Section II

TANGEDCO
Bid Ref. No: CE/D/CNR//R-APDRP (Part-B)/Specn. No: E-1069/ 2013-14
SECTION-II TECHNICAL SPECIFICATION FOR DESIGN AND DRAWINGS FOR CIVIL WORKS 1.0 GENERAL REQUIREMENTS
The tenderers shall carefully study the technical specifications and shall intimate the purchaser in case any error/ omission is found. As a result of such interaction, if some corrections/ modifications are required, the same shall be brought to the notice of all the tenderers before the date of submission. 2.0 2.1 SCOPE OF WORK The Scope of Contract under the Specification covers the following:
"Detailed Engineering, design & drawings, construction of 33/11KV indoor Substations Control room including erection, testing and commissioning on turnkey basis. 2.2 The scope includes supply of all labour, technical personnel, materials and equipments for execution of works and getting all materials tested at site laboratory or approved laboratories outside, submitting test reports, arranging supervision of manufacturer for specialised items. After award of work, the contractor shall submit a detailed quality assurance programme for all the materials and types of works. 2.3 The intending tenderers are advised to visit the site to have a first hand information about the site conditions such as, access to site, access for construction and erection, clearance available and all other relevant details before submission of tender. Necessary precautions shall be taken to carryout the work without any damage to the existing structures and/ or without any stoppage of the running plant. Non-familiarity with the site conditions will not be considered a reason either for extra claims or for not carrying out work in strict conformity with time schedule drawing and specifications. 2.4 Also tenderer has to decide the logistics and timings for the transport of construction materials and equipments, taking the site location into consideration.
Volume-II,Section-II,Specn.Civil works
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3.0
DESIGN AND DESIGN LOADINGS
3.1 Design of all components of the sub station cum office building shall be done using softwares (STAAD-PRO or SAP 2000). 3.2 All design and drawings, all foundations, structures, cable trenches, sump pits, drains, central oil collecting pit, culverts, road and all other civil facilities in the scope of this contract shall be designed for the worst combination of following loads as applicable: and as per IS 875 part (5). (a) Dead Loads: Self weight of foundation, structures, weight of equipment including impact/vibration loads. (b) Live Loads: (latest version ) (c) Wind Loads: The live loads shall be considered as per IS:875 Part-2
Wind Loads shall be considered as per IS:875 part (3)
(d) Seismic Loads: Seismic loads shall be considered as per IS:1893 (latest version) 3.3 All under ground facilities like Basement floor, etc shall be designed for earth pressure including swelling pressure and sub-soil water pressure under worst conditions likely to be encountered in the life of structures. In addition, a surcharge load of 2.5 tonne per Sq.m (Minimum) or actual whichever is more shall also be considered in the design. 3.4 R.C.C. pre-cast covers of cable/pipe trenches shall be designed for a live load of 1000 Kg/Sq.m. Trenches at road crossings shall be designed for class A loading as per relevant IRC codes. 3.5 R.C.C. road, platforms etc. shall be designed for the load of heaviest transformer. 3.6 All culverts shall be designed for class A loading except for culverts which may be required for road-cum-rail track. These shall be designed for the load of heaviest transformer and checked for class A load in. 3.7 Super-imposed loads, equipment loads, crane load, wind loads, seismic loads and temperature loads shall also be taken into account as per relevant Indian standards.
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3.8 Dead loads shall include the weight of structures complete with finishes, fixtures and partitions shall be taken as per relevant Indian standards. 3.9 Super-imposed loads in different areas shall include live loads, minor equipment loads, cable trays, small pipe racks/hangers and erection, operation and maintenance loads. Equipment loads shall constitute, if applicable, all load of equipments to be supported on the building frame. 3.10 For crane loads if any, an impact factor of 30% and lateral crane surge of 10% (lifted weight + trolley) shall be considered in the analysis of frame according to provisions of IS:875. The horizontal surge shall be 5% of the static wheel load. 3.11 The wind loads shall be computed as per IS 875, Seismic coefficient method shall be used for the seismic analysis as per IS 1893 with importance factor 1.5. Wind and Seismic forces shall not be considered to act simultaneously. 3.12 Floors shall be designed to carry loads imposed by equipment, cables piping travel of maintenance trucks and equipment and other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable and piping loads, shall also be considered additionally for floors where these loads are expected. 3.13 In addition, beams shall be designed to carry loads imposed by equipment, cables, piping, loads of maintenance trucks and equipment and other loads associated with building. 3.14 For consideration of loads on structures, IS:875, the following minimum superimposed live loads shall, however, be considered for the design. a. Roof 1.5 KN/m2 0.75 KN/m2 (i) 5 KN/m2 (ii)10 KN/m2 for accessible roofs for in-accessible roofs for offices For equipment floors or (minimum) actual requirement, if higher than 10 KN/M2 based on equipment component weight and layout plans.
b. RCC-Floor
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c. d. e. f.
Stairs & balconies 5 KN/m2 Toilet Rooms 2 KN/m2 Chequered plate floor 4 KN/m2 Walkways 3 KN/m2
3.15 Any additional load coming in the structure shall be calculated as per IS:875. 3.16 Any other additional loads, due to communication / data towers, shall be considered in the design of structures as per the manufacturer data. 3.17 The following information shall be submitted for review and approval to the purchaser: a) Design criteria shall comprise the codes and standards used, applicable climatic data including wind loads, earthquake factors maximum and minimum temperatures applicable to the building locations, assumptions of dead and live loads, including equipment loads, impact factors, safety factors and other relevant information. b) Structural design calculations and drawing (including construction/ fabrication) for all reinforced concrete and structural steel structures both in soft and hard copies. 4.0 DRAWINGS
4.1 Drawings of all components covered in this specification shall be done using AUTOCAD. 4.2 Within One month from the date of taking over of site, the tenderer has to furnish the sequence of submission of detailed Engineering design, data and drawings for the Sub station cum office building. 4.3 The sequence of submission of all drawings shall be such that all information is available for checking each drawing, when it is received. The purchaser will return a copy of each drawing to the contractor marked either 'approved' 'approved as noted' or 'returned for corrections. The notation 'approved' 'approved as noted' shall authorise the contractor to proceed with the work/ manufacture of the equipment covered by such drawings subject to the corrections, if any, noted thereon. When print of
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drawings have been returned for correction, the contractor shall revise the drawings as necessary and shall resubmit fresh prints for approval in the same routine as before. 4.4 Any work/ fabrication work performed prior to the approval of the designs and drawings by the purchaser will be at the contractors risk and cost. The purchaser shall have the right to ask the contractor to carry out any change in the designs which may be deemed necessary in the opinion of the purchaser to make the work/ equipment conforming to the provisions of these specifications with no additional cost to the purchaser. However, approval by the purchaser of the contractors designs and drawings shall not relieve the contractor of his obligations to meet all the requirements of those specifications and or of his responsibility for the correctness of designs and drawings. 4.5 Unless otherwise specifically provided for in the schedule or in the specifications or in the drawings the contractor shall furnish all the materials, accessories and appurtenant parts called for in the specifications or shown on the drawings and any thing shown on the drawings but not mentioned in the specifications or any thing called for in the specifications but not shown on the drawings, if required or shown in both. 5.0 SUBMISSION OF DETAILED DESIGN AND DRAWINGS FOR THE SUBSTATION CUM OFFICE BUILDING 5.1 After award of contract, successful bidder shall be required to submit the designs, layout & construction drawings, detailed working drawings along with bar bending schedule for all foundations, cable/pipe trenches and all other structures and items of work related to the substation cum office building covered under the scope of work under clause 2.0 of this specification. This shall be submitted progressively and in no case the first set of design and drawings shall be submitted not later than 30 days from the date of issue of letter of acceptance to the contractor. 5.2 The construction drawings shall consist of general arrangement drawing, Foundation drawing showing location of footings or piles, pile cap, basement side wall, transformer foundation etc, roads, road side drains, fire protection walls, and all other related items/services required for the project. Detailed drawings along with design calculations & bar bending schedule for all foundations and all other civil works shall be submitted by the contractor for approval.
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5.3 All construction drawings and design calculations for all civil and structural works shall be submitted to the purchaser for scrutiny and approval. All designs and drawings shall be got approved within a period of two months from the date of issue of letter of acceptance. 5.4 The Design calculations and construction drawings in triplicate should be submitted to the Engineer for approval. After drawings and design calculations have been accorded final approval, the contractor shall submit ten (10) prints and one soft copy in compact Disc of such approved design and detailed working drawings for distribution purpose. In addition, the contractor shall be required to furnish two (2) prints of all final drawings and one soft copy in CD as actually constructed and marked `As Built after completion of all works and acceptance of the same by purchaser. 6.0 CONTRACT DRAWINGS
The drawings bearing the purchasers approval or drawings corrected in accordance with the comments of the purchaser shall be deemed to be contract drawings and no variation there from shall be taken without the purchaser written consent.
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TECHNICAL SPECIFICATION FOR CIVIL WORKS D1. CONCRETE AND ALLIED WORKS 1.1. SCOPE This Specification covers the general requirements for concrete to be used on jobs using on-site production facilities including requirements in regard to the quality, handling, storage of ingredients, proportioning, batching, mixing and testing of concrete and also requirements with regard to the quality, storage, bending and fixing of reinforcement. This also covers the transportation of concrete from the mixer to the place of final deposit and the placing, curing, protecting, repairing and finishing of concrete.
