as specified. The minimum nominal thickness
of nonload bearing internal walls shall be 100mm. The minimum nominal thickness of external
panel walls in framed construction shall be 200 mm.
The workmanship shall generally conform to the requirements of IS:2572 for concrete block
masonry, IS:6042 for light weight concrete block masonry and 15:6041 for autoclaved cellular
concrete block masonry works.
From considerations of durability, generally concrete block masonry shall be used in
superstructure works above the damp-proof course level.
Concrete blocks shall be embedded with a mortar, which is relatively weaker than the mix of the
blocks in order to avoid the formation of cracks. Cement mortar of proportion 1:6 shall be used for
the works.
The thickness of both horizontal and vertical joints shall be 10mm. The first course shall be laid
with greater care, ensuring that it is properly aligned, leveled and plumb since this will facilitate in
laying succeeding courses to obtain a straight and truly vertical wall. For the horizontal (bedding)
joint, mortar shall be spread over the entire top surface of the block including front and rear shells
as well as the webs to a uniform layer of 10mm. For vertical joints, the mortar shall be applied on
the vertical edges of the front and rear shells of the blocks. The mortar may be applied either to
the unit already placed on the wall or on the edges of the succeeding unit when it is standing
vertically and then placing it horizontally, well pressed against the previously laid unit to produce
a compacted vertical joint. In case of two cellblocks with slight depression on the vertical sides
these shall also be filled up with mortar to secure greater lateral rigidity. To assure satisfactory
bond, mortar shall not be spread too far ahead of actual laying of the block as the mortar will
stiffen and lose its plasticity. Mortar while hardening shrinks slightly and thus pulls away from the
edges of the block. The mortar shall be pressed against the units with a jointing tool after it has
stiffened to effect intimate contact between the mortar and the unit to obtain a weather tight joint.
The mortar shall be raked to a depth of 10mm as each course is laid to ensure good bond for the
plaster.
Dimensional stability of hollow concrete blocks is greatly affected by variations of moisture
content in the units. Only well dried blocks should be used for the construction. Blocks with
moisture content more than 25% of' maximum water absorption permissible shall not be used.
The blocks should not be wetted before or during laying in the walls. Blocks should be laid dry
except slightly moistening their surfaces on which mortar is to be applied to obviate absorption of
water from the mortar.
As per the design requirements and to effectively control cracks in the masonry, RCC bound
beam/studs, joint reinforcement shall be provided at suitable locations. Joint reinforcement shall
be fabricated either from mild steel wires conforming to IS:280 or welded wire fabric/high strength
deformed basis.
For jambs of doors, windows and openings, should concrete blocks shall be provided. If hollow

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 units are used, the hollows shall be filled with concrete of mix 1:3:6. Hold fasts of doors/windows
should be arranged so that they occur at block course level.
At Intersection of walls, the courses shall laid up at the same time with a true masonry bond
between atleast 50% of the concrete blocks.
Curing of the mortar joints shall be carried out for atleast 7 days. The walls should only be lightly
moistened and shall not be allowed to become excessively wet.
Double scaffolding shall be adopted for execution of block masonry work.
Cutting of the units shall be restricted to a minimum. All horizontal and vertical dimensions shall
be in respectively, adopting modular co-ordination for walls, opening locations for doors, windows
etc.
Concrete blocks shall be stored at site suitably to avoid any contact with moisture from the
ground and covered to protect against wetting.

8.11. DAMP-PROOF COURSE

8.11.1. Materials and Workmanship

Where specified, all the walls in a building shall be provided with damp-proof course cover plinth
to prevent water from rising up the wall. The damp-proof course shall run without a break
throughout the length of the wall even under the door or other openings. Damp-proof course shall
consist of 50 mm thick cement concrete of 1:2:1 nominal mix with approved water-proofing
compound admixture confirming to IS: 2645 in proportion as directed by the manufacturer.
Concrete shall be with 10 mm down graded coarse aggregates.
If he surface of brickwork/stone masonry work shall be leveled and prepared before laying the
cement concrete. Side shuttering shall be properly fixed to ensure that slurry does not leak
through and is also not disturbed during compaction. The upper and side surface shall be made
rough to afford key to the masonry above and to the plaster. Damp-proof course shall be cured
properly for atleast seven days after which it shall be allowed to dry for taking up further work.

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 9.PLASTERING

9.1. RELEVANT IS CODES

IS:1542 : Sand for plaster
IS:1661 : C.P. for application of ferrous metals in building
IS:2394 : C.P. for application of lime plaster finish

9.2. PLASTERING
Cement mortar used for plastering shall be of the mix proportions and thickness as specified on
the drawings or bill of quantities or particular specifications for the various different parts of the
works.
The materials used i.e. cement, sand and water shall be of the same quality and of the same
specifications as indicated for plain and reinforced cement concrete works in this tender.
Sand further shall meet the specifications as laid down in IS:1542-1977 Specification for sand for
plaster.
For plastering on old existing surfaces polymers shall be added as bonding agents.
The surfaces that are to be applied with plaster shall be thoroughly cleaned to remove dust, dirt,
loose particles, oil, soil, slats etc. that may be sticking to the surfaces. The surfaces shall be
washed clean and watered properly for 4 hours before applying plaster.
Plaster shall not, in any case, be thinner than specified. It shall have uniform specified
thickness. When smooth finishing is required the cement plastering shall be floated over with
neat cement within 15 minutes after application of the last coat of plastering.
The plaster shall be protected from the sun and rain by such means as the Engineer-in-Charge in
charge may approve. The plastered surfaces shall be cured for 7 (seven) days. Construction
joints in plastering shall be kept at places approved by the Engineer-in-Charge. When the
thickness of the plaster specified is to be made up in more than one layer, the second layer shall
be applied only when the lower coat is still green. After applying the first layer the surface should
be roughed and wherever specified, approved brands of additives like water proofing compounds
shall be added in specified quantities as recommended by the manufacturer of the compound, or
as directed by the Engineer-in-Charge.
Wherever scaffolds are necessary for plastering they shall be provided. Stage scaffolding shall be
provided for ceiling plaster. To ensure even thickness and true surface, patches of plaster about
15 cms x 15 cms shall be first applied both horizontally as vertically 2 m apart. Plastering shall be
done from top to bottom and care shall be taken to avoid joints on continuous surface.
Sand face plaster shall consist of first layer of 16mm average thick cement plaster in cement
mortar 1: 6 (One part cement and Six parts coarse sand). A second layer of 4 mm average thick
in cement mortar 1:4 (one part cement and four part coarse sand) shall be applied. After the
application of final coat, the surface shall be finished with the application of sponge rubber or as
directed to obtain a uniform sand particle surface finish.
In case any other finish like rough cast finish or dry dash finish is specified in the drawings the
same shall be provided as directed by the Engineer-in-Charge. Surfaces, which are to be
plastered, shall be roughened while they are still green or raked so as to give proper bond
between the surface and plaster.
All corner, edges, junctions shall be truly vertical or horizontal as the case may be and carefully
finished. Rounding or chamfering of corners shall be carried out with proper templates to the
required size and shapes.
No additional charges for works like scaffolding curing etc. are payable over and above the rates
quoted for brickwork. The rates quoted shall be deemed to be inclusive of all such works.

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 Gypsum Plaster
Gypsum shall be fulfill the following bacteriya Stucco
1. Colour of Finished surface White
2. Bulk Density kg/m3 650-750
3. Setting time in Min 10-20
4. Coverage at 13mm (One coat) Not Applicable
(m2/1000 kg)
5. Coverage at 3mm (Stucco) Min 280
(m2/1000 kg)
6. Surface Smoothness More
7. Compressive Strength (KN) Min 70

9.3. NEERU
9.3.1. Material

Neeru shall be made of the best description of lime slaked with fresh water and sifted. The lime to
be reduced to fine powder by grinding it on a stone or in a hand mill, with a thick solution of
mussalla to be made or as may be desired by the engineer. The neeru thus prepared shall be
kept moist until used and the quantity to be prepared at one time shall be such that it can be
consumed in eight days.

9.3.2. Workmanship

All stone or brick masonry shall be thoroughly wetted and joints raked out to a depth of at least
20mm and walls washed before any plastering is done. The surface shall then rendered with fine
sand, to the specified thickness and roughness. The surface shall then be floated or set with a
thin coat, 3mm thick of cement and polished, well with a trowel or flat board. The cement mortar
shall be used within 30 minutes after it leaves the mixing board or mill. Before any plasterwork is
started patches of plaster 150mm x 150mm shall be put on at every 3 meters apart as gauges so
as to ensure an even thickness throughout the work. Cement plaster shall be done in even
square or strips. Care shall be taken to keep the whole surface thoroughly wetted for at least a
week. The finishing surface shall be as specified and directed. If neeru finish is specified then the
same shall be applied to the prepared and partially set but somewhat plastic surface with steel
trowel to a thickness slightly exceeding 1.5 mm and rubbed down to 1.5mm thickness and
polished to a perfectly smooth and even finish working from top to bottom. The surface shall be
then colored, if required with 3 coats of white or colour wash for which no extra payment shall be
made.

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 10.FLOORING

10.1. RELEVANT IS CODES

IS:777 : Glazed earthen ware tiles
IS:1237 : Cement Concrete flooring tiles
IS:1443 : C.P. for laying & finishing of cement concrete flooring tiles
IS:2114 : C.P. for laying in-situ terrazzo floor finish

10.2. GENERAL
The materials and workmanship conform to the provisions of the following codes and standards.
In particular and with such other standards as mentioned hereinafter. BIS: 269, 385, 515, 653,
712, 809, 1077, 1195, 1196, 1197, 1198, 1237, 1344, 1443.

10.3. CEMENT CONCRETE FLOORING

10.3.1. General

Flooring shall consist of a sub-base laid on the compacted earth or sand fill as required, a base
course laid on the sub-base and then a finishing layer of concrete, Terrazzo or any other material
as specified to be laid. The materials for filling (Earth or sand as specified in drawings) shall be
brought from the source as approved by the Engineer-in-Charge.

10.3.2. Filling

The surface to receive the filling shall be first cleared free of all roots, vegetation and wetted.
Filling in plinth or other specified levels shall proceed in layers of 15 cm. Along with the
construction of building, it shall be watered and well rammed in layers as mentioned above and
compacted to the satisfaction of the Engineer-in-Charge. Care shall be taken to remove all roots,
vegetation, foreign matter, etc. from the earth used for filling. After thorough consolidation,
required quantity of the filling corresponding to the thickness of floor shall be scrubbed to make
space for the flooring. Where sand filling is specified, the sand shall be clean, free from
vegetation and other deleterious materials and same procedure followed as for earth filling. In
case of sand filling, if required, flooding shall be done to achieve required compaction.

10.3.2.1. Preparation of Bed

The bed for flooring shall be prepared either level or sloped as per relevant drawings or as
instructed by Engineer-in-Charge. Care shall be taken that there are no roots, vegetation, foreign
matter, etc.

10.3.2.2. Sub-Base

On the prepared bed as indicated above, boulder, or gravel or broken bricks or sand or cement
concrete (1:4:8 as per BIS: 465) shall be laid to thickness as specified. This layer shall be beaten
with rammers until thoroughly consolidated. All the material used shall conform to the required
specifications.

The materials proportion, mixing, laying, and curing, etc. for cement concrete shall be carried out
as specified.

The finished work shall be of uniform depth over the whole floor with surface even and parallel to
the prepared bed as per drawing or as directed by Engineer-in-Charge.

a. Boulders as Sub-base Course

Boulders shall be laid over the prepared bed as per general specification and shall be of size
100 to 150 mm and shall be of approved quality. Boulders being used shall be free from

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 decay, weathering and be stacked in such heaps in place as directed by Engineer-in-Charge,
the thickness being as specified in the relevant drawings.
b. Sand Layer
c. Sand for sand layer to be laid over the prepared bond shall be clean, free from admixture as
per specification. Sand layer shall be spread in one or more layers to the thickness as
indicated in drawings or schedule of item watered and rammed.

10.3.3. Base Coarse

10.3.3.1.Cement Concrete

It shall be of specified mix and shall generally conform to “Construction Specification for Cement
Concrete”.

10.3.3.2.Panels

To prevent construction cracks, the floor space shall be divided into square or rectangular panels.
The base course of specified thickness shall be laid in alternate panels or any other pattern as
approved by Engineer-in-Charge. The panels shall be of uniform size, not exceeding 4.0 m. in
any direction for a floor having thickness 40 mm and above. Alternate panels shall be laid on
different days.

Construction joints shall be formed in between the sequential panels cast, with straight edges, 20
mm deep and 12 mm wide in groove form. These joints on completion of work, shall be cleaned
and washed free of dust with the help of brush and shall be treated with hot bitumen poured in
the gap, over which fine sand shall be spread to arrest the flow of bitumen.

10.3.3.3.Shuttering

The panels shall be bounded by glass strips having the same depth as the concrete floor. These
shall be fixed in position with their top at proper level, giving slope. The floors shall butt against
masonry of wall before it is plastered.

10.3.3.4.Concreting

Cement concrete shall be placed in position with or without MS reinforcements as shown in

drawings and beaten with trowel and finished smooth or left rough as directed by the Engineer-in-
Charge. Beating shall cease as soon as surface is found covered with cream of mortar. The
surface shall be checked with the help of straight edge and made true. The shuttering shall be
removed next day. Care shall be taken to see that edges are not damaged and fresh mortar from
adjacent panels is not splashed over them. The joints between panels shall come out as fine
straight line. MS reinforcement used for concrete base course with reinforcement shall conform to
relevant BIS Specifications as detailed in drawings. Before placing of those reinforcements, they
shall be cleared of scales with wire brush and oily stains removed.

10.3.4. Floor Finish Plain Cement Finish

Finishing of the surfaces shall follow immediately after the completion of base course. The
surface shall be left for some time till the moisture disappears from it. Use of dry cement or
cement and sand mixture sprinkled on the moisture shall not be permitted.

Fresh quantity of cement at 2.2 kg per square metre of flooring shall be mixed with water to form
thick slurry and spread over the surface, while the concrete is still green. It shall be pressed twice
by means of iron floats, once when the slurry is applied and second time when cement starts
setting.

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 The junction of floor with wall plaster, clods or skirting shall be rounded off uniformly where so
required upto 25 mm radius or as directed. The men engaged on finishing operations shall be
provided with raised wooden platform to sit on, so as floor finish is specified, the top surface of
floor finish shall be chequered with mesh or similar impression before the finish has set.

10.3.5. Curing
Each finished portion of floor, on completion, shall be kept wet with ponding or moist sand or
moist gunny bags as per specifications. At no time, cement concrete layer, plain or reinforced
shall be allowed to dry during curing time.

10.4. GRANOLITHIC (IPS) FLOORING

The requirement for filling, preparation of bed, sub-base and base course concrete shall be same
as in clauses above.

10.4.1 Finished Layers

Granolithic finish of the thickness as indicated in drawings or as specified shall consist of 2 layer of
M15 grade cement concrete. The first layer of concrete shall be laid with 10 mm to 6 mm grade
aggregate and well compacted. Within 15 minutes of laying this course the second layer with 6
mm down aggregate shall be laid. The cement and aggregates for the top layer shall be mixed dry.
Sufficient quantity of washed sand and water shall be mixed so as to make it plastic but not
flowing. This mixture shall be laid on the first layer so that the two layers firmly grip together. The
top layer shall be well tamped, spaded, trowelled and finished with neat cement slurry or with non-
skid finish as required. At the junction of adjoining panels a thin string shall be given.
The casting of the granolithic finish layer shall be done in rectangular or square panels not
exceeding 1.8 M on any side, using glass strips of height equal to the specified thickness of the
floor finish. Required slope in the floor shall be given in the base course concrete without reduction
in thickness.

10.4.2. Curing
Curing shall be done as per above mentioned clause.

10.5. ERRAZZO (MOSAIC) TILE

The tiles shall be approximately 22 mm thick of approved shade, color and chips. The tiles shall be
pressure made conforming to IS:1237 in all respects. The sizes of the tiles shall be as given in
table below:
Table 13 : Sizes of Terrazzo Tiles
Sr. Nominal Actual Nominal Actual Thickness
Not less than
Length (cm) Length (cm) Breadth (cm) Breadth (cm) (mm)

1 20 19.85 20 19.85 20
2 25 24.85 25 24.85 22
3 30 29.85 30 29.85 25

10.5.1. Tolerances
Tolerances on length and breadth shall be ± 1 mm. Tolerance on thickness shall be ± 5 mm. The
range of dimension in any one direction of tiles shall not exceed 1 mm on length and breadth and
3 mm on thickness.
10.5.2. Manufacture

The tiles shall be manufactured under hydraulic pressure of not less than 140 kg/cm2 and shall
be given the first grinding with machine before delivery to the site. The proportion of cement to
aggregate in the backing of the tiles shall not be leaner than 1:3 by weight. Similarly the
proportion of cement to marble chips aggregate in the wearing layer of the tiles and the proportion

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 of pigment to be used therein shall not exceed 10% by weight of cement used in the mix. The
finished thickness of the upper layer shall not be less than 5 mm for size of marble chips from the
smallest upto 6 mm, and also, not less than 5 mm for size of marble chips ranging from the
smallest upto 12 mm, and not less than 6 mm for sizes of marble chips varying from the smallest
upto 20 mm.

10.5.3. Laying

The sub-grade concrete or the R.C.C slab on which the tiles are to be laid shall be cleaned,
wetted and mopped. The bedding for the tiles shall be with lime mortar of either:
i. 1:1:2 (lime putty:surkhi :coarse sand)
ii. 1:3 (lime putty :surkhi)
iii. 1:3 (lime putty : coarse sand)
The bedding ingredients shall be thoroughly mixed by volume in the dry form. Care shall be
taken to ensure that there are no hard lumps present. Water shall then be added and the
ingredients thoroughly mixed. The average thickness of the bedding mortar shall be 30 mm.
Lime mortar bedding shall be spread, tamed and corrected to proper levels and allowed to be
hardened for a day before the tiles are set. Over this bedding, neat grey cement slurry of honey
like consistency shall be spread at the rate of 44 kg of cement per sq.m. over such an area as
would accommodate about twenty tiles. Tiles shall be washed clean and shall be fixed in this
grout one after another each tile being gently tapped with a wooden mallet till it is properly
bedded and in level with the adjoining tiles. The joints shall be kept as thin as possible not
exceeding 1.5 mm and in straight lines or to suit the required pattern.

The surface of the flooring during laying shall be the frequently checked with a straight edge
atleast 2 m long, so as to obtain a true surface with the specified slope. In situations where full
size tiles cannot be fixed, these shall be cut (sawn) to the required size and their edge rubbed
smooth to ensure a straight and true joint. Tiles, which are fixed in the floor adjoining the wall,
shall enter not less than 12 mm under the plaster, skirting or dado. The junction between the wall
plaster and tile work shall be finished neatly and without any waviness. After laying the tiles, the
surplus cement grout shall be cleaned off.

10.5.4. Curing, Polishing and Finishing

After laying the tiles the day after all the joints shall be cleaned of the grey cement grout with a
wire brush or trowed to a depth of 5 mm and all dust and loose mortar removed and cleaned.
Joints shall then be grouted with grey or white cement mixed with or without pigment to match the
shade of the topping of the wearing layer of the tiles. The same cement slurry shall be applied to
the entire surface of the tiles in a thin coat for protecting the surface from abrasive damage and
fill the pin holes that may exist on the surface.

The floor shall then be kept wet for a minimum period of 7 days. The surface shall thereafter be
grounded evenly with machine fitted with coarse grade grit blocks No.60. Water shall be used
profusely during grinding. The surface shall be washed thoroughly with water to remove all
grinding mud, cleaned and mopped. Then it shall be corrected with a thin coat of grey or white
cement, mixed with or without pigment to match the colour of the topping of the wearing surface
in order to fill any pin hole that appear. The surface shall be again cured, the second grinding
shall then be carried out with machine fitted with fine grade grit blocks No. 120.

The final grinding shall be carried out with the machine fitted with finest grade grit blocks No. 320,
the same day after the second grinding described above.

The small areas or where circumstances so required hand polishing may be permitted in lieu of
machine polishing after laying. For hand polishing coarse grade stone No. 60 Water shall be used

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 for 1st rubbing stone of medium grade No.80 for second rubbing and stone of fine grade No.120
for final rubbing and polishing.

After the final polish oxalic acid shall be dusted over the surface of 33 gm/sq.m sprinkled with
water and rubbed hard with a ‘namdah’ block (pad or woolen rags). The following day the floor
shall be wiped with a moist rag and dried with a soft cloth and finished clean.
If any tile is disturbed or damaged, it shall be refitted or replaced, properly jointed and polished.
The finished floor shall not sound hollow when tapped with a wooden mallet.

10.6. TERRAZZO (MOSAIC) IN-SITU FLOORING

The requirements for filling, preparation of bed, sub- base and base course concrete shall be
same as above.

Trained worker shall carry out terrazzo works.

10.6.1. Material
Best quality marble chips of uniform tint and color, 6 mm maximum and 3 mm minimum size, as
approved by Engineer-in-Charge shall be used. They shall be machine crushed, free from foreign
matter and of approved quality.

10.6.2. Preparation of Surface and Laying Over Base Course Concrete

Total thickness of cast-in-situ Terrazzo shall be atleast 40 mm unless otherwise indicated. This
shall be in two layers bottom layer of M:15 concrete bedding with 10 mm down aggregate of
specified thickness and the top layer of 10 mm thickness, consisting of a mix of cement and
marble chips in the proportion of 1:1/2 marble powder : 2 marble chips). The bottom layer shall be
laid in bays not exceeding 1.2 m on either side and leveled 10 mm below the finished floor level.

The cement and marble chips including powder shall be mixed dry. Water shall be added
gradually after through mixing until the mix become plastic but flowing.

Within one hour of laying of the bottom layer of cement concrete the upper layer of marble chips
and cement paste shall be laid over a coat of cement slurry and the surface tamped lightly and
finished to the required level and slope.

While the bottom layer is still plastic glass dividing strips 35 mm wide x 16 SWG thick shall be fixed
on the base course concrete with proper anchoring features to allow top edge to be flushed with
the finished floor. The strip shall be laid, forming panels not exceeding 1.2 m x 1.2 m size.

10.6.3. Curing, Polishing and Finishing

The floor shall then be kept wet for a minimum period of six days. The surface shall thereafter be
ground evenly to the satisfaction of the Engineer-in-Charge with machine grinders in three phase
with grade stones from coarse to fine grade. The surface shall receive wash of neat cement
mixed with or without pigment and cured before every grinding operation.

After final grinding, surface shall be cleaned and oxalic acid shall be dusted over the surface @
35 grams. per sq.m. sprinkled.

10.7. GLAZED TILE FLOORING

10.7.1. White Glazed Tiles

The glazed tiles shall conform to IS:777-1970. They shall be flat and true to shape and free from
cracks, crazing spots, chipped edges and corners. The glazing shall be of uniform shade.

10.7.2. Size and Tolerance

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 The tiles shall be of nominal sizes such as 150 x 150 mm and 100 x 100 mm or as specified. The
thickness of the tiles shall be 5 mm, or 6 mm as specified. The tolerance on facial dimension
value shall be ± 1.0 mm and ± 0.5 mm on thickness.

The top surface of the tiles shall be glazed. The glaze shall be either glossy or matt as specified.
The underside of the tiles shall be completely free form glaze in order that the tiles may adhere
properly to the base. The edge of the tiles shall be preferably free form glaze, however any glaze
if unavoidable, shall be permissible on any one edge of the tile.

10.7.3. Coloured Tiles

The sizes and specifications shall be the same as for the white glazed tiles described above. The
only difference shall be in the colour.

10.7.4. Decorative Tiles

The type and size of the decorative tiles shall be as follows:

a. Decorated white background tiles shall be of 152 x 152 x 6 mm and 108 x 108 x 6 mm sizes.
b. Decorated and having coloured background shall be of 152 x 152 x 6 mm and 108 x 108 x 6
mm sizes.
c. Fantasy glazed tiles (108 x 108 x 6 mm) other specifications will be the same as that of white
glazed tiles.

10.7.5. Preparation of Surface and Laying

Sub grade concrete or the R.C.C slab on which the tiles are to be laid shall be cleaned, wetted
and mopped. The bedding for the tile shall be with 1:3 (cement: coarse sand) mortar or as
specified, having average 10 mm thickness. The bedding thickness under the tiles shall not be
less than 5 mm.

The mortar shall be spread, tamped and corrected to proper levels and allowed to harden
sufficiently to offer a fairly rigid cushion for the tiles to be set and to enable the mason to place
wooden plank across and square on it. Over this mortar bedding neat grey cement slurry of
honey - like consistency shall be spread at the rate of 3.3 kg of cement per sq. m over such an
area as would accommodate about twenty tiles. Tiles shall be soaked in water washed clean and
shall be fixed in this grout one after another each tile gently being tapped with a wooden mallet till
it is properly bedded and in level with the adjoining tiles. The joints in between the tiles shall be
kept as thin as possible and in straight lines or to suit the required pattern.

The surface or the flooring during laying shall be frequently checked with a straight edge about 2
m long, for obtaining a true surface with the specified slope. Where full size tiles cannot be fixed
these shall be cut (sawn) to the required size and their edge rubbed smooth to ensure straight
and true joints. The tiles, which are fixed in the floor adjoining the wall, shall enter not less than
10 mm under the plaster, skirting or dado. After laying the tiles the surplus cement grout shall be
cleaned off.

10.7.6. Pointing and Finishing

The joints shall be cleaned off the grey cement grout with wire brush or trowel to a depth of 2 mm
to 3 mm and all dust and loose mortar removed. Joints shall then be flush pointed with white
cement added with pigment if required to match the colour of the tiles. The floor shall then be kept
wet for 7 days. After curing, the surface shall be washed and cleaned. The finish floor shall not
sound hollow when tapped with a wooden mallet.

10.8. KOTA STONE FLOORING

Kota Stone Slabs- shall be of selected quality hard, sound, dense and homogeneous in texture,
free from cracks, decay, weathering and flaws. They shall be hand or machine cut to the requisite

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 thickness and shall be of the colour indicated in the drawings or as directed.

The top (exposed) face of the slabs shall be polished before being brought to site, unless
otherwise specified. The slabs shall conform to the size required and samples shall be got
approved before starting the work. 20, 30 or 40 mm or specified thickness slabs shall be used.

10.8.1. Tolerances
Of ±2 mm shall be allowed for the thickness. In respect of length and breadth of slabs, a
tolerance of ± 5 mm shall be allowed.

10.8.2. Dressing
Each slab shall be cut to the required size and shape and fine chisel dressed on the sides to the
full depth, so that a straight edge laid along the side of the stone shall be in full contact with it.
The sides (edges) shall be table rubbed with coarse sand or machine rubbed before paving. All
angles and edges of the tiles shall be true, square and free from chipping and the surface shall be
true and plane.

10.8.3. Surface Preparation and Laying

Sub-grade concrete on the R.C.C slab on which the slabs are to be laid shall be cleaned, wetted
and mopped. The bedding for the slabs shall be with cement mortar 1:4 or with lime mortar 1:1:1
(lime putty : surkhi : coarse sand) as given in the description of item. The average thickness of
the bedding mortar under the slab shall be 20 mm and the thickness at any place under the slab
not be less than 12 mm.

Mortar of the specified mix shall be spread under the area of each slab, roughly to the average
thickness as specified. The slab shall be washed clean before laying. It shall be laid on top,
pressed, tapped with wooden mallet and brought to level with the adjoining slabs. It shall be lifted
and laid aside. The top surface of the mortar shall then be corrected by adding fresh mortar at
hallows. The mortar is allowed to harden a bit and cement slurry of honey -like consistency shall
be spread over the same at the rate of 4.4 kg of cement per sq.m. The edge of the slab already
paved shall be buttered with grey or white cement with or without admixture of pigment to match
the shade of the kota stone slabs as given or specified. The slab to be paved shall then be
lowered gently back in position and tapped with wooden mallet till it is properly bedded in level
with and close to the adjoining slabs with as fine joint as possible. All the subsequent slabs shall
be laid in the same manner. After each slab has been laid, surplus cement on the surface shall be
cleaned off. The flooring shall be cured for at least 7 days.

Slabs, which are fixed in the floor adjoining the wall, shall enter atleast 12 mm under the plaster
skirting or dado. The junction between wall plaster and floor shall be finished neatly and without
any wavings.

10.8.4. Polishing and Finishing

Shall be done as described in the above article of ‘Terrazzo Tile Flooring’ except that:
a. First polishing with coarse grade carborundun stone shall not be done.
b. Cement slurry with or without pigment shall not be applied on the surface before polishing.

10.9. MOSAIC FINISHED DADO OR SKIRTING

For skirting and dado the brickwork or concrete surface shall be raked and shall be well watered
for four hours. A dubbing coat of cement mortar 1:3 (1 cement: 3 sand) of sufficient thickness
shall be applied so as to bring the surface in line with the plastered surface. The surface shall be
carried by lines with trowel so as to receive mosaic tiles or the top layer or cement and marble
chips in proportion of 1:1/2:2 (1 cement: ½ marble powder: 2 marble chips) of 7 mm thickness
with 3-5 mm size for flooring including dividing strips (20 mm x 15 SWG) @ 600 mm c/c.

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10.10. HARDONITE FLOORING
These specifications cover the guidelines for providing hardonite topping (industrial flooring) for
floor subjected to heavy wear and tear viz., workshop and stores, engine room, and Generator
room etc.

The item includes providing hardonite topping as specified to the thickness and satisfaction of the
Engineer-in-Charge, supply of all material, labour, tools and plant required for completing the
work in best workmanlike manner.

10.10.1. Workmanship
The person executing the topping shall be an experienced mason familiar with flooring works of
similar nature. Flooring shall be laid uniformly, the tolerance for variation of level being + 3 mm.
Hardonite material shall be mixed with cement concrete thoroughly to give a uniform mix.

10.10.2. Preparation of Surface

Hardonite shall be laid over a wet concrete surface screened to receive the topping. The base
shall be leveled to within + 12 mm.

10.10.2.1. Preparation of Topping

Hardonite shall consist of a mixture of cement concrete in proportion of 1:2:4 and well graded iron
fillings added in a proportion of 1.50 kg/bag of cement.

10.10.2.2. Application
Hardonite shall be placed uniformly in a layer of specified thickness and finished with a steel
troned. Care shall be taken to place hardonite in a separate layer while the base concrete is steel
wet.

10.10.2.3. Trowelling
Surface of floor shall be finished with steel trowel only and trowelled just sufficient so as to give a
finished surface. The surface shall be left for some time till moisture disappears from it. Trowelling
shall be done three times at intervals so as to produce a uniform hard surface in no case cement
should come up to the surface.

10.10.2.4. Curing
The entire surface shall be kept uniformly wet for seven days.

10.10.2.5. Opening for use

The surface shall be allowed to be used only after curing period is over.

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 11.DISTEMPERING AND PAINTING

11.1. GENERAL
Engineer’s approval shall be obtained before commencing the painting work. All paints and
preserves shall be of approved make and colour and their application shall conform to the
manufacture’s instructions. Where more than one undercoat is specified it shall be applied in
coats of distinctive tints. Workmanship shall conform to the requirement of IS:2395 Unless the
manufacturer’s instructions state otherwise48 hours drying time shall elapse between successive
applications of any primer and 24 hours between applications of all subsequent coats. The
surface of bituminous paints shall be left at least 3 days before further handling.
No paints in any coats shall be applied until the engineer is satisfied that the surface is clean and
dry. And that any previous coat is satisfactory and has hardened adequately. When a surface has
been approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper between coats. No paint shall be applied to a
surface, which is damp, dirty or otherwise inadequately prepared.

11.2. CONCRETE, BRICKWORK AND PLASTER

Where specified to be painted, concrete and plaster shall be rubbed smooth and any cracks,
blister holes and other imperfections cut out, filled and made good. The surface shall be dried
to the satisfaction of the engineer before painting is commenced and drying time if at least 28
days shall be allowed after laying brickwork and plaster or stripping formwork from concrete.
The surface shall be brushed to remove any efflorescence and then painted with the
following:
1. for interior brick work and concrete, apply two coats of oil paint up to 1 meter height and for
remaining part two coats of plastic emulsion paint over a coat of primer.
2. For exterior brickwork and concrete, apply two coats of cement based paint over a coat of
primer with a water repellant coat of siliconate solution of approved make.
Where painting with plastic emulsion is specified, all uneven surface shall be made up by use
of putty of appropriate quality, after the surface has been thoroughly cleaned of all dust and
dirt and sand papered.

11.3. IRONWORK AND UNGALVANISED STEELWORK

Structural steelwork shall be shot blasted to a "white metal" finish, and grease and oil removed
prior to painting. Priming shall immediately follow blast cleaning and no cleaned surface shall be
left unprimed for more than four hours. Only primers that chemically inhibit corrosion shall be
used. Where the iron or steelwork is not in contact with raw or treated water, the primer shall be
red lead complying with IS: 57. Where there is a possibility that the steel or ironwork may come in
contact with water, the priming treatment shall be non toxic, zinc chromate or equivalent. Where it
is anticipated that further welding will be required. an approved welding primer shall be applied to
the areas to be welded and re primed with the main primer when welding has been completed.
Primer coats shall not be less than 0.05 mm each.

After erection, all damaged areas shall be made good, and re primed where the original coat has
spread under the primer, the affected surface shall be cleaned down to bare metal to the
satisfaction of the Engineer and then re primed.

Repainting shall be carried out as soon as possible after erection. If` it is to he exposed to
weather or condensation, it shall receive one further coal of primer.

Metalwork in intermittent or permanent contact with raw or treated water shall have two finishing
coats of an approved coal tar pitch epoxy paint such as "Epilux 5" by Berger Paints, or equivalent.
The total coating shall be minimum of 0.125 mm thick.

After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting down to

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 a smooth uniform surface. When the surface becomes dry, be undercoat of synthetic enamel
paint conforming-to IS:2932 of optimum thickness shall be applied by brushing with minimum of
brush marks. The coat shall be allowed to hard dry. The under coat shall then be wet rubbed
cutting down to a smooth finish, taking adequate care to ensure that at no place the undercoat is
completely removed. The surface shall then be allowed to dry.

The first finishing coat of paint shall be applied by brushing and allowed to hard dry. The gloss
from the entire surface shall then be gently removed and the surface dusted off. The second
finishing coat shall then be applied by brushing.

At least 24 hours shall elapse between the application of successive coats. Each coat shall very
slightly in shade and this shall be got approved by the Engineer

11.4. GALVANISED STEELWORK

Newly galvanised steelwork shall be primed with an etch primer such as calcium
plumbate. Steelwork that has been galvanised for a long period so that the surface has oxidised
adequately to allow adhesion of under-coats, need not have an initial coat of each primer.

After priming, galvanised steelwork in constant or intermittent contact with raw or treated
water shall be given two coats of an approved coat of tar pitch epoxy paint such as "Epilux 5" by
Berger Paints, or equivalent. The total coating shall have a minimum thickness of 0.1 25 mm.

Protective coats for galvanised steelwork not in contact with water shall be:
1. One coat of micaceous iron oxide paint for interior galvanised steel work.
2. Two coats Of micaceous iron oxide paint for external galvanized steelwork. Galvanised
steelwork not in contact with water shall be finished with at least one coat of gloss paint on top
of an approved undercoat.

11.5 BITUMINOUS SURFACES

Metalwork items that have been given a shop treatment of bituminous paint shall be painted with
two coats of` an approved anti-bleed paint before applying a coat of decorative finishing paint.

11.6 ALUMINIUM SURFACES

Aluminum surfaces shall be worked clean, dried and thoroughly degreased before painting, by an
appropriate solvent (such as one consisting of equal parts of white spirit and light solvent naptha).
Flame cleaning shall not be permitted. The clean degreased surface shall be treated to ensure
paint adhesion either by mechanical roughening, chemical adhesion, or etch primers or wash
primers applied in strict conformity with the manufacturer's instructions or by other treatment
approved by the Engineer. The pretreated surface shall receive a priming coat with an inhibiting
pigment containing not less than 20% by weight of fine chromate or other approved chromate in a
suitable water-resisting vehicle.

The priming coat shall not contain any copper or mercury compounds and it shall also be free
from graphite and carbonaceous materials and shall not contain any lead. Priming coat shall
consist of a tung-oil phenolicresin which is pigmented with equal parts of zinc tetoroxy chromate
and red iron oxide.

Aluminum surfaces in contact with concrete, or resting on pads on concrete, shall be painted with
two coats bituminous paint, and the concrete surfaces shall also receive two coats bituminous
paint.

11.7 WOODWORK
Woodwork for painting shall be carefully rubbed down, treated with preservatives and knotted,
stopped and primed in the shop. Care shall be taken to ensure that priming is thoroughly brushed
into every part of the surface and in particular at end grains, joint and notches where two coats

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 are to be applied. Primers for wood shall he of a standard equivalent to, or better than
"Aluminum Wood Primer Sealer A519-3697" by I.C.I. Paints.

After the woodwork has been fitted and all defects in the surfaces have been made good and
re primed, one coat of approved undercoat shall be applied to internal surfaces and two coats
to external surfaces. An undercoat of quality equal to or better than "Delux Undercoat A522 line"
shall be used.

'Timber work shall be decoratively finished with one coat of finishing paint of standard equal to, or
better than "Delux Gloss Finish A365 line".

11.8. WATERPROOF CEMENT PAINT

11.8.1. Surface Preparation

The wall should be washed thoroughly with clean soft water and freed of all loose particles, dust,
dirt, lichen, moss, efflorescence and Lime wash by Scrubbing with a wire brush. Inequality and
holes shall be filled up with cement paste, which should be allowed to set. To get even uniform
mat finish it is necessary to keep the surface damp throughout the operation. In hot dry weather
the wall should be frequently sprinkled with water to keep it moist.

11.8.2. Mixing the paint

Loosen the contents by either rolling the drum or shaking the container before opening it. Take
one measure of water by volume in a clean pot and add two volumes of approved quality
waterproof cement paint conforming to IS: 5410. Stir well to make a paste of high consistency
then add one more measure of water constantly stirring the mixture. The final composition of
water and paint is now 1:1 by volume. Keep stirring the mixture all the time and use it up within an
hour. Do not use the mix if it is left over 'for more than two hours.

11.8.3. Method of Application

Wet the surface by any convenient method. A small surface can be wetted by brush. When
applying paint surface should be damp and not wet. While applying the first coat brush hard into
the surface to cover pores and cavities to ensure better bond. Twelve hours after applying the
first coat cure the surface by sprinkling the water. Before applying the second coat damp the
surface and after the application of second coat cure it as directed above. In hot climate repeat
curing at least twice at the interval of six hours for optimum best results.

11.8.4. Curing

After sprinkling fine spray of water should cure each application paint normally after twelve hours
when paint film is hardened satisfactorily. In summer when weather is hot, curing may be done
little earlier. Water marks may be left over the surface if a stream of water is allowed to flow
before the paint film is hardened.
11.9 SILICON PAINT
11.9.1. Preparation
A solution for application shall be prepared from Syltrit 1772 or equivalent. The Manufacturer's
instructions shall be followed. This solution shall be prepared to a concentration of about 3 %
solids by mixing 1 kg. of water dilatable solution of sodium methyl siliconate with 9 kg. of water.
Concentration higher than 3% solids are not recommended as they may cause a white precipitate
of sodium carbonate formation.

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11.9.2. Application

A flooding technique should be used in applying to obtain the best penetration. When spraying,
the solution should not be atomized or misted, but flowed on in a solid stream, with the spray gun
held, at a distance just enough to eliminate foaming on the masonry surface. If foaming is allowed
then certain visible marks might appear after application. The run down of 150 to 300 mm should
be maintained with generous overlapping of passes. Dipping and brushing methods are also
suitable. After application of the solution, the treated surface should be allowed to dry at least 24
hours to develop maximum water repellency. This interval may be shortened somewhat by force
drying at temperatures to 30 degree C. Though this removes the water quickly, time must still be
allowed for the curing. Reaction between the solution and the surface being treated. Until the
reaction is complete the applied film still remains water soluble and any rain failing during this
time can wash it out. So application should be done in dry weather or at least in absence of rain
and fog.

11.9.3. Spraying Equipment

Spraying equipment shall be hand operated stirrup pump with stainless steel nozzle fitted with
PVC or polyethylene delivery pipe. Components of the spraying, equipment that are in contact
with the treating solution should be of black iron, mild steel, stainless steel, Teflon, PVC or
polyethylene. They should not be of aluminum or galvanised steel. .

11.9.4. Safety

The solution should always be applied in a liquid stream, not by misting or fogging. If misting
occurs, avoid inhalation. Contact with the eyes or skin should be treated immediately by flooding
the area with large quantities of water for at least 15 minutes.

11.10. RELEVANT IS CODES

IS:63 : Whiting for paints

IS:133 : Enamel, interior, undercoating & finishing colour as required
IS:2395 : C.P. for painting concrete, masonry & plaster surfaces
IS:5410 : Cement paint, colour as required
IS:5411 : Plastic emulsion paint for interior use

11.11. DISTEMPERING

11.11.1. Type

Distempering shall be of the oil or water bound type as specified.

11.11.2. Material

Dry distemper or oil bound washable distemper of approved brand and manufacture for water
bound and oil bound respectively conforming to IS:426 shall be used. The proportions of the mix
shall be as per the approved manufacturer’s instructions.

The dry distemper shall be stirred slowly in clean warm water using 8.6 liters of water per kg. of
distemper or as specified by the approved makers. The mixture shall be well stirred before and
during use to maintain an even consistency.

Thinner as stipulated by approved manufacturer shall be used in case of distemper for oil bound
type.

Dry distemper shall not be mixed in larger quantity than is actually required for one day work.

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11.11.3. Preparation of Surface and Priming Coat

The surface shall be thoroughly brushed free from mortar dropping and other foreign matter and
sand papered smooth.

