Steel Structures

CONSTRUCTION OF STEEL
STRUCTURES & SHEDS AT

KADAPA

Site: Hindustan Petroleum Corporation Ltd.,
Kadapa IRD Project Site,
Rajampeta-Kadapa Road; SH-31,
Peddapalli Village, Siddhout Mandal, YSR Dt
Siddhout Mandal,

CONSTRUCTION OF STEEL STRUCTURES & SHEDS KADAPA

H I N D U S T A N P E T R O L E U M C O R P O R A T I O N L I MI T E D

Page 2 of 148

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Page 3 of 148
INDEX

SL.
NO.
SECTION
1 PROJECT DESCRIPTION & SCOPE OF WORK
2 TIME SCHEDULE
3 UNPRICED BOQ
4 SPECIAL CONDITIONS OF CONTRACT
5 QUALITY ASSURANCE PLAN
6 SHE GUIDELINES
7 TESTING OF CONSTRUCTION MATERIALS
8
SPECIFICATIONS FOR CONCRETE & REINFORCEMENT,
CIVIL & ARCHITECTURAL WORKS
9 STRUCTURAL STEEL WORKS
10 STANDARD SPECIFICATION FOR FIELD PAINTING
11 SPECIFICATION FOR GALVALUME SHEET
12 SPECIFICATION FOR TURBO VENTILATOR
13 LIST OF MAKES, MANUFACTURERS, BRANDS
14 SAFETY IN CONSTRUCTION



Page 4 of 148

LIST OF DRAWINGS

SL. NO DESCRIPTION
1 8 BAY TT GANTRY PLAN, ELEVATION & SECTION
2 CALIBRATION SHED
3 CAR AND SCOOTER PARKING SHED
4 DOSING SHEDS
5 FIRE PUMP HOUSE
6 FOAM BLADDER SHED
7 LUBE DRUM YARD & GREASE DRUM SHED
8 LUBE GODOWN & ENGG. STORE
9 MAINTENANCE & REPAIR SHED
10 SEALING PLATFORM
11 STANDARD GRATING.(TYPICAL)
12 TLF PRODUCT PUMP HOUSE
13 TWD PRODUCT PUMP HOUSE
14 WATCH TOWER 7.5 M HT
15 HPCL ,KADAPA BOUNDRY PLAN WITH COORDINATES

REMARK : DRAWINGS PERTAINING TO PIPE TRESTLES WILL BE ISSUED BY
HPCL TO THE CONTRACTOR UPON ISSUE OF LOI/FOI.



Page 5 of 148

PROJECT

DESCRIPTION &

SCOPE

OF

WORK



Page 6 of 148

PROJECT DESCRIPTION/ SITE
INFORMATION

1.0 Hindustan Petroleum Corporation Limited (hereinafter referred to
as "HPCL"), proposes to Construct a New POL Depot at KADAPA,
ANDHRA PRADESH.

The site addresses is as below:
Hindustan Petroleum Corporation Limited,
Kadapa IRD Project Site,
SH-31, KADAPA-TIRUPATHI
Peddapalli Village, Siddhout Mandal,
Kadapa - YSR district,
AP - 516237

The brief scope of work includes but not limited to the following:

A. Construction of following Steel Structures & Sheds including their
foundations and associated Civil,Structural & Architectural Works

Steel Structural Industrial Sheds

i. Tank Truck Gantry( 8 bay) # 2 nos
ii. Tank Truck Gantry ( 2 bay) # 1 no
iii. Tank Truck Filling Pump house
iv. Tank Wagon Decanting Pump house
v. Fire Water Pump house
vi. Car/Scooter Parking shed
vii. Calibration Shed
viii. Lube ware House
ix. Engineering Store
x. Grease Drum Shed
xi. Maintenance & Repair Shed
xii. Sealing Platform Shed
xiii. Watch Towers # 5 nos
xiv. Foam Shed
xv. Dosing Shed
xvi. Pipe Rack

B. Other general civil works and common items as per Schedule of
Quantities.



Page 7 of 148

The scope of work of the Contractor as covered in this bid document
generally includes but is not limited to the following:

1) Carrying out Total station survey and establishment of the corners
of each Structure and Shed as per Plot Plan and co-ordinates
issued by HPCL.
2) Establishment of control pillars for the above.
3) Carrying out grid survey @ 5m c/c bothways and furnishing the
level details.
4) Carrying out excavation as per the AFC drawings issued by HPCL.
5) Providing foundations as per AFC drawings with anchor
bolts/sleeves for facilitating erection of the structures.
6) Preparation & submission of Fabrication drawings for the
Structures and Sheds in line with the AFC drawings issued by HPCL
and as per this bid document.
7) Supply, Testing, Fabrication, welding and erection of Steel
Structures either at Site or in an approved Workshop.
8) Providing surface preparation & painting for the structures.
9) Providing brickwork, plaster and painting for the Sheds.
10) Providing Roof sheeting & cladding with specials
11) Providing all other items as per BOQ.

Scope of Supply:

All the items required for the works including Steel, Cement, bricks,
sand, Structural steel, etc as required for completion of the works
envisaged in this bid document shall be supplied by the contractor only.

HPCL shall not supply any of the items required for the works.

Scope of HPCL:

HPCL shall provide the GA Plans,Elevations and Sections along with the
required structural detailing for the Sheds and structures envisaged in
this bid document.

The design of these structures and sheds will be done by HPCL through a
separate Consultant and HPCL will provide the Approved For Construction
Drawings. These drawings shall be issued by HPCL within 10 days of
issue of LOI/FOI.

Scope of Contractor:

The Contractor shall review the AFC drawings issued by HPCL and



Page 8 of 148
prepare the fabrication drawings for the various sheds and structures. In
case of any discrepancies, the Contractor shall furnish same to HPCL,
who will in turn issue revised drawings.

The contractor shall furnish the Fabrication drawings for review and
approval of HPCL progressively. All such drawings shall carry Bill of
Materials, Joint details, Splicing details and all other detailing required
for fabrication and erection.

Site Visit:

The bidder is advised to visit and examine the site of works and their
surroundings and obtain for himself and on his own responsibility all
information that may be necessary for preparation of the bid and
entering into the contract. The cost of visiting the sites shall be at
bidders own expenses. No extra claim on account of non-familiarity of
site conditions shall be entertained during execution of works.

The prospective bidders are requested to thoroughly read and
comprehend the various sections of this tender document and visit the
sites before quoting for the tender and offer their most competitive rates
for the job.

IMPORTANT NOTES

1. These notes to be read in conjunction with the schedule of
quantities and is integral part of the same.

2. Job also includes all testing, as envisaged in the tender
document and as directed by Engineer In Charge. No
separate payment shall be made for the same.

The bidders are required to go through the tender document thoroughly
and carefully and offer their most competitive rates for the job.

In case of any clarifications contractor may contact Shri V Vishwanath,
Sr. Manager-E&P, Engg & Projects Deptt, Gresham Assurance House,
2
ND
Floor, A-1595 (3), 1-A, Sir P M Road, 132, Shahid B Singh Road,
Fort, Mumbai- 400 001 on 022-22608531 regarding any queries. Party
may also contact Shri M. S. Rao, Manager- Project Site on
09997035560 regarding any queries.



Page 9 of 148

TIME

SCHEDULE



Page 10 of 148

TIME SCHEDULE

DESCRIPTION OF WORK:

CONSTRUCTION OF STEEL STRUCTURES AND INDUSTRIAL
SHEDS AT KADAPA DEPOT PROJECT SITE

LOCATION
COMPLETION PERIOD
FROM DATE OF ISSUE
OF FOI/LOI/PO
KADAPA
DEPOT PROJECT SITE
KADAPA, ANDHRA PRADESH
8 MONTHS

NOTE:

1) Time for completion shall be reckoned from the date of issue of
Fax/ Letter of Intent/Purchase Order, whichever is earlier by HPCL.



Page 11 of 148

SCHEDULE

OF

QUANTITIES



Page 12 of 148

S.N Item Description Unit Qty
CONSTRUCTION OF STEEL STRUCTURES & SHEDS
EXCAVATION
Earthwork in excavation below Ground Level in all kinds of
soils up to hard strata to a maximum depth of 2.0 m
below existing FGL ;staking out of work as per
specifications; taking spot levels on edges & centerline @
3m c/c as per specifications; bailing out of water if
encountered; providing side strutting if required,
segregating the excavated earth in to serviceable and
unserviceable earth; stacking the serviceable earth
separately for enabling reuse for backfilling or any other
purpose as per instructions of HPCL; carting away and
disposing the unserviceable earth and disposing off
beyond Plant boundaries to suitable dumping
spots/unobjectionable places; obtaining approval from
Mining Department/Applicable departments by payment of
royalty; Right of way payments; loading at HPCL
premises; transportation to dumping
spots/unobjectionable places; unloading & leveling at
dumping spots/unobjectionable places;

1 For depth up to and including 1.5 M Cum 5700
2 For depth above 1.5 M and upto and including 3.0 M Cum 1955
3 For depth more than 3.00 M Cum 165
BACK FILLING
Backfilling around sub-structure with serviceable &
reusable soils available from excavation and stacked
earlier within the new Plant boundary including re-
excavating, shifting to the site of backfilling, backfilling in
layers of 200 mm; watering; compacting; testing to
achieve 95% MDD as per lab results all complete as per
instructions of HPCL.

4 UPTO 1.5 M Cum 4800
5 FROM 1.5 M TO 3 M Cum 400
6 SAND FILLING
Supplying and filling approved quality sand in foundation
or under floor, trenches, pits and other places, at all
locations in layers of 200 mm thickness including watering
and ramming, all lead, lift and depth complete as per
drawing and specification and direction of the Engineer
Cum 2590
7 MURRUM FILLING
Same as Item 6 above but with supplying & providing
approved quality Murrum of PI not greater than 21 and
laboratory MDD not lower than 1.65 g/cc for filling as per
Tender Specification for Back filling,General site Grading &
Cum 1675



Page 13 of 148
plinth filling, around the foundation,etc as applicable
including cost of supply of murrum from Borrow Pits
outside HPCL Plant;testing,spreading in layers of 200 mm
thick, watering and compacting with plate vibrator/hand
compactor as decided by the site-in-charge till min.
95%MDD of lab test is achieved ;testing; Complying all
the requirement of Mining Dept/Applicable Dept of AP
State including applicable Royalty Payment; ROW
payments; Transportation to Site for all applicable leads &
lifts complete in all respect as per Tender
Specification/Scope of Work etc, as directed by HPCL.
8 ANTITERMITE TREATMENT
Supplying and injecting with approved quality chemical
emulsion at the rates and concentrations as per IS 6313-
1981 Part II for pre constructional anti termite treatment
and creating a chemical barrier under and all round the
column pits, foundation, wall trenches, plinth filling,
junctions of wall and floor, expansion joints, apron,
surrounding of pipes, conduits etc., along the perimeter of
the building including all bye works complete as per
specification and direction of Engineer (only ground floor
plinth area of the building will be measured for the
payment in the following three stages. i) 50% after
completion of the foundations ii) 30% after completion of
the ground floor flooring iii) 20% after completion of all
treatment works including ground floor doors & windows.
Work to be executed by M/s Pest Control (India) or any
other approved agency and specified guarantee for 10
(ten) years shall be furnished by the bidder.
Sqm 800
Supplying, Providing & injecting approved chemical
emulsions consisting of chloropyrifos for pre-constructional
anti-termite treatment including applicable testing and
creating a chemical barrier around column pits, wall
trenches, basement excavations, top surfaces of plinth
filling, junction of wall & floor, along the external
perimeter of the building, expansion joints, surrounding of
pipes, conduits, etc. Any treatment required for
maintaining continuity of the barrier by providing
treatment around plinth protection and corridor shall be
provided without any separate measurement.

The anti-termite treatment shall be provided as per BIS
6313(Part-2)-latest revision. The chemicals used shall be
any one or combination of the following with concentration
shown against each in aqueous emulsion: Chemicals
concentration: Chloropyrifos 1% by wt(IS:8944-latest
rev),Lindane-1% by wt(IS:632 latest rev).



Page 14 of 148

The various steps & rates of application given in
IS:6313(Part-2) shall be followed in toto.

9 PLAIN CEMENT CONCRETE
Supplying and Laying Plain Cement Concrete of Grade
1:4:8 with stone aggregate of 40mm down size (including
shuttering if required) in all leveling courses under
Foundation, Floors, Pipelines, Pits, trenches etc., at all
depths complete all as per Drawings and Specifications
and instruction of the Engineer.
Cum 500
CONCRETE FOR PLINTH PROTECTION
Supplying and Laying Plain Cement Concrete of following
Grades (including Shuttering if required) in Plinth
Protection, foundation, floors, aprons, pits, drains and
other mass Concrete works, Steps, Coping of wall etc., at
all level as per Drawings, Specifications and instruction of
Engineer.

10 a) 1:3:6 Grade Concrete,using 20 mm down graded
coarse aggregate.
Cum 10
11 b) 1:2:4 Grade Concrete,using 20 mm down graded
coarse aggregate.
Cum 69
RCC
Supplying and Laying of design mix, Reinforced Cement
Concrete of following Grades (excluding Shuttering and
Reinforcement) at all depths and heights in all types of
Foundations, Footings, equipment foundations, pile cap,
columns, pedestal, wall, lintels, ducts, beams, brackets,
slabs of all shapes, sills, parapets, bands and any other
works both in under ground and Superstructures all
complete as per Drawings, Specification and instruction of
Engineer. For design mix, Moderate exposure shall be
considered.

12 M-25 Grade Design Mix Concrete, using 20 mm down
graded coarse aggregate IN SUB-STRUCTURE
Cum 1095
13 M-25 Grade Design Mix Concrete using 20 mm down
graded coarse aggregate IN SUPER-STRUCTURE
Cum 79
14 M20 Grade Design Mix Concrete using 20 mm down
graded coarse aggregate IN FLOORING with Floor
Hardner.
Providing & laying 150mm thick RCC of Grade M 20 for
internal floor paving including side shuttering with
channels; placing reinforcement (reinforcement shall be
considered under separate item) with cover blocks; screed
/axial vibrating including providing reinforcement laps at
channel ends for panel sizes as shown in drawings,
spraying Nitofloor hardtop @ 5 kg/sq.m or approved
Cum 355



Page 15 of 148
equivalent as an integral hardener during concreting itself,
finishing, curing, etc all complete.
15 SHUTTERING
Providing, Fixing and Stripping of Shuttering of approved
quality plywood or steel plate on steel frame for all types
of Structures, anchor pockets etc at all depths and heights
not covered in respective items including Centering /
Scaffolding, all complete as per Drawings, Specifications
and directions of the Engineer so as to obtain a smooth
surface of concrete free from honeycombing.
Sqm 4510
16 REINFORCEMENT STEEL
Supplying and Fabricating and Fixing in position Steel
Reinforcements of Grade Fe-415 conforming to IS-1786-
1985 at all levels and positions including the Cost of
transport, Straightening, Cutting, Bending, Cranking,
Binding, Welding, Provision of necessary Chairs and
Spacers, Preparation of bar bending schedule, Drawings,
getting the same approved etc., as per Drawings and
Specifications and including Cost of binding wire, Labor
etc., all complete for Reinforced Concrete. Only approved
chairs, spacers & overlaps shall be paid.

MT 120
17 WATER PROOFING ADMIXTURE
Providing and mixing of approved water proofing
admixture Liquid water proofing compound (Prolapin 421
IC/Plastocretes - N or equivalent) as per the
manufacturer's specification including cost of material,
complete, with all bye works as per drawing and
instruction of the Engineer.

Litre
s
100
18 GROUTING FOR COLUMN BASES ETC
Providing & Grouting of M30 grade with 12mm
downgraded aggregate including tamping for Equipment
Base plates, Anchor holes etc., with Cement Concrete of
the following Grades (including Shuttering wherever
necessary) at all levels and as per Drawings, Specifications
and direction of the Engineer.
Cum 5
19 RANDOM RUBBLE MASONRY IN SUBSTRUCTURE

Supplying, Providing and laying random rubble stone
masonry in CM 1:5 for Compound wall in sub-structure &
superstructure, using approved quality rubble stones
including double scaffolding with pipes, payment of all
applicable royalty & ROW payments and for all leads &
lifts. Rate to include dressing of stones, watering prior to
laying, providing and laying bond stones (Header)at 1m
Cum 640



Page 16 of 148
C/C that is @ 1bond stone/ 0.50 sq.m surface area of wall
for super-structure & sub-structure & marking the same
with oil paint , supplying & providing key stones, raking
the joints upto a depth of minimum 6mm below ; curing
the masonry after construction, providing scaffolding
required if any, etc., complete in all respect as per Tender
Specification/Scope of Work etc and as directed by HPCL
Engineer -in-charge. In case of non-availability of Bond
stones of size 200mm x 200mm x required length, bond
blocks of PCC 1:2:4 with two s-bars of 8mm dia shall be
provided at no extra cost to HPCL.The stones must be
properly dressed and laid to plumb and must give a square
cut appearance at the pillars.
20 RAISED POINTING
Providing and constructing raised pointing for all the
random rubble masonry joints above ground level in CM
1:3 having pointing thickness of 6mm and 10mm wide
over the raked joints including double scaffolding,
application of mortar for pointing, curing the same, etc.,
complete in all respect as per Tender Specification/Scope
of Work etc, as directed by HPCL Engineer -in-charge.

Sqm 860
21 BRICK WORK
Providing BRICK WORK with frog/indent, conforming to
class B as per IS:1077 having crushing strength of not
less than 35 kg/cm2, in 1:4 cement mortar in all types of
foundation and superstructure at all depths/heights
including bands, projections, pillars, parapets,
ornamentals of any shape, cornices, all complete including
cut work, curing, scaffolding, including filling of joints with
CM 1:5 and racking of joints, etc., with all bye-works as
per specifications, drawings and directions of the Engineer.
Cum 351
22 BRICK WORK 135 MM THICK
Providing BRICK WORK 135 mm thick using class B bricks,
having crushing strength of not less than 35 kg/cm2, in
1:4 cement mortar, including providing reinforcement at
every 3rd courses with 2 MS bars of 6 mm dia. and
distribution 6 mm dia at 30 cm centre to centre in all
locations and heights, as per drawing and as directed by
engineer including filling of joints with CM 1:4 and racking
of joints.(Reinforcement will not be paid separately)

Sqm 10
23 EXTERNAL PLASTER 20 MM THICK
Providing 20 mm thick external sponge finish cement
plaster 1:4 (1 cement : 4 sand) as per architectural
shapes marked in the drawings, at all depths and heights
Sqm 1245



Page 17 of 148
in two coats of 12mm & 8mm. 2nd coating 8mm shall be
finished with sand faced plastering on faces of walls,
pillars, projection, bands, cornices, fins, sills, etc.,
including raking out joints if any left out, necessary
dabbing, curing, scaffolding, providing chicken mesh at
junctions of columns, beams etc., complete at all heights
as per specification and drawings, second layer with water
proofing compound (to be paid under relevant items).
24 INTERNAL PLASTER 12 MM THICK
Providing 12 mm thick cement plaster 1:4 (1 cement: 4
sand) smooth finish with water proofing compound (to be
paid under relevant items) as per architectural shapes
marked in the drawings, at all depths and heights in one
layer on internal faces of walls, pillars, projection, bands,
cornices etc., including necessary dabbing, curing,
scaffolding, providing chicken mesh at junctions of
columns, beams etc. complete at all heights as per
specification and drawings.
Sqm 580
25 PLASTER 6 MM THICK
Providing 6 mm thick cement plaster 1:4 (1 cement: 4
sand) to ceiling of slabs, chajjas including drip course,
bands, beams, columns, loft slabs, staircases, and any
other location at all heights wherever required with all bye
works dabbing, curing, scaffolding, including providing
chicken mesh at junction of columns, beams etc. complete
at all heights and levels as per specification and drawings.
Sqm 50
26 PLASTER 12 MM THICK WITH CEMENT FLOAT
Providing 12mm thick cement plaster CM 1:4 (1 cement :
4 sand) to apron, drain and any other location at all
heights including floating coat of neat cement @ 2.2
kg/sqm wherever required with all bye-works dabbing,
curing, complete all heights and levels as per specification
and drawings and as directed by engineer.
Sqm 50
27 CEMENT PAINTING
Providing and applying waterproof cement paint of
approved make and shade with textured finish in two
coats at all locations over and including a priming coat
over wall surface, etc., including preparation of surface
complete with all bye works, specification and direction of
the Engineer.
Sqm 560
28 ACRYLIC EXTERNAL PAINTING
Supplying,Providing & applying 1 coat of APEX DURACAST
Finetex (prod. code 1003)undercoat followed by 1 coat of
Exterior wall primer(Prod.code 0065) after rectifying
surface imperfections such as holes, dents and cracks by
filling with a mixture of white cemnet & fine sand in the
Sqm 1520



Page 18 of 148
ratio of 1: 3 or with Asian Paints wall putty and followed
by 2 coats of APEX WEATHERPROOF EXTERIOR
EMULSION(Prod. CODE 0012) of Asian Paints make as per
the manufacturer's specifications, including providing
necessary double scaffolding & surface preparation,
thoroughly wetting surface & complete with curing . Rate
to be applicable for all heights & levels.
29 SOLING
Providing hard core with hard granite stone boulders in
aprons and flooring including laying, packing, filling
interstices with good quality spalls, dry and wet
consolidation with mechanical means, binding with good
quality murrum/sand(cost inclusive) with all bye works
complete for hard core up to 230 mm thick below floor and
115 mm thick, below apron as per specification and
instruction of the Engineer (Consolidated thickness will be
paid).

Cum 1190
30 ALUMINIUM WINDOWS
Supplying, Providing and fixing in position aluminum
glazed windows in approved colour anodized (25 micron in
Bronze / Brown / Black colour) extruded aluminum
windows/doors sections of Hindalco/Jindal as per the
detailed drawings with all necessary fittings such as
Glazing clips, imex hinges, sliding handle lock, concealed
lock, Dead locks, rollers with bearing (Japanese make)
with zinc plated screws etc of reputed make with 5mm
thick clear glass of selected quality, EPDM gasket lining.
All joints to be sealed with poly-sulphide dow corning
sealant. All aluminum sections should be machine cut &
mechanically assembled etc complete as per attached drgs
& instructions from HPCL.The job has to be executed by an
approved agency as given in the approved list of
fabricators. Single shutter fixed glass windows using a)
Outer frame SP 4770 @ .818 kg/m;
b) Shutter frame SP 4768 @ 1.078 kg/m
Sqm 72
31 ROLLING SHUTTERS
Supplying, fabricating and fixing of rolling shutters of
approved make, as per IS:6248, made of MS laths
interlocked together at the end by end locks mounted on
specially designed pipe shaft with brackets, side guides
and arrangement for inside and outside locking, top cover,
spring and complete with two coats of synthetic enamel
paint of approved shade and colour over a primer coat,
making chases in wall/floor, grouting the clamps in PCC -
M15 (20mm down size aggregate) all complete as per
Sqm 44



Page 19 of 148
specifications, drawings and instruction of Engineer with
80x1.25mm thick MS laths, push and pull hand operated
with mechanical device chain and crank. The rolling
shutter should have provision of manual opening by
operating handle from outside. Necessary hardware viz.
bushing, handle, gear box etc is included in the item
scope.
32 PRESSED STEEL DOOR FRAME
Supplying, fabricating and fixing in position, pressed steel
frames for doors manufactured from commercial steel
sheet 1.2mm thick including provision of hinges, lock
jambs, beads, brace ties with 4.00mm pressed mild steel
welded adjustable lugs with split tail end, mortar guards,
lock strike plate, shock absorbers, etc. and painting with
two coats of approved synthetic enamel paint over primer
coat, as per drawing and instructions of the Engineer,
including provision and filling with PCC 1:3:6.

RM 25
33 MS DOOR SHUTTER
Supplying and fixing MS door shutters consisting of MS
box sections, flats, tubes, sheets, meshes etc.,
double/single hung including lugs, locking arrangements
as per drawing and painting steel works with two coats of
approved synthetic enamel paint over and including a coat
of priming complete with all bye works as per specification
and direction of the Engineer
KG 15
34 MS WINDOW GRILL
Supplying, fabricating and fixing MS guard bars/grill made
out of MS flats, rods, square bars, etc., to steel windows /
ventilators including two coats of synthetic enamel paint
over primer coat, all complete as per drawing/approved
designs, specifications and directions of the Engineer.
KG 1100
35 ALUMINIUM VENTILATOR
Supplying, Providing & fixing in position coloured anodized
(25 micron in Bronze / Brown / Black colour) extruded
aluminium ventilators with alternate shutters fixed and
alternate louvered ventilators such that handle is provided
for operating the louvers as per detailed drawings with all
necessary fittings such as openable handles shutter rollers
with zinc plated screws, etc. of reputed make with 5 mm
thick Reflective glass of approved colour shade fixed with
EPDM gasket lining. All joints should be sealed with similar
colour poly-sulphide dow corning sealant. All aluminium
sections should be machine cut & mechanically assembled
etc. complete as directed by Engineer in charge. The glass
shall be 5mm thick(min). Outer frame shall be 25mm x
Sqm 20



Page 20 of 148
75mm x 1.5mm thk coloured anodized (12 micron in
Bronze / Brown / Black colour) extruded aluminum
section. Louvers shall be box type.
36 WATER PROOFING FOR CHAJJAS
Providing and applying on top of Chajjas waterproofing
treatment by applying 1mm thick in two or more coats
Brush bond waterproofing system of Fosroc or equivalent
approved by Consultant, IPS concrete 40 mm thick with
proper slope and wattas with wall, mixed with Conplast
x421 IC of Fosroc plasticizing waterproofing admixture at
200ml per 50kg. of cement, finsihing the IPS etc.
complete.
Sqm 80
PRECAST CONCRETE COVERS
Providing & erecting in position precast concrete trench
cover units of specified sizes and thickness using
reinforced cement concrete of grade M25 with 20 mm
down graded coarse aggregates including formwork to
give fair and smooth finish, casting, vibrating using
storing, providing lifting arrangement, loading / unloading
transporting, load testing etc., complete but excluding cost
of reinforcement, all as per specification and as directed
by the engineer.

