Typical Details of Switchyard Requirement

CHENNAI PETROLEUM CORPORATION LIMITED
Manali, Chennai- 600 068.

(A group company of Indian Oil)
TENDER ENQUIRY DOCUMENT FOR 110KV SWITCHYARD
DOMESTIC TENDER
(TENDER ENQUIRY DOCUMENT NO. 6104 EL SPC 610 001)
FICHTNER Consulting Engineers (India) Private Limited
Cost of the Tender Enquiry Document: Rs.5, 000/- (Non- refundable)
5.8 MGD Seawater Desalination Project Tender Enquiry Document for 110 kV Switchyard
Table of Contents
PART - I : COMMERCIAL SECTION NO SECTION A SECTION B SECTION C SECTION D SECTION E DESCRIPTION ISSUE OF TENDER ENQUIRY DOCUMENT INSTRUCTION TO BIDDERS GENERAL CONDITIONS (GCC) SPECIAL (SCC) CONDITIONS
OF
CONTRACT CONTRACT
OF
SAMPLE FORMS AND PROCEDURES
PART - II : TECHNICAL
SECTION A SECTION B SECTION C
SCOPE OF WORK TECHNICAL SPECIFICATION FOR ELECTRICAL WORKS TECHNICAL SPECIFICATION STRUCTURAL WORKS PRICE SCHEDULE
FOR
CIVIL &
SECTION D
Overall contents SWYD
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PART - I
Commercial
Content for Part I Swyd
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Table of Contents
PART - I
COMMERCIAL
SECTION NO SECTION A SECTION B SECTION C SECTION D SECTION E
DESCRIPTION ISSUE OF TENDER ENQUIRY DOCUMENT INSTRUCTION TO BIDDERS GENERAL CONDITIONS (GCC) SPECIAL (SCC) CONDITIONS
OF
CONTRACT CONTRACT
OF
SAMPLE FORMS AND PROCEDURES
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SECTION A
Issue of Tender Enquiry Document
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Table of Contents
SECTION A-1 SECTION A-2 SECTION A-3
ISSUE LETTER OF TENDER ENQUIRY DOCUMENT .........................3 NOTICE INVITING TENDER ...................................................................4 NOTICE INVITING TENDER ABRIDGED VERSION .........................8
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SECTION A-1 ISSUE LETTER OF TENDER ENQUIRY DOCUMENT

Tender Enquiry Document No.: 6104-EL-SPC-610-001 6104 / -November2004
Subject:
Tender for Lump sum Turnkey Contract: Design, Engineering, Manufacture, shop testing, inspection, supply, transportation to site, unloading, storage, installation and commissioning and performance testing of 110kV switchyard with control room and accessories as per specification for the 5.8 MGD Sea Water Desalination Project for Chennai Petroleum Corporation Limited (CPCL) at North Chennai, Tamilnadu
One set of tender enquiry document containing the following: (i) (ii) (iii) One copy marked ORIGINAL One copy of schedule of prices marked PRICE BID One copy marked BIDDERS COPY
Is issued to Name of the bidder Address of the bidder : .. . ... ... ... The fee for this tender enquiry document is Rs.5,000/- (Rupees five thousand only) non refundable. The tender enquiry document is sold vide receipt No. dated
Project Manager (CPCL) FICHTNER Consulting Engineers (India) Private Ltd.
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SECTION A-2 NOTICE INVITING TENDER TENDER ENQUIRY DOCUMENT NO. 6104-EL-SPC-610-001 (Domestic Competitive Tendering)
1.0 Sealed Lumpsum turnkey (LSTK) tenders are invited from competent firms with sound technical and financial capability for the installation of switchyard for 5.8 MGD (26.367 MLD) seawater Desalination Project for CPCL at North Chennai, Tamilnadu, India. Price of Tender Enquiry Document Last date for submission of bid
Name of Work
Design, engineering, manufacture shop testing, inspection, supply, transportation to site, unloading, storage, installation and commissioning of 110kV switchyard with control room and accessories as per specification. 2.0 QUALIFICATION CRITERIA
Sale Period
Rs. 5,000/-
Nov 25, 2004 To Dec 09, 2004
Dec.21, 2004.
The bidders who intend to participate shall meet following qualification criteria: 2.1 EXPERIENCE CRITERIA The bidder should be a turnkey contractor having executed one switchyard project of double main bus scheme having minimum five bays and voltage levels not less than 110kV on a lump sum turnkey basis of value not less than Rs.340 Lakhs during the last seven years. The executed project shall be in satisfactory operation for a period not less than one year. Certificate from client for one year satisfactory operation after commissioning shall be furnished by the bidder. The seven-year period shall be reckoned as on 31.10.2004. 2.2 FINANCIAL CRITERIA
a) The average annual financial turnover of the bidder during the last three financial years ending 31st March 2004 should be at least Rs. 425 Laks. b) The net worth of the bidder shall not be negative.
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4.0
GENERAL 1) Non-transferable tender enquiry document can be purchased on any working day (Monday to Friday) from 25.11.2004 to 09.12.2004 between 10.00 am to 16.00 hrs from Project Manager [CPCL] FICHTNER Consulting Engineers (India) Pvt. Ltd., Ganesh Chambers, 64, Eldams Road, Chennai -600018. Ph -+91 4424359158 Fax -+91 44 24344579 e-mail: mail@chn.fichtner.co.in . on written request and upon payment of non- refundable document fee as per the price details mentioned above payable through crossed demand draft only in favor of FICHTNER Consulting Engineers (India) Private Ltd, payable at Chennai. Request for sending Tender enquiry document by Post by Courier or down loading from web site or any other mode shall not be entertained. If any of the day identified above happens to be FICHTNER holiday, the next working day shall be implied. 2). Tenders will be received at the Office of M.KALAIVANAN Room No. 210, Project Building Senior Manager Contracts Cell Chennai Petroleum Corporation Limited (A group company of Indian Oil) Manali, Chennai -600 068 Tamilnadu, India Ph -+91 4425944336 Fax: +91 4425941216. Tamilnadu, India Ph -+91 4425944336 Fax: +91 4425941216. up to 14.00 hrs. on 21.12.2004. The unpriced part of tender shall be opened on the same day i.e on 21.12.2004 at 14.30 hrs, in the presence of authorised representative (s) of attending bidder(s). Time and date of opening of price bids shall be intimated only to qualified and techno-commercially acceptable bidder(s) at a later date. Tenders must be accompanied by Earnest Money Deposit (EMD) in the form of Crossed Demand Draft or Bank Guarantee from any scheduled / Nationalised Bank in favour of Chennai Petroleum Corporation Limited. Tenders not accompanied with requisite EMD or EMD not being in the requisite form specified in Notice Inviting Tender shall be considered as non-responsive and such tenders will be rejected. Value of Earnest Money deposit is Rs.8,50,000 (Rupees eight laks fifty thousand only)
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3) 4)
The experience and financial turnover of the bidding entity shall only be considered for Pre-qualification. Bidders to note that the experience are financial credentials of the group companies, affiliates, subsidiaries of the bidding entity shall not be taken into account for qualification. The experience and financial criteria shall be met by the bidder who shall submit or who have submitted bid. Bids on consortium or joint venture basis shall not be considered. Bidders shall submit PF and ESI Registration Certificate on their own company name along with the techno-commercial cover of the tender. The Bidders shall furnish documentary evidence by way of copies of work orders, completion certificates of previously completed jobs and Annual turn over statement supported with Audited Balance Sheets, Profit & Loss Account statement along with the Bid to establish their experience and finance credentials in line with prequalification criteria as given in the NIT. The details shall be furnished as per the FORMATS C&D specified under the section Sample forms & Procedures of tender enquiry document. Bidders to note that the reference(s) furnished by them alone in the above formats shall be considered for evaluation. Further, the bidders shall submit all the documents as specified in bidding document. If the bidder has executed/completed similar nature of work (as called in Experience Criteria of NIT), is a part of combined work order, then it is the responsibility of the bidder to produce documentary evidence from Client to establish value and description of such works etc., shall meet the experience criteria of tender Bidder shall ensure submission of complete information / documentation in the first instance itself. CPCL/FICHTNER reserve the right to complete the evaluation based on the details furnished by the agencies without seeking any subsequent additional information. Bids not in compliance with Bidding document or with incomplete information / documents are liable for rejection. Issuance of tender enquiry document or submission of tender enquiry document by itself shall not amount to pre-qualification or entitle the agency to participate in the bidding. Bidder submitting their bids should not be under liquidation, court receivership or similar proceedings for which necessary self declaration has to be furnished. CPCL/FICHTNER reserve the right to use in-house information for assessment of capability of Bidder. CPCL/FICHTNER shall not be responsible for any costs or expenses incurred by Bidder in connection with the preparation of delivery of Bids, including costs and expenses related with visits to the site. CPCL/FICHTNER take no responsibility for delay, loss or non-receipt of bid documents sent by post and offers received late are liable to be rejected.
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5) 6) 7) 8)
9)
10)
11)
12) 13) 14)
15)
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16) 17) 18) 19) 20) 21) 22)
Fax / Telex / Telegraphic / E-Mail / Computer Floppy bids will not be accepted. Canvassing in any from by the agency himself or by any other agency on their behalf may lead to disqualification of their bid. The Indian experience shall only be considered for the purpose of qualification. Central public sector enterprises shall be extended price preference as per Govt. guidelines in force from time to time. Bids received late due to any reason whatsoever shall be rejected. CPCL/FI reserve the right to reject partly or wholly any / all bids without assigning any reasons thereto. Clarification, if any, can be obtained on or before 13.12.04 from Project Manager [CPCL] FICHTNER Consulting Engineers (India) Pvt. Ltd., Ganesh Chambers, 64, Eldams Road, Chennai -600018. Ph -+91 4424359158 Fax -+91 4424344579 e-mail:mail@chn.fichtner.co.in
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SECTION A-3 NOTICE INVITING TENDER ABRIDGED VERSION TENDER ENQUIRY DOCUMENT NO. 6104-EL-SPC-610-001
(Domestic Competitive Tendering)
Sealed tenders are invited on lumpsum turnkey basis from competent firms with sound technical and financial capability for the installation of switchyard as per following details required for the 5.8 MGD (26.367 MLD) Seawater Desalination Project for CPCL at North Chennai, Tamilnadu. Price of Tender Document Last date for submission of Tender
Name of Work
Sale Period November 25, 2004 To December 09, 2004
Design, engineering, manufacture, shop testing, inspection, supply, transportation to site, unloading, storage, installation and Rs. 5,000/commissioning of 110kV switchyard electrical system with control room as per specification.
December 21, 2004.
Bidders are requested to visit web site: www.cpcl.co.in for qualification details before purchase of the tender enquiry document
For further Clarifications if any Contact PM (CPCL), FICHTNER Consulting Engineers (India) Pvt. Ltd., Ganesh Chambers, 64,Eldams Road, Teynampet, Chennai-600 018, Tamilnadu. E-mail: mail@chn.fichtner.co.in Phone - +91 44 24359158, Fax - +91 44 24344579.
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5.8 MGD Seawater Desalination Project Tender Enquiry Document for 110kV Switchyard
SECTION B
Instructions to Bidders
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TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0
GENERAL .............................................................................................................................................. 3 TENDER DOCUMENTS..................................................................................................................... 3 VALIDITY PERIOD OF THE OFFER ............................................................................................. 3 SUBMISSION OF THE TENDER ..................................................................................................... 3 GENERAL CONDITIONS OF TENDER ......................................................................................... 3 BIDDERS RESPONSIBILITY FOR TENDER .............................................................................. 7
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SECTION B INSTRUCTIONS TO BIDDERS 1.0 GENERAL The Bidder is advised to read these instructions carefully and to ensure that his response complies fully with the requirements of the tender. Failure to provide the information and documents required by this Invitation to Bid may render the Bid to be unacceptable. A detailed set of Instruction to Bidders (ITB) in covered under Section 2 of the General Conditions of Contract (GCC). These set supplement those in the GCC. Acknowledgement Bidder shall complete and return the acknowledgement letter as per format furnished in section E Sample forms and procedures confirming whether or not he will be submitting the bid. Bidder must indicate the address of his bidding office in the acknowledgement letter / fax. 2.0 TENDER DOCUMENTS Two sets of tender documents are provided herewith, marked ORIGINAL and BIDDERS COPY. Bidder shall return the ORIGINAL tender document along with his offer and BIDDERS COPY shall be retained by him as his reference copy. Bidder shall sign and stamp each page of original tender document as token of his acceptance to the terms and conditions prescribed therein. The tender document is not transferable to any other agency. See also clause 2.3 of the General Conditions of Contract. 3.0 VALIDITY PERIOD OF THE OFFER Tender submitted by Bidders shall remain valid for acceptance for a minimum period of 6 (six) months from the date of opening of the tender. All the other conditions of tender validity shall be as per clause 2.18 of GCC. 4.0 4.1 4.2 5.0 5.1 SUBMISSION OF THE TENDER Tender must be submitted by the time and date mentioned in the Notice Inviting Tender at the address stated therein. Tender must be submitted in one original + five copies in the manner prescribed in the Invitation to Bid and Section 2 of GCC. GENERAL CONDITIONS OF TENDER Unpriced commercial The bidder is advised that Owner/Consultant intends to fully evaluate the technical and unpriced commercial submissions. It is important that bidder clearly establish his ability giving to Owner/Consultant a high level of confidence that the bidder will be able to perform the works within the Time Schedule and meeting the criteria requirements listed in the tender document. Failure to do so may result in disqualification of the tender. The general information required from the bidder along with his offer are listed in clause 2.4
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of the GCC. As a minimum, the following shall be covered in support of his ability to perform the works to the satisfaction of the Owner and as per the intent of the specifications: 5.1.1 Information about Bidder's Firm Information about bidder as per Appendix-II, Page 82 of the GCC along with the following details: a) In case the Bidder is a Partnership firm, certified copy of the partnership deed together with a certified extract from the registrar of firms containing names and addresses of all the partners of the firm should be furnished along with the bid. In case of a company (whether private or public) certified copy of the Certificate of Incorporation together with certified Memorandum of Articles of Association and a list containing names and addresses of all the directors should accompany the bid. In case of a proprietorship firm, the name and address of proprietor, should be furnished.
b)
c)
In addition he shall furnish the following documents (a) Audited Balance sheet including Profit and Loss Accounts for the preceding three (3) years.ie., 2001-02,2002-03,2003-04 Income Tax PAN No. Attested copy of registration certificate under State Sales Tax Act in the prescribed proforma. Solvency Certificate from a Nationalised Bank.
(b) (c)
(d) 5.1.2
Safety Policy and Quality Assurance A brief description of the bidder's safety policy and quality assurance systems and a statement detailing how these will be implemented for the project. A list of procedures, practices and work instructions which will be used to control the engineering, procurement and inspection activities
5.1.3
Experience Details The bidder should submit Details of experience and Concurrent commitments as per APPENDIX-III in Page 89 of the GCC.
5.1.4
Equipment Details The Bidder should submit complete details of Construction equipments, other tools and
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tackles to be deployed at site in the proforma enclosed as ANNEXURE- IV in page 90 of the GCC. 5.1.5 Concurrent Commitments The tender is required to furnish information on the other ongoing works he is executing and the status of these in the proforma furnished in Appendix-V in page 91 of the GCC. 5.1.6 Bar Chart The Bidder shall prepare and submit the proposed completion schedule bar chart in accordance with the overall completion date. 5.1.7 Organisation chart for Execution of Works Organisation charts together with an assignment schedule. The bidder shall also furnish a write up on the execution methodology of the proposed package. 5.2 Price Bid All rates set forth in Bidder's quotation, shall be in Indian Rupees. 5.3 Language of Bid The tenders and all correspondence incidental to and concerning this tender shall be in the English language only. The lump sum price schedule as well as break up of the same shall be in figures as well as in words in English language and duly signed by the bidder. 5.4 5.4.1 Tender Opening On the date of opening of tenders only Part 1 of the tender shall be opened as noted in the Invitation to bid. The Price Part (Part 2) of the only technically acceptable bidders shall be opened at a later date. Bidder shall be prepared to furnish clarification / information and attend discussions as required by the Owner at short notices. Tenders from those bidders who fail to furnish the required clarifications called for within the time frame stipulated by the Owner / Consultant to his satisfaction may not be considered for further evaluation. During the opening of unpriced Part (Part 1) only the names of firms who have submitted the tender and EMD furnished by them shall be read out and no other information, whatsoever shall be given. During the opening of priced part (Part 2), only the summary of prices quoted shall be read out and no other information, whatsoever shall be given. Power of Attorney The tender shall be signed by the legally authorized person to act on behalf of the bidder. Bidder shall submit Power of Attorney in favour of the person who is authorized to enter into commitments of behalf of the bidder. Refer clause 2.7.2 of the GCC.
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5.4.2
5.4.3
5.5 5.5.1
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5.5.2
The Owner will not be bound by any Power of Attorney granted by the Bidder or changes in the composition of the firm made subsequent to submission of the bid or the award of the contract. Owner may, however, recognise such Power of Attorney and changes after obtaining proper legal advice, the cost of which will be chargeable to the Bidder. Purchase Preference to Public Sector Enterprises Owner / Consultant reserve the right to give Price Preference to public sector enterprises as admissible under the existing Indian Government Policy, on merits of the case.
5.6
5.7
5.7.1
Earnest Money Earnest Money Deposit (EMD) shall be paid by crossed demand draft or through a Bank Guarantee (BG) from any Nationlised / Scheduled Bank in the format furnished as per Appendix VI of GCC in favour of Chennai Petroleum Corporation Limited. If the earnest money deposit is furnished in the form of a Bank Guarantee, it shall be on a stamp paper of value not less than Rs. 60 /- (Rupees Sixty only). The Bank Guarantee shall be valid for a period of eight (8) months from the date of opening of the tender. The claim period for the BG shall be valid for 60 days beyond the validity of the bid. This additional time period is to ensure that owners interests are protected till the acceptance of the order by the successful bidder. The validity of the BG shall be extended in case of extensions in bid validity sought during bid evaluation. Tenders without the earnest money deposit will be rejected. If EMD is paid through demand draft then the demand draft shall be drawn in favour of Chennai Petroleum Corporation Limited payable at State Bank of India, MRL branch (Code No: 2233), Manali, Chennai 600 068, India.
5.7.2
5.7.3
The EMD shall not be accepted and the bid shall be rejected under the following circumstances: The name of the package mentioned in the BG is different from the package for which bids have been invited. The firm on whose behalf the BG has been furnished is different from the bidder. The EMD is not of the prescribed value.
5.7.4
EMD shall not be applicable in the following cases: In line with the Indian Government Directives, Small Scale Industrial Units registered with National Small Scale Industries Corporation (NSIC) under the Single Point Registration Scheme shall be exempted from submitting EMD for items registered with NSIC and up to the monetary limit specified in the registration certificate. Indian Central Public Sector Enterprises
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5.7.5
If the bidder, after submitting his tender, revokes his offer or modifies the terms and conditions thereof during the validity of his offer except where the owner has given opportunity to do so, the earnest money shall be liable to be forfeited. Should an Invitation to Bid be withdrawn or cancelled by the Owner, which it shall have the right to do at any time, the earnest money paid with the bid will be returned. Should the successful bidder fail or refuse to sign the agreement or furnish the security deposit as per Section 4 of GCC, the earnest money shall be forfeited without prejudice to his being liable to any further loss or damage incurred in consequence by the owner. Cost of Tendering All direct and indirect cost for preparation of Bidders tender shall be to Bidders account.
5.7.6 5.7.7
5.8
5.9
Arrangement of Tender The tender shall be neatly arranged and typewritten on white paper with consecutively numbered pages. They should not contain any terms and conditions printed or otherwise, which are not applicable, to the tender. Insertions, postscripts, additions and alterations shall not be recognised unless confirmed by the Bidder's signature.
6.0 6.1
BIDDERS RESPONSIBILITY FOR TENDER Although all the details presented in this tender enquiry document such as conditions of contract, scope of work, Technical specifications and drawings have been compiled with all reasonable care, it is the Bidder's responsibility to ensure that the information provided is adequate and clearly understood. Bidder shall inspect the site and surroundings area and shall satisfy himself of the existing facilities and shall collect any other information that he may require before submitting the bid. Claims and objections due to ignorance of existing conditions will not be considered after submission of the bid and during implementation. Bidder's tender is the responsibility of Bidder and no relief or consideration can be given for errors and omissions. Clarifications / Amendments by Owner / Consultant Owner / Consultant may issue clarifications/amendments in the form of addendum/corrigendum during the bidding period and may also issue amendments subsequent to receiving the bids. For the addendum/corrigendum issued during the tendering period, Bidders shall confirm the inclusion of addendum/corrigendum in their bid. For clarifications issued by Owner/Consultant subsequent to receiving the tenders, the Bidder shall confirm receipt and for any impact on the quoted prices, the Bidder shall follow the instructions issued along with addendum/corrigendum. Bidders shall examine the tender documents thoroughly and submit to Consultant any
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6.2
6.3 6.4 6.4.1
6.4.2
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6.4.3
apparent conflict, discrepancy or error. Consultant shall issue appropriate clarification or amendment, if required. Any failure by Bidder to comply with the aforesaid shall not excuse the bidder from performing the services in accordance with the agreement, if subsequently awarded the contract. Exceptions or Deviations No deviations or exceptions shall be accepted to the following tender conditions: i) ii) iii) iv) v) vi) vii) viii) ix) Security deposit. Defect Liability period. Suspension & Termination Time Schedule Schedule of Lumpsum Prices Penalty/Compensation for delay/Liquidated damages Force Majeure Arbitration Scope of work and scope of supply
6.5
Deviation on other conditions, if felt absolutely necessary should be furnished as per format furnished in Section E Sample forms and Procedures under Part I of this tender enquiry document. Such deviations, if acceptable shall be cost on the quoted prices, wherever applicable. 6.6 Confidentiality of Documents Bidder shall treat the tender documents and contents therein as private and confidential. If at any time, during the tender preparation period, bidder decides to decline to bid, all documents must be immediately returned to Consultant. 6.7 Caution and Disclaimer Bidder shall make his own interpretation of any and all information provided in the tender enquiry document. Owner / Consultant shall not be responsible for the accuracy or completeness of such information and/or interpretation. Bidder shall be responsible for obtaining and verifying all necessary data and information and although certain information is provided in the tender enquiry document it shall be confirmed by the bidder 6.8 6.8.1 Bid Evaluation Criteria Tender is the responsibility of Bidder and no relief or consideration can be given for errors and omissions made by the Bidder inadvertently or advertently. Tender with incomplete information is liable for rejection. The Techno-commercial part of Tender shall be evaluated as per Bid evaluation criteria, wherever indicated in the Tender document. Non-submission of details / documents as specified in this tender document above may lead to rejection of Tender.
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6.8.2 6.8.3
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6.8.4
The complete scope of work has been defined in the Tender document. Only those Bidders who undertake total responsibility for the complete scope of work as defined in the Tender document shall be considered. The time schedule for completion is given in the Tender document. Bidder is required to confirm to the completion period unconditionally. The Tender of the Bidder quoting completion time more than the time schedule specified in the Tender document may not be considered for evaluation.
6.8.5
6.8.6
In case the Tender does not fully comply to the requirement of Tender document and the Bidder stipulates / retains exceptions and deviation to the clauses of Tender document considered unacceptable in the opinion of Owner/ Consultant, the Tender will be rejected. Proposed deployment of resources like manpower, equipment, tools and tackles shall be looked into to ensure performance of work within stipulated time period. Owner/Consultant reserve the right to assess Bidders capability to execute the work by taking into account various aspects such as Concurrent Commitments, performance etc. and accordingly decide whether respective price bids shall be opened and considered for further evaluation. Performance will be based on inhouse data of Owner/ Consultant. Opening of Price Part of Tender Priced commercial part of only those Bidders, whose Tenders are considered technocommercially acceptable shall be opened. Bidders selected for opening of their Price Part shall be informed about the date of Price Part opening for deputing their authorised representative (limited to one person only) to attend the opening. During Price Part opening, only Total Price shall be read out. The date of opening of the tender shall be intimated to technically and commercially acceptable Bidders at a later date.
6.8.7 6.8.8
6.9
6.10
Evaluation of Price Bid
6.10.1 The Lumpsum price quoted by the Bidder shall be considered for the purpose of evaluation and comparison. 6.10.2 If necessary, to arrive at the evaluated price, wherever applicable, loading on total quoted lumpsum price shall be done as detailed in Bid Evaluation Criteria. 6.10.3 Priced Bids containing overwritings / erasures in the quoted rates shall be liable to be rejected. Cutting shall be avoided. However, in case any cutting is unavoidable same shall be duly attested by the signatory of Tender, failing which such Priced Bids shall be liable for rejection. 6.10.4 In arriving at the final evaluated prices of the Bidders, any uncalled for lumpsum/ percentage / or adhoc reduction, if any, offered by the Bidders in the Schedule of Price shall not be considered for the purpose of evaluation. However, such reduction / rebate is from the recommended Bidder, then, such rebate shall be taken into account while awarding the work.
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SECTION C
General Conditions of Contract
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SECTION D
Special Conditions of Contract
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TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
GENERAL ................................................................................................................................. 5 SCOPE OF SUPPLY OF MATERIALS, SERVICES & FACILITIES .................................... 5 MEASUREMENT OF WORKS & TERMS OF PAYMENT ................................................... 5 CONSTRUCTION WATER AND POWER ............................................................................. 6 INSURANCE FOR MEN & MATERIALS .............................................................................. 6 TIME SCHEDULE .................................................................................................................... 6 INCOME TAX........................................................................................................................... 6 CONTRACT .............................................................................................................................. 6 SALES TAX, EXCISE & CENVATABLE AND BENEFITS ................................................. 6
10.0 LABOUR LAWS & REGULATIONS ...................................................................................... 7 11.0 ESCALATION........................................................................................................................... 7 12.0 STIPULATIONS AND DEVIATIONS TO TENDER CLAUSES ........................................... 7 13.0 PRICE SCHEDULE .................................................................................................................. 8 14.0 UNDERGROUND AND OVERHEAD STRUCTURES .......................................................... 8 15.0 DEDUCTION FOR UNCORRECTED WORK ........................................................................ 8 16.0 DRAWINGS .............................................................................................................................. 8 17.0 CONSTRUCTION EQUIPMENT AND SITE ORGANISATION:.......................................... 9 18.0 CONSTRUCTION..................................................................................................................... 9 19.0 TEMPORARY WORKS.......................................................................................................... 10 20.0 EXECUTION OF WORK AND CONSTRUCTION EQUIPMENTS .................................... 10
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21.0
RESPONSIBILITIES OF CONTRACTOR/COORDINATION WITH OTHER AGENCIES .......................................................................................................................... 10
22.0 EXISTING SERVICES ........................................................................................................... 11 23.0 FRONTS FOR WORKS WHERE OTHER AGENCIES ARE INVOLVED.......................... 11 24.0 MATERIAL SUPPLY ............................................................................................................. 11 25.0 CONTRACTOR'S FIELD OFFICE, GODOWN, WORKSHOP AND CAMP FACILITIES ............................................................................................................................ 11 26.0 UTILISATION OF LOCAL RESOURCES ............................................................................ 12 27.0 MAINTENANCE OF WORKS ............................................................................................... 12 28.0 TESTING & TEST CERTIFICATES...................................................................................... 12 29.0 TESTS AND INSPECTION:................................................................................................... 12 30.0 QUALITY ASSURANCE: ...................................................................................................... 13 31.0 STATUTORY APPROVALS:................................................................................................. 13 32.0 PROJECT SCHEDULING & MONITORING:....................................................................... 13 33.0 ACCEPTANCE OF OFFER .................................................................................................... 16 34.0 SUB-LETTING OF THE WORK............................................................................................ 16 35.0 SUB-CONTRACTOR.............................................................................................................. 16 36.0 FAILURE OF THE CONTRACTOR ...................................................................................... 16 37.0 MECHANICAL COMPLETION ............................................................................................ 17 38.0 TRIAL OPERATION .............................................................................................................. 17 39.0 FINAL TEST ............................................................................................................................ 17 40.0 LIQUIDATED DAMAGES & PENALTY ............................................................................. 17 41.0 COMPLETION DOCUMENT: ............................................................................................... 18
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42.0 CONTRACT DOCUMENT..................................................................................................... 18 43.0 DEFECTS LIABILITY PERIOD ............................................................................................ 18 44.0 SPARE PARTS & SPECIAL TOOLS & TACKLES.............................................................. 19 45.0 DISTRIBUTION SCHEDULE FOR ELECTRICAL, CIVIL AND STRUCTURAL DOCUMENTS / DRAWINGS ................................................................................................ 20 ANNEX 1 TO SPECIAL CONDITIONS OF CONTRACT ........................................................... 21 ANNEX - 2 TO SPECIAL CONDITIONS OF CONTRACT............................................................ 22 ANNEX - 3 TO SPECIAL CONDITIONS OF CONTRACT........................................................... 23
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SECTION D SPECIAL CONDITIONS OF CONTRACT

1.0 1.1 GENERAL The Special Conditions of Contract shall be read in conjunction with the general conditions of contract, Schedule of Rates, specifications of work, drawings and any other document forming part of this contract wherever the context so requires. Not withstanding the sub divisions of the document into these separate sections and volumes every part of each shall be deemed to be supplementary to and complementary of every other part and shall be read with and into the contract so far as it may be applicable to do so. Where any portion of the Special Conditions of Contract is repugnant to or at variance with any provisions of the General Conditions of Contract then unless a different intention appears, the provision of the Special Conditions of Contract shall be deemed to override the provisions of the General Conditions of Contract only to the extent that such repugnancy or variations in the Special Conditions of Contract are not possible of being reconciled with the provisions of General conditions of Contract. Wherever it is stated any where in this tender document that such and such supply has to be effected or such and such a work is to be carried out, it shall be understood that the same shall be effected / carried out by the Contractor at his own cost, unless a different intention is specifically and expressly stated herein or otherwise explicit from the context. The materials, design and workmanship shall satisfy the applicable standards, specifications contained herein and Codes Referred to. Where the Technical Specifications stipulate requirements in additional to those contained in the Standard Codes and Specifications, those additional requirements shall also be satisfied. In the absence of any Standard / Specifications covering any part of the work covered in this tender document, the instructions / directions of Engineer-in-Charge will be binding on the Contractor. The items given in Price Schedule shall be read in conjunction with materials and job specifications and in case of any irreconciliable conflict between them, the provisions in the item under Price Schedule will override the corresponding provision only of the material and job specifications, which cannot be reconciled. In such cases, the decision of the Engineer-in-Charge shall be final and binding on the Contractor. SCOPE OF SUPPLY OF MATERIALS, SERVICES & FACILITIES The Scope of supply of materials, services and facilities shall be as detailed in Annex 1 to the Special Conditions of Contract. 3.0 MEASUREMENT OF WORKS & TERMS OF PAYMENT The mode of measurement, billing and terms of payment shall be as detailed in Annexure-2 to this Special Conditions of Contract.
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1.3
1.4
1.5
1.6
2.0
FICHTNER India
4.0
CONSTRUCTION WATER AND POWER Clause 6.6.& 6.7 of GCC are modified to include the intent as hereunder. Construction Water and Construction Power will not be provided by Owner for this work. Contractor shall make his own arrangement for Supply of Construction Water and Power for execution of this work.
5.0
INSURANCE FOR MEN & MATERIALS The contractor shall take a comprehensive insurance policy covering the material and men including that of his sub contractors involved in the entire scope of his contract including but not limited to freight, storage, erection and construction and commissioning.
6.0 6.1 6.2
TIME SCHEDULE The works shall be executed strictly as per the time schedule attached as Annexure 3 to the Special Conditions of Contract. Monthly / weekly construction programmes will be drawn up by the Contractor in consultation with the Engineer-in-charge and approved by him based on availability of materials, work fronts and the joint programme of execution as referred to above. The Contractor shall scrupulously adhere to the Targets / Programmes by deploying adequate Personnel, Construction Equipment, Tools and Tackles and also by timely supply or required materials coming within his scope of supply as per contract. In all matters concerning the extent of Targets set out in the monthly/weekly programme and the degree of achievement, the decision of Engineer-in-Charge will be final and binding on the Contractor. Contractor shall give every day category-wise labour and equipments report along with the progress of work done on previous day in the proforma prescribed by the Engineer-inCharge. INCOME TAX Income Tax at the prevailing rate as applicable from time to time shall be deducted from the Contractors bills as per Income Tax Act, and quoted rates shall be deemed to include this.
6.3
7.0
8.0
CONTRACT The entire work covered in this Tender document shall be treated as works contract. Bidder should quote for this work accordingly. The quoted price should be firm and should include all taxes, duties, octroi, excise, and freight. Insurance (Inclusive of transportation, storage, erection and commissioning, workmen insurance) etc., whatsoever. SALES TAX, EXCISE & CENVATABLE AND BENEFITS The quoted price shall be deemed to be firm and inclusive of all taxes including Sales Tax on Works Contract, duties, octroi, levies and applicable cenvatable benefits etc. till the completion of the Contract and the Contractor shall not be eligible for any increase
FICHTNER India
9.0 9.1
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whatsoever even there is increase in statutory levies etc., by the order of the state/central Govts. 9.2 9.3 Excise duty if applicable should be included by the Contractor in their quoted rates and no increase on this account will be entertained by the Owner under any circumstances. Cenvatable Excise duty paid by the bidder shall be reimbursed at actuals on production of documentary evidence. Bidders shall indicate the Cenvatable Excise duty considered by them in their offer as per proforma enclosed and furnish documents so that Owner can avail the CENVAT benefit. Even though Cenvatable Excise duty shall be reimbursed by Owner at actuals on documentary evidence, this shall be limited to the Cenvatable Excise duty component indicated by the bidders in their offer. Further in case the actual amount of Cenvatable Excise Duty paid falls less than the amount indicated in their offer, the shortfall shall be recovered from the Lumpsum Price. The Cenvatable Excise duty shall be included in the rates quoted by the bidder. For both indigenous and imported materials supplied, bidder shall furnish the documents to the Owner to avail the CENVAT benefit. i) It is to be noted that the agency shall be required to submit the documentary evidence(s) for Cenvatable Excise duty paid by them to the concerned authorities for Owner to claim CENVAT benefit. ii) Necessary invoice indicating Ex-works Cenvatable Excise duty paid shall be raised to enable Owner to claim Cenvat. The details of Cenvatable Excise duty paid shall be submitted with each RA bill for release of payment. iii) In case documentary support for claiming Cenvat as per Excise Rules is not submitted to the OWNER, the Cenvatable Excise duty element included in the bill shall be recovered.
10.0 10.1 11.0
LABOUR LAWS & REGULATIONS Contractor shall obtain licenses from rates concerned authorities under all applicable laws and regulations and furnish copy of the same to Owner, before starting of work. ESCALATION The prices shall be kept FIRM till the completion of work. admissible under any circumstances. No escalation will be
12.0
STIPULATIONS AND DEVIATIONS TO TENDER CLAUSES Bidders are advised to submit quotations strictly based on the terms, conditions and specifications contained in the Tender documents and not to stipulate any deviations. However, if becomes unavoidable, deviations should be stipulated with reference to the Clause No. Para and Page no of the relevant specification as given in the tender document and should be submitted only in the prescribed form given in the tender document. Deviations, if any, mentioned anywhere else shall not be taken cognizance of. Any wilful attempt by the Bidders to camouflage the deviations by giving them in the covering letter or in any other documents that are enclosed may render the tender itself nonresponsive. Owner / Consultant reserves the right to evaluate the offers containing deviations with financial implications after accounting cost for such deviations as determined by Owner/ Consultant.
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13.0
PRICE SCHEDULE All items of work in the Price schedule shall be carried out as per the Specifications, Drawings and instructions of the Engineer-in-Charge and the Rates quoted are inclusive of all materials, consumable, labour, supervision, tools and tackles as well as preparatory, incidental, immediate/auxiliary/ancillary or enabling works.
14.0
UNDERGROUND AND OVERHEAD STRUCTURES All existing structures, overhead lines, existing pipelines and utilities have to be identified by the Contractor and noted by him before taking up the execution of work irrespective of whether the same has been intimated to him by the owner or not. Contractor shall execute the work in such a manner that the existing structures, utilities, pipelines etc. are not disturbed / damaged during implementation of work under this contract and it is the responsibility of the bidder to make good any such losses.
15.0
DEDUCTION FOR UNCORRECTED WORK If the Engineer-in-Charge deems it inexpedient to correct work damaged or not done in accordance with the Contract, an equitable deduction from the contract price shall be made thereof and the decision of the Owner / Consultant shall be final.
16.0
DRAWINGS The drawings accompanying the tender document are indicative of nature of work and issued for tendering purpose only. Purpose of these drawings is to enable the Bidder to make an offer in line with requirements of the Owner. However, no extra claim whatsoever shall be entertained for any variation in the "Approved for Construction" and "Tender Drawings" regarding any changes/units. Construction shall be as per drawings/specifications issued approved by the Engineer-in-Charge during the course of execution of work. Detailed construction drawings on the basis of which actual execution of work is to proceed will be furnished to the Contractor progressively based on the detailed construction programme evolved after the award of work and also based on construction progress achieved.
16.1
Chief Electrical Inspectorate to Government The contractor has to prepare necessary physical, schematic electrical layout drawings conforming to Indian Electricity rules and shall get it approved by the electrical inspectorate at his risk and cost. The additional works insisted by the electrical inspectorate during the course of approval is to the account of contractor only. The contractor who is a Electrical A grade contractor has to examine such items of work in tender stage itself and offer in the tender itself. The actual execution of the works has to proceed based on the detailed working drawings only. This will be furnished from time to time during the progress of the work. The Contractor shall be deemed to have gone through the drawings and bring to the notice of the Engineer-in-Charge discrepancies if any, therein before actually carrying out the work.
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FICHTNER India
Copies of all detailed working drawings relating to the works shall be kept at the Contractor's office on the site and shall be made available to the Engineer-in- Charge at any time during execution of the contract. The drawings and other documents issued by the Owner shall be returned to the Owner on completion of the works. 17.0 17.1 CONSTRUCTION EQUIPMENT AND SITE ORGANISATION: CONSTRUCTION EQUIPMENT The Contractor shall without prejudice to his overall responsibility to execute and complete the work as per specifications and Time schedule, progressively deploy adequate equipments and tools and tackles and augment the same as decided by the Engineer-in-Charge depending on the exigencies of the work so as to suit the construction schedule. The Bidder shall submit a list of construction equipments he proposes to deploy for the subject work. No construction equipment will be supplied by the Owner. SITE ORGANISATION Subject to the provisions in the tender document and without prejudice to Contractor's liabilities and responsibilities to provide adequate qualified and skilled personnel on the work, Contractor shall deploy site organisation and augment the same as decided by the Engineer-in-charge depending on the exigencies of work. The Bidder shall submit the details of minimum site organisation proposed by him, as per Proposal Form given in the tender document. 18.0 18.1 CONSTRUCTION RULES AND REGULATIONS CONTRACTOR shall observe in addition to Codes specified in respective specification, all national and local laws, ordinances, rules and regulations and requirements pertaining to the WORK and shall be responsible for extra costs arising from violations of the same. The contractor has to abide by IE rules and regulations and take appropriate action to employ Rule 3 person on their own in time and required electrical "C certificate holders during execution. 18.2 PROCEDURES Various procedures, field quality plan and method statements to be adopted by Contractor during the construction as required in the respective specifications shall be submitted to Owner in due time for approval. No such construction activity shall commence unless approved by Engineer-in-charge in writing. 18.3 FIELD INSPECTION Contractor shall have at all times during the performance of the WORK, a competent superintendent with required qualification in electrical engineering on the premises. Any instruction given to such Superintendent shall be construed as having been given to the contractor.
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17.2
FICHTNER India
The contractor has to arrange for inspection by electrical inspectorate and as well as TNEB authorities for issue of safety certificate and energisation of power, HT service respectively. 19.0 TEMPORARY WORKS All temporary works, ancillary works, enabling works, including de-watering of surface and subsoil water, preparing approaches and working areas, wherever they are required for execution of the work, shall be the responsibility of the Contractor, and all costs towards the same shall be deemed to have been included in the quoted rates / prices 20.0 EXECUTION OF WORK AND CONSTRUCTION EQUIPMENTS The Contractor shall be entirely responsible for executing the work covered under this Tender document in a workmanlike and expeditious manner as per the time schedule, specifications, drawings and construction aids such as arc welding sets, gas cutting sets, cranes, chain pulley blocks, transportation equipments, tools and tackles as well as testing appliances such as test pumps, air compressors etc and the necessary supervisory personnel, skilled, semi-skilled and unskilled labour shall be provided by the Contractor to achieve the monthly/weekly targets and the overall time schedule. Preparing approaches and working area fur the movement and operation of cranes, leveling the areas for assembly and erection shall be the responsibility of the Contractor. 21.0 RESPONSIBILITIES OF CONTRACTOR/COORDINATION WITH OTHER AGENCIES The Contractor's responsibility covers the coordination of all the works involved and the expenses of site mobilisation and demobilisation including clearing activities. The quoted rates for various items are deemed to have appropriately catered for these and no separate claim whatsoever is entertainable. Work shall be carried out in such a manner that the work of other agencies operating at the site is not hampered due to any action/inaction of the Contractor. Proper co-ordination with other agencies will be Contractor's responsibility. It shall be the responsibility of the Contractor to obtain the approval for any revision and/ or modifications decided by the Contractor from the Owner/Engineer-in-Charge before implementation. Also such revisions and/or modifications if accepted/approved by the Owner/Engineer-in-Charge shall be carried out at no extra cost to the Owner. Any changes required during and/or after approval of detailed construction drawings due to functional requirements or for efficient running of system keeping the basic parameters unchanged and which has not been indicated by the Contractor in the data-drawings furnished along with the offer will be carried out by the Contractor at no extra cost to the Owner. It shall be entirely the Contractor's responsibility to provide, operate and maintain all necessary construction equipment, scaffoldings and safety gadgets, cranes and other lifting tackles, tools and appliances to perform the work in a workman like and efficient manner and complete all the jobs as per time schedule. Preparing approaches and working area for the movement and operation of the equipment including side booms and cranes, leveling the areas for assembly, laying, installation/erection shall also be the responsibility of the Contractor. The Contractor shall
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FICHTNER India
Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page: D : 10
acquaint himself with access availability to provide suitable allowances in his quotation. The Contractor may have to build temporary access roads to aid his own work which shall also be taken care while quoting for the work. The procurement and supply in sequence and at the appropriate time of all materials and consumables shall be entirely the Contractor's responsibility and his rates for execution of work will be inclusive of supply of all these items. Contractor shall not use any of the equipment or materials issued to him by Owner for installation purposes for laying temporary lines, manufacturing erection aids etc. Misuse of materials will be seriously viewed and deduction at penal rates will be made from the Contractor's bill for such quantities that are misused. 22.0 22.1 EXISTING SERVICES Structures, drains, pipes, cables, overhead wires and similar utility services encountered in the course of the works shall be protected from damages by the contractor at his own cost. Should any damage be done by the contractor to any of the existing structures, mains, pipes, cables or utilities whether above or below ground etc, whether or not shown on the drawings the contractor must make good or bear the cost of making good the same without delay to the satisfaction of the Engineer-in-Charge / utility departments.. FRONTS FOR WORKS WHERE OTHER AGENCIES ARE INVOLVED The work involved under this contract includes such works as have to be taken up and completed after other agencies on the job have completed their jobs. The Contractor will be required and bound to take up and complete such works as and when the fronts are available for the same and no claim of any sort whatsoever shall be admissible to the Contractor on this account. Only extension of time limit shall be admissible, if the availability of work fronts to the Contractor is delayed due to any reasons not attributable to the Contractor. 24.0 24.1 MATERIAL SUPPLY The procurement and supply in sequence and at appropriate time of all equipment, plants, accessories, materials (under Contractor's scope of supply) and consumables required for completion of works under this contract should be entirely contractors responsibility. It shall be the responsibility of the contractor to supply the best equipment, new and in first class condition for the work. The specifications provided in the contract are to provide the contractor with performance criteria for all major equipment, components and facilities. CONTRACTOR'S FIELD OFFICE, GODOWN, WORKSHOP AND CAMP FACILITIES Contractor shall, if required by him, for the entire duration of the execution of the work arrange construction of Contractor's office, warehouse, workshops and Camp Facilities/Residential Accommodation and for any purpose in connection with providing infrastructure required for the execution of the Contract. The Contractor shall at his own cost construct all temporary buildings/facilities and provide suitable water supply and
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23.0
24.2
25.0
FICHTNER India
sanitary arrangement as required. Such facilities as constructed by Contractor shall be maintained by Contractor at his own cost. 26.0 26.1 UTILISATION OF LOCAL RESOURCES The Contractor shall ascertain the availability of local sub-Contractors and skilled/unskilled manpower and engage them to the extent possible for performance of works. The Contractor shall not recruit personnel of any category from among those who are already employed by the other agencies working at the site but shall make maximum use of local labour available. MAINTENANCE OF WORKS The Contractor shall take care for cleaning the work site from time to time and keep the approach road for easy access to work site and also from safety point of view. Working site should be always kept cleaned upto the entire satisfaction of the Engineerin-Charge. Before handing over any work to Owner, the Contractor in addition to other formalities to be observed as detailed in the document shall clear ' the site to the entire satisfaction of Engineer-in-Charge. TESTING & TEST CERTIFICATES The Contractor shall carry out tests, when directed and submit certificates for every batch of materials as required by and for the approval of the Engineer-in-Charge. 29.0 TESTS AND INSPECTION: The Contractor shall carry out the various tests as enumerated in the Technical Specification of this tender and technical documents that will be furnished to him during the performance of the work at no extra cost to the owner. All the tests either on the field or at outside laboratory concerning the execution of the work and supply of materials by the Contractor shall be carried out by the Contractor at his own cost. The work is subject to inspection at all times by the Engineer-in-Charge. The Contractor shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this tender, the technical documents that will be furnished to him during performance of work and the relevant codes of practice. The Contractor shall provide for purpose of inspections access ladders, lighting, equipment for testing necessary instrument etc. at his own cost, low voltage lighting equipment for tray fixing and inspection work. Compressed air for carrying out the works shall be arranged by the Contractor at his own cost. Any work not conforming to the execution drawings, specifications or codes shall be rejected forthwith and the Contractor shall carry out the rectification at his own cost.
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26.2
27.0 27.1 27.2
28.0
FICHTNER India
All results of inspection and test will be recorded in the inspection reports, proforma of which will be approved by the Engineer-in-Charge. These reports shall form part of the Completion Documents. Any work not conforming to the execution drawings, specifications or codes shall be rejected and the Contractor shall carry out the rectification at his Own risk and cost. 30.0 30.1 QUALITY ASSURANCE: Bidder shall include in his offer the Quality Assurance Programme containing the overall quality management and procedures which is required to be adhered to during the execution of contract, After the award of the contract, detailed quality assurance programme to be followed for the execution of contract under various divisions of works will be mutually discussed and agreed to. STATUTORY APPROVALS: The approval from any authority required as per statutory rules and regulations of Central / State Government shall be the Contractor's responsibility unless otherwise specified in the tender document. The application on behalf of the Owner for submission to relevant authorities along with copies of required certificates complete in all respects shall be prepared and submitted by the Contractor well ahead of time so that the actual construction/commissioning of the work is not delayed for want of the approval inspection by concerned authorities. The inspection of the works by the authorities shall be arranged by the Contractor and necessary coordination and liason work in this respect shall be the responsibility of the Contractor. However statutory fees paid, if any, for all inspections and approvals by such authorities shall be reimbursed at actuals by the Owner to the Contractor on production of documentary evidence. Any change/addition required to be made to meet the requirements of the statutory authorities shall be carried out by the Contractor free of charge. The inspection and acceptance of the work by statutory authorities shall, however, not absolve the Contractor from any of his responsibilities under this contract. PROJECT SCHEDULING & MONITORING: The following schedules/documents/reports shall be prepared and submitted by the Bidder/Contractor for review/ approval at various stages of the contract. 32.1 32.1.1 ALONG WITH TENDER: Time Schedule: The Bidder is required to submit a Project Time Schedule in Bar Chart Form, along with the Tender. The Schedule shall cover all aspects like sub-ordering, manufacturing and delivery, sub-contracting and construction within the completion time indicated in the Tender Document. The Owner interface activities shall be clearly identified with their latest required dates. Owner reserves the right to disqualify the Bidder if the above Schedule submitted by the Bidder is not in line with the overall project requirement.
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31.0 31.1
31.2
30.3
32.0
FICHTNER India
32.1.2
Scheduling & Monitoring System: The Bidders should describe their system of Project Scheduling and monitoring, the extent of computerisation, level of detailing, tracking methodology etc. with the name of computer packages and sample outputs.
32.2 32.2.1
AFTER THE AWARD OF CONTRACT Overall Project Schedule: The Contractor shall submit within 4 weeks off FAX OF ACCEPTANCE, a sufficiently detailed overall, Project Schedule in the activity network/bar chart form, clearly indicating the major milestones, inter-relationship/interdependence between various activities together with analysis of critical path and floats. The network/bar chart will be reviewed and approved by Engineer-in-Charge and comments if any shall be incorporated in the network/bar chart before issuing the same for implementation. The network thus finalised shall form part of the contract document and the same shall not be revised without the prior permission from Engineer-in-Charge during the entire period of contract.
32.2.2
Progress Measurement Methodology: The Contractor is required to submit within four weeks of award of WORK, the methodology of progress measurement of sub-ordering, manufacturing/delivery subcontracting, construction and commissioning works and the basis of computation of overall services/physical progress reported. Owner reserves the right to modify the methodology in part or in full.
32.2.3
Functional Schedules. The Contractor should prepare detailed functional schedules in line wit network/bar chart for functional monitoring and control and submit schedule progress charts/graphs for each function viz. engineering ordering, manufacturing/delivery and construction.
32.3
PROJECT REVIEW MEETINGS: The Contractor shall present the programme and status at various review meetings as required.
32.3.1
Weekly Review Meeting: Level of Participation: Contractor/Consultant/ Site In charge and Job Engineers. Agenda a) Weekly programme viz actual achieved in the past week and programme for next week.
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b) Remedial Actions and hold up analysis. c) Client query/approval. 32.3.2 Monthly Review Meeting: Level of Participation : Senior Officers of Owner/Consultant and Contractors. a) Progress Status/Statistics. b) Completion Outlook. c) Major hold ups/short fall d) Assistance required / remedial measures e) Critical issues /solutions f) Client query/approval 32.4 32.4.1 PROGRESS REPORTS: Monthly Progress Report : This report shall be submitted on a monthly basis within Ten Calender days from cut-off date as agreed upon, covering overall scenario of the work. The report shall include but not be limited, to the following: a) Brief introduction of the work. b) Activities executed/achievements during the month c) Schedule v/s actual percentage progress and graphs/charts for engineering, subordering, manufacturing / delivery, sub-contracting, construction and overall work. d) Quantum wise status of purchase orders against schedule shall also be indicated. e) Areas of concern/problem/hold ups, impact and action plans. t) Resources deployment status. g) Annexures giving status summary for Material Requisitions and deliveries,' subcontracting and construction. Distribution: Owner Consultant : Two copies : Two copies.
Consultant Site office : One Copy
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B. Weekly Report: This report (6 copies) will be prepared and submitted by the Contractor on weekly basis and will cover following items: a) Activities programmed and completed during the week. b) Resource deployed men and machine. c) Quantity achieved against target in construction. d) Record of Mandays utilised. e) Construction percentage progress, schedule and actual. 33.0 ACCEPTANCE OF OFFER The Bidder shall acknowledge the receipt of ORDER / FAX OF ACCEPTANCE/ LETTER OF ACCEPTANCE within 15 days of mailing of the same and any delay in acknowledging the receipt will be a breach of contract and compensation for the loss caused will be recovered by the Owner by forfeiting the Earnest Money Deposit/Tender bond. 34.0 SUB-LETTING OF THE WORK The Bidder shall indicate in his offer the works, which he intends to sublet to the subContractors. The Contract Agreement will specify the major works for which the Contractor proposes to engage the Sub-Contractor. The Contractor from time to time propose any addition or deletion to the list and will submit proposals in this regard to the Engineer-in-Charge for approval well in advance so as maintain the progress of work. Such approval of the Engineer-in-Charge will not relieve the Contractor from any of his obligations, duties and responsibilities under the contract. 35.0 SUB-CONTRACTOR At the commencement of the job the Contractor shall supply to the Engineer-in- Charge, list of all Sub-Contractors or other persons or firms engaged by the Contractor to work at the Site. Any Bidder who had submitted the tender for this tender and does not get the contract because of his being not the lowest will be prohibited from working as subContractor for execution of this contract. List of unsuccessful Bidders shall be provided for in the Contract Agreement. 36.0 FAILURE OF THE CONTRACTOR If the Contractor fails to complete the work and the order is cancelled, the amount due to the Contractor on account of work executed, if payable, shall be paid only after due recoveries as per the provisions of the contract and that too after alternative arrangements to complete the work has been made.
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37.0
MECHANICAL COMPLETION When the construction of the PLANT/UNIT/SYSTEM has been completed, other than in minor aspects which do not prevent commissioning, all civil engineering is completed, all equipment and machinery are installed and aligned, all piping and instrumentation services are completed, all electrical works are completed, all hydrostatic/pneumatic testing is done, safety valves & pressure relief valves set and checked, speed and direction of rotation of all prime movers is checked, relays are set and all scales, meters, measuring devices and recorders are calibrated and set, etc, then the PLANT is treated as mechanically completed and ready for pre-commissioning activities. The date of readiness for pre-commissioning as aforesaid shall be deemed to be the date of mechanical completion of the PLANT (hereinafter called MECHANICAL COMPLETION) for the purpose of this CONTRACT.
38.0
TRIAL OPERATION After mechanical completion of the complete works under the scope of the contractor shall commission all the equipment under the scope of works and demonstrate to the various parameters as per the contract specification to .the Engineer in Charge. On successful completion of the same the Engineer in charge shall certify that the equipment under the scope of works is ready for Final Test.
39.0
FINAL TEST The contractor in advance shall submit to Engineer in charge procedure for Final Test and the final test shall be carried out as per the approved procedure. Final test is deemed to have been completed when the contractor with proper intimation to engineer in charge shall demonstrate the parameters of complete system (along with all mechanical, electrical and C&I components of the system) as applicable in the contractors scope for a period of seven consecutive days. Other conditions as specified in clause 8.3 of GCC shall also applicable for the Final Test.
40.0
LIQUIDATED DAMAGES & PENALTY Liquidated damages payable by contractor to the owner for the delay in completion of each part shall be as follows: 1. An amount of 0.5% of contract price for every week of delay or part there of up to a maximum of 10% of contract price shall be levied for delay in engineering on part of the contractor. Delay in Engineering: Delay in the submission of drawings as per the approved drawings schedule, extended to the individual deliverables of the contractor. 2. An amount of 0.5% of contract price for every week of delay or part there of up to a maximum of 10% of contract price shall be levied for delay in completion of final test as per the approved procedure for final test. Successful Final Test:
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Successful Final Test is deemed to have been completed when the contractor with proper intimation to owners engineer shall demonstrate the parameters of complete system (along with all mechanical, electrical and C&I components of the system) as applicable in the contractors scope for a period of seven consecutive days. 40.1 PENALTY CLAUSE ON EQUIPMENT PERFORMANCE Penalty will be calculated as follows 41.0 41.1 Performance of the system up to 95% of guaranteed value No penalty Below 95% for every percentage of drop the procedure to arrive at penalty will be as per the guidelines given in the tender document. Below 90% the system will be rejected and CONSULTANT/OWNER will have the right to invoke the performance bank guarantee of the contractor.
COMPLETION DOCUMENT: The following document shall be submitted by the Contractor, in triplicate, as a part of the completion documents. These will be in addition to those mentioned in relevant clauses of the General Conditions of Contract. a) The Technical document according to which the work was carried out. b) Completion Certificates for embedded and covered up work. c) Certificate of final levels as set out for various work. d) Test Report qualifying the details of tests carried out on equipment/materials. e) Six sets of construction drawings and one set of reproducible drawing showing therein the work as executed duly approved by Engineer-in- Charge. Reproducible of the latest drawings shall be provided to the Contractor for preparation of construction drawings.
42.0 42.1
CONTRACT DOCUMENT The following shall form the contract documents: a) Statement of Agreed Variations, if any. b) The detailed Letter of Acceptance along with its enclosures. c) Fax of Acceptance awarding the works to the Contractor. d) Addendum/Corringendum to tender documents issued if any. e) Original tender documents issued with its enclosures.
42.2 43.0 43.1
All other documents and correspondence exchanged prior to issue to fax of Acceptance/Letter of Acceptance whichever is earlier, shall be treated as null and void. DEFECTS LIABILITY PERIOD Defects liability Period for all switchyard equipment including mechanical, electrical and instrumentation 12 Months from the date specified in the Completion Certificate as the date of completion of the Work. Defect liability for all civil works and buildings works - 60 Months from the date specified in the Completion Certificate as the date of completion of the Work.
FICHTNER India
43.2
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43.3
The Contractor shall carry out all the necessary works and all associated activities as may become necessary for rectification or replacement of the defective equipment or structure during the defects liability Period entirely at his cost. The portion of the works so rectified I replaced shall be liable for guarantee for a further period of one (1) year for items falling under sub clause 42.1 and for five (5) years for items falling under sub clause 42.2 from the date of successful completion of the replacement I rectification. During the aforesaid defect liability the contractor shall pay and make good to CPCL and all other persons or parties legally entitled thereto all losses, damages, costs and expenses they or any of them may incur or be put or be liable to by reason or in consequence of the operations of the contractor or of the failure from whatever causes of the works or any of them during the time the contractor is responsible thereof or parties as aforesaid from and against the same and from and against all actions. Suits, claims and demands whatsoever by reason of an account thereof or CPCL will be at liberty to encash the Performance Bank Guarantee and pay to such other persons or parties entitled as aforesaid the amount of such losses, damages, cost of expenses without prejudice to CPCL's right to seek additional compensation if any through legal means.
44.0 44.1
SPARE PARTS & SPECIAL TOOLS & TACKLES FOR COMMISSIONING The Contractor shall procure and supply spare parts for start-up and commissioning and are included in his scope of work. The Lumpsum quoted price shall be deemed to be inclusive of provision of such spares and additional spares, if any, required during commissioning. All the commissioning spares shall be procured by the contractor well before start up and commissioning.
44.2
FOR TWO YEARS NORMAL OPERATION & MAINTENANCE The Bidders shall submit the list including unit & quantity of recommended spares for two years normal operation & maintenance in unpriced part as per format and item wise price shall be submitted in priced part. Prices of Spares shall remain valid during currency of contract; Owner may order -such spares any time during currency of contract. Spare Parts will be delivered at site, preferably along with the equipment, if not, latest by the completion of the work. The Contractor shall also procure and supply the Mandatory Spares listed elsewhere in this document. The Lumpsum quoted prices shall be deemed to be inclusive of provision of such spares. Special Tools & tackles One set of special Tools and tackles required for testing, commissioning and normal operation of the entire equipment is included in the scope of work .
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45.0
DISTRIBUTION SCHEDULE FOR ELECTRICAL, CIVIL AND STRUCTURAL DOCUMENTS / DRAWINGS The distribution of Electrical, Civil and Structural documents / drawings shall be as follows: Sl. No. Document Total Copies Distribution Owner Consultant HQ SITE 4 2 6
All drawings, calculations, documents, write-ups for all revisions Approved drawings, calculations, documents etc. - Hard Copy - Soft Copy As built drawings - Hard Copy - Soft Copy Reproducible of approved & As built drawings
12
12 2 12 2 2
4 1 5 1 1
4 5 1
4 1 2 1 -
The construction work shall only start after design & drawing is approved by the Owners Consultant. No construction shall commence prior to obtaining of written approval from the Owner / Owners Consultant. Any approval given by the Owners Consultant to the designs & drawings shall not relieve the Contractor of his responsibilities for the correctness of the same and for execution of the work in accordance with the terms of the specifications. Detailed drawings approved by the Owners Consultant shall supercede the general drawings when they differ from them. The drawings bearing the Owner / Owners Consultants approval or drawings corrected in accordance with the comments of the Owner / Owners Consultant shall be deemed to be contract drawings and no variation there from shall be taken without the Owners written consent.
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ANNEX 1 TO SPECIAL CONDITIONS OF CONTRACT
1.0 1.1 2.0 2.1
SCOPE OF SUPPLY OF MATERIALS All materials required for the works shall be in the scope of the Contractor. SCOPE OF SERVICES All services required to meet the intent of this specifications is in the scope of the Contractor.
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ANNEX - 2 TO SPECIAL CONDITIONS OF CONTRACT 1.0 1.1 1.2 1.3 MEASUREMENT OF WORKS All measurements will be taken by the Contractor in the presence of the Engineer or his representative. Payment will be made based on the quantities calculated from these measurements. All measurements shall be taken on finished works for the purpose of payments. Measurement of weights will be in metric tonnes (corrected to the nearest kilogram) and will be made based on the execution drawings. Where materials are bought out and weights are not indicated in the drawing, packing lists as received from the suppliers will be referred for the weights. Linear measurements will be in metres rounded off to the nearest centimeter. If physical measurements are impractical, dimensions shall be taken from the execution drawings. For steelwork, the weight for payment shall be assessed from the approved fabrication drawings. Welds, bolts, nuts, washers, shims, packing etc shall not be taken into consideration. The rates shall be deemed to be inclusive of such items. Temporary or enabling works connected with the contract such as templates, shoring, etc shall be deemed to have been allowed for in the rates quoted. The arrangement of the electrical system shall be verified with respect to the approved drawings. The make and ratings of electrical components and accessories shall be verified with respect to approved drawings. The quantity of electrical components and accessories and the length of electrical cables shall be verified with respect to approved drawings / packing list. TERMS OF PAYMENT Payment will be made against the work done on the basis of item rates as accepted in the contract in the terms and manner as described below: 80% on receipt of materials at contractors yard. 10% on mechanical completion. 5% on commissioning 5% on successful performance guarantee test run of units and acceptance thereof by engineer-in-charge.
1.4 1.5 1.6 1.7 1.8 1.9 2.0
The above payments are subject to deduction towards retention money, Income Tax and other recoveries applicable as per terms of contract. Further break-up of above payment terms, if deemed necessary for any progressive payment of individual item may be mutually arrived at between Engineer- in-Charge and contractor.
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ANNEX - 3 TO SPECIAL CONDITIONS OF CONTRACT 1.0 TIME SCHEDULE Name of Work Time of Completion
Design, Engineering, Manufacture, shop testing, inspection, supply, transportation to site, unloading, storage, installation and 6 (Six) Months commissioning of 110kV switchyard electrical system with control room as per specification for the 5.8 MGD Sea Water Desalination Project for CPCL at North Chennai, Tamilnadu. Tender No. : 6104-EL-SPC-610-001
The time of completion shall be reckoned from the date of issue of Fax of Acceptance or Letter of Acceptance of Tender whichever is issued earlier. The time includes mobilization at site, carrying out and handing over all works under the tender in all respects as per specifications, codes, drawings, instructions of the Engineer / Owner.
---------------------------------------(SIGNATURE OF THE BIDDER)
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SECTION E
Sample Forms and Procedures
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Doc. No.6104-EL-SPC-610-001 Rev. R0 Page: E : 1
TABLE OF CONTENTS
FORMAT - A FORMAT - B FORMAT- C FORMAT - D FORMAT- E FORMAT - F
ACKNOWLEDGEMENT LETTER TO INVITATION TO BID ......................... 3 CHECK LIST OF INFORMATION TO BE FURNISHED BY THE BIDDERS WITH THE TENDER ............................................................................................ 5 EXPERIENCE CRITERIA FORMAT FOR 110KV SWITCHYARD ................. 6 FINANCIAL CRITERIA FORMAT FOR 110KV SWITCHYARD .................... 8 DEVIATIONS SCHEDULE (TECHNICAL)........................................................ 9 DEVIATIONS SCHEDULE (COMMERCIAL) ................................................. 10
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FORMAT - A
ACKNOWLEDGEMENT LETTER TO INVITATION TO BID

TENDER DOCUMENT NO 6104-EL-SPC-610-001
TO The Project Manager, Desalination Project - CPCL FICHTNER CONSULTING ENGINEERS PVT. LTD. Ganesh Chambers, 64 Eldams Road,Chennai 600 018 Sub: Tender for design, Engineering, Manufacture, shop testing, inspection, supply, transportation to site, unloading, storage, installation and commissioning of 110kV switchyard with control room and accessories as per specification for the 5.8 MGD Sea Water Desalination Project for CPCL at North Chennai, Tamilnadu. Tender No. : 6104 EL SPC-610-001 Dear Sir, We acknowledge receipt of your invitation to Bid which was received on .and understand that the documents received remain the property of Chennai Petroleum Corporation Ltd., . We indicate below our intentions with respect to the Notice inviting tender. A. i. ii. iii. iv. v. We intend to bid as requested and furnish following details with respect to our quoting office. Postal Address Telephone Number Telex Number Telefax Number Contact Person : : : : :
Chennai Office Address if any i. ii. iii. iv. Postal Address Contact Person Telephone no. Fax No. : : : :
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B.
We are unable to Bid for the reasons given below and hereby return the Tender Documents. Reasons for non submission of bid. Companys Name :
Signature Name Designation Note :
: : :
Immediately on receipt of the tender document, bidder shall furnish the acknowledgement Letter to ITB as per the above Proforma. All the future correspondence shall be made with the bidders quoting office.
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FORMAT B
CHECK LIST OF INFORMATION TO BE FURNISHED BY THE BIDDERS WITH THE TENDER
Bidders are requested to use this check list proforma to ensure that they have provided all the required information to make their tender complete. Copy of this proforma duly filled in shall be submitted along with the Techno-commercial part (Part 1) of the offer. All items except item 1b shall be in One (1) original + Four (4) copies. Item 1b will be the Tender Document set marked ORIGINAL. If any document / information is not furnished the bidder shall enter the reason for not doing so in the remarks column. ATTACHED INFORMATION TO BE FURNISHED BY S.NO REMARKS BIDDER YES NO 1 Signed and Stamped copy of the a. Letter of Submission of Tender (as per Appendix-I of GCC) b. ORIGINAL tender document with addenda, if any. c. Time Schedule (Section 4 SCC, Annexure 3 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Information about Bidder as per GCC Appendix-II and IIA Experience criteria Formats - C filled Financial Criteria Format - D filled Income Tax PAN No. Annual Report showing balance sheet and profit & loss account statement for previous 3 years Solvency Certificate from bankers Declaration that the bidder is not under court receivership, liquidation and similar proceedings Power of Attorney in the name of person signing the tender Details of Bidders quality assurance and Safety practices Details of past experience in works of similar nature (as per Appendix-III of GCC) Details of equipment proposed to be used for the tendered works(as per Appendix-IV of GCC) Details of bidders concurrent commitment (as per Appendix-V of GCC) Overall schedule for execution of works and site organization chart Exceptions and Deviations Form Any other information / documents the bidder desires to enclose.
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FORMAT-C EXPERIENCE CRITERIA FORMAT FOR 110kV SWITCHYARD
Bidders shall furnish their experience details with reference to the work which pre-qualify them in line with the Experience Criteria. Bidders shall use separate forms for each reference job. Sl.No. 1 (a) 1 (b) Description Name and postal address of Client Contact person in the Client's office Ph. No. 2 (a) 2 (b) 2 (c) 2 (d) Fax No. Client's Order No. Capacity of Switchyard Value of the order Valid A Grade License issued by Secretary Licensing Board, Tamilnadu Details to be furnished by the Bidder
Chennai Petroleum Corporation Limited (A Group Company of Indian Oil) Project Contracts
Page Pre-Qualification of contractors for 110kV Switchyard for Installation of 5.8 MGD Seawater Desalination Plant on Package basis 1 of 2
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Sl.No. 2 (e) 2 (f) Scope of Work
Description
Details to be furnished by the Bidder
3 (a)
Confirm if the copy of order reveals the Capacity of switchyard and the Scope of Work, Else, confirm if a certificate from the client indicating the above details is enclosed. (Please note that this reference will not be considered in the absence of this document). Completion Dates: a) Date of Order b) Contractual Completion Date c) Actual Completion Date
3 (b)
d) Reasons for delays if any Confirm if a copy of certificate from the client for oneyear satisfactory operation is enclosed. (Please note that this reference will not be considered in the absence of this certificate)
AUTHORISED SIGNATORY NAME: DESIGNATION: DATE:
Chennai Petroleum Corporation Limited (A Group Company of Indian Oil) Project - Contracts
Page Pre-Qualification of contractors for 110kV Switchyard for Installation of 5.8 MGD Seawater Desalination Plant on Package basis 2 of 2
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FORMAT - D FINANCIAL CRITERIA FORMAT FOR 110KV SWITCHYARD