A priming coat of whiting shall be applied over the prepared surface in case of water bound
distempering and distemper primer or cement primer shall be applied in the case of oil bound
distemper. The white washing coat shall be used as priming coat for distemper.

11.11.4. Application

After the primer coat is dried for atleast four hours, the entire surface shall be coated uniformly
with proper distemper brushed in horizontal strokes, immediately followed by vertical ones which
together shall constitute one coat.

Subsequent coats shall be applied in the same way and only after the previous coat has dried.
Enough distemper shall be mixed to finish one room at a time. The finished surface shall be even
and uniform and shall no brush marks. After each days work, the brushes shall be washed in hot
water and hung down to dry. Old brushes, which are dirty or caked with distemper, shall not be
used.
11.12. DECORATIVE FINISH CEMENT PAINT

11.12.1. Surface Preparation

Plastered surface shall be thoroughly cleaned of dust, dirt, grease, oil marks, etc. before the coat
is applied. All the holes and depressions should be filled with gypsum prior to application of the
paint. The surface shall be wet with clean water before paint is applied. Application of primer shall
be as per specifications recommended by approved manufacturer and as directed by the
Engineer-in-Charge.

11.12.2. Preparation of Mix and Application

Any approved cement paint shall be mixed in such quantities as can be used up within an hour of
mixing. The solution shall be applied on the prepared surface with good quality brushes and no
brush mark shall be visible on the finish work.
11.13. PAINTING

11.13.1. Painting General

Paints, oils, varnishes etc. of approved brand and manufacture conforming to relevant Indian
Standard Codes shall be used. Ready mixed paints as received from approved manufacturer
without any admixture shall be used. The Contractor shall obtain permission for the make and
color of the paint he proposes to use and if required, polish for wood work shall be tested as per
IS:5807 (parts I and II).

Whenever thinning is necessary, the brand of thinner recommended by approved manufacturer

or as instructed by Engineer-in-Charge shall be used. Paints, oil, varnishes, thinner, etc. shall be
brought to the site in the original containers in sealed condition and shall be kept in the joint
custody of Contractor and Engineer-in-Charge.

11.13.2. Commencing the Work

Painting except priming coat shall generally be taken in hand after all other building work is
practically finished. Approval of Engineer-in-Charge shall be sought before commencing the work.

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11.13.3. Workmanship

All the work shall be carried out wherever applicable as per IS:1477 (Parts I & II) and IS:2338
(Part I)

11.13.4. Preparation of Surface

The surface shall be thoroughly cleaned. All dirt, dust, scales and grease shall be removed before
painting is started. The surface shall be perfectly dry to permit good absorption. The prepared
surface shall receive approval from Engineer-in-Charge for commencing the painting work. For
wood surfaces, a priming coat without coloring material should be applied after which all the
holes, cracks etc shall be stopped with putty and all knots properly killed with quick lime.

Specially for wood surface, knots if visible shall be covered with red lead conforming to BIS:103.
Holes and identification on the surface shall be filled with wood putty and rubbed smooth. Surface
should be thoroughly dry.

11.13.5. Application

Paint shall be thoroughly stirred in the container when pouring into smaller containers for use.
It shall be continuously stirred while applying on the surface. The painting shall be applied evenly
and smoothly in the direction of grains of wood and perpendicular to it. Each coat shall be allowed
to dry before the next coat is applied.

Specified number of coats shall be applied and atleast 24 hours shall elapse between application
of the first coat and the subsequent second coat. No painting shall be carried out on exterior work
in wet weather condition or on surface which are not entirely dry.

Each coat shall be lightly rubbed down with sandpaper or fine pumice stone and cleaned of dust
before the next coat is laid. No left over paint shall be put back into stock tins.

The finished surface shall be free from hair or brush marks, strokes, clogging of paint puddles in
the corners of panels, angles of moulding, etc.

11.14. PAINTING WITH SYNTHETIC ENAMEL/ENAMEL PAINT

11.14.1. Material

Synthetic enamel/enamel paint of approved brand and manufacture and of required shade shall
be used for the topcoat only. The paint for under coat shall be of shade to match the topcoat, as
recommended by approved manufacturer shall be used.

11.14.2. Preparation of Surface

The surface shall be thoroughly cleaned. All dirt, scales and grease shall be removed before
painting started. The surface shall be perfectly dry to permit good absorption. The prepared
surface shall receive approval from Engineer-in-Charge for commencing the painting work.

Specially for wood surfaces, knots if visible shall be covered with red lead conforming to IS:103.
Holes and indentation on the surface shall be filled with good putty and rubbed smooth. Surface
should be thoroughly dry.

11.14.3. Application

11.14.3.1. Under Coat

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 One coat of the specified paint of shade matching with the shade of the top coat shall beapplied
and allowed to dry overnight. It shall be rubbed next day with the finest grade of wet abrasive
paper to ensure smooth and even surface, free from brush marks and all loose particles dusted
off.

11.14.3.2. Top Coat

Top coats of specified paint in the desired shade shall be applied after the under coat is
thoroughly dried. Additional finishing coat shall be applied if found necessary to ensure a properly
uniform glossy surface.

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 12.EXPANSION JOINTS AND CONSTRUCTION JOINTS

12.1 GENERAL
The item of providing expansion joints and construction joints in concrete includes all the material,
labour, tools and plants necessary for completing the item in best workmanlike manner.

12.2 MATERIAL
The Material to be used in the joints shall be ribbed PVC water stop of specified width approved
by the Engineer, bitumen impregnated fibre board as filler conforming to IS:10566 and approved
sealant material (In case of movement joint only). In addition, IS:12220-1987 and 1838 shall also
be adhered.

12.3 JOINTS IN FLOOR

Joints in floor shall be provided as specified on drawings. In case of PVC water stops to be
provided horizontal position flat-footed PVC water stops shall be used. The water stops shall be
provided in such a way that half the portion of water stop (width wise) is embedded in the
concrete and half remains exposed for next concrete. Steel reinforcement shall not be
discontinued where construction joints in floor are provided.

12.4. JOINTS IN WALLS

12.4.1. Expansion Joint

Expansion joints shall be provided in the roof slab and wall and divide wall is of R.C.C. The joints
shall be so located that in no case the slab shall be more than 45 metres long in one stretch. The
general layout of roof slab showing the position of expansion joint is given in the accompanying
drawing. The two adjoining portions of the roof slab at the expansion joints shall be separated by
a gap of about 25 mm width which shall be bridged by means of 230 mm wide water stop. These
water stops shall be fixed in such a manner that it is equally embeded in each portion of the slab
on either side of the joint and shall be located at mid section of the slab. The joint shall be
continuous in length and shall be properly joined together or welded at all junction along its
length. The gap between the adjacent slab below the water stops shall be filled with filler material
like thermocol or such compound which may be approved by the Engineer.

This may be achieved by placing a strip of filler material in position adjacent to the face of
concreted slab panel while concreting the adjoining panel. The space above, water stop shall be
filled with sealant material overlaid by filler material like thermocol and polysulphide sealant as
shown in the drawing.

The expansion joints in the end wall and divide wall shall be provided in such a manner that the
joint shall divide the structure longitudinally and transversely as shown in the drawing. The two
adjacent parts of the wall shall be separated by a gap of about 25 mm width which shall be
bridged by 300 mm wide PVC water stop. However, no gap shall be provided in the footing of the
wall. The gap on water face shall be treated with polysulphide sealant material as shown in the
drawing. The water stops shall be either PVC or either equivalent approved by the Engineer as
per specifications given hereinafter.

12.4.2. Construction Joint

The construction joints shall be generally provided at the end of the concreting or colcreting
operation of an element or a member of a structure, or at boundary of the panels or segments or
at pre-determined locations. The construction joints in the R.C.C. slab shall be characterised by
the continuance of the reinforcing steel, being a structural R.C.C. member. The concreting of a

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 slab at the joint shall be done by laying the concrete against the vertical stopping off boards, the
adjoining panels being cast butting against each other.
Const6ruction joints in the side wall and the divide wall of reservoir shall be of two types (i)
horizontal construction joints and (ii) vertical construction joints.

The horizontal construction joints shall be serrated type where stones from the lower lift of the
wall shall be projecting out sufficiently and will be embedding into the over laying lift of the wall
masonry giving a well bonded, and consequently, a water tight joint. The vertical construction
joints in the wall shall be of tongue and groove type. The groove of these joints shall be 300 mm x
300 mm and it shall be provided 300 mm away from the water face of the wall. These joints shall
be provided with PVC water stop at a depth of 200 mm from water face which shall be primarily
responsible for the water from water face which shall be primarily responsible for the water
tightness of the joints. These joints shall have a plain finish for a depth of 300 mm from water face
by virtue of its casting against vertical face of the centering of vertical face of the previously cast
panels cast butting against each other while the remaining depth beyond300 mm shall have
masonry facing which will present a rough surface and thus provide a good bond between the
consecutive panels.

In the case of divide wall the water stop shall be located at the centre of the key which shall be
located at the centre of divide wall. The key shall be of the same dimensions as that in the end
walls.

The construction joints in the bottom layer of the floor which shall be case in colcrete shall be cast
against vertical stopping off boards. On the water face the vertical joints shall have a groove
provided with bitumen of 12 mm x 20 mm size which shall be filled with polysulphide sealant
material.

No such special treatment need be done for the joints provided in the roof slab, bottom layer of
the floor and the horizontal joints in the wall. The joints in roof slab and bottom layer of the floor
shall however, be staggered with those in the overlaying layers such as brick bat coba, I.P.S. and
top R.C.C. layer of the floor to minimise the chances of leakage by increasing its path, if any.

12.4.3. Complete Construction Joints

These joints are provided in the top layer of the floor of the reservoir with a view to localise
shrinkage cracks at these joints. These joints are characterised by complete discontinuity of steel
without any initial gap as in the case of expansion joints. The joints between the adjacent panels
of the floor shall be provided with a groove at top of dimension 12 mm x 20 mm and it shall be
filled with polysulphide sealant and they shall be provided with water stops as specified earlier.

The joint between top layer of the floor and the walls or between the top layer of the floor and the
column footing, shall also be provided with a groove of 12 mm x 20 mm which shall be filled with
sealant material as per specifications given below:

Joint Fillers : Joint fillers shall be of durable, compressible and non-extruding material. It shall be
non-staining, non-absorbent and compatible with sealant material used.

Sealant Material : The joint sealing compounds should be capable of properly ensuring water
tightness in vertical and horizontal and inclined joints in water retaining and other structures
having severe service conditions in respect of anticipated movement or exposure to weather.
Typical uses include expansion joints in the walls of water tanks, and in roof and deck slabs
exposed to the weather.

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The compound should be flexible, durable and weather proof and should have sufficient elasticity
to allow joint movements of the concrete components wherever necessary.

The sealant shall be polysulphide rubber sealing compound conforming to BS 4254 of 1967 or
ASA-A 116-1-1960 or any other equivalent specifications. It shall be capable of cold pouf
application for horizontal joints and cold application of vertical and inclined joints. The sealing
compounds shall be suitable for use in the tropics where it will be subjected to high ambient
temperatures, humidity and very strong sunlight. It shall not degrade under these conditions and
shall be suitable for use with raw and treated water including water dosed with chlorine. The
sealant shall be odour and taint free from lead. It shall be available in choice of colours and shall
give a though, permanent seal, be waterproof, non-staining and remain resilient. Sealing
compounds for vertical and horizontal joints shall be used complete with the appropriate quantity
of primer as per manufacturer’s instruction for use. The primers should ensure good adhesion to
the concrete and should be specially developed for respective sealing compounds. The sealants
shall be applied with pressure guns or without guns as specified by the manufacturers. Sealing
compound shall be fully cured before water is permitted to come in contact.

The sealant material should be formulated as to have a storage period of one year at a
temperature of 40oC.

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 13.EPOXY COATING, BITUMINOUS, POLYMER PAINTING

13.1. EPOXY COATING

13.1.1. General

Epoxy coating is to be applied to the internal surface of the unit wherever specified. The thickness
of epoxy film shall be 300 microns.
13.1.2. Materials

A solvent free epoxy coating like “Araldite GY 255” manufactured by Hindustan CIBA Geigy
Limited, Bombay or equivalent product of FOSROC is to be used for forming the film. Incase of
use of an equivalent it should be got approved by the Employer placing supply orders. Materials
used and process of application to the concrete of other surfaces should be strictly according to
the instructions of the suppliers of the epoxy. Araldite GY 255 one part by weight is to be mixed
with 1 part by weight of Hardener H Y 45. The viscosity should be such that it is convenient for
brush application.

13.1.3. Subsurface Preparation

The concrete surface should be cleaned thoroughly by sand blasting. The mild steel parts also
are to be cleaned to be free of grease and thoroughly sand blasted. The coverage should not be
more than 6 sq.m. for concrete and 5 sq.m. for mild steel per kg of epoxy respectively.

The moisture content of concrete before application of epoxy coating shall be less than 4%. This
has to be checked properly through a small sample. To achieve this epoxy coating shall be done
in hot season.

13.1.4. Curing

The curing should be done for 7 days at room temperature. if the temperature is less than 15°c
the space should be warmed up by incandescent lamps, heaters, blowers or infrared lamp. The
instructions of the supplier manufacturer of the product both as for use of materials and
application take priority over the above instructions and they should be followed very rightly.

13.2. BITUMINOUS PAINTING

Two coats of bituminous paint of 80/100 grade, with 1.65 kg/m2 spread will be provided on
internal face of sludge sump.

13.2.1. Material

The material shall be of best quality un-pigmented bituminous base pain of such a composition as
to satisfy the requirements of IS-9862.with total volatile matter contained in the paint shall not
exceed 55% by weight.

At least 95% of the solid materials shall be soluble, in carbon di-sulphide or in benzene, and the
closed flash point as determined in Abel's apparatus shall not be less than (86 F)30 C. The paint
shall remain liquid and retain its consistency at the ordinary atmospheric temperature when
packed in suitable containers. The drying time shall not he less than 2 hours and not more than 8
hours, and after drying, paint shall not shoe any surface cracks, tendencies to powder or
discoloration due to weathering action or expansion and contraction. It shall also be able to resist
the action of acids and alkalis. It shall not soften under the action of mineral turpentine. The film
resulting from brushing the material on a strip of tinned iron, 30 standard wire gauge after being
allowed to dry at room temperature not below (65 F) 18.3 C for 48 hours shall not, when bent
double over a (quarter inch)6 mm dia rod, show any signs of flaking or cracking. The time
occupied for the actual bending shall not exceed one second. When the paint has dried hard, a

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 4H pencil should not be capable of scratching it. The weight of the paint shall be firm 0.83 to 1.25
kg per liter, the component of the paint shall he such as not to react with water chlorinated or
otherwise and develop poisonous or harmful elements thereto. The paint shall be of' Indian
manufacture of approved make and quality

13.2.2. Application

All corners and junctions shall be properly rounded off to present a uniform and smooth finish.
After complete curing of the plaster, it will be allowed to day up. After drying the moisture content
shall be brought to a value less than 4% by using a below-lamp. The surface should be well
cleaned with smooth brush to make it dust free. The coating shall be allowed to dry and kept in
dry condition till final setting takes place.

13.3. POLYMER PAINTING

Polymer paint shall be elastomeric (450% elongation), thermoplastic, fire retardant, coating skin
tensile strength 18 to 21 kg/cm2, antifungal, antibacterial anticorrosive graft polymer paint of
approved make Meta Chem or equivalent. Fire retardant coating shall confirm BS 3119
specifications

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 14.DOOR, WINDOWS, GRILLS, SHUTTERS, ETC.

14.1. RELEVANT IS CODES

IS:1003 (I) : Timber paneled and glazed door & ventilator shutters
IS:1003 (II) : Timber paneled and glazed window & ventilator shutters
IS:1038 : Steel doors, windows & ventilators
IS:1081 : Fixing & glazing of metal doors, windows & ventilators
IS:1361 : Steel windows for industrial buildings
IS:2202 : Wooden flush door shutter (solid core type)
IS:2202 (I) : Plywood face panels
IS:2202 (II) : Particle board and hardboard face panel
IS:4020 : Methods of test for wooden flush doors
IS:6248 : Metal rolling shutters & rolling grills
IS:7452 : Hot rolled steel sections for doors, windows & ventilators
IS:10451 : Steel sliding shutters
IS:10521 : Collapsible gates

14.2. GENERAL
The items under this clause cover doors, windows, grills, rolling shutters, collapsible gates
etc. normally required to be provide in a building used whether for residential, office,
laboratory or industrial purpose.

Doors and windows Shutter shall be of Teakwood as specified in the bill of

quantities/drawings or as directed by the Engineer. The sizes of the above items and
locations of the same shall be as shown in the drawings.

The frames and shutters shall be of either steel or wood of thickness of members as shown
on the drawings. The material used shall be of good quality seasoned timber of specified
wood or rolled steel sections as the case may be.

They shall be provided with all necessary fittings like hold fasts, hinges, locking arrangements
stoppers, eyes and hooks, tower bolts, handles, fixing lugs etc., of sizes and quality grade as
specified.

They shall be provided in complete form including painting, glazing, fixing in position true to
level and plumb.

Steel rolling shutters shall be of approved make and shall conform to IS 6248 - 1979. Metal
rolling shutters and rolling grills.

The builder’s hardware shall all be as per relevant Indian Standards.

14.3. WOODWORK IN DOORS, WINDOWS, PARTITIONS, LOUVERS, RAILINGS ETC.

Wood used for all work shall be the best of the respective class specified, and properly
seasoned by at least 6 months air drying, suitable for joiner's work, should be of natural
growth, uniform in texture, straight grained, free from sapwood, dead knots, open shakes,
boreholes, rot, decay and any and all other defects and blemishes.

The thickness specified for joiner's wrought timbers are, unless otherwise specified, prior to
planning and 3 mm will be allowed from the thickness stated for each wrought faces.

All joining shall be wrought on all faces and finished off by hand with sandpaper, with slightly

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rounded arises.

The joints shall be pinned with hard wood pins and put together with white lead. Jointing shall
be by means of mortise and tenor or dovetailed joints as approved.
Any joiner's work which shall split, fracture, shrink, or show flaws or other defects due to
unsoundness, inadequate seasoning or bad workmanship, shall be removed and replaced
with sound material at the Contractor's expense.

Doors, windows and ventilator frames, transoms and mullions shall be rebated. All
dimensions shall be as per drawings. The top framing member of doors and top and bottom
framing of windows and ventilators shall project about to mm below finished floor. Surface
coming in contact with brickwork shall be painted with bitumen as directed by the Engineer-in-
Charge. Each of the door and window frames shall be provided with 3 Nos. M. S. 225 x 25 x 6
flat split holdfasts on each side. These holdfasts shall be embedded in masonry of concrete
work. The work shall conform to IS:4021.

The doors shall be paneled or solid flush doors as described in the item of work. All flush
doors shall be supplied with approved fittings such as hinges, mortise lock of approved make
with handles on both sides, oxidised brass tower bolts and latch arrangements, door stops
etc. and as shown in drawings but exclusive of door closers. Door closers, where separately
specified shall be of heavy duty hydraulic type to be approved by Engineer-in-Charge
Paneled doors shall have the same fittings except in place of union lock, an aldrop shall be
provided. Each door leaf shall have two 250 mm tower bolts, two aluminum or oxidised brass
handles, and one door stopper be made of weatherproof plywood. Flush doors shall conform
to IS:2202 (Part-I).

Doors will generally have no sills but if a few have to be provided, the Contractor shall do so
at no extra cost to the Owner.

The type of window shall be as specified. Each shutter shall have one pair of hinges, two
tower bolts (one 225 mm long and another 150 mm long), one handle and one hook with eye
and pegstay. Ventilators shall have two M. S. hold fasts and hinges, one handle and one hook
and eye at each and one small tower bolt in the centre. Where so directed by the Engineer-in-
Charge, the doors and windows shall be provided with parliamentary type hinges at no extra
cost.

The workmanship of all door and window shutters shall conform to the requirements of
IS:1003 (Part-I & II) and IS:2202 (Part-I). If required, flush door panels shall be got tested as
per IS:4020.

Cupboards, almirahs and shelves shall be provided as per Engineer-in-Charge. The doors
could be of either hinged type or sliding type as approved by the Engineer-in-Charge. All
dimensions as furnished in the drawings shall be followed. Fixtures and fittings as shown on
drawings or as directed by Engineer-in-Charge shall be used.

Railings and architraves shall conform to the shape shown on drawings or as approved and
fixed by means of screws (counter sunk or otherwise) or bolts.

The finish expected is of a very high order and the work shall be all-inclusive weather or not
all detailed specifications have been spelt out and the work shall be free from blemish.

No iron bars or grills are proposed to be provided in the windows or ventilators. Glass louvred
ventilators where specified shall be provided.

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 Glazed windows, louvres, ventilators and doors shall be provided with either clear or
pinheaded glass 5.5 mm thick which shall be free from all blemishes and shall conform to
IS:1761. It should be clearly understood that glass which does not have uniform refractive
index or which is wavy will be rejected. Woodwork shall not be painted, oiled or otherwise
treated before the Engineer has approved it.

14.4. STEEL DOORS, WINDOWS AND FITTINGS

The steel doors, windows, ventilators shall conform or IS:4351 and IS:1038. All steel doors
windows, ventilators, louvres etc. shall be of sizes as specified and conform to the description
in the respective item of work. Whether or not specifically mentioned, all fixtures and fittings
necessary for the satisfactory operation of the doors and windows shall be provided. Doors,
windows and ventilators shall be obtained from an approved manufacturer. Specific approval
for such purchase shall be obtained before hand. Sample shall also be got approved before
further manufacture starts, unless this is waived in writing by the Engineer-in-Charge. All steel
doors shall be of pressed steel (18 gauge) flush type with or without removable transome. All
doors shall be provided with a three way bolting device and locking arrangement with
duplicate keys and handles of both sides and operable from either side. The Contractor shall
obtain windows with friction hinges in place of windows with pegstays if so directed by the
Engineer-in-Charge. For centre hung and top hung ventilators suitable spring catch/pulley
and chord arrangement shall be provided for facility of opening. Whenever fly mesh over
windows have been called for, they shall be fixed on the window and suitable lever type or
rototype arrangement shall be provided for opening or closing of the glazed panels from
inside. Prior approval of Engineer shall be taken before order is placed with the manufacturer.

Where specified, steel doors supplied shall be airtight. For this purpose, the Contractor shall
provide necessary padding material such as rubber, felt or any other approved material.

14.5. ROLLING SHUTTERS

The rolling shutters shall conform to the size indicated in drawings and shall be of quality
specified in the Schedule of Quantities. The rolling slats shall be in one piece and be made of
heavy gauge steel sheets minimum 18 SWG in thickness. A cylindrical hood shall be provided
on the top to enclose the shutter when it is open. The rolling shutters shall be provided with
suitable locking arrangements and deep channel guides, In case galvanised rolling shutters
are specified the rolling shutter shall be made of hot dip galvanised slats, hood, deep channel
guides all preferably in one piece.

In case of hand operated pull & push type rolling shutters of sizes larger than 10 sq.m. in area
and in case of very large gear operated and/or as directed by the Engineer, rolling shutters
shall be provided with ball bearings for smooth & efficient operation. In case of large rolling
shutters & depending upon local wind conditions, the rolling shutters should be provided with
special locking type of wider channel guides or it shall be provided with central moveable
channel supports to take up design wind pressures in the area.

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 15.HAND RAILING

Hand railing and vertical posts shall be made from galvanised mild steel / Stainless Steel pipes and its
fittings. The design and materials specifications of the railing shall be approved by the Engineer to whom
the Contractor shall submit manufacturer's drawings showing positions of vertical posts, joints, expansion
joints and joint details and all fixing details. Fabrication shall not start until these drawings have approved
by the Engineer.

Hand railing and vertical posts fabricated from galvanised mild steel pipes or stainless steel and its fittings
shall conform to the following requirements.

The height of the top railing shall be 1000 mm above finished floor level unless otherwise shown. There
shall be total 3 horizontal rows. Top row shall be of 32 mm dia and middle two rows shall be of 25 mm dia
GI medium class pipe / SS materials. The lower railing shall 550 mm above finished floor and Toe plate
should be provided at the bottom of the rail of the size100mm wide x 5 mm thick subject to the Engineer's
approval these and other leading dimensions may be varied slightly to suit manufacturer's standard
products.

a. Unless otherwise shown, vertical posts shall be made of galvanised mild steel tubes (medium class)
/Stainless Steel of 40 mm nominal bore and fittings such as Tees, Bends, Crossed etc. of heavy
class conforming to IS:1239.
b. Unless otherwise shown, top horizontal post shall be made of galvanised mild steel or Stainless
Steel materials tubes (medium class) of 32 mm nominal bore and fittings such as Tees, Bends,
Crossed etc. of heavy class conforming to IS:1239.
c. Unless otherwise shown, lower two horizontal post shall be made of galvanised mild steel tubes
(medium class) / SS of 25 mm nominal bore and fittings such as Tees, Bends, Crossed etc. of heavy
class conforming to IS:1239.
d. In general the vertical posts shall be spaced at 1.5 metre c/c and shall be built into the concrete or
bolted to the MS plate embedded in concrete as shown on detailed drawing.
e. Hand railing and vertical posts shall be painted with 2 coats of approved paint.

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 16.RUNGS

Rungs shall be provided in all manholes/inspection chambers/pumping stations over 0.6 mm in depth
and shall be of cast iron conforming to IS:5455. These rungs shall be fixed staggered in two vertical
runs, 300 mm apart horizontally and 300 mm c/c vertically. The top rung shall be 450 mm below the
manhole/inspection chamber cover and the lowest not more than 300 mm above the benching. The
rungs shall be of 20 mm diameter with epoxy paint for corrosion resistance or equivalent as approved by
Engineer in Charge.

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 17.PIPING WORK

17.1. MANUFACTURING / SUPPLYING LAYING AND JOINTING OF RCC PIPES

17.1.1. Scope:

This Specification covers the requirements for manufacturing, testing, supplying, jointing and,
testing at work sites, of Reinforced Cement Concrete (RCC) pipes, of both pressure and non
pressure varieties used for pumping mains, sewers and storm water drains.

17.2. Applicable Codes

The manufacturing, testing, supplying, jointing and testing at work sites of RCC pipes shall
comply with all currently applicable statutes, regulations, standards and Codes. In particular, the
following standards, unless otherwise specified herein, shall be referred. In all cases, the latest
revision of the Codes shall be referred to. If requirements of this Specification conflict with the
requirements of the Codes and standards, this Specification shall govern.

17.3. Materials

IS: 458 Specification for Concrete Pipes (with and Without Reinforcement).
IS:3597 Method of Tests for Concrete Pipes.

IS:5382 Specification for Rubber Sealing Rings for Gas Mains, Water Mains and
Sewers.

17.3.1. Codes of practice

S: 456 Code of Practice for Plain and Reinforced Concrete.

IS: 783 Code of Practice for Laying of Concrete Pipes.
IS: 376 Safety Code for Excavation Work.

17.4. Design

Design of RCC pipes shall be in accordance with the relevant clauses of IS: 458. The details of
reinforcement shall be as per Clause 5.2 of IS: 458. The ends of pipes shall be in accordance
with relevant clauses of IS: 458.

17.5. Manufacturing

17.5.1. General
1. The method of manufacture shall be such that the form and the dimensions of the finished
pipes are accurate within the limits specified in relevant IS: 458. The surfaces and edges of the
pipes shall be well defined and true, and their ends shall be square with the longitudinal axis. The
ends of the pipes shall be further reinforced by an extra ring of reinforcement to avoid breakage
during transportation.
2. The RCC pipes and rubber rings shall be systematically checked for any manufacturing
defects by experienced supervisors so as to maintain a high standard of quality.
3. Engineer shall at all reasonable times have free access to the places where the pipes and
collars / rubber rings are manufactured for the purpose of examining and testing the pipes
and collars / rubber rings and of witnessing the test and manufacturing.
4. All tests specified either in this Specification or in the relevant Indian Standards shall be
performed by Supplier / Contractor at his own cost and in presence of Engineer if desired for
this, sufficient notice before testing of the pipes shall be given to Engineer.
5. If the test is found unsatisfactory, Engineer may reject any or all pipes of that lot. The ecision
of Engineer in this matter shall be final and binding on Contractor and not subject to any

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 arbitration or appeal.

17.5.2. Materials

Materials should conform to the requirements given in IS

17.5.3. Curing

Pipes manufactured in compliance with IS: 458 shall be either water cured or steam cured in
accordance with the relevant requirements of IS: 458.

17.5.4. Dimensions

1. The internal diameter, wall thickness and length of barrel and collar of pipes, reinforcement
(longitudinal and spiral), type of ends and minimum clear cover to reinforcement and strength
test requirements shall be as per the relevant clauses / tables of IS: 458 for different class of
pipes.
2. The tolerances regarding overall length, internal diameter of pipes or socket and barrel wall
thickness shall be as per relevant clauses of IS: 458.

17.5.5. Workmanship and finish

1. Pipes shall be straight and free from cracks except that craze cracks may be permitted. The
ends of the pipes shall be square with their longitudinal axis so that when placed in a straight
line in the trench no opening between ends in contact shall exceed 3 mm in pipes up to 600
mm diameter (inclusive), and 6 mm in pipes larger than 600 mm diameter.
2. The outside and inside surfaces of the pipes shall be smooth, dense and hard, and shall not
be coated with cement wash or other preparation unless otherwise agreed to between
Engineer and the manufacturer or supplier.
3. The pipes shall be free from defects resulting from imperfect grading of the aggregate, mixing
or molding.
4. The pipes shall be free from local dents or bulges greater than 3.00 mm in depth and
extending over a length in any direction greater than twice the thickness of barrel.
5. The deviation from straight in any pipes throughout its effective length, tested by means of a
rigid straight edge parallel to the longitudinal axis of the pipe shall not exceed, for all
diameters, 3 mm for every meter run.
17.6. Testing
1. All pipes for testing purposes shall be selected at random from the stock of the manufacturer
and shall be such as would not otherwise be rejected under the criteria of tolerances as
mentioned in IS: 458.
2. During manufacture, tests on concrete shall be carried out as per IS: 456. The manufacturer
shall supply, when required to do so by Engineer the results of compressive tests of concrete
cylinders or cubes made from the concrete used for the pipes. Every pressure pipe shall be
tested by the manufacturer for the hydrostatic test pressure.
3. The specimen of pipes for the following tests shall be selected in accordance with Clause 9.1
of IS: 458 and tested in accordance with the methods described in IS: 3597
a. Hydrostatic test.
b. Three edge bearing test or sand bearing test.
c. Absorption test.
d. Bursting test.
Note: Three edge bearing strength to produce 0.25 mm crack in case of special design of pipes
shall be as follows:

1000 mm Ø 7400 kg/m

1100 mm Ø 8200 kg/m

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17.7. Sampling and inspection
1. In any consignment, all the pipes of same class and size and manufactured under similar
conditions of production shall be grouped together to constitute a lot. The conformity of a lot
to the requirements of this Specification shall be ascertained on the basis of tests on pipes
selected from it.
2. The number of pipes to be selected from the lot shall be in accordance with column 1 and 2
of Table 9 of IS: 458.
3. Pipes shall be selected at random. In order to ensure randomness, all the pipes in the lot
may be arranged in a serial order and starting from any pipe, every “r th” pipe be selected till
the requisite number is obtained, “r” being the integral part of N/n where “N” is the lot size
and “n” is the sample size.
4. All the pipes selected shall be inspected for dimensional requirements, finish and deviation
from straight.
5. The number of pipes to be tested for tests shall be in accordance with column of Table 9 of
IS: 458. These pipes shall be selected from pipes that have satisfied the requirements
mentioned above.
6. A lot shall be considered as conforming to the requirements of IS: 458 if the following
conditions are satisfied.
a. The number of defective pipes (those not satisfying one or more of the requirements for
dimensions, finish and deviation from straight) shall not be more than the permissible
number given in Column 3 of Table 9 of IS: 458.
b. All the pipes tested for various tests shall satisfy corresponding requirements of the tests.
c. In case the number of pipes not satisfying requirements of any one or more tests, one or
two further sample of same size shall be selected and tested for the test or tests in which
failure has occurred. All these pipes shall satisfy the corresponding requirements of the
test.
17.8. Marking
The following information shall be clearly marked on each pipe including the details given by
Engineer In charge of RMC:
1. Internal diameter of pipe.
2. Class of pipe.
3. Date of manufacture, and
4. Name of manufacturer or his registered trademark or both.

17.9. Carting and Handling

1. Pipes and fittings / specials shall be transported from the factory to the work sites, at places
along the alignment of pipe line as directed by Engineer. Contractor shall be responsible for
the safety of pipes and fittings / specials in transit, loading / unloading. Every care shall be
exercised in handling pipes and fittings / specials to avoid damage. While unloading, the pipes
and fittings / specials shall not be thrown down from the truck on to hard surfaces. They
should be unloaded on timber with steadying ropes or by any other approved means.
2. Padding shall be provided between coated pipes, fittings / specials and timber skids to avoid
damage to the coating. Suitable gaps between pipes should be left at intervals in order to
permit access from one side to the other. In case of spigot socket pipes while unloading, as far
as possible pipes shall be unloaded on one side of the trench only. The pipes shall be
checked for any visible damage (such as broken edges, cracking or splaying of pipe) while
unloading and shall be sorted out for reclamation. Any pipe which shows sufficient damage to
preclude it from being used shall be discarded. Dragging of pipes and fittings / specials along
concrete and similar pavement with hard surfaces shall be prohibited. Wherever a section of
pipe, or a fitting is to be lifted or moved, it shall be handled carefully with belt slings. The belts
shall be constructed so that no metal bears against the pipe and so that the bearing is uniform.
The width of the belts shall be adequate to prevent any damage to the pipe coating. The pipe
section may at no time be dropped but shall be lowered carefully into position and may not be

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 slide along the ground. If it is to be rolled, it may be done only on slides or ground specially
prepared so as to prevent any damage to the coating.
3. All State and local laws be observed during transportation. The Contractor shall secure
permits and licenses and provide all signals, guards and lights that may be required. Upon
delivery the pipe sections and fittings shall be placed on specially prepared ground to protect
them from distortion and damage. The ground shall be prepared so that they will rest evenly
and will have uniform bearing throughout their lengths. Valve and sluice gates shall be placed
on blockings.

17.10. Storage
Each stack of pipes shall contain only pipes of same class and size, with consignment or batch
number marked on it with particulars of suppliers wherever possible. Storage shall be done on
firm level and clean ground and wedges shall be provided at the bottom layer to keep the stack
stable. The stack shall be in pyramid shape or the pipes laid lengthwise and crosswise in
alternate layers. The pyramid stack shall be made for smaller diameter pipes for conserving
space in storing them. The height of the stack shall not exceed 1.5m.

Fittings / specials shall be stacked under cover and separated from pipes. Valves and sluice
gates shall be placed on blockings.

Rubber rings shall be stored in a clean, cool store away from windows, boiler, electrical
equipment and petrol, oils or other chemicals. Particularly in the field where the rubber rings are
being used it is desirable that they should not be left out on the ground in the sun or overnight
under heavy frost or snow conditions.

17.11. Jointing
1. Jointing of RCC pipes shall be done as per the requirements of following Specifications and
as per the relevant IS. The type of joints shall be as specified in the Contract / Drawing. After
jointing extraneous material if any, shall be removed from the inside of the pipe and newly
made joints shall be thoroughly cured. In case, rubber sealing rings are used for jointing,
these shall conform to IS: 5382.

2. Spigot and Socket Joint (Rigid)

The spigot of each pipe shall be slipped home well into the socket of the pipe previously laid
and adjusted in the correct position. The opening of the joint shall be filled with stiff mixture of
cement mortar in the proportion of 1:1, which shall be rammed with caulking tool.

3. Collar Joint (Rigid)

After laying the RCC pipes at proper alignment and gradient their abutting faces shall be
coated with hot bitumen in liquid condition by means of a brush. The wedge-shaped groove in
the end of the pipe shall then be filled with a tarred gasket in one length for each joint. The
collar shall then be slipped over the end of the pipe and the next pipe butted well against the
tarred gasket by suitable appliances approved by Engineer so as to thoroughly compress the
tarred gasket into the grooves, care being taken that the concentricity of the pipes and levels
are not disturbed during this operation. The collar shall then be placed symmetrically over the
end of the two pipes and the space between the inside of the collar and the outside of the
pipe filled with a mixture of cement and sand in the proportion of 1:1, tempered with just
sufficient water to have a consistency of the semi dry conditions, well packed and thoroughly
rammed with caulking tools. The joints shall be finished off with a filled sloping at 45o to the
side of the pipe. The finished joints shall be protected and cured thoroughly as directed by
Engineer. Any plastic solution or cement mortar that may have been squeezed into the inside
of the pipe shall be removed so as to leave the inside of the pipe perfectly clean.

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 4. Spigot and Socket Joint (Semi-flexible)
This joint is composed of specially shaped spigot and socket ends on the RCC pipes. A
rubber ring shall be lubricated and then placed on the spigot which is forced into the socket of
the pipe previously laid. This compresses the rubber ring as it rolls into the annular space
formed between the two surfaces of the spigot and socket, stiff mixture of cement and mortar
in the proportion of 1:1, shall then be filled into the remaining annular space and rammed with
a caulking tool.

5. Collar Joint (Semi-flexible)

This joint is made up of a loose collar which covers two specially shaped pipe ends. Each
end shall be fitted with a rubber ring, which when compressed between the spigots and
collar, seal the joint. Stiff mixture of cement mortar in the proportion of 1:1, shall then be filled
into the remaining annular space and rammed with a caulking tool.

6. Spigot and Socket Joint (Flexible)

The RCC pipe with the rubber ring accurately positioned on the spigot shall be pushed well
home into the socket of the previously laid pipes. The manufacturer’s instructions shall be
used, and the manufacturer’s instructions shall be deemed to form a part of these
Specifications. The rubber rings shall be lubricated before making the joint and the lubricant
shall be soft soap water or an approved lubricant supplied by the manufacturer. Flush Joint
(Internal)

This joint shall be generally used for culvert pipe of 60 cm. diameter and over. The ends of
the pipes are specially shaped to form a self centering joint with an internal jointing spaces
1.3 cm wide. The finished joint is flush with both inside and outside with the pipe wall. The
jointing space is filled with cement mortar in the proportion of 1:1, mixed sufficiently dry to
remain in position when forced with a trowel or rammer.

7. Flush Joint (External)

This joint is suitable for pipes which are too small for jointing from inside. This joint is
composed of specially shaped pipe ends. Each end shall be butted against the other and
adjusted in correct position. The jointing space shall then be filled with cement mortar in the
proportion of 1:1, sufficiently dried and finished off flush. Great care shall be taken to ensure
that the projecting ends are not damaged as no repairs can be readily affected from inside
the pipe.
17.12. Cleaning of pipes
1. If as a result of the removal of any obstruction, Engineer considers that damages may have
been caused to the pipe lines, he shall be entitled to order the stretch to be tested
immediately. Should such test prove unsatisfactory Contractor shall amend the work and carry
out such further tests as are required by Engineer.
2. It shall also be ascertained by Contractor that each stretch from manhole to manhole or the
stretch as directed by Engineer is absolutely clear and without any obstruction by means of
visual examination of the interior of the pipeline suitably enlightened by projected sunlight or
otherwise.

17.13. Testing at work site

1. After laying and jointing of RCC pipes is completed the pipe line shall be tested at work site as
per the following Specifications and as directed by Engineer. All equipment for testing at work
site shall be supplied and erected by the Contractor and shall be rectified by him / her to the
full satisfaction of Engineer. Water used for test shall be removed from pipes and not released
to the excavated trenches.
2. After the joints have thoroughly set and have been checked by Engineer and before backfilling
the trenches, the entire section of the sewer (or storm water drain) shall be proved by

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 Contractor to be water tight by filling in pipes with water to the level of 1.50 m. above the top of
the highest pipe in the stretch and heading the water up for the period of one hour. The
apparatus used for the purpose of testing shall be approved by Engineer. Contractor if
required by Engineer shall dewater the excavated pit and keep it dry during the period of
testing. The loss of water over a period of 30 minutes should be measured by adding water
from a measuring vessel at regular 10 minutes intervals and noting the quantity required to
maintain the original water level. For the approval of this test the average quantity added
should not exceed 1 liter / hour / 100 linear meters / 10 mm nominal internal diameter. Any
leakage including excessive sweating which causes a drop in the test water level will be visible
and the defective part of the work should be removed and made good.
3. In case of pressure pipeline the completed stretch of pipeline shall be tested for site test
pressure of 0.15g/sq.cm. The site test pressure should not be less than the maximum
operating pressure plus the calculated surge pressure, but in no case should it exceed the
hydrostatic test pressure, as specified in IS: 458.

17.14. Measurement
1. All RCC pipes shall be measured according to the work actually done and no allowance will be
made for any waste in cutting to the exact length required. The measurement for pipes shall
be in running meters nearest to a cm. of length along the centre line of pipe as actually laid at
work sites.

17.15. Rate
1. The rate for providing, laying and jointing of RCC pipes shall be deemed to include the cost of
collars / rubber rings, jointing material, testing and the extra excavation required for ordinary
bedding of pipes and also for collars and pipe sockets if any.

17.16. Notes
1. If any damage is caused to the pipeline during the execution of work or while cleaning / testing
the pipeline as specified, Contractor shall be held responsible for the same and shall replace
the damaged pipeline and retest the same at his own cost to the full satisfaction of Engineer.
2. Water for testing of pipeline shall be arranged by Contractor at his own cost.

