Special Condition Rob

E-Tender No.
DY/CE/C/KOTA/21/2017
WEST CENTRAL RAILWAY
Special conditions
&
specifications of contract
Name of work- Construction of ROB including approaches at Chainage 122626
between Khilchipur-Jirapur
Jirapur of Span 3 x 30.5m (Composite Steel Girder) and at
chainage 162343 between Biyavara - Chatta ofSpan 3 x 18.3 m (Composite Steel
Girder) along with all other ancillary civil engineering works in the State of Madhya
Pradesh in connection with Ramganjmandi
Ramganjmandi- Bhopal New BG Rail Line Project
Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

West Central Railway, Jabalpur.
Signature Not
1
Verified
Digitally signed by
JON SINGH MEENA
Date: 2017.07.21
17:38:09 IST
Reason: IREPS-CRIS
Location: New Delhi
E-Tender No. DY/CE/C/KOTA/21/2017
IMPORTANT CODAL PROVISIONS
These are Important Codal Provisions for General Guidance. However, work will be
carried out as per relevant codes.
1.0 Earthwork
1.1 Earthwork in embankment/blanketing
(a) For Earthwork in formation for Gauge conversion projects RDSOs guide line for Earthwork in
Railway projects GE G-1 with latest amendment will be applicable.
(b) For earthwork in formation/ blanketing for New Line and doubling projects guide line &
specifications for design of formation for Heavy Axle Load GE-0014 will be applicable.
1.2 Earthwork in cuttings :-

For earthwork in cutting RDSO guide line for cutting in Railway formation GE G- 2 with latest
amendment will be applicable.
1.3.0 Quality Control of Compacted Earth / Blanket layer
1.3.1 Compacted Earth: Degree of compaction of each layer of compacted soil should be ascertained by
measurement of dry density / Relative Density of soil at location selected in specified pattern. The
method of sampling, frequency of tests, method f tests to be conducted and acceptance criteria to be
adopted are as under.
a) Method of Sampling Various methods of selection of sample points for check of in-situ dry density are
in vogue. The sampling adopted has to be such that effectiveness of proper compaction having been
done for the entire area under consideration can be judged. For this, the Engineer will lay down in detail
the method to be adopted in detail depending on site Conditions and accordingly records of checks
done are to be properly maintained. However, in absence of such procedure laid down, following
method should be adopted.
Suggested Method of Sampling: For each layer, a minimum of one sample at a Pre
determined interval (in compliance with the requirement ) along the centre line of the
alignment, would be taken in a staggered pattern so as to attain a minimum frequency of tests
as given in sub Para 1.4.1 b. For subsequent layer, the stagger should be such that the point
of sampling does not fall vertically on the earlier sampling points of the layer immediately
below. Additional sampling points can be taken, as considered necessary.
1.4 QUALIFYING AND QUALITY ASSURANCE TESTS (Mandatory)

Qualifying tests as part of pre-selection of good earth for track sub grade, embankment fill is required
to be carried out. Also, quality of compaction is required to be done to ensure good quality
construction.
i) Selection of soil: For selection of soil to be used as embankment fill CBR test is required to be
conducted on material. CBR test is conducted on ground soil, embankment fill, prepared sub- grade &
blanket material to ensure the minimum specified CBR value of these materials to be used in
construction. This test is carried out on soil sample in laboratory as per procedure given in IS:2720 (Part
16)-1987 & in field as per IS:2720 (Part 31) 1969.

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ii) Quality Assurance Test on Compacted Layer : Quality Assurance Tests are required to be
conducted on part completion stages of formation, prior to clearing for further earthwork, track
linking work:
Heavy Proctor test is required to be conducted to determine the Maximum Dry Density of soil as per
IS: 2720 (part 8). In-situ density is measured in the field by Sand Replacement Method (IS: 2720
part 28) or Core Cutter Method (IS: 2720 part 29) to calculate the degree of compaction. This shall be
determined in laboratory as per BIS procedure with the specified frequency of earthwork quantity, as
envisaged in Guidelines of Earthwork in Railway Projects, GE:G-1, July, 2003. Brief procedure of
these above tests has been given in Annexure-2 of GE-0014.
1.4.1 Frequency of Quality Assurance Tests

a) CBR test for selection of formation materials and other tests required for ensuring conformation of the
materials (blanket, sub grade) as per specification e.g. size gradation, Cu, Cc, Los Angles Tests,
OMC/MDD etc. shall be conducted at following frequency :
i) Embankment Fill : one set of tests for every 5000 cum.
ii) Prepared sub grade : One set of tests for every 2000 cum.
iii) Blanket material: one set of tests for every 500 cum.
b) In-situ Degree of Compaction (or In-situ dry density measurement) test shall be conducted on each
compacted layers in random pattern at following frequency for the different layers:
i) Embankment fill: One density measurement at every 500 sqm surface area of each compacted layers.
ii) Blanket and Prepared Sub grade: one density measurement at every 200 sqm surface area of each
compacted layers.
iii) In case of bank widening, sampling should be done at an interval of minimum 200 meters on widened
side(s) of embankment.
1.5 RECOMMENDED SPECIFICATIONS OF BLANKET MATERIAL (Mandatory)

1.5.1 Specifications of the material for blanket layer over prepared sub-grade should be such that it is well-
graded sandy gravel layer of adequate hardness. Particles size gradation curve should be more or less
within Enveloping Curves of blanket material as shown in Fig. 9 below & Grading Percentages within
the range given in Table-5 below and should also have following criteria satisfied:
i) Cu > 7 and Cc between 1 and 3.
ii) Fines (passing 75 microns) : 3% to 10%.
iii) Los Angeles Abrasion value < 35%.
iv) Minimum required Soaked CBR value 25 of the blanket material compacted at 100% of MDD In
exceptional cases on technical and economic considerations, LAA value may be relaxed up to 40% by
Pr CE on Open Line & CAO/C in construction projects.
v) Filter Criteria should be satisfied with prepared sub grade / sub grade layer just below blanket layer,
as given below :
Criteria1: D15 (blanket) < 5 x D85 (sub-grade)
Criteria2: D15(blanket) > 4 to5 D15 (sub-grade)
Criteria3: D50(blanket) < 25 x D50 (sub-grade)
1.5.2 Filter Criteria is optional, at present. This can be adopted with the experienced gained of its
compliance for different types of soils with blanket.

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Table-5:Grading
5:Grading Percentage of Blanket Material
Sr. No. IS Sieve Size Percent Passing (by weight)
1. 40mm 100
2. 20mm 80-100
3. 10mm 63-85
4. 4.75mm 42-68
5. 2mm 27-52
6. 600micron 13-35
7. 425micron 10-32
8. 212micron 6-22
9. 75micron 3-10
Fig.9: Enveloping Curves for Blanket Material
2.0 Cement Concrete work

2.1 IRS code of Practice for plain, reinforced & Pre-stressed
Pre stressed concrete will be apply for General Bridge
construction.
2.2 For Road bridges, the construction shall comply with the standard specifications and Codes of
Practices for Road Bridges issued by Indian Road Congress.
2.3 For building & other construction works provisions of Plain and Reinforced Concrete Code of
Practices IS-456-2000
2000 will be followed.
2.4 MATERIALS

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2.4.1 General :Water, cement, lime and fine aggregate shall be as specified in Chapter-26 of Mortar
Unified Standard Specifications for Works & Materials. Fine aggregates are divided into four
Zones as described in Table 26.1 of Chapter 26 of Unified Standard Specifications for Works &
Materials. Most of the natural sand found in the country has grading corresponding to one or other of
these zones. Typical good sand falls in Zone II Grading. However Finer Sand ( Zones III and IV ) and
Coarse sand ( Zone - I ) may be used with suitable. Adjustments in the ratio of quantities of Fine to
Coarse aggregates as indicated in Table 3.15 of Unified Standard Specifications for Works &
Materials for Nominal Mix Concrete. Fine sand coming under Zone IV grading should not be used
except where the concrete is closely controlled by the use Design Mix. With nominal mix concrete,
it is not advisable to use Zone IV Sand under any circumstances and Zone I sand should be avoided if a
lean concrete mix is desired.
2.4.2 Coarse Aggregate
2.4.2.1 Size and Grading
(i) Stone aggregate and gravel

It shall be either graded or single sized as specified. Nominal size and grading shall be as under:
(a.) Nominal sizes of graded stone aggregate or gravel shall be 40, 20, 16, or 12.5 mm as specified. For
any one of the nominal sizes, the proportion of other sizes as determined by the method
prescribed in Annexure 3.1 of Unified Standard Specifications for Works & Materials shall be in
accordance with Table.3.1 below.
TABLE 3.1 of Unified Standard Specifications for Works & Materials

GRADED STONE AGGREEGATE OR GRAVEL
IS Sieve Percentage passing (by weight) for nominal size of

Designation
40 mm 20 mm 16 mm 12.5 mm
80 mm 100 - - -
40 mm 95 to 100 100 - -
20 mm 30 to 70 95 to 100 100 100
16 mm - - 90 to 100 --
12.5 mm - - - 90 to 100
10 mm 10 to 35 25 to 55 30 to 70 40 to 85
4.75 mm 0 to 5 0 to 10 0 to 10 0 to 10
(b) Nominal sizes of single sized stone aggregate or gravel shall be 63, 40, 20, 16,12.5 or 10 mm as
specified. For any of the nominal size, the proportion of other sizes as determined by the method
prescribed in Annexure 3.1 of Unified Standard Specifications for Works & Materials shall be in
accordance with Table.3.2 below.