Tenderer shall indicate herein his annual turnover during the following 3 years based on the audited balance sheet/profit and loss account statement. FINANCIAL YEAR 2000-2001 2001-2002 2002-2003 Average Annual Turn Over during the above three financial years.: Rs._________ NOTE: 1. Copies of audited balance sheets with Profit & Loss account statement for last 3 years shall be submitted along with the offer. 2. Tenderer shall indicate herein his Net Worth details during the following 3 years based on the audited balance sheet/profit and loss account statement on the following basis: Net Worth: FINANCIAL YEAR 2000-2001 2001-2002 2002-2003 Reserve + Capital - Accumulated loss. Capital ( Rs.) Accumulated Loss ( Rs.) NET WORTH (RS) ANNUAL TURNOVER (RS)
Reserve ( Rs.)
(STAMP & SIGNATURE OF BIDDER)
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FORMAT-E
DEVIATIONS SCHEDULE (TECHNICAL)
1. Deviations to tender documents, if any, shall be indicated only in this schedule. 2. Deviations listed elsewhere will be summarily rejected and shall be ignored. 3. Attach more sheets in this format, if required. Sno Cl.No/Page No./Volume No. Description as specified Deviation taken
SIGNATURE OF BIDDER-----------------------NAME DESIGNATION COMPANY SEAL DATE -------------------------------------------------------------------------------
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FORMAT F
DEVIATIONS SCHEDULE (COMMERCIAL)
1. Deviations to tender documents, if any, shall be indicated only in this schedule. 2. Deviations listed elsewhere will be summarily rejected and shall be ignored. 3. Attach more sheets in this format, if required. Sno Cl.No/Page No./Volume No. Description as specified Deviation taken
SIGNATURE OF BIDDER-----------------------NAME DESIGNATION COMPANY SEAL DATE -------------------------------------------------------------------------------
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PART - II
Technical
Content for Part II Swyd
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Table of Contents
PART - II
TECHNICAL
SECTION A SECTION B SECTION C
SCOPE OF WORK TECHNICAL SPECIFICATION FOR ELECTRICAL WORKS TECHNICAL SPECIFICATION STRUCTURAL WORKS PRICE SCHEDULE
FOR
CIVIL &
SECTION D
Content for Part II Swyd
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page: II
SECTION A
Scope of Work
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Table of Contents
1.0.0 2.0.0 3.0.0 4.0.0
SCOPE OF WORK ................................................................................................................ 3 TESTS .................................................................................................................................... 9 DOCUMENTATION ............................................................................................................. 9 LOCAL CONDITION.......................................................................................................... 13
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SECTION-A1 SCOPE OF WORK 1.0.0 1.1.0 1.1.1 SCOPE OF WORK Introduction The site is located in the Tamil Nadu Industrial Development Corporation (TIDCO) lands in Urnemedu Village, Ponneri Taluk, Tiruvallure District that is about 45 km north of chennai and 5 km south of Minjur. The EHV switchyard will be used for receiving power from Grid through two (2) nos. 20 MVA power transformer. Drg no. 20-6104-E-202, Rev. A shows plant switchyard scheme. Work Description Electrical Works The requirement of this contract is to Design, engineering, manufacturing, shop testing, transport to site including transit insurance, unloading at site, erection, testing and commissioning including storage & erection insurance of the following for Chennai Petroleum Corporation Ltd., Manali, Chennai. EHV switchyard shall be supplied and installed complete with all the equipment, accessories etc. and any other equipment to make the switchyard complete. It shall consist of but not limited to ; 1. 2. 3. 4. 5. 6. 7. 8. EHV Circuit breakers EHV Isolators & Earth switches Current Transformers & Capacitor Voltage Transformers. Lightning arresters Control panels Relay panels Tariff metering panel Complete, Power, control and instrumentation cables from switchyard equipment to Contractor supplied panels in control room and cabling between equipment / panels supplied by the Contractor. Bus bar materials, Overhead line conductors, earthing conductors, lightning masts, Bay marshalling kiosks, CT / CVT junction boxes, ACDB, DCDB, insulator assemblies, hardware, clamps and connectors & other miscellaneous items Galvanised steel structures like towers, girders, equipment support structures etc.
FICHTNER India
1.1.2 1.1.3 1.2.0 1.2.1
9.
10.
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11. 12. 13.
Illumination system for switchyard TNEB metering area and control room including lighting panels, poles / masts / towers, fixtures & accessories. Switchyard underground earthing, Equipment Earthing & lightning protection of switchyard and TNEB metering area. Galvanised iron chain wire fence and gate for Switchyard / TNEB metering area, cable tray works in trenches including inserts and support angles, Nickel coated brass cable glands, tinned copper cable lugs etc. 110V DC battery & battery charger system exclusively for switchyard. For the two (2) nos. 20 MVA Power transformer supplied by others termination of ACSR conductor to transformer HV bushing. It is proposed to control the 110 kV switchyard from the RO plant main control room through a SCADA system. The switchyard control panel shall have a common local / remote selector switch per bay. Signals shall be extended by this Contractor to a marshalling panel in the switchyard control room so to repeat the Controls / Alarms / Indications / metering of the 110 kV switchyard to the SCADA system (supplied by others) in the main control room. Controls & protection cables required for the Power transformers. The 6.6 kV side switchboard is supplied & installed by others. 6.6 kV side phase & neutral side CTs required for transformer protection shall be supplied by others. The specification for these CTs shall be provided by this Contractor. REF, standby earth fault & Differential protection relays required for transformer protection shall be supplied by this Contractor. The metering equipment required for the 110 kV line incomer (located within TNEB metering area) will be supplied and installed by TNEB. The terminal steel structure within the TNEB metering area shall be supplied by this contractor and the twin moose conductor shall be terminated to this steel structure. The lightning arrestor, isolators, CTs, PTs and tariff metering panel within the TNEB metering area will be supplied and installed by TNEB. The complete civil work required for the TNEB tariff metering room is in the scope of this contractor. It is the responsibility of the Contractor to obtain all statutory approvals from CEIG / TNEB and other relevant authorities. Miscellaneous items like Danger & other sign boards, rubber mats, sand buckets along with sand, required amount of portable trolley mounted CO2 and DCP extinguishers. Cable & cable carrier system between all equipment supplied by the Contractor shall be included in the scope of supply.
14. 15. 16.
17.
18.
19. 20.
21. 1.2.2
Civil Works The scope of work in this tender covers apart from the work as per the specification and design & drawings, supply of all labour, technical personnel, materials and equipment required for proper completion of the work. Temporary access to the site to be arranged by
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the contractor. It shall also include the other related works although they may not be specifically mentioned in the subsequent clauses and all such incidental items not mentioned of the job as a whole, all as desired and as directed by the owner. The Contractor shall give all notices, pay all taxes, fees, duties etc., that are required for all work including temporary works. Broadly the scope covers the following buildings, structures, facilities and works : 1.2.2.1 Buildings, Structures and Facilities Transformer yard 110 kV Switch yard Towers and other steel structures like lightning mast ,steel cage ladders Cable trenches including precast covers within the switchyard Switchyard Control Room and tariff metering room
1.2.2.2 Details of Work

Topographical survey of the switch yard area. Soil investigation including Soil improvement techniques and determining the type of foundation to be adopted for different structures in the switchyard area. Earthwork excavation and back filling. Transformer foundations including rail track, soak pit, sump pit, jacking pads, firewalls etc. Tower and equipment foundations including piling or stone columns or any other suitable foundations
Fabrication and erection of towers and other steel structures like lightning mast, steel cage ladders, Platforms gratings etc
RCC and brick masonry works Glazed aluminum partitions and Glazed aluminum doors False ceiling and false floor . Suitable water proofing over control room and tariff metering room including roof drainage Fabrication and erection of steel / Aluminium doors, and aluminium glazed windows Filling the oil pits with granite stones Roads in the switch yard area and drainage Fencing around switchyard area and fabrication and erection of main and wicket gates Crushed stone filling Switchyard control room and tariff metering room building will be plinth filling, floor finishes, wall finishes, painting, water supply, drainage ,sanitary works etc,
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1.2.3
Any other civil item of work not specifically covered above but required for completion and proper functioning of the substation shall be deemed to form part of scope.
Spare Parts Special Tools & Tackles For Spare parts, special tools and tackles, refer Clause 44.0 of Part I, Section D Special Conditions of Contract of this Tender Enquiry Document.
1.2.4
Completion In Scope The intention of this specification is to prescribe a complete work which the tenderer shall under take in full compliance with the contract documents. Although every required item of work may not be explicitly described in the specification, bidder shall take every care to ensure to offer all the equipment and accessories to complete the installation except those listed under exclusions below.
1.2.5
Exclusions Power transformers Fire alarm system in the switchyard control room Additional fire fighting system like sprinkler system for transformers, fire hydrant etc. 6.6 kV power cables from transformers to 6.6 kV switchboard.
1.2.6
Terminal Points Following terminal points shall be applicable for the scope of work under this tender. EHV power shall be tapped off from TNEB Melur substation (by others). The contractor shall supply and install the steel structure within the TNEB metering area and terminate the twin moose conductor to this structure (Refer drawing : 10-6104-E-401 (C)). DC supply and ACDB shall have necessary feeders to cater the loads of the power transformers and TNEB tariff metering area (supplied by others). The marshalling panel provided in the switchyard control room for interface to the main control room shall have adequate terminals to take the control cables from the transformers to the Main control room through it. All cabling between power transformer & switchyard control, relay panels shall be carried out by this Contractor. However, cabling between the transformer and the main control room RTCC panel shall be by others. Two (2) nos. LV auxiliary supply (415V, 50 Hz) will be provided by the Owner which will serve as the incomer to Bidder supplied ACDB. Further distribution of AC power supply for the use in the switchyard is in the scope of the vendor. The ACDB shall have an auto changeover switch which shall changeover from one supply to the other in case of under voltage in the first supply. Gantry for terminating conductor at transformer HV bushings (Transformer supplied by purchaser) shall be supplied & installed by this Contractor.
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1.3.0 1.3.1
Design Criteria Current Ratings
1.3.1.1 The switchyard shall be designed for 1250 Amps, continuous current. The switchyard shall be designed for a fault level of 40 kA for 3 secs. 1.3.2 Main and bay bus conductors a) b) The main bus and bay cross over conductors shall be of ACSR conductors of suitable size. The conductor size of stranded conductors shall be based on the maximum load current, suitability under short circuit conditions, corona / voltage gradient and effect of solar radiation. The temperature of the conductor when carrying full load current shall not exceed 85 C with a maximum ambient air temperature of 50 C. Necessary calculations to establish the above shall be furnished during detailed engineering.
c) d) 1.3.3
Design parameters The switchyard shall be designed considering the following design parameters. a. Design voltage level 1. Nominal 2. Highest system voltage 3. Basic impulse levels : : : 110 kV (rms) 123 kV (rms) 550 kV peak 230 kV peak 1250A 40 kA for 3 sec. 100 KAp
4. Power frequency withstand : voltage b. c. d. e. Rated current :
Short time current and duration : Dynamic rating :
Minimum clearances as per CBIP 1. Phase to phase 2. Phase to earth 3. Ground clearance : : : 1100mm 1100mm 4600mm
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4. Section clearance
4000mm 2500mm ACSR
5. Minimum height of earthed : part of live equipment f. g. Conductor Insulator string 1. Type 2. Creepage distance h. : : :
Anti fog type 3800 mm
Maximum design tension at 10C for conductors 1. All bay buses in the switchyard : 1000 kg per conductor Bidder to decide. 1000 kg on Plant structure (max) 2000 kg / sub conductor
2. Interconnection conductors : to plant 3. Line entry i. Bus post insulator 1. Type : :
solid core 800 kg. 3800 mm
2. Ultimate cantilevers strength : 3. Creepage distance 1.3.4 1.3.5 :
The lightning protection of switchyard shall be done by tower peaks & with shield wires provided on switchyard structures and the adequacy of protection shall be checked. The criteria for deciding phase to phase clearance in case of strung conductors shall take into account that the conductor swing of one of the conductors (say R phase ) with maximum wind velocity at maximum sag conditions. The adequacy of the cantilever strength specified shall be checked considering the following : a) b) (Sum of normal loads + wind loads or seismic load) x 2.5. (or) Sum of normal loads + wind loads or seismic load + short circuit force.
1.3.6
whichever is higher 1.3.7 1.3.8 The switchyard shall be designed for the seismic coefficient and wind pressures as applciable for the site condition. The switchyard panels shall have an outer paint shade of RAL-7032.
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1.3.9
The switchyard equipment shall be suitable for tropical humid and dusty environment. The design ambient temperature shall be 50 C. Equipment marshalling / terminal cabinets shall be provided with canopy to prevent entry of rainwater into the cabinet. TESTS Shop Testing All equipment and accessories shall be subjected to routine and acceptance tests as laid down in relevant standards and else where in this specification.
2.0.0 2.1.0
2.2.0
Test Witness Tests shall be performed in presence of Purchaser's representatives, if so desired by the Purchaser. The Purchaser's representatives shall be given full access to all tests. The contractor shall give at least 2 weeks advance notice. Prior to giving test notice, the contractor should have taken full approval of drawings/Technical data etc. and have furnished the particulars of proposed tests and procedures for conducting the tests and obtained Purchaser's approval.
2.3.0 2.4.0 2.5.0
Type test certificates for all tests as required by relevant standards, carried out on identical equipment shall be furnished by contractor immediately after placement of order. If identical equipment as offered has not been type tested, the same shall be performed. There shall be no extra cost/claim on this account at a later date for conducting the test. Test report in six(6) copies shall be submitted for Purchaser's approval, prior to despatch. No despatch shall be made unless written approval of the report is issued and clearance for despatch is given. DOCUMENTATION Drawings For Approval The contractor shall furnish drawings as indicated in technical specification for each item for approval of the Purchaser / Consultant according to agreed time schedule. Contractor shall furnish, if requested, additional drawings, calculations, information to the Consultant/Purchaser to enable him to examine/study the drawings for approval. If incomplete drawings/documents not meeting the Consultant's requirements are sent, the responsibility for any delay in approval shall be that of contractor. The Detailed design shall include, but not limited to .

3.0.0 3.1.0 3.1.1 3.1.2 3.1.3
SLD
Switchyard layout & section drawings

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Cable trench / tray layout in switchyard area & switchyard control room Cable tray arrangement outside switchyard
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Design & GA drawings for steel structures. Sag tension calculation Short circuit force calculations Bus conductor sizing calculation Underground earth mat layout & design calculation Battery & battery charger sizing calculation Lighting layout drawing (indoor & outdoor) with calculations Power & control cable schedule Switchyard control room panel / equipment layout Interconnection drawings GA drawings of all equipment Relay setting calculation Scheme wiring and terminal details of all equipment CT / CVT burden check calculation Lightning protection layout with calculation CT knee point voltage calculations Furnishing of quantities of all electrical items involved in the scope of work. Generation of all data from soil investigation and topographical survey, Evaluation of foundation parameters .preparation and submission of design basis with criteria and information required for approval, for the completion of the switch yard and control room work. Design and analysis of towers and their foundations, equipment supporting structures and their foundations, transformer foundations, cable trenches, buildings etc ,submission of design report with calculations for approval with all necessary documents, catalogues etc. Preparation and submission of all construction drawings (Layout, Architectural and Structural) required for the complete execution of civil works, material selection and material take off. SUFFICIENT DETAILING SHALL BE DONE IN ALL DRAWINGS SO THAT NO DIFFICULTY IS FACED BY SITE ENGINEERS DURING EXECUTION. Furnishing of quantities of all civil items involved like excavation, PCC, RCC, formwork, reinforcement etc. based on approved drawings. Handing over of all the documents in editable format in the compact disc along with a set of hard copies as per section C1.1
3.1.4
Where drawings are returned to the contractor with comments, the contractor shall re-submit the revised drawings for approval.
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3.1.6
If any subsequent alterations are found necessary and approved by the Consultant / Purchaser, all drawings and data affected by such alterations shall be duly revised and re-submitted for the approval as said above without any cost implication. Contractor shall be responsible for correctly incorporating all the points conveyed to him and re-submit the drawings to the Purchaser for final approval. If the contractor is unable to incorporate some of the comments, such non-compliance shall be clearly stated in a forwarding letter with reasons without delay. However, it shall be Purchaser's / his Consultant's discretion to accept or reject the non-compliance.
3.1.8 3.1.9
3.1.10 Work shall be carried out exactly as indicated on the approved drawings and data and no alterations shall be made without the written approval of the Consultant / Purchaser. 3.1.11 Approval of drawings by Purchaser / his Consultant shall not relieve the contractor of his contractual obligations and responsibility for engineering, design, workmanship, materials and performance of the equipment. 3.2.0 3.2.1 As Built Drawings All the drawings/documents supplied by the contractor for Purchaser's comments / approval, if required, shall be revised / modified, after Purchaser / Consultant's approval, to incorporate all the modifications/changes necessitated at various stages of execution of contract viz. During inspection & testing at works and site During erection, commissioning of individual equipment During integrated commissioning of total system Due to changes in associated connecting equipment not supplied by the contractor (based on the information furnished by the Purchaser / Consultant) Contractor shall furnish as-built drawings required for normal operation, maintenance, testing of all equipment in specified number of copies. All the approved drawings, manufacturer's drawings, installation drawings are included in as-built drawing.
3.3.0 3.3.1 3.3.2 3.3.3
Documents and Test Reports Contractor shall furnish any relevant calculations asked for. It shall also contain the manufacturer's catalogues, operation and maintenance manuals etc. Contractor shall furnish bound volumes of copies of factory routine and type test certificates for all equipment. After completion of site testing of all the equipment, contractor shall furnish the site test results of all equipment. This shall also clearly indicate the rectifications carried out during testing in case site test results vary very widely with factory test results. Commissioning engineer's observations shall be clearly indicated against corresponding equipment, identified by manufacturer's serial numbers.
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3.3.4
Contractor shall furnish bound volume indicating list of spares supplied for each equipment. The volume shall contain manufacturer's catalogue number of components with description. It shall also indicate precautions to be taken for storing. Operation, Instruction and Maintenance Manuals / Catalogues Instruction manual shall give step by step procedure for 1. 2. 3. 4. Erection, testing and commissioning Operation Maintenance and Repair
3.4.0
3.4.1
Instruction manual shall also contain: 1. 2. 3. 4. List of spare parts with ordering specification and manufacturer's catalogues List of consumables with specifications, brand names and annual consumption figures. Drawings relevant for erection, operation, maintenance and repair of the equipment. Procedure for ordering spares.
3.4.2
Contractor shall submit the following drawings / data / documents in specified number of copies and reproducible prior to handing over the installation to the Purchaser. All drawings approved by Consultant / Purchaser. Equipment manufacturing drawings submitted for information to Consultant / Purchaser. Equipment drawings required for operation and maintenance . Inspection reports, factory and site test certificates in bounded volume As built drawings incorporating all site modifications. Instruction manuals and catalogues List of spares
3.5.0
Number of Copies The contractor shall submit drawings, documents AS BUILT drawings, instruction manuals etc. as per Clause 45.0 of Part I, Section D, Special Conditions of Contract. Drawing / documents to be submitted for approval shall include. 1. 2. 3. 4. 5. General arrangement & layout drawing Complete technical particulars Foundation plan, loading & fixing details Structural loading diagram. Design & GA drawings for steel structures.
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6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Cable trench sectional details. Type test certificates of all equipment Technical leaflet SLD showing instrument transformer, control switches, protection etc. Sizing calculation for various equipment Erection key diagram Equipment control schematics Bill of material Wiring diagrams & terminal list for all equipment Detailed erection & commissioning procedures O&M manual Routine test, type test, special test certificate Quality assurance plan (QAP) indicating customers hold point.
Drawings & document listed are minimum requirement only. All other necessary write-up, control schemes shall be submitted. Bidder may note that nothing in this specification shall be construed to relieve their responsibility for design, manufacture, testing & performance of switchyard equipment. 4.0.0 LOCAL CONDITION It will be imperative for Bidders to fully inform himself of all local conditions & factors which may have any effect on the execution of the works covered under this document and specification. Purchaser will not entertain any request for clarifications from the Bidders, regarding such local conditions. The Contractor shall obtain and pay for all permits, licences, and statutory approvals from local authorities for completion of work. Original copies of these approvals shall be delivered to the purchaser or his authorised representative and will become property of the purchaser. It must be understood and agreed that such factors have properly been understood and considered while submitting the bid. No claim whatsoever will be entertained by the Purchaser neither any change in the time schedule of the Contract nor any financial adjustments arising thereof shall be permitted by the Purchaser.
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SECTION B
Technical Specification Electrical Works
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B : I
SECTION - B TECHNICAL SPECIFICATION FOR ELECTRICAL WORKS
SECTION B1 SECTION B2 SECTION B3 SECTION B4
TECHNICAL SPECIFICATION LIST OF DRAWINGS TECHNICAL SCHEDULE APPROVED VENDOR
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B : II
SECTION B1
Technical Specification
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B1 : 1
Table of Contents
SECTION B1.1 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0 3.0.0 1.0.0 ANNEX - I ANNEX II SECTION B1.7 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0
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EHV CIRCUIT BREAKERS ........................................................................................... 4 .......................................................................................................................................... 7 EHV ISOLATORS ........................................................................................................... 8 ........................................................................................................................................ 10 EHV CURRENT TRANSFORMERS............................................................................ 12 ........................................................................................................................................ 13 EHV VOLTAGE TRANSFORMERS............................................................................ 15 ........................................................................................................................................ 16 LIGHTNING ARRESTOR............................................................................................. 18 ........................................................................................................................................ 20 EHV SWITCHYARD CONTROL, RELAY PANELS ................................................. 21 SPECIFIC REQUIREMENTS FOR CONTROL & RELAY PANELS........................ 24 SCADA I/O LIST ........................................................................................................... 26 MISCELLANEOUS ITEMS .......................................................................................... 29
EQUIPMENT TO BE SUPPLIED ................................................................................................... 4 TESTS DRAWING, DATA AND MANUALS ........................................................................................... 7 EQUIPMENT TO BE SUPPLIED ................................................................................................... 8 TESTS DRAWINGS, DATA & MANUALS............................................................................................. 11 EQUIPMENT TO BE SUPPLIED ................................................................................................. 12 TESTS DRAWING, DATA AND MANUALS ......................................................................................... 14 EQUIPMENT TO BE SUPPLIED ................................................................................................. 15 TESTS DRAWING, DATA AND MANUALS ......................................................................................... 17 EQUIPMENT TO BE SUPPLIED ................................................................................................. 18 TESTS DRAWING, DATA & MANUALS ............................................................................................... 20 EQUIPMENT TO BE FURNISHED ............................................................................................. 21
SECTION B1.2
SECTION B1.3
SECTION B1.4
SECTION B1.5
SECTION B1.6
EQUIPMENT TO BE SUPPLIED ................................................................................................. 29 CODES & STANDARDS .............................................................................................................. 29 SPECIFIC REQUIREMENTS ....................................................................................................... 29 POWER, CONTROL & INSTRUMENTATION CABLES .......................................... 33 INTENT ........................................................................................................................................ 33 CODES & STANDARDS .............................................................................................................. 33 TECHNICAL REQUIREMENTS.................................................................................................. 33 CABLE DRUM .............................................................................................................................. 34 TESTING........................................................................................................................................ 34 SPECIAL MAINTENANCE TOOLS & TACKLES ..................................................................... 36 FICHTNER India
SECTION B1.8
7.0.0 ANNEX - I
DRAWING, DATA & MANUALS ............................................................................................... 36 SPECIFIED DATA SHEET ........................................................................................... 37 ILLUMINATION SYSTEM .......................................................................................... 39 SCOPE OF THIS TENDER ........................................................................................................... 39 GENERAL REQUIREMENTS...................................................................................................... 39 DESIGN CRITERIA ...................................................................................................................... 39 SPECIFIC REQUIREMENTS ....................................................................................................... 39 LIGHTING PANELS (LPS) .......................................................................................................... 40 TESTS ........................................................................................................................................ 40 GENERAL ELECTRICAL ITEMS ............................................................................... 41 DRAWING, DATA & MANUALS ............................................................................................... 40 SCOPE OF SUPPLY...................................................................................................................... 41 STANDARDS ................................................................................................................................ 41 SPECIFIC REQUIREMENTS ....................................................................................................... 41 EARTHING & LIGHTNING PROTECTION ............................................................... 42 SCOPE OF SUPPLY...................................................................................................................... 42 CODES & STANDARDS .............................................................................................................. 42 TARIFF METERING PANELS ..................................................................................... 44
SECTION B1.9 1.0.0 2.0.0 3.0.0 4.0.0 4.5.0 5.0.0 6.0.0 1.0.0 2.0.0 3.0.0 1.0.0 2.0.0
SECTION B1.10
SECTION B1.11
3.0.0 DESIGN CRITERIA .......................................................................................................................... 42 SECTION B1.12 1.0.0 EQUIPMENT TO BE SUPPLIED ..................................................................................................... 44 2.0.0 TECHNICAL REQUIREMENT ........................................................................................................ 44 3.0.0 TESTS SECTION B1.13 2.0.0 1.0.0 2.0.0 ........................................................................................................................................ 45 BATTERY AND BATTERY CHARGER..................................................................... 46 4.0.0 AFTER AWARD OF CONTRACT FOR APPROVAL .................................................................... 45 1.0.0 INTENT OF SPECIFICATION ......................................................................................................... 46 TECHNICAL REQUIREMENTS.................................................................................................. 46 ERECTION, TESTING AND COMMISSIONING....................................................... 51 GENERAL...................................................................................................................................... 51 PRE-COMMISSIONING AND COMMISSIONING CHECKS ................................................... 54 SECTION B1.14
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SECTION B1.1 EHV CIRCUIT BREAKERS
1.0.0 1.1.0 1.2.0
EQUIPMENT TO BE SUPPLIED 110 kV 1250 Amp, 40 kA for 3 sec, SF6 puffer type circuit breaker shall be provided. Specific requirement a) Tie beams between foundations of breakers of different phases are recommended, since additional load in the form of vibration may be transferred to the foundations during closing / opening operation. Design of circuit breaker shall be such that contacts shall not close automatically upon loss of gas/air pressure. SF6 breakers shall be provided with temperature compensated SF6 density switch with separate trip, alarm and blocking contacts. D.C circuits for two trip coils shall be separate and each of them shall be monitored. Manually operated energy tripping push button or any other device conveniently located for mechanical tripping of all the three phases simultaneously shall be provided. SF6 topping up kit along with SF6 bottles having at least 10% capacity of the Total SF6 gas in 5 nos. SF6 breakers.
b) c) d) e)
f) 1.3.0
Technical Requirements The circuit breakers shall comply with requirements in the following table :
-----------------------------------------------------------------------------------------------------------------------Sl.No Description Requirements -----------------------------------------------------------------------------------------------------------------------1. 2. 3. 4. 5. Quantity Type Execution of poles Nominal / highest system voltage Rated current 5 nos. (As per SLD) SF6 outdoor 3 nos. single pole, gang operated with trip free mechanism. 110 kV / 123 kV 1250 Amps
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-----------------------------------------------------------------------------------------------------------------------Sl.No Description Requirements -----------------------------------------------------------------------------------------------------------------------6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Short circuit breaking current & duration Making current Operating duty First pole clear factor Impulse with stand voltage One minute power frequency withstand voltage Line charging current breaking Cable charging current breaking Small inductive current breaking Over voltage factor while switching off above current Type of operating mechanism Operating mechanism to be suitable Control voltage No. of trip coils per pole No.of aux. contacts Environment at the location of installation Reference ambient temperature SF6 gas filling plant Gas evacuation & filling unit 40 kA for 3 sec. 100 kAp O - 0.3 sec CO - 3 min - CO 1.3 550 KVp 230 kV (rms) As per IEC-56 As per IEC-56 To switch the associated transformers magnetising currents. Not more than 2.3 p.u. Stand alone pneumatic mechanism 3 phase 415 / 1 phase 240V operation 110V DC, +10%, -15% 2 nos. 10 NO+10NC (min) Heavily polluted saline and dusty 50C Required no. of gas cylinder to be provided required
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-----------------------------------------------------------------------------------------------------------------------Sl.No Description Requirements -----------------------------------------------------------------------------------------------------------------------25. 26. 27. Gas reprocessing &filling unit Cantilever strength Creepage distance a) b) 28. 29. 30. for support insulator for interrupt insulator 3800 mm 3800 mm 60 m.sec 100.m.sec Control cubicle Outdoor, weather & vermin proof, sheet steel (3mm thick)clad with hinged type front door with locking device, housing operating mechanism, other controls / selection such as local-remote selector switch, close-normal-trip control switch, thermostat controlled space heater with ON-OFF switch, all aux. contacts wired up to terminal block with 20% spare terminals shall be provided. Support structures Hot dip galvanised supporting steel structures specifically designed for breaker mounting shall be supplied. Each equipment shall be provided with 2 Nos. grounding pad with 2 Nos M10 bolts. not required 800 Kg
Total break time (max) Total make time(max)
31
32. 33. 33.1 33.2 33.3 33.4 33.5 33.6
Earthing pads Applicable Standards Circuit breakers Insulators Large hollow porcelain Clamps and connectors Hop dip galvanising Spec. and acceptance sulphur hexafluride (SF6)
IEC-56 IS:2544 IS:5621 IS:617 IS:2629 & IS:2633 IEC:376
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2.0.0 2.1.0 2.1.1 2.1.2
TESTS Shop testing. Each circuit breaker and accessories shall be subjected to routine tests as laid down in relevant standard. Each circuit breaker along with base frame and operating mechanism shall be completely assembled and checked at manufacturer's works for correct alignment and operation before despatch. DRAWING, DATA AND MANUALS Along with the Bid Following drawings, data and details shall be furnished with the bid: a. b. c. d. e. General arrangement drawings of circuit breaker showing constructional feature and also disposition of various fittings. Completely filled in sheets of Technical schedules. Technical leaflets on EHV circuit breakers offered explaining the function of various parts, principle of operation and special features. Type test report and typical routine test report of identical circuit breakers as offered in bid. A list of manufacturing and supply record of identical circuit breaker as offered.
3.0.0 3.1.0 3.1.1
3.2.0
After award of contract The contractor shall submit four (4) copies of the following drawings / data for Purchaser's approval : a. b. c. d. e. f. g. i. General arrangement drawing. Transport dimension with weight The foundation and anchor bolt details for all equipment including dead load and impact load with direction. Drawing and data sheets for each piece of equipment. Complete control schematics and electrical inter-connecting diagrams. Assembly drawing for erection at site with part numbers and schedule of materials. Maintenance manual for individual equipment Any other relevant data, drawings and information necessary for review of the equipment and also erection, operation and maintenance.
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SECTION B1.2 EHV ISOLATORS
1.0.0 1.1.0 1.2.0 1.2.1 1.2.2 1.2.3
EQUIPMENT TO BE SUPPLIED 110 kV, 1250 A, 40 kA for 1 sec. double break, horizontal upright mounted AC motor driven isolators and earth switches as shown in the main one line diagram. Specific requirements The isolators shall comply with the requirements specified here in under. Isolators shall be of the double break type suitable for horizontal upright type of mounting. Main blades of the isolators shall be 415v, 3ph AC., motor operated. However, it shall also be possible to operate them manually in the event of failure of power supply / on outage of the driver motor. The earth blades shall be manually operated type. Tripping of drive, loss of AC drive supply and DC control supply shall be detected for giving alarm. Isolators shall be electrically interlocked with the circuit breakers in accordance with the switchyard safety interlocking scheme. Necessary special accessories such as castell keys and / or solenoid interlocking required on the isolator side for satisfactory operation of scheme shall be included. For earthswitch manual operation, Provision for connecting external interlocks in the solenoid circuit shall also be provided. The design of the auxiliary switches for the isolators shall be such that signalling of the closed position shall not take place unless the contact system has reached such a position that the rated current and the rated short time current can be carried safely: signalling of the open position shall not take place unless the contact system has reached a position of atleast 80% of the clearance distance of the isolating distance. For Bus selection isolators, required number of early make and Late break auxiliary contacts shall be provided for busbar protection CT switching. The EHV isolators shall be gang operated. Technical Requirements The isolators shall comply with the requirements indicated below.
1.2.4
1.2.5
1.2.6 1.2.7 1.3.0
1.0 1.1 1.2 1.3 1.4
Rating Application Quantity Nominal / highest system voltage Frequency Outdoor As per SLD 110 kV / 145 kV 50Hz
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1.5 1.6 1.7
No. of phases Rated current for site conditions Short time current a) Rating and duration
3 1250 A
40 kA for 3 secs. 100 kAp
1.8 2.0 2.1 2.2 2.3 2.4
Rated peak short circuit circuit current (peak) Design Requirements Ambient temperature Insulation level Type Type of mounting Pad locking arrangement
50C 550 kV (peak) Double break Horizontal upright. To be provided in both open & close position Motor driven / manual Manual Silver plated copper
2.5
Operating device a) b) For isolator For earth switch
2.6 3.0 3.1 3.2
Type & material of contacts for isolators & earth switches Insulator Data Rated voltage Creepage distance Type
110 kV 3800 mm Solid core 800 Kg 230 kV rms 550 kVp
3.3 3.4 3.5
Minimum cantilever strength One minute p.f. withstand voltage Impulse withstand voltage
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4.0 4.1
Miscellaneous Aux. supply a) Electrical 110 V DC (+10%, - 15%) for control and interlock ; 3 Ph, 415V / 1 Ph 230V AC for motor drive Necessary, to be provided 8NO+8NC for isolators (Necessary no. of Early make & Late break auxiliary contacts for bus selection isolators to be provided) 4NO+4NC for earth switch
4.2
a) b)
Interlock with circuit breaker Minimum no. of NO&NC aux. contacts
4.3
Mechanism box Operating mechanism box with all accessories such as local remote selector switch, openclose push button, openclose indicators, reversible starter with O/L relay, single phasing preventer, motor, fuses, aux. contactors etc. shall be housed in a weather- proof box made of sheet steel (thickness not less than 2 mm), thermostat controlled space heater with ON / OFF switch shall be provided.
4.4 4.5 4.6
Supporting structures Earth pads Applicable Standards a) b) Insulators Isolators
Hot dip galvanised lattice type Each equipment shall be provided with 2nos. grounding pads with 2nos M10 bolts.
IS : 2544 IS : 9921 / IEC : 1128
2.0.0 2.1.0 2.1.1 2.1.2
TESTS Shop testing Each isolators and accessories shall be subjected to routine and acceptance tests as laid down in relevant standard. Each isolators along with its base frame and operating mechanism shall be completely assembled and checked at manufacturers works for correct alignment and operation before despatch.
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3.0.0 3.1.0 3.1.1 3.1.2
DRAWINGS, DATA & MANUALS Drawings, Data & Manuals The following drawings and data shall be furnished with the bid. General arrangement drawings of various types of isolators showing constructional feature and disposition of various components and space requirement, phase to phase and phase to earth / earth structure clearance during operation/travel of the moving contact. Completely filled up Technical schedules Technical literature of the switch. Type test report of identical switch. List of supplies and operation record of identical switch. After award of contract, the drawings shall be submitted for approval and record in requisite numbers. The various drawings & data to be furnished shall include:Drawing mentioned in clause 3.1.2 Foundation and anchor bolt details for all the equipment including dead load and impact load with direction.
3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9
3.1.10 Transport dimensions with weight. 3.1.11 Assembly drawing for erection at site with part numbers and schedule of materials. 3.1.12 Control schematic for the disconnecting switch & earth switch. 3.1.13 Any relevant data, drawing and information necessary for review / understanding, though approval of the drawings might not have been specifically mentioned. 3.1.14 Any other relevant drawings and data necessary for erection, operation and maintenance. 3.1.15 Instruction manual & data sheets.
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SECTION B1.3 EHV CURRENT TRANSFORMERS
1.0.0 1.1.0 1.2.0
EQUIPMENT TO BE SUPPLIED Design manufacture, shop testing, packing transporting and delivery at site of 110 kV oil filled hermetically sealed single phase current transformers of current ratios specified below. The rated burden for the metering and 5P20 cores is indicated in the SLD. The same shall be verified considering all the loads, relays connected, future addition & lead burden. Accuracy class shall be as per SLD. The knee point voltage for PS class cores shall be decided considering all the loads / relays connected, including future addition & lead burden as recommended by relay manufacturer. Technical Requirements The current transformers shall comply with requirements mentioned below. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Quantity Type Nominal system voltage & frequency Highest system voltage No. of cores Ratio Short time thermal rating Dynamic rating Class of insulation : : : : : : : : : As per SLD Outdoor, oil filled hermetically sealed Live tank. 110 kV, 50Hz 123 kV As per SLD As per SLD 40 kA for 3 secs. 100 kA Oil immersed class A 40 C 800 kg
1.3.0 1.4.0
Maximum temp. rise of winding : above ambient of 50 C Cantilever strength of CT at the terminal :
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12. 13. 14. 15. 16.
1.2/50 mic. sec impulse voltage 1minute power frequency withstand voltage creepage distance Oil level gauge, filling & drain plugs Secondary terminal box
: : : : :
550 kVp 230 kV rms 3800 mm To be provided Weather-proof, sheet steel clad (3mm thick) with shorting type terminals (Tariff metering core shall be brought to a lockable separate terminal box). Separate terminal box for individual CT core for tariff metering To be provided.(except for tariff metering) 2nos to be provided with M10 bolts
a) for individual CT core b) common for all CT secondaries 17. 18. 18.1. 18.2. 18.3. 18.4. 18.5. 18.6. 2.0.0 2.1.0 2.1.1 TESTS Shop Testing Grounding pads Applicable standards Current transformers Bushings Large hollow porcelains Insulator Insulating oil Hot dip galvanising
: : : : : : : : : :
IS:2705 IS:2099 IS:5621 IS:2544 IS:335 IS:2633& IS:2629
Each current transformer and accessories shall be subjected to routine & acceptance tests as laid down in relevant standard :
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3.0.0 3.1.0 3.1.1
DRAWING, DATA AND MANUALS Along with the bid General arrangement drawings of each piece of equipment showing constructional features and disposition of various components and accessories. The drawing shall also indicate the space requirement, phase and phase to ground / grounded structure clearances. Guaranteed technical particulars of the equipment being offered. Type test reports of identical equipment. List of supplies and operation record of identical equipment as offered. After award of contract :All the drawings listed above and guaranteed technical particulars. Complete magnetisation curves of the CTs showing the knee point voltage. Transport dimensions with weight. Foundation and anchor bolt details for all the equipment including dead load & impact load with direction. Assembly drawing for erection at site with part numbers and schedule of materials. Instruction manuals.
3.1.2 3.1.3 3.1.4 3.2.0 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6
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SECTION B1.4 EHV VOLTAGE TRANSFORMERS 1.0.0 1.1.0 EQUIPMENT TO BE SUPPLIED 110 kV class capacitive voltage transformers shall be provided for the EHV line bays and Electro-magnetic voltage transformer shall be provided for EHV buses as shown in main one line diagram. Specific requirements a) Means shall be provided in each secondary output leads of each EMVT to protect the VT secondary branch circuit from the abnormal voltage surges that may occur on the primary side. The secondary shall also include suitable number of links for each secondary as per the requirement of fuse failure detection relays. The burden of the EMVTs shall be adequate for the loads connected and shall also consider future bay in the case of bus VTs.
1.2.0
b) 1.3.0
Technical Requirements: The Capacitor voltage transformers / Electro-magnetic shall comply with the requirements indicated below : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Quantity Application : : As per SLD Outdoor 110/123kV 50 Hz Effectively earthed < 0.8 110000 / 3 110/3 As per SLD Metering / protection As per SLD As per SLD As per SLD 1.2continuous & 1.5 for 30 secs.
Normal/Highest system voltage : Power frequency System neutral earthing type Coefficient of earthing Rated primary voltage Rated secondary voltage No. of secondary windings Application Rated burden Rated power factor Accuracy class Rated voltage factor : : : : : : : : : : :
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15. 16. 17. 18. 19. 20. 21. 22.
Class of winding insulation Max. winding temp. at rated Creepage distance Rated capacitance High frequency range 1.2/50 micro sec. impulse voltage One minute power frequency withstand voltage Secondary terminal box
Oil immersed class-A
: As per table -II of IEC- 186 burden considering design ambient of 50 C : : : : : : 3800 mm By BIDDER 50-200 Hz 550 KVp 230 kV rms Weather proof box, sheet steel clad (Min. 2mm thick) complete with fuse/ MCB, terminals & wiring for neutral shorting and earthing shall be provided. 2 nos shall be provided with M10 bolts.
23. 24.
Grounding pads Applicable standards 1. Voltage transformers
IS :3156 IS:9348,IEC:358 IS:3156 part IV, IEC:186 IS: 2099 IS:5621 : IS: 2544 IS:2544 IS:2629 & IS:2633
2. Coupling capacitors & capacitor : 3. Capacitor voltage Transformer : 4. Bushings 5. Large hollow porcelains 6. Insulators 7. Hot dip galvanising 2.0.0 2.1.0 2.1.1 TESTS Shop Testing : : : :
Each VT and accessories shall be subjected to routine and acceptance tests as laid down in relevant standard.
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3.0.0 3.1.0 3.1.1
DRAWING, DATA AND MANUALS Along With the Bid General arrangement drawings of each piece of equipment showing constructional features and disposition of various components and accessories. The drawing shall also indicate the space requirement, phase to phase and phase to earth / earth structure clearances. Guaranteed technical particulars of the equipment being offered. Type test reports of identical equipment. List of supplies and operation record of identical equipment as offered. After Award of Contract All the drawings listed above and guaranteed technical particulars. Transport dimensions with weight. Foundation and anchor bolt details for all the equipment including dead load & impact load with direction. Assembly drawing for erection at site with part numbers and schedule of materials. Instruction manuals.
3.1.2 3.1.3 3.1.4 3.2.0 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5
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SECTION B1.5 LIGHTNING ARRESTOR 1.0.0 1.1.0 1.2.0 EQUIPMENT TO BE SUPPLIED 96 kV 10kA nominal discharge current, discharge class-3, metal oxide gapless lightning arresters shall be provided as per the enclosed SLD. Specific Requirements a) b) Arrester shall be suitable for installation in effectively earthed system. Surge monitor shall be provided for each arrester and the same shall be mounted at eye level height to facilitate easy reading of the counter mechanism and leakage current detectors. The arrester shall be mounted on an insulating base. Insulated copper conductor of adequate size and length shall be used for connecting discharge counter terminal and lightning arrester earth terminal. Insulation level of the same shall not be less than 5kV. Suitably sized bypass copper shunts shall be provided for bypassing the discharge counter for removal/maintenance of the counter.
c) d)
e) 1.3.0
Technical Requirements The lightning arrester shall comply with the particulars indicated hereunder. 1.0 1.1 1.2 1.3 General Quantity Installation System voltage a) Nominal b) Highest 1.4 1.5 1.6 Type of earthing Type of arrester Ratings i) ii) Rated arrester voltage / : continuous operating voltage Rated frequency : 96 kV 50 Hz : : : : 110 kV 123 kV Effectively earthed Gapless : : As per SLD Outdoor
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iii)
Nominal discharge current of 8/20 micro second wave shape
10 kA
1. 7
Performance Data Impulse current with stand a) b) Low current long duration discharge : : Class-3 65 kA Class-3 200 micro. sec Class-3
High current short duration test : value (4/10 mic.s.wave) Low current long duration test value Virtual duration of rectangular wave Line discharge class (as per IEC TC 37 WG-4 1985) : : :
c) d) e)
1.8
Arrester Housing Withstand test Voltages a) b) One minute power frequency dry & wet 1.2/50 micro second impulse
: : : : : 230 kV rms 550 kVp 3800 mm
1.9 1.4.0 1.4.1 1.4.2 1.4.3 1.4.4
Creepage distance
Additional Requirements Minimum cantilever strength of arrester assembly Pressure relief class (as per IEC 99) Minimum prospective symmetrical fault current (as per IEC 99) Accessories required a) b) Discharge counter Grading rings : : 800 Kg 40 kA
: : :
40 kA Yes Yes
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c) d) 1.5.0 1.5.1 1.5.2 1.5.3 2.0.0 2.1.0 2.1.1 3.0.0 3.1.0 3.1.1
Leakage current detector Insulating base
: :
Yes Yes
Applicable Standards Lightning arrestor for alternating current systems Insulators Large hollow porcelain insulators TESTS Shop Testing Each lightning arrestor and accessories shall be subjected to routine and acceptance tests as laid down in relevant standard. DRAWING, DATA & MANUALS Along with the bid General arrangement drawings of each piece of equipment showing constructional features and disposition of various components and accessories. The drawing shall indicate also the space requirement, phase to phase and phase to earth/earth structure clearances. Discharge characteristic of lightning arrestors. Guaranteed technical particulars of the equipment being offered. Type test reports of identical equipment. List of supplies and operation record of identical equipment as offered. After award of contract All the drawings listed above and guaranteed technical particulars. Transport dimension with weight. Foundation and anchor bolt details for all the equipment including dead load & impact load with direction. Assembly drawing for erection at site with part numbers and schedule of materials. Instruction manuals. : : : IS : 3070, IEC-99 IS : 2544 IS : 5621
3.1.2 3.1.3 3.1.4 3.1.5 3.2.0 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5
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SECTION B1.6 EHV SWITCHYARD CONTROL, RELAY PANELS
1.0.0
EQUIPMENT TO BE FURNISHED a. b. c. d. EHV control panel. EHV relay panel as per specification referred to herein under. Tariff metering panel Synchronising panel
1.1.0 1.1.1
Control Panels Control panel housing various controls, metering, indication, annunciation, synchronising, mimic diagram etc. shall be supplied. The control panel shall be located in the switchyard control room. The switchyard control and interlocking shall be a hard wired system. Supplier shall furnish the block interlock diagrams for the switchyard for approval. The scheme as approved by Purchaser shall be provided. All auxiliary relays, timers, switches, hardware, etc. required for the scheme are deemed to be included by the Supplier. Control and indication shall be provided for each of the breaker and isolator. Discrepancy type control switch shall be used for the control. Each bay shall have a common local / remote selector switch. It shall be possible to control the switchyard from main control room DCS system (by others) when remote is selected. The abnormal conditions of each circuit breaker, alarm & trip condition of each protective relay DC supply failures, abnormal condition of each isolator like drive overload, AC & DC supply failure for a group of two isolators shall be annunciated. For all bays, mimic with discrepancy type control switches for breakers and isolators, semaphores for earth switches, meters & annunciation shall be provided. In the event of shortage of contacts in circuit breakers, isolators, earth switch, contact multiplying relays shall be used. The same shall be two coil, latching, electrically reset type. Specific requirements The specific requirements for the control panels components shall be as per Annex - I.
1.1.2 1.1.3
1.1.4
1.1.5
1.1.6 1.1.7 1.1.8
1.1.9
Schedule of Equipment - EHV Control Panel The equipment shown in SLD shall be provided as a minimum. Other standard equipment and wiring as required shall also be provided.
P2Sec B1-Swyd
FICHTNER India
1.2.0 1.2.1
EHV Switchyard relay panels Equipment to be furnished All the protective relays, auxiliary relays, timers, interposing CT, PT etc. as required for the functioning of the scheme shall be provided in simplex type of relay panels. Main equipment protection shall be with numerical relays.
1.2.2 1.2.3
The protections envisaged for shall be as shown in EHV single line diagram drawing No. 10-6104-E-202. The functional requirements and characteristics of the relays shall be so selected to suit the requirement. Any additional protection considered necessary by the Supplier shall also be provided. All hard ware, auxiliary relays, timers etc. required for tripping/interlocking scheme shall be provided by the Supplier. DC circuit for Main-1 & Main-2 protections shall be separate and each of them shall be monitored. Separate master trip relays shall be provided for Main-1 & Main-2 protections. Supervision relays for the same shall also be provided for Alarm / SCADA system. The line protection shown in the single line diagram is preliminary. It is the responsibility of the Contractor to liase with the SEB authorities and finalise the requirement of the 110 kV line protection. Certain specific requirements / notes on control and relay panel are detailed in Annex - I at the end of this section. Necessary equipment and wiring shall be provided by the Supplier. Additional Requirements The following shall be provided in the SCADA for monitoring : a) b) Alarm points from protection relays, (individual alarm points for each protection operation shall be provided) lockout relays, supervision relays & auxiliary relays. Status points of switchyard equipments (CB, Isolators & Earth switches), Selector switches (Local / Remote, Busbar protection In / Out, Synchronisation In / out etc.) Analog Points :
1.2.4 1.2.5 1.2.6 1.2.7
1.3.0 1.4.0 1.4.1
c)
Necessary number of transducers shall be provided in the switchyard control panel for Analog outputs to SCADA system (Voltage, Current, kW, kVAR for lines ; current kW, kVAR, kWH, kVARH and voltage & frequency for main buses). 1.4.2 Adequate spare contacts shall be provided for the trip relays and auxiliary relays and the same shall be wired to the terminal block. All spare contacts of the protective relays shall also be wired to the terminal block.
P2Sec B1-Swyd
FICHTNER India
CONTROL PHILOSOPHY Conventional hard-wired control panels with necessary controls, meters, annunciators, mimic etc. shall be provided for each bay in the switchyard control room. Control of the entire switchyard shall be carried out from these control panels. All necessary status signals, alarms, measurements, mimic shall be made available in the SCADA for monitoring / control of the 110 kV switchyard when remote is selected in the switchyard control panel. All necessary transducers and contacts, auxiliary relays required for this purpose shall be provided by this Contractor. 1.5.0 Data to be furnished with the bid i) ii) iii) iv) v) 1.6.0 Descriptive literature/pamphlets on each relay, auxiliary relay, Meters, Transducers, ICTs, IVTs, etc. Main one line diagram, diagram showing VTs, CTs connected meters, relays, with parameters of equipment. Typical calculation for CT/VT parameter selection. Detailed write-up on protection system offered. Detailed block logic diagram for interlocking / control of switchyard equipment.
After Award of Contract, for Approval i. ii. iii. iv. v. vi. vii. Design calculation for CT/PT sizing. Main one line diagram showing CT,PT,& other equipment. General arrangement drawing for Control, Relay, Metering & RTCC panels showing dimensional details, panel fixing arrangements etc. Control schematics for the complete switchyard Relay setting calculations Terminal plan & interconnection details. Cable schedule.
P2Sec B1-Swyd
FICHTNER India
ANNEX - I SPECIFIC REQUIREMENTS FOR CONTROL & RELAY PANELS a) The Control & Relay panels shall be of simplex type, floor mounted, free standing. The panels shall have a degree of protection not less than IP-42 and shall be fabricated with sheet steel thickness 2.5 mm for equipment bearing surface and 2 mm for sides, rear and bottom portions. The panels shall be provided with anti-vibration pads. The pre-treatment of the sheet steel shall involve degreasing, rust/scale removal, phosphating and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer followed by two coats of synthetic enamel paint. The final finished thickness of paint film on steel shall be about 100 microns. All the equipment on the front of panel shall be flush mounted. The centre line of switches, push buttons and indicating lamps shall be not less than 750mm from bottom of the panel. Centre lines of relays, meters and recorders shall not be less than 450mm from the bottom of the panel. Control switches/push buttons/selector switches and relay resetting knobs shall be located at a height not less than 1.2m from the bottom of the panel. No auxiliary relay shall be mounted on front of the control panel. They shall be mounted either internally or in the respective relay panel. Mimic diagrams of size not less than 8mm in width shall be provided on the control panel. The colour of the mimic shall be as per relevant standards. The annunciators of visual and audible type shall be provided on the control panel . The annunciation systems shall be suitable to accept fleeting faults of 15 m. sec duration. All the wiring shall be carried out with 650V grade, stranded copper conductor wires with PVC insulation. For CT/PT circuits the wires size shall be 2.5sq.mm/lead and other circuits it shall be 1.5sq.mm/lead. All wiring meant for power supply to transducers, recorders shall be suitably fused or designed to limit short circuit current. Means for detection of blown or open circuited fuses shall be provided. Terminal blocks shall be 650V grade,10amps rated, stud type terminals with terminal marking. The insulation between any two terminals and terminal to frame work shall withstand 2kV rms for one minute. Terminal blocks for CT&VT secondary leads shall be disconnecting / stud type. CT secondary leads shall also be provided with short circuiting and earthing facility. A clearance of 250mm shall be maintained between terminal blocks and gland plate and 150mm between two rows of terminal blocks. At least 20% spare terminals shall be provided. The tariff meters (export & import) in each line feeder shall be 0.2 accuracy and of digital type acceptable to SEB. The KWhr & trivector meters shall be provided with suitable pulse transmitting contacts for interfacing the same with power management system at a later date. The tariff meters shall be mounted in separate panels. All indicating lamps shall be provided with suitably rated series resistors and shall be LED type.
FICHTNER India
b)
c) d)
e) f) g) h)
i)
j)
k)
P2Sec B1-Swyd
l)
All the push buttons shall be of momentary contact type, the colour of PBs for various function will be decided later. Push buttons shall be suitably shrouded to prevent inadvertent operation. All PBs shall have 2NO+2NC contacts. Each control & relay panel shall be provided with necessary arrangement for receiving, distributing, isolating and fusing of D.C and A.C supplies for various control, signaling, lighting and space heater circuits. If miniature circuit breakers (MCBs) are used in VT secondary circuits, they shall have adequate auxiliary contacts for blocking trip circuits of voltage dependent protection and annunciation. Where high speed protection are involved, the speed of operation of MCB shall be less than 5 milliseconds. All the panels shall be equipped with a continuous earth bus with connectors and clamps between panels for interpanel connection of the earth bus. All the metallic cases of relays, Instruments and other panel mounted equipments shall be connected to the earth bus by 2.5sq.mm copper wires. CT and PT secondary neutral or common lead shall be earthed at one point only at the terminal block and such earthing shall be made through links. Separate copper earthing flat shall be provided in the panel for cable screens of static equipment. TESTS Control & relay panels shall be subjected to the following tests : a) b) c) d) e) f) Mechanical operation test. High voltage test (2000V for 1 minute) Megger test Verification of wiring as per approved drawings. Electrical control, interlock and sequential operation tests. All routine tests shall be carried out on all associated component equipments as per relevant standards and test certificates shall be furnished.
m)
n)
o)
p)
Acceptance Tests: a) b) The equipment shall be demonstrated for proper operation, including operation of meters, alarms & indications. Certified copies of all type and routine test certificates shall be submitted for the Purchaser's approval before despatching the control/relay panel.
P2Sec B1-Swyd
FICHTNER India
ANNEX II SCADA I/O LIST The following are the minimum requirement of DCS Digital & Analog input / output per equipment / feeder. 1.0 1.1 Digital Inputs 110 kV CB (Typical for lines, transformers & B/C feeders) CB status Open & close CB operating mechanism trouble CB SF6 Gas pressure low (alarm) CB SF6 gas pressure very low (lock-out) CB L/R selector switch on Local 1.2 110 kV Isolators / Earth switches (Typical for lines, transformers, B/C & Bus PT feeders) Isolator status Open & close Isolator operating mechanism fail (Grouped alarm per feeder) Isolator L/R selector switch on Local (Grouped alarm per feeder) Earth switch status Open & Close 1.3 Line relay panel (Typical) IDMT over current protection operated IDMT earth fault protection operated Local breaker back-up (50 LBB) operated Over voltage protection operated Under voltage relay operated Line VT fuse failure relay operated Line relay panel DC fail Line protection relay fail Line lockout relay operated Line lockout relay supervision operated Line CB trip circuit-1 supervision operated Line CB trip circuit-2 supervision operated 1.4 Transformer Relay Panel (Typical) Transformer differential protection operated Transformer instantaneous over current protection operated Transformer IDMT overcurrent protection operated Transformer instantaneous earth fault protection operated Local breaker back-up (50 LBB) operated Transformer LV REF (64R) operated Transformer overfluxing relay (61) operated Transformer neutral over current (51N) operated Transformer buchholz alarm operated Transformer winding temperature high alarm Transformer oil temperature high alarm Transformer OLTC surge relay alarm
P2Sec B1-Swyd
FICHTNER India
Transformer buchholz trip operated Transformer winding temperature trip operated Transformer oil temperature trip operated Transformer PRD trip operated Transformer OLTC surge relay trip operated Transformer relay panel DC-1 fail Transformer relay panel DC-2 fail Transformer main-1 protection relay fail Transformer main-2 protection relay fail Transformer main-1 lockout relay operated Transformer main-2 lockout relay operated Transformer main-1 lockout relay supervision operated Transformer main-2 lockout relay supervision operated Transformer CB trip circuit-1 supervision operated Transformer CB trip circuit-2 supervision operated 1.5 Bus- Tie Relay Panel (Typical) Local breaker back-up (50 LBB) operated Bus tie relay panel DC fail Bus tie lockout relay operated Bus tie lock-out relay supervision operated Bus tie CB trip circuit-1 supervision operated Bus tie CB trip circuit-2 supervision operated Bus PT fuse failure relay operated Bus under voltage relay operated 1.6 Busbar Protection Relay Panel (Typical) Bus zone-1 (Main bus) busbar protection operated Bus zone-2 (Transformer bus) busbar protection operated Bus check zone busbar protection operated Busbar protection lockout relay operated (for each feeder) Busbar protection lockout relay supervision operated (for each feeder) Busbar protection CTs supervision operated Busbar protection relay panel DC-1 fail Busbar protection relay panel DC-2 fail 1.7 Control panel (Typical for Lines, Transformer, Bus tie & Bus PT / ES) Control panel DC-1 fail Control panel DC-2 fail DCS / control panel selector switch on Control panel Synchronising selector switch ON Annunciator DC supply fail Annunciator AC supply fail Synchronising permissive ON RTCC Panel (Typical) By others OLTC L/R selector switch on Local RTCC panel DC fail Tap position upper limit reached Tap position lower limit reached
FICHTNER India
1.8
P2Sec B1-Swyd
1.9
110V DC system 110V DC battery charger-1 fail 110V DC battery charger-2 fail Charger-1 on boost mode Charger-2 on boost mode DC system on back-up power supply Battery voltage low Charger input power supply fail Tariff metering panel (Main & Check) Tariff metering panel DC fail TVM fail Fuse failure relay operated
1.10
2.0
Digital outputs / Control outputs Close / Open operation of all 110 kV CBs Close / Open operation of all 110 kV Isolators Tap position Raise / Lower (By others)
3.0 3.1
Analog Inputs Lines (Typical) Voltage Current kW kVAr kWH kVArH Transformer (Typical) Current kW kVAr kWH kVArH Tap position (by others) Bus Tie / Bus PT Bus-1 voltage Bus-1 frequency Bus-2 voltage Bus-2 frequency
3.2
3.3
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FICHTNER India
SECTION B1.7 MISCELLANEOUS ITEMS
1.0.0 1.1.0
EQUIPMENT TO BE SUPPLIED Bay marshalling kiosks, CT / CVT / EMVT junction boxes, ACDB, DCDB, Lighting panels, Bus post insulators, insulator strings with fitting, hardware, connectors, clamps, ACSR conductors, tubular Aluminium buses as required for the entire switchyard shall be provided. CODES & STANDARDS All the equipment, accessories and materials shall conform to latest revision of relevant IEC & IS standards.
2.0.0
3.0.0 3.1.0 3.1.1
SPECIFIC REQUIREMENTS Bay Marshalling Kiosk (BMK) The BMK shall be outdoor free standing type, dust & vermin proof conforming to IP 55, made of sheet steel (2 mm thick). Terminal blocks with removable acrylic glass cover shall be arranged / segregated voltage wise / equipment wise. Required number of cubicle lamps with door switch, space heaters with thermostat & ON/OFF switch, Power socket and fuses / MCBs. shall be provided inside the BMK. Gaskets shall be used for doors, & gland plates. For each switchyard bay, One bay marshalling kiosk shall be provided. It shall be used for a) Distributing auxiliary AC / DC power supply to circuit breakers isolators with required number of MCBs / Fuses. (AC / DC power supply for circuit breakers & isolators shall be from separate feeders. Bringing all auxiliary contacts of circuit breakers, isolators & earth switches. Required number of auxiliary contacts shall be taken to switchyard control & relay panels for contact multiplication, interlocking, indication, CT switching etc. Any other contacts from circuit breakers, isolators & earth switch operating mechanisms shall also be brought to the BMK for further routing it for alarm / control circuits.
3.1.2 3.1.3 3.1.4
b)
3.2.0 3.2.1
CT / EMVT Junction Box The junction box shall be of outdoor type, conforming to IP 55 and shall be mounted on the Y of CT / EMVT structure.
P2Sec B1-Swyd
FICHTNER India
3.2.2
The junction box shall be used for bringing all the taps of individual cores of CT / EMVTs to the junction box for forming the neutral wonder to enable taking four (4 ) core cables to control & relay panels. ACDB / LDBs The substation service loads shall be supplied through an AC distribution board (ACDB), sheet steel clad (2mm thick), free standing, floor mounting, dust & vermin proof conforming to degree of protection IP 54. The board shall be designed for operation on 415V 10% 3 ph, 50 Hz 5%, 4W, 50KA system and shall include all loads, but not limited to the following: a. INCOMER
3.3.0
ACDB shall have two incomers. In case of an under voltage in one incomer power supply shall be changed over automatically to the other incomer. Incomer shall be provided with lamps, voltmeter and ammeter with selector switches. b. OUTGOING FEEDER
Suitably rated MCBs / switch fuse feeders as required shall be provided. Lighting and Power sockets outlets feeders shall be provided protected by a 30 mA ELCB in addition to MCBs. Portable sump pump & starter shall be offered for cable trench draining etc. At least 20% spare feeders shall be provided in addition to 3 no. feeders for purchasers use. 3.4.0 DCDB All control & protection equipment requiring DC shall be supplied through a DC distribution board (DCDB), having one incomer, sheet steel clad (2mm thick), free standing, floor mounting, dust & vermin proof conforming to degree of protection IP 54. The board shall be designed for operation on 110V 10% V DC system. One feeder shall be provided from station DCDB. The total DC load requirement shall be given by the successful bidder during detailed engineering for arriving at the battery capacity. At least 20% spare feeders shall be provided in addition to 3 nos. feeders for purchasers use. 3.5.0 3.5.1 Air-conditioner The switchyard control room shall be Air-conditioned and shall be split air-conditioning type. The rating of the Air-conditioning shall be suitably sized by the Bidder considering the room size, Heat loads of panels, Lighting fixtures, etc. Insulators, Hardware The insulators and hardware shall comply with the specification furnished herein under. The hardware shall be corona free upto a falling power frequency visible discharge voltage. All hardware components shall be smooth and as far possible shall have round exposed surface.
3.6.0 3.6.1
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FICHTNER India
3.6.2
Technical Requirements
The insulators and hardware shall comply with the particulars indicated below : -----------------------------------------------------------------------------------------------------------------------SL. NO DESCRIPTION UNIT DATA -----------------------------------------------------------------------------------------------------------------------1 Post insulator 1.1 1.2 1.3 1.4 1.5 Type Nominal / highest system voltage Creepage distance Cantilever strength With stand voltages a) 1 min power frequency b) 1.2/50micro sec. impulse(dry) 1.6 2.0 Puncture voltage Disc Insulator 1) Voltage class 2) Type 3) Creepage distance 4) Electromechanical strength 5) With stand voltages a) 1 min power frequency (dry) b) 1 min power frequency (wet) c) 1.2/50 micro sec impulse(dry) d) 1.2/50 micro.sec impulse (wet) 85 KV 50KV 125KV 125KV 11KV Anti-fog type 430 mm per disc 8200(min) kg kV KVp 230 550 1.3 times corresponding flashover voltages. KV mm Kg Solid core 110 kV / 123 kV 3800 mm 800
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FICHTNER India
-----------------------------------------------------------------------------------------------------------------------SL. NO DESCRIPTION UNIT DATA -----------------------------------------------------------------------------------------------------------------------2.1 3.0 3.1 3.2 Puncture Voltage Insulator string assembly Requirement in items 1.1 to 1.3, 1.5 & 1.6 above shall be complied with. Applicable standards 1) 2) 3) 4) 4.0 4.1.0 4.2.0 4.3.0 4.4.0 post insulators suspension insulators Insulators fittings Hot dip galvanising process : : : : IS:2544 IS:731 IS:2486 IS:2629 & 2633 1.3 times corresponding flash over voltage.
Bus conductors, clamps, connectors and hardware As specified earlier, bus conductors of ACSR of required size shall be supplied. The clamps and connectors shall be suitable for the termination arrangement to the respective equipment. The hardware for the insulator string shall be suitable for the insulators chosen. All equipment shall be smooth polished and corona free.
P2Sec B1-Swyd
FICHTNER India
SECTION B1.8 POWER, CONTROL & INSTRUMENTATION CABLES 1.0.0 INTENT This specification covers the design, manufacture, inspection and testing at manufacturer's works, packing and loading at works and transportation to site of Power and Control Cables. 2.0.0 CODES & STANDARDS The cables shall comply with the latest edition of following standards. i) IS:1554 (Part - I) - 1988 PVC insulated (heavy duty) electric cables for working voltage upto and including 1100 V. Conductors for insulated electric cables and flexible cords PVC insulation and sheath of electric cables Test method for insulation and sheath of electric cables and cords Methods of tests for cables Specification for mild steel wires, formed wires and tapes for armouring of cables (Rev.2) Fictitious calculation method for determination of dimensions of protective coverings of cables Specification for drums for electric cables.
ii) iii) iv) v) vi)
IS:8130 - 1984 IS:5831 - 1984 IEC 540 & 540 A IS:10810 1984 IS:3975 - 1988
vii)
IS:10462 (Part I) - 1983
viii) 3.0.0 3.1.0 3.1.1 3.1.2 3.1.3
IS:10418 1982
TECHNICAL REQUIREMENTS General The cables shall generally be laid on ladder type cable trays or shall be drawn through rigid steel conduits or buried in ground. Armouring shall be of single round wire of galvanized steel for multicore cables and aluminium for single core cable. The outer sheath of all power and control cables shall have Fire Retardant Low Smoke (FRLS) characteristics and shall not propagate flame. The cables shall meet the requirements of additional tests specified for the purpose. The colour of the FRLS PVC outer sheath shall be black.
FICHTNER India
P2Sec B1-Swyd
3.2.0 3.2.1 3.2.3
LV Power Cables The LV power cable shall be 1100V grade, heavy duty type, suitable for 415V 10%, 3 phase, 50Hz 5% solidly grounded system. The conductor shall consist of stranded H4 grade aluminium (for a size above 16 mm) / copper (for size upto and including 16 mm) suitable for 70C operating temperature. These conductors shall conform to latest edition of IS 8130. The conductor shall have an electrically and thermally stable PVC insulation around it and extruded PVC inner sheath (Type ST1) over the insulation. Armouring over the inner sheath shall be of galvanised steel strips for cables with calculated diameter greater than 13 mm and for cables with calculated diameter less than 13 mm shall be of single round GI wire. FRLS PVC outersheath (Type ST1) shall be provided over the armour. Single core cables shall be provided with non- magnetic aluminium round wire armouring. Control Cables The control cables shall be 1100V grade, multicore, armoured cable suitable for use in 240V 10%, 1 phase, 50 Hz 5% AC solidly earthed system / 110V DC unearthed system. The conductor shall consist of stranded (min 7 strands), annealed copper wire of minimum 2.5 mm cross sectional area, suitable for 70 C operating temperature. The control cables shall have PVC insulation (Type A) capable of withstanding electrical and thermal stresses without deterioration with extruded PVC inner sheath (Type ST1) over it. Armouring over the inner sheath shall be of galvanised steel strips for cables with calculated diameter greater than 13 mm and for cables with calculated diameter less than 13 mm shall be of single round GI wire. FRLS PVC outersheath (Type ST1) shall be provided over the armour. The cores of the cables shall be provided with printed numerals as per relevant IS for core identification. CABLE DRUM Cable drum shall be non returnable and made of good quality wood, pressure impregnated against fungal and insect attack. The ends of each length of cable shall be sealed before despatch. TESTING The cables shall be subject to shop tests in accordance with the relevant standards and as given below :
3.2.4
3.2.5 3.3.0 3.3.1 3.3.2 3.3.3
3.3.4 4.0.0 4.1.0 4.2.0 5.0.0
5.1.0 5.1.1
Routine and Acceptance Tests The following minimum routine tests shall be conducted on each drum of cable as per IS:1554, Part-I. a. Annealing test (for copper)
FICHTNER India
P2Sec B1-Swyd
b. c. d. e. f. g. h. i. 5.1.2 5.1.3 5.2.0
Tensile test (for Aluminium) Wrapping test (for Aluminium) Conductor resistance test Test for thickness of insulation and sheath Hot set test for insulation Tensile strength and elongation at break test for insulation and sheath High voltage test Insulation resistance (volume resistivity) test.
Acceptance tests on drums chosen at random for acceptance of the lot. Any other routine test required as per relevant standard shall also be conducted. Type Tests The following type tests shall be conducted on each size of LT power and control cables. Additional price, if any, for conducting individual, type tests shall be furnished separately in the bid.
5.2.1 5.2.2 5.2.3
Test for armour wires inclusive of measurement of armour DC resistance of power cables. Tensile strength and elongation at break of insulation, inner and outer sheath. To prove the FRLS characteristics, the following additional tests shall be conducted at works on any one size of each type of cable, namely LT power and control cables. Oxygen index test as per ASTM D 2863. Minimum value of oxygen index shall be 30. Flammability tests on finished cables as per the requirements of IEEE 383 and IEC 332-1. Smoke generation by outer sheath under fire as per ASTM D 2843. The cables shall meet the requirements of light transmission of minimum 40% after the test. Acid gas generation by outer sheath under fire as per IEC/754-1 and the maximum acid gas generation shall be less than 20% by weight.
5.3.0 5.3.1
Test Certificates Certified reports of all the type, acceptance and routine tests carried out at the works shall be furnished in required quantities for approval to Purchaser and Consultant.
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FICHTNER India
6.0.0 6.1.0 7.0.0 7.1.0 7.1.1
SPECIAL MAINTENANCE TOOLS & TACKLES A set of special maintenance tools and tackles which are necessary or convenient for splicing ,jointing and termination of different types of cables shall be supplied. DRAWING, DATA & MANUALS Drawings, data & manuals shall be submitted in quantities and procedures as specified hereunder, besides the different information asked for, elsewhere in this specification. To Be Submitted With The Bid a. b. c. d. Manufacture's catalogues giving cable construction details and characteristics. Cable current ratings for different types of installation, inclusive of derating factors for ambient temperature, grouping etc. Write up with sketches illustrating manufacturer's recommended method of splicing, jointing, termination etc. of the different types of cables. Type test certificates on similar types of cables.
7.1.2
To Be Furnished By Successful Bidder For Approval and Subsequent Distribution a. Cable data/drawings.
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FICHTNER India
ANNEX - I SPECIFIED DATA SHEET Sl. No. 1.0.0 1.1.0 1.2.0 1.3.0 1.4.0 1.4.1 1.4.2 Description POWER CABLE Voltage grade Frequency Earthing system Conductor Material Max. withstand temperature a) b) 1.4.3 1.4.4 1.5.0 1.5.1 1.5.2 1.6.0 1.6.1 1.6.2 1.7.0 1.7.1 1.7.2 2.0.0 2.1.0 2.2.0
P2Sec B1-Swyd
Unit
Data
V Hz -
1100V for 415V system 50 a) Solidly earthed system for 415V system
C C -
Annealed Cu / Al
Normal condition Short circuit condition
70 160 Stranded H4
Conductor type Grade Insulation Material Reference standard Inner sheath Material Type Outer sheath Material Type CONTROL CABLE Voltage grade Frequency
PVC IS 1554
PVC ST1
FRLS PVC ST1
V Hz
FICHTNER India
1100 50
Sl. No. 2.3.0 2.4.0 2.4.1 2.4.2
Description Earthing system Conductor Material Max. withstand temperature a) b) Normal condition Short circuit condition
Unit -
Data Solidly earthed system
Annealed Cu
C C -
70 160 Stranded As per IS 8130
2.4.3 2.4.4 2.5.0 2.5.1 2.5.2 2.6.0 2.6.1 2.6.2 2.7.0 2.7.1 2.7.2
Conductor type Grade Insulation Material Type Inner sheath Material Type Outer sheath Material Type
PVC A
PVC ST1
FRLS PVC ST1
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FICHTNER India
SECTION B1.9 ILLUMINATION SYSTEM
1.0.0
SCOPE OF THIS TENDER One (1) lot of equipment and wiring materials for switchyard outdoor lighting shall be supplied. The equipment shall include lighting poles, lighting fixtures complete with lamp & control gear and also necessary control through lighting panels (LPs) and wiring for the above. Lighting for switchyard control room and battery room shall also be provided.
2.0.0 2.1.0 2.1.1 3.0.0
GENERAL REQUIREMENTS Codes and Standards All indoor & outdoor lighting fixtures & LPs shall be designed ,manufactured & tested in accordance with latest applicable Indian standard except where modified by this specification. DESIGN CRITERIA The design of the illumination system shall conform to the following as minimum requirement. a. b. c. b. Outdoor switchyard lighting Switchyard control room Battery room 50 lux. 400 lux. 150 lux.
For all fittings maintenance factor of 0.7 shall be assumed.
4.0.0 4.1.0
SPECIFIC REQUIREMENTS For outdoor switchyard lighting, fixtures shall be HPSV flood lighting fixture made out of heavy gauge Al. body and front glass held by AL./cast Al. alloy ring with weather-proof gasket. The fittings shall be rotatable to fix at any angle. The reflecting surface shall be bright polished and anodised. The other parts namely MS cradle base, and main body shall be finished with stove enamel paint. The light fixture shall be complete with HPSV lamp, control gear housed in weather proof box. Separate poles / towers shall be used for switchyard lighting. Switchyard structures shall not be used for mounting lighting fixtures For Switchyard control room lighting, Fixtures shall be surface mounted mirror optic decorative luminaire suitable for twin fluorescent lamps. For Battery room lighting, Industrial corrosion resistant luminaire for twin fluorescent lamps.
4.2.0 4.3.0 4.4.0
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FICHTNER India
4.5.0
LIGHTING PANELS (LPS) The LPs shall be located inside the switchyard control room in a sheet steel clad (2mm thick) dust & vermin proof switch board suitable for wall mounting. The LP shall have TPN MCB incoming with ELCB and adequate SPN MCB for outgoing with 20% spare outlets for future use. The MCB shall have 10 kA fault rating. One feeder from MLDB shall be provided for incomer of switchyard lighting panel by Purchaser. Further distribution shall be in bidders scope.
5.0.0 5.1.0
TESTS Shop Tests The equipment shall be subjected to shop tests in accordance with relevant standards to prove the design and the general qualities.
5.2.0
Test Certificates Copy of test certificates of all the equipment shall be furnished for review/approval by Purchaser / Consultant.
6.0.0 6.1.0 6.2.0
DRAWING, DATA & MANUALS To be submitted with bid: manufacturer's catalog for the lighting fixture, construction & characteristics. To be furnished by successful bidder for approval and subsequent distribution. a. b. Detailed design calculation for selection of number / type of fittings to meet the illumination requirement specified. Finalised fixture technical details such as lumen data, dimensional details, wiring diagrams and technical leaflets , mounting details etc.
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FICHTNER India
SECTION B1.10 GENERAL ELECTRICAL ITEMS
1.0.0
SCOPE OF SUPPLY The scope of supply of various general electrical items shall include all the materials, that are required to complete the installation which shall include, but not limited to, the following : 1. Materials for cable laying such as cable trays (within switchyard area, switchyard control building, and for cabling between switchyard transformer & switchyard control building), supporting steel, clamps-general & trefoil type (for single core cables), cable ties, identification tags, rigid GI metal conduits, etc. Fence, fence post, gates etc. Items used during operation and maintenance such as hand gloves, shock treatment charts, danger boards, caution boards, rubber mat, first aid kit etc.
2. 3. 2.0.0
STANDARDS The materials to be supplied under this section shall conform to relevant codes & standards.
3.0.0 3.1.0 3.1.1
SPECIFIC REQUIREMENTS Cabling Materials Cable Trays All cable trays to be used shall be prefabricated ladder type hot dip galvanised, with thickness of galvanising average 910 g / sq.m and shall be of standard widths (150, 300 , 600 mm).Cable tray arrangement shall be subjected to approval for which detail drawing shall be submitted at least 2 months prior to taking up of erection.
3.1.2
Cables Trays Supporting Steel All steel work supporting cables trays shall be made of GS Steel channels/angles of adequate size and painted with 2 coats of synthetic enamel paint.
3.1.3
Clamps, Ties, Identification Tags & Sealing Cable clamps used shall be MS painted. Aluminium trefoil clamps shall be used for single core power cables. Cable ties used for bunching of control and instrument cables shall be of nylon or polypropylene material. Cable identification tags shall be MS galvanized plates of suitable size with cable numbers marked thereon. Identification tags shall be fixed at the entry and exit points and at regular interval of 30m along the route length. Cable entry points at building and exit points from trenches shall be suitably sealed.
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FICHTNER India
SECTION B1.11 EARTHING & LIGHTNING PROTECTION
1.0.0
SCOPE OF SUPPLY The contractor shall supply the following earthing and lightning protection system. i. ii. iii. Entire switchyard under ground and above ground earthing, of equipment, towers etc. as per approved design. Complete lightning protection system - to protect the outdoor switchyard from direct lightning strokes. Earthing of all the panels in the switchyard control building & Lightning protection for the building shall also be provided.
2.0.0
CODES & STANDARDS The entire system of grounding & lightning protection design shall conform to relevant IS and IEEE standards.
3.0.0 3.1.0 3.1.1
DESIGN CRITERIA Grounding System The grounding design calculation shall conform to ANSI / IEEE Standard 80-1986.The data for calculation shall be as follows. a. b. c. d. e. f. The fault current shall be equal to the maximum value of interrupting capacity of circuit breaker (40 kA). Fault clearing time shall be 1 second. The gravel or crushed rock resistivity shall be 3000 ohm metre. The ground resistance of switchyard grounding system shall be not more than 1 ohm. The effect of shield wires and neutral conductor shall not be taken into consideration for design of substation grounding system. Soil resistivity of 100 ohm m may be assumed for bid purpose. The actual value will be furnished to the successful bidder.
3.1.2
Grounding Material Galvanised iron flats rods of required size shall be used as per approved design. In any case the minimum size shall be 75 x 10 mm. GI strip shall be used for above ground earthing.
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FICHTNER India
3.1.3
Measurement of Ground Resistance After completion of grounding system installation, the measurement of ground resistance shall be performed by the contractor. Before measurement, the overhead ground wires shall be disconnected from the substation. The method of measurement shall be as per relevant standards / codes.
3.2.0
Lightning Protection System The lightning protection system for the switchyard shall be done by providing tower peaks on switchyard structures. The lightning protection system shall be designed using Razevig method. Contractor shall furnish necessary calculation for approval.
P2Sec B1-Swyd
FICHTNER India
SECTION B1.12 TARIFF METERING PANELS 1.0.0 1.1.0 2.0.0 2.1.0 2.2.0 2.3.0 EQUIPMENT TO BE SUPPLIED Two (2) nos. tariff metering panels (one each for main tariff metering & check tariff metering) for two transformer bays as indicated in 110 kV SLD (Drg no. 20-6104-E-202). TECHNICAL REQUIREMENT Tariff metering panel with metering equipment shall be installed in the switchyard control room. One panel each shall be provided for main metering & check metering. The main metering equipment & check metering equipment consists of tri-vector meter (import). The tri-vector meters shall be of digital type with class 0.2 accuracy. The tri-vector meters shall have facility for storing information like maximum demand, power factor, frequency, Billing registers of all energy quantities etc. as 15 minute block for a minimum period of 15 days. Separate tariff meter shall be provided for each transformer feeder (2 nos.). The tariff meter shall as a minimum suitable for reading the following parameters : i) ii) iii) iv) v) 2.5.0 Kilo watt hour Kilo VAR hour Kilo volt ampere hour Kilo watt, Kilo VAR & KVA along with maximum demand over a period of time. Power factor, frequency along with maximum / minimum readings over a period of time.
2.4.0
The Kilo watt hour & kilo VAR hour metering shall be suitable for single or two rate tariff. Thus they shall be equipped with separate registers for high tariff and low tariff. Each register shall comprise of a 6 digit cyclometer type indicator. The time for change in tariff shall be signalled from two time clocks (main & stand by). Two nos. time clocks shall be provided for switching purpose (main & standby clocks). The time clocks shall be suitable for operation from 110V DC supply. The clock shall be provided for switching tariff changes, peak demand recording periods and for resetting demand indicators & printometers at predetermined time intervals. Adjustment shall be possible to cover tariff changes during different periods over 24 hrs. A selector switch shall be provided to change from main to standby clock. The demand metering shall be able to measure the demand of individual parameter at any point of time along with the maximum demand registered over a preset period of time which will be reset after the preset time has elapsed. Tariff meter for each outgoing feeder shall have a serial port suitable for Ethernet protocol, which permits direct transfer of data between an ethernet network and 12 such devices via another serial port. In addition each tariff meter shall be provided with an internal modem. It shall be possible for 12 such devices to communicate over telephone network through a serial port.
FICHTNER India
2.6.0
2.7.0
2.8.0
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2.9.0
Tri-vector meters shall be installed in IP-42 panels of cold rolled sheet steel thickness not less than 2 mm. The panels shall have undergone degreasing, rust / scale removal, phosphating sand blasting & oven drying process. The phosphate coating shall be sealed by the application of two coats of ready mix stoving type zinc chromate premier followed by two coats of synthetic enamel paint. The panel shall be suitable for bottom entry front access only.
2.10.0 All equipment on the front shall be flush mounted. 2.11.0 The panel shall be complete with door limit switch operated cubicle lighting, 5A switched power socket, hygrostat controlled space heater, terminal block, panel earth bus, body earth pads etc. 2.12.0 All wiring shall be carried out with 600 / 1000V grade stranded 1.5 sq. mm copper conductor wires with PVC insulation. For CT & VT circuits 2.5 sq. mm copper conductor wire with PVC insulation shall be used 2.13.0 Terminal blocks shall be klipon type 600V grade, 10 Amps rated stud type terminals with markings. Terminals for VTs secondary leads shall be stud, disconnecting type. CT secondary leads shall be provided with short circuiting and earthing facility. A clearance of 250 mm (min.) shall be maintained between terminal blocks and gland plate and 150 mm between 2 rows of terminal blocks for ease in termination. At least 20% spare terminals shall be provided. 2.14.0 All accessories & instruments shall be connected to the earth bus through a 2.5 mm Cu conductor, PVC sheathed earth cable. 3.0.0 TESTS The tariff metering panels shall be subject to following tests as per relevant standards : a) b) c) d) 4.0.0 Meters caliberation test High voltage test (2 kV for 1 mt) Megger test Verification of wiring as per approved drawings
AFTER AWARD OF CONTRACT FOR APPROVAL a) b) c) d) e) Panel general arrangement drawing Scheme drawing Wiring drawing Catalogues of the meters / accessories Operation & maintenance manual
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FICHTNER India
SECTION B1.13 BATTERY AND BATTERY CHARGER
1.0.0
INTENT OF SPECIFICATION This specification covers the design, manufacture, assembly, testing at manufacturer's works, loading at works transportation to site and commissioning at site in a properly packed condition including transit insurance of 110 V DC system (Battery & Battery charger) complete with all accessories for efficient and trouble-free operation of 110 kV switchyard for CPCL, Chennai.
2.0.0 2.1.0 2.1.1
TECHNICAL REQUIREMENTS Battery The 110 kV DC battery system required for 110 kV switchyard system shall be suitably sized for 2 hrs. capacity for the required load, taking into account the temperature correction, design margin and ageing compensation factors. The requirement of the DC system is to supply power to the following : i) ii) iii) Control & protection of major electrical equipment Alarm & indication Emergency DC lighting
2.1.2
2.1.3
The battery shall be of Ni-cad type. The 110V DC system shall be unearthed. The DC system shall have 20% spare capacity. Each DC system shall have 2 x 100% chargers & 1 x 100% battery. The terminal voltage variation of the DC system shall be 10%. For any configuration of operation. End cell voltage shall be 1.1V / Cell and number of cells shall be so chosen to restrict the DC system voltage variation as indicated above if required voltage drop diodes could be used. However, a nominal battery voltage of DC system shall be not more than 110V DC. The Boost / Equalise change voltage of the changer shall be so chosen to charge the batteries from end cell voltage to full changed condition in 12 hours. Batteries shall be placed on suitably sized battery racks. The configuration of mode of operation of the DC system shall be as per the Drg no. 30-6104E-211. Battery Chargers Battery charger of suitable capacity shall be provided for quick boost charge or trickle charging the battery in addition to catering the load.
2.1.4 2.1.5
2.1.6 2.1.7 2.1.8 2.2.0 2.2.1
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2.2.2 2.2.3
The battery charger shall be of solid state control rectifier type, completely automatic and self regulating changer shall be of constant voltage current limiting type. Automatic voltage regulation shall be provided to maintain the float charger DC output voltage with 1% of set voltage from no load to full load and for AC line voltage variation of 10%. The float change controller will have lead limit features, which shall come into operation under load limit condition and would provide over riding control over voltage sensing circuit. The configuration and mode of operation of the DC system shall be as per Drg. no. 30-6104E-211. Construction Features i) The charger shall be of sheet metal, enclosed, dust and vermin proof, suitable for mounting on RCC floor otherwise specified. Sheet steel shall be 2 mm thick cold rolled free from flaws and imperfection. The panel shall conform to the degree of protection IP 42. All doors, removable covers shall be gasketed around with neoprene gasket. Ventilating louvres if provided shall be covered with fine wire mesh. All live parts shall be properly shrouded. This shall ensure complete safety to personnel while doing routine maintenance by opening panel doors. Bottom cable entries to the charger shall be provided. The bottom of the charger shall be fitted with a removable gland plate for fixing the glands. Required number of cable glands shall be supplied. Crimping type tinned copper lugs shall be provided for external cable connections. All incoming and outgoing cables shall be terminated in suitably rated terminal blocks. All metal surfaces shall be thoroughly cleaned, sand blasted, pickled and degreased to remove mill scale, rust, grease and dirt. After cleaning, the under surface shall be prepared by applying two coats of high quality epoxy based primer. The under surface shall be made free from all imperfections before undertaking the finishing coat. Name plate of approved design shall be provided at each cubicle and at each instrument & device mounted on or inside the cubicle. Plate size shall be minimum 20 x 75 mm for instrument/device and 40 x 50 mm for panels. Individual panel number and caution notice on suitable metal plates shall be affixed at the block of each vertical panel. Each charger panel shall be provided with the following. vii) Internal illumination lamp with door switch.
2.2.4 2.2.5 2.2.6
ii) iii) iv)
v)
vi)
Thermostat controlled space heater. One (1) no. 3 pin, 5 A, receptacle with plug.
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FICHTNER India
The above shall be rated for 240 V 10%, 50 Hz 5%, 1 phase, AC supply and shall have individual switch fuse units. 2.2.7 Annunciation Each float cum boost charger shall have, but not limited to the following annunciations. i) ii) iii) iv) v) vi) vii) viii) ix) x) 2.2.8 SCR fuse failure. Filter capacitor fuse failure Charger overload Charger fail/trip DC output fuse failure AC input supply failure AC input under voltage DC voltage low DC voltage high DC system earth fault
The annunciation system shall have audio-visual arrangement and shall incorporate acknowledge, reset and test push buttons. On occurrence of fault, the corresponding window lights up and stays in lighted condition until the fault is cleared and the reset push button is pressed. Atleast 20% spare annunciation windows with accessories shall be provided. The alarm contacts shall be rated 0.5 A at 110 V DC and 5 A at 240 V AC.
2.2.9
2.2.10 The bidder shall also provide necessary push buttons for testing and resetting all alarms and to cancel audible alarms. 2.3.0 2.3.1 2.3.2 Wiring Panel wiring shall be carried with minimum 2.5 mm stranded copper conductor, with PVC insulation. Wires shall be neatly bunched and adequately supported so as to prevent sagging. Wiring termination shall be made with solderless crimping type tinned copper lugs and shall be provided with numbered ferrules in both ends of wire. The ferrule numbering shall be in accordance with IS:375. The control terminal blocks shall be of 650 V grade. All terminal blocks shall be stud type. Each terminal shall have a maximum of two (2) wires terminated to it. 20% spare terminals shall be furnished. Ground Bus A GI ground bus of cross section 50 x 6 mm shall be furnished along the entire length of the charger panel and all devices shall be grounded to the ground bus. Two (2) nos. ground terminals, one (1) at each end of the panel shall be provided, connected to the above ground bus. Each ground terminal shall comprise of two-bolt drilling with M 10 GI bolts and nuts to receive purchaser's ground grid connection.
2.3.3
2.4.0 2.4.1
2.4.2
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2.5.0 2.5.1 2.5.2 2.5.3
Tests All equipment and components thereof shall be subject to tests as per relevant IS standards. The tests shall include, but not limited to, the following. Type test certificates for tests conducted earlier on similar cells shall be furnished for approval of purchaser/consultant. The tests on battery charger shall include a. b. c. Dielectric test Voltage regulation check from 0 to 100% load with 10% input voltage variation Ripple content measurement
2.5.4 2.5.5 2.5.6 2.5.7
Routine and acceptance tests on battery. Routine tests on all component parts. All tests shall be performed in presence of Purchaser's representatives, if so desired by the Purchaser. Certified reports of all tests carried out at the works shall be furnished in required quantities. The equipment shall be despatched from works, only after the approval of test reports. Type test certificates on any equipment, if so desired by the Purchaser shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design. Drawings, Data And Manual Following drawings, data and manuals shall be submitted in required quantities besides the different information asked for, elsewhere in this specification. To be submitted with Bid Battery layout drawing with dimensions. General arrangement drawing of charger panel. Battery cell voltage characteristics. Technical leaflets on battery and battery charger. Schematic drawing of float and boost charger circuit. Battery A.H. calculations. To be submitted after award of contract The successful contractor shall furnish all drawings/data for approval in four (4) copies to Consultant and two (2) copies to Purchaser which shall not be limited to :
2.6.0 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 2.6.9
2.6.9.1 Dimensional battery layout drawing in plan and sections including loading data.
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2.6.9.2 Take-off terminal connection details. 2.6.9.3 Dimensional G.A. drawing of battery charger clearly showing device disposition, cable entry, space requirements, etc. 2.6.9.4 Charger foundation plan and loading. 2.6.9.5 Schematic and wiring diagrams of charger. 2.6.9.6 Schematic diagram of all cards 2.6.9.7 Write-up on operation & control philosophy of the Battery and Battery charger. 2.6.9.8 Detailed bill of material. 2.6.9.9 In addition to the above, the successful Contractor shall furnish to Purchaser and Consultant, battery and battery charger instruction manual indicating installation method, check-ups, pre-commissioning tests, detailed trouble shooting procedures, method of operation and maintenance.
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SECTION B1.14 ERECTION, TESTING AND COMMISSIONING
1.0.0 1.1.0
GENERAL The successful tenderer will be required to carry out at site complete erection as well as start up commissioning including performance test of equipment supplied by him under scope of this tender based on drawings, specification and bill of quantities to be submitted by him and got approved by PURCHASER/CONSULTANT. The Contractor shall be completely responsible for the satisfactory erection, testing, commissioning, start up and performance tests of the equipment not withstanding that, he may be assisted by the purchaser's authorised representative. For complete erection and commissioning, the successful tenderer shall be responsible for providing at his cost all necessary tools, tackles and instruments as required. 415V construction power and water will be provided by purchaser on chargeable basis at one point at the site to be mutually agreed. The Contractor shall make necessary arrangements for further distribution to the work-spot. The installation shall be carried out only by electrical Contractor, holding a valid license, issued by relevant authorities for carrying out installation work of the voltage classes involved, under the direct supervision and person holding valid certificates of competency for the same voltage classes, issued or recognised by the state Government. The tenderer shall furnish with his tender the particulars of the license held by him/the electrical Contractor he proposes to engage for carrying out the installation work against this specification. The successful tenderer shall furnish to the purchaser the names and particulars of certificates of competency of the supervisors and workmen to be engaged for carrying out the installation work against this specification. The electrical work shall also comply with standard norms and practices adopted by the relevant state Electricity Board. Requisite factory and site test reports shall be supplied by the successful tenderer. The installation shall have to be approved by statutory Government Authorities like Electrical Inspector, Factory Inspector, Insurance Officials etc. It shall be the responsibilities of Contractor to prepare and submit all necessary drawings, calculations, test certificates to electrical inspectorate and obtain approval prior to installation and commissioning work and also arrange inspection by them after installation. After inspection any modification in the equipment of installation that may be demanded by them shall have to be carried out by the Contractor at no extra cost to the purchaser. The Contractor shall take all necessary steps to enable the purchaser to get the installation approved by the above authorities and shall render all necessary assistance to the purchaser in the matter. INSTALLATION OF EQUIPMENT The installation work shall be carried out in a neat, workman like manner and in accordance with the best engineering practices.
1.2.0
1.3.0
1.4.0
1.5.0
1.6.0
1.7.0 1.7.1
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1.7.2 1.7.3 1.7.4 1.7.5 1.7.6
During erection, testing and commissioning of the substation, safety of equipment and operating personnel, ease of operation and maintenance shall be given prime consideration. The equipment and installation shall conform to the latest publication of IS:10118 - Code of practice for Selection, Installation and Maintenance of Switchgear and Control gear. The equipment and installation shall conform to the earthing and other essential provisions specified therein for installation and operation of electrical plants. The equipment and installation shall also comply with the regulations published by the Tariff Advisory Committee - General Insurance. All equipment including individual components, fitting and accessories shall be properly stored at site so as to obviate any deterioration of electrical properties and mechanical damages. All equipment shall also be checked physically for the completeness of all components and devices before taking up for installation. All equipment shall be thoroughly cleaned of packing materials, scales, rust, oil, grease etc., prior to commencement of the installation work. The supplier shall repair all minor defects in the equipment, if required, prior to installation in consultation with equipment manufacturer so that manufacturer's guarantee is not affected in any way. In case of any major damage to the equipment, the same shall be rectified or replaced only by the manufacturer's representative with the approval of the purchaser.
1.7.7 1.7.8 1.7.9
1.7.10 All equipment and accessories shall be installed strictly in accordance with the manufacturer's instructions/drawings. Equipment supplied in sections or in dismantled condition shall be reassembled at site with all associated accessories as per the manufacturer's instructions. 1.7.11 All electrical installation work shall be planned well in advance so that all openings, sleeves, inserts, mounting channels, foundation bolts, holes etc., required for the installation can be incorporated during the execution of civil engineering work. In case additional openings, sleeves etc., are required after completion of civil engineering work, the supplier shall make necessary arrangement for the same by drilling / cutting chases, holes etc. and shall make good all damaged portions of the work, at his own cost. 1.7.13 All electrical equipment operating on 415V or higher voltage shall be provided with caution notice boards of approved type and shall be affixed permanently in a conspicuous position. Where a group of equipment is located within a switch / control room or within a fenced area, the notice board shall be fixed at the entrance. 1.7.14 In accordance with the requirement of the Indian Electricity Rules, the following shall be provided : i) ii) Danger boards and shock treatment charts. 750mm wide tested rubber mats of thickness not less than 6mm shall be provided in front of all switchboards.
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FICHTNER India
1.8.0 1.8.1
TESTING AND COMMISSIONING The testing of all electrical equipment as well as the system as a whole shall be carried out at site to ensure that the equipment and its components are in satisfactory condition and will successfully perform its functional operation. The inspection of the equipment shall be carried out to ensure that all materials, workmanship and installation conform to the accepted design, engineering and construction standards as well as accepted codes of practice. All tests shall be carried out by the Contractor using his own instruments, testing equipment as well as qualified testing personnel. The results of all tests shall conform to the specification requirements as well as any specific performance data guaranteed during finalisation of the contract. At site all equipment shall be energised only after certification by the personnel performing the test that the equipment is ready for energising and with concurrence of the purchaser. The various commissioning checks/tests to be carried out on the various equipment shall be in accordance with details indicated in clause 2.0.0 of this specification. GUARANTEE All equipment shall be guaranteed for design, material, workmanship and satisfactory performance. The guarantee for smooth, trouble- free and satisfactory operation shall cover individual items as well as the system as a whole.
1.8.2 1.8.3 1.8.4 1.8.5 1.9.0 1.9.1
1.10.0 LOCKS 1.10.1 All doors of all substation cubicles, operating cabinets, terminal boxes shall be provided with locking facility. Three set of keys shall be handed over to the Purchaser after installation. 1.11.0 CONSUMABLES All consumables required for the installation, testing and commissioning and two years' normal operation shall be supplied by Contractor. Contractor shall furnish a list of such consumables recommended by manufacturer of each equipment. Further, first fill of oil/lubricant for site testing shall be deemed to be included in the quoted price for supply. 1.12.0 ERECTION, TESTING & COMMISSIONING PROGRAMME 1.12.1 Tenderer shall furnish the organisation chart of his site office indicating also administrative and financial powers of site incharge. It shall also indicate a list of supervisory staff (with in 15 days from the placement of LOI)indicating names, designation, experience etc., who will be posted at site for the following : a) b) c) Day to day execution of work & supervision Testing & Commissioning For coordination with Purchasers Representative.
1.12.2 Contractor shall furnish a detailed bar chart, a programme of erection and commissioning from equipment delivery, sequence of erection citing various milestones and get approved by CONSULTANT / PURCHASER atleast 4weeks prior to commencement of work at site.
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1.13.0 CO-ORDINATION WITH OTHER CONTRACTORS 1.13.1 The electrical Contractor may have to work along with other Contractors/agencies for some other jobs assigned by the PURCHASER at the same time and at the same place at the site. Electrical Contractor shall not object to this arrangement and extend his full co-operation to other Contractor to the satisfaction of CONSULTANT/PURCHASER. 1.13.2 Contractor shall obtain necessary written permission from the purchaser prior to working on the existing equipment and strictly adhere to the safety regulation while working on the existing equipment. 1.13.3 Contractor shall plan the installation of the new equipment suiting to the operational requirements of the plant, if installation of new equipment requires shut down/disconnection of existing equipment. 1.14.0 HANDING OVER 1.14.1 Acceptance of finished work carried out by the Contractor is contingent upon the successful testing of all electrical apparatus, systems and associated wiring. 1.14.2 If the completed plant or any portion there of supplied by Contractor at any time before or after installation be found to be defective or not conforming to specification or if it fails to fulfill the requirement of the contract, the PURCHASER may reject the same. In such an event, the Contractor shall replace the same without affecting the committed milestones to the satisfaction of the Purchaser. 2.0.0 PRE-COMMISSIONING AND COMMISSIONING CHECKS All the equipment and accessories included in scope of this contract shall be tested at site after installation during commissioning. The tests & pre-commissioning checks shall include but not limited to the following. 2.1.0 General Phasing Out By means of phasing rods if available, or by measuring voltages on voltage transformer secondary. In case of generators, synchroscope connections should be checked by back charging upto the generator V.Ts with the generator disconnected. Functional Checking a. b. Check all closing, tripping, supervision and interlock of control devices. Check operation of all alarm circuits
Cable Testing a. b. All 3.3 kV cables and above to be high voltage tested All 415 and 230 V power cables to be meggered
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Earthing a. Measure resistance of each earth well / rod by isolating the same from station grid as well as from other earth wells / rods and then measure resistances of two earths at a time by DC drop method. Check continuity of grid conductors and wires Soil resistivity tests
b. c. 2.2.0
Circuit Breakers A. Preliminary Checks Check nameplate details according to specification Check for physical damage Check tightness of all bolts, clamps and connecting terminals Check earth connections Check cleanliness of insulators and bushings Check all moving parts are properly lubricated Check heaters provided Gas leak check B. Commissioning Checks Check alignment of breaker trucks for free movement, check correct operation of shutters Slow closing / opening operation Functional check on control wiring for correctness of connections, continuity and IR values Manual operation of breakers (only after filling oil in the tank) Power closing / opening operation manually and electrically Breaker closing and tripping time Trip free and anti-pumping operation IR values, resistance and minimum pick up voltage of coils Contact resistance Simultaneous closing of all three phases
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Pole descrepancy tests Single and three phase auto-reclose operation. Calibration of pressure switch setting Insulation check on the power circuit 2.3.0 Isolators Check nameplate details according to specification Check for physical damage Check tightness of all bolts, clamps and connecting terminals Check cleanliness of insulators Insulation resistance of each pole Manual and electrical operation and interlocks Correctness of connections, continuity and insulation resistance values of control circuits and meters (wherever applicable) Pneumatic control operation (wherever applicable) Contact resistance of each pole / gap between male and female contacts Earth connections of structures and operating handle Motor current (wherever applicable) Clearance in open and closed positions Simultaneous closing of all phases 2.4.0 Current Transformers A. Preliminary Checks Check nameplate details according to specification Check for physical damage Check tightness of all bolts, clamps and connecting terminals Check for oil level and leakage Check connections Check cleanliness of insulators and bushings
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B.
Commissioning Checks Megger between windings and winding terminals to body Polarity test a) Ratio identification checking of all ratios on all cores by primary injection of current
Magnetisation characteristics, secondary winding resistance Capacitance and tan delta test Dielectric test of oil (whichever applicable) Spare CT cores, if any, to be shorted and earthed Checking of pressure of gas, whichever applicable (This shall be done as per manufacturers instructions) 2.5.0 Voltage Transformers Check nameplate details according to specification Check for any physical damage Check cleanliness of insulators Check tightness of all bolts, clamps and connecting terminals Check earthing connection Insulation resistance test Polarity test Ratio test on all cores Line connections as per connection diagram Dielectric test of oil (wherever applicable) Open delta test with low voltage, wherever required Check oil level and leakages Measure core loss from LT side High potential test if required Capacitance and tan-delta test if possible
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2.6.0
Control Panels Preliminary Checks Check nameplate details of every associated equipment according to specification Check for physical damage Check tightness of all bolts, clamps and connecting terminals Check cleanliness Check earthing Commissioning Checks Switch developments Each wire shall be traced by continuity tests and it should be made sure that the wiring is as per relevant drawings. All interconnections between panels / equipment shall be similarly checked. All the wires should be meggered to earth Checks on relays Checks on meters Settings of relays, other alarm, tripping devices and interlocks as per schemes Phase angle checks measurement of magnitude and phase angle of current transformer secondary currents and potential transformer secondary voltages. Functional checking of all control circuit e.g. closing, tripping, control, interlock, supervision, and alarm circuits including proper functioning of the component equipment.
2.7.0
Relay Panels Check nameplate details according to specification Check for physical damage Check internal wiring Megger all terminals to body Megger AC to DC terminals Check operating characteristics by secondary injection Check minimum pick up voltage of DC coils Check operation of electrical / mechanical targets
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Relay settings Check CT and VT connection with particular reference to their polarities for directional distance type relays. 2.8.0 Meters Check nameplate details according to specification Check for any physical damage Check calibration by comparing it with a sub-standard meter Megger all insulated portions Check CT and VT connections with particular reference to their polarities for power type meters. 2.9.0 Battery & Battery Charger Battery Check nameplate details according to specification Check for physical damage Dimensional check of plates (before assembly) Sp. gravity test Cell voltage check Capacity test as per IS Initial charging cycle Battery Charger Nameplate details according to specification Check for physical damage Check connection Functional check of auxiliary devices, such as alarms, indicating lamps etc. Insulation test of all circuits Measurement of voltage regulation No load current and voltage (AC) and voltage and current (both AC and DC) at different loads
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Voltage at 84th Cell (while boost charging) 2.10.0 Cables Preliminary Checks Check details as per specification Check for physical damage In case of oil filled cables, check oil leakage, oil pumping device, pressure gauge, oil tank etc. Commissioning Check List Megger test between each core and armour / sheath Continuity check Connections In case of Impregnated paper-insulated cables, lead or lead alloy sheathed cable high voltage test for 15 minutes between conductors and conductor and sheath. Potheads Check for oil or compound leaks Check that pot heads are filled to the proper level oil or compound 2.11.0 Any other pre-commissioning and field test not included in the above list and which are specified in the relevant standards, Electricity rules, code of practice etc. shall be carried out at no extra cost to purchaser. Also if the purchaser wishes any particular test to be repeated or newly carried out, the same shall be done by the Contractor at no extra cost to purchaser. Stringing work, Tubular busbar and Power connector i) ii) iii) iv) v) Physical check Electrical clearance check Testing of torque by torque trenches on all busbar, power connectors and other accessories. Multivolt drop test on all power connectors Sag and tension check on conductors.
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2.12.0 Site Testing Procedures, Formats. Contractor shall submit specified copies of site testing procedures, test formats along with details of site test instruments proposed to be deployed at site along with respective valid calibration certificates, six weeks prior to commencement of site testing, for approval by PURCHASER/CONSULTANT. Only procedures and test formats approved by PURCHASER / CONSULTANT shall be used for site testing. After completion of commissioning of all equipment and prior to handing over six sets of such signed test data in the agreed / approved formats shall be furnished prior to issue of provisional acceptance of the equipment / installation.
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SECTION B2
List of Drawings
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SECTION-B2 LIST OF DRAWINGS
SL. NO. 1. 2. 3.
DESCRIPTION
DRAWING NO.
110 kV SWITCHYARD SLD 110 kV SWITCHYARD LAYOUT 110V DC SYSTEM SCHEME DIAGRAM
20-6104-E-202 10-6104-E-401 30-6104-E-211
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SECTION B3
Technical Schedules
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Table of Contents
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0
SWITCHYARD TECHNICAL DETAILS ............................................................................... 3 EHV CIRCUIT BREAKERS .................................................................................................... 4 EHV ISOLATORS WITH EARTH SWITCH .......................................................................... 7 EHV CURRENT TRANSFORMERS....................................................................................... 9 EHV VOLTAGE TRANSFORMERS .................................................................................... 10 LIGHTNING ARRESTERS.................................................................................................... 12 EHV SWITCHYARD CONTROL PANEL............................................................................ 13 MISCELLANEOUS ITEMS................................................................................................... 16 CABLES.................................................................................................................................. 19 ILLUMINATION SYSTEM ................................................................................................... 21 GENERAL ELECTRICAL ITEMS ........................................................................................ 22 EARTHING LIGHTNING PROTECTION ............................................................................ 22 TARIFF METERING PANEL (MAIN & CHECK) ............................................................... 23 BATTERY.............................................................................................................................. 24 BATTERY CHARGER........................................................................................................... 26
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SECTION B3 TECHNICAL SCHEDULES
Bidder shall furnish the following technical particulars for the equipment offered by him. -----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars/ Data -----------------------------------------------------------------------------------------------------------------------1.0 SWITCHYARD TECHNICAL DETAILS 1.1 1.2 1.3 1.4 Rated voltage 1.2 / 50 micro sec impulse withstand voltage One min. power frequency withstand voltage Current ratings a. Continuous for main bus b. Continuous for bay buses 1.5 Minimum air clearance a. Phase to phase b. Phase to ground c. Live point to ground d. Section clearance 1.6 1.7 1.8 1.9 Bay width Phase to phase spacing Size of the switchyard Design tensions a. Main bus b. Bay bus c. End towers (for connections to line) 1.10 1.11 Total creepage distance for all equipment Protected creepage distance kg kg kg mm mm mm mm mm mm m m mxm Amps Amps kV kV peak kV
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------1.12 Factor of safety adopted for the structural design a. Normal condition b. Short circuit condition c. Seismic condition 1.13 Visual discharge voltage for all equipment with fitting & insulator assemblies for falling power frequency voltage Radio interference voltage for all the switchyard equipment with fittings & insulator assemblies RIV level 1.15 Type of design for main & bay buses a. Strung bus or tubular bus b. Material 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 EHV CIRCUIT BREAKERS Make, type, country of manufacture Applicable standard Rated voltage Type of circuit breaker Reference ambient temperature Rated continuous current a. Rated short circuit breaking current and rated making current C Amp kA kA / sec kV micro volts kV
1.14
b. Short circuit withstand current rating & duration 2.8 Temperature rise of contacts over an ambient of 50C while carrying rated current
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------2.9 Rated operating duty 2.10 2.11 2.12 2.13 2.14 Total break time Total make time Rated transient recovery voltage for short line faults No. of breaks in series Insulation level a. One minute P.F withstand voltage b. c. 2.15 Impulse withstand voltage Switching surge withstand voltage kV peak kV peak kV peak m.sec m.sec kV
Minimum clearance in air a. Between live parts b. Between live parts & earth c. Centre to centre distance between phases mm mm mm Yes / No
2.16 2.17 2.18 2.19 2.20 2.21
Trip free Type of operating mechanism Normal method of tripping Emergency method of tripping No. of trip coils Rated voltage and permissible variations: a. for Trip coils b. for Closing coils c. for Operating mechanism motor
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------2.22 Burden (watts) a. Trip coils b. Closing coils 2.23 2.24 2.25 Rated line charging current Rated cable charging current Maximum over voltage when switching off a. Unloaded transformer b. Unloaded lines c. Cable charging d. Capacitor banks 2.26 When switching off asynchronous system a. Maximum current b. Maximum recovery voltage between contacts 2.27 No. of operation circuit breakers can perform without inspection, replacement of contacts a. At rated breaking current b. At rated continuous current 2.28 2.29 2.30 2.31 Creepage distance for the interrupter insulator Type and creepage distance for the support insulator Cantilever strength of circuit breaker at the terminal pad Whether pressure switches for Sulphur hexafluoride pressure low alarm, trip, lockout closing, lockout opening are provided. mm mm kg kA
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------2.32 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Leakage rate of Sulphur hexafluoride per year. EHV ISOLATORS WITH EARTH SWITCH Make, type, and country of manufacture Reference standard Rated voltage & frequency Rated current Reference ambient temperature Short time withstand current & duration a. Dynamic withstand current b. Max. current isolator can safely interrupt c. Transformer magnetising current breaking d. Making current (for earth switch only) 3.8 3.9 Maximum temperature rise of current carrying parts Insulation test values a. One minute power frequency wet withstand voltage i. Between poles & earth ii. Across isolating distance b. Impulse withstand voltage i. Between poles & earth ii. Across isolating distance kV peak kV peak kV kV Volts, Hz A C kA Sec kA peak A A A % / year
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------3.10 Material a. Main contact b. Arcing contact c. Current carrying parts 3.11 3.12 Whether contacts are silver faced Clearance a. Between poles b. Between live parts earth c. Between live parts when switch is open i. Between same pole ii. Between adjacent pole 3.13 3.14 Phase spacing Type of interlock a. External b. Earth switch 3.15 Insulators a. Type of insulator (solid core) b. Cantilever strength c. Total creepage distance d. Applicable standards 3.16 Operating mechanism (motor / manual) a. Main blade b. Earth blade mm mm mm mm mm
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------4.0 4.1 4.2 4.3 4.4 EHV CURRENT TRANSFORMERS Make & country of manufacture Applicable standards Rated voltage class Insulation withstand level : a. b. 4.5 4.6 Impulse withstand voltage 1.2 / 50 micro sec wave One minute power frequency withstand voltage kV peak kV rms
Number of cores per CT Whether it is possible to adjust tap setting of any core independent of other cores Relaying cores a. b. c. d. e. f. Accuracy class (for 5P20) Rated burden (for 5P20) Accuracy limit factor (5P20) Minimum knee point voltage VK for PS class Maximum excitation current at VK, VK/2 volts (PS class) Maximum secondary resistance (PS class) Ohms mA Volts VA Yes / No
4.7
4.8
For metering cores: a. b. c. Accuracy class Rated burden Rated power factor VA
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------d. 4.9 Instrument security factor Short time thermal current rating a. b. 4.10 4.11 Current Rated time kA sec kA peak
Dynamic current rating Maximum temperature rise of winding at rated primary current and rated burden, when referred to specified ambient temperature Class of insulation of winding Cantilever strength at terminal Type and creepage distance of insulator housing m EHV VOLTAGE TRANSFORMERS
4.12 4.13 4.14 5.0
kg
CVT -------------5.1 5.2 5.3 5.4 Manufacturer & country of manufacture Applicable standards Type of VT Insulation withstand level a. b. 5.5 5.6 5.7 Impulse withstand voltage 1.20/50 micro sec. wave One minute power frequency withstand voltage kV peak kV rms
EMVT ------------
Number of secondary windings for each VT Rated primary voltage Rated secondary voltage kV V
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------CVT EMVT -------------- -----------5.8 Rated VA burden for each each secondary winding VA 5.9 5.10 Rated power factor Accuracy class for each secondary winding a. b. 5.11 Winding 1 Winding 2
Method of connection a. b. i. ii. Primary winding Each secondary winding Winding 1 Winding 2
5.12 5.13
Rated voltage factor Maximum temperature rise of winding at 110% excitation and rated burden when referred to specified ambient temperature Class of insulation of windings Capacitor data a. High voltage capacitance b. Intermediate voltage capacitance c. Nominal intermediate voltage d. Equivalent capacitance for carrier coupling e. Maximum permissible impedance at power frequency of carrier coupling device Ohms mm PF PF kV PF C
5.14 5.15
5.16
Insulator type and total creepage distance
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------CVT EMVT -------------- -----------5.17 5.18 Radio interference voltage Details of high speed switch(es) on secondary winding (alternative to fuses) a. Make, type, coil rating other technical details 5.19 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Cantilever strength LIGHTNING ARRESTERS Make, type & country of manufacture Arrester type Applicable standards Arrester class Rated arrester voltage Rated frequency Nominal discharge current (8/20 micro sec wave) Minimum discharge capability Residual voltage corresponding to a. b. 6.10 6.11 6.12 Steep current impulse Lightning impulse A kV rms kV rms kV rms kV rms kV Hz kA KJ / kV kV peak A kg Volts
Reference current (IEC TC37-WG-4 1985) Reference current (IEC TC37-WG-4 1985) Over voltage withstand capability for a. 10 cycles b. 1 second c. Continuous
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------6.13 Energy discharge capacity KJ / kV 6.14 6.15 6.16 6.17 6.18 Maximum residual voltage at nominal discharge current Discharge voltage at 5 kA discharge current Discharge voltage at 10 kA discharge current Discharge voltage at 20 kA discharge current Impulse current withstand a. High current short duration (4 / 10 micro second wave) b. Low current long duration c. Virtual duration of rectangular wave 6.19 6.20 6.21 6.22 6.23 7.0 7.1 7.2 One minute power frequency (dry) withstand voltage of arrester housing Impulse withstand test voltage of arrester housing with 1.2/50 micro-second wave Total creepage distance of whole arrester housing Cantilever strength of complete arrester Pressure relief class (as per IEC 99) EHV SWITCHYARD CONTROL PANEL Make a. Degree of protection for enclosure of panel b. Sheet steel thickness mm kA peak A peak micro-second kV rms kV rms kV peak
kV peak kV peak
kV peak mm kg
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------7.3 Applicable standards 7.4 Indicating meters a. b. c. 7.5 Meter size Accuracy Type KWH METER a. b. 7.6 a. b. 7.7 Accuracy Whether pulse transmitting facility provided TRI VECTOR METER Make Type Yes / No
TRANSDUCERS a. b. c. d. Accuracy Output current No. of channels Type no. & make mA DC
7.8.
Describe annunciators scheme, features, sequence and size as offered (please attach write-up) Mimic material and width Indication lamps a. Make b. Type c. Rating, voltage / watts
Yes/No mm
7.9 7.10
V/W
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------7.11. Push buttons a. Make b. Number included c. No. of NO + NC contacts d. Function 7.12. Semaphore indicator a. b. c. d. Make Rating No. of coils Size offered i. for CB ii. for isolator main & earth switch e. nos. offered 7.13. Control Switch. / Selector Switch. a. Make b. Rating (DC inductive breaking capacity) 7.14. Hooter / Bell a. Make 7.15. EHV Switchyard Relay Panel a. Panel make and country of manufacture b. - Degree of protection for enclosure of panel - Sheet steel thickness c. Mounting of relays mm V/ Amps Watts No.
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars/ Data -----------------------------------------------------------------------------------------------------------------------d. Relay Particulars (furnish following data as applicable for all the relays offered. Attach necessary sheets as required) - Control voltage - Current rating - Voltage rating - Operating temperature range - Applicable standards - Aux. supply operating range - Online automatic testing facility provided - Online manual testing facility provided e. Relay types offered (list each relay and furnish the data for each relay used) f. 8.0 8.1 All the relays offered are type tested Yes/No V A V C
MISCELLANEOUS ITEMS ACDB / DCDB (fill in separately for ACDB & DCDB) a. Make b. Type (Draw-out / non drawout) c. Sheet steel thickness d. Degree of protection e. Busbar details - Material - Rated voltage - No. of phases mm
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars/ Data ------------------------------------------------------------------------------------------------------------------------ Current rating - Fault level withstand f. No. of switch fuse feeders x ratings : 1 x incomer x .A X outgoing x .A 8.2 Insulator and hardware (fill in for bus post insulator as well as insulator string) a. Insulator / Insulator string - Manufacture & country of manufacture - Applicable standard - Type of insulator (antifog / normal) - Insulating material - No. of units per string - Creepage distance i. Disc unit ii. String assembly - One minute power frequency withstand (dry) i. Single disc ii. String assembly / buspost - One minute power frequency (wet) withstand i. Disc unit kV kV kV kV mm mm
ii. String assembly / buspost
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars/ Data ------------------------------------------------------------------------------------------------------------------------ Impulse withstand voltage (dry) i. Disc unit kV peak kV peak kV peak kV peak kV peak
ii. String assembly / buspost - impulse withstand voltage (wet) i. Disc unit
ii. String assembly / buspost - Electro mechanical strength of each disc - Live parts to earth clearance (sparkover distance) - Cantilever strength (for bus post insulator only) - Tensile strength (for bus post insulator only) - Visual discharge voltage for falling power frequency voltage (string and bus post insulators) - Compression strength (for bus post insulator only) - Radio interference voltage for string and bus post insulator i. 8.3 Test voltage
kg mm kg kg
kV kg
kV micro volt
ii. Radio interference voltage INSULATOR HARDWARE a. Manufacture b. Applicable standard c. All ferrous parts are hot dip galvanised
Yes/No
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars/ Data -----------------------------------------------------------------------------------------------------------------------8.4 BUS CONDUCTORS, CLAMPS AND CONNECTORS a. Flexible conductor - Size of conductor for main bus & bus coupler bay buses - Size of conductor for other bay buses - The temperature rise of the conductor while carrying the rated current - Purity of aluminium / copper 8.5 Clamps and Connectors a. Whether material specification of the clamping and connectors are as per specification b. Temperature rise of the clamp while carrying the rated current c. Minimum thickness at any part of the clamps d. 9.0 9.1 9.2 9.3 9.4 9.5 Coronal extinction voltage for falling power frequency voltage C mm V Yes/ No % ACSR
CABLES Make Type Applicable standard Voltage grade Maximum conductor temperature a. Continuous b. Short time C C
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------9.6 Conductor a. Material b. Size c. No. & diameter of wire in each conductor 9.7 Insulation a. Material b. Type c. Thickness 9.8 Inner sheath a. Material b. Type c. Thickness d. Extruded? e. Approx. outside dia over sheath 9.9 Armouring a. Material b. Size c. D.C resistance at 20 9.10 Outer sheath a. Material b. Type c. Thickness ohm / km mm mm mm No. / mm sq.mm
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------9.11 Approx. overall diameter mm 9.12 9.13 10.0 10.1 Standard drum length with tolerance Net weight of cables ILLUMINATION SYSTEM Lighting Fixtures a. For outdoor switchyard i. Type ii. Make iii. Quantity x Watts iv. Designed lux level b. For switchyard control room i. Type ii. Make iii. Quantity & watts iv. Designed lux level c. For Battery room i. Type ii. Make iii. Quantity & watts iv. Designed lux. level 10.2 Lighting Panel a. Make b. No. of ways / circuits c. Incoming TPN MCB with ELCB rating / make d. Outgoing SP MCBs. i. Number ii.Rating mm kg / km
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------10.3 WIRING a. Main cables type / size b. Cables to fixtures type / size c. Method of cabling conduit / size 11.0 11.1 GENERAL ELECTRICAL ITEMS Cable Trays a. Make b. Type c. Width 11.2 11.3 Cable ties, clamps, identification tags, etc. provided? Rigid metal conduits, RCC hume pipes offered for Trench / rail crossing / in equipment foundations? Fence height / material details Granite metal work a. Size of metal b. Depth of spreading 11.6 All other standard items like hand gloves, shock treatment charts, rubber mats caution boards etc. furnished? EARTHING LIGHTNING PROTECTION Earthing a. Main grid conductor i. Material ii. Cross section b. Equipment connections i. Material ii. Cross section
11.4 11.5
Yes/No
12.0 12.1
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Unit Particulars / Data -----------------------------------------------------------------------------------------------------------------------13.0 TARIFF METERING PANEL (MAIN & CHECK) 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 Make of tri-vector meter Rated voltage & frequency (110V / 50 Hz) Rated current (1 amp) Type (Digital type) Accuracy class (0.2) Burden at rated voltage Is the Tri-vector meter bi-directional type Is the Tri-vector meter suitable for 2 part tariff Auxiliary power supply requirement (110V DC 10%) V DC VA V / Hz Amp
13.10 Does the tri-vector meter have maximum demand indicator as called for in the specification i) ii) iii) Does the tri-vector meter have A serial port suitable for Ethernet protocol A telemetry port for future communication through telephone lines
13.11 Construction of panel : i)