17.17. Laying and jointing of Pipes and Fittings / Specials

17.17.1. Excavation
1. Before excavating the trench the alignment of pipeline shall be approved by Engineer. The
excavation of trenches and pits for manholes / chambers shall be carried out in accordance
with the Specification and shall be done such that it does not get far ahead of the laying
operation as approved by Engineer.
2. To protect persons from injury and to avoid damage to property, adequate barricades,
construction signs, red lanterns and guards as required shall be placed and maintained
during the progress of the construction work until it is safe for the traffic to use the roadways.
The Contractor shall provide sign boards at salient points in streets and keep men to guide
the traffic at his own cost. The relevant Indian Standards and the rules and regulations of
local authorities in regard to safety provisions shall be observed.
3. Trial pits may be dug by the Contractor, without being directed to do so, along the lines of the
trenches as shown on the drawings in advance of the excavations for the purpose of
satisfying himself as to the location of underground obstructions or conditions. The Contractor
shall proceed with caution, in any excavation and shall use every means to determine the
exact location of underground structures, pipelines, conduits etc., and prior to excavation in
the immediate vicinity thereof. The Contractor shall be solely responsible for the cost of
protection or repair or replacement of any structure, pipeline, conduit etc., above or below
ground which may be broken or otherwise damaged by his operations.
4. Suitable fencing shall be provided along the sides of trenches and pits. The posts of fencing

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 shall be of timber securely fixed in the ground not more than 3 m apart and they shall not be
less than 75 mm in diameter or less than 1.2 m above the surface of the ground. There shall
be two rails, one near the top of the posts and the other about 500 mm above the ground and
each shall be of 50 mm to 70 mm in diameter and sufficiently long to run from post to post to
which it shall be bound with strong rope. The method of projecting rails beyond the posts and
tying them together where they meet will not be allowed on any account. All along the edges
of the excavated trenches a bank of earth about 1.2 m high shall be formed where required
by Engineer for further protection.
5. The lighting, barricading, guarding of the trenches and the maintenance of watchman shall be
done by the Contractor at his cost. At every 30 meters interval and at every change in the
gradient, sight rails shall be provided and fixed by the Contractor at his own cost. The sight
rails and boning rods for checking the excavation and inverts of the pipes shall be of the
quality approved by the Engineer. In all streets in the City/Town at every 15 meters interval,
blank board shall be provided by the Contractor at his own cost, to facilitate crossing of the
trench by the public residing on the either side.
6. The road metal and also the rubble packing shall first be stripped off for the whole width of
the trench / pit and separately deposited in such place or places as may be determined by
Engineer.
7. During excavation, large stones and rubble shall be separated and removed from the
excavated soil and stacked separately. The material from excavation shall be deposited on
either side of the trench leaving adequate clear distance from the edges of the trench and pit
or as may be necessary to prevent the sides of the trench / pit to slip or fall or at such a
distance and in such a manner so as to avoid covering fire hydrants, sluice values, manhole
covers, etc. and so as to avoid abutting the wall or structure or causing inconvenience to the
public and other service organization or otherwise as Engineer may direct.
8. Contractor shall take into account additional excavation if any as Engineer may require in
order to locate the position of water pipes, drains, sewers, etc. or any other works which may
be met with, in or about the excavation of trenches / pits while quoting the rates for
excavation. Such service lines if met with during excavation shall be properly maintained by
Contractor, by means of shoring, strutting, planking over, padding or otherwise as Engineer
may direct, and shall be protected by Contractor from damage during the progress of the
work.
9. Wherever extra width of excavation shall be necessary for shoring and strutting, of the
trenches on account of the nature of the soil, such extra width required to accommodate the
shoring boards shall not be paid for separately and the rates quoted for trench work are
deemed to be inclusive of all such incidental work.
10. All precautions shall be taken during excavation and laying operations to guard against
possible damage to any existing structures/pipelines of water, gas, sewage etc.
11. If the work for which the excavation has been made is not complete by the expected date of
the setting in of monsoon which is First week of June or the setting in of rain whichever is
earlier, or before the day fixed by Engineer for filling in any excavation on account of any
festival or special occasion, Contractor shall backfill such excavation and consolidate the
filling.
12. Utmost care shall be taken to see that the width of the trench at the top of pipe is not more
than [External diameter of pipe in mm + 500 mm] + [400 mm for every 1500 mm Depth of
cutting] or as specified in the Cross Section Drawing (in case there is any difference, the
latter shall prevail). In case additional width is required it shall be provided only in the top
portion from the ground level up to 300 mm above the crown of pipe. If any extra width is
provided in the area below this portion, Contractor shall have to provide remedial measures
in the form of lime concrete or rubble masonry or otherwise at the discretion and to the
satisfaction of Engineer. If rock is met with, it shall be removed to 15 cm below the bottom of
pipes and fittings / specials and the space resulting shall be refilled with lean cement
concrete of adequate depth, properly consolidated to give the curved seating. The bottom of

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 the trench shall be properly trimmed to permit even bedding of the pipeline. Bottom of
trenches / pits shall be saturated with water and well rammed wherever Engineer may
consider it necessary to do so. For laying of pipes larger than 1200 mm in diameter, in earth
and moorum, the curvature of the bottom of the trench should match the curvature of the pipe
as far as possible, subtending an angle of 120 degrees at the centre of the pipe.
13. Wherever a socket or collar of pipe or fitting / special occurs a grip is to be cut in the bottom
of the trench or concrete bed to a depth of at least 75 mm below the bed of the pipe so that
the pipe may have a fair bearing on its shaft and does not rest upon its socket. Such grip
shall be of sufficient size in every respect to admit the hand; all around the socket in order to
make the joint and the grip shall be maintained clear until the joint has been approved by
Engineer.
14. When welding is to be carried out with the pipes and specials in the trench, additional
excavation of not more than 60 cm in depth and 90 cm in length shall be made at joints in
order to facilitate welding.
15. The excess excavated material shall be carried away from site of works to a place up to a
distance as directed by Engineer. This shall be done immediately so as not to cause any
inconvenience to the public or traffic. If the instructions from Engineer are not implemented
within seven days from the date of instructions to cart the materials and to clear the site, the
same shall be carried
out by Engineer at Contractor’s risk and cost and any claim or dispute shall not be
entertained in this respect.
16. Refilling of trenches, where the excavation is in rock shall be with the surplus soft soil from
pits located within 200 meters from the reach in question.
17. It is to be distinctly understood that no extra payment shall be made for the excavation from
borrow pits located within 200 meters for obtaining earth for refilling, any instructions of the
Engineer to bring earth from beyond 200 meters for refilling shall be detailed in writing and a
separate extra payment shall be made for the additional conveyance. No payment shall be
made for disposal of soil for excavation, surplus to or unsuitable for filling.

17.17.2. Work included in Excavation

Unless otherwise directed on the project Specifications, all of the following items are included in
the excavation:
1. Removing all surface obstructions including shrubs, jungle etc.,
2. Making all necessary excavations true to line and grade,
3. Furnishing and installing all shoring and bracing as necessary or as directed,
4. Pumping and bailing out water to keep trenches free of water during pipe laying and
jointing and thereafter until joints mature,
5. Providing for uninterrupted surface water flow during work in progress,
6. Providing for disposing off water flows from storm, drains, nallas or other sources,
suitably,
7. Protecting all pipes, conduits, culverts, railway tracks, utility poles, wire fences, buildings,
and other public and private property adjacent to or in the line of work,
8. Removing all shoring and bracing which is not ordered to be left in place or not required
by the project plans or Specifications to remain in place,
9. Hauling away and disposing of excavated materials not necessary or else unsuitable for
back filling purposes. The extra excavated soil will have to be properly dressed in soil
banks along with the trench as directed,
10. Back filling the trenches as directed or as per Specifications,
11. Restoring all property injured or disturbed by these construction activities to the condition
as near its original condition as possible,
12. Restoring the surfaces and repairing of all roads, streets, alleys, walks, drives, working
spaces, and rights of way to a condition as good as prior to excavation
13. In case the Engineer orders that the location of trench be moved a reasonable distance,

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 on account of the presence of an obstruction or due to such other cause or if a changed
location is authorized at the Contractor’s request, the Contractor shall not be entitled to
extra compensation or to a claim for damage. If however such change is made at the
orders of the Engineer, which involves abandonment of excavation together with the
necessary back fill, will be measured, classified and paid for in the same manner as for
other trench excavation and back fill of the same character. In case the trench is
abandoned in favor of new location at the Contractor’s request, after its approval, the
abandoned excavation and back fill shall be at Contractor’s expense.

17.17.3. Minimum earth cover

If a profile is not furnished for a pipeline, the main will be constructed with a minimum earth
cover of 1000 mm from the top of the pipeline, unless otherwise indicated on plans and ordered
by the Engineer.

17.17.4. Dewatering
During the excavation, if subsoil water is met with, Contractor shall provide necessary
equipment and laborers for dewatering the trenches / pits by bailing out water or water mixed
with clay. If pumping out subsoil water is found to be necessary, Contractor shall provide
sufficient number of pumps for the same. In both the above cases the excavation shall be done
to the required level and the pipes shall be laid to proper alignment and gradient. Contractor
shall also make necessary arrangement for the disposal of drained water to nearby storm water
drain or in a pit if allowed by Engineer. In no case the water shall be allowed to spread over the
adjoining area. Before discharging this water into public sewer / drain, Contractor shall take
necessary permission from the local authorities. 2. The Contractor shall be responsible for the
adequate pumping, drainage and bailing out of water from the excavation. Failure to make such
provisions which results in unsuitable sub grade conditions, and which will require any special
foundations as directed by the Engineer, such foundations shall be placed at the entire cost of
the Contractor and will not be measured or paid for as separate pay items. If the Contractor
selects to undercut the trench and use gravel or tile bailing, drainage of well pointing, the
additional work will be considered as incidental work and additional compensation will not be
allowed
17.17.5. Special foundation in poor soil
1. Where the bottom of the trench at sub grade is found to consist of material which is unstable
to such a degree that in the opinion of Engineer, it cannot be removed and replaced with
approved material thoroughly compacted in place to support the pipe properly, a suitable
foundation for the pipes, consisting of piling, timbers or other materials, in accordance with
relevant Drawings and as instructed by Engineer shall be constructed.
2. During the progress of the work, should the foundation for the pipeline be in soft, yielding or
spongy materials which are unsuitable for the sub grade of the pipeline and which is not the
result of the Contractor's negligence, to make proper provisions for adequate drainage of the
excavation, the Contractor shall remove such unsuitable sub grade materials to the depth
directed by the Engineer. The Contractor shall fill the excavated depth in the manner
hereinafter described or as directed by the Engineer.
3. The Contract unit for foundation shall be one cubic meter. The foundations will be measured
for payment complete in place. The contract unit price shall be the total compensation for
furnishing all labor, tools, materials, equipment and incidentals necessary to complete the
work, including all excavation and disposal of surplus material.
4. Gravel Foundations
a. The space resulting from removal of unsuitable material shall be filled with gravel. No
extra payments will be made on this account, except for lead charges if any beyond
50m.
b. Concrete Foundations
c. The space resulting from removal of unsuitable materials shall be filled with a

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 concrete foundation and the concrete shall conform to relevant Specifications.

17.17.6. Wooden shoring

1. Contractor shall suitably design polling boards, walling and struts to meet different soil
conditions that might be encountered in excavating trenches / pits. The horizontal and
vertical spacing of struts shall be such that not only the sides of trenches shall be
prevented from collapse but also easy lowering of pipe in trenches shall be ensured without
creating undue obstructions for the excavation of the work. Any inconvenience and / or
delay that might be caused in lowering pipes in trenches as a result of adopting improper
spacing of struts by Contractor shall be his sole responsibility. While taking out shoring
planks the hollows of any form must simultaneously be filled in with soft earth well rammed
with rammers and with water.
2. Engineer may order portions of shoring to be left in the trenches / pits at such places,
where it is found absolutely necessary to do so as to avoid any damage which may be
caused to buildings, cables, gas- mains, water mains, sewers, etc. in close
proximity of the excavation, by pulling out the shoring from the excavations. Contractor
shall not claim, on any reason, whatsoever for the shoring which may have been left in.

17.17.7. Steel plate shoring

1. Where the subsoil conditions are expected to be of a soft and unstable character in trench /
pit excavation the normal method of timbering may prove insufficient to avoid subsidence of
the adjoining road surfaces and other services. In such circumstances Contractor will be
required to use steel trench sheeting or sheet piling adequately supported by timber struts,
walling, etc., as per the instructions, manner and method directed by Engineer. Contractor
shall supply, pitch, drive and subsequently remove trench sheeting or piling in accordance
with other items of the Specification.

17.17.8. Boning staves and sight rails

1. In laying the pipes and fittings / specials the centre for each manhole / chamber or pipe
line shall be marked by a peg. Contractor shall dig holes for and set up two posts (about
100 mm X 100 mm X 1800 mm) at each manhole / chamber or junction of pipe lines at
nearly equal distance from the peg and at sufficient equal distance there from to be well
clear of all intended excavation, so arranged that a sight rail when fixed against the post
will cross the centre of the manhole / chamber or pipe lines. The sight rail shall not in any
case be more than 30 m apart. Intermediate rails shall be put up if directed by Engineer.
2. Boning staves of 75 mm X 50 mm size shall be prepared by Contractor of various lengths,
each length being of a certain whole number of meters and with a fixed tee head and fixed
intermediate cross pieces, each about 300 mm long. The top edge of the cross piece must
be fixed below the top edge of this tee head, at a distance equal to as the case may be,
the outside diameter of the pipe or the thickness of the concrete bed to be laid. The top of
cross pieces shall indicate different levels such as excavation for pipe line, top of concrete
bed, top of pipe, etc. as the case may be.
3. The sight rail of size 250 mm X 40 mm shall be screwed with the top edge resting against
the level marks. The centre line of the pipe shall be marked on the rail and this mark shall
denote also the meeting point of the centre lines of any converging pipes. A line drawn
from the top edge of one rail to the top edge of the next rail shall be vertically parallel with
the bed of the pipe and the depth of the bed of pipe at any intermediate point may be
determined by letting down the selected boning staff until the tee head comes in the line of
the sight from rail to rail.
4. The post and rails shall be perfectly square and planed smooth on all sides and edges.
The rails shall be painted white on both sides and the tee hands and cross piece of the
boning staves shall be painted black.
5. For the pipes converging to a manhole / chamber at various levels, there shall be rail fixed

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 for every different level. When a rail comes within 0.60 m of the surface of the ground,
higher sight-rail shall be fixed for use with the rail over the next point.
6. The posts and rails shall in no case be removed until the trench is excavated, the pipes
are laid and Engineer gives permission to proceed with the backfilling.

17.17.9. Bedding
1. The bedding for pipe shall be provided as specified in the Drawings or as per direction of
Engineer.

17.17.10. Concrete cushion, embedment and encasement

1. Concrete embedment and encasement wherever required, shall be constructed as per the
details given in approved Drawings or as directed by the Engineer. Where concrete
bedding is to be placed beneath the pipeline, the sub-grade shall be prepared to
dimensions as shown in the Drawings. The bottom of the trench may be sloped on the
sides or kerbed, but the thickness of concrete shall be as specified in
the Drawings or as directed by the Engineer. Dry mix will not be permitted.
2. For earth, granular material or concrete embedment, each pipe section shall have uniform
bearing on the sub grade for the full length of the pipe barrel, suitable excavation shall be
made to receive the pipe, bell or collar and allow adequate room for proper workmanship
in making the joint. Adjustment to line and grade shall be made by scraping away or filling
in with gravel or concrete and not by wedging or blocking up the bell. Pipe sockets and
barrels shall be clean and free from dirt at the time of jointing.
3. The concrete for bedding portion will be mixed moist or damp to give a slump of not more
than 25 mm and for sides and top portions of encasement, if specified, will be mixed to
obtain a slump between 25 mm and 80 mm. All water in the trench must be
disposed off prior to placing of concrete. There should be no cleavage line between the
bedding concrete and the side embedment concrete. Clear out space shall be left for
jointing and lowering pipe in place and bringing to grade by tamping under pipe or
removing excess concrete under pipe. After the joint is made, the remainder of the
concrete embedment may then be poured and thoroughly tamped to make bond with
original concrete. Care must be exercised in tamping to prevent lifting of the pipe of
alignment or grade. Back filling shall be done in a careful manner and such time after the
concrete cushion, embedment or encasement is placed, as not to damage the concrete in
any way.
4. All pipes shall be so laid that the contact in the joint between the two lengths of pipe shall
be uniform throughout the circumference of the joint. Where curves in the alignment are
indicated on the Drawing and the curves are flat, standard pipe will be used with the
outside edge of the joint pulled away from the seat to make a smooth joint. Where curves
are sharp, standard or specially made bends will be used.

Openings at end of day's work openings in tees, deep cut connections, shall be capped
and sealed.

17.17.11. Laying of pipes and fittings / specials

1. All precautions shall be taken during excavation and laying operations to guard against
possible damage to any existing structure / pipe line of water, gas, sewage, etc. After
excavation of trenches, pipes shall not be lowered unless the dimensions of trenches and
bedding work for pipes at the bottom of the trenches are approved and measured by
Engineer. Pipes and fittings / specials shall be carefully lowered in the trenches.
2. The pipes and specials shall be stacked along the alignment in advance with utmost care
during the transit so that they are not damaged. Any damage due to these reasons shall
be Contractor's liability. The pipe shall be lowered and laid only after the trenches are
finally ready and levels duly checked by the Engineer. It shall be seen that no damaged

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 pipe is lowered in the trench. Every precaution shall be taken to prevent foreign materials
from entering the pipes when they are being placed in the line. Normally the socket ends
shall face the upstream. When any portion of the excavation shall have been carried down
to the necessary depth, the Contractors shall obtain permission from the Engineer before
commencing the laying of pipes or concrete or the construction of masonry.
3. Special arrangements such as cranes, tripods with chain pulley block for lowering the
pipes and fittings / specials shall be made by Contractor. In no case pipes and fittings /
specials shall be dropped. Slings of canvas or equally non abrasive material of suitable
width or special attachment to fit the ends of pipes and fittings / specials shall be used to
lift and lower the coated pipes and fittings / specials. The pipes and fittings / specials shall
be inspected for defects and be rung with a light hammer preferably while suspended to
detect crack, wherever applicable. If doubt persists, further confirmation shall be done by
pouring a little paraffin on the inside of the pipe at the suspected spot. No sign of paraffin
should appear on the outside surface.
Pipes and fittings / specials damaged during lowering or aligning shall be rejected by
Engineer.
4. All the pipes are to be laid perfectly true both in alignment and to gradient specified. Pipes
in a trench shall be laid and fitted previous to the jointing being commenced. In case of
spigot and socket pipe the socket end of the pipe shall face upstream, except when the
pipe line runs uphill in which case the socket ends should face the upgrade of a slope.
After placing a pipe in the trench, the spigot end shall be centered in the socket and the
pipe forced home and aligned to required gradient. The pipes shall be secured in place
with approved backfill material tamped under it except at the socket. Pipes and fittings /
specials which do not allow a sufficient and uniform space for joints shall be removed and
replaced with pipes and fittings / specials of proper dimensions to ensure such uniform
space. Precaution shall be taken to prevent dirt from entering the jointing space. At times
when pipe laying is not in progress, the open ends of pipe shall be closed by a watertight
plug or other means approved by Engineer. During the period that plug is on, the
Contractor shall take proper precautions against floatation of the pipe owing to entry of
water into the trench. In the case of pipes, with joint to be made with loose collars, the
collars shall be slipped on before the next pipe is laid. The pipes shall be laid such that the
marking on pipes appears at the top of the pipes.
5. Properly fitted temporary wooden stoppers shall be provided to close the ends of all
incomplete pipe lines. The stoppers are only to be removed when pipes are being laid and
jointed. Pipe laying and jointing shall be started and completed only section wise as per
the instruction of the Engineer. During the progress of pipe laying the open ends of pipe
shall be closed and water tight. Sight rails shall be provided at all change of direction or
gradients at distance of @ 30 m along straight lengths. All the invert levels shall be
confirmed from the sight rails with the help of proper boning rods as per the standard
practice. The pipe shall be jointed with cement mortar 1:1 and proper caulking shall be
done. After a particular section of the pipe is laid and jointed hydraulic testing shall be
done section wise.
6. Just prior to placing each pipe section in the line, damaged coating shall be repaired and
the interior shall be cleaned off all foreign materials. Cleaning shall be accomplished by
brushing, blowing with compressed air and washing with water or as specified by the
Engineer.
7. The item for laying of pipe line also includes labour work for lowering, laying and jointing
various pipes including jointing with specials, levelling, etc. The Contractors shall transport
pipes and specials from stores, for their various sections in such quantities as may be
required for laying. Ordinarily no surplus stock shall remain on completion of any section.
In case however, such pipe etc. become surplus in any sections, the Contractor shall
remove the same to the next section for use in the work. It is likely that on completion of
the whole work, some pipes and specials etc. may become surplus at the site and the

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 Contractors shall arrange to hand over the same in good condition to the Engineer at the
Owner’s store as may be directed if required by Owner. The Contractor shall supply a list
of stock so returned to the Engineer. No extra payment shall be made to the Contractors
for these works. The rates for laying the pipes shall cover the cost of loading, transporting
and unloading as may be required. The fortnight report for pipes collected and laid should
be sent to the Engineer.
8. The cutting of pipe for inserting valves, fittings or specials shall be done in a neat and
workman like manner without damage to the pipe so as to leave a smooth end at right
angles to the axis of the pipe. For this purpose, pipe cutting machine shall be used.

17.17.12. Jointing
1. Pipes shall be laid to the lines and grades given in the plans, with the ends abutting to
form a even joint without shoulders or unevenness of any kind along the invert of the
pipes. No joint shall be made under water. The ends of the pipes shall be dry and kept
clean before and during laying and jointing operations.
2. All joint work shall be done in an approved manner by skilled workmen so that the
completed pipeline shall have a continuous, smooth and uniform interior surface.
Extruded joint material shall be removed from the interior of the pipe. In cold weather
protective measures must be taken to ensure a satisfactory joint.
3. Jointing for pipes and fittings / specials shall be done in accordance with the relevant
Specifications depending on type of pipes being used.

17.17.13. Closure sections and connections to structures

1. Closure sections shall be constructed where required by the Contractor’s operations.
Connections to pipe specials shall be made as approved by the Engineer. Lining and
coating of the pipe lines, which must be cut to provide for closure pieces or to permit the
proper location of valves structure shall be repaired by the Contractor. No separate
payment will be made for closure pieces installed, but the same will be measured as it is a
pipe in place and along the pipeline.
2. The cutting of pipe for inserting valves, fittings or specials shall be done in a neat and
workman like manner without damage to the pipe so as to leave a smooth end at right
angles to the axis of the pipe. For this purpose, pipe cutting machine shall be used.

17.17.14. Temporary stoppages of work

1. At times when pipe laying is not in progress, or at the end of the day’s work, the open ends
of pipe shall be closed by a watertight plug or other means approved by Engineer. During
the period that plug is on, the Contractor shall take proper precautions against floatation of
the pipe owing to entry of water into the trench.

17.17.15. Backfilling
1. Trenches shall be backfilled with approved selected excavated material only after the
successful testing of the pipe line. The tamping around the pipe shall be done by hand or
other hand operated mechanical means. The water content of the soil shall be as near to
the optimum moisture content as possible. Filling of the trench shall be carried out
simultaneously on both sides of the pipe in such a manner that unequal pressure does not
occur. Back filling shall be consolidated by watering, ramming, care being taken to avoid
damage to the pipe line. In case of mild steel pipes / specials, the spiders provided during
assembly and welding shall be retained until the trench is refilled and consolidated. Where
timbers are placed under the pipe line to aid alignment, these timbers shall be removed
before backfilling.
2. Reinstatement of road / footpath
Reinstatement of road / footpath shall be done as per the requirements of local authorities
and the relevant Specifications after the completion of work.
17.17.16. Clearing of site

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 All surplus materials, and all tools and temporary structures shall be removed from the site as
directed by Engineer and the construction site left clean to the satisfaction of Engineer.
17.17.17. Measurement
1. The measurements for excavation in trenches shall be done in following manner and will be
paid accordingly.

Length As per actual length of pipe and fittings / specials laid at work
site.

Width & cross As per Drawing.

Depth Average depth of trench from ground level to invert of pipe plus
thickness of bedding

2. Excavation of asphalt road and reinstatement of road shall be measured on per square
meter basis and the length and width at top of trench shall be considered same as those
mentioned for excavation of trench.
3. The measurement for removal of excess excavated material up to a specified distance shall
be as per the relevant item(s) in the schedule of Quantities and Rates and shall be
measured on cubic meter basis. In case of soil 30% deduction shall be done to take
account for voids where as it will be 40% in case of rubble.
4. Measurement for pipes and fittings / specials shall be in accordance with the relevant
clause(s) of Specification for particular types of pipes.
17.17.18. Notes
1. Fencing provided along the sides of trenches and pits shall not be paid for separately and
Contractor shall take into account the costs of such works and quote accordingly.
2. In case of the metal packing or dressed stones not being deposited as specified or being
mixed up with excavated materials and not available for the reinstatement of road /
pavement, the cost of the new metal packing or dressed stones required shall be charges
to Contractor by Engineer.
3. Service lines if damaged during excavation shall be made good either by Contractor or by
other agency as Engineer may decide and the cost of the same shall be borne by the
Contractor wholly in either case.
4. Contractor shall not be paid any additional compensation for excess excavation over what
is specified as well as for any remedial measures that are specified.
5. The excess excavated material shall be carried away from site of works as specified, failing
which in view of public safety and traffic convenience Engineer may carry out the work by
any other agency at Contractor's risk and cost.

17.17.19. All works to be clear clean and perfect

The Contractors shall after completion or whenever required by the Engineer in charge, prove all
pipes and fitting to be clear clean and perfect, and for this purpose shall at their own expense and
in the presence of the Engineer in charge or his appointee, provide suitable instruments and
appliances and pass them through the pipes and shall, if required, throw in water and show that it
passes freely through every portion of the work. Brick, mortar and rubbish shall not be allowed to
fall into the manholes of sewer lines while fixing or if allowed, shall be removed by the
Contractors at their own expense

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17.18. CENTRIFUGALLY CAST (SPUN) DUCTILE IRON PIPE

The material of construction for the pipe line shall be Ductle Iron (DI) with internal cement mortar
lining (Class K7 and K9)

17.18.1. Scope of Work

Laying in trenches centrifugally cast (spun) ductile iron pressure pipes of class K7 and K9 as per
IS: 8329: 2000 (Code of practice for use and laying of ductile iron pipes) including jointing (tyton
push joint), bends of all degrees, tees, collars, tapers, crosses, flange sockets & spigots,
branched pipes, chamfering etc. where required. Testing of pipes should be done as per IS:
8329: 1994.

17.18.2. Applicable Codes

Important IS codes applicable in case of Ductile iron pipes, fittings, jointing & laying are:

Sr. IS Codes Description

1 8329 Centrifugally cast (spun) ductile iron pressure pipes for water, gas and
sewage - specification
2 9523 Ductile iron fittings for pressure pipes for water, gas and sewage
3 12288 Code of practice for use and laying of ductile iron pipes
4 12820 Dimensional requirements of rubber gasket for mechanical joints and
push-on joints for use with cast iron pipes and fittings for carrying water,
gas and sewage

17.18.3. Hydrostatic Test

All pipes shall be tested hydrostatically at a pressure , to perform the test, pressure shall be
applied internally and shall be steadily maintained for a period of minimum 15 seconds during
which the pipes may be struck moderately with a 700 g hammer. The pipes shall withstand the
pressure test and shall not show any sign of leakage, sweating or other defects of any kind.

17.18.4. Restoration and cleaning up

Where any road, payment, shrubbery, fences, poles or other property and surface structures
have been damaged, removed or disturbed during the course of work, such property and surface
structures shall be replaced or repaired after completion of work.

All roads, pavements, paved footpaths, curbing, gutters, shrubbery, fences, poles or other
property and surface structures removed of disturbed, as a part of the work shall be restored to a
condition equal to that before the work began.

All surplus materials, and all tools and temporary structures shall be removed from the site as
directed by the executing authority.

17.19 Guidelines & Specifications for DWC Pipes::

Technical Specifications

Class SN 8 Structured Double Wall (Non-Smooth External Annular Corrugated wall & Smooth
Internal wall) Polyethylene Piping System for non-pressure underground Sewerage & Drainage
Applications

17.19.1 Scope
This specification covers the requirements for manufacturing, supplying, transportation, handling,
stacking, installation, jointing, and testing of Class SN 8 Structured Double Wall (Non-Smooth

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 External Annular Corrugated wall & Smooth Internal wall) Polyethylene Piping System for non-
pressure underground Sewerage & Drainage Applications herein after called the DWC PE Piping
System.

17.19.2 Applicable Codes

The manufacturing, testing at factory, supplying, transportation, handling, stacking, installation,

jointing, and testing at sites shall comply with all currently applicable statutes, manuals,
regulation, standards & codes. If requirements of these specifications are at variance with any
other standards, this particular document shall govern the proceedings.

IS 16098- Structured Wall Plastics piping Systems for non-pressure drainage and sewerage-
2 Specification
Part 2: Pipes and fittings with non-smooth external surface, Type B

Other Indian standards which are integral part of above standard as normative references form a
significant portion of this specification document.

17.19.3 Manufacturing

The DWC PE Piping System of stiffness class designation SN 8 shall confirm to the Indian
standards as mentioned above and. Each pipe shall be coupler (on-line or off-line) and spigot
type along with rubber sealing ring (as designated under above international specifications).

17.19.4 Transportation

The arrangement of loading the pipes in a telescopic manner is advised, i.e. smaller diameters
inserted into the next higher sizes of pipes. While loading the pipes onto the truck, care should be
taken that the coupler- end should be arranged alternatively in the corresponding layers so as to
avoid the damage to the coupling/ socket ends.

17.19.5 Handling
Following Recommendations shall be followed while handling the pipes:

Adherence to National Safety requirements

Pipes to be smoothly lowered to the ground

Pipes should not be dragged against the ground to avoid the damages to the Coupler/pipes.

800mm and larger diameter pipes are carried with Slings at two points spaced approximately
at 3 Meters apart

For smaller diameters (400mm – 800mm) one lift point shall be sufficient & can be handled
either manually or mechanically

Do not use a loading Boom or Fork Lift directly on or inside pipe.

17.19.6 Pipe Storage at Site

Stockpiling shall be done temporarily on a Flat Clear Area as per Fig. 1 & 2.

For avoiding collapse of Stacks, use Wooden Posts or Blocks

Stacking shall not be higher than 2.5 Meters

While stacking, alternate the socket/coupler ends at each row of stacked pipes as per Fig. 2.

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 Fig 1 Fig 2

17.19.7 Lowering, Laying & jointing of Pipes

The width of a Sewer Trench depends on the soil condition, type of side protection needed and
the working space required at the bottom of Trench for smooth installations. Increase in width
over required minimum would unduly increase the load on pipe and cost of road restoration.
Considering all above factors, the Minimum Trench Width is specified as per Table below :-

**
Indicative Trench Widths
Pipe Diameter (mm) Trench Width (M)
75-200 0.6
250 0.7
300 0.8
400 0.9
600 1.2
800 1.3
1000 1.8
**
In actual practice the trench width can be as narrow as possible but adequate to allow the
workmen to execute the job satisfactorily.

The pipe segment between two manholes shall be laid approximately in straight line without any
vertical undulations. However, on the strength of its flexibility, the DWC PE Piping system can be
laid in very smooth curve if found necessary. The piping system shall rest on the carefully
prepared bedding portion of the Backfill Envelope and at appropriate jointing locations the
trenches shall be excavated deeper to accommodate the bulges of coupler-spigot joints.
However, special care shall be ensured as mentioned below:-

Excavation of trenches shall be carried out in accordance with the drawing & specifications
and as directed by the field engineer as well.

The piping system shall be laid and jointed in true to gradient with the help of sight rails and
boning rods as detailed in CPHEEO, MoUD, GoI Manual on Sewerage and sewerage
treatment. The levels need be checked with calibrated modern Levelling Instrument. Specific
care shall be taken to prevent entry of sand / mud /slush/ any other foreign material etc into
the system during the installation operation.

The structural property of the system suggests that a minimum cover of 500 mm adequate even
for maximum quantum of superimposed (live) load.

In case of wider trenches than required (above table), the permission of the competent authority
shall be necessary.

The bedding area is an essential portion of Back fill Envelope and shall be constructed with
proper bedding material as computed in accordance with appropriate international code of
practice for structural bedding design mentioned in the list of normative references under IS
16098-2.The bedding shall be laid to specified thickness and gradient with proper manual
compaction of the aggregate.

The moulded on-line coupler (or separate coupler integrated to the pipe in case of lower sizes)
will have a suitable internal surface for push-fitting the said end over the spigot end of the next

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 pipe. On first valley of the corrugation of said spigot end (destined to receive the pushed coupler)
the sealing rubber ring of standard quality shall be placed so that the coupler end of the pipe
smoothly but tightly slides over the sealing ring for making an absolute watertight joint. Similar
system is also used for fabricated accessories or moulded fittings required such as Tee, Bends,
Elbows, Reducer end caps for the purpose of installation of the system related to
drainage/sewerage.
For quality connections following steps are to be ensured, failing which the performance aspects
are to be severely compromised:-

The non-coupler (socket) end needs to be thoroughly cleared and shall be free from any
foreign material

Clean and lubricate the coupler end of the pipe, if required.

Lubricate the exposed Gasket in the same manner, if required.

Keep the non-coupler end free from dirt, backfill material, and foreign matter so that the joint
integrity is not compromised.

Push the coupler into non-coupler and align properly. Always push coupler end into non-
coupler end.

For smaller diameter pipes simple manual insertion shall be sufficient. It should be ensured that
the coupler end is adequately ‘homed’ within non-coupler end to ensure installation and tight
joining seal. Therefore prior to insertion always place a ‘Homing Mark’ on appropriate corrugation
of the ‘Non-Coupler End’.

17.19.8 Construction of backfill envelope and final backfilling of the trenches

DWC PE Piping System with well compacted Backfill Envelope along with the bottom and sides
of trench (native soil) work together to support soil overburden and superimposed (traffic) loads.
The carefully constructed Backfill Envelop has three distinct but non-isolated stages.The
construction need to be done stage by stage as per the sequence stated below:

Bedding portion

Up to Haunch level

Remaining portion

The material for backfill envelop shall be in accordance with the structural design of flexible
buried conduit as per relevant international codes. It can be the same material that were removed
in the course of excavation or it can be fine sand/course sand/gravel / moram /other form of
course / fine aggregates depending on the effected Design Load [Overburden + Superimposed
(Live) load]. However, in no circumstances, the flexible pipe should not be embedded in cement
concrete (un- reinforced or reinforced) which invariably induces undesired rigidity in the system.

The remaining portion of backfilling which do not contribute to the structural integrity of the
system may be the materials that were removed in the course of excavation or any other
foreign material as may be required to suit the particular site condition. These materials shall
consist of at least clean earth and shall be free from large clod or stone above 75 mm, ashes,
refuse and other injurious materials.

After completion of bedding portion of the Backfill envelop and subsequent lying of pipes, etc,
first the haunch portion & then upper portion of Backfill Envelope shall be constructed as per
design around the pipe. Voids must be eliminated by knifing under and around pipe or by
some other indigenous tools.

The compaction, by hand rammers or compactors with necessary watering to a possible
maximum level of proctor density shall be ensured.

Backfilling shall start only after ensuring the water tightness test of joints for the concerned
sewer segments. However, partial filling may be done keeping the joints open.

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Precautions shall be taken against floatation (if at all necessary) as per the specified
methodology and the minimum required cover.

17.19.9.Continuity Test /Hydraulic Testing

Continuity of the pipe segments in between two manholes is required to be ensured in the same
modality as practiced for non-pressure RCC pipeline. Hydraulic testing of pipes shall be done, by
the contractor. The procedure for hydraulic testing shall be similar to that for non-pressure RCC
pipes.

The Mode of Measurement etc shall be of the same as applicable to RCC pipes.

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 18.VALVES

Gate Valves shall be either solid wedge or knife gates unless specifically defined on the drawings.

18.1. SOLID WEDGE GATE-TYPE SLUICE VALVES

18.1.1. General
All valves shall be double-flanged. Valves of Indian manufacture and in the size ranging 50mm to
300mm shall conform to BIS 780 and those of size ranging from 350 mm and larger to BIS:2906.
Imported valves shall conform to the relevant British or American Standards. The materials used
in construction, the design and all other relevant features shall be such that the valves are entirely
suitable for use on sewer/sludge pipelines, force mains and within sewage pumping stations.
Valve shall be of suitable pressure rating which shall not be less than twice the normal operating
pressure. PN rating shall be 1.6 for all types of valves.

18.1.2. Design
The design of the valves will be such that erosion, cavitation, vibration and head loss (in the fully
open position) shall be a minimum external lubrication. The valves should be capable of being
opened and closed against working pressure which exceed the maximum working pressures by
15 percent.

18.1.3. Materials
The materials used for the manufacture of each component shall be the best available for the
specific purpose and shall not, in any case be inferior to the following:
Cast Iron : BIS. 210 Grade 20
Stainless Steel : BIS. 1570 Grade, BS 970 Type EN, ASTM A 473.
Gun Metal : BIS.1400-LG 2 -C or the equivalent Indian Std.
Cast Steel : Plain Carbon Steel complying with BIS. 1570 Grade, or BS: 970
Grade 431 S 29.

18.1.4. Valve Bodies

a. Castings
The structure of the castings shall be homogeneous and free from non-metallic inclusions and
other injurious defects. All surfaces of castings, which are not machined shall be smooth and
shall be carefully fettled to remove all foundry irregularities.

b. Forgings
All major stress bearing forgings shall be made to a standard specification, which shall be
submitted if required to the Engineer-in-Charge for approval before work is commenced. Forging
shall be subjected to non-destructive tests to detect flaws if any. Forging shall be heat treated for
the relief of residual stresses. The name of the maker and particulars of the heat treatment
proposed for such forging shall be submitted to the RMC. The Engineer-in-Charge or his inspector
may inspect such forging at the place of manufacture with a representative of the Contractor.

c. Workmanship
Workmanship and general finish shall be of first class commercial quality and in accordance with
best workshop practice.
All similar items of the valve and their component parts shall be completely interchangeable.
Spare parts shall be manufactured from the same materials as the originals and shall fit in place
of all similar items.

All parts, which can be worn or damaged by dust shall be totally enclosed in dust proof housings.

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 Protective coating shall comply with BS 1218 Clause 16, for use in tropics, or BIS 2906,
Clause 7.

18.1.5 Spindle Details

The spindles shall be of Bronze and to permit the solid wedge gate to be so raised as to permit
an unimpeded flow passage through the valve in open position. Where handwheels are provided
the direction of rotation and the words ‘OPEN’ shall be marked prominently on the upper side. All
spindles contacting surfaces in the valve body shall be bushed with gunmetal.

18.1.6. Valve Gates

Each face of the gate shall be lined with heavy gunmetal rings, which will match with
corresponding rings in the body. The rings shall be force fitted by special fixtures and riveted in
the case of valves in the size range 450 mm and larger. When finally assembled, the body and
wedge faces shall provide a watertight bearing surface. When shut, the gates shall ride on the
body seats, to allow for wear.

18.1.7. Operation
The tops of the spindles or gears operated with extension spindles or tee keys shall be provided
with caps of dimensions conforming to BIS 2906 Table III. The direction of opening shall be
indicated on the caps.

18.1.8. Lubrication
At the points where lubrication is needed the Contractor shall furnish full details of the method to
be employed. The requirement of the requisite lubricating equipment and lubricants for
commissioning and operating and maintaining the valves for one year shall be furnished by the
Contractor.

18.1.9. Spare Parts

One spare spindle and nut shall be supplied under this contract for each group of 10 sluice valves
or less of the different sizes. The Contractor shall take this into account while quoting the rates for
individual items. No separate payment shall be made for this work. In addition the Contractor
shall submit a list of recommended spares for 5 years of operation and maintenance of all
mechanical, electrical and instrumentation works covered under this contract. Spares supplied
shall be new, unused and interchangeable with the corresponding components they are intended
to replace.

18.1.10. Flanges
Valves of sizes from 80 mm to 300 mm shall have flat flanges as per BIS:1538 Part IV Table I.
Valves of sizes from 350 mm and larger shall have raised flanges as per BIS: 4504, Table 10/11
for 10 bar valves. The flange to flange distances shall be as per BIS:780 for 80 mm - 300 mm
valves and BIS : 2906 for 350 mm and larger valves.

18.1.11. Jointing Materials

Each valve shall be supplied under this Contract, with all-requisite joint rings, nuts, bolts and
washers for making the joints on all the valves to be installed under this Contract. Jointing
material between the connecting flanges shall conform to the requirements of BIS 638- 1965.
Unless otherwise specified bolting used for jointing exposed connections shall be carbon steel,
conforming to BIS 210 Grade 20 Grade B, with galvanized finish. Bolting for buried joints and
joints that could come into contact with raw sewage shall be Stainless Steel, as per Clause 2.02
A3. Boltholes shall be off-centre and in correct adjustment longitudinally.

18.1.12. Special Requirements - 450 mm and Larger Valves

Sluice valves in the size range 450 mm to 1200 mm shall have, in addition to the above
requirements, the following features.

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 a. The valves shall have machined gun metal gate slides. Hard bronze shoes shall be provided
on the gate and machined gunmetal channels in the body. The bronze shoes will be
machined accurately to give a close working clearance with the channels.
They shall provide corrosion resistant bearing surfaces and minimize sliding friction and
vibration while maintaining accurate alignment. The use of cast iron channels with brass
lining will be permitted if the lining is at least 6mm thick. The use of other materials for
holding the channels in position will not be permitted.
b. The valves shall be provided with spur gearing consisting of machined mild steel pinions and
cast iron wheels for valves installed underground. The pinion shafts shall run in gun metal
bushes in a cast iron bearing bracket with provision for lubricating by a grease gun.
Gear wheel ratios will be such that a force of 270 Newton's applied on each end of a bar in
combination with a Tee Key or extension spindle at the following distances from the key
centre will permit smooth operation.