37 Unit weight up to and including 100 kg Cum 10
38 GI WATER SPOUTS
Providing & fixing GI water spouts of 40 mm NB light
variety pipes including making grooves and making the
surface smooth after finish of work.
RM 40
39 DAMP PROOF COURSE
Providing & laying 40mm thk Damp proof course with PCC
1: 1 1/2:3(cement: sand: coarse aggregates,10mm &
down) in two layers with shuttering & curing such that
after each layer,bitumen 80/100 shall be provided by
brush application @ 1.5 kg/sq.m and sprinkled with fine
sand.
SqM 242
40 PVC RAIN WATER DOWNTAKE PIPES
Supplying, jointing, cutting and fixing in position U PVC
rain water down HG pipes of 150mm dia of following
diameters, including all necessary specials like bends,
shoes, tees, clamps etc. jointing as per manufacturers
recommendation, complete as per specifications, drawings
and directions of the Engineer.
RM 485
41 MS GRATING
Preparation of all necessary fabrication drawings including
bill of materials, Supply of steel, consisting of flats size
25x6 & 25x3 or any other size as directed including
straightening of raw steel if required, fabrication of MS
SqM 660



Page 21 of 148
Gratings as per drawings (including preparation of
supplementary sketches and detailed bill of materials)
including welding electrodes and all other consumables, as
required, cleaning and preparation of all steel surfaces to
Swedish Standard SA 2 for painting, supply and
application of 2 coats of red oxide zinc phosphate primer
and 2 coats of synthetic enamel paint so as to achieve
min. DFT of 120 microns,. Loading, transportation and
unloading and delivery at erection site of all fabricated
grating structures, erection, alignment and welding,
including rectification if any, site assembly all as per
technical specifications and drawings, touch up painting,
including supply of paint, where paint is damaged.
42 STRUCTURAL STEEL WORK & Surface preparation
bill of materials, supply of steel consisting of plates, rolled
steel joists, channels, angles, chequered plates etc and
also rectangular / square hollow steel sections, insert
plates in RCC/Brickwork, anchor bolts for steel structure,
sleeve pipes, anchor nuts, washers etc ,straightening of
raw steel if required, fabrication of steel structures as per
drawings (including preparation of supplementary sketches
and detailed bill of materials) supply of bolts, nuts,
washers, shims, packs, putty. gas, welding electrodes and
all other consumables, as required and carrying out
surface preparation to SA 2 by shot or grit or copper
slag blasting, all complete. The scope includes loading,
transportation ,unloading and delivery at erection site of
all fabricated structures, erection, alignment and welding
of all structures true to line, level, plumb and dimension,
including rectification if any, splicing, site assembly all as
per technical specifications and drawings, surface
preparation, all complete. CONTRACTOR WILL BE
PERMITTED TO CARRY OUT FABRICATION AT AN
APPROVED WORKSHOP OUTSIDE HPCL PREMISES AND
TRANSPORT SAME. HOWEVER, ALL THE APPLICABLE
TAXES & DUTIES WOULD BE BORNE BY CONTRACTOR
AND JOB SHALL BE CARRIED OUT UNDER SUPERVISION
OF A THIRD PARTY INSPECTOR.
MT 385
43 STRUCTURAL STEEL WORK WITH PIPES
bill of materials, supply of steel consisting of plates,
angles, chequered plates, tubes etc and also rectangular /
square hollow steel sections, insert plates in
RCC/Brickwork, anchor bolts for steel structure, sleeve
pipes, anchor nuts, washers etc ,straightening of raw steel
MT 16



Page 22 of 148
if required, fabrication of steel structures as per drawings
(including preparation of supplementary sketches and
detailed bill of materials) supply of bolts, nuts, washers,
shims, packs, putty. gas, welding electrodes and all other
consumables, as required. The scope includes loading,
transportation ,unloading and delivery at erection site of
all fabricated structures, erection, alignment and welding
of all structures true to line, level, plumb and dimension,
per technical specifications and drawings, touch up
painting, including supply of paint, where paint is
damaged.
44 ANCHOR BOLTS
Supply and fixing in position MS foundation bolts of
various sizes as per IS-5624-1993 and washers as
directed at site. The Nut, washers etc will not be paid
separately and theoretical structural weights of the
foundation bolt will only be taken for measurement and
payment.
KG 7830
45 HANDRAIL OF 40 NB PIPE
bill of materials for hand railing work, supply of steel
consisting of tubes etc and also rectangular / square
hollow steel sections, insert plates in RCC/Brickwork,
anchor bolts for steel structure, sleeve pipes, anchor nuts,
washers etc ,straightening of raw steel if required,
fabrication of steel structures as per drawings (including
preparation of supplementary sketches and detailed bill of
materials) supply of bolts, nuts, washers, shims, packs,
putty. gas, welding electrodes and all other consumables,
as required. The scope includes loading, transportation
,unloading and delivery at erection site of all fabricated
structures, erection, alignment and welding of all
structures true to line, level, plumb and dimension,
per technical specifications and drawings, touch up
painting, including supply of paint, where paint is
damaged. (Measurement will be of Pipe in running meter
and not handrail).
RM 2100
46 STRUCTURE FOR MONORAIL
bill of materials, supply of Ceiling Mounted Monorail
Structural Member with overhead hanger assemblies for
suspending monorail from overhead steel support
structure, with all necessary plates, rolled steel joists,
channels, angles, etc and also rectangular / square hollow
KG 3650



Page 23 of 148
steel sections, insert plates in RCC/Brickwork, anchor bolts
for steel structure, sleeve pipes, anchor nuts, washers etc
,straightening of raw steel if required, fabrication of steel
structures as per drawings (including preparation of
supplementary sketches and detailed bill of materials)
supply of bolts, nuts, washers, shims, packs, putty. gas,
welding electrodes and all other consumables, as required.
The scope includes loading, transportation ,unloading and
delivery at erection site of all fabricated structures,
erection, alignment and welding of all structures true to
line, level, plumb and dimension, including rectification if
any, splicing, site assembly all as per technical
specifications and drawings, touch up painting, including
supply of paint, where paint is damaged.

47 PAINTING 1 COAT OF IZS PRIMER
Supply & painting with airless spray application for
Inorganic zinc silicate primer of DFT 65 microns DFT.
MT 400
48 PAINTING INTERMEDIATE COAT
Supply and application of intermediate coat of HB MIO
Epoxy 100 microns DFT .
MT 400
49 PAINTING ONE COAT OF PU PAINT
Supply and application of finish painting of Acrylic modified
Polyurethane- 1 x 40 microns DFT after erection.

MT 400
50 HUME PIPE 500 DIA
Supplying and laying in position RCC pipes of size 500mm
with collars, conforming to IS:458 for pipe culverts, cable
crossings etc. including cutting the pipe if necessary,
lowering, laying in position to proper levels, slopes etc.
caulking the joints with spun yarn soaked in neat cement
slurry and finishing with cement mortar 1:2 (1 cement : 2
sand) curing etc. all complete as per drawings,
specifications and directions of Engineer-in-Charge. The
excavation, PCC and curb wall at ends shall be paid under
relevant items. The scope of work includes backfilling &
compaction in layers.
RM 20
51 ROOF SHEETS
Preparation of sheeting drawings, procurement,
transportation and delivery at erection site of colour
coated steel sheets for roof & side cladding shall be of
Galvalume/zincalume BHP steel sheet made of cold rolled
steel of 300 MPA minimum yield strength conforming to
ASTM A366 or AS 1595. Base metal thickness shall be
0.6mm and total thickness of colour coated profiled sheet
shall be 0.68mm. Fixing of sheets with all flashings,
Sqm 5030



Page 24 of 148
corners, ridges, cutting, bending of sheets to a required
shape & size and erecting them in roof & sides with all
fixing arrangement as per manufactures instructions and
complete in all respect as per drawings and specifications.
(Net laid area to be measured.)

52 SHEETS FOR VERTICAL CLADDING
Preparation of sheeting drawings, procurement,
transportation and delivery at erection site of colour
coated steel sheets for roof & side cladding shall be of
Galvalume/zincalume BHP steel sheet made of cold rolled
steel of 300 MPA minimum yield strength conforming to
ASTM A366 or AS 1595. Base metal thickness shall be
0.6mm and total thickness of colour coated profiled sheet
shall be 0.68mm. Fixing of sheets with all flashings,
corners, ridges, cutting, bending of sheets to a required
shape & size and erecting them in roof & sides with all
fixing arrangement as per manufactures instructions and
complete in all respect as per drawings and specifications.
(Net laid area to be measured.)

Sqm 1570
53 FLASHING
Supplying & providing Flashing in 0.60 mm TCT Prepainted
Galvalume or equivalent specification sheets of minimum
width 800mm(High) including Screws and clips including
all applicable scaffolding with longitudinal and side lapping
as applicable for Chennai as per manufacturer
specifications. Length of flashing without laps shall be
measured.
RM 535
54 EAVES GUTTER
Supplying & providing Eaves gutter with brackets including
Screws and clips including all applicable scaffolding with
longitudinal and side lapping as applicable for Silvassa as
per manufacturer specifications. Laps shall not be
measured.

RM 370
55 RIDGE
Supplying & providing Ridge cover in 0.60 mm TCT Pre-
painted Galvalume or equivalent specification sheets of
minimum width 800mm (High)including Screws and clips
including all applicable scaffolding with longitudinal and
side lapping as applicable for Chennai as per manufacturer
specifications. Length of ridge without laps shall be
measured.
RM 445
56 TURBO VENTILATOR
Supply & fixing 24 inch diameter Stainless Steel(SS 304)
Each 16



Page 25 of 148
Turbo ventilator on the roofing with base plate and
including suitable modification of sheeting/mountings, etc
all complete as per Manufacturer's specifications. The
Manufacturer shall provide minimum 5 year warranty
which shall be extended to HPCL

57 WELD MESH
Supplying & Providing welded wire mesh of size 25mm x
25mm x4mm with suitable angle iron/flat stiffeners @ 1m
c/c and suitably supported to give rigidity all complete.
However,the angle stiffeners shall be measured under
structural item.
Sqm 90
58 SWING PLATFORM
Supplying , fixing erecting swing platform safety stairways
of retractable type made of Structure steel , with staircase
of 1.5mm thick steel sheet. Fully balanced pair of spring
boxes having Springs of Spring Steel material, fully
covered type, with spring tension adjustment feature. The
mounting bracket with columns will be painted with
Enamel Paint. Staircase will be of galvanized steel.
TECHNICAL DATA : Model : S1A-4, Make : TECHNIKA
Maximum Approach Length : 1650, Width of Clear Passage : 600
Load Capacity : 160
Balancing : Spring Balanced on boths sides
Hand Rail : Movable type made of Steel Pipes
Nos. of Steps : 04 Nos.
Staircase design: Self aligning, Anti Skid type with
Perforated holes.
Hydrocarbon resistant rubber bumper below last step to
prevent spark with tanker.
Pull Chain and Parking Lock Device

Each 26
59 INSERT PLATES

Supply, fabrication and erection of insert plates of
structural steel quality conforming to IS: 2062 and shall
be provided with mild steel lugs as per drawings/
standards. Mild steel lugs shall conform to IS: 432. The
insert plates are to be placed in position duly tied to the
reinforcing bars with PVC ties before casting of concrete.
The insert plates are to be so placed that there is no direct
contact of insert plate anchor rods with the reinforcement.

KG

500
60 GI PIPE SLEEVES
Supplying, cutting and fixing in position in civil work
during construction GI pipe sleeves of various dia as

KG

1500



Page 26 of 148
required and as per instructions of HPCL for leaving entries
for various facilities like cables etc.

61 SHALITEX BOARD FILLING
Providing and fixing in position 20 mm thick bitumen
impregnated fibre board (Shalitex or equivalent)
conforming to IS: 1838 (Part-1) including cost of primer,
sealing compound in expansion joints.

SqM 162
62 CHEQUERED PLATES
Supplying, fabricating and fixing in position chequered
plates of 6 mm thickness conforming to I.S. 3502
including supply and fixing of handles by cutting holes in
plates, with all contractors labour, tools and plants etc.
complete in all respects at all locations like trenches,
staircases, platforms etc as directed by HPCL.

SqM 150
63 SHORING AND STRUTTING
supplying, fixing and maintain necessary sheathing,
shoring and bracing etc., in steel or wood, as may be
required to support the sides of the excavation, to protect
workmen in the trench and to prevent any trench
movement which might any way injure or delay the work,
change the required width of the trench, make unsafe
condition for adjacent pavements, utilities, buildings or
other structures above or below ground. Sheathing,
shoring and bracing shall be withdrawn and removed as
the backfilling is being done, except when the Engineer
may agree that such sheathing, shoring and bracing be
left in place, at the Contractor's request. In any case, the
Contractor shall cut off any such sheathing at least 600
mm below the surface and shall remove the cut off
material from the trench. All sheathing, shoring and
bracing which is left in place under the foregoing
provisions shall be removed in a manner so as to not
endanger the completed work or other structures, utilities
or property, whether public or private.
SqM 200

NOTES TO BOQ:

1. Scope of Work , Supply of Material, Technical Specifications,
QAP, ITP( Inspection Test Plan) Requirement of relevant
Codes , SCC( Special Conditions to Contract), GTC (General
Terms & Conditions) , Schedule of Rates ,Statutory Rules &



Page 27 of 148
Guide Lines as applicable, Minimum Equipment /
Machineries Deployment and any other requirement to
complete the Job / Work as per this Tender Document shall
be deemed to be included in SOR item.
2. For all Items preparation of Design and Construction
Drawing as per relevant code & Tech. Specifications of this
Tender & vetting after review by HPCL through Third Party
approved by HPCL, Quality Control , Inspection & Job
procedure, Project Scheduling & Monitoring Document as
per SCC , Submission of all these documents to HPCL for
approval deemed to included in quoted rates.
3. The Water and Electrical power required for constructional
activity shall be in the Scope of Contractor & shall be
deemed to be included in SOR Items.
4. All the Testing and Third Party Charges for Items as per
tender documents elicited in various sections shall be borne
by contractor and deemed to be included in quoted rates.
5. All Tools & Tackles, Equipments, and items brought to site by
contractor will be permitted to be taken out only after completion
of work & fulfillment of necessary formalities.
6. Rate for all items to include deployment of qualified Quality
Control & Safety Engineer at site from the date of LOI till
completion of job as per PO. QC Engineer & Safety Engineer
deployed as per above will report to HPCL site-in-charge on daily
basis for complying all the QC/safety jobs mentioned in the PO.
7. The Drawings/QAP/ITP /Job procedures attached along with
tender document are for guidance/ tender purpose only. The
successful bidder to submit the above for HPCL approval as per
the job requirements during the execution of the job.



Page 28 of 148

SPECIAL

CONDITIONS

OF

CONTRACT



Page 29 of 148
1.0 GENERAL

1.1 Special Conditions of Contract (SCC) shall be read in conjunction
with the General Conditions of Contract (GCC) also referred to as
General Terms & Conditions of Works Contract, Schedule of
Quantities, specifications of work, drawings and any other
document forming part of this Contract wherever the context so
requires.

1.2 Not withstanding the sub-division of the document into these
separate sections and volumes, every part of each shall be deemed
to be supplementary of every other part and shall be read with and
into the Contract so far as it may be practicable to do so.

1.3 Where any portion of the GCC is repugnant to or at variance with
any provisions of the Special Conditions of Contract, then unless a
different intention appears, the provision(s) of the Special
Conditions of Contract shall be deemed to override the provision(s)
of GCC 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 GCC.

1.4 Wherever it is stated in this Bidding Document that such and such
a supply is to be affected or such and such a work is to be carried
out, it shall be understood that the same shall be affected and /or
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. Contract Price shall be deemed to have
included such cost.

1.5 The materials, design & workmanship shall satisfy the applicable
relevant Indian Standards, the job specifications contained herein
& codes referred to. Where the job specifications stipulate
requirements in addition to those contained in the standard codes
and specifications, these additional requirements shall also be
satisfied. In the absence of any Standard / Specifications / Codes
of practice for detailed specifications covering any part of the work
covered in this bidding document, the instructions / directions of
Engineer-in-Charge will be binding upon the Contractor.

1.6 In case of contradiction between relevant Indian standards, GCC,
Special Conditions of Contract, Specifications, Drawings and
Schedule of Rates, the following shall prevail in order of
precedence.



Page 30 of 148
i) Detailed Purchase Order along with Statement of Agreed
Variations, if any, and its enclosures.
ii) Fax of Intent (FOI)/Letter of Intent(LOI)
iii) Schedule of Quantities
iv) Special Conditions of Contract
v) Instructions to Bidders
vi) General Conditions of Contract
vii) Technical Specifications
viii) Relevant Indian Standards.
ix) Drawings/ Data Sheets

1.7 SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF
HPCL

1.7.1 Contractor shall provide and maintain minimum four number of
standard lengths of IS Stamped Fire hoses, 6 No.s of IS Stamped
DCP Fire extinguishers and 12 No.s fire buckets with sand. The
hoses shall be connected to the nearest Fire hydrant point such
that in case of any fire, water cane be used for firefighting. These
items can be taken back by the Contractor after completion of
work. Sand shall also be maintained dry by the Contractor with
fresh supply, whenever required. Work permit may not be issued
by HPCL in the absence of above items.

1.7.2 Safety Helmets shall be provided to all the employees of
Contractor including that of his labour contractors.

1.7.3 Safety Belts and Harnesses shall be provided by the Contractor in
adequate number for the workers working at heights.

1.7.4 Proper earthing shall be provided for all equipments and
generators.

2) THE WORK

2.1 Scope of Work & Scope of Supply

2.1.1 The scope of work and Scope of Supply covered in this
Contract will be as described in Scope of work provided in
the Instructions to bidders, Schedule of Quantities, Technical
Specifications, Drawings, etc.

2.2 Time Schedule

The Completion period for this job shall be as given in this bid



Page 31 of 148
document.

2.2.1 Time is the essence of this Contract. The period of completion
given includes the time required for mobilization as well as testing,
rectifications, if any, retesting, demobilization and completion in all
respects to the satisfaction of the Engineer-in-Charge.

2.2.2 A joint programme of execution of work will be prepared by the
Engineer-in-Charge and Contractor. This programme will take into
account the time of completion period of the Contract.

2.2.3 Monthly execution programme will be drawn up by the Engineer-in-
Charge jointly with the Contractor 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 / Programme by deploying adequate personnel,
Construction Equipment, Tools and Tackles and also by Timely
Supply of required materials coming within his scope of supply as
per Contract. In all matters concerning the extent of target set out
in the monthly programme and the degree of achievement, the
decision of the Engineer-in-Charge will be final and binding upon
the Contractor.

2.2.4 Contractor shall give every day category-wise labour and
equipment deployment report along with the progress of work
done on previous day in the pro-forma prescribed by the Engineer-
in-Charge.

2.3 Measurement of Works

2.3.1 Mode of measurement will be as specified in Specifications or SOR.

2.4 Temporary Works

2.4.1. All temporary works, enabling works, including dewatering of
surface and subsoil water, preparation and maintenance of
temporary drains at the work site, preparation and maintenance
of approaches to working areas, adequate lighting, wherever
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 prices.

2.5 Quality Assurance
2.5.1 Detailed quality assurance program to be followed for the
execution of Contract under various divisions of works will be
mutually discussed and agreed to.



Page 32 of 148

2.5.2 The Contractor shall establish, document and maintain an effective
quality assurance system as outlined in the specifications and
various codes and standards.

2.5.3 The Owner/Consultant or their representative shall reserve the
right to inspect/witness, review any or all stages of work at
shop/site as deemed necessary for quality assurance and / or
timely completion of the work.

2.5.4 In case Contractor fails to follow the instructions of Engineer-in-
Charge with respect to above clauses, next payment due to him
shall not be released unless and until he complies with the
instructions to the full satisfaction of Engineer-in-Charge.

2.6 Leads

2.6.1 For the various works, in case of contradiction, leads mentioned in
the Schedule of Quantities shall prevail over those indicated in the
Technical specifications.

3.0 ROYALTY, INCOME TAX, SERVICE TAX AND PRICES

3.1 Royalty

3.1.1 Proof of royalty payments shall be furnished by the Contractor to
HPCL at the time of billing.

4.0 PROVIDENT FUND, LABOUR, LABOUR LAWS AND SITE
REQUIREMENTS

4.1 Provident Fund

4.1.1 The Contractor shall strictly comply with the provisions of
Employees Provident Fund Act and register himself with Regional
Provident Fund Commissioner (RPFC) before commencing work.
The Contractor shall deposit Employees and Employers
contributions to the RPFC every month. The Contractor shall
furnish along with each Running bill, the challan / receipt for the
payment made to the RPFC for the preceding month. The
Contractor shall furnish the code number allotted by the RPFC
Authority to the Engineer-in-Charge before commencing the work.

4.1.2 In case the RPFC challan / receipt, as above, is not



Page 33 of 148
furnished, Owner shall deduct 16% (sixteen percent) of the
payable amount from Contractors running bill and retain the
same as a deposit. Such retained amounts shall be refunded
to Contractor on production of RPFC Challan / receipt for the
period covered by the related running bill.

4.2 Labour License

4.2.1 Before starting of work, Contractor shall obtain a license from
concerned authorities under the Contract Labour (Abolition and
Regulation) Act 1970, and furnish copy of the same to Owner.

4.3 Labour Relations

4.3.1 In case of labour unrest/labour dispute arising out of non
implementation of any law, the responsibility shall solely lie with
the Contractor and they shall remove/resolve the same
satisfactorily at his cost and risk.

4.3.2 The Contractor shall at all times take all reasonable precautions to
prevent any unlawful, riotous or disorderly conduct by or amongst
his staff and labour and to preserve peace and protection of
persons and property in the neighborhood of the Works against
such conduct.

4.4 Site Cleaning

4.4.1 The Contractor shall clean and keep clean the work site from time
to time to the satisfaction of the Engineer-in-Charge for easy
access to work site and to ensure safe passage, movement and
working.

4.4.2 The Contractor shall dispose off the unserviceable materials, debris
etc., to the earmarked area within the premises or any other
location outside the premises as per the Contract and/or as
decided by the Engineer-in-Charge. No extra payment shall be paid
on this account.

4.4.3 Review/Approval of Drawings, Design and other documents
submitted by Contractor

4.5.3.1 HPCL/Consultant will normally require and utilize a maximum
time frame of seven (07) working days from the date of Receipt
for Review/Approval of Drawings and other documents submitted



Page 34 of 148
by Contractor. Upon Review of the submitted documents, HPCL
may give their comments and ask for modification/resubmission
after necessary rectifications/ modifications and the time frame of
7 working days will be applicable for same.

4.5 Protection of Existing Facilities

4.5.1 Contractor shall obtain all clearance (work permit) from the Owner,
as may be required from time to time, prior to start of work. Work
without permit shall not be carried out within the existing
premises.

4.5.2 Contractor shall obtain plans and full details of all existing and
planned facilities/services/utilities from the Owner and shall follow
these plans closely at all times during the performance of work.
Contractor shall be responsible for location and protection of all
facilities/utilities and structures at his own cost.

4.6.3 Despite all precautions, should any damage to any structure /
utility etc. occur, the Contractor shall contact the Owner / authority
concerned and Contractor shall forthwith carry out repair at his
expenses under the direction and to the satisfaction of Engineer-in-
Charge and the Owner/concerned authority.

4.5.3 Contractor shall take all precautions to ensure that no damage is
caused to the existing facilities etc., during construction. Existing
structures/ facilities/ utilities damaged / disturbed during
construction shall be repaired and restored to their original
condition by Contractor after completion of construction to the
complete satisfaction of Owner.

4.6 Work Front

4.6.1 The work involved under this Contract may include such works as
have to be taken up and completed after other agencies have
completed their jobs. The Contractor will be required and bound to
take up 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 availabilities of work fronts to the Contractor are delayed due
to any reason not attributable to the Contractor and the same is
clearly recorded.



Page 35 of 148
4.7 Site Facilities
4.7.1 The Contractor shall arrange for the following facilities at
site, for workmen deployed/engaged by him / his sub-
contractor, at his own cost:

i) Arrangement for First Aid.
ii) Arrangement for clean & potable drinking water.
iii) A crche where 10 or more women workers are
having children below the age of 6 years.
iv) Any other facility/utility as may be required under the
Contract as per the existing legislation/regulations.

4.8 Contractor's Site Office and Stores

4.8.1 Owner shall provide land only for contractors site office and
stores and fabrication yard, if any at site. However, same shall
be dismantled prior to submission of Final Bill.

4.8.2 The Contractor shall remove all temporary buildings / facilities
etc., before leaving the site after completion of works in all
respect.

4.9 Construction Power and Water

4.9.1 Owner shall not provide power and the Contractor shall be
exclusively responsible to make his own arrangements for
supply of power, without any extra cost to the Owner.

4.9.2 Water required for the works shall be arranged by the Contractor.
The contractor has to make all necessary arrangement for
drawing water including making temporary storage, pumping
etc.

4.10 CEMENT :

Cement required for execution of the job under the scope of
this tender shall be supplied by the contractor at his own
cost. Cement used shall be 43 Grade Ordinary Portland Cement
(OPC). In case 43 grade OPC is not available, Portland Slag
Cement or Portland Pozzolanic Cement may be permitted by HPCL
after review of the same. Contractor to include the cost of cement
required for execution of various items included in this tender in
their quoted rates. Cement shall be of Grade as specified in the
SOQ and shall conform to relevant BIS standards of latest edition.



Page 36 of 148
Contractor to produce Invoice Copy of every batch of cement
procured at site to EIC. However, HPCLs decision with regard to
the specific brand of cement to be procured for the execution of
the work shall be final and binding on the contractor.

Sample from every batch of cement brought to site shall be tested
for standard test as per the specification of relevant IS standards
in approved Laboratory and Test Certificate shall be submitted to
EIC for verification. Only after obtaining approval of EIC, cement
shall be put into use. Manufacturers Batch Test Certificates
backed by Factorys Invoice for the batch will be acceptable for
entry of cement to Site. Contractor shall bring cement well in
advance before full consumption of previous lot. No claims for
extension of completion period for stoppage of work on account of
non-availability of cement / delays is testing procedures will be
entertained/accepted by HPCL.

