LAYOUT AND CONSTRUCTION While laying out industrial enterprises or their group, layout of buildings, installations and communication

lines shall be such that the most favourable conditions for the production processes and that of workmen are effected and rational and economic utilization of land are achieved. General layout of industrial enterprises or their groups shall provide for: Functional zoning of territory with consideration for technological links, sanitary, safety and fire protection requirements, type of transportation and priority of constructional sequence. Securing rational production, transportation and communication links of the enterprises. Planning and organizing vehicular and pedestrian traffic taking into consideration their safety and minimum time required to reach place of work. Possibility of expansion and/ or reconstruction of enterprises by utilizing vacant areas within the industrial site and possible development of adjoining territory. Creating a better industrial architectural aesthetic in the area as a whole. Sites for enterprises shall be chosen and earmarked according to its functional utilization zones such as Raw Materials handling and storages Production Shops Auxiliary Shops Storages At the time of selection of site, additional land availability for possible expansion of the enterprise shall be provided for on the basis of master plans LOCATION OF BUILDINGS AND STRUCTURES Production, auxiliary and ancillary buildings, as well as closed storage facilities shall be integrated into large-size buildings in all cases where such integration is economically founded and admissible from the point of view of production, construction, sanitary and hygienic and fire safety considerations and also from the safety of point of view. Distances between buildings and structures shall be the least in relation with technological transportation, communication lines and other relevant conditions but not less than the distances required as fire fighting or health hazard requirement. The requirement for constructional facilities, erection proper and operation thereafter shall be taken into account while planning the general layout.

Possibility of construction and commissioning of plants by commissioning of complexes or stages shall be provided in preparing general layout plan of the plant. The buildings and structures shall be located so as to take into consideration soil and hydro-geological conditions at site. Buildings and structures accommodating equipment causing considerable dynamic loading to create vibration of soil strata shall be located at definite distances from nearby buildings and structures with precision instruments (mechanisms). The distances shall be determined by calculations taking into consideration the engineering and geological conditions obtained in the area, physical and mechanical properties of the soil, as well as measures to eliminate influence of dynamic loading and vibrations on the soil. Production and testing stations with specially harmful processes, explosion and fire prone as well as store houses of combustible and easily inflammable materials poisonous and of dangerous composition shall be located in accordance with corresponding norms and regulations. Storages of easily inflammable combustible oil products or materials of poisonous composition shall not be placed in such parts of the building which are exposed to wind. ( Wind data that shall be taken after many years of observation ) Units with open sources of fire or sparks, shall not be placed on the wind side in relation to open storages of inflammable/ combustible oil products or other materials. Buildings, structures and open units having process producing gas, smoke and dust that pollute atmosphere and or manufacturing explosives and fire hazard causing materials shall not be placed on the wind side in relation to other production units/ buildings. Cooling ponds, water reservoirs and slime pits etc shall be designed and located in such a way that adjoining structures, apartments, offices etc do not get flooded when the water/ liquid overflows or spills in case of bursting of bunds etc. Cooling tower basins shall be so placed that their long side s perpendicular to the direction of summer wind. Buildings and structures shall be located to suit light and wind directions, providing for the most favourable lighting and air circulation and prevention of dust accumulation. The disposition shall comply with the following requirements: Direction of lighting and ventilation shall be 45 110 to the meridian of the longitudinal axis Longitudinal axis of the buildings and openings shall be perpendicular to or at an angle to aeration projections at not less than 45 of the summer wind direction In areas where sad or dust is carried in the atmosphere, building openings shall be placed away from wind side. Lines of greenery of width not less than 20 m and screens shall be provided to reduce effect of such action. Buildings shall be placed with their longitudinal side parallel to the main direction of wind or at an inclination of not less 45. Open side of the yard shall be placed on the side opposite to wind direction. Minimum variation in layout, types of buildings, paths and roads etc shall be provided to obtain uniformity and economy. Fire service stations shall be located in isolation, with proper approaches to main roads and shall individually cater to a group of shops/ plants/ enterprises. TRACK ENTRY, THROUGH LINES AND DISTANCES BETWEEN BUILDINGS AND STRUCTURES