5
Panel sheet steel thickness Cable entry Access to the panel Ingress protection class Panel space heater (hygrostatically controlled) Panel illumination & small power socket Size of panel wiring
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mm
ii) iii) iv) v) vi) vii)
mm
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------14.0 BATTERY 14.1 14.2 14.3 14.4 14.5 14.6 Battery Manufacturer Type of battery No. of batteries Number of cells Voltage rating 14.7 14.8 14.9 14.10 14.11 14.12 Nominal cell voltage rating Nominal float charging voltage Nominal boost charging voltage Nominal cell discharge voltage
10 hour rating at 27C to 1.85 V / cell One (1) minute rating to 1.85 V cell Rated capacity at maximum ambient temperature (50C) AH Rated capacity at minimum ambient temperature (8.5C) AH Continuous load and duration a. Type of plates - Positive - Negative b. Type and material of container
14.13 14.14
Type of rack Number of racks / battery
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------14.15 Number of cells / rack 14.16 14.17 14.18 14.19 Type of rack rows / tiers Inter row, inter tier connectors and end take off furnished? Connection hardware with 5% extra furnished? Cable termination at positive negative and intermediate tap provided? Recommended specific gravity of electrolyte at the end of full charge and at first filling Type of separator Material and thickness of separator 14.22 14.23 14.24 14.25 Float charging current Boost charging current (initial & final) Internal resistance of one cell Short circuit current for dead short Across battery terminals at Yes/ No Yes/ No Yes/ No
14.20
14.21
14.25.1 Float charge voltage (in kA) 14.25.2 Boost charge voltage (in kA) 14.25.3 Equalising charge voltage 14.25.4 Only due to battery (in kA) 14.26 Cell voltage characteristics during charging furnished? Yes/No
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------14.27 Charging current of a fully discharged battery at 12 hours charging rate Charging efficiency of the battery Overall dimension of
14.28 14.29
14.29.1 Each cell (L x B x H) 14.29.2 Battery (L x B x H) 14.29.3 Battery layout furnished 14.30 Approximate weight (kgs) Yes/ No
1430.1 Each cell 14.30.2 Complete battery 14.31 14.32 14.33 15.0 List of accessories Spare parts as specified provided with equipment Ventilation requirements BATTERY CHARGER Float cum Boost Charger 15.1 15.2 15.3 15.4 15.5 Manufacturer type and ref. standard Input voltage with % variation Input frequency with % variation Output DC voltage Output current
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------15.6 Time required to fully charge the completely discharged battery under boost charging Float cum Boost Charger 15.7 15.8 15.9 15.10 15.11 Maximum AC input during boost charging Ripple in DC output Charger efficiency at rated output Temperature rise above ambient of 50C Regulation for 0-100% rated load with 10% voltage variation and - 5% to + 5% frequency variation Power factor at rated load Charger provided with a. Automatic voltage b. Current limiting circuitry and constant current regulator c. Smoothing filter circuit d. Soft start feature 15.14 SCR elements provided with a. Surge protection b. Fast acting semi conductor fuses 15.15 AC Switch a. Make b. Type c. Rating Yes/No Yes/No Yes/No Yes/No
15.12 15.13
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------15.16 AC Contactor a. Make b. Type c. Rating d. Coil rating Float cum Boost Charger 15.17 AC / DC fuse a. Make b. Type 15.18 Rectifier transformer a. Make b. Type c. Rating d. Insulation class e. Voltage ratio 15.19 Blocking diodes a. Make b. Type c. Current rating for 1 minute / 1 hour d. Peak inverse voltage continuous / surge 15.20 SCR a. Make b. Type c. RMS current rating d. Peak inverse voltage continuous / surge e. Max. temp rise above an ambient of 50C
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------15.21 DC Contactor a. Make b. Type c. Rating 15.22 Indicating lamps a. Make b. Wattage c. Rating 15.23 Push Button a. Make b. Type c. Rating d. No. of contacts 15.24 Meters a. Make b. Type c. Accuracy d. Size 15.25 Control terminals a. Make b. Type c. Rating
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-----------------------------------------------------------------------------------------------------------------------Sl. No. Description Particulars/ Data -----------------------------------------------------------------------------------------------------------------------15.26 Annunciator a. Make b. Type c. No. of windows 15.27 DC Switch a. Make b. Type c. Rating 15.28 Panel a. Make 15.29 15.30 15.31 15.32 15.33 15.34 List of accessories Heat output of the panel (furnish calculations) Overall dimensions of battery charger panel Approximate weight of charger panel Schematic diagram and write up of charger enclosed? Spare parts as specified provided with equipment SIGNATURE OF BIDDER _________________________ NAME DESIGNATION COMPANY SEAL DATE _________________________ _________________________ _________________________ Yes/ No
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SECTION B4
Approved Vendor List
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B4: 1
SECTION B4 APPROVED VENDOR LIST 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 110 kV circuit breakers 110 kV isolators 110 kV current transformer 110 kV voltage transformer 96 kV surge arrestors Control and relay panels Protection relays Tariff meters Insulators Battery & battery charger ABB / CGL / Siemens / Alstom Hivelm / Elpro / Versatek ABB / CGL / Alstom ABB / CGL / Alstom Oblum / Lamco / CGL / Alstom / Elpro ABB / Elpro / Alstom / Enpro ABB / Siemens / Alstom L&T / SEMS WSI / JSI / Modern Exide / HI-rel / Power Electronics / SAFT NIFE / Amararaja
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B4: 2
5.8 MGD Seawater Desalination Project Tender Enquiry Document for 110 KV Switchyard
SECTION C
Technical Specification for Civil & Structural Works
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : C : 1
SECTION-C1 GENERAL REQUIREMENTS.................................................................................. 6

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 SITE RELATED INFORMATION .................................................................................................... 6 SCOPE OF WORK............................................................................................................................. 6 SITE INVESTIGATIONS .................................................................................................................. 6 CONSTRUCTION FACILITIES ....................................................................................................... 7 PLANT LEVELS................................................................................................................................ 7 TRANSPORTING GOODS & MATERIALS.................................................................................... 8 METHODS OF CONSTRUCTION ................................................................................................... 8 DESIGN AND CONSTRUCTION REQUIREMENTS..................................................................... 8 COORDINATION AT SITE .............................................................................................................. 8 DESIGN AND DRAWING SUBMISSION ....................................................................................... 8
SECTION C2 DESCRIPTION OF BUILDINGS,STRUCTURES AND FACILITIES.............. 10

1.0.0 2.0.0 GENERAL........................................................................................................................................ 10 SWITCHYARD STRUCTURES & FOUNDATIONS .................................................................... 10
SECTION - C3 STRUCTURAL DESIGN AND DETAILING REQUIREMENTS .................... 12 SECTION - C3.1 TECHNICAL SPECIFICATION FOR DESIGN OF SWITCHYARD STRUCTURES ................................................................................................................ 12
1.0.0 2.0.0 3.0.0 4.0.0 SCOPE .............................................................................................................................................. 12 CODES AND STANDARDS........................................................................................................... 12 DESIGN, DETAILING AND CONSTRUCTIONAL ASPECTS.................................................... 12 DETAILS TO BE SUBMITTED...................................................................................................... 16
SECTION - C-3.2 TECHNICAL SPECIFICATION FOR DESIGN OF SWITCHYARD CIVIL WORKS............................................................................................................................ 18

1.0.0 2.0.0 3.0.0 SCOPE .............................................................................................................................................. 18 CODES AND STANDARDS........................................................................................................... 18 DESIGN , DETAILING AND CONSTRUCTION ASPECTS ........................................................ 18
SECTION C4 TECHNICAL SPECIFICATIONS....................................................................... 27 SECTION-C4.1 TECHNICAL SPECIFICATION FOR FABRICATION & ERECTION OF SWITCHYARD STRUCTURE ..................................................................................... 27
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 SCOPE .............................................................................................................................................. 27 CODES & STANDARDS ................................................................................................................ 27 DRAWINGS AND LISTS................................................................................................................ 28 MATERIALS.................................................................................................................................... 28 FABRICATION................................................................................................................................ 29 INSPECTION AND TESTING ........................................................................................................ 33 ERECTION....................................................................................................................................... 33
SECTION-C4.2 TECHNICAL SPECIFICATION FOR EARTHWORK IN EXCAVATION & BACKFILLING............................................................................................................... 36

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0
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SCOPE................................................................................................................................................. 36 CODES AND STANDARDS.............................................................................................................. 36 SETTING OUT ................................................................................................................................... 36 INITIAL LEVELS............................................................................................................................... 37 CLEARING AND GRUBBING ETC. ................................................................................................ 37 EXCAVATION AND CUTTING ....................................................................................................... 37 EXCAVATION IN ROCK.................................................................................................................. 37 VARIATION IN EXCAVATION....................................................................................................... 38 FICHTNER India
9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0
KEEPING WORKS SITE FREE FROM WATER ............................................................................. 38 PROTECTION OF WORK ................................................................................................................. 39 SHORING AND STRUTTING........................................................................................................... 39 DISPOSAL .......................................................................................................................................... 39 BACKFILLING AND FILLING IN PLINTH .................................................................................... 39 TESTING AND ACCEPTANCE CRITERIA..................................................................................... 40
SECTION-C4.3 TECHNICAL SPECIFICATION FOR PILING ................................................. 41

1.0.0 PILING ............................................................................................................................................. 41
SECTION C4.4 INTENTIONALLY OMITTED ........................................................................... 47 SECTION-C4.5 TECHNICAL SPECIFICATION FOR PLAIN AND REINFORCED CONCRETE WORK ...................................................................................................... 48
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 16.0.0 17.0.0 18.0.0 19.0.0 SCOPE .............................................................................................................................................. 48 CODES AND STANDARDS........................................................................................................... 48 MATERIALS.................................................................................................................................... 49 GRADES AND PROPORTIONING................................................................................................ 50 MIXING............................................................................................................................................ 51 PLACING ......................................................................................................................................... 51 COMPACTION ................................................................................................................................ 52 CONSTRUCTION JOINTS ............................................................................................................. 52 CURING AND PROTECTING........................................................................................................ 53 FINISHING ...................................................................................................................................... 53 FORMWORK & CENTERING ....................................................................................................... 53 REINFORCEMENT ......................................................................................................................... 54 STEEL EMBEDMENTS .................................................................................................................. 55 EXPANSION & ISOLATION JOINTS ........................................................................................... 55 PRECAST CONCRETE ................................................................................................................... 58 WATERPROOFING OF CONCRETE TO STRUCTURES............................................................ 59 TESTING.......................................................................................................................................... 60 ACCEPTANCE CRITERIA ............................................................................................................. 61 STORAGE AND HANDLING OF MATERIALS........................................................................... 64
SECTION-C4.6 TECHNICAL SPECIFICATIONS FOR PRECAST RCC ROOFING UNITS........................................................................................................... 66

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 1.0.0 2.0.0 3.0.0 4.0.0
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SCOPE .............................................................................................................................................. 66 CODES OF PRACTICE ................................................................................................................... 66 JOB PLANNING .............................................................................................................................. 66 MOULDS.......................................................................................................................................... 66 DIMENSIONAL TOLERANCES .................................................................................................... 67 PLACING THE REINFORCEMENTS............................................................................................ 69 CONCRETE PLACEMENT............................................................................................................. 69 SURFACE FINISH........................................................................................................................... 69 MARKING OF UNITS..................................................................................................................... 70 REMOVING MOULDS ................................................................................................................... 70 CURING ........................................................................................................................................... 70 STORAGE ........................................................................................................................................ 71 PROTECTION.................................................................................................................................. 71 LOAD TESTS................................................................................................................................... 71 ERECTION....................................................................................................................................... 72 SCOPE .............................................................................................................................................. 74 CODES AND STANDARDS........................................................................................................... 74 MATERIALS.................................................................................................................................... 75 STORAGE AND HANDLING ........................................................................................................... 75 FICHTNER India
SECTION-C4.7 TECHNICAL SPECIFICATION FOR MASONRY WORKS .......................... 74
5.0.0 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0
WORKMANSHIP ............................................................................................................................ 75 SCOPE .............................................................................................................................................. 81 CODES AND STANDARDS........................................................................................................... 81 MATERIALS.................................................................................................................................... 81 GRADING UNDERBED ................................................................................................................. 83 WATERPROOFING WITH PREFABRICATED POLYETHYLENE AND POLYMERIC ASPHALT ........................................................................................................................................ 83 WATER PROOFING WITH HESSIAN BASED BITUMEN FELTS............................................. 84 WATERPROOFING WITH FIBRE GLASS TISSUE REINFORCED BITUMEN FELT ............. 86 WATER PROOFING OF ROOFS WITH BRICK LIME CONCRETE AND PRESSED FLAT TILES ............................................................................................................................................... 86 ELASTOMERIC MEMBRANE WATERPROOFING.................................................................... 87 ACCEPTANCE CRITERIA ............................................................................................................. 88
SECTION-C4.8 TECHNICAL SPECIFICATION FOR WATERPROOFING........................... 81
SECTION-C4.9 TECHNICAL SPECIFICATION FOR WATER SUPPLY, DRAINAGE AND SANITARY WORKS...................................................................................................... 89
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 SCOPE .............................................................................................................................................. 89 CODES AND STANDARDS........................................................................................................... 89 MATERIALS.................................................................................................................................... 91 GENERAL........................................................................................................................................ 92 INSTALLATION ............................................................................................................................. 92
SECTION-C4.10 TECHNICAL SPECIFICATION FOR PAINTING COLOUR WASHING ETC................................................................................................................................. 101

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 SCOPE ............................................................................................................................................ 101 CODES AND STANDARDS......................................................................................................... 101 MATERIALS.................................................................................................................................. 102 WHITE WASHING, COLOUR WASHING AND DISTEMPERING .......................................... 103 PAINTING AND POLISHING ..................................................................................................... 104 ACCEPTANCE CRITERIA ........................................................................................................... 106
SECTION-C4.11 TECHNICAL SPECIFICATION FOR FLOOR AND FLOOR FINISHING.................................................................................................................... 107

1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 SCOPE ............................................................................................................................................ 107 CODES AND STANDARDS......................................................................................................... 107 BOULDER SOLING ...................................................................................................................... 107 CEMENT CONCRETE FLOORING ............................................................................................. 108 FLOOR FINISHES......................................................................................................................... 108
SECTION-C4.12 TECHNICAL SPECIFICATION FOR DOORS, WINDOWS, LOUVRES, ROLLING SHUTTERS & GLAZING .................................................. 119
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 SCOPE ............................................................................................................................................ 119 CODES AND STANDARDS......................................................................................................... 119 MATERIALS & WORKMANSHIP............................................................................................... 120 STORAGE AND HANDLING ...................................................................................................... 124 ASSEMBLY AND ERECTION..................................................................................................... 124 HARDWARE AND FIXTURES.................................................................................................... 125
SECTION-C4.13 TECHNICAL SPECIFICATION FOR FALSE CEILING AND FALSE FLOORING ................................................................................................................... 126
1.0.0 2.0.0 3.0.0 SCOPE ............................................................................................................................................ 126 CODES AND STANDARDS......................................................................................................... 126 MATERIALS.................................................................................................................................. 126
SECTION-C4.14 TECHNICAL SPECIFICATION FOR ROAD WORK ................................. 129