For all computation purposes, the theoretical cement consumption
shall be considered as per CPWD standards. Cement cost shall be
recovered for under-consumption at the penal rate of Rs.7000/-
per MT. Empty cement bag shall be the property of the contractor.
Theoretical weight of cement in a bag will be considered as 50 Kgs.
Contractor shall maintain necessary weighing scale at site for the
purpose of random checking of the weight of cement bags by
representative of HPCL.

The contractor will be required to maintain a stock register for
receipt, issuance and daily consumption of cement at site. Cement
shall be regulated on the basis of 1st receipt to go as 1st issue.
Cement not consumed within 3 months after bringing to site shall
not be used and shall be removed from site with prior written
permission of EIC.

All RA bills including the final bills will be accompanied by Cement
Consumption Statements giving the detailed working of cement
used.

Contractor shall construct suitable temporary godown at site for
storage of cement under his lock and key. The contractor will be
fully responsible for safe custody of cement.

HPCL will not entertain any claims by the Contractor for theft, loss
or damages to cement. Contractor shall not remove from the site
any cement bags at any time.



Page 37 of 148
Permissible wastage shall be total 3% of the theoretical
consumption for the purpose of reconciliation.
4.11 STEEL :

Entire quantity of reinforcement steel required for the
project shall be supplied and provided at site by the
contractor at his own cost. HPCL shall not supply any
reinforcement steel. The contractor shall make necessary
arrangement at his own cost for unloading, storage of steel in the
open duly fenced under locking arrangement. The Contractor shall
produce invoice for the reinforcement steel to EIC for every batch
of procurement along with Manufacturers Test Certificate.

No claim towards additional wastage due to lap length / full length
bars or other consideration including rolling margin will be
entertained. No payment will be made or measurement recorded
for binding wires which shall be of specified gauge and shall be
provided by the contractor.

All binding wires required for tying the reinforcement in position
etc. will be supplied by the contractor. Cost of this binding wire
and labour will be included in the item for binding and placing
reinforcement in position.

It will be necessary that the contractor get the steel tested at his
own cost at a HPCL approved laboratory as per the testing
schedule or as per the EICs advise, for properties specified in IS -
1786 latest edition before using it in the work.

The contractor will be required to maintain a register for recording
details of steel receipt, steel utilised and balance at site.

Final bill will be accompanied by steel consumption statement.

In every case, it shall be the contractors responsibility to ensure
the standard of quality and the correctness of quantity of steel
procured at site by him. The permissible wastage (wastage defined
as bars having less than 3 mt. Length) shall be of 3% of theoretical
consumption for the purpose of reconciliation. Recovery for less
consumption as per theoretical consumption will be effected at
Rs.60,000/- per MT. All scrap (scrap defined as pieces of steel bars
measuring less than 3 mt. in length) shall be the property of the
contractor. The wastage quantity shall not be considered to be
included within the theoretical quantity and no extra shall be
payable on account of wastage.



Page 38 of 148
Measurement of reinforcement shall be restricted to theoretical
weight as per BIS code.

4.12 Construction

4.12.1 Rules and Regulations

4.11.2 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 compliance to the same.

5.0 Procedures

5.1 Various procedures and method statements to be adopted by
Contractor during the construction as required & sought by HPCL
and as per the respective specifications shall be submitted to
Engineer-in-Charge in due time for approval.

5.2 Security

5.2.1 As the premises at HPCL is a protected area, entry into the area
shall be restricted and may be governed by issue of photo gate
passes. The Contractor shall arrange to obtain through the
Engineer-in-Charge, well in advance, all necessary entry
permits/gate passes for his staffs and labourers and entry and exit
of his men and materials shall be subject to vigorous checking by
the security staff. The Contractor shall not be eligible for any claim
or extension of time whatsoever on this account.

5.2.2 It shall be the responsibility of the contractor to safeguard all his
materials/owned from theft, damage etc. For this purpose the
contractor shall be allowed to keep his own security inside HPCL
premises.

5.3 Drawings and Documents

5.3.1 Drawings accompanying the Bidding Document are indicative of
scope of work and issued for bidding purpose only. Purpose of
these drawings is to enable the bidder to make an offer in line with
the requirements of the owner.

5.3.2 The contractor as per `scope of work shall carry out preparation of
detailed drawings. Detailed drawings as needed shall be prepared
by contractor and got reviewed/ approved by Engineer-in-Charge/
Consultant before taking up the work.



Page 39 of 148

5.4 Contractor's Billing System

5.4.1 HPCL will provide an approved format for Measurement sheets, Bill
Summary and Bill Abstract. Contractor has to ensure that these
data are updated for each subsequent RA and Final Bill.

HPCL will utilize these data for processing and verification of the
Contractors bill.

5.4.2 Contractors RA Bills shall be accompanied by progress
photographs.

5.5 Site Organization

5.5.1 The Contractor shall without prejudice to his overall responsibility
to execute and complete the works as per specifications and time
schedule progressively deploy adequate qualified and experienced
personnel together with skilled / unskilled manpower and augment
the same as decided by Engineer-in-Charge depending on the
exigencies of work to suit the construction schedule without any
additional cost to Owner.

5.5.2 The Contractor shall provide all necessary superintendence during
the execution of the Works and as long thereafter as the
Engineer-in-Charge may consider necessary for the proper
fulfilling of the Contractors obligations under the Contract Such
superintendence shall be given by sufficient persons having
adequate knowledge of the operations to be carried out (including
the methods and techniques required, the hazards likely to be
encountered and methods of preventing accidents) for the
satisfactory and safe execution of the Work. The workmen
deployed by the Contractor should also possess the necessary
license etc., if required under the existing laws, rules and
regulations.

5.6 Responsibility of Contractor

5.6.1 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 change required
during functional requirements or for efficient running of system,
keeping the basic parameters unchanged and which has not been



Page 40 of 148
indicated by the contractor in the data / drawings furnished along
with the offer shall be carried out by the contractor at no extra cost
to the owner.

5.6.2 All expenses towards mobilization at site and demobilization
including bringing in equipment, work force, materials,
dismantling the equipment, clearing the site etc. shall be deemed
to be included in the prices quoted and no separate payments on
account of such expenses shall be entertained.

5.6.3 It shall be entirely the contractors responsibility to provide,
operate and maintain all necessary construction equipment, steel
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.

5.6.4 Preparing approaches and working area for the movement of his
men and machinery.

5.6.5 The procurement and supply in sequences and at the appropriate
time of all materials, and consumables shall be entirely the
contractors responsibility and his rates for execution of work will
be inclusive of supply of all these items.

5.7 Coordination with other agencies

5.7.1 Contractor shall be responsible for proper coordination with other
agencies operating at the site of work so that work may be carried
out concurrently, without any hindrance to others. The Engineer -
in - Charge shall resolve disputes, if any, in this regard, and his
decision shall be final and binding on the Contractor.

5.8 Underground and overhead structures

5.8.1 The Contractor will familiarize himself with and obtain information
and details from the Owner in respect of all existing structures,
and utilities existing at the job site before commencing work. The
Contractor shall execute the work in such a manner that the said
structures, utilities, etc. are not disturbed or damaged, and shall
indemnify and keep indemnified the Owner from and against any
destruction thereof or damages thereto.

5.9 Documents required with final bill

5.9.1 Statement of final bills - issue of No Claim/ No Due Certificate



Page 41 of 148

The Contractor shall furnish a No-Claim/No-Due declaration
indicating that there are no balance dues to his sub-vendor/sub-
contractors /labour contractors along with the Final Bill.

5.10 Working hours

5.10.1 The work shall be carried out if required on round-the clock basis
including holidays as it is a Greenfield site. Contractors quoted
rates are deemed to include expenditure towards working on
round-the clock basis and holidays. However, Contractors
representative shall be available for overseeing the works at all
times.

6.0 TESTS, INSPECTION AND COMPLETION

6.1 Tests and Inspection

6.1.1 The Contractor shall carry out the various tests as enumerated in
the technical specifications of this Bidding Document and technical
documents that will be furnished to him during the performance of
the work at no extra cost to the Owner.

6.1.2 All the tests either on the field or at outside laboratories
concerning the execution of the work and supply of materials by
the Contractor shall be carried out by Contractor at his cost.

6.1.3 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 bidding document,
the technical documents that will be furnished to him during
performance of work and the relevant codes of practice.

6.1.4 For material supplied by Owner, Contractor shall carry out the
tests, if required by the Engineer-in-Charge, and the cost of such
tests shall be reimbursed by the Owner at actual to the Contractor
on production of documentary evidence.

6.1.5 All results of inspection and tests will be recorded in the inspection
reports, pro-forma of which will be approved by the Engineer-in-
Charge. These reports shall form part of the completion
documents. Any work not conforming to execution drawings,
specifications or codes shall be rejected and the Contractor shall
carry out the rectifications at his own cost.



Page 42 of 148
6.2 Final Inspection

After completion of all tests as per specification the whole work will
be subject to a final inspection to ensure that job has been
completed as per requirement. If any defect is noticed, the
Contractor will be notified by the Engineer-in-Charge and he shall
make good the defects with utmost speed. If, however, the
Contractor fails to attend to these defects within a reasonable time
(time period shall be fixed by the Engineer-in-Charge) then
Engineer-in-Charge may have defects rectified at Contractors cost
by engaging a third party.

6.3 Inspection of Items

6.3.1All inspection and tests on the items shall be made as required by
specifications forming part of this contract. Various stages of
inspection and testing shall be identified after receipt of Quality
Assurance Program from the contractor / manufacturer. All
incoming materials shall be accompanied by a IMIR (Incoming
Material Inspection Report)

6.3.2 Inspection calls shall be given for association of Owner, as per
mutually agreed program in prescribed pro-forma, giving details of
item and attaching relevant test certificates and internal inspection
report of the contractor.

6.3.3 The contractor shall ensure full and free access to the inspection
engineer of Owner at the contractors premises at any time during
contract period to facilitate him to carry out inspection and testing
assignments.

6.3.4 The contractor shall provide all instruments, tools, necessary
testing and other inspection facilities to inspection engineer of
Owner free of cost for carrying out inspection.

6.3.5 Where facilities for testing do not exist in the contractors
laboratories, samples and test pieces shall be drawn by the
contractor in presence of Inspection Engineer of Owner and duly
sealed by HPCL engineer and sent for tests in HPCL approved lab
at the contractors cost.

6.3.6 The contractor shall comply with the instructions of the Inspection
Engineer fully and with promptitude.

6.3.7 All inspections and tests shall be made as required by the
specifications forming part of this contract. All costs towards



Page 43 of 148
testing etc. shall be borne by the contractor within their quoted
rates.

6.4 Documentation

6.4.1 Completion Documents

The following documents shall also be submitted by the Contractor
in triplicate as part of completion documents:

a) Test certificate for materials supplied by the Contractor.
b) Certified records of field tests on materials / equipment, as
applicable.
c) Material appropriation statement as required.
d) Six sets of drawings showing therein the as built conditions
of the work duly approved by the Engineer-in-Charge along
with one set of reproducible on polyester film (drawings
prepared by Contractor) along with soft form of the same.
e) Other documents as mentioned in Technical Specification.

6.4.2 "AS BUILT" Drawings

Upon completion of work, the Contractor shall complete all
drawings to "As built status (including all vendor / Sub - vendors
drawings for bought out items) and provide the Owner, the
following:

a. One complete set of all original tracings / reproducible
along with the soft form of the same.
b. Six complete sets of prints.
7.0 OTHERS

7.1 Project Scheduling and Monitoring

7.1.1 The following schedules / documents / reports shall be prepared
and submitted by the CONTRACTOR for review / approval at
various stages of the contract.
7.2 After placement of Purchase Order

Upon placement of Purchase Order, Contractor has to furnish a
detailed bar chart within 15 days of issue of FOI/LOI.

7.3 Project Review Meetings

7.3.1 The CONTRACTOR shall present the program and status at various



Page 44 of 148
review meetings as required.

Monthly Review Meeting Level of Participation: Senior Officers of
Owner & Contractor.

Agenda

a) Progress Status / statistics.
b) Completion Outlook
c) Major hold ups / slippages.
d) Assistance required.
e) Critical issues.
f) Client query / approval.

Venue : site

7.3.2 Progress Reports

I) Monthly Progress Report

This report shall be submitted in three copies on a monthly
basis within Ten calendar 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) Scheduled vs actual percentage progress and progress
curves for sub-ordering, manufacturing / delivery, sub-
contracting, construction activities and overall quantum
wise status of purchase orders against scheduled.
d) Areas of concern / problems / hold ups, impact and
action plans.
e) Resource deployment status.

Distribution: OWNER - Two copies & One at Site.

II) Daily Report:

Daily report in duplicate and any other additional
information/data/guideline/job procedure sought by
Engineer-in-Charge shall be submitted without fail to HPCL at



Page 45 of 148
site by contractor.

7.4 General Environment Requirement

The contractor has to ensure efficient use of natural resources like
water, fuel oil and lubricants. The contractor should ensure proper
awareness to workers to maintain a green and clean environment
inside/outside the building premises. The contractor must collect
and dispose of all the waste and scrap materials at the designated
place only as directed by Engineer-in-Charge.

7.5 Supervisory Personnel

Qualification and experience of key supervisory construction
personnel to be deployed for this works shall be as given
hereunder. CONTRACTOR shall submit bio data of key supervisory
personnel meeting the requirement as given hereunder, after
award, which will be reviewed and approved by Engineer-in-
charge. However, deployment of qualified and experienced
supervisory personnel of the CONTRACTOR shall be commensurate
with the project work load and as approved by Engineer-in-Charge
and / or OWNER .

Designation/
Category
Minimum
Qualification
No. of
Personnel
Discipline
to which
should
belong
RESIDENT CONSTRUCTION
MANAGER / RESIDENT
ENGINEER / SITE-IN-
CHARGE
Degree in Engg./Diploma
with relevant experience in
construction.
1 Mechanical/
Civil
CIVIL ENGINEER Degree in Engg./Diploma
in Civil with relevant
experience in construction.
1 Civil
LEAD WELDING / NDT
ENGINEER
Degree/Diploma with
relevant experience in
welding / NDT
3 Mechanical/
Metallurgy
LEAD QA / QC ENGINEER Degree/Diploma in Engg.
with relevant experience in
QA/QC
1 Mechanical
LEAD SAFETY OFFICER Degree / Diploma in Engg.
With Relevant experience
in Construction Safety
1 Mechanical

7.6 DUE TO LACK OF SPACE INSIDE THE TERMINAL PREMISES,
HPCL WILL PERMIT THE CONTRACTOR TO CARRY OUT THE
ENTIRE FABRICATION WORK AT A SHOP OUTSIDE THE
TERMINAL PREMISES SUBJECT TO THE FOLLOWING:



Page 46 of 148
CONTRACTOR SHALL BE LIABLE TO BEAR ANY
ADDITIONAL EXPENSES TOWARDS EXCISE DUTY, ETC.
HPCL SHALL NOT UNDERTAKE ANY LIABILITY
WHATSOEVER ON THIS ACCOUNT.
THE SHOP SHALL BE INSPECTED & CLEARED BY HPCL
PRIOR TO TAKING UP THE FABRICATION WORK.
THE ENTIRE FABRICATION WORK SHALL BE
SUPERVISED BY ENGINEERS FROM A THIRD PARTY
AGENCY NAMELY, DNV,BV,SGS OR LLOYDS OR ANY
OTHER TPI APPROVED BY HPCL. THE COST OF SUCH
SUPERVISION SHALL BE BORNE BY THE CONTRACTOR
ONLY.
CONTRACTOR SHALL BE RESPONSIBLE FOR ANY
OMISSIONS, MISTAKES AND MISDEMEANOURS BY THE
SHOP.
TRANSPORTATION FROM SHOP TO SITE & HANDLING
SHALL BE THE RESPONSIBILITY OF THE CONTRACTOR.
ANY OTHER ACTIVITY REQUIRED FOR THE JOB SHALL
BE HANDLED BY THE CONTRACTOR.
THE RATES QUOTED BY THE CONTRACTOR SHALL BE
INCLUSIVE OF ALL THE ABOVE ACTIVITIES.

8.0 General

8.1 It shall be distinctly understood that notwithstanding the reviews
and suggestions if any, by the Engineer-in-charge, the sole and
ultimate responsibility for the stability and performance of the form
work and staging and all other temporary works shall be that of the
contractor.

8.2 The partners or Directors of the Contractor shall meet the officers
of the HPCL at the site of works or at their respective offices
whenever requested to do so.

8.3 Any apparatus deemed necessary by the HPCL or its consultants
for proper control shall be provided by the contractor at his own
cost.

8.4 HPCL may ask for any tests to be performed on any construction
material. Such test shall be performed at the contractors
expenses either at site, in the site laboratory or elsewhere as
directed by the Site Engineer-in-charge. The opinion of the
Engineer-in-charge on the mode of testing and interpretation of the
results thereof shall be final and binding on the contractors and
shall be without appeal.



Page 47 of 148

8.5 In addition to previous stipulations, the contractor shall be
represented at site at all times during the tenure of the contract by
responsible and qualified engineers approved by HPCL. Such
engineers shall form the contractors project management and site
supervisory team. They shall be in constant attendance upon all
activities of the work.

8.6 Limited area will be provided within the Premises by HPCL for
storing materials. However, partition and temporary roof if required
for ensuring proper storage shall be provided by the Contractor.
Safety & Security of the materials brought by the party will be
totally their own and HPCL cannot be held responsible in any
manner.

8.7 Labour camp shall not be erected within HPCL premises
nor
workmen shall be allowed to live at the site.

Frequency of testing of various materials shall be as per QAP/ITP.
Testing of various materials should be carried out as per the
relevant IS standards mentioned in the technical specifications
attached to the tender. Party should submit manufacturer's
certificates for the various materials and the above tests will be
carried out in addition to the certificates submitted. Cost of
testing should be borne by the party. In case of delay in
testing materials, HPCL reserves the right to have the same tested
at party's cost.

8.8 HPCL RESERVES THE RIGHT TO DELETE ANY OF THE ITEMS
LISTED IN THE DETAILED SCHEDULE OF QUANTITIES/BOQ PRIOR
TO OPENING OF PRICED BIDS.

8.9 Monthly Bills shall be submitted with progress photographs.

8.10 The Contractor shall take up the TLF Gantry work on top-most
priority. The Contractor shall adhere to the instructions of HPCL
site- in-Charge with regard to the fronts to be taken up on priority
from time to time so as to provide work fronts to other Contractors.



Page 48 of 148
APPENDIX -1 TO SCC

TERMS OF PAYMENTS

1.1 The basis and terms of payment without prejudice to any other
mode of recovery available to Owner, shall be as given below:

1.2 The Contractor shall be paid monthly running account bills at
stages of completion of individual item / work, based on the joint
measurement, in the following manner after deductions of
necessary dues payable by Contractor to the Owner such as
Retention money, Taxes, Duties etc. in accordance with various
provisions made elsewhere in this document.

1.3 SPECIAL PAYMENT TERMS

Following payment shall be made to the contractor against the
running bills subject to the rate awarded to him and the clause
regarding retention money as per general terms and conditions.

1. Structural steel items including chequered plates and
gratings:

50% on supply of materials
15% after fabrication
30% after erection,welding,bolting
5% on completion & acceptance of all jobs as per SOR.

2. Balance Jobs as per Schedule of Quantities

95% on completion of the items
5% on completion and acceptance of all jobs as per
SOR including applicable testing.



Page 49 of 148

QUALITY

ASSURANCE

PLAN



Page 50 of 148

1.1] QA PLAN

1.2] ITP

1.3] DRAWING SCHEDULE

1.4] PROGRESS REPORT AND SCHEDULE

1.5] WAIVER AND DEVIATION

1.6] PROCUREMENT OF BOUGHT OUT MATERIALS

1.7] CALIBRATION RECORDS

1.8] INSPECTION TEST STATUS

1.9] QUALITY RECORDS

1.10] IDENTIFICATION AND TRACEABILITY

1.11] VENDOR DOCUMENT FOR REVIEW AND RECORDS

1.12] DOCUMENTS UNDER REVIEW CATEGORY.

1.13] FINAL DOCUMENTS



Page 51 of 148

QUALITY ASSURANCE PLAN AND INSPECTION &
TESTING PLAN REQUIREMENTS

1.1] QA PLAN

VENDOR DURING BIDDING STAGE SHALL SUBMIT HIS QUALITY
ASSURANCE PLANS (QAP) CONSISTING OF RELEVANT PROCEDURES
COVERING VARIOUS ACTIVITIES LIKE DESIGN AND ENGINEERING,
MATERIAL PROCUREMENT , MANUFACTURE INSPECTION AND TESTING,
DOCUMENTATION, DISPATCH TO SITE , ERECTION AND
COMMISSIONING WHEREVER APPLICABLE AND MAINTENANCE OF
QUALITY RECORDS IN THE POST ORDER STAGE. THE VENDOR SHALL
SUBMIT THE QAP TO THE SITE ENGINEER FOR APPROVAL WITHIN 2
WEEKS FROM THE DATE OF RECEIPT OF LOI/PO WHICHEVER IS
EARLIER. THE QAP SHALL BE APPROVED BY THE AUTHORIZED
REPRESENTATIVE OF HPCL WITHIN A WEEK OF SUBMISSION

1.2] ITP

VENDOR SHALL SUBMIT INSPECTION AND TEST PLAN FOR APPROVAL
WITHIN 2 WEEKS OF LOI/PO AND BEFORE COMMENCEMENT OF
MANUFACTURE TO THE SITE ENGINEER AS WELL AS TO THE THIRD
PARTY INSPECTION AGENCY (TPIA) THAT THE VENDOR WISHES TO
APPOINT FOR CARRYING OUT INSPECTION AND TESTING. THIS
DOCUMENT SHOULD CLEARLY SPECIFY THE NAME, DESIGNATION OF
THE PERSON CONCERNED (WITH TELEPHONE/MOBILE NO AND EMAIL)
AND COMMUNICATION ADDRESS OF THE TPI. THE ITP SHALL BE IN
ACCORDANCE WITH BS:1868/6755 (PART -1) AS APPLICABLE.

1.3] DRAWING SCHEDULE

VENDOR SHALL SUBMIT A TOTAL INDEX OF DRAWINGS AND
DOCUMENTS REQUIRED FOR APPROVAL/REVIEW/RECORDS ALONG
WITH THE SCHEDULED DATE OF SUBMISSION OF EACH
DRAWING/DOCUMENT WITHIN 2 WEEKS FROM DATE OF ISSUE OF LOI/
PO WHICHEVER IS EARLIER.

1.4] PROGRESS REPORT AND SCHEDULE

VENDOR SHALL SUBMIT MONTHLY PROGRESS REPORT AND UPDATE
PROCUREMENT ENGINEERING AND MANUFACTURING SCHEDULE EVERY
MONTH STARTING FROM 2 WEEKS FROM DATE OF ISSUE OF FOI/PO
WHICHEVER IS EARLIER.



Page 52 of 148

1.5] WAIVER AND DEVIATION

VENDOR SHALL STRICTLY COMPLY WITH THE PO STIPULATIONS AND
NO DEVIATIONS SHALL BE PERMITTED.

1.6] PROCUREMENT OF BOUGHT OUT MATERIALS

ALL CRITICAL MATERIALS SUCH AS CASTING, FORGING, FITTING,
PRESSURE HOLDING PARTS ELECTRICAL AND INSTRUMENT
ACCESSORIES ETC. SHALL BE PURCHASED BY THE VENDOR FROM SUB-
VENDORS HAVING BV, LRIS OR CEIL APPROVAL. VENDOR SHALL
SUBMIT A LIST OF BOUGHT OUT MATERIALS FOR HPCL APPROVAL
WITHIN 2 WEEKS FROM THE DATE OF ISSUE OF FOI/PO WHICHEVER IS
EARLIER.

1.7] CALIBRATION RECORDS

VENDOR SHALL USE ONLY CALIBRATED MEASURING AND TEST
INSTRUMENTS AND MAINTAIN CALIBRATION RECORDS. VENDOR SHALL
FURNISH RECORDS OF CALIBRATION OF MEASURING AND TEST
INSTRUMENTS INCLUDING RECALIBRATION RECORDS TO THIRD PARTY
INSPECTION AGENCY ON DEMAND.

1.8] INSPECTION TEST STATUS

INSPECTION AND TEST STATUS OF PRODUCTS SHALL BE IDENTIFIED BY
USING MARKINGS. AUTHORIZED STAMPS, TAGS, ROUTE CARDS,
INSPECTION CARDS ETC. DURING THE COURSE OF MANUFACTURE TO
CLEARLY INDICATE ACCEPTANCE/ REJECTION OF TESTS/STAGES OF
INSPECTION PERFORMED DURING ITS MANUFACTURING CYCLE. THE
IDENTIFICATION OF TEST STATUS SHALL BE MAINTAINED AND
RECORDS SUBMITTED AS AND WHEN DEMANDED BY HPCL/TPIA.

1.9] QUALITY RECORDS

VENDOR SHALL MAINTAIN QUALITY RECORDS AS PER HIS
PROCEDURES. INSPECTION REPORTS & TEST RECORDS COPIES SHALL
BE FURNISHED TO HPCL/TPIA.

1.10] IDENTIFICATION AND TRACEABILITY

VENDOR SHALL ESTABLISH AND MAINTAIN A STANDARD WRITTEN
PROCEDURE FOR IDENTIFYING THE PRODUCTS FROM APPLICABLE
DRAWING SPECIFICATIONS OR OTHER DOCUMENTS DURING ALL
STAGES OF PRODUCTION DELIVERY AND INSTALLATION. A COPY OF



Page 53 of 148
THIS STANDARD PROCEDURE SHALL BE MADE AVAILABLE TO
HPCL/TPIA. THE VENDOR SHALL ENSURE THAT EACH PRODUCT WHICH
IS GOING IN THE PROCESS OF FABRICATION / MANUFACTURE /
CONSTRUCTION / ERECTION HAS PROPER IDENTIFICATION
THROUGHOUT THE PROCESS INCLUDING THE FINAL OUTPUT.