Gates or openings to road vehicles shall be of sufficient width to allow the widest truck to pass with a total clearance of 1.5 m but shall not be less than 4.5 m. For railway entry the width shall not be less than 5.0 m. Width of passes or distance between structures shall be assumed considering the most compact dimensions of roadway or railway, pavements, on-ground/ underground/ overground network and areas of greenery but not less than distances as per following ???? Track entry into buildings shall normally be dead-ended. Where through lines are to be provided they shall be only special cases on sufficient grounds. Track entering into a building shall have a straight length of not less than the length of a wagon or loco whichever is longer. In the case of expansion or reconstruction of a plant the straight section can be reduced to 2 m. Distance between buildings or structures and railway tracks shall not be less than that given in the following table: Distance from tracks to buildings Buildings/ Structures Outside of walls, projecting parts, pilasters, stairs, columns etc In absence of access from buildings Access available Access available but with protective fencing, parallel to building (length not less than 10 m ) Individual Bunkers, columns, trestles, loading structures, platforms, ramps, drains etc Fencing, supports of ducts, communication lines and pipelines Construction stages midway ( out of stations ) Construction stages at stations Silos, store houses upto 10000 m3 capacity Distance in m 3.1 6 5 As per standard 3.1 2.75 2.45

1 a) b) c) d) e) f) g) h)

For special rolling stocks inside plants it shall be as per size of such stocks and the material transported. ROAD ENTRY AND DISTANCE BETWEEN BUILDINGS AND STRUCTURES Roads shall be designed for the full turnover of movement in the enterprise, load intensity of vehicles, intensity and density of traffic etc during and after construction in accordance with the stage of construction of the enterprise. To facilitate movement of construction and erection materials and equipment stable and hard roads and pavements are made as far as possible in the final alignment however the final finishing of the road surface shall usually be done later in the final stage. Construction of temporary roads ( other than in permanent alignment ) are allowed under special consideration of technical necessity. At dead-ends of roads turning round space of not less than 12 m dia shall be provided. Size of such space shall depend on the size of transport equipment plying.

Tunnels, bridges, galleries trestles and pipeline structures shall be clear of the road by not less than 1 m horizontally and in height not less than 5 m taking into account the sizes of auto-equipment plying on the road. For access of fire fighting stock, roads shall be provided: From one side if width of structure is less than 18 m. From both sides if width is greater than 18 m. From all sides of an area exceeding 10 ha and width exceeding 100 m. If the layout does not permit provision of such approaches due to technological/ production needs, paths with slag or boulders for a width of 3.5 m with suitable slopes to the sides shall be provided. Distance from approaches to the nearest through road shall not be greater than 25 m. Distance from edge of Road to buildings or structures shall not be less than that given in the following table: Distance from roads to buildings Buildings/ Structures 1 a) b) c) d) 2 3 4 5 Outside edge of building walls With no access to buildings of length up to 20 m With access to buildings exceeding 20 m With 2 accesses for auto & electric equipment With 3 accesses for auto & electric equipment With access to railway tracks running parrallel Fencing of an area Fencing of protected areas Outside edge of supports or trestles Distance in m 1.5 3.0 8.0 12.0 3.75 1.5 5.0 0.5

VERTICAL PLANNING ( Site leveling and final floor levels ) Vertical planning is to be done when the built-up coefficient in a plant area is more than 25%. It is also to be done in the case of large plants with tracks and other engineering networks. In other cases selective planning only in areas where buildings and structures are put up or planned is to be done. Selective planning is also to be done when the soil is rocky or when existing forests, plantation and greenery are to be preserved or under unfavourable hydro-geological conditions. Surface slopes shall be not less than 0.003 nor more than 0.05 for clayey soils; 0.03 for sandy soils; 0.01 for soils loose and liable to be washed away (e.g. fine sand ); and 0.03 for frozen soils.