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1.0.0 2.0.0 3.0.0 4.0.0 1.0.0 2.0.0 3.0.0
SCOPE ............................................................................................................................................ 129 CODES AND STANDARDS......................................................................................................... 129 EXECUTION.................................................................................................................................. 130 QUALITY CONTROL & TOLERANCE ...................................................................................... 153 SCOPE ............................................................................................................................................ 156 CODES AND STANDARDS......................................................................................................... 156 MATERIAL & INSTALLATION.................................................................................................. 156
SECTION-C4.15 TECHNICAL SPECIFICATION FOR GATE & FENCING ........................ 156
SECTION-C4.16 INTENTIONALLY OMITTED ....................................................................... 158 SECTION-C4.17 TECHNICAL SPECIFICATION FOR SOIL INVESTIGATION ................ 159
1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 16.0.0 17.0.0 18.0.0 19.0.0 20.0.0 21.0.0 22.0.0 SCOPE ............................................................................................................................................ 159 CODES AND STANDARDS......................................................................................................... 159 EQUIPMENT AND PERSONNEL................................................................................................ 160 SETTING OUT............................................................................................................................... 160 EQUIPMENTS ............................................................................................................................... 160 BORING THROUGH SOIL........................................................................................................... 161 ROCK DRILLING.......................................................................................................................... 161 COLLECTION OF SAMPLES ...................................................................................................... 162 TRIAL PITS ................................................................................................................................... 163 STANDARD PENETRATION TEST (SPT) ................................................................................. 163 STATIC CONE PENETRATION TEST........................................................................................ 163 DYNAMIC CONE PENETRATION TEST................................................................................... 164 PLATE LOAD TEST ..................................................................................................................... 164 CYCLIC PLATE LOAD TESTS.................................................................................................... 164 VANE SHEAR TEST..................................................................................................................... 164 IN-SITU PERMEABILITY TEST ................................................................................................. 165 MENARD PRESSUREMETER TEST........................................................................................... 165 BLOCK VIBRATION TEST.......................................................................................................... 165 WAVE PROPAGATION TEST ..................................................................................................... 165 MEASUREMENT OF EARTH RESISTIVITY............................................................................. 166 LABORATORY TESTS ................................................................................................................ 167 SOIL REPORT ............................................................................................................................... 167
SECTION C-5 DATA DRAWINGS AND MAPS.......................................................................... 169 ANNEX 1 ANNEX 2 ANNEX 3 ANNEX 4 SCHEDULE OF BUILDING FINISHES ............................................................. 169 TOPOGRAPHIC DATA ........................................................................................ 170 GE-TECHNICAL DATA....................................................................................... 171 LOCATION MAP................................................................................................... 172
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SECTION-C1 GENERAL REQUIREMENTS 1.0.0 SITE RELATED INFORMATION The salient information regarding the location, access and the general information for the sites for the plant and the related works is given in Section C2 2.0.0 SCOPE OF WORK The detailed scope of civil works for 110 KV switchyard is given section B1.0.0 3.0.0 SITE INVESTIGATIONS The Contractor shall carry out additional site investigations as deemed necessary and shall submit the detailed work procedures and program for all site investigation work prior to undertaking the work. The sub-Contractor(s) for such site investigation shall be approved by the Owner. The Contractor shall do the job in such a way that he satisfies himself and the Owner/Engineer on the accuracy and sufficiency of the study and gets the Owner/Engineer approval on this regard. The Contractor shall submit full report of the work to Owner and Engineer for review and approval. 3.1.0 TOPOGRAPHICAL SURVEY Topographical information, maps, drawings before the site filling as available with the Owner are enclosed with this tender document as information for the Bidder refer C5 Annex 2. The Contractor shall confirm the final filled up level of the site before start of construction work to establish the plant to proper lines and levels. The Contractor shall submit a final drawing to the Owner which shall include the final graded levels of the site, filling areas etc. 3.2.0 GEO-TECHNICAL SURVEY Geotechnical information for various areas of the project as per proposed layout and as available with the Owner are enclosed with this tender document as guidance for the Bidder to quote after making his own assessment of the site(s) refer Annex 3. The site has been subsequently filled to a height of EL(+) 1.800m above chart datum with the FFL of EL(+)2.400m. This shall be considered while determining foundation design and detailing. Comprehensive geo-technical site investigation shall be carried out by the Contractor and upon his full responsibility based on the general layout of the switchyard, in order to have complete and clear information regarding the type of soil layers, physical and chemical characteristic of soil, allowable bearing pressures, prediction of settlements geo-technical features etc. for safe and economical design of the plant buildings, structures and equipment foundations. Minimum requirement specifications of geo-technical soil investigation is given in Section C4.17.
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4.0.0
CONSTRUCTION FACILITIES The Contractor shall provide all temporary offices, laboratories, sanitary conveniences, store, workshop, compounds, parking areas, etc. necessary for the completion of the works. The setting and layout of these shall be in such a manner as to not interfere with the construction and operation of the plant when completed and shall be to the general approval of the Owner / Engineer. The temporary buildings shall be handed over to Owner at the end of the Contract or otherwise disposed of as directed by the Engineer. All temporary buildings shall be maintained in a clean condition and operated efficiently. All buildings must at all times be open to the inspection of the Owner / government authorities and, the Contractor shall comply with any instruction given by him for the proper cleaning, disinfection, and general maintenance in a sanitary and hygienic condition of the buildings. In order to enable the Owner for providing the space for the Contractors site offices, canteen, locker rooms, storage sheds and any other facilities required by Contractors personnel, the Contractor shall give a layout and the area requirement and any other information which may facilitate the Owner in providing space for these temporary site facilities. Layout of temporary offices for Owner / Consulting Engineer shall be provided for approval. The area of these buildings shall be as per the list at the end of this clause. In addition to his own facilities, the Contractor shall be responsible for mobilization to supply the following items. The details and quality of the facilities proposed by the Contractor shall be submitted to the Owner and approved by Owner: 1. 2. Offices for site personnel of the Contractor and the Owner (separate office room for 4 persons of the Owner / Engineer) with telephone, Fax and PC. Temporary canteen / pantry inside temporary office building for Owners personnel and Contractors personnel as per site requirement with attendant / office help for miscellaneous duties Toilet and sanitary services according to acceptable standards and cleanliness. Temporary workshops, if required. (only location shall be approved) Construction equipment in good working order Temporary access to the site
3. 4. 5. 6.
The Contractor shall be fully responsible for mobilization and demobilization of the temporary site facilities. 5.0.0 PLANT LEVELS The Owner shall establish a datum on site at the commencement of the contract and all levels shall be referred to this datum. Surveying instruments with high quality and one second accuracy and in appropriate quantities shall be used by the Contractor during Construction. The Contractor is fully responsible to provide final topography drawings to the Owner.
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6.0.0
TRANSPORTING GOODS & MATERIALS The Contractor is fully responsible for transporting the goods and material from the places of origin to the Site and for Custom Clearances, if any. The Contractor is also fully responsible for taking all the measures and for getting the necessary permits for local land transport of heavy or abnormal goods or materials.
7.0.0
METHODS OF CONSTRUCTION The Contractor shall submit documents with the details of methodology of construction and the equipment he proposes to utilize for all major structures and foundations. The Contractor shall also submit his testing and quality assurance plan for these for the approval of the Owner.
8.0.0
DESIGN AND CONSTRUCTION REQUIREMENTS The design of all buildings, structures and civil work shall be as per the requirements of Section C2 & C3 of this specification and the construction of buildings, structures and civil work shall conform to the requirements of Section C4.1 through C4.17 of this specification.
9.0.0
COORDINATION AT SITE The Contractor shall at all times maintain accesses, facilities without hindrance to others, carry out his work in such a way and in close coordination with other agencies working at the site so that the work proceeds in a systematic and planned way. No stoppage of work due to disputes arising from lack of coordination shall be entertained by the Owner / Engineer.
10.0.0 DESIGN AND DRAWING SUBMISSION 10.1.0 During Bid Stage The drawings issued with this specification and forming a part of the documents for bidding purposes are intended to be descriptive of the character of the works and used in conjunction with the requirements of the specification and shall in no way limit the responsibility of the Contractor to supply all plant equipment, materials and services necessary to provide a complete and functional system. Any omission from both drawings and the specification or express reference to any detail or work necessary and obviously intended shall not relieve the Contractor of his responsibility to include such detail or work in his supply. The details of buildings shown on the tender drawings supplied by the Owner have not been finally fixed since these are dependent on the size and shape of the equipment and materials forming the works and the space required for installation, maintenance, access etc. The tender drawings attached only portray the basic layout of the scope of works and the Bidder shall incorporate these requirements into his bid drawings. The Bidder has to ensure that the information provided within the specification is sufficient for him to state his final lump sum price. After the bid has been submitted the Bidder is deemed to have checked all documents and drawings and they are without restriction accepted by him. No claim resulting from omissions from or discrepancies in the bid documents shall be accepted by the Owner.
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12.2.0 After award of contract The Contractor shall submit his detailed schedule for submission of all information, documentation, calculations, drawings, schedules etc within such periods or dates, which are required to guarantee a smooth handling of the project without delays. The construction programme shall be submitted within 14 days after the Letter Of Intent (LOI) is issued, so as to match the completion period of the contract for successful commissioning. After award of contract, the Contractor shall submit the designs, layout and construction drawings and detailed working drawings along with bar bending schedule for all structures and items covered under the scope of this contract. This shall be submitted progressively and in no case the 1st set of design and drawings shall be submitted later than 30 days from the date of issue of the LOI to the Contractor. The quality of the submitted documents must be in accordance with acceptable national practice and allow a speedy checking procedure. Documents not fulfilling these requirements shall be returned to the Contractor without comment for improvement and resubmission. It is solely at the discretion of the Engineer to decide whether or not documents are acceptable. The design drawings shall consist of general arrangement drawings showing location of tower and various equipment foundation along with cable trenches, road, roadside drains and drains inside the switchyard, transformer foundation, central oil collecting and sump pits, oil water separator and all other related items/services required for the project. Subsequently detailed drawings along with design calculation and bar bending schedule for the foundations and all other civil works shall be submitted by the Contractor for approval. Detailed dimension drawings and design calculation for all civil and structural works shall be submitted to the Owner / Owners Consultant for scrutiny and approval. All designs and drawings shall be got approved within a period of six months from the date of issue of Letter of Acceptance (LOA).
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SECTION C2 DESCRIPTION OF BUILDINGS,STRUCTURES AND FACILITIES 1.0.0 1.1.0 GENERAL BRIEF SITE INFORMATION The location map of the proposed plant site is shown in drawing no K3Z12-DWG-M0001 [C5 -Annex 4] .The plant site lies to the eastern side of the ash pond for the North Chennai Thermal Power Station and was converted from salt pans to petrochemical park by TIDCO. Motorable road from the east or the west of the ash pond leads to with in approx. 350m of the plant site . Close to the middle eastern side road of the ash pond there is a nullah with a concrete culvert through which the plant site can be accessed. This is the take off point for the access road. The entire area ( as it was formerly salt pans) is generally 0.5m below the Chart Datum. The top 3-5 m of soil consists of very loose to loose silt with SPT value around 1. 2.0.0 2.1.0 2.1.1 SWITCHYARD STRUCTURES & FOUNDATIONS Transformer Yard The transformers shall be founded on piles (to be confirmed after soil investigation). Individual transformers shall have its own pit which would cover the area of the transformer and cooler banks, so as to collect any spillage of oil or oil drainage in case of emergency. The oil pit shall be filled with granite stones of 40 mm size uniformly graded to a depth of 150 mm spread on galvanized steel floor gratings The individual oil pits shall be connected to an oil collection pit, which shall be sized to accommodate oil volume of the largest transformer connected to it, without backflow. The oil pit shall be connected to an oil water separator, with a separate chamber for separated oil, with provision for pumping and reuse of oil. Dimensions of the discharge pipe shall consider rainfall intensity also. The water shall be discharged into the nearest drain by gravity flow or pumping. Fire barrier walls shall be provided where required from layout considerations and as per relevant regulations. Transformer rails as per profile indicated by the transformer manufacturer shall be provided for installing and removal of the transformer for maintenance from the unloading / loading point to its final position on its foundation. Rail track foundation shall incorporate jacking pads foundation at intersections of rail racks, if any. Pulling hooks shall be provided at suitable locations for pulling the transformers over the rails. 110 KV Switchyard All steel structure for the switchyard shall be hot double dip galvanised structure with welded / bolted connection at shop and bolted connection at site. All bolts and nuts shall also be galvanised. Minimum zinc consumption shall be 910 gms per square meters of exposed surface. The major steel structures in the switchyard are towers, beams, lighting masts etc. They all shall be of latticed construction using angle sections. In addition supporting structure
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2.1.2
2.2.0
FICHTNER India
for equipment, such as isolator, lightning arresters, etc shall also be provided. These structures may be of tube section or latticed as the case may be. Lighting masts shall be provided with cage ladder. Where platforms are provided on lighting masts for mounting of lighting fixtures, they shall have protection handrails formed of galvanised section. Platforms shall be of galvanised gratings. All towers and heavy equipments shall be supported on piles (to be confirmed after soil investigation) A minimum of 100 mm thick crushed stone shall be spread in the switchyard area extending one meter beyond the fence. Necessary drainage arrangement to take care of on line cleaning water shall be provided. A double swing gate of adequate width (minimum 3.5 m wide) and a wicket gate shall be provided. Gates should not be self- locking. Fencing of 2.5 m height (chain link fencing) including 3 strands of barbed wire on top shall be provided. All trenches shall be of RCC. The trench wall shall project 150 mm above the paved / graded level to prevent ingress of storm water. All trenches shall be filled with sand after cable laying is complete before covering the same with trench cover. All trenches shall be given a slope of minimum 1 in 750 and the slope shall lead to a sump, where pump can be installed for drainage. 2.3.0 Switchyard Control Room The switchgear and control room shall be single storied RCC framed brick clad structure. Plinth protection shall be provided all around the building. Roof shall be suitably sloped to effect proper drainage. No openings shall be permitted on the roof excepting those essential so as to exercise proper control on air conditioning. Partition between control room and adjoining rooms shall be of glazed aluminium partition with 300 mm high brickwork at bottom for toe protection. All the doors shall be single leaf glazed aluminium doors for all cabins. For movements of panels suitably sized double leaf aluminium glazed doors shall be provided. Control room wall up to the false ceiling level shall be of aluminium- glazed partition on either side of air lock. In other area cladding shall be of brickwork. UPS room shall be provided with brickwork cladding all round to reduce sound nuisance. Sufficient openable and fixed windows / ventilators shall be provided for natural day lighting and ventilation. These shall be of robust and leak tight construction suitable for the sea environment. The opening and closing mechanism for openable joinery items shall be within easy reach. The control room bay shall be provided with aluminium false ceiling such as LUXALON. False ceiling shall be designed aesthetically and properly arranging the supply air diffuser, return air grills, fire protection sprinklers, fire detectors and lights. The control room shall have a structural RCC floor with openings through which the cables will enter the panels. The control room building shall be fully air-conditioned and shall have toilet and bathroom facilities. The finishes for control room shall be as per C5 Annex -1
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SECTION - C-3 STRUCTURAL DESIGN AND DETAILING REQUIREMENTS SECTION - C-3.1 TECHNICAL SPECIFICATION FOR DESIGN OF SWITCHYARD STRUCTURES
1.0.0
SCOPE This specification covers the structural design requirements for Switchyard Structures.
2.0.0
CODES AND STANDARDS The following Codes and Standards (latest editions) shall be referred to : IS : 800 IS : 802 (All Parts) IS : 806 IS : 1161 Code of practice for general construction in steel Code of practice for use of structural steel in overhead Transmission Line Towers Code of practice for use of steel tubes in general building Construction. Steel tubes for structural purpose.
As the Bureau of Indian Standards have adopted IS : 802 (Part 1 / Sec 1) : 1995 (Third Revision) and IS : 802 (Part 1 / Sec 2) : 1992 (Third Revision) these codes shall supersede IS : 802 (Part 1) : 1977 (Second Revision). The Contractor shall adopt the design concepts as per the revised standards. 3.0.0 DESIGN, DETAILING AND CONSTRUCTIONAL ASPECTS The loading for the design of switchyard structures shall be as per IS: 802 Part 1/Sec 1:1995 (latest edition). Following loads shall be considered : a) b) c) d) e) g) h) i) Dead load due to equipment and structure. Wind load on towers, conductors, ground wires and insulator strings calculated as per Cl. 8 and 9 of IS: 802. Temperature effects consisting of effect of temperature variation and sag tension as per Cl. 10 of IS:802. Climatic loads as per Cl. 11.2 of IS:802. Anti cascading loads as per Cl. 11.3.1 of IS:802. Torsional and longitudinal loads caused by breakage of conductor as per Cl. 11.3.2 and 16 of IS:802. Construction and maintenance loads Seismic loads as per IS:1893-2002. Short circuit forces including snap effect in the case of bundled conductors.
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Switchyard structures shall be designed for the worst combination of above loads. The factor of safety for design of members shall be considered as 2 for normal & broken wire conditions and 1.5 for combined short circuit and broken wire conditions. Short circuit forces and wind forces shall not be considered simultaneously. Foundations shall be designed for a factor of safety 2.2 for normal and broken wire condition and 1.65 for combined short circuit and broken wire conditions. Design of foundation shall be carried out as per IS: 4091. 3.1.0 Dead Loads Dead loads consist of the weights of the complete structure with finishes, fixtures, partitions, wall panels and all equipment of semi-permanent nature, piping, cable trays etc. The piping loads, cable tray loads shall be listed separately so that they can be excluded from dead load when dead loads are acting as stabilising load for uplift. The following unit weight of material shall be considered for computation of loads. Loads given in IS:875 (part-I) shall be made use for the material not listed below. Materials Structural steel 3.2.0 Imposed Loads Imposed loads in different areas shall include live loads, minor equipment loads, cable tray loads, erection loads, operation/ maintenance loads etc. The loads considered shall not be less than that specified in IS:875 (Part II). The loads listed hereunder are the minimum loads for the areas involved. Special use areas shall be investigated and loads revised upward as necessary. Floors and supporting members, which may be subjected to heavy equipment live loads shall be designed on the basis of the weight of equipment or specifically defined live loads, whichever is greater. a) b) The specific minimum floor live loads are listed below Chequered plate/gratings Walkways : : 5 kN/sqm 3 kN/sqm : Unit weight 78.5 kN/cum
Live load reduction shall be in accordance with the provisions of IS:875 and IS:1893 in case of seismic analysis. 3.3.0 Seismic Load Seismic forces shall be as per IS:1893 : 2002. Particular attention is drawn to calculation of the design base shear as per relevant clause of the code while using response spectrum method. For switch yard buildings seismic coeficient method shall be used. The importance factor for all plant buildings and structures shall be taken as 1.5 and for other minor structures as per IS:1893:2002. Dynamic lateral soil / liquid pressure shall be considered in design wherever significant.
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3.4.0
Equipment Load
Static loads of major equipments shall be based on the manufacturers data of the specified equipments and shall be considered in design in addition to the live load. However, where the uniform floor live load adequately accounts for the equipment moving weight, the weight of such equipment as a dead load is not to be considered
Weight of equipments, ducts, conduits, etc. supported by structure shall include maximum possible loading conditions i.e. flooded conditions and associated impacts, test loading, anchorages and constraint effects. 3.5.0 Wind Loads Wind load shall be in accordance with IS : 802 (Part 1 / Sec 1) : 1995. For arriving at the design wind speed as per the code, the following values shall be adopted for the different factors, Basic Wind Speed K1 factor K2 factor = = = 50 m/s 1.0 Corresponding to Terrain Category 2
Reliability level 1 shall be adopted. The wind pressure on the Towers, Conductor, Ground wire and Insulator strings shall be in line with Clause 8 and Clause 9 and Sub Clauses thereof of the same code. 3.5.1 3.5.2 Wind shall always be assumed to act perpendicular to the Conductor / Rigid bus for structural analysis purposes. Diagonal wind / inclined wind shall be considered for isolated self supporting structures like lighting and lightning masts, poles only. Switchyard structures, which are interconnected either by beams or rigid buses, need not be analysed for inclined wind loading. Temperature and Temperature Variations This shall be as per Clause 10 of IS : 802 (Part 1 / Sec 1) : 1995. However, the minimum temperature of conductors shall be taken as 10C and maximum temperatures of current carrying conductors exposed to sun shall be taken as 75C for ACSR conductor where static ground wires are involved the maximum temperature shall be taken as 53C. 3.7.0 3.7.1 3.7.2 Other Loads Short Circuit Forces in combination with wind or seismic forces along with other normal forces shall be considered for the structural analysis of tower / structures. Other loads shall be as per IS : 802 (Part 1 / Sec 1) : 1995, broadly classified as, 1. Climatic Loads 2. Failure containment loads and
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3.6.0
FICHTNER India
3. Construction and maintenance loads These loads shall be computed in line with Clause 12 and Sub - Clauses thereof of IS : 802 (Part 1 / Sec 1) : 1995. 3.7.3 3.8.0 Anti Cascading checks, Tension limits, Broken wire condition and Strength Factors related to Quality shall be as per IS - 802 (Part 1 / Sec 1) : 1995. Permissible stresses, slenderness ratios of members, minimum thickness of steel members, net sectional area of tension members and bolting and framing shall be as per IS : 802 (Part 1 / Sec 2) : 1992. All switchyard structures shall be designed for the worst combination of dead loads, live loads, wind loads and thermal loads as per IS : 802 (latest), Seismic forces as per IS : 1893 (latest), loads due to deviation of conductor, load due to unbalanced tension in conductor, torsional load due to unbalanced vertical and horizontal forces, erection loads, short circuit forces including `Snap in the case of bundled conductors etc.
3.9.0
3.10.0 Wind & Seismic forces shall not be considered simultaneously in any load combination. 3.11.0 The design of structure shall be based on the condition where stringing is done only on one side i.e. all the three conductors broken on the other side. A factor of safety of 2.0 under normal and broken wire condition and 1.5 under combine short circuit and broken wire conditions shall be adopted for design. 3.12.0 Three-dimensional analysis shall be carried out for structures like towers and girders while two dimensional analysis may be adopted for equipment support structures. Any non-standard software used shall be validated with manual calculations. 3.13.0 Vertical load of half the span of conductors/ string and the earth wires on either side of the beam shall be taken into account for the purpose of design. Weight of man the tools shall be considered as 150 kgs for the design of structures. 3.14.0 Terminal/line take off gantries shall be designed for a minimum conductor tension. The distance between terminal gantry and dead end tower shall be taken as 200 meters. The design of these terminal gantries shall also be checked considering 30 deg. Deviation of conductor in both vertical and horizontal planes. For other gantries the structural layout requirements shall be adopted in design. 3.15.0 The girders shall be connected with lattice columns by bolted joints. 3.16.0 All pipe support used for supporting equipments shall be designed for the worst combination of dead loads, erection loads, wind loads/seismic forces, short circuit forces and operating forces acting on the equipment and associated bus bar as per IS:806. The material specification shall be as per IS:1161 read in conjunction with IS:806. 3.17.0 If luminaries are proposed to be fixed on gantries/towers, then the proper loading for the same shall be considered while designing. Also holes for fixing the brackets for luminaries should be provided wherever required. 3.18.0 Foundation bolts shall be designed for the loads for which the structures are designed.
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3.19.0 Lightning mast shall be 50 m in height (47.5 m lattice structure plus 2.5 m pipe and designed for diagonal wind condition. Lighting masts shall be provided with a structural steel ladder within its base up to a height of 25 meter. The ladder shall be provided with protection rings. Two platforms shall be provided one each at 12.5 m and 25.0 m height for mounting of lighting fixture. The platforms shall also have protection railing. The details for lighting fixtures would be as per the approved drawings. 3.20.0 For materials and permissible stresses IS:802, part1, section 2 shall be followed in general. However, additional requirements given in following paragraphs shall be also considered. 3.20.1 Minimum thickness of galvanized lower member shall be as follows: Members Leg members, ground wire peak members / main members Other members Redundant members Minimum thickness (mm) 5 4 4
3.20.2 Maximum slenderness ratio for leg members, other stressed members and redundant members for compression force shall be as per IS:802. 3.20.3 Minimum distance form hole center to edge shall be 1.5 x bolt diameter. Minimum distance between center to center of holes shall be 2.5 x bolt diameter. 3.20.4 The minimum bolt diameter shall be 16 mm. 3.20.5 Each tower shall be provided with step bolts not less than 16 mm diameter and 175 mm long spaced not more that 450 mm apart, staggered on faces on one leg extending from about 0.5 meters above ground level to the tower. The step bolt shall conform to IS:10238. Ladders on towers with lighting appliances shall be provided with safety guards. 3.21.0 The fabrication and erection works shall be carried out generally in accordance with IS:802. A reference however may be made to IS:800 in case of non-stipulation of some particular provision in IS:802. All materials shall be completely shop fabricated and finished with proper connection, materials and erection marks for ready assembly in the field. 3.22.0 Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded in first stage concrete while the foundation is cast. The Contractor shall ensure the proper alignment of these bolts to match the holes in the base plate. 4.0.0 4.1.0 DETAILS TO BE SUBMITTED The Contractor shall submit the following along with the bid: a. Design basis for civil and structural works including description of software to be used. b. Structural loading diagram
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c. Cable trench sectional details d. Detailed lay out of the buildings indicating location of equipment, taking in to account of clearances for cable trays, piping etc 4.2.0 The Contractor shall submit the following after award of Contract in line with the scope of work: a. Design report for design of civil & structural works in switchyard area including detailed calculation b. Structural loading diagram c. Cable Trenches sectional details d. Design and detailed drawings for towers, girders and all equipment supporting structure including fastener and foundation bolts etc. e. Design and detailed drawings for all civil works such as equipment foundations, equipment support foundations etc. f. Design and detailed drawings for preparation of the yard such as paving, granite stone fill, roads, drainage, soak pits etc.
g. Design and detailed drawings for transformer foundations and other accessories to the transformers such as rail support, jacking pad support etc. h. Design and drawings for Switchyard Control Building. f. In addition to the above requirements the Supplier / Contractor shall provide any other drawing or document to enable the Owner or his representative to carry out his responsibilities for the completion of the project.
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SECTION - C-3.2 TECHNICAL SPECIFICATION FOR DESIGN OF SWITCHYARD CIVIL WORKS 1.0.0 SCOPE This specification covers design and constructional requirement for all civil works such as foundation for towers, equipment and equipment support structures, cable trenches, paving, drains, control room etc. 2.0.0 CODES AND STANDARDS The following Codes and Standards (latest editions) shall be referred to : IS : 456 IS : 802 IS : 875 IS : 1893 IS : 1080 IS : 190 1 IS : 4091 IRC-6 3.0.0 3.1.0 Codes of Practice for plain and reinforced concrete. Code of Practice for use of structural steel in overhead (All Parts) Transmission Line Towers. Code of Practice for structural safety of building (All Parts) Loading standards. Criteria for earthquake resistant design. Code of practice for Design and Construction of simple spread foundation. Code of practice for structural safety of building foundation. Code of Practice for Design and Construction of Foundations for transmission line towers and poles. Indian Road Congress Standard Specification and Code of practice for Road Bridges.
DESIGN , DETAILING AND CONSTRUCTION ASPECTS The type of foundation system, i.e. isolated, strip, raft or pile to be adopted shall be decided based on the structure, loading arrangement, load intensity and soil strata. Design of foundations at various levels shall be dependent upon the soil bearing capacity at that level. All foundations shall be designed for the most critical load combination of dead loads, live loads, inertia forces, wind and seismic loads, short circuit forces and secondary effects such as shrinkage, rise and fall in temperature, swelling and shrinking pressure of soil etc and other relevant loading from service condition arrived based on detailed structural analysis of the switchyard gantry structures, equipment superstructures etc. For switchyard foundations anchor bolt with mechanical anchorage shall be provided along with foundation concrete. Bolts in pocket shall not be adopted.
3.2.0
3.3.0
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3.4.0
All tower / gantry structures and lightning mast foundations shall have stub angle embedded in the foundation while equipment supporting structures shall have foundation bolts and base plate type of connection for transferring load from the superstructure to the foundations. Foundation for all towers equipment support structure, equipments and poles shall be designed as per the recommendations of IS : 4091. The structural design of the foundation shall be done as per limit state method of design as given in IS:456 and considering the following partial safety factors on working load: Normal and broken wire condition Broken wire condition with short circuit forces 1.5 1.2
3.5.0
3.6.0 3.7.0
The foundation design shall be done based on soil parameters obtained from the soil investigation report. Normally, all the four legs of tower / gantry structures column / equipment supporting structures shall be supported on a common foundation until and unless the leg spacing of structures at foundation level and soil conditions permit isolated foundation under each leg of the structure. For checking the stability the following factor of safety shall be used: Normal and broken wire condition Broken wire condition with short circuit forces 2.2 1.65
The stability of the foundations shall be checked against overturning, bearing on soil, uplifting, sliding etc. 3.8.0 The chimney provided for the towers shall be designed as a composite member for combined action of axial forces viz. compression and tension and bending moments due to both the horizontal shears in both the longitudinal and transverse directions. A minimum of 4 numbers 12 mm diameter bars or 0.15% of cross section area of the chimney, whichever is more shall be provided and spacing of the main bar shall not be more than 300 mm. The centroidal axis of the stub shall coincide with the axis of the chimney. The design of the foundation shall take into consideration the additional forces resulting from eccentricity introduced due to any reason.
3.9.0
3.10.0 The bottom slab / pad shall be designed both for bearing pressure as well as dead load of foundation and over weight of earth. The actual soil pressure under the footing shall be considered to calculate the maximum moments and shears at various sections.
3.11.0
The presence of surface / sub soil water shall be considered in the design of all foundations and underground faculties.
3.12.0 All underground facilities like cable trenches, sump pits, oil collecting pit, soak pit, drains etc shall be designed for earth pressure including swelling pressure and sub soil water pressure under worst condition. The walls of the cable trenches shall withstand a surcharge of 20 kN/m in addition to the earth pressure. Walls and base slab shall be designed as uncracked section as per IS-3370. All water retaining / storage structures
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shall be designed assuming liquid upto the height of wall irrespective of provision of any over flow arrangement. No pressure relieving devices shall be permitted in underground structures. 3.13.0 RCC precast cover slabs of cable / pipe trenches shall be designed for a live load of 10 kN/sqm. Cable trenches crossing roads shall be designed for Class B loading as per Indian Road Congress Standard Specification and Code of practice for Road Bridges, IRC-6, Section-II. 3.14.0 Cover slabs of sump pits , oil collection pits etc shall be designed for a live load of 5 kN/sqm in addition to equipment loads and maintenance loads ,if any. 3.15.0 Jacking platforms, rail track, anchor block etc shall be designed for the load of the heaviest transformer. 3.16.0 Switchyard control building shall be designed for the most critical combinations as listed below: 3.16.1 Dead Load 3.16.1.1Dead loads consist of the weights of the structure complete with finishes, fixtures, partitions, wall panels and all equipment of semi-permanent nature including partitions, roofing, piping, cable trays, bus ducts etc. 3.16.1.2The following unit weight of material shall be considered for computation of loads : Materials Plain Cement Concrete Reinforced Cement Concrete Structural Steel Brick work Floor finish 3.16.2 Equipment Load The imposed load generally shall include the panel loads and as explained in clause 3.5.0 of section C3.1 3.16.3 Earth Pressure Loads Earth pressure for all underground structures shall be calculated using coefficients of earth pressure at rest. In addition to earth pressure and ground water pressure, etc. a minimum surcharge load of 20 kN/sqm shall also be considered for the design of all underground structures including channels, sumps, cable and pipe trenches, etc. to take into account the vehicular traffic in the vicinity of the structure.
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Unit Weight 24 kN/m 25 kN/m 78.5 kN/m 19 kN/m 24 kN/m
FICHTNER India
3.16.4 Imposed Load Imposed loads in different areas shall include live loads, minor equipment loads, cable trays, erection loads, operation / maintenance loads etc. The loads considered shall not be less than that specified in IS : 875 (Part II). Switchgear room floor Battery room floor Flat roof Chequered plate and grating Control room floor 3.16.5 Wind Load Wind loads on structures shall be calculated as per provisions of IS : 875 (Part 3). The wind shall be assumed to blow in any direction and most unfavourable condition shall be considered. Basic Wind Speed K1 factor K2 factor = = = 50 m/s 1.0 Corresponding to Terrain Category 2 : : : : : 15 kN/m (including hung loads) 20 kN/m 1.5 kN/m + Equipment load 5 kN/m 10kN/m2
The external / internal pressure coefficients shall be as per respective clauses of IS : 875. 3.16.6 Seismic Load Seismic forces shall be as per IS : 1893-2002. As per IS : 1893, the site falls in Zone-III. Importance factor shall be taken as 1.5. 3.16.7 The individual members of the frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force and torsion. Permissible stresses for different load combinations shall be taken as per IS:875 (Part-V) and other relevant IS codes. Wind and seismic forces shall not be considered to act simultaneously. Load factors shall be based on the factors given in the relevant codes of practice in general all loads which are variable (including earth and ground water pressure) shall be treated as live loads for purpose of determining the load factor. 3.17.0 The chimney / pedestal of the foundations shall at least be 300 mm square providing a minimum clear concrete cover of not less than 100 mm over any part of the stub angle in case of dry locations and at least 450 mm square with minimum clear cover of not less than 150 mm over any part of the stub angle in case of wet locations.
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3.18.0 The chimney / pedestal top shall extend 250 mm (minimum) above Finished Ground Level and coping shall be up to 50 mm below the joint between the bottom bracing and the leg members. 3.19.0 The embedded end of the stub angle shall have a 150 mm thick clear concrete cover upto the top of the lean concrete sub-base in the case of dry foundations and a 200 mm thick clear cover in the case of wet, partially submerged and fully submerged foundations. 3.20.0 The joints between the tower stubs and the superstructure bracing members shall be 300 mm above ground level. 3.21.0 Clear cover to reinforcement shall not be less than 75 mm at the bottom. 3.22.0 The minimum thickness of footing slab for foundations shall not be less than 250 mm in dry locations and 300 mm in case of wet locations. 3.23.0 The footing slabs of all foundations shall be cast without construction joints. However, construction joint shall be allowed between footing slab and pedestals / chimneys. 3.24.0 The bed of the cable and pipe trenches along the length shall be provided with a slope of 1:750 to 1:1000 by laying PCC (1:2:4) in second stage to drain out rain / seepage water without comprising the clearance required between the bottom most tray of cable trench and the bed of cable trench. 3.25.0 Suitable expansion joints shall be provided in cable / pipe trenches and liquid retaining structures as per IS specification with PVC water stop, bitumen impregnated filler boards, bitumen sealing compound as per specifications or as directed by the Engineer-in-Charge. water proofing cement additive shall be used for the construction of cable trenches to ensure water tightness. 3.26.0 Water from the cable trenches shall be collected in suitable sumps from where the water shall be disposed off by pumping into the nearest storm water drain. 3.27.0 The weight of a single RCC cover shall not be more than 75 kg. Suitable lifting hooks shall be provided for easy handling. The top of the trenches shall be kept 150 mm above FGL. Suitable lugs of reinforcement steel shall be welded to edge protection angles for ensuring fixity in the concrete. Necessary embedded steel plates shall be provided for supporting the cable trays. 3.28.0 The size of the transformer soak pit shall be 1 m bigger all around than the plan size of transformer including its cooling bank. The depth shall be adequate to accommodate the full quantity of oil contained in the transformer plus 50% of emulsifier water in voids of gravel filling inside the soak pit. 3.29.0 The gravel size to be filled in the soak pit shall be of 60 mm to 40 mm nominal size and it shall be ensured that 40% of voids are available in the gravel filling after its packing in soak pit. The top of the gravel filling inside the soak pit shall be 200 mm below the top of the rail. 3.30.0 The soak pit of the transformers shall be connected to the central oil pit through underground RCC pipes and manholes. The pit shall be closed type and waterproof construction with necessary manholes and rungs etc for maintenance purpose.
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3.31.0 Fire barrier walls of 380mm thickness or as per statutory requirements shall be provided where required from layout considerations and as per relevant regulations. 3.32.0 Transformer rails as per profile indicated by the transformer manufacturer shall be provided for installing and removal of the transformer for maintenance from the unloading / loading point to its final position on its foundation. Rail track foundation shall incorporate jacking pads foundation at intersections of rail racks, if any. Pulling hooks shall be provided at suitable locations for pulling the transformers over the rails. 3.33.0 The area around the transformer shall be paved with 100 thick RCC slab and galvanised chain link fence . RCC fence posts shall be erected and a gate shall be provided. The portion of the fence covering the rail track shall be made of removable type for movement of transformer during erection / maintenance. The gate shall not be self- locking and shall have a provision for locking. 3.34.0 A common RCC central oil collecting pit shall be provided for all the auto-transformers. This pit shall be closed type and waterproof construction with necessary manholes and rungs etc. for maintenance purposes. 3.35.0 The size of the oil collecting pit shall be adequate to accommodate the full quantity of oil contained in the largest transformer including rain water and mulsifier water required for the biggest transformer and to ensure that no oil/mulsifier water remains in the transformer soak pit/drain pipes and the level of soak pit shall be accordingly decided. 3.36.0 The size of RCC pipes to be used for connecting the soak pit of the transformers to the central oil collecting pit shall not be less than 300 mm diameter and shall be of class NP4 conforming to IS:458 (latest) as per recommendations of Tariff Advisory Committee. 3.37.0 The central oil collecting pit shall have provision for installing 2 nos. of 100% capacity sump pumps with all accessories like suction and discharge pipes for transferring discharge to oil water separator such that each pump can pump oil/rain water/emulsifier discharge of the biggest transformer in the switchyard. A suitable size RCC oil water separator shall be designed and provided by the Contractor in a manner that oil would be separated from water and same shall be retained in oil water separator while water shall be disposed off to the nearest storm water drain. 3.38.0 Suitable drainage arrangement shall be designed and provided by the Contractor to drain off the rainwater quickly and efficiently from switchyard area. For this purpose, the yard shall be sloped away from control building and also from cable trenches, so as to prevent ingress of rainwater into them. 3.39.0 All surface drains shall be constructed with brick masonry in cement-sand mortar 1:5 (1 cement : 5 Coarse sand) and these shall be plastered inside with cement sand mortar 1:3 (1 cement : 3 fine sand). The thickness of plaster shall be not less than 12 mm. The bricks to be used for the construction of drains shall be of class 70 conforming to relevant IS Code. The longitudinal slope of drains shall be so decided that there is no accumulation of silt in the drains and rainwater is disposed off as quickly as possible without causing any flooding in the switchyard area. However, the slope of drains shall not be lesser than 1:1000. Run-off co-efficient of 1 shall be considered for concrete surface and 0.6 for unpaved gravel pitched surface.
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3.40.0
The minimum width of any drain shall not be less than 450 mm and depth of drain shall not be less than 300 mm.
3.41.0 All internal roads shall be of 4 m wide and shall be designed and constructed to suit soil parameters furnished in the soil investigation report and shall be terminated at the boundary / fence. 3.42.0 Grading of concrete Unless required otherwise, cement used shall be Ordinary Portland Cement 43 grade conforming to IS 8112. Special cement, as appropriate, shall be used for structures, or portions of structures, exposed to chemicals. All structural concrete shall be design mixes. Ready mix concrete may be used where feasible, minimum cement content shall be 350 kg/m3 of concrete unless otherwise specified in the detailed soil investigation report. The following grades of concrete as per IS : 456 shall be adopted for the type of structures noted against each. M 35 M 30 1:3:6 1:4:8 CM 1 : 1 3.43.0 Clear Cover Clear cover to reinforcement shall be as follows : Top mm Piles Footings / Pile caps Column / Pedestal Slab Grade Beam Beam above ()0.000 Lintel beams Precast units 75 50 40 25 40 25 20 25 Bottom mm 75 75 40 25 40 25 20 25 Sides mm 75 50 40 25 40 25 20 25 RCC structures below ground (min). RCC structures above ground (min). Base slab of drains Mud mat Grout for all structures
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3.44.0 All reinforcement shall be of high yield strength deformed bars confirming to IS : 1786 (Minimum yield strength - 415 N/mm). 3.45.0 Minimum thickness of structural elements The following minimum thickness shall be followed : a. b. c. d. e. f. h. i. j k. l. Roof slab Ground floor slab (non - suspended) Water Retaining Slab / Walls Cable / Pipe Trenches / Underground pit / Launder walls and base slab All footings (including raft foundations) Parapets / Chajjas Precast louvers / fins Precast trench cover slabs / floor slabs Precast trench covers with vehicular load Paving Paving with vehicular load 125 mm 150 mm 200 mm 125 mm 250 mm 125 mm 50 mm 100 mm 200 mm 100 mm 200 mm
3.46.0 Pile foundation, if adopted, shall be of cast-in-situ bored piles as per IS:2911. The minimum diameter of piles shall generally be 450 mm. The allowable load capacity of the pile in vertical compression shall be limited to its structural capacity where capacity from soil indicates higher capacity. The uplift and lateral capacities shall be restricted to 20% and 5% respectively of the allowable load capacity in vertical compression. However, the pile capacities to be adopted shall be the least of the estimated design values and that obtained from the pile load test. Maximum permissible lateral deflection at pile head shall be 5 mm. A minimum of two pile group shall be provided below every column / foundation unless the pile caps are tied together to act as a unit. Only straight piles shall be used. The actual length of pile shall in no case be less than the design length. 3.47.0 The switchyard control room shall be a single storeyed RCC framed brick clad structure. 3.48.0 The finishes of the control room shall be in accordance with C5 Annex 1 3.49.0 For movements of panels suitably sized double leaf aluminium glazed doors shall be provided. Windows shall be of sliding type with powder coated aluminium glaze using 6mm thick sheet glass in all accessible areas and fixed windows with powder coated aluminium glaze using 6mm thick sheet glass in all non-accessible areas. 3.50.0 The finished formation levels, layers of gravel, levels of foundation plinth, cable trench tops, as applicable shall be such as to ensure the perfect matching of these items with
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corresponding items of existing installations. The connection of the drains, trenches, etc., with the battery limits shall be properly coordinated with the power plant systems. 3.51.0 A minimum of 100 mm thick crushed stone shall be spread in the switchyard area extending one meter beyond the fence. Before laying gravel fill, the top layer of soil shall be treated suitably by injecting approved anti weed chemicals as per manufacturers recommendation. The bidder shall submit for approval the details of chemical proposed to be used along with the bid and before application of the same. A double swing gate of adequate width (minimum 3.5 m wide) and a wicket gate shall be provided. Gates shall be of 2.5m height and should not be self- locking. Fencing of 2.5 m height (chain link fencing) including 3 strands of barbed wire on top shall be provided. 3.52.0 The trench shall be covered with precast R.C.C. cover of suitable thickness and joints shall be pointed with cement mortar 1:3 to prevent entry of rain water from top. 3.53.0 Sunshade of 600mm projection with a minimum thickness of 100mm has to be provided for doors and windows exposed to sun. 3.54.0 Where ever provision for Air conditioner has been specified an A.C opening or frame has to be provided in the wall.
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SECTION C4 TECHNICAL SPECIFICATIONS SECTION-C4.1 TECHNICAL SPECIFICATION FOR FABRICATION & ERECTION OF SWITCHYARD STRUCTURE 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for supply, fabrication, galvanising, inspection, testing, and erection of structural steel work for switchyard structures. 2.0.0 CODES & STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: IS:800 IS:802 IS:806 IS:808 IS:813 IS:1161 IS:1367 IS : 209 IS:1367 IS:1573 IS:1852 IS:2016 IS:2062 IS:2633 Code of Practice for use of structural steel in general building construction. Code of practice for use of structural steel in overhead transmission line towers Code of Practice for use of steel tubes in general building construction. Rolled steel beams, channels and angle sections Scheme of symbols for welding Steel tubes for structural purposes. Technical Supply Conditions for Threaded Steel Fasteners Zinc Ingot Technical supply conditions for threaded steel fasteners Electroplated coatings for zinc on iron and steel Rolling and cutting tolerances for hot-rolled steel products. Plain washers Steel for general structural purposes Methods of testing uniformity of coating on zinc coated articles
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IS:3063 IS:4759 IS:6610 IS:6639 IS:7205 IS:7215 AISC 3.0.0 3.1.0
Spring washers for bolts, nuts and screws Hot dip zinc coatings on structural steel and other allied products Heavy washers for steel structures Hexagon bolts for steel structures Safety code for erection of structural steel work Tolerances for fabrication of steel structures American Institute of Steel Construction Specification for the Design, Fabrication and Erection of Structural Steel for Buildings
DRAWINGS AND LISTS Unless otherwise stated, the Contractor shall be responsible for all necessary lists such as indents, rivet and bolt lists, material lists, Dispatch lists and lists for all bought out items. Fabrication work shall not be taken in hand until the relevant shop drawings have been approved by the Engineer. The Contractor shall take into account any revisions in drawings furnished by the Engineer at no extra cost. MATERIALS Structural steel All structural steel shall be of tested quality. Rolled steel sections and plates shall conform to IS:2062. Steel tubes where used for equipment support structure shall conform to IS:1161.
3.2.0
4.0.0 4.1.0
4.2.0
Bolts and nuts All bolts and nuts shall be galvanised of mild steel and shall confirm to IS : 6639. Unless shown or specified all bolts and nuts shall be hexagonal. All nuts shall fit tight. Mechanical properties shall conform to property class 4.6 and 4 of IS:1367 for bolts and nuts respectively.
4.3.0
Washers Plain washers shall be made of mild steel, unless otherwise specified and shall conform to IS:2016. Spring washers shall be provided for those parts which carry dynamic loads and where black bolts for connections are permitted. Heavy washers shall conform to IS:6610 and spring washers to IS:3063.
4.4.0
Electrodes Mild steel electrodes shall conform to IS:814 and high tensile steel electrodes to IS:1442. The Contractor shall furnish to the Engineer a certificate issued by the manufacturer to the effect that the electrodes supplied are in accordance with the
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above specifications. For welding in any particular position, the electrodes used shall be those recommended by the manufacturer for use in that position. 4.5.0 Galvanising Galvanising of switchyard structures shall conform to IS:4759. 4.6.0 Other Materials Other materials used in association with steel work shall comply with the appropriate Indian Standard specifications. 4.7.0 4.7.1 General requirements regarding supply of materials by Contractor Before ordering bought out items, special accessories, equipment etc. and materials of any description, the Contractor and his sub Contractors shall submit, the names of the proposed manufacturers or suppliers together with the specification of the materials for the approval of the Engineer and shall, thereafter, send copies of the orders to the Engineer. In addition to the special provisions made hereafter as to the sampling and testing of materials by particular methods, samples of materials and workmanship proposed to be employed in the execution of the works comprised in this Contract may be called for any time by the Engineer and when so called for by the Engineer, the same shall be furnished by the Contractor free of cost without delay. The samples, when approved, shall be kept by the Engineer who shall reject all materials or workmanship not in conformity with the quality and character of the approved samples. Suitable labeled boxes for the storage of the said samples shall be provided by the Contractor free of cost. The Contractor shall furnish to the Engineer the following certificates, if required, before commencement of fabrication : i) ii) A certificate stating the process composition of the steel supplied. of manufacture and chemical
4.7.2
4.7.3
Test certificates by the manufacturer giving the results of each of the specified mechanical tests applied to the structural steel, bolts, nuts and washers and the chemical composition of the same.
5.0.0 5.1.0 5.1.1
FABRICATION Workmanship General All workmanship shall be equal to the best practice in modern structural shops. Greatest accuracy shall be observed in the manufacture of every part of the work and all similar parts shall be strictly interchangeable.
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5.1.2
Templates Templates used throughout the work shall be all steel, steel bushed in such cases as the Engineer may consider necessary. In cases where actual materials have been used as templates for drilling similar pieces the Engineer shall decide whether they are fit to be used as parts of the finished structure.
5.1.3
Straightening All materials shall be straight and if necessary before being worked shall be straightened and/ or flattened by pressure unless required to be of curvilinear form and shall be free from twists.
5.1.4
Clearance The erection clearances for cleated ends of members connecting steel to steel should preferably be not greater than 2.0 mm at each end. The erection clearance at ends of beams without web cleats should be not more than 3 mm at each end, but where for practical reasons greater clearance is necessary, suitably designed seatings should be provided.
5.1.5
Shearing, flame cutting and planing
5.1.5.1 Shearing or flame cutting may be used at the Contractor's option provided that a mechanically controlled cutting torch shall be used for the flame cutting and that the resulting edge shall be reasonably clean and straight. Sheared members shall be free from distortion at sheared edges. 5.1.5.2 The edges and ends of all flange plates and web plates of plate girders and built-up columns of plates forming chords or web members of lattice girders and all cover plates, the ends of all angles, tees, channels and other sections forming the flanges of plate girders and columns and chords and web members of lattice girders shall be planed. 5.1.5.3 The ends of all stiffeners shall be planed or ground to fit tightly between the main angles or flanges. Care shall be taken to ensure a full bearing of the stiffeners at the supports and at other points where concentrated load is applied. The ends shall not be drawn or caulked. 5.1.5.4 The butting surfaces at all joints of girders or columns shall be planed so as to butt in close contact throughout the finished joint. 5.1.5.5 The ends of all built-up girders and of all columns shall be faced. The bearing surfaces of all slabs and plates for caps and bases of columns and for seatings for heavy girders shall be machined. 5.1.5.6 Unless clean, square and true to shape, all flame cut edges shall be planed. 5.1.5.7 Cold sawn ends if reasonably clean and flame cut ends of sections not inferior to sawn ends in appearance need not be planed except for butting ends.
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5.1.6
Holing
5.1.6.1 Holes for black bolts shall be not more than 1.5 mm larger than the nominal diameter of the bolt, unless specified otherwise. All holes, except as stated hereunder shall be drilled to the required size or sub-punched 3 mm less in diameter and reamed thereafter to the required size. All matching holes for black bolts shall register so that a gauge 1.5 mm less diameter than the hole can pass freely through the members assembled for bolting. All holes for turned and fitted bolts shall be drilled and reamed, if necessary, to a tolerance of only plus 0.13 mm unless specified otherwise. When the number of thicknesses to be riveted exceeds three or the total thickness is 90 mm or more, the holes shall be drilled or reamed in position after assembly, except when steel-bushed jigs are used. The parts shall be firmly bolted together during such block drilling and taken apart for removal of burrs after drilling. 5.1.6.2 Holes in purlins, side sheeting, runners, packing plates and lacing bars may be punched full size. 5.1.6.3 All punching and sub-punching shall be clean and accurate and all drilling free from burrs. No holes shall be made by gas cutting process. 5.1.7 Assembly
5.1.7.1 All parts assembled for bolting shall be in close contact over the whole surface and all bearing stiffeners shall bear tightly at both top and bottom without being drawn or caulked. 5.1.7.2 The component parts shall be so assembled that they are neither twisted nor otherwise damaged and specified cambers, if any, shall be provided. 5.1.8 Bolting Bolted construction shall be permitted only in the case of field connections. Unless otherwise specified, faces of heads and nuts bearing on steel work shall be machined. All such bolts shall be provided with washers having a hole of 1.6 mm larger in diameter than the barrel of bolt and thickness not less than 6.5 mm so that the nut, when tightened, shall not bear on the unthreaded body of the bolt. In all cases, where the full bearing area of the bolt is to be developed, the threaded portion of the bolt should not be within the thickness of the parts bolted together. The threaded portion of each bolt shall project through the nut by at least one thread. Tapered washers shall be provided for all heads and nuts bearing on levelled surface. 5.2.0 Welding The welding and the welded work shall conform to IS:816 unless otherwise specified. All welding shall be restricted to shop and shall involve base plates, gussets etc. only. 5.3.0 5.3.1 Galvanising General Structural steelwork for switchyard or other structures as may be specified in the Contract shall be hot dip galvanised in accordance with IS : 4759.
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5.3.2
Surface Preparation
5.3.2.1 All members to be galvanised shall be cleaned, by the process of pickling of rust, loose scale, dirt, oil, grease, slag and spatter of welded areas and other foreign substances prior to galvanising. Pickling shall be carried out by immersing the steel in an acid bath containing either sulphuric or hydrochloric acid at a suitable concentration and temperature. The concentration of the acid and the temperature of the bath can be varied, provided that the pickling time is adjusted accordingly. 5.3.2.2 The pickling process shall be completed by thoroughly rinsing with water, which should preferably be warm, so as to remove the residual acid. 5.3.3 Procedure
5.3.3.1 Galvanising shall be carried out by hot dip process in a proper and uniformly heated bath. It shall meet all the requirements when tested in accordance with IS:2633 - Methods of Testing Weight, Thickness and Uniformity of coatings on hot dipped galvanised articles. The zinc coating shall be uniform, clean and of a standard thickness on the entire surface of the material galvanised. The acceptable values of the coating of zinc on the steel materials shall be in accordance with Table No. I below : Kind of material Structural steel members except bolts, nuts and washers. For Bolts, nuts and washers Coating Average Value Over 910 gm/m
Over 750 gm/m
5.3.3.2 The surface preparation for galvanising and the process of galvanising itself, shall not adversely affect the mechanical properties of the materials to be galvanised. Where members are of such lengths as to prevent complete dipping in one operation, great care shall be taken to prevent warping. 5.3.3.3 Materials on which galvanising has been damaged shall be acid stripped and regalvanised unless otherwise directed, but if any member becomes damaged after having been dipped twice the same shall be rejected. Special care shall be taken not to injure the skin on galvanised surfaces during transport, handling and erection. Damages, if any, shall be made good in accordance with the provisions of this specification or as directed by the Engineer. 5.4.0 5.4.1 Marking, packing and dispatching Each piece shall be distinctly marked before delivery, in accordance with an approved marking diagram and shall bear such other marks as will facilitate erection. For easy identification at site, a small distinguishing mark for each building shall be painted on each end of every member before dispatch from fabrication shop. The fabricated steel work shall be dispatched in such portions as may be found convenient for erection or as ordered by the Engineer.
FICHTNER India
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5.4.2
All projecting plates or bars and all ends of members at joints shall be stiffened, all straight bars and plates shall be bundled, all screwed ends and machined surfaces shall be suitably packed and all rivets, bolts, nuts, washers and small loose parts shall be packed separately in cases so as to prevent damage or distortion during transit. INSPECTION AND TESTING The Engineer shall have free access at all times to those parts of the manufacturer's works which are concerned with fabrication of the steel work and shall be afforded all reasonable facilities for satisfying himself that the fabrication is being undertaken in accordance with the provisions of this specification. Unless specified otherwise, inspection shall be made at the place of manufacture prior to despatch Tolerance for fabricated structures shall be as per IS:7215. Should any structure or part of a structure be found not to comply with any of the provisions of this specifications, it shall be liable to rejection. No structure or part of the structure, once rejected shall be resubmitted for test, except in cases where the Engineer considers the defect as rectifiable. Defects which may appear during fabrication shall be made good with the consent of and according to the procedure laid down by the Engineer. All gauges and templates necessary to satisfy the Engineer shall be supplied by the manufacturer. The Engineer may, at his discretion, check the test results obtained at the manufacturer's works by independent tests at the Government Test House or elsewhere, the costs of such tests shall be borne by the Contractor Before dispatch from fabrication shop, proto type of each structure shall be shop assembled and checked for fabrication tolerance. Also if ordered, by the Owner, the same shall be presented for inspection. ERECTION General The material shall be verified with marking on the marking plan or shipping lists which shall be supplied by the Contractor. Any material found damaged or defective shall be stacked separately and the damaged or defective portions be painted in distinct colour. Such material is to be dealt with under the orders of the Engineer without delay. The field assembling of the component parts of a structure shall involve the use of method and appliances not likely to produce injury by twisting, bending or otherwise deforming the metal. No member slightly bent or twisted shall be put in place until the defects are corrected and members seriously damaged in handling shall be rejected.
6.0.0 6.1.0
6.2.0 6.3.0
6.4.0 6.5.0 6.6.0
6.7.0
7.0.0 7.1.0 7.1.1 7.1.2
7.1.3
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7.1.4
All small bends or twists received by members shall be rectified before such members are put in place; any serious bends or damage shall be reported at once to the Engineer by the Contractor for instructions. The straightening of bent edges of plates, angles and other shapes shall be done by methods not likely to produce fracture or other injury. Following the completion of the straightening of a bend or buckle, the surface of the metal shall be carefully inspected for evidence of incipient or other fractures. Setting Out The Contractor shall assume full responsibility for the correct setting out of all steel work and erecting it correctly as per alignment and levels shown on the drawings and plumbing of vertical members. Datum points will be fixed by the Engineer near the work site. Notwithstanding any assistance rendered to the Contractor by the Engineer, if at any time during the progress of the work any error should appear to arise therein, on being required to do so, the Contractor at his own cost shall remove and amend the work to the satisfaction of the Engineer.
7.1.5 7.2.0
7.3.0 7.3.1
Field bolting All relevant portions in respect of bolted construction of the Specification for Fabrication of Structural Steel work shall also be applicable for field bolting in addition to the following. Bolts shall be inserted in such a way so that they may remain in position under gravity even before fixing the nut. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible materials. When assembled, all joint surfaces, including those adjacent to the washers, shall be free of scales except tight mill scales. They shall be free of dirt, loose scales, burns, and other defects that would prevent solid seating of the parts. Tolerances applicable in the fit of the bolts shall be in accordance with relevant Indian Standard Specifications. All other requirements regarding assembly and bolt tightening shall be in accordance with this Sub-Clause. Bedding, grouting and Dry pack Bedding shall be carried out with cement grout or mortar having a compressive strength of 250 kg per sq cm at 28 days for main column bases and 200 kg per sq cm at 28 days for secondary column bases. For the main column the Contractor shall provide screed bars of mild steel flats and fix them in mortar. The Engineer will be the sole authority in deciding "main" and "secondary" columns and his decision in this matter will be binding on the Contractor within the terms of this contract. The bedding shall not be carried out until a sufficient number of columns has been properly aligned, levelled and plumbed and sufficient girders, beams, trusses and bracings are in position to the satisfaction of the Engineer. Immediately before grouting, the space under the base plate and around bolts shall be thoroughly cleaned and made free from excessive moisture.
7.3.2
7.3.3
7.4.0 7.4.1
7.4.2
7.4.3
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7.4.4
The grout or mortar shall be mixed as thick as possible consistent with fluidity and shall be poured under pressure with pressure grouting machine, until the space has been filled with mortar. The space between bottom of base plate and top of concrete surface shall be filled with dry pack cement mortar of 1:1.5. The dry pack mortar shall have water cement ratio such that it can be rolled into a ball. The mortar is packed by means of wooden stick head from one end to other of base plate. Correction of misfits Correction of minor misfits, a reasonable amount of reaming and cutting of excess-stock from rivets will be considered a legitimate part of the erection. Any error in shop work which prevents the proper assembling and fitting up of parts by the moderate use of drift pins or a moderate use of reaming and slight chipping or cutting shall immediately be reported to the Engineer and his approval of the method of correction obtained.
7.4.5
7.5.0 7.5.1 7.5.2
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SECTION-C4.2 TECHNICAL SPECIFICATION FOR EARTHWORK IN EXCAVATION & BACKFILLING 1.0.0 SCOPE This specification covers the requirement of site clearing, excavation, conveyance, disposal & backfilling in all types of soil for foundations, basements, trenches, drains, culverts including necessary shoring, dewatering, protective fencing etc. The work to be provided for by the Contractor unless otherwise specified shall include furnishing all labour, supervision, services, materials, scaffolds, equipment, tools and plants transportation etc. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder : IS:1200 IS:1498 IS:2720 IS:3764 IS:4081 IS:9759 SP-27 3.0.0 Part 1 - Method of Measurement of building and engineering works - Earth work Classification and identification of soils for general engineering purposes Methods of test for soils (Relevant Part) Excavation works - Code of safety Safety code for blasting and related drilling operations Guidelines for dewatering during construction Handbook of Method of Measurement of Building Works
SETTING OUT Contractor shall prepare and submit for approval, design and working drawings showing the approaches, slopes, berms, shoring, sheet piling, sumps for de-watering, space for temporary stacking of spoils, disposal area, fencing etc. as may be requested by the Engineer. The work shall be set out to exact dimensions as shown on the drawings and shall be checked and approved by the Engineer before commencement of excavation. In firm soil, the sides of excavation in foundations shall be kept vertical up to a depth of 1.5 m from the bottom and for greater depths the sides shall be widened by forming steps of 300 mm on either sides after every 1.5m from the bottom. Where soil is soft, loose or slushy, the width of steps shall be suitably increased or the side sloped or shored up, as directed by the Engineer. Working space shall be approved by the Engineer.
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In case of excavation for pipes, the authorized width of excavation shall be 600 mm plus outer diameter of pipe or the width of bedding as shown in the drawing whichever is higher, upto a depth of 1.5 m. For higher depths, the width shall be widened by forming steps of 300 mm on either side after every 1.5 m from the bottom. 4.0.0 INITIAL LEVELS Initial levels either in a definite grid pattern or as directed by the Engineer shall be taken by the Contractor jointly with the Engineer over the original ground prior to starting actual excavation work and after setting out. These initial levels will be used for preparing cross-section for volume measurement or for cross-checking the depths obtained from tape measurements. 5.0.0 CLEARING AND GRUBBING ETC. The area to be excavated shall cleared out of trees, logs, stumps, bush, vegetation, rubbish, slush etc. and leveled up. Trees upto 300 mm girth shall be uprooted. Trees above 300 mm girth shall be cut upto 600 mm below ground level. Useful materials, saleable timber shall be the property of the Owner and hence shall be handed over. All the spoils and unserviceable materials and rubbish shall be burnt or removed from site to approved disposal areas as may be specified. 6.0.0 EXCAVATION AND CUTTING The Contractor shall excavate, remove materials of any nature or description which may be encountered and excavate to depths, widths and inclinations as shown on the drawings and/ or as directed. The bed of the excavation shall be made level and firm by watering and ramming. The Contractor shall not remove any tree without permission. Undercutting shall not be permitted, Sides of excavation shall be cut sharp true to line. When machines are used for excavation, the last 300 mm before reaching the required level shall be excavated manually or by such equipment that the soil at the required final level will be left in its natural condition. While carrying out excavation for drain work, the sides and bottom shall be cut to the exact shape, slope and gradient as shown on the drawings. The surface shall be properly dressed. Excavated material shall not be placed within 1.5 m from the edge of any excavation or half of trench depth whichever is more. 7.0.0 EXCAVATION IN ROCK Blasting where permitted shall be carried out as specified in IS:4081. Where blasting is prohibited, rock excavation shall be by chiseling, wedging or any other approved method. Contractor shall construct and maintain magazine of adequate capacity adhering standard safety norms for storing of explosives required for blasting work.
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8.0.0 8.1.0
VARIATION IN EXCAVATION Bad Soil Should the bottom of any excavation at design depth appear to be soft, unsound or unstable, the Contractor shall report the matter to the Engineer and if the Engineer so directs, shall excavate the same to indicated depths. The extra depth shall be filled up with concrete or such other materials as the Engineer shall direct. Such extra excavation and filling shall be paid for at appropriate item rate.
8.2.0
Excavation Too Deep If the Contractor excavates to levels deeper than those shown on drawings for any reason other than those stated in Clause 8.1.0, he shall fill it up at his own expense to the proper level with lean concrete 1:4:8 or compacted sand filling as directed. No payment will be made for excavation taken down to depths more than those shown on the drawings or for the filling carried out as directed.
8.3.0
Slips and Falls Every precaution shall be taken against slips and falls of earth, clay, sand or other materials in the excavations, but in the event of any such occurring, the Contractor shall at his own expense make good the space affected by slips or falls even if the affected area is outside the dimension of the work ordered. The Engineer will determine in each case whether such affected area is to be filled up in whole or in part with concrete, brickwork or masonry of the quality used in the adjoining work or where only a part is to be so filled, the materials to be used for this remaining part. If in the opinion of the Engineer there is a possibility of the newly constructed work having been damaged or disturbed by such collapse, the work shall be laid bare at the expense of the Contractor for inspection. Any damage caused shall be made good by the Contractor, at his own expense.
8.4.0
Soil/Sub-soil Water Condition Boring and sub surface data regarding the nature of soil, sub-soil water furnished to the Contractor shall be taken as guidance only and variation there from shall not affect the terms of Contract. The Contractor must satisfy himself regarding the character and volume of all work under this item and expected surface, and/or sub-soil water to be encountered.
9.0.0
KEEPING WORKS SITE FREE FROM WATER Pumping The Contractor shall provide and operate pumps and all other equipment necessary to drain the sub-soil water, rain water etc. to the nearest sewer or drain through properly laid pipes or channels and keep excavation pits, trenches etc. free from water at all times during excavation, backfilling and the continuance of the contract. Adequate care shall be taken to prevent movement of water through freshly laid concrete or masonry work.
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Sumps made for dewatering shall be kept clear of the foundation. Method of dewatering shall be approved by the Engineer and no extra claim shall me made for dewatering the foundations and subsoil, but in no case the pumping arrangement shall be such that there is any movement of sub-soil or blowing-in due to differential head of water during pumping. 10.0.0 PROTECTION OF WORK The Contractor shall support and maintain adjoining and abutting property and structures to render work safe to persons and property. The Contractor shall provide necessary decking, guard, fencing, planking with red flags and red lights at night to maintain safe pedestrian and vehicular traffic near all open excavations. The Contractor shall provide and maintain proper approaches for workmen and for inspection. The roads and approaches around the excavated pits should be kept clear at all times so that, there is no hindrance to the movement of men and materials and equipment of other agencies connected with the project. 11.0.0 SHORING AND STRUTTING Shoring and strutting shall be used as directed when excavation is to be carried out in soft or slushy soil which is likely to collapse during the excavation of the work. The shoring shall be either open or close boarded type depending on the nature of the soil and depth of excavation and the type adopted shall be as directed by the Engineer. While excavating in very unstable ground requiring support throughout the period of excavation, runners shall be used and shall be driven always in advance of the excavation. The size and spacing of different members to be used in shoring shall be as directed by the Engineer, depending on the site conditions. If however slips do occur, the same shall be removed by him and backfilled later by him at his own expense. The withdrawal of shoring & shoring material shall be done very carefully to prevent the collapse of pit or trench. No claim shall be entertained for any material which cannot be removed and is lost or buried. 12.0.0 DISPOSAL The excavated earth shall be disposed off in the following manner or as directed by the Engineer : i) By keeping separately the materials suitable for backfilling/area filling and material not suitable at areas to be designated by the Engineer but within the stipulated lead. The excess material remaining after back-filling/area filling shall be spread evenly so as to allow natural flow of water in the area.
ii)
13.0.0 BACKFILLING AND FILLING IN PLINTH Earth used for filling shall be free from organic and other objectionable matter. As far as possible, materials obtained from excavation in foundation shall be used. The earth shall be basically CNS soil (Cohesive Non-Swelling Soil). All clods of earth shall be broken
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or removed. Where excavated material is mostly rock, the boulders shall be broken into pieces not bigger than 150 mm in size and mixed with fine materials consisting of decomposed rock, moorum or earth and the mixture shall be used for filling. Highly expansive soils like black cotton soil shall not be used for filling. Sand if used for filling shall be free from dust, organic and other objectionable matter and shall not contain more than 10% of clay. Fill materials shall not be dropped directly upon or against any structure or facility where there is danger of displacement or damage. Filling shall be started after the concrete / masonry has fully set and shall be carried out in such a manner so as not to cause any undue lateral thrust on any part of the structure. All space between foundation (concrete or masonry) and the sides of excavation shall be filled to the original surface after making allowance for settlement. Fill shall be placed in horizontal layers not exceeding 200 mm loose thickness. Each layer shall be watered and compacted with proper moisture content and with such equipment as may be required to obtain a compaction / density not less than 95% of maximum density as obtained from standard proctor compaction test. Trucks or heavy equipment for depositing or compacting fill shall not be used within 1.5 metres of building walls, piers, or other facilities which may be damaged by their weight or operation. The methods of compaction shall be subject to the approval of the Engineer. Pushing of earth for filling shall not be adopted under any circumstances. Fill adjacent to pipes shall be free of stones, concrete etc. When filling has reached the appropriate level, the area shall be flooded with water for a minimum period of 24 hours to allow the fill to settle. The filling shall be allowed to dry and then compacted and dressed to the required level. All filling work shall be finished with a top earth cushion consisting of locally available soil / excavated earth of specified thickness overlying the ash / earth fill. Filling in trenches for pipes shall be commenced as soon as the joints of pipes have been tested and passed. Filling of trenches shall be carried out simultaneously on both sides of pipes to avoid unequal pressure on the pipe. The earth shall be spread on the sides and top of the pipes in layers not exceeding 200 mm (uncompacted thickness), watered, rammed and consolidated, taking care that no damage is caused to the pipe below. 14.0.0 TESTING AND ACCEPTANCE CRITERIA 14.1.0 Excavation On completion of excavation, the dimensions of the pits will be checked as per drawings after the pits are completely dewatered. The work will be accepted after all under-cuts are set right all over excavations are filled with lean concrete or compacted earth as directed and all necessary shoring strutting done, all temporary approaches to the bottom of trenches provided, all to the satisfaction of the Engineer. 14.2.0 Backfilling /Plinth Filling All filling shall be done to the compaction not less than 95% of maximum density as obtained from standard proctor compaction test. The backfilling work will be accepted only after the Engineer is satisfied with the degree of compaction.
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SECTION-C4.3 TECHNICAL SPECIFICATION FOR PILING 1.0.0 1.1.0 PILING Codes and Standards IS:456 IS:2911 1.2.0 Materials Cement shall conform to IS:269 or IS:455 or IS:6909. Steel shall conform to IS:432 (Part I), IS:1139, IS:1786 or IS:226. Bentonite shall conform to Appendix-A of IS:2911 (Part I/Section-2) 1979. 1.3.0 Workmanship Piles shall be cast-in-situ reinforced concrete bored piles capable of being tested for bearing capacity after 28 days of casting. Workmanship shall generally conform to IS:2911 (Part I/Section-2) 1979 and the tests shall be conducted in accordance with partIV of IS:2911. 1.3.1 Boring The piles shall be carefully and accurately positioned and formed by boring or grabbing the earth out for subsequent filling of hole with concrete. In general, the hole shall be kept cased with a lead-in tube to prevent ingress of soil. In soils, which are liable to flow into the borehole, the bottom of the casing shall be kept sufficiently lower than the level of the boring to prevent the boring to prevent the inflow of soil and the formation of cavities in the surrounding ground. Alternatively, the inflow of ground water and soil shall be controlled by the use of a head of water slurry shall be kept at least one meter above the standing water level. Boring shall be continued until an appropriate strata/ level of forming the piles as directed by the Engineer is reached. On reaching the level, borehole shall be cleaned and concrete operation shall be commenced. 1.3.2 Cast-in-situ Driven Piles Cast-in-situ concrete driven piles shall be installed by driving a metal casing with a shoe at the tip and displacing the material laterally. The metal casing shall be of sufficient thickness and strength to hold its original form and show no harmful distortion after it and adjacent casing have been driven and the driving core. The cast- in-situ concrete driven piles shall be installed using a properly designed detachable shoe at the bottom of the casing. During installation of the piles the final set of penetration of the pile per blow of hammer shall be checked taking the average of last 10 blows. The concrete in piles shall be cast upto minimum height of 600 mm above the designed top level, which shall be stripped off at the time of construction of pile cap.
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Code of practice for plain and reinforced concrete. Code of practice for design and construction of pile foundations
FICHTNER India
1.3.3
Concreting Materials and methods of manufacture of cement concrete shall in general be in accordance with the method of concreting under the conditions of pile installation. Consistency shall be suitably adjusted to the mode of placement, the slump of concrete being between 100 and 180 mm in water free bores having widely spaced reinforcement and between 150 and 180 mm for placing in drilling mud by tremmie.
1.3.3.1 Precautions in concreting At all stages of work care shall b taken to prevent voids in concrete. Reinforcement shall not be allowed to distort or displace. Volume of concrete shall be checked at frequent intervals to maintain a sufficient head of concrete above the bottom of the withdrawing casing tube. When concreting under water or drilling mud, an efficient tremmie technique for placement of concrete shall be employed. If tremmie concreting is adopted, the bottom of borehole shall be cleared of all accumulated sand, muck and loose materials by controlled airlift flushing with fresh bentonite slurry. Concrete shall be done in one continuous operation. 1.3.4 Withdrawal of casings Extraction of casing shall be done in such a way that no necking or shearing of the concrete in the shaft takes place. 1.3.5 Sequence of piling Sequence of piling shall be such that there is no damage caused to the concrete recently laid in the adjacent piles. Sequence of piling shall be as approved by the Engineer. 1.3.6 Finishing of pile heads The top level of concrete in the piles shall be brought up sufficiently above the required finished level or cut-off level to allow for slumping or withdrawal above the cut-off level for removal of laitance and weak or unconsolidated concrete. Any defective concrete and the head of the completed pile shall be cut out, made good with new concrete and well bonded to the old concrete. The top shall be finished smooth and level. 1.3.7 Record of piling Complete records of boring and concreting process for each pile shall be maintained by the Contractor and the counter sign of the Engineer obtained. The record shall indicate the following: a. b. c d.
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the sequence of installation of piles; dimensions and mark of the pile and its reinforcement details; depth bored with details of bore long holes as shown in Appendix-D of IS:2911 (Part-I/ Section-2); commencement and completion of concreting;
FICHTNER India
e. f. g.
ground water level, cut-off level and working level; when drilling mud is used, the specific gravity of the fresh supply and contaminated mud in the hole before concreting is commenced; cube strength results of samples taken from each pile; pile test start and completion dates; any other important observations.
1.4.0
Tolerance in Workmanship Tolerance limits for the completed piles at the cut-off level shall be given below: Displacement : Shall not exceed 75 mm in any direction from its true position shown in the drawings (both vertical & batter piles) : Shall not deviate more than 2 in 100 (vertical piles) : Shall not deviate more than 2% (about 1o) beyond the batter prescribed for raker piles
Verticality Batter
Any pile deviating beyond these limits and/or in a manner that the resulting eccentricity cannot be taken care of by redesign of the pile cap, then such piles shall either be replaced or supplemented by one or more additional piles as required. The extra cost of redesigned pile caps or the supplementary piles shall be borne by the contractor. 1.5.0 Testing of concrete Concrete shall be tested to ascertain its cube strength at 7 days and 28 days. The number of piles for which test cubes are to be taken would be as follows: Pile group 2 to 4 5 to 8 above 8 1.5.1 No. of piles 1 2 every 4th pile
Six cubes shall be taken in accordance with IS:1199 for testing a set of three cubes after 7 days and the second set of three cubes after 28 days.
1.5.2 The method of testing concrete cubes shall be as defined in IS:516 and the strength requirements and acceptance criteria of concrete shall be as specified in IS:456.
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1.6.0
Load test on piles Individual piles or a group of piles shall be tested to one and a half the safe load or to the load at which the total settlement attains a value of 12 mm or 40 mm for single piles or group respectively, whichever is earlier.
1.6.1
The loading shall be done by reaction form the kentledge of adequate capacity for the full test load. Test pit shall be excavated by open excavation through all types of soils and disintegrated rock to required depth. The base of the pit shall be minimum 3 m x 3 m size with adequate side slopes and provisions for shoring, dewatering etc. The excavated material shall be dumped sufficiently away from the edge of the excavation so as not to endanger the stability of pit. The hydraulic jack for transferring the load to the pile shall be of capacity 25% in excess of the test load and shall be provided with calibrated pressure gauge. The contractor shall furnish to the Engineer necessary test certificates from approved authorities to certify that the pressure gauges are calibrated before putting into operation The deflection dial gauges to measure the settlement of pile shall have 0.02 mm sensitivity and the reading shall be taken to an accuracy 0.01 mm. There shall preferably be three dial gauges. The contractor shall furnish to the Engineer necessary test certificates for each dial from approved authorities before putting the dial gauges into operation.7.6.4 Before any load test is performed the Contractor shall obtain approval of the set-up and the load from the Engineer. Care shall be taken to ensure that the centre of gravity of kentledge is on the axis of pile and lead applied by the jack is co-axial with the pile. The test loads shall be applied in increments of 20% of the assumed safe load. The pile cap for the selected pile group to be tested shall be cast of a mix capable of sustaining the test load or preferably of same mix as prescribed for the pile and shall be preferably level. The pile cap shall be provided such that the required conditions of actual use are fulfilled. In case of single piles, one M.S. plate 50 mm thick shall be set on the pile head such that its surface is perfectly horizontal. The hydraulic jack shall be inserted between the M.S. plate and the kentledge frame. The jack shall be so placed that the load is transferred centrally to the pile. The dial gauges shall rest at equal distance around pile/pile cap and shall be fixed to a datum bar whose ends shall rest on immovable supports. The supports for the datum bar with reference to which the settlement of the pile will be measured shall be at least 5 d away clear from the piles, where d is the diameter of the pile, subject to a minimum of 1.5 m. Each of loading shall be maintained till the rate of movement of the pile top is not more than 0.1 mm per hour in sandy soils and 0.02 mm per hour in case of clayey soils or a maximum of 2 hours whichever is greater. For this purpose, the type of soil met at pile tip shall be considered. The estimated safe load may be maintained for 24 hours and settlements should be observed every hour during this period.
1.6.2
1.6.3
1.6.5
1.6.6
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1.6.7
For each increment, application of load shall be smooth as far as possible. Time and settlement observations shall be made at the commencement and completion of each increment load is kept constant at about 15 minute intervals. The load on the pile may be removed in one stage by releasing the jack steadily after completion of the test and rebound observations made for 2 hours. The load settlement curve shall be drawn for the pile load test conducted. The safe load on single pile shall be two-thirds of the final load at which the settlement attains the value of 12 mm, unless it is specified that a total settlement different from 12 mm is permissible in a given case on the basis of nature and type of structure. In the later case the safe load shall correspond to actual total settlement permissible.
1.6.8 1.6.9
1.6.10 The safe load on group piles shall be two thirds of the final load at which the total settlement attains a value of 40 mm. 1.6.11 Recording of Data The contractor shall keep the following records of all the tests performed and shall obtain counter signature of the Engineer or his representative. i) Details of Piles a. b. c. d. e. f. g. ii) Pile designation/location etc. Date of casting of pile Concrete cube strength in the pile Pile length from cut-off level Description of strata at which the pile was found Pile test commenced on Pile test completed on
Details of Instruments used a. b. c. d. Make and specification of jack, pressure gauge and dial gauge Capacity of jack Calibration of pressure and dial gauges Design load of pile, description of location and identification marks of pile
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e.
Readings for settlement and rebound are to be entered in the following format
Settlement/ Time (1) Load (2)
Settlement/ Dial-1 rebound (3) (4)
Settlement/ Dial-2 rebound (5) (6) Dial-3 rebound Remarks (7) (8) (9)
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SECTION C4.4 INTENTIONALLY OMITTED
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SECTION-C4.5 TECHNICAL SPECIFICATION FOR PLAIN AND REINFORCED CONCRETE WORK 1.0.0 SCOPE This specification covers the requirement in respect of materials, workmanship and quality for plain and reinforced concrete for all types of structures in foundation and superstructure. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed hereunder: Cement IS:269 IS:4032 IS:6452 IS:8041 IS:8112 IS:12330 Aggregate IS:383 IS:2386 IS:2430 Coarse and fine aggregates from natural sources for concrete Methods of test for aggregates for concrete Methods of sampling of aggregates for concrete Ordinary and low heat Portland cement Method of chemical analysis of hydraulic cement. High alumina cement for structural use Rapid hardening Portland cement High strength ordinary Portland cement Sulphate resisting Portland cement
Concrete Plain and Reinforced IS:456 IS:460 IS:516 IS:1199 IS:1607 IS:1834 Code of practice for plain and reinforced concrete Test sieves Methods of test for strength of concrete Methods of sampling and analysis of concrete Methods for test sieving Hot applied sealing compounds for joints in concrete
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IS:2645 IS:2750 IS:2974 IS:3370 IS:9013 IS:9103 IS:9893 IS:10262 IS:10297 IS:10566 IS:10790 Steel IS:432 IS:1566 IS:1568 IS:1786 IS:2502 IS:2751 3.0.0
Integral cement water proofing compounds Steel scaffolding Code of practice for design and construction of machine foundations Code of practice for concrete structures for the storage of liquids Method of making, curing and determining compressive strength of accelerated cured concrete test specimens. Admixtures for concrete Precast concrete lintels and sills Recommended guidelines for concrete mix design. Code of practice for design and construction of floors/roofs using pre-cast reinforced/pre-stressed concrete ribbed or cored slab units. Methods of tests for pre-formed fillers for expansion joints in concrete paving and structural construction Methods of sampling of steel for pre-stressed and reinforced concrete.
Mild steel and medium tensile steel bars and hard-drawn steel wire for concrete reinforcement Hard-drawn steel wire fabric for concrete reinforcement Wire cloth for general purposes High strength deformed steel bars and wires for concrete reinforcement Code of practice for bending and fixing of bars for concrete reinforcement Code of practice for welding of mild steel plain and deformed bars used for reinforced concrete construction.
MATERIALS All materials that shall be used for works covered under this specification shall conform to following standards / specification. 1. Aggregate 2. Cement Machine crushed blue granite conforming to IS:383 Ordinary Portland Cement conforming to IS:269 of grade 43 Rapid Hardening Portland Cement conforming to IS:8041 High strength Ordinary Portland Cement conforming to IS:8112
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3. Reinforcement -
Sulphate Resisting Portland Cement conforming to IS:12330 Conforming to IS:432/IS:1786/IS:1566 Conforming to IS:2062 16 SWG annealed iron wire Approved non extruding, resilient fillers River or pit sand conforming to IS:2116 PVC/Rubber/Metallic - GI, Aluminium, copper Conforming to IS:9103 Clean, potable conforming to IS:456.
4. Embedded plates 5. Binding wire 6. Joint filler 7. Sand 8. Water stops 9. Admixtures 10. Water -
Source of coarse & fine aggregate shall be approved by the Engineer. The cement has to be tested and test certificates for each consignment of cement procured have to be submitted by the Contractor to ensure conformity with the relevant standards. The Engineer may reject such cements supplied in the event of unsatisfactory tests or in the event of deterioration due to age or bad storage etc. Decision of the Engineer shall be final in this regard. Admixtures shall be used only after getting permission from the Engineer and as per the instruction of the manufacturer. 4.0.0 GRADES AND PROPORTIONING Any grades of concrete designated in IS:456 as shown on the drawings or as per the Engineer's instructions shall be used. Design mix concrete shall be used on all concrete work. That is, the concrete mix shall be designed with preliminary tests. The mix shall be designed as per "Handbook on concrete mixers", SP:23, BSI while designing the mix, the strength, durability, minimum cement content, maximum water ratio allowed and work ability necessary for the job by most economical use of the various ingredients shall be considered by the Contractor. The water cement ratio, coarse aggregates and grading for each mix shall be predetermined from the results of cube tests of trial mixes. The mix proportions determined thus shall be followed at site and shall in no way relieve the Contractor of his responsibility as regards the prescribed strength mix. The theoretical consumption of cement will be calculated based on cement per cubic metre of concrete as per design mix. In case, the Contractor has to use more than the minimum cement content specified, no increase in rate is payable due to the extra cement consumed and the extra cement consumed will be deducted at specified issue rates. The mix proportions, however, shall be revised if the results of the cube tests during the construction show consistently lower than the prescribed one. No claim to alter the rates of concrete work will be entertained due to such changes in mix designs, as the Contractor will be responsible to produce the concrete of required grade. The aggregates shall be measured by weigh batching only.
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The maximum size of aggregates used shall be as indicated in IS:456 or in Schedule of Items. Nominal mix concrete in accordance with IS:456 for grade M20 or lower may the used if shown on drawings or approved by the Engineer. In all cases the proportioning of ingredients and works control shall be in accordance with IS:456 and shall be adopted for use after the Engineer is satisfied regarding its adequacy and after obtaining his approval in writing. 5.0.0 MIXING Mixing should be carried out in mechanical mixers. Hand mixing can however be permitted by Engineer in special cases subject to additional 10% extra cement without extra cost. When hand mixing is permitted, it shall be carried out on a clean, hard and water-tight platform. Water cement ratio shall be rigidly controlled during mixing. Mixers shall be fitted with automatic devices to discharge measured quantity of water to the mixing pan. The water shall not be admitted to the drum until all the cement and aggregate constituting the batch are thoroughly mixed. Mixing shall continue until the concrete is uniform in colour and not less than 2 minutes and forty (40) revolutions after all the material and water are in the drum. Regular checks on mixer efficiency shall be carried out as directed by the Engineer. Only those mixers whose efficiencies are within the tolerances specified in IS:1791 will be allowed to be employed. Batching plant where used shall conform to IS:4925. The entire content of the drum shall be discharged before the ingredients for next batch are fed into the drum. No partly set or remixed or excessively wet concrete shall be used. Such concrete shall be immediately removed from site. Each time the work stops the mixer shall be thoroughly cleaned and when the next mixing commences, the first batch shall have 10% additional cement at no extra cost to the Owner to allow for loss in the drum. 6.0.0 PLACING Concrete shall be transported from the mixing plant to the forms as rapidly as possible by means which will prevent segregation, consolidation or drying out in hot weather. Concrete shall be placed within thirty (30) minutes after commencement of mixing. At the time of placing concrete in very hot weather, care shall be taken to see that the temperature of wet concrete does not exceed 38oC. Before placing concrete, all formwork, embedments and reinforcement shall be checked for completeness, location, dimension. It should also be square and plumb. All chips and saw dust or other foul matter shall be removed from within the forms. The base surface shall be well moistened and puddles wiped up. Earth foundation on which direct placement of concrete is allowed will be rammed and consolidated as directed by the Engineer such that it does not crumble and get mixed up with the concrete during or after placement, before it has sufficiently set and hardened. concrete will always be placed against moist surface but never on pools of water. In case the foundation cannot be dewatered completely, special procedure and pre-caution, as directed by the Engineer will have to be adopted. A layer of mortar of thickness between 12 mm to 25 mm as directed, of the same or less W/C ratio and the same proportion as that of concrete being placed and /or cement slurry will be spread thoroughly on the foundation or construction joint just prior to placement of concrete. The cost of application of such cement slurry
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and/or mortar will be deemed to be included in the unit rate of concrete. Placing equipment and accessories shall be kept clean and free of partially set grout and concrete, and maintained in proper working order. Walking on reinforcement layers is not permissible. Walkways of wooden planks or similar can be placed with removal supports and should be independent of reinforcement. In general, placing shall be direct, by transporting buckets. Where it is necessary to deposit the concrete at level differences of more than 1.5 m, short chutes shall be used. Short chutes and hoppers shall be so designed and installed that segregation will not take place. In cases where chutes are impracticable due to excessive drop to placing level, hoppers and sectional tubes (elephant trunks) shall be used. After the concrete has been placed, it shall be spread, if necessary and thoroughly worked around reinforcement or other embedded fixtures into concrete form and shape. Vibrators shall not be used for pushing the concrete into the adjoining areas. Care must be taken to ensure that the inserts, fixtures, reinforcement and formwork are not displaced during or immediately after the placement and bring the concrete surface out of the alignment beyond tolerance limits, the Engineer may direct to remove the portion and reconstruct or repair the same at the Contractor's expense. The rate of placement of concrete shall be such that no cold joint is formed and fresh concrete is placed always against green concrete which is still plastic and workable. No concrete shall be placed in open, while it rains. During rainy season, no placement in open is to be attempted unless sufficient tarpaulins or other similar protective arrangement for complete covering the still green concrete from rain is kept at the site of placement. If there has been any sign of washing of cement and sand, the entire affected concrete shall be removed immediately. 7.0.0 COMPACTION Concrete in general shall be consolidated by vibration using high frequency mechanically driven vibrators. Concrete shall be placed in layers at least 300 mm deep in walls and approximately 450 mm in mass pouring. Vibrators shall not penetrate more than 50 mm into the surface of previously placed layers but shall completely vibrate the working layer. Care shall be taken not to over-vibrate any concrete and especially those with higher slumps. Under no circumstances vibrators shall be attached to or allowed to touch reinforcement. Spare vibrators in good operating condition shall be on hand during placing operations. 8.0.0 CONSTRUCTION JOINTS In general, construction joints shall be limited to those indicated on the drawings. In mass concrete, construction joints may not be indicated in the drawings but shall be made at breaks, offsets or other convenient levels as controlled by volume, plant capacity and time factors. Such construction joints shall be so located that they do not impair the strength of the structure. In walls and columns, height of each lift shall not generally exceed 1.5 m unless otherwise specified in the drawings or directed by the Engineer. Method of forming all construction joints shall conform to the provisions of IS:456. All construction joints shall be cleaned with wire brush and water to remove all laitance and loose material to expose the aggregates. Immediately before placing fresh concrete, the surface of previously placed concrete shall be coated with a thin coat of cement mortar slurry of the same proportion as that of concrete. PVC water stops shall be
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provided in construction joints below ground level and proper shear key is to be formed for construction joint above ground level. Where locations of the joints are not specified, it will be in accordance with the following: a. In a column, the joint shall be formed 75 mm below the soffit of the beam or the edge of the anchored bar of the beam framing into it whichever is lower. The Contractor shall refer to the beam reinforcement drawing before deciding on the location of the joint at column-beam junction. Concrete in a beam shall preferably be placed without a joint, but if provision of a joint is unavoidable, the joint shall be vertical and at the middle one third of the span, clearing the cross beam location, if any. A joint in a suspended floor slabs shall be vertical and at the middle one third of the span and at right angles to the principal reinforcement. In general, construction joints shall be located preferably in a low shear stress zone and at right angles to the direction of the principal stress.
b.
c. d.
Any deviation from the above shall be approved by the Engineer. As soon as the concrete has hardened sufficiently, hardened it shall be covered either with sand, Hessian, canvas or similar materials and kept continuously wet for at least seven (7) days after final setting. Curing by continuous sprinkling of water will be allowed if the Engineer is satisfied with the adequacy of arrangements made by the Contractor. 9.0.0 CURING AND PROTECTING Curing of concrete with water shall comply with IS:456. Curing compound shall be used subject to approval by the Engineer. Finished floors shall be protected carefully until completely set. Protection of concrete against extreme weather conditions shall comply with the code. 10.0.0 FINISHING No touching-up will be permitted to the concrete after removal of formwork. Where damages, honey-combing or other unsatisfactory finishes have occurred to the concrete surfaces, they shall be rectified in a manner as directed by the Engineer, at no extra cost. If in the opinion of the Engineer the concreting is unsatisfactory, demolition of the entire concrete work and reconstruction of the same shall be carried out by the Contractor, as directed by the Engineer at his own cost. All unformed surface shall be finished with wooden float and formed surface shall be finished with cement mortar using fine sand and by sack rubbing. 11.0.0 FORMWORK & CENTERING Form work in general shall conform to IS:456. For complicated work, the Contractor shall submit his proposal of formwork before starting the work for approval of the Engineer. The number of props, their sizes and dispositions shall be such as to be able to safely carry the full dead load and
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constructional loads. However, approval of the Engineer to this effect shall not relieve the Contractor of his responsibility for proper work and safety. All forms of beams, slabs and members shall be so designed and erected that the sides can be removed without disturbing the soffit shutter and supports there to. Beam soffit shall be provided with an upward, camber of 6mm for each 3M of horizontal span or as directed by the Engineer. Vertical props shall be supported on wedges or sole plates or other measures where by the props can be gently lowered while commencing to remove the shuttering. Columns shuttering shall not be over 1.5 M in height a piece. Before removal of the shuttering the concrete shall be examined and its removal order taken from the Engineer. In no circumstance shall forms be struck until the concrete reaches a strength of atleast twice the stress to which the concrete may be subjected at the time of striking. Shuttering shall not be removed until the number of clear days specified in IS:456 have elapsed since the last day of placing concrete in the member concerned. All formwork shall be removed without such shock or vibration as would damage the reinforced concrete. Before the soffits and struts are removed, the concrete surface shall be exposed, where necessary, in order to ascertain that the concrete has sufficiently hardened. The specified period may be extended if desired by the Engineer on account of delayed hardening caused by low atmospheric temperature. 12.0.0 REINFORCEMENT The reinforcement bending shall be carried out as per the approved bar bending schedule prepared based on design drawing and availability of reinforcing bar in Owner's stores. Workmanship shall conform to IS:2502. All reinforcement shall be free from loose mill scale, rust, oil, grease and paint. Reinforcement shall not be bent or straightened in a manner that will injure the materials and all bars shall preferably be bent cold. Hot bending shall not be permitted for bars whose strength have been increased by cold working. Reinforcement bars shall be placed and maintained accurately in positions as shown in the drawings. The correct cover to the reinforcement shall be maintained by use of precast concrete blocks. All intersections of longitudinal and transverse bars or stirrups and all laps shall be securely tied together with approved binding wire. The binding wire shall be so placed that it touches all the four corners of the intersection and the two ends shall be looped with pliers and the ends shall be turned into the body of the concrete. The cost of the binding wire and spacer/ cover blocks shall be included by the Contractor in his rate for reinforcement work. Welded joints may be used but in all cases of important connections, tests shall be made to prove that the joints are of the full strength of bars connected. Welding shall be done in accordance with IS:2751 and special precautions shall be adopted for cold worked bars. Butt welding between the ends of a rod in line, whereby stress is transferred across the section may be adopted only for mild steel bars. In case of tack welding for fixing reinforcements in their position, no special precaution need be taken.
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13.0.0
STEEL EMBEDMENTS All embedments shall be accurately set, rigidly fastened and suitably anchored by welding lugs. Anchor bolts shall be set to template and firmly secured in vertical and horizontal line and required positions. Exposed surfaces of embedded materials are to be painted with one coat of red oxide zinc chrome and/ or bituminous paint. Correct location and alignment as per drawings/instruction of all anchor bolts, anchor sleeves, inserts, hangers, conduit pipes and other embedded fixtures shall be entirely the responsibility of the Contractor.
14.0.0 EXPANSION & ISOLATION JOINTS 14.1.0 General Expansion and isolation joints in concrete structures shall be provided at specified places, as per details indicated on the drawings. The materials and types of joints shall be as specified hereinafter. In case of liquid retaining structures, additional precautions shall be taken to prevent leakage of liquids as may be specified on the drawings or as directed by the Engineer. All materials are to be procured from reliable manufacturers and must have the approval of the Engineer. Where it is the responsibility of the Contractor to supply the material, the Engineer may demand test certificates for the materials and/or instruct the Contractor to get them tested in an approved laboratory free of cost to the Owner. Approved samples of the material to be incorporated in the works shall be with the Engineer. Joints shall be formed true to line, level, shape, dimension and quality as per drawings and specifications. Prior approval of the method of forming the joints should be obtained from the Engineer before starting the work. 14.2.0 Bitumen Board/Expanded Polystyrene Board Bitumen Board Bitumen impregnated fibre board of approved manufacturer as per IS:1838 may be used as fillers for expansion joints. It must be durable and water proof. It shall be compressible and possess a high degree of rebound. The dimensions of the board should be equal to that of the joint being formed. It should, preferably be manufactured in one piece, matching the dimension of the joint and not prepared by cutting to size smaller pieces from larger boards at site. At the exposed end, the joint shall be sealed with approved sealing compound to a depth of at least 25 mm after application of an approved primer. The sealing compound and the primer shall be applied as specified by the manufacturer. Fixing of Joint Filler The concrete surface shall be made clean, smooth and free from dirt or loose particles. When the surface is completely dry, a coat of hot blow bitumen conforming to IS:702 of grade 85/25 shall be given with brush or spray. When the bitumen is still hot the premoulded joint filler fibre board shall be pressed against the surface and held in position till the time it takes to adhere. When more than one layer of filler are specified each layer shall be made to adhere to the preceding layer with a few patches of bitumen between the two layers. After placing the filler in position, the surface of the filler against which further concreting is to be done is given a coat of bitumen.
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Filling of joint sealing compound Sealing compound shall be of Grade A conforming to IS: 1834. Bitumen shall conform to IS:3384. Before application of the sealing compound the sides of the joint are sprayed or brushed with bitumen primer. The primer is then allowed to dry out thoroughly for at least 24 hours and then filled with a mix of 30 % fine sand and 70 % sealing compound by weight. Expanded Polystyrene Boards If required, commercial quality of expanded polystyrene products commonly used for thermal insulations may also be used as filler material in expansion joints. The thickness may vary from 12 mm to 50 mm. The material will have to be procured from reliable manufacturers as approved by the Engineer. The method of installations will be similar to that recommended by the manufacturers for fixing on cold storage walls. A coat of bitumen paint may have to be applied on the board against which concrete will be placed. 14.3.0 Joint Sealing Strips Joint sealing strips shall be provided at the construction, expansion and isolation joints as a continuous diaphragm to contain the filler material and/or to exclude passage of water or any other material into or out of the structure. The sealing strips will be either metallic like G.I., Aluminium or copper, of non-metallic like rubber or P.V.C. Sealing strips will not have any longitudinal joint and will be procured and installed in largest practicable lengths having a minimum number of transverse joints. The material is to be procured from reputed manufacturers having proven records of satisfactory supply of joint strips of similar make and shape for the jobs. The jointing procedure shall be as per the manufacturer's recommendations, revised if necessary, by the Engineer. The Contractor is to supply all labour and material for installation including the material and tools required for jointing, testing, protection, etc. If desired by the Engineer, joints in rubber seals may have to be vulcanised. Metal Sealing Strips Metal sealing strips shall be either G.I., Aluminium or Copper and formed straight, U shaped, z shaped or any other shape and of thickness as indicated in the drawing and Schedule of Items and/ or as instructed by the Engineer. The transverse joints will be gas welded using brass rods and approved flux and will be tested by an approved method to establish that it is leak proof. In case it is found that the joints cannot be made leak proof, longer lap length and different method of brazing which will render it leak proof, will be adopted by the Contractor without any additional cost to the Owner. The edges shall be neatly crimped and bent to ensure proper bond with the concrete. a) G.I. Strips : G.I Strips shall be minimum 1.5 mm thick and 150 mm in width unless specified otherwise. The standard of Galvanising shall be as per relevant Indian Standards
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for heavy duty work. The strips shall be strong, durable, without any rust or crease. At the joints, the over-lapping should be for a minimum length of 50 mm. b) Aluminium Strips : Aluminium strips shall be minimum 18 swg. thick and 300 mm wide unless specified other wise and shall conform to IS:737 of 19000 grade or 31000 grade (Designation as per IS:6051). A minimum lap of 50 mm length is required at the joints. c) Copper Strips : The Copper strips shall be minimum 18 swg. In thickness and 300 mm width unless specified otherwise and shall conform to the relevant Indian Standards. It should be cleaned thoroughly before use to expose fresh surface, without any reduction in gauge. A minimum lap of 50 mm is length is required at the joints. Non-metallic Sealing Strips These will be normally in Rubber or P.V.C. Rubber or P.V.C. joint seals can be of shape having any combination of the following features : a. b. c. d. e. Plain Central bulb Dumb-bell or flattened ends Ribbed and Corrugated Wings V-shaped
As these types of seals can be easily handled in very large lengths unlike metal strips, transverse joints will be allowed only under unavoidable circumstances and without the specific approval of the Engineer. The method of forming these joints, laps etc. shall be specified by the Manufacturer and/or as approved by the Engineer taking particular care to match the central bulbs and the edges accurately. a) Rubber Sealing Strips : The minimum thickness of rubber sealing strips shall be 3 mm and the minimum width 100 mm. The actual size and shape will be as shown in drawings/Schedule of Items and/or as directed by the Engineer. The material will be natural rubber and the resistant to corrosion, abrasion and tear and also to attacks from the acids, alkalies and chemicals normally encountered in service. The physical properties will be generally as follows. The actual requirements may be slightly different as decided by the Engineer. Sp. Gr. Shore Hardness Tensile Strength Max. safe continuous temperature Ultimate Elongation
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: 1.1 to 1.15 : 65 A to 75 A : 25 - 30 N/mm : 75C : Not less than 350%