1.11] VENDOR DOCUMENT FOR REVIEW AND RECORDS

GENERAL

1] ALL DOCUMENTS SHALL BE IN ENGLISH LANGUAGE AND SI
SYSTEM OF UNITS.

2] REVIEW OF THE VENDOR DRAWING BY THIRD PARTY
INSPECTION AGENCY / HPCL WOULD BE ONLY TO REVIEW THE
COMPATIBILITY WITH BASIC DESIGN AND CONCEPTS AND IN
NO WAY ABSOLVE THE VENDOR OF HIS RESPONSIBILITY TO
COMPLY WITH PO REQUIREMENTS, APPLICABLE CODES,
SPECIFICATIONS AND STATUTORY RULES/REGULATIONS.

3] SUBMISSION OF DOCUMENTS FOR REVIEW/RECORDS SHALL
COMMENCE WITHIN 2 WEEKS FROM THE DATE OF ISSUE OF
FOI/PO

4] THE VENDOR SHALL SUBMIT ALL DRAWINGS AND DOCUMENTS
IN THREE COPIES AS STIPULATED IN THE VENDOR DATA
REQUIREMENT ALONG WITH DOCUMENTS INDEX. THE
DOCUMENTS SHALL ALSO BE SUBMITTED IN SOFT COPIES TO
EXPEDITE THE PROCESS OF APPROVAL/REVIEW.

VENDOR SHALL ENSURE THAT EACH DRAWING SHALL CONTAIN
THE FOLLOWING INFORMATION:

PO NO NAME OF EQUIPMENT, TAG NO., NAME OF PROJECT,
CLIENT, DRAWING/DOCUMENT TITLE, DRAWING NO., REVISION
AND DATE.

THE DRAWING DOCUMENT SHALL BE CHECKED APPROVED AND
DULY SIGNED STAMPED BY THE VENDOR REVISIONS AND DATE.

1.12] DOCUMENTS UNDER REVIEW CATEGORY.

FOLLOWING REVIEW CODES SHALL BE USED FOR REVIEW OF VENDOR
DOCUMENTS / DRAWINGS.

AFI: APPROVED FOR INSPECTION



Page 54 of 148

AFM: APPROVED FOR MANUFACTURING / FABRICATION AS PER
COMMENTS
VENDOR SHALL RESUBMIT THE SAME AFTER INCORPORATING
THE COMMENTS BEFORE CARRYING OUT FINAL INSPECTION
BY TPIA AND DESPATCH.

NOT APPROVED: RESUBMISSION REQUIRED IN CASES OF
MAJOR NON- CONFORMITIES WITH RESPECT TO PO
SPECIFICATIONS.

1.13] FINAL DOCUMENTS

FINAL DRAWINGS/DOCUMENTS CONSISTING OF TECHNICAL DATA
MANUAL AS A COMPILATION OF AS-BUILT CERTIFIED DRAWING AND
MANUFACTURING DATA AND TEST RECORDS DULY CERTIFIED BY
HPCL/TPIA SHOULD BE SUBMITTED IN THREE SETS ALONG WITH SOFT
COPY OF THE SAME.

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS OF THE
MATERIAL/EQUIPMENTS (WHEREVER APPLICABLE) SHALL ALSO BE
SUBMITTED IN THREE SETS AND IN SOFT FORMAT.



Page 55 of 148

SAFETY, HEALTH
AND
ENVIRONMENT
REQUIREMENTS
(SHE POLICY)



Page 56 of 148

SAFETY , HEALTH & ENVIRONMENT POLICY

SPECIFICATION FOR SAFETY HEALTH AND ENVIRONMENT
(SHE) MANAGEMENT

CONTENTS

---------------------------------------------------------------------------------
CLAUSE NO. TITLE
__________________________________________________________

1.0 SCOPE

2.0 REFERENCES

3.0 REQUIREMENT OF SAFETY, HEALTH AND ENVIRONMENT (SHE)
3.1 MANAGEMENT RESPONSIBILITY

3.2 HOUSE KEEPING

3.3 SAFETY, HEALTH & ENVIRONMENT

4.0 DETAILS OF SHE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 ON AWARD OF CONTRACT

4.2 DURING JOB EXECUTION



Page 57 of 148
1.0 SCOPE

This specification establishes the Safety Health and Environment
(SHE) management requirement to be complied with by the
Contractors during construction.

Requirements stipulated in this specification shall supplement the
requirements of SHE Management given in relevant Act (s) /
legislations like General Conditions of Contract (GCC), Special
Conditions of Contract (SCC) and Job Specifications. Where
different documents stipulate different requirements, the most
stringent shall be adopted.

2.0 REFERENCES

This document should be read in conjunction with following:

- General Conditions of Contract (GCC)
- Special Conditions of Contract (SCC)
- Job Specifications

3.0 REQUIREMENTS OF SAFETY HEALTH & ENVIRONMENT (SHE)
MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS

3.1 MANAGEMENT RESPONSIBILITY

3.1.1 The Contractor should have a documented SHE policy to cover
commitment of their organization to ensure health, safety and
environment aspects in their line of operations.

3.1.2 The SHE management system of the Contractor shall cover the
SHE requirements including but not limited to what is specified
under Para 1.0 and para 2.0 above.

3.1.3 Contractor shall be fully responsible for planning and implementing
SHE requirements. Contractor as a minimum requirement shall
designate / deploy the following to co-ordinate the above :

No of workers
deployed
Responsible Qualified Personnel
Up to 250 Designate one safety supervisor
Above 250 & up to 500 Deploy one qualified and experienced
safety Engineer / officer
Above 500 One additional safety (for every 500
or less)

Contractor shall indemnify & hold harmless Owner / HPCL & either
representatives free from any and all liabilities arising out of non -
fulfillments of SHE requirements.



Page 58 of 148

3.1.4 The Contractor shall ensure that the Safety, Health and
Environment (SHE) requirements are clearly understood &
faithfully implemented at all levels at site.

3.1.5 The Contractor shall promote and develop consciousness for
Safety, Health and Environment among all personnel working for
the Contractor. Regular awareness, program site meetings shall be
arranged on SHE activities to cover hazards involved in various
operations during construction.

3.1.6 Arrange suitable first aid measures such as First Aid Box, trained
personnel to give First Aid, Stand by Ambulance or Vehicle and
install fire protection measures such as : adequate number of steel
buckets with sand and adequate fire extinguishers to the
satisfaction of HPCL/Owner.

3.1.7 The Contractor shall evolve a comprehensive planned and
documented system for implementation and monitoring of the SHE
requirements. This shall be submitted to HPCL/Owner for approval.
The monitoring for implementation shall be done by regular
inspections and compliance to the observations thereof. The
Contractor shall get similar SHE requirements implemented at his
sub-contractor(s) work site/office. However, compliance of SHE
requirements shall be the sole responsibility of the Contractor. Any
review / approval by HPCL/Owner shall not absolve contractor of
his responsibility / liability in relation to all HSE requirements.

3.1.8 Non-Conformance on SHE by Contractor (including his Sub-
contractors) as brought out during review/audit by HPCL/Owner
representatives shall be resolved forthwith by Contractor.
Compliance report shall be provided to HPCL/Owner.

3.1.9 The Contractor shall ensure participation of his Resident Engineer /
Site-in-Charge in the Safety Committee / SHE Committees
meetings arranged by HPCL/Owner. The compliance of any
observations shall be arranged urgently. He shall assist
HPCL/Owner to achieve the targets set by them on SHE during the
project implementation.

3.1.10 The Contractor shall adhere consistently to all provisions of SHE
requirements. In case of non-compliance or continuous failure in
implementation of any of SHE provisions; HPCL/Owner may
impose stoppage of work without any Cost & Time implication to
Owner and/or impose a suitable penalty for non-compliance with a
notice of suitable period, up to a cumulative limit of 1.0% (one
percent) of Contract Value with a maximum limit of Rs. 10 lakhs.
This penalty shall be in addition to all other penalties specified
else where in the contract. The decision of imposing stoppage
work, its extent & monitory penalty shall rest with HPCL/Owner &
binding on the Contractor.



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3.1.11 All fatal accidents and other personnel accidents shall be
investigated by a team of Contractors senior personnel for root
cause & recommend corrective and preventive actions. Findings
shall be documented and suitable actions taken to avoid
recurrences shall be communicated to HPCL/Owner. Owner / HPCL
shall have the liberty to independently investigate such
occurrences and Contractor shall extend all necessary help and
co-operation in this regard.

3.2 HOUSE KEEPING
3.2.1 Contractor shall ensure that a high degree of house keeping is
maintained and shall ensure inter alia the followings wherever
applicable:

a. All surplus earth and debris are removed/disposed off from
the working areas to identified location(s).

b. Unused/Surplus Cables, Steel items and steel scrap lying
scattered at different places within the working areas are
removed to identified location(s).

c. All wooden scrap, empty wooden cable drums and other
combustible packing materials, shall be removed from work
place to identified location(s).

d. Roads shall be kept clear and materials like: pipes, steel,
sand boulders, concrete, chips and bricks etc. shall not be
allowed on the roads to obstruct free movement of men &
machineries.

e. Fabricated steel structural, pipes & piping materials shall be
stacked properly for erection.

f. Water logging on roads shall not be allowed.

g. No parking of trucks / trolleys, cranes and trailers etc. shall
be allowed on roads which may obstruct the traffic
movement.

h. Utmost care shall be taken to ensure over all cleanliness and
proper upkeep of the working areas.

i. Trucks carrying sand, earth and pulverised materials etc.
shall be covered while moving within the premises.

j. Only properly designed steel scaffolding materials to be used
for working at heights more than 3.0M. Double scaffolding



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using wooden ballis may be allowed for working at height
less than 3.0M

3.3 SAFETY, HEALTH AND ENVIRONMENT

3.3.1 The Contractor shall provide safe means of access to any working
place including provisions of suitable and sufficient scaffolding at
various stages during all operations of the work for the safety of
his workmen, and, HPCL/Owner. Contractor shall ensure
deployment of appropriate equipment and appliances for
adequate safety and health of the workmen and protection of
surrounding areas.

3.3.2 The Contractor shall ensure that all their staff and workers
including their sub-contractor(s) shall wear Safety Helmet and
Safety shoes. Contractor shall also ensure use of safety belt,
protective goggles, gloves etc. by the personnel as per job
requirements. All these gadgets shall conform to relevant IS
specifications or equivalent.

3.3.3 Contractor shall ensure that a proper Safety Net System shall be
used at appropriate locations. The safety net shall be located not
more than 30 feet (9.0 meters)below the working surface at site
to arrest or to reduce the consequences of a possible fall of
persons working at different heights.

3.3.4 Contractor shall ensure that flash back arrester shall be used
while using Gas Cylinders at site. Cylinders shall be mounted on
trolleys.

3.3.5 The Contractor shall assign to his workmen, tasks commensurate
with their qualification, experience and state of health for driving
of vehicles, handling and erection of materials and equipments.
All lifting equipments shall be tested certified for its capacity
before use. Adequate and suitable lighting at every work place
and approach there to, shall be provided by the Contractor before
starting the actual operations at night.

3.3.6 Hazardous and/or toxic materials such as solvent coating, or
thinners shall be stored in appropriate containers.

3.3.7 All hazardous materials shall be labeled with the name of the
materials, the hazards associated with its use and necessary
precautions to be taken.

3.3.8 Contractor shall ensure that during the performance of the work,
all hazards to be health of personnel, have been identified,
assessed and eliminated.

3.3.9 Chemical spills shall be contained & cleaned up immediately to



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prevent further contamination.

3.3.10 All personnel exposed to physical agents such as ionizing
radiation, ultraviolet rays or similar other physical agents shall
be provided with adequate shielding or protection
commensurate with the type of exposure involved.

3.3.11 Where, contact or exposure of hazardous materials could
exceed limits or could otherwise have harmful affects,
appropriate personal protective equipments such as gloves,
goggles, aprons, chemical resistant clothing and respirator shall
be used.

- A Crche where 10 or more female workers are having
children below the age of 6 years.

- Reasonable Canteen facilities are made available at
appropriate location depending upon site conditions.

3.3.13 Suitable facilities for toilet, drinking water, proper lighting shall
be provided at site and labour camps, commensurate with
applicable Laws / Legislation.

3.3.14 Contractor shall ensure storage and utilization methodology of
materials that are not detrimental to the environment. Where
required, Contractor shall ensure that only the environment
friendly materials are selected.

3.3.15 All persons deployed at site shall be knowledgeable of and
comply with the environmental laws, rules & regulations
relating to the hazardous materials substances and wastes.
Contractor shall not, dump, release or otherwise discharge or
dispose off any such materials without the express
authorization of HPCL/Owner.

4.0 DETAILS OF SHE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract:

The Contractor shall prior to start of work submit his Safety Health
and Environment Manual or procedure and SHE Plans for approval
by HPCL/Owner. The Contractor shall participate in the pre-start
meeting with HPCL/Owner to finalise SHE Plans including the
following :

- Job procedure to be followed by Contractor for activities
covering. Handling of equipment, Scaffolding, Electric
Installation, describing the risks involved, actions to be
taken and methodology for monitoring each activity.



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- HPCL/Owner review / audit requirement.

- Organization structure along with responsibility and
authority records / reports etc. on SHE activities.

4.2 During job execution

4.2.1 Implement approved Safety Health, and Environment
management procedure including but not limited to as
brought out under para 3.0. Contractor shall also ensure to:

- arrange workmen compensation insurance, registration
under ESI Act, third party liability insurance etc., as
applicable.

- arrange all HSE permits before start of activities (as
applicable) like hot work, confined space, work at heights,
storage of chemical / explosive materials and its use and
implement all precautions mentioned therein.

- submit timely the completed checklist on SHE activities,
Monthly SHE report, accident reports, investigation reports
etc. as per HPCL/Owner requirements. Compliance of
instructions on SHE shall be done by Contractor and
informed urgently to HPCL/Owner.

- ensure that Resident Engineer / Site-in-Charge of the
Contractor shall attend all the Safety Committee / SHE
meetings by HPCL/Owner. Only in case of his absence from
site that a second senior most person shall be nominated by
him in advance and communicated to HPCL/Owner.

- display at site office and work locations caution boards, list of
hospitals, emergency services available.

- Provide posters, banners for safe working to promote safety
consciousness.

- carryout audits / inspection at sub contractor works as per
approved SHE document and submit the reports for
HPCL/Owner review.

- Assist in SHE audits by HPCL/Owner, and submit compliance
report.

- Generate & submit HSE records / report as per SHE Plan.

- appraise HPCL/Owner on SHE activities at site



Page 63 of 148

STANDARD

SPECIFICATION

FOR

TESTING OF

CONSTRUCTION

MATERIALS



Page 64 of 148
TESTING OF CONSTRUCTION MATERIALS

The contractor shall carryout the following tests as minimum and as
directed by the Engineer-in-charge.

1. WATER: Suitability for construction/ concreting purposes as per IS
456-2000
Periodicity: One test at the beginning of the project and once
in every 3 months and/or change of source
2. SAND
Tests to be conducted
a. Particle size - Lab
b. Silt content - Field
c. Bulking of sand-Field
d. Percentage of Deleterious material / Organic impurities - lab
Is code for material - IS-383-1970
IS code for testing - IS-2386 (Part I) to IS-2386 (Part VIII)
Periodicity of testing
Whenever there is a change in source of supply or as directed by
the Engineer-in-Charge.
Silt content shall be checked daily & recorded.
Remarks
1. Silt content should not exceed 8%.
Sand (for plastering)
a) Particle size - Lab
b) Silt content - Field
c) Percentage of Deleterious /organic impurities - Lab.

IS code for material - IS-1542
IS code for testing - IS-1727



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Periodicity of testing
Same as above, Test shall be repeated for Minimum qty. 500 sq. m
of plastering.
Remarks
1. Silt content not to exceed 8%
2. Sand to be sieved in sieve size 4.75 mm

3. COARSE AGGREGATE
a. Percentage of Soft deleterious materials- Field (Visual)
b. Particle size distribution
c. Aggregate value :
1. Crushing - Lab
2. Impact - Lab
3. Elongation Index & Flakiness Index

IS code for material - IS-383-1970
IS code for testing - IS-2386 (Part I) to IS 2386 (Part VIII)
Periodicity of Testing
Minimum 45 cum. Tests to be repeated for every 45 cum of coarse
aggregate or part thereof.

4. CEMENT
All the Tests required as per BIS Specifications to be conducted at
an approved lab. Manufacturer Batch test certificate also shall be
submitted to HPCL prior to use.Samples shall be drawn from each
lot/batch of cement supplied to Site by Contractor.

As per BIS Specifications and/or change of supplier.



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Remarks
Cement is to be tested, if supplied by the contractor. Cement is to
be tested, if stored for more than 3 months.

Approved manufacturers: Ultratech, ACC, Birla cements, India
Cements or any other brand approved by HPCL

5. CEMENT CONCRETE

a. Slump test - Field
b. Cube strength - Lab
As per IS:456-2000.
Full details are given in the specifications sections of this tender
document.

6. REINFORCEMENT STEEL(CRS)

a. Free from defects - Field (Visual)
b. Weight - Lab
c. Size - Lab
d. Ultimate tensile stress - Lab
e. Yield stress - Lab
f. Elongation percentage - Lab
g. Bend Re-bend test - Lab
h. Chemical analysis-Lab
IS code for material
IS-432 for mild steel
IS-1786 for Tor steel



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As per IS:1786 and/or change of supplier
Remarks
a. Steel shall be tested if stored in open yard for more than one
year.
Approved manufacturers: SAIL, RINL, VIZAG, TISCO

7. BRICKS


a. Compressive Test - Lab
b. Water absorption - Lab
c. Efflorescence - Lab
d. Percentage of Deleterious material - Lab.
e. Dimension test-Lab

IS code for material - IS-1077-1986
IS code for Testing - IS-3495 (Part I) to IS-3495 (Part III)

Minimum 20000 bricks but tests shall be repeated for every 40000
or part thereof depending on the volume of work.

8. Murrum:
Tests to be conducted:
a) Max.Dry density
b) Plasticity index
c) Optimum Moisture Content.
Tests for every 45 cu.m of filled work or part thereof and change in
source.



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9. Structural steel:
a. Weight - Lab
b. Size - Lab
c. Ultimate tensile stress - Lab
d. Yield stress - Lab
e. Elongation percentage - Lab
f. Bend Re-bend test - Lab
g. Chemical analysis-Lab

Structural steel manufactured by SAIL,VIZAG,RINL,TISCO or
JINDAL only shall be used. Plates manufactured by Essar or any of
the above parties is acceptable.

Periodicity of testing shall be as per applicable BIS standard.

Initially, sample of all sections shall be tested for conformance to
BIS requirements and upon satisfactory results only will be
permitted to be used.
Bolt samples also will be tested as per BIS requirements.

10. Galvalume sheets:
Material will be tested for conformance to respective standards.



Page 69 of 148

TECHNICAL

SPECIFICATIONS

FOR

CONCRETE AND

REINFORCEMENT,

CIVIL & ARCHITECTURAL

WORKS



Page 70 of 148

1. CONCRETE AND STEEL REINFORCEMENT

1.1 GENERAL:

This section describes and specifies work required for plain and
reinforced cement concrete including reinforcement and form work.
Unless otherwise specified or agreed in writing by the EIC, all
materials and methods used in the production, testing and
handling of concrete shall comply with the latest editions or
amendments of the relevant Indian Standards.EIC REFERS TO
ENGINEER-IN-CHARGE OF HPCL.

1.2 MATERIALS:

All materials shall be obtained from sources approved by the EIC.
The agreed source or quality of any material shall not be changed
during the course of the contract except with the approval of the
EIC.

Whenever requested by the EIC, the Contractor shall provide a
certificate from the manufacturer, for each and every delivery of
material, showing the source, quantity delivered and confirming
that the material has been tested and conforms to the required
Indian Standard.

1.3 TESTING OF CONCRETE MATERIALS :

Prior to the commencement of concrete work, the contractor shall
get all materials tested in the laboratories approved by the EIC and
shall keep the approved samples in the site office for inspection at
any time of the concreting operation. The test certificates shall be
submitted to EIC for review & approval. During construction also,
the materials shall be sampled and tested as often as deemed
necessary and also as per the "Periodicity of Testing by the EIC.
Samples shall be taken and tested in accordance with the latest
revision of relevant Indian Standard Specifications and the cost
thereto shall be borne by the Contractor.

1.4 CEMENT :

The cement used throughout the work shall be to the approval of
the EIC. Manufacturer Batch Test certificate shall be obtained and
produced to EIC for each delivery of cement and it shall comply



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with the requirements of as mentioned in the "Technical
Specification - Materials. Test samples of cement may be drawn
from each consignment as delivered and tested by the EIC.
Additionally, bags shall be drawn as per requirement of this tender
and tested at HPCL approved laboratory prior to use in the work.
The Contractor shall store the cement in storage sheds to be
constructed by the Contractor for this purpose at site. The cement
shall be delivered to the site in bags sealed with the
manufacturer's seal and different types of cement shall be stored
separately. The storage sheds with watertight walls and roof, shall
be maintained in a perfectly dry and well ventilated condition, 12"
above ground level and the cement shall be stored a per
instructions issued by EIC. It shall be turned over from the bottom
as and when required by the EIC. Any cement which has been
deteriorated or caked or which has been damaged due to any
reason whatsoever shall not be used. No cement shall be used for
the works that has been stored at site for more than three months.
Should the results of lab tests show that any samples does not
comply with the specified requirement, the whole consignment
from which the sample was taken, shall be rejected and forthwith
removed entirely from the site and replaced with cement of
satisfactory quality. Any work carried out with the failed cement
shall also be dismantled or corrective action taken by the
Contractor as per instructions of EIC.

1.5 SAND :

Sand to be used for concrete shall be well graded mixture from
coarse to fine grains, complying with the requirements of IS
383(Latest edition). It shall be clean, hard and free from salt,
earth, clay and other impurities. Fine sand confirming to Zone - IV
shall not be used. It will comply with sieve analysis in accordance
with IS 2386 Part I & II.
Unless initially clean, all sand shall be thoroughly and carefully
cleaned by screening and washing in fresh and clean water. The
screened and washed sand shall not contain more than 8% by
volume of clay, dust and silt immediately after allowing it to settle
for 3 hours in water.

Field tests shall be carried out regularly to ensure the suitability of
sand.

Sample loads shall be available at site for inspection of the EIC and
if approved by him all sand in the work shall be of quality at least
equal thereto.
In case of sand containing moisture the proportions of concrete



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materials shall be adjusted to give the correct mixture.

In case of non-availability of river sand, crushed sand may be
permitted by HPCL.Decision of HPCL in this regard shall be final &
binding on the Contractor.

1.6 COARSE AGGREGATE :

The coarse aggregate for the reinforced concrete work shall consist
of crushed black trap, granite with the approval of the EIC and
shall be free from dust confirming to IS - 383 latest edition. If
considered necessary by the EIC, the aggregate shall be washed
specially until acceptable cleanliness is obtained. The use of
laminated stone, flat or flaky material will not be permitted. The
aggregates of different sizes shall be stored in separate stacks in
clean state and free from all dirt.

When required by the EIC the tests indicated in I.S. 383 or IS-
2386 (all parts ) shall be got carried out by the Contractor at his
cost to show the acceptability of the materials.

Stowage piles of aggregate shall have good drainage, preclude
inclusion of foreign matter and preserve the gradation.

1.7 WATER :

Water used for all purpose in this contract shall be free from oil,
acid, vegetable matter, salts or dirt of any kind which will have
adverse effect on cement or steel in the case of reinforced
concrete. Initial test for water for establishing suitability for use in
concrete shall be carried out. Whenever called for, the Contractor
shall produce test results for water being used on work. The water
quality shall conform to IS-456-2000.

1.8 ADMIXTURES:

Admixtures or Cement containing additives (such as accelerators,
retarders, water proofing agents etc.) shall not be used unless
specified or otherwise directed or approved by the EICs). The
Admixtures shall confirm to IS-9103 latest edition. The Contractor
shall furnish full details of the admixtures prior to use in works.

1.9 FORM WORK :

The form work shall be designed and constructed in such a manner
that all concrete work shall be true to line, level and size, and free



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from honeycombing, pinholes, surface irregularities and every
other defect whatsoever.
All form work shall be adequately propped, braced and framed to
prevent deformation under weight and pressure of wet concrete,
constructional loads, wind, vibrations and other forces. All joints in
shuttering shall be close fitting to prevent the loss of cement paste
or mortar from the concrete.

All form work shall be carefully cleaned and coated with an
approved proprietary mould oil before use, care being taken to
keep all reinforcement away from contact with such oil. All moulds
shall be free from sawdust, shavings, dirt, mud or other debris by
hosing with water or oil free compressed air.

The shuttering for beams and slabs shall be erected so that the
shuttering on the sides of the beams and of the soffits of the slabs
can be removed without disturbing the beam bottoms. For beams
having spans greater than 6 meters and for cantilevers, the form
work shall be given adequate upward camber as directed by the
EIC.

Details of all temporary work (timbering, staging etc.) are to be
submitted for the approval of the EIC and the form work shall be
inspected and approved by the EIC before concrete is placed within
it. Notwithstanding such approval, any damage or consequences
arising there from shall be the Contractor's entire responsibility.

1.10 PROPORTIONS FOR CONCRETE:

The contractor shall design concrete mixes to produce concrete of
the required strengths. Notwithstanding the acceptance by the EIC
of any mix design and series of trial mixes, variations may be
made to the proportions when considered necessary by the EIC.

For both Nominal as well as Design mix concrete, the quantity of
cement shall be determined by weight. Where standard bags of
cement are used, their weight shall be checked at frequent
intervals and any loss in weight due to leakage etc. shall be made
good.