5

SINGLE SIZED (UNGRADED) STONE AGGREGATE OR GRAVEL
IS Sieve Percentage passing (by weight) for nominal size of
Designation
63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
80mm 100 - - - - -
63mm 85-100 100 -- -- -- --
40mm 0-30 85-100 100 -- -- --
20mm 0-5 0-20 85-100 100 - -
16mm -- -- -- 85-100 100 --
12.5mm -- -- - -- 85-100 100
10mm 0-5 0-5 0-20 0-30 0-45 85-100
4.75mm -- -- 0-5 0-5 0-10 0-20
2.36mm -- -- -- -- -- 0-5
(c) When stone aggregate or gravel brought to site is single sized (ungraded), it shall be mixed with
single size aggregates of different sizes in the proportion to be determined by field tests to obtain
graded aggregate of specified nominal size. For the required nominal size, the proportions of other
sizes in mixed aggregate as determined by the method prescribed in Annexure 3.1 of Unified
Standard Specifications for Works & Materials shall be in accordance with Table 3.1 above.
2.4.3 Construction Joints
2.4.3.1 Construction joints for structures other than bridges will be provided as Under (based on
Para 4.4.5 of Indian Railway Unified Standard Specifications(works & materials):-
(a) Concreting shall be carried out continuously up to the construction joints, the Position and details
of which shall be as shown in structural drawing as directed by the Engineer. Number of such joints
shall be kept minimum. The Joints shall be kept at places where the shear force is the minimum.
These shall be straight and shall be at right angles to the direction of main reinforcement.
(b) In case of columns the joints shall be horizontal and 10 to 15 cm below the bottom of the beam running
into the column head. The portion of the column between the stepping off level and the top of the slab
shall be concreted with the beam.
(c) When stopping the concrete on a vertical plane in slabs and beams an approved Stop board shall be
placed with necessary slots for reinforcement bars or any Other obstruction to pass the bars freely
without bending. The construction joints shall be keyed by providing triangular or trapezoidal filler
nailed on the stop-board. Inclined or feather joints shall not be permitted. Any concrete flowing
through the joints of stop-board shall be removed soon after the initial set. When concrete is stopped
on a horizontal plane, the surface shall be roughened and cleaned after the initial set.
(d) When the work has to be resumed, the joint shall be thoroughly cleaned with wire brush and loose
particles removed.
(e) Fig. 4.2, in Chapter-4 of Indian Railway Unified Standard Specifications (Works & Materials) may be
referred to comply with above details for construction joints. 2.4.3.2 Construction Joints shall be
avoided as far as possible and in no case the locations of such joints shall be changed or increased
from those shown on the drawings, except with express approval of the Engineer. The joints shall be
provided in a direction perpendicular to the member axis.

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Location, preparation of surface and concreting of construction joints shall conform to the additional
specifications given in Appendix-A of IRS Concrete Bridge Code (Clause 8.5.3) which is
reproduced below
(a) Construction joints should be positioned to minimize the effect of the discontinuity on the durability,
structural integrity and appearance of the structure.
(b) As far as possible, joints should be positioned in non-aggressive zones, but if aggressive zones cannot
be avoided, joints should be sealed.
(c) Joints should be positioned where they are readily accessible for preparation and concreting, the
preparation of the joints is more likely to be satisfactory where the cross section is relatively small and
where reinforcement is not congested.
(d) As far as possible, joints for fair faced concrete should be located where they conform with the
architectural features of the construction. Unless they are masked in this way, the position of the
joints are always obvious, even when the concrete is given a textured finish.
(e) If substantial changes in the cross section of a member are necessary, the joints should be formed
where they minimize stresses caused by temperature gradients and shrinkage.
(f) Joints should be located away from regions of maximum stress caused by loading, particularly where
shear and bond stress are high. Construction joints between slabs and ribs in composite beam should
be avoided. As a general rule, joints in column are made as near as possible to the beam hunching,
joints in beams and slabs should normally be made at the centre or within the middle third of the span.
(g) The minimum number of joints should be used and their construction should be simple. They should
be either horizontal or vertical, because concreting sloping surfaces are usually unsatisfactory.
(h) Where concrete is placed in vertical members e.g. walls, columns and the like, the lift of concrete
shall finish level or at right angles to the axis of the member, the joint line matching the features of
the finished work. Concreting shall be carried out continuously up to the construction joint.
(i) Laitance, both on the horizontal and vertical surfaces of the concrete, should be removed before fresh
concrete is cast. The surface should be roughened to promote good adhesion. Various methods for
removal can be used but they should not dislodge the coarse aggregate particles. Concrete may be
brushed with a stiff brush soon after casting while the concrete is still fresh, and while it has only
slightly stiffened.
(j) If the concrete has partially hardened, it may be treated by wire brushing or with a high pressure water
jet, followed by drying with an air jet, immediately before the new concrete is placed.
(k) Fully hardened concrete should be treated with mechanical hand tools or grill blasting, taking care not
to split or crack aggregate particles.
(l) The best time for treating the joint is a matter of judgments because it depends on the rate of setting
and hardening (which is itself dependent on the temperature of the concrete). Before further concrete
is cast, the surface should be thoroughly cleaned to remove debris and accumulated rubbish, one
effective method, being air jet.
(m) Where there is likely to be a delay before placing the next concrete lift, protruding reinforcement
should be protected. Before the next lift is placed, rust, loose mortar or other contamination should be
removed from the bars and where conditions are particularly aggressive and there has been a
substantial delay between lifts, the concrete should be cut back to expose the bars for a length of
about 50mm to ensure that contaminated concrete is removed.
(n) In all cases, when construction joints are made to essential it is to ensure that the joint surface is not
contaminated with release agents, dust or curing membrane, and that the reinforcement is fixed firmly
in position at the correct cover.

7
(o) When the form work is fixed for the next lift, it should be inspected to ensure that no leakage can
occur from the fresh concrete. It is a good practice to fix a 6mm thick sponge which seals the gap
completely.
(p) The practice of first placing a layer of mortar or grout is not recommended. The old surface should be
soaked with water without leaving puddles, immediately before starting concreting, then the new
concrete should be thoroughly compacted against it. When fresh concrete is cast against existing
mature concrete or masonry, the older surfaces should be thoroughly cleaned and soaked to prevent
the absorption of water from the new concrete. Standing water should be removed shortly before the
new concrete is placed and the new concrete should be thoroughly vibrated in the region of the joint.
3.0 REINFORCED CEMENT CONCRETE

3.1 GENERAL
Reinforced cement concrete work may be cast-in-situ or pre-cast as may be directed by the Engineer
according to the nature of work. Reinforced cement concrete work shall comprise of the following
which may be paid separately or collectively as per the description of the item of work.
a) Form work (Centering and Shuttering)
b) Reinforcement
c) Concreting : (1) Cast-in-situ (2) Pre-cast
3.1.1 Selection and Preparation of Test Sample for steel reinforcement:
This shall be done in accordance with provisions of IS:1786. All test pieces shall be selected by the
Engineer or his authorized representative either
a) From cutting of bars
or
b) If he so desires, from any bar after it has been cut to the required or specified size and the test piece
taken from any part of it. In neither case, the test pieces shall be detached from the bar or coil except
in the presence of the Engineer or his authorized representative. The test pieces obtained in
accordance with above shall be full sections of the bars as rolled and shall be subjected to physical
tests without any further modifications. No reduction in size by machining or otherwise shall be
permissible except in case of bars of size 28mm and above. No test piece shall be annealed or
otherwise subject to heat treatment. Any straightening which a test piece may require shall be done
cold.
3.1.2 Retest
Should any one of the test pieces first selected fail to pass any of the tests specified above, two further
samples shall be selected for testing in respect of each failure. Should the test pieces from both these
additional samples pass, the materials represented by the test samples shall be deemed to comply with
the requirement of the particular test. Should the test piece from either of these additional samples fail,
the material represented by the test samples shall be considered as not having complied with standard.

8
3.1.3 Guidelines for use of Steel Items in Railway Projects/Contracts.
(a) All Reinforcement Steel (TMT Bars) and Structural Steel shall be procured as per specifications
mentioned in BISs documents IS: 1786 and IS: 2062 respectively. Independent tests shall be
conducted, wherever required, to ensure that the Materials procured conform to the Specifications.
(b) These steel shall be procured only from those firms, which are established, reliable, indigenous &
primary producers of steel, having Integrated Steel Plants (ISP), using iron ore as the basic raw
material and having in-house iron rolling facilities, followed by production of liquid steel and crude
steel, as per Ministry Of Steels guidelines.
(c) However, only certain isolated sections of structural steel, not being rolled by ISPs, can be procured
from the authorized re-rollers of ISPs or authorized licensee of BIS having traceability system and
who use billets produced by ISPs. Traceability shall be ensured by an officer specially authorized by
the concerned SAG officer of the Zonal Railway on case to case basis for this purpose.
3.2 FORM WORK (CENTERING AND SHUTTERING)

3.2.1 Removal of Form work (Stripping time)
In normal circumstances and where ordinary Portland cement is used, forms may generally be
removed after the expiry of the following periods. (Based on Clause 9.5.1of IS: 14687-1999)
Type of Formwork Minimum Period

before striking
Form work
(a) Vertical formwork to columns, walls, beams
16 24 hours
(b) Soffit formwork to slabs (Props to be refixed
immediately after removal of formwork) 3 days
(c ) Soffit formwork to - beams (Props to be

refixed immediately after removal of formwork) 7 days
(d) Props to slabs

(1) Spanning up to 4.5m
(2) Spanning over 4.5 m 7 days
14 days
(e) Props to beams and arches:
(1) Spanning up to 6m 14 days
(2) Spanning over 6m 21 days

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3.3 SAMPLING AND ACCEPTANCE CRITERIA OF STRENGTH OF DESIGN

CONCRETE MIX (Extract from IS: 456-2000)
3.3.1 General:
Samples from fresh concrete shall be taken as per IS: 1199 and cubes shall be made, cured and tested
at 28 days in accordance with IS: 516.
3.3.2 Frequency of sampling
3.3.2.1 Sampling Procedure -

A random sampling procedure shall be adopted to ensure that each concrete batch Shall have a
reasonable chance of being tested that is, the sampling should be spread over the entire period of
concreting and cover all mixing units.
3.3.2.2 Frequency
The minimum frequency of sampling of concrete of each grade shall be as shown in Para 3.5 below.
3.3.3 Test Specimen
Three test specimens shall be made from each sample for testing at 28 days. Additional samples
may be required for various purposes such as to determine The strength of concrete at 7 days or at
the time of striking the formwork, or to determine the duration of curing, or to check the testing error.
Additional samples may also be required for testing samples cured by accelerated methods as
described in IS: 9013. The specimen shall be tested as described in IS: 516.
3.3.4 Test Results of Sample

The test results of the sample shall be the average of the strength of three specimens. The
individual variation should not be more than 15percent of the average. If more, the test results of the
sample are invalid.
3.4 ACCEPTANCE CRITERIA
3.4.1 Characteristic Compressive Strength Compliance Requirement

(Clause 16.1 and 16.3 of IS: 456)
Specified Grade Mean of the Group of 4 Non- Individual Test
(1) Overlapping Consecutive Test Results in N/mm2
Results in N/mm2 Min. (3)
Min. (2)
M 15 and above. fck + 0.825 x established fck - 3 N/mm2
standard deviation
(rounded off to nearest 0.5 N/mm2 )
Or
fck + 3 N/mm2 ,
whichever is greater
NOTE
In the absence of established value of standard deviation, the values given in Table 8 may be
assured, and attempt should be made to obtain results of 30 samples as early as possible to
establish the value of standard deviation.