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b)
P.V.C. Sealing Strips The minimum thickness of P.V.C sealing strips will be 3 mm and the minimum width 100 mm. The actual size and shape will be as shown in drawings/Schedule of Items and/or as directed by the Engineer. The material should be of good quality Polyvinyl Chloride highly resistant to tearing, abrasion and corrosion as well as to chemicals likely to come in contact with during use. The physical properties will generally be as follows. The actual requirements, which will be directed by the Engineer, may vary slightly. Sp. Gr. Shore Hardness Tensile Strength Maximum Safe Continuous Temperature Ultimate Elongation : 1.3 to 1.35 : 60 A to 80 A : 10 - 15 N/mm2 : 70 deg C : Not less than 275%
14.4.0
Bitumen Compound When directed, the gap in expansion joints shall be thoroughly cleaned and bitumen compound laid as per manufacturer's specifications. The compound to be used shall be of approved manufacturer and shall conform to the requirements of IS:1834.
14.5.0
Isolation Joints Strong and tough alkathene sheet or equivalent, about 1 mm in thickness and as approved by the Engineer shall be used in Isolation Joints. It shall be fixed by an approved adhesive compound on the cleaned surface on the already set concrete, to cover it fully. Fresh concrete shall be laid against the sheet, care being taken not to damage the sheet in any way.
14.6.0 Rubber Pad Hard foundation quality rubber pads of required thickness and shapes be put below machine or other foundation as shown on the drawing or as directed by the Engineer. The rubber shall have a unit weight of 930 Kg/m3, shore hardness - 65 A to 70 A and be of best quality of approved manufacture, durable, capable of absorbing vibration and must be chemically inert in contact with moist or dry earth or any other deleterious material expected under normal conditions. 15.0.0 PRECAST CONCRETE All precast work shall be carried out in a yard for the purpose. This yard shall be dry, properly leveled and having a hard and even surface. If the ground is to be used as a soffit former of the units, it shall be paved with concrete or masonry and provided with a layer of cement plaster with smooth neat cement finish or a layer of M.S. sheeting. The yard, lifting equipment, curing tank, finished material storage space etc. shall be designed such that the units are not lifted from the mould before seven (7) days of curing and can be removed for erection after twenty eight (28) days of curing. The moulds shall preferably be of steel or of timber lined with G.I. sheet metal. The yard shall preferably be fenced.
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Lifting hooks, where necessary or as directed by the Engineer, shall be embedded in correct position of the units to facilitate erection, even though they may not be shown on the drawings, and shall be removed and the hooks finished after erection if directed by the Engineer. Precast concrete units, when ready, shall be transported to site by suitable means approved by the Engineer. Care shall be taken to ensure that no damage occurs during transportation. All adjustments, leveling and plumbing shall be done as per instructions of the Engineer. The Contractor shall render all help with instruments, materials and men to the Engineer for checking the proper erection of the precast units. Chipped or cracked or otherwise damaged pre-cast elements will be rejected. After erection and alignment, the joints shall be filled with grout or concrete as directed by the Engineer. If centerings have to be used for supporting the precast units, they shall not be removed until the joints have attained sufficient strength and in no case before fourteen (14) days. The joint between precast roof planks shall be pointed with 1:2 cement : sand mortar where called for in the drawings. 16.0.0 16.1.0 WATERPROOFING OF CONCRETE TO STRUCTURES General Waterproofing of concrete structures shall be done by either suitable extraneous treatments like applying paints, fixing bitumen felts etc. installing water bars at the joints. The design, material and workmanship shall conform to the relevant I.S. codes where applicable. The Engineer's approval of the materials shall be obtained by the Contractor before procurement. If desired by the Engineer, test certificates for the materials and samples shall be submitted by the Contractor free of charge. The materials shall be best quality available indigenously, fresh clean and suitable for the duties called upon. 16.2.0 Water Bar/Seal Water bearing structures and underground structures may have water bar/seals installed at the joints. They may be either metallic, rubber or P.V.C. the material and installation will be as described under clause 14.3.0. 16.3.0 Waterproofing Admixtures a) In Concrete The admixture shall be procured from reliable and reputed manufacturers and approved by the Engineer. The method of application and other details shall conform to the manufacturer's specification and/or as instructed by the Engineer. The Contractor shall have the service of the manufacturer's supervisor at no extra cost to the Owner to supervise the work, if desired by the Engineer. Cost of the admixture used is not payable seperately to the Contractor if the addition of the admixture is stated in the drawing/Schedule of Items. b) In Plaster The concrete surface, to be plastered, shall be hacked to Engineer's satisfaction, cleaned thoroughly and kept wetted for 24 hours. The plaster shall be in cement
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sand mortar mixed is proportion varying from 1:1 to 1:4 by volume along with the approved waterproofing admixture and laid in appropriate thickness and in layer not exceeding 15 mm or as per manufacturer's specification. The additive shall be of quality and type approved by the Engineer. If desired by the Engineer, the Contractor shall have the work supervised by the manufacturer's supervisor at no extra cost to the Owner. On completion, the plastered surface shall be cured continuously for a minimum period of fourteen (14) days like concrete. 16.4.0 Bituminous or Tar Coating The surface to be waterproofed shall be rendered absolutely dry, clean and dust free. The surface shall be sand papered, cleaned and completely coated with hot coal tar pitch of approved manufacture and quality as per IS:216 (not heated above 375oF) using not less than 2 kg. per Sq.m. or with hot asphalt i.e. bitumen according to IS:73 (not heated above 400oF) using not less than 1.5 kg per Sq.m. When the first coat has completely dried up and approved by the Engineer, the second coat shall be applied in the same manner using not less than 1.25 Kg. per Sq.m. in case of coal tar and 1 kg per Sq.m. in case of asphalt. Immediately after application of the second coat and before it is dried up, sand shall be spread on the surface to cover it completely. Sufficient time shall be allowed after spreading of sand before backfilling is done in order to allow the final coat to dry up completely. 17.0.0 TESTING 17.1.0 Cement The Contractor shall submit to the Engineer the manufacturer's certificate for each consignment of cement procured if cement is supplied by him. If required by the Engineer, representative samples shall taken from each consignment and tests for fineness (by hand sieving), setting time and compressive strengths as per IS:269 shall be carried out, free of charge by the Contractor. 17.2.0 Aggregates Coarse and fine aggregate and the grading shall be as per IS:383. It shall be free from organic or clay coatings and other impurities, flaky particles, and any other material liable to affect the strength, durability or appearance of concrete. Washing of aggregates by approved means shall be carried out, if desired by the Engineer. The Contractor shall carry out any or all the tests on aggregates as may be required by the Engineer in accordance with IS:2386. The acceptance criteria of samples tested shall be in accordance with the requirements of relevant Indian Standards. 17.3.0 Admixture 17.3.1 Air Entraining Agents Initially, before starting to use Air Entraining Agents, relationship between percentage of air entrained and the cylinder tube crushing strength vis-a-vis quantity of Air Entraining Agents used for all types of concrete will be established by the Contractor free of charge by carrying out sufficiently large number of tests. After that, at regular intervals and whenever directed by the Engineer, the Contractor will check up free of charge, the actual
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percentage of air entrained and corresponding curing strengths to correlate with the earlier test results. 17.3.2 Other Admixture Tests for establishing the various properties of any other admixtures which may be required to be added shall be carried out by the Contractor free of charge to the Owner. 17.4.0 Concrete Sampling, making up, curing and testing of specimen will comply with IS:456, IS:516 and IS:1199. Unless otherwise instructed by the Engineer, frequency of works tests shall be as indicated below. The criteria for acceptance shall be in accordance with IS:456. Sampling procedure, shall generally conform to IS:456. Sampling frequency for each grade of concrete M15 and above shall be six (6) cubes for each 50 m3 or part thereof, or per day concreting volume, whichever is less. Out of each set of six (6) cubes, three (3) cubes shall be tested at seven (7) days and the remaining three (3) cubes at twenty eight (28) days. If there is a change in batch of cement, a separate set of samples consisting of six (6) cubes shall be taken for each batch. In case, the stripping time for shuttering needs to be reduced or early age strength is required to be known in specific cases, the Contractor shall carry out at short notice testing of cubes at one (1) day and three (3) days after accelerated curing as per IS:9013. The required number of additional samples for the same shall also be taken. To control the consistency of concrete from every mixing plant/machine, slump tests and/or compacting factor tests as per IS:1199 shall be carried out by the Contractor every two hours or as directed by the Engineer in addition to the slump measured when making test cubes. 18.0.0 ACCEPTANCE CRITERIA 18.1.0 Structural Criteria Acceptance criteria of concrete shall be generally in accordance with Clause 15 of IS:456. Immediately after stripping the formwork, all concrete shall be carefully inspected and any defective work or small defects either removed or made good before the concrete has thoroughly hardened. The acceptance criteria of concrete shall be in accordance with IS:456. However, in exceptional circumstances, the Engineer may, at his discretion, accept a concrete of lower strength than specified and which is otherwise unacceptable according to IS:456. Payment for such accepted concrete will be made only at reduced rate prorata to the strength obtained. Concrete work found unsuitable for acceptance shall have to be dismantled and replacement is to be done as per specification by the Contractor. No payment for the dismantled concrete, the relevant formwork and reinforcement, embedded fixtures, 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 be made good, free of charge by the Contractor, to the satisfaction of the Engineer.
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18.2.0 Dimensional Criteria The permissible variation from dimension, lines given in the drawing shall be within tolerances specified in the relevant IS codes/other applicable standards or as indicated by the Engineer. Generally the following tolerances shall be considered. Tolerances for R.C. Buildings : i) Variation from the plumb a. In the lines and surfaces of columns, piers, walls and in arises 5 mm per 2.5 m or 25 mm, whichever is less. b. For exposed corner columns and other conspicuous lines In any bay or 5 m max. In 10 m or more ii) 5 mm 10 mm
Variation from the level or from the grades indicated on the drawings a. In slab soffits, ceilings, beam soffit, and in arises In 2.5 m In any bay or 5 m max. In 10 m or more 5 mm 8 mm 15 mm
b. For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines In any bay or 5 m max. In 10 m or more iii) 5 mm 10 mm
Variation of the linear building lines from established position in plan and related position of columns, walls and partitions. In any bay or 5 m max. In 10 m or more 10 mm 20 mm
iv) v)
Variation in the size and locations of sleeves, openings in walls and floors - 5 mm except in the case of and for anchor bolts Variation in cross-sectional dimensions of columns and beams and in the thickness of slabs and walls Minus Plus 5 mm 10 mm
vi)
Footings a. Variation in dimension in plan Minus Plus FICHTNER India
5 mm 50 mm
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b. Misplacement or eccentricity 2% of footing width in the direction of misplacement but not more than 50 mm c. Reduction in thickness Minus vii) Variation in steps a. In a flight of stairs Rise Tread b. In consecutive steps Rise Tread Tolerances in other Concrete Structures a. All structures i. Variation of the constructed linear outline from established position in plan In 5 m In 10 m or more 10 mm 15 mm 1.5 mm 3.5 mm 3 mm 5 mm 5% of specified thickness subject to a max. of 50mm
ii. Variations of dimensions to individual structure features from established positions In 20 m or more In buried construction 25 mm 50 mm
iii. Variation from plumb, from specified batter or from curved surfaces of all structures In 2.5 m In 5 m In 10 m or more In buried-construction 10 mm 15 mm 25 mm Twice the above amounts
iv. Variation from level or grade indicated on drawings in slab, beams, soffits, horizontal grooves and visible arises In 2.5 m In 7.5 m or more In buried construction
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5 mm 10 mm Twice the above amounts

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v.
Variation in cross-sectional dimensions of columns beams, buttresses, piers and similar members Minus Plus 5 mm 10 mm
vi. Variation in thickness of slabs, walls, arch sections and similar members Minus Plus 5 mm 10 mm and similar members
b. Footing for columns, piers, walls, buttresses i. Variation of dimension in plan Minus Plus ii. Misplacement or eccentricity -
5 mm 10 mm
2% of footing width in the direction of misplacement but not more than 50 mm iii. Reduction in thickness 5% of specified thickness subject to a max. of 50 mm Tolerances in other types of structures shall generally conform to those given in 2.4 of Recommended Practice for Concrete Formwork (ACI 347) Tolerances in fixing anchor bolts shall be as follows : i. ii. Anchor bolts without sleeves 1.5 mm in plan Anchor bolts with sleeves 5.0 mm in elevation a. For bolts upto and including 28 mm dia 5 mm in all directions b. For bolts 32 mm dia and above 3 mm in all directions iii. Embedded parts - 5 mm in all directions
19.0.0 STORAGE AND HANDLING OF MATERIALS 19.1.0 Cement Cement shall be stored in easily countable stacks with consignment identification mark above ground level in perfectly dry and watertight sheds. Bulk cement shall be stored in air tight containers. Cement shall be stored in a manner so as to facilitate removal of first-in first-out basis. Any cement considered defective by the Engineer shall not be used by the Contractor and shall be removed from the site immediately. Cement that has been in store for six (6) months or more shall be tested for quality. Should at any time the
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Engineer have reasons to consider that any cement is defective, then irrespective of its origin, date of manufacture and manufacturer's test certificate, such cement shall be tested immediately at the Contractor's cost at an approved laboratory and until the test results are found satisfactory the cement shall not be used on any work. The Contractor is not entitled to any claim of any nature of this account. 19.2.0 Coarse and fine aggregate Aggregates shall be stored in easily measurable stacks on brick soling or an equivalent platform so that they do not come in contact with dirt, clay, grass or any other injurious substances at any stage. Aggregate of different size shall be kept in different stacks. If so desired by the Engineer, aggregate from different sources shall be stacked separately with proper care to prevent intermixing. Any aggregate delivered at site in a wet condition or becoming wet at site due to rain or any other means shall be kept in storage for atleast twenty four (24) hours to obtain adequate drainage before it is used for concreting or the water content of the mix must be suitably adjusted as directed by the Engineer. 19.3.0 Reinforcement Reinforcement bars shall be stored off the ground and under cover if so desired by the Engineer. If necessary, a coat of cement wash shall be given to bars to guard against rusting. Reinforcing steel shall be stored consignment wise and diameter wise.
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SECTION-C4.6 TECHNICAL SPECIFICATIONS FOR PRECAST RCC ROOFING UNITS
1.0.0
SCOPE These specifications cover the furnishing of all labour, materials and equipment, manufacture, curing, storage, handling and erection of precast concrete roofing units and other structural members. The following clauses are in addition to and take precedence over the general provisions under the head of precast concrete in the specification No.C2 "Technical Specifications for Plain and Reinforced Concrete Works".
2.0.0
CODES OF PRACTICE The work shall be done in accordance with IS:456/IS:10297. If so directed by Engineer, reference may also be made to British Standard Code of Practice CP:116:1965 "The Structural Use of Precast Concrete". However, the provisions of this specification take precedence over the provisions of the code of practices.
3.0.0
JOB PLANNING The Contractor shall carefully plan his work in minute detail covering all stages of construction. Before the erection work starts, the casting yard should have been completed and should be in a smooth working order. It should be well laid out and so planned that work on any unit may not affect the work on adjacent units. Adequate weather protection should also be provided. Working details of erection method, devices, attachments, etc., shall be worked out well in advance and got approved by the Engineer. It shall be clearly understood that the Contractor shall be entirely responsible for the planning and safety, timely and successful completion of the work. His responsibility in this regard shall not be absolved by the approval by the Engineer to any of the Contractor's planning methods, suggestions, details, etc. The Contractor shall submit to the Engineer a detailed drawing including a write-up clearly specifying his layout plan and details of casting yard, curing pond, method of casting, storing and handling the precast units. He shall further submit from time to time such additional details as may be called for by the Engineer. The precast units shall be cast at site unless the Contractor satisfies the Engineer that units can be safely and promptly transported from the off site casting yards. In such a case, cost of transporting, loading, unloading, damage in handling, etc shall be included in the tendered unit rates and will not be paid for separately by the Owner.
4.0.0
MOULDS The moulds should be carefully manufactured in tolerances acceptable to Engineer. They must be sturdy in construction to withstand the required number of re-uses. They should be sufficiently tight to prevent loss of grout or mortar during placing and compacting of concrete. Higher pressure and greater strains in the side formwork during vibrating shall also be considered in the design of the moulds.
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The Contractor shall have enough number of moulds for each type of units proposed. This shall be carefully worked out to the satisfaction of the Engineer duly considering deshuttering period, number of units to be cast, time schedule, etc. If at any stage the Engineer considers that additional moulds are required, the same shall be immediately provided by the Contractor at no extra cost. The number of re-uses to be permitted for any type of mould shall be decided by the Engineer and shall be binding on the Contractor. For steel moulds, more than 45 uses will not be permitted. Bond preventive which does not discolour the surfaces and which is approved by Engineer may be used on the mould surface. Easy removal of the flat units may not still be possible due to the "suction" created by the differential atmospheric pressure. Air or water forced between the casting and the mould equalises the pressures and destroys the "suction" and for this purpose, air chambers may be provided by the Contractor at the centre of the mould, connected by means of suitable pipes to a compressed air source. The moulds shall have provisions to hold firmly and maintain all projecting reinforcement or other inter-connecting devices together with bolts, fixing blocks etc., so that they are within the specified tolerances on completion. All inserts etc., shall be checked before erecting the precast units. The method of fixing and holding the inserts (required for lifting, joint connections, etc.) in their correct location during concreting, shall be carefuly planned. Through ties will not be permitted. 5.0.0 DIMENSIONAL TOLERANCES The moulds shall be so constructed that each finished unit has the exact dimensions shown on drawing within the tolerances as to the length, cross section, straightness or bow, squareness, length of shorter sides, twist, flatness and the position of reinforcement and inserts mentioned herein below: 5.1.0 Length Upto 3 m 3 m to 4.5 m 4.5 m to 6 m Additional for every subsequent 6 m 5.2.0 Cross Section (Each direction) Upto 50 cm 50 cm to 75 cm Additional for every subsequent 25 cm
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: : : :
6 mm 9 mm 12 mm 6 mm
: : :
6 mm 9 mm 3 mm
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5.3.0
Straightness or bow (Deviation from intended line) Upto 3 m 3 m to 6 m 6 m to 12 m Additional for every subsequent 6 m : : : : 6 mm 9 mm 12 mm 6 mm
5.4.0
Squareness When considering the squareness of a corner, the longer of the two adjacent sides being checked should be taken as the base line. The shorter side should not vary in its distance from a perpendicular so that the difference between the greatest and shortest dimensions exceeds: Length or shorter sides upto and including 2m Over 1.2 m but less than 2m 2 m and over
: : :
6 mm 9m 12 m
For the purpose of this requirement, any effortdue to lack of straightness should be ignored; squareness should be measured with respect to the straight lines which are most nearly parallel with the features being checked. 5.5.0 Twist Any corner should not be more than the tolerance stated from the plane containing the other three corners. Upto 60 cm wide and upto 6 m in length Over 60 cm wide and for any length 5.6 0 Flatness The maximum deviations from a 1.5 m straight edge placed in any position on nominally plane surface should not exceed 6 mm. : 6 mm
12 mm
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5.7.0
Position of Reinforcement Tolerance for the position of reinforcement shall not exceed those specified in the drawing, or those below, whichever are smaller: (a) (b) Cover the actual concrete cover to all steel at any point should not be smaller than the required nominal cover by more than 3 mm. The effective depth of fully or nearly fully stressed tensile reinforcement should not be less than that given on the drawings by an amount exceeding 5% of the effective depth of the section being considered or 6 mm, whichever is greater.
5.8.0
Position of connecting bolts and other devices If and where proposed, the position of individual connecting bolts, bolt holes, projecting steel or other devices in any associate group (e.g. the joint of two precast units) should be within 3 mm of its true position in the group in which they are cast. The longitudinal location of any such group should be within 6 mm of its true position in the unit in which it is cast, provided that such tolerances does not adversely affect the proper assembly of the whole structure.
6.0.0
PLACING THE REINFORCEMENTS Reinforcement shall be placed and maintained in position within the specified tolerance. Where practicable, the reinforcement shall be preformed into rigid cages, spot welding being permissible for this purpose. Where welded wire fabric is proposed, the mesh shall be bent to shape before placing in the moulds. Care shall be taken in assembling the cage because the tolerances for placing are quite small. Where tying wire or clips are used, care shall be taken to ensure that the projecting ends do not encroach into the concrete cover. Provisions shall be made to ensure that the reinforcements are maintained in their correct position during concreting. Spacer blocks made of mortar comparable in strength and durability with main concrete shall be used to have uniform and required cover. Other kinds of spacers shall be approved by the Engineer.
7.0.0
CONCRETE PLACEMENT The moulds must be thoroughly cleaned of all rubbish before concrete is placed. Any means which will mechanically distribute the concrete is satisfactory. The vibration shall be done by internal vibrators or a surface vibrator approved by Engineer. The method of placing concrete shall conform to specification C1.7 - "Technical Specifications for Plain & Reinforced Concrete Works".
8.0.0
SURFACE FINISH A perfect and smooth finish shall be achieved by the use of high quality concretes and by using properly designed moulds having a hard, smooth surface. The concrete surfaces shall be smooth and even. Only very minor surface blemishes shall occur and there should be no staining or decolouration from the bond preventive. Minor surface defects
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shall be made good, subject to the approval of the Engineer, provided the strength, durability and appearance are not impaired by such defects. The unformed surface shall be finished smooth using wooden float. 9.0.0 MARKING OF UNITS Each unit shall be clearly marked. The code shall include a letter identifying the type of casting, the mould number, the casting date and a directional work for orientation during erection. 10.0.0 REMOVING MOULDS The side shuttering may be removed 24 hours after casting. The casting can be lifted from the mould after the concrete has attained sufficient strength to take lifting and handling stresses depending on the self-weight and method of handling. Generally, the bottom shutter may be removed 7 days after casting. However, the Engineer may permit earlier removal if he is convinced that no damage will be caused to the casting by taking special care during handling. However, the Engineer may also require the de-shuttering periods to be extended if he is not satisfied with the product and considers such extension desirable. All moulds shall be removed without any shock, jolts or vibration that might damage the concrete and cause cracking. 11.0.0 CURING Curing of concrete shall start as soon as the concrete has sufficiently set, even if the castings have not been removed from the moulds. The surfaces should not, however, be ponded during the first 24 hours. There should be two storage/curing areas, one under cover and one in the open air. The covered area may be erected by tarpaulin supported on a light frame work and should be large enough to contain the output of the casting yard for a period of six days. The method of curing should be such that the precast unit will remain undistorted, be free from cracks and will not cause, by its shrinkage, undue cracking in the structure into which it is to be built and that the concrete will have satisfactory durability and strength. The general method of curing in the covered shed will be to cover the entire surface of the casting with damp hessain, canvas, gunny bags or similar absorbent material kept constantly damp. Alternatively, a curing pond may be used. If the products are stacked in tiers, it is necessary to ensure that as much as possible of surface of the concrete is thoroughly wetted. The castings may preferably be covered, after dampening, by an impermeable sheet like polythene, to retain the moisture escaping from the concrete. Membrane curing compounds, if proposed, shall be approved by the Engineer before being adopted. After six days under cover the products shall be kept moist in the open for a further period of 4 days.
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The Engineer may require the curing period extended if the concrete is to be stored under abnormal conditions or is likely to suffer distortion or cracking from differences in temperature, moisture content or restrain within the concrete. The Engineer may, however, approve a reduction in curing period, to a minimum of 16 hrs, under normal conditions, provided that the mix of concrete is so designed as to give a works cube strength which is in excess of the design strength by at least 52 kg/cm for 25 daysstrength, or 55 Kg/cm for 7 days strength. Steam curing may be resorted to at the option of the Contractor. If the concrete is cured at an elevated temperature, use of calcium chloride as an admixture is prohibited. 12.0.0 STORAGE The products shall be stored for at least three weeks before erection. They may be stored in a vertical position supported by a "A" frame. If stored in horizontal position, they should rest on proper packings both on the ground as well as between castings. Particular attention is directed to the inherent dangers of breakage and damage caused by supporting on other than two positions and also by careless placing of packing (e.g. not vertically one above the other). Packing pieces should not discolour, disfigure or otherwise permanently mark the units. Units should also be properly protected against damage being caused by the crushing and chafing effects of lifting and transport equipment. Whatever the type of storing adopted, the casting should be placed on a level and rigid bed, otherwise they are liable to distort or crack. The storage shall be so arranged as to permit the removal of the oldest castings without disturbing others. During handling, care shall be taken to avoid damage by shock loading, at all stages and from whatever cause. 13.0.0 PROTECTION At all stages and until completion of the work, precast units and any other concrete associated therewith should be properly protected. This is particularly important in the case of thin units. The protection can be provided by timber strips, hessain, etc. but must not be such as will damage, mark or otherwise disfigure the concrete. The Contractor shall perform quality control tests covering the entire process of manufacture and keep records certified by the Engineer. 14.0.0 LOAD TESTS In addition to the quality concrete tests prescribed in the Specification No.C2 "Technical Specification for Plain and Reinforced Concrete Works", load tests shall be carried out on precast elements as indicated below. Atleast 1% of the number of precast units in each type shall be tested either to destruction or for test loads to be specified later as the case may be.
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14.1.0 Non-destructive test Precast members shall be loaded for one hour at its full span with a load equal to full dead load (weight of screed and finished) plus 1.25 times the live load considered in the design. Recovery, one hour after removal of test load, should not be less than 75% of the maximum deflection recorded during the test or (if this cannot be achieved) of the maximum deflection during a re-test. 14.2.0 Destructive test Precast members shall be loaded at its full span with a total load of 95% of the design ultimate load within 15 minutes of time when this test becomes operative. A deflection exceeding 1/40 of the test span shall be regarded as failure. 14.3.0 Before starting of the test, the Contractor shall submit a detailed note on procedure of testing, manner of application of the loads, position of instruments, supporting stands, etc. and obtain Engineer 's approval in writing. Provision shall also be made for safety posts between the bearing supports in the event of a sudden collapse of the structure under test. The height of bearing supports shall be atleast 1.0 metre to ensure free access to the lower surface of the structure to be tested. Load tests shall be carried out in the presence of the Engineer or his authorised representative. Engineer shall have right to select any unit for testing. In the event of specimen not fulfilling the test conditions, Engineer shall select another sample from the batch and order for testing. If the second specimen also does not fulfill the test conditions, Engineer shall have right to reject the entire batch of the precast units and in such a case the total cost of precast units in that batch including reinforcements and steel embedments shall be recovered from Contractor. Quoted rates in "Schedule of Quantities" for precast members shall be deemed to include the cost of testing etc complete. No separate payment shall be made for tests. The Engineer reserves the right to get any specimen tested independently through an approved laboratory. The right of acceptance or otherwise of the precast element shall rest with the Engineer. The Contractor shall provide at his cost, all instruments, equipments, materials, loading platforms, loads etc, that may be required to satisfactorily conduct the load test. The instruments shall be recently calibrated and the calibration certificate shall be submitted by the Contractor. The instruments shall be of an accuracy as shall be specified by the Engineer. If a unit is damaged, cracked, etc., the same may be rejected by the Engineer. Such rejected unit shall not be paid for and shall be forthwith removed from the site of works by the Contractor. Satisfactorily withstanding a load test shall not be considered a ground for accepting any unit rejected by the Engineer. 15.0.0 ERECTION Erection and jointing of individual units shall be done true to the alignment. The method and sequence of erection shall be approved by Engineer.
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Every care shall be taken to see that no damage results during any stage of erection. The Contractor shall submit a detailed erection scheme well in advance of erection. His methods and equipment will take into account all forces that may occur during erection. The erection procedure should ensure that the units are laterally stable and would not buckle, twist etc. All handling, erection etc shall be by mechanical means. After erection of precast units at site, the hooks provided for lifting purposes shall be cut flush to the surface of the slab, if so directed by the Engineer at no extra cost.
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SECTION-C4.7 TECHNICAL SPECIFICATION FOR MASONRY WORKS 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for brickwork and plastering. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Indian Standards Institution and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: Brick work IS:1077 IS:1542 IS:1597 IS:1661 IS:1905 IS:2116 IS:2185 IS:2212 IS:2250 IS:2572 IS:2691 IS:3414 IS:3495 IS:3696 IS:5134 IS:5454 SP:20
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Common burnt clay building bricks Sand for plaster Code of practice for construction of stone masonry Code of practice for application of cement and cement-lime plaster finishes Code of practice for structural use of un-reinforced masonry. Sand for masonry mortars Specification for Hollow Cement Concrete Blocks Code of practice for brickwork Code of practice for preparation and use of masonry mortars Code of practice for construction of hollow concrete block masonry Burnt clay facing bricks Design and installation of joints in buildings Methods of tests of burnt clay building bricks Safety code for scaffolds and ladders Bitumen impregnated paper Methods of sampling of clay building bricks Explanatory handbook on masonry works
FICHTNER India
3.0.0 3.1.0
MATERIALS Cement Cement used shall conform to IS:269.
3.2.0
Sand The sand shall be approved river or pit sand and it shall conform to IS:2116 for masonry mortar and to IS:1542 for plaster mortar.
3.3.0
Bricks The bricks used shall be at least chamber burnt second class (class B) bricks conforming to IS:1077 having a minimum compressive strength of 50 Kg/cm2. Bricks are to be whole, uniform texture, sound, well burnt, free from cracks, square and well shaped, uniform in size, uniform red cherry or copper colour and shall emit a clear ringing sound when struck. Slight distortion or rounded edges are permitted provided no difficulty arises during laying of uniform course. Water absorption after 24 hours immersion shall not exceed 20% by weight. Dimensional tolerance shall not exceed 8%. Representative samples shall be submitted and approved samples shall be retained by the Engineer for future comparison.
3.4.0 3.5.0
Intentionally omitted Stone Masonry Building stones shall be obtained from the quarries approved by the Engineer. These shall be free from decay, sand holes, reins, flaws, cracks and other defects. Store not suited for the particular class of work defined shall be rejected and shall be removed from the site at once, by the Contractor.
4.0.0
STORAGE AND HANDLING Bricks shall not be dumped at site. These shall be stacked in regular tiers on firm ground, even as these are unloaded, to minimise breakage and defacement of bricks. Bricks selected from different situation of use in the work shall be stacked separately.
5.0.0 5.1.0
WORKMANSHIP Brick work IS : 2212 shall be followed as general guidance for construction of brick work masonry. The whole of the brickwork shall be carried out by the Contractor in a uniform manner. All the bricks shall be kept under water till they are completely soaked and used on the works on their becoming skin dry.
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The Contractor shall set out and build all brickwork to the dimension, thickness and heights shown on the drawings. The Contractor shall build all brickwork in English bond and half brick walls and casing to pipe, chases etc. in stretcher bond. Brickbats shall not be used except where required for bond. The Contractor shall lay bricks in full mortar beds with shoved joints. The joints are not to exceed 10 mm in thickness and are to be full of mortar, close, well finished and neatly struck. The vertical joints in any course shall not be nearer than quarter of a brick length from those in the course below. All joints shall be of same width except for small variations to maintain bond. The brickwork shall be laid plumb and trim to line and level. No portion of brickwork shall be raised more than 1 metre above another at one time. If the mortar in any course has begun to set, the joints shall be raked out before another course is laid. The top course of brickwork in reinforced concrete framed structure shall be wedged against reinforced concrete surface and joint well filled with mortar. The Contractor shall flush up thoroughly with mortar all joints as the work proceeds. Where brickwork is to receive plaster, the joints shall be raked to a depth of 12 mm to provide proper bond. Where the brick work shall abut a concrete surface, the concrete surface laitance shall be hacked/chipped thoroughly to have a good bond with brick wall. The brickwork as it progresses shall be thoroughly watered on its faces and top. New work shall be properly bonded with the old work. The surface of unfinished work shall be cleaned and thoroughly wetted before joining new work to it. Any work in which the mortar perishes shall be dismantled and rebuilt by the Contractor at his own expense. The Contractor shall carry out work in as clean a manner as possible and shall remove excess material and mortar droppings daily. Where brick walls, are to receive plaster, excess materials and mortar droppings shall be removed and the surface shall be brushed clean. During cleaning operations, adjacent work shall be protected and any damage resulting from improper protection shall be made good by the Contractor at his own cost. Reinforcement if shown in the drawing shall be provided fully embedding in mortar after thoroughly cleaned. These shall be lapped with dowels if left in RC columns or welded to steel columns. Encasing of structural steel shall be done by building masonry work round flanges, webs etc., and filling the gap between steel and masonry by minimum 12 mm thick mortar. Encased members shall be wrapped with chicken wire mesh when shown on drawings or instructed by the Engineer. The minimum lap in chicken wire mesh shall be 50 mm. Other steel embedments shall be generally embedded in mortar and masonry unit shall be cut as required. 5.2.0 Block work IS : 2572 shall be followed as general guidance for construction of hollow concrete block masonry. Blocks shall be used only after shrinkage has taken place. The moisture content must not exceed the limit specified in IS : 2185. Composite cement - lime - sand
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mortar of proportion 1 : 1 : 8 shall be used. Mortar shall meet the requirements of IS : 2250. The blocks shall be laid with full mortar bedding. All voids shall be filled with full mortar bedding. All voids shall be filled with PCC at plinth level and window sill level, etc. Masonry work shall be cured by keeping it constantly moist on all faces for a minimum period of seven days. 5.3.0 Stone Masonry The Contractor shall furnish all labour, materials and equipment required for the construction of all stone masonry work required as mentioned. IS : 1597 shall be followed as general guidance for stone masonry construction. 5.3.1 Laying The stones shall be laid on their broadest face. Stratified stones shall be laid on their natural bed, i.e. with the strata perpendicular to the pressure. The courses shall be built perpendicular to the pressure. Where there is to be variation in the depth of courses, larger stones are to be placed in the lower courses, the thickness of courses, decreasing gradually towards the top of the wall. To give sufficient lateral bond, a stone in any course should overlap the stone in the course below, i.e joints parallel to the pressure in two adjoining courses should not lie too closely in the same vertical line. To give sufficient transverse bond, the prescribed number of headers must extend from front to back of thin walls or from outside wall to the interior of thick walls. At all angle junctions of walls, the stones at each alternative course shall be so carried into each of the respective walls as to unite the work thoroughly. Where breaks are unavoidable in carrying up the work continuously in horizontal courses, sufficient long steps shall be left to join the old and new work. The practice of building two thin faces tied with occasional through stones and filling up the middle with small stuff or even dry packing is strictly prohibited. If it is necessary to move a stone after it has been placed on the mortar bed, it should be lifted clear and rest and not made to slide it over stones already laid. 5.3.2 Watering To prevent absorption of water from the mortar, the stones shall be sufficiently wetted before laying. All masonry shall be kept watered for three weeks from the date of building in place, unless otherwise instructed by the Engineer. At the close of the days work or for other periods of cessation of work, the top of all unfinished masonry is to kept well flooded.
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Should the mortar perish, i.e. become dry, white or powdery through neglect of watering, the work shall be pulled down and rebuilt. All masonry shall be washed down of all stains on completion of work. 5.3.3 Jambs for Door and Window Openings Jambs for door and window openings shall be formed with quoins of the full height of the course in the case of coursed masonry. The quoins shall be in breadth atleast one and half times the depth of the course and in length atleast twice the depth. For each side of door openings two of these quoins shall be stones of the full thickness of the walls. Unless rebating of the whole frames into the masonry is specially specified. Chisel dressing to the width of door and window frames shall be done to secure a close fit between the frames and the masonry. A rebate shall be made in the frame where plastering is to join with the frame as shown in the standard designs for doors and windows and the plaster shall be keyed well into the rebate to form a neat joint. The lump sum contract rates is for all classes of masonry and are inclusive of quoins, jambs, and chisel dressing as demanded by the above and by the following masonry sub-specifications. 5.3.4 Mortar and Materials to Conform to Standard Specification The mortar to be used for each class of masonry shall conform to the particular standard specification for that class of mortar and the standard specifications for the materials used therein. 5.3.5 Holes for Passages of Water etc. Care shall be taken to see that holes for passage of water wherever necessary as from terraces, bath rooms, recesses for downfall pipes, etc. are provided during construction and neatly finished off by pointing or plastering as ordered. Well seasoned wooden plugs of sizes and quality approved by the Engineer are to be built in as work proceeds for fixing door and window shutter appliances, hangers, picture rails, and for any other purpose decided necessary by the Engineer. Holes are also to be cut in the sill-stones to receive the uprights of door - frames, in cases where there is no threshold plate to the frame. 5.3.6 Iron, Stone, Concrete or other Fixtures and Buttresses etc. All iron, stone, concrete or other fixtures, returns, buttresses, counterforts etc., shall be built and bonded into the work as it proceeds and not inserted or joggled on after the masonry is advanced. 5.3.7 Chisel Drafting Corners and Rounding Interior Corners of Rooms The vertical exterior corners of buildings and pillars buildings in coursed rubble in mortar, first and second sort and random rubble in mortar shall be chisel drafted 38 mm width on either side, or such other width as may be specified. At the entrances of doors, windows, archway and other openings, the corners against which doors or windows will open shall be chamfered 25 mm width and chisel - drafted beyond the chamfer 38 mm as above extent when parliamentary hinges are used, in which case chisel - drafting only is necessary.
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All interior corners of rooms and projecting angles shall be rounded to 25 mm radius. The projecting angles will in such cases be chamfered as necessary and the rounding for both interior corners and projecting angles will then be done in the plaster. Similarly, rounded, chamfered and chisel - drafted corners shall be done wherever they may be shown on the drawings. 5.4.0 Plastering Unless otherwise specified, all plaster work shall be carried out according to IS:1661. The thickness and proportion of cement plaster shall be as specified in the drawing. The surface to be plastered shall be cleaned of all extraneous matter and rubbish. In brickwork the joints shall be raked and concrete surface roughened by chipping or hacking. Any shuttering material adhering to the concrete shall be removed. The Contractor shall make plaster pads of the required thickness of plaster for correctness of plumb, line and level. The surface shall be thoroughly watered and soaked and aerated and all holes shall be closed before starting plastering operation. Plaster, when more than 15 mm thick shall be applied in two coats - a base coat followed by the finishing coat. The under coat shall be of sufficient thickness to fill up all unevenness in the surface, no single coat, however, shall exceed 15 mm in thickness. For one coat plaster work, the plaster shall be laid slightly thicker than the specified thickness and the surface then leveled with flat wooden rule to the required thickness. The plaster shall be well pressed into the joints and the surface finished as specified. For two coats of plaster work, the first coat shall be applied as described above except that the surface shall be left rough and keys formed for the application of second coat. The second coat shall be applied a day or two after the first coat has set, but the first coat shall not be allowed to dry. The second coat shall consist of mortar ground very fine and shall be laid on with a wooden rule to a specified thickness, rubbed smooth and leveled and the surface plastered completely the same day. The leveling shall be continued till the plaster is quite dry and all moisture which exudes from the plaster shall be wiped off with a fine cloth. The surface shall be kept dry until exudation of moisture ceases, during the process of rubbing. 5.5.0 5.5.1 Finish Sand faced plaster The plaster shall be applied in two coats. The first coat or the scratch coat should be approximately 14 mm and shall be continuously carried out without breaks to the full length of wall or naturing breaking points such as doors, windows etc. The scratch coat shall be dashed on the prepared to true and even surface and then lightly roughened by cross scratch lines to provide bond for finish coat. The scratch coat shall be cured for atleast 7 days and then allowed to dry. The second coat shall be 6 mm thick and it shall not be applied until atleast 10 days have elapsed after the application at first coat. Before application of the second coat, the scratch coat shall be evenly damped. This coat shall be applied from top to bottom in one operation and without joints, finish shall be straight, true and even. Only approved river
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sand shall be used for the second coat and for finishing work. Sand for finish shall be of even coarse size and shall be dashed on the surface and sponged. 5.5.2 5.6.0 Intentionally omitted Curing The brick shall be cured for a period of fourteen (14) days after laying and the plaster shall be cured for a period of seven (7) days. 5.7.0 Expansion & Separation Joints Location and details of expansion joints shall be strictly as shown in the drawings and specified in schedule of items. Expansion joint filler boards and sealing strips shall have minimum transverse joints. Transverse joints shall be approved by the Engineer. Separation joints shall be with standard water proof paper or with alkathene sheets about 1 mm in thickness. Length and sealing of taps shall be to the satisfaction of the Engineer. 5.8.0 Damp Proof Course The proportion of cement to aggregates shall be 1:2:4 using 6 mm down stone chips with a water proofing admixture. The percentage of waterproof admixture shall be as per manufacturer's specification but not less than 2% by weight of cement. The brick masonry surface shall be leveled, flushed up and prepared as directed to receive the damp-proof course. The thickness of damp proof course shall be 40 mm. In masonry walls of buildings it shall normally be placed above the external ground level. It shall be laid for the full width of the wall. The top surface shall be kept rough or ribbed for mortar for brickwork coming over it, for proper adhesion. All exposed surfaces of the damp-proof course shall be finished fair and smooth. It shall be cured for at least 7 days. After the surface has partially set, hot bitumen shall be applied in two coats at the rate of 1.7 kg per sq.m per coat and dry sand spread over it. 5.9.0 Brick - on - edge coping and plinth protection The top course of all plinths, parapets, steps and tops of walls below R.C.C slabs, beams etc. shall be laid with brick - on - edge, unless shown otherwise. Care shall be taken that bricks forming the top corners and ends of walls shall be properly radiated and keyed into position as specified in IS : 2212. Plinths of all buildings shall be protected by 12 mm thick cement plaster (CM 1 : 3) over PCC paving of minimum 750 mm width. Proportion of PCC shall be 1 : 2 : 4 with min. thickness of 100 mm. Paving shall be laid in upward slope of 1 in 50 over a 75 mm thick dry graded aggregate grouted with sand. Storm water drain shall be provided by the side of plinth protection.
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SECTION-C4.8 TECHNICAL SPECIFICATION FOR WATERPROOFING
1.0.0
SCOPE This specification covers the requirements in respect of materials, workmanship and quality for water proofing of roofs and other underground structures.
2.0.0
CODES AND STANDARDS

Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions
as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: IS : 73 IS : 702 IS : 3384 IS:1322 IS:1346 IS:1580 IS:1609 IS:2645 IS:3067 IS:7193 3.0.0 3.1.1 Paving Bitumen Industrial bitumen Specification for Bitumen primer for use in water proofing and damp proofing Bitumen felts for water proofing and damp proofing Code of practice for waterproofing of roofs with bitumen felts Bituminous compound for water proofing and caulking purposes. Code of practice for laying damp-proof course using bitumen felts Integrated cement water proofing compounds (1987) Code of practice for general design details and preparatory work for dampproofing and waterproofing of building. Specification for glass fiber base coal tar pitch and bitumen felts.
MATERIALS Bituminous Polymeric membrane for roof waterproofing Bituminous Polymeric membrane used for waterproofing roofs shall be 90 micron thick HMHDPE Centre core (Tear index greater than 150) protected on both sides with polymeric bitumen of softening point exceeding 115oC and penetration of 55 8 and further covered on both sides with protective thermofusible polyethylene film. Elongation at break shall be 300% or higher, tensile strength of 220 N/5 cm or higher, pliability of 5oC or lower and heat resistance 100C or higher.
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For precast roofs, the top HMHDPE layer shall be substituted with embossed aluminium foil 75 microns thick. Product to be used for cast-in-situ roof slab shall be MULTIPLAS STANDARD and that for roof with precast slab panels shall be MULTIPLAS ALUMINIUM or approved equivalent. 3.1.2 Bituminous polymeric membrane for underground damp proofing The membrane used for water proofing underground structures shall be 7 layered membrane similar to 5 layered roofing membrane, but reinforced with a non woven polyester mat of minimum 140 g/m for additional mechanical strength and covered with additional layer of polymeric asphalt. Product to be used shall be MULTIPLAS HYPER or approved equivalent. 3.1.3 Bitumen Felt It shall conform to IS:1322 and the number of layers shall be as specified in the schedule of items. Bitumen primer shall conform to IS 3384. The bonding materials shall consists of blown type bitumen conforming to IS : 702 or residual bitumen to IS : 73 or a mixture of the two to withstand local conditions of prevailing temperature or gradient of roof surface. 3.1.4 Fiber Glass Tissue Reinforced Bitumen Felt It shall conform to IS:7193, consisting of reinforced glass fibber base coated on both sides with bitumen modified with thermo plastic polymers. 3.2.0 Bonding Materials Bonding materials used for applying the polymeric bituminous membrane on surfaces shall be fiber and solvent based, rubber modified bituminous primer of density 0.92 g/cm3 with viscosity 500 to 10,000 cps. Ordinary bitumen wherever used shall be of blown type conforming to IS:702 or residual bitumen conforming to IS:73 or a mixture thereof. 3.3.0 Water proofing admixture The water proofing admixture shall conform to IS: 2645 and shall be approved by the Engineer. 3.4.0 Cement Cement shall conform to IS:269. 3.5.0 Aggregates The aggregates shall conform to IS:383. Fine aggregate shall be river sand or pit sand from approved pits. Coarse aggregate shall be stone chips of size not exceeding 6 mm. 3.6.0 Metal Flashings Wherever specified on drawings the metal flashings of 18 g or 20 g galvanised iron.
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4.0.0
GRADING UNDERBED The surface to receive the underbed shall be roughened and thoroughly cleaned with wire brush and water. Oil patches if any shall be removed with detergent. The surface shall be soaked with water and all excess water removed just before laying of the underbed. The underbed shall be laid to provide an ultimate run off gradient not less than 1 in 100 or as directed by the Engineer. Upto a thickness of 25 mm the underbed shall usually be composed of cement and sand plaster. For higher thickness the underbed shall be made with cement concrete. The underbed shall be finished to receive the waterproofing treatment direct or insulation as the case may be. The underbed shall not be laid under direct hot sun and shall be kept in shade immediately after laying so as to avoid quick loss of water from the mix and separation, from the roof surface. The underbed shall be cured under water for at least 7 days. The following are the brief details of the types of grading underbed :
4.1.0
Plaster The grading plaster shall be maximum 25 mm thick. It shall consist of cement and sand in ratio 1 : 4 (nominal) by volume. The sand and cement shall be thoroughly mixed dry and then water added. Each batch of mix. Shall be consumed before the initial set starts. The plaster shall be fully compacted to the desired grade in continuous operation. The surface shall be even and reasonably smooth.
4.1.2
Concrete Concrete shall be used where the underbed is more than 25 mm thick. It shall consist of cement concrete 1 : 2 : 4 nominal mix by volume with 12.5 mm down stone chips and sand. The aggregate shall be mixed dry and minimum quantity of waters shall be added to make the mix workable. The mix shall be laid to proper grade, fully consolidated and surface shall be smooth and even.
5.0.0 5.1.0 5.1.1
WATERPROOFING WITH PREFABRICATED POLYETHYLENE AND POLYMERIC ASPHALT Workmanship Waterproofing for roof with polymeric bituminous membrane. The roof slabs shall be cleaned of all dust, dirt, grit etc. and if rough it shall be made reasonably smooth either by clipping of projections or by applying a thin coat of cement slurry of cement sand and water. The roof surface shall be regraded prior to waterproofing with cement mortar. At the places of drain outlets, projecting pipes, parapet walls and expansion joints etc. the surface shall be prepared in indicated in IS: 1346. Over the hardened and finished surface of the roof slab, fiber and solvent based, rubber modified bituminous primer of density 0.92 g/cm3 and viscosity 500 to 10,000 cps is applied at the rate of 250 g/cm2. First membrane of multiplas standard (or approved equivalent) shall be unrolled and extended starting at the fillet end parallel to the largest part of the roof endeavoring to center the membrane over the drain at the lowest point of the roof. One of the ends are bonded by fusing the lower asphalt layer and
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ensuring that a transverse area, with a minimum width of 20 cm is completely adhered to the substrata. Then one of the men on the application team stands on the area that is bonded to the substrata while another stretches and flattens the membrane at the other end. Once the membrane is stretched, opposite end is bonded to the substrata by fusing the asphalt also on a transverse area with a minimum width of 20 cm ensuring that transverse joints are staggered. While this is being done, the first applicator unrolls the following roll of membrane placing it parallel to the first and extending 10 cm over the same (overlap) fusing and stretching it as with the first membrane. The overlap is kept open with help of a trowel and flame is directed uniformly inside and towards both membrane, working the flame in opposite direction in advance of the applicator. When asphalt starts to flow, applicator should press both membrane with his foot on the opposite side holding the torch until a thin string of fluid asphalt appears, indicating correct fusing and bonding. External fusing of the overlap is finished off by leveling and homogenizing exterior asphalt with the trowel, having previously heated the area with torch. In case of roofs with parapets, a chase 75 mm deep shall be cut in the parapet masonry at about 150 mm above the roof level and the membrane shall be laid as flashing in widths with a minimum overlap of 100 mm. The lower edge of the flashing shall overlap the membrane laid on the flat portion, and the upper edge of the flashing shall be tucked into the groove made in the parapet. After the flashing has been properly bonded, the chase shall be cleaned and shall be filled up with cement mortar 1 : 4 flush with the face of the wall, and allowed to set by adequate curing. For gutters, the membrane shall be laid over a primer coat, and finally painted with a coat of hot bitumen at not less that 1.5 kg/sqm. The membrane treatment shall be carried down into the outlet pipes to a minimum depth of 100 mm. After the treatment is over, the surface shall be covered with 20 mm plaster of cement mortar 1:4 reinforced with chicken wire mesh marked off into squares 600 mm wide with expansion joints provided at a distance of 3 m. 5.1.2 Damp proofing for underground structures Waterproofing for underground structures wherever indicated in the drawings shall be done with polymeric bituminous membrane strengthened with high quality polyester for resisting static water pressure. Half brick thick brick work in cm 1 : 4 shall be provided as protection to waterproofing on external side faces. Membranes shall be fastened with the vertical surfaces for height exceeding 4.5 m. Prior to application of the membrane, the surface shall be coated with fibre and solvent based rubber modified bituminous primer of density 0.92 g/cm and viscosity 500 to 10,000 cps applied at the rate of 250 g/m. 6.0.0 6.1.0 6.1.1 WATER PROOFING WITH HESSIAN BASED BITUMEN FELTS Workmanship Waterproofing for roof The roof slab shall be cleaned of all dust, dirt, grit etc. and if rough it shall be made reasonably smooth either by chipping of projections or by applying a thin coat of cement slurry of cement, sand and water.
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The roof surface shall be regraded prior to waterproofing either with cement mortar or lime-surkhi mortar. At the places of drain outlets, projecting pipes, parapet walls and expansion joints etc. the surface shall be prepared as indicated in IS:1346. The workmanship in general shall conform to IS:1346 unless otherwise specified. Over the hardened and finished surface of the roof slab, a thin layer of approved bitumen primer shall be first brushed over the roof surface and allowed to dry. The felt shall be first cut to the required lengths and laid out flat on the roof in position at right angles to the direction of run-off gradient and shall be brushed clean of dusting materials. Each length of felt thus laid in position shall be rolled up for a distance of half of its length. Then the bonding material heated to correct temperature shall be poured on to the roof across the full width of the rolled felt as the latter is steadily rolled out and pressed down. Excess bonding material shall be squeezed out at the ends and removed as the laying proceeds. When the first half of the strip of felt has been bonded to the roof, the other half shall be rolled up and then unrolled on to the hot bonding material in the same way. Minimum overlaps of 100 mm shall be allowed at the end and the sides of strips of felt. All overlaps shall be firmly bonded with hot bitumen. The laying of the second layer of felt shall be so arranged that the joints are staggered with those of the layer beneath it. In case of roofs with parapets, a chase 75 mm deep shall be cut in the parapet masonry at about 150 mm above the roof level and the felt shall be laid as flashings in widths with a minimum overlap of 100 mm. The lower edge of flashing shall overlap the felt laid on flat portion of the roof and the upper edge of the flashing shall be tucked into the groove made in the parapet. After the flashings have been properly bonded, the chase shall be cleaned and shall be filled up with cement mortar (1:4) flush with the face of the wall and allowed to set by adequate curing. In case of drain mouths, waterproofing shall be done as specified for the roof excepting that the treatment shall be carried inside the drainpipes overlapping at least 100 mm. For gutters, a priming coat shall first be applied. Over this, a specified number of layers of felt shall be laid and bonded together with hot bitumen and finally painted with a coat of hot bitumen at not less than 1.5 kg /sqm. The felt layers laid separately in the gutters shall be overlapped with the corresponding layers on the roof proper. The felt treatment shall be carried down into the outlet pipes to a minimum depth of 100 mm. After the treatment is over, the surface shall be covered by pea-sized gravel or grit at the rate of 0.6 cum per 100 sqm. On flashings and at drain mouths a finish of two coats of approved bituminous primer shall be provided. 6.1.2 Damp Proofing For Under Ground Structures Damp proofing for under ground structures wherever indicated shall be done as per recommendations of IS:1609 - 1976 clause 5.2(b), for heavy treatment with three layers of felt. The method of laying damp proofing treatment shall be as per clause 6 of IS:1609.
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7.0.0 7.1.0 7.1.1 7.1.2
WATERPROOFING WITH FIBRE GLASS TISSUE REINFORCED BITUMEN FELT Workmanship Waterproofing for roofs shall be according to the guidelines in IS:1346. Other aspects shall be the same as in clause 5.1.1. Damp Proofing of Under Grounding Structures It shall be done as per guidelines laid in IS:1609 - 1976 clauses 5.2(b) & 6. The felt layers shall be fastened to the wall surface wherever the height exceeds 4.5 m. Half brick wall in C M 1.4 shall be erected as protection to the external face of the waterproofing.
8.0.0 8.1.0 8.1.1
WATER PROOFING OF ROOFS WITH BRICK LIME CONCRETE AND PRESSED FLAT TILES Lime Concrete Terracing Materials Brick aggregate shall be 25 mm nominal size unless otherwise specified in the description of the item. Lime mortar shall be of 1:2 mix (1 lime putty : 2 surkhi), unless otherwise specified in the description of the item. The volume of wet mortar to be used will be 50% of stacked volume of brick aggregate, unless otherwise specified in the description of the item. The brick aggregate shall be kept moist for a period of not less than 6 hours before use in the concrete mix.
8.1.2
Laying Lime concrete shall be laid in a single layer, spread and rammed, with wooden rammers of weight not exceeding 2 Kg, to the specified average thickness, slopes and levels. The concrete shall be used when it is quite fresh, concrete left over from the previous days works shall in no circumstances be used. During the preliminary ramming , the surface shall be tested and kept perfectly true and even by means of a trowel, straight edge and sprit level. The concrete shall then be further consolidated by two rows of labours sitting close and beating the concrete in uniform with thappies (weight 1 to 2 kg) across the entire width of the roof and thus slowly traversing the length of the roof. Special care shall be taken to consolidate the concrete property at this junction with the parapet wall. This beating shall be continued for three to four days or until the mortar is almost set and the wooden thappies rebound from the surface readily when struck on it. While the beating is in progress, the surface shall be liberally sprinkled with a mixture of Gur and boiled solution of bael fruit, in the proportion of 1.75 kg of Gur to 1 kg bael fruit boiled in 60 litres of water. As soon as the beating is completed, the mortar that has come on top shall be softened by the addition of the solution of Gur and bael and smoothened with a float or trowel to a fine polish. No plaster shall be used on any account for finishing the roof.
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8.1.3
Curing The concrete shall be kept wet after each days work, and for such a period of time as the Engineer-in-Charge may direct. The wetting shall be done by spreading straw or gunny bags and watering very frequently , so as to ensure through setting of the concrete.
8.1.4
Finish The slope of the finished terrace shall not be less than 1 in 50, unless a fatter slope is permitted by the Engineer-in-Charge in writing. The roof surfaces shall slope from all sides towards the outlets. The minimum thickness of the concrete at a junction with khurra shall be 5 cm. The lime concrete shall overlap the cement concrete base of the khurra by 75 mm and shall be rounded to the edges of the khurra. The lime concrete shall also be rounded at the junction of roof slab and parapet. The finished lime concrete shall present a smooth surface with correct slopes and uniform rounding wherever they occur. The concrete should be leak proof and free from cracks.
8.1.5
Thickness The average finished thickness of the laid concrete over the entire area shall be minimum of 100mm.
8.2.0 8.2.1
Lime Concrete Terracing with Tile Bricks Paving Lime Concrete Terracing The specification shall be same as described in 7.1.1 to 7.1.5 except that the terrace concrete shall be finished rough and not with fine polish and rounding the concrete at junctions with parapet walls, chimney stacks, raised sky lights etc. shall not be done as, this will interfere with the tile paving to come on its top.
8.2.2
Tile Bricks Paving The tiles shall be of first quality machine pressed of size 200x200x20 mm of ISI make. The laying of the tiles shall be done on a bed of cement mortar 1:3 (1 cement : 3 sand by volume) mixed with approved water proofing compound confirming to IS: 2646.
9.0.0
ELASTOMERIC MEMBRANE WATERPROOFING The roof slab shall be cleaned of all dust, dirt, grit etc. and if rough it shall be made reasonably smooth either by chipping of projections or by applying a thin coat of cement slurry of cement, sand and water. The chemical used shall be high solid content liquid applied elastomeric waterproofing membrane with separate wearing course as per ASTM C-898. Thickness of the membrane shall be 1.5 mm. This treatment shall include application of polymerised mastic over the roof to achieve smooth surface and primer coat. Wearing course of the top membrane shall consist of 25 mm thick PCC (1:2:4) cast in panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized chicken wire mesh and sealing of joints
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using sealing compound / elastomeric water proofing membrane. Pathways for handling of materials and movement of personnel shall be provided with 22 mm thick chequered cement concrete tiles as per IS:13801 for a width of 1000 mm in place of PCC. 10.0.0 ACCEPTANCE CRITERIA The surface level shall be such as to allow quick draining of water without leaving any pool anywhere. The finishing course shall be fully secured and shall have an even density. There shall not be any bubble formation or crushed or squeezed insulation or underbed. The Contractor shall give a guarantee in writing for all works executed under this specification supplemented by a separate and unilateral guarantee from the specialised agency for the roof waterproofing treatment work. The guarantee shall be for materials and workmanship for five (5) years in case of normal treatment, ten (10) years for heavy treatment and fifteen (15) years for extra heavy treatment. The mode of execution of the guarantee shall be acceptable to the Owner.
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SECTION-C4.9 TECHNICAL SPECIFICATION FOR WATER SUPPLY, DRAINAGE AND SANITARY WORKS 1.0.0 SCOPE This specification covers the requirements in respect of materials, installation and quality for water supply, drainage and sanitary works. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Some of the relevant available codes are listed thereunder: Roof Drainage System IS:1230 IS:1626 IS:1729 IS:1742 IS:2527 Cast iron rain water pipes and fittings Asbestos cement building pipes, gutters and fittings (spigot and socket type) Specification for sand cast iron spigot and socket soil, waste and ventilating pipes, fittings and accessories. Code of practice for building drainage. Code of practice for fixing rainwater gutters and down pipes for roof drainage.
Pipes and fittings for sanitary plumbing and drainage IS:404 IS:405 IS:458 IS:651 IS:771 IS:774 IS:775 IS:778 IS:781
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Lead pipes Lead sheet and strip Concrete pipes (with and without reinforcements) Salt glazed stoneware pipes and fittings Glazed fire clay sanitary appliances Flushing cistern for water-closets and urinals (other than plastic cisterns) Cast iron brackets and supports for wash basins and sinks Copper alloy gate, globe and check valves for water works purposes. Cast copper alloy screw down bib taps and stop valves for water services
FICHTNER India
IS:782 IS:783 IS:804 IS:1172 IS:1239 IS:1536 IS:1537 IS:1703 IS:1711 IS:1726 IS:1742 IS:1795 IS:2065 IS:2104 IS:2326 IS:2470 IS:2548 IS:2556 IS:2963 IS:3004 IS:3006 IS:3076 IS:3114 IS:3311 IS:3486 IS:3597
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Caulking lead Code of practice for laying of concrete pipes Rectangular pressed steel tanks Code of basic requirement for water supply drainage and sanitation Mild steel tubes and l and other wrought steel fittings Centrifugally cast(spun) iron pressure pipes for water, gas and sewage Vertically cast iron pressure pipes for water, gas and sewage. Ball valves (horizontal plunger type) including floats for water supply purposes Self closing taps for water supply purposes Cast iron manhole covers and frames Code of practice for building drainage Pillar taps for water supply purposes Code of practice for water supply in buildings Water meter boxes (domestic type) Automatic flushing cisterns for urinals (other than plastic cisterns) Code of practice for installation of septic tanks Plastic seats and covers for water-closet Vitreous sanitary appliance (vitreous china) Copper alloy waste-fittings for wash basins and sinks Plug cocks for water supply purposes Chemically resistant glazed stoneware pipes and fittings Low density polyethylene pipes for potable water supplies Codes and practice for laying of cast iron pipes Waste plug and its accessories for sinks and wash basins Cast iron spigot and socket drain pipes Methods of test for concrete pipes
FICHTNER India
IS:4127 IS:4346 IS:4984 IS:4985 IS:5219 IS:5329 IS:5961 IS:7634 IS:8008 IS:10124 3.0.0
Code of practice for laying of glazed stoneware pipes Washers for use with fittings for water services Specification for high density poly-thelene pipes for potable water supplies, sewage and industrial effluents Unplasticized PVC pipes for potable water supplies Cast copper alloy traps (`P' & `S' (Part-I) traps) Code of practice for sanitary pipe work above ground for buildings Cast iron gratings for drainage purposes Code of practice for plastic pipe work for potable water supplies Injection moulded high density polyethylene (HDPE) fittings for potable water supplies Fabricated PVC fittings for potable water supplies
MATERIALS Sanitary Fittings All sanitary fittings shall be procured from approved vendors and shall conform to the requirements of the relevant IS Codes listed above. The sizes shall be as specified in the General Technical Specification, where not specific, the same shall be as per Engineers approval. Glazed earthenware fittings shall be of Hindustan Sanitary ware or approved equivalent make, while colour and one piece construction. All metallic fixtures like taps, stop cocks, soap holders etc. shall be of Chromium Plated (CP) brass, GEM or approved equivalent make PVC fixtures shall be CALIPLAST or approved equivalent make. All wall fittings shall be fixed with wooden cleats and CP brass screws and washers. Pipes and Fittings Pipes and specials shall be of standard quality conforming to IS : 3486. Stoneware pipes shall conform to IS : 651. RCC pipes for underground sewer shall be P1 class conforming to IS : 450. Cast iron rain water pipes shall conform to IS : 1230. Water supply lines of GI, PVC, HDPE shall conform to IS : 239, IS : 4985 and IS : 4984 respectively, PVC fittings for water supply lines shall conform to IS : 10124.
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The Contractor shall submit to the Engineer samples of all materials, fittings and appliances for approval well in advance of starting the work. All materials, fittings and appliances used in the work shall conform to the approved samples. 4.0.0 GENERAL All water supply, drainage and sanitary works shall be executed by a licensed or authorized plumbing supervisor or a license or authorized plumber and shall be in accordance with the requirements of relevant codes. For items such as earthworks, excavation, concrete, brick work, stonework, painting etc. relevant specifications for these shall apply, unless other wise specified. Unless otherwise specified, all exposed work such as cisterns, brackets etc. shall be painted with one coat of red oxide paint and two coats of oil paint of approved colour. The diameter of pipes and fittings wherever mentioned shall mean the internal diameter or nominal bore, unless otherwise specified. The job shall include the cost of making necessary chases, holes etc., in walls, floors and in other places and also making good on completion of the works. Any damage caused to floors, walls etc. during execution of the sanitary and plumbing works shall be made good by the Contractor at his own cost to the satisfaction of the Engineer. 5.0.0 INSTALLATION All execution will be done on the basis of drawings /instruction given by the Engineer. Fittings meant for operation shall be located and oriented to allow easy reach and operation, maintenance, repairs and replacements of pipes, fittings and fixtures must be conveniently possible. 5.1.0 5.1.1 LAYING AND JOINTING OF PIPES Cast iron soil and waste pipe line
5.1.1.1 Laying Cast iron pipes, socket and spigot shall be of standard quality conforming to IS:3486 (heavy duty) when the pipe has to be laid underground for sewer and waste line. The laying of cast iron pipelines shall commence only after the bottom of the trench at various points have been leveled and aligned in accordance with the drawings. The sides of the trenches shall be as vertical as possible, and the width at the bottom shall be 400 mm wider than the diameter of the pipe. Where joints are made, the trench shall be widened suitably to provide room for caulking joints. Shoring and timbering shall not be used without prior approval of the Engineer. For pipes buried in the ground, the Contractor shall take care to maintain always a minimum cushion of earth over the pipes as indicated in the drawings. All pipes, water mains, cables etc. met within the course of excavation shall be carefully protected and supported. All pipes and fittings shall be sounded with a light hammer and check properly to detect any crack or blow holes before laying. The excavated material shall be thrown on one side of trench and the pipes stacked on the other side. The inside of socket and the outside of spigot shall be
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thoroughly cleaned of all foreign matter before laying. The pipes shall be laid with their socket ends facing the direction of the flow. The pipes shall be lowered in the trenches by a method as approved by the Engineer. The pipes shall then be jointed by caulking as specified in Clause 5.1.1.2. After each section of the pipeline has been laid it shall be tested for water - tightness before backfilling the trench. On successful completion of testing, the trench shall be backfilled with the excavated earth in layers of 200 mm and shall be watered and rammed. Any subsidence occurring in the line of trenches after backfilling shall be repaired by the Contractor at his own cost. Where the pipelines cross roads, the sides of the trenches shall be suitably shored. When the pipe line has to be laid above ground vertically by the side of wall, it shall be securely fixed to the wall with wooden plugs and nails. 5.1.1.2 Jointing The type of jointing for C.I. pipes conforming to IS:3486 shall be socket and spigot either with molten lead or lead wool and gasket conforming to IS:782. If the joints used are spigot and socket type, the spigot shall be carefully centered in the socket by one or more laps of clean white hemp spun yarn with about 25 mm overlap. Sufficient yarn only shall be forced into the socket to leave a correct depth of lead for caulking. The pipe shall then be examined again for line and level and the proper depth of each joint shall be tested before running the molten lead. For pouring of molten lead a ring of hemp rope shall be wrapped round the pipe at the end of the socket and the joint shall be covered with stiff damp clay. The rope shall then be removed carefully leaving a V-shaped large hole at the top of the joint to pour the molten lead. Lead shall be poured in one operation only. After a section of convenient length of pipe has been laid, lead shall be caulked sufficiently with caulking tools and hand hammered till the excess lead removed and the joint shall be made neat and clean. Depth of lead in joints from the top of socket shall be 37 mm for 150 mm dia pipes and 25 mm for 100 mm dia pipes. The type of joint CI pipes conforming to IS:1729 shall be socket and spigot with cement and sand mortar (1:1) and gasket yarn. The spigot shall be carefully inserted and centered in the socket by one or more laps of thin clean hemp spun yarn and shall be forced into the socket to leave a correct depth of 30 mm all-round and level and the proper depth of each joint shall be tested before inserting the cement mortar. The joints shall then be carefully be leveled to the edge of the socket. Each joint shall be adequately cured by covering with wet clothes and pouring water at frequent intervals. The packing ring or washer for the flanged joints shall be rubber for the full diameter of the flange with proper pipe hole and bolt holes cut out suitably. The packing shall be smeared with graphite paste or a mixture of red lead and white lead and shall be introduced between the flanges of both the pipes and nuts tightened in opposite pairs keeping the longitudinal axes of adjoining pipe lines in exactly the same straight line. Lead washers shall be provided along with bolts to prevent any leakage through bolt holes.
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5.1.2
Stoneware pipes
5.1.2.1 Laying Stoneware pipes shall conform to IS:651. The laying of stoneware pipelines shall commence only after the bottom of the trench at various points have been leveled as shown in the drawings. The Centre line excavated to correct depth, slope and width at all points. The pipes shall be carefully laid to the alignment, levels and gradients as shown on the drawings. The trench shall be excavated wide enough under the sockets to allow hands to pass for making joints. The pipes between manholes shall be laid truly in straight lines and without any vertical or horizontal deviations on a bed of concrete as shown on the drawings. While laying pipes, portion of concrete under each socket shall be dug and taken off so that the barrel of the pipe gets full support on the concrete bed. Pipes shall be haunched with concrete tangential upto the crown of the diameter of the pipe. When it crosses under a road, the pipe shall be fully encased in concrete. The Contractor shall take precautions to maintain always a minimum cushion of earth over the pipes. All pipes shall be carefully examined with a light hammer of soundness before laying. After each section of the pipelines has been laid, the joints shall be allowed to set properly and shall be inspected and tested as directed by the Engineer. Backfilling of the trench shall be carried out only after the approval of the Engineer. After testing, the trench shall be backfilled with selected earth in layers of 200 mm and shall be watered and thoroughly rammed. All pipes, water mains, cables etc. met within the course of excavation shall be carefully protected and supported. When the pipelines cross roads, the trenches shall have vertical sides with suitable shoring. Any subsidence in the line of trench after backfilling shall be repaired by the Contractor at his own cost. The contractor shall prepare drawings showing all the details required for the work mentioned above and other pipe laying works and got it approved by the owner before commencement of work. 5.1.2.2 Jointing The type of jointing for stoneware pipes shall be socket and spigot as indicated on the drawings. The inside of the socket shall be first painted with a thin layer of cement mortar (1:2) and a gasket of yarn dipped in cement slurry shall be inserted in the socket of the pipe with the wooden caulking tool and wooden mallet in such a way that the gasket shall fully encircle the spigot with a slight overlap. When the spigot end received the gasket, it shall be wrapped round with two or three turns of treated spun yarn at its ends before being inserted into the socket. The rest of the joint shall then be completely filled with cement sand mortar (1:1) having very little water and the joint shall be leveled to form a smooth splayed fillet at an angle of 45. All excess of cement mortar left inside the pipe joint shall be neatly cleaned off and the joint shall be adequately cured by covering with wet gunny bags and pouring water at frequent intervals. In jointing stoneware pipes, care shall be taken that the pipes are kept concentric and the socket, specially on the underside shall be completely filled with cement mortar. Where settlement of earth is envisaged, the joint shall be made with bitumastic filler or any other materials as approved by the Engineer.
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5.1.3
Concrete pipes
5.1.3.1 Laying R.C.C. pipes for underground sewers shall be of P1 class conforming to IS:458 unless otherwise specified. The laying of pipes shall conform to IS:783. The pipes shall be laid to line and grade. 5.1.3.2 Jointing The type of jointing for concrete pipes shall be with loose concrete collars and the joints shall be packed from either side with spun yarn dipped in cement slurry as specified for jointing stoneware pipes. Stiff cement mortar (1:1) shall be filled from both sides and splayed at an angle of 45o on both sides. The joint shall be adequately cured as specified for joints in stoneware pipes. 5.1.4 Cast iron rainwater pipes Deleted 5.1.5 Galvanized steel water supply pipes Screwed galvanized steel pipes conforming to IS:1239 shall be jointed with screwed joints and screwed fittings of the same materials as that of the pipes. Any burns remaining on the pipe ends after the treads are out shall be removed. An approved jointing compound together with a grummet of a few strands of fine yarn shall be used for jointing pipes and fittings. Any pipe threads exposed after jointing shall be painted or in the case of underground piping thickly coated with approved bituminous compound to prevent corrosion. The depth at which the underground water supply pipe is to be laid be as shown on the drawings. The service pipe passing into or beneath the building shall be laid at least 200 mm below the ground floor level and accommodate in a previously laid sleeve in the structure where it enters the building. The space between the sleeve and the pipe at its entry into and exit from the building shall be filled with a bituminous material for a minimum of 150 mm at both ends. Piping shall not be buried in walls or floors as far as possible. However, when unavoidable, piping shall be buried for the shortest distance necessary and adequate protection shall be provided against damage. Galvanized steel piping shall be secured by iron or steel clamps and hooks when fixed on walls. All pipe work shall be completely watertight and the joints shall be such that there are no projections of jointing materials or the like in the interior of pipes. Before the pipe line is commissioned, all piping and fittings shall be flushed clean.
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5.1.6
High Density Polyethylene water supply pipes All high density polyethylene pipes shall have screwed ends and shall be jointed with screwed fittings of the same materials of that of the pipes. Any burrs remaining on the pipe ends after cutting threads shall be removed. If necessary, an approved jointing compound with a few strands of fine yarn may be used for jointing pipes and fittings. All exposed high density polyethylene pipes shall be installed with PVC saddles screwed on 25 mm thick wooden blocks securely fixed on walls at suitable intervals, not exceeding 1 m. Pipe wherever installed in wall chasing shall be fixed as in the case of galvanized steel pipes.
5.1.7
PVC water supply pipes PVC pipes for water supply lines shall be heavy duty PVC pipes of Class 4 conforming to IS:4985 and all fitting shall conform to IS:10124. All exposed pipes shall be installed with PVC saddles screwed on 25 mm thick wooden blocks securely fixed on walls at suitable intervals, not exceeding 1 m. Pipe wherever installed in wall chasing shall be fixed as in the case of galvanized steel pipes.
5.2.0 5.2.1
Testing and Acceptance Criteria Cast iron soil and waste pipe line On completion of laying, the cast iron, soil, waste and ventilation pipelines shall be tested by the Contractor at his own cost to detect leakages and any other defects in the pipelines. Test shall be conducted using proper apparatus with attachment for smoke making machine for applying smoke to the pipelines under pressure. Only cotton waste of brown paper soaked in creosote oil shall be used and fired to obtain dense and pungent smoke. While conducting smoke test, top of soil, waste and ventilation pipes shall be kept open till smoke starts coming out of the openings. The openings shall then be securely plugged with expanding rubber or any other approved plug. The floor traps and other openings for connecting sanitary fixtures shall be sealed with water or other approved plug. The floor traps and other openings for connecting sanitary fixtures shall be sealed with water or other approved plug. The entire pipeline shall be tested in suitable sections as directed by the Engineer. The entire length of the pipelines including all joints under tests shall be closely observed for any sign of smoke leakage. All leakages and defects shall be rectified by the Contractor to the satisfaction of the Engineer.
5.2.2
Underground Sewerlines The drainage system shall be tested in accordance with the provision of IS:1742. All defects and deficiencies detected during the test shall be promptly rectified by the Contractor to the satisfaction of the Engineer.
5.2.3
Galvanized steel water supply pipes After the laying and fixing of all galvanized steel water supply pipes and fittings are completed, the line shall be slowly and carefully charged with water to a test pressure of 5 kg per sq cm or the specified working pressure plus 50% as may be prescribed by the Engineer. Care shall be taken that air in pipelines is completely exhausted while filling
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the pipelines with water. This pressure shall be maintained for at least one hour, unless otherwise specified. The pipes and fittings shall then be inspected for any leakage of water. Defects in pipes and fittings, if detected, shall be remedied by the Contractor at his own cost. 5.3.0 5.3.1 Septic tank and effluent disposal Septic Tank Septic tank shall consist of the tank itself with inlet and outlets therefrom complete with all necessary earthwork and backfilling. The details of septic tank shall be as per IS:2470. This item shall also include ventilating pipe of at least 100 mm dia whose top shall be provided with a suitable mosquito proof wire meshes and cowl. Ventilating pipe shall extend to a height of about 2 meter when the septic tank is at least 15 meter away from the nearest building and to a height of 2 meter above the top of building when it is located closer than 15 meter. Ventilating pipes can be connected to the normal soil ventilating system of the building where allowed. Necessary inspection chambers, wherever required, shall be provided for pipeline from the building to the septic tank. 5.3.2 Effluent Disposal The effluent from the septic tank shall be disposed by allowing it into an open channel or a body of water if the concerned authority approves or into a soak pit for absorption by soil or shall be allowed to be absorbed by soil through open jointed S.W. pipes laid in a trench filled with broken bricks. Soak pit It shall consist of a 900 mm dia pit 1000 mm in depth below the invert level of the inlet pipe. The pit shall be lined with stone, brick or concrete blocks set in cement mortal (1:6) and filled with brick bats. Inlet pipe shall be taken down to a depth of 900 mm from the top as an anti-mosquito measure. Open jointed S.W. pipe/Dispersion trenches Minimum dia of S.W. pipe shall be 150 mm nominal. The trench for laying pipe shall be minimum 600 mm depth. The joints of the pipes shall be left unsealed. The entire length of the pipe within the trench shall be buried in a 250 mm layer gravel or crushed stone of uniform size on top of the gravel/ crushed stone layer is a 150 mm bed of well graded coarse aggregate. Ordinary soil is used for filling the top of the trench. 5.3.3 Commissioning Septic Tank After the Septic tank has been proved water tight and the sewage system is checked, the tank shall be filled with water to its outlet before the sewage is let into the tank. It shall be seeded with well digested sludge obtained from septic tank or sludge digestion tank. In the absence of digested sludge, small quantity of delaying organic matter such as digested cowdung may be introduced.
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5.4.0
Inspection pits and trap pits Construction of pits shall commence only after the pipes have been laid in position to true line and levels as shown on the drawings and to the satisfaction of the Engineer.
5.4.1
Inspection pits Inspection pit shall be constructed as per IS standards. Unless otherwise specified, all inspection pits shall be constructed with rubble masonry in cement mortar (1:4). Half round channels of size suitable for the inlet and outlet pipe diameters shall be formed on the floor of the pit with PCC M10. The floor of the pit shall be haunched towards the channel as shown on the drawings. Inside of pits shall be finished with cement-sand plaster (1:4) and finished smooth with cement punning. Care shall be taken to avoid unevenness on the surface and sharp bends in the channel. The invert level after finishing shall be as indicated by the Engineer.
5.4.2
Intercepting/master trap pits The pits for the glazed stoneware master trap shall be constructed as per IS standards. The construction and finishing of the pit shall be haunched towards the intercepting/master trap.
5.4.3
Gully trap pits Gully trap pits shall be constructed as per IS standards. The construction and finishing of the pit shall be as described above for inspection pits. The cast iron grating shall be set flush with the finished ground/floor level.
5.5.0
Installation of sanitary appliances All sanitary appliances shall be fixed in position rigidly on floor and walls as per IS standards or as directed by the Engineer. All appliances shall be from the approved manufacturer and approved colour. The contractor shall prepare drawings showing all the details required for the inspction pits and trap pits mentioned above and got it approved by the owner before commencement of work.
5.5.1
Indian Water Closet (IWC) - Squatting type Squatting type water closet shall be fitted on trap and shall be jointed with gasket yarn and cement mortar. Rim of the pan shall be leveled properly and set flush with the finished floor. The pan shall be connected to cast iron high level pull and let go type flushing cistern of 15 liters capacity as per IS standards. The flushing cistern shall be supported on a pair of CI cantilever brackets firmly embedded in the wall in cement mortar (1:4) or screwed to wall with suitable plugs. Height of the bracket from the top of pan shall be as per IS standards. The flush pipe from the cistern shall be 32 mm dia tested quality galvanized steel pipe (light quality) and connected to the pan inlet by means of hemp and putty joint.
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5.5.2
European Water Closet (EWC) - Pedestal type Pedestal type water closet shall be rigidly fixed on the finished floor by means of 75 mm long brass screws with suitable plugs. The flushing cistern shall be of porcelain or cast iron or cast iron low level push down cistern of capacity as indicated in the Schedule of Items. The cistern shall be supported on a pair of cast iron or rolled steel cantilever brackets firmly fixed on wall with brass screws and suitable plugs. The flush pipe from the cistern shall be 40 mm dia chromium plated brass end and fitted to the closet by means of rubber adopter. The closet shall be provided with double plastic seat cover conforming to IS:2548 and chromium plated hinges.
5.5.3
Urinals Standing type urinals shall be firmly fitted on finished wall by means of 50 mm long brass screws and suitable plugs. Height of the lip from the standing point shall be as per IS standards. Urinals shall be fitted with cast iron automatic flushing cistern of 5 liters capacity. Flushing pipes shall be of galvanized steel pipes of required size and connected to the urinal with 15 mm dia PVC connector fitted with brass cap and lining at one end. The joint to the inlet of urinal shall be neatly finished with putty joints. The arrangement of waste pipes and discharge to the floor trap shall be as shown on the drawings or as directed by Engineer. For single urinal the discharge may be direct to the floor trap through a 40 mm dia waste pipe. For a range of urinals, the discharge may be collected in a common waste pipe of 50 mm dia leading to the floor trap. Each urinal shall be connected to the common discharge pipe by 40 mm dia waste pipes. Alternatively, the discharge from each urinal through 40 mm dia pipe shall be lead to the 100 mm W.G half round channel laid on the floor leading to the floor trap.
5.5.4
Wash hand basin Wash hand basin shall be fitted in position to true level on a pair of cast iron brackets plugs. The basin shall be fitted with 15 mm dia approved quality chromium plated pillar tap and 32 mm dia waste fittings. The type of waste pipe and their connections shall be as shown in the drawings or as directed by the Engineer.
5.5.5
Sink Porcelain sink of size 60 cm x 30 cm shall be leveled properly and fitted in position on a pair of cast iron cantilever brackets firmly embedded in the wall in cement mortar (1:4). The sink shall be fitted with chromium plated brass waste fittings of standard size. The type of waste pipes and their connections shall be as shown on the drawings or as directed by the Engineer.
5.5.6
Other miscellaneous fittings (e.g. mirror, towel rails, soap cases etc.) All such fittings shall be of type and sizes as per IS standards and as directed by the owner and shall be fitted in position true to line, level and plane as directed by the Engineer.
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5.6.0
Water tanks All tanks for storage of water shall be as indicated in the drawings and shall be completely watertight and properly covered with dust, light and mosquito proof cover approved type as shown on drawings or as described in the bill of quantities. They shall be fitted with a ball valve of the inlet pipe. A mosquito proof overflow pipe shall be fixed to the tank with the pipe invert about 25 mm above the top of water line. Approved type of stop valve shall be provided for every outlet pipe. All outlet and inlet pipes shall be fixed as shown in the drawings. The tanks will be constructed of RCC, the inside surface of shall be painted with anti-corrosive drinking water paints as indicated in the drawing. All storage tanks, water supply fittings and pipes before being put into commission shall be disinfected with liquid chlorine by the Contractor at his own cost.
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SECTION-C4.10 TECHNICAL SPECIFICATION FOR PAINTING COLOUR WASHING ETC. 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for finishing works to masonry, concrete and steel such as white washing, colour washing, distempering and painting. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Indian Standards Institution and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality, and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: White washing, colour washing and distempering IS:427 IS:428 IS:6278 Painting IS:5 IS:102 IS:123 IS:1477 IS:2074 IS:2338 IS:2339 IS:2395 IS:2932 Colours for ready mixed paints and enamels Ready mixed paint, brushing, red lead, non-setting, priming Ready mixed paint, brushing, finishing, semi gloss, for general purposes Code of practice for painting of ferrous metals in buildings Ready mixed paint, air drying, red oxide-zinc chrome, priming Code of practice for finishing of wood and wood based materials. Aluminium paint for general purposes in dual container Code of practice for painting concrete, masonry and plaster surface Enamel, synthetic, exterior, a. IS:2933 undercoating b. finishing Distemper, dry colour as required Distemper, oil emulsion, colour as required Code of practice for white washing and colour washing
Enamel, exterior, a. undercoating b. finishing

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IS:5410 3.0.0 3.1.0
Specification for cement paint, colour as required
MATERIALS Distemper Dry Distemper shall be made from suitable pigments, extenders lime proof tinters, water soluble binders confirming to IS:427. Oil bound washable distemper shall be of oil emulsion type containing suitable preservatives confirming to IS:428.
3.2.0
Gum and blue pigment Gum and blue pigment for white wash shall be of best quality and of approved make.
3.3.0
Water Proof Cement Paint Waterproof cement paint shall be made from best quality white cement and lime resistant colours with accelerators, water proofing agents and fungicides. The paint shall confirm to IS:5410.
3.4.0
Paint The painting and finishing materials for use in the work shall conform to relevant Indian Standards specifications and shall be best brands of approved make produced for each kind of work. Aluminium paint shall be in two back containers and shall resist weathering. The acrylic emulsion paint, after it is dried, shall be able to withstand washing with mild soap and water without any deterioration in colour or without showing flaking, blistering, or peeling.
3.5.0
Primer coat Unless otherwise specified, the primer coat for concrete steel and ironwork shall be as specified by the manufacturer.
3.6.0
Varnish Varnish shall be best quality alkyd varnish suitable for brushing over the tint of paint or light natural wood and shall not darken or yellow with age.
3.7.0
French Polish The French polish shall be made from the best quality shellac, denatured spirit and other suitable alcohol soluble ingredients made by a well known approved manufacturer and shall conform to IS:348. French polish shall not be used on bare wood. It shall only be used as finishing coat on wood after the wood is pretreated with a liquid wood filler conforming to IS:345 is applied and rubbed out.
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4.0.0 4.1.0
WHITE WASHING, COLOUR WASHING AND DISTEMPERING Mixing The slaked lime shall be screened to pass through a sieve of 49 meshes per sq.cm. and dissolved in a tub with sufficient quantity of water and shall be well mixed to give a thin creamy consistency. It shall then be strained through a clean coarse cloth and clean gum dissolved in hot water added to it at the rate of 2 kg for each cubic meter of lime and ultramarine blue added to the mixture in small proportion just sufficient to give a very light bluish tint. Colour wash shall be prepared in the same way as for white washing except that necessary amount of colouring matter shall be added to lime wash to obtain the colour specified. No blue shall be added in this case. The entire quantity shall be mixed strictly in accordance with the manufacturer's instructions unless these are varied by the Engineer. Distemper shall not be mixed in a larger quantity than is actually required for a day's work and hot water shall be used in preparing the mixture.
4.2.0
Preparation of Surface Before white wash is laid on new wall, the surface of wall shall be well cleaned and brushed and all patching must be scraped properly. After cleaning the surface, all holes, cracks and patches shall be made good with approved materials. Masonry cracks shall be cleaned out and patch filled with mortar similar to the original surface and finished with cement wash. For all internal painting the surface shall be made smooth by application of approved paste fillers before applying primer. The distemper shall not be applied on damp walls and shall be applied in dry weather. The surface to be distempered shall be thoroughly cleaned of dust, dirt, grease, oil marks, cement marks, loose scales etc. and rubbed with sand paper to give a uniform smooth surface.
4.3.0
Workmanship White wash shall be applied with brush, each coat consisting of vertical stroke from top downwards followed by opposite stroke upwards over the first stroke and horizontal stroke from left to right followed by stroke right to left. Each coat must be allowed to dry before the next coat is applied. On completion, the surface when it becomes dry, shall present a uniform white appearance. When dry, no coat of white wash shall show any patches, hair cracks or streaks nor shall it come off when rubbed with hands. White washing shall be done in 3 coats unless otherwise specified. Doors, windows, floors etc. must be protected from white wash splashes. Any splashes and droppings shall be removed and cleaned. Colour wash shall be applied in the same manner as specified for white wash. During application, the solution shall be stirred continuously and wash shall be applied with care to avoid any cut shade or brush marks on the walls when the work is complete. For all new work, the surface to be colour washed shall first be treated with a priming coat of lime wash. Unless otherwise specified, two coats of white wash shall first be applied
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before colour wash is applied. Number of coats of colour wash shall be as specified in the drawings or in the Schedule of Rates. The colour wash, whether applied inside or outside of a building shall be of uniform tint and shade. The workmanship for distempering shall conform to IS:427 and IS:428 unless specified otherwise. Distempering shall be done with proper distemper brushes of approved quality. The finished surface shall be of absolutely uniform shade throughout and free from brush marks. On drying, the distemper shall not come off on touch and shall not crack. Distemper shall be applied in two coats over one coat of priming. The priming coat shall be as specified and the primer shall be in accordance with the recommendation of the manufacturer. Before applying the primer, the plastered surface shall be washed with a solution of 100 gm of zinc sulphate to one litre of water and then allowed to dry. Succeeding coats shall not be applied until the previous coat has been approved by the Engineer. The first coat shall always be of a lighter tint and shall be applied with care. In case the finish is not up to the standards, the entire surface shall be sandpapered and a fresh coat or coats of distemper shall be supplied without any extra cost. All decorative mouldings, cornices, bands etc. shall be finished according to detailed drawings. All splashes of distemper shall be removed by the Contractor at his own cost. The surface to be coated with waterproof cement paint shall be washed and brushed down. As soon as the moisture has disappeared, the surface shall be given one coat of paint. Care shall be taken so that the paint does not dry out too rapidly. After four to six hours, water shall be sprinkled over the surface to assist curing and prevent cracking. After the first coat has dried (24 to 48 hours), the second coat shall be applied in a similar manner. The finished surface shall be kept moist by occasional sprinkling with water for seven days after painting. 5.0.0 5.1.0 PAINTING AND POLISHING Preparation of surface The surfaces of iron and steel work to be painted shall be cleaned free of dirt, oil, rust, mill scale and be thoroughly dry before painting. The steel shall be cleaned by grit blasting and provided with a shop coat of approved metal protection such as red oxide. Cleaning, degreasing, derusting and descaling wherever necessary shall be carried out as specified in IS:1477 (Part I). All galvanised iron surfaces shall be pre-treated with a compatible primer according to the manufacturer's direction. The surfaces of wood shall be rubbed down smooth. All nails and screws shall be sunk below the surface and filled with mastic after applying an under coat. Small knots that do not justify cutting and sap streaks shall be covered with minimum two coats of pure shellac coating applied thinly and extended 25 mm beyond the area. All large, loose or resinous knots shall be removed and filled with sound wood. All work shall be done as per IS:2338. 5.2.0 Painting Painting of iron and steel work shall generally be carried out as per IS:1477. The paint manufacturer's specification/instructions shall be followed as far as possible at all times. Particular attention shall be paid to the following:
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a. b. c. d.
Proper storage to avoid exposure, as well as extremes of temperature. Surface preparation prior to painting including grit blasting. Mixing and thinning Application of paints and the recommended time limit on time intervals between coats.
Painting operations shall not proceed until the Engineer has the opportunity to inspect the condition of prepared surface to be painted. Paint shall be thoroughly mixed and not more than 1/2 kg of recommended thinner per 4.5 kg litres of paint shall be added if thinning is necessary. Exterior paint shall not be performed during the period of inclement weather. Interior painting may proceed during such periods only with the approval of the Engineer. Prior to application of subsequent coat, the Engineer shall be given the opportunity to inspect the prior coat. Should the work be judged by the Engineer be inferior, a supplementary coat shall be applied at no additional cost. The number of coats including the primer coat shall be applied as specified. Each coat shall be allowed to dry sufficiently before the succeeding coat is applied. The type of intermediate and finish coat and the number of coats to be applied shall be as specified. Intermediate and finish coats may be oil bound, bituminous, aluminium or other types of paints. Aluminium paint shall conform to IS:2339. The intermediate and finish coats for structural steel work, sheet metal work and cast iron work shall be applied as specified in IS:1477 (Part II). 5.3.0 Clear Synthetic Varnish The varnish shall be applied on wood surface after a) filling, b) staining and c) sealing operations are carried out in accordance with IS:2338. The application of a combination of filler and stain shall not be permitted. For the finishing coats of varnish. The surface shall be allowed to dry and be rubbed down lightly, wiped off and allowed to dry. The varnish shall be applied liberally with a brush and spread evenly over a portion of the surface with light strokes to avoid frothing. It shall be allowed to flow on while the next section is being laid on. Excess varnish shall be then scrapped of the brush and the first section be crossed, recrossed and then laid of lightly. The varnish once it has began to set shall not be retouched. In case of any mistake in application the varnish shall be removed and the work started afresh. The varnish shall be minimum of two coats, with the first coat being a flatting varnish. This shall be allowed to dry hard and be flatted down, before applying the next coat. Sufficient time must be allowed between coats to get a hard dry surface before next coat is applied. All work shall be as per IS:2338. 5.4.0 French polish All unevenness of the surface shall be rubbed down to smoothness with sand paper and well dusted. All pores shall be filled up with a whiting in water or methylated spirit with a suitable pigment like burnt siemme or umber.
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After application of filter the French polish shall be applied with a polish moistened pad of woolen cloth covered by a fine cloth and rubbed hard in a series of overlapping circles for uniform application. A trace of linseed oil may be used on the pad for ease of application. The surface shall be allowed to dry before further coats are applied in the same manner. The finishing shall be done with a fresh piece of clean fine cloth damped with methylated sprit and rubbing gently to get a uniform glossy surface 6.0.0 ACCEPTANCE CRITERIA a) b) c) d) All the painted surface shall be uniform and pleasing in appearance. The colour, texture etc. shall match exactly with those of approved samples. All stains, splashes and splatters of paints shall be removed from surrounding surface. All varnished and polished surfaces shall be of uniform texture and high glossy finish.
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SECTION-C4.11 TECHNICAL SPECIFICATION FOR FLOOR AND FLOOR FINISHING 1.0.0 SCOPE This specification covers requirements in respect of material, workmanship and quality for soling, concrete floor and floor finishes work. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest additions as published by Bureau of Indian Standards and all other such as may be directed published by them during currency of the contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed here under : IS : 777 IS : 2114 IS : 2571 IS : 3461 IS : 3462 IS : 4457 IS : 5318 IS : 5491 3.0.0 Specification for glazed earthenware wall tiles. Code of practice for laying in-situ terrazo floor finish Codes of practice for laying in-situ concrete flooring Specification for PVC asbestos floor tiles. Specification for unbacked flexible PVC flooring Ceramic unglazed vitreous acid-resistant tiles Code of practice for laying PVC flooring Code of practice for laying in-situ granolithic concrete floor topping.
BOULDER SOLING The boulders for soling shall be granite, basalt or similar hard stone approved by the Engineer and generally shall be 200 mm thick. The sub grade shall be dressed to correct level and shall be rammed or rolled to proper consolidation before laying the soling. Stones shall be placed close to each other. The specified thickness shall be made up in one layer only. The voids between the stones shall be hard packed first with smaller pieces and hammered into place so as to completely fill up the void along with moorum as binding material and the layer is watered and compacted well by roller / mechanical compactor. No stone after packing shall move or tilt in any direction when walked over. In case of building enclosing heavy machinery like gas turbine / steam turbine, the compaction shall be by roller of 8/10 MT capacity.
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4.0.0 4.1.0 4.1.1
CEMENT CONCRETE FLOORING Materials Cement Ordinary Portland cement shall conform to IS:269.
4.1.2
Aggregate The aggregates shall conform to IS:383. The size of coarse aggregate shall be 40 mm down graded. Grading of coarse aggregates shall conform to Table 1 of IS:2571. The fine aggregates shall be either of grading zone 1 or 2 of Table 2, IS:2571.
4.2.0
WORKMANSHIP The workmanship shall generally conform to the specification for Plain & Reinforced concrete (C:2) and also to IS:2571. For ground floor slab or paving in open area, where the slab has to be laid over a consolidated ground, soling, a kraft paper shall be spread over the area and kept moist before concreting. The floor shall be laid in alternate panels, of size not exceeding 4 m to reduce risk of cracking, intermediate panels being filled in after two or three days. Alternately flooring may be laid using glass strips between panels . For paving in open area, contraction joint and expansion joints shall be provided as per IS specification. The expansion joints shall be filled with bitumen impregnated boards 25 mm thick of approved manufacturer and top 25 mm shall be covered with approved mastic sealing compound.
5.0.0 5.1.0
FLOOR FINISHES Indian Patent Stone (IPS) with ironite topping It shall consist of a under bed and a topping laid on an already laid and matured concrete base.
5.1.1
Thickness The total thickness of finish shall be 40 mm of which the topping shall be 12 mm. While the topping shall be uniform thickness the under bed may vary in thickness to provide necessary slopes.
5.1.2
Mix For underbed, it shall be 1:2:4 mix using 10 mm down graded stone chips. For toppings of heavy duty, the proportion of metallic hardener shall be strictly as specified by the manufacturer. In absence of such direction, one (1) part of metallic hardener shall be mixed dry with 4 parts of cement by volume. To this mixture, 6 mm nominal size stone chips shall be added in portion of 1:4 (mixture of hardener & cement : stone chips) by volume. Minimum quantity of water to be added to make it workable.
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5.1.3
Laying The topping including the underbed shall be laid in alternate bays or in chequered board pattern. No panel shall be cast in contact with another already laid till the contraction of latter has already been taken place. The maximum area of each panel shall be 3 sq.m of which no side shall be more than 2 m long. A cement grout shall be applied and worked into the surface to receive the finish, the under bed then laid, compacted and leveled to proper grade with a screed or float. The topping shall be applied evenly on the underbed while it is not fully set, but firm enough and rolled and pressed to get full bond. The topping shall be troweled to a dense finish to the satisfaction of the Engineer-in-Charge. All trowel marks shall be mopped out with a cloth to give a clean smooth surface.
5.1.4
Curing After the surface is sufficiently set, the finished floor shall be kept moist for 7 days for curing.
5.2.0
Indian Patent Stone (IPS) with Non-Metallic Surface Hardener Finish It shall consist of an underbed and a topping on which the hardener shall be laid.
5.2.1
Thickness The total thickness of finish shall be 40 mm of which the topping shall be 12 mm including the hardener finish.
5.2.2
Mix Mix for underbed and topping shall be same as for IPS flooring.
5.2.3
Hardener Hardener shall be non-metallic abrasion resistant surface hardener NITOFLOR HARDTOP or equivalent.
5.2.4
Laying The topping and underbed shall be laid as for IPS flooring. While the topping is still green, the hardener shall be applied by dry shake-on-system. Cleaning of surface, surface preparation, curing and trowel finish shall be as per manufacturers specifications and recommendation. The surface hardener application rate shall be as follows : Heavy duty : 7 kg/m Medium duty : 5 kg/m Light duty : 3 kg/m
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5.3.0
Precast Terrazo Tile Finish It shall consist of manufactured terrazo tiles and an underbed.
5.3.1
Thickness The total thickness of finish including underbed shall be minimum 40 mm for floors and 30 mm for skirting. The skirting shall project 6 mm out from the adjacent wall finish. The necessary cutting into the surface receiving tile finish shall also be done.
5.3.2
Tiles The tiles shall be hydraulically pressed under strict quality control in a shop. The size of tiles shall be 250 x 250 x 20 mm. The topping of tiles shall not be less than 10 mm. Maximum tolerance allowance in length & breadth shall be 1 mm and the thickness 3 mm. All angles of tiles shall be right angles, all arises sharp and true, colour and texture of wearing face uniform throughout, and face shall be plane, free from pin holes and other blemishes. The topping of tiles shall be composed of cement, (grey or white or mixture of two) colour pigment, marble dust and marble chips (chips size 3 to 20 mm) in such a proportion so as to produce the desired colour, texture & pattern approved by the Engineer-in-charge. The backings shall be composed of 1 part of ordinary grey cement, 1 1/2 part of sand and 3 parts of 6 mm down graded stone chips mixed with water. First grinding shall be given to the tiles at the shop before delivery. Tiles shall be packed properly to prevent damage during transit and storage. The tiles must be stored carefully to prevent staining of damp, rust, oil and grease or other chemicals.
5.3.3
Underbed The underbed for floor shall consist of a mix of 1 part cement, 1 1/2 parts coarse sand and 3 parts machine crushed 10 mm down stone chips by volume. For skirting, the mix shall consist of 1 part cement and 3 parts coarse sand. Only sufficient water to be added to give workable consistency.
5.3.4
Laying The underbed mortar shall be evenly spread and brought to proper grade and consolidated. The surface shall be roughened for better bond. Before the underbed has time to set and while it is still fairly moist but firm, cement shall be hand dusted over it or a cement slurry applied and tiles shall immediately be placed upon and firmly pressed by wooden mallet onto the underbed until it achieves the desired level. The tiles shall be kept soaked for about 10 minutes just before laying. The joints between tiles shall be also as possible and not more than 1.5 mm wide. When tiles are required to be cut to match the dimensions, these shall be sawn and edges rubbed smooth. The location of cut tiles shall be planned in advance and approval of the Engineer-in-charge taken. The floor tiles shall atleast enter 12 mm under the skirting tiles.
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After fixing, the floor shall be kept moist and allowed to mature undisturbed for 14 days. If desired, aluminium or glass dividing strips shall be used for forming the panels. 5.3.5 Grinding and Polishing After sufficient curing, the surface shall be ground with fine grit blocks. It shall again be cleared with water, the slurry (mixture of cement & pigment) applied again to fill up any pinholes that might have appeared and allowed to be cured again for five days. The surface is ground again with very fine grit blocks to get smooth surface without any pinhole. The grinding shall be done by a suitable machine. Where grinding machine cannot be used, hand grinding may be allowed. The choice of grit blocks at different stages of polishing shall be as per manufacturer's recommendations. The surface shall be cleaned with water, dried and covered with oil free clean saw dust if directed by the Engineer-in-charge. The final polishing shall be postponed till before handing over if so desired by the Engineer-in-charge. Just before handing over, the surface shall be dusted with oxalic acid at the rate of 0.33 gm per sq.m, water sprinkled on to it and finished by buffing with felt or hessian bobs. The floor shall be cleaned with soft moist rag and dried. If desired by the Engineer-incharge, wax polish shall be applied. However, all excess wax polish to be wiped off and surface to be left glossy but not slippery. 5.4.0 Acid Resistant Tile Finish This shall include all varieties of special tiles used for specific chemical/acid resistance function and an underbed over already laid concrete or masonry. 5.4.1 Thickness The total thickness of finish shall be 46 mm of which the tile shall be 25 mm, acid proof mortar 6 mm, bitumen 3 mm and cement mortar underbed 12mm. 5.4.2 Tiles The tiles shall be of best approved manufacture, conforming to IS:4457 and resistant to the chemical likely to come in contact. The tiles shall have straight edges, uniform thickness, plain surface, uniform non-fading colour and textures. The water absorption after 24 hours of soaking shall not be more than 2% by weight. The compressive strength of tiles shall not be less than 700 kg/cm2. The surface shall be abrasion resistant and durable. 5.4.3 Underbed The underbed shall be laid in three layers. The first layer shall be composed for 1 part cement and 3 parts river sand with just enough water to make the mix workable. This layer shall be trovelled level and cured with water for at least 3 days prior to application of the second layer. The second layer consist of 3 mm thick hot blown bitumen conforming to IS:702 of grade 85/25 and shall be applied in three coats with brush or
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spray. The third layer acid proof mortar as specified by manufacturer shall be applied. The acid proof mortar shall have equal chemical resistant properties desired. 5.4.4 Laying The tiles shall be embedded in the acid proof mortar and the gap between the tiles shall be grouted to the full depth of tile. The setting and fixing shall be strictly as per the manufacturer's specification and shall be approved by the Engineer-in-charge. 5.4.5 Curing The joints in the floor shall be cured with the solution of 25% proof hydrochloric acid or as specified by the manufacturer. 5.5.0 In-situ Terrazzo Finish It shall consist of an underbed and a topping laid over an already laid and matured concrete base. 5.5.1 Thickness Unless otherwise specified the total thickness of the finish shall be minimum 40 mm for horizontal and 25 mm for vertical surface of which the topping shall be not less than 10 mm. While the topping shall be of uniform thickness the underbed may vary in thickness to provide necessary slopes. The vertical surface shall project out 6 mm from the adjacent plaster or other finish. Necessary cutting into the surface receiving the finish shall be done to accommodate the specified thickness. All junctions of vertical with horizontal shall be rounded neatly to uniform radius of 25 mm. 5.5.2 Underbed The underbed for floors and similar horizontal surfaces shall consist of a mix of 1 part cement, 1-1/2 parts sand and 3 parts stone chips by volume or cement sand mixture 1:3 . For vertical surfaces the mix shall consist of 1 part cement to 3 parts sand by volume. The sand shall be coarse. The stone chips shall be 10 mm down well graded. Only sufficient water to be added to give a workable consistency. Stone chips are machine crushed blue granite metal. Topping : The mix of the topping shall be composed of cement, colour pigment, marble dust and marble chips. Proportions of the ingredients shall be such as to produce the terrazzo of colour, texture and pattern approved by the Engineer. The cement shall be white or grey or a mixture of the two to which pigment shall be added to achieve the desired colour. To3 parts of this mixture 1 part marble powder by volume shall be added and thoroughly mixed dry. To 1 part of this mix 1 to 1-1/2 parts of marble chips by volume shall be added and thoroughly mixed dry again. The pigment must be stable and nonfading. It must be very finely ground. The marble powder shall be from white marble and shall be finer than I.S. Sieve No. 30. The size of marble chips may be between 3 mm to 20 mm.
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Sufficient quantity to cover all visible area shall be prepared in one lot to ensure uniform colour. Water to make it just workable shall be added to a quantity that can be used up immediately before it starts to set. 5.5.3 Laying The underbed shall be laid in panels. The panels shall not be more than 5 sq.m in area of which no side shall be more than 2.5 m long. For exposed locations the maximum area of a panel shall be 2.0 sq.m. The panel shall be laid in alternate bays or chequered board pattern. No panel shall be cast in contact with another already laid until the latter has contracted to the full extent. Dividing strips made of aluminium or glass shall be used for forming the panels. The strips shall exactly match the total depth of underbed plus topping. These strips shall be left in place and the rates shall be inclusive of these. After laying, the underbed shall be levelled compacted and brought to proper grade with a screed or float. The topping shall be laid after about 24 hours while the underbed is still somewhat 'green' but firm enough to receive the topping. A slurry of the mixture of cement and pigment already made shall be spread evenly and brushed in just before laying the topping. The topping shall be rolled for horizontal areas and thrown and pressed for vertical areas to extract all superfluous cement and water and to achieve a compact dense mass fully bonded with the underbed. The surface of the topping shall be troweled over, pressed and brought to a smooth dense surface showing a minimum 75% area covered by marble chips in an even pattern of distribution. 5.5.4 Curing The surface shall be left for curing for about 12 to 18 hours and then cured by allowing water to stand on the surface or by covering with wet sack for four days. 5.5.5 Grinding and Polishing When the surface has sufficiently hardened it shall be watered and ground evenly with rapid cutting coarse grade (no.60) grit blocks, till the marble chips are exposed and the surface is smooth. Then the surface shall be thoroughly washed and cleaned. A grout with already prepared mixture of cement and pigment shall be applied to fill up all pinholes. This surface shall be cured for seven (7) days by keeping it moist and then ground with the fine grit blocks (no. 120). It shall again be cleared with water, the slurry applied again to fill up any pinholes that might have appeared and allowed to be cured again for five (5) days. Finally the surface is ground again third time with very fine grit blocks (no. 320) to get smooth surface without any pin hole. The grinding shall be done by a suitable machine. Where grinding machine cannot be used hand grinding may be allowed when the first rubbing shall be with carborundum stone of coarse grade (no.60), second rubbing with medium grade (no.120). The surface shall be cleaned with water, dried and covered with oil free clean sawdust if directed by the Engineer. The final polishing shall be postponed till before handing over if desired by the Engineer.
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Just before handing over the surface shall be dusted with oxalic acid at the rate of 0.33 gm per sq.m., water sprinkled on to it and finished by buffing with felt or hessian bobs. The floor shall be cleaned with soft moist rag and dried. If desired by the Engineer, wax polish shall be applied. However, all excess wax polish to be wiped off and the surface to be left glossy but not slippery. The choice of grit blocks at different stages of polishing shall be as per manufacturer's recommendations. 5.6.0 Ceramic Floor Tile / Glazed Wall Tile Finish This finish shall be composed of glazed earthen ware tiles with an underbed laid over a concrete or masonry base. 5.6.1 Thickness The total thickness shall be between 20 mm and 25 mm including the underbed. The tile finish on vertical surface shall project out 6 mm uniformly from the adjacent plaster or other wall finishes. The necessary cutting into the surface receiving the finish, to accommodate the specified thickness shall be done. 5.6.2 Tiles The glazed tiles shall be of earthenware, covered with glaze, white or coloured, plain or with designs, of 150 mm x 150 mm nominal sizes and 6 mm thick unless otherwise specified. The tolerance shall be 1.5 mm for length and breadth and 0.5 mm for thickness. Specials like internal and external angles, beads, coves, cornices, corner pieces etc. shall match. The top surface of the tiles shall be glazed with a gloss or matt unfading stable finish as desired by the Engineer. The tiles shall be flat and true to shape. The colour shall be uniform and fractured section shall be fine grained in textures, dense homogenous. The tiles shall be strong and free from flaws like cracks, chips, craze, specks, crawlings etc. and other imperfections. The edges and the underside of the tiles shall be completely free from glaze and the underside shall have ribs or indentations for better anchorage with the fixing mortar. The coloured tiles, when supplied, shall preferably come from one batch to avoid difference in colour. 5.6.3 Underbed The mix for the underbed shall consist of 1 part cement and 3 parts coarse sand by weight mixed with sufficient water or any other mix if specified. 5.6.4 Laying Same as cl. 5.2.4 5.6.5 Finishing The joints shall be cleaned and flush pointed with white cement and cured for seven (7) days by keeping it wet. The surface shall be cleaned with soap or suitable detergent, washed fully and wiped with soft cloth to prevent scratching before handing over.
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5.7.0
Carborandum Tile Finish It shall consist of manufactured carborandum tile and an underbed.
5.7.1
Thickness The total average thickness including underbed shall be minimum 40 mm for floors and 30 mm for skirting unless otherwise specified.
5.7.2
Tiles The tiles shall be heavy duty carborandum tile `STILAN or equivalent, machine made under quality control in a shop. The tiles shall be pressed hydraulically to a minimum of 140 kg/cm. Each tile shall bear on its back, permanent and legible trade mark of the manufacturer. All angles of the tiles shall be right angles, all edges sharp and true, colour and texture of the wearing face uniform throughout. Maximum tolerance / allowance for length and breadth shall be 1 mm and the thickness + 3 mm along the wearing surface of the tile and the wearing surface shall be plane and free from pin-holes and other blemishes. The tiles shall be composed of a backing and topping. The topping shall be of uniform thickness not less than 6 mm. The total thickness including the topping shall be as specified but not less than 20 mm in any case. The backing shall be composed of 1 part ordinary grey cement, 2 parts and sand 4 parts of stone chips by volume and mixed with water. The topping shall be carborandum grit (passing 1.18 mm mesh but retained on 0.67 mm mesh) and shall be sprinkled on the surface at the rate of 1.35 kg/m and worked into the surface, to achieve a smooth and uniform surface. The tile shall be cured at the shop atleast 14 days before delivery to the site. Tiles shall be packed property to prevent damage during transit and storage. The tiles must be stored carefully to prevent staining by damp, rust, oil and grease, or other chemicals. Tiles made in each batch shall be kept and used separately so that the colour of each area of the floor may remain uniform. The manufacturer shall supply along with the tiles the grout mix containing cement and pigment in exact proportions as used in topping of the tiles. The containers of the grout mix shall be suitably marked to relate it to the particular type and batch of tiles.
5.7.3
Underbed The underbed for floors and similar horizontal surfaces shall be 1 part cement, 2 parts coarse sand and 4 parts stone aggregate by volume mixed with sufficient water to form a stiff workable mass. For skirting and dado and all vertical surfaces it shall be about 10 mm thick and composed of 1 part cement and 3 parts coarse sand by volume.
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5.7.4
Laying The underbed mortar shall be evenly spread and brought to proper grade and consolidated to a smooth surface. The face shall be roughened for better bond. Before the underbed has time to set and while it is still fairly moist but firm, cement shall be hand-dusted over it or a cement slurry applied and the tiles shall be immediately placed upon the firmly pressed by wooden mallet onto the underbed until it achieves the desired level. The tiles shall be kept soaked for about 10 minutes just before laying. The joints between tiles shall be as close as possible and not more than 1.5 mm wide. Special care shall be taken to check the level of the surface and the lines of the joints frequently so that they are perfect. When tiles are required to be cut to match dimension. These shall be sawn and the edges rubbed smooth. The location of cut tiles shall be planned in advance and approval of the Engineer taken. At the junction of horizontal surface with vertical surface, the tiles on the former shall enter at least 12 mm under the latter.
5.8.0
PVC or Vinyl Asbestos Tile / Sheet Finish This shall include various types of tiles or sheets manufactured from PVC, set with a sticker on concrete or masonry or practicle base. An underbed may be required to secure desirable surface and grade.
5.8.1
Thickness The thickness of the tiles / sheets shall be 2 mm for light duty and 3.2 mm for heavy duty applications. The total average thickness including the underbed shall be 40 mm.
5.8.2
Tiles Unless otherwise specified, the tiles/sheets shall conform to the requirements of IS:3461 and IS:3462 and shall be of approved dimensions. The tolerance in dimensions shall be 1.5 mm. The face of the tiles shall be free from porosity, blisters, cracks, embedded foreign matters or other physical defects which affect appearance or serviceability. All edges shall be cut true and square. The colour shall be non-fading and uniform in appearance insoluble in water and resistant to alkalies, cleaning agents and usual floor polishes. Each tile shall be marked on the back legibly and indelibly with manufacturers trade mark, the thickness, sizes , batch number and date of manufacture. Tiles / sheets shall be delivered securely packed and stored in a clean, dry, well ventilated place at a temperature near about to that the tiles / sheets shall be called upon to stand ultimately.
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Adhesive to be used for sticking the tiles or sheets shall be neoprene based rubber adhesive of approved make and approved by the manufacturer of the tile. The adhesive shall have a short drying time and long life in addition to toughness. 5.8.3 Underbed The underbed where required to make-up the specified thickness or to give the required grade or to get the right type of surface shall be composed of 1 part cement : 2 parts of coarse sand : 4 parts stone aggregate 10 mm down size, mixed with just sufficient water to make it workable. 5.8.4 Laying The tiles or sheets shall be kept in the room to be tiled for at least 24 hours to bring them to the same temperature as the room. For air-conditioned space, the air-conditioning shall be completed before tiling is taken-up. The surface to receive this finish shall be firm, even textured, but not too smooth, without undulations and other deficiencies. If an underbed is laid, the same shall be cured for at least 7 days by keeping it moist and then fully dried. The surface shall be thoroughly cleaned. All loose dust particles shall be removed. Oil and grease, if any, shall be completely cleaned by use of detergent. The adhesive shall be applied to fully dry surface in desired thickness uniformly. The adhesive shall also be applied to the backs and edges of the tiles or sheets and allowed to surface dry. The tiles and sheets shall be placed neatly on the surface exactly to the approved pattern and set with a suitable tool. If the edges tend to curl up, weights shall be used to keep the edges down. Special care shall be taken to avoid formation of air pockets under the tiles or sheets. The joints shall be very fine. Any adhesive squeezed out through the joints shall be removed immediately. 5.8.5 Finishing If any adhesive mark is there on the surface, a soft cloth soaked in solvent shall be used to wipe it off. The surface shall be cleaned with soft water and soap, dried and polished with an approved type of polish just before handing over. 5.9.0 Epoxy Floor Coating Epoxy floor coating shall consist of a solvent based, two pack system with epoxy resins and amine curing agents, chosen to withstand high degrees of chemical and abrasive action. 5.9.1 Thickness Thickness of the epoxy coating including screeding shall be minimum 3 mm. Total thickness of finish including underbed shall be 40 mm when applied on floors of buildings. In pits and dyke areas, no underbed is required to be provided.
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5.9.2
Materials The screed shall be solvent free combination of epoxy resin, modified amine hardeners filled with specially graded and selected chemically inert aggregates of high strength. The system shall include an epoxy resin primer and screed which are both supplied in preweighed units ready for on-site mixing and application. An epoxy resin sealing coat of specified thickness shall form the topping coat.
5.9.3
Underbed Underbed shall be similar to that PVC floor finish.
5.9.4
Laying The surface shall be sound, clean and dry in order to achieve maximum adhesion with the primer coating. The primer shall be applied by brush and shall be allowed to become tacky. The screed shall be prepared as per manufacturers specification and laid in specified thickness evenly over the base floor by trowel. The finished, cured screed shall have a slightly granular texture of uniform brown. The epoxy resin topping shall be applied atleast 24 hours after the laying of the screed. This topping shall be applied by brush or sprayed to a specified thickness in two coats with 3-5 hours interval between them. Care shall be taken to finish the topping perfectly smooth and devoid of any bubbles and unevenness. The newly laid floor shall be protected from dust or moisture and allowed to be used only after a minimum lapse of 48 hours.
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SECTION-C4.12 TECHNICAL SPECIFICATION FOR DOORS, WINDOWS, LOUVRES, ROLLING SHUTTERS & GLAZING 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for doors, windows louvres, Rolling Shutters and glazing work. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: Metal Doors & Windows IS:733 IS:1038 IS:1361 IS:1948 IS:1949 IS:4351 Wrought aluminium and aluminium alloy bars, rods and sections (for general engineering purposes) Steel doors, windows and ventilators Steel windows for industrial buildings Aluminium doors, windows and ventilators Aluminium windows for industrial buildings. Steel door frames
Timber Doors IS:4021 IS:1003 IS:2191 IS:2202 Timber door, window and ventilator frames Timber paneled and glazed shutters. Wooden flush door shutter (cellular and hollow core type) Wooden flush door shutters (solid core type)
Rolling Shutters IS:6248 Glazing IS:1081 IS:2835