In the case of Nominal Mix concrete, aggregates shall be measured
by volume, cement by weight and mixing water in graduated cans.
In the case of controlled concrete all aggregates and cement shall
be measured by weight in approved weigh batching equipment.
Mixing water shall be measured in graduated cans. For all works
involving M-20 & higher, mobile weigh batchers approved by HPCL



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shall be used.

While calculating the amount of mixing water, the moisture content
of the aggregates shall be taken into account. The design mix shall
be in accordance with IS:10262-latest edition.

READY MIX CONCRETE :

The provision in this section shall apply to all concrete grades and
is to be considered as a supplementary to general provisions for
Plain Cement Concrete & Reinforced Cement Concrete works.

Ready mix concrete (RMC) may be manufactured in a central
automatic weigh batching plant and transported to the job by
agitating Transit mixers. The RMC is to be sourced from reputed &
approved batching plants as mentioned in the approved list of
manufacturers or suppliers only. The design mix has to be
submitted to HPCL before concreting and the same has to be
approved by HPCL before concreting is done.

The design mix is to be carried out as per IS-10262.

The standard deviation for concrete mix design will be considered
as per Table 8 of IS-456-2000.

The proportion of fine aggregates to coarse aggregates should be
adjusted so as to keep them within the specified limits as
mentioned in IS-383.
The Bidders have to submit the Quality Assurance Plan of theirs as
well as the RMC plant for approval and shall strictly adhere to the
same.

The admixtures used shall confirm to IS-9103.

APPLICABLE CODES AND SPECIFICATIONS;

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



Page 75 of 148
In case of discrepancy between this specification and those referred to
herein, this specification shall govern.

APPLICABLE IS SPECIFICATIONS AND CODES OF PRACTICE:

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

IS-10262: Recommended guidelines for concrete mix design.

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

IS 1489 - Specification for portland - pozzolona cement.

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

IS 455: - Specification for Portland Slag Cement

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

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

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

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

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

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

IS 4926: Ready Mix Concrete - Code Of Practice

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

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

IS 2645:- Specification for integral cement waterproofing compound.

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

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



Page 76 of 148

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

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

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

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

Concrete shall be mixed by mechanical mixer only and no hand mixing
shall be allowed for RCC works.

GENERAL:

The quality of materials and method and control of manufacture and
transportation of all concrete work irrespective of mix, whether
reinforced or otherwise, shall conform to the applicable portions of this
specification. Engineer shall have the right to inspect the source/s of
material/s, the layout and operation of procurement and storage of
materials, the concrete batching and mixing equipment, and the quality
control system. Such an inspection shall be arranged and Engineers
approval obtained, prior to starting of concrete work.

MATERIALS FOR STANDARD CONCRETE:

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

CONSISTENCY:

The consistency of the concrete shall be such that it flows sluggish
during pumping of concrete into the forms and around the reinforcement



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without any segregation coarse aggregate from mortar. The slump tests
are mandatory and shall be carried out at regular intervals so that the
consistency concrete can be monitored.

PLACING OF CONCRETE:

Concreting shall commence only after inspection and written approval by
EIC.

Shuttering shall be clean and free from deposits of foreign materials and
proper de-shuttering agent shall be applied to the surface.
Proper arrangements shall be provided for conveying the concrete the
place of deposition without disturbing the reinforcement.

COMPACTION:

All RCC works shall be cured for a minimum period of 14 days or more as
advised by EIC.

INSPECTION AND RECTIFICATION OF DEFECTS:

Immediately on removal of forms, the RCC works shall be examined by
the Engr. -in-Charge before any defects are made good.
The work that has sagged or contains honey combing to an extent
detrimental to the structural safety or architectural concept shall be
rejected.

Surface defects on a minor nature may be accepted and the same shall
be rectified as follows :

a) Bulges due to movement of forms, ridges at forms, ridges at form
joints shall be carefully chipped and then rubbed with a grinding
stone.
b) Honeycombed and other defective areas must be chipped out, the
edges being out as straight as possible and perpendicular to the
surface. Shallow patches are first treated with a coat of thin grout (1
cement : 1 sand) and then filled with mortar similar to that used in



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concrete. Large and deep patches shall be filled up with concrete held
in place by forms and shall be reinforced.
c) Holes left by bolts shall be filled carefully with mortar. Holes
extending right through the concrete shall be filled with mortar with a
pressure gun.
d) The same amount of care to cure the material in patches should be
taken as with the whole structure.

POST TREATMENT OF SURFACE :
The surface which has to receive plaster or where it has to be joined with
brick masonry walls shall be properly roughened immediately after the
shuttering is removed.

ACCEPTANCE CRITERIA OF CONCRETE WORK : will be as per IS-
456-2000.

MEASUREMENT
All measurements shall be as per IS 1200

1.11 MIXING OF CONCRETE:

Mixing of concrete shall continue until there is a uniform
distribution of material and the concrete is uniform in colour and
consistency and for at least two minutes.

Mixes and weigh batches shall be maintained in first class condition
throughout the contract and any mixer or plant which is faulty shall
not be used. The drums on all mixers shall revolve at the speed
recommended by the maker. A mixer of any type which has been
out of use for more than 20 minutes shall be thoroughly cleaned
out before any fresh concrete is mixed. All equipment shall be
maintained in a clean serviceable condition and their accuracy
periodically checked.

1.12 SLUMP TEST :

The Contractor shall keep at the site of the works for the EICs use



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or his representative a standard slump test mould and shall
provide facilities throughout the construction for tests to be made
as and when the EIC may require.

1.13 COMPRESSIVE STRENGTH :

Concrete shall confirm to IS-456-2000.

The Contractor shall keep on site minimum 12 no.s standard 15
cm test cube moulds and ancillary equipment for preparing test
cubes. The testing of cubes and compilation of results shall be in
line with IS:456-2000 requirements. Acceptance criteria shall be as
per IS:456-2000.

Any part of the work from which the cubes fail to give the required
minimum compressive strength shall be dealt with by the
Contractor as directed by the EIC and at the expenses of the
Contractor.

The concrete is also liable to be rejected or repaired as per the
instructions of the EIC/EIC if it is porous or honeycombed, its
placing has been interrupted without providing a construction joint
or the reinforcement has been disproportionately displaced. The
rejected concrete has to be demolished and redone to the
satisfaction of the EIC free of cost.

The Contractor shall keep a daily record (Concrete Pour Card )
showing the date when each portion of concrete is poured , curing,
removal of form work and test cube results at 7 days and 28 days
period. They shall be sent immediately to the EIC/EIC.

1.14 TRANSPORTING, PLACING AND COMPACTING OF CONCRETE :

The concrete shall be transported maintaining required workability
in a manner such as to avoid the segregation of the constituent
materials, and loss of any of the ingredients. It shall be deposited
as nearly as practicable in its final position to avoid re- handling. It
shall be placed and compacted before setting commences and
should not be subsequently disturbed. Methods of pouring should
be such as to preclude segregation, and to avoid displacement of
reinforcement and movement of form work. Concrete Pumping
needs to be arranged for conveying the concrete from transit
mixers to work spot.

The concrete should be thoroughly compacted and fully worked
around the reinforcement, around embedded fixtures and into the



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corner of the form work without formation of honeycombing,
pinholes or surface irregularities and any other defects whatsoever.

The use of mechanical vibrators having capacity of producing
vibrations at a rate not less than 5000 cycles per minute is
recommended. Over vibration or vibration of very wet concrete is
harmful. In addition to mechanical vibration, sufficient hand tools
must be used to assure full consolidation around reinforcement and
at edges and corners.

The deposition of concrete shall be carried out as continuously as
possible to reduce to minimum joints between new concrete and
concrete which has set. Where construction joints are necessary
they shall be formed at right angles to the axis of the member
concerned by the insertion of rigid stopping off forms, against
which concrete can be properly rammed or as per the advise of
EIC.

No unset concrete shall be brought into contact with unset
concrete containing cement of different type. Special permission
and instructions shall be obtained when concrete has to be
deposited under water.

Accumulation of set concrete on the reinforcement shall be
avoided. Before fresh concrete is deposited upon or against any
concrete which has already hardened, the surface of hardened
concrete shall be well roughened if necessary by chipping and
laitance removed. The surface shall then be swept clean with wire
brushes, thoroughly wetted and covered with a thin layer of
cement mortar.

1.15 PROTECTION OF CONCRETE :

Newly placed concrete shall be protected by approved means from
rain, sun and drying winds. Concrete placed below the ground shall
be protected from falling earth during and after placing. Approved
means shall be taken to protect immature concrete from damage
by debris, excessive loading, vibration, abrasion, deleterious
ground-water, mixing with earth or other materials that may
impair the strength and durability of concrete.

1.16 CONSTRUCTION JOINTS :

Before construction commences, the Contractor shall submit to
the EIC, for his approval, sketches showing proposed positions of
construction joints.



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Each section of concrete shall be poured continuously between
construction joints. Shuttering to all construction joints should be
so made that it produces on the face of joints a suitable grooved or
indented surface to act as a sheer key or bond for the subsequent
concrete. Inclined joints shall not be permitted.

If the concrete has been allowed to harden excessively, the surface
shall be chipped over its whole surface to a depth of at least
3/8"and thereafter thoroughly washed. If the concrete has not fully
hardened, all laitance shall be removed by scrubbing the wet
surface with wire brushes to avoid dislodgement of particles of
aggregate. Before fresh concrete is added to the other site of a
construction joint the surface of the old concrete will be thoroughly
wetted and then covered with a thin layer of cement mortar of the
same quality as that in the concrete.

No distortion or displacement of reinforcement from the positions
shown on the drawings shall be permitted at construction joints.

Water stoppers shall be provided to the construction joints of
terrace slabs, kitchen and bathroom slabs, and water retaining
structures where water leakage poses serious problems.

1.17 STRUCTURAL JOINTS :

Expansion joints or other permanent structural joints shall be
provided in the positions and of the form described in the drawings
or elsewhere. In no case shall the reinforcement, corner protecting
angles or other fixed metal items, embedded or bonded into
concrete run continuously through as expansion joint. The placing
of concrete on either side of the expansion joint shall be done
separately after an interval of at least 7 days.

1.18 CUTTING INTO CONCRETE :

No concrete shall be cut into, nor shall it be interfered with in any
way, without the prior approval in writing of the EIC. Necessary
holes shall be provided as required for plumbing work and for
electrical pipes etc. at the time of execution.

1.19 CURING OF CONCRETE :

Exposed surfaces of concrete shall be kept continuously in a damp



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or wet condition for at least seven days from the date of placing of
concrete.

Approved curing compounds may be used in lieu of moist curing
with the permission of the EIC. Such compounds shall be applied to
all exposed surfaces of the concrete as soon as possible after the
concrete has set.

1.20 SUPERVISION :

Constant and strict supervision of all the items of the construction
is necessary during the progress of the work, including the
proportioning and mixing of the concrete. Supervision is also of
extreme importance to check the reinforcement and its placing
before being covered.

Before any important operation, such as concreting or striking off
the form work is started, adequate notice shall be given to the EIC.

1.21 CONTRACTOR'S RATES TO INCLUDE :

The rates of contractor for providing and laying cement concrete in
various grades or proportions in the Schedule of Quantities shall,
apart from any other factors specified elsewhere in the tender
documents, include for the following:

(a) For all factors and method of work described in these
specifications.

(b) For all materials, labour, tools and plants, scaffolding, etc. mixing,
conveying and placing concrete in position, ramming, vibrating,
trawling, curing, providing necessary scaffolding and removing the
same after the work is complete.

(c) Unless otherwise specified in the Schedule of Quantities the cost
for concrete items shall include for providing and fixing form work
as described inclusive of erecting, propping to required heights,
bracing, providing stays, struts, bolts, nuts and everything
necessary to keep the forms rigid, smoothening the surface to
receive concrete as per detailed drawing, striking and stripping
form work after the concrete is cured, hacking the concrete surface
required to receive plaster etc.

(d) The reinforcement in case of Reinforced Concrete work will be paid
for separately unless otherwise stated in the particular items, but
rate shall include for pouring concrete and packing around



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reinforcement.

(e) The measurement of concrete will be as per detailed drawings,
shapes and size based on net structural sizes as per drawings
including rendering wherever required.

(f) Rates for concrete items shall cover for any shape of structural
members, beams, facias, etc.

(g) Formation and treatment of contraction and expansion joints
(where water bars like copper strips or joint fillers like 'Shalitex'
are specified, such materials shall be paid for separately.

(h) Design of mixes where so required by specification in an approved
Laboratory and on tests of materials and work required in the
opinion of the EIC and described in these specifications.

(i) Fixing all inserts like pipes, plugs, forming holes etc. as described.

(j) Weigh-batching using a Mechanical/Mobile weigh-batcher or a
batching plant .

(k) For taking out dowel bars, etc. through shuttering.

(l) In case where at the junctions of beams, columns, slabs, the
composition of concrete mix or specified strength be different for
columns, beams and slabs, then in such cases only the richer
concrete among those specified for in all these members shall be
used at the junctions and rate quoted for columns, beams and
slabs or any member entering such junctions shall allow for the
same. Rate shall also cover for spill over of richer concrete in
beams to natural angle of repose of wet concrete required from
practical considerations, while concreting the junctions.

(m) For forming drip moulds in Chajjas, sills, etc. and where shown in
the drawings or as directed.

(n) For work at all levels.

2 STEEL REINFORCEMENT :

2.1 CRS BARS :
CRS BARS confirming to IS-1786 latest edition shall be used.

2.2 CLEANING OF REINFORCEMENT :
Before steel reinforcement is placed in position, the surface of the



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reinforcement shall be cleaned of rust, dust, grease and other
objectionable substances.

2.3 CUTTING OF REINFORCEMENT :
Before the reinforcement bars are cut, the contractor shall study
the lengths of bars required as per drawings and shall carry out
cutting only to suit the sizes required as per drawings.

2.4 PLACING AND SECURING :
Reinforcement bars shall be accurately placed and secured in
position and firmly supported or wedged by precast concrete
blocks of suitable thickness, at sufficiently close intervals, so that
they will not sag between the supports or get displaced during the
placing of concrete or any other operation of the work. It is most
important to maintain reinforcement in its correct position without
displacement and to maintain the correct specified cover.
Contractor shall be responsible for all costs for rectification
required in case the bars are displaced out of their correct position.

2.5 BINDING WIRE :
The reinforcement shall be securely bound wherever bars cross or
wherever required with 20 gauge soft annealed steel wire.

2.6 WELDING :

Welding of bars shall be adopted for members as approved by EIC.

2.7 BENDS ETC :
Bends, cranks etc. on steel reinforcement shall be carefully
formed, care being taken to keep bends out of winding. Otherwise,
all rods shall be truly straight. If any bend shows signs of
brittleness or cracking, the rod shall be removed immediately from
the site. Heating of reinforcement of bar to facilitate bending will
not be permitted. The bars shall always be bent cold.

High strength deformed bars shall in no case be heated to facilitate
bending or cranking.

2.8 INSPECTION OF REINFORCEMENT :
No concreting shall be commenced until the EIC has inspected the
reinforcement in position and until his approval has been obtained.

A notice of at least 24 hours shall be given to the EIC by the
Contractor for inspection of reinforcement.



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If in the opinion of the EIC any material is not in accordance with
the specification or the reinforcement is incorrectly spaced, bent or
otherwise defective, the contractor shall immediately remove such
materials from the site and replace the same and rectify any other
defects in accordance with the instruction of the Project Engineer
to his entire satisfaction.

2.9 NET MEASUREMENTS :
Reinforcement shall be placed as shown on the structural drawings
and payment will be made on the net measurements from
drawings. Authorised laps, dowels, chairs and pins in
reinforcement shall be paid for. The Contractor shall allow in his
quoted rate for all wastage which will not be paid for.

2.10 RATES QUOTED FOR REINFORCEMENT SHALL IN ADDITION TO
ANY FACTORS MENTIONED ELSEWHERE SHALL ALSO INCLUDE
FOR :
(a) All cutting to lengths, labour in bending and cranking, forming
hooked ends, handling, hoisting and everything necessary to fix
reinforcement in work as per drawings.

(b) Cost of binding wire required as described.

(c) Cost of PVC/precast blocks to maintain cover and holding
reinforcement in position.

(d) For fabricating and fixing reinforcement in any structural member
irrespective of its location, dimensions and level.

(e) Removal of rust and every other undesirable substances, using
wire brush etc. as described.

(f) Stock piling of reinforcement as described.

(g) Work at all levels.

TECHNICAL SPECIFICATIONS FOR CIVIL & ARCHITECTURAL WORKS

1) PLASTERING

1.1) External Plastering:

Cement plastering on concrete or masonry surface shall include fixing
Chicken wire mesh to joints of B.B. masonry and RCC members.



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a) Sand face plaster 20mm thick
in two coats -For External walls.
(with water proofing compound)

1.2) Chicken wire mesh:

Shall be used only at joints between RCC & brickwork only for internal &
external plaster as given below:
Chicken wire mesh made out of 24 gauge wire with opening of 15mm x
15mm(max) as approved, over junctions of RCC and brickwork or any
other similar material nailing the chicken mesh with wire nails at 200 -
250mm C/C prior to plastering etc.(The nailing shall be with power drills
only). Lapping of chicken wire mesh on each other shall not be less than
100mm. Width of chicken mesh shall be 150mm.Chicken mesh needs to
be provided upto 75mm on either side of joint

1.3) External Plastering

The procedure shall be, as under:

1) Raking out joints of brick masonry.

2) Chipping of all protruded parts if any from concrete surfaces.

3) Fixing Chicken mesh at junctions of B.B. masonry and R.C.C.
member.

4) Watering the external surface prior to plastering.

5) Applying 1
st
coat average thickness 12mm of cement and sand
mortar (1:2) with approved water proofing component by making
mortar patches at 2m interval (Thiyya) with accurate line, level
and plumb.

6) Make impression of wire brush when the plaster is not set
completely to have a key to receive second coat of plaster.

7) Curing shall be done for 1
st
coat for 48 hrs.

8) 2
nd
coat then shall be provided with in 48 hrs. average thickness
8mm using cement and sand mortar, (1:4) making thiyyas at 2m.
internal and in line and level, plumb.

9) The plastered surface shall be tamped with a wooden float or
sponge to achieve a sand faced finish evenly on the whole surface
plastered.



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10) Water proofing compound to be mixed in 1
st
and 2
nd
coat of
cement plaster as per manufacturers instructions. The water
proofing compound shall bear IS - 2645: 1975 mark.

11) Curing for 7 days shall be carried out by sprinkling water, or
spraying the water on plastered surfaces continuously.

2) PAINTING

2.1) General

i) All painting work shall proceed from top to bottom. In case of
internal painting ceiling shall be painted before walls.

ii) Materials to be used shall be of 1
st
quality from approved
manufacturers of approved shade.

iii) Work shall be carried out by experienced and skilled workers.

iv) Surface shall be thoroughly cleaned of all dust, dirt, mortar drops
oil paints, scales etc. by wire brushing, scraper tools.

v) In case ready mixed paints are used and if thinning is required,
only the brand recommended by the paint manufacturer shall be
used.

vi) All subsequent coats shall be applied only after the previous coat
has dried thoroughly. One coat shall constitute of one horizontal
stroke immediately followed by one vertical stroke, in all cases.

2.2) CEMENT PAINT

1) Material

The cement Paint shall be (conforming to IS 5410) of approved brand
and manufacture.

The cement Paint shall be brought to the site of work by the contractor
in its original containers is sealed condition. The material shall be
brought in at a time in adequate quantities to suffice for the whole work
or at least a fortnights work. The materials shall be kept in the joint
custody of the Contractor and the Engineer-in-Charge.



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The empty containers shall not be removed from the site of work till the
relevant item of the work has been completed and permission obtained
from the Engineer-in-Charge.

2) Preparation of Surface

For New Work, the surface shall be thoroughly cleaned of all mortar
dropping, dirt dust, algae, grease and other foreign matter by brushing
and washing. Pitting in plaster shall be made good and a coat of water
proof cement Paint shall be applied over patches after wetting them
thoroughly.

3) Preparation of Mix

Cement Paint shall be mixed in such quantities as can be used up within
an hour of its mixing as otherwise the mixture will set and thicken,
affecting flow and finish. Cement Paint shall be mixed with water in two
stages. The first stage shall comprise of 2 parts of cement Paint and one
part of water stirred thoroughly and allowed to stand for 5 minutes. Care
shall be taken to add the cement Paint gradually to the water and not
vice versa. The second stage shall comprise of adding further one part of
water to the mix and stirring thoroughly to obtain a liquid of workable
and uniform consistency. In all cases the manufacturers instructions
shall be followed meticulously. The lids of cement Paint drums shall be
kept tightly closed when not in use, as by exposure to atmosphere the
cement Paint rapidly becomes air set due to its hygroscopic qualities. In
case of cement Paint brought in gunny bags, once the bag is opened, the
contents should be consumed in full on the day of its opening. If the
same is not likely to be consumed in full, the balance quantity should be
transferred and preserved in an airtight container to avoid its exposure
to atmosphere.

4) Application

a) The solution shall be applied on the clean and wetted surface with
brushes or spraying machine. The solution shall be kept well
stirred during the period of application. It shall be applied on the
surface which is on the shady side of the building so that the direct
heat of the sun on the surface is avoided. The method of
application of cement Paint shall be as per manufacturers
specification. The completed surface shall be watered after the
days work.
b) The second coat shall be applied after the first coat has been set
for at least 24 hours. Before application of the second or
subsequent coats, the surface of the previous coat shall not be
wetted.



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c) For new work, the surface shall be treated with three or more
coats of water proof cement Paint as found necessary to get a
uniform shade.
d) For old work, the treatment shall be with one or more coats as
found necessary to get a uniform shade.

5) Precaution

Water proof cement Paint shall not be applied on surfaces already
treated with white wash, colour wash, distemper dry or oil bound,
varnishes, Paints etc. It shall not be applied on gypsums, wood and
metal surfaces. If water proofing cement is required to be applied on
existing surface, previously treated with white wash, colour wash etc.,
the surface shall be thoroughly cleaned by scrapping off all the white
wash, colour wash etc. completely. Thereafter, a coat of cement primer
shall be applied followed by two or more coat of water proof cement.

2.3) EXTERNAL ACRYLIC PAINT

1) Material

The paint shall be (Texured exterior paint/Acrylic smooth exterior
paint/premium acrylic smooth exterior paint) of approved brand and
manufacture. This paint shall be brought to the site of work by the
contractor in its original containers in sealed condition. The material shall
be brought in at a time in adequate quantities to suffice for the whole
work or at least a fortnights work. The materials shall be kept in the
joint custody of the contractor and the Engineer-in-Charge. The empty
containers shall not be removed from the site of work till the relevant
item of work has been completed and permission obtained from the
Engineer-in-Charge.

2) Preparation of Surface

For new work, the surface shall be thoroughly cleaned off all mortar
dropping, dirt dust, algae, fungus or moth, grease and other foreign
matter of brushing and washing, pitting in plaster shall make good,
surface imperfections such as cracks, holes etc. should be repaired using
white cement. The prepared surface shall have received the approval of
the Engineer in charge after inspection before painting is commenced.

3) Application

a) Before pouring into smaller containers for use, the paint shall be
stirred thoroughly in its container, when applying also the paint
shall be continuously stirred in the smaller containers so that its



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consistency is kept uniform. Dilution ratio of paint with potable
water can be altered taking into consideration the nature of surface
climate and as per recommended dilution given by manufacturer.
In all cases, the manufacturers instructions & directions of the
Engineer-in-charge shall be followed meticulously. The lids of paint
drums shall be kept tightly closed when not in use as by exposure
to atmosphere the paint may thicken and also be kept safe from
dust.
b) Paint shall be applied with a brush on the cleaned and smooth
surface. Horizontal strokes shall be given, First and vertical strokes
shall be applied immediately afterwards. This entire operation will
constitute one coat. The surface shall be finished as uniformly as
possible leaving no brush marks.
c) The specifications in respect of scaffolding, protective measures,
measurements and rate shall be as described under.

3) SCAFFOLDING

1) Wherever scaffolding is necessary, it shall be erected on double
supports tied together by horizontal pieces, over which scaffolding
planks shall be fixed. The scaffolding shall preferably be of steel
pipes. No steel pipes, ballies, bamboos or planks shall rest on or
touch the surface which is being painted.

2) For all exposed brick work or tile work, double scaffolding having
two sets of vertical supports shall be provided. The supports shall
be sound and strong, tied together with horizontal pieces over
which scaffolding planks shall be fixed.

Note : In case of special type of brick work, scaffolding shall be got
approved from Engineer-in-Charge in advance.

3) Where ladders are used, pieces of old gunny bags shall be tied on
their tops to avoid damage or scratches to walls.

4) For Painting of ceiling, proper stage scaffolding shall be erected.

4) Door Frames, Shutters

Pressed steel door frames shall be as per respective IS specifications.

5) Windows & ventilators:

The sections shall be from JINDAL.



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Openable Windows

The windows shall be provided with PVC weather strips PVC weepholes
with EPDM rubber gasket, fixing clips, U beading taper clips, PVC lining
for water tightness with approved type of interlocking and "locking
arrangement with all suitable fixture including cleaning and
polishing all aluminium sections from inside and outside with petrol and
or other suitable agents etc complete, including providing and fixing
6mm thick plain glass.

Openable Ventilators

Ventilators shall be with Imex hinges 10-4 bar of Ebco;openable handles
shutter rollers with bearings and zinc plated screws with 6m thick
reflective glass and EPDM gasket.

Polysulphide dow corning sealant shall be used for sealing the joints with
masonry.

1) Aluminium Sections

Aluminium sections used for fixed/openable windows, ventilators,
partitions, frame work & doors etc. shall be suitable for use to
meet architectural designs to relevant works and shall be subject
to approval of the Engineer-in-Charge for technical, structural,
functional and visual considerations. The aluminium extruded
sections shall conform to IS 733 and IS 1285 for chemical
composition and mechanical properties. The stainless steel screws
shall be of grade AISI 304.

The permissible dimensional tolerances of the extruded sections
shall be as per IS 6477 and shall be such as not to impair the
proper and smooth functioning/operation and appearance of door
and windows.