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3.4.2 Quantity of Concrete Represented by Strength Test Results

The quantity of concrete represented by a group of 4 consecutive test results shall include the batches
from which the first and last samples were taken together with all intervening batches. Where the mean
rate of sampling is not specified the maximum quantity of concrete that four consecutive test results
represent shall be limited to 60cum.
3.4.3 Structural adequacy of the parts affected shall be investigated and any Consequential action as needed
shall be taken to the satisfaction of Engineer-in- charge.
3.4.4 Concrete of each grade shall be assessed separately.
3.4.5 Concrete is liable to be rejected if it is porous or honey combed; its placing has been interrupted
without providing a proper construction joint, the reinforcement has been displaced beyond the
tolerances specified; or construction tolerances have not been met. However, the hardened concrete
may be accepted after carrying out suitable remedial measures to the satisfaction of the Engineer-in-
charge.
3.5 RECOMMENDED LIST OF TESTS ON MATERIALS AND WORKS
Materi Test Field/Lab. Test Frequency of
al Procedure Testing
Cement (a) Field / Annexure 3.5 (AS per site
Concret Slump Test Lab of requirement
e Chapter-3 of
IRUSS.
(b) Cube Lab IR Concrete Quantity of Number of
Test Bridge Code concrete in the samples
work (cum)
15
6 15 1
16 30 2
31 50 3
51 & above 4
4 plus one
additional
sample for each
additional 50 cum
or
part thereof.
Material Test Field/ Test Frequency of
Lab Procedure Testing for all sizes
Quantity
Steel for High Strength For Casts/ Heats For Casts/
Reinfor Deformed Steel Below 100 tonnes Heats of
cement Bars/TMT 2 Per Cast 100 tonnes or
In RCC (a) Nominal Lab/Field IS:1786:2008 More
Mass Lab/ Field IS:1608 3 Per Cast
(b)Tensile test Lab/Field IS:1599
(c)Bend Test Lab/Field IS:1786:2008
(d) Rebend Test
3.6 To achieve good quality work, a good working knowledge and experience is required in concrete
work. Practical training in concrete technology to all Engineers i.e. contractors Engineers and

11
Railway Engineers should be imparted by contractor through trainers dealing with concrete in the
field duly approved by the Chief Engineer (Construction) at his cost. No extra payment will be made
to the contractor on this account.
4.0 Bridge Works: Super Structure-Concrete
4.1 CONCRETE FOR SUPERSTRUCTURE

4.1.1 Additional Requirements
Concrete shall meet with any other requirements as specified on the drawing or as directed by the
Engineer. Additional requirements shall also consist of the following overall limits of deleterious
substances in concrete:
a) The total chloride content of all constituents of concrete as a percentage of mass of cement in mix
shall be limited to values given below:
- Prestressed Concrete : 0.1 per cent
- Reinforced concrete exposed to chloride in service : 0.2 per cent
(e.g. structures located near sea coast)
- Other reinforced concrete construction : 0.3 per cent
b) The total sulphuric anhydride (SO2) content of all the constituents of concrete as a percentage of
mass of cement in the mix shall be limited to 4 per cent.
4.1.2 Size of Coarse Aggregate

The size (maximum nominal) of coarse aggregates for concrete to be used in various components of
bridges shall be given as Table 20.3.

Coarse Aggregate Size
Components Maximum Nominal
Size of Coarse Aggregate
(mm)
i) RCC well curb 20
ii) RCC/ PCC well staining 40
iii) Well cap or Pile Cap Solid type piers and abutments 40
iv) RCC work in girders, slabs, wearing coat, 20
kerb, approach slab, hollow piers and
abutments, pier / abutment caps, piles
v) PSC work 20
vi) Any other item As specified by Engineer
Maximum nominal size of aggregates shall also be restricted to the smaller of the following values:
a) 10mm less than the minimum lateral clear distance between main reinforcements
b) 10mm less than the minimum clear cover to the reinforcements. The proportions of the various
individual size of aggregates shall be so adjusted that the grading produces densest mix and the
grading curve corresponds to the maximum nominal size adopted for the concrete mix.
4.1.3 Construction Joints

Construction Joints shall be avoided as far as possible and in no case the locations of such joints shall
be changed or increased from those shown on the drawings, except with express approval of the

12
Engineer. The joints shall be provided in a direction perpendicular to the member axis. Location,
preparation of surface and concreting of construction joints shall conform to the additional
specifications given in Appendix-A of IRS Concrete Bridge Code (Clause 8.5.3) which is
reproduced below -
(a) Construction joints should be positioned to minimize the effect of the discontinuity on the durability,
structural integrity and appearance of the structure.
(b) As far as possible, joints should be positioned in non-aggressive zones, but if aggressive zones cannot
be avoided, joints should be sealed.
(c) Joints should be positioned where they are readily accessible for preparation and concreting, the
preparation of the joints is more likely to be satisfactory where the cross section is relatively small
and where reinforcement is not congested.
(d) As far as possible, joints for fair faced concrete should be located where they conform with the
architectural features of the construction. Unless they are masked in this way, the position of the joints
are always obvious, even when the concrete is given a textured finish.
(e) If substantial changes in the cross section of a member are necessary, the joints should be formed
where they minimize stresses caused by temperature gradients and shrinkage.
(f) Joints should be located away from regions of maximum stress caused by loading, particularly where
shear and bond stress are high. Construction joints between slabs and ribs in composite beam should
be avoided. As a general rule, joints in column are made as near as possible to the beam hunching,
joints in beams and slabs should normally be made at the centre or within the middle third of the span.
(g) The minimum number of joints should be used and their construction should be simple. They should
be either horizontal or vertical, because concreting sloping surfaces are usually unsatisfactory.
(h) Where concrete is placed in vertical members e.g. walls, columns and the like, the lift of concrete
shall finish level or at right angles to the axis of the member, the joint line matching the features of
the finished work. Concreting shall be carried out continuously up to the construction joint.
(i) Laitance, both on the horizontal and vertical surfaces of the concrete, should be removed before
fresh concrete is cast. The surface should be roughened to promote good adhesion. Various methods
for removal can be used but they should not dislodge the coarse aggregate particles. Concrete may be
brushed with a stiff brush soon after casting while the concrete is still fresh, and while it has only
slightly stiffened.
(j) If the concrete has partially hardened, it may be treated by wire brushing or with a high
pressure water jet, followed by drying with an air jet, immediately before the new concrete is placed.
(k) Fully hardened concrete should be treated with mechanical hand tools or grill blasting, taking care not
to split or crack aggregate particles.
(l) The best time for treating the joint is a matter of judgments because it depends on the rate of setting
and hardening (which is itself dependent on the temperature of the concrete). Before further
concrete is cast, the surface should be thoroughly cleaned to remove debris and accumulated rubbish,
one effective method, being air jet.
(m) Where there is likely to be a delay before placing the next concrete lift, protruding reinforcement
should be protected. Before the next lift is placed, rust, loose mortar or other contamination should be
removed from the bars and where conditions are particularly aggressive and there has been a
substantial delay between lifts, the concrete should be cut back to expose the bars for a length of about
50mm to ensure that contaminated concrete is removed.

13
(n) In all cases, when construction joints are made to essential it is to ensure that the joint surface is not
contaminated with release agents, dust or curing membrane, and that the reinforcement is fixed firmly
in position at the correct cover.
(o) When the form work is fixed for the next lift, it should be inspected to ensure that no leakage can
occur from the fresh concrete. It is a good practice to fix a 6mm thick sponge which seals the gap
completely.
(p) The practice of first placing a layer of mortar or grout is not recommended. The old surface should be
soaked with water without leaving puddles, immediately before starting concreting, then the new
concrete should be thoroughly compacted against it. When fresh concrete is cast against existing
mature concrete or masonry, the older surfaces should be thoroughly cleaned and soaked to prevent
the absorption of water from the new concrete. Standing water should be removed shortly before the
new concrete is placed and the new concrete should be thoroughly vibrated in the region of the joint.
5. Bridge Works: Superstructure-Steel
5.1 FABRICATION OF STEEL WORK

5.1.1 Codes of Specifications:- The work shall be done in accordance with the following codes and
specifications and any other requirements that may be prescribed in special cases.
(a) Bridge Work
1. IRS Steel Bridge Code
2. IRS Specification No.B-1-2001 for Steel Girder Bridges
3. IRS Specification No P-31 Zinc Chromate red oxide primer.
The fabrication and erection of the steel work shall be in accordance with IRS: B1-2001
supplemented by relevant provisions of this Specifications.
(b) Iron and steel tanks and staging:- IRS Specification No.B-3-61 Part 4
5.1.2 Quality of Steel:- The structural steel will be used as per IS Code 2062 2011 as required grade &
Quality.
5.1.3 HSFG Bolts: - HSFG Bolts may also be used in lieu of rivets with the approval of Chief
Engineer/Const. However RDSO guidelines No.BS-111(Revision-2) Nov-13 (or latest updated) shall
be strictly followed.
5.1.4 Tolerances
Tolerances in dimensions of components of fabricated structural steel work shall be specified on the
drawings and shall be subject to the approval of the Engineer before fabrication. Unless otherwise
specified, all parts of an assembly shall fit together accurately within tolerances specified in Table
21.2 below. A machined bearing surface, where specified by the Engineer, shall be machined within a
deviation of 0.25 mm for surfaces that can be inscribed within a square of side 0.5m