1.1.1 The two parts viz. Specific Technical requirement for the project and this specification are complementary and are to be read together for correct interpretation of the provisions of this specification. Where requirements of the two sections conflicts, those of Specific Technical requirement for the project shall govern. 1.1.2. It shall be very clearly understood that the specifications given herein are brief and do not cover minute details. However, all works shall have to be carried out in accordance with the relevant standards and codes of practices or in their absence in accordance with the best accepted current Engineering practices or as directed by ENGINEER from time to time. The decision of ENGINEER as regards the specification to be adopted and their interpretation and the mode of execution of work shall be final and binding on CONTRACTOR and no claim whatsoever will be entertained on this account. 1.2 APPLICABLE CODES AND SPECIFICATIONS All standards, tentative Specification, Specifications, Codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy, between this Specification and those referred to herein, this Specification shall govern. MATERIALS I.S.269 - Specification for ordinary, rapid Hardening and low heat Portland cement. I.S.1489 - Specification for Portland -pozzolana Cement.
(a) 1. 2.
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3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13. 14. (b) 1. 2. 3. (c) 1. 2. 3. 4. 5. 6. 7. 8. 9.
I.S.650 - Specification for standard sand for testing of cement. I.S.383 - Specification for coarse and fine aggregates from natural sources for concrete. I.S.2386 - Methods of test for aggregate for concrete (Parts I to VIII) I.S.516 - Method of test for strength of concrete. I.S.1199 - Method of sampling and analysis of concrete. I.S.3025 - Method of sampling and testing (Physical and Chemical) of water used in industry. I.S.1139 - Specification for hot rolled mild steel, medium tensile steel and highyield strength steel deformed bars for concrete reinforcement. I.S.1786 - Specification for cold worked steel high strength deformed bars for concrete reinforcement. I.S.4990 - Specification for plywood for concrete shuttering work. I.S.2645 - Specification for integral cement water proofing compounds. I.S.4461 - Cold worked steel bars for the reinforcement of concrete. I.S.4031 - Methods of physical tests for hydraulic cement. EQUIPMENT I.S.1791 - Specification for batch type concrete mixers. I.S.2505 - Specification for concrete / vibrators (immersion type) I.S.2750 - Specification for steel scaffoldings. CODES OF PRACTICE FOR CONCRETE I.S.456 - Code of practice for plain and reinforced concrete. I.S.3935 - Code of practice for construction. I.S.2751 - Code of practice for welding of mild steel bars used for reinforced concrete construction. I.S.2502 - Code of practice for bending and fixing of bars for concrete reinforcement. I.S.3558 - Code of practice for use of immersion vibrators for consolidating concrete. I.S.3414 - Code of practice for design and installation of joints in building. I.S.4014 - Code of practice for steel tubular (Part I & II) scaffolding. I.S.2571 - Code of practice for laying in-situ cement concrete flooring. I.S.1343 - Code of practice for pre stressed concrete.
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(c) 1. (e) 1. 2.
CONSTRUCTION SAFETY I.S.3696 - Safety code for scaffolds and ladders (Part I & II) MEASUREMENT I.S.1200 - Method of measurement of building works. I.S.3385 - Code of Practice for measurement of Civil Engineering works.
Note: 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. 1.3. MATERIALS FOR 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. The quality of materials, method, control, manufacture and transportation of all concrete irrespective of mix, whether reinforced or otherwise, shall conform to the applicable portion of this specification. ENGINEER shall have the right to inspect the sources of materials, the layout and operation of procurement and storage of materials, the concrete batching and mixing equipment, and take quality control systems such an inspection shall be arranged of concrete work. 1.3.1 CEMENT a) Unless otherwise specified in Section C or called for by ENGINEER/ OWNERS, cement shall be ordinary Portland cement conforming to not less than Grade 43 of relevant I.S. and in 50-kg bags. The use of bulk cement will be permitted only with the approval of ENGINEER. Changing of brands on type of cement within the same structure will not be permitted without approval of ENGINEER. While purchasing cement or before commencing the work for every batch of cement consignments, the CONTRACTOR should satisfy himself about the quality of cement by conducting initial test on
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concrete cubes in the presence of the representative of the PURCHASER and only after establishing the suitability, the cement should be used on work. To have quick evaluation results, the above specimens should be cured by steam curing and tested immediately at CONTRACTORs cost at an approved laboratory. CONTRACTOR shall not be entitled to any claim of any nature on this account. 1.3.2. AGGREGATES a) `Aggregate in general designates both fine and coarse inert materials used in the manufacture of concrete. `Fine Aggregate is aggregate most of which passes through 4.75mm IS sieve. `Coarse Aggregate is aggregate most of which is retained on 4.75mm IS sieve. b) All fine and coarse aggregates proposed for the use in the work shall be subject to ENGINEER's approval and after specific materials have been accepted, the source of supply of such materials shall not be changed without prior approval of ENGINEER. STORAGE OF AGGREGATES All coarse and fine aggregates shall be stacked separately in stock piles in the material yard near the work site to avoid inter-mixing of different aggregates. Contamination with foreign materials and earth during storage and while heaping the materials shall be avoided. The aggregate must be of specified quality not only at the time of receiving at site but more so at the time of loading into mixer. Coarse aggregates shall be piled in layer not exceeding 1.20 metres in height to prevent coning or segregation. Each layer shall cover the entire area of the stockpile before succeeding layers are started. Aggregates that have become segregated shall be rejected. Rejected materials after remixing may be accepted, if subsequent tests demonstrate conformity with required gradation. SPECIFIC GRAVITY Aggregates having a specific gravity below 2.6 (Saturated surface dry basis) shall not be used without special permission of ENGINEER. FINE AGGREGATE Fine aggregate except as noted above, and for other than lightweight concrete shall consist of natural sand to I.S.383. The sand shall be
c)
d)
1.3.3.
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clean, sharp, hard, strong and durable and shall be free from dust, vegetable substances, adherent coating, clay alkali, organic matter, mica, salt, or other deleterious substances, which can be injurious to setting qualities/strength/durability of concrete. i) SCREENING AND WASHING Sand shall be prepared for use by such screening or washing, or both as necessary to remove all objectionable foreign matter while separating the sand grains to the required size fractions. FOREIGN MATERIAL LIMITATIONS The percentages of deleterious substances in sand delivered to the mixer shall not exceed the following. Percent by weight Uncrushed Crushed Material finer than 75 micron I.S. sieve 3.00 15.00 Shale 1.00 -Coal and lignite 1.00 1.00 Clay lumps 1.00 1.00 Total of all the above substances including items (i) to (iv)for uncrushed 5.00 2.00 sand and items (iii) and (iv) for crushed sand. _______________________________________________________________ iii) GRADATION Unless and otherwise directed or approved, the grading of sand shall be within the limits indicated hereunder: I.S. Sieve Designation grading Zone-I 10 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron 100 90-100 60-95 30-70 15-34 5-20 0-10 Percentage passing for Zone-II Zone-III 100 90-100 75-100 55-90 35-59 8-30 0-10 100 90-100 85-100 75-90 60-79 12-40 0-10 i) ii) iii) iv) v)
ii)
Zone-IV 100 95-100 95-100 90-100 80-100 15-50 0-15
Where the grading falls outside the limits of any particular grading zone of sieves, other than 600 I.S. Sieve, by total amount not
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exceeding 5 percent, it shall be regarded as falling within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron I.S. sieve or to percentage passing any other sieve size on the coarser limit of Grading Zone-I or the finer limit of Grading Zone-IV. Fine aggregates conforming to Grading Zone-IV shall be used unless mix designs and preliminary tests have shown its suitability for producing concrete of specified strength and workability. iv) FINENESS MODULUS The sand shall have fineness modulus of not less than 2.2 or more than 3.2. The fineness modulus is determined by adding the cumulative percentages retained on the following I.S. sieve sizes (4.75mm, 2.36mm, 1.18mm, 600 micron, 300 micron and 150 micron) and dividing the sum by 100.