Aluminium glazed doors, windows etc. shall be of sizes, sections
and details as shown in the drawings. The details shown in the
drawings may be varied slightly to suit the standards adopted by
the manufacturers of the aluminium work, with the approval of
Engineer-in-Charge. Before proceeding with any fabrication work,
the contractor shall prepare and submit, complete fabrication and
installation drawings for each type of glazing doors, windows,
ventilators and partition etc. for the approval of the Engineer-in-
Charge. If the sections are varied, the contractor shall obtain prior
approval of Engineer-in-Charge and nothing extra shall be paid on



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this account.

2) Anodising

Standard aluminium extrusion sections are manufactured in
various sizes and shapes in wide range of solid and hollow profiles
with different functional shapes for architectural, structural glazing,
curtain walls, doors, window & ventilators and various other
purposes. The anodizing of these products is required to be done
before the fabrication work by anodizing/electro coating plants
which ensures uniform coating in uniform colour and shades. The
extrusions are anodized up to 30 micron in different colours. The
anodized extrusions are tested regularly under strict quality control
adhering to Indian Standard.

3) Protection of Anodizing Finish : It is mandatory that all aluminium
members shall be wrapped with self adhesive non-staining PVC
tape, approved by Engineer-in-Charge.

4) Measurement: All the aluminium sections including snap beading
fixed in place shall be measured in running meter along the outer
periphery of composite section correct to a millimeter. The weight
calculated on the basis of actual average (average of five samples)
weight of composite section in kilogram correct to the second place
of decimal shall be taken for payment. (Weight shall be taken after
anodizing). The weight of cleat shall be added for payment. Neither
any deduction nor anything extra shall be paid for skew cuts.

5) Rate:

The rate shall include the cost of all the materials, labours involved
in all the operations as described in nomenclature of item and
particular specification.

6) Float Glass

The glass shall be clear float glass and should be approved by the
Engineer in Charge. It shall be clear, float transparent and free
from cracks subject to allowable defects. The float glass shall
conform to the IS 14900.

7) Thickness :

The thickness of float glass shall depend on the size of panel. The
tolerance in thickness shall be as under:



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Nominal Thickness (in mm ) Tolerance (in mm )
4.0 0.3
5.0 0.3
6.0 0.3
8.0 0.6

8) EPDM- GASKETS

The EPDM Gaskets shall be of size and profile as shown in drawings
and as called for, to render the glazing, doors, windows, ventilators
etc. air and water tight. Samples of gaskets shall be submitted for
approval and the EPDM gasket approved by Engineer-in-Charge
shall only be used. The contractor shall submit documentary proof
of using the above material in the work to the entire satisfaction of
Engineer-in-Charge.

The EPDM gasket shall meet the requirements as given in Table
below:

TABLE EPDM GASKET

SL
NO
Description Standard
Follow
Specification
1 Tensile strength Kg.f/cm2 ASTM-D 412 70 Min.
2 Elongation at break % ASTM-D 412 250 Min.
3 Modulus 100% Kgf/cm2 ASTM-D 412 22 Min.
4 Compression set % at 0o
CC 22 Hrs.
ASTM-D 395 50 Max.
5 Ozone resistance ASTM-D 1149 No visible
cracks

9) SEALANT

The sealants of approved grade and colour shall only be used. The
silicone for perimeter joints (between Aluminium section and
RCC/Stone masonry) shall be of make approved by the Engineer-
in-Charge.

10) Method of Application

Surface Preparation : Clean all joints and glazing pockets by



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removing all foreign matter and contaminants such as grease, oil,
dust, water, frost, surface dirt, old sealants or glazing compounds
and protective coatings.

11) Masking

Areas adjacent to joints shall be masked to ensure neat sealant
lines. Masking tape shall not be allowed to touch clean surfaces to
which the silicone sealant is to adhere. Tooling shall be completed
in one continuous stroke immediately after sealant application and
before a skin forms and masking shall be removed immediately
after tooling.

12) Application

Install backer rod of appropriate size and apply silicone sealant in a
continuous operation using a positive pressure adequate to
properly fill and seal the joint. The silicone sealant shall be tooled
with light pressure to spread the sealant against backing material
and the joint surfaces before a skin forms. A tool with convex
profile shall be used to keep the sealant within the joint. Soap or
water shall not be used as a tooling aid. Remove masking tape as
soon as silicone joint is tooled.

13) Tolerance

A tolerance of + 3 mm shall be allowed in the width of silicone
joints. The depth of the joints at throat shall not be less than 6
mm.

DOOR, WINDOW, VENTILATOR AND PARTITION FRAMES

1) Frame Work

First of all the shop drawings for each type of
doors/windows/ventilators etc. shall be prepared by using
suitable sections based on architectural drawings, adequate to
meet the requirement/ specifications and by taking into
consideration varying profiles of aluminium sections being
extruded by approved manufacturers. The shop drawings shall
show full size sections of glazed doors, windows, ventilators etc.
The shop drawings shall also show the details of fittings and
joints. Before start of the work, all the shop drawings shall be
got approved from the Engineer-in-Charge. Actual measurement
of openings left at site for different type of door/window etc.



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shall be taken. The fabrication of the individual
door/windows/ventilators etc. shall be done as per the actual
sizes of the opening left at site. The frames shall be truly
rectangular and flat with regular shape corners fabricated to
true right angles. The frames shall be fabricated out of section
which have been cut to length, mitered and jointed
mechanically using appropriate machines. Mitered joints shall be
corner crimped or fixed with self tapping stainless steel screws
using extruded aluminium cleats of required length and profile.
All aluminium work shall provide for replacing damaged/broken
glass panes without having to remove or damage any member
of exterior finishing material.

2) Fixing of Frames

The holes in concrete/masonry/wood/any other members for
fixing anchor bolts/fasteners/screws shall be drilled with an
appropriate electric drill. Windows/doors/ventilators etc. shall be
placed in correct final position in the opening and fixed to Sal
wood backing using stainless steel screws of star headed,
counter sunk and matching size groove. of required size at
spacing not more than 250 mm c/c or dash fastener. All joints
shall be sealed with approved silicone sealants. In the case of
composite windows and doors, the different units are to be
assembled first. The assembled composite units shall be
checked for line, level and plumb before final fixing is done.
Engineer-in-Charge in his sole discretion may allow the units to
be assembled in their final location if the situation so warrants.
Snap beadings and EPDM gasket shall be fixed as per the detail
shown in the shop drawings.

Where aluminium comes into contact with stone masonry, brick
work, concrete, plaster or dissimilar metal, it shall be coated
with an approved insulation lacquer, paint or plastic tape to
ensure that electrochemical corrosion is avoided. Insulation
material shall be trimmed off to a clean flush line on completion.
The contractor shall be responsible for the doors, windows etc.
being set straight, plumb, level and for their satisfactory
operation after fixing is complete.

3) Measurements

All the aluminium sections including snap beadings fixed in
place shall be measured in running meter along the outer
periphery of composite section correct to a millimeter. The
weight calculated on the basis of actual average (average of five



Page 96 of 148
samples) weight of composite section in kilogram correct to the
second place of decimal shall be taken for payment (weight
shall be taken after anodizing). The weight of cleat shall be
added for payment. Neither any deduction nor anything extra
shall be paid for skew cuts.

4) Rate

The rate shall include the cost of all the materials, labour
involved in all the operations as described in nomenclature of
item and particular specification.

DOOR, WINDOWS AND VENTILATOR SHUTTERS

1) Material, fabrication and dimensions of aluminium doors,
windows and ventilators manufactured from extruded
aluminium alloy sections of standard sizes and designs complete
with fittings, ready for being fixed into the building shall be as
per IS 1948.

2) Tolerances

The sizes for doors, windows and ventilators frames shall not
vary by more than 1.5 mm.

3) Material

Aluminium alloy extruded sections used in the manufacture of
extruded window sections shall conform to IS 733. Hollow
aluminium alloy sections used shall conform to IS 1285.

4) Glass Panes

Glass panes shall weigh at least 7.5 kg/m2 and shall be free
from flaws, specks or bubbles. All panes shall have properly
squared corners and straight edges.

5) Screws

Screws threads of machine screws used in the fabrication of
aluminium doors, windows and ventilators shall conform to IS
1362.



Page 97 of 148

LIST OF APPROVED AND NOMINATED MANUFACTURERS/
SUPPLIERS OF MATERIALS AND SUB-CONTRACTORS.

NOTE:

1. All materials to be used should be as per the list given below.

2. Wherever contractor proposes to use "equivalent" makes (i.e. other
than specified), the same shall be done only after obtaining prior
approval from HPCL in writing.

3. All material to be used shall be of first quality unless otherwise
specified in view to maintain quality and design standards.

4. The final selection of the make of materials to be used of following list
shall be decided by HPCL

5. If any other material or name of supplier is not mentioned in the list
the same should be approved from the Client / Consultant.

SR
NO
MATERIAL APPROVED
MANUFACTURER/SUB
CONTRACTOR/SUPPLIERS
CIVIL WORK
1. Cement Pls refer RCC list
2. White cement

Birla,J.K.
3. Mild and Tor steel

Pls refer tender list
4. Water-proofing compound

MBT, Fosroc, Ciba geigy.
5 Aluminum window Fabricators : Prior approval from HPCL is to be
taken for aluminium fabrication
work.

Note: Items mentioned in above list & any other item not
mentioned but required at site will be as per the final approval of
Client / Consultant.

TECHNICAL SPECIFICATIONS FOR GENERAL CIVIL WORKS

1.0) EXCAVATION: includes removal of vegetation; providing side
strutting and or any protection required for collapse, etc up to all
depths. Excavation shall be carried out in hard rock and soft rock



Page 98 of 148
also as per requirements.

2.0) Backfilling shall be carried out with approved soils available from
excavation. In case any additional murrum is required, same shall
be brought from outside quarries. Layer wise compaction shall be
carried out. Compaction, MDD and OMC shall be tested.

3.0) Filling with murrum shall be carried out in layers of 200mm.

4.0) Murrum shall be free from boulders and vegetation. Material shall
be brought from approved quarries. Murrum shall be compacted
with mechanical compactors or rollers.95% MDD shall be achieved
for testing clearance. Filling shall be in 200mm layers.

5.0) Plain Cement Concrete shall be with 1: 4:8 by volume.

ANTITERMITE TREATMENT

1.0 GENERAL

1.1 Pre-constructional anti-termite treatment is a process in which soil
treatment is applied to a building in early stages of its
construction. The purpose of anti termite treatment is to provide
the building with a chemical barrier against the subterranean
termites.

1.2 Anti termite treatment being a specialized job, requires thorough
knowledge of the chemicals, soils, termite to be dealt with and the
environmental conditions, in order to give effective treatment and
lasting protection to the property undergoing treatment. It is
therefore, imperative that the works of anti-termite treatment
should be got executed through specialized agencies only. The
specialized agency should be preferably a member of the Indian
Pest Control Association and shall have sufficient experience of
carrying out similar works of magnitude envisaged in this tender.

1.3 The pre-constructional soil treatment is required to be applied
during the construction stages of the sub-structure upto plinth
level. The contractor has to be watchful of the various stages of
sub-structure works and arrange to carry out the soil treatment in
time after proper co-ordination with other constructors if any,
working at site.

1.4 The scope of pre-constructional anti-termite treatment covers the
soil treatment with approved chemicals in water emulsion in
foundation trenches for columns, plinth beams, pile caps, brick



Page 99 of 148
walls, service trenches, lift pits, steps, ramps etc., in top surfaces
of plinth filling, at junction of walls and floor, in expansion joints
etc., in stages as detailed in this specifications and drawings,
unless otherwise stipulated, the anti-termite treatment will be
carried out as per IS : 6313 (Part-II) and / or as per direction of
the Consultant.

2.0 CODES & STANDARDS

The relevant Indian Code for Antitermite treatment is given below:

IS 6313 (Part 2) 2001 Anti-termite measures in building -
Pre construction chemical treatment

3.0 SITE PREPARATION

3.1 In order to ensure uniform distribution of the chemical emulsion
and to assist penetration, the following site preparation shall be
carried out:

a) Remove all trees, stumps, logs or roots from the building site.

b) Remove all concrete from work if left anywhere, levelling pegs,
timber off-cuts and other builders debris from the area to be
treated.

c) If the soil to be treated is sandy or porous, preliminary
moistening will be required to fill capillary spaces in soil in
order to prevent the loss of emulsion through piping or
excessive percolations.

d) In the event of water logging of foundation, the water shall be
pumped out before application of chemical emulsion and it
should be applied only when the soil is absorbent.

e) On clays and other heavy soils where penetration is likely to
be slow and on sloping sites, where run-off of the treating
solution is likely to occur, the surface of the soil should be
scarified to a depth of 75 mm at least.

f) All sub floor levelling and grading should be completed, all
cutting, trenches and excavations should be completed with
back filling in place, borrowed fill must be free from organic
debris and shall be well compacted. If this is not done
supplementary treatments should be made to complete the
barrier.



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4.0 CHEMICAL TO BE USED

4.1 The effectiveness of chemical depends upon the choice of the chemical,
the dosage adopted and the thoroughness of application.The chemical
solutions or emulsions are required to be dispersed uniformly in the soil
and to the required strength so as to form an effective chemical barrier
which is lethal and repellent to termites.

4.2 The chemical Chlropyrophos in water emulsion, after approval from the
Consultant, shall be used uniformly over the area to be treated.

4.3 The contractor should produce voucher (s) for the chemical
purchased and should get verified the sealed container(s) of the
specified chemical from the Consultant in-Charge before preparing
the emulsion / use for the treatment.

5.0 MODE AND RATE OF APPLICATION :

5.1 The chemical emulsion as stated above will be applied uniformly by
sprayers at the prescribed rates as detailed below in all the stages
of the treatment.

5.2 Treatment in Foundation Trenches: In case of normal wall load
bearing structures, column pits, wall trenches and basement, the
treatment shall be at a rate of5 ltrs./sqm of surface area of the
bottom and sides to a height of atleast 300 mm. After the
foundation work, the sides shall be treated at a rate of 7.5
ltrs./sqm of vertical surface of substructure on each side. After the
earth filling is done, treatment shall be done by rodding the earth
at 150 mm centers close to wall surface and spraying the chemical
with the above dose i.e. 7.5 ltrs./sqm. In case of framed
structure, the treatment shall start at a depth of 500mm below
ground level. From this depth the backfill around the columns,
beams and R.C.C. basement walls shall be treated at a rate of7.5
ltrs./sqm of the vertical surface and at a rate of 5 ltrs / sqm for the
horizontal surface at the bottom in the trenches / pits.

5.3 Treatment on Top Surfaces of Plinth Filling : The top surface of the
filled earth within plinth walls shall be treated with chemical
emulsion at the rate of 5 litres / sqm of the surface area before
sub-base to floor is laid, if filled earth has been well rammed and
the surface does not allow the emulsion to seep through, holes
upto 50 to 75mm deep at 150mm centers both ways shall be made
with crow bars on the surface to facilitate saturation of the soil
with the emulsion.



Page 101 of 148
5.4 Treatment at Junction of Walls and Floors : Special care shall be
taken to establish continuity of the vertical chemical barrier on the
inner wall surfaces from the finished ground level (or from level
where the treatment had stopped) upto the level of the filled earth
surface. To achieved this a small channel 30 x 30 mm shall be
made at all the junctions of wall / column with floor (before laying
sub-grade) and rod holes made in the channel upto the finished
ground level at 150 mm apart and the iron and moved backward
and forward to break the earth and chemical emulsion poured
along the channel at a rate of 7.5 litres (or at recommended
quantity) per sqm. of the vertical wall / column surfaces so as to
soak the soil right up to the bottom. The soil shall be tamped back
into place after this operation.

5.5 Treatment for Expansion Joints : The soil beneath the expansion
joints shall receive special attention when the treatment under
5.02.00 above is in progress. This treatment shall be
supplemented by treating through the expansion joint after sub-
grade has been laid at the rate of 2 litres per metre length of
expansion joint.

6.0 PRECAUTIONS

6.1 Utmost care shall be taken to see that the chemical barrier is
complete and continuous. Each part of the area shall receive the
prescribed dosage of chemical emulsion.

6.2 The treatment should not be carried out when it is raining or when
the soil is wet with rain or sub-soil water.

6.3 Once formed, the treated soil barrier shall not be disturbed. If by
chance, treated soil barriers are disturbed, immediate steps shall
be taken to restore the continuity and completeness of the barrier
system.

7.0 HEALTH HAZARDS AND SAFETY MEASURES

7.1 All the chemicals mentioned above are poisonous and hazardous to
health. These chemicals can have an adverse effect upon health
when absorbed through the skin, inhaled as vapours or spray mist
or swallowed. Persons handling or using these chemicals should be
warned of these dangers and advised that absorption through the
skin is the most likely source of accidental poisoning. They should
be cautioned to observe carefully the safety precautions given in
7.02.00 to 7.05.00 particularly when handling these chemicals in
the form of concentrates.



Page 102 of 148

7.2 These chemicals are usually brought to the site in the form of
emulsifiable concentrates. The containers should be clearly labeled
and should be stored carefully so that children and pets cannot get
at them. They should be kept securely closed.

7.3 Particular care should be taken to prevent skin contact with
concentrates. Prolonged exposure to dilute emulsions should also
be avoided. Workers should wear clean clothing and should wash
thoroughly with soap and water specially before eating and
smoking. In the event of severe contamination, clothing should be
removed at once and the skin washed with soap and water. If
chemicals splash into the eyes they shall be flushed with plenty of
soap and water and immediate medical attention should be sought.

7.4 The concentrates are oil solutions and present a fire hazard owing
to the use of petroleum solvents. Flames should not be allowed
during mixing.

7.5. Care should be taken in the application of chemicals / soil -
toxicants to see that they are not allowed to contaminate wells or
springs which serve as source of drinking water.

8.0 GUARANTEE

8.1 The contractor has to furnish the guarantee for 10 (ten) years from
the date of completion of work, stating that in case of
reappearance of termites within the building area due to defective
materials or workmanship or due to any other reasons, the
contractor will carry out the necessary post constructional
treatment to keep the entire area free from termite, once again,
without any extra cost of the Department during the guarantee
period.



Page 103 of 148

STRUCTURAL

STEEL

WORKS



Page 104 of 148
SPECIFICATION FOR STRUCTURAL STEEL WORKS

1.0 SCOPE

The specification covers the requirements for material, storage,
fabrication, assembly, test/examinations, transportation,
erection and painting of all types of bolted and/or welded
structural steel works for general construction work. Fabrication
of structures shall also include fabricating with either or any of
the following:

a) Built up sections/plate girders made out of rolled section
and/or plates.

b) Compound sections made out of rolled sections.

c) Rolled sections

d) Plates including chequered plates

e) Gratings and other sections

These specifications generally cover the broad requirements for
the work.

2.0 REFERENCE I.S. CODES & SPECIFICATIONS

2.1 I.S. CODES:

IS: 800, 816, 819, 822, 919, 1024, 1261, 1323, 1477, 2074,
7205, 7215, 7307, 7310, 7318, 9595 and other relevant IS
Codes.

SP: 6 (1)

3.0 FABRICATION DRAWINGS

3.1 The Contractor shall ensure accuracy and correctness of the
drawings. Unchecked and unsigned drawings shall not be used
for the purpose of proceeding with the work.

3.2 The Contractor shall not proceed with the fabrication of
structures unless other wise same are approved by HPCL.

The Contractor shall ensure that the following aspects are in
order:



Page 105 of 148

i) Structural layout, orientation and elevation of
structures/members.

ii) Sizes of members.

iii) Critical joint details.
3.3 Fabrication drawings shall be drawn to scale and shall convey
the information clearly and adequately. Following information
shall be furnished on such drawings.

Reference to design drawing number (along with revision
number) based on which fabrication drawing has been
prepared.

Structural layout, elevations & sections (with distinct erection
marking of all members)

Framing plans, member sizes, orientation and elevations.

Layout and detailing of rain water pipes and gutters showing
all necessary levels, connections and provisions wherever
required.

Detailing of shop/field joints, connections, splices, for
required strength and erection.

Location, type, size and dimensions of welds and bolts.

Shapes and sizes of edge preparation for welding.

Details of shop and field joints/welds.

Bill of materials Lists.

Quality of structural steel, plates etc. welding electrodes,
bolts, nuts, and washers to be used.

Erection assemblies identifying all transportable parts and
sub-assemblies with special erection instructions, if required.

Method of erection and special precautions to be taken
during erection as required.

3.4 The Contractor shall additionally ensure accuracy of the
following and shall be solely responsible for the same:



Page 106 of 148

a) Provision for erection and erection clearance.

b) Marking of members

c) Cut length of members

d) Matching of joints and holes.

e) Provision kept in the members for other interconnected
members.

f) Bill of materials List.

3.5 Connections, splices and other details where not shown on the
designs shall be suitably designed and shown on the fabrication
drawings based on good engineering practice developing full
member strength. Design calculations for such
connections/splices shall be submitted to the Engineer-in-
Charge along with the fabrication drawings.

3.6 Any substitution or change in section shall be allowed only when
prior written approval of the Engineer-in-Charge has been
obtained. Fabrication drawings shall be updated incorporating
all such substitutions/changes by the Contractor at no extra
cost.

3.7 In case during execution of the work, the Engineer-in-Charge on
review of drawings considers any modifications/substitutions
necessary to meet the design parameters/good engineering
practice, these shall be brought to the notice of the Contractor
who shall incorporate the same in the drawings and works
without any extra cost to HPCL.

3.8 Contractor shall incorporate all the revisions made in the design
drawings during the course of execution of work in his
fabrication drawings, and resubmit the drawings at no extra
cost in case of any revisions. All fabrication shall be carried out
only as per the final AFC drawings.

3.9 The Contractor shall supply two prints each of the final/as built
drawings along with their transparencies to Engineer-in-Charge
for reference and record.

4. MATERIALS



Page 107 of 148

4.1 General :

All materials shall conform to their respective specifications .
The use of equivalent or alternative materials shall be permitted
only in very special cases and for all such cases prior written
approval of the Engineer-in-Charge shall be obtained.

4.2 Receipt & Storing of Materials

4.2.1 Each section shall be marked for identification and each lot shall
be accompanied by manufacturers test reports. Additionally,
samples shall be selected from each lot and tested at a HPCL
approved Laboratory for conformance to BIS specifications.

4.2.2 All sections shall be checked, sorted out and arranged by grade
and quality in the fabrication yard. Any instruction given by the
Engineer-in-Charge in this respect shall be strictly followed.

4.2.3 All materials shall be free from defects such as pitting, cracks,
laminations, twists etc. Defective material shall not be used and
all such rejected material shall be immediately removed from
the fabrication yard/site. The decision of the Engineer-in-Charge
in this regard shall be final and binding.

4.2.4 Welding wires and electrodes (packed in their original cartons)
shall be stored separately by quality and lots inside a dry and
enclosed room. Electrodes shall be kept perfectly dry to ensure
satisfactory operation and weld metal soundness.

4.2.5 Each lot of electrodes, bolts, nuts etc. shall be accompanied by
manufacturers quality/test certificates.

4.2.6 All bolts (including nuts & washers) shall be checked, sorted out
and arranged diameter wise by grade and quality in the store.

4.3 Material Test

4.3.1 The Contract shall submit manufacturers test certificates for all
the materials supplied by him. Additionally, tests shall be
conducted on samples drawn from the materials delivered at
Site as per frequency given in this tender document.

4.3.2 The Contractor shall ensure that all materials brought to site are
duly approved by the Engineer-in-Charge. Contractor shall
submit IMIR (Incoming Material Inspection Report) for all



Page 108 of 148
materials in the format approved by HPCL. This report shall
provide the information on the status of the material and shall
also carry a traceability to the Test certificates. Rejected
materials shall not be used and shall be removed from site
forthwith. All the sections shall carry the brand marking of the
approved manufacturer.

5.0 FABRICATION

5.1. General

5.1.1 Fabrication of structures shall be done strictly as per "Approved
for Construction fabrication drawings (prepared by the
Contractor based on the latest design drawings) and in
accordance with IS: 800 & other relevant I.S. Codes and I.S.
Hand Book SP:6 (1).

5.1.2 Prior to commencement of structural fabrication, undulations in
the fabrication yard if any, shall be removed and area leveled
by the Contractor.

5.1.3 Any defective material used in the work shall be replaced by the
Contractor at his own expense. Necessary care and precautions
shall be taken so as not to cause any damage to the structure
during any such removal and replacement.

5.1.4 Any faulty fabrication pointed out at any stage of work by the
Engineer-in-Charge, shall be made good or replaced by the
Contractor at his own cost.

5.1.5 Tolerances for fabrication of steel structures shall be as per IS
:7215

5.2 Fabrication Procedure

5.2.1 Straightening & Bending

5.2.1.1 All materials shall be straight and, if necessary, before being
worked shall be straightened and/or flattened (unless required
to be of curvilinear form) and shall be free from twists.

5.2.1.2 Bending of rolled sections and plates shall be done by cold
process to shape/s as shown on drawings.

5.2.2 Clearances



Page 109 of 148
The erection clearance for cleared ends of members shall be not
greater than 2mm at each end. The erection clearance at ends
of beams without web cleats and end plates shall be not more
than 3mm at each end but where for practical reasons, greater
clearance is necessary, suitably designed seating approved by
the Engineer-in-Charge shall be provided.

5.2.3 Cutting

5.2.3.1 Prior to cutting, all members shall be properly marked showing
the requisite cut length;/width, connection provisions e.g.
location and dimensions of holes, welds, cleats etc. Marking for
cutting shall be done judiciously so as to avoid wastages or
unnecessary joints as far as practicable. Marking shall be done
by placing the members on horizontal supports/pads in order to
ensure accuracy. Marking accuracy shall be limited to + 1mm.

5.2.3.2 Cutting shall normally be carried out by pug cutter. Cutting may
be affected by shearing, cropping or sawing. Gas cutting by
mechanically controlled torch shall be permitted for mild steel.
Hand flame cutting shall be avoided for cutting the members.

5.2.3.3 Except where the material is subsequently joined by welding, no
loads shall be transmitted into metal through a gas cut surface.