The floor level of the buildings or structures planned, shall be higher than the adjoining areas by not less than 150 mm ( in sites prone to water accumulation the floor levels of major shops may be kept 500 above the terrace level. The cellar or other under ground floors shall be higher than the level of the ground water table by not less than 0.5m. Where structures have to be put up below water table, suitable and effective insulation shall be taken. In the design of subsoil structures, buoyancy of such construction shall be considered in design. Pavements constructed within the plant premises shall have the following: If adjoining buildings have proper drain pipes from roof, the width may be increased by 0.5 m over the calculated requirement. If proper drainage arrangement is not provided for the buildings, the pavement shall be not less than 1.5 m from the building. Not nearer than 2 m from the edge of road or sidewalk. Not nearer than 3.75 m from centre line of nearest BG railway track When the pavement is adjacent to the main road the pavement level shall be higher than that of the road by not less than 150 mm. If there shall be a necessity to provide drainage from structures under construction, suitable drainage channels 1 m away from the temporary scaffolding shall be provided. LOCATION OF SERVICE NETWORKS 1. A combined network of service lines shall be designed for an industrial enterprise or groups located in selected areas. 2. Method of laying network ( ground, over-ground or underground ) shall be decided on the technical and economic merits and needs. 3. Laying of networks of different types and purposes shall as far as possible be located in common collectors, trenches, channels, overhead structures and shall be in accordance with respective sanitary, firefighting, safety rules as may be applicable. 4. Laying of networks in common carriers shall involve minimum occupation of area and shall not interfere building foundations etc. 5. Pipe networks of combustible gases or easily inflammable liquids shall not be located under buildings and structures. A. UNDERGROUND NETWORKS 1. As a rule underground service lines shall be laid beyond road surface where traffic takes place. Where necessary the lines may be laid in channels/ collectors under greenery or foot paths, in extreme cases of necessity only they may be under the road. Ventilation pits, emergency manholes, entrances etc shall not be made on the road but may be made under the greenery or similar areas free from buildings and structures. When service lines are laid in trenches they may be provided on the sides of the roads 2. Gas pipelines with pressure upto 6 kg/cm2 can be laid along with other pipe mains or cables in tunnels or other collecting troughs provided proper ventilation and lighting is provided in the tunnel/ troughs.

The following combination of lines shall not be laid in common tunnels/ducts a) Gas lines and power cables and lighting cables b) Lines carrying hot material and other lines of cold materials or inflammable or combustible liquids c) Fire hydrant mains and inflammable combustible liquids and cables of high or low currents. d) Water lines and sewerage lines e) Oxygen lines and other combustible gas lines f) Pipes carrying poisonous liquids and power cables 3. Tunnels with fire causing or explosive materials or inflammable liquid pipes or pipes carrying poisonous liquids shall be provided with exits at both ends and also at every 60 m length. 4. No service lines laid in trenches shall be located at distances less than those given in the following tables 5. Depth of mains shall be : a) Between top of under ground piping or electrical cables or casing and foot of rail - 1m b) Between top of under ground piping or cabls or their casing and road crest - 1m c) Between under ground pipes and cables as well as between high voltage lines and other communication cables 0.5 m d) Between pipes for different purposes ( except for sewerage pipes crossing water mains and for pipes for poisonous and foul smelling liquids ) - 0.2 m e) Between top of gas pipes and foot of rail - 1.8 m B. NETWORK ON GROUND ( Surface Network ) When service networks are laid on surface they shall be protected from damages and unfavourable atmospheric influences Laying of gas pipelines, sewerage lines and pipes carrying substances liable to cause explosions, fire or air pollution in case of leakage or breakage shall not be permitted. Surface and underground lines laid in trenches etc which require periodical inspection & maintenance and hence access to them, shall not be laid near each other. C. OVER-HEAD NETWORK No fire hydrant mains, sewerages or storm water pipes shall be laid overhead. They may, however, be grouped together with other main and laid in common supports on galleries or supported on walls of buildings and structures. Overhead network shall not be provided for :

a) b) c)

Pipes for easily inflammable liquids and gases over highlines, separately erected columns and supports made of inflammable materials or over inflammable walls of buildings and roofs ( except for the buildings dealing with the production/ consumption of above type of liquids or gases ) Pipes for combustible liquids and gases over galleries if mixture of products can cause explosion or fire. Gas pipes for gas fuels over walls and roofs of buildings housing explosive materials; other buildings or structures where gas is not used; over storages for combustible or easily inflammable materials; or together with electric wires. On galleries used for pipes for easily inflammable liquids, provision for servicing & maintenance passages only shall be made. Overhead pipes for easily inflammable shall be laid at a distance of not less than 3 m from walls of buildings with openings. The distance can be reduced to 0.5 m from walls without openings. Minimum Horizontal Distances in m from Underground Networks to Buildings/ Structures