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Metal rolling shutters and rolling grills
Code of practice for fixing and glazing of metal (steel and aluminium) doors, windows and ventilators Flat transparent sheet glass for glazing and framing purposes
FICHTNER India
IS:3548
Code of practice for glazing in buildings
Builder's Hardware IS:204 IS:205 IS:208 IS:281 IS:363 IS:723 IS:1823 IS:2209 IS:2681 IS:3564 IS:3847 IS:4992 IS:6607 3.0.0 3.1.0 3.1.1 Tower bolts Non-ferrous metal butt hinges Door handles Mild steel sliding door bolts for use with padlocks Hasps and staples Steel counter sunk head wire nails Floor door stoppers Mortice locks (vertical type) Non-ferrous metal sliding door bolts for use with padlocks Door closers (hydraulically regulated) Mortice night latches Door handles for mortice locks (vertical types) Rebated mortice locks (vertical type)
MATERIALS & WORKMANSHIP STEEL DOORS, WINDOWS, VENTILATORS ETC. Door Frames Frames shall be rolled or pressed sections from 18 g sheet conforming to IS:4351. They shall be mortised, reinforced, drilled and tapped for hinges and lock and bolt strikes. Where necessary, frames shall be reinforced for door closures. Welded construction with mitred corners shall be used. Rubber door silencers shall be furnished for the striking jamb. Loose 'T' masonry anchors shall be provided. Frames shall finish flush with floor and adjustable floor anchors shall be supplied. Frames shall be brought to site with floor ties/ weather bars installed in place.
3.1.2
Double Plate Flush Door Shutters Door shutters shall be 45 mm thick, completely flush design and shall comprise of two outer sheets of 18 g steel sheets, rigidly connected and reinforced inside with continuous vertical 20 g stiffeners, spot welded in position at no more than 150 mm on centres. Both edges of doors shall be joined and reinforced full height by steel channels placed immediately inside and welded to the door faces. Top and bottom of doors shall be reinforced horizontally by steel channels running full width of door. Doors shall not have
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more than 2.5 mm clearance at jambs and head, shall have proper bevel on lock stiles and rails to operate without binding, and shall be reinforced at corners to prevent sagging or twisting. Pairs or double doors shall have meeting-stile edges beveled or rebated. Doors shall be mortised, reinforced, drilled and tapped in shop for hinges, locks and bolts. They shall also be reinforced for closures, push-plates and other surface hardwares where necessary. Any drilling and tapping required for surface hardware shall be done at site. Where necessary, provision shall be made for fixing glazing, vision panels, louvres etc. glazing mouldings shall be of 18 g steel and suitable for fixing 6 mm glass. Louver blades shall be V or Z shaped and made out of 16 g sheets. A sample door shall be fabricated and got approved from engineer in charge before proceeding manufacturing of steel doors. 3.1.3 Sliding Doors Sliding doors shall be double plate construction made out of 18 g steel sheets with adequate stiffness. The Contractor shall specify the weight of the door in his shop drawing and submit the manufacturer's catalogue of the sliding gear he proposes to use. Where shown on drawings or call for in the Schedule of Items, the Contractor shall make provisions for openings in the door for monorail beams. Doors shall close positively to exclude rain water from seeping in. Sliding doors shall withstand specified wind loads without buckling or jamming. The door shall slide freely under all ambient conditions. 3.1.4 Steel Windows, Sashes, Ventilators, etc. These shall conform in all respects to IS:1038 and IS:1361. The details as called for in the above codes shall be applicable for coupling mullions, transoms, weather bars, pivot arrangements for ventilators, etc. All welds shall be dressed flush on all exposed and contact surfaces. Where composite unit openings are provided the individual window units shall be joined together with requisite transoms and mullions. All windows shall be outside glazed, fixed with putty or metal glazing beads. All welds at the corner of casement shall be done by flash butt welding process and dressed flush on all exposed and contact surfaces. 3.2.0 ALUMINIUM DOORS, WINDOWS AND FRAMES Aluminium sections for fabricating doors, windows, partitions etc., shall be extruded sections conforming to IS:1948 & IS:1949 or as manufactured by Indian Aluminium Company Ltd. or approved equivalent. The alloy used shall conform to IS designation HE 9-WP of IS:733. Extruded sections shall have a minimum 2 mm wall thickness. All sections shall be approved by the Engineer before fabrication is taken up. Doors, frames, mullions, transoms etc. shall be anodized in a bath of sulphuric acid to provide a clear coating of minimum 0.06 mm thickness. The anodised materials shall then be sealed by immersing in boiling water for 15 minutes. A protective transparent coating shall be applied to the sections before shipment from the factory.
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All work shall be fitted and shop assembled to a first class job, and ready for erection. Shop joints shall be made to hair lines and then welded or braced by such method as will produce a uniform colour throughout the work. Work on the above, other than described, shall be neatly finished with concealed fasteners. Glazing beads shall be snap fit type, without visible screws and shall be of sizes to accommodate 6 mm thick glazing. 3.3.0 3.3.1 TIMBER DOORS Materials All timber shall be best quality well seasoned specified species free from large or loose knots cracks or other defects. Where specified, timber shall be treated with approved wood preservative before starting the joinery work, the Contractor shall have the rough timber approved by the Engineer. Plywood shall be of waterproof exterior quality or with decorative surface veneer as specified.
The core for solid core doors shall confirm to IS 2202 and be of waterproof exterior quality block board or waterproof exterior quality wood particleboard. Manufacturer's literature and test certificates shall be submitted for the approval of the Engineer. The Contractor shall give a guarantee that the adhesive used is phenol-formaldehyde BWP type confirming to IS:848. The thickness shall be as specified in the drawing.
Fixtures for doors, windows, furniture etc. shall be as shown on drawing or specified in the "Schedule of Fixtures". These shall be of heavy type, best quality and from approved manufacturer. The Contractor shall have to mention the name of the manufacturer for different types of joinery hardwares, fittings and fixtures. Samples of each type of fittings shall have to be submitted to the Engineer for obtaining approval before bulk supply. 3.3.2 Workmanship The work shall be done by skilled carpenters as per details shown on drawing or instructed by the Engineer. Framing timber and other work shall be close-fitting with proper wood joinery, accurately set to required lines or levels and rigidly secured in place. The surface of frames etc. which will come in contact with masonry after fixing, shall be given two coats of approved paint before fixing. Mastic caulking shall be done after fixing external door and window frames. Special care shall be taken to match the grain of timber or plywood which will be subsequently polished. Screwing or nailing will not be permitted to the edge of plywood or chip-board sheets. All exposed plywood edges shall be finished with teakwood timber lipping unless otherwise shown on drawings. All carpentry work after finishing shall be sand papered smooth. A prime coat paint shall be given after inspection of the Engineer to all surfaces other than those which shall be subsequently polished or covered with laminated plastic sheet. When shown on drawings, decorative ply or laminated plastic sheets shall be bonded under pressure to the surface to be finished. The adhesive used shall be of approved brand and bought to site in sealed containers. The rate of application and the length of time for which the pressure is to be applied shall be as per the manufacturer's instruction.
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The edge of sheets shall be protected by teakwood timber lipping. However, where available factory made ready for use material of reputed manufacturer shall be used. All frames shall be square and flat at the time of delivery and shall be checked for dimensions and corner angles. After fixing they shall be on a fine vertical plane. All external door and window frames shall be caulked with mastic. 3.4.0 PVC DOORS & WINDOWS PVC doors and windows shall be obtained from reputed manufacturers and shall be SINTEX or approved equivalent quality. The material used shall be unplasticised PVC having superior impact resistance. Density of the material shall be 1.4 grams/cm3 and tensile stress and bending stress of 480 and 770 kilopascal/cm. The outer section wall thickness shall be min. 2.8 mm. The section shall be reinforced with steel sections concealed inside a cavity of PVC sections. Corners shall be welded, transom / mullions welded or mechanically joined. Weather sealing shall be by double sealing with elastomeric weather strip, the corners being glued. Opening for PVC doors / windows shall be 10 mm more than the window / door size. The doors shall be fixed to the wall by expandable fasteners or by brackets. Manufacturers recommendation shall be followed for installation. 3.5.0 ROLLING SHUTTER (HAND OPERATED, MECHANICAL GEAR OPERATED AND ELECTRICALLY OPERATED) Rolling shutters shall be fabricated from 18 gauge steel and machine rolled with 75 mm rolling centres with effective bridge depth of 12 mm lath sections, interlocked with each other and ends locked with malleable cast iron chips to IS:2108 and shall be designed to withstand a wind load of 200 Kg/m2 without excessive deflection. The guides shall be either rolled or pressed deep channel sections 75 mm and 25 mm wide fitted with necessary fitting and fixtures. The suspension shaft shall be formed from heavy duty tubes conforming to IS:1161 and of sufficient diameter so as to resist deflection due to weight of the rolling shutter. The deflection shall not exceed 5 mm/ metre width. The shaft shall be provided with CI pulleys and helical springs for counter balancing the weight of the shutter adequately. The springs shall be approved high tensile flat springs conforming to Grade 2 of IS:4454. These shall be fitted inside the fabricated housing of either ends which counter-balance the shutter curtain. The ball bearings shall be double row self-aligning ball bearings fitted inside C.I. housing fixed on side brackets holding the suspension shaft at either end. The roller assembly shall be designed so as to be capable of producing sufficient torque to ensure easy operation of the rolling shutter in any position. The spring tension shall be adjustable by means of suitable adjustments holes drilled on the rims of the pulley.
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The hood cover shall be made of 20 gauge galvanized sheets with necessary stiffeners and framework to prevent sag. The bottom lock plate shall be made of 5 mm thick M.S. plate and 95 mm wide reinforced with angle/T iron of suitable section with 6 mm dia M.S. rivets interlocked with last stride of curtain. The locking arrangement shall consist of sliding bolts at both ends of the bottom plate fitted to engage with suitable receiving pockets at the bottom of guide channels. Unless otherwise specified, for overall area of rolling, shutters up to 9 sq.m pull and push type hand-operated shutters shall be used; for area between 9 and 12 sq.m pull and push type shutters shall be provided with ball bearings; for area larger than 12 sq.m mechanical gear type or electrically operated shutters shall be supplied. 3.6.0 GLAZING Glass for glazing shall be of the following types : 4 mm thick transparent sheet glass conforming to IS : 2835 generally used for openable shutters of windows. 5.5 mm thick wired glass conforming to IS : 5437 generally used for fixed shutters of windows. 6.3 mm thick laminated safety glass conforming to IS : 2553 generally used for fixed glazed partitions. 5.5 mm thick transparent sheet glass used for aluminium glazed doors.
All glass shall be cut according to the sizes required as per drawings. Glazing of metal doors, windows and ventilations shall conform to IS : 1081 either with putty or metal clips. The Contractor shall thoroughly clean all glass and replace all putty or glass damaged during the work. All glass shall be cut according to the sizes required as per drawings. Glazing of metal doors, windows and ventilators shall conform to IS:1081 either with putty or metal clips. The Contractor shall thoroughly clean all glass and replace all putty or glass damaged during the work. 4.0.0 STORAGE AND HANDLING All metal doors, windows etc. shall be packed and crated properly before despatch and shall be stored under cover in a way to prevent damage or distortion. Special care shall be taken to prevent staining of aluminium products by rust or mortar etc. Glass shall be brought to site in manufacturer's original packing. 5.0.0 ASSEMBLY AND ERECTION The Contractor shall assemble and install all doors, windows, lourves, etc. including transoms mullions for composite units in respective places keeping proper lines and levels, and in approved workman like manner, to give trouble free and leak proof installations. The installations shall be done according to the instructions of the
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manufacturer and/or as approved by the Engineer-in-charge. If required by the Engineerin-charge, the installation shall have to be carried out under the supervision of the manufacturer's staff. After installation of steel doors, windows etc. all abrasions to shop-coat of paint shall be retouched and made good with the same quality of paint in shop coat. All coupling mullions, transoms, frames etc. in contact with adjacent steel and other members shall be well bedded in mastic. Door shutters, partitions, hardware fixtures shall be fixed only after major equipments have been installed in rooms. 6.0.0 HARDWARE AND FIXTURES Hardware and fixtures shall be best quality from the approved manufacturers and able to withstand repeated use. The Contractor has to provide the required number / size of fixture for trouble free operation and adequate strength. Door closers shall be suitable for shutter weight and shall be guaranteed against manufacturing defect for one year and any defect found within this period shall be rectified or the door closer replaced without extra cost to the Owner. The Contractor shall submit samples of each type of hardware to the Engineer-in-charge and the approved samples shall be retained by the Engineer-in-charge for comparison of bulk supply.
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FICHTNER India
SECTION-C4.13 TECHNICAL SPECIFICATION FOR FALSE CEILING AND FALSE FLOORING 1.0.0 SCOPE This specification covers the requirements in respect of materials, workmanship and quality for suspension system and ceiling panels required for false ceiling work and false flooring work. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the contract, shall govern in respect of design, workmanship, quality, and properties of materials and methods of testing. Some of the relevant available codes are listed here under : IS : 848 IS : 1642 IS : 2095 IS : 2441 IS : 3087 IS : 3129 IS : 4671 3.0.0 3.1.0 Synthetic resin adhesives for plywood Code of practice for fire safety of buildings Gypsum plaster boards Code of practice for fixing ceiling coverings Wood particle for fixing ceiling coverings Law density particleboard Expanded polystrene for thermal insulation purposes
MATERIALS Ceiling Panels and False Ceiling Ceiling panels shall be of best quality material in thickness and properties called for in the 'Schedule of Items'. The Contractor shall submit test certificate to the Engineer for approval before bulk supply. The ceiling panels may be manufactured by reputed manufacturers and shall be as follows Perforated aluminium panels Aluminium panels shall be square edged plain panels, 84 mm wide 15 mm deep with 25 mm recessed flanges, formed out of 0.5 mm thick aluminium alloy electrically powder coated in standard colours. LUXALON 80C or approved equivalent shall be used.
3.2.0
Floor Panels for False Flooring Floor panels for false flooring shall be of 35 mm thick particleboard fire retardant type (Novateak or approved equivalent) faced on top with 2 mm thick vinyl P.V.C. tiles having
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antistatic and antiskid quality. The underside of the floor panels shall be provided with two coats of fire resistant paint over a coat of approved primer. The floor panels shall be made of particleboard bonded with phenol formaldehyde and it shall be of fire/termite resistant, moisture proof quality. Each panel shall have PVC clippings on all edges. The floor panels shall be of completely removable type. The false floor should be suitable to take a point load of 450 kg. The clearance under the floor shall be as per drawing, the floor panels shall be cut wherever required for providing suitable outlets for cables etc. 4.0.0 INSTALLATION The contractor shall prepare a layout for false ceiling showing the framing and the cut outs for AC/Electrical fixtures and other services and get the same approved before commencement of work. 4.1.0 4.1.1 Suspension System Suspension system for false ceiling panels Suspension system shall consist of the grid supporting the ceiling panels, intermediate runner supports for the grid if any and hangers, wall angles etc. required to suspend the grid of the runners from structural walls, slabs and beams or trusses. anodized aluminium grid ceiling system from the approved supplier shall be used. All members of the suspension system shall be of sufficient strength and rigidity to carry the ceiling boards or sheets in a true and level plane without exceeding a deflection of 1/360th of their span. Samples of suspension system shall be submitted to the Engineer and approval obtained. Main runners shall be extruded anodized (25 microns) aluminium Tee section of minimum 25 mm 35 mm size. Secondary runners shall be aluminum Tee section of minimum size 25 mm 25 mm. Wall angles shall be of minimum size 38 mm 38 mm. Generally the grid dimensions of 610 mm 610 mm shall be adopted. Angle cleats or other suitable fixing device shall be fixed to the structural beam or slab above for fixing of hangers. Main runners shall be hung by M.S. flats or galvanised tie rod at maximum 1.2 m centres. Extra hangers shall be provided at light fixtures that are supported from the ceiling system. The spacing of main and cross runners shall be to suit the ceiling panel size and as recommended by the supplier. The cross runners shall intersect the main runners at perfect right angles and positively locked together with intersection clips. Cutouts for light fixtures, diffusers etc. shall be the exact dimensions and in exact locations. 4.1.2 Suspension System for Aluminium Panels The panels shall be supported on formed carriers, 15 mm wide at top and 43 mm deep, made out of 0.91 min. thick aluminium alloy electrically powder coated in stain black with protruding cars to hold panels in a module of 100 mm (16 mm gap between the panels) at a maximum spacing of 1.3 metres. Carriers shall be suspended from the slab / roof by 4 mm dia galvanised steelwire/rod hangers with height adjustment suspension springs made out of galvanised spring steel hangers, fixed to slab by J hooks and nylon inserts. Edges of the ceiling shall be trimmed with suitable matching edge profiles to cover the gap between the false ceiling and the walls.
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4.1.3
Supporting arrangement for false flooring The supporting arrangement for false flooring shall consist of pedestal made out of aluminium zinc, alloy rod with check nut into 25 mm. dia O.D. and 17 mm thick base plates. The pedestal shall be fixed on the floor @ 600 mm c/c with araldite (or other approved method (including surface preparation. The pedestal heads will receive main end cross M.S. cold roll formed 40 mm x 40 mm x 3.15 mm thick channels including provision of additional angles 50 x 50 x 6 mm and ISMC 100 at cable entries and sides of well as required. The pedestals will have level adjustments to 25 mm for levelling. Each pedestal shall be able to support a load of 2500 kg without deformation. All steel framework shall be hot dip galvanised.
4.2.0
Fixing of Ceiling and Floor Panels The Contractor shall submit sample panels and get the approval of the Engineer. Installation of ceiling and floor panels shall be strictly as per manufacturer's instruction. The hold down clips for ceiling panels shall be used at the rate of minimum one per 1.2 metre length of perimeter or as per manufacturer's specification. These shall however be omitted in access panels which shall be located as per the instruction of the Engineer. Finished ceiling and floor shall be at the correct plane and present a pleasing and uniform appearance, free from sags, wraps, disfigured or damaged boards. Joints, exposed grids etc. shall be in true lines and symmetrically placed.
5.0.0
ACCEPTANCE CRITERIA Finished ceiling and floor shall be at the correct plane and present a pleasing and uniform appearance, free from sags, warps, disfigured or damaged boards. Joints, exposed grids etc. shall be in true lines and symmetrically placed in manner shown on drawings. Cutouts for light fixtures, diffusers, cable ducts etc. shall be to the exact dimensions and in exact locations.
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SECTION-C4.14 TECHNICAL SPECIFICATION FOR ROAD WORK 1.0.0 SCOPE This specification covers the requirement in respect of materials, workmanship and quality for road work like sub-grade preparation, sub-base layer, water bound macadam, bitumen macadam, premix carpet, concrete roads and pavements, drains, pipe culverts etc. However, for general requirements testing etc. for concrete roads and pavements the technical specification STD-ST-SPC-590-200 (Plain and Reinforced Concrete Works) shall be referred. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by Indian Road Congress and Bureau of Indian Standards shall govern in respect of design, workmanship, quality and properties of materials and methods of testing. Specification for road and bridge works of Ministry of Shipping & Transport (Roads wing) Published by IRC Some of relevant available codes are listed here under. IRC - 19 IRC SP IRC - 47 IRC - 48 IRC - SP - 11 IRC - 15 & 58 IS : 458 IS : 783 IS : 2720 IS : 73 IS : 217 IS : 454
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: : : : : : : : : : : :
Standard specification and code of practice for Water Bound Macadam. 11 Hand Book of quality control for construction of roads and runways. Standard specification and code of practice for bitumen road. Standard specification for bitumen road's surface dressing using pre-coated aggregates. Handbook of quality control for construction for roads and runways. Specification for Concrete Road. Specification fro Concrete Pipes. Code of Practice for Laying of Concrete Pipes. Methods of Test of Soil ( All parts). Specification for paving bitumen. Specification for cut back bitumen. Specification for digboi type cut back bitumen.
FICHTNER India
IS : 1200 (Part-17) IS : 456 IS : 1838 IS : 1834 IS : 6509
: : : : :
Method of measurement for roadwork including air field pavements. Code of Practice for Plain and Reinforced concrete. Specification for Preformed fillers for expansion joints in concrete pavements and structures. Specification for hot applied sealing compounds for joints in concrete. Code of Practice for installation of joints in concrete pavements.
3.0.0 3.1.0 3.1.1
EXECUTION SUB GRADE PREPARATION Excavation After the earthwork in cutting, and the earthwork in embankments have been done properly upto the final road level with gradients and camber as per drawings and proper consolidation of the filling is completed, earthwork in box cutting shall be taken in hand. Before starting of Box cutting, the Contractor shall obtain Engineer's approval of cutting and embankment work. The surface of the formation for a width equal to that of the sub-base course shall be properly prepared before any further courses are laid. Surface shall be cut to a depth below the ground level equal to depth of sub-base course due allowance being made for compaction. Preparation of sub-grade also includes removal of any and all foreign substance accumulation and removing undulations upto 150 mm by filling and cutting as required. The sub-grade shall be dressed parallel to the finished profile. The excavated spoils shall be transported and utilized in filling of low areas or as directed by the Engineer. The filling shall be done in layers or as directed by the Engineer. The filling shall be done in layers of 150 mm and clods and lumps shall be broken and consolidation done to the satisfaction of the Engineer. In case of presence of weak soil-pockets below the formation, the Contractor shall excavate and remove such soil to an extent as instructed by the Engineer. extra depth shall then be filled up with 38 mm down stone-metal and voids in metal shall be filled up with moorum. Then, the filling shall be rammed and rolled uniformly with a road-roller of 8 tonnes minimum weight. These operations of removing week soil pockets and filling with stone metal shall be done by the Contractor and paid at the earthwork rates plus the cost of stone metal only. If, by mistake the depth of box cutting is made more than required, the Contractor shall make up the extra depth by metal consolidation, as specified above, at his own cost.
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After the top layer/WBM course is laid and compacted, the existing surface at the shoulders of the road must be scarified. Fresh quantity of approved earth must be extracted from the surplus earth obtained by box cutting spreading in layers for building up the berms. The layer of earth must be compacted by at least three passes of 8 - 10 tonne rollers. The edges must be well compacted by suitable means to prevent edge slips and the work properly trimmed and dressed. 3.1.2 Rolling After the box cutting is completed, the sub grade shall be compacted with powered road roller 8-12 tonnes. The roller shall run over the sub grade till the soil is evenly and densely compacted, to achieve a dry density of not less than 95% of maximum density as obtained from standard proctor compaction test. There shall be a minimum of five (5) roller passes. All the undulations on the surface, which develop due to rolling, shall be made good with earth and quarry spills as approved by Owner and the sub grade re-rolled. The top of the sub grade shall be dressed evenly to the required camber and necessary drainage arrangement at the time of rolling shall be provided. Care shall be taken to avoid excessive rolling of the formation. If, after rolling, the formation is higher than required, the excess earth shall be removed by carefully cutting and dressing and the formation shall be rolled as specified above. In case after rolling the formation is depressed below the required level, the Contractor shall continue the process of filling and rolling as above till the correct level is attained upto a limit as decided by the Engineer at Contractor's cost. 3.2.0 3.2.1 Soling (Sub-base) Description This work shall consist of laying and compacting rubbles or boulders on prepared sub grade in accordance with the requirements of these specifications. The material shall be laid in one or more layers as shown on the drawings and according to lines, grades and cross sections shown on the drawings or as directed by the Engineer. 3.2.2 Materials The materials to be used for the work shall be rubbles or boulders and gravel from approved quarries. The maximum size of stone shall be 150 mm. The length and breath of stone shall not be more than twice of its depth. The stones shall be hard, tough and durable and free of earth, loam or vegetable matter. The flaky material shall not be used. 3.2.3 Spreading and Compacting The soling shall be laid as per the cross section as shown on the drawing and the finished thickness after consolidation shall be as directed by the Engineer. The boulders shall be laid flat with their broad faces resting over the sub grade to have good seating. The stones shall be hand packed as close as possible and bedded firmly. The voids in the soling shall be filled with stone chips and small stones and hammered and wedged into position. Gauge pegs shall be driven in to indicate the thickness of the stones to be laid. Any hollows formed during rolling shall be filled in with spills during the process of consolidation so as to conform with the gradient, camber and cross section of the road and leave an even finished solid surface.
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The soling shall be rolled by a 8 to 12 tons power roller after blinding with approved quality moorum. The shoulder shall be rolled first to wedge the stones firmly at the edges and then rolling shall proceed towards the centre. The rolling shall be done longitudinally at the shoulder and worked towards the centre of the pavement overlapping on each successive trip by at least one-half of the width of the roller while starting and 300 mm width while finishing. In case of super elevated strips, the rolling shall commence from the inner edge and proceed towards the outer edge. The roller shall be operated at the lowest speed possible. The speed in any case shall not be greater than 3 km per hour. Rolling shall be continued till a satisfactory surface is obtained. Wherever use of power roller is not feasible, suitable hand roller may be used as per instructions of the Engineer. 3.2.4 Bad Workmanship The soling if not done as per the specification, if instructed by the Engineer, the whole soling over the defective portion shall be taken out, re-laid and compacted with a road roller as specified earlier, by the Contractor at his own cost. 3.3.0 3.3.1 Sand-Gravel Sub-base Description The work shall consist of laying and compacting of a mix of sand and gravel in specified proportion over a prepared sub-grade to the required lines, grades and cross-section in layers as per requirement of this specification. 3.3.2 Materials Sand Sand shall be medium hard, strong, free from organic and deleterious matter and shall be from a source approved by the Engineer. Sea sand shall not be approved. Gravel Gravel shall be clean, well graded and free from any vegetation organic clay or other materials and shall be from a source approved by the Engineer. GRADING FOR GRANULAR SUB-BASE MATERIALS Sieve Designation 80 mm 63 mm 4.75 mm 75 micron CBR Value (Minimum) for fraction of material passing 20 mm sieve
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Percent by Weight passing Grading 1 100 90-100 35-70 0-20 30% Grading 2 100 90-100 40-90 0-25 25% Grading 3 100 90-100 50-100 0-30 20%
FICHTNER India
3.3.3
Mixing, Spreading and Compacting The sand and gravel shall be mixed thoroughly in specified proportions by approved means. The moisture content shall be brought to within two (2) percent of the optimum moisture content for the mixed materials as per IS : 2720 part viii. The sand gravel mix shall be spread over the prepared sub-grade in layer not exceeding 200 mm thick (uncompacted thickness) and compacted by power rollers (8-10 tonnes) to achieve a field dry density of 90 percent of maximum proctor laboratory dry density. The layer shall be compacted to the required camber, slope and line. Further layer shall be placed only after the layer already laid has been compacted to the required density and approved by the Engineer based on the test results. The finished surface shall be dressed to required camber and level and excess material removed and disposed off by the Contractor at his own cost as instructed by the Engineer.
3.4.0 3.4.1
Water Bound Macadam (Sub-base/Base Course) Description Water bound macadam shall consist of clean, crushed aggregates mechanically interlocked by rolling and bonded together with screenings, binding material, where necessary and water, laid on a prepared sub grade or sub-base, as the case may be, and finished in accordance with the requirements of these specifications and in conformity with the lines, grades and cross-sections shown on the drawings or otherwise directed by the Engineer.
3.4.2
Materials Coarse Aggregate Coarse aggregate and shall be of crushed blue granite. Aggregate shall be hard and durable and shall be free from excess of flat, elongated, soft and disintegrated particles, dirt and other objectionable matter and shall be from a source approved by the Engineer. Crushed aggregate shall meet the following requirements :PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WATER BOUND MACADAM Type of Test Test Method Requirements Construction 60% max Sub-base Los Angeles Abrasion Value* IS:2386 (Part IV) or 50% max Aggregate Impact Value IS:2386 (Part IV) Or IS:5640 ** 50% max IS:2386 (Part IV) Base a) Los Angeles Abrasion Value * 40% max IS:2386 (Part IV) or Or Aggregate Impact Value IS:5640 ** b) Flakiness Index *** IS:2386 (Part I) 15% max
FICHTNER India
Sl. No. 1.
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Aggregate may satisfy requirements of either of the two tests.
** Aggregates like brick metal, kankar and laterite which get softened in presence of water, shall be tested for impact value under wet conditions in accordance with IS:5640. *** The requirements of flakiness index shall be enforced only in case of crushed or broken stone and crushed slag.
GRADING REQUIREMENTS OF COARSE AGGREGATES Grading No. 1. Size Range 90 mm to 40 mm Sieve Designation 100 mm 80 mm 63 mm 40 mm 20 mm 2. 63 mm to 40 mm 80 mm 63 mm 50 mm 40 mm 20 mm 3. 50 mm to 20 mm 63 mm 50 mm 40 mm 20 mm 10 mm Percent by weight passing the sieve 100 65-85 25-60 0-15 0-5 100 90-100 35-70 0-15 0-5 100 95-100 35-70 0-10 0-5
Following test shall be conducted on samples of aggregate : i) Sieve analysis ii) Impact tests iii) Water absorption test iv) Wetting and drying test Screenings Screenings shall generally be of same material as the coarse aggregate and meet the following gradings :
Maximum water absorption shall be 1% The samples shall be subjected to alternate wetting and drying for 3 days and shall not show signs of disintegration.
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GRADINGS FOR SCREENINGS Grading Classification A Size of Screenings 12.5 mm Sieve Designation 12.5 mm 10.0 mm 4.75 mm 150 micron B 10 mm 10 mm 4.75 mm 150 micron Percent by weight passing the sieve 100 90-100 10-30 0-8 100 85-100 10-30
Where drawing/Schedule of items specify non-plastic material like moorum is specified, the liquid limit and plastic limit of such material shall be below 20 and 6 respectively and the fraction passing 75 microns sieve shall not exceed 10%. Binding Materials Gravel of suitable plasticity available from local quarries may be used as binding materials and the same shall be approved by the Engineer. When sample of the binding material is wetted and squeezed in hand the following characteristics shall be noted : i) ii) iii) 3.4.3 The material shall be extremely gritty. It can be formed into definite shapes that retain their form even when dried. When the wetted sample is patted in the palm of the hand it will compact into a dense cake that cannot be penetrated easily with a blunt stick.
Construction Operation
3.4.3.1 Preparation of Base The sub grade /sub-base to receive the water bound macadam coarse shall be prepared to the specified grade and camber and made free of dust and other extraneous material. Any ruts or soft yielding places shall be corrected in an approved manner and rolled until firm. Where water bound macadam is to be laid until firm. 3.4.3.2 Inverted Choke Intentionally omitted. 3.4.3.3 Spreading Coarse Aggregate The coarse aggregates shall be spread uniformly upon the prepared surface. The spreading shall be done from stockpiles along the side of the roadway or directly from vehicles. In no case shall the aggregate be dumped in heaps directly on the surface prepared to receive
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the aggregate nor shall hauling over the uncompacted or partially compacted base be permitted. The surface of the aggregates spread shall be carefully checked with template and all high or low spots remedied by removing or adding aggregate as may be required. No segregation of large or fine particles shall be allowed and the coarse aggregate as spread shall be of uniform gradation with the pockets of fine material. The coarse aggregate shall not normally be spread more than three (3) days in advance of the subsequent construction operations. 3.4.3.4 Rolling Immediately following the spreading of the coarse aggregate, rolling shall be started with three wheeled power rollers of 8 to 10 tonne capacity or tandem roller or vibratory rollers of approved type. The weight of the roller depends upon the type of the aggregate and be indicated by the Engineer. Except on superelevated portions where the rolling shall proceed from inner edge to the outer, rolling shall begin from the edges gradually progressing towards the centre. First the edge/ edges shall be compacted with roller running forward and backward. The roller shall then move inwards parallel to the centre line of the road, in successive passes uniformly lapping preceding tracks by at least one half width. Rolling shall continue until the aggregates are thoroughly keyed and the creepage of aggregates ahead of the roller is no longer visible. During rolling slight sprinkling of water may be done, if necessary. Rolling shall not be done when the sub grade is soft or yielding or when it causes as wave-like motion in the sub grade or sub-base course. Wherever use of power roller is not feasible, suitable hand roller may be used as per the instructions of the Engineer. The rolled surface shall be checked transversely and longitudinally with templates. If irregularities noticed, which exceed 12.5 mm when tested with a 3m straight edge, the surface shall be loosened and aggregates added or removed as required and re-rolled until the entire surface conforms to desired camber and grade. In no case shall use of screenings be permitted to make up depressions. 3.4.3.5 Applications of Screenings After the coarse aggregate has been rolled, screenings to completely fill the interstices shall be applied gradually over the surface. These shall not be damp or wet at the time of application. Dry rolling shall be done while the screenings are being spread so that vibrations of the roller cause them to settle into the voids of the coarse aggregate. The screenings shall not be dumped in piles but be spread uniformly in successive thin layers either by the spreading motion of hand shovels or by mechanical spreaders, or directly from trucks. Trucks operating for spreading the screenings shall be so driven as not to disturb the coarse aggregate. The screenings shall be applied at a slow and uniform rate (in three or more application) so as to ensure filling of all voids. This shall be accompanied by dry rolling and brooming with mechanical brooms, handbrooms or both. In no case shall the screenings be applied
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so fast and thick as to form cakes or ridges on the surface in such a manner as would prevent filling of voids or prevent the direct bearing of the roller on the coarse aggregate. These operations shall continue until no more screenings can be forced into the voids of the coarse aggregate. The spreading, rolling and brooming of screenings shall be carried out in only such lengths of the road, which would be completed within one day's operation. 3.4.3.6 Sprinkling and Grouting After the screenings have been applied, the surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be used to sweep the wet screenings into voids and to distribute them evenly. The sprinkling, sweeping and rolling operations shall be continued, with additional screening as necessary, until the coarse aggregate has been thoroughly keyed, well-bonded and firmly set in its full depth and a grout has been formed of screening. Care shall be taken to see that the base or sub grade does not get damaged due to the additional of excessive quantities of water during construction. 3.4.3.7 Application of Binding Material After the application of screenings, the binding material gravel with plasticity index less than six (6) -where it is required to be used shall be applied successively in two or more thin layers at a slow and uniform rate. After each application, the surface shall be copiously sprinkled with water, the resulting slurry swept in with hand brooms, or mechanical brooms to fill the voids properly, and rolled during which water shall be applied to the wheels of the rollers if necessary to wash down the binding material sticking to them. These operations shall continue until the resulting slurry after filling of voids, forms a wave ahead of the wheels of the moving roller. 3.4.3.8 Setting and Drying After the final compaction of water bound macadam course, the road shall be allowed to dry overnight. Next morning hungry spots shall be filled with screenings or binding materials as directed, lightly sprinkled with water if necessary and rolled. No traffic shall be allowed on the road until the macadam has set. The Engineer shall have the discretion to stop hauling traffic from using the completed water bound macadam course if in his opinion it would cause excessive damage to the surface. 3.4.3.9 Second Layer of WBM (where specified) Before laying the second layer of WBM, the surface shall be scarified and reshaped to the required camber and profiles and all ruts, depressions, potholes etc. made good. The second layer shall be laid after the surface preparation is approved by the Engineer. The specification for second layer of WBM shall be similar to the first. 3.5.0 3.5.1 Tack Coat ( for Bitumen Roads ) Description The work shall consist of application of a single coat of low viscosity liquid bituminous material to an existing road surface preparatory to another bituminous construction.
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3.5.2
Materials Binder : The binder used for tack coat shall be bitumen of a suitable grade as directed by the Engineer and conforming to IS : 73, 217 or 454, as applicable, or any other approved cutback.
3.5.3
Construction Operations
3.5.3.1 Preparation of Base The surface on which the tack coat is to be applied shall be thoroughly swept and scraped clean of dust and any other extraneous material before the application of the binder. 3.5.3.2 Application of Binder Binder shall be heated to the temperature appropriate to the grade of bitumen used and approved by the Engineer and sprayed on the base at the rate specified below. The rate of spread in terms of straight-run bitumen shall be 5 kg. per 10 sqm area for an existing bitumen treated surface and 10 kg per 10 sqm area for an untreated water bound macadam surface. The binder shall be supplied uniformly with the aid of sprayers. The tack coat shall be applied just ahead of the oncoming bituminous construction. 3.6.0 3.6.1 Bituminous Macadam Binder Course Description This work shall consist of construction, in a single course, of 50 mm / 75 mm thickness of compacted crushed aggregates premixed with a bituminous binder, laid immediately after mixing, on a base prepared previously in accordance with the requirements of these specifications and in conformity with the lines, grades and cross sections shown on the drawings or directed by the Engineer. 3.6.2 Materials
3.6.2.1 Binder The binder shall be straight run bitumen of a suitable grade as directed by the Engineer complying with IS : 73. 3.6.2.2 The aggregates shall satisfy the physical requirements set forth in Table-I. TABLE I PHYSICAL REQUIREMENTS OF AGGREGATES FOR BITUMINOUS MACADAM Los Angeles Abrasion * Aggregate Impact Value * Flakiness Index Stripping Value Water Absorption value *
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IS : 2386 IS : 2386 IS : 2386 IS : 6241 IS : 2386
35% Maximum (Part IV) 30% Maximum (Part IV) 35% Maximum 25% Maximum 2% Maximum
Aggregates may satisfy requirements of either of the two tests