1.3.4. COARSE AGGREGATE Coarse aggregate for concrete, except as noted above and for other than lightweight concrete shall conform to I.S. 383. This shall consist of natural stone and shall be clean, and free from elongated, flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali, mica, organic matter of other deleterious matter. i) GRADING Coarse aggregate shall be either in single size or graded. In both cases, the grading shall be within following limits. ---------------------------------------------------------------------------------------IS Percentage Passing for Percentage Sieve single aggregate of passing for Designominal size graded aggregate of nation nominal size --------------------------------------------------------------------------------------40 20 16 12.5 10 40 20 16 12.5 mm mm mm mm mm mm mm mm mm -------------------------------------------------------------------------------------63mm 100 ----100 ---40mm 85-100 100 ---95-100 100 --20mm 0-20 85-100 100 --30-70 95-100 100 -16mm --85-100 100 ---90-100 -10mm 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85 4.75mm -0-5 0-5 0-10 0-10 0-10 0-10 0-10 0-10 2.36mm ----0-5 --------
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The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable flaky and laminated pieces, mica and shale, if present, shall be only in such quantities that will not in the opinion of ENGINEER, affect adversely, the strength and/or durability of concrete. The maximum size of coarse aggregate shall be 40mm for class A concrete and 20mm for class B concrete. The maximum size of coarse aggregate shall be the maximum size specified above but in no case greater than 1/4 of the maximum thickness of the member, provided that the concrete can be placed without difficulty so as to surround all reinforcement thoroughly and fill the corners of the form. For heavily reinforced concrete member, the nominal maximum size of the aggregate shall be 5mm less than the minimum clear distance between the reinforcing main bars or 5mm less than the minimum cover to the reinforcement whichever is smaller. The amount adherent shall not exceed 1% when determined by laboratory sedimentation tests as per I.S.2386. After 24 hours immersion in water, a previously dried sample shall not have gained more than 10% of its over dry weight in air, as determined by I.S.2386. i) FOREIGN MATERIAL LIMITATIONS The percentage of deleterious substance in the delivered to the mixer shall not exceed the following: Uncrushed i) Material finer than 75 micron I.S.sieve ii) Coal and lignite iii)Clay lumps iv) Soft Fragments v) Total of all the above substances 1.4. a) 3.00 1.00 1.00 3.00 5.00
aggregate
Percent by weight Crushed 3.00 1.00 ----
WATER Water used for both mixing of mortar / concrete and curing shall be free from injurious amounts of deleterious materials. Potable water is generally satisfactory for mixing of mortar / concrete and curing concrete. The relevant essential Water tests pertaining to access the suitability for construction standards shall have to be done before commencement of work.
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b)
The suitability of water for making concrete shall be ascertained by the compressive strength and initial setting time test specified in I.S.456. The sample of water taken for testing shall be typical of the water proposed to be used for concreting, due account being paid to seasonal variation. The sample shall not receive any treatment before testing other than that envisaged in the regular supply of water proposed for use in concrete. The sample shall be stored in a clean container previously rinsed out with similar water. Average 28 days compressive strength of atleast three 150mm concrete cubes prepared with water proposed to be used shall not be less than 90% of the average strength of three similar concrete cubes prepared with distilled water. The initial setting time of test block made with the appropriate test cement and the water proposed to be used shall not be less than 30minutes and shall not differ by more than 30 minutes from the initial setting time of control test block prepared with the appropriate test cement and distilled water. The test blocks shall be prepared and tested in accordance with the requirements of I.S.4031. Where water can be shown to contain an excess of acid, alkali, sugar or salt, ENGINEER may refuse to permit its use. As a guide, the following concentrations represent the maximum permissible values. To neutralise 100 ml sample of water, using phenolphthalein as indicator, it should not require more than 5 ml. of 0.02 Normal NaOH. The details of test shall be as given in IS.3025. To neutralise 200ml sample of water using methyl orange as an indicator, it should not require more than 10ml of 0.1. Normal HCL. The details of test shall be as given in IS.3025. Presence of solids, when tested in accordance with the method indicated below, shall not exceed the following: Percent Method of Test (Ref. to Clause No. in S.3025/60) Organic 0.02 10 & 11 (Organic Solids Total solids minus Ignited Residue)
c)
d)
e)
(i)
(ii)
(iii)
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Inorganic Sulphates (as SO4) Alkali Chlorides (as Cl) 1.5. i)
0.30 0.05 0.20
11 (Ignited residue) 20 24
REINFORCEMENT SUPPLY The supply of steel shall be arranged by the contractor himself. Reinforcement if supplies are arranged by CONTRACTOR shall be either plain round mild bars Grade 1 as per IS.432 (Part 1) or medium tensile steel bars as per IS.432 (Part 1)and High Yield Strength deformed bars of minimum Fe 415 grade as per IS:1786. Wire mesh or fabric shall be in accordance with IS 1566. Substitution of reinforcement will not be permitted except upon written approval from ENGINEER. No advance amounts shall be paid to the contractor towards purchase of steel. Note The tenderer, in his tender, shall give details of Fe 415 grade. viz. sizes (diameter) available, necessary test reports and manufacturers certificate on the every consignment of steel that are brought to site shall be furnished to the Engineer then and there and approval of Engineer shall be obtained before proceeding the works.
ii) a)
STORAGE The reinforcement shall not be kept in direct contact with the ground but stacked on top of an arrangement of timber sleepers or the like. If the reinforcing rods have to be stored for long duration, they shall be coated with cement wash before stacking and/or be kept under cover or stored as directed by ENGINEER. Fabricated reinforcement shall be carefully stored to prevent damage, distortion, corrosion and deterioration. QUALITY All steel shall be of Grade-I quality unless specifically permitted by ENGINEER. No re-rolled material will be accepted. If demanded by ENGINEER, CONTRACTOR shall submit the manufacturers test
b)
c)
iii) a)
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certificate for steel. Random tests on steel supplied by CONTRACTOR may be performed by OWNER as per relevant Indian Standards. All costs incidental to such tests shall be at "CONTRACTOR's expense. Steel not conforming to Specifications shall be rejected. b) All reinforcement shall be clean, free from grease, oil, and paint, dirt loose mill scale, loose rust, dust bituminous material or any other substances that will destroy or reduce the bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used. All bars shall be rigidly held in position before concreting. No welding of rods to obtain continuity shall be allowed unless approved by ENGINEER. If welding is approved, the work shall be carried out as per I.S.2751 according to best modern practices and as directed by ENGINEER. In all cases of important connections, tests shall be made to prove that the joints are of the full strength of bars welded. Special precautions, as specified by ENGINEER, shall be taken in the welding of cold worked reinforcing bars and bars other than mild steel. LAPS Laps and splices for reinforcement shall be as shown on the drawings. Splices in adjacent bars shall be staggered and the locations of all splices, except those specified on the drawings, shall be approved by ENGINEER. The bars shall not be lapped unless the length required exceeds the maximum available lengths of bars at site. BENDING Reinforcing bars supplied bent or in coils, shall be straightened before they are cut to size. Straightening of bars shall be done in cold and without damaging the bars. This is considered as a part of reinforcement bending fabrication work. All bars shall be accurately bent according to the sizes and shapes shown on the detailed working drawings/ bar bending schedules. They shall be bent gradually by machine or other approved means. Reinforcing bars shall not be straightened and re-bent in a manner that will injure the material. Bars containing cracks or splits shall be rejected. They shall be bent cold, except bars of over 25mm in diameter which may be bent hot if specifically approved by ENGINEER, Bars which depend for their strength on cold working, shall not be bent hot, shall not be heated beyond cherry red colour (not exceeding
iv)
v) a)
b)
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845C) and after bending shall be allowed to cool slowly without quenching. Bars incorrectly bent shall be used only if the means used for straightening and re-bending be such as shall not, in the opinion of ENGINEER, injure the material. No reinforcement shall be bent when in position in the work without approval, whether or not it is partially embedded in hardened concrete. Bars having kinks or bends other than those required by design shall not be used. vi) FIXING Reinforcement shall be accurately fixed by any approved means and maintained in the correct position shown in the drawings by the use of blocks, spacers and chairs as per IS.2503 to prevent displacement during placing and compaction of concrete. Bars intended to be in contact at crossing points shall be securely bound together at all such points with number 16 gauge annealed soft iron wire. The vertical distances required between successive layers of bar in beams or similar members shall be maintained by the provision of mild steel spacer bars at such intervals that the main bars do not perceptibly sag between adjacent spacer bars. COVER The cover to reinforcement shall be in accordance with clause 26.4 of IS 456-2000. Unless indicated otherwise on the drawings, clear concrete cover for reinforcement (exclusive of plaster or other decorative finish) shall be as follows: At each end of reinforcing bar, not less than 25mm or less than twice the diameter of the bar. For a longitudinal reinforcing bar in a column, not less than 40mm, not less than the diameter of the bar. In case of columns, of minimum dimension of 200mm or under with reinforcing bars of 12mm and less in diameter, a cover of 25mm may be used. For longitudinal reinforcing bars in a beam, not less than 25mm, nor less than the diameter of the bar. For tensile, compressive, shear or other reinforcement in a slab or wall not less than 15mm or less than diameter of such reinforcement. For any other reinforcement not less than 15mm nor less than the diameter of such reinforcement. For footings and other principal structural members in which the concrete is deposited directly against the ground, cover to the bottom reinforcement shall be 75mm. If concrete is poured on layer of lean concrete the bottom cover may be reduced to 50mm.