Valve size range (mm) Distance of application of force (mm)

450-900 600
1200 750

Valves installed above ground shall be provided with worm gearing. These shall be machined cut,
with bronze wheel and steel worm enclosed in a cast iron gear case which shall be mounted on a
fitting connected to the valve cover flange and shall be complete with indicator column.

The worm shafts shall be equipped with ball thrust bearing and gunmetal bushes. The gearbox
shall be oil filled and sealed. The worm shaft bearing shall be provided with grease gun nipples.
The gear ratios shall be so selected that the maximum force required to develop the requisite
operating torque shall not exceed 180 Newton's.
All valves of size 450 mm or more shall have valve gate indicator columns with 10 mm
graduations and indicating the fully open and closed positions. The indicator assembly should be
sufficiently watertight to prevent entry of rainwater into the worm gear box in outdoor valves.

18.1.13. Factory Tests

All the valves shall be tested at the factory for smooth, trouble free operation and operating
torque requirements by operating between fully open and fully closed position three times. The
hydrostatic tests shall consists of -
a. Application of a pressure equal to 1 and a half times the maximum working pressure
specified in this section with both ends closed and valve fully open, for ten minutes. No
leakage of water should occur through the metal, flanged joints or valve packing gland, nor
should any permanent deformation of any part occur.
b. The pressure shall then be reduced to the working pressure and the wedge gate lowered,
thus closing the valve. The stipulated pressures shall then be maintained for 5 minutes on
each side in turn during which no leakage should occur on the downstream side of the valve
seating.

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 19.WATER SUPPLY AND SANITARY WORKS

19.1. MANHOLES/INSPECTION CHAMBERS

19.1.1. Scope

This Specification covers the requirements for providing and construction ancillary works such as
manholes, scraper manholes, vent shafts, etc.
19.1.2 Applicable Codes

The following standards, unless otherwise specified herein, shall be referred. In all cases, the
latest revision of the Codes shall be referred to. If requirements of this Specification conflict with
the requirements of the Codes and standards, this Specification shall govern.

IS: 111 Code of Practice for Ancillary Structures (Part I) - Manholes.

IS: 555 Cast Iron Steps for Manhole.
IS: 1077 Common Burnt Clay Building Bricks
IS: 3102 Classification of Burnt Clay Bricks.
IS: 395 Method of Sampling and Testing Clay Building Bricks.
IS: 2212 Code of Practice for Brick Work.

19.1.3. Location

Manholes / Inspection chambers shall be constructed at places approved by the Engineer-in-

Charge.

19.1.4. Excavation

Excavation, shoring, dewatering etc. for the pits of manholes / Inspection chambers, laying of
pipes and fittings/specials shall be done in accordance with Engineer-in-Charge requirements
described elsewhere in the document.

19.1.5. Bed Concrete

The bed concrete (min grade M15) for manholes/Inspection Chambers shall be done in
accordance with Engineer-in-Charge's requirements described elsewhere in the document.

19.1.6. Bricks

Bricks used for construction of manholes / Inspection chambers shall conform to the relevant
Indian Standards. They shall be sound, hard, homogeneous in texture, well burnt in kiln without
being vitrified, table moulded, deep red, cherry or copper coloured, of regular shape and size and
shall have sharp and square and parallel faces. The bricks shall be free from pores, chips, flaws
or humps of any kind. Bricks containing unground particles and/or which absorb water more than
1/6th of their weight when soaked in water for twenty-four hours shall be rejected. Overburnt or
underburnt bricks shall be liable to rejection. The bricks shall give a clear ringing sound when
struck and shall have a minimum crushing strength of 50 kg/sq.cm, unless otherwise noted in
drawings. The class and quality requirements of bricks shall be as laid down in IS: 1077.

The size of the brick shall be 23.0 x 11.5 x 7.5 cm unless otherwise specified; but tolerance upto
+ 3 mm in each direction shall be permitted. Only full size brick shall be used for masonry work.
Brickbats shall be used only with the permission of Engineer-in-Charge to make up required wall
length or for bonding. Sample bricks shall be submitted to the Engineer-in-Charge for approval
and bricks supplied shall conform to approved samples. If required by the Engineer-in-Charge,
brick samples shall be tested as per IS:3495 by Contractor. Bricks rejected by the Engineer-in-
Charge shall be removed from the site within 24 hours.

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19.1.7. Cement Mortar

Mortar for brick masonry shall be prepared as per IS:2250, Manholes / Inspection chambers shall
be constructed in brick masonry with cement mortar (1:3) unless otherwise specified. Gauge
boxes for sand shall be of such dimensions that one bag containing 50 kg of cement forms one
unit. The sand shall be free from clay, shale, loam, alkali and organic matter and shall be of
sound, hard, clean and durable particles. Sand shall be as approved by the Engineer-in-Charge.
If required by the Engineer-in-Charge and shall be thoroughly washed till it is free of any
contamination. For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
condition. Water shall then be added and mixing continued to give a uniform mix of required
consistency. Cement mortar shall be used within 25 minutes of mixing. Mortar left unused in the
specified period shall be rejected.
The Contractor shall arrange for tests on mortar samples if so required by Engineer-in-Charge.
Retempering of mortar shall not be permitted.

19.1.8. Brick Masonry

All bricks shall be thoroughly soaked in clean water for at least one hour immediately before
being laid. Brick work 230 mm thick and over shall be laid in English Bond unless otherwise
specified. 115 mm thick brick work shall be laid with stretchers. For laying bricks, a layer of mortar
shall be spread over the full width of suitable length of the lower course. Each brick shall be
pressed into the mortar and shoved into final position so as to embed the brick fully in mortar.
Bricks shall be laid with frogs uppermost.

All brickwork shall be plumb and square unless otherwise shown on drawing and true to
dimensions shown. Vertical joints in alternate courses shall come directly one over the other and
be in line. Horizontal courses shall be leveled. The thickness of brick course shall be kept
uniform. For walls of thickness greater than 230 mm both faces shall be kept in vertical planes
unless otherwise specified. All interconnected brickwork shall be carried out at nearly one level
(so that there is uniform distribution of pressure on the supporting structure) and no portion of the
work shall be left more than one course lower than the adjacent work. Where this is not possible,
the work shall be raked back according to bond (and not saw-toothed) at an angle not exceeding
45 degrees. But in no case the level difference between adjoining walls shall exceed 1.25 m.
Workmanship shall conform to IS:2212.

Brick shall be so laid that all joints are well filled with mortar. The thickness of joints shall not be
less than 6 mm and not more than 10 mm. The face joints shall be raked to a minimum depth of
12 mm by raking tools daily during the progress of work when the mortar is still green, so as to
provide a proper key for the plastering to be done. When plastering is not required to be done,
the joints shall be uniform in thickness and be struck flush and finished at the time of laying. The
face of brickwork shall be cleaned of all dirt before another course is laid on top. If mortar in the
lower course has begun to set, the joints shall be raked out to a depth of 12 mm before another
course is laid.

19.1.9. Cement Plaster

All joints in masonry shall be raked to a depth of 12 mm with hooked took made for the purpose
when the mortar is still green and in any case within 48 hours of its laying. The surface to be
rendered shall be washed with fresh clean water free from all dirt, loose material, grease etc. and
thoroughly wetter for 6 hours before plastering work is commenced. Concrete surfaces to be
rendered will however be kept dry. The wall should not be too wet but only damp at the time of
plastering. The damping shall be uniform to get uniform bond between the plaster and the wall.

Cement shall be mixed thoroughly in dry condition and then just enough water added to obtain a
workable consistency. The quality of water, sand and cement shall be as per relevant IS. The

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 mortar thus mixed shall be used immediately and in no case shall the mortar be allowed to
remain for more than 25 minutes after mixing with water.

Curing of plaster shall be started as soon as the applied plaster has hardened enough so as not
to be damaged. Curing shall be done by continuously applying water in a fine spray and shall be
carried out for at least 7 days.
Plastering shall be done on both faces of brick masonry in cement mortar (1:2) and 20 mm thick
unless otherwise specified.

Plastering work shall be carried out in two layers, the first layer being 14 mm thick and the second
layer being 6 mm thick. The first layer shall be dashed against the prepared surface with a trowel
to obtain an even surface. The second layer shall then be applied and finished leaving an even
and uniform surface, trowel finished unless otherwise approved by the Engineer-in-Charge.

19.1.10. Cement Concrete Channel

The channel for the manhole shall be constructed in cement concrete of M15 grade. Both sides of
the channel shall be taken up to the level of the crown of the outgoing sewer. They shall be
benched up in concrete and rendered in cement mortar (1:1) of 20 mm thickness and formed to a
slope of 1 in 12 towards the channel.

19.1.11. Pipe Entering or Leaving Manhole / Inspection Chamber

Whenever a pipe enters or leaves a manhole / inspection chamber, bricks on edge must be cut to
a proper form and laid around the upper end of the pipe so as to form an arch. All around the
pipes, there shall be a joint of cement mortar (1:2) 13 mm thick between it and the bricks.

19.1.12. Cast Iron Steps

Cast iron steps shall be as per IS:5455. The steps shall be of grey cast iron of grade 15 as per
IS:210. The steps shall be clean, well cast and they shall be free from air and sand holes, cold
shuts and wrappings. The portion of the step which projects from the wall of the manhole /
inspection chamber shall have a raised chequered design to provide an adequate non-slip grip CI
steps shall weigh not less than 5.5 kg each and shall be of 150 mm x 375 mm overall dimensions.
These steps shall be coated with a black bituminous composition. The coating shall be smooth
and tenacious. It shall not flow when exposed to a temperature of 63 degrees C and shall not be
brittle as a chip of at temperature of 0 degree C.

Where the depth of invert of manhole exceeds 800 mm, cast iron steps of approved pattern shall
be fixed in the brick work at the interval of 300 mm vertically and staggered at 380 mm
horizontally centre to centre. In case of pipe diameter greater than 600 mm, box type CI steps
weighing 19 kg each shall be provided at 300 mm vertically in channel of manhole / inspection
chamber.

19.1.13. Frame and Covers

Frame and covers for manholes shall be of required type and dimensions as per the relevant
drawings prepared by the Contractor. Following information shall be clearly marked on each
cover.
• Year of manufacture,
• Identification mark of the purchaser
• SEWERS/SWD
• Arrow showing direction of flow

Preferable Makes: KK Manholes and Gratings S.S. Manholes

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 Bharat Pipes and Covers and approved by
Engineer In charge

19.1.13.1. Cast Iron Frame and Cover

The cast iron frame and cover shall be of gray cast iron as per IS: 1726. The general
requirements for casting and coating of CI frame and cover shall be as specified for CI steps in
Clause 15.15.10. The covers shall have a raised chequered design to provide an adequate non-
slip grip. The rise of the chequer shall be not less than 4 mm. The locking device for the cover
shall be provided as approved by the Engineer-in-Charge. The CI covers for the load test shall be
selected at one for every lot of fifty or part thereof for each type and size manufactured and as
approved by the Engineer-in-Charge. The frame shall be fixed in cement concrete of M15 grade
all round and finished with neat cement. The manhole frame shall have 560 mm diameter clear
opening and shall weigh not less than 208 kg. Including cover. In case of rectangular CI frame
and cover of 900 mm x 600 mm clear opening, the total weight shall not be less than 275 kg. In
case of scraper manhole the frame shall have clear opening of 1200 mm x 900 mm and shall
weigh not less than 900 kg including cover. The manhole / inspection cover and frame shall be
painted with three coats of anti-corrosive paint after fixing in position.

19.1.13.2. Fibre Reinforced Concrete Frame and Cover

Fibre reinforced concrete frame and cover shall be capable of withstanding load of 35 tonnes.
The frame shall be fixed in cement concrete of M15 grade all around and finished with neat
cement. The fibre-reinforced frame shall have clear opening of 560 mm diameter and weighing
103 kg. The cover shall have a minimum thickness of 100 mm and weighing 78 kg. The fibres
shall constitute 1% of the weight of the concrete in the form of 50 mm to 100 mm long high tensile
steel wires. For the cover, MS sheet lapping of 18 gauge shall be provided to avoid damage to
the edges. Similarly for frame, MS angle/flat shall be provided along the edge. Both MS sheet and
angle shall be painted with black bituminous paint. The cover should have suitable lifting
arrangement. The fibre reinforced frame and cover shall be manufactured as approved.

19.1.13.3. Reinforced Cement Concrete Frame and Cover

Reinforced cement concrete frame and cover for manholes shall be of required
dimensions and shape as shown on the drawing prepared by the Contractor and approved by the
Engineer-in-Charge. The frame and cover shall be cast in cement concrete of M20 grades.
Minimum cover to the reinforcement shall be 40 mm. The edges of frame and covers shall be
provided with mild steel angles to avoid damages to the corners. These angles shall be painted
with black bituminous paint. The covers should have suitable lifting arrangement.

19.1.14. Drop Manhole

When a sewer connects a main sewer, and where the difference in level between water line
(peak flow levels) or main line and the invert level of branch lines is more than 600 mm or a drop
of more than 600 mm is required to be given in the same sewer line and it is uneconomical or
impractical to arrange the connection within 600 mm, a drop connection shall be provided for
which a manhole shall be constructed as per relevant drawing, incorporating a vertical drop pipe
from the higher sewer to the lower one. This pipe shall be provided outside the shaft and encased
in concrete. A continuation of the branch sewer should be built through the shaft wall to form a
rodding and inspection eye, which should be provided with a half blank flange. The diameter of
the black drop should be at least as large as that of the incoming pipe. The drop pipe should
terminate at its lower end with a plain or duck-foot bend turned so as to discharge its flow at 45
degrees or less to the direction of the flow in the main sewer. The pipe unless of cast iron should
be surrounded with 150 mm thick concrete.

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 In the case of sewers over 450 mm in diameter the drop in level may be accomplished by one of
the following approved methods.
a. A cascade,
b. A ramp,
c. By drops in previous manholes.

19.1.15. RCC Manhole

M20 grade of concrete used for construction of RCC manhole shall have min cement content of
300kg/cum of concrete. Min cover to the reinforcement shall be 50mm. The construction of RCC
manholes are proposed at major road junction according to the vehicular movement of the roads.
Also RCC manholes are proposed in the main sewers pipelines along the nalla /river for
avoidance of damage.
19.2. VENT SHAFTS

19.2.1. General

Vent shafts shall be erected at places shown on the Drawings of longitudinal sections of the
sewers or as directed by Engineer.

19.2.2. RCC Vent Shafts

1. RCC vent shaft shall be of precast RCC M20 with cowl, 125mm and 225mm internal and
external dia. respectively at top, 300 and 450 mm internal and external dia. at bottom and
6.0 m overall length, The vent shaft shall be embedded in concrete of M10 grade and
anchored by 2 nos. of 16 mm diameter and 600 mm long MS bars. The vent shaft shall be
connected to manhole as specified in (b) above through a brick masonry flue chamber. The
vent shafts shall be provided with GI flyproof mesh of 26 guage.

19.2.3. Measurement for Vent Shaft

1. The rate quoted in Schedule of Quantities and Rates for Vent shaft shall be deemed to include
the cost of RCC vent shaft, necessary excavation to manhole inclusive of concrete
encasement, erecting, etc. complete. The measurement for vent shaft shall be on per number
basis.

19.2.4. Testing of Materials:

The various materials to be used in the work shall be subject to mandatory tests in accordance
with latest relevant specifications with upto date corrections. These tests shall be got done as
directed by Engineer. All expenditure required for testing the samples, conveyance, packaging,
etc. including cost of material shall be borne by the contractor himself.For all field tests, the
contractor shall setup laboratory and arrange / keep the required equipments at site. The record
of test shall be kept for checking by the employer/engineer.

19.2.5. Requirements for Cement:

The Contractor shall procure 43/53 grade (conforming to IS : 12269) Or 43 grade (conforming to
IS : 8112) Ordinary Portland Cement or Sulphate resisting cement (conforming to IS 12330) as
required in the work, from reputed manufactures of cement such as ACC, L&T (ULTRA-TECH),
J.P. Rewa, Vikram, Shri Cement, Birla Jute, Ambuja and Cement Corporation of India, etc., as
approved by Ministry of Industry, Government of India, and holding license to use ISI certification
mark for their product whose name shall be got approved from Engineer. Supply of cement shall
be taken in 50kg. Bags bearing manufacture’s name and ISI marking, samples of cement
received at site shall be taken by the Engineer and got tested in accordance with provisions of
relevant BIS codes and QA/QC manual. In case test results indicate that the cement arranged by

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 contractor does not conform to the relevant BIS codes, the same shall be rejected and shall be
removed from the site by the contractor at his own cost within a week’s time of written order from
the Engineer to do so. Adequate water proof cement storage shed with proper protection against
moisture and water shall be constructed by the contractor at site of work. The contractor shall be
responsible for the watch and ward and safety of the cement godown. The contractor shall
facilitate the inspection of the cement godown by the Engineer at any time.

The Contractor shall supply free of charge the cement required for testing. The cost of tests shall
be borne by the Contractor. The cost of all tests as per IS/QA-QC Manual each consignment shall
be borne by Contractor and if any additional tests are required then the cost shall be borne by the
Employer. The actual issue and consumption of cement on work shall be regulated and proper
accounts maintained. The theoretical consumption of cement shall be worked out as per
procedure prescribed and shall be governed by conditions laid therein.

19.3. SEPTIC TANK

The sewer line shall be connected to a septic tank of adequate capacity and design including
necessary soak pit. All the works involved, such as excavation, refilling, accessories, fittings, vent
pipe, cowl cap, etc. as specified & directed shall be carried out.
19.4. MISCELLANEOUS

If any damage is caused to the other services such as water supply pipeline, sewer, cable, etc.
during the construction of manholes and erection of vent shafts, the Contractor shall be held
responsible for the same and shall replace the damaged services to the full satisfaction of the
Engineer-in-Charge. The interior of manholes shall be cleared of all debris after construction and
before testing the same for water tightness by the Contractor.

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 20.ROAD SIDE DRAINS

20.1. APPLICABLE CODES AND SPECIFICATIONS

The following specifications, standards and codes are referred to in this part
All earthwork shall be according to Engineer-in-Charge specified under Section n
“Earthwork”.

20.2. SLAB CULVERT

Slab culverts shall be constructed at specified locations of the existing cross drainage works as
directed by the Engineer-in-Charge. The Concrete works specifications for construction of RC
slab and the rubble masonry specifications for the supporting rubble walls shall be followed as
per Employer’s Requirements described elsewhere:

20.2.1. Bitumen at Location of Contact

The bitumen to be used on the top of the bed concrete at the location of contact of RCC slab
above in two coats shall be straight run bitumen of specified grade.

20.2.2. Graded Gravel Free Draining Backfill

On each side of the uncoarsed rubble walls supporting the slab culvert a free draining backfill of
thickness 200 mm shall be provided. The material for this backfill shall be granular consisting of
sound, tough, durable particles of crushed or uncrushed gravel, crushed stone or brickbats which
will not become powdery under loads and in contact with water.
The material shall be free from soft, thin, enlongated or laminated pieces and vegetable or other
deleterious substances. It shall be graded and shall meet the
grading requirements given in hereunder.

Sieve Designation Percent Passing by Weight

10 mm 100
4.75 mm 30-65
425 microns 5-30
150 microns 0-10

20.2.3. Weep Holes

Weep holes as shown on the drawings or as directed by the Engineer-in-Charge shall be

provided in the masonry to drain water from the backfilling. Weep holes shall be of asbestos
cement pipes conforming to IS: 6908 in rubber walls with necessary M10 concrete cushioning 75
mm thick. They shall extend through the full width of the masonry at a spacing of 1.5 m c/c and
with slope of about 1 vertical to 20 horizontal towards the drainage face.
20.3. PIPE DRAINS

Wherever required, pipe drains shall be provided for cross drainage purposes. The
sequence of construction shall be as follows:

laying of sand/shingle bedding on the original ground

laying of PCC of M10 grade
laying of concrete pipes of NP3 class as per IS:458
Constructing embankment above in compacted murum, laying of the sub-base and
Water bound Macadam as specified hereinabove.
The details of above works as directed by Engineer-in-Charge shall be followed.

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20.3.1. Materials for Pipe Drains

All materials used in the construction of pipe drains shall conform to Engineer-in-Charge. RCC
pipes class NP3 shall conform to IS: 458.
Each consignment of cement concrete pipes shall be inspected, tested if necessary, and
approved by Engineer-in-Charge at the place of manufacture or at site before their in Corporation
in the Works.

20.3.2. Excavation for pipes

The foundation bed for pipe drain shall be executed true to the lines and grades shown on the
drawings or as directed by the Engineer-in-Charge. The pipes shall be placed in shallow
excavation of the natural ground in open trenches cut in the existing embankment, taken down to
levels as shown in the drawings. Where trenching is involved, its width on either side of pipe shall
not be less than 150 mm nor more than one-third the diameter of pipe. The sides of the trench
shall be as nearly vertical as possible.

When during excavation, the material encountered is soft, spongy or other unstable soil, unless
other special construction methods are called for as indicated on drawings, such unsuitable
material shall be removed upto a depth of 600 mm or as directed by the Engineer-in-Charge.
Before placing any backfill material, exposed surface of the soft soil shall be lightly compacted
with one pass of 0.5 T roller. On the lightly compacted surface, coarse sand and shingle shall be
spread in two successive layers of 300 mm and each layer shall be compacted by rolling with a
min 0.5 T roller and with a minimum of 10 passes each, both in longitudinal and transverse
directions.

When bed rock or boulder strata are encountered, excavation shall be taken down at least 200
mm below bottom level of pipe as directed by Engineer-in-Charge and space filled with approved
sand and shingle and thoroughly compacted to provide adequate support for the pipes. Trenches
shall be kept free from water until the pipes are installed and the joints have been hardened.
20.3.3. Bedding for pipe

The bedding surface shall provide a firm foundation of uniform density throughout the length of
the pipe drain and shall conform to the specified level and grade. The pipe shall be bedded in a
cradle of concrete having a mix not leaner than M-10. The pipe shall be laid on the concrete
bedding before the concrete has set.

20.3.4. Laying of pipes

No pipes shall be placed in position until the foundations have been approved by Engineer-in-
Charge. When pipes are to be laid adjacent to each other, they shall be separated by a distance
at least equal to or greater than half the diameter of pipe subject to a minimum of 450 mm.
The laying of pipes on the prepared concrete foundation shall start from the outlet and proceed
towards the inlet and be completed to the specified lines and grades. The pipes shall be fitted and
matched so that when laid they form a drain with a smooth uniform invert. Any pipe found
defective or damaged during laying shall be removed at the cost of the Contractor.

20.3.5. Jointing

All the joints shall be made with care so that their interior face is smooth and consistent with the
interior surface of the pipes. The ends of the pipes should be so shaped as to form a self-
centering joint with jointing space 13 mm wide. The jointing space shall be filled with cement
mortar (1 cement to 2 sand) mixed sufficiently dry to remain in position when forced with a trowel
or rammer. Care shall be taken to fill all voids and excess mortar shall be removed. After
finishing the joints shall be kept covered and damp for at least four days.

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20.3.6. Back filling

Trenches shall be backfilled with selected materials as per Employer’s Requirements given in this
part. Backfilling upto 0.3 metre above the top of pipe shall be carefully done and murum shall be
thoroughly consolidated under the haunches of the pipe.

20.3.7. Concrete Encasement

Concrete encasement shall be provided at places wherever directed by the Engineer-in-Charge.

Concrete shall be of M 20 grade. MAKES AND SPECIFICATIONS OF MATERIAL (GENERAL
CIVIL WORKS)

20.4. Double Wall Corrugated (DWC) Pipe

Double Wall Corrugated Pipe of Polyethylene (PE) with smooth internal and profiled external
surface for non-pressure underground drainage and sewerage as per ISO 21138-3 in 6 meter
length bar of SN4/ SN8. With coupling arrangement.

The pipe shall be confirming to ISO 21138-3 and also IS 16098 (Part-2):2013. The pipes and
specials shall be ISI marked.

20.4.1. LAYING OF PIPES

a) The pipes are to be laid with sockets facing up the gradients beginning at the lower end.
No pipe to be laid until the trench has been excavated its required depth for a distance of
20 M in front of the pipe to be laid (This distance may vary as directed by the Engineer).

b) All the pipes are to be laid perfectly true, both in line and on gradient. The pipes in a
trench shall be all laid and fitted previous to the jointing being commenced.

c) Properly fitted temporary wooden stoppers shall be provided and constantly used to close
the ends of all incomplete pipe lines. The stopper is only to be removed when pipes are
being and jointed.

20.4.2. Bedding of HDPE (DWC) Pipe

The bedding for stoneware pipes shall be of murum bedding filling in plinth and floors murum
bedding in trenches with approved murum from excavated materials or brought from outside
15cm to 20cm layers including watering and compaction complete.
These DWC HDPE Pipe and DWC HDPE Corrugated Pipe are flexible, tough and available as
per IS-16098(Part -2):2013

20.4.3. Dimensions

The width of a sewer trench depends on the soil condition, type of side protection and the working
space required at the bottom of trench for smooth installations. Increase in width over required
minimum would unduly increase the load on pipe and cost of road restoration. Considering all
above factors, the minimum trench width is specified as per below Table.

20.4.4. Marking

The following information shall be clearly marked on each pipe including the details given by
Engineer In charge of RMC: Internal diameter of pipe.

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 Class of pipe.
Date of manufacture, and
Name of manufacturer or his registered trademark or both.

20.4.5. Shoring/mild steel sheet piling

The protective shoring works shall be strong enough to prevent caving in of trench walls or
subsidence contagious areas adjacent to trench.

For wider and deeper trenches, (a system of wall plates wales) and struts of heavy timber
section is commonly used as per the requisite structural design.

In non-cohesive soils with high water table, continuous interlocking mild steel sheet piling may be
necessary to prevent excessive movements due to ground water percolation. Such sheet piling
shall extend 1.5 m below the trench bottom unless the lower soil strata are adequately cohesive.

20.4.6. Underground services

The underground public and private utility services exposed due to the excavation shall be
effectively supported under the guidance of the owners of such services.

20.4.7. Dewatering

Sewer installation trenches shall be adequately dewatered for the placement of pipe at proper
gradient till the pipe is integrated through socket and spigot joint/coupler assembly with the
already laid segment. Precautions are to be taken to arrest floating of installed sewer segments
against buoyant forces in case of sudden accumulation of water in the trench. The diameter wise
minimum cover necessary to counteract the buoyant forces .

20.5. Works to facilitate House Sewer Connections:

The work involves the laying of DWC HDPE pipes from the property boundaries / road side
chambers to the street manholes as per drawings, site layout and as directed by the Engineer to
facilitate house sewer connections.
No work shall be carried out inside the property boundaries.
This work is classified as under:
• With road side chamber. A road side chamber of 90 x 60 cm shall be constructed close to
the property boundaries, inside the road width. The proposed location of the roadside
chamber shall be such that it shall be possible to connect at least two properties to the
roadside chamber with minimum length of pipes. Provision for extra future connection into
the road side chamber may be kept as directed / approved by the Engineer. Wherever
construction of road side chambers is not possible due to site constrain (for road widths
between facing property boundaries less than 4 metres) the pro rata payment shall be
applicable.
The murrum bedding as per standard drawing shall be provided for the HDPE DWC pipes. HDPE
DWC pipes are to be plugged with end cap near the property boundaries as shown in the
Drawing and / or as directed by the Engineer.
20.6. Dismantling & reinstatement of BT & WBM roads

The Contractor shall be paid actual depth of dismantling & reinstatement of the road to its original
conditions earthwork if any up to 0.5 meter depth which come in the way of sewer trench
alignment. The quantity shall be measured in Cu. mtr.
20.7. Reinstating the road surface

The road surface shall be remade using 1 layers of 80mm compacted trap stone of 200 mm thick,

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1 layers of 40 mm compacted trap stone of 100 mm thick, spreading and compaction of soft
murrum of 100 mm thick, and as a bearing surface 20 mm thick premix carpet (as per clause 511
& 512 of M.O.R.T. &H Specifications) and seal coat, as per clause 513 of M.O.R.T. &H
Specifications. The road restoration shall be carried out as soon as possible after completion of
inspection, testing and approval of the pipeline and manhole by the Engineer.
Cement Concrete Pavement / Roads:
The restoration of dismantled existing concrete pavement shall be measured in cubic meters. The
thickness of the concrete for the restoration works shall be same as the thickness of existing
pavement. The re- concreting shall be done with utmost care and cement slurry shall be applied
on the edges of old cement concrete pavement before laying the fresh concrete. The grade of
concrete shall be M-15 for bottom 15 cm. layer & M-20 for top layer of 15 cm. The works shall be
done in accordance with the Standard Specifications and the M.O.R.T. & H / IRC Specifications
shall be followed for the repair/ restoration works.

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 VOLUME II
MECHANICAL SPECIFICATIONS

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 PREAMBLE
1.0 The Volume II: Mechanical Specifications are to be read for the purpose of pricing in
conjunction with "Volume-I : Conditions of Contract" of the Tender Documents containing
instructions to Tenderer and General Conditions of Contract; “Volume II : Scope of
Work” under this tender; “Volume II : Civil Specifications”, “Volume II : Electrical
Specifications” “Volume II : Operation and Maintenance”, Volume II : Quality Control and
Quality Assurance” and “Volume-V : Financial Bid” of this tender.
2.0 The prices quoted in the Volume V: Financial Bid shall be all inclusive value for the work
described including all costs and expenses which may be required in and for the
execution of the work described together with all general risks, liabilities and obligations
set forth or implied in the document on which the tender is based.
3.0 All works shall be carried out strictly as per detailed specifications whether actually
specified or not. If not specified work shall be carried out as per directions of
Owner/Engineer I/C.
4.0 The total amount entered in the Volume V : Financial Bid document shall be written in
ink and shall be entered both in figures and words.
5.0 Specifications of items of work are described in Section D for each item of Volume V :
Financial Bid shall read this in conjunction with other technical specifications and specific
technical requirements and quote accordingly.
6.0 No separate payment whatsoever shall be made for dewatering if required to be done
during excavation, laying of PCC and RCC laying and jointing of pipes, construction of
manholes, testing and backfilling etc. and Contractor should quote accordingly.
7.0 If Tenderer needs any clarification, they shall obtain the same in writing from
Owner/Engineer. No notice will be taken of any verbal discussions in such matters.
8.0 Abbreviations used in the Volume II : Mechanical Specifications have the meanings
shown below:
mm Millimetre CI Cast Iron
cm Centimetre GI Galvanized Iron
m Metre GSW Glazed Stone Ware
km Kilometre BBCC Burnt Brick Cement Concrete

sq.m Square Metre RCC Reinforced Cement Concrete

cu.m Cubic Metre PCC Plain Cement Concrete
M.T. Metric Ton Wt Weight
SWG Standard Wire Gauge Kg Kilogram
R.M. Running Metre I.D. Internal Diameter
nos. Numbers C.M. Cement Mortar
MS Mild Steel IS Indian Standards
M.D Metre Depth of Manhole SS Stainless Steel

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 1. SCOPE OF MECHANICAL WORKS

The scope of the work shall include but not be limited to the following:

1.1. GENERAL
The contract includes design, manufacture, testing at works and Manufacturer plant, supply and
delivery at site, unloading, storing till the time of erection, installation, testing and commissioning
of mechanical equipment as mentioned in the following sections.
1.2. MECHANICAL EQUIPMENT
The details of the Mechanical equipment required for this contract are presented under tender
document: Mechanical Equipment and to be read in conjunction with ‘Volume IIA : Scope of
Work’.
Note:
1. Contractor should provide spares and list of spares required for one year after handing over
the plant.
2. All other miscellaneous items necessary for completing the installation and commissioning of
the equipment under this contract, as per the existing codes of practice.
3. Technical specific requirements shall conform to Volume IIA - Scope of Work and Volume IID -
Electrical Specifications, if any should be brought out separately in deviation schedule.

1.3. SUGGESTIONS & GUIDELINES::

For the Blowers For Aeration constant speed Centrifugal Single Stage integrally Geared Air
Blower shall be needed, as per following specifications:

General Specifications For Centrifugal Single Stage Integrally Geared Air Blower
The Air Blower shall be of single stage integrally geared centrifugal type only. Special tool
required for maintenance shall be delivered with the compressor.

Regulation type
Regulation shall be possible in the range of 100-45% (or less) of the project design flow at all
project design temperatures and at design pressure. The compressor shall be constructed with
two independent regulation possibilities to optimize the efficiency when regulating in the (A)
Isoentropic Head (compression and temperature) and (B) when regulating the flow. The
regulation should be achieved with the help of dual vane control i.e. Inlet Guide Vanes (IGVs)
and Variable Vane Diffusers (VVDs) so as to ensure maximum energy saving during complete
range. The regulation should be fully automated and contain a program for continuous
optimization of compressor efficiency with respect to changes in inlet temperature, differential
pressure and the required flow. The Isoentropic efficiency is not allowed to drop more than 7%
when regulating the flow from 100% to 45% at max project design temperature and pressure.

Air Blower Specification to be followed:

Description Minimum required specifications
Casing Inner Volute grey cast iron GG20-PN4 / EN1561 / GG25 cast
iron

Outer volute ductile cast iron GGG40-PN4/ EN1561 / GG25

cast iron
Impeller Aluminium AlCu2MgNi, open radial flow type with backward
leaning blades.
Gearwheels High tensile 15CrNi6
Shaft fast High tensile 15CrNi6
Shaft slow High tensile 34CrNiMo6
Coupling As per technology provider’s recommendation
Filter material As per technology provider’s recommendation
Machine mounts St. SIS 1312, for damping natural rubber hardness 60
Oil Cooling Water & air cooling is allowed
Acoustic enclosure Al-Zn coated steel, isolated with glass wool or similar
Motor IP55, insulation class F with temperature rise F and
temperature measurement in the winding as well as of anti
condensation heater. The motors shall be suitable to operate
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 on HT voltage supply.
Cone diffuser Steel St. 37-2
Compensator Steel St. 37-2
Check Valve Body ; Grey Cast Iron GG25 , Plates: CuAl9Ni
Vibration levels (P≤ 300 kW) ≤ 2.8 mm/sec RMS 10-1000 Hz in accordance to ISO 10816-1
Vibration levels (P>300 kW) ≤ 4.5 mm/sec RMS 10-1000 Hz in accordance to ISO 10816-1
Noise level ≤ 80 LEVEL db(a) at 1 meter away from unit in accordance to
ISO 3746

Impeller type
a) The impeller shall be of the semi open radial flow type, induced S-shaped with strong backward
leaning blades, machined as one, not welded, casted or riveted. The impeller shall be statically
and dynamically balanced. The Supplier must demonstrate that the impeller/shaft design is
designed for operating at peripheral speeds up to 115% of the rated operating speed. The axial
gap between the impeller and compressor casing must be adjustable by means of machined
spacers in order to assure the prescribed gap. Gap adjustments by means of machining of
casings or shafts may not be accepted
Shaft seals
a) The shaft seals shall be of a non-contact, multi-point, labyrinth type with small clearances and
sufficient touch points to minimize air leakage out of or into the casing while the compressor is
running in the specified operating range or during start and shutdown and to ensure a 100% oil
free air supply.
Gear Box
a) The gearbox shall be of ample size and rated to transmit the maximum torque and power input
requirements to the compressor under all operating conditions and continuous duty. The service
factor shall be minimum 1.4. All exposed machined surfaces shall be coated with a corrosion-
resistant compound prior to shipment.
b) The gear drive housing shall be of cast iron, EN1561/GG25 Cast Iron, sufficiently rigid to maintain
the shaft positions under maximum loads. The gear housing shall be horizontally split in order to
allow easy inspection and maintenance. The gear housing assemblies shall be machined to close
tolerances for bearing fit, gear alignment and oil tightness
Oil Lubrication System
a) A complete lube oil system shall be provided with each compressor. The system shall be capable
of supplying clean lube oil at suitable pressure and temperature to lubricate the speed increasing
gears and bearings. All components of the lubricating system shall be installed integral with the
compressor base plate and arranged to permit ease of accessibility for operation, maintenance,
inspection and cleaning.
b) The package shall include one gearbox drive shaft driven primary oil pump and one electric motor
driven pre-lubrication oil pump, each of adequate capacity to supply lubrication for the air
compressor/gearbox when operating under normal duty, during normal start/stop and during run
down in case of power loss. The electric motor driven oil pump will operate at start/stop of
compressor and at low oil pressure, activated by the control system located in the local control
panel
c) The lube oil filter shall be duplex cartridge type suited for the oil pump capacity, with replaceable
cartridges which can be replaced without stopping the compressor. The filter grade shall be
capable of removing particles over 10 microns with a clean oil filter and a pressure drop not
exceeding 350 mbar at design temperature and flow. Filter cases shall be suitable for operation at
a pressure not less than the relief valve setting. A visual gauge or an electric pressure switch
shall indicate when the filters are contaminated and requires replacement.
d) Strainers shall be manually cleaned and equipped with a magnetic trap. Design and installation
shall permit ready access for cleaning.
e) An oil cooler for each compressor shall be furnished and shall be of the air-to-oil or water-to-oil
type. The cooler shall be capable of maintaining required cooling rate at all specified ambient
temperatures. Each cooler shall be rated to dissipate the total emitted heat from the compressor

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 gearbox. Air-to-oil cooler shall be furnished with an electric motor-driven air blast fan. Water-to-oil
cooler shall be furnished with a cooling-water, flow control valve and an on-off water solenoid
valve. Water piping to skid edge shall be fitted with isolation valves.
Local Control Panel
a) Each compressor shall be furnished with an integrated and dedicated rack based PLC,
sequencing panel. All controls shall go into a safe condition by failure and not allow the machine
to be operated with any defective control.
b) The Local Control Panel set-up shall include the Load Sharing functionality i.e. no Master Control
Panel needed.
c) The local control panel shall consist of the following:
Low voltage system -with main switch and motor overload relays for auxiliary equipment such as
blow-off valve, variable diffuser, and inlet guide vanes. Further, monitoring of the drive motor's
temperature sensors, and relay for control of drive motor's main switch, with wiring to:
Control system - with automatic PLC with current overload circuit to limit power consumption of
the compressor, and all necessary control circuits for oil pressure, oil temperature, surge limit,
and recirculation.
The front panel shall be equipped with Human Machine Interface with a screen of minimum 6"
color touch panel with indication of process values Low voltage and control systems mounted in a
steel panel, IP54, and internally wired.
Terminal strip for external wiring.
Inlet filter / silencer
a) Each compressor shall be provided with an inlet filter / silencer designed for maximum air flow at
absolute minimum pressure drop and connected directly to the inlet of the compressor via a
flexible connection.
b) Filters shall be removable through easily accessible doors and have a removal efficiency of 99%
on 10 micron. The filter has to have a minimum standard of EU3 in accordance to DIN 24185.
c) In case the compressor is to be installed in a sandy environment, a sand trap and pre-filter has to
be installed at the air intake.
Bearings
Drive shaft radial and thrust bearings can be either Hydrodynamic type sleeve type bearings or
Duplex Ball and Roller bearings. The use of hydrodynamic thrust bearings on the high speed shaft
shall be avoided as to reduce the mechanical losses and instead the thrust load from the high
speed pinion shaft shall be transferred to the low speed shaft using high precision thrust collars on
the pinion shaft. Steel backed tilting pad radial bearings with white metal on the bearing surfaces
shall be used on the high speed pinion shaft. Radial and thrust bearings shall be pressure
lubricated with sufficient oil film thickness under all operating conditions. All bearings shall be rated
for a L10 bearing life of minimum 100.000 hours.