14

FABRICATION TOLERANCES
A. INDIVIDUAL COMPONENTS
1. Length
a) Member with both ends finished for contact + 1mm
bearing
b) Individual components of members with end + 0 mm
plate connection - 2 mm
c) Other members + 2mm
i) Up to and including 12M + 3.5mm
ii) Over 12M
2. Width
a) Width of built-up girders + 3mm
b) Deviation in the width of members required to + 0mm
be inserted in other members - 3mm
3. Depth
Deviation in the depths of solid web and open web + 3mm
girders -2 mm
4. Straightness
a) Deviation from straightness of columns L/3000 subject to a maximum of
15mm where L is length of member
i) In elevation + 5mm
- 0 mm
ii) In plan L/1000 subject to a maximum of
10mm
5. Deviation of centre line of web from centre line of 3mm
flanges in built-up members at contact surfaces
6. Deviation from flatness of plate of webs of built up 0.005 d to a maximum of 2mm where
members in a length equal to the depth of the d is depth of the member
member
7. Tilt of flange of plate girders 0.005 b to a maximum of 2mm where
a) At splices and stiffeners, at supports, at the top b is width of the member
flanges of plate girders and at bearings
b) at other places 0.015b to a maximum of 4mm where b
is width of the member
8. Deviation from square ness of flange to web of columns and box girders
L/1000, where L is nominal length of
the diagonal
9. Deviation from squareness of fixed base plate (not D/500 where D is the distance from
machined) to axis of column. These dimensions the column axis to the point under
shall be measured parallel to the longitudinal axis consideration on the base plate
of the column at points where the outer surfaces of
the column sections make contact with the base
plate.
10 . Deviation from squareness of machined ends to D/1000, where D is as defined in 9
axes of columns above

15
11 Deviation from squareness of machined ends to D/1000, where D is as defined in 9

axes of beams or girder above
12 Ends of members abutting at joints through cleats 1/600 of depth of member subject to a
or end plates, permissible deviation from maximum of 1.5mm
squareness of ends
5.1.5 Guidelines for procurement of Steel Items in Railway Projects/ Contracts.
(a) All Reinforcement Steel (TMT Bars) and Structural Steel shall be procured as per specifications
mentioned in BISs documents IS: 1786 and IS: 2062 respectively. Independent tests shall be
conducted, wherever required, to ensure that the materials procured conform to the Specifications.
(b) These steel shall be procured only from those firms, which are Established, Reliable, Indigenous &
Primary Producers of Steel, having Integrated Steel Plants (ISP), using iron are as the basic raw
material and having in-house iron rolling facilities, followed by production of liquid steel and crude
steel, as per Ministry Of Steels guidelines.
(c) However, only certain isolated sections of structural steel, not being rolled by ISPs, can be procured
from the authorized re-rollers of ISPs or authorized licensee of BIS having traceability system and
who use billets produced by ISPs. Traceability shall be ensured by an officer specially authorized by
the concerned SAG officer of the Zonal Railway on case to case basis for this purpose.
6.0 Bridge Works-Miscellaneous
6.1 POT BEARINGS AS PER RDSO GUIDE LINES.(As per para 22.4 of IRUSS
(W&M)Vol.II-2010)
6.1.1 General
Pot type bearings shall consist of a metal piston supported by a disc or reinforced elastomeric
confined within a metal cylinder to take care of rotation. Horizontal movement, if required, shall with
a system of sealing rings be provided by sliding surfaces of PTFE pads sliding against stainless steel
mating surfaces. The pot bearings shall consist of cast steel assemblies or fabricated structural steel
assemblies. Provisions of IRC-83 (Part I) shall be applicable for all metallic elements. Provisions of
IRC:83 (Part II) shall be applicable for all r elements. When any item is not covered by IRC:83 (Parts
I and II), the same shall be as per guidelines given hereunder and BS:5400 (Sections 9.1 and 9.2),
except that no natural rubber shall be permitted. If there is any conflict between BS on the one hand
and IRC on the other, the provisions of IRC will be guiding.

16
6.1.2 Welding
(a) Tolerances
i) Plan dimensions : -0 to +5mm
ii) Overall height : -0 to +3mm
iii) Height of elastomeric : + 5 percent
iv) Height of any steel component
a) Machined : -0 to + 1mm
b) Un machined : Class of IS :4897
v) Stainless steel sliding surface
a) Flatness : 0.0004L,
where L=length in direction of measurement
b) Surface Finish : Ra < 0.25 pm as per IS:3073
(b) Painting
(i) All non-working surfaces shall be coated with two coats of epoxy primer and one or more coat each
of epoxy intermediate and finish, total thickness < 0.150 m or any other painting scheme as
approved by the Engineer.
(ii) Silicon grease shall be applied at the PTFE /SS interface after testing.
(iii) Anchor sleeves shall be cement coated at the manufacturers works.
6.1.3 Test
Raw Materials: Necessary test certificates for all raw materials listed in Para 22.4.3 above shall be
furnished by the manufacturers. Reference may also be made to Para for tests on elastomeric.
6.1.4 Test on Casting: Tests specified in IS:1030 shall be performed. Castings shall be ultrasonically tested
and certificates submitted. Quality level of castings shall be level 3 as per IS:9565.
6.1.5 Test on Welding: All welding shall be tested by Dye Penetration method. Butt welding shall be
tested by Ultrasonic method. Soundness of welding shall be certified by the manufacturer.
6.1.6 Acceptance test on Bearing
i) All bearings shall be checked for overall dimensions.
ii) All bearings shall be load tested to 1.1 times maximum design capacity including seismic force.
Bearing tested at higher loads cannot be used.
iii) A pair of bearings selected at random will undergo testing in order to determine the coefficient of
friction . The coefficient of friction shall be < 0.05 at the design load.
iv) Two bearings selected at random shall be tested for permissible rotation.
6.1.7 Installation of POT cum-PTFE Bearings
a) General
i) Care shall be taken during installation of the bearings to permit their correct functioning in
accordance with the design scheme.
ii) To prevent contamination, dismantling of the bearings at site shall not be done.
iii) The load shall be transferred on to the bearings only when the bedding material has developed
sufficient strength. The props for the form work shall be removed only after lapse of appropriate time.
In special cases, this can be ensured by suitable devices like jacks etc.
iv) Temporary clamps and shims (introduced to maintain working clearance) shall be removed at an
appropriate time, before the bearing is required to permit movement.
v) Permitted installation tolerance of the bearing from plane of sliding shall be maintained.
vi) Cement based non-shrink grout with air releasing additive and epoxy based grout,
whichever is specified, shall be first tried at the site. For the proprietary grout mixes,

17
appropriate instructions from the manufacturer shall be followed specially with regard
to the following:
a) Preparation concrete cleaning, roughening, pre-soaking, etc
b) Forms sturdiness, leak proofing, shape, header funnel vents, etc.
c) Bearing Base cleaning, etc.
d) Placement mixing, consistency, time period, finishing etc.
e) Protection curing, ambient temperature, etc.
b) In-situ Casting of Superstructure
i) Form work around the bearing shall be carefully sealed to prevent leakage.
ii) Sliding plates shall be fully supported and care taken to prevent tilting, displacement or distortion of
the bearings under the weight of wet concrete.
iii) Bearings shall be protected during concreting operation. Any mortar contaminating the bearing shall
be completely removed before it sets.
c) Seating of bearing
A. Using Template
(i) Template with required rigidity and matching holes corresponding to the base of the bearing shall be
used.
ii) All the anchors shall be fitted to the lower face of the template using the anchor screws but with steel
washer replacing the elastomeric washers. Separate screws may be used in case of inconvenience in
the length of the original anchor screws.
iii) The template assembly shall be located with regard to level and alignment. It shall be ensured that the
top of the anchors lie in a horizontal plane at the required elevation. The anchors shall be tied / welded
to reinforcements to avoid displacement during concreting.
iv) Concreting of the pedestal / pier cap shall be done to a level leaving a gap of 25- 50mm below the
template.
v) The template and steel washers shall be removed prior to placement of the bearing assembly with
temporary clamps. The bearing assembly shall be fitted to the anchors with the help of anchor screws
and elastomeric washers. Level at the bearing shall be
checked.
vi) The gap below the bearing assembly shall be grouted with cement based grout. Reference may be
made to Para 22.4.6 (a) (vi)
B. Without Template with Gap
i) Pockets commensurate with the sizes of the anchors shall be kept in pedestals during concreting of the
same. The pedestal shall be cast approximately 25mm short of the required finished level.
ii) Anchors shall be fitted to the bearing bottom with elastomeric washers and anchor screws. The
bearing assembly shall be seated in the location on steel chairs / packs. The anchors fitted below the
bearing shall go into pockets in the bed block. Level and alignment of the bearing shall be checked. It
shall be ensured that the bearing sits in a horizontal plane.
iii) The gap below the bearing assembly including anchor pockets shall be grouted with cement based
grout.
C. Without Template without Gap

Elongated pockets commensurate with the sizes of the anchors shall be kept in pedestals during
concreting of the same. The geometry and location of the anchor pockets (with tapered funnel
extension, if required) shall be such that after placement of the bearing the pockets can be
successfully grouted. The pedestal shall be cast 5mm to 15mm short of the required finished level.
The required level shall be achieved by chipping before placement of the bearing. Careful control

18
shall be exercised to cast at the exact finished level or 1mm to 3mm down from the required finished
level.
D. Seating of bearings shall be as per manufacturers instructions.
6.1.8 Inspection and Testing

Where any patents are used, the manufacturers certificate with test proofs shall be submitted along
with the design and got approved by the Engineer before their use in work
6.1.9 Tests and Standards of Acceptance
The materials shall be tested in accordance with these specifications and shall meet the prescribed
criteria. The work shall conform to these specifications and shall meet the prescribed standards of
acceptance. Model Quality Assurance plan (QAP) issued by RDSO for POT-PTFE bearing is attached
as Annexure(Tech)-A(8 pages) of this section.
Annexure (Technical) A
MODEL QUALITY ASSURANCE PLAN FOR POT-PTFE BEARINGS
1. Name of Manufacture: 2. Drg. No.:

3. Name of Project/Railway:.. 4. Authority(CA No./LOA No./Order No.)
Inspection details
Inspecting Extent of
Characteristic
Agency Inspection
Fabricators
Component
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Checked
Records
Type of
criteria
control
quality
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW Physical Test As per Mill Mill 1.Verification RDSO/ One Fabricator IS:1030 Manufacturers
MATERI UTS, Yield TC& test TC and of reference Authorized integral s record Cast steel test certificate
AL: Stress, required by Challan document. Inspecting Test piece Co-related shall shall be
1.1 Cast Steel Elongation%, RDSO/Author 2.Completevis official of per heat With Mill generally furnished.
(CS) Reduction of ized ual Zonal TC & test comply with .UST shall Be
Area, inspecting inspection. Railway report. Grade 280- conducted as
Impact test at 0 official of 520Wor340- per provision of
Degree Zonal 570W relevant
centigrade or-20 Railway (Grade/class specification
Degree for sub- From Govt. As per before
Zero zone Lab ./ relevant processing the
Micro Exam; NABL approved material for
Hardness test approved Drg.). manufacturing.
Chemical Test lab IS:9565 UST after load
C, Mn, Si, P, S, Level-III test shall
Cr, Ni, Mo, Cu ,V also be carried
Ultrasonic 100% out.
Testing
(On cast steel
100%before&
after load Test

19
Annexure (Technical) A (Contd)
Inspection details
Characteristic
Fabricators
Component
Agency Inspection
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Checked
Records
Type of
criteria
control
quality
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
1.2 Mil Mechanical As per Mill 1.Verification of RDSO/ One test Fabricators IS: 2062-11, Manufacturers
d Test Mill TC and reference Authorized piece per record E250, test certificate
Stee UTS, Yield TC& test Challan document. Inspecting thickness Correlated Quality shall be
l Stress, required 2.Completevisual official of per heat. with BO is furnished. UST
Elongation by inspection. Zonal Mill TC & generally shall be
%, RDSO/ Railway test report. used. conducted as
Bend test Authorize 100% However per provision
,Impact test d Quality C of relevant
at 0 degree inspectin shall specification
centigrade g be used for before
or-20 official of sub processing the
degree for Zonal zero material for
sub-zero Railway condition. manufacturing.
zone from ( As UST after load
Chemical Govt. specified in test
Test Lab approved shall also be
C, Mn, Si, ./NABL Drg.). carried out.
P,S,CE. approved IS:4225or
Physical lab. ASTMA435
condition
i.e. Pitting,
rusting,
rolling
defect, etc.
Ultrasonic
Testing of
plates(100
%)
1.3 Stai Physical As per Mill 1.Verification of RDSO/ One test Fabricator Stain less Manufacturers
nles Test Mill TC and reference Authorized pc. records. steel test certificate
s UTS, Yield TC& test Challan document. Inspecting Per heat shall shall be
Stee Stress, required 2.Complete official of conform to furnished.
l Elongation by visual Zonal AISI Sample from
(S.S %,Hardness RDSO/ inspection. Railway 316L/xO2C each lot of S.S
.) Chemical Authorize r1 shall be drawn
Test C, d 7Ni12Mo2 by authorize
Mn, Ni, Cr, inspectin ofIS:6911 inspecting
P,S, Si, g Or official and
Mo official of (Grade/class tested in Govt./
Zonal As NABL
Railway per relevant approved
from approved laboratory.
Govt. Drg.)
Lab
./NABL
Approved
lab.

20
Annexure (Technical) A (Contd)

Inspection details
Characteristic Inspecti Extent
Fabricators
Component
ng of
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Agency Inspecti
Checked
Records
Type of
criteria
control
quality
on
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
1.4 PTFE a) Tensile As per Manufact 1.Verificat RDSO/ One test Fabricat Grade A Manufactur
(confined & strength manufacturer urer ion Authori pc for ors ofBS:378 ers test
dimpled) b) % of certificate & test of zed Full record. 4 certificate
Elongation test required certificate reference Inspecti Lot of or shall be
At break. by RDSO/ & Challan document. ng supply equivalent furnished.
c) Authorized 2. official (Grade/cl Sample
Dimensional inspecting Complete of ass as from each
Stability official visual Zonal per lot of PTFE
d) From Govt.lab./ inspection Railway relevant shall be
Resistance to NABL . specificati drawn by
heat approved lab on/ authorize
e) approved inspector
Durometer Drg.). and tested
Hardness in
f) Specific Govt./NAB
Gravity. L
g) Density approved
h) Electric laboratory.
strength
(Proof test)
i)
Appearance
and finish
1.5 Elastomeric ( Physical As per Mill TC Manufact Verificatio RDSO/ From Fabricat IRC:83 Test
Neoprene properties & tests urer n Authori each ors (Part-III) certificate
WRT/ a) required by test of zed batch at record. &(Part-II) shall be
Bayprene110 Hardness(IR RDSO/ certificate reference Inspecti Random andIS:340 furnished
or HD) Authorized &Challan document. ng 0 (as by
equivalent/D b) Minimum Zonal Railway official per manufactur
enka Tensile inspecting of relevant er.
strength official Zonal test Sample
(MPA) fromGovt.lab/N Railway procedure from each
c) Minimum ABL ) lot of
Elongation Approved lab Elastomeric
at break(%) as
d) Max. prescribed
Compression in
set specificatio
(%) n shall be
e) drawn by
Accelerated authorize
ageing inspecting
f) Max. official of
change in RDSO/
hardness. Zonal
g) Max. Railway
change in and
tensile tested in
strength. Govt.
h) Max. /NABL
change in approved
elongation laboratory.

21
Annexure (Technical) A (Contd.)

Inspection details
Characteristic
Inspecti Extent
Fabricators
Component
ng of
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Agency Inspecti
Checked
Records
Type of
criteria
control
quality
on
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
Chemical As per Manufact Verificati RDSO/ From Fabricat IRC:83 Test
Test Mill TC urer on of Authoriz each ors (Part-II) certificate
i) Ash & test reference ed batch at record. &IS:3400(a shall be
content shall tests certificate documen Inspecti Random s furnished
not exceed required & Challan t. ng per relevant by
5% by official test manufactur
ii) The raw RDSO/ of procedure) er.
elastomericri Authoriz Zonal Sample
c( ed Railway from each
polychloropr Zonal lot of
ene) Railway Elastomeri
Content of inspecti cric as
the ng prescribed
compound official in
shall not from specificatio
be lower than Govt.lab n shall be
60%. / drawn
iii) Sp. NABL by
Gravity Approve authorize
d lab inspecting
official of
RDSO/
Zonal
Railway
and tested
in Govt./
NABL
approved
laboratory.
1.6 Brass sealing Ring Physical As per Manufact Verificati RDSO/ One test Fabricat IS:410,CuZ Test
(20mmwidex2mm properties Mill TC urer on of Authoriz pc ors n37 certificate
Thick) (i) Tensile & test reference ed for full record. (HB) shall be
strength tests certificate documen Inspecto Lot Or furnished
(N/mm2), required & Challan t. r of (Grade/clas by
(ii) by appointe supply s As manufactur
Elongation % RDSO/ d by per relevant er.
(iii) Bend Authoriz Zonal approved One
test ed Railway Drg.). sample for
(iv) ickers Zonal full lot of
Hardness Railway sealing
Chemical inspecti ring supply
Test Cu, Pb, ng shall be
Fe and total official drawn by
Cu + Pb + from RDSO/
Fe & Govt. Authorized
Remainder lab Zonal
Zn /NABL Railway
approve inspecting
d lab official and
tested in
Govt./
NABL
approved
laboratory.

22
Annexure (Technical) A(Contd)

Inspection details
Characteristic
Inspectin Extent of
Fabricators
Component
g Inspection
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Agency
Checked
Records
Type of
criteria
control
quality
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
1.7 Bolts & Physical As per Mill Manufactur Verificati Authoriz As per Fabricato IS:1364& Test
Nuts properties TC & er test on of ed relevant rs IS: 1367 certificate
(i) Tensile test certificate reference Inspector specificati record. (property shall be
strength required by & Challan document. appointe on class8.8) furnished
(MPA) RDSO/ d by Or by
(ii) Hardness Authorized Zonal (Grade/clas manufactur
(BHN) inspecting Railway s as per er. One
(iii) Head official relevant sample for
soundness from Govt. approved each lot of
test lab/ Drg.). Bolts &
(iv) NABL Nuts supply
decarburizati approved shall be
on. lab drawn by
& Visual & authorize
Chemical Measureme inspecting
Test nt official of
C,P & S Zonal
Dimensional Railway
check as and tested
per in
specification Govt./NAB
L
approved
laboratory.
1.8 Adhesi Peel of As per Mill Manufactur Verificati Zonal One Fabricato Adhesive Test report
ve for strength TC & test er on of Railway. sample rs for shall be
bonding required by test reference per lot. record. bonding furnished to
PTFE Zonal certificate document. PTFE to inspecting
Railway &Challan backing official.
inspection plates
official shall
from produce a
Govt./NAB bond with
L a
Approved minimum
lab. peel
strength of
4N/mm
width
when
tested in
accordance
with
BS:5350
(Part
C9)
1.9 Paint Verification Visual Manufactur Verificati Zonal Each Batch Fabricato As per Paint
of er on of Railway. rs relevant should be
Manufacture test reference record. Specificati as per IRS:
s Test certificate document. on B1
Certificate, & Challan
Inspection
Certificate,
Chalan

23

Inspection details
Characteristic
Fabricators
Component
Agency Inspectio
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
n
Checked
Records
Type of
criteria
control
quality
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
2.0 Manufacturin Dimension Visual & As per Measureme Manufacturer 100 % Fabricator IRC 83 Internal
g al Measureme approve nt of s s Part- report shall
2.1 Process inspection nt d dimension inspecting record. III & be
a) plan drawing official as per furnished,
dimension drawin However
b) individual g random
height check may
of the be
component done in
c) Thickness presence of
of Zonal
elastomericri Railway
c pad inspecting
official.
2.2 Check after Dimension Visual& As per Measureme Manufacturer 100% Fabricator IRC 83 Internal
attachment of al Measureme approve nt of s s Part- report shall
stainless steel inspection nt d dimension inspecting record. III, be
plate drawing official IS:822 furnished,
a) Flatness & However,
b) Surface IS:365 random
Finish 8 check may
be
done in
presence of
Zonal
Railway
inspecting
official.
2.3 NDT test DP Test, DP Test of As per Visual Manufacturer 100% Fabricator IS:365 Internal
DP test on weld weld, visual approve inspection inspecting s 8- report will
welding Size, visual &gauge d & official/Zonal record. 1981 be
of the top WPSS verification Railway/ furnished
plate and & Drg of RDSO by the
bearing safter dimension manufactur
load by e and final
test gauge. clearance
will be
given
by RDSO.