vii)
a) b)
c) d) e) f)
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g)
h)
i)
j)
k)
l)
m)
n)
For concrete surface exposed to the weather / the ground after removal of forms, such as retaining walls, grade beams, footing sides and top etc., not less than 50mm for bars larger than 16mm dia nor less than 40mm for bars 16mm dia or smaller. Increased cover thickness shall be provided as indicated on the drawings, for surfaces exposed to the action of harmful chemicals (or exposed to earth contaminated by such chemical), acid, alkali, saline atmosphere, sulphurous smoke etc. For reinforced concrete members, totally or periodically immersed in sea water or subject to sea water spray, the cover of concrete shall be 50mm more than specified in (a) to (e) above. For liquid retaining structures, the minimum cover to all steel shall be 40mm or the diameter of the main bar, whichever is greater. In the presence of sea water and soils and water of a corrosive character the cover shall be increased by 10mm. Protection to reinforcement in case of concrete exposed to harmful surroundings may also be given by providing dense impermeable concrete with approved protective coatings, as specified on the drawings. In such a case, the extra cover mentioned in (h) and (i) above, may be reduced by ENGINEER to those shown on the drawings. The correct cover shall be maintained by cement mortar cubes or other approved means. Reinforcement for footings, grade beams and slabs on subgrade shall be supported on precast concrete blocks as approved by ENGINEER. The use of pebbles or stones shall not be permitted The 28 days crushing strength of cement mortar cubes precast concrete cover blocks shall be atleast equal to the specified strength of concrete in which these cubes blocks are embedded. The minimum clear distance between reinforcing bars shall be in accordance with IS.456 or as shown in drawings. INSPECTION Erected and secured reinforcement shall be inspected and approved by ENGINEER prior to placement of concrete. For all sub stations taken up in coastal areas fusion bonded epoxy coating reinforcement steel shall be used. CONSISTENCY AND SLUMP The concrete mix proportions chosen should be such that the concrete is of adequate workability for the placing conditions of the concrete
viii)
ix)
1.6. a)
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and can properly be compacted with the means available. Suggested ranges of workability of concrete measured in accordance with IS 1199 are given below: Placing Conditions Blinding concrete; Shallow sections; Pavements using pavers Mass concrete; Lightly reinforced Sections in slabs, Beams, walls, columns; Floors; Hand placed pavements; Canal lining; Strip footings. Degree of Workability Very low Low Slump (mm) See5.6.below 25-75
Heavily reinforced sections in slabs, beams, walls, columns, slip formwork, Pumped concrete. Trench fill, In situ piling. Tremie concrete
Medium High Very high
50-100 75-100 100-150 See 5.6.c below
NOTE: For most of the placing conditions, internal vibrators (needle vibrators) are suitable.The diameter of the needle shall be determined based on the density and spacing of reinforcement bars and thickness of sections. For tremie concrete, vibrators are not required to be used. b) In the 'very low" category of workability where strict control is necessary, for example pavement quality concrete, measurement of workability by determination of compacting factor will be more appropriate than slump (see. IS 1199) and a value of compacting factor of 0.75 to 0.80 is suggested. In the 'very high' category of workability, measurement of workability by determination of flow will be appropriate (see IS 9103) TESTING OF CUBES Arrangement shall be made by CONTRACTOR to have the cubes tested in an approved laboratory at his expense, with the prior consent of the ENGINEER.
c)
1.7.
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i)
SAMPLING FOR STRENGTH OF CONCRETE At least 6 test cubes of each class of concrete shall be made for every 15 cu.m. concrete or part thereof. At least one sample shall be taken from each shift. Such samples shall be drawn on each day for each type of concrete. Of each set of 6 cubes, three shall be tested at 7 days age and three at 28 days age. The laboratory test results shall be tabulated and furnished to ENGINEER. ENGINEER will pass the concrete if the acceptance criteria as per clause 16 of IS: 456-2000 is met with. NOMINAL / DESIGN MIX CONCRETE Concrete grade shall be designated on drawings. Concrete in the works shall be "DESIGN MIX CONCRETE or "NOMINAL MIX CONCRETE. Design mix is preferred to nominal mix. If design mix concrete can not be used for any reason on the work for Grades M25 or lower, nominal mixes may be used with permission from Engineer. CONCRETE grade M25 and above shall be DESIGN MIX CONCRETE. DESIGN MIX CONCRETE For Design Mix Concrete, the mix shall be designed according to IS: 10262 and SP: 23 to provide the grade of concrete having the required workability and characteristic strength not less than appropriate values given in IS: 456. The design mix shall in addition be such that it is cohesive and does not segregate and should result in dense and durable concrete and also capable of giving the finish as specified. For liquid retaining structures, the mix shall also result in water tight concrete. The CONTRACTOR shall exercise great care while designing the concrete mix and executing the works to achieve the desired result. The minimum cement content for different grades of Concrete for RCC / P.C.C works shall be as per IS 456-2000 or as specified in the drawings/schedule. It shall be CONTRACTOR's sole responsibility to carry out the mix designs in a reputed Institution / Research Institute at his own cost. He shall furnish to ENGINEER at least 30 days before concreting operations, a statement of proportions proposed to be used for the various concrete mixes and the strength results obtained. The strength requirements of the concrete mixes ascertained on 150mm cubes as per IS: 516 shall comply with the requirements of IS: 456.
ii)
a)
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(b)
CONSISTENCY Slump tests shall be carried out as often as demanded by ENGINEER and invariably from the same batch of concrete from which the test cubes are made. Slump tests shall be done immediately after sampling. ADMIXTURES Admixtures may be used in concrete only with the approval of ENGINEER based upon evidence that, with the passage of time, neither the compressive strength nor its durability reduced. Calcium chloride shall not be used for accelerating setting of the cement for any concrete containing reinforcement, or embedded steel parts. When calcium chloride is permitted to be used, such as in mass concrete works, it shall be dissolved in water and added to mixing water in an amount not to exceed 1 percent of the weight of the cement in each batch of concrete. When admixtures are used, the designed concrete mix shall be corrected accordingly. Admixtures shall be used as per manufacturers instructions and in the manner and with the control specified by ENGINEER. No extra cost will be paid for admixtures. Water Proofing Agent Where specified and approved by ENGINEER, water proofing agent conforming to IS.2645, shall be added in quantity specified by Engineer.
1.8.
1.9. a)
TESTS Engineer if he so desires may order tests to be carried out on cement, sand, coarse aggregate, water in accordance with the relevant Indian Standards. Tests on cement shall include fineness test test for normal consistency test for setting time test for soundness test for tensile strength test for compressive strength test for heat of hydration (by experiment and by calculations) in accordance with IS: 269.
i) ii) iii) iv) v) vi) vii)
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i) ii) iii) iv) v) vi)
Tests on sand shall include. Sieve test test for organic impurities. Decantation test for determining clay and silt content specific gravity test test for unit weight and bulkage factor test for sieve analysis and fineness modulus.
i) ii) iii) iv) v) vi) vii)
Tests on coarse aggregate shall include. Sieve analysis specific gravity and unit weight of dry, loose and clodded aggregate. Soundness and alkali aggregate reactivity. Petrographic examination. Deleterious materials and organic impurities. Test for aggregate crushing value. Any or all these tests would normally be ordered to be carried out only if ENGINEER feels the materials are not in accordance with the specifications or if the specified concrete strengths are not obtained and shall be performed by CONTRACTOR or at an approved test laboratory. If the test cubes of the work do not give the stipulated strengths, ENGINEER reserves the right to ask CONTRACTOR to dismantle such portions of the work, which in his opinion are unacceptable and re-do the work to the standard stipulated at CONTRACTORs cost. The unit rate for concrete shall be all-inclusive, including making preliminary mix design and test cubes, works-cubes, testing them as per Specification, slump tests, optional tests, etc. complete. LOAD TEST ON MEMBERS OR ANY OTHER TESTS: In the event workmanship reconstruction be load tested of any work being suspected of faulty materials or or both, ENGINEER requiring its removal and may order, or CONTRACTOR may request that it should in accordance with the following provisions.
b)
c)
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i)
The test load shall be 125 percent of the maximum superimposed load for which the structure was designed. Such test load shall not be applied before 56 days after the effective hardening of concrete. During the test, struts strong enough to take the whole load shall be placed in position leaving a gap under the members. The test load shall be maintained for 24 hours before removal. If within 24 hours of the removal of the load, the structure does not show a recovery of at least 75 percent of the maximum deflection shown during the 24hours under load, the test loading shall be repeated after a lapse of at least 72hours. The structure shall be considered to have failed to pass the test if the recovery after the second test is not at least 75 percent of the maximum deflection shown during the second test. If the structure is certified as failed by the ENGINEER, the cost of the load test shall be borne by the CONTRACTOR. Any other tests, e.g. taking out in an approved manner concrete cores, examination and tests on such cores removed from such parts of the structure as directed by ENGINEER, sonic testing etc. shall be carried out by CONTRACTOR if so directed. UNSATISFACTORY TESTS Should the results of any test prove unsatisfactory, or the structure shows signs of weakness, undue deflection or faulty construction CONTRACTOR shall remove and rebuild the member or members involved or carry out such other remedial measures as may be required by ENGINEER/ OWNER. CONTRACTOR shall bear the cost of redoing, unless the failure of the member or members to fulfil the test conditions is proved to be solely due to faulty design.
ii)
iii)
d)
1.10. PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL INSPECTION AND APPROVAL (a) Before the concrete is actually placed in position, the inside of the formwork shall be inspected to see that they have been cleaned and oiled. Temporary openings shall be provided to facilitate inspection, especially at bottom of columns and wall forms, to permit removal of saw dust, wood shavings, binding wire, rubbish, dirt etc. Openings shall be placed or holes drilled so that these materials and water can be removed easily. Such openings/ holes shall be later suitably plugged.