Sourcing of critical parts

Critical parts as PLC, motor and frequency converter (if required) should be widely available and
allow sourcing from multiple and different suppliers.
Following has to be provided for each compressor by the supplier:
• Outlet pressure transmitters, inlet temperature transmitter and a thermal mass flow meter.
The unit should allow for communication to main SCADA control system.
• Inlet Air Filter Differential Pressure Switch
• Oil Temperature Transmitter
• Oil Pressure Transmitter
• Oil Filter Differential Pressure Switch

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 • Variable Vane Diffuser Position Transmitter
• Inlet Guide Vane position transmitter
• Gear vibration accelerometer transmitter
• Blower reverse rotation detector
Performance Guarantee
a) At the performance test the design point and the following 4 guarantee points must be tested and
compliance with guaranteed performance proved: -
Operating conditions on site:
1. Barometric Pressure (Normal) bar abs
2. Relative Humidity (Normal) %
3. Inlet Temperature (Normal) .C
4. Inlet Pressure Loss (Design) bar
5. Discharge Pressure (Design) bar abs

b) The guaranteed performance points shall be demonstrated at a witnessed test on a calibrated

test bed at the vendor factory. The guaranteed performance shall be subject to a test tolerance of
0/+2% on the flow, 0/+2% on head/pressure and +/- 4% on shaft power consumption when
measured per the energy balance method defined in ISO 5389 or ASME PTC 10-1997, refer to
sect. 6.
Air Blower technology having maximum power saving will be given preference.
Number of blowers for the STP(2 W + 1 SB):
The STP shall have and Utilize total 3 Number of Blowers only and shall work as per 2W+1SB
arrangement to have energy optimization for the STP.
1.4. SUBMERSIBLE MIXERS HIGH SPEED /HIGH RPM MIXERS
MANUFACTURER REQUIREMENTS
The mixer specified herein shall be the design and fabrication of a single manufacturer which
shall have sole source responsibility for said equipment. The manufacturer shall have mixing
equipment of this principal design and of comparable capacity in successful operation in the field
for a minimum period of 10 years.
MIXER DESIGN
The mixer shall be capable of handling raw, screened sewage. It shall be possible, with the
exception for floor-mounted mixers, to easily raise and lower the mixer without the need for
personnel to enter the tank. The mixer shall be mounted on a square guide bar system or on a
fixed floor mount. A sliding guide bracket for the guide bar shall be an integral part of the mixer
unit. The mixer, with its appurtenances and cable, shall be capable of continuous submergence
without loss of watertight integrity to a depth of 20 m. Parts exposed to the mixed liquid shall be
made of either stainless steel AISI 304 or better or solid corrosion-resistant composite material.
Nuts, bolts, and washers shall be made of stainless steel AISI 304 or better.
MOTOR
The motor shall be directly connected to the propeller. The motor shall be a squirrel cage
induction motor, housed in an air filled, watertight chamber. The stator windings and stator leads
o
shall be insulated with moisture resistant Class H (180 C) insulation. The stator shall be trickle
impregnated with Class H varnish and shall be force fitted into the stator housing. The motor shall

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be capable of up to at least 30 evenly spaced starts per hour. Thermal switches set to open at
o o
140 C and close at a minimum of 70 C, shall be embedded in the stator lead coils to monitor the
temperature of each phase winding. These thermal switches shall be used in conjunction with
and supplemental to external motor overload protection and shall be connected to a control
panel. The combined service factor (effect of voltage, frequency and specific gravity variations)
shall be at least 1.10. The motor shall have a voltage tolerance of plus or minus 5%. A motor
performance chart shall on request be provided showing curves for torque, current, power factor,
input power, output power, and efficiency. This chart shall also include data on starting and no-
2
load characteristics. The power cable shall include two 1.5 mm conductors for the monitoring of
thermal switches and optional protecting sensors.
CABLE ENTRY
The cable entry seal shall consist of two cylindrical elastomer bushings without epoxies, silicones
or other secondary sealing systems. The junction chamber and motor compartment shall be air-
filled and separated by a terminal board which shall protect the motor interior from foreign
material. Connection shall be made between the threaded compressed type binder posts thus
securely affixing the cable wires to the terminal board. The terminal board shall be sealed off from
the stator housing with two O-rings.
BEARINGS
The mixer shaft shall rotate on three permanently lubricated bearings. The main bearing shall be
an angular contact ball bearing to take up axial loads. There shall be two support bearings – one
single row angular contact ball bearing to take up axial and radial loads and one cylindrical roller
bearing to take radial loads. The bearings shall be pre-loaded by a bearing loading nut located at
the upper end of the motor shaft in order to reduce shaft deflection and increase bearing and seal
life. All bearings shall have a minimum rated life of 100,000 hours.
MECHANICAL SEALS
Each mixer shall be provided with a liquid chamber for the shaft sealing system. A drainage and
inspection plug for the sealing liquid shall be easily accessible from the outside. Each mixer shall
be provided with a dual mechanical shaft seal system consisting of two independent seals
assembled into one plug-in unit. The seals shall operate in a liquid reservoir that
hydrodynamically lubricates the seal faces at a constant rate. The inner mechanical face seal
shall have rings of corrosion resistant cemented carbide (WCCR) and aluminum oxide (Al2O3).
The outer seal shall have rings of WCCR or silicon carbide (RSiC). Only the outer seal shall be
exposed to the mixed media. Each seal interface shall be held in contact by its own spring
system. The seals shall require neither maintenance nor adjustment.
OIL
The oil chamber shall be filled with a medical white oil of paraffin type. The oil shall be free from
aromatic hydrocarbons and be approved according to FDA 172.878.
MIXER SHAFT
Propeller shaft and motor shaft shall be the same unit, without couplings. The shaft shall be made
of solid stainless steel EN 10088-3, AISI 431, or comparable.
PROPELLER
The propeller shall be of clogging-resistant back-swept design. The propeller shall be capable of
handling solids, fibrous materials, heavy sludge, and other matter found in normal sewage
applications. The fit between the propeller and the shaft shall be a sliding fit employing a single
screw and washer for securing the propeller to the shaft. The propeller shall be made of AISI 316
stainless steel or abrasive-resistant high-chrome alloy.
JET RING AND VORTEX PROTECTION SHIELD
The mixer shall optionally incorporate a jet ring a full 360° around the propeller in order to
maximize hydraulic efficiency and minimize power consumption. The mixer shall be prepared for
an optional incorporation of a vortex protection shield, preventing air vortices and thereby
protecting the propeller and maintaining performance.

PRODUCT TESTING

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 The manufacturer shall have the capability of acceptance testing the mixer regarding thrust and
power according to ISO 21630:2007, on request. The mixer manufacturer shall perform the
following inspections and tests on each mixer before shipment from the factory:
1. Motor insulation test for detection of insulation defects.
2. Tightness test of the assembled mixer using a vacuum method.
3. Dry-run test to establish mechanical integrity and correct rotation.
The manufacturer shall on request be able to provide a written report stating that the foregoing
steps have been done for each mixer at time of shipment.
1.5. SUBMERSIBLE MIXERS (LOW RPM MIXERS)
MANUFACTURER REQUIREMENTS
The mixer specified herein shall be the design and fabrication of a single manufacturer which
shall have sole source responsibility for said equipment. The manufacturer shall have mixing
equipment of this principal design and of comparable capacity in successful operation in the field
for a minimum period of 10 years.
Mixer Design
The mixer shall be capable of handling raw, screened sewage. It shall be possible, with the
exception for floor-mounted mixers, to easily raise and lower the mixer without the need for
personnel to enter the tank. The mixer shall be mounted on a 50x50 mm guide bar system, or on
a 3” (76 mm) cantilever pipe system, or on a fixed floor mount. A sliding guide bracket for the
guide bar or a fixing plate for the pipe shall be an integral part of the mixer unit. The mixer, with its
appurtenances and cable, shall be capable of continuous submergence without loss of watertight
integrity to a depth of 20 m. Major mixer components excluding stand and propeller blades shall
be of grey cast iron, ASTM A-48 Class 35B, or EN1561-GJL250 with smooth surfaces devoid of
blow holes or other irregularities. All cast iron surfaces coming in contact with the mixed liquid
shall be protected by a factory applied spray top coat of oxiranesther (Duasolid) paint finish on
the exterior of the mixer. Nuts, bolts, and washers shall be made of stainless steel AISI 304 or
better.
MOTOR
The motor shall be directly connected to the propeller. The motor shall be a squirrel cage
induction motor, housed in an air filled, watertight chamber. The stator windings and stator leads
o
shall be insulated with moisture resistant Class H (180 C) insulation. The stator shall be trickle
impregnated with Class H varnish and shall be force fitted into the stator housing. The motor shall
be capable of up to at least 30 evenly spaced starts per hour. Thermal switches set to open at
o o
140 C and close at a minimum of 70 C, shall be embedded in the stator lead coils to monitor the
temperature of each phase winding. These thermal switches shall be used in conjunction with
and supplemental to external motor overload protection and shall be connected to a control
panel. The combined service factor (effect of voltage, frequency and specific gravity variations)
shall be at least 1.10. The motor shall have a voltage tolerance of plus or minus 5%. A motor
performance chart shall on request be provided showing curves for torque, current, power factor,
input power, output power, efficiency, and data on starting and no-load characteristics. The power
2
cable shall include two 1.5 mm conductors for the monitoring of thermal switches and optional
protecting sensors.
GEAR UNIT/GEAR BOX:
The gear box shall be of a two-stage, cylindrical, helical type equipped with high precision, low
loaded gears designed for infinite life. The motor shaft shall be provided with an integral driving
gear. The gearbox intermediate shaft containing the first driven gear shall mate with the motor
shaft driving gear. The intermediate shaft shall rotate in two spherical roller bearings and contain
a second driving gear. The propeller shaft shall contain the second driven gear and rotate in one
single row and one double row angular contact ball bearing.
CABLE ENTRY
The cable entry seal shall consist of cylindrical elastomer bushings, without epoxies, silicones or
other secondary sealing systems. The junction chamber shall be air-filled.
BEARINGS

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 The motor shaft shall rotate on two permanently lubricated bearings. The inner bearing shall be
single row deep grove ball bearing and the main bearing a spherical roller bearing. All bearings
shall have a minimum rated life of 100,000 hours.
MECHANICAL SEALS
Each mixer shall have an oil chamber for the shaft sealing system, and a second separate oil
chamber for the gear box. Plugs for drainage and inspection of the oil shall be easily accessible
from the outside. Each mixer shall be provided with three seals to separate the various parts of
the mixer. The outer seal on the propeller shaft shall be a mechanical seal made of corrosion
resistant cemented carbide (WCCR). The seals shall operate in an oil reservoir that
hydrodynamically lubricates the seal faces at a constant rate. Only the seal faces of the outer
seal shall be exposed to the mixed media. The inner seal on the propeller shaft shall be a nitrile
rubber lip seal isolating the propeller shaft oil chamber from the gear box oil chamber. The third
seal shall be a nitrile rubber lip seal mounted on the motor shaft to isolate the gear box oil
chamber from the stator housing. The seals shall require neither maintenance nor adjustment.
OIL
The oil chamber shall be filled with a medical white oil of paraffin type. The oil shall be free from
aromatic hydrocarbons and be approved according to FDA 172.878. The gear box chamber shall
be filled with a gear box oil of type Mobilgear 630 or similar.
PROPELLER SHAFT
The propeller shaft shall be made of stainless steel ASTM/AISI 431 or EN10088-3-1.4057, or
comparable.The Manufacturer shall give the MOC (Material of construction)data sheet of the
same to substanciate the same.
PROPELLER
The propeller shall consist of two fibreglass reinforced polyurethane blades each integrated with
stainless steel shaft for mounting in a cast iron hub. The blades shall be capable of flexing and
absorbing changing hydraulic loads. Each blade shall be mounted into a socket in the side of the
hub and will be held in place by a keyed propeller shaft, to resist torsion forces. The propeller
shaft shall be bolted axially to the hub and lock washer system shall be used. The propeller blade
shape shall be a clogging-resistant, back-swept design which starts at the hub leaving no part of
the shaft exposed.
PRODUCT TESTING
The manufacturer shall have the capability of acceptance testing the mixer regarding thrust and
power according to ISO 21630:2007, on request. The mixer manufacturer shall perform the
following inspections and tests on each mixer before shipment from the factory:
1. Motor insulation test for detection of insulation defects.
2. Tightness test of the assembled mixer using a vacuum method.
3. Dry-run test to establish mechanical integrity and correct rotation.
The manufacturer shall on request be able to provide a written report stating that the foregoing
steps have been done for each mixer at time of shipment.

1.6. FINE BUBBLE AERATION SYSTEM :

The fine bubble aeration system will comprise:
A. Stainless steel droplegs.
B. PVC manifolds and air distributors.
C. PVC diffuser holders and retainer rings.
D. Stainless steel supports and anchors
E. Bolts, nuts and gaskets for aeration system flange connections.
F. Air distributor purge systems.
G. Membrane disc diffusers with integral O-ring gaskets and subplates.

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The following design features will be incorporated in the fine bubble aeration system:
• Fabricated manifold with fixed threaded union joints for connection to the air distributors.
• Manifold sections connected with fixed threaded union or flanged joints to prevent rotation or
blow apart.
• Manifold, distributor connections and supports designed to resist thrust generated by
expansion/contraction of the air distributors over a temperature range of 70°C
• Air distributors perpendicular to the air manifold
• Fabricated distributors with single diffuser holders solvent welded to the crown of the air
distributor for complete air seal and strength.
• Distributors and holders designed to resist a dead load of 90kg applied vertically to the outer
edge of the diffuser holder.
• Air distributor sections joined with positive locking fixed threaded union or flange type joints
for all submerged header joints to prevent blow apart and rotation. Bell and spigot, slip on or
expansion type joints are not acceptable for submerged joints.
• Threaded union joints designed with spigot section connected to one end of the distribution
header, a threaded socket section connected to the mating distribution header, an “O” ring
gasket and a threaded screw on retainer ring. Solvent welding shall be done in the factory.
• Air distributor support spacing at a maximum of 2400mm.
• All supports designed to allow for thermal expansion and contraction forces over a
temperature range of 70°C and to minimize stress build up in the piping system
• Supports designed to be adjustable without removing the air distributor from the support.
• Diffuser assembly comprising: diffuser membrane with integral ‘O’ ring, sub-plate, holder,
retaining ring and air flow control orifice.
• Integral check valve incorporated into the membrane diffuser assembly
• PVC support plate incorporated to form an air plenum under the diffuser and support for the
membrane when the air is off
• Retainer ring threads designed with minimum cross section of 3mm and to allow for one
complete turn to engage threads.
• A liquid purge system to drain the entire submerged aeration piping system for each aeration
grid including airlift purge eductor line and manual control valve.
• Two parts by weight of titanium dioxide per 100 parts of resin will be added to PVC
compounds for manifolds, air distributors, joints and PVC diffuser assembly components to
minimize ultraviolet light degradation.
• All PVC joints will be factory solvent welded. Field solvent welding will NOT be permitted.
• Circular membrane diffuser discs with integral O-ring will be manufactured of EPDM synthetic
rubber compound with precision die formed slits. Thermoplastic materials (i.e. plasticized
PVC or polyurethane) are not acceptable.
• Carbon black will be added to the EPDM material for resistance to ultraviolet light.
• The maximum tensile stress on the diffuser will be limited to 10 psi (69 kPa) when operating
3 2
at 2.4 SCFM/sq. ft. (43.9 Sm /h per m ) of material. Proportionately thicker material is to be
furnished for larger diameter disc diffusers to limit the maximum tensile stress and to resist
stretching.
• The Diffuser system shall be designed so that the flow rate per Disc Diffuser shall be 3
Nm3/Hr/m2 of Diffuser Area and the diffuser system shall guarantee SOTE of 6 % Per
Meter of Submergence and the test report of the same shall have to be given by the Diffuser
manufacturer.

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1.7. FINE BUBBLE AERATION SYSTEM
Aeration system shall be fixed grid, membrane disc fine bubble aeration system
B. The size of each membrane disc cannot exceed 229 mm
The fine bubble aeration system will comprise:
 Stainless steel droplegs.
 PVC manifolds and air distributors.
 PVC diffuser holders and retainer rings.
 Stainless steel supports and anchors
 Bolts, nuts and gaskets for aeration system flange connections.
 Air distributor purge systems.
 Membrane disc diffusers with integral O-ring gaskets and subplates.
The following design features will be incorporated in the fine bubble aeration system:
• Fabricated manifold with fixed threaded union joints for connection to the air distributors.
• Manifold sections connected with fixed threaded union or flanged joints to prevent rotation or
blow apart.
• Manifold, distributor connections and supports designed to resist thrust generated by
expansion/contraction of the air distributors over a temperature range of 70°C
• Air distributors perpendicular to the air manifold
• Fabricated distributors with single diffuser holders solvent welded to the crown of the air
distributor for complete air seal and strength.
• Distributors and holders designed to resist a dead load of 90kg applied vertically to the outer
edge of the diffuser holder.
• Air distributor sections joined with positive locking fixed threaded union or flange type joints
for all submerged header joints to prevent blow apart and rotation. Bell and spigot, slip on or
expansion type joints are not acceptable for submerged joints.
• Threaded union joints designed with spigot section connected to one end of the distribution
header, a threaded socket section connected to the mating distribution header, an “O” ring
gasket and a threaded screw on retainer ring. Solvent welding shall be done in the factory.
• Air distributor support spacing at a maximum of 2400mm.
• All supports designed to allow for thermal expansion and contraction forces over a
temperature range of 70°C and to minimize stress build up in the piping system
• Supports designed to be adjustable without removing the air distributor from the support.
• Diffuser assembly comprising: diffuser membrane with integral ‘O’ ring, sub-plate, holder,
retaining ring and air flow control orifice.
• Size of membrane disc can not be exceed 229mm
• Integral check valve incorporated into the membrane diffuser assembly
• PVC support plate incorporated to form an air plenum under the diffuser and support for the
membrane when the air is off
• Retainer ring threads designed with minimum cross section of 3mm and to allow for one
complete turn to engage threads.
• A liquid purge system to drain the entire submerged aeration piping system for each aeration
grid including airlift purge eductor line and manual control valve.
• Two parts by weight of titanium dioxide per 100 parts of resin will be added to PVC
compounds for manifolds, air distributors, joints and PVC diffuser assembly components to
minimize ultraviolet light degradation.

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 • All PVC joints will be factory solvent welded. Field solvent welding will NOT be permitted.
• Circular membrane diffuser discs with integral O-ring will be manufactured of EPDM synthetic
rubber compound with precision die formed slits. Thermoplastic materials (i.e. plasticized
PVC or polyurethane) are not acceptable.
• Carbon black will be added to the EPDM material for resistance to ultraviolet light.
• The maximum tensile stress on the diffuser will be limited to 10 psi (69 kPa) when operating
3 2
at 2.4 SCFM/sq. ft. (43.9 Sm /h per m ) of material. Proportionately thicker material is to be
furnished for larger diameter disc diffusers to limit the maximum tensile stress and to resist
stretching.

1.8. CONTROL PANEL

Scope of Supply
A complete control system will be supplied for the activated sludge section of the plant. This will
include a master control panel with an Operator Interface, Programmable Logic Controller,
Control Switches, and Indication Lamps.
The following system components will be controlled by the activated sludge plant control panel.

• Decant Mechanism

• Waste Sludge Pumps

• Air Blower Equipment

• Air Control Valves

Local control stations will be included for the Decanters.

Motor Starters will be located in a separate Motor Control Center.
Control Panel
The control panel enclosure shall be a heavy duty, free standing, NEMA 12 or equivalent,
enclosure with a flange mounted disconnect. The panel shall be made of 10 gauge steel and
fully braced. The doors shall be heavy duty 3-point latching doors with a padlocking handle. The
master circuit breaker disconnect shall be on the far right, and be interlocked with the doors. The
panel shall have a white enamel finish on the inside and shall include an internal light and power
socket.
Control voltage power shall be provided by an isolation transformer with surge suppression. In
addition a voltage conditioner shall be used for PLC power supply, and surge suppressers shall
be used with all relays and contactors.
An Uninterruptible Power Supply system [UPS] will supply power to the PLC and MMI/Display
Unit. The unit will be line-interactive. providing no breaks in output power, regardless of what
happens to the input power. The power output is a true Sine-Wave Output with brownout boost
voltage protection. The system will have lightning and surge protection. The unit will have a
digital display with alarm contacts for UPS running and battery low. The system will be able to
provide backup power to the PLC and MMI for 30 minutes.
Programmable Logic Controller (PLC)
The Programmable Logic Controller [PLC] shall consist of a Allen Bradley SLC 504 or equal, with
16k program memory and up to 1024 Discrete I/O capacity. RAM memory shall be protected by a
backup battery with further memory protection from an EEPROM. The processor shall have LED
Indicators showing Run, Fault, and Battery Low status. Typical Scan Time is 1ms/1k ladder logic.
The processor is equipped with a RS232 port for direct modem communications. A Modem shall
also be provided with auto answer for remote technical support. The modem shall be a Motorola,
3220+ or equal.

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Interface (MMI)
A Man-Machine Interface Terminal (MMI) shall be mounted on the front of the main control panel
for control of the activated sludge plant. It will provide a display of the process parameters and
equipment status. The display will have an associated keypad. The system will allow operator
changes to set points and control of equipment. The terminal shall include an alarm annunciator
with a dedicated alarm page and allow acknowledgment of alarms.
Control Logic
Decanter speed will be controlled with a Variable Frequency Drive which controls the speed of
the decanter actuator motor. The VFD will be microprocessor based, and allow programming of
the torque curve, speed and voltage, over current and overload protection. It will have protective,
warning and self-diagnosis functions. The unit will have programmed automatic fault restarts and
low power ride through. The control unit display will be mounted in a easily accessible location.
The units will be enclosed type mounted in the control panel.
The decanter drive speed is determined by the PLC in order to maintain a uniform vertical
lowering of the decanter weir. The maximum decanter travel is controlled by limit switches
mounted on the decanter actuator.
In addition, there will be a local decanter control panel for each basin consisting of a 4-position
switch enclosed in a NEMA 4X or equivalent enclosure. The local station allows manual raise and
lower control as well as off and automatic control.
The plant controls will operate on a time cycle basis. The process elapsed time will be displayed
on the display terminal. Two tanks will operate on a complementary basis so that while one tank
is in aeration the other tank is in settling or decant phase. The cycle will automatically adjust for
high flow conditions to increase the throughput capacity in high flow conditions. In automatic
operation, the processor will at all times maintain the proper sequence of operation even in the
event of power failure. All phases of the process and equipment will be interlocked so that the
process cannot be upset. If an equipment failure takes place an alarm will be displayed on the
operator terminal until cleared. The display will indicate the time of the alarm and status. Time
critical sequences and other process variables can be adjusted via the operator interface terminal
as follows: [1] Aeration blower run time. [2] The waste sludge pump start time and running time.
[3] The decanter lowering rate. [4] Special process variables such as DO control setpoints if
required.
The control system will monitor the dissolved oxygen (DO) in the process basins and use the DO
signal to modulate the blower output according to a standard PID algorithm (either by changing
the blower speed, via a VFD, in the case of positive displacement blowers, or by changing the
position of the inlet guide vanes or throttling valve in the case of centrifugal blowers).

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 2. MATERIALS & WORKMANSHIP
2.1. INTRODUCTION
This part of the specification sets out the general standards of materials to be supplied and the
workmanship required to be ensured by the Contractor and mention of any specific material or
plant does not necessarily imply that such is included in the works. All component parts of the
works shall, unless otherwise specified comply with the provisions of this part or be subject to the
approval of the Engineer.
The names of the manufacturers of materials and equipment proposed for incorporation in the
Works together with performance capacities, certified test reports and other significant
information shall be furnished by the Contractor.
2.2. COMPLIANCE WITH STANDARDS
Where reference is made in the Specification to the British Standard Specification (hereinafter
abbreviated to ‘BS’) issued by the British Standards Institution of 2, Park Street, London W.I., or
to an Indian Standard Specification (IS) issued by the Bureau of Indian Standards, (earlier known
as Indian Standard Institution), Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110 002,
American Society for Testing and Materials (ASTM) issued by ASTM 1916 Race Street,
Philadelphia, P.A., 19103, U.S.A or American National Standards Institute (ANSI) issued by ANSI
1430, Broadway, New York, N.Y., 10018, U.S.A or to any other equivalent standard it shall be to
the latest revision of that standard at the tender opening date.
All details, materials and equipment supplied and workmanship performed shall comply with
these standards.
2.3. MATERIALS - GENERAL
All materials incorporated in the Works shall be the most suitable for the duty concerned and shall
be new and of reputed make/approved quality, free from imperfections and selected for long life
and minimum maintenance.
All submerged moving parts of the Plant, or shafts spindles, etc. of the submerged moving parts
or faces etc. in contact with various chemicals, shall be corrosion resistant materials. All parts in
direct contact with various chemicals shall be completely resistant to corrosion or abrasion by
these chemicals and shall maintain their properties without aging due to the passages of time,
exposure to light or any other cause.
2.4. WORKMANSHIP - GENERAL
Workmanship and general finish shall be of first class quality and in accordance with best
workshop practice.
All similar items of the Plant and their component parts shall be completely interchangeable.
Spare parts shall be manufactured from the same materials as the originals and shall fit all similar
items. Machining fits on renewable parts shall be accurate and to specified tolerances so that
replacements made to may be readily installed.
All equipment shall operate without excessive vibration and with minimum noise. All revolving
parts shall be truly balanced both statically and dynamically so that when running at normal
speeds at any load up to the maximum there shall be no vibration due to lack of balance.
All parts, which can be worn or damaged by dust shall be totally enclosed in dust proof housings.
All materials incorporated in the work shall be most suitable for duty concerned, free from
imperfections, selected for long life and minimum maintenance.
All necessary accessories required for satisfactory and safe operation of the plant shall be
supplied by the Contractor unless it is specifically excluded from his scope.
All valves shall be closing on clockwise rotation of the hand wheel. The effort required to
close/open under all operating conditions shall be limited to 7 kg. The direction of opening/closing
shall be cast on the hand wheel.
All flanges shall be drilled in accordance with requirements of IS: 1538.
All flanges shall be full or spot faced on the backside. The flange thickness be uniform
throughout.

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 Flange outside periphery shall be concentric with the bore. Flanges shall be finished smooth on
periphery also.
Castings and fabricated materials shall be finished smooth all over.
2.5. NAME PLATES
Each item of the plant shall have permanently attached to it in a conspicuous position, a
nameplate and rating plate, each of stainless steel. Upon these shall be engraved or stamped,
the manufacturer’s name, type and serial number of Plant, details of the loading and duty at
which the item of plant has been designed to operate, and such diagrams as may be required by
the Engineer-in-Charge. All indicating and operating devices shall have securely attached to them
or marked upon them designations as to their function and proper manner of use.
Details of proposed inscriptions shall be submitted to the Engineer-in-Charge for approval
before any labels are manufactured. Such nameplates, rating plates and designations
shall be of stainless steel with engraved or stamped lettering items such as valves shall
have direction of rotation for closing and opening indicated.
Nameplates, rating plates and labels shall be of a non-flame propagating materials, either non-
hygroscope or transparent plastic with engraved lettering of a contrasting colour. Fixing shall be
by means of non-corrosive screws, drive rivets or adhesives shall not be used.
Warning labels shall be provided where necessary to warn of dangerous circumstances or
substances. Inscriptions or graphic symbols shall be black on a yellow background and to
internationally recognised standards.
Instruction labels shall be provided where safety procedures such as wearing of protective
clothing are essential to protect personnel from hazardous or potentially hazardous conditions.
These labels shall have inscriptions or graphic symbols in white on a blue background.
2.6. NUTS, BOLTS, STUDS AND WASHERS
Nuts, bolts, studs and washers for incorporation in the plant shall conform to the requirements of
the appropriate standard. Nuts and bolts shall be of the best quality of specified grade, machined
on the shank and under the head and nut. Bolts shall be of one-piece construction and shall be of
sufficient length so that only one thread shall show through the nut in the fully tightened condition.
Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the screwed
portion of such a diameter that it will not be damaged in driving and shall be marked in a
conspicuous position to ensure correct assembly at Site.
Washers, locking devices and anti-vibrations arrangements shall be provided where necessary
and shall be subjected to the approval of the Engineer-in-Charge. Jointing hardware for the entire
plant shall be provided with sufficient spares to cater for site losses.
Where bolts pass through structural members taper washers shall be fitted, where necessary, to
ensure that no bending stress is caused in the bolt.
Where there is a risk of corrosion, bolts nuts and studs shall be designed so that the maximum
stress does not exceed half the yield stress of the material under any conditions. All bolts, nuts
and washers which are subject to frequent adjustment or removal in the course of maintenance
and repair shall be made of nickel-bearing stainless steel.
The Contractor shall supply all holding down, alignment and leveling bolts complete with
anchorage’s, nuts, washers and packing required to attach the plant to its foundations, and all
bed plates, frames and other structural parts necessary to spread the loads transmitted by the
Plant to concrete foundations without exceeding the design stresses.
The material of nut, bolts, studs and washers for wetted/submerged areas shall be of SS:316 and
others shall be of GI (specifically nut bolts of Aerators, bridge, Filter press, gates, screens, CL2
dozer, sludge agitator should be only of S.S. either submerged stage or open in air).
2.7. ALLOWANCE FOR WASTAGE
The Contractor shall supply to the satisfaction of the Engineer-in-Charge reasonable excess
quantities to cover wastage of those consumable which will be normally subject to waste during
erection, commissioning and setting to work.

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2.8. PAINTING - GENERAL
The Contractor shall be responsible for the cleaning, preparation for painting, and priming or
otherwise protecting, as specified, all parts of the plant at the place of manufacture prior to
packing.
Parts may be cleaned but surface defects may not be filled in before testing at the manufacturer’s
works. Parts subject to hydraulic test shall be tested before any surface treatment. After test, all
surfaces shall be thoroughly cleaned and dried out if necessary by washing with an approved
dewatering fluid prior to surface treatment. Except where the specification provides to the
contrary all painting materials shall be applied in strict accordance with the paint manufacturer’s
instructions.
All protective coatings shall be suitable for use in warm humid climates.
2.9. PAINTING AT PLACE OF MANUFACTURER
All stages in painting including cleaning and surface treatment in the manufacturer’s works shall
be available for inspection.
Steel and cast iron parts shall be sand blasted to near white cleaning before painting. Edges,
sharp covers etc. shall be ground to a curve before sand blasting.
A primer coat of a zinc rich epoxy resin based coating with at least at 75 microns dry film
thickness is to be provided. In addition the parts are to be provided with adequate number coats
or coal tar epoxy polyamine coating to a dry film thickness of 175 microns including primer
coating.
2.10. PAINTING AT SITE
Immediately on arrival at the site, all items of plant shall be examined for damage to the paint
coat applied at the manufacturer’s works, and any damaged portions shall be cleaned down to
the bare metal, all rust removed, and the paint coat made good with similar paint.
Steel and cast iron parts received at site shall be provided with adequate number of further coats
of coal tar epoxy polyamine coating to a total dry film thickness of 275 microns including the
primer coats. All sharp edges, nuts, bolts and other items difficult to be painted shall receive a
brush coat of specified paint before application of each coat of epoxy based coal tar paint giving a
total dry film thickness of at least 275 microns. In the case of fabricated steelwork this work shall
be done after assembly.
Before painting is commenced the Contractor shall submit for the approval of the Engineer-in-
Charge, full details of the paints he proposes to use together with colour charts for the gloss
finishes.
All paint and coating thickness shall be measured by approved Elcometer or coating thickness
gauge.

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 3. ERECTION, TESTING AND COMMISSIONING

3.1. TESTING - GENERAL

Testing of the plant at the manufacturer’s premises will be required in accordance with the
Conditions of Contract. All inspection, examination and testing shall be carried out in accordance
with appropriate standards.
All instruments used for such tests shall be calibrated and certified by an approved independent
testing authority not more than 2 months prior the test in which they are used. The Engineer-in-
Charge reserves the right to impound any instrument immediately after test for independent
testing. A certificate shall be produced by the Contractor prior to carrying out every test showing
the reading obtained calculations and full details of the calibration certificates referred to.
If the Engineer-in-Charge witnesses a test he shall be given a copy of the test results and
certificates immediately. Whether he witnesses a test or not, copies of test certificate shall be
sent to the Engineer-in-Charge. No item of the plant shall be forwarded to the site until its test
certificate has been approved in writing by the Engineer-in-Charge. Six copies of the test
certificates shall be supplied in suitable folders with proper index.
Certificates shall be clearly identified by serial or reference number where possible to the material
being certified and shall include information required by the relevant Reference Standard or
Specification clause.
3.2. INSPECTION AT MANUFACTURER’S PREMISES
The inspection of all equipment required to be supplied to complete the works shall be done as
detailed in this specification. Only defect free and sound material meeting the technical
requirements of this specification and in accordance with a high standard of engineering would
be acceptable to the Engineer-in-Charge.
For meeting these requirements of inspection, testing (including testing for chemical analysis and
physical properties) shall be carried out by the Contractor and certificates submitted to the
Engineer-in-Charge who will have the right to witness or inspect the above mentioned
testing/inspection at any stage desired by him. Calibration certificates or test instruments shall be
produced for the Engineer’s consent in advance of testing and if necessary instruments shall be
recalibrated or substituted before the commencement of the test. Items of plant or control
systems not covered by standards shall be tested in accordance with the details and programme
agreed between the Engineer and Contractor.
If during or after testing, any item of the plant fails to achieve its intended duty or otherwise prove
defective it shall be modified or altered as necessary, retested and reinspected as required by the
Engineer.
At least 15 days notice shall be given to the Engineer before the specified tests are carried out.
No material is to be delivered to site without the above described inspection having been carried
out or officially waived in writing by the Engineer-in-Charge.
Third party inspection along with the Engineer In charge wherever necessary shall be arranged
by the Contractor at his cost
3.3. TESTS AT MANUFACTURER’S PREMISES
3.3.1. Pumps
Hydrostatic testing: All pressure parts of pumps prior to assembly, shall be subjected to
hydrostatic tests to the satisfaction of Engineer-in-Charge at 1.5 times the maximum pressure
obtained with the delivery valve closed and suction pressure at maximum, or twice the working
pressure whichever is higher for a duration of 10 minutes.
Balancing Test: Impeller and pump rotating assembly shall be dynamically balanced.
Performance Test: Each pump shall be tested for full operating range individually to BS:5316:
Part 2. Test shall be carried out for performance at rated speed with minimum NPSH as available
at Site. Pump performance shall be within the tolerance limits specified in BS:5316 : Part 2.
3.3.2. Motors

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 Motors shall be offered for routine and type tests in accordance with IS : 4029 and IS:325 at the
manufacturer’s works. Test certificates shall be endorsed to the effect that the motors are
properly balanced and free from vibration. In addition, a test shall be required to establish the
maximum transient starting current.
3.3.3. Pipe work
Testing of pipes/fittings shall be carried out in accordance with relevant standard.
3.3.4. Valves
All valves shall be hydrostatically tested close ended. Body, seat/door and back seat-test
pressure shall be 15 bar, 10 bar and 6 bar respectively.
Valves shall be tested with associated actuators for general performance.
3.3.5. Hoists
(a) The hoist shall be completely assembled in the Contractor’s or sub Contractor’s works
and shall be subjected to the tests as specified in IS:807/IS: 3177. The Contractor shall
provide the test weights.
(b) In addition a vertical deflection test shall be carried out with the ‘Safe Working Load’
suspended from the hook with the crab in the center of the span. The ratio of deflection to
span shall not exceed that specified in IS 807. Manufacturer’s test certificates for
mechanical items shall be furnished.
3.3.6. Electrical Instruments
All electrical instruments shall be tested as specified under electrical specifications.
3.3.7. Other Equipment
Other equipment like mixers, air blowers, agitators, etc. shall be tested at plants and at works as
per the relevant IS standards, and applicable standards with test certificate furnished for approval
before dispatch.
3.4. ERECTION - GENERAL
The Contractor’s staff shall include at least one competent erection engineer with proven,
suitable, previous experience on similar contracts to supervise the erection of the Works and
sufficient skilled, semi skilled and unskilled labour to ensure completion of the works in time.
The Contractor shall not remove any representative, erector or skilled labour from the site without
the prior approval of the Engineer-in-Charge.
One erection engineer who shall be deemed to be the Contractor’s representative shall be
conversant with the erection and commissioning of the complete works.
Should there be more than one erector, one shall be in charge and the Contractor shall inform the
Engineer-in-Charge in writing which erector is designated as his representative and is in charge.
Erection engineer is to report progress and planning to the Engineer or his representative who will
have one mobile phone with him.
The Contractor’s erection staff shall arrive on the site on date to be agreed by the Engineer-in-
Charge. Before they proceed to the Site, however, the Contractor shall first satisfy himself, as
necessary, that sufficient plant of his (or his sub-Contractor’s) supply has arrived on site so that
there will be no delay on this account.
The Contractor shall be responsible for setting up and erecting the plant to the line and levels of
reference given by the Engineer in writing, and for the correctness (subject as above mentioned)
of the positions, levels dimensions and alignment of all parts of the works and for provision of all
necessary instruments, appliances and labour in connection therewith. The checking of setting
out of any line or level by the Engineer or Engineer-in-Charge shall not in any way relieve the
Contractor of his responsibility for the correctness thereof.
Erection of Plant shall be phased in such a manner so as not to obstruct the work being done by
other Contractors or operating staff who may be present at the time. Before commencing any
erection work, the Contractor shall check the dimensions of structures where the various items of
Plant are to be installed and shall bring any deviations from the required positions, lines or
dimensions to the notice of the Engineer. Plant shall be erected in a neat and workmanlike

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 manner on the foundations and at the locations shown on the approved drawings. unless
otherwise directed by the Engineer, the Contractor shall adhere strictly to the aforesaid approved
drawings. If any damage is caused by the Contractor during the course of erection to new or
existing plant or buildings or any part thereof, the Contractor shall, at no additional cost to the
Employer, make good, repair or replace the damage, promptly and effectively as directed by the
Engineer and to the Engineer’s satisfaction.
During erection of the plant the Engineer will inspect the installation from time to time in the
presence of the Contractor’s site representative to establish conformity with the requirements of
the specification. Any deviations and deficiencies found or evidence of unsatisfactory
workmanship shall be corrected as instructed by the Engineer.
3.5. RECORD, PROCEDURES AND REPORTS
The Contractors shall maintain records pertaining to the quality of installation/erection work and
inspection, testing, compliance with all technical requirements in respect of all his work as
described in the previous paragraphs. The reporting formats shall be in the approved formats.
The Contractor shall submit such records to the Engineer after the completion of any particular
work before submitting the bill of shop inspection reports, shop testing reports, material test
reports, based on which dispatch clearances are provided, all the quality control reports of
welding, erection and alignment records.
All the above mentioned records shall be submitted in the final form duly countersigned by the
Engineer-in-Charge attesting conformity to specifications and his approval of installation and duly
incorporating all the additions, alternations, and information as required by the Engineer, on the
basis of preliminary reports giving the progress of the work. Such records notwithstanding any
records submitted earlier with bill of supply/progress etc. shall be duly bound and submitted to the
Engineer in six copies by the Contractor on his notification of the mechanical completion of
erection.
3.6. COMPLETION OF ERECTION
The completion of plant under section by the Contractor shall be deemed to occur, if all the units
of the plant are structurally and mechanically complete and will include among other such
responsibilities the following :
• Plant in the scope of the Contractor has been erected installed and grouted as per
specifications.
• Installation checks are completed and approved by the Engineer.
• The erected plant is totally ready for commissioning checks.
At the stage of completion of erection, the Contractor shall ensure that all the physical, aesthetic
and workmanship aspects are totally complete and the plant is fit and sound to undergo
commissioning checks/tests on completion.
Upon achieving the Completion as described above, the Contractor shall notify the Engineer by a
written notice intimating such mechanical completion of units and notify the Engineer for
inspection and acceptance of Mechanical Completion. The Engineer/Engineer-in-Charge
shall proceed with the inspection of such units within 14 days of such a notice. Thereafter:
• The Engineer shall certify completion when there are no defaults in the works and the plant
is acceptable or
• The Engineer shall inform the Contractor list of deficiencies for rectification hereinafter
referred as Punch List and the Contractor shall complete the rectification work within a jointly
agreed period before tests on or approval of the same before proceeding with the Tests on
Completion or
• The Engineer may inform the Contractor that the Works are acceptable with 'punch' list
(Items which do not hamper operability, safety or maintainability) and allow the Contractors
to proceed with the pre-commissioning checks followed by Tests on Completion when the
Contractor undertakes to complete such outstanding works within an agreed time during
Defects Liability Period.
Taking over shall be based on rectification of all deficiencies as advised by punch lists.