24
Annexure (Technical) A(Contd.)

Inspection details
Characteristic
Fabricators
Component
Agency Inspectio
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Checked n
Records
Type of
criteria
control
quality
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
2.4 Hardness Hardness measureme As per drg. Fabricators Manufacturer 100% Fabricator IRC Internal
a) On tester nt and record & inspecting s 83 report
major steel relevant check. official/Zonal record. Part- will be
component specificatio check. Railway III furnished,
s n however,
b) On the random
hard check
facing will be done
zone in
presence of
Railway
representativ
e
inspecting
authority.
2.5 Corrosion Visual and As per drg. Fabricators Manufacturer 100% Fabricator IRC Internal
Protection measureme and record & inspecting s 83 report
a) grit nt relevant check. official/Zonal record. Part- shall be
ballasting specificatio Railway III furnished.
b) Zn n However,
Metalizing total
c) Painting DFT shall
be
checked
randomly
from
2.6 Assembly Dimension Visual and As per drg. Measureme Manufacturer 100% Fabricator IRC During
a) Parallel al measureme and nt of inspecting s 83 assembly all
is im Inspection nt relevant dimensions. official/Zonal record. Part- the
b) Overall specificatio Railway III bearing
Height n components
should be
checked for
proper
cleanliness
and
2.7 Marking IRC 83 Fabricators Manufacturer 100% Fabricator IRC During

Part- record. s s 83 internal
III inspecting record. Part- final
official/Zonal III inspection
Railway the same
component
shall have to
be
fixed on
each
bearing.

25
Annexure (Technical) A(Contd.)

Inspection details
Characteristic
Inspecting Extent
Fabricators
Component
Agency of
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Checked Inspectio
Records
Type of
criteria
control
quality
n
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
2.8 Tolerance of Dimensio Visual and As per Measureme 100% Fabricato IRC Inspection
fit n measureme relevant nt of Manufactur rs 83 records to
between al nt Drg. dimensions. er record. Part- be furnished.
different Inspection s III However
component inspecting random
of official/ checking may
bearing Zonal be
a) Piston Railway done in-
Cylinder presence of
b) inspecting
Elastomericri authority
c pad of Zonal
& Cylinder Railway.
c) Guide &
Adjacent
component
d) Pin &
Cylinder
2.10 Load Test Load One As per Fabricators RDSO Random Fabricato IRC- Deflection test
a) Deflection Testing bearing relevant record. (One rs 83 will be
Test parameter will be Drg. bearing record. Part- done for all
b) Co- s as tested will be III bearings
efficient per IRC- per lot tested by
of friction 83Part- of25nos.or per lot of manufacturer
test III part 25nos or and
c) Combined part) checking record
Load test For other to be
d) Rotation cases as per furnished by
test code. the
manufacturer.
However test
shall be
carried out on
the
bearings
randomly
selected by the
RDSO official.
2.9 Overall Dimensio Visual and As per Measureme Manufactur 100% Fabricato As Checking
dimension of n measureme relevant nt of er rs per records to
any al nt Drg. dimensions. inspecting record. releva be furnished.
un-machined Inspection agency nt However
cast specif random
steel icati checking may
component on be
done by
inspecting
authority of
Zonal
Railway.

26

Inspection details
Characteristic
Inspectin Extent
Fabricators
Component
g of
Acceptance
Frequency
Operation
Document
Reference
&Type of
Remarks
Checked Agency Inspect
Records
Type of
criteria
control
quality
ion
check
No.
Sr.
1 2 3 4 5 6 7 8 9 10 11
3.0 Final Part Visual and As per Measur RDSO 100% Fabricator IRC After load
Inspection dimension measureme relevant ement s 83 testing, DP
Over all checking, nt Drg. of record. Part- Test &
dimensional overall & dimensi III ultrasonic
check height specification on testing of
of finished inspection bearings to
bearing and after be done by
load RDSO to
test condition check for
of damage
components during testing.
inspection Final
clearance given
by
RDSO.
Firm should
keep the
records of hard
facing
and submit the
same to
inspection
official at
the time of
inspection
and inspection
official
of RDSO should
also
check hardness
of hard
facing
randomly.
Note:
1. Firm should maintain traceability of raw material used for fabrication of every POT-PTFE
bearings and the record should be made available to the inspecting authority on demand.
2. Certificate of elastomeric should not be older than 6 months.
3. Certificate of PTFE should not be older than 1year.

27
ADDITIONAL SPECIAL CONDITIONS FOR THE WORK
1.0 INTRODUCTION:
Khilchipur to Biaora section is situated in Rajgarh District of state of Madhya Pradesh. The proposed
work includes mainly bridge related works between Section Khilchipur to Biaora at two locations.
2.0 GENERAL INSTRUCTIONS

2.0 The tenderers should inspect and study the site conditions of the section, availability of materials and
local labour, approach roads, local rules and bye-laws, clearances required from mining or
environment department. etc. before submission of the tender.
2.1 All work under the schedules i.e. Schedule-A, Schedule-B, and Schedule-C to be executed as per laid
down relevant special conditions/ specifications and Indian Railways Unified Standard Specifications
(Materials and Works) Vol.-I & II 2010 as corrected up to date, Unified Standard Schedule of Rates
of West-Central Railway, 2011 as corrected up to date for the present contract.
2.2 USSOR Schedules as a whole consists of three Schedules: Schedule A, (for Earthwork), Schedule
B(for Bridge work) and. Schedule C ( for Non Schedule items ).
2.3 No claim of any kind whatsoever will be entertained if the execution of the work is held up or delayed
on any account. The contractor should plan the execution of the various works in close co-ordination
with Engineer or his authorized representative.
3.0 SCOPE OF WORK

The scope of work under this tender broadly includes following works:-
3.2.1 Construction of ROB as per list given below -
(i) ROB :-
SN Chainage Bridge Type Proposed
No. Span Type
1 122626 8 Composite steel girder 3X30.0 M Jirapur Khilchipur(SH-14)
2 162343 18 Composite steel girder 3X18.0 M Biaora-Chhatta Road(Connecting

Road to NH-46)
(ii) Scope of work involves Composite steel girder , transportation, launching of girders, approaches of
ROB, PCC / RCC and other ancillary works, etc.
(iii) Design of Sub-structure of ROB including approaches as per approved GAD by the Railway.
(iv) Launching scheme will be given by contractor for approval of Railway.
(v) In situ casting on casting bed and launching of super structure.
(vi) Transportation of fabricated steel girders by road from fabrication depot.
(vii) Launching of girders for bridges mentioned in (vi) along with other works.
(viii) Earthwork in approaches of bridges.

28
Contractor will require to execute. Various items of tender schedule as per requirement of section ,
in accordance with GCC. Contractor will finish entire work in completion period as given in the
tender. However contractor will be required to make progress as given below during currency of
agreement.
3.2 Brief of Working Area -- This work is to be carried out between Khilchipur and Biaora cities as
part of New Rail line project between Ramganjmandi and Bhopal. Entire stretch of proposed tender
comes under M.P state. Working conditions are normal.
3.3 The above list of bridges is indicative and is only for guidance. The no. of bridges, or type of bridges
and type of construction, span size or no. of span may change as per requirement and as per decision
of Engineer- in- charge during execution of work. No claim of any kind on such
changes/modifications will be entertained. The work is to be executed as per approved drawings or
standard drawings and as per instructions of Engineer- in- charge. Experienced engineers and
supervisors in bridge works are to be deployed for work under this item.
3.3.1 List of Codes and Manuals
The work shall be done according to Standard Specifications, architectural and structural drawings to
be supplied by the Railway. Indian Railway Standards and Indian Standard Rules and Codes of
practice as revised from time to time and available from the Manager, Government of India,
Publications Branch, Patiala House, New Delhi with Director BIS, Manak Bhawan ,
Bahadurshah Zafar Marg, New Delhi respectively must be followed with regard to design, material
and workmanship. The list of important codes and specification is given below:
S.No Code
1 IS: 9103 Admixtures for Concrete.
2 IS: 9012 Recommended practice for Shotcreting.
3 IS: 3764-Safety Code for excavation work.
4 IS: 7293-Safety Code for working with construction machinery
5 IS: 2062 Structural Steel Codes.
6 IS: 823 Manual Metal Arc Welding Codes.
7 IS: 456 Code of Practice for Plain and Reinforced Concrete 2000.
8 IS: 1893 Criteria for Earthquake Resistant Design of Structures.
9 IS: 800 Code of Practice for use of Structural Steel.
10 IS: 2720 Code of Practice for Soil Investigation (All parts).
11 IS:1343 code of practice for pre-stressed concrete
12 BS-14: Durability of Concrete, RDSO publication.
13 IS: 456 (Latest edition): Code of Practice for plain and reinforced concrete
14 IS: 800- (Latest edition): Code of Practice of use of structural steel in general building
15 construction (Revised Eighth Re-print April-1977 (incorporation amendments No: 1& 2).
16 IS: 432 Part-I: Code of Practice for Mild steel and medium tensile steel bars.
17 IS: 383(Latest edition): Specification for coarse and fine aggregates from natural sources
for concrete (second revision).
18 IS: 516-(Latest edition): Method of test for strength of concrete
19 IS: 1199-(Latest edition): Method of sampling and analysis of concrete.
20 IS: 1904-( latest version): Code of practice for design and construction of foundations in
soils:

29
21 General requirements (third revision).