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(b)
The various trades shall be permitted ample time to install drainage and plumbing lines, floor and trench drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames, and other miscellaneous embedment to be cast in the concrete as indicated on the drawings or as is necessary for the proper execution of the work. CONTRACTOR shall co-operate fully with all such agencies, and shall permit the use of scaffolding, formwork etc. by other trades at no extra cost. All embedded parts, inserts etc. supplied by OWNER or CONTRACTOR shall be correctly positioned and securely held in the forms to prevent displacement during depositing and vibrating of concrete. All anchor bolts shall be positioned and kept in place with the help of properly manufactured templates unless specifically waived in writing by ENGINEER. The use of all such templates, fixtures etc. shall be deemed to be included in the rates. Slots, openings, holes, pockets etc. shall be provided in the concrete work in the positions indicated in the drawings or as directed by ENGINEER. Reinforcement and other items to be cast in concrete shall have clean surfaces that will not impair bond. Prior to concrete placement all work shall be inspected and approved by ENGINEER and if found unsatisfactory, concrete shall not be poured until after all defects have been corrected at CONTRACTORs cost. Approval by ENGINEER of any and all materials and work as required herein shall not relieve CONTRACTOR from his obligation to produce finished concrete in accordance with the drawings and Specifications. RAIN OR WASH WATER No concrete shall be placed in wet or on a water-covered surface. Any concrete that has been washed by heavy rains shall be entirely removed, if there is any sign of cement and sand having been washed away from the concrete mixture. To guard against damage, which may be caused by rains, the works shall be covered with tarpaulins immediately after the concrete has been placed and compacted before leaving the work unattended. Any water accumulating on the surface of the newly placed concrete shall be removed by approved means and
(c)
(d)
(e)
(f)
(g)
(h)
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no further concrete shall be placed thereon until such water is removed. To avoid flow of water over/ all-round freshly placed concrete, suitable drains and sumps shall be provided. (i) BONDING MORTAR Immediately before concrete placement begins, prepared surfaces except formwork, which will come in contact with the concrete to be placed shall be covered with a bonding mortar.
1.11. TRANSPORTATION a) All buckets, containers, or conveyer used for transporting concrete shall be mortar-tight. Irrespective of the method of transportation adopted, concrete shall be delivered with the required consistency and plasticity without segregation or loss of slump. However, chutes shall not be used for transport of concrete without the written permission of Engineer and concrete shall not be re-handled before placing. b) RETEMPERED OR CONTAMINATED CONCRETE Concrete must be placed in the final position before it becomes too stiff to work. On no account water shall be added after the initial mixing. Concrete, which has become stiff or has been contaminated with foreign materials shall be rejected and disposed off as directed by ENGINEER. CLEANING OF EQUIPMENT All equipment used for mixing, transporting and placing of concrete shall be maintained in clean condition. All pans, buckets, hoppers, chutes, pipelines and other equipment shall be thoroughly cleaned after each period of placement. ENGINEERS
c)
1.12 PROCEDURE FOR PLACING OF CONCRETE: APPROVAL OF EQUIPMENT & METHODS a)
Before any concrete is placed, the entire placing programme, consisting of equipment, layout, proposed procedures and methods shall be submitted to ENGINEER for approval if so demanded by ENGINEER and no concrete shall be placed until ENGINEER's approval has been received. Equipment for conveying concrete shall be of such size and design as to ensure a practically continuous flow of concrete during depositing without segregation of materials considering the size of the job and placement location.
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b)
TIME INTERVAL BETWEEN MIXING AND PLACING Concrete shall be placed in its final position before the cement reaches its initial set and concrete shall normally be compacted in its final position within thirty minutes of leaving the mixer, and once compacted it shall not be disturbed. AVOIDING SEGREGATION Concrete shall, in all cases, be deposited as nearly as practicable directly in its final position, and shall not be re-handled or caused to flow in a manner which will cause segregation, loss of materials, displacement of reinforcement, shuttering or embedded inserts or impair its strength. For locations where direct placement is not possible, and in narrow forms, contractor shall provide suitable drop and "Elephant Trunks to confine the movement of concrete. Special care shall be taken when concrete is dropped from a height, especially if reinforcement is in the way, particularly in columns and thin walls.
c)
d ) PLACING BY MANUAL LABOUR Except when otherwise approved by Engineer, concrete shall be placed in the shuttering by shovels of other approved implements and shall not be dropped from a height more than 1.0metre or handled in a manner, which will cause segregation. e) i) PLACING BY MECHANICAL EQUIPMENT The following specification shall apply when placing of concrete by use of mechanical equipment is specifically called for while inviting bids or is warranted considering the nature of work involved. The control of placing shall begin at the mixer discharge. Concrete shall be discharged by a vertical drop into the middle of the bucket or hopper and this principle of vertical discharge of concrete shall be adhered to throughout all stages of delivery until the concrete comes to rest in its final position. ii) TYPE OF BUCKETS Central-bottom-dump buckets of a type that provides for positive regulation of the amount and rate of deposition of concrete in all dumping position, shall be employed.
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iii) OPERATION OF BUCKET In placing concrete in large open area, the bucket shall be spotted directly over the position designated and then lowered for dumping. The open bucket shall clear the concrete already in place and the height of drop shall not exceed 1.00m. The bucket shall be opened slowly to avoid high vertical bounce. Dumping of buckets on the swing in any manner, that results in separation of ingredients or disturbance of previously placed concrete, will not be permitted. f) PLACEMENT IN RESTRICTED FORMS Concrete placed in restricted form by barrow, buggies, cars, short chutes or hand shovelling shall be subject to the requirements for vertical delivery of limited height to avoid segregation and shall be deposited as nearly as practicable in its final position.
1.13. CHUTING Where it is necessary to use transfer chutes, specific approval of Engineer must be obtained to type, length, slopes, baffles, vertical terminals and timing of operations. These shall be so arranged that an almost continuous flow of concrete is obtained at the discharge and without segregation. To allow for the loss of mortar against the sides of the chutes, the first mixes shall have less coarse aggregate. During cleaning of chutes, the waste water shall be kept clear of the forms. Concrete shall not be permitted to fall from the end of the chutes by more than 1m.Chutes when approved for use shall have slopes not flatter than 1 vertical :3 horizontal and not steeper than 1vertical :2 horizontal. Chutes shall be of metal or metal lined and of rounded cross section. The slopes of all chute sections shall be approximately the same. The discharge end of the chutes shall be maintained above the surface concrete in the forms. 1.14 PLACING CONCRETE IN LAYERS Concreting, once started, shall be continuous until the pour is completed. Concrete shall be placed in successive horizontal layers of uniform thickness ranging from 150 to 900 mm as directed by Engineer. These shall be placed as rapidly as practicable to prevent the formation of cold joints or planes of weakness between each succeeding layer within the pour. The thickness of each layer shall be such that it can be deposited before the previous layer has stiffened. The bucket leads or other units of Deposit shall be spotted progressively along the face of the layer with such overlap as will
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facilitate spreading the layer to uniform depth and texture with a minimum of shovelling. Any tendency to segregation shall be corrected by shovelling stones into mortar rather than mortar on to stones. Such a condition shall be corrected by redesign of mix or other means, as directed by Engineer. 1.15. BEDDING OF LAYERS The top surface of each pour and bedding planes shall be approximately horizontal unless otherwise instructed. 1.16. COMPACTION Concrete shall be compacted during placing, with approved vibrating equipment until the concrete has been consolidated to the maximum, practicable density, is free of pockets of coarse aggregate and fits rightly against all form surfaces, reinforcement and embedded fixtures. Particular care shall be taken to ensure that all concrete placed against the form faces and into corners of forms or against hardened concrete at joints is free from voids or cavities. The use of vibrators shall be consistent with the concrete mix and caution exercised not to over vibrate the concrete to the pointing that segregation result. i) TYPE OF VIBRATORS Vibrators shall conform to IS specifications. Type of vibrator to be used shall depend on the structure where concrete is to be placed. Shutter vibrators to be effective, shall be firmly secured to the formwork which must be sufficiently rigid to transmit the vibration and strong enough not to be damaged by it. Immersion vibrators shall have "no load frequency, amplitude and acceleration as per I.S.2505 depending on the size of the vibrator. Immersion vibrators in sufficient numbers and each of adequate size shall be used to properly consolidating all concrete. Tapping of external vibrating of forms by hand tools or immersion vibrators will not be permitted. ii) USE OF VIBRATORS The exact manner of application and the most suitable machines for the purpose must be carefully considered and operated by experienced men. Immersion vibrators shall be inserted vertically at joints not more than 450mm apart and withdrawn when air bubbles cease to come to the surface. Immersion vibrators shall be withdrawn very slowly. In no case shall immersion vibrators be used to transport concrete inside the vibration at the top of a lift e.g. in column or wall.
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iii)
MOULDING SUCCESSIVE BATCHES When placing concrete in layer, which are advancing horizontally as the work progress, great care shall be exercised to ensure adequate vibration, blending and moulding of the concrete between the succeeding layers. PENETRATION OF VIBRATOR The immersion vibrator shall penetrate the layer being placed and also penetrate the layer below while the under layer is still plastic to ensure good bond and homogeneity between the two layers and prevent the formation of cold joints. VIBRATING AGAINST REINFORCEMENT Care shall be taken to prevent contact of immersion vibrators against reinforcement steel. Immersion vibrators shall not be allowed to come in contact with reinforcement steel after start of initial set. They shall also not be allowed to come in contact with forms or finished surfaces. USE OF FORM ATTACHED VIBRATORS Form attached vibrators shall be used only with specific authorisation of ENGINEER. USE OF SURFACE VIBRATORS The use of surface vibrators will not be permitted under normal conditions. However, for thin slabs, such as highways, runways and similar construction, surface vibration by specially designed vibrators may be permitted, upon approval of ENGINEER.
iv)
v)
vi)
vii)
1.17. STONE POCKETS AND MORTAR BONDAGES The formation of stone pockets or mortar pondages in corners and against faces of forms shall not be permitted. Should these occur, they shall be dug out, reformed and refilled to sufficient depth and shape for thorough bonding, as directed by ENGINEER. 1.18. PLACEMENT INTERVAL Except when placing with slip forms, each placement of concrete in multiple lift work, shall be allowed to set for at least 24 hours after the final set of concrete and before the start of a subsequent placement.