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 The erection period indicated by the Contractor would be deemed to cover all the activities up to
completion as stipulated in previous paragraphs, notice of completion by the Contractor,
inspection by the Engineer for completion, and Contractor rectification of all deficiencies as
noticed by the deficiency/punch list, and acceptance by the Engineer of such rectification, prior to
Tests on Completion.
Minor defects, which in the opinion of Engineer which do not hamper operability and
maintainability will not be taken into account for deciding mechanical completion. Such defects
shall be rectified concurrent to commissioning checks before Tests on Completion. However, the
Engineer's decision in this regard is final.
The commissioning period as notified by the Contractor shall be deemed to occur beyond the
date of completion and shall include all periods of pre-commissioning, trails and Tests on
Completion.
It is in the Contractor's interest to offer the sections/units/systems, progressively under identified
milestones within overall erection period, duly completed for inspection by the Engineer-in-
Charge, obtain his 'punch' list, for rectification of any deficiencies pointed out by the Engineer and
to achieve Mechanical Completion before undertaking the Tests on Completion within the
specified erection period. The Engineer also reserves a right to withhold the cost as estimated to
be equivalent to the rectification of deficiencies pointed out to the Contractor until such a time
such deficiencies are rectified to the satisfaction of the Engineer.
3.7. SETTINGTOWORK
On completion of erection the Contractor shall request the Engineer-in-Charge to carry out the
installation inspection.
After the plant has been set to work the Contractor shall continue to operate the Plant for a period
of one week.
3.8. INSTALLATION INSPECTION
In addition to the progressive supervision and inspection by the Purchaser the Contractor shall
offer for inspection to Engineer, the completely erected Plant/Part of Plant on which tests are to
be carried out. After such inspection by Engineer-in-Charge, each equipment/sub-system shall be
tested by the Contractor in accordance with the applicable standards in the presence of Engineer.
Such tests shall include but not be limited to the tests specified in following clauses.
Pumps, Piping and valves

• The erected pipework shall be subjected to a hydraulic test at 1.5 times the maximum
pressure or twice the working pressure whichever is higher to test the soundness of joints.
Provision of necessary pumps, gauges, blank flanges, tappings etc. for carrying out these
tests shall be included in the Contract.
• Leakage tests shall be carried out on all erected pipe work, pumps and valves immediately
after erection and where possible before being built in.
• Operating tests shall be conducted on valves.
• The pump set shall be tested for satisfactory operation. The vibration and noise level shall
be checked to be within specified limits.
Motors: Condition of winding insulation be tested and insulation values shall be restored to
required level by suitable heating arrangements locally.
Hoists: The hoist and lifting tackle shall be tested to 125% of the safe working load. The
Contractor shall arrange the test load.
Mixers, agitators, air blowers, etc. After erection, these shall be tested for its performance.
• Electrical Panels Insulation
• Test High Voltage Power Frequency test
• Performance Test
Cables
• Insulation Test

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 • Continuity Test
• High Voltage Power Frequency Test
• Instrumentation
Performance of the instrumentation shall be checked as per the design requirements.
3.9. COMMISSIONING
3.9.1. Scope
At the time of commissioning, the Engineer-in-Charge will appoint his representative as
commissioning engineer. The Contractor shall carry out commissioning tests in the presence of
the commissioning engineer. Though the mechanical completion may have been checked and
clarified by the site engineers, the commissioning engineer may verify any mechanical completion
checks to satisfy himself that the plant is fit and sound, if such checks had not been witnessed by
him. It will be the responsibility of the Contractor to make all arrangement for carrying out these
tests. The evaluation of test results and decision passed by the commissioning engineer
regarding the test results will be final and binding on the Contractor. Any additional tests or
repetition of tests to establish satisfactory operation of any equipment shall be carried out by the
Contractor at no extra cost.
3.9.2. Miscellaneous
Completion checks and commissioning tests on items not covered under above , shall be carried
out by the Contractor as per the instructions of the Engineer-in-Charge.
3.9.3. Commissioning Date
No item of plant will be certified as commissioned by the Purchaser unless it has successfully
passed all the tests called for under the Contract and the following documentation are duly
complied and submitted in final formats in duly bound volumes.
A completion of all shop inspection results/reports of the plant/machinery with due attestation that
the Plants have been manufactured to specified standards (6 copies)
All erection/construction quality control checks in appropriate approved formats for all installation
works with attestation that installation has been carried out as per acceptable/stipulated
standards (6 copies).
All “As built drawing” and O & M and Erection manuals. Soft copies of drawings and documents
will furnished by the Contractor.
3.10. TENDER DRAWINGS
The following drawing shall be submitted by the bidder with tender:

1. Plant Layout with unit sizing

2. Process Flow Sheet with process design/calculations
3. Hydraulic Flow Diagram with hydraulic design/calculations
4. Process & Instrumentation Diagram
5. Single Line Diagram for all Electrical Installations with load calculations
6. Outline dimensional drawing
a. Pumps
b. Gates-Motorised/Manual
c. Valves-Motorised/Manual
d. Chlorinators
e. Electrical Panels
7 Performance Curve for

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 a. Pumps
b. Aerators

c. Blowers
8 Instrumentation - Catalogues for all the instruments
3.11. DRAWINGS FOR APPROVAL
The following mechanical drawings shall be submitted for approval including GA drawings,
technical data sheets Quality assurance plan and other related documents to the Engineer In
Charge for the approval and further action:

a. Knife gate valves

b. Non-Return valve
c. H.O.T./E.O.T. Crane
d. Gates
e. Manual and mechanical Coarse /Fine screens
f. Degritter
g. Primary and Secondary Clarifier
h. Diffusers
i. Air blowers
j. Submersible pumps
k. Chlorination system
Sludge Dewatering units
l. If any as per technology selected
3.12. CONSTRUCTION DOCUMENTS
The Construction Documents are certified Drawings submitted by the Contractor to the Employer
or Engineer-in-Charge during the course of the Contract for approval.
The Engineer-in-Charge may require the Contractor to submit for approval additional drawings if
they are necessary to enable him to satisfy himself that the items are well designed, that they
comply with the Employer’s Requirements and that they are suitable for their intended purpose.
These drawings shall form the agreed basis for the execution of the Works. If an approved
drawing is revised, revised copies shall be submitted for approval as above and no such revised
drawing shall be used for the purposes of the Contract until it has been approved in place of the
earlier issue of the drawing.
Approval of drawings by the Engineer-in-Charge shall not be held to relieve the Contractor of his
responsibilities under the Contract. Drawings should be got approved from the Dy. Director &
Chief Manager and Industrial Safety before starting the site work.
Two nos. of `Approved copies of each drawing will be returned to the Contractor when approval is
given if the Contractor so requests.
The Engineer-in-Charge will not permit construction to start on a part or section of the Works
unless Construction Documents for that part or section have been approved.
3.13. AS-BUILT DRAWINGS
These drawings shall be complied by the Contractor and shall constitute a permanent record of
the Works as executed. These shall include all such drawings, schedules, documentation and
calculations as necessary for a complete understanding of the Work design, operation and
maintenance.
A3 and smaller sized As-Built Drawings shall be provided on durable paper for reproduction by

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 photocopier. As-Built Drawings larger than A3 shall be provided as a paper copy and also
produced in the form of black lines on a durable translucent film from which further paper prints
can be taken by others as required. In addition drawings shall be provided as AutoCAD Revision
14 software copy.
Text shall be provided in an industry standard work processing, spreadsheet or database format
as appropriate.
3.14. INFORMATION REQUIRED ON AS-BUILT DRAWINGS
The As- Built Drawings shall consist of the fully up-dated versions of the approved Construction
Documents incorporating any additional information which will assist the Employer in operating
maintaining and if necessary modifying or extending the Works at a later date. These drawings
should extend and supplement the information given in Operating and Maintenance Manuals.
3.15. OPERATING AND MAINTENANCE MANUALS
3.15.1. General
The Contractor shall compile operating, maintenance and overhauling instructions for the whole
of the Plant. The instructions shall consist of one volume of :
a. General descriptive text (including drawings for illustration) of the Works described section
by section.
b. Complete operational instructions for the treatment plant. This shall be termed the
Operators Manuals. It shall be aimed at the operational staff and shall be written in clear
unambiguous text complete with drawings which necessary for clarification of any issues.
The manual shall comprehensively detail what to do on a day to day basis and also what to
do in the event of fault develop. It shall in addition provide a complete list of the process
maintenance tasks the operator should carry out including the intervals between these
tasks.
c. Essential Instructions for mechanical and electrical maintenance of the Plant. These
instructions shall be short and concise and set out in consolidated schedule the inspection,
lubrication, cleaning and any other type of servicing operations required. The Contractor
shall prepare typical maintenance log sheets that the Employer can subsequently use for
daily, weekly, monthly or other periodic maintenance and shall form record sheets of plant
maintenance operations.
d. Instructions for use of skilled maintenance personnel in fault location, carrying
out routine replacement, withdrawing, dismantling, overhauling, re assembling and testing
the various items of Plant.
e. Manufacturer’s Technical Documentation subdivided into categories for:
• civil
• process
• electrical
• electrical building services
• mechanical building services
• instrumentation and control
f. Civil As-Built Drawings
g. Comprising the FDS and PLC code
h. Electrical As-Built Drawings: The electrical drawings shall be complete sets including all
information necessary for maintenance and spares replacement.
i. Electrical and mechanical building services As-Built Drawings: The drawings shall be
complete sets including all information necessary for maintenance and spare replacement.
j. Necessary records for the Plants and Works
3.16. SUBMISSION OF DOCUMENTS AND DRAWINGS
Eight (8) copies of each drawing and document shall be submitted by the Contractor to the
Engineer-in-Charge for approval. The Engineer-in-Charge will return two (2) approved copies to
the Contractor and retain six (6) for the Engineer-in-Charge’s office and field use. The contractor,
shall also arrange to get the approval on these drawings from the Dy. Director of Industrial Safety
and health at his own cost.

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 The Engineer-in-Charge will signify his approval or disapproval of the Preliminary Phase
Drawings within 15 calendar days of submission.
Construction Documents shall be submitted in accordance with the timetable set down in the
Program.
The Engineer-in-Charge will signify his approval or disapproval of the Construction Documents
within 15 calendar days of submission of each submission.
Draft copies of the O & M Manuals shall be submitted to the Engineer-in-Charge for his approval
at least 24 calendar days prior to the commencement of Tests on Completion.
The Engineer-in-Charge will signify his approval or disapproval of the O & M Manuals within 28
calendar days of submission.
Draft As-Built Drawings shall be submitted 30 calendar days prior to the
commencement of Tests on Completion.
The Engineer-in-Charge will signify his approval or disapproval of the As-Built Drawings within 15
calendar days of submission.
The Final As-Built Drawings shall be submitted prior to the issue of any Taking Over Certificate.
3.17. NOTICE OF OPERATIONS
The Contractor shall give full and complete written notice of all important operations to the
Engineer-in-Charge sufficiently in advance to enable the Engineer-in-Charge to make such
arrangements as the Engineer-in-Charge may consider necessary for inspection and for any the
purpose. The Contractor shall not start any important operation without the written approval of the
Engineer-in-Charge.

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ELECTRICAL SPECIFICATIONS

Page 215 of 263

 ELECTRICALSPECIFICATIONS

1. Electrical Works:

1.1. Codes & Standards:

The following codes and standards shall be applicable for continuous performance of all electrical
equipment’s to be supplied, delivered at site, erected, tested and commissioning. The electrical
equipment’s offered shall comply with the relevant Indian standards specifications. Fire insurance
regulations, tariff advisory committee regulations, and particular to Indian electricity rules in all
respect with all its latest amendments up to date.
For guidelines to the Tenderer, few of the Indian Standards are indicated below: -
1. IS:116 - Circuit breakers for AC System.
2. IS:159 - Busbar and Busbars connections.
3. IS:3043 - Code of practice of earthing.
4. IS:10116 - Code of practice for installation of switchgear.
5. IS:10116 - Code of practice for selection, installation and
maintenance of fuse (up to 650 Volts).
6. IS:3165 - Potential Transformers.
7. IS:3203 - Climate proofing of electrical equipment’s.
8. IS:3427 - Metal enclosed switchgear and central gear.
9. IS:3419 - Specification for fittings for rigid PVC non-metallic conduit.
10. IS:3537 - Gas separated relays.
11. IS:3639 - Fittings and accessories for power Transformer.
12. IS:3837 - Accessories for rigid steel conduits.
13. IS:4064 - Heavy duty Air Break switches and composite. Switch fuse
units for voltage and exceeding 100V.
14. IS:4064 - Switch fuse units for Industries etc.
15. IS:4237 - General requirements for switchgears not exceeding 1000
Volts.
16. IS:4615 - Switch socket outlet.
17. IS:5133 (Part-I) - Sheet steel boxed.
18. IS:3070 (Part-I) - Lighting Are stores.
19. IS:2034 - L.T. capacitors.
20. IS:192 - Electric power switchgear for indoor and outdoor
installation.
21. IS:PUB 26 - Circuit Breakers.
22. IS:9535 - Specification for conduits for electrical installation.
23. IS:240 (Part-I & II) - For H.T. insulator of 33KV grade and above.
24. IS:335 - Insulating Transformer Oil.
25. IS:374 - Ceiling fans.
26. IS:375 - Marking and arrangement for switchgear boards main
connections auxiliary wiring
27. IS:415 - Tungsten filament lamps.
28. IS:692 - Paper insulated cables.
29. IS:694 - PVC insulated cables and cords for power lighting.

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30. IS:722 - Three phase watt hour meters with MDI.
31. IS:732 - Electrical wiring installation (up to 650V)
32. IS:1087 - Single pole tumbler switch 5 Amps.
33. IS:1248 - Direct reading electrical indicating instruments.
34. IS:1255 - Installation and maintenance of paper insulated power
cables up to 33 KV.
35. IS:1293 - 3 Pin lugs and sockets outlets.
36. IS:1554 - PVC insulated cables – heavy duty.
37. IS:1567 - Metal clad switches up to 100 Amps.
38. IS:1651 - Lead acid cell batteries.
39. IS:1653 - Rigid steel conduits for electric wiring.
40. IS:1771 - Industrial light fittings with accessories.
41. IS:6600 - Loading of oil immersed transformer.
42. IS:6946 - Reliable (flexible) non-metallic conduits for electrical.
43. IS:7098 (Part-II) - Fox XLPE type cables.
44. IS:5216 - Guide for safely procedure and practices in electric work.
45. IS:5578 - Guide for marking of insulated conductors.
46. IS:5792 - 11/22 KV drop out fuses.
47. IS:5820 - Pre-cast concrete cables covers.
48. IS:5908 - Method of measurement of electrical installation in
building.
49. IS:6381 - Specifications for construction and testing of electrical
apparatus.
50. IS:1818 - Isolation and earthing switches.
51. IS:1886 - Code practice for installation of transformers
52. IS:1947 - Flood lights.
53. IS:2026 - Transformers.
54. IS:9242 - Degree of protection provided for enclosure for switchgear.
55. IS:9242 - HRS cartridge fuse units up to 650 Volts.
56. IS:2251 - Code of practice for Danger Notice Plates.
57. IS:2268 - Code bell/buzzers.
58. IS:2274 - Code of practice for wiring installation (exceeding 650
Volts)
59. IS:3854 - Switches for domestic and similar purpose.
60. IS:2312 - Exhaust fans.
61. IS:2309 - Code of practice for lighting protection.
62. IS:2418 - Tubular fluorescent lamps for general lighting service.
63. IS:2544 - Porcelain post top insulators for BBW Class.
64. IS:2509 - PVC electrical conduits.
65. IS:2516 - A.C.Circuit breakers.
66. IS:2667 - Fittings for rigid steel conduits for electrical wiring.
67. IS:2692 - 11/22 KV drop out fuses.

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 68. IS:2575 - Enclosed distribution fuse boards and cut outs for voltage
up to 1000 V.
69. IS:2705 - Current transformer.
The entire electrical installation work shall be strictly complied with the codes, standards, rules
and regulations framed under the Indian Electricity Act. Further it shall be strictly carried out as
per the regulations and rules set out by “Tariff Advisory Committee and/or Fire Insurance
Regulations”.
1.2. Terminal Points:
The Bidder shall get the HT Power Supply from JSEB/ supply utility from the two different
Tapping Point made available by JSEB to fulfill power requirement of the proposed Sewage
Treatment Plant.
The Scope of electrical works shall include design, manufacture, supply, delivery to site,
inspection and testing at the manufacturer’s works, erection/ installation, testing and
commissioning of all the electrical equipment/systems required for the STP on turnkey basis, as
specified in this Section and the enclosed drawings, so as to make the system complete in all
respects. The brief description of scope is given below.
(a) Temporary arrangements to be made by the Tenderer for the power required for construction
work and to operate existing raw sewage pumping machinery for bypass / disposal of sewage in
adjacent Nala for construction phase or till regularized and functional power connection is
obtained from JEB/ supply utility for proposed STP.
(b) Construction of 11/22 KV inbuilt sub-station as per approved drawing. Tentative location is
identified in the proposed layout drawing enclosed however the exact location will be decided in
consultation with JEBL / supply utility in charge / Engineer In-charge of RMC.
(c) Providing 11/22 KV SF6 Gas filled 3 Panel ring main unit ( RMU) with one VCB & two isolator
(motor operated) or as suggested by JEB/ supply utility, 11/22 KV SF6 Gas filled VCB Panel with
one isolator, two VCB, 11 / 22 KV / 440V indoor transformer of required capacity. Capacity of
transformer will be calculated on the basis of prevailing norms of JEB/RMC/any other authority,
11/22 KV cabling between RMU & RMU to VCB and VCB to transformer all within substation
building.
(d) Wiring of substation building and provision of standard safety equipment’s in the same as
approved by the JEB and the electrical inspector/RMC.
(e) Incoming 11/22 KV supply cable to this substation shall be covered in the scope of work.
(f) The Tenderer has to obtain from JEB/RMC/any other approving authority, all necessary
approvals right from the approval of scheme sanction of load to the releasing of power supply and
bringing completion report from JEB/RMC. RMC shall help Tenderer in documentation to obtain
such approvals, however the responsibility to achieve the same lies with the Tenderer. Tenderer
will be fully responsible to obtain regularized and functional power connection from JEB for
proposed STP within time frame stipulated in the Tender. No time extension will be granted on
this ground.
(g) All necessary charges pertaining to power connection related to JEB authorities shall be borne by
the Bidder.
(h) Provision of 1100 V grade XLPE insulated extruded inner and outer PVC sheathed aluminum
conductor, armored cable of adequate size from the transformer up to PCC with APFC Panel up
to the load point etc. complete along with the end termination with gland and crimping type of
lugs.
(i) Provision of a complete indoor and outdoor cabling system. 1100 V grade, XLPE, aluminum
conductor, armored cables shall be provided for distribution of power to various DBs/ panels and
individual loads in the STP, while 1100 V grade, PVC insulated, extruded inner and outer PVC
sheathed, stranded copper conductor, armored cables shall be provided for control and
instrumentation. These cables shall be laid in trenches, trays, pipes/conduits, buried in ground, as
required, depending on the plant layout. The entire cabling system shall be as per the approved
drawings.
(j) Complete plant indoor and outdoor lighting system shall be provided by using Hybrid electricity
e.g. solarpower, Wind power.

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(k) Complete plant indoor and outdoor Earthing and lighting protection system comprising electrode
pits and conductors shall be provided inside and outside the plant to ensure proper system
neutral Earthing and safety Earthing. The entire Earthing and lightning protection system shall be
as per the approved drawings and IS.
(l) LV capacitor bank, with control Panel consisting of automatic power factor correction (APFC)
relay, shall be provided to improve the overall plant ‘of’ up to a maximum of unity.
(m) Local Start/Shop push button stations shall be provided near all motors.
(n) All the motors shall conform to the requirements of latest editions of application Indian Standards.
The motors shall be squirrel cage, TEFC type and shall be rated for continuous duty. The winding
degree of protection of enclosure shall be IP 54 for indoor motors and IP 55 for outdoor motors
and IP 56 for outdoor motors located near water bodies. (o) Complete electrical works within
the terminal points comprising of the following: (i.) 2 Panel Ring Main Unit, 11/22 KV SF6 Gas
filled with two Isolators. (ii.) 2 VCB Panel with Safety Relays. (iii.) 1 Nos. Transformers of
suitable rating. (iv.) PCC with APFC. (v.) MCC Panels as per requirement. (vi.) Local
Panels & Start Stop Push Button Stations. (vii.) Internal Illumination to the Lux Levels indicated
in the Electrical Specifications. (viii.) External Illumination to the Lux Levels indicated in the
Electrical Specifications. (ix.) Power & Control Cables. (x.) Earthing with Earthing Pits. (xi.)
All the MCC Panels and PCC shall be integrated type using PLC Remote I/Os or Distributed
System for integration of the plant electrical data on SCADA.
1.3. Detailed Specifications/ Requirements of Scope of Work
(a) Design, Manufacture, inspection and testing at works, supply at site erection, final check-up,
painting, testing, and commissioning of the electrical equipment as detailed in the items with brief
description shall form the scope of work of the successful Tenderer.
(b) The scope of work also includes civil work such as excavation, laying of sand and bricks on
cables laid, closing the excavation, making Earthing pit chambers, foundation and pedestal for
electrical equipment, grouting of cable tray supports in walls, making entries for cable conduits in
walls and making good the surface to the original one, embedding concealed conduits, junction
boxes, etc., in walls and ceiling and making good the surface, foundation for street lighting poles,
providing covers, chequered plates on cable trenches, etc.
(c) Co-ordination with local authorities, such as JEB/RMC, Electrical Inspectorate the State
Government, chief electrical authority, etc. for obtaining all the statutory approvals needed,
preparing, submitting and obtaining approval of all electrical drawings and documents as well as
obtaining approval of the electrical installation from these authorities shall also form a part the
scope of the work.
(d) Preparation and submission of As-Built drawings on soft-copy installation, operation and
maintenance manuals of the equipment supplied along with their catalogues shall also be
furnished by the successful Tenderer.
1.4. System Design Parameters
The electrical equipment’s/ items selected for this project shall be suitable for operation of
technical parameters specified below:
a) Incoming power supply AC, 11/22 KV, 3 Phase, 50 Hz
Plant power distribution voltage AC, 415 V, 3 Phase, 4 Wire, 50 Hz
Lighting and space heating AC, 230 V, 1 Phase, 2 Wire
DC alarm, control and protection 24 V, 2 Wire, DC
AC control AC, 230 V, 1 Phase, 2 Wire
Potential transformer secondaries AC, 110 V, 3 Phase, 50 Hz or as specified
by JEB
0
Ambient temperature 50 C
System Earthing Solidly earthed
Voltage variation + 10 % of rated voltage
Frequency Variation + 5 % of rated frequency
Combined voltage and frequency + 10%
variation

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 Fault Level 350 MVA (11KV), 40KA
l)
(415V) 6 KA (230V)
Tap changing gear On load tap changer
1.5. Standard Specifications of Electrical Works and Components
All the electrical work & equipment specifications will be as per the attached General Work
Specification for electrical works specified in the following section.

A. Design Criteria

(i) Estimation of Load

The following assumptions are made to arrive at the maximum electrical demand of the water
treatment plant.

a) Load Factor
i Motors : 0.7
ii. Auxiliary load (valve actuators, crane etc.) : 0.9
iii. Lighting load :: 1.0

b) Diversity Factor
i. Motors 1.2
ii. Auxiliary load (valve actuators, crane etc.) 1.5
Iii. Lighting load 1.2

c) Power factor of Motors : As per the Manufacturer’s Catalogue

d) Efficiency of Motors : As per the Manufacturer’s Catalogue

(ii) Equipment
o
b) All the indoor electrical equipment will be rated and sized for 45 C design ambient temperature,
o
while all the outdoor electrical equipment will be rated and sized for 50 C design ambient
temperature.
c) The capacity of the transformers will be calculated based on the total simultaneous maximum
demand (calculated based on the load factors and diversity factors) plus 10% contingency. A
transformer with the next higher standard rating recommended in the Indian Standards will be
selected.The 100% standby transformer shall be provided.
d) All the power cables will be sized based on the continuous current rating of the load permissible
voltage drop and short circuit current rating. The voltage drop will be limited to 2.5 % at rated
equipment current rating.
e) The rating factors for variation in ground temperature, variation in ambient air temperature,
grouping of cable, type of laying, depth of laying etc., will also be considered for cable sizing.

(iii) Illumination
The illumination levels to be considered for the design of lighting system for various areas as
follow:
1. Area Illumination level (Lux)
Office / Control Room 300
Switchboard Room 250
Area Illumination level (Lux)
Other indoor areas, if any 150
Outdoor areas and roads 30
Maintenance Factor – Outdoor area 0.6
- Indoor areas 0.7

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 (iv) Earthing:
i. The material of Earthing conductor laid above ground or buried in concrete will be galvanized steel.
ii. The size of the Earthing conductor will be designed as per the Indian Standards / IEEE. The value of
fault current will be calculated based on the transformer capacity, its impedance and the main supply
system fault level. Fault current withstand time for sizing of earth conductor will be taken as three
seconds. While sizing the buried earth conductor, a corrosion allowance of at least 20% will be
taken.
iii. Main Earthing conduction outside and inside the building will be planned in such a manner that the
equipment are connected to the Earthing system by two connections in a reliable manner.

(v) Protections
The following protections will be provided for various electrical equipment.
1. HV Substation
a. VCB for transformer
2. LV switchboard
a. Thermal overload and shot circuit protection features of MCCBs/ACBs for all feeders.
b. Overload protection by thermal (bimetal) relays with single phasing preventer (SPP) for
contactors for motor feeders.

(vi) Metering
The following metering will be provided on the LV switchboard:
1. LV Incomer
a. Ammeter with selector switch
b. Voltmeter with selector switch
c. Kilowatt meter
d. Power factor meter
e. Kilowatt-hour meter
f. Load monitor unit with MODBUS communication parts
2. LV Outgoing Feeders
a. Ammeter with selector switch

(vii) Indicating Lamps

The following indications will be provided on the LV switchboard.
1) LV Incomer
Supply ‘ON’ (Red, Yellow & Blue) or Legend R, Y, B
2) LV Motor Feeders
Motor “ON’, ‘OFF” & ‘Trip’ indications (Red, Green & Amber).

(viii)General
a. The main LV switchboard is proposed with ‘Form – 4’ enclosure as per the Indian Standards. All
indoor boards/panels and motors are proposed with a degree of protection of IP 54, while all
outdoor equipment will be with a degree of protection of IP 55.
b. The method of starting of motors will be ‘Direct-On-Line’ (DOL) for motors with rating up to and
including 5 HP, ‘Star-Delta’ for motor rating above 5 HP up to 30 HP , ‘Soft Starter’ for motor
rating above 30 HP , and VFD’ for motor rating above 75 HP.
c. LV power cables will be with stranded aluminum conductor, XLPE insulation, extruded inner
and outer sheaths and galvanized flat/wire armoring, control cables will be with stranded copper
conductor, PVC insulation, extruded inner and outer sheaths and galvanized flat/wire armoring.
d. Decorative type fluorescent lamp lighting fixtures will be used in the office/conference room,
while industrial type mid-bay Magnetic Induction / LED /HPMV/MH lighting fixtures will be used
in other indoor areas. For outdoor areas including roads, floodlight/street lighting fixture with
Magnetic Induction / LED/ HPSV lamps along with G.I. octagonal poles are proposed.
e. All the electrical equipment, accessories and systems will confirm to the latest editions of the
Indian Standards or other equivalent international standards.

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B. Transformer
General:
The intent of this specification is to define the general requirement s for power transformers.

Standards: The transformers shall comply with the latest edition of the following and other relevant
Indian Standards
IS : 335 Insulating oil
IS : 1271 Classification of Insulating Materials
IS : 2026 ( Part I) Power Transformer - General
IS : 2026 ( Part II) Power Transformer - Temperature Rise
IS : 2026 ( Part III) Power Transformer - Insulation level and dielectric tests
IS : 2026 ( Part IV) Power Transformer – Terminal marking, tapping and connection
IS : 2099 High voltage porcelain bushing
IS : 3639 Power Transformer fittings and accessories
IS : 6600 Guide for loading of Oil Immersed Transformers

Construction:
The transformer shall be Indoor oil immersed type. Transformer tank shall be welded sheet steel
construction and provided with gasketed steel cover plates, Base shall be suitably reinforced to
prevent any distortion during lifting.
Base channels shall be provided with skids and pulling eyes to facilitate handling. All covers and
seals shall be oil and air-tight and shall not be affected by mineral or synthetic oil action. The
radiators shall be of fixed type.
All fasteners and bolts etc. shall be galvanized or zinc passivated. All surfaces to be painted shall
be thoroughly cleaned, descaled, made free from rust and given a priming coat of rust resisting
paint following by two finishing coats of approved shade, to withstand specified atmospheric
conditions.
Unless otherwise stated the tank together with filter pipes and other fittings shall be designed to
withstand without permanent distortion:

a) Full vacuum of 760 mm of Hg for filling of oil by vacuum.

b) Internal gas pressure of 0.35 kg/cm2 with oil at operating level.

Terminals and cable/marshalling Box:

Winding shall be brought out and terminated on bushings/cable box as specified in the data
sheet. Cable box shall be sullied with cable lugs and glands. The neutral of the star connected
winding shall be brought out a separate bushing terminal inside cable box.
All doors, covers and plates shall be 600 mm from floor level and provided with gland plate and
cable glands as required. Top surface shall be sloped. An extra neutral bushing shall be provided
for neutral grounding of transformer having a secondary voltage of 433 V. The natural bushing
shall be mounted before bifurcation of the neutral, on the tank side to facilitate leading the earth
conductor down to the ground level.
Marshalling box shall be provided as required.
Cooling:
Type of cooling shall be oil natural / air natural (ONAN)
Oil:
Transformer shall be supplied with first filling of oil and extra 10 % oil shall be a supplied non-
returnable drum.

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Accessories:
Accessories as specified in the parameters shall be included in the scope of supply. Conservator
shall be complete with oil filling plug and cap, oil drain valve, purging device and plain oil level
gauge in addition to magnetic oil level gauge.
Explosion vent shall be rotatable in all directions and provided with sight gauge and equalizer
pipe connection. Bottom drain valve shall be of suitable diameter to drain off 90 % of the oil in ten
minutes. Thermometer pocket shall be with mercury in glass thermometer (00-1200C).
Core and Winding:
Transformer shall be double wound, core type with cold rolled grain oriented silicon steel
laminations perfectly insulated and clamped to minimize vibration and noise. Care shall be taken
to insulate core-fastening bolts and to reduce losses and avoid hot points.
The insulation structure for the case to bolts and case to clamp plates shall be such as to
withstand a voltage of 2000V for one minute. The complete case and coil assembly shall be dried
in vacuum and shall be immediately impregnated with oil after the drying process to ensure
elimination of air and moisture from the insulation. All parts of magnetic circuit shall be bounded
to earth system. Winding of transformer shall be of copper and shall be designed to withstand the
22KV system dynamic and short circuit stresses.
Tapings and Control:
These shall be on high voltage side and connected to off circuit tap changing gear as specified in
data sheet.
The tap changing arrangement shall change over taps on all the phases simultaneously. Under
conditions of external short circuit, the tap changing equipment must be capable of carrying the
same current as the windings.
Off circuit tap-changing gear shall have an external operating handle preferably mounted on the
transformer side with locking arrangement and position indicator.
Noise:
The audible sound lever measured at 1 meter from the external surface of the transformer shall
not exceed 250 db (A)
Earthing:
Transformer shall be provided with two main frame Earthing terminal on opposite sides, which
shall be separate from the neutral terminal of star connected winding. Cable/Marshalling box etc.
shall be separate from the neutral terminal of star connected winding. Cable/Marshalling box etc.
shall be provided with one Earthing terminal in addition.
Performance Requirements:
The performance requirements for the transformer shall be as follows:
• Transformer shall operate without injurious heating at the rated KVA at any voltage
within+10% of the rated voltage of particular tap.
• Transformer shall be designed for 110% continuous overloading capacity.
• Overloads shall be allowed within the conditions defined in the loading guide of the applicable
Standards. Under these conditions, on limitations by terminal bushings, tap changers or other
auxiliary equipment shall apply.
• The neutral terminal of windings with star connection shall be designed for the highest over-
current that can flow through this winding.
• Every care shall be taken to ensure that the design and manufacture of the transformer shall
be such as to reduce noise and vibration to the level obtained in good modern practice. The
supplier shall ensure that the noise level shall not be more than 250 dB (A).

Page 223 of 263

• For transformer with tapings, full power tapings shall be provided.
If the commissioning of the plant is likely to be delayed by the rejection of transformer, the
Engineer reserves the right to accept the rejected transformer until the replacement of
transformer is made available.
Transporting the rejected and replacement of transformer as well as installation and
commissioning of both transformers shall be at the Contractor’s cost.
Parameters for Transformer
0 0
1.0 Site Conditions : @ 35 – 40 C
1.1 Maximum ambient temp
0
1.2 Minimum ambient temp : 15 C
1.3 Relative Humidity : @ 98%
1.4 Altitude : 4 to 5 M above MSL
1.5 Environment : Tropical
2.0 Operating Conditions
2.1 Primary Voltage : 11 kV
2.2 Earthing System
Primary : Not applicable
Secondary : Solidly earthed
3.0 General Data
3.1 Duty : Continuous
3.2 Type of cooling : ONAN
3.3 Installation : Indoor
3.4 Oil type : Mineral (as per IS 335)
3.5 Temperature rise
0
Oil : 50 C
0
Winding : 55 C
3.6 Painting : Epoxy
3.7 Colour Shade : Shade 632 as per IS-5 (Admiralty Grey)
4.0 Electrical Data
4.1 No. of windings : Two
4.2 Phase :3
4.3 Frequency : 50 Hz+5%
4.4 Inter phase connection : Delta / Star
4.5 Vector group : Dyn-11
4.6 Insulation Class :A
4.7. Winding insulation : Uniform
4.8 H.V. Phase sequence : UVW
4.9 Impulse voltage withstand : (1.2/50 u S) 75 kV
Capacity
4.10 One minute power frequency
Voltage withstand capacity : 28 kV
5.0 Specific Requirement
5.1 Rating : 120% of total plant load
5.2 Voltage ratio : 11 kV X 440
5.3 % impedance : As per IS: 2026
5.4 off circuit tap changer : + 5% in step of 2.5%
5.5 Overload capacity : 20%
5.6 Terminal details
Terminal location HV : On one side
Terminal location LV : Opposite to HV terminal
5.7 Connection details

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 Primary : Cable box
Primary Cable Size/Type : Armored XLPE
Secondary : Cable Box
6.0 Accessories
6.1 Sampling Valve : Yes
6.2 Conservator : Yes
6.3 Conservator drain plug : Yes
6.4 Rollers (Bi-directional) : Yes
6.5 dial Type thermometer with : Yes
Contacts
6.6 Silica Gel breather : Yes
6.7 Air release plug
6.8 Drain cum bottom filter valve : Yes
6.9 Lifting lugs : Yes
6.10 Cross channels with towing
lugs : Yes
6.11 Shut off valve for radiators : Yes
6.12 Thermometer pocket with
Thermometer : Yes
6.13 Separate neutral bushing
Outside terminal box : Yes
6.14 Top oil filter valve : Yes
6.15 Inspection cover : Yes
6.16 Disconnection chamber : Yes

6.18 Lugs and cable glands : Yes

6.19 Oil Gauge : Yes
6.20 Explosion vent: : Yes
6.21 Radiator : Yes

7.0 Tests:
The following tests shall be carried out as per IS: 2026
• Routine tests.
• 2KV withstand test for all wiring.
• Zero phase sequence impedance test.
• Temperature rise test.
• Short circuit test.

Certificates for type tests carried out in last three years on transformers of similar design shall be
submitted for review.

8.0 Inspection
Inspection: Category A

C. Power Capacitors
General:
Power capacitor banks of suitable KVAR rating shall be provided across the main bus bar of
PMCC with Automatic Power Factor Correction Relay (APFC) for maintaining the power factor of
the installation at not less than unity.

The Contractor shall submit detailed calculations for arriving at the correct KVAR rating.
Standards:
Unless otherwise specified, the units shall conform to the following Indian Standards:
IS: 22534 Specification for Shunt Capacitors for Power Systems

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IS: 5535 (PartII) Shunt Reactors

Construction:
The capacitor shall be of All Polypropylene (APP) type consisting of elements wound from high
purity soft annealed aluminum foil and layer of biaxial oriented polypropylene. The element must
be assembled either in parallel or in series parallel combination for desired capacity and voltage
ration with proper insulation. It shall be housed in a metal container. The leads shall be taken out
through bushing and unit shall be hermetically sealed after fine vacuum drying and impregnated
with highly purified nom PCB oil.

The capacitor shall be either with internal element fuse or external fuse with internal discharge
resistance.

The capacitor bank shall comprise of suitable number of single phase units in series parallel
combination. However the number of parallel units in each to the series stack shall be such that
failure of one unit shall not create an over voltage on the units parallel with it. The complete bank
with the accessories shall be metal enclosed, indoor floor mounted and free standing type. Each
capacitor case and cubicle shall be earthed to a separate earth bus.

Each unit shall be fitted with a low loss discharge device to discharge capacitor to reduce the
voltage to 50 V within one minute as per IS: 22534. The unit shall be capable to withstand
satisfactorily an over voltage up to 110% of its rated voltage and 135% of rated KVAR including
manufacturing tolerances.

Each capacitor unit shall be individually protected by HRC fuse rated for load current and
interrupting capacity so that a faulty capacitor unit can be disconnected without causing the motor
to be disconnected.

The capacitor bank shall be complete with all parts that are necessary for efficient operation. This
shall include steel rack assembly, copper bus bars, copper connecting strip, foundation channel,
fuse, fuse clip etc. The fuse breaking time shall be coordinated with the pressure built up within
the unit to avoid explosion.

Parameters for Power Capacitor

1.0 Site Conditions
0 0
1.1 Maximum ambient temp. : @ 35 – 40 C
0
1.2 Minimum ambient temp. : 15 C
1.3 Relative Humidity : @ 98%
1.4 Altitude : 4 to 5 M above MSL
1.5 Environment : Tropical
2.0 Output (KVAR) : To be decided by the Tenderer
3.0 Rated Voltage : 415 V+10%
4.0 Rated frequency : 50 Hz+5%
5.0 No. of phases :3
6.0 Location of capacitors : Indoor
7.0 Nature of control : By APFC relay
8.0 Type of capacitor bank : All polypropylene (APP)
9.0 Insulation level : 2.5 kV (rms)

Tests:
All tests shall be conducted in accordance with the latest edition of IS: 22534 and as applicable
for the controls. Type test certificates for similar capacitor units shall be furnished.

Page 226 of 263

 Inspection: Category A

D. LT Switch Boards and Control Cabinets Main PCC

The main PCC shall be metal clad totally enclosed, rigid, floor mounted, air insulated, cubicle type
for use on 415 V, 3 phase, 50 Hz system. The PMCC shall be single front, non-draw out type
compartmentalized.
Each PCC shall consist of several compartments.
The equipment shall be designed for operation in high ambient temperatures and high humidity
tropical atmospheric conditions. The equipment shall be for indoor installation. 10% spare feeders
with minimum one (1) no. of each type and rating shall be provided in PCC, complete in all
respects. PCC shall contend additional spare feeder for DG connection which shall carry the full
capacity of plant load.

MCC/ Control Panel

The MCC/Control Panel shall be metal clad totally enclosed, rigid, floor mounted, air insulated,
cubicle type for use on 415 V, 3 phase, 50 Hz system. The PMCC shall be single front, non-draw
out type and non-compartmentalized type. MCC with double front construction may be accepted if
substantiated by data where the size of sigle front cannot be accommodated in the Room.
The Local / MCC cum Control Panel shall have all controls mounted on the body and with only
user required controls approachable from the outside. No live part should have direct access in
the Panel.
The equipment shall be designed for operation in high ambient temperatures and high humidity
tropical atmospheric conditions. The Sub PMCC/ Control Panel shall house the Intelligent Logic
Controllers. The equipment shall be for indoor installation.
10% spare feeders with minimum one (1) no. of each type and rating shall be provided in MCC
complete in all respects. All the Panels (LT) should be fuse less and should use MCB/MCCB/ACB
as per application.
The DG incomer shall be design for the entire plant load in case of power failure, with electro-
mechanical interlock with main incomer.

Standards:
The equipment shall be designed to conform to the requirements of:
IS: 25623 and IEC 439 Factory built assemblies of switchgear and control gear
IS: 4237 General Requirements for switchgear and control gear
not exceeding 1000 volts
IS: 2147 Degrees of protection provided by enclosures for low voltage
switchgear and control gear
IS: 375 marking and arrangement of bus bars
IS: 2959 AC conductors of Voltage not exceeding 1000 volts
IS: 4064 (Part II) Air break switches and fuse combination units for voltage not
exceeding 1000 volts
IS: 694 and IS: 25130 PVC insulated cables and aluminum conductors
IS: 12425 Direct action electrical indicating instruments
IS: 9224 Low voltage fuses
IS: 2516 Alternating current circuit breakers
IS: 2705 Current transformers
IS: 3156 Voltage transformers

Construction:
The structure of the panels shall be totally enclosed, free standing / wall / support mounted as
applicable for the type of main or MCC, with the assemblies made up of requisite rigid welded
structure frame made of structural steel sections and of dust and vermin proof construction with

Page 227 of 263

cold rolled sheet steel sections and of dust and vermin proof construction with cold rolled sheet
steel of not less than 2 mm thickness or of pressed and former sheet steel of not less than 3 mm
thickness.
The doors, covers, barriers etc. shall be made of minimum 1.6 mm thick steel. All Panel doors,
removable covers, gland plates shall be provided with gaskets. The structure shall contain
horizontal bus bars running throughout the length of the unit and be readily accessible.
Each vertical section shall be divided into the following well defined zones by metallic insulated
barriers:
• Main bus bar chamber at top
• Unit chamber
• Cabling chamber at the right hand side or at the bottom of the unit chamber
• Vertical riser chamber behind unit chamber

The structure shall be mounted on a rigid base frame of folded sheet steel of minimum 3 mm
thickness and 75 mm height.
The maximum height of floor mounting cubicle panels shall be 2500mm (maximum) and for wall-
mounted Panel shall be 1500 mm.
The Panel shall be provided with a degree of protection of not less than IP 52 as per IS: 2147.
Panel shall be extendable on both sides by addition of vertical sections.
Provision shall be made for permanently earthing the frame and other metal parts of the Panel
through an aluminum earth bar running throughout the full length of the Panel at the bottom. It
shall be possible to earth the Panel at two independent points through earthing terminals.

Metal Treatment and Finish:

All steel work used in the construction of PCC & MCC be given degreasing, derusting,
phosphatising, and passivation treatment followed by (a) two coats of red oxide primer and two
coats of final stove enamel paint of shade 631 of IS:5 or (b) epoxy powder coating.

Bus Bars:
The bus bars shall be air insulated and made of high conductivity, high strength aluminum
complying with the requirements of grade E91E of IS: 50252. The bus bars shall be suitably
braced with non-hygroscopic SMC supports, to provide a through symmetrical fault withstand
capacity of LV side of transformer for one second. The neutral as well as the earth bar shall also
be capable of withstanding the above fault level. Ridges shall be provided on the SMC supports to
prevent tracking between adjacent bus bars. Porcelain insulator will not be accepted. The main
horizontal bus bars shall be positioned at the top portion and suitable colour identification shall be
provided. Suitable barrier shall be provided in front of the vertical bus bar against accidental
contact. High tensile bolts and spring washers shall be provided at all bus bar joints. An earth bus
bar joints. An earth bus of adequate site made of copper flat shall be provided at the bottom of the
Panel.

Unit Module:
Each module shall be suitable for mounting a required number of power contactors, bimetal relay,
auxiliary contactors, push buttons, isolator, ACB, MCCB, MCB, control fuses, main fuses,
indicating lamps, meters, power and control contacts, terminal block cum secondary isolating
contacts etc., to suit non-reversing, reversing and assisted start motor applications. Isolator,
meters with selector switches, indicating lamps, push buttons & bimetal relay reset button shall be
mounted on the module door.
The main and control contacts shall be self aligning type suitable for taking a mismatch up to +/-
4mm.
The main power contacts shall be capable of withstanding a short circuit current.
The module shall be connected to the vertical bus bars by plug-in contacts. The contacts shall be
between copper and copper both silver plated even if bus bars are of aluminum.

Page 228 of 263

Each vertical Panel shall be fitted with a label on the front and rear. The PMCC as a whole shall
also be fitted with a label indicating the switch gear rating and duty. Each relay, instrument,
switch, fuse, contactor etc. shall be provided with a separate label. The RMC shall approve type
and wording of all labels.