5.2.3.4 Shearing, cropping and gas cutting shall be clean, square, free
from any distortion & burrs, and should the Engineer-in-Charge
find it necessary, the edges shall be ground afterwards, to make
the same straight and uniform at no extract cost to the Owner.

5.2.4 Holing

5.2.4.1 Holes for bolts shall not be formed by gas cutting process.

Holes through more than one thickness of material of
members such as compound stanchions and girder flanges
shall, where possible, be drilled after the members are
assembled and tightly clamped/bolted together.

5.2.4.2 Holes may be drilled in one operation through two or more
separable parts and burrs removed from each part after drilling.

5.2.4.3 Holes in connecting angles and plates, other than splices, also in
roof members and light framing, may be punched full size
through materials not over 12mm thick, except where required
for close tolerance bolts.



Page 110 of 148

5.2.4.4 All matching holes for black bolts shall register with each other
so that a gauge of 2mm less in diameter than the diameter of
hole shall pass freely through the assembled members in the
directions at right angle to such members. Finished holes shall
be not more than 2mm in diameter larger than the diameter of
the black bolt passing through them.

5.2.4.5 Holes for turned and fitting bolts shall be drilled to a diameter
equal to the nominal diameter of the shank or barrel subject to
tolerance specified in IS:919. Parts to be connected with close
tolerance or barrel bolts shall be firmly held together by tacking
bolts or clamps and the holes drilled through all the thicknesses
in one operation and subsequently reamed to size. Holes not
drilled through all the thicknesses in one operation shall be
drilled to a smaller size and reamed out after assembly. Where
this is not possible, the parts shall be drilled and reamed
separately.

5.2.4.6 To facilitate grouting, holes shall be provided in column bases or
seating plates exceeding 300mm in width for the escape of air.

5.2.4.7 To avoid accumulation of water in gusseted column bases of
laced, battened or box type stanchions, suitable reverse U-type
holes shall be provide at the junction of base plate and column
section in the vertical gussets for draining out of any water.

5.2.5 Assembly

5.2.6.1 All bolts shall be provided such that no part of the threaded
portion of the bolts is within the thickness of the parts bolted
together. Washers of suitable thickness shall be used under the
nuts to avoid any threaded portion of the bolt being within the
thickness of parts bolted together.

5.2.6.2 The threaded portion of each bolt shall project through the nut
at least by two threads .At column bases, double nuts shall be
used and the projection above the top nut shall not be less than
two threads.

5.2.6.3 Flat washers shall be circular and of suitable thickness.
However, where bolt heads/nuts bear upon the beveled
surfaces, they shall be provided with square tapered washers of
suitable thickness to afford a seating square with the axis of the
bolt.



Page 111 of 148

5.2.7 Welding

5.2.7.1 General

a) Welding shall be in accordance with IS: 816, IS: 819,
IS:1024, IS:1261, IS: 1323 and IS: 9595 as appropriate.

b) The Contractor shall make necessary arrangement for
providing sufficient number of welding sets of the required
capacity, all consumables, cutting and grinding equipment
with requisite accessories/ auxiliaries, equipments &
materials required for carrying out various tests such as per
QAP/ITP.

c) Adequate protection against rain, dust & strong winds shall
be provided to the welding personnel and the structural
members during welding operation. In the absence of such a
protection, no welding shall be carried out.

d) It shall be the responsibility of the Contractor to ensure that
all welding is carried out in accordance with the terms of this
specification and relevant IS codes. The Contractor shall
provide all the supervision to fulfill this requirement.

5.2.7.2 Preparation of Member for Welding

a) Edge Preparation

Edge preparation/beveling of fusion faces for welding shall be
done strictly as per the dimensions shown in the drawings. In
case, the same are not indicated, edge shall be prepared
(depending on the type of weld indicated in the drawings) as
per the details given in IS:9595. Beveling of fusion faces
shall be got checked and approved by the Engineer-in-
Charge. The tolerances on limits of gap, root face & included
angle shall be as stipulated in IS:9595.

e) Cleaning

Welding edges and the adjacent areas of the members
(extending upto 2mm) shall be thoroughly cleaned of all oil,
grease, scale and rust and made completely dry. Gaps



Page 112 of 148
between the members to be welded shall be kept free from
all foreign matter.

f) Preheating

Preheating of members, shall be carried out as per IS : 9595
when the base metal temperature is below the requisite
temperature for the welding process being used. Preheating
shall be done in such a manner that the parts, on which the
weld metal is being deposited, are above the specified
minimum temperature for a distance of not less than 75mm
on each side of the weld line. The temperature shall be
measured on the face opposite to that being heated.
However, when there is access to only one face, the heat
source shall be removed to allow for temperature
equalization (1 minute for each 25mm of plate thickness)
before measuring the temperature.

g) Grinding

1) Column splices & butt joints of struts and compression
members (depending on contact for load transmission)
shall be accurately ground and close-butted over the
whole section with a tolerance not exceeding 0.2mm
locally at any place. In column caps & bases, the ends of
shafts together with the attached gussets, angles,
channels etc. shall be accurately ground so that the parts
connected butt over minimum 90% surface of contact. In
case of connecting angles of channels, care shall be taken
so that these are fixed with such accuracy that they are
not reduced in thickness by grinding by more than 2mm.
2) Ends of all bearing stiffeners shall be ground to fit tightly
at both top and bottom. Similarly bottom of the knife
edge supports along with the top surface of column
brackets shall be accurately ground to provide effective
bearing with a tolerance not exceeding 0.2mm locally at
any place.
3) Slab bases and caps shall be accurately ground over the
bearing surfaces and shall have effective contact with the
ends of stanchions. Bearing faces which are to be grouted
direct to foundations need not be ground if such faces are
true & parallel to the upper faces.

5.2.7.3 Welding Processes



Page 113 of 148
Welding of various materials under this specification shall be
carried out using one or more of the following processes.

- Manual Metal Arc Welding Process (MMAW)
- Submerged Arc Welding Process (SAW)
- Gas Metal Arc Welding Process (GMAW)
- Flux Cored Arc Welding Process (FCAW)

The welding procedure adopted and consumables used shall be
specifically approved by the Engineer-in-Charge. A combination
of different welding processes or a combination of electrodes of
different classes/makes may be employed for a particular joint
only after qualifying the welding procedures to be adopted and
obtaining the written approval of the Engineer-in-Charge.

5.2.7.4 Approval & Testing of Welders

The Contractor shall satisfy the Engineer-in-Charge that the
welders are suitable for the work upon which they will be
employed. For this purpose the welders shall have satisfied the
relevant requirements of IS: 7318. If the welders will be
working to approved welding procedures, they shall have
satisfied the relevant requirement of IS:7310.

Adequate means of identification shall be provided to enable
each weld to be traced to the welder by whom it was made.
The Contractor shall intimate the Engineer-in-Charge sufficiently
in advance, the commencement of tests, to enable him to be
present to witness the same.

5.2.7.5 Approval & Testing of Welding Procedures

The Contractor shall carry out procedure tests in accordance
with IS:7307 to demonstrate by means of a specimen weld of
adequate length on steel representative of that to be used, that
he can make welds with the welding procedure to be used for
the work to the complete satisfaction of the Engineer-in-Charge.
The test weld shall include weld details from the actual
construction and it shall be welded in manner simulating the
most unfavourable instances of fit-up, electrode condition etc.
which are anticipated to occur on the particular fabrication.
Where material analyses are available, the welding procedure



Page 114 of 148
shall be carried out on material with the highest carbon
equivalent value.

After welding but before the relevant tests given in IS:7307 are
carried out, the test weld shall be held as long as possible at
room temperature , but in any case not less than 72 hours and
shall then be examined for cracking. The examination procedure
shall be sufficiently rigorous to be capable of revealing
significant defects in both parent metal and weld metal.

After establishing the welding method the contractor shall finally
submit to the Engineer in charge for his approval the welding
procedure specification in standard format given in IS:9595
before starting the fabrication .

5.2.7.5 Sequence of welding

a) As far as practicable all welds shall be made in a sequence
that will balance the applied heat of welding while the welding
progresses

b) The direction of the general progression in welding on a
member shall be from points where the parts are relatively
fixed in position with respect to each other towards points
where they have a greater relative freedom of movement.

c) All splices in each component part of a cover plated beam or
built up member shall be made before the component part is
welded to other component parts of the member.

d) Joints expected to have significant shrinkage shall be welded
before joints expected to have lesser shrinkage.

e) Welding shall be carried continuously to completion with
correct number of runs.

f) The Contractor shall choose the welding sequence after
carefully studying each case such as to minimize distortion and
shrinkage & submit the same to the Engineer-in-Charge for
comments and approval.

5.2.7.7 Welding Technique

a) After faces are carefully aligned and set with proper gaps,
the root pass of butt joints shall be executed properly so as



Page 115 of 148
to achieve full penetration with complete fusion of the root
edges.

b) On completion of each run, all slag and spatters shall be
removed and the weld and the adjacent base metal shall be
cleaned by wire brushing and light chipping. Visible defects
such are cracks, cavities and other deposition faults if any,
shall be removed to sound metal before depositing
subsequent run of weld.

c) All full penetration butt welds shall be completed by
chipping/gouging to sound metal and then depositing a
sealing run of weld metal on the back of the joints Where
butt welding is practicable from one side only, suitable
backing steel strip shall be used and joint shall be arranged
in such a way as to ensure that complete fusion of all the
part is readily obtained.

d) While welding is in progress care shall be taken to avoid any
kind of movement of the components, shocks, vibrations to
prevent occurrence of weld cracks.

e) Any deviation desired from the recommended welding
technique and electrodes shall be adopted only after
obtaining written approval of the Engineer-in-Charge.

5.2.7.8. Inspection & Testing of Welds

The method of inspection shall be according to IS:822 and
extent of inspection and testing shall be in accordance with the
relevant applicable standard or in the absence of such a
standard, as specified by the Engineer-in-Charge. Welds shall
not be painted or otherwise obscured until they have been
inspected, approved and accepted.

The Engineer-in-Charge or his representative shall have access
to the Contractors work at all reasonable times and the
Contractor shall provide him with all facilities necessary for
inspection during all stages of fabrication and erection with, but
not limited to, the following objectives.

i) To check the conformity with the relevant standards and
suitability of various welding equipments and their
performance.

ii) To witness/approve the welding procedure qualification.



Page 116 of 148

iii) To witness/approve the welders performance qualification.

iv) To check whether shop/field welding being executed is in
conformity with the relevant specifications and codes of
practice.

Inspection and testing of all fabricated structures shall be
carried out by the Contractor by any, or a combination of all the
following methods as directed by the Engineer-in-Charge and no
separate payment shall be made for inspection and testing of
welds/fabricated structures.

A. Visual Inspection

All finished welds (i.e. 100 percent) shall be visually
inspected for identification of the following types of weld
defects & faults.

a) Weld defects occurring at the surface such as blow
holes, exposed porosity, unfused welds etc.

b) Surface cracks in the weld metal or in the parent metal
adjacent to it.

c) Damages to the parent metal such as undercuts,
burning, overheating etc.

d) Profile defects such as excessive convexity or
concavity, overlapping, unequal leg lengths, excessive
reinforcement, incompletely filled grooves, excessive
penetration beads, root grooves etc.

e) Distortion due to welding i.e., local shrinkage, camber,
bowing, twisting, rotation, wariness etc.

f) Linear, eccentric, angular and rotational misalignment
of parts.

g) Dimensional errors.

B. Mechanical Tests



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The mechanical testing (such as tensile load tests, bend
tests, impact tests etc.) shall be done in accordance with the
relevant standards and as per the instructions of the
Engineer-in-Charge.

C. Magnetic Particle/Dye Penetration/Ultrasonic Examination:

The examination shall be done at random as directed by the
Engineer-in-Charge. Whenever such tests are directed, the
tests shall be carried out on joints chosen by him. The tests
shall be carried out by employing approved testing procedure
in accordance with IS:822.

D. Radiographic Examination

Radiographic examination shall be carried out only in special
cases for random joints as directed by the Engineer-in-
Charge. The Contractor shall carry out penalty radiographic
tests in case of any failure/cut-outs/excessive repairs for
which the cost shall be borne by him. The Contractor shall
make necessary arrangement at his own expense for
providing the radiographic equipment, films and all other
necessary materials required for carrying out the
examination. The tests shall be carried in the presence of the
Engineer-in-Charge by employing approved testing
procedure in accordance with IS:822. The Contractor shall
fulfill all the statutory safety requirements while handling X-
ray and Gamma-ray equipment and provide the Engineer-in-
Charge all the necessary facilities at site such as dark room,
film viewer etc., to enable him to examine the radiographs.

5.2.7.8 Repair of Faulty Welds

No repair of defective welds shall be carried out without proper
permission of the Engineer-in-Charge and his approval for the
corrective procedure.

Welds not complying with the acceptance requirements as
revealed during inspection & testing of welds or erection or in-
situ condition, shall be corrected either by removing & replacing
or as follows:



Page 118 of 148
SL
NO
DESCRIPTION CORRECTION
Excessive convexity Reduced to size by removal of excess
weld metal
Shrinkage cracks in
parent plates and craters
Defective portion removed down to
sound metal and rewelded
Under cutting Additional weld metal to be
deposited
Improperly fitted and
misaligned parts
Welding cut & edges suitably
prepared and parts rewelded
Members distorted by
the heat of welding
Member straightened by mechanical
means or by careful application of
limited amount of heat, temperature
of such area not to exceed 650
degree Centigrade dull red heat

In removing defective parts of a weld, gouging, chipping, oxygen
cutting or grinding shall not extend into the parent metal to any
substantial amount beyond the depth of weld penetration, unless
cracks or other defects exist in the parent metal. The weld or
parent metal shall not be undercut in shipping, grinding, gouging
or oxygen cutting.

Any fabricated structure or its component which, in the opinion of
Engineer-in-Charge, is defective and/or beyond any correct action
shall be removed forthwith from the site as instructed by the
Engineer-in-Charge without any extra claim.

5.2.8 Splicing

5.2.8.1 Splicing of built up/compound/latticed sections shall be done in
such a fashion that each component of the section is joined in a
staggered manner.

5.2.8.2 Where no butt weld is used for splicing, the meeting ends of two
pieces of joist/channel/built up section shall be ground flush for
bearing on each other and suitable flange and web splice plates
shall be designed and provided for the full strength of the
flange/web of the section and welds designed accordingly.

5.2.8.3 Where full strength butt weld is used for splicing (after proper
edge preparation of the web and flange plates) of members
fabricated out of joist/channel/angles/built up section, additional
flange and web plates shall be provided, over and above the full



Page 119 of 148
strength butt welds, to have 40% strength of the flange and
web.

5.2.8.4 Prior approval shall be obtained by the Contractor for locations
of splices where not shown on design drawings. Only a single
splice at approved location shall be allowed for members upto a
length of 6 to 7m. Maximum two numbers of splices shall be
allowed for members exceeding this length.

5.2.9 Machining /Grinding

5.2.9.1 End of all bearing stiffeners shall be machined or ground to fit
tightly at top and bottom without any air gap.

5.2.9.2 While machining or grinding care shall betaken so that the
length or thickness of any part does not get reduced by more
than 2.0 mm.

5.2.9.3 For all machining or grinding works for cap plates, the clearance
between the parts joined shall not exceed 0.2mm at any
location.

6.0 MARKING FOR IDENTIFICATION

6.1 Each component shall be distinctly marked (with paint) before
delivery in accordance with the marking diagrams and shall bear
such other marks as will facilitate erection.

6.2 For small members which are delivered in bundles or crates, the
required marking shall be done on small metal tags securely
tied to the bundle.

7.0 SHOP ERECTION

The steel work shall be temporarily shop erected complete or as
directed by the Engineer-in-Charge, so that the accuracy of fit
may be checked before dispatch. However, this assembly may
not be required in case of fabrication, welding and assembly at
Site.

8.0 INSPECTION & TESTING OF STRUCTURES

8.1 The Engineer-in-Charge (or his authorized representative) shall
have free access at all times to those parts of the Contractors
works which are concerned with the fabrication of the steel work
and shall be provided with all reasonable facilities for satisfying



Page 120 of 148
himself that the fabrication is being undertaken in accordance with
the provisions of these specifications & other relevant IS Codes.

8.2 Should any structure or part of a structure be found not to comply
with any of the provisions of this specification (or relevant I.S.
Codes as referred to), it shall be liable to rejection. No structure or
part of the structure, once rejected shall be resubmitted for
inspection, except in cases where the Engineer-in-Charge or his
authorized representative considers the defect as rectifiable.

8.3 Defects which may appear during/after fabrication/erection shall be
made good only with the consent of the Engineer-in-Charge and
procedure laid down by him.

8.4 All necessary gauges and templates shall be supplied free to the
Engineer-in-Charge by the Contractor whenever asked for
during inspection. The Engineer-in-Charge may at his
discretion, check the test results obtained at the Contractors
works by independent tests at a test house, and the cost of such
tests shall be borne by the Contractor.

9.0 SHOP PAINTING

9.1 Steel surface shall not be painted within a suitable distance of any
edges to be welded if the paint specified would be harmful to
welders or impair the quality of the welds. Welds and adjacent
parent metal shall not be painted prior to deslagging, inspection
and approval by the Engineer-in-Charge.

9.2 Parts to be encased in concrete shall have only one coat of primer
and shall not be painted after erection.

10.0 PACKING

10.1 All items shall be suitably packed in case these are to be
dispatched from the fabrication shop to the actual site of erection
so as to protect them from any damage/distortion or falling during
transit. Where necessary, slender projecting parts shall be
temporarily braced to avoid warping during transportation.

10.2 Small parts such as gussets, cleats etc., shall be securely wired on
to their respective main members.

10.3 Bolts, nuts washers etc. shall be packed in crates.



Page 121 of 148
11.0 TRANSPORTATION

Loading and transportation shall be done in compliance with
transportation rules. In case, certain parts cannot be transported
in the lengths stipulated on the drawings, the position details of
such additional splice joints shall be got approved by the Engineer-
in-Charge.

12.0 SITE (FIELD) ERECTION

12.1 Plant & Equipment

The suitability and capacity of all plant and equipment used for
erection shall be to the complete satisfaction of the Engineer-in-
Charge.

12.2 Storing & Handling

All steel work shall be so stored and handled at site so that the
members are not subjected to excessive stresses and any
damage.

12.3 Setting Out

Prior to setting out of the steel work, the Contractor shall get
himself satisfied about the correctness of levels, alignment,
location of existing concrete pedestals/columns/ brackets and
holding down bolts/pockets provided therein. Any minor
modification in the same including chipping, cutting and making
good, adjusting the anchor bolts etc. If necessary, shall be carried
out by the Contractor at his own expense. The positioning and
leveling of all steel work including plumbing of columns and placing
of every part of the structure with accuracy shall be in accordance
with the drawings and to the complete satisfaction of the Engineer-
in-Charge.

12.4 Tolerance

Tolerances for erection of steel structures shall be as per limits
given in IS:800.

13.0 SAFETY & SECURITY DURING ERECTION

13.1 THE CONTRACTOR SHALL COMPLY WITH IS:7205 for necessary
safety and adhere to safe erection practices and guard against



Page 122 of 148
hazardous as well as unsafe working conditions during all stages of
erection.

13.1 During erection, the steel work shall be securely bolted or
otherwise fastened and when necessary, temporarily braced/guyed
to provide for all loads to be carried by the structure during
erection till the completion, including those due to the wind,
erection equipment & its operation etc. at no extra cost to the
owner. For he purpose of guying, the Contractor shall not use
other structure in the vicinity without prior written permission of
the Engineer-in-Charge.

13.2 No permanent bolting or welding shall be done until proper
alignment has been achieved.

13.3 Proper access, platform and safety arrangement shall be provided
for working and inspection, (at no extra cost to the owner)
whenever required.

14.0 FIELD CONNECTIONS

14.1 Field Bolting

Field bolting shall be carried out with the same care as required for
shop bolting.

14.1 Field Welding

All field assembly and welding shall be executed in accordance with
the requirements for shop assembly and welding. Holes for all
erection bolts - where removed after final erection shall be
plugged by welding. Alternatively erection bolts may be left duly
secured.

15.0 GROUTING

15.1 Prior to positioning of structural columns/girders/trusses over the
concrete pedestals/columns/brackets, all latiance & loose material
shall be removed by wire brushing & chipping. The bearing
concrete surfaces shall be sufficiently leveled, hacked with flat
chisels to make them rough, cleaned (using compressed air) and
made thoroughly wet. All pockets for anchor bolts shall also be
similarly cleaned and any excess water removed. Thereafter, the
structural member shall be erected, aligned & plumbed maintaining
the base plates/shoe plates at the levels shown in the drawings,
with necessary shims/pack plates/wedges.



Page 123 of 148

15.2 After alignment and plumbing of the structure, the forms shall be
constructed all around and joints made right tight to prevent
leakage. Grouting (under the base plates/shoe plates including
grouting of sleeves & pockets) shall be done with non-shrink grout
having compressive strength (28 days) not less than 40N.mm2.
Non shrink grout shall be of free flow premix type and of approved
quality and make. It shall be mixed with water in proportion as
specified by the manufacturer. Ordinary 1:2 cement/sand mortar
grout shall be used only for small, isolated structures e.g.
operating platforms not supporting any equipment, pipe supports,
cross overs, stairs & ladders. The thickness of grout shall be as
shown on the drawings but not less than 25 mm nor more than
40mm in any case.

15.3 The grout mixture shall be allowed to harden for a period as
decided by the Engineer-in-Charge. At the end of this period, the
shims/wedges/pack plates may be removed and anchor bolts
tightened uniformly. The alignment of the structure shall now be
rechecked and if found correct, the voids left by the removal of
shims/wedges/pack pleas (if removed) must be filled up with a
similar mixture of grout. In case after checking, serious
misalignment is indicated, the grout shall be removed completely
and fresh grouting done after making appropriate correction of
alignment.

16.0 SCHEME AND SEQUENCE OF ERECTION

The Contractor shall furnish the detailed scheme and sequence of
erection to match with the project schedule and get the same
approved by the Engineer-in-Charge. All necessary co-ordination
and synchronization shall be done with the Civil Contractor where
Civil works are not included in the scope of structural contractor at
no extra cost so as to match with the project schedule.

17.0 PAINTING AFTER ERECTION

17.1 General

17.1.1 The scope of painting after erection shall be at the sole discretion
of the Engineer-in-Charge and the Contractor shall obtain written
instruction in this regard sufficiently prior to taking up any
procurement of paint and execution of painting work after
erection of steel structures.



Page 124 of 148
17.1.2 The contractor shall carry out the painting work in all respects
with the best quality of approved materials (conforming to
relevant IS Codes) and workmanship in accordance with the
best engineering practice. The Contractor shall furnish
characteristics of paints (to be used) indicating the suitability for
the required service conditions. The paint manufacturers
instructions supplemented by Engineer-in-Charges direction, if
any shall be followed at all times. Particular attention shall be
paid to the following.

Proper storage to avoid exposure & extremes of
temperature.
surface preparation prior to painting.
Mixing & thinning.
Application of paint and the recommended limit on time
intervals between consecutive coats.

17.1.3 Painting shall not be done in frost or foggy weather, or when hu
midityis such as to cause condensation on the surfaces to be
painted.

17.1.4 Surface which shall be inaccessible after site assembly shall
receive the full specified protective treatment before assembly.

17.1.5 Primers & finish coat paints shall be from the same
manufacturer in order to ensure compatibility. Painting colour
code shall be finalized in consultation with HPCL.

17.1.6 Primer Application:

Primer specifications as specified in the drawing/Tender shall be
adopted.

17.1.7 Final Paint Application

Painting procedure as applicable for the painting specifications
specified in the drawing/tender shall be adopted.

17.2 Inspection & Testing of Painting Works

17.2.1 All painting materials including primers & thinners brought to site
by the Contactor for application shall be procured directly
from reputed and approved manufacturers and shall be
accompanied by manufacturers test certificates. Paint
formulations without certificates shall not be accepted.



Page 125 of 148
17.2.2 The Engineer-in-Charge at his discretion may call for additional
tests for paint formulations. The Contractor shall arrange to have
such tests performance including batch wise test of wet paints for
physical & chemicals analysis. All costs shall be borne by the
Contractor.

17.2.3 The painting work shall be subject to inspection by the Engineer-
in-Charge at all times. In particular, the stage wise inspection
will be performed and Contractor shall offer the work for
inspection and approval at every stage before proceeding with
the next stage. The record of inspection shall be maintained.
Stages of inspection are as follows:

a) Surface preparation
b) Primer application
c) Each coat of paint

17.2.4 Any defect noticed during the various stages of inspection shall
be rectified by the Contractor of the entire satisfaction of the
Engineer-in-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stage of
work the Contractor shall be responsible for making good
any defects found during final inspection. Dry film thickness
(DFT) shall be checked and recorded alter application of each
coat. The thickness shall be measured at as many locations as
decided by the Engineer-in-Charge. The Contractor shall provide
standard thickness measuring instrument such as elcometer (with
appropriate range for measuring dry film thickness of each coat)
free of cost to the Engineer-in-Charge whenever asked for.



Page 126 of 148
SPECIFICATION FOR MISCELLANEOUS STEEL WORKS

1.0 GENERAL

1.1 All materials supplied by the Contractor shall conform to their
respective specifications, given in this tender document.

1.2 The Contractor shall furnish test certificates for all materials prior
to their use in the works.

2.0 ANCHOR BOLTS

2.1 Material

Materials for anchor bolts, nuts, locknuts, washers, pipe sleeves
and anchor plates shall conform to their respective specification
given in this tender document.

2.2 Fabrication

Fabrication of anchor bolts and their complete assemblies shall be
strictly in compliance with the specifications and
drawings/standards. Anchor bolts shall have coarse type threads
conforming to IS:4218.

2.1 Placement

Anchor bolt assemblies shall be placed in position strictly as per
drawings and securely held during pouring and vibrating of
concrete with necessary templates and other dummy structures to
prevent their dislocation.