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1.19. SPECIAL PROVISION IN PLACING When placing concrete in walls with openings, in floors, of integral slab and beam construction and other similar conditions, the placing shall stop when the concrete reaches the top of the opening in walls or bottom horizontal surface of the slab, as the case may be. Placing shall be resumed before the concrete in place takes initial set, but not until it has had time to settle as determined by ENGINEER. 1.20. PLACING CONCRETE THROUGH REINFORCING STEEL When placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarse aggregate. Where the congestion of steel make placing difficult it may be necessary to temporarily move the top steel aside to get proper placement and restore reinforcing steel to design position. 1.21. BLEEDING Bleeding or free water on top of concrete being deposited into the forms shall be a cause to stop the concrete pour and the conditions causing this defect corrected before any further concreting is resumed. 1.22. CONSTRUCTION JOINTS AND KEYS a) Concrete shall be placed without interruption until completion of the part of the work between predetermined construction joints, as specified herein after. Time lapse between the pouring of adjoining units shall be as specified on the drawing or as directed by ENGINEER. b) If stopping of concreting becomes unavoidable anywhere, a properly formed construction joint shall be made where the work is stopped. Joints shall be either vertical or horizontal, unless shown otherwise on drawings. In case of an inclined or curved member, the joints shall be at right angles to the axis of the member. Vertical joints in walls shall be kept to a minimum. Vertical joints shall be formed against a stop board: horizontal joints shall be level and wherever possible arranged so that the joint lines coincide with the architectural features of the finished work. Battens shall be nailed to the formwork to ensure a horizontal line and if directed, shall also be used to form a grooved joint. For tank walls and similar work, joints shall be formed as per I.S.3370. Concrete that is in the process of setting shall not be disturbed or shaken by traffic either on the concrete itself or upon the shuttering.
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Horizontal and vertical construction joints and shear keys shall be located and shall conform in detail to the requirements of the plans unless otherwise directed by ENGINEER. Where not described, the joint shall be in accordance with the following. 1.23. COLUMN JOINT In a column, the joint shall be formed 75mm below the lowest soffit of the beams including haunches if any. In flat slab construction, the joint shall be 75mm below the soffit of column capital. At least 2 hours shall elapse after depositing concrete in columns, piers or walls, before depositing in beams, girders or slabs supported thereon. 1.24 BEAM AND SLAB JOINTS Concrete in a beam shall be placed throughout without a joint but if the provision of a joint is unavoidable the joint shall be vertical and at the centre or within the middle third of the span unless or otherwise shown on drawings. Where a beam intersects a girder, the joints in the girder shall offset a distance equal to twice the width of the beam and additional reinforcement provided for shear. The joints shall be vertical throughout the full thickness of the concrete member. All joints in a slab shall be vertical and parallel to the principal reinforcement. Where it is unavoidably at right angles to the principal reinforcement, the joint shall be vertical and at the middle of the span. 1.25. JOINT IN LIQUID RETAINING STRUCTURES Vertical construction joints in watertight construction will not be permitted unless indicated on the drawings. Where a horizontal construction joint is required to resist water pressure, special care shall be taken in all phases of its construction to ensure maximum water tightness. 1.26. DOWELS Dowels for concrete work, not likely to be taken up in the near future, shall be wrapped in tar paper and burlap. 1.27. MASS FOUNDATIONS Mass foundations shall be poured in lifts not exceeding 1.5m in height unless otherwise indicated on the drawings or approved by Engineer.
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1.28. TREATMENT OF CONSTRUCTION JOINTS ON RESUMING CONCRETING A drier mix shall be used for the top lift of horizontal pours to avoid laitance. All laitance and loose stones shall be thoroughly and carefully removed by wire brushing/backing and surface washed. Just before concreting is resumed, the roughened joint surface shall be thoroughly cleaned and loose matter removed and then treated with a thin layer of cement grout of proportion specified by Engineer and worked well into the surface. The new concrete shall be well worked against the prepared face before the grout mortar sets. Special care shall be taken to obtain thorough compaction and to avoid segregation of the concrete along the joint plane. 1.29 CURING, PROTECTING, REPAIRING AND FINISHING CURING All concrete shall be cured by keeping it continuously damp for the period of time required for complete hydration and hardening to take place. Preference shall be given to the use of continuous sprays, or ponded water, continuously saturated coverings of sacking, canvas, hessian or other absorbent materials, or approved effective curing compounds applied with spraying equipment capable of producing a smooth, even textured coat. Extra precautions shall be exercised in curing concrete during cold and hot weather as outlined herein after. The quality of curing water shall be the same as that used for mixing concrete . Certain types of finish or preparation for overlaying concrete must be done at certain stages of the curing process and special treatment may be required for specific concrete surface finish. CURING WITH WATER Fresh concrete shall be kept continuously wet for a minimum period of 10 days of placing of concrete, following a lapse of 12 to 14hours after laying concrete. The curing of horizontal surfaces executed during winds shall however begin immediately the concrete has hardened. Water shall be applied to unformed concrete surfaces, within 1hour after concrete has set. Water shall be applied to formed surfaces immediately upon removal of forms. Quantity of water applied shall be controlled so as to prevent erosion of freshly placed concrete.
ii)
iii)
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iv)
CONTINUOUS SPRAYING Curing shall be assured by use of ample water supply under pressure in pipes, with all necessary appliances of hose, sprinklers and spraying devices. Continuous fine mist spraying or sprinkling shall be used unless otherwise specified or approved by ENGINEER. ALTERNATIVE CURING METHODS Wherever in the judgment of ENGINEER, it may be necessary to omit the continuous spray method, covering of clean sand or other approved means such as wet gunny bags which will prevent loss of moisture from the concrete, may be used. No type of covering will be approved which would stain or damage the concrete during or after the curing period. Covering shall be kept continuously wet during the curing period. CURING EQUIPMENT All equipment and materials required for curing shall be on hand and ready for use before concrete is placed. PROTECTING FRESH CONCRETE Fresh concrete shall be protected from the elements, from defacements and damage due to construction operations by leaving forms in place for an ample period as specified later in this specification. Newly placed concrete shall be protected by approved means such as tarpaulins from rain, sun and winds. Steps as approved by Engineer shall also be taken to protect immature concrete from damage by debris, excessive loading vibration, abrasion or contact with other materials etc. that may impair the strength and or durability of the concrete. Workman shall be warned against and prevented from disturbing green concrete during its setting period. If it is necessary that workmen enter the area of freshly placed concrete, ENGINEER may require that bridges be placed over the area. REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE Immediately after the shuttering is removed, the surface of concrete shall be very carefully gone over and all defective areas called to the attention of ENGINEER who may permit patching of the defective areas or also reject the concrete unit either partially or in its entirety. Rejected concrete shall be removed and replaced by CONTRACTOR at no additional expense to owner. Holes left by form bolts etc. shall be filled up and made good with mortar composed of one part of cement
v)
vi)
vii)
viii) a)
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to one and half parts of sand passing 2.36 mm IS sieve after removing any loose stones adhering to the concrete. Mortar filling shall be struck off flush at the face of the concrete. Concrete surfaces are finished as described under the particular items of work. b) Superficial honey combed surface and rough patches shall be similarly made good immediately after removal of shuttering, in the presence of ENGINEER and superficial water and air holes shall be filled in. The mortar shall be well worked into the surface with a wooden float. Excess water shall be avoided. Unless instructed otherwise by ENGINEER, the surface of the exposed, concrete placed against shuttering shall be rubbed down immediately on removal of shuttering to remove fine or other irregularities, care being taken to avoid damaging the surface. Surface irregularities shall be removed by grinding. If reinforcement is exposed or the honey combing occurs at vulnerable position e.g. ends of beams and columns it may be necessary to cut out the member completely or in part and reconstruct. The decision of Engineer shall be final in this regard. If only patching is necessary, the defective concrete shall be cut out till solid concrete is reached (or to a minimum depth of 25mm) the edges being cut perpendicular to the affected surface or with a small under cut if possible. Anchors, tees or dovetail slots shall be provided whenever necessary to attach the new concrete securely in place. An area extending several centimetres beyond the edge and the edges and the surfaces of the prepared voids shall be saturated with water for 24 hours immediately before the patching material is placed. USE OF EPOXY The use of epoxy for bonding fresh concrete used for repairs will be permitted upon written approval of ENGINEER. Epoxies shall be applied in strict accordance with the instructions of the manufacturer. METHOD OF REPAIR Small size holes having surface dimension about equal to the depth of the hole, holes left after removal of form bolts, grout insert holes and slots cut for repair of cracks shall be repaired as follows. The holes to be patched shall be roughened and thoroughly soaked with clean water until absorption stops. A 5mm layer of grout of equal parts of cement and sand shall be well brushed into the surface to be patched,
c)
d)
e)
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followed immediately by the patching concrete, which shall be well consolidated with a wooden float and left slightly proud of the surrounding surface. The concrete patch shall be built upon weather conditions, it shall be worked off flush with a wooden float and a smooth finish obtained by wiping with Hessian, a steel trowel shall be used for this purpose. The mix of patching shall be of the same materials and in the same proportions as that used in the concrete being repaired, although some reducing in the maximum size of the coarse aggregates may be necessary and the mix shall be kept as dry as possible. Mortar filling by air pressure (guniting) shall be used for repair of areas to large and/or too shallow for patching with mortar. Patched surfaces shall be given a final treatment to match the colour and texture of the surrounding concrete. White cement shall be substituted for ordinary cement, if so directed by ENGINEER to match the shade of the patch with the original concrete. f) CURING OF PATCHED WORK The patched areas shall be covered immediately with an approved non staining, water-saturated material such as gunny bags, which shall be kept continuously, wet and protected against sun and wind for a period of 24 hours. Thereafter, the patched area shall be kept wet continuously by a final spray of sprinkling for not less than 10days. APPROVAL BY ENGINEER All materials, procedures, and operations used in the repair of concrete and also the finished repair work shall be subject to the approval of ENGINEER. All fillings shall be tightly bonded to the concrete and shall be sound, free from shrinkage cracks after the fillings have been cured and dried. FINISHING This specification is intended to cover the treatment of concrete surface of all structures. Areas requiring special finish not covered by this specification shall be clearly indicated on the drawings and special specifications shall be furnished. FINISH FOR FORMED SURFACES The type of finish for formed concrete surfaces shall be as follows, unless otherwise specified by the ENGINEER. For surface against which backfill or concrete is to be placed, no treatment is required except repair of defective areas.