Name of network

Foundations of Buildings & Structures

Supports of outside lighting, contact networks & communication lins 1.5 3 1 1 1 1 1 1.5

Axis of Railway tracks but not less than depth of trench upto embankment foot 4 4 4 3.75 4.75 7.75 10.75 4

Water Pipings and Sewerage Gravity Sewerage and Water Drain Drains Gas Pipings in low Pressure upto 0.05 kg/cm2 Medium Pressure upto 3 kg/cm2 High Pressure: more than 3 kg/cm2 upto 6 kg/cm2 More than 6 kg/cm2 upto 12 kg/cm2 Heat pipings ( from outside

5 3 3 2 4 7 10 2

Automobile Roads Stone Outside ( Kerbs) edge of ditch or foot of embankment 2 1 1.5 1.5 1.5 1.5 2.5 2.5 1.5 1 1 1 1 1 1 1

Foundation of supports of high voltage lines Upto 1 kV From 1 33 Above kV 33kV 1 1 1 1 1 1 1 1 2 2 2 5 5 5 5 2 3 3 3 10 10 10 10 3

wall of channel) Power & communication cables

0.6

0.5

3.25

1.5

0.5

5*

10*

*These relates only to power cables. The distance from communication cables should be taken from special norms as applicable. Notes : For electric traction railways The distance from c.l. upto the power cables & communication cables & heat pipings should be taken as not less than 10.75m. The distance between water pipings & foundations of buildings & structures can be reduced upto 3m provided the water pipings are laid in casings Minimum distance in m in horizontal plane between underground networks
Name of networks Water pipings Sewerage Drain & water drain Gas Pipings Low pressure upto 0.05 kg/cm2 1 1 1 0.4 0.5 0.5 0.5 1 1 2 Low pressure up to 3 kg/cm2 1 1.5 Low pressure upto 3 - 6 kg/cm2 1.5 2 Low pressure upto 6 12 kg/cm2 2 5 5 0.4 0.5 0.5 0.5 1 1 4 Power cables upto 35 kV 0.5 0.5 0.5 1 1 1 2 0.1 0.5 0.5 2 Communication cables Heat piping to outside wall of channel 1.5 1 1 2 2 2 4 2 1 -

Water pipings Sewerage Drain & Water drain Gas Pipings a) b) c) d) Power cables Communication cables Heat pipings

See note 2 1.5 1 1 1.5 2 0.5 0.5 1.5

See note 2 0.4 0.4 1 1.5 2 5 0.5 0.5 1

1.5 0.4 0.4 1 1.5 2 5 0.5 0.5 1

0.5 0.5 0.5 1 1 1 2 0.5 1

1.5 2 0.4 0.4 ( D not more than 300 mm ) 0.5 0.5 ( D not more than 300 mm ) 0.5 0.5 ( D not more than 300 mm ) 0.5 0.5 ( D not more than 300 mm ) 1 1 1 1 2 2

Note : When it is impossible to provide gap between heat pipings & electrical cables it is necessary to provide heat insulation of heat

pippins so that additional heatings of soil at any time of year does not exceed 10 C for cables with voltage upto 10 kV and 5 C for cables with voltage 35 220 kV. When drinking water piping is laid together with sewerage pipings in parallel, the distance between pipings shall be not less than 1.5 m with water pipes upto 200 mm and not less than 3 m for water pipes dia more than 200 mm. On these sections water pipings should be made of metal. Under the same conditions but with pipings located below sewerage pipings the given distances should be increased by the difference between the levels of depth at which pipings are laid. When two or more gas pipings are laid in the same trench on parallel the distance between them should be for pipes with diameter : Upto 300 mm Not less than 0.4 m More than 300 mm Not less than 0.5 m The table gives the distances ( gas pipings made of steel )