FICHTNER India
The aggregates for bituminous macadam for different thickness shall conform to the grading A or B given in Tables II & III. TABLE II AGGREGATES GRADING FOR 75 MM COMPACTED THICKNESS OF BITUMINOUS MACADAM SIEVE DESIGNATION 63 mm 50 mm 40 mm 25 mm 20 mm 12.5 mm 4.75 mm 2.36 mm 75 micron PERCENT BY WEIGHT PASSING THE SIEVE Grading A Grading B 100 -90 - 100 -35 - 65 100 20 - 40 70 - 100 -50 - 80 5 - 20 --10 - 30 -5 - 20 0-5 0-4 TABLE III AGGREGATES GRADING FOR 50 MM COMPACTED THICKNESS OF BITUMINOUS MACADAM SIEVE DESIGNATION 50 mm 50 mm 40 mm 25 mm 20 mm 12.5 mm 4.75 mm 2.36 mm 75 micron 3.6.2.3 Proportioning of Materials The binder content for premixing shall be 3.5 and 4.0 percent by weight of the total mix for aggregate grading A and B respectively, except when otherwise directed by the Engineer. The quantities of aggregates to be used shall be sufficient to yield the specified thickness after compaction. PERCENT BY WEIGHT PASSING THE SIEVE Grading A Grading B 100 -90 - 100 -90 - 100 -50 - 80 100 -70 - 100 10 - 30 --15 - 35 -5 - 20 0-5 0-4
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3.6.2.4 Variation in Proportioning of Materials The Contractor shall have the responsibility for ensuring proper proportioning of materials and producing a uniform mix. A variation in binder content of 0.3 percent by weight of total mix shall, however, be permitted for individual specimens taken for quality control tests. 3.6.3 Construction of Operation
3.6.3.1 Weather and Seasonal Limitations Bituminous macadam shall not be laid during rainy weather or when the base course is damp or wet. 3.6.3.2 Preparation of Base The base on which bituminous macadam is to be laid shall be prepared, shaped and conditioned to the specified lines, grade and cross sections as directed by the Engineer. The surface shall be thoroughly swept and scraped clean and free from dust and foreign matter. 3.6.3.3 Tack Coat A tack coat shall be applied over the base. 3.6.3.4 Preparation and Transport of Mix. Hot mix plant of adequate capacity shall be used for preparing the mix. The temperature of binder at the time of mixing shall be in the range 150 Deg. - 165 Deg. C and that of aggregates in the range 125 Deg. - 150 Deg C provided that the difference in temperature between the binder and aggregate at no time exceed 25 Deg C. Mixing shall be thorough to ensure that the homogenous mixture is obtained in which all particles of the aggregates are coated uniformly. The mixture shall be transported from the mixing plant to the point of use in suitable vehicles. The vehicles employed for transport shall be clean and be covered over in transit if so directed by the Engineer. 3.6.3.5 Spreading The mix shall be spread immediately after mixing by means of a self propelled mechanical paver with suitable screeds capable of spreading, tamping and finishing the mix to the specified lines, grade and cross sections. However, in restricted locations and in narrow widths, where the available plants cannot operate in the opinion of the Engineer, he may permit manual laying of the mix. The temperature of mix at the time of laying shall be in the range 110- 135 C.
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In multi-layer construction, the longitudinal joint in one layer shall offset that in the layer below by about 150 mm. However, the joint in the topmost layer shall be at the centerline of the pavement. Longitudinal joints and edges shall be constructed true to the delineating lines parallel to the centerline of the road. All joints shall be cut vertical to the full thickness of the previously laid mix and the surface painted with hot bitumen before placing fresh material. 3.6.3.6 Rolling After the spreading of mix, rolling shall be done by 8 to 10 tonne power rollers or other approved plant. Rolling should start as soon as possible after the material has been spread. Rolling shall be done with care to keep from unduly roughening the pavement surface. Rolling of the longitudinal joint shall be done immediately behind the paving operations. After this, the rolling shall commence at the edges and progress towards the center longitudinally except that on super-elevated portions, it shall progress from the lower to the upper edge parallel to the centerline of the pavement. The initial or breakdown rolling shall be done as soon as it is possible to roll the mixture without cracking the surface or having the mix pick up on the roller wheels. The second or intermediate rolling shall follow the breakdown rolling as closely as possible and be done while the paving mix is still at a temperature that will result in maximum density. The final rolling shall be done while the material is still workable enough for removal of roller marks. When the roller has passed over the whole area once, any high spots or depressions, which become apparent shall be corrected by removing or adding fresh material. The rolling shall then be continued till the entire surface has been rolled to compaction, there is no crushing of aggregate and all roller marks have been eliminated. Each pass of the roller shall uniformly overlap not less than one third of the track made in the preceding pass. The roller wheels shall be kept damp if necessary to avoid the bituminous material from sticking to the wheels and being picked up. In no case shall fuel-lubricating oil be used for this purpose. Rolling operations shall be completed in every respect before the temperature of the mix falls below 80C. Rollers shall not stand on newly laid material while there is a risk that it will be deformed thereby. The edges along and transverse of the bituminous macadam laid and compacted earlier shall be cut to their full depth so as to expose fresh surface which shall be painted with a thin surface coat of appropriate binder before the new mix is placed against it. Wherever use of power roller is not feasible, suitable hand roller may be used as per the instructions of the Engineer. The bituminous macadam shall be provided with final surfacing without any delay. If there is to be any delay, the course shall be covered by a seal coat before allowing any traffic over it.
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3.7.0 3.7.1
Open Graded Premix Carpet Description This work shall consist of laying and compacting an open-graded carpet of 2 cm thickness in a single course composed of suitable small sized aggregates premixed with a bituminous binder on a previously prepared base, to form a wearing course, in accordance with the requirements of these specifications.
3.7.2
Materials
3.7.2.1 Binder The binder shall be bitumen of a suitable grade, as directed by the Engineer and satisfying the requirements of IS : 73, 217, 454 or other approved cutback as applicable. 3.7.2.2 Aggregate The aggregate shall consist of angular fragments of clean, hard, tough and durable rock of uniform quality throughout. They shall be obtained by crushing rock and be free of elongated and flaky pieces, soft and disintegrated materials and vegetable or other deleterious matter. They shall preferably be hydrophobic type. The aggregates shall satisfy the quality requirements set forth in Table I except that the Flakiness Index shall be limited to a maximum of 30%. 3.7.2.3 Proportioning of Materials The materials shall be proportioned as per quantities given in Table IV. TABLE IV QUANTITIES OF MATERIALS REQUIRED FOR 10 SQM. OF ROAD SURFACE FOR 2 CM THICK OPEN-GRADED PREMIX CARPET Aggregates of carpet a) b) Stone chippings - 12 mm size; passing 20 cm sieve and retained on 10 mm sieve Stone chippings - 10 mm size; passing 12.5 mm sieve and retained on 6.3 mm sieve 0.18 cum 0.09 cum
Binder for premixing (quantities in terms of straight run bitumen) a) b) For 0.18 cum of 12 mm size stone chippings at 52 kg per cum For 0.09 cum of 10 mm size stone chippings at 56 kg per cum Total 9.5 kg 5.1 kg ---------14.6 kg ----------
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3.7.3
Construction Operation
3.7.3.1 Weather and Seasonal Limitations Open graded premix carpet shall not be laid during rainy weather or when the base course is damp wet or when the atmospheric temperature in shade is 16 deg C or below : 3.7.3.2 Preparation of Base The underlying base on which the bituminous carpet is to be laid shall be prepared, shaped and conditioned to the specified lines, grade and cross section in accordance with Table V or as directed by the Engineer. The surface shall be well cleaned by removing caked earth and other foreign matter with wire brushes, sweeping with brooms and finally dusting with sacks as necessary. 3.7.3.3 Tack Coat A tack coat complying with clause 3.5.0 shall be applied over the base preparatory to laying of the carpet. Application of tack coat shall, however, not be necessary when the laying of carpet follows soon after the provision of the bituminous course. 3.7.3.4 Preparation of Premix Mixers of approved type shall be employed for mixing the aggregates with the bituminous binder. The binder shall be heated to the temperature appropriate to the grade of bitumen approved by the Engineer, in boilers of suitable design avoiding local overheating and ensuring a continuous supply. The aggregates shall be dry and suitably heated to a temperature as directed by the Engineer before these are placed in the mixer. After about 15 seconds of dry mixing, the heated binder shall be distributed over the aggregates at the rate specified. The mixture of binder with chipping shall be continued until the chippings are thoroughly coated with the binder. The mix shall be immediately transported from the mixer to the point of use in suitable vehicles or wheelbarrows. The vehicles employed for transport shall be clean and be covered over in transit if so directed. 3.7.3.5 Spreading and Rolling The premixed material shall be spread on the road surface with rakes to the required thickness and camber or distributed evenly with the help of a drag spreader, without any undue loss of time. The camber shall be checked by means of camber boards and inequalities evened out. As soon as sufficient length of bituminous material has been laid rolling shall commence with 8 to 10 tonne power rollers, preferably of smooth wheel tandem type, or other approved plant. Rolling shall begin at the edges and progress toward the centre longitudinally, except that on the superelevated portions it shall progress from the lower to upper edge parallel to the centreline of the pavement.
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When the roller has passed over the whole are once, any high spots or depressions, which become apparent shall be corrected by removing or adding premixed materials. Rolling shall then be continued until the entire surface has been rolled to compaction and all the roller marks eliminated. In each pass of the roller preceding track shall be overlapped uniformly by at least 1/3 width. The roller wheels shall be kept damp to prevent the premix from adhering to the wheels and being picked up. In no case shall fuel/lubricating oil be used for this purpose. Wherever use of power roller is not feasible, suitable hand roller may be used as per the instructions of the Engineer. Rollers shall not stand on newly laid material while there is a risk that it will be deformed thereby. The edges along and transverse of the carpet laid and compacted earlier shall be cut to their full length so as to expose fresh surface which shall be painted with a thin surface coat of appropriate binder before the new mix is placed against it. 3.7.3.6 Seal Coat A seal coat conforming to clause 3.8.0 shall be applied to the surface immediately after laying the carpet. No traffic shall be allowed on the road till the seal coat has been placed. 3.8.0 3.8.1 Seal Coat Description This work shall consist of application of a seal coat for sealing the voids in a bituminous surface laid to the specified levels, grade and camber. Seal coat shall be either of the two types, as specified below : Type A : Liquid seal coat comprising of an application of the bituminous binder followed by a cover of stone chippings. Type B : Premixed seal coat comprising of a thin application of fine aggregate premixed with bituminous binder. 3.8.2 Materials
3.8.2.1 Binder The Bidder shall be bitumen of a suitable grade as directed by the Engineer and conforming to the requirements of IS : 73, 217, 454 as applicable or any other approved cutback. The quality of binder to be utilized, in terms of straight run bitumen shall be 9.8 kg and 6.8 kg per 10 sqm area for Type A and Type B seal coat respectively. 3.8.2.2 Stone Chippings for Type A Seal Coat The stone chippings shall consist of angular fragments of clean, hard, tough and durable rock of uniform quality throughout. They shall be free of elongated or flaky pieces, soft or disintegrated stone, vegetable or other deleterious matter. Stone chippings shall be of 6
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mm size defined as 100 percent passing through 10 mm sieve and retained on 2.36 mm sieve. The quantity used for spreading shall be of 0.09 cum. per 10 sqm area. The chippings shall satisfy the quality requirements spelled out in Table I except that the upper limit for flakiness Index shall be 30%. 3.8.2.3 Fine Aggregate for Type B Seal Coat The fine aggregate shall be sand or fine grit and shall consist of clean, hard, durable, uncoated dry particles and shall be free from dust, soft or flaky material, organic matter or other deleterious substances. The aggregate shall pass 1.7 mm sieve and be retained on 180 micron sieve. The quantity used for premixing shall be 0.06 cum. per 10 sqm. area. 3.8.3 Construction Operations
3.8.3.1 Preparation of Base The seal coat shall be applied immediately after the laying of bituminous course, which is required to be sealed. Before application of seal coat materials the surface shall be cleaned free of any dust or other extraneous matter. 3.8.3.2 Construction of Type A Seal Coat The binder shall be heated in boilers of suitable design, to the temperature appropriate to the grade of bitumen approved by the Engineer and sprayed on the dry surface in a uniform manner preferably with the help of mechanical sprayers. Excessive deposits of binder caused by stopping or starting of the sprayer or through leakage of any other reason shall be suitably corrected before the stone chippings are spread. Immediately after the application of binder, stone chippings in a dry and clean state, shall be spread uniformly on the surface, preferably by means of a mechanical gritter, otherwise manually so as to cover the surface completely. If necessary, the surface shall be broomed to ensure uniform spread of chippings. Immediately after the application of the cover material, the entire surface shall be rolled with a 8 - 10 tonne smooth wheeled roller. Rolling shall commence at the edges and progress towards the center except in super elevated portions where it shall proceed from the inner edges to the outer. Each pass of the roller shall uniformly overlap not less than one third of the track made in the preceding pass. While rolling is in progress additional chippings shall be spread by hand in whatever quantities required to make up irregularities. Rolling shall continue until all aggregate particles are firmly bedded in the binder and present a uniform closed surface. 3.8.3.3 Construction of Type B Seal Coat Mixers of approved type shall be employed for mixing the aggregates with the bituminous binder. The binder shall be heated in boilers of suitable design, to the temperature appropriate to the grade of bitumen approved by the Engineer. Also the aggregates shall be dry and suitably heated to a temperature directed by the Engineer before the same are placed in the mixer. Mixing of binder with aggregates to the specified proportions shall be continued till the later are thoroughly coated with the former. The mix shall be immediately transported from the mixing plant to the point of use and spread uniformly on the bituminous surface to be sealed.
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As soon as sufficient length has been covered with the premixed material, the surface shall be rolled with 8 - 10 tonne smooth wheeled power rollers. Rolling shall be continued till the premixed material completely seals the voids in the bituminous course and a smooth uniform surface is obtained. Wherever use of power roller is not feasible suitable hand roller may be used as per the instructions of the Engineer. 3.8.4 Opening to Traffic In the case of Type B seal coat, traffic may be allowed soon after final rolling when the premixed material has cooled down to the surrounding temperature. However, as regards Type A seal coat traffic shall not be permitted until the following day. 3.9.0 3.9.1 CONCRETE ROADS AND PAVEMENTS MATERIALS
3.9.1.1 Ordinary Portland cement This should comply with the requirements of IS : 269, IS : 455 or IS : 1489. 3.9.1.2 Aggregates (General) Aggregates should comply with the requirements of IS : 389 - Specification for coarse and fine aggregates from natural sources for the concrete work. In order to make good the concrete for roadwork it is important to avoid crushed aggregates of poor particle shape. Weather rock, and very angular, flaky or splintery aggregates should not be used. 3.9.13 Coarse aggregates This should be furnished in at least two separate sizes with separation at 20 mm when combined material graded from 5 to 38 mm is specified and at 25 mm when combined material graded from 20 to 50 mm is specified. Gap graded single sized coarse aggregate as alternate to the continuously graded may be used particularly where grading of fine aggregate is fine to very fine. 3.9.1.4 Fine aggregate Fine aggregate shall be natural sand and should comply with IS : 383. Bulking due to presence of moisture in the fine aggregate should be accounted for when the volumetric batching is employed. 3.9.1.5 Water Water used in mixing or curing of concrete shall be clean and of potable quality.
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3.9.1.6 Reinforcement Bar mats This shall conform to the requirements of IS : 432/IS : 1786/IS : 1139. The bars shall be of the size and spacing shown on the plans. All junctions of longitudinal and transverse bars shall be securely tied or welded together. Load transfer devices Dowel and tie bars shall be of plain round steel bars conforming to the requirements of IS:432. 3.9.1.7 Expansion joint filler The material for filling the expansion joints shall be of premoulded, non-extruding and resilient type of approved quality. The premoulded joint filler shall be of thickness shown on the drawings or as stated in the bill of quantities. It shall be 25 mm less in depth than the thickness of the slab and of the full width between road forms. Holes to accommodate dowel bars shall be bored or punched out accurately. The joint filler shall comply with the requirements of IS:1838 - Specification for Preformed Fillers for Expansion Joints in concrete, non-extruding and resilient type (bitumen impregnated fiber). 3.9.1.8 Joint sealing compound The sealing compound shall comply with the requirements of IS:1834 - Specification for Hot Applied Sealing Compound for joints in concrete. 3.9.1.9 Waterproofing under layer Waterproofing paper used as under layer be of a brand of approved quality. The paper shall be unrolled with an order lap of not less than 10 cm. 3.9.1.10 Forms All side forms shall be of mild steel unless use of wooden sections is specifically permitted. The steel forms shall be of M.S. channel sections and their depth equal to the thickness of the pavements. The sections shall have a length of at least 3 m except on curves where shorter sections may be used. Side shuttering shall be provided at curves as per the drawings or as directed. When set to grade and staked in place, the maximum deviation of the top surface of any section from a straight line shall not exceed 3 mm in vertical plane and 5 mm in horizontal plane. The method of connection between sections shall be such that the joint formed shall be free from movement in any direction. The use of bent, twisted or worn out forms shall not be permitted. At least 3 stake pockets for bracing pins or stakes shall be provided for each 3 m of form and the bracing and support must be ample to prevent the springing of the forms under pressure of the concrete, or the weight of machinery operating on the forms. Contractor shall arrange for sufficient number of forms so that the forms in position are not disturbed within 12 hours of concreting or longer if in the opinion of the Engineer it would be necessary.
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3.10.0 Construction Operations 3.10.1 Form setting Forms shall be jointed neatly and shall be set with exactness to the required grade and alignment. After the forms are placed and aligned, the earth under the base of the form shall be thoroughly damped in an approved manner. Sufficient rigidity shall be obtained to support the forms in such a position during the entire operation of compaction and finishing. All forms shall be cleaned and oiled each time before they are used. 3.10.2 Placing of reinforcements The overall dimensions of the bar mats shall be such that when properly placed into the work, the extreme longitudinal wires of the mat shall be located not less than 50 mm nor more than 100 mm from the edges of the slab. Except for dummy joints, the length of the bar mat shall be such that when properly placed into the work, the reinforcement shall be clear of transverse joints by not less than 50 mm and not more than 100 mm when measured from the centre of the joint to the ends of the longitudinal wire of the fabric. While overlapping the bar mats in either direction, the overlap shall be at least equal to the spacing between the bars in the respective direction. The bar mats shall be placed in position as shown on the drawings. For placing the top layer of the reinforcement, the first stage of concreting shall be brought upto the level of the reinforcement and lightly compacted by a screed vibrator to obtain uniform level. The reinforcement bar mats shall then be placed on the compacted layer of the concrete and then the remaining depth shall be filled in with concrete. The time lag between laying of the two courses shall not exceed the initial setting time of the cement used. Displacement of the reinforcement during concreting operation shall be prevented. 3.10.3 Fixing dowel bars The dowel bars in expansion joints and transverse construction joints shall be placed and supported in such a manner that they shall be truly parallel with the gradient and the centreline to the pavement, and they shall remain in position during the placement and compaction of the concrete. They shall be placed at the mid depth of the slab and the drawings. Half-length of the dowel bars shall be painted with one coat of hot bitumen of approved make or equivalent as shown on the drawings or as directed by the Engineer. 3.10.4 Fixing tie bars Tie bars in longitudinal joints shall be placed approximately the mid depth of the slab and shall be securely held in the slabs on both sides of the joints. 3.10.5 Transporting and placing of concrete The concrete shall be mixed in quantities required for immediate use and shall be deposited in position to the required depth and width of the pavement, sections, in successive batches and in continuous operation without the use of intermediate forms or bulk continuous between joints. The spreading shall be as uniform as possible to avoid rehandling of concrete.
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3.10.6 Compaction and finishing The surface of the pavement shall be compacted either by means of power driven finishing or by a vibration screed. For areas where the width of the slab is very small, hand compaction and finishing may be adopted. Immediately after the tamping or screeding has been completed and before the concrete has hardened the surface shall be inspected for irregularities with a profile checking template and any needed corrections made by adding or removing of concrete followed by further compaction and finishing. 3.10.7 Floating As soon as practicable after the concrete has been struck off and a compacted it shall be further smoothened and compacted by means of longitudinal float operation from a foot bridge. 3.10.8 Straight edging After the longitudinal float has been completed and excess water has disappeared but while the concrete is still plastic, the slab surface shall be tested for trueness with a 3 m straight edge swung from handles 1 m longer than one half width of the slab. Any depressions found shall be filled immediately with freshly mixed concrete, struck, compacted and refinished. High areas shall be cut down and refinished. The Contractor shall include the removal of the rejected concrete and for laying of the fresh concrete in his lump sum price. Unless otherwise specified, and for laying of the pavement surface shall be obtained by belting or brooming or by a combination of both as directed by the Engineer. 3.10.9 Edging After belting and/or brooming has been completed, but before the concrete has taken its initial set, the edges of the slab shall be carefully finished with a edger of 6 mm radius and the pavement edge shall be left smooth and true to line. 3.11.0 JOINTS 3.11.1 Expansion Joints : Expansion joints shall be formed at the intervals shown on the drawing at right angles of the longitudinal axis of the pavement. The width of the joint shall be as shown on the drawing and shall be straight, truly vertical and shall extend from the bottom of the slab. The expansion joint shall be filled with an approved pre-moulded joint filler, which shall extend from the bottom of the slab to 25 mm below the finished surface of the concrete. A timber or metal cap shall be fitted temporarily on the top of the joint filler and the top of this cap shall be flush with the finished surface. Care shall be taken that filler and the cap are set accurately in position and are maintained in position during placing and compaction of concrete. After the pavement has been struck off and finished the metal cap shall be removed. Under no circumstances shall any concrete be left above the expansion joint material or across the joint at any point. After about 15 days of concreting the cavity on the top of the joint filler shall be carefully cleaned of all loose materials and sealed with an approved joint sealing compound. The sealing shall not be done until the concrete is quite dry. The sealer and any primer required shall be applied strictly in
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accordance with manufacturer's instructions. The joints shall be sealed flush with the surface of the concrete. The end of the sliding half of the dowel bar shall be provided with a PVC or G.I. sheets cap at least 75 mm long and minimum 25 mm length of this cap shall be filled with cotton waste dipped in hot bitumen as shown on the drawings. 3.11.2 Longitudinal and transverse construction joints These shall be of top champhered and sealed type and shall be formed by placing the concrete against the face of the slabs concreted earlier. The face of the old concrete slabs shall be painted with bitumen before placing of fresh concrete. Tie bars shall be used at construction joints and shall be of the dimensions and at spacing as shown on the drawings. 3.11.3 Curing Immediately after finishing operations have been completed the entire surface of the newly laid concrete shall be covered against rapid drying and cured in accordance with the following methods. Failure to provide sufficient cover material of whatever kind required or inadequate supplies of water to take care of both curing as well as other requirements shall be adequate cause for immediate suspension of concreting. 3.11.4 Initial curing Immediately after completion of finishing operations, the surface of the pavement shall be entirely covered with wetting burlap, cotton or jute mats. The mats used shall be of such length (or width) that as laid they shall extend at least 450 mm beyond the edges of the slab. The mats shall be placed so that the entire surface and both the edges of the slab are completely covered. The covering shall be placed as soon as the concrete has set sufficiently to prevent marring of the surface. Prior to being placed, the mats shall be thoroughly saturated with water and shall be placed with the wettest side down. The mats shall be so placed and weighed down as to cause them to remain in intimate contact with the surface covered, and the covering shall be maintained fully wetted and in position for 24 hours after the concrete has been placed or until the concrete is sufficiently hard to be walked on without suffering damage. Water shall be gently sprayed so as to avoid damage to the fresh concrete. If it becomes necessary to remove a mat for any reason, the concrete slab shall not be exposed for a period of more than half an hour. Worn burlap or burlap with holes shall not be permitted. Burlap reclaimed from previous use other than curing concrete shall be thoroughly washed prior to use for curing purposes. If burlap is furnished in strips, the strip shall be laid overlap at least 150 mm. Burlap shall be placed from suitable bridges. Walking on freshly laid concrete to facilitate placing burlap is not permitted. 3.11.5 Final curing Upon removal of the burlap the slab shall be thoroughly wetted and then finally cured as under:
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"Exposed edges of the slab shall be banked with a substantial berm of earth. Upon the slab shall then be laid a system of transverse and longitudinal dykes of clay about 50 mm high immediately covered with a blanket or sandy soil free from stones to prevent the drying up and cracking of clay. The rest of the slab shall then be covered with sufficient sandy soil so as to produce a blanket of earth not less than 37 mm depth after wetting. The earth covering shall be thoroughly wetted while it is being placed on the surface and against the sides of the slab and kept thoroughly saturated with water for 14 days and thoroughly wetted down during the morning of the 15th day and shall thereafter remain in place until the concrete has attained the required strength and permission is given, the covering shall be removed and the pavement cleaned and swept. If the earth covering becomes displaced during the curing period, it shall be replaced to the original depth and shall be re-saturated". 3.11.6 Removing of Forms Forms shall not be removed from freshly placed concrete until it has set at least 12 hours. They shall be carefully removed and in such a manner that no damage shall be done to the edges of the pavement. After the forms have been removed, the ends of all joints shall be cleaned and any honeycombed areas painted up with 1:2 mortar, after which the sides of the slabs shall be covered with earth to the level of the top of the slab. All ditches and drains shall be so placed as to provide effective drainage. 3.11.7 Opening to Traffic Traffic shall be excluded from the newly constructed pavement for a period of 28 days where ordinary portland cement is used. Before the pavement is opened to traffic it shall be cleaned and the joints shall be filled and trimmed or topped out as required. The joint or line of separation between adjacent strips or slabs of concrete, when the pavement is constructed in lanes or strips shall be cleaned and filled with bituminous material as directed. 3.11.8 Repair of Existing Roads Pot holes or patches and ruts in existing bitumen road, concrete road and WBM road shall be repaired by removal of all loose material by cutting in rectangular patches and replacing with suitable materials. The repair shall be done as under : Potholes, patches and ruts shall be drained of water and out to regular shape with vertical sides, and then be filled either with i) ii) coarse aggregate and screenings conforming to the specification for water bound macadam and compacted with rollers or other approved rammer or premixed material conforming to the specification for open graded premix carpet and compacted with rollers or other approved means after painting the sides and bottom of the holes with a thin application of bitumen or a combination of both as directed by the Engineer.
In case, however it is found that there has been damage to the granular sub-base as well, the area of the damaged surface shall be repaired by removal of all loose materials, out to regular shape with vertical sides and re-laid with graded material as per specification of
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granular sub-base and then surfaced with water bound macadam as per specification for the same. Further any making up the level of existing soling shall also be done as per procedure given above for repair of granular sub-base and as directed by the Engineer. 3.12.0 PIPE CULVERTS 3.12.1 Materials The drainage pipes unless otherwise shown on drawings or instructed by the Engineer, shall be made of RCC (Hume pipe) and shall be Class NP2. Pipe culverts shall be made of reinforced concrete pipe (Hume Pipe) and shall be of class NP2 as decided by the Engineer or shown in the drawing. All pipes shall meet the requirements of IS:458 and shall be procured from approved manufacturers with collars as per manufacturers standard specifications. The Bidder shall specifically mention the particular manufacturer's product he proposes to use. Cement shall be Ordinary Portland Cement as per IS:269. Aggregate shall be as per IS:383 - Maximum size shall not exceed one-third the thickness of the pipe or 20 mm whichever is smaller. For bedding concrete for laying the pipes, the maximum size of aggregate shall be 38 mm. Fine aggregate for concrete shall be as per IS:383. 3.12.2 Laying of Pipes Laying of Hume pipes and collars shall be done as per IS:783. Pipes shall be laid either in trenches or on supports as per drawing and/or Engineer's instructions. All pipe sections and collars shall be inspected carefully for defects before laying in the trenches. Broken or defective pipe shall not be used and shall be properly marked and removed from site as soon as the defects are detected. Pipes shall be laid true to line and grade as specified in the drawings and/or Engineer's instruction. The bedding of the pipes shall be 'First class bedding' or ordinary bedding as per IS:783. The profile of cutting of trenches, free working space provided on each side of the pipe, etc. shall be decided at site by the Engineer as per site condition. Side slope, shoring, bailing out water etc. as required shall be done by the Contractor without any extra cost to the Owner. Side slips, if there be any, shall be removed by the Contractor without any extra cost to the Owner. After laying of the pipes are completed, backfilling of the trenches shall be done in layers of 150 mm, clods and lumps broken, watered and compacted with iron rammers to the satisfaction of the Engineer. The surplus spoils shall be transported and filled in low areas within the plant area, as instructed by the Engineer. The filling shall be done as per specification. All pipes and fittings shall be gradually lowered into the trench or placed on the supports by approved means taking due care not to damage them. Under no circumstances the pipes shall be dropped into the trench or on supports from a height. The joints of pipes shall be grouted with 1:2 cement - sand mortar and the procedure of jointing shall be as per IS:783.
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Pipes laid in trenches in earth shall be bedded evenly and firmly and as far up the haunches of the pipes as consistent with the load expected to be transmitted from the backfill through the pipe to the bed. This shall be done either by excavating the bottom of the trench to fit the curve of the pipe or by compacting the earth under and around the curve of the pipe to form an even bed. Where the pipe is laid in trench in rock, hard clay, shale or other hard materials, the space below the pipe shall be excavated and replaced with an equalising bed of concrete (1:4:8 mix), sand or compacted earth as approved by the Engineer. In no place shall the pipe be laid directly on such hard material. If end protection wall is shown in drawing, the wall shall be constructed with first class quality locally available bricks from approved source. All civil works connected with the protection work, like concrete, brick masonry, plastering etc. shall be done as per relevant Indian Standards and in accordance with approved construction drawings. All materials used shall also conform to Indian Standards. 3.12.3 Road Side Drains The roadside drains shall be with P.C.C 1:3:6 bed concrete, R.R masonry work in cement mortar 1:5 with adequate thickness for side walls as shown in the drawing and/or as instructed by the Engineer. The sides and bottom shall be neatly dressed after excavation. Proper connection shall be made to the culverts as per instruction of the Engineer. The excavation spoils shall be transported and filled in the areas outside the plant area as instructed by the Engineer. 4.0.0 QUALITY CONTROL & TOLERANCE The Contractor shall establish and maintain quality control for the various aspects of the work, method, materials and equipment used. All works performed shall conform to the lines, grades, cross sections and dimensions shown on the drawings or as directed by the Engineer. Permitted tolerances for road works are described hereinafter. i) Horizontal Alignment :
Horizontal alignments shall be reckoned with respect to the centre line of the carriageway as shown on the drawings. The edges of the carriageway as constructed shall be correct within a tolerance of 25mm there from. The corresponding tolerance for edges of the roadway and lower layers of pavement shall be 40mm. ii) Longitudinal Profile :
The levels of the sub grade and different pavement courses as constructed, shall not vary from those calculated with reference to the longitudinal and cross-profile of the road shown on the drawings or as directed by the Engineer. beyond tolerances mentioned below : Sub-grade 25mm Sub-base 20mm Base course 15mm Wearing course 10mm
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Tolerance in wearing course shall not be permitted in conjunction with the positive tolerance for base course if the thickness of the former is thereby reduced by more than 6mm. iii) Surface Regularity of Sub grade and Pavement courses :
The surface regularity of completed sub-bases, base courses and wearing surfaces in the longitudinal and transverse directions shall be within the tolerances indicated in Table V. The longitudinal profile shall be checked with a 3 m long straight edge, at the middle of each traffic lane along a line parallel to the centre of the road. The transverse profile shall be checked with a set of three chamber boards at intervals of 10 m. TABLE - V PERMITTED TOLERANCES OF SURFACE REGULARITY FOR PAVEMENT COURSES Longitudinal profile with 3 metre straight edge Maximum number of Permissible in any length exceeding mm 30 ----30 --Maximum permissible variation from specified profile undulations permitted 300 meters mm ----30 -30 -Cross Profile
Sl. Type of Construction No.
Ma x.
1. 2. 3. 4.
5.
6. 7. 8. 9. 10.
Earthen sub grade Granular sub base Water bound macadam with over size metal (40-90 mm size) Water bound macadam with normal size metal (20-50 mm and 40-63 mm size), Bituminous penetration Macadam Surface dressing** (two coat over WBM (20-50 mm or 4063 mm size metal), bituminous penetration macadam or built-up spray grout Open graded premix carpet, mix seal surfacing Bituminous macadam Semi-dense carpet Asphaltic Concrete Concrete Pavements
25 15 15 12
15 12 12 8
12
--
--
30
--
10 10 10 8 8
------
------
------
30 20*** 20*** 10*** 10***
6 6 6 4 4
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Notes 1. **For surface dressing in all other cases, the standards of surface evenness shall be the same as those for the surface receiving the surface dressing. 2. *** These are for machine laid surfaces. If laid manually due to unavoidable reasons, tolerance upto 50% above these values in this column may be permitted at the discretion of the Engineer. However, this relaxation does not apply to he values of maximum undulation for longitudinal and cross profiles mentioned in columns 3 and 8 on the table. 3. Surface evenness requirements in respect of both the longitudinal and cross profile should be simultaneously satisfied.
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SECTION-C1.4.15 TECHNICAL SPECIFICATION FOR GATE & FENCING 1.0.0 SCOPE This specification covers the requirement in respect of materials, workmanship and quality for M.S. gates, barbed wire fencing and chain link fencing. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the Contract, shall govern in respect of design, workmanship, quality and properties of materials and method of testing. Some of the relevant available codes are listed hereunder: IS:1161 IS:2721 3.0.0 Steel tubes for structural purposes. Galvanised steel chain link fabric.
MATERIAL & INSTALLATION Angle Iron Post Angle Iron Post shall be rolled angle section conforming to IS : 2062 and shall be double dip galvanised. Precast Concrete Posts Concrete mix shall be cast in smooth steel forms made to correct dimensions as per drawing and concrete shall be compacted by table vibrators or needle vibrator to give smooth finish. Curing of concrete shall be done by submerging the posts in water tank for minimum 15 days. Precast posts shall be installed in PCC 1:3:6 foundation of size 450 x 450 mm, with a minimum embedment depth of at least 600 mm. Damage to the post shall be avoided during installation of the posts in position, aligning and leveling. Diagonal post bolted to the vertical posts shall be provided at every eighth bay and on either side of the corner posts. Spacing of the posts shall be not greater than 3 m or as per drawing whichever is less. All hardware used shall be of hot-dip galvanized steel. Chain link fence Chain link shall conform to IS : 2761. It shall be procured in rolls of appropriate length and width and shall consist of 10 G hot dip galvanized steel wires woven in the form of zigzag mesh giving an opening size of 50 mm square.
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Chain link shall be secured to the posts with 6 mm dia GI hooks / rings. Tension wire shall be provided through the mesh at top, center and bottom of the erected chain link mesh and shall be of 3 mm dia hot dip galvanized wire and shall be stretched to keep the chain link in taut position. 25 mm 6 mm GI flat stretcher bar shall be provided at the end posts to tie the tension wires. Barbed Wire Fence Barbed wire shall conform to IS : 278 Barbed wire shall be made from hot dipped galvanized wire of 12 G, 2 ply with barbs of 18 G spaced at 100 mm. Barbed wire shall be procured in bundles of standard weights and shall be fully stretched across the posts and secured with G.I. hook bolts and washers. Spacing of horizontal wires shall not be greater than 225 mm or as specified in the drawing. Diagonal wires shall be provided in each bay between two adjacent posts. No wire shall be left loose or sagging. Gate Gate shall be fabricated out of tubular sections conforming to IS : 1161 and shall be hot dipped galvanized. Outer frame shall be 65 NB (medium) tube and diagonal 50 NB (medium) tube 50 mm sq. welded mesh with 4 mm dia GI wire fabric shall be welded to 25 mm 6 mm thick GI flat which in turn shall be welded to the outer tubular frame. The gate shall be provided with 20 mm wide 80 mm dia flat M.S. roller at the bottom. The gate frame shall be fixed to GI tubular post or RCC post.
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SECTION-C4.16 INTENTIONALLY OMITTED
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SECTION-C4.17 TECHNICAL SPECIFICATION FOR SOIL INVESTIGATION 1.0.0 SCOPE This specification describes the methods and procedures for soil boring, field and laboratory testing of soil samples. It also outlines the contents of the soil report. 2.0.0 CODES AND STANDARDS Unless specifically mentioned otherwise, all applicable codes and standards in their latest editions as published by the Bureau of Indian Standards and all other such as may be published by them during the currency of the contract, shall govern in respect of design, workmanship and methods & procedures of testing. Some of the relevant available codes are listed hereunder. IS: 1498 IS: 1888 IS: 1892 IS: 2131 IS: 2132 IS: 2720 IS: 2809 IS: 2810 IS: 2911 IS: 4078 IS: 4434 IS: 4968 IS: 5249 IS: 5529 IS: 6926 IS: 9214 Classification and identification of soils for general engineering purposes Method of load tests on soils Code of practice for sub-surface investigation for foundations Method of standard penetration test for soils Code of practice for thin-walled tube sampling of soils Methods of test for soils(ALL PARTS) Glossary of terms and symbols relating to soil engineering Glossary of terms and symbols relating to soil dynamics Load test on piles(PART 4) Indexing and storing of drill cores. Code of practice for in-situ vane shear test for soils Method of sub-surface sounding for (ALL PARTS) soils Method of test for determination of in-situ dynamic properties of soils Code of practice for in-situ permeability tests Diamond core drilling for site investigation for river valley project (Optional). Method of determination of modulus of sub grade reaction (k-value) of soils in field
IS: 10060 Code of practice for subsurface investigation for powerhouse sites
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In the event of any conflict between the requirements in the specification and the abovereferred codes, the former shall govern. 3.0.0 EQUIPMENT AND PERSONNEL The Contractor shall ensure that all machinery, equipment, instruments, etc., mobilised by him at site are in proper working order and accurately calibrated. If necessary, the Contractor shall obtain from independent and approved testing laboratories such reports/ certification as the Engineer may require to satisfy himself about the reliability of the Contractor's machinery, equipment, instruments, etc. The Contractor shall ensure that the field investigation and laboratory work are performed by competent technical personnel and labour who are specifically qualified and experienced in soil investigation work. Interpretation and recommendation shall be the direct responsibility of the top technical personnel in the Contractor's organisation. 4.0.0 SETTING OUT The Contractor shall be responsible to perform the necessary survey work to locate the bore holes/ test locations on ground and obtain the ground levels at these locations with respect to the grids and benchmark provided by the Owner/ the Engineer. All the investigations shall be carried out at locations shown in drawing. Contractor shall arrange to mark these locations on site and get the same approved. If there is any site obstruction at given location, the location may be shifted by maximum 3 to 5 m, to a convenient location. If it is necessary to shift more than 3 to 5 m, the same may be done in consultation with the Engineer. The contractor shall prepare a sketch showing all the points of investigation and submit along with the results. 5.0.0 EQUIPMENTS Before starting the investigations, all the equipments shall be carefully, inspected to make sure that they are as per the relevant IS Specifications and in good working conditions. Following points may be particularly observed. i. The drilling equipments shall be rotary drill and heavy-duty shell and auger capable of making a borehole of minimum 150 mm diameter. The drilling threaded ends. The drilling rods shall not have any bends, the inside should be clear without any blockage and should maintain verticality when connected together or with any test equipment. The cutting edge of the standard penetration spoon and disturbed sampling tube should be free from any bends / damage and shall have dimensions as per specifications. The undisturbed sampling tube shall have minimum 100 mm diameter and area ratio within 10% for soft clay and 15% for others. The undisturbed tube connector shall have a non-return ball valve and slush tube. The hosepipe and swivel shall be in good condition with proper joints to ensure no leakage and effective circulation of bentonite slurry.
ii.
iii.
iv.
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6.0.0
BORING THROUGH SOIL The method and diameter of boring shall be approved by Engineer. Minimum diameter of borehole shall be 150 mm. Uncased holes are permitted only up to a depth where the side can stand unsupported. In case of side fall is noticed, the holes shall be stabilised immediately by using bentonite slurry or providing casing pipes as directed by the Engineer. Water shall not be added while boring above water table level. Mud circulation/ bentonite slurry shall not be used in three of the boreholes in which water sample is to be collected for analysis. Casing pipes, where used, shall be stopped 150 mm short of the bottom of the bore at any stage of boring, particularly before collection of undisturbed samples or before conducting Standard Penetration Tests. Bore holes shall generally be sunk up to the hard stratum or to a depth of 25 m below the ground level whichever is earlier, unless otherwise specified in the Schedule of Items/drawing or instructed by the Engineer. Drilling must be continued into rock or hard stratum having SPT value more than 75 for at least two bore holes. If rock/hard stratum having SPT value more than 75 is met with at a shallower depth, it shall be ensured that it is really the rock /hard stratum by continuing the boring into the stratum by 3m. Boring in rock shall be carried out by rotary core drilling, as per Clause 7.0.0. The Contractor shall send copies of daily boring records to Owner and the Engineer at the end of each day. These records shall include the field observations with regard to visual description of soil strata, level of ground water table, drilling fluid consumption, presence of lime, mica, etc. Bore holes shall be backfilled with bentonite/ mud cement grout after all samples and other information are obtained from the boreholes.
7.0.0
ROCK DRILLING During boring operation, once the rock strata is encountered, the normal method of boring operation as described under Clause 6.0.0 earlier shall have to be stopped and drilling operation will be resorted to for determining depth and nature of rock strata, in a manner as described below. Rotary core drilling technique with continuous core recovery should be adopted for drilling through rock. The tenderer shall indicate in his tender the type of coring bit he proposes to use. The behavior of rock mass is governed more significantly by the nature of fractures in the rock than by the type and hardness of the material composing the rock itself. Hence, good drilling technique should be adopted to obtain an intact sample truly representative of the in-situ material and for achieving highest percentage of recovery possible. Variations in the speed of rotation, the downward pressure on the core barrel, the pressure at which the drilling fluid is introduced into the hole and the length of hole drilled (run length) prior to removal of the core are major items which must be controlled by the driller. In general, coring should be initiated with short runs both because the upper portions of rock masses are commonly highly fractured and also because the elevations of any core losses can be more accurately determined. If conditions indicate that it is possible, the length of the runs may be determined by the length of the core barrel.
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In zones which are highly fractured or where the barrel continuously becomes blocked, it is essential that short runs be used even though this means removal of the entire string of drilling tools every 300 mm. or less. Reduced bit pressure should be resorted to when rod vibration or chatter occurs. The pressure under which the drilling fluid should be introduced into the hole will be the minimum to be consistent with adequate removal of cuttings from the hole and proper cooling of the bit. To minimise the erosive action of the drilling fluid on the core and thereby to improve core recovery, double tube core barrels should be used. The casing and core barrel to be used shall be of designation BX or NX. During the drilling operation for each bore hole the Contractor shall record the rate of sinking of drill rods, ground water table elevations, if any, nature, type and sequence of rock drilled. From the recovered cores, the Contractor shall determine nature of fractures and degree of weathering of the rock for each borehole. The Contractor shall also note and record any appreciable loss of drilling fluid throughout the entire drilling operations for each borehole. The Contractor shall also determine the percentage recovery ratio and rock quality designation from the recovered cores for each stage of core advance and for all the boreholes. The Contractor shall furnish all the informations mentioned above fully verified and signed by the Engineer at site and submit them in triplicate to the Engineer. The drilling operation shall be terminated either 3 meters in hard rock or 95% of core recovery whichever is later. In addition to the above-mentioned points, the Contractor shall also take into consideration the provisions of the latest revisions of the relevant BIS Codes of Practice along with Amendments, if any. 8.0.0 8.1.0 COLLECTION OF SAMPLES Sampling Depths Soil samples shall be taken generally at intervals of 1.5m and each change of strata in bore holes. Disturbed and undisturbed samples, wherever possible shall be collected. All samples collected shall be suitably and uniquely labeled. 8.2.0 Undisturbed Soil Samples Soil samplers shall conform to relevant Indian standards. Undisturbed samples shall be 90 mm in diameter and 450 mm long. The type of sampler shall be appropriate for the soil to be collected. The undisturbed samples need not be collected when the SPT value is greater than 50. All care shall be exercised by the Contractor not to disturb the soil during sampling operation. The sampler shall be forced in one continuous motion, not driven, into the ground below the casing. The sample shall be shipped to the laboratory in such a manner as not to cause any disturbances to or loss of moisture from the sample. The soil sample shall not be removed from the sampler tube and the ends shall be filled with paraffin and sealed with metal/ plastic caps. The Contractor shall have, at site, adequate number of samplers at all times.
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8.3.0
Disturbed Soil Samples Disturbed soil samples shall be collected from thin walled samplers or split spoon samplers of SPT. The samples shall be collected in airtight jars.
8.4.0
Ground Water Sample Ground water sample shall be collected from any three of the boreholes. Care shall be taken to ensure that no other extraneous water, slurry or storm water, etc., gets mixed with natural ground water in the borehole before collection. One litre of ground water shall be collected in clean and airtight container to be sent to the laboratory for immediate testing.
9.0.0
TRIAL PITS Trial pits shall be of minimum 3 m. x 3 m. size at base so as to permit easy access for a visual examination of the walls of the pit and to facilitate sampling and insitu testing operations. Precautions shall be taken to ensure the stability of pit wall, if necessary even by the provision of shoring. Arrangements shall be made for dewatering if the pit is extended below water table. In-situ tests shall be conducted and undisturbed samples obtained immediately on reaching the specified depths, so as to avoid substantial moisture changes in the subsoil. After completion of tests and examination, the pits shall be suitably backfilled as directed by the Engineer. Unless specified otherwise, the excavated soil shall be used for this purpose.
10.0.0
STANDARD PENETRATION TEST (SPT) The equipment and procedure for Standard Penetration Test shall conform to IS:2131. The bottom of borehole shall be cleaned of mud slurry before conducting the Standard Penetration Test (SPT). The SPT shall be conducted generally at 1.5 m intervals and at changes of soil strata, as per IS:2131. The blow count shall be recorded. If the blow count exceeds 75 or if the penetration is less than 25 mm per 50 blows, the test shall be stopped.
11.0.0 STATIC CONE PENETRATION TEST The test equipment and procedure shall meet the requirements of IS:4968 (Part III). This test shall not be carried out on gravelly soils and for soils having SPT value greater than 50. The capacity of the equipment to be used for test shall not be less than 3.0 tonnes but preferably 10.0 tonnes. The cone resistance and cone & friction resistance shall be measured at pre-determined intervals. The rate of pushing shall be 1 cm per second. Unless otherwise specified it shall be conducted up to a depth of 25 m. If the penetration is found to be difficult at a shallower depth due to occurrence of fragment of rock or boulder the test shall be terminated and be executed at adjacent location as directed by the Engineer. The results shall be prescribed in graphical form as well as in tabular form as given in Appendix-A of IS:4968 (Part III). The Contractor shall carefully interpret the results of boring and sounding.
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12.0.0
DYNAMIC CONE PENETRATION TEST The test equipment and procedure shall meet the requirement of IS:4968 (Part II). The driving shall not be done for more than 30 cm at a time after which it shall be stopped for a minute or two. Pumping shall, however, be continued. The tests shall be terminated when the blow counts exceed 35 for 100 mm penetration when the cone is dry and 20 for 100 mm penetration when the cone is penetrated by circulating slurry. The results shall be reported in a suitable tabular form giving below counts for every 30-cm. penetration supplemented by a graphical plot of blow count versus depth.
13.0.0 PLATE LOAD TEST Plate load tests shall be conducted at the specified founding depth by making test pit of sufficient size as per IS: 1888. Side protection, if required, shall also be provided by the Contractor at no extra cost. The Contractor shall provide suitable access to the bottom of the pit. The load shall be applied to the plate by hydraulic jack of suitable capacity jacking against a fixed platform loaded with sand bags or heavy truss anchored in the ground. The increment of each loading shall be such that the ultimate load is reached in not less than ten increments. The water table level shall be noted in the nearest borehole at the time of testing. If water table is within test zone to a depth of 3 times the width of plate, it is advisable to conduct the test at higher level. The pit shall be backfilled with excavated earth in layers not exceeding 300 mm and well compacted. 14.0.0 CYCLIC PLATE LOAD TESTS The equipment and set up for cyclic plate test shall be similar to plate load test described above. The testing procedure shall be as per IS: 5249. The duration of each loading and unloading cycle shall be decided based on the type of soil under investigation. The initial loading and unloading cycles up to the safe bearing capacity of soil should be with smaller increments in load. The magnitude of load increment should be such that the ultimate load is reached in five to six increments. Based on the above test, the Contractor shall recommend the co-efficient of sub- grade reaction, co-efficient of elastic uniform compression. 15.0.0 VANE SHEAR TEST The test shall be conducted in soft to firm clays and sensitive clays. The test shall also be conducted in case of stiff fissured clays where samples cannot be taken. Tests may also be conducted by direct penetration from ground surface. The equipment used for vane shear tests shall be as per IS : 4434. Straightness of vane shall be checked while the entire assembly of vane connected with the rod is being lowered to the bottom of boreholes. Samples shall be collected from the levels at which the tests have been conducted. The results shall be reported in a suitable tabular form.
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16.0.0 IN-SITU PERMEABILITY TEST In-situ permeability test shall be performed in the boreholes specified or as directed by the Engineer for the determination of the permeability coefficient of the soil. The tests shall be conducted as per IS : 5529 (Part I) using pumping in/out method with piezometer installations. 17.0.0 MENARD PRESSUREMETER TEST This test shall be carried out as per IS : 1892 to the full depth of boreholes, to assess the coefficient of earth pressure at rest and the stress-strain modulus of soil. The tests shall be carried out at every 3.0 m. intervals. The Contractor shall submit, for approval of the Engineer, detailed arrangement drawings for the tests including the detail of the equipment proposed. 18.0.0 BLOCK VIBRATION TEST In-situ dynamic properties of the soil shall be determined by performing Block vibration tests in accordance with IS:5249 at the location and depth indicated. A plain concrete block in concrete grade M 15 and of size 1500 x 750 x 700 mm shall be cast, at the specified founding depth for machine foundations. The test pit should be of suitable size having sufficient clearance for conducting the test. Forced vibration and free vibration tests shall be conducted. The wave propagation test for determination of shear modulus shall also be conducted by exciting the block to the steady state vibrations in the vertical direction. The block shall have suitable provisions to fix the oscillator in different modes and at different frequencies. By suitable and adequate instrumentation, the soil responses to the excitation are measured and various dynamic properties are computed. Based on these tests, the Contractor shall recommend design values to be adopted in design. Before backfilling the pit, the concrete block shall be dismantled and disintegrated and all rubbish shall be disposed off as directed by the Engineer. 19.0.0 WAVE PROPAGATION TEST The wave propagation tests for determination of Elastic and shear modulus may be conducted by making seismic waves to pass through the ground by impact of a hammer and determining the time of travel of these waves between two points at known distance apart by measuring the phase difference between vibration at two pointer under steady vibrations. 19.1.0 Steady state vibration test In case of uniform soil extending up to infinite depth. When the test is conducted using a phase meter the phase angle corresponding to different distances between the geophones should be recorded and a curve plotted between the phase angle and the distance. From the curve the distance `S between the geophones for a phase difference of 90 should be determined. 19.2.0 Hammer tests The equipments used for the hammer test shall be as per IS : 5249.
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A suitable location in the area where this test is to be conducted is selected and radial lines arranged out from this point for a distance of 30 m to 40 m. points are marked on these lines at 2 m intervals. A velocity pick - up or a geophone is fixed at the origin of the radial lines and waves are generated near this point by impact of a 10 kg hammer falling through a height of 2 m on a steel plate of 150 mm x 150 mm resting on the surface of the ground. An acceleration pick - up is placed at a known distance along one of the radial lines, the pick - ups is amplified through universal amplifies and fed to two channels of the same pen recorder. The time taken by the waves to travel the distance the two pick - ups can be obtained from these recorder. The test is repeated for different known distance between the pick - ups along all the marked lines one by one. The test may be repeated at different locations to obtain a representative value of wave velocities in the area under investigation. Alternatively, the time taken by the waves to travel a known distance may be obtained directly by feeding the output of the pick - ups to a timer. The in-situ density of the soil should be determined by the method specified in IS: 2720. Determination of value of average Velocity, Elastic modulus and shear modulus of soil is as per the IS: 5249. 20.0.0 MEASUREMENT OF EARTH RESISTIVITY Resistivity measurement at the site will reveal whether the soil is homogeneous or non uniform. Resistivity of earth is depending on its moisture content. It is advisable to conduct earth resistivity tests, during the dry season in order to get conservative results. The measurement of the earth electrode resistance is to be done as per IS:3043 in order to get the closet true value of earth resistance. 20.1.0 Test Locations In the elevation of earth resistivity for substations and generating stations, at least eight test locations shall be chosen from the centre of the station to cover the whole site. This number shall be increased for very large station sites. 20.2.0 Test Procedure WENNERS four electrode method is recommended for these types of field investigations. At the selected test site, in the chosen direction, four electrodes are driven in to the earth along a straight line at equal intervals, s. The depth of the electrodes in the ground shall be of the order 10 to 15 cm. The Megger is placed on a steady and approximately level base, the link between terminals and the four electrodes are connected to the instrument terminals as per IS:3043. An appropriate range on the instrument is thus selected to obtain clear readings avoiding the two ends of the scale as far as possible .The readings are taken while turning
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the crank at about 135 rev/min resistivity. The resistivity calculations shall be done and necessary corrections are to be effected as per IS : 3043. 20.3.0 Testing of Soil Uniformity During the course of above tests, it would be desirable to get information about the horizontal and vertical variations in earth resistivity over the site under consideration for the correct computation of the resistivity to be used in the design calculations. The vertical variations may be detected by repeating the tests at a given location in a chosen direction with a number of different electrode spacings, increasing from 2 to 250 metres or more, preferably in the steps 2, 5, 10, 15, 25, and 50 metres or more. When the earth resistivity readings for different electrode spacings in a direction is with in 20 to 30 percent, the soil is considered to be uniform. When the spacing is increased gradually from low values, at a stage, it may be found that the resistivity readings is more or less constant irrespective of the increase in the electrode spacing. The resistivity for this spacing is noted and taken as the resistivity for that direction. In a similar manner, resistivities for at least eight equally spaced directions from the center of the site are measured. These resistivities are plotted on a graph sheet in the appropriate directions choosing a scale. A closed curve is plotted on the graph sheets jointing all the resistivity points plotted to get the polar resistivity curve and the average resistivity of the site is found out in accordance with IS : 3043. 21.0.0 LABORATORY TESTS It is not the intent nor is it practical to specify all technical details and requirements of soil testing in the laboratory that would enable the proper evaluation of the soil parameters used in the detailed engineering stage. The Engineer reserves the right to direct the Contractor to perform any particular test during the course of the investigation. The Contractor shall keep furnishing preliminary copies of all test results to the Owner and the Engineer for their review. 22.0.0 SOIL REPORT The soil report shall include but not limited to the following. a. b. c. Detailed write up on the procedures adopted in all phases of the work. Plan of borehole and field test locations. Individual bore logs indicating various soil strata encountered, their thicknesses and classifications, sampling locations, ground level, laboratory test results, SPT blow counts, ground water level and pertinent data. Cross section of soil profile in two perpendicular and diagonal directions and all load test curves & consolidation curves. Detailed test results, laboratory observations both in tabular and graphical form and necessary extracts from technical literature used in calculation, evaluation, & recommendations.
d. e.
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f. g.
Recommendation for type, depth, ultimate, and safe bearing pressure and settlement of foundations for various structures. A summary of all design parameters.
The Contractor's recommendations shall include specific and definitive information on the following, supported by detailed calculations. a. Founding depths for various foundations and corresponding safe soil bearing capacities evaluated from both strength and settlement considerations. Values obtained from field tests and laboratory tests shall be compared and suitable interpretation shall be furnished. Consolidation and settlement characteristics. Coefficient of subgrade reaction. Dynamic properties of soil. Type and capacity (vertical and lateral) of piles and data/ information on related aspects. Anticipated problems during foundation construction and recommended solutions. Harmful chemical contents in soil and ground water, if any, and recommendations to protect underground structures from their harmful effects. Specification for soil to be used for backfilling. Swelling characteristic of soil clearly indicating all swelling pressure etc. Grade preparation for roads Coefficient of earth pressure to be adopted for design of retaining structure.
b. c. d. e. f. g. h. i. j. k.
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SECTION C-5 DATA DRAWINGS AND MAPS ANNEX 1 SCHEDULE OF BUILDING FINISHES BUILDING/ ROOM Switchgear Room Administration room Control Room Battery Room FLOOR Granolithic Flooring (Cement Concrete in 1:1:2) Precast Terrazo tiles / PVC tiles. PVC Acid / Alkali resistant tiles. WALL Oil bound distemper. Oil bound distemper. Acrylic Emulsion. CEILING Lime Wash of 3 or more coats. Lime Wash of 3 or more coats. LUXALON false ceiling. Lime Wash of 3 or more coats. Lime Wash of 3 or more coats. Lime Wash of 3 or more coats.
Acid / Alkali resistant brick lining upto 2100mm height from floor. Chemical resistant chlorinated rubber paint above 2100mm. Toilets Heavy duty Ceramic Tiles. Glazed tiles for 2100mm height. Waterproof cement paint above 2100 mm. Staircases Precast Terazzo Tiles with Glazed tiles for 2100mm nosing. height. Waterproof cement paint above 2100 mm.. All external walls shall be cement based water proof paint. SCHEDULE OF ROOF FINISHES BUILDING All RC Roof buildings
ROOF FINISH Brick jelly lime concrete and Pressed flat tiles.
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ANNEX 2 TOPOGRAPHIC DATA
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ANNEX 3 GEO-TECHNICAL DATA
Refer Soil Investigation Report attached with this tender document.
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ANNEX 4 LOCATION MAP
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ANNEX C3 TO SECTION C3
Specific Requirements
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : ANX-C3 : 1
1.0.0 1.1.0
SPECIFIC REQUIREMENTS General This section covers the specific requirements common to all facilities. The design and construction of buildings, structures etc. will take into account requirements for operation and maintenance of all equipment, durability of the structure and the construction and the needs of its users. The life of the plant shall be taken as 50 years and this shall be taken into account in the specifications. The buildings will have good architectural features. The surrounding areas will be properly micro levelled and graded.
1.1.1
Architectural Concept for Buildings The architectural design concept of buildings will be evolved considering the functional, technical and other requirements for efficient operation, ensuring comfortable working environment for personnel, satisfying the aesthetic requirements. Special care will be taken to provide elegance and aesthetics, with effective use of appropriate treatment, materials, fittings and finishes. Windows of adequate size and numbers - located appropriately - shall be provided to suit natural day lighting and ventilation even for areas, which are ventilated by other means.
1.2.0 1.2.1
Materials Of Construction Cement & Concrete The cement used for the concrete in the substructure and superstructure for the buildings and structures shall be suitable for the highly corrosive coastal environment and the chemical content of the soil and the internal contents of structure with which they will be in contact with. Concrete shall be dense and non-porous and shall be approved design mixes except for very minor applications.
1.2.2
Masonry & Plastering Masonry used for cladding walls for buildings shall be first quality bricks or concrete blocks. Plaster rendering on masonry walls shall be dense and non-porous with additives if necessary to impart these qualities.
1.2.3
Joinery Rolling shutters, doors and windows with appropriate fittings and hardware all of which, shall be of corrosion resistant material. Teak wood joineries will be used. Glazing shall be with 6mm thick plate glass.
1.2.4
Painting & Protection of Concrete, Masonry & Reinforcement Concrete elements in contact with soil shall be protected with bituminous membrane / coating protection system. Minor foundations in contact with soil may be given coats of bitumen paint. Reinforcement shall be corrosion resistant steel such as TISCON CRS / SAIL TMTHCR, if in contact with saline conditions and account of this will be taken while determining the development length for rebars. Additional measures to increase the durability of concrete structures are listed in Cl. 2.7.0 of this annex.
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1.2.5
Floor Finishes Floor finishes shall be selected to suit the function of the area. The suggested floor finishes for the various areas of the plant are furnished in Annex 1 of Section C, Part-II. The floor shall be finished non-slip wherever water or liquids are being stored, transported or processed.
1.2.6
Protection to Steel Work Steel structural members, inserts, floor gratings etc shall be either galvanized or given an approved epoxy based painting system as per specifications. In Cl. 2.12.0 of this annex, specific types of paint / protection systems are listed as a minimum requirement for generalpurpose steel structures.
1.3.0
Roof Access All roofs will be provided with access through a staircase/ cage ladder. Roof weather proofing where they are not suitable for general for foot traffic shall have access paths, minimum 1000 mm wide, with tiles to approach any equipment located on the roof.
1.4.0
Platforms and Walkways Platforms will be provided for all major equipment, which are not directly accessible from the floors, for operation / maintenance. Platforms and connecting walkways will have a minimum width of 750 mm. Platforms in front of the entry will be at least 900 mm wide. Platforms located close to each other will be connected with walkways. All steel platforms above grade level will be constructed with kick plates at edge of the platform to prevent tools or materials from falling off. It will consist of 8 mm thick steel plate projecting 100 mm above the platform surface. Kick plate will be painted with the same type of coating as the material to which it is attached.
1.5.0 1.5.1
Stairs and Ladders Steel Stairs All steel staircases will normally have minimum clear width (back to back of stringer) of 1000 mm and maximum inclination with horizontal of 35.750. However, in case of space restriction, minimum clear width up to 750 mm and slope up to 450 may be provided. The vertical height between successive landings will not exceed 5 m. Channels (minimum MC200) will be provided as stair stringers. Treads will be minimum 250 mm wide of chequered plate/grating, with suitable nosing, and spaced equally so as to restrict the rise to maximum 180 mm (200 mm in exceptional cases).
1.5.2
Steel Ladders Ladders will be provided to platforms, walkways, instruments and equipments, which do not require frequent access. Ladders will preferably be vertical and its angle with vertical will not exceed 50. Ladders will be of minimum 450 mm clear width with 20 mm diameter MS galvanised rungs spaced at 300 mm (maximum). Ladders will be provided with a safety cage of minimum 750 diameter clear when the top of ladder is more than 4.5 m above the landing level. However safety cages will start at 2.5 m above the lower landing level.
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1.5.3
RCC Stairs All stairs will have maximum riser of 180 mm and a minimum tread of 250 mm. Minimum width of stairs will be 1200 mm generally. All stairs normally will have not more than 15 risers in one flight. Aluminium angle nosing with minimum 50 x 25 x 3 angle or PVC nosing will be provided for edge protection of RCC stairs.
1.6.0
Handrails Handrails will be provided at appropriate places to ensure safety e.g. around all floors/roof openings, projections / balconies, walkways, platforms, steel stairs etc. Generally, all handrails will be of 32 mm nominal bore MS pipes (medium class) as per IS:1161 galvanised using 910 gm/sq. m of zinc. Handrails for platforms, walkways and projections will be a three-rail system with the top rail 1000 mm above the walkway surface, the intermediate rail 450 mm below the top rail and toe plates at the bottom. Handrail post spacing will be limited to 1500 mm as far as possible but can be proportioned to the length of the protected horizontal opening. In such a case spacing will not exceed 1850 mm center to center of posts. Handrails will be shop fabricated for specific locations and field welded or bolted to the erected structural steel. For RCC stairs, handrails with aluminium balustrade & aluminium rail will be provided, unless specifically mentioned otherwise.
1.7.0
Edge Protection Wherever possible around floor openings an RCC kerb of 100 mm width and 150 mm high shall be provided. All concrete edges, where breakage of concrete corner is expected, will be provided with angles at least L 50x50x6 with lugs for edge protection e.g. all round edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers and supporting edges of pre-cast covers etc.
1.8.0
Anchor Bolts and Insert Plates Anchor bolts will be designed for working stress, in tension and shear, for embedded length of the anchor bolts and pipe sleeves. Shear and crushing strength of concrete will also be checked. Increase in allowable stress for loading including seismic and wind loads will not be permitted in design of anchor bolts. Insert plates will be designed/checked for shear and bending moment. All lugs will be checked for tension. Bond strength of concrete will also be checked. Lugs using steel bars will preferably be fillet welded to the plate to transfer full strength of the lug.
1.9.0
Vertical Headroom All accessible areas will be provided with a minimum clear headroom as follows, unless otherwise specified: Finished floors to ceiling (buildings) Doors, Walkways, Platforms, Stairs etc. False ceiling of office areas : : :
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3500 mm 2100 mm 2400 mm

Safety cage for ladders Other plant roads and truck access
: :
2500 mm As per relevant standards (Min. 5000)
1.10.0 Expansion / Construction / Contraction Joints Expansion and construction joints will be provided wherever required. All expansion and construction joints of underground structures in RCC will be made watertight using PVC ribbed water stops with central bulb. However, kicker type (externally placed) PVC water stops may be used for the base slabs and in other areas where it is required to facilitate concreting. The minimum thickness of PVC water stops will be 6 mm and minimum width 225 mm. At other joints these will be 150 mm wide. Two part polysulphide sealant conforming to IS:12118 will be used for sealing of joints in contact with water. For other cases, bitumen sealing compound conforming to IS:1834 will be used. Preformed bitumen impregnated fibreboard conforming to IS:1838 will be used as joint filler. PVC water bar will be specified as per relevant IS specifications. 1.11.0 Brick Masonry and Parapet Wall All walls in RCC framed structure will be non-load bearing infill panel walls. External walls of all buildings will be at least 230mm thick. All internal walls will be at least 230mm thick except for internal partition walls, which may be of 115mm thick. 50 mm thick DPC (1:1.5:3) with water proofing admixture will be provided at plinth level before starting masonry work. Minimum density of brickwork to be used will be as per IS: 2185. Cement sand mortar of 1:6 for 230mm thick wall and 1:4 for 115 mm thick wall will be used. Two nos. of 6 mm diameter bars will be provided at every third layer. All upstands and parapet walls on roof will be of RCC construction, minimum height of parapet walls will be 750 mm and thickness 125 mm. 1.12.0 Drainage 1.12.1 Floor drainage For all buildings and areas, suitable arrangement for draining out water collected from leakage, floor washing, fire fighting, etc. will be provided. Gully traps, inspection pits, collecting pits etc. will be located suitably and designed considering flow volume, easy access, maintenance and safety. All drains inside the building will have minimum 40 mm thick galvanised grating covers. In areas where heavy equipment loads would be coming, pre-cast RCC covers will be provided in place of grating. These drains will lead the water to drain sump. Garland drains will be provided around all buildings to receive the drainage water from roof and floor and lead them to the plant storm water drainage system.
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1.12.2 Roof drainage Roof drainage system will be provided for quick and efficient draining of rainwater from roof to avoid seepage and damage to roof. The runoff gradient for the roof will not be less than 1 in 100. Roof drainage system will consist of roof drain heads, rainwater down take pipes and fixtures. System will be designed to handle design requirements for the specific site and will be in accordance to stipulations of IS:1742 and IS:2527. Roof drains will conduct water to storm drains through down take pipes. Rain water down take pipes will be of UPVC pipe IS : 4985. 1.12.3 Trenches The invert of trenches shall be provided with a slope of 1: 500 minimum for cable trenches and 1:250 for pipe trenches towards sumps, which shall be connected to the storm water drainage network. 1.12.4 Sumps In case of underground structures, sumps with pumping arrangement will be provided at suitable location to collect and pump out any incidental water collection to nearest storm water drains. 1.13.0 Waterproofing of Underground Structures All underground structures like the trenches shall be designed for inherent leak tightness with plasticiser cum waterproofing cement additives conforming to IS:9103. In addition, limits on permeability as given in IS:2545 will also be met with. The concrete surface of these structures in contact with soil will be provided with minimum bituminous membrane based protection in the case of major structures and with two coats of bituminous painting of grade 85/25 conforming to IS:702 @ 1.7 kg/sq.m (minimum) for minor structures to serve as protection and water / damp proofing. In case the leak-tightness test does not meet the acceptance criteria as per codes, provision shall be made on the inner surface of walls and base slab so that waterproofing grout can be injected to stop leakages. 1.14.0 Anti Termite Treatment Pre-constructional anti termite treatment will be given to all vulnerable areas susceptible to termite attack and will include column pits, wall trenches, foundations, filling bellow the floors etc. as per IS: 6313 and other relevant Indian Standards. 1.15.0 Plinth Level Finished floor level (plinth level) of all buildings will be EL (+) 2.70 m. of Class 3 conforming to
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1.16.0 Statutory Requirements Provisions of safety, health and welfare according to Factories Act will be complied with at design stage. Comfortable approach to railings, fire escape, locker room for workmen, pantry, toilets, rest room etc. as applicable shall be adhered to Adequate number of exits will be provided in a building. For fire safety requirements of buildings IS:1641 and IS:1642 will be followed in addition to other statutory requirements. All masonry firewalls will be minimum 350 mm thick. 2.0.0 2.1.0 Structural Design & Detailing Requirements General This section covers the minimum requirements for the design and detailing for structures. Other accepted International codes (BS, ACI etc) may be used wherever relevant Indian standard codes have not been published. All structures, building foundations, equipment foundation, underground structures, trenches, pits, etc. will be designed as per latest relevant IS / IRC codes in general. Construction, in general, will follow provisions of IS: 456 / IS 800, IS:3370 for water retaining structures. All structures will be designed for the most critical combinations of dead loads, imposed loads, equipment loads, piping loads, wind loads, seismic loads, forces developed due to differential settlement and any other loading conditions which can occur during the design life of the facility. 2.2.0 2.2.1 Design Methodology for RCC Structures General All designs of RCC structures will be carried out by limit state method as per IS / IRC unless use of working stress method is specifically mentioned. Design strength of materials and design loads will be calculated using appropriate partial safety factors over characteristic strength and characteristic loads as per IS / IRC. For reinforcement detailing IS:5525 and SP:34 will be followed. The walls will be provided with reinforcement on both faces for sections 150 mm or more, even if not required from design consideration. Refer Section C3.2, Part - II also. 2.3.0 Minimum Heights for Pedestals of Steel Columns Pedestals for steel columns for building structures Top of RCC foundations (pedestals) will normally be kept at a lower level so that the column base plates together with gussets and stiffeners remain below finished floor level (FFL) unless specified otherwise. Foundation levels for columns will be decided to accommodate underground services, pits, trenches, etc.
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Stair and ladder pedestal will be kept 150 mm above the Finished Floor Level. Pedestals for steel columns for equipment structures a) Equipment in open area b) Equipment in covered area c) Structures and equipment 2.4.0 Grouting Non-shrink flowable grout will be used for under pinning work below base plate of columns. Non-shrink cum plasticiser admixture will be added in the grout. For grouting of base of foundation high strength ready mixed non-shrink flowable grout will be used. Crushing strength of the grout will generally be one grade higher than the base concrete. Minimum grade of grout will be M 25. Nominal thickness of grouting will be at least 50mm for columns and pedestals of major equipment. For secondary posts, stair and ladder base, etc. grouting will not be less than 25mm thick. 2.5.0 Minimum Cover to Foundation Bolts Minimum distance from the centre line of foundation / anchor bolt to edge of pedestal will be the maximum of the following: a) Clear distance from the edge of base plate / base frames to the outer edge of the pedestal will be minimum 50mm. b) Clear distance from the face of pocket to the outer edge of pedestal will be 75mm. c) Clear distance from the edge of sleeve or anchor plate to the edge of pedestal will be 75mm. 2.6.0 Miscellaneous Requirement Fillets at the junction of roof and vertical walls will be provided with cast- in- situ cement concrete 1:2:4 (nominal mix) followed by 12mm thick 1:4 cement mortar. A screed layer not less than 100 mm thick of cast- in- situ concrete of nominal mix 1:3:6 will be provided below all water retaining structures. A sliding layer of craft paper or bitumen paper will be provided over the screed layer to destroy the bond between screed and base slab. In case of leakage in the underground structures injection-grouting method will be applied to repair the structure according to the requirement of IS: 6494. For switchyard foundations anchor bolt with mechanical anchorage will be provided along with foundation concrete. Bolts in pocket will not be adopted. However, pockets upto 500 mm can be allowed. Foundation for all switchyard towers will be designed per IS: 4091. Contact between foundation and the soil strata will be ensured for all conditions and combinations of loading. Plywood formwork will be used for all water retaining / conveying structures and for all over ground concrete works. For other areas steel / plywood formwork will be used.
: : :
as required (300mm min) as required (150mm min) as per Vendor data subject to Vendor data minimum as specified above.
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Unless specified 20 mm and down graded aggregates will be used for all structural concrete works. However 40 mm and down graded aggregates may also be used under special conditions for foundation. Tolerance for formed and concrete dimension will be as per IS:456. All edges of outdoor concrete elements shall be chamfered. 2.7.0 2.7.1 Corrosion Protection Measures for Concrete Structures Indoor Dense and durable concrete will be used. Concrete below ground shall be M35 and above ground shall be M30 as a minimum. The reinforcement will be as specified earlier with protection where exposed to saline conditions, such as use of CRS / TMT bars. Water / cement ratio will generally be restricted to 0.55. Plasticizer, if required, may be used. 2.7.2 Outdoor or exposed Dense and durable concrete will be used. Regarding concrete grade, cement and reinforcement, the stipulations as stated above will be applicable. Water / cement ratio will generally be restricted to 0.50. Plasticizer, if required, may be used. Clear cover to reinforcement will be increased by minimum 10 mm, over the values as specified for normal condition as mentioned in Cl. 3.43.0 of section C3.2. A coat of water repellent siliconate based (transparent) paint will be applied over the final finished surface. 2.7.3 RCC members (Underground sub-soil condition) Water / cement ratio will generally be restricted to 0.45. Clear cover to reinforcement will be 50 mm for thin sections like trenches. Reinforcement of piles will not be bundled and lapping of bars will be staggered. 2.8.0 Structural Steel Work Design of structural steel work will include generally, but not be limited to the steel constructions listed below: i) Galvanised latticed / tubular structures for switchyard ii) Platforms and walkways iii) Ladders, staircases, handrails etc. 2.8.1 Materials Chequered plates will conform to IS: 3502. All gratings will be pressure locked type (preferably electro-forged) manufactured in accordance with applicable Indian Standard
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Codes. All chequered plates and gratings will be galvanised. Pipes for handrail will be as per medium grade of IS: 1161 and will be galvanised. Refer clause Cl.4.4, Section C4.1 of Part - II. 2.9.0 2.9.1 Minimum Thickness and Sizes Of Steel Elements Minimum Thickness The minimum thickness of various components of a structure and hot rolled sections will be as follows. The minimum thickness of rolled shapes will mean flange thickness regardless of web thickness. Structural steel members exposed to significantly corrosive environment will be increased suitably in thickness or suitably protected otherwise as per good practice and sound engineering judgement in each instance. a) b) c) d) e) f) h) Trusses, purlins, girts and bracing : 6 mm Gussets : 8 mm Stiffeners : 8 mm Base plates / Insert plates : 10 mm & above Chequered plates : 6mm o/p & above Grating flats : 5 mm Minimum thickness of structural members other than gratings and chequered plate directly exposed to weather and inaccessible for painting and maintenance will be 8 mm.
For tower members refer clause 3.20 of Section C3.1, Part - II. 2.9.2 Minimum Sizes The flange width of purlins supporting roof sheeting will not be less than 50 mm. Width of steel rolled section connected to other member will be at least 50 mm. The depth of beams for platform of all structures will not be less than 125 mm. 2.10.0 Slenderness And Depth Ratio The slenderness ratio of main members in tension, compression or bending will be in accordance with IS:800. The following limiting ratios of depth to span will be considered as a general guide. a) Truss b) Rolled beams and girders for rafters c) Roof purlins and girts 2.11.0 Painting Painting surface preparation for structural steel works will have grit blasting. All steel structures will receive two coats of epoxy primer and two finish coats of epoxy paint. The total dry film thickness of epoxy painting will be limited to 250 microns including primer coat. First coat of primer will be given in shop after fabrication but before dispatch to erect at site after surface preparation as described below. The second coat of primer will be applied after erection and final alignment of the erected structures. Two finish coats will also be applied after erection.
1 / 10 1 / 24 1 / 45
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2.12.0 Corrosion Protection for Steel Structures 2.12.1 Indoor Primer coat will consist of one coat of chlorinated rubber based zinc phosphate primer having minimum DFT of 50 microns. Intermediate coat (or under coat) will consist of one coat of chlorinated rubber based paint pigmented with titanium dioxide or equivalent with minimum DFT of 50 microns. Topcoat will consist of one coat chlorinated rubber paint of approved shade and colour with glossy finish and DFT of 50 microns. Total DFT will not be less than 150 microns. 2.12.2 Outdoor Primer coat will consist of one coat of epoxy resin based zinc phosphate primer having minimum DFT of 100 microns. Intermediate coat (or under coat) will consist of epoxy resin based paint pigmented with titanium dioxide or equivalent with minimum DFT of 100 microns. Topcoat will consist of one coat of epoxy paint suitably pigmented of approved shade and colour with glossy finish and DFT of 75 microns. Additionally, finishing coat of polyurethane of minimum DFT of 25 microns will be provided. Total DFT will not be less than 300 microns. All other steel members like shutters, doors, pipe supports etc will be painted as per details given above. For galvanised structures, rate of zinc coating will not be less than 910 g/sqm, unless otherwise specified. 2.13.0 Drainage and Sewerage All drainage lines for storm water, sewage and waste drainage etc will preferably be laid in service aisles close to the road. Separate network will be provided for lines of storm water, sewage, and waste drainage. 2.13.1 Surface Drainage All the paved and unpaved areas will be adequately drained. The surface drainage system will be designed for surface washings and / or rain / fire water as the case may be. Unpaved open areas will be drained through RCC drains and connected to main storm drains. The paved area will be sloped towards the drains with a minimum slope of 1 in 100. The maximum drainage travel extent will be limited to 10 metres. The surface drainage from uncontaminated area will be connected to the nearest open storm water drains through rectangular drains. Contaminated area surface drainage will be collected through separate network.
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The interconnecting pipes and rectangular drains will be sized for carrying the design discharge when running full. The maximum velocity for pipe drains and open drains will be limited to 2.4 m/sec and 1.8 m/sec respectively. However minimum velocity for self-cleaning of 0.6 m/sec will be ensured. Slope of drain will not be milder than 1 in 1000. Minimum cover of 450 mm will be provided over drainage pipes in paved areas. Garland drains, minimum 300 mm wide will be provided all round the building to lead away roof drainage to plant drainage system. Garland drains will be of RCC construction. Plinth protection in PCC grade M15 will be provided between building wall and drain with appropriate slope. Refer clause 3.39.0 of Section C3.2 for additional details. 2.13.2 Storm Water Drainage System The plant storm water drainage system will take into account the topography of the plant area, area drainage patterns and intensity of rainfall etc. The drainage system will be designed for precipitation intensity equal to hourly rainfall for a return period of 50 years. All storm water drainage will preferably be conveyed through open storm water drains provided on both sides of the roads, where required, and will be designed to drain the appropriate catchment area including road surface, open and covered area etc. The drains will be minimum 450 mm wide at the base. In the main plant area all open drains rectangular in cross section will be in RCC of grade M20. The thickness of side and bottom will be minimum 125 mm or as per design considerations, whichever is higher. The pipes for water drainage system will be of concrete of class NP2 conforming to IS:458. However for road crossings etc. higher strength pipe of class NP3 will be provided. Diameter of pipes used for drainage / culverts will be between 600 mm to 1200 mm. Beyond 1200 mm box drains / culverts will be provided. Surface drains will normally have a bed slope not milder than 1 in 1000 along longitudinal direction and RCC pipes will have such slopes so as to have effective discharge. The maximum velocity for pipe drains and open drains will be limited to 2.4 m/sec and 1.8 m/sec respectively. However, minimum velocity for self-cleaning of 0.6 m/sec will be ensured at peak flow condition (i.e. 3 times average flow) for pipes flowing at half full. Suitable manholes will be provided to pipe drainage lines at every 30 m intervals, at junctions and at change of gradient, alignment and diameter of pipe and will be of RCC construction. Minimum size of manholes will be 1.0 m x 1.0 m. All manholes will be designed considering maintenance, inspection and cleaning of pipes. Easy accessibility and safety will also be given due consideration. The cushion over the pipes for storm culverts will be minimum 600 mm. Where less cushion is available, pipe will be encased in RCC M20. Suitable RCC structures will be provided at drops / falls to prevent scouring or damage to surface.
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Invert of drainage pipe / drain will be decided in such a way that the water can easily be discharged above the high water level in water course outside the plant boundary to which the storm water is to be led. 2.13.3 Plant Effluent Drainage (Oily Waste Drainage) The oily waste will be drained / collected through a separate sewer system consisting of underground (over ground if required) RCC NP2 pipes of minimum 300 mm diameter or more as per design requirement. Catch pits will be provided at the source location and they will be interconnected by buried pipes. No bends and branches will be provided in the pipeline. Manholes will be provided at all junctions of pipes. Catch pits will have a minimum internal dimension of 600 mm x 600 mm. They will be of RCC construction and provided with covering of MS galvanized gratings. The main and branch connection pipes will be sized for the expected maximum discharge subject to a minimum of 250 mm NB and 100 mm NB respectively. The pipes will be adequately sloped for drainage and will carry flow to neutralisation pit / ETP / Oil water separator as required. 2.13.4 Sewage System Cast Iron Pipes of Class LA conforming to IS : 1536 will be used below ground level for sewage disposal. Pipes connecting toilet facilities to manholes will be minimum 100 mm diameter NB. Pipes connecting various manholes will be minimum 150 mm diameter NB. Sewers will have such slopes so as to have effective discharge. Sewers will be designed for a minimum self-cleaning velocity of 0.75 m/sec for peak flow condition (assumed as 3 times the average flow) and pipes flowing half full. The maximum velocity will not exceed 2.4 m/sec. Suitable manholes will be provided to pipe sewage lines at every 30 m intervals, at junctions and at change of gradient, alignment and diameter of pipe and will be of RCC construction. Details of manholes will be as per IS:4111 ( Part-I ). Minimum size of manholes will be 1.0 m x 1.0 m. All manholes will be designed considering maintenance, inspection and cleaning of pipes. Easy accessibility and safety will also be given due consideration. Separate septic tanks will be provided at suitable locations for each building block. Overflow from the septic tank will be led to the soak pit. 2.14.0 Inter Plant Trenches All cable and pipe trenches will be of RCC with minimum M20 grade. Trenches located outside the buildings will project at least 150 mm above finished formation level to avoid entry of storm water into the trenches. The bottom of trench will be provided with suitable slope for draining out collected water into a sump pit. Trenches will be covered using precast RCC cover of minimum M20 grade, each not weighing more than 75 kg and will be provided with a lifting hooks. 2.15.0 Roads Roads will be of water bound macadam type and will be designed in accordance with the provision of the relevant IRC Codes of Practices.
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The sub-base will be of 300 mm thick sand gravel mix of 1:1 layer. Wearing course will be provided in accordance with the provision of the relevant IRC codes of practices. Kerbs of PCC or stone will be provided to distinguish carriageway. The geometric design of roads will be done in accordance with IRC-73. Road widths and curves will have adequate space for maneuvering of vehicles. Transverse camber of 1 in 60 will be provided for the roads and a slope of 1 in 40 will be provided on shoulders. Finished top (crest) of roads will be 200 mm above the surrounding grade level. Minimum radius of curvature along the inner side of the carriageway will be generally 15 m. However, for minor roads this will be reduced suitably as per layout requirements and site conditions. Road width and turning radii will also be checked for to take largest foreseeable vehicles and equipment, which can reasonably be expected. All service and utility lines crossing under roads will be taken through concrete pipes / ducts and designed for imposed loading. Number of such crossings will however be kept to a minimum. 2.16.0 Paving 2.16.1 R C C Paving RCC paving of grade M20, minimum 125 mm thick laid to a slope of 1 in 100 towards the nearest drain, with reinforcement placed 50 mm from the top surface, will be provided in the areas specified. The minimum thickness of paving carrying vehicular loads will be 200 mm The underbed will consist of well-compacted ground supporting the sub base and base course which will be similar to the roads. 2.16.2 PCC Paving PCC paving of nominal mix of grade M15, 100 mm thick laid over 150 mm thick compacted rubble soling will be provided around all building as plinth protection to a width of 750 mm or the distance between the brick wall to the garland drain. 2.16.3 Stone Aggregate Paving Entire switchyard area and main transformer yard area will be provided with 150 mm thick paving of 40 mm size stone aggregate. Before laying the paving, the ground surface will be treated with anti-weed chemicals as per manufacturer recommendations. For auxiliary transformer yard, paving of stone aggregate of 75 mm thick using 20 / 40 mm size aggregate will be provided after compacting the under bed and treating with anti-weed chemicals.
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SECTION D
Price Schedule
P2Sec D-Swyd-with note
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Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : D : 1
Table of Contents
SCHEDULE - D1.0 SCHEDULE - D2.0 SCHEDULE D3.0 SCHEDULE D4.0 SCHEDULE D5.0
SCHEDULE OF LUMPSUM PRICE ........................................................... 4 SCHEDULE FOR BREAK-UP OF LUMPSUM PRICE.............................. 5 NET CENVATABLE EXCISE DUTY ......................................................... 9 PRICE SCHEDULE OF RECOMMENDED SPARES REQUIRED FOR TWO YEARS OF TROUBLE FREE NORMAL OPERATION ................ 10 UNIT RATES .............................................................................................. 11
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NAME OF TENDERER : NAME OF WORK : 110 kV SWITCHYARD FOR THE PROPOSED 5.8 MGD DESALINATION PLANT AT NORTH CHENNAI
1. 2. 3.
This is a LUMPSUM contract. The price shall remain firm for the quantum of work as specified in this document. Details of the items in this schedule shall be read in conjunction with the corresponding specification, drawings and other tender documents. Rates / Prices shall be quoted both in figures and in words in clear legible writing. No overwriting is allowed. All scoring and cancellations should be countersigned by the Tenderer. In case of illegibility, the interpretation of the Engineer shall be final. All entries shall be in English language. THE BIDDER SHALL VISIT SITE AND MAKE HIS OWN ASSESSMENT / ESTIMATE AND FURNISH THE SPECIFICATIONS & QUANTITIES BASED ON WHICH HIS LUMPSUM PRICE IS BASED. Every page of this schedule shall be signed by the Tenderer. Unless specifically mentioned otherwise, in the specification the tenderers shall quote for the complete work. The quoted LUMPSUM price shall include for provision of all necessary equipment, consumables, power, temporary works, levies, taxes, insurance, royalties, establishment, temporary roads, contingencies, overheads and profits as well as qualified and experienced personnel for completion of work in all respects and all incidental items not specifically mentioned but reasonably implied and necessary to complete the work according to the contract. In the interpretations of the various specifications, the Owners / Consultants decision is final and binding.
4. 5.
6.
COMPANY SEAL
SIGNATURE OF TENDERER DATE :
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SCHEDULE - D1.0 SCHEDULE OF LUMPSUM PRICE Sl No. Description Total Price (Inclusive of all taxes, duties etc)
1. Design, Engineering, testing, inspection, supply, transportation of materials to site, storing at site, installation, pre-commissioning test and finally commissioning the 110 kV switchyard with all accessories as per scope of supply, terms & conditions, specifications etc. The lumpsum price shall include all structural works viz. Supply, fabrication and erection of equipment support structures, tower structures and other structures etc. compelte as per drawings, specifications and instructions of the Engineer-in-Charge. The lumpsum price shall also include civil works such as excavaton and backfilling equipment and equipment support foundatios, tower foundations, transformer foundations, trenches, soak pits, baffle walls, switchyard control building, internal roads within the switchyard area, fence , gates, laying granite stones in the switchyard area, paving around the transformer, rail track and jacking pad foundation, false ceiling, false flooring, drainage, water proofing, finishes, painting etc. complete as per drawings, specifications and the instructions of the Engineer-in-Charge, including other related works and incidental items not mentioned, but reasonably implied and necessary for the completion of the job as a whole, including supply of all labour, mandatory spares, materials, equipment machinery, tools & tackles as per tender document are as desired and as directed by the Engineer-in-Charge. Total contract price quoted (In figure) Rs _________________________________ (In words) Rs _________________________________ Notes : 1. Price not to be filled in technical part of tender document
SIGNATURE OF TENDERER ________________ NAME ________________
DESIGNATION ________________ COMPANY SEAL

DATE FICHTNER India
________________
SCHEDULE - D2.0 SCHEDULE FOR BREAK-UP OF LUMPSUM PRICE 1. 2. 3. 4.

Sl.NO.
The prices to be entered in this schedule shall be the scope of supply fully in accordance with requirements of this specification. All pages of the schedule of prices shall be signed by the bidder. Over writing and corrections shall be avoided. All the price schedules shall be submitted in a separate sealed envelope duly marked.
DESCRIPTION QTY./ UNIT PRICE EXCISE DUTY CST TRANSPORTATION CHARGES TRANSIT INSURANCE UNIT SUPPLY PRICE (4+5+6+7+8) TOTAL SUPPLY PRICE COL (3) x COL (9) UNIT PRICE (IN RUPEES)
(1) 1.0 1.1
(2) SUPPLIES Design, Engineering, manufacture, shop testing, inspection, supply, transportation to site complete with all accessories of 110 kV Switchyard as per scope of supply and terms & conditions, specifications etc. Design, Engineering and Construction of complete civil and structural works viz. fabrication and erection of structural steel towers,
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
1 Lot
1.2
FICHTNER India
(1)
(2) equipment support structures, excavation and backfilling related to equipment and tower foundations, transformer foundations, trenches, soak pits, baffle walls, switchyard control building, internal roads within the switchyard area, fence , gates, laying granite stones in the switchyard area, paving around the transformer, rail track and jacking pad foundation etc. complete as per drawings, specifications and the instructions of the Engineer-inCharge, including other related works and incidental items not mentioned, but reasonably implied and necessary for the completion of the job as a whole, all as desired and as directed by the Engineer-inCharge. Installation of all electrical equipment required for the 110 kV switchyard (identified in cl. 1.1) Carrying out pre commissioning checks and finally commissioning the 110 kV switchyard equipment identified in cl. 1.1.
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
1.3
1.4
FICHTNER India
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
1.5
Lumpsum price on firm price basis for recommended spares including packing and forwarding FOR of all the spares. Lumpsum price on firm price basis for special maintenance tools including packing and forwarding FOR of all the above tools
1.6
1.7
Sub Total (1.1+1.2+1.3+1.4+1.5+1.6) Total Contract price quoted (in figures) ___________________________________ (in words) Rupees ___________________________________________________
PRICE ADJUSTMENT DATA Whether the supply prices are firm (Yes/No) If the answer for the above is NO, indicate the price adjustment formula Maximum ceiling on price variation as percentage of the quoted lumpsum price
2.0
2.1
2.2
2.3
FICHTNER India
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
3.0
Installation and commissioning charges of all items identified in the specification including storage, site services, insurance etc. Validity of prices upto
4.0
SIGNATURE OF TENDERER NAME
________________________ ________________________
DESIGNATION ________________________
COMPANY SEAL
DATE
________________________
FICHTNER India
SCHEDULE D3.0 NET CENVATABLE EXCISE DUTY
Sl.No 1.0
Description Cenvatable excise duty for which CENVAT benefit can be availed by the owner
Amount(Rs)
SIGNATURE OF TENDERER ________________________ NAME _________________________
DESIGNATION _________________________ COMPANY SEAL DATE _________________________
FICHTNER India
SCHEDULE D4.0 PRICE SCHEDULE OF RECOMMENDED SPARES REQUIRED FOR TWO YEARS OF TROUBLE FREE NORMAL OPERATION Sl. No. Item No. Description Qty. recommended Unit Price Total Price
Note :
1. 2. 3. 4.
Prices not to be filled in the tender document. The unit rates indicated above shall include all taxes, duties and transportation charges (on F.O.R. Site basis). The price of these spares shall not be included in total lumpsump price The above prices shall not be considered for evaluation. SIGNATURE OF TENDERER ________________________ NAME _________________________
DESIGNATION _________________________ COMPANY SEAL DATE _________________________
FICHTNER India
SCHEDULE D5.0 UNIT RATES
The unit rate for the following equipment shall be provided for addition / deletion of the equipment as per the final agreed configuration of the switchyard. The unit rates indicated shall include supply & installation (including the civil works) and commissioning of the equipment. Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Equipment Description 110 kV, 1250 A, 40 kA for 3 sec. circuit breaker (3 ph) 110 kV, 1250 A, 40 kA for 3 sec. isolator without earth switch (3 ph) 110 kV, 1250 A, 40 kA for 3 sec. isolator with single earth switch (3 ph) 110 kV, 1250 A, 40 kA for 3 sec. isolator with double earth switch (3 ph) 110 kV, 40 kA for 3 sec. line feeder main tariff meter current transformer (As per SLD) single phase 110 kV, 40 kA for 3 sec. line feeder current transformer (As per SLD) single phase 110 kV, 40 kA for 3 sec. transformer feeder current transformer (As per SLD) single phase 110 kV, 40 kA for 3 sec. bus tie current transformer (As per SLD) single phase 96 kV, 10 kA, lightning arrester (single phase) 110 kV main tariff meter line PT (as per SLD) single phase 110 kV Bus PT (as per SLD) single phase Unit Rates
SIGNATURE OF TENDERER NAME
________________________ ________________________
DESIGNATION ________________________ COMPANY SEAL DATE ________________________
FICHTNER India

Typical Details of Switchyard Requirement

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Typical Details of Switchyard Requirement

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CHENNAI PETROLEUM CORPORATION LIMITED

Manali, Chennai- 600 068.

TENDER ENQUIRY DOCUMENT FOR 110KV SWITCHYARD

FICHTNER Consulting Engineers (India) Private Limited

Cost of the Tender Enquiry Document: Rs.5, 000/- (Non- refundable)

SAMPLE FORMS AND PROCEDURES

SECTION A SECTION B SECTION C

Overall contents SWYD

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page: I

Content for Part I Swyd

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page: I

SECTION NO SECTION A SECTION B SECTION C SECTION D SECTION E

SAMPLE FORMS AND PROCEDURES

Content for Part I Swyd

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page: II

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : A : 1

SECTION A-1 SECTION A-2 SECTION A-3

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SECTION A-1 ISSUE LETTER OF TENDER ENQUIRY DOCUMENT

Project Manager (CPCL) FICHTNER Consulting Engineers (India) Private Ltd.

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : A : 3

Nov 25, 2004 To Dec 09, 2004

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : A : 4

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12) 13) 14)

16) 17) 18) 19) 20) 21) 22)

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : A : 7

Sale Period November 25, 2004 To December 09, 2004

December 21, 2004.

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : A : 8

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B : 1

1.0 2.0 3.0 4.0 5.0 6.0

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6.3 6.4 6.4.1

Evaluation of Price Bid

Doc. No.6104-EL-SPC-610-001 Rev. : R0 Page : B : 9

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1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

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RESPONSIBILITIES OF CONTRACTOR/COORDINATION WITH OTHER AGENCIES .......................................................................................................................... 10

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SECTION D SPECIAL CONDITIONS OF CONTRACT

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6.0 6.1 6.2

10.0 10.1 11.0

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27.0 27.1 27.2

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Consultant Site office : One Copy

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42.2 43.0 43.1