g)
ix) a)
b)
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For surface below grade which will receive water proofing treatment the concrete shall be free of surface irregularities, which would interfere with proper application of the waterproofing materials which is specified for use. Unless specified, surface which will be exposed when the structure is in service shall receive no special finish, except repair of damaged or defective concrete, removal of fins, and abrupt irregularities, filling of holes left by form ties and rods and clean up of adhering debris. c) Surfaces which will be exposed to the weather and which would normally level shall be sloped for drainage, unless the drawing specifies a horizontal surface or shows the slope required, the tops of narrow surfaces show the slope required, the tops of narrow surfaces such as stair treads, walls, curbs, and parapets shall be sloped across the width approximately 1 in 3. Broader surfaces such as walkways, road, parking areas and platforms shall be sloped about 1 in 50. Surfaces that will be covered by backfill or concrete, subfolders to be covered by backfill or concrete, sub-floors to be covered with concrete topping, terrazzo or quarry tile, and similar surfaces shall be smooth screeded and levelled to produce even surfaces. STANDARD FINISH FOR EXPOSED CONCRETE Exposed concrete shall mean any concrete, other than floors or slabs, exposed to view upon completion of the job. Unless otherwise specified on the drawings, the standard finish for exposed concrete shall be smooth finish. A smooth finish shall be obtained with the use of lined or plywood forms having smoothed and even surfaces and edges. Panels and form linings shall be of uniform size and be as large as practicable and installed with closed joint. Upon removal of form the joint marks shall be smoothed off and all blemishes, projections etc. removed leaving the surfaces reasonably smooth and unmarred. INTEGRAL CEMENT CONCRETE FINISH When specified on the drawings an integral cement concrete finish of specified thickness for floors and slabs shall be applied either monolithic or bonded, as specified on the drawings, as per IS 2571. The surfaces shall be compacted and then floated with a wooden float or power floating machine. The surface shall be tested with a straight edge and any high and low spots eliminated. Floating or trowelling of
d)
e)
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the finish shall be permitted only after all surface water has evaporated. Dry cement or mixture of dry cement and sand shall not be sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen the mix. f) RUBBED FINISH A rubbed finish shall be provided only on exposed concrete surfaces as specified on the drawings. Upon removal of forms, all fins and other projections in the surfaces shall be carefully removed, offsets levelled and voids and/or damaged sections immediately saturated with water and repaired by filling with concrete or mortar of the same composition as was used in the surface. The surfaces shall then be thoroughly wetted and rubbed with carborundum or other abrasive. Cement mortar may be used in the rubbing, but the finished surfaces shall not be brush coated with either cement or grout after rubbing. The finished surfaces shall present a uniform and smooth appearance. PROTECTION All concrete shall be protected against damage until final acceptance by ENGINEER/OWNER.
g)
1.30. FORM WORK i) The formwork shall consist of shores, bracing, sides or beams and columns bottom of slabs, etc., including ties, anchors, hangers, inserts etc. complete which shall be properly designed and planned for the work. False work shall be so constructed that vertical adjustments can be made to compensate for take up and settlements. Wedges may be used at the top or bottom of timer shores, but not at both ends, to facilitate vertical adjustment or dismantling of a formwork. Only steel scaffolding and steel centering materials should be used for all RCC works. ii) DESIGN OF FORMWORK The design and engineering of the formwork as well as its construction shall be the responsibility of CONTRACTOR. If so instructed, the drawings and/or calculations for the design of the form work shall be submitted to ENGINEER's approval and thereon. Such approval shall not however relieve contractor of the full responsibility for the design and construction of the form work. The design shall take into account all the loads vertical as well as lateral that the forms will be carrying including live and vibration loadings.
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iii)
TOLERANCES Tolerance is a specified permissible variation from lines, grade or dimension given in drawings. No tolerances specified for horizontal or vertical building lines or footings shall be construed to permit encroachment beyond the legal boundaries. Unless otherwise specified, the tolerances on the shapes, lines and dimensions will be permitted as per I.S. 456:2000. TYPE OF FORM WORK Form work may be of timber, plywood, metal, plastic or concrete. For special finishes the formwork may be lined with plywood, steel sheets, oil tempered hard board, etc. Sliding forms and slip forms may be used with the approval of ENGINEER. FORMWORK REQUIREMENTS Forms shall conform to the shapes, lines, grades and dimensions including camber of the concrete as called for on the drawings. Ample studs, walers, braces, ties, straps, shores, etc. shall be used to hold the forms in proper position without any distortion whatsoever until the concrete has set sufficiently to permit removal of forms. Forms shall be strong enough to permit the use of immersion vibrators. In special cases, form vibrators may also be used. The shuttering shall be close boarded. Timber shall be well seasoned, free from sap, shakes, loose, knots, worm holes, warps or other surface defects in contact with concrete. Faces coming in contact with the concrete shall be free from adhering grout, plaster, paint, projecting nails, split, or other defects, joints shall be sufficiently tight to prevent loss of water and fine materials from concrete. Plywood shall be used for Exposed Concrete surfaces. Where called for, Sawn and wrought timer may be used for unexposed surfaces. Inside faces of forms for concrete surfaces, which are to be rubbed, finish shall be planed to remove irregularities or unevenness in the face. Formwork with linings will be permitted. All new and used form timber shall be maintained in a good condition ith respect to shape, strength, rigidity, water tightness, smoothness and cleanliness of surfaces. Form timber unsatisfactory in any respect shall not be used and if rejected by ENGINEER shall be removed from the site.