2.2 Tolerances

Tolerances allowed for anchor bolts positioning shall be:

- For sleeved bolts, one tenth of the bolt nominal diameter.
- For bolts without sleeves, one twentieth of the bolt nominal
diameter.

2.3 Protection

The exposed surfaces of bolts shall be properly covered (after
greasing of bolts and packing of sleeves) with jute cloth so as to
protect them from damage till final erection of structure/equipment
is over.



Page 127 of 148

3.0 METAL INSERTS

3.1 Material

Materials required for fabricating metal inserts shall conform to
their respective specification given in this tender document.

3.2 Fabrication

Fabrication of inserts shall be done strictly as per
drawings/standards and in compliance with the requirements given
in Specification for Structural Steel Works.

3.3 Placement

Metal inserts shall be correctly embedded (in plain
concrete/reinforced concrete) as per their location shown on the
drawings. Care shall be taken that these are securely held in
position and do not get disturbed during concreting. Where
necessary, these may be welded to the reinforcement bars.
Suitable templates, spacers, dummy structures and temporary
staging shall be provided. Necessary cutting in the formwork and
adjustment of reinforcement bars shall be done for the placement
of metal inserts where required.

3.4 Painting

The exposed surfaces of inserts shall be given one coat of primer
after surface preparation to SA 2 as per painting specifications.

4.0 CHEQUERED PLATES

4.1 Material

Chequered plates shall be of mild steel and conforming to IS 3502.
Chequering shall be closed or open ended or of any other pattern
as shown on drawings and approved by HPCL.

4.2. Fabrication Drawings

Fabrication shall be as per AFC drawings.

4.3 Fabrication



Page 128 of 148
Chequered plates shall be fabricated as per "Approved for
Construction fabrication drawings (prepared by the Contractor
based on design drawings). These shall be perfectly flat and
without any dents/deformations and shall be cut to he required
size and shape. Holes/ notches/openings of the required size, if
any, shown on drawings shall be made. Nosing angle may be
provided for staircase treads or nosing may be made by cold
bending of chequered plates. All edges shall be made smooth and
even. All chequered plate units shall be given distinct erection
marks in accordance with the marking drawings. Stiffeners shall be
welded with the chequered plates where shown on drawings.

4.4 Erection/Fixing

Chequered plates shall be fixed to the bearing members by
welding/bolting/screwing as shown on drawings. All bolts/screws
shall be of counter sunk type so that the heads remain flush with
the top of plate. Where welding is used for fixing, stitch welds of
minimum 50mm length with a pitch of 150mm shall be used.
Continuous sealing run of weld shall be provided along the junction
of two consecutive chequered plates parallel to the span. For
removable flooring, details as shown on drawings shall be followed.

4.5 Painting

Chequered plates shall be cleaned (both the surfaces) .Thereafter
surface preparation; primer application & painting shall be carried
out on both faces after fabrication.

5.0 GRATINGS

5.1 Categories

The gratings shall be of two categories :

i) Category A - Fabricated by the contractor as per design
drawings/standards

ii) Category B - Ready made bought out from an approved
manufacturer

5.2 Material

Materials for fabrication and fixing of Gratings shall conform to
their respective specification given in this tender document.



Page 129 of 148

5.3 Fabrication Drawings

Fabrication shall be in accordance with AFC drawings.

5.4 Fabrication

5.4.1 Category "A" Gratings

These shall be fabricated strictly as per the "Approved for
Construction fabrication drawings prepared by the Contractor
based on design drawings and standards. All units shall be given
distinct erection marks in accordance with the marking drawing. All
notchings in the flats shall be punched and not flame-cut.
Continuous all around welding shall be done along the contact-lines
between two flats on both the surfaces. All fabrication shall be
done in a shop under strict supervision. Clamps shall be
fabricated as shown on drawing/standard.

5.4.2 Category "B" Gratings

These shall be as per manufacturers detailed designed to carry
loads as specified on the design drawing supplied to the contractor.
The deflection shall not exceed span/200 or 6mm
whichever is minimum. The maximum clear size of voids in the
grating shall be limited to 30mm x 55mm. The contractor shall
make necessary notches/opening in the grating as shown
in the drawings. All edges affected by such notches/openings
shall be suitably stiffened by welding additional flats of the
requisite size. All units shall be given distinct erection marks in
accordance with the marking drawings. Before procurement the
Contractor shall submit the design calculations, drawings and
manufactures literature / catalogues and get the same reviewed
by the Engineer-in-Charge. The Contractor shall submit sample
gratings for inspection and approval by the Engineer-in-Charge
whenever asked for.

5.5 Erection / Fixing

Gratings shall be fixed to the bearing members by welding /
clamping and bolting as indicated in the drawings. Minimum
length and maximum pitch of welds shall be 50mm and 150mm
respectively where stitch welding is used for fixing along the lines
of supports. The edges of two consecutive gratings shall be bolted
with minimum two bolts on each side of the grating panel.



Page 130 of 148
5.6 Painting

5.6.1 Painting

Surface preparation; primer application & painting shall be as per
specifications of this tender document.

6.0 TUBULAR HAND RAILING

6.1 Material

Materials for fabrication and fixing of Tubular Hand Railing shall
confirm to their respective specification given in this tender
document.

6.2 Fabrication

Hand railing shall be fabricated strictly as per the "Approved for
Construction fabrication drawings prepared by the Contractor
based on design drawings and standards. All tubes shall be
straight and without any dents / deformations. Tubes shall be cut
and ends shall be prepared to a neat and workman-like finish. All
elements shall be directly welded. All welded joints shall be
cleaned and filed or ground smooth, if required, to have a smooth
surface and aesthetically pleasant appearance. Splicing of top rail
shall not be allowed. Tubes shall be cold bent to shape and
curvature in case of discontinuous ends of handrails. Ripples,
kinds and / or dents at bends shall not be accepted.

Lower ends of vertical posts shall be cut and splayed (for grouting
in pockets in the concrete members). For removable type of
handrailing, suitable base plates (with provision for bolting) shall
be welded to the lower end of vertical posts. All units shall be
given distinct erection marks in accordance with the marking
drawing.

6.3 Erection / fixing

Hand railing, shall be fixed to the bearing members by welding /
bolting / grouting as indicated on the drawings. Local notching
shall be made in the floor plate / grating to accommodate vertical
posts / their base plates which shall always be welded to the main
supporting member. When the posts ate to be fixed in concrete
members, suitable pockets shall be made in concrete for grouting
as shown on drawings / standards.



Page 131 of 148
6.4 Painting


7.0 MILD STEEL RUNGS

7.1 Material

All materials shall confirm to their respective specifications given in
this tender document.

7.2 Fabrication

Rungs shall be fabricated as per enclosed standards / drawings.
Mild steel bars shall be straightened if required, cut and bent to
shape.

7.3 Fixing

Rungs shall be fixed in position as per detailed drawing and firmly
tied / welded with reinforcement to prevent their displacement
during vibrating of concrete.

7.4 Painting


8.0 LIGHT GUAGE STEEL STRUCTURAL SECTIONS

8.1 Material

All material required for fabrication and fixing in position of Light
Guage Steel Structural Sections shall confirm to their respective
specification given in this tender document.

8.2 Fabrication

Fabrication of members shall be done strictly as per the "Approved
for Construction fabrication drawings prepared by the Contractor
based on the latest design drawings and in accordance with IS:800
and other relevant IS Codes.



Page 132 of 148

All members shall be straight and free from any dents /
deformations / twists. Members shall be cut to the required sizes
and ends prepared to a neat and workman like finish. Holes (for
sag rods and cleat bolts) of appropriate size shall be drilled and all
members / components shall be given distinct erection marks in
accordance with the marking drawings.

8.3 Erection

Structural members shall be erected in proper sequence and
aligned properly without causing any twist. Permanent bolting /
welding shall be done only after proper alignment has been
achieved. Proper access, working platforms and safely
arrangements shall be provided by the Contractor for working and
inspection.

8.4 Painting


9.0 EXPANSION FASTENERS

9.1 Material

Expansion fasteners (medium and heavy duty) shall be of mild
steel / high tensile steel with rust proof coating.

9.2 Classification

The expansion fasteners shall be designated as medium and heavy
duty depending on their usage. The broad classification is given
below for general guidance.

9.2.1 Medium Duty (Mild steel/High tensile steel)

- Ladders and stairs supports.

- Cables and cable trays supports.

- Electrical panels and fixtures.

- Hangers for pipes and cable trays.



Page 133 of 148

- Pipe supports.

9.2.2 Heavy Duty (Mild steel/High tensile steel).

- Platform supports (beam and columns)

- Knee brackets for pipes/ multi tiers cable trays / walkways
etc.

Note:- Expansion fasteners shall not be used for

1. Members supporting equipment and pipes subjected to
vibrations.

2. Cantilever connections designed to cater for effective
cantilever spans greater than 1000mm and 1000Kgs of
concentrated load at the free end.

9.3 Selection

The Contractor shall submit to the Engineer-in-Charge
manufactures catalogues along with the specimens of expansion
fasteners (proposed to be used for the job) for his selection and
approval. Selected fasteners shall be capable to carry the specified
loads.

9.4 Testing

If so desired by the Engineer-in-Charge, the Contractor shall carry
out all the requisite tests (pullout test, torque test etc.) of
specimen expansion fasteners (representative of those to be used)
from approved laboratory / test house and submit the report to
him for approval. The decision of the Engineer-in-Charge
regarding the adequacy of strength and load carrying capacity of
the expansion fastener shall be final and binding to all. The cost of
all such tests shall be borne by the Contractor.

9.5 Installation

The Contractor shall install the expansion fasteners at their correct
location (to suit the requirement of fixtures as shown in drawings)
as per the procedure laid down by the manufacturer. Location of
all holes shall be pre-marked on the concrete surfaces and then
holes drilled carefully with an electric drill to the correct
recommended size and depth. Holes shall be exactly round and



Page 134 of 148
true perpendicular to the concrete surface. Edge distance and
pitch of fasteners shall be as recommended by the manufacturer.
The Contractor shall suitably shift the hole with the approval of the
Engineer-in-Charge in case any reinforcement bar is met with while
drilling the hole in RCC structure. Necessary staging shall be
provided for working and the Contractor shall take requisite safety
precautions so as not to cause any damage to the existing
structure / equipment. Any damage done, while executing the job,
shall be made good by the Contractor at his cost.

9.6 Protection

The exposed surfaces of expansion fasteners shall be properly
greased & covered with jute cloth so as to prevent them from
damage.



Page 135 of 148

STANDARD

SPECIFICATION

FOR

SHOP

AND

FIELD PAINTING



Page 136 of 148

STANDARD SPECIFICATION FOR SHOP AND FIELD PAINTING

1.0 GENERAL

1.1 These technical specifications shall be applicable for the work
covered by the Contract. It is understood that Contractor shall
complete the work in all respects with best quality materials and
workmanship, best engineering practice, Manufacturer
recommendations and instructions of HPCL.

1.2 All the items covered in this specification are required to be
supplied by the Contractor only.

2.0 SCOPE
Scope of work covered in this specification shall include but not
limited to the following:

1. Surface preparation for all components covered in this Contract.

2. Selection, procurement and application of primers, paints and
other materials on various metallic surfaces including providing all
requisite scaffolding, spray equipment, compressors, applicators,
brushes, etc.

3. Lettering, marking as per HPCL requirements.

3.0 CODES AND STANDARDS

3.1 REFERENCE STANDARDS
IS : 5
IS : 101
ASTM STANDARDS

3.2 SURFACE PREPARATION STANDARDS

SWEDISH STANDARD : SIS-05-5900-1967/ISO-8501-1-1988
THIS STANDARD CONTAINS PHOTOGRAPHS OF THE VARIOUS
STANDARDS ON FOUR DIFFERENT DEGREES OF RUSTED STEEL.

MANUFACTURERS BROCHURES AND INSTRUCTIONS WITH
RESPECT TO STORAGE, SURFACE PREPARATION, MIXING AND
THINNING, APPLICATION AND CURING INTERVALS.

4.0 EQUIPMENT



Page 137 of 148
All tools, brushes, rollers, spray guns, abrasive materials, sand,
hand/ power tools for cleaning, scaffolding materials, air
compressors, instrument for measuring humidity, etc required for
the works shall be supplied by the Contractor.

5.0 SURFACE PREPARATION, COATING APPLICATION AND
DOCUMENTATION

5.1 GENERAL

5.1.1 In order to achieve the maximum durability, Copper slag blast
cleaning shall be followed.

5.1.2 Mill scale, rust, rust scale, etc. shall be fully removed by copper
slag blast cleaning to SA 2.5 of SWEDISH IVONSK STANDARD:
SIS-055900-Latest Edition.

5.1.3 Copper slag blast cleaning shall not be performed where dust can
contaminate surfaces undergoing such cleaning or in conditions
where the humidity exceeds 85%.
5.1.4 The first coat of primer must be applied on dry surface
immediately and in any case within 4 hrs of cleaning of surface.

5.1.5 Blasting and painting shall in general be avoided during
unfavorable weather conditions.

5.2 PROCEDURE FOR SURFACE PREPARATION

5.2.1 GRIT BLAST CLEANING

The surface shall be blasted with Copper slag at a pressure of
about 7 kg/ sq.cm at appropriate distance and angle using
compressed air and copper slag to give a white metallic luster.
Surface profile shall be uniform to provide good key for paint
adhesion. Copper slag will normally be available in round shape.

5.3 COATING PROCEDURE AND APPLICATION

5.3.1 Copper slag blasted surface upon inspection and clearance by HPCL
shall be coated with one complete application of primer as soon as
practicable and in no case later than 4 hrs on the same day.
Applied paint shall have the required Dry Film Thickness (DFT)
after drying.

5.3.2 Each coat shall be in a proper state of cure or dryness before the
application of succeeding coat. Manufacturers instructions shall be
followed for intercoat interval.



Page 138 of 148

5.3.3 The type of application may be Airspray or Airless spray or Brush
application as per manufacturer recommendation and HPCL
instructions for getting satisfactory results.

5.3.4 For each coat, the painter should know the WFT corresponding to
the specified DFT and standardize the paint application technique
accordingly. This has to be ensured in a qualification trial by
Contractor.

5.4 SCAFFOLDING

Double scaffolding shall be used for working at heights and all the
painters shall be provided with Safety belts for ensuring accident
free working.

5.5 DOCUMENTATION

1. A written quality Plan with procedure for qualification trials and for
actual work.

2. Daily progress Report with details of humidity, surface preparation,
surface profile, Dry film thickness particulars of applications,
number of coats applied, type of materials used, methodology-Air
or Airless or Brush, progress of work vs programme.

3. Code and Batch numbers of primers and paint materials used.

4. Type of testing equipments and their calibration.

5. Elcometer readings for the various components jointly recorded
with HPCL.

6. Paint consumption statement along with the Theoretical
consumption requirements.

6.0 RECOMMENDED MANUFACTURERS

ASIAN PAINTS
BERGER PAINTS
GOODLASS NEROLAC
JENSON AND NICHOLSON
SHALIMAR PAINTS

7.0 DELETED



Page 139 of 148

8.0 INSPECTION AND TESTING

8.1 All painting materials including primers and thinners brought to
site by the Contractor for application shall be directly procured
from Approved manufacturers as per specifications and shall be
accompanied by Manufacturer Test Certificates.

8.2 HPCL may call for tests for the primers and paints including
verification of batchwise tests for physical and chemical analysis.
The Contractor shall carry out the same at his own cost and
provide the results to HPCL.

8.3 The painting work shall be subjected to inspection by HPCL at all
times. Stages of inspection are as follows:

1) Surface preparation
2) Primer application
3) Each coat of paint

All records of inspection shall be maintained in Registers and
jointly signed by HPCL and Contractor.

Any defect noticed during the various stages of inspection shall be
rectified by the Contractor to the satisfaction of HPCL before
proceeding further. Irrespective of the inspection, repair and
approval at intermediate stages of work, Contractor shall be fully
responsible for making good any defects found during Final
inspection or during the Defect Liability period. DFT shall be
checked and wherever shot same shall be made up with additional
coats.

8.4 The shades of successive coats should be slightly different in colour
in order to ensure application of individual coats in consultation
with manufacturer.

8.5 Calibrated Digital Elcometers, surface profile gauges and any other
inspection instrument required by HPCL shall be provided by the
contractor at site.

The contractor shall arrange expert technical support at site by
paint Manufacturer who will cross verify independently regarding
surface preparation and DFT and quality and provide a report to
HPCL.



Page 140 of 148
TECHNICAL SPECIFICATIONS FOR PRE-PAINTED
GALVALUME SHEETS

Pre-Painted Alu-Zinc Steel Sheets

Pre-painted Alu-Zinc alloy coated steel sheet (55% Aluminium
43% Zinc 1.6% Silicons)

Zinc coating AZ 150
Coating Regular modified polyester painting
Painting thickness (Top) 25 microns
Painting thickness
(bottom)
5~7 microns epoxy primer service coat
Surface paint reflection Matt finish (Optional-Gloss)
Tensile strength 570 N/mm2 min
Application
Structural quality JIS G3321 according
to ASTM A-792 grade 550



Page 141 of 148
TECHNICAL SPECIFICATIONS FOR WIND VENTILATOR
(TURBO-VENTILATOR)

ITEM SPECIFICATIONS
MOC of vanes SS 304
MOC of Top plate SS 304
MOC of bottom ring SS 304
Ht 410mm
Center width 735mm
Dia of top plate 500mm
No. of vanes 42; Roll formed
Thickness of vanes 0.45mm
No. of bearings 2
Bearing type SKF; Permanently lubricated & sealed
Fasteners SS 304
Shaft SS 304
Approved make Mukta or equivalent, mfd in India



Page 142 of 148

LIST OF RECOMMENDED MAKES/ MANUFACTURERS/

1.00.00 GENERAL

1.01.00 The makes and manufacturers shall be preferably from the following list.
In case the same is not available in the market or incase of a change in trade name,
equivalent makes/ re-designated manufacturer shall be used with the approval of
Consultant. For Items which have been missed in the current list, vendor shall seek
details from owner during execution.

1.02.00 In case of items not covered in the list, the material shall be best
available in the market and each item should have BIS certification mark.

Sl.No Description Manufacturers
1 CEMENT OPC/PPC ACC,
GUJARAT AMBUJA
RAJASHREE,
ZUARI,
ULTRA TECH CEMENT
LAFARGE
2 REINFORCEMENT STEEL HCR TMT STEEL SAIL,
TATA STEEL, RINL
3 WATER PROOF CEMENT PAINT SNOWCEM
ASIAN,
BERGER
JOHNSON & NICHOLSON
SHALIMAR
ICI
NEROLAC
4 STRUCTURAL STEEL SAIL
RINL
TATA
JINDAL
5 SYNTHETIC ENAMEL PAINT ASIAN
SHALIMAR
NEROLAC
JOHNSON & NICHOLSON
BERGER

6 ALUMINIUM DOORS/ WINDOWS/
VENTILATORS
INDAL, AJIT INDIA, HINDALCO,
JINDAL



Page 143 of 148
Sl.No Description Manufacturers
7 WATER PROOFING Llyod, Shalimar
8 Waterproof Cement Paint Snocem, Asian, Berger
9 Paint & Varnish M/s Asian Paints; M/s Goodlas Nerolac;
M/s Garware Paints Ltd.;
M/s I.C.I. Paints;
M/s Berger (British) Paints;
M/s Jenson Nicholson;
M/s Noble Paints or equivalent
approved manufacturer.
10 PVC Door
Rajashri plastic, Thermodeck , Sintex
11 Water Proofing Compound
Accoproof, Cico; Impermo
or equivalent approved manufacturer.

Wherever approved makes are not available, HPCL will approve equivalents based
on Contractors request and subject to the brands/makes/samples meeting BIS
Specifications/specs of this bid document.



Page 144 of 148

SAFETY REQUIREMENTS FOR
CONSTRUCTION WORKS



Page 145 of 148

SAFETY REQUIREMENT FOR CONSTRUCTION WORKS
A GENERAL
11 This specification deals with the subject matter of safety and
protection to be observed in the Civil Construction. This shall be
followed along with all related statutory requirements/obligation
including Governmental byelaws, codes, ordinance of local or
central authorities related to the construction work.

1.2. In case of complicated work like deep excavation, intricate
shuttering and formwork, excavation in loose soil and below water
table, stacking of excavated earth etc., work plan with necessary
drawings and documents have to be prepared by the Contractor
and got approved by the Engineer.

1.3 Necessary reference shall be made to the following Indian
Standard Codes on safety requirements for various type of work :

2.0 INDIAN STANDARD

4130 - 1991 Demolition of Buildings
3764 - 1992 Excavation Work
4014 - (P-II) - 1967 Scaffolding, Steel Tubular
3696 - (P-I & P-II) Scaffolds and Ladders 1987 to 1991
4138 - 1977 Working in Compressed Air
7293 - 1974 Working with Construction Machinery
8989 - 1978 Erection of Concrete Framed Structures

3.0 EXCAVATIONS

3.1. No excavation or earth work below the foundation level of an
adjoining building shall be taken up unless adequate steps are
taken to prevent damage to the existing structure or fall of any
part.

3.2 Every accessible part of an excavation, pit or opening in the
ground into which there is a danger of persons falling shall
be suitably cordoned off upto a height of one metre suitably
placed from the edge of the excavation as far as practicable.
Red tape & warning boards shall be used.
3.3. No material or load shall be placed or stacked near the edge
of the excavation or opening in the ground. The excavated
material shall not be placed within 1.5 m of the trench or
half of the depth of the trench whichever is more.
3.4 Cutting shall be done from top to bottom. No undercutting of
sides of excavation shall be allowed.



Page 146 of 148
3.5 Materials shall not be dumped against existing walls or partition
to a height that may endanger the stability of the walls.
3.6 While withdrawing piled materials like loose earth, crushed
stone, sand, etc. from the stock piles, no over hanging shall
be allowed to be formed in the existing dump.
3.7 No material on any of the sites of work shall be so stacked or
placed as to cause danger or inconvenience to any person or
public or any other agency at work.

4.0 SCAFFOLDING, LADDERS & SHUTTERING

4.1 For all work that cannot be done from the ground level or from
part of any permanent structure or from other available
means of support, soundly constructed scaffoldings of
adequate strength shall be used as a safe means of access to
places of work.

4.2 All scaffolding shall be securely supported or suspended and
wherever necessary be properly braced to ensure stability.

4.3 All working platform and stages from which workers are liable
to fall shall be of adequate width depending on the type of
work done and closely boarded and planked.

4.4 Every ladder shall be securely fixed at top and bottom. A ladder
more than 5 m long shall have a prop.

4.5 No portable single ladder shall be over 8 m in length.

4.6 Unfinished scaffolding which is under construction shall be
prominently marked as unsafe and any access points shall be
closed.

4.7. Shuttering

The above remarks shall be applicable for shuttering also.
Shuttering, particularly for slabs, should be treated as a
scaffold. Unfinished shuttering should be marked as dangerous.
Similarly the finished form work should be adequately
supported & care being taken to avoid trap door effects.



Page 147 of 148
5.0 SAFETY APPLIANCE

5.1 Those engaged in white washing and mixing or stacking of
cement bags or any materials which is injurious to the eyes,
shall be provided with protective goggles.

5.2. The Contractor shall not employ men below the age of 18 and
women on the work of painting with products containing lead
in any form.

5.3. All necessary personnel safety equipment such as safety
helmets, safety boots, safety belts, leather gloves for
welders, clear glass safety goggles etc., as considered
adequate by the Engineer have to be kept available for the
use of persons employed at the site of work and maintained
in condition suitable for immediate use and Contractor shall
take steps to ensure proper use of equipment by the
workers.

5.4 Sign boards 1 x 1.5 m in size with the following wording shall
be erected at the access to these areas. "CONSTRUCTION
AREA, HELMET REQUIRED BEYOND THIS POINT.

5.5 Arrangement for rendering prompt and adequate first aid to the
injured persons shall be maintained at every work site .
Depending upon the magnitude of the work, the availability
of an ambulance at a very short notice (a telephone call)
shall be ensured.

First-aid arrangements commensurate with the degree of hazard
and with the number of workers employed shall be maintained in
a readily accessible place throughout the working hours. At least
one experienced first-aid attendant with his distinguishing badge
shall be available on each shift to take care of injured persons.
Arrangements shall be made for calling the medical officer, when
such a need may arise. It is recommended that foreman/assistant
foreman/supervisor/permanent workmen who are normally
present at each working phase in each shift are given adequate
training on first-aid methods to avoid employment of a separate
attendant.

6.0 MISCELLANEOUS

6.1 The Contractor shall provide necessary cordoning off and lights
to prevent accidents.



Page 148 of 148
6.2 To ensure effective enforcement of the rules and regulations
relating to safety precautions, the arrangements made by
the Contractor shall be open to inspection by the Engineer-
in-Charge.

6.3. All sources of ignition shall be prohibited in areas where
flammable liquids are stored, handled and processed.
Suitable warning and `NO SMOKING signs shall be posted in
all such places. Receptacles containing flammable liquids
shall be stacked in such a manner as to permit free passage
of air between them.
6.4 All combustible materials shall be continuously removed from
such areas where flammable liquids are stored, handled and
processed. All spills of flammable liquids shall be cleared up
immediately. Containers of flammable liquids shall be tightly
capped.

7.0 REPORTING OF ACCIDENT
7.1 All accidents, major or minor must be reported immediately.
The Contractor, will provide first aid to the injured person
immediately and the injured person shall report to the first
aid station along with the `INJURED ON WORK form duly
filled in quintuplicate and submit to the Officer of the First
Aid Station.

7.2. Serious Injury
In case of serious injury, the following procedure shall be
adopted by the Contractor:

a) Provide First Aid at his own First Aid Station.

b) Take the injured person to the Hospital along with the
"INJURED ON WORK form duly filled in.

c) Reporting the accident to the Owner/Engineer by the
Contractor.

7.3 Fatal Accident
Fatal accident must be reported immediately to the
Engineer/Owner as well as to the Police.
8.0 PENALTY

Failure to observe the Safety Rules will make the Contractor
liable to penalty by way of suspension of work, fine and
termination of contract.

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