22 IS: 2386-(Latest edition): Methods of test for aggregates for concrete.
23 IS: 2502-(Latest edition): Code of practice for bending and fixing of bars for concrete
reinforcement.
24 IS: 3025 Methods of sampling and test (Physical and chemical) for water and waste
water.
25 IS: 8112-(Latest edition): Specification for 43 Grade OPC (First revision).
26 IS: 12269-(Latest edition): Specification for 53 Grade OPC.
27 IS: 9103-(Latest edition): Specification for admixtures for concrete (first revision).
28 IS: 2505-(Latest edition): Concrete Vibrators-Immersion type-General requirements
29 IS: 4656-(Latest edition): Specification for form vibrators for concrete.
30 IS: 3764-(Latest edition): Code of safety for excavation of work (First revision).
31 IS: 73-(Latest edition): Paving Bitumen-Specification (Second revision).
32 IS: 10262-(Latest edition): Guide lines for concrete mix design.
33 Various IS codes of testing for soils.
34 IS: 1786-1985(Latest edition): Code of practice for cold twisted bars for concrete
reinforcement.
35 IS: 875-1964(Latest edition): Code of practice for structural safety of buildings and
loading standards.
36 IRC code for items not specifically covered by any other Railway codes or provisions
mentioned in these documents.
37 IS: 961(Latest edition) Structural steel (High Tensile).
Specifications and criteria laid down for the Indian Railway Unified Standard
Specifications (Works and Materials) Volume I & II with all correction slips. regarding
the quality of raw material, workmanship, execution and finishing etc.
38 Indian Railway Schedule of Dimension for Broad Gauge 2004 with latest correction slip.
39 Indian Railway Unified Standard Specifications (Works and Materials) Volume I & II
with all correction slips.
40 Any other relevant Indian Railway Standards Indian Standard specification and Indian
Road Congress standard.
41 For any item not covered by the code of practice-Standard specifications indicated here in
above the relevant provisions from IS Standards and code of practice shall apply.
42 IS: 455-(Latest edition): Specification for Portland slag cement.
43 IS: 1489-(Latest edition): Specification for Port land Pozzalana Cement.
44 Engineering Code of Railway.
45 Indian Railway Works Mannual-2000 with all correction slips.
Wherever any reference to Code, Specifications etc., is made in this document, it shall be taken as a
reference to the latest version thereof including all amendments and corrections etc.
In the event of any difference of opinion in regard to any item of work not explicitly covered by
specifications or Codes in or in regard to the interpretation of specifications including codes, the
directions and decisions of the Chief Engineer(Construction), in-charge shall be final and binding on
the successful tenderer.
Priority wise references:

In case of any discrepancy of disagreement between different specifications to be followed for any
item of work, the following reference shall be adopted in the order of precedence as they appear
below:

30
(i) Provision in Tender schedule

(ii) Provision in Technical specification
(iii) Provision of IRS Codes viz-Concrete bridge code, sub structure and foundation code, and RDSO
guidelines.
(iv) IS Codes.
(iv) Indian Roads Congress specifications.
(v) British Standard Specifications.
(vi) American Standard Specifications.
(vii) Provisions of any other relevant Codes decision of Chief Engineer(Construction) for the application of
any other codes shall be final and binding.
Specification and/or the relevant Indian Standard Code of Practice and/or relevant IRC code,
MOST specifications and/or manufacturers recommended specifications, as appropriate and
decided by the Engineer whose decision in this regard shall be final and conclusive.
The work shall be carried out as per the provisions of various codes and manuals with their respective
latest amendment as indicated below, contractor should also arrange to produce respective Codes for
ready reference at site (with amended up to date).
NOTE: Latest additions and up to date correction slips in all the relevant codes will be applicable as
for as this work is concerned.
3.3.2 Handing over of site for execution of work
(i) The contractor shall take due care and protection for any sort of service lines i.e. Electrical cable,
water pipeline, Telephone cable/lines etc. under/above the ground level and adopt such method of
earthwork so as not to cause any damage to these existing structure/lines. Cost for any damage shall
be recovered from contractor as decided by Engineer-in-charge and whose decision shall be final &
binding on contractor/s.
3.3.3 The tenderer is required to inspect the site of works and acquaint himself with the site conditions
availability of approaches for transporting of men and materials, space and other factors relating to
works availability of labour etc.
i) The contractor should make his own arrangement for measuring tools i.e. tape, gauge, vernier, steel
tape, survey instruments during execution of work for checking by Railways officers/supervisors for
the work done by the contractor. Cost of the same will be borne by Contractor and Railway will not
pay for the same. If the contractor do not comply the Instructions of Engineer in-Charge a
penalty of Rs.10,000 per month will be made from contractors bill subject to a maximum
penalty of Rs. 50000.
ii) Contractor should submit completion drawing ROB and structures on reproducible tracing films of
50-microndouble matt type of approved quality available in market in size of 594x 841 mm
indicating all details of completed yard along with notes of general and technical nature.
Nothing extra will be paid for completion drawings. However, failing it, a recovery of
Rs.5,000/- per station, Rs.5,000/- per Important/Major bridges, Rs.3,000/- per minor bridges
& structures each will be made from contractor.

31
3.3.4 Service Roads:
The Railway do not undertake to provide any service road made for the movement of the contractor
vehicle. The contractor can however make use of the available service road, where they exist free of
charge. However the railway shall not undertake to maintain them and the contractor shall maintain
them at his own cost. In other places, the contractor should make his own arrangements for the
movement of the vehicles and no extra rate shall be paid for this. The Railway reserves the right to
make use of the roads constructed and maintained by the contractor as and when necessary without
any payment to the contractor.
In the event of the contractor making the service roads where railway land is not available or cannot
be given by the Railway for this purpose, it shall be clearly noted that contractor shall make this own
arrangements for obtaining the required land for his temporary use and the railway shall not take any
responsibility in this respect. Any temporary structure required shall be provided by the tenderer at his
own cost and should be removed after the completion of the work and no longer required.

32
SPECIAL CONDITIONS / SPECIFICATION FOR NS ITEMS
1 For NS/1 Rough stone fillings behind abutments This item is for filling of contractor`s
boulders/stones behind wing wall, return wall, retaining wall etc. with hand packed boulders and
cobbles with smaller size boulders towards the back including all lead, lift, labour, material & other
incidental charges. Execution of work should be complete in all respect as per instruction of
Engineer-in-charge. Rate is inclusive of all lead, lift, taxes, royalties.
Mode of payment-Payment unit for this item is cum.

2. NS-2 :- Carrying out detailed structural analysis & design. ( Most economical) as per
approved GAD along with preparation of detailed structural / working drawings with proof
check from IIT/NIT?CEERI New Delhi, SERC/ Chennai.
2.0 The contractor is expected to submit his own design and drawings based on West Central Railways
GAD, which shows only general details of Bridges as proposed by railway. This GAD indicates the
arrangements of the proposed bridge structures with main dimensions and clearances required. However,
contractor shall make out their design and drawing strictly adhering to the leading dimensions as
indicated in railways drawing. Design and drawing shall be submitted duly proof checked. The designer
may visit the site and acquaint himself with the condition under which the Bridges are to be designed.
2.1 Loading and Design Criteria:
Railway bridges : Railway bridges should be designed for 25T loading. Design should be an
accordance with Railway Bridge rules / codes and with reference to IS Codes wherever required.
2.2. Contractors design should fulfill the following requirements
i.) It shall ensure soundness of design.

ii.) It shall be economical and ensure speedy construction.
iii.) It should match the local surround aesthetically.
NOTE: In all the above cases, railways decision shall be final and binding on the contractor.
B.0 Structural details of various components:-

B.1 Foundation:
Type and depth of foundation and safe bearing capacity of soil near the site of foundation as shown in
the railways GAD is tentative. The type and depth of foundation will be ascertained by the designer
based on bore hole legs / site conditions.
B.2 Sub-structure:
The component of sub-structure comprising Piles, Pile Cap, Columns, Pier, Abutments Capping
beams, Bearings, etc. should be designed as shown in the GAD. The abutments pier and pier cap shall
be designed to have future inspections of bearings. Pedestals and pier caps shall be designed to
accommodate bearings.
B.3 All safety measures and precautions required for the safe execution and for safety of the bridge from
wind, seismic and other considerations should be incorporated in the design and drawing. The
contractor should submit a list indicating the deviation from IRC/IRS codes/specification if any and

33
list out the specifications which are being adopted from codes other than IRC/IRS along with the
Design.
C.0 Submission of design and drawings including design for temporary works required for execution of
works and launching of girders etc:
D.0 The contractor shall submit the detailed design calculations for approval to the railway. The design
shall be submitted in sufficient details giving references to the prescribed literature books /codes
referred to in the design. After incorporating the changes which are found necessary in the opinion of
the railway, the contractor/s shall submit two copies of revised design calculations for the bridges
which again will be subjected to technical scrutiny, if found necessary, in the opinion of the railway.
D.1 Contractor shall submit structural design & drawings of all components. Contractor shall
submit drawings, designs and specifications, including temporary arrangements, shuttering, bar
bending schedule, etc., duly proof checked by any IIT/NIT/CEERI- New Delhi/ SERC- Chennai for
approval of the railway administration.
D.2 Design is to be done with due consideration of RDSO guidelines. Provision of inspection ladder and
inspection platform shall be designed as per railways requirement.
D.3 The design calculations to be submitted to the railway for approval shall be in any of the
following formats:-
i) Design done manually supported by the step- by- step detailed structural calculations.
ii) Alternatively design may be submitted in the form of computer input file/data along one sample
manual calculations accompanied by a source code computer programme on compact disk along with
the listing with description of the variables used in the analysis and design of the structure.
D.4 Design shall be submitted by the contractor/s in SI units and shall be submitted with full explanatory
notes wherever required. If during the scrutiny to the detailed design calculations and drawings, any
changes therein which are necessary in the opinion of the railway/proof checker shall be incorporated.
D.5 The contractor shall modify the design and drawings as considered necessary as result of check made
by railways. All necessary clarifications must be furnished by the contractor in writing or in personal
discussions as considered necessary by railways. For this no extra payment, no travelling expenses etc.
will be paid.
D.6 A complete set of final design for the bridges on bond paper, neatly typed in double space in bind
volumes shall be submitted by the contractor/s for Railways record. The design report shall contain
the index, the design methodology detail design calculations (each calculations being neatly explained
with reference to clauses of various codes and references). Each page of design should be signed by
Designer, Contractor & Proof checking authority.
D.7 Approval to the drawing and design calculation by the Railway shall in no way relieve the
responsibility of contractor for the soundness, correctness and safety of the structure designed by
him/them.
D.8 Approved design calculations and drawings will also be submitted in soft copies.