Air Circuit Breaker (ACB):

Circuit breakers shall be operated by a motor spring charging type of mechanism.
The motor operated spring charged mechanism shall be complete with motor, opening spring,
closing spring and all accessories to make the mechanism a complete operating unit.
The tripping spring shall be charged by the closing action, to enable quick tripping. Closing of the
circuit breaker shall automatically initiate recharging of the springs to enable the mechanism to be
ready for the next closing stroke.
Charging time for the springs shall not exceed 30 seconds. It shall be possible to manually
charged the springs in an emergency. Transfer from motor to manual charging shall automatically
disconnect the charging motor.
The charging mechanism shall be provided with mechanical indicators to show “charged” and
“Discharged” conditions of the springs. Failure of any spring, vibration or mechanical shock shall
not cause tripping or closing of the circuit breaker.
Only one closing operation of the circuit breaker shall result from each closing impulse (manual or
electrical), even if the breaker trips while the control device (manual or electrical) is being held in
the “close” position.
The circuit breaker mechanism shall make one complete closing operation, once the push button
has been operated and the first device in the control scheme has responded, even though the PB
is released before the closing operation is complete, subject to the condition that there is no
counter-impulse for tripping.
Means shall be provided to manually open and close the breakers slowly, when the operating
power is not available, for maintenance and adjustments. A local manual trip device shall be
provided on the operating mechanism. All operating mechanisms shall be provided with “ON”-
”OFF” mechanical indication.
Closing coils and other auxiliary devices shall operate satisfactorily at all voltages between 255-
110 % of the control voltage. Trip coils shall operate satisfactorily between 70-110 % the rated
control voltage.

Moulded Case Circuit Breaker (MCCB):

MCCBs shall be of the air break, quick make, quick break and trip free type and shall be totally
enclosed in a heat resistant, molded, insulating material housing.
MCCBs shall have an ultimate short circuit capacity not less than the prospective short circuit
current at the point of installation.
MCCBs shall have a service short circuit breaking capacity equal to the ultimate short-circuit
capacity.
Each pole of MCCB shall be fitted with a bi-metallic thermal element for inverse time delay
protection and a magnetic element for short circuit protection. Alternatively, they shall be fitted
with a solid state protection system. Such a protection system shall be fully self-contained,
needing no separate power supply to operate the circuit breaker tripping mechanism. Thermal
element shall be adjustable. Adjustments shall be made simultaneously on all poles from a
common facility. Thermal elements shall be ambient temperature compensated.
The MCCBs shall be provided with the following features.
• Common trip bar for simultaneous tripping of all poles
• Shrouded terminals
• Time for clearing short circuit current of 20 sec.
• 2 NO + 2 NC auxiliary contacts

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Miniature Circuit Breaker (MCB)
MCB shall be hand operated, air break, quick make, quick break type.
Operating mechanisms shall be mechanically trip-free from the operating knob to prevent the
contacts being held closed under overload or short-circuit conditions.
Each pole shall be fitted with a bi-metallic element for overload protection and a magnetic element
for short-circuit protection.
Multiple pole MCBs shall be mechanically linked so that tripping of one pole simultaneously trips
all the other poles.
The magnetic element tripping current classification shall be of the type suitable for the connected
load. Where this is not specified, it shall be Type C.
The short circuit rating shall be not less than that of the system to which they are connected.

Motor Starters:
Each feeder shall have two modes of operation – Manual Mode & auto Mode. In Manual Mode,
the essential safety interlocks shall be provided with hardwire system. Also the starter shall have
facility of Local/Remote Start/Stop in Manual Mode. In Auto Mode, the starter shall operate on
PLC command.
Air break starter contactor shall be electro-magnetic type for uninterrupted duty as per IS: 2959
unless specified otherwise. The main contacts shall be of Silver or Silver Alloy. The insulation
class for the coils shall be class ‘E’. Each Contactor shall be provided with 2 NO + 2NC auxiliary
contacts. In case these are not available in the main contactor an additional auxiliary contactor
shall be provided.
Thermal overload relay with single phasing preventor shall be of three-element positive acting bi-
metallic ambient temperature compensated type with adjustable setting. These relays shall be
hand reset type. The hand reset button shall be flush with the front door of the control module and
shall be suitable for resetting the overload relay with the module door closed.
Relay shall be either directly connected or CT operated as per manufacturer’s recommendation
depending on motor KW rating. Reset button shall be independent of start/stop push button.

Control/Selector Switches:
All control/selector switches shall be flush mounted on module door and shall be rotary, stay put,
maintained contact type with phosphor bronze contacts. Ammeter selector switches shall have
make before break feature.
The selector switches shall have four positions for reading three phase currents and fourth shall
be ‘OFF’ position. The voltmeter selector switch shall have five position – three for the phase-to-
phase voltage, the forth for phase to neutral voltage and fifth shall be ‘OFF’ position. Remote
/Local / Off selector switches for motor feeders shall be lockable in ‘OFF’ position. Properly
designated escutcheon plates clearly marked to show the operating position shall be provided
with all switches.
Current transformers shall be cast resin wound primary or bar primary type and shall be able to
withstand the thermal and mechanical stresses arising from the maximum short circuit and
momentary duties of the equipment. The secondary rating of current transformers shall be 1A.
The polarity markings shall be clearly marked on the CTs and the lead termination of the terminal
block.
The core laminations of the CTs shall be high-grade silicon steel. Magnetisation characteristics,
performance calculation and protection settings of the CTs shall be provided.
The accuracy class for CTs shall be 1.0 and 5 P-20 for metering and protection purposes
respectively. Where multi-ratio current transformers are provided, VA ratings of the current
transformers shall be indicated, a label shall be provided, clearly indicating the connection
required for alternative ratios.
These connections shall also be shown on Panel wiring diagrams. Identification labels shall be

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fitted giving type, ratio, output and serial numbers and duplicate rating labels shall be fitted on the
exterior of the mounting chamber suitably located to enable reading without the removal of any
cover or metal sheeting forming part of the structure of the switch board.

Indicating Lamps:
Panel mounting type low power consumption LED type status indicating lamps suitable for
specified
voltage shall be used. Lamps shall be provided with suitable current limiting series resistors.
Translucent lamp covers shall be provided to diffuse light.

Push Buttons:
Start/stop push buttons shall be suitable for Panel mounting and comprise of a contact element
and
actuator.
The contacts shall be of silver alloy of 10 A continuous current rating at 240V AC. Each push
button shall be provided with 2 NO + 2 NC contacts. Colour of push buttons shall be as per
relevant IS/standard code of practice. Emergency stop push buttons shall be lockable in operated
position.
Push button knob for emergency stop push buttons shall be shrouded to prevent accidental
operation.

Space Heaters:
Each individual cubicle shall be provided with space heaters to prevent moisture condensation
and maintain cubicle temperature 50 C above the ambient.
The space heaters shall be located at the bottom of the switchboard and shall be controlled
through a thermostat with an adjustable settings and a manually operated switch. For space
heater 6 A DP switch and two HRC fuses shall be provided.
Each vertical Panel shall also be provided with 6A plug socket & switch for hand lamp connection.
Space heaters shall be provided only if the average humidity in the region is more than 250% for
more than 3 months in a year.

Contactors:
Power contactors shall be air break type, having three power contacts and 2 NO + 2 NC auxiliary
contacts conforming to IS: 2959. Contactors provided shall be AC 3 Duty type as per IS: 3947
part 4.
It shall be capable of making and breaking starting current of motors of corresponding rating.
Auxiliary contacts shall be rated for at least 6 A and shall be break before make type. Insulation
class of coil shall be minimum class B.
Contacts shall drop out at voltage down to 70% of rated coil voltage and pick up at 255% of rated
coil voltage.

Switches:
Switches shall be air break type as per IS: 4047. The switch operating handle shall be front
mounted and interlocked with the door such that the door cannot be opened when the switch in
‘ON’. The live parts shall be shrouded with suitable insulating barriers so as to prevent accidental
contact with the live parts after opening the module front door. Motor control switches shall be
suitable for reliable and safe starting and stopping of 3 phase AC motors even under heavy
starting locked rotor conditions. Switches shall be heavy duty, quick make and quick break type
AC 3 duty. Switch contacts shall be silver plated and contact springs shall be of stainless steel.
Switch handles shall have provision for locking in both open and closed positions. Mechanical
ON-OFF indication shall be provided on the switches.

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Indicating Meters(Analog / Digital):
Ammeters and voltmeters shall be of moving iron industrial type grade of accuracy class 1.5. The
size of the instrument shall be 144 mm sq. for starter and fuse switch compartments. Ammeter
with suppresses scale current rating shall be provided for specific requirements. Indicating
instruments shall be mounted flush on the module doors.
Instrument dials shall be white with black numbers and lettering. Dials shall be parallax free. All
indicating instruments shall have provision for zero adjustment outside motor cover.
Normal maximum meter reading shall be of the order of 60% of normal full scale deflection. Watt-
hour meters shall be of the induction type and shall be provided with reverse running stop. One
no. power factor meter shall be provided for the incoming feeder of PMCC.

Internal Wiring:
Internal wiring for control circuits shall be made with 650 V grade single or multistrand copper
PVC wires. The minimum size of control wiring shall be 2.5 sq. mm copper for power & CT circuits
and 1.5 sq. mm copper for other circuits. The wiring shall be terminated in the respective
terminals with suitable crimp type sockets. There shall not be more than two wires connected to a
terminal. Horizontal as well as vertical wire ways shall be provided. At the top, a horizontal wire
way shall connect the inter Panel wiring.
Internal wiring terminal blocks shall be of 650 V grade with contacts of rating not less than 10
amps. They shall be of the screw type with barriers between adjacent contacts. The wire
termination to the terminal block shall be of the screw type suitable for crimp type sockets.

Power Cable Termination:

Gland plates of adequate size & thickness shall be provided at the bottom of cable chamber to
facilitate cable entry from bottom. Compression type gland shall be provided. Crimp type sockets
made of tinned copper or aluminum shall be provided for terminating cables. Suitable shrouds
shall carrying out maintenance of one feeder. The individual cores of power and control cables
shall be neatly dressed and supported at regular intervals inside the cable chamber, before
connecting them to the relevant terminals. Termination kits for cable terminations shall be
provided, as required.

Labels:
Labels shall be anodizedaluminum with white engraving on black background. They shall be
property secured with fasteners.

Control / Auxiliary Power Circuits:

Control circuit voltage shall be 230 V AC achieved through suitably rated control transformer. Two
(2) Nos. control transformers, each 100% rated shall be provided with selector switch and control
buses. Auxiliary power supply voltage shall be 240 V AC, tapped from before the switch-fuse unit
of the incomer with isolating switch and fuses.
All wiring for control & auxiliary power circuits shall be colour coded as follows:

AC circuits - Red, Yellow or Blue determined by the phase,

With --- which the wire is associated.
AC phase wire White
AC neutral Black
DC circuits Grey
Earth connections Green
Engraved core identification ferrules, marked to correspond with the wiring diagram shall be fitted
to each wire and each core of multi core cables terminated on the panels. Ferrules shall fit tightly
on the wires, without falling off when the wire is removed. Ferrules shall be of white colour with
black lettering. All wires forming part of a tripping circuit shall be provided with an additional red
ferrule marked ‘T’.

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Each wire shall be identified by a letter to denote its function followed by a number to denote its
identity, at both ends. Unused cores of multicore cables shall be ferruled U1, U2 etc., at both ends
and connected to spare terminals. Spare auxiliary contacts of electrical equipment shall be wired
to terminals blocks.

Control Wiring Terminal Blocks:

Terminal blocks shall be of the 650 V grade, stud type of rating not less than 10A. Brass studs of
at least 6 mm dia with fine threads shall be used and securely locked within the mounting base to
prevent turning.
Each terminal shall comprise two threaded studs, with a link between them, washers, matching
nuts and locknuts for each stud. Insulated barriers shall be provided between adjacent terminals.
Not more than two wires shall be connected on any one stud. Where duplication of terminal block
is necessary, suitable solid bonding links shall be incorporated in the design of the terminal block.
Provision shall be made to insert terminal labels or shrouds between two successive insulating
barriers.
Connections to the terminals shall be at the front. Terminals shall be numbered for identification
and grouped according to function and engraved black-on-white labels shall be provided on the
terminal blocks describing the function of the circuit.
Terminals for circuits with voltage exceeding 125 V shall be shrouded. Terminal blocks at different
voltages shall be segregated into groups and distinctively labelled.
Current transformer secondary leads shall be brought to terminal blocks, where a facility shall be
provided for short circuiting and grounding the secondary. Terminal block shall be arranged with
at least 100 mm clearance between any two sets. Separate terminal stems shall be provided for
internal and external wiring respectively.
All wiring shall be terminated on terminal blocks, using crimping type lugs or claw type
terminations. 20% spare terminals shall be provided in each terminal block.

Test Terminal Blocks:

Test terminal blocks shall be provided for secondary injection and testing of relay equipment. A
suitable metering block shall be provided for the connection of a portable precision instrument to
be operated when required, for specific plant testing purposes.
The terminal blocks shall be provided with suitable shorting links or alternatively shall be of the
type suitable for use with a portable test plug-in-arrangement.

Earthing of Switchgear / Distribution boards:

Each switchgear / Distribution board shall be provided with an earth bus running along its entire
length. The earth bus shall be located at the bottom of the board / Panel.
Earth bus shall be of copper. Earth bus shall be adequately sized to carry the rated symmetrical
short circuit current of the associated board / Panel for one second.
Earth bus shall be supported to withstand stresses generated by the short circuits & momentary
current of the associated switchgear / distribution boards.
Positive connections of all non-current carrying metallic parts and the frames of equipment
mounted in the switchgear / distribution board to the earth bus shall be maintained through
insulated conductors of adequate size.
All instrument and relay cases shall be connected to earth bus by means of 650 V grade, PVC
insulated, stranded, and tinned copper, 2.5 sq.mm conductor, looped through the earth terminals
of the case.
The scope of work will also include the rubber mat required to be spread in front of all the panels.
The mat shall have a thickness of 12.5 mm and shall have dielectric strength suitable for the
Panel voltage ratings.
Separate earting using copper strip and two earth pits with copper plates shall be provided for
instrumentation.

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 Parameters for PCC & MCC:

1.0 Site Conditions

1.1 Maximum ambient temp. : @ 350 – 400C
1.2 Minimum ambient temp. : 150C
1.3 Relative Humidity : @ 98 %
1.4 Altitude : 4 to 5 M above MSL
1.5 Environment : Tropical
2.0 Ratings :
2.1 Rated voltage , phase and
frequency : 415 V, 3 phase, 4 wire, 50 Hz
2.2 Type of construction : Single front-fixed type compartmentalized
2.3 Maximum system voltage : 457 V
2.4 One minute power frequency
withstand voltage :
Power circuit : 2500 V
Control circuit : 1500 V
Aux. circuit connected to
secondary of CT s : 2000 v
2.5 Continuous current rating of bus
bar under site reference ambient
temperature of 500C. : To be decided by the Contractor on the
basis of the plat load.
2.6 Short circuit withstand for bus
bars and droppers :
Short time (1 sec) at 415 V : to be decided by the Contractor based on the fault level
available at HV side and the impedance of the
transformer
Dynamic rating : To be decided by the Contractor based on the fault level
at LV side
3.0 Starters :
3.1 Type
Motors ≤ 5 kW – DOL
Motors > 5 kW – Star-Delta
Motors > 55 KW – Soft Starter/VFD
3.2 Contactor Rated Duty as per IS:
2959 and 25544 : Uninterrupted
3.3 Utilization category as per IS :
2959 and 25544 : AC3
4.0 Cable Entry : Top or Bottom

Tests:
The design of the switchgear / distribution board shall have been type tested in accordance with
the relevant sections of IS: 25623. In absence of type test certificates, the following type tests
RMC.
have to be carried out by the Contractor free of charge to me MMC.
• Verification of short time current withstands and peak current withstand of main and vertical
bus bars.
• Temperature rise tests on main bus bars, b\vertical risers, power contacts and control
contacts.
• Routine test shall be conducted on the Panel in accordance with is: 25623.
• Dielectric tests.

E. Motors
Materials, workmanship and standard: All the materials used in the manufacture of motors shall
be of high grade free from defects and imperfection.
The motors shall be built to conform to the Indian Standard Specification as listed below along
with other relevant codes.

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:
IS : 325 : Induction Motors
IS : 1231 : Dimensions of 3 phase foot mounted induction motors
IS : 4691 : Degrees of protection provided by enclosure from rotating electrical
machinery.
IS : 4729 : Measurement and Evolution of vibration of rotating electrical machinery.
IS : 6362 : Methods of cooling of rotating electrical machines

Workmanship shall be first class and workmen, skilled in their trades, shall do all work. Machining
of fits and finish shall conform to the modern shop practice.

Type:
Squirrel cage, horizontal shaft mounting, induction motor suitable for Waste Water Treatment
Plant environment shall be offered. The motors for indoor duty shall be TEFC with IP-44
protection. Motors for outdoor duty shall be TEFC with IP-55 protection.

Insulation:
Motors shall be provided with class F insulation with temperature rise limited to class B insulation.
The insulation shall be given tropical and fungicidal treatment for successful operation of motor in
hot, humid and tropical climate as per applicable standard. For motors for outdoor duty, account
shall be taken of heating due to direct solar radiation.

Speed:
Speed shall not be more than 1500 RPM. The manufacture shall furnish the recommended
standard and the economical speed.

Cooling:
Motors shall be cooled by self-ventilation only.

Bearings:
Motors shall preferably have grease lubricated ball or roller bearings. The bearings shall be
adequate to absorb thrust produced by the motor and driven equipment assembly. Bearings shall
be lubricated by grease injection from outside, in motor running condition without removal of
bearing covers. Labyrinth seal shall be provided to prevent loss of grease and to protect entry of
dust.
In case of oil lubricated bearings, a drain plug and oil level sight glass be provided.

Terminal Box:
Terminal box of the motor shall be suitable for top and bottom entry of cables and capable of
being rotated through 3600 in step of 900. The box shall be of weatherproof spring washer, check
nuts, cable glands and lugs. The terminal box shall have sufficient space for installation of
termination kit.
Separate terminal box shall be provided for space heater etc.

Overloads:
The motor shall have the standard short time overload capacity permitted by the applicable
standard. The motor ratings shall be at least 15 % over the BHP required by pump / equipment at
duty point or 10 5 above the maximum HP required by the pump / equipment in its entire
operating range, whichever is higher.

Variation withstand capacity:

The motor shall be capable of producing rated output without reduction in life span when operated
under either of the following variations in supply conditions:

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• Variation of supply voltage from rated value + 10 %
• Variation of supply frequency from rated value + 5 %
• Combined voltage and frequency variation 10%(absolute sum)
The motor shall be capable of starting and accelerating the driven equipment with applicable
method of starting without exceeding the temperature rise limit as 255% of rated voltage at motor
terminals.

Noise and vibration:

The motor shall be designed to operate with least noise and vibration. Special precaution shall be
taken for smooth running of the motor. The noise level must be within the limit of international
standards.

Shaft:
The rotor shaft shall be forged to shape from open hearth carbon or alloy steel and heat treated to
obtain high rigidity.
The shaft shall be designed to rotate without vibration and distortion at 25 % over the rated speed
and shall have ample strength and stiffness to resist twisting on short circuit. The normal speed
and the critical speed of the shaft shall be stated.

Fans:
For TEFC motors axial flow fans shall be mounted n rotor shaft for efficient circulation of air. Fans
shall be of corrosion resistant die cast Aluminum or Polypropylene. They shall be suitable for
rotation in either direction without affecting motor performance.

Lubrication System:
The bearing shall be equipped with all accessories and devices for lubricating the bearings while
the motor is in service. Oil cooling / grease cooling arrangement shall be provided.

Number of Starts:
The motor shall be designed to allow the required number of consecutive starts for the application
envisaged with at least 1 hot restart.

Space Heater:
The outdoor motors and indoor motors rated 30 KW & above shall be provided with space heater.

Balancing:
All rotating of the motor shall be balanced both statically and dynamically so as to run perfectly,
smoothly vibration-free. Site balancing of the motor and driven equipment shall also be done
during trial running before commissioning.

Earthing:
Two earth terminals shall be provided for the motors on base. One separate earth terminal shall
be provided inside the terminal box.

Painting:
External parts shall be finished and produce a neat and durable surface which will percent rusting
and corrosion. The surface shall be degreased and all rust, scales, sharp edges removed and
treated with red oxide primer and two coats of finish paint as per shade approved by EIC.

Parameters for Motor:

1 Site Conditions
0 0
2 Maximum ambient temp. : @ 35 – 40 C

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 0
3 Minimum ambient temp. : @15 C
4 Relative Humidity : @ 98 %
5 Altitude : 4 to 5 M above MSL
6 Environment : Tropical
7 Application : Sewage Transfer Pumps / Wash Water
pump / Air Blowers / Scraper / Booster
Pumps
8 Type : Sq. cage induction type
9 System voltage phase, frequency : 415 V, 3pH, 3 wire, 50 Hz
10 Starting method : DOL / Star-Delta / Soft starter / VFD
11 Starting current restriction : 6 x FLC in DOL and 2 x FL C in S/D
12 Type of insulation : Class F
13 Space heaters : For motors rated 30 kW and above

Tests:
The following routine tests in accordance with IS: 325 of latest edition shall be performed in
presence of the Engineer.

• Insulation resistance test

• Measurement of no load current and speed at rated voltage and rated frequency.
• Measurement of locked rotor current at reduced voltage or rated voltage and at rated frequency.
• High voltage test.
• Reduced voltage running up test at no load to check the ability of motor to run up to full speed
at no load in both the directions of rotation with one third of rated line voltage applied to stator
terminals.
The following additional test shall be performed to verify the performance, characteristics and
guarantees. They shall be in accordance with IS: 325 of latest edition.
• Measurement of stator resistance.
• Temperature rise test
• Momentary overload in torque test
• High voltage test
• Over speed test
Each type and rating of the motors should have been type tested in accordance with IS: 325. In
absence of type test certificates, type tests shall be carried out without any extra cost to the RMC.
Inspection: Category B

F. Power and Control Cables

Cable of 11/22 KV/ (Earthed) grade shall be armored & conform to IS: 70925 (Part II). The size of
the cable shall be suitable for adequate electrical loading with multi-stranded. Compacted, circular
shaped, aluminum conductors. The conductor screen and insulation screen shall both be f
extruded semi-conducting compound and shall be applied along with the XLPE insulation in a
single operation of triple extrusion so as to obtain continuously smooth interfaces.
The metallic screen of each core shall consist of copper tape with minimum overlap of 20%.
The manufacture shall suitably design the semi conducting screen and shall clearly indicate the
thickness and resistively of screed for both conductor and insulation. The thickness of this screen
and resistively shall be as per requirement of relevant IS.
The eccentricity of the cores shall not exceed 10% and then 2%. Method of curing for cable shall
be day curing / gas curing / gas curing / steam curing.
XLPE insulation shall be suitable for a continuous conductor temperature of 900C and short
circuit conductor temperature at 2500C.
The cable shall have distinct extruded PVC inner sheaths and outer sheaths of black color as per

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 IS: 53251. The armoring shall be of galvanized steel as per relevant IS.

LT Cable
Cables for low & medium voltage and industrial heavy-duty application. Shall be multi core XLPE
insulted PVC sheathed and armored of voltage grade 1100 V conforming to IS: 1554 Part I.
Conductor shall be stranded Aluminum / Copper for power cable and stranded Copper of size 2.5
mm 2 for control cables.
Cable for internal wiring purpose in conduits shall be single core stranded copper conductor, PVC
insulated conforming to IS: 694.
All cable shall be delivered to site as complete coils with wrapping in non-returnable drums and
seals intact, accompanied by manufactures test certificate and indicating the date of test.
The length of cable on each drum shall be determined be determined by the manufacture
considering the transport limitations from works to site.
The Contractor shall obtain RMC’s approval for the drum length before packing cables on drums.
No joints shall be allowed unless the actual length required is more than a drum length.
Construction of 650 / 1100 V grade cables:
The cables shall be of stranded aluminum / copper conductor, extruded inner and outer PVC
sheath, flat / round galvanized steel armoured.
Cables up to 10 sq. mm conductor size have round steel wire armour. Above 0.00 sq. mm. size
flat steel armour shall be used. For 31/2n core cables the current carrying capacity of the neutral
conductor shall be 75 % of that of the main phase conductors.
The cables shall operate satisfactorily without any damage / deformation in shape and size at site
0
conditions and at a continuous conductor temperature of 70 C.
The cables shall successfully withstand the rated short circuit current for the duration specified by
0
the manufacture without exceeding conductor temperature of 160 C.
Cores shall be identified by different coloring PVC insulation. Following clour scheme shall be
adopted.

Single Core : : Red, Black, Yellow or Blue

Twin Core Red, and Black
Three Core Red, Yellow and Blue
Three & half Core Red, Yellow, Blue and Black
Neutral of 31/2 Core Black

For multi core cables, cores shall be numbered. Further spare cored shall be provided in control
cables as follows:
Upto 5/C : : No spare core
Above 5/C up to 9/C 1 spare core
Above 9/C up to 14/C 2 spare core
Above 14/C 3 spare core

Control cable cores shall be 3/C, 5/C, 7/C, 9/C, 14/C & 19/C The
cable sixes shall be selected based on the following criteria:
• Continuous current of the circuit
• Maximum voltage drops of 10% during starting and 3% during normal running condition of the
equipment.
• Short circuit withstands time corresponding to system fault current and fault clearing time by the
circuit protection.
• Various de-rating factors for ambient air temperature, type of laying grouping etc.

G. Lightning Arrestor

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 The lightning arrestor shall be nonlinear type station class suitable for non-effectively earthed, 50
HZ System, conforming to IS: 3070. The lightning arrestor shall consist of line to earth terminal
stud, no. of spark gaps on series of linear resistors, the whole assembly housed in mechanically
sealed porcelain bushing. Neoprene rubber gasket shall be provided between metal caps and
porcelain.
Non-linear resistor shall be of silicon carbide block finished at both ends to ensure good electrical
contact. Spring shall be provided to keep good electrical contact between terminals, non-linear
resistor and spark gap, mounting brackets shall be hot dip galvanized suitable for installing
lightning arrestor on structure.
Lightning arrestor shall be of hermetically sealed self-supporting construction suitable for mounting
on structures. They shall have adequate thermal discharge capacity for switching surges, long
duration surges and multiple strokes. The lightning arrestors shall be capable of withstanding the
internal pressures developed during above discharge without operation of the pressure relief
devices.
Arrestors shall be designed to withstand the seismic design co-efficient specified in IS. Arrestors
shall be provided with pressure relief device, which will prevent shattering of porcelain in case
excessive gas pressure builds up.
Outer insulators shall be of porcelain having adequate mechanical strength and rigidity for
satisfactory operation under climatic conditions. Porcelain shall be finely glazed and shall be free
from imperfections. All metal parts of the lightning arrestors shall be of non-rusting and non-
corroding metal or if made of steel / iron, the same shall be galvanized or metalized. Bolts, screws
and pins shall be provided with lock washers, key or equivalent locking facility.
Arrestors shall incorporate anti-contamination feature to prevent arrestor failure consequent to un-
even voltage gradient shall be capable of discharging over voltages occurring during switching of
unloaded transformers.
Spacers for gaps and valve elements or valve blocks shall be of ceramic material to provide robust
construction and with excellent mechanical and electrical properties.
Arrestor shall be complete with insulation bases having provision for bolting to flat surface of
supporting structure. Grading rings shall be provided on each complete arrestor unit for proper
stress distribution as dictated by the voltage class. Arrestors shall be complete with line and earth
side terminals with clamps and connectors as per requirement.
The complete assembled arrestor shall be subjected to routine and acceptance tests as per IS:
3070 part I, in presence of the Engineer. Type test report of similar type & rating of arrestor shall be
furnished.

H. Specifications of Variable Frequency Drive General References

The drive should be designed to meet the following specifications:
• NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and
Operation of Adjustable Speed Drive Systems.
• IEC 146 - International Electrical Code.

Product Ratings
• Input Power
The drive should be self-adjustable to accept an input supply voltage of AC, 3 phase &
neutral of 415 V ± 10%, 50 C/s ± 5%.

• Environment
Storage ambient temperature range: -10 to 50 degree centigrade.
Operating ambient temperature range: 5 to 50 degree centigrade without derating.

• Output Power
The output voltage should be adjustable from 0 to rated input voltage. The output frequency
range should be adjustable from 0 to 100Hz. The inverter section shall produce a pulse width
modulated (PWM) waveform using latest generation techniques.

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 • Design Hardware
The drive hardware shall be employ the following power components
• Diode or fully gated bridge on the input.
• DC bus inductor on all ratings as required.
• Switching logic power supply operating from the DC bus.
• Phase to phase and phase to ground MOV protection.
• Gold plated plug-in connections on printed circuit boards.
• Microprocessor based inverter logic isolated from power circuits.
• Latest generation inverter section.
• Inverter section shall not require commutation capacitors.
• Customer Interface common for all horsepower ratings. Interface shall include an LCD
digital display, programming keypad and operator keys option.
• Common control connection for all ratings.
• Optimized for 4 kHz carrier frequency at 44kW (60HP) or less, and 2 kHz at 55kW
(75HP) and larger.
• Peripheral Interface to enable attaching common options.

• Control Logic
The drive should be programmable or self-adjusting for operation under the following
conditions.
• Operate drive with motor disconnected.
• Controlled shut down, when properly fused, with no component failure in the event of an
output phase to phase or phase to ground short circuit and annunciation of the fault
condition.
• Adjustable PWM carrier frequency within a range of 2-25 kHz. Selectable Sensor less
Vector or V/Hz mode.
• Selectable for variable or constant torque loads. Selection of variable torque shall provide
115% of rated VT current for up to one minute. Selection of constant torque shall provide
150% of rated CT current for up to one minute.
• Multiple programmable stop modes including - Ramp, Coast, DC-Brake, Ramp-to-Hold
and S-curve.
• Multiple acceleration and deceleration rates.
• All adjustments to be made with the door closed.

I. Power Conditioning
The drive should be designed to operate on an AC line which may contain line notching and up to
10% harmonic distortion. An input isolation transformer shall be required for protection from
normal line transients and the K factor shall be 4.0 or less.
PF shall after rectification if required for lower frequencies not be lower than 0.95.

Features

Interface
The drive shall provide a removable Human Interface Module with integral display to show drive
operating conditions, adjustments and fault indications. The display should be removable under
power without causing a fault and shall be visible and operable without opening the enclosure
door. The module also shall provide LED indication of drive direction and commanded direction.
The display should be capable of remote mounting by means of cable connection up to 10 meters
(33ft) from the drive and shall be capable of being used as a hand-held terminal.

Control Mode
Programming shall provide the ability to select sensor less vector or v/hz mode. The sensor less

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 vector mode shall use the motor nameplate data plus motor operating data, such as IR drop,
nominal flux current and flux up time. The volts per hertz mode shall be programmed for squared,
cubed, straight line, preprogrammed or full custom patterns.

Current Limit
Programmable current limit shall be from 20% to 160% of constant torque rating. Current limit
should be active for all drive states; accelerating, constant speed and decelerating. The drive
shall employ Pl regulation with an adjustable gain for smooth transition in and out of current limit.

Acceleration/Deceleration
Accel/Decel setting shall provide separate adjustments to allow either setting to be adjusted from
0 seconds to 3600 seconds. A second set of remotely selectable Accel/Decel setting shall be
accessible with Control interface option. An adaptive current limit circuit shall be disabled in
programming for fast acceleration of low inertia loads.

Speed Regulation
The programmable speed regulation modes shall include the following:
• Open Loop
• Slip Compensation with 0.5% speed regulation
• Droop - Negative Slip Compensation with 0.5% speed regulation
• Traverse Function
• Closed loop encoder feedback with 0.1% speed regulation
• Process PI control

Speed Profiles
Programming capability shall allow the user to produce speed profiles with linear
acceleration/declaration or “S-Curve” profiles that provide changing accel/decel rates. S-Curve
profiles shall be selectable for fixed or adjustable values.

Adjustments
The digital interface should be used for all set-up, operation and adjustment settings. All
adjustments shall be stored in nonvolatile memory (EEPROM). No potentiometer adjustments
shall be used. The drive shall provide EEPROM memory for factory default values.

Process Pi Control
The internal process Pl regular shall have both proportional and integral gain adjustments well as
error inversion and output clamping functions. The feedback shall be configured for normal or
square root functions.
If the feedback indicates that the process shall be moving away from the set point, the regulator
shall adjust the drive output until the feedback equals the reference. Process control shall be
enabled or disabled with a hardwire input.
Transitioning in and out of process control shall be tuned for faster response by preloading the
integrator. Protection should be provided for a loss of feedback or reference signal.

Fault Reset/Run
The drive shall provide up to nine automatic fault reset and restarts following a fault condition
before locking out and requiring manual restart.
The automatic mode should be not applicable to a ground fault, shorted output faults and other
internal microprocessor faults. The time between restarts shall be adjustable from 0.5 seconds to
30 seconds.

Skin Frequencies
Three adjustable set points that lock out continuous operation at frequencies which may produce

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mechanical resonance shall be provided. The set points shall have a bandwidth adjustable from
0Hz to 15 Hz.

Run On Power Up
A user programmable restart function should be provided to automatically restart the equipment
after restoration of power after an outage. A maintained 2-wire start input shall be provided for
this function.

Line Loss Restart

This programmable function shall select the reconnect mode of the drive after recovery from a line
loss condition. The reconnect modes shall be – Last Speed.
Speed Search, Track Volts, or Use Encoder. Disabling this feature will force the drive to start from
zero hertz.

Fault Memory
The last four faults as well as operating frequency drive status and power mode shall be stored at
the time of fault. Information should be maintained in the event of a power loss.

Overload Protection
The drive shall provide Class 20 motor overload protection. Overload protection should be speed
sensitive and adjustable for motors with speed ranges of 2:1, 4:1 and 10:1. A viewable parameter
shall store the overload usage in percent. An alarm bit shall be used to adjust a process to
eliminate an overload trip.

Auto Economizer
This feature automatically shall reduce the output voltage when the drive shall be operating in an
idle mode (drive output current less than programmed motor FLA).
The voltage should be reduced to minimize flux current in a lightly loaded motor thus reducing kW
usage. If the load increases, the drive shall automatically return to normal operation.

Terminal Blocks
Separate terminal blocks shall be provided for control and power wiring.

Flying Start
The drive should be capable of determining the speed and direction of a spinning motor and
adjusts its output to “pick-up” the motor at the rotating speed. The flying start feature should be
operable with or without encoder feedback.

Ride Through
The control logic should be capable of “riding through” a power outage of up to 2 seconds in
duration.

Analog Output
An output signal should be jumper selectable for 0 – 10V DC or 0 – 20 mA which shall be user
programmable such that it shall be proportional to one of 13 process parameters including output
frequency, output current, encoder feedback, output power and other.

A programmable offset should be provided to allow modification of the analog output to obtain 2-
10 V DC or 4 - 20 mA. Programmable gain adjustments for both upper and lower settings shall
allow for system calibration.

Reference Signals
The drive should be capable of the following input reference signals:

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 • Digital pulse input
• Digital MOP
• Remote potentiometer
• Serial
• 0 - 10 V DC
• HIM (program/Control Panel)
• 4-20 mA
The remote potentiometer should be also programmable to be used as a trim pot for the 0 - 10V
DC or 4 - 20 mA signals. Programmable gain adjustments for both upper and lower setting shall
allow for system calibration. The analog inputs shall be programmable for normal, inverted or
square be root operation.

Loss of Reference
In the event of loss of the 4 - 2 0 mA reference signal, the drive should be user programmable to
the following:
• Fault and stop
• Alarm and maintain last reference within 10%
• Alarm and go to preset speed
• Alarm and go to minimum speed
• Alarm and go to maximum speed
• Active for Process Pl reference or feedback

Digital I/O
Contact output ratings shall be 115V AC/30V DC, 5.0 Amp resistive, 2.0 Amp inductive. All four
contacts shall be provided with programmable to 17 different conditions. Factory settings shall be
as follows:
• Form A Run Contact
• Form C Fault Contact
• Form C Alarm Contact
• Form A At Speed Contact

Operator Devices
The drive shall provide an option for Start, Stop, and Jog. Reverse and Speed Control as an
integral part of the Human Interface Module.

Control Interface
All control interface cards shall provide input terminals for access to fixed drive functions that
include start, stop, external fault, speed, and enable.
Four additional inputs shall be to be programmed to one of 24 different input Modes for functions
such as reverse, preset speed access, jog, second accel/decel time access, process trim,
speed/torque, and local control selection.
Inputs shall be programmable to configure the drive for standard 3-wire, 2-wire, EC, 4-20 mA DC
and serial operation requirements.

Remote I/O Communication

This be option shall provide a Single Point Remote I/O interface board. The board should be
configurable for 1/4, 1/2, 3/4, or full rack with a baud rate of 57.6, 115, or 230k baud. The Remote
I/O board may be set up to control drive logic and speed reference commands and monitor drive
status and process parameters.

J. Internal and External Illumination and Other Electrical Works

General:

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Illumination system shall consist of lighting fixtures complete with fluorescent tubes / incandescent
lamps / sodium vapour lamps. All materials, fittings and appliances used in the installation shall
conform to the relevant IS specification and shall be anticorrosive painted for treatment plant area.

Illumination Levels:
The following minimum levels of illumination shall be provided in the respective areas:
Area Illumination Level
Platforms and Chlorine house
Offices, Laboratory : 200 lux
Switch Gear rooms : 150 lux

Area Illumination Level

Transformer substation yard/ clarifier bridges : 100 lux
Toilets, Staircase : 70 lux
Plant Outdoor area : 50 lux
Roads etc. : 15 lux

Area Lighting/External Electrification

Scope
The scope of this specification covers design, manufacture, inspection of manufacturer’s works and
installation of MS/high Tensile Steel galvanized octagonal street light poles. The specifications of
poles are as under: -

Specifications of Octagonal Poles:

This specification determines the requirements of the octagonal poles in respect of design,
manufacture, testing and supply of galvanized poles, base plate and bracket arms for use in street
lighting.

This specification covers tapered octagonal single piece columns of required mounting height.

High tensile steel round as well as octagonal poles of 3mm thickness with hot dip galvanized in the
bath tub up to 9-11 meter. Single pole with minimum thickness of galvanizing as 36 micron.
Contractor may use M.S. steel poles with 4mm thickness single pole of 9-11m. length with hot dip
galvanized in the bathtub up to 12 mtr. single pole with minimum thickness of galvanizing 86 micron.

Galvanized base plate of special steel having thickness of 20mm is to be considered alternatively
Bidder can quote for MS base plate with 25mm thickness.

Octagonal poles shall be of flanged type to be fixed on the foundation bolts.

Possible loading configurations for different types of octagonal poles are indicated in respective GA
drawings.

The pole shall be provided with a common base plate of suitable size.

Galvanized iron junction box of adequate size, 2.7mm thick (water tight – IP 66 grade) shall be
provided for each street light pole. The box shall have arrangement to receive designed size and
number of cables. The terminal strip selected shall be suitable for the same.

The box shall also be provided with a required rating/capacity MCB for controlling the individual
lighting fixture. It shall be wired up in the respective phase. 3 x 25 sq. mm PVC insulated multi-
strand copper wires shall run from the junction box to the lighting fixture. The sires shall run
through the pipe. The wires shall be protected to avoid any damage at the entry point by providing
rubber grommet. A suitable clamping arrangement shall also be provided. An arrangement for

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earthing to the pole shall be provided.

Two numbers of 50mm dia G.I. conduits shall be provided in the foundations from the directly
buried main cable up to the junction box for incoming and outgoing cables with G.I. clamps of size
25 x 3 mm.

Suitable cement concrete foundation for the octagonal pole shall be designed by the successful
Tenderer considering soil bearing capacity of 10 Tons/sq.mtr.

An earthing bolt (M6) shall be provided with a suitable nut to receive two number of 8 SWG G.I.
earth wire.

General Standards

The methods and materials used shall comply with BSEN 10025 with yield strength of 355 Mega
Pascal for octagonal pole shaft.

Hot dip galvanizing shall be in accordance with IS 2629-1966 except otherwise modified by
provisions of this specification for poles and brackets.

Material

The steel used for manufacture of octagonal pole shaft and bracket shall be as per BSEN 10025
grade 355 Mega Pascal or equivalent and the material for the base plate, brackets, flange plates
shall be as per IS 1062.

The steel used shall be welded, ageing resistant and suitable for hot dip galvanizing when such
surface protection is required.

Manufacture

The octagonal pole shall be evenly tapered with single longitudinal welding from base to top. It
shall be fabricated in one single section and shall be no circumferential weld joint.

Electrodes used shall be compatible with the grade of steel being used and have mechanical
properties at least equal to those of the steel used. All welds shall comply with the following basic
requirements: -

Base Plate

100% penetration between plates of all thickness. No fissures on inside or outside surface. No
under cutting on the outside surface. Blowholes, spherical inclusions beyond standard minimum
thickness shall be refused. Detectable angular inclusions shall not be acceptable.

Longitudinal Welds
60% penetration between plates of all thickness. No fissures on inside or outside surface. No
undercutting on outside surface. No blowholes.

Galvanising

All components of the columns and brackets shall be hot dip galvanized after completion of
fabrication. No further touching up, finishing or modification shall be done after galvanizing. The
overall length of each section/bracket shall be immersed in one dipping operation.

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The galvanizing coating shall be smooth, continuous and uniform. It shall be free from acid spots
and shall not scale or blister nor be removable while handling or packing.

There shall be no impurities in the zinc nor additives to the smelter bath which could have a
deleterious effect on the zinc coating.

Before pickling, all welding, drilling, cutting, binding etc. must be completed and all grease, paint,
varnish, oil, welding slag etc. completely removed. All protuberances, which would affect the life of
the galvanizing should be also be removed.

During pickling each article shall be completely immersed in one dip. Care shall be taken to ensure
that the pickling solution is completely removed.

Weight of Zinc Coating

The weight of zinc deposited shall be not less than 86 microns.