34
E.0 Preparation of Drawings

The drawing shall be considered as final only after the approval of competent authority of the
Railways. Even after final approval, Railway reserves the right to ask for modifications, alterations in
the drawings without any extra cost.
All the drawings prepared at various stages shall be on computerized prints like AUTO CAD. The
contractor/s shall submit six sets of working arrangement drawings and six sets of detailed drawing
including revisions, if any, complete in all respect, for being used as contract drawing for construction
after approval by the railways.
F.0 Submission of Drawings
The drawings shall be submitted in original in reproducible tracing film of minimum thickness 75
microns double matt type of approved quality available in the market in A-1 size 594 x 841 mm
indicating the details of proposed structures in black, colour and with all notes of general and technical
nature of the drawing.
The drawings and design so submitted shall be treated as the property of West Central Railway,
Jabalpur. The railway shall reserves the rights to use these drawings and design at location other than
or which the drawing and design have been submitted by the contractor. No extra payment shall be
made on this account.
G. Clarification
Notwithstanding the approval in the design/drawing by the railways if any doubt arises during the
execution of work, the contractor shall always issue clarifications as and when required by the
railways.
In addition to the above contractor shall submit the following details:-
i. The contractor shall submit detailed technical specifications for the various items involved
ii. Any changes required in the design at the execution stage shall be carried out by the designer within the
rates quoted by him for the works. The rates quoted should cover the cost of site visit as required during
the design and construction stages.
MODE OF PAYMENT :
(i) 40% Payment will be made after submission of detail design and drawing duly proof
checked from NIT/ IIT .
(ii) 60% Payment will be made after approval by Railway.
3.0 NS/3 & NS - 4:- STEEL WORK IN BUILTUP SECTION WELDED AND BOLTED WITH RS
JOINT, TEE, ANGLE,CHANNEL, BARS, FLATES, AND PLATES.
The specification for NS items of schedule- C- NS-3 & NS-4, same as per USSOR- 2011 Item No
081030/081031 &081030/081032 shall be applicable.
4.0 NS/5- Casting, Supplying, Transporting & Launching precast reinforced concrete facia panel of
thickness 180mm in M-35 design mix:-

35
4.1 This item involves the work of providing and laying in position cement concrete of M-35 grade for
RCC facia panel of thickness 180mm in M-35 design mix as per approved drawing.
4.2 The items includes cost of casting, supplying, transporting & launching in position `precast RCC facia
panel of thickness 180mm including all labour, machineries, materials, shuttering, cantering vibrating,
curing etc except cement & reinforcement steel which will be paid separately under relevant
USSOR-2011 item as per consumption required according to mix design duly approved by Railway for
M-35 grade of concrete.
4.3 The cement used shall be generally 43/53 grade ordinary Portland cement conforming to IS: 8112 and
12269.
4.4 Only machine mixed and automatic weigh batched concrete shall be used during entire work. No hand
Mix concrete shall be allowed. The concrete shall be placed with the help of transit mixer or concrete
pump.
4.5 Measurement: Dimensions of length, breadth and thickness shall be measured correct to nearest Cm.
Areas shall be worked out to nearest 0.01sqm. and the cubic contents of consolidated concrete shall be
worked out to nearest 0.01 cum. Any work done in excess over the specified dimensions or sections
shown in the drawing shall be ignored.
4.6 Concrete shall be of M-35 grade as per mix design only.
4.7 Date of casting and name of casting depot shall be engraved segment on each unit.
4.8 The depot where casting of RCC facia panel of thickness 180mm in M-35 design mix is proposed shall
be inspected by railway officials in order to ensure quality of raw material and quality control in
concreting. All arrangements for casting will be done in presence of concerned SSE (W)/XEN/AXEN.
Casting of RCC facia panel of thickness 180mm in M-35 shall be done in presence of Engineers
representative who will put a passing mark on each piece. Transportation of RCC facia panel of
thickness 180mm in M-35 will be allowed only after inspection by the Engineer-in-charge.
4.9 After casting and inspection of the precast RCC facia panel of thickness 180mm in M-35, the contractor
will have to transport them by his own mechanical means viz. Tractor or trucks/Trailers/crane etc. to
both bridge sites in Jirapur- Khilchipur Road and Chhatta-Biaora Road at ROB location. All loading and
unloading of casted segment of RCC facia panel of thickness 180mm in M-35 at the ROB site will be
done by means of crane or any other mechanical means to avoid any damage to the precast RCC facia
panel of thickness 180mm in M-35 .
4.10 Damage to RCC facia panel of thickness 180mm in M-35 during transportation and stacking etc. will be
rectified with the epoxy mortar and re-offer for inspection in case of minor damage. In case of major
damage, a fresh RCC ballast retainers, slabs will be cast free of cost and penalty as deemed fit shall be
imposed on both cases.

36
4.11 Mode of Payment:
The mode of payment for this item shall be as under:
1. Casting RCC facia panel of thickness 180mm in M-35 as directed by 50% of the accepted
Engineer in charge rates.
2. Transporting & Unloading RCC facia panel of thickness 180mm in M-35 30% of the accepted
ROB site as directed by Engineer in charge rates.
3. Launching in position RCC ballast retainers, slabs including finishing and 20% of the accepted
cleaning at site as directed by Engineer in charge rates
5.0 NS-6 & NS 7 :Providing and Laying in position precast/ cast-in-situ machine batched, machine
mixed and machine vibrated design mix M-30/35 grade concrete in foundation and sub structure
respectively
This item involves the work of Providing and Laying in position precast/ cast-in-situ Weigh batched,
machine mixed and machine vibrated design mix M-30/35 Reinforced Cement Concrete in RCC Box,
sub-structure of abutment, piers, wing walls, return walls etc. as per approved drawings, design,
specifications and special condition of contract.
5.1 The items includes cost of all labour , machineries & tools, materials, shuttering, centering vibrating,
curing etc except cement & reinforcement steel which will be paid separately under relevant USSOR-
2011 item as per consumption required according to mix design duly approved by Railway for M-30/35
grade of concrete.
5.2 The concrete shall be manufactured by automatic weigh batching plant of suitable capacity load cell
and placed by transit mixer and/ or concrete pump. No hand Mix concrete shall be allowed.
5.3 Measurement: Dimensions of length, breadth and thickness shall be measured correct to nearest Cm.
areas shall be worked out to nearest 0.01sq.m. & the cubic contents of solidated concrete shall be
worked out to nearest 0.01 cum. Any work done in excess over the specified dimensions or sections
shown in the drawing shall be ignored.
5.4 The depot where casting of slabs is proposed shall be inspected by railway officials in order to ensure
quality of raw materials, and quality control in concreting. All arrangements for casting, and curing will
be done in presence of Engineer-in- charge.
5.5 Casting of slab shall be done in presence of Engineers representative who will put a passing mark on
each piece. Transportation of slabs to the bridge site will be allowed only after inspection by the
Engineer-in-charge.
END OF TENDER DOCUMENT

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E-Tender No.

WEST CENTRAL RAILWAY

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

IMPORTANT CODAL PROVISIONS

1.1 Earthwork in embankment/blanketing

1.2 Earthwork in cuttings :-

1.3.0 Quality Control of Compacted Earth / Blanket layer

1.4 QUALIFYING AND QUALITY ASSURANCE TESTS (Mandatory)

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

1.4.1 Frequency of Quality Assurance Tests

1.5 RECOMMENDED SPECIFICATIONS OF BLANKET MATERIAL (Mandatory)

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

Sr. No. IS Sieve Size Percent Passing (by weight)

Fig.9: Enveloping Curves for Blanket Material

2.0 Cement Concrete work

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

2.4.2 Coarse Aggregate

2.4.2.1 Size and Grading

(i) Stone aggregate and gravel

TABLE 3.1 of Unified Standard Specifications for Works & Materials

IS Sieve Percentage passing (by weight) for nominal size of

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

TABLE 3.2 of Unified Standard Specifications for Works & Materials

2.4.3 Construction Joints

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

3.0 REINFORCED CEMENT CONCRETE

3.1.1 Selection and Preparation of Test Sample for steel reinforcement:

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

3.1.3 Guidelines for use of Steel Items in Railway Projects/Contracts.

3.2 FORM WORK (CENTERING AND SHUTTERING)

Type of Formwork Minimum Period

(c ) Soffit formwork to - beams (Props to be

(d) Props to slabs

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

3.3 SAMPLING AND ACCEPTANCE CRITERIA OF STRENGTH OF DESIGN

3.3.2.1 Sampling Procedure -

3.3.4 Test Results of Sample

3.4 ACCEPTANCE CRITERIA

3.4.1 Characteristic Compressive Strength Compliance Requirement

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

3.4.2 Quantity of Concrete Represented by Strength Test Results

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

4.0 Bridge Works: Super Structure-Concrete

4.1 CONCRETE FOR SUPERSTRUCTURE

4.1.2 Size of Coarse Aggregate

TABLE 20.3 of Unified Standard Specifications for Works & Materials

4.1.3 Construction Joints

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

5. Bridge Works: Superstructure-Steel

5.1 FABRICATION OF STEEL WORK

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

TABLE 21.2 of Unified Standard Specifications for Works & Materials

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

11 Deviation from squareness of machined ends to D/1000, where D is as defined in 9

5.1.5 Guidelines for procurement of Steel Items in Railway Projects/ Contracts.

6.0 Bridge Works-Miscellaneous

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

C. Without Template without Gap

Signature of Tenderer/tenderers For Chief Administrative Officer (Const)

D. Seating of bearings shall be as per manufacturers instructions.

6.1.8 Inspection and Testing