Brackets

The bracket shall be hot dip galvanized after fabrication. The bracket shall be manufactured as per
the GA drawing and with best workmanship. The bending of the pipes shall be without any
kinks/visible marks. Arms shall be symmetrical.

Electricals

The octagonal pole shall be provided with a door flush with the pole surface without any projection.
Required door reinforcement shall be determined by the manufacturer. Inside the door a suitable
plate shall be welded for mounting 6A MCB and neutral link. Three core 2.5 sq.mm. copper wires
shall be run for each luminaire individually.

Cable Laying

The cable laying shall be from supply point to the feeder pillar Panel and from feeder pillar Panel to
street lighting poles.

The cable from supply point up to the feeder pillar shall be laid underground in excavated trench
RCC pipe and HDPE pipe. The trench shall be at least 0.7 mtr. deep and 0.4 mtr. wide sand
cushioning of 20mm shall be provided before laying the cable. The cable shall be protected with
good quality bricks on all the sides. At road crossings, the cable shall be laid in 100mm dia RCC
hume pipe of NP-2 class.

The cable from feeder pillars to the lighting poles shall be laid in suitable sized HDPE pipes buried
at a depth of 0.7 mtrs. Loop of at least 1 mtr. shall be provided on either side of the pole.

Cables as far as possible shall be laid in complete, uncut lengths from one termination to the other.
Magnetic induction / LED light fittings/ HPSV/MH Fittings

The fixture for housing 150 WMagnetic induction / LED light fittings HPSV/MH SON (T) should
integral street light lantern with semi cut off with prismatic bowl with single piece cast alum. Body
nickel-chrome plated reflector with unbreakable acrylic cover and necessary control gear electronic
‘ignitron’ necessary wiring with choke condenser etc. erected on provided brackets.

This item is for supplying and erecting integral 150 Watt HPSV/MH/HPMV fixtures with semi cut off
prismatic bowl, with unbreakable acrylic cover suitable for 150 Watt. HPSV lamp with necessary

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holder fuse, choke, condenser and control gear box. The lantern should be erected on the provided
bracket on the pole. The fixtures should be tested for acceptance in manufacturer works in
presence of RMC’s representative with satisfying all the technical details as given in relevant IS.
The fixtures should have following technical details and features.

The Street light fixture should be complete with all parts and accessories such as housing
assembly facetted mirror, felt gasket, lamp holder, lamp holder bracket, toggle, lead for gear
compartment, gear try, ballast, capacitor, ignitor, terminal block, pole clamp, unbreakable
polycarbonate acrylic cover etc. It should have following features:

Light distribution pattern confirm to IS and BS specifications.

Facility for cut off/semi cut off light distribution as per CIE recommendations. Optimum lamp holder
position with respect to the mirror system for use with various light resources.

Use of aluminium/stainless steel polymetal met acrylic cover. Universal geared tray incorporative
ballast, condenser, ignitor, connector, suitable for flexible choice of light source, pre wired for
operation.

A felt gasket impregnated with insecticides and water repellent chemical.

Simplicity in replacement of bowl assembly, optical unit and gear trey.

Single piece construction diacaste aluminium housing (Contractor/ manufacturer should mention
the percentage of copper for corrosion resistivity MBV treated and hear resistance housing.

High purity, highly brighten anodized aluminium facetted mirror with special peet of blue for excellent
optical control and protecting reflectivity and abrasion.

Electrited ceramic lamp holder confirming to the DEC/finger set.

Sticking bracket to hold the acrylic cover when it is open.

Hexagonal bracket for holding the mask arm gift effectively.

Stainless steel toggle hooks for clamping the acrylic cover over the canopy for prevention of entry
of insects.

Aluminium lead for gear compartment.

Zinc plated and yellow passivated hard.

Skirted lamp holder as per IEC figure test.

Pot optics reflector for the fitting.

Cast aluminium in one piece with facility of toe in angle.

Magnetic Induction/ LED/HPSV/MH Lamp (SON-T)

The Contractor will have to supply 150 watts SON (T) lamp which is operating on single phase 50
Hz 230/250 volts A.C. electric supply. They have to supply the approved makes as specified in this
Tender. The sodium vapour lamps should be tested in presence of RMC’s representative in the

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manufacturing work before dispatch.

Trench

Trench shall be of suitable width and 0.7 mtr. deep for laying provided L.T. cable and refilling the
same with screened sand bed for 20 cms to embed the cable and bricks placed on both side and
top all over the run and with excavated earth without stones or hard materials and making the
surface proper with 15 cms. Crown on the top when more than on cable is to be laid in the same
trench additional bricks should be used to form another compartment. After laying of the cable in
above manner the trench should be backfilled with the excavated soil without hard stones and
should be provided with 15 cm crown on top all over.

Area Light Control

1) All area lights inside premises are proposed to be controlled from one control pillar.
2) For metering the energy consumption, a separate 1 phase/3 phase energy meter shall be
provided in the control pillar.
3) The cable between 6 way feeder pillar and the area light control pillar shall be laid by the
agency.
4) For automatic ON/OFF operation of the area light automatic timer shall be provided with energy
saving device.

Light fittings:

The lighting fixtures shall comply with the following requirements:

The fixture shall be suitable for operation on a nominal supply voltage of 240 volts, signal phase,
50 Hz with voltage variation of 10%. All fixtures shall be designed for minimum glare. The finish of
all parts of the fixtures shall be such that no bright spots are produced, either by direct light source
or by reflection. For multi lamp fluorescent fittings, the circuit shall be designed in such a manner to
reduce the stroboscopic effect to a minimum.

The lighting fixture ballast shall comply with the following requirements.
• Fluorescent light fittings shall be of high power factor type and shall be supplied with control
gear and all necessary accessories for mounting.
• The ballast shall be of the inductive and heavy duty type copper winding filled with polyester or
equivalent. They shall be free from hum and protected from the atmosphere. The ballast shall
have low power less. HPSV lamp ballasts shall be provided with taps. For multi lamp fittings a
separate choke shall be provided for each lamp.
• Outdoor lighting for lagoon areas, screens &grit chambers and building periphery shall be
carried out with sodium vapor lamp fixtures. All other indoor areas shall be illuminated by using
fluorescent tube fixtures or high bay sodium vapor luminaries complete with reflectors. Office
areas shall have decorative type fixture.
• All lighting fixtures shall be supplied complete with lamps and all necessary accessories for
satisfactory operation. Lighting fixture reflector shall generally be manufactured from sheet steel
or aluminum of not less than 20 SWG. They shall be readily removable from the housing for
cleaning and maintenance without disturbing the lamps and without the use of tools. The
following type of lighting fixtures shall be supplied:
• Fluorescent lamp lighting fixture of standard channel mounted type, suitable for surface
mounting, completely wired, complete with mounting accessories, control gear etc., and with 1
No.36/40 watt fluorescent tube.
• Industrial type fluorescent lamp lighting fixtures suitable for surface mounting, complete with

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 internal wiring, mounting rail, vitreous enameled sheet steel reflector, control gear, mounting
accessories and with 2 Nos. 36/40 Watt fluorescent tubes.
• Decorative type fluorescent lamp lighting fixtures suitable for surface mounting, complete with
mounting rail and internal wiring, vitreous enameled sheet steel reflector, louver, control gear,
mounting accessories and with 2 Nos.36/40 Watt fluorescent tubes.
• Industrial bulk head type fixture with 60 W incandescent lamp.
• Industrial fixture with VE reflector with 60 W incandescent lamp.
• 250/150/70 W color corrected outdoor heavy duty HPSV light fixture provided with clear heat
resistant front glass with tropicalizing gasket and other accessories and lamp. The fixture shall
have a cast aluminum housing.
• Each fixture shall be complete with a four way terminal block for the connection and looping of
incoming and outgoing supply cable. Each terminal shall be able to accept two Nos... 2.5
sq.mm copper conductor cables and shall be provided with an earthing terminal suitable for 12
SWG GI wire.
• Incandescent lamp fixtures shall be well glass type, complete with a cast housing and reflector
both of which shall be vitreous enameled. The fixture shall be suitable for satisfactory use in
mildly acidic atmosphere.
• Lighting fixture starters shall be of safety type i.e., if the lamp fails to ignite at the first start, no
further starting shall be possible without attending to the lamp. Starters shall have bimetal
electrodes of high mechanical strength.
• The enamel finish shall have a minimum thickness of 2 mils for outside surface and 1.5 mils
for inside surface. The finish shall be non-porous and free from blemishes, blisters and fading.
On completion of manufacture, all surfaces of the fixture shall be thoroughly cleaned and
digressed. The fixture shall be free from scale, rush, and sharp edges and burrs.
• All light reflecting surfaces shall have optimum light reflecting coefficient such as to ensure the
overall uniform light output.
• The fixture capacitors shall be suitable for operation at 240 V + 10%, single phase, 50 HZ, with
a suitable value of capacitance to correct the power factor of the corresponding lamp circuit to
the extent of 0.925 lag. The capacitors shall be hermitically sealed preferably in a metal
container to prevent see page of impregnating material and ingress of moisture.
• Lamp holders for fluorescent tubes shall be of spring loaded, low contact resistance bi-pin
rotor type, resistant to wear and suitable for operation at the specified temperature without
deterioration in insulation value, contact resistance or lamp hording quality.
• Lamp holders for incandescent lamps shall be GLS type.
• Louvers shall be of polystyrene egg box type. Appropriate captive type fixing devices shall be
incorporated for securing the louvers.
• Emergency light fitting shall be 240 V self-contained 2 x 10 W fluorescent tube with built in Ni -
cd battery having charging facility and six hours back-up time. The emergency light fitting shall
be provided at strategic locations of each house / area.

Receptacle Units

Industrial type receptacle units of approved make of 5/15A, 240 V, 6 pin socket outlet with
interlocked switches conforming to IS: 32554 and sockets conforming to IS: 1293 shall be supplied.
The units shall be suitable for mounting flush on stoveenameled sheet steel boxes generally
conforming to IS: 5133 (Part I). At each floor/room of every building, 2 Nos., of such receptacle units
shall be provided. 4115 V, 63 A, 4 pin power receptacles with switch shall be provided for welding

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sets. Welding sockets shall be provided at ground floor pipe gallery of filters and shall beefed from
415V PMCC. Welding socket shall be operated for maintenance purpose during plant shutdown
when all the motor feeders form the PMCC are switched off.

Ceiling Fans:

Ceiling fan shall be suitable for 240 V, 1 phase, 50 Hz and shall be complete with standard
mounting accessories such as suspension rod, top and bottom canopy, regulator, rubber reel etc.

The fan shall be of 1200 mm sweep and shall conform to IS: 374. Fans shall be provided in offices,
control rooms, Laboratory and Store.

Exhaust Fans:

Impeller shall be with blades of aero foil design. Blades shall be mounted on stream lined hub.

Impeller shall be mounted directly on motor shaft.

Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be provided with
suitable support.

In case of vane axial fans, guide vanes shall be provided on the discharge side. Motor shall be
totally enclosed and rated for 240V, 1phase, 50 Hz. The speed of the fan shall not exceed 1500
rpm.

Tests:

Type tests, acceptance tests and routine tests for the lighting fixtures, accessories and receptacles
covered by this specification shall be carried out as per the relevant standard.

Manufacturer’s type and routine test certificates shall be submitted for tests conducted as per
relevant standards for the fixtures, accessories and receptacles.

The following routine tests shall be conducted as per the relevant Indian Standards.
a) Each fixture shall be tested at 1500 Volts (rms), 50 Hz, AC for one minute and no flash over or
breakdown shall occur between current carrying parts and ground.
b) Insulation resistance of each fixture shall be tested at 500 V DC and the insulation resistance
so measured shall not be less than 2 megaohms between all current carrying parts and
ground.
c) All luminaries provided with glass covers shall be subjected to thermal shock- proof test. This
test shall be conducted to ensure that the cover glass will withstand sudden variation in
surface temperature due to rainfall or splashing water when the lighting fixture is lit. The cover
glass shall be heated in an oven to attain a steady temperature of 1000 C and then plunged
into cold water. No crack should develop.
d) Contractor shall ensure use of calibrated test equipment having valid calibration test
certificates from standard laboratories traceable to National.

Inspection: Category C

Wiring for Illumination System:

General:

Wiring shall include switches, small power receptacles, lighting distribution boards complete with

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junction boxes, pull boxes, terminal blocks, glands, conduits & accessories and supporting &
anchoring materials.

All materials, fttings and appliances used in the installation shall conform to the relevant IS
specification and shall be suitable for application in Waste Water treatment plant

Type:

Wiring is to be done in the looping system without any jointing. Phase wires shall be looped in
switch control points and neutral shall be looped at outlet points. For recess conduit system MS
conduit and for surface conduit system GI conduit shall be used. Recess conduit system shall be
used in office, laboratory, control room etc.:

Point wiring:

Point wiring shall include all works necessary to complete wiring of a switch circuit of any length
from the tapping point on the distribution circuit to the following via switch with
- Ceiling rose and connector: for ceiling / exhaust fan points
- Back plate: for fluorescent fittings with down rods etc.,
- Socket outlet: for socket outlet points
- Lamp holder: for wall brackets, bulk head and similar fittings.

The following shall be included in point wiring:

- Switch board
- Ceiling rose or connectors as required
- Any special or suitable round block for neatly housing the connector and covering the fan hook
in case of fan point.
- Wooden box, bushed conduit, porcelain tubing where cable passes through wall etc.,
- Metallic covering on conduit up to 1.5 m from floor.
- Earth wire from six-pin socket outlet point/fan regulator/fixture to common conduit earth wire
system.
- All wood or metal blocks, boards and boxes, sunk or surface type for mounting fan regulator
etc.
- All fixing accessories such as clips, rails, screws, pin plugs, wooden plugs etc., as required.
- Connection to ceiling rose, connectors, socket outlet, lamp holders, switch and fan regulator
etc.,
- Looping the same switch board and inter connections between points on the same circuit
- Providing fish wire in conduits for recessed conduit works.

Load on Circuit:

Lighting circuits and small power circuits for sockets, exhaust fans/axial flow fans shall be
separate. Each circuit shall not be loaded more than 60% of MCB rating. It shall, however, be
ensured that in one switchboard, wiring of one circuit is only provided.

Size of Conductor:

The smallest copper conductor to be used for lighting circuits shall be 1.5 mm2 and for power
circuits 2.5 mm2. Neutral conductor and earth continuity wire shall be brought to each switchboard

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situated in rooms and halls. These shall be terminated inside the switchboard situated connectors.
The switchboard shall be of adequate size to accommodate one number 5 amps socket outlet and
required Nos... Of piano key type control switches with spares for future use.

PVC insulated cables conforming to IS: 694 – 1977 drawn in one conduit shall not occupy more than
60% of conduit capacity.

Rigid Steel Recessed Conduit

In this system of wiring, no bare or twist joints shall be made in through run of cables. If the length
of final circuit / sub-main is more than the length of the standard coil, joints shall be made by
means of approved mechanical connectors in suitable and approved junction boxes.

The chase in the wall shall be neatly made and in ample dimensions to permit the conduit to be
fixed in the manner desired. In case of buildings under construction, conduits shall be buried in the
wall before plastering. These shall be grouted and covered with 1:4 cement and mortar, neatly
finished at the plane of the un-plastered brick work and cured. Under no circumstances finished
plastered surfaces shall be allowed to be chased for the conduit work. Before taking up chasing on
the wall, the routes shall be marked and got approved by the Engineer. The horizontal chase shall
be avoided as far as possible. In case of exposed brick / rubble masonry work, special care shall
be taken to fix the conduit and accessories in position along with the building work.

MS Conduit pipes shall be fixed by heavy gauge saddles secured to suitable wood plug or other
approved manner at an interval of not more than one meter but on both ends of couples or bends
or similar fittings. Saddles shall be fixed at a distance of 30 cm from the center of such fittings. The
saddles shall not be less than 20 gauge for larger diameter of conduits.

All conduits after erection shall be tested for electrical continuity.

Fixing of standard bends or elbows in roof slab shall be avoided and all curves shall be maintained
by bending the conduit itself with a long radius which will permit easy drawing of wires.

Suitable junction / inspection boxes according to requirement shall be provided to permit periodical
inspections and to facilitate replacement of wires. Such boxes shall be located and arranged
suitably so that are not in irregular positions. These locations shall also be specifically shown in the
conduit layout of the shop drawings and approval shall be obtained before installation, however,
number of such boxes shall be minimized. The boxes shall be mounted flush with the wall or
ceiling. Minimum 65 mm depth junction boxes shall be mounted flush with the wall or ceiling and
depth of boxes in other places shall be as per IS: 2667-1977.

All outlets such as switches, wall sockets, etc., shall be flush mounting type.
Inspection: Category C

Earthing
General

Earthing system for the plant shall be carried out in compliance with the requirements of IS: 3043
and the following specifications:

Pipe Electrode

GI pipe electrodes shall be of medium class, 40 mm dia and 3 m in length. Galvanizing of the pipe
shall conform to relevant Indian Standard. GI pipe electrodes shall be tapered at the bottom and

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provided with holes of 12 mm dia drilled not less than 75 cm from each other and up to 3 m height
from bottom. The electrode shall be buried in the ground vertically with the top not less than 200 mm
below ground level.

Plate Earth Electrode

For plate electrodes, minimum dimensions of the electrode shall be 600 mm x 600 mm x 6 mm
thick. Heavy duty CI/MS frame with cover shall be suitably embedded in the masonry enclosure.
For instrumentation earth, the plate of same size but of copper shall be used.

Where-ever the hard soil/ roc is available at site at 1 to 1.5 meter below the ground level the CU-
CU / GI- GI chemical bore earthing shall be used to maintain the earthing resistance.

Location

Normally earth electrodes shall not be situated less than 2 m from any building. Minimum two (2)
Nos. of earth electrodes shall be provided for each building. Care shall be taken that the
excavation for earth electrodes may not affect the column footing or foundation of the building.

The location of the earth electrode shall be such that the soil has reasonable chances of remaining
moist, as far as possible. Entrances, pavement and roadways shall be avoided for locating the
earth electrodes.

Earthing Lead Connection

In case of plate earth electrodes, the earthing lead shall be securely bolted to the plate with two
bolts, nuts, check nuts and washers. In the case of the of pipe electrodes, they shall be connected
by means of bolt, nuts, washers and cable socket. All connecting materials shall be GI
construction. The earthing lead will be securely connected at the other end of above ground main
earthing grid.

Equipment Earthing Connection:

Each transformer body and neutral, GOS & lightning arrestor shall be connected to separate earth
electrodes by two separate distinct earth lids. LT motors, switchgear, distribution boards and other
electrical equipment shall be earthed at two separate points and connected to earth electrodes
through above ground main earthing grid (65 x 10 mm x GI Flat) and 65 x 10 mm GI flat risers
(from earth electrodes to above ground main earthing grid).

Size of Earthing Conductor:

The earth strips shall be of galvanized steel and shall be of the following sizes:
Main earthing grid :: 65 mm x 10 mm
LT Switchgears / Switchboards / Capacitor Panels 50 mm x 6 mm
Motors, Lighting Distribution Boards 25 mm x 6 mm
Junction Boxes, lighting fixtures, PB stations, small 12 SWG
motors,
Exhaust fans etc.

The earthing system shall be designed in such a way that overall earth resistance is less than one
ohm.

The soil resistivity shall be measured at site by the Contractor. If required, number of earth

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 electrodes to be increased by the Contractor to achieve the required earth resistance.

Earthing Pit

Earthing pit shall be of minimum 1200 mm x 1200 mm. An inspection chamber of size 400 mm x
400 mm x 400 mm in cement concrete of 1:3:6, 50 mm thick for side walls and 100 mm thick for
bottom, shall be provided. The chamber shall be provided with CI cover on MS frame. The cover
shall be hinged to the frame and shall be with padlocking arrangement. The frame and cover shall
be painted with anticorrosive paint.

Testing

The Engineer may ask the Contractor to carry out earth continuity tests, earth resistance
measurements and other tests in his presence. The Contractor shall have to bear the cost of all
such tests.

Lightning Protection

For tall structures & buildings, lightning protection system shall be provided as per relevant IS with
horizontal & vertical air terminations, down conductors with test links and separate earth electrodes.

K. Specifications for Street Lighting System

Scope of Work

The street lighting for the road shall be designed as per IRC, I.S. Codes and specifications and
National electric code. The street lighting shall be designed with average illumination (E.A.V) of 30
lux and minimum illumination of 12 lux and uniformity ratio of 0.4. For the junctions, the average
illumination level should be kept move.

Scope of work covered under this Tender shall be supply of the necessary equipment, installation,
erection, testing and commissioning of the Street Lighting system as per the drawings/specifications,
but not limited to following: -
a) Supply, installation, testing and commissioning of outdoor feeder Panel to receive power from
with CT & PT & metering section.
b) Supply, installation, testing and commissioning street light fittings with steel tubular pole,
junction box earthing etc.
c) Supply, installation, testing and commissioning 1100-volt grade cables.
d) Getting the drawing and complete work approved from Electrical Inspector i.e. for all
substation equipment.

Employer reserves the right to procure any item from above and free issues the same to successful
Tenderer for installation for economical reason. Final decision will be conveyed after price Bid
opening to the successful Tenderer.

Indian Standard Specifications

The particular specification for the work is as detailed hereinafter. These specifications shall be
read in conjunction with the relevant Indian Standard, Chief fire officer’s recommendations and the
obtainable local practice as detailed in various regional handbooks of practice and the work shall
be executed accordingly. Where the specifications in any of the standards are at variance with the
Specifications detailed herein, the most stringent amongst them shall govern. Contractor shall
ensure that execution of total work is in accordance to this.

Quality of Materials & General Standards of work

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The nominated subcontractor under this Contractor commits himself to use first class material and
assumes full responsibility for the quality of all material incorporated or brought for incorporation in
the work. The work shall be executed in accordance with best engineering practice and as per
directions of Consultants.

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2. TECHNICAL SPECIFICATIONS FOR DIESEL GENERATING SET
2.1. GENERAL SCOPE OF WORK:
The scope of work shall cover the supply, installation, testing and commissioning of 2 No.
Suitable rating to run the entire process, Diesel run generator with prime output capacity and its
associated equipments including civil foundation works complete with parallel operation for the
SUPPLY utility is to be erected for RMC STP ( 50% capacity ), SPS, The work shall be carried
out as per the latest applicable IS, IER, CPCB Norms and Code of Practice. Necessary statutory
approval / no objection certificate / clearance if any required from the competent authority shall
be obtained by the contractor at their own cost.
2.2. INTRODUCTION:
The suitable rating of DG Set with prime output capacity are required to be supplied with acoustic
enclosure as per CPCB norms. DG set with acoustic enclosure shall be installed outside the
building with skid mounting in an independent foundation. The location shall befinalized in
consultation with Manager (Engineering), SUPPLY. Associated Electrical control panel of the DG
set can be located inside the acoustic enclosure or outside the acoustic enclosure as per
manufacturer standard. In case, Electrical control panel has to be installed outside the acoustic
enclosure, location of room to house Electrical control panel nearest to the acoustic enclosure
shall be decided in consultation with the City Engineer, SUPPLY.
a) The above sets shall automatically start one after the other upon mains power failure, run up
to full speed within 6 seconds of power failure. The set shall be provided with a multiple start
mechanism with indication of alarm for “failed to start” condition. A Tachometer switch shall
be provided to control the start mechanism and also for the “run” indications.
b) The acoustic treatment shall ensure a maximum sound pressure not more than 75 dB (A) at
1 Mtr. from the acoustic enclosure in free field condition, while running on partial or full load.
This condition shall be applicable to the engine exhaust noise levels also. A vertical type
“Critical” silencer shall be fitted on the exhaust pipe after the flexible coupling to reduce the
exhaust noise. The pipe shall be thermally insulated with ceramic insulation and covered
overall with aluminum jacketing.
2.3. DESIGN DATA AND TECHNICAL SPECIFICATION
2.4. DIESEL ENGINE:
Scope: This section covers engine rating, standard components of a diesel engine including
exhaust pipe.
a) Engine Rating :
The engine shall be of standard design of the original manufacturers. It should be 4 stroke
engine, radiator cooled, naturally aspirated/turbo charged diesel engine developing
suitable BHP for giving a power rating as per ISO 8528-Part-1 in KVA at the load terminals
of alternator running at 1500 rpm at ambient temperature of 40 Deg C, for height at 1000
Meter above MSL and at 50% RH. The engine shall be capable for delivering specified
Prime Power rating at variable loads for PF of 0.8 lag with 10% overload available in
excess of specified output for one hour in every 12 hours. The average load factor of the
engine over period of 24 hours shall be 0.85 (85%) for prime power output. The testing
procedure shall be as per standards mentioned above. The engine shall conform to ISO:
8528-Part 1/ISO 3046/ BS 5514 and as amended upto date.
b) Necessary test certificate for the engine noise and emission level as per CPCBguideline
shall be furnished.
c) Engine shall be fitted with following accessories subject to the manufacturer’s design;
(i) Dynamically balanced fly-wheel
(ii) Necessary single bearing / close coupled and guard for alternator and engine.
(iii) Air cleaner (dry/oil bath type) as per manufacturer standard
(iv) An electronic governor to maintain engine speed at all conditions of load.
(v) Base fuel tank of minimum capacity of 990 liters.
(vi) Dry exhaust manifold with suitable exhaust residential grade silencer to reduce the
noise level
(vii) The following display shall be provided at control panel:-
(a) Start/stop key switch Page 256 of 263
 (b) Lube oil pressure indication
(c) Water temperature indication
(d) RPM indication
(e) Engine Hours indications
(f) Battery charging indication
(g) Low lube oil trip indication
(h) High water temperature indication
(i) Over speed indication
(viii) All moving parts of the engine shall be mechanically guarded in such a manner that a
human finger cannot touch any moving part.
d) Governor:
Electronic governor of class A1 as per ISO 3046/BS 5514 with actuator shall be provided
as per standard design of manufacturer. Governor shall be a self-contained unit capable of
monitoring speed.
e) Lubricating Oil System:
Necessary priming pump for the lube oil circuit as per recommendation of manufacturer
shall be installed, to keep bearings primed.
f) Exhaust piping:
The work includes necessary cladding of exhaust pipe using not less than 50 mm thick
glass wool/mineral wool/rock wool, density not less than 46 km/m sq. and aluminium
cladding (0.80 mm thick) for the complete portion. The exhaust pipe work includes
necessary supports, foundation etc. to avoid any load & stress on turbo charger/exhaust
piping. The exhaust pipe support structure shall be got approved by Manager
RMC before execution.
(Engineering), MMC
g) Optimum Silencer Location:
Location of the silencer in exhaust system has very definite influence on both reduction of
noise and back pressure imposed on the system. The preferred silencer locations are
given in the Table below, where L is length of the total exhaust system measured from
exhaust manifold in meters. Please note that locating the silencer as peroptimum silencer
location is mandatory. For high rise buildings, suitable arrangements have to be provided.
OPTIMUM LOCATION OF SILENCER (IN METERS)

In-line Engine ‘V’ Engine

Best 2L/5 (4L – 1.5)/5
Second best 4L/5 (2L – 4.5)/5
Worst Location of L/5 or 3L/5 or at tail end (3L – 10)/5 or at the tail end
Silencer of exhaust piping of exhaust piping

h) Exhaust stack height: In order to dispose exhaust above building height, minimum exhaust
stack height should be as follows:-

(i) For DG set upto 1000 KVA H = h+0.2 x / KVA

Where = Height of exhaust stack H = Height of build ing

(ii) Care should be taken to ensure that no carbon particle emitted due to exhaust
leakage enters and deposits on alternator windings and on open connection.
i) Cooling System:
a) System should be designed for ambient temperature of 40 deg. C
b) Water softening / de mineralizing plants should be used, if raw water quality is not
acceptable.
c) Coolant should be used mixed with additive (in suitable proportion) as per
recommendation of OEM/Manufacturer for various engine models.
d) Radiator fan flow should be free from any obstruction.
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j) ALTERNATOR:
Scope: This section covers technical requirement of the alternator.
a) SYNCHRONOUS ALTERNATOR: Self excited, screen protected, self regulated, brush
less alternator, horizontal foot mounted in single/double bearing construction (specify
one only) suitable for the following:

Rated PF: 0.8 (lag) Rated voltage : 415 volts Rated frequency :

50 Hz No. of phases : 3

Degree of Protection : IP-4x

Ventilation : Self ventilated air cooled Ambient Temperature : 40 deg C

maximum Insulation class : F/H

Temperature Rise : Within class F/H limits at rated load

Voltage Regulation : +/- 1% Voltage variation: +/- 5%

Overload duration/capacity : 10% for one hour in every 12 hours

of continuous use

Frequency variation : As defined by the Engine Governor (+/- 1%)

Excitation : Self excited system

Type of AVR : Electronic

Alternator should be with permanent magnet generation.

Standard : IS-4722 & IEC: 34 as amended upto date.

b) Fault tripping: In the event of any fault e.g. over voltage/high bearing temperature/high
winding temperature or an external fault, the AVR shall remove the excitation voltage to
the alternator. An emergency trip shall also be provided.
c) Standards: The alternator shall be in accordance with the following standards as are
applicable:

(i) IS-4722/BS”: 2613/1970 the performance of rotating electrical machine.

The performance characteristics of the alternator shall be as below: Efficiency at full load
0.8 P.F.
For DG set efficiency shall not less than 93.5%.

k) BATTERY/ELECTRICAL SYSTEM:
Battery capacity and copper cable sizes for various engine capacity should be as indicated
in the table below. Cable sizes shown are for maximum length of 2 m. If length is more,
cable size should be selected in such a way that voltage drop does not exceed 2 V.

l) FOUNDATION:
Genset with acoustic enclosure: A PCC foundation (1:1/2:3, - M-30 grade) of approximate
depth of 300 mm is required so as to provide leveled surface for placement of the acoustic
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 enclosure. About 300 mm foundation height shall be above ground level and shall be
provided by contractor. The length and breadth of foundation shall be at least 250 mm
more than the size of the enclosure. In case manufacturer’s recommendations require
more depth/width etc. than manufacturers recommendation shall be followed.

m) ACOUSTIC ENCLOSURE:
a) As per CPCB norms, restriction has been imposed for new DG sets upto 1000 KVA for
noise level. Therefore, should be type tested at the climatic conditions specified in para.(q)
through one of the authorized laboratory.

n) DAILY FUEL SERVICE TANK:

Free Standing Capacity of daily fuel tank shall be suitable to run the plant for next 24 Hrs
after power failure, complete with fittings and accessories including fuel pump of suitable
capacity as per the manufacture standard. A pipe line shall be laid from the fuel tank to
engine/acoustic enclosure.
The Pump shall be controlled in such a way that the pump switch on itself automatically in
case the level controller fails in the DG sets.

o) GENERAL DESIGN GUIDELINES:

a) To avoid re-circulation of hot air, durable sealing between radiator and canopy is
must.
b) Exhaust piping inside the enclosure must be lagged (except bellow).

p) SPECIFICATIONS FOR ACOUSTIC ENCLOSURE:

a) The construction should be in such a way that it prevents entry of rain water
splashing into the enclosure and allow free & quick flow of rain water to the ground
in the event of heavy rain. The details construction shall confirm to the details as
under.
b) The enclosure shall be fabricated out of the CRCA sheet of thickness not less than
1.6 mm on the outside cover.
c) The hinged doors shall be made from not less than 1 6 SWG (1.6 mm) thick CRCA
sheet and will be made air tight with neoprene rubber gasket and heavy duty locks.
d) All sheet metal parts should be processed through 7-tank process. e) The
enclosure should be powder coated.
e) The batteries should be accommodated in the enclosure in battery rack.
f) The canopy should be provided with high enclosure temperature safety device.
g) The enclosure shall be provided with suitable size and No. of hinged type doors
along the length of the enclosure on each side for inspection, operation and
maintenance purpose. Sufficient space will be provided inside the enclosure on all
sides of the DG set for inspection, easy maintenance and repairs.
h) The canopy should be as compact as possible with good aesthetic look. j) The
complete enclosure shall be of modular construction
i) The forced ventilation shall be as per manufacturer design using either engine
radiator fan or additional blower fan(s). If the acoustic enclosure is to beprovided
with forced ventilation then suitable size of axial flow fan with auto start
arrangement should be provided. The forced ventilation arrangement shall be
provided with auto stop arrangement to stop after 5 minutes of the stopping of DG
sets if necessary as per manufacturers design.
j) The acoustic enclosure should be suitable for cable connection/connection through
bus-trunking. Such arrangements on acoustic enclosure should be water proof and
dust-(proof conforming to IP-65 protection).

q) INSPECTION AND TESTING:

a) The successful tenderer will arrange staff/fuel for test run at his cost.
b) DG set testing shall necessarily carried out at factory / manufacture premises in
presence of representative of SUPPLY.
c) For testing, following procedure will be followed:
All major items / equipments i.e. engine & alternator in assembled Page 259 of 263
condition,
 associated electrical control panels etc. shall be offered for inspection and testing
at factory / manufacturers works. The successful tenderer shall give a notice of
minimum two weeks for carrying out such tests. The Engineer- in- charge / or his
authorized representative of RMC shall witness such inspection & testing at
mutually agreed date. The cost of the representative’s visit to the factory will be
borne by TENDERER.
d) The department also reserves the right to inspect the fabrication job at factory and
the successful tenderer has to make arrangement for the same.
e) DG set will be tested on load at KW rate. During testing, each of the DG sets
covered under scope of work, shall be operated for a 2 hours on rated KW
following one hour on 10% overload after continuous run of the 2 hours. During
testing all controls/operations safeties will be checked and proper record will be
maintained. Any defect/abnormality noticed during testing shall be rectified. The
testing will be declared successful only when no abnormality/failure is noticed
during the testing. The DG set will be cleared for dispatch to site only when the
testing is declared successful by authorized representative of SUPPLY.

r) SITE TRIAL RUN / RUNNING-IN-PERIOD:

After successful testing of the DG set, a trial run at available load will be carried out for 18
Hours for three continuous days (6 hrs each day) at SUPPLY site. The DG set will be
operated and a log of all relevant parameters will be maintained during this period. The
arrangement of staff for trial run and diesel during such period will be made the successful
tenderer. The DG set will be said to have successfully completed the trial run, if no break
down or abnormal/unsatisfactory operation of any component of the entire installation
included in the scope of work of the contractor, occurs during this period. After the DG set
has operated without any major break down/trouble, it shall be taken over by the SUPPLY
subject to guarantee clause of this contract. This date of taking over of the DG set, after
trouble free operation during the trial run/ running- in period, shall be the date of
acceptance / taking over.

s) AUTO SYNCHRONIZING CUM AUTO LOAD SHARING MV PANEL

Provision for Auto Synchronizing Cum Auto Load Sharing MV Panel for Front access, Free
Standing, dust and vermin proof, Indoor switch board suitable for 415V, 3Ph, 4Wire,50Hz
fabricated from 2mm thick CRCA M.S sheet with hinged, gasket and lockable doors
having structural reinforcement with suitable angle/Flat section, 3mm thick gland plates,
lifting hooks, including power coated paint finish of siemens gray texture shade over metal
surface cleaned and treated with seven tank process with interconnection shall be
provided.

Any other items left above and necessary for each design, manufacturing erection and
commissioning shall be the responsibility of the tenderer.

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3. SPECIFICATION FOR INSTRUMENTATION WORKS
3.1. Instrumentation works for STP & SPS

Control Philosophy:
The following control philosophy for the different unit operations in the STP. The plant should be
capable to auto control depending upon the level in the Raw Sewage Sump (Wet well) with a
provision of manual operation / override. For transfer of wastewater into the downstream
treatment units, the interlocking will be done depending upon the level of wastewater in the
sump.

a) Raw Sewage Pumps:

Raw Sewage Pumps operation shall be in auto. Ultrasonic Type Level Transmitter shall be
provided for auto start/stop of pumps. The arrangement shall be such that under no condition, dry
run of pump occurs. Also adequate number of pumps shall start/stop based on levels in the sump.
By interfacing this to PLC, the PLC should generate configurable alarms.
b) Flow Measurement:
Ultrasonic open channel / pipe meter to be provided to measure and transmit the flow reading to
the central SCADA through PLC. Ultrasonic flow measuring devices shall be installed on outlet and
bypass pipelines.

c) Process Basin:
Process Basins (Primary & Secondary) shall have:
- PLC based automation system with application software based on Rockwell hardware or
equal to control all pumps, valves, blowers, VFD, decanters, limit switches and probes as per
Tenderer’s design including I/Os with 20 % spares, power supplies, UPS.
- HMI Panel to comprise up-to-date standard PC with monitor, printer, mouse, internet
connection, RS-view, RS-links (gateway version), entire process and operator software with
dynamic flow charts, pictures, screens, alarms, historical trends, reports etc.
- Automation system to monitor continuously in each tank the followings:
a. Incoming Sewage volume
b. Process quantity
c. Discharge quantity
d. DO-level
e. Temperature
f. Oxygen Uptake Rate
g. Energy requirements
h. Blower speeds
i. Equipment operation hours

d) Chlorination system:
Auto switch-over facility of chlorinator to filled toner shall be provided. Chlorine Leak Detector shall
be provided to detect chlorine gas, which shall initiate the audio-visual alarm in case of chlorine
leakage.

e) All Sumps:
All the sump pits shall be provided with individual capacitance type level switch for cutting off the
pump in case of low sump level. Audio-visual alarm in case high level in the sump. Auto start for
the pump shall be provided with design level in the tank.

f) All Valves:
All pneumatically / electrically for process system shall operate through the PLC/Control Panel.

g) Dosing Systems:
All Chemical solutions shall Auto Stop in case of low level in dosing solution tank with Alarm

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3.2. SCADA (Supervisory Control & Data Acquisition):
The STP shall be designed for automatic operation through PLC and SCADA based system with
HMI interface. Provision shall be made for each facility to operate process unit manually, if for
any reason the need arises. The control system shall be selectable to either “Off”, “Manual” or
“Automatic” modes. In the “off” mode, power failure shall be annunciated but no further action
shall be taken. Annunciation shall be provided on the central HMI. Gas generation and utilisation
shall also be monitored through SCADA

Pressure Measurement
Pressure Indicators shall be provided at the individual discharge of all pumps / blowers /
compressors/gas holder/chamber.
Alarms
Audio-visual alarms shall be activated on the following conditions.
i) “Low-Low” Level in Inlet Sump
ii) “High-High” Level in Inlet Sump
iii) High DO level in Bio Reactor/basin& Blowers ON or Low DO level and required number of
blowers not operating.
iv) Other alarms as required by the Tenderers technology, which should be identified and
stipulated, by the Bidder including alarms for tertiary treatment if adopted by the Tenderer.
3.3. Technical Requirements for PLC & Control Unit / Desk
The treatment plant instrumentation shall be linked to a PLC. The conceptual PLC- operating
plant philosophy & technical Requirements is as follows.
The objective of the PLC is to provide control function for total plant operation as descried above.
i) Record Data of listed drives / parameters in plant – i.e. operating hours per day etc.
ii) Record and provide Trending of critical parameters as listed below.
iii) Provide Alarm of faults / breakdowns.
iv) The data record and trending data, alarms from the PLC should go to a printer which should
record the information as follows:
a. Alarms as and when it takes place with time and detail of fault.
b. Data record of drives – to be automatically printed on a daily basis at a given time – say
1200 hrs. However a facility should be provided to take a status print out at any required
moment
using a manual signal – this signal can be given from a pressure sensitive keyboard.
c. Trending data of the listed parameters to be available as follows;
- for the past 25 hour period.
- for the past 24 hour period
- for the past 7 day period
d. The Trending data should be printed automatically for past 24 hr period at a given set
time every day-say 1200 hrs and the record for the past 25 hrs, 24 hrs. and 7 day be
available by giving a signal from the pressure sensitive keyboard.
The PLC shall give the following type of alarms:

a. Normal Alarms
All alarms are software alarms – to be printed on the printer, accompanied with an audio-visual
alarm for a definite time, however whenever there has been an alarm of any tube there shall be a
facility which will enable to give a normal audio – visual alarm also when the plant is under
operation in an “attended” mode-i.e. there is an operator.
This audio-visual alarm facility is to be disabled when the plant is under “non attended” mode.

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 b. Emergency Alarms
Emergency audio / visual / telephonic alarm is to be activated in case of an emergency fault in the
“non attended mode”. (The Emergency faults are to be listed by the Tenderer as per their control
philosophy for the process).
3.4. PLC Specifications:
a. The PLC shall have adequate I/O per card.
b. There shall be 10% spare I/O of each type.
c. Retentivity shall be 100% to save the recorded data and saving the programmed logic, other
attributes connected with system for power & system failure.
d. Change in programme / modifications to programme shall be possible by a portable lap top
computer.
3.5. Plant Operation Modes
The plant shall be operated in three modes;
a. Automatic Mode – i.e. when there is no operator required for the plant, and all sections of the
plant
are to operate only in the auto mode only.
b. Non Automatic (Manual) Mode- i.e. operator normally will be required for all operations.
c. Semi Automatic Mode – i.e. for certain component/module requiring manual operation when
auto
system is not functioning. Provision shall be made for isolation of each automatic mode
locally.

Control Unit
a. The PLC, printer, Panel display instruments, all drive units, VDU, Alarm accept buttons, data
print signed buttons etc shall be connected to the Computer.
b. All accessories including furniture, desk, storage cupboards, modem for fax and internet,
chairs, air-conditioner and other connected housekeeping shall be provided.
3.6. Computer:
Desktop Computers (2 Nos.) of HP/Lenovo/Sony or equivalent make of following configuration
shall be provided:

Intel Core i5/i7 (2.2 GHz, 8GB DDR3 RAM, 500 GB SATA HDD, 17” Digital/
lcd Display, 8 X DVD-RW Drive, Multimedia Kit, UPS, HP Laser A3 Size Printer or HP All in One,
Internet
Port (100 MBPS to 1 GHz) with latest Software like Windows 7 Professional etc.

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