iv)
v) a)
b)
c)
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d)
Shores supporting successive storeys shall be placed directly over those below or be so designed and placed that the load will be transmitted directly to them. Trussed supports shall be provided for shores that cannot be secured on adequate foundations. Formwork, during any stage of construction showing signs of distortion or distorted to such a degree that the intended concrete work will not conform to the exact contours indicated on the drawings shall be repositioned and strengthened. Poured concrete affected by the faulty formwork, shall be removed entirely and the formwork corrected prior to placing new concrete. Excessive construction camber to compensate for shrinkage, settlement etc. that may impair the structural strength of members will not be permitted. Forms for substructure concrete may be omitted when in the opinion of ENGINEER the open excavation is firm enough to act as the form. Such excavations shall be slightly larger than required by the drawings to compensate for irregularities in excavation and to ensure the design requirements. Forms shall be so designed and constructed that their removal will not damage the concrete. Face formwork shall provide true vertical and horizontal joints conforming to the architectural features of the structure as to location of joints and be as directed by ENGINEER. Where exposed smooth or rubbed concrete finishes are required the form shall be constructed with special care so that resulting concrete surfaces require a minimum finish. BRACINGS, STRUTS AND PROPS Shuttering shall be braced, strutted, propped and so supported that it shall not deform under weight and pressure of the concrete and also due to the movement of men and other materials. Bamboo shall not be used as props or cross bearers. The shuttering for beams and slabs shall be so erected that the shuttering on the sides of the beams and under the soffit of slabs can be removed without disturbing the beam bottoms. Re-propping of beams shall not be done except when props have to be reinstated to take care of construction loads
e)
f)
g)
h)
i)
vi)
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anticipated to be in excess of the design load. Vertical props shall be supported on wedges or other measures shall be taken where by the props can be gently lowered vertically while striking the shuttering. If the shuttering for column is erected for the full height of the column, one side shall be left open and built up in sections as placing of concrete proceeds or windows may be left for pouring concrete from the sides to limit the drop of concrete to 1.0m or as directed by ENGINEER. vii) MOULD OIL Care shall be taken to see that the faces of formwork coming in contract with concrete are perfectly cleaned and two coats of mould oil or any other approved materials applied before fixing reinforcement and placing concrete such coating shall be insoluble in water, nonstaining and not injurious to the concrete. It shall not become flaky or be removed by rain or wash water. Reinforcement and/or other items to be cast in the concrete shall not be placed until coating of the forms is complete. Adjoining concrete surfaces shall also be protected against contamination from the coating material. CHAMFERS AND FILLETS All corners and angles exposed in the finished structure shall be formed with mouldings to form chamfers or fillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise specified, shall be 20mm x 20mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced to the same texture as the forms to which it is attached. VERTICAL CONSTRUCTION JOINT CHAMFERS Vertical construction joints on faces, which will be exposed at the completion of the work, shall be chamfered as above except where not permitted by ENGINEER for structural or hydraulic reasons. WALL TIES Wire ties passing through the walls shall not be allowed. In their place bolts passing through sleeves shall be used. REUSE OF FORMS Before reuse, all forms shall be thoroughly nails removed, holes that may leak suitably
viii)
ix)
x)
xi)
scrapped, cleaned, plugged and joints
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examined and when necessary, repaired and the inside retreated to prevent adhesion, to the satisfaction of ENGINEER. Warped timber shall be resized. CONTRACTOR shall equip himself with enough shuttering to complete the job in the stipulated time. xii) REMOVAL OF FORMS The stripping time for forms shall be in accordance with clause 11.3 of IS 456-2000. CONTRACTOR shall record on the drawing or a special register the date upon which the concrete is placed in each part of the work and the date on which the shuttering is removed there from. In no circumstances shall forms struck until the concrete reaches a strength of at least twice the stress due to self weight and any construction/erection loading to which the concrete may be subjected at the time of striking formwork. In normal circumstances (generally where temperatures are above 20oC) forms may be struck after expiry of the following periods: -------------------------------------------------------------------------------------Type of Form work Minimum Period Before Striking Form work. -------------------------------------------------------------------------------------a) Vertical formwork to columns, walls, beams 16-24 hours b) Soffit formwork to slabs 3 days (Props to be refixed immediately after removal of formwork) c) Soffit formwork to beams 7 days (Props to be refixed immediately after removal of formwork) d) Props to slabs: 1) Spanning up to 4.5m 7 days 2) Spanning over 4.5m 14 days e) Props to beams and arches: 1) Spanning up to 6m 14 days 2) Spanning over 6m 21 days -----------------------------------------------------------------------------------Striking shall be done slowly with utmost care to avoid damage to raises and projections and without shock or vibration by gently easing the wedges. If after removing the form work, it is found that timber has been embedded in the concrete, it shall be removed and made good as specified earlier.
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Reinforced temporary opening shall be provided, as directed by ENGINEER to facilitate removal of formwork which otherwise may be in accessible. Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar structures shall be loosened not sooner than 24 hours nor later than 48 hours after the concrete has been deposited. Ties, except those required to hold forms in place, may be removed at the same time. Ties withdrawn from walls and grade beams shall be pulled towards the inside face. Cutting ties back from the faces of walls and grade beams will not be permitted. For liquid retaining structures no sleeves for through bolts shall be used nor shall through bolts be removed. The bolts, in this case, shall cut at 25mm depth from the surface and then the hole shall be made good by sand cement mortar of the same proportions as the concrete just after striking the form work. 1.31. FOUNDATION BEDDING, BONDING AND JOINING i) All surfaces upon or against which concrete will be placed shall suitably prepared by thoroughly cleaning, washing, dewatering,as may be indicated in the plans or directed by ENGINEER, to meet the various situations encountered in the work. ii) Prior to construction of form work for any item where soil will act as bottom form, approval shall be obtained form ENGINEER as to the suitability of the soil. PREPARATION OF EARTH STRATA OF FOUNDATIONS All earth surfaces upon which or against which concrete is to be placed shall be well compacted and free form standing water, mud or debris. Soft yielding soil shall be removed and replaced with suitable earth well compacted as directed by ENGINEER where specified, lean concrete shall be provided on the earth stratum for receiving concrete. The surface of absorptive soils against which concrete is to be placed shall be made moisture thoroughly so that no moisture will be drawn from the freshly placed concrete and later shall help to cure the concrete.
iii)
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iv)
PREPARATION OF CONCRETE SURFACES The preparation of concrete surfaces upon which additional concrete is to be placed later, shall preferably be done by scarifying and cleaning while the concrete is between its initial and final set. This method shall be used wherever practicable and shall consist of cutting the surface with picks and stiff brooms and by use of an approved combination of air and water jet as directed by ENGINEER. Great care shall be taken in performing this work to avoid removal of too much mortar and the weakening of the surface by loosening of aggregate. When it is not practicable to follow the above method, it will be necessary to employ air tools to remove laitance and roughen the surface. The final required result should be a pitted surface from which all dirt, unsound concrete laitance and glazed mortar have been removed. BONDING TREATMENT (MORTAR) After rock or concrete surfaces upon which new concrete is to be placed have been scarified, cleaned, and wetted as specified herein, they shall receive, a bonding treatment, immediately before placement of the concrete. The bonding medium shall be a coat of cement-sand mortar. The mortar shall have the same cement- sand proportions as the concrete, which shall be placed on it. The water-cement ratio shall be determined by placing conditions and as approved by ENGINEER. Bonding mortar shall be placed in sufficient quantity to completely cover the surface about 10mm thick for rock surface and about 5mm thick for concrete surfaces. It shall be brushed or broomed over the surface and worked thoroughly into all cracks, crevices and depressions. Accumulations or puddles of mortar shall not be allowed to settle in depressions and shall be brushed out to a satisfactory degree, as determined by ENGINEER. Mortar shall be placed at such a rate that it can be brushed over the surface just in advance of placement of concrete. Only such area shall be covered with concrete before initial set in mortar taken place. The amount of mortar that will be permitted to place to any one time, or the area, which it is to cover, shall be in accordance with ENGINEER's directions.
v) a)
b)
c)
d)
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vi)
CLEANING AND BONDING FORMED CONSTRUCTION JOINTS Vertical construction joints shall be cleaned as specified above or by other methods approved by ENGINEER. In placing concrete against formed construction joints, the surfaces of the joints, where accessible, shall be coated thoroughly with the specified bed joint bonding mortar immediately before they are covered with concrete or by scrubbing with wire brooms dipped into the fresh concrete. Where it is impracticable to apply such a mortar coating, special precautions shall be taken to ensure that the new concrete is brought into intimate contact with the surface of the joint by careful puddling and spading with aid of vibrators and suitable tools. EXPANSION AND CONTRACTION JOINTS Provision shall be made for expansion and contraction in concrete by use of special type joint located as shown on the drawing. Contraction by joint surfaces shall be treated as directed by the specification on the drawing or as directed by ENGINEER.
vii)
1.32. HOT WEATHER REQUIREMENT a) All concrete work performed in hot weather shall be in accordance with I.S: 456 except as herein modified. b) Admixture may be used only when approved by ENGINEER. c) Adequate provisions shall be made to lower concrete temperatures by cool ingredient, eliminating excessive mixing, preventing exposure of mixers and conveyors to direct sunlight and the use of reflective paint on mixers etc. The temperature of the freshly placed concrete shall not be permitted to exceed 38 C. d) Consideration shall be given to shading aggregate stockpiles from direct rays of the sun and sprayings stockpiles with water, use of cold water when available, and burying insulating shading and/or painting white the pipe lines and water storage tanks and conveyance. e) In order to reduce loss of mixing water the aggregates, wooden forms, sub-grade, adjacent concrete and other moisture absorbing surfaces shall be well wetted prior to concreting placement and finishing shall be done as quickly as possible.
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f)
Extra precautions shall be taken for the protection and curing of concrete. Consideration shall be given to continuous water curing and protection against high temperatures and drying hot winds for a period of at least 7days immediately after concrete has set and after which normal curing procedures may be resumed.
1.33. PLACING CONCRETE UNDER WATER i) Under all ordinary conditions all foundations shall be completely dewatered and concrete placed in the dry. However, when concrete placement under water is necessary, all work shall conform to IS.456 and the procedure shall be as follows: ii) METHOD OF PLACEMENT Concrete shall be deposited under water by means of tremies, or drop bottom buckets of approved type. DIRECTION, INSPECTION AND APPROVAL All works requiring placement of concrete under water shall be designed, directed and inspected with due regard to local circumstance and purposes. All under water concrete shall be placed according to the plans or specifications and as directed and approved by ENGINEER.
iii)
1.34. PRECAST CONCRETE i) Pre-cast units shall comply with I.S: 456 and with the following requirements: All pre-cast units shall be cast on a suitable bed or platform with firm foundation and free from wind. CONTRACTOR shall be responsible for the accuracy of the level or shape of the bed or platform. A suitable serial number and the date of casting shall be impressed or painted on each unit. ii) STRIKING FORMS Side shutters shall not be struck in less than 24 hours after depositing concrete and no pre-cast unit shall be lifted until the concrete reaches strength of at least twice the stress to which the concrete may be subjected to at the time of lifting.
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iii)
PRECAST UNITS The lifting and removal of precast units that shall be undertaken without causing shock, vibration or undue bending stresses to or in the units. Before lifting and removal takes place, CONTRACTOR shall satisfy ENGINEER or his representative that the methods he proposes to adopt for these operations will not over stress or otherwise affect seriously the strength of the precast units. The reinforced side of the units shall be distinctly marked. CURING All precast work shall be protected from the direct rays of the sun for at least 7 days after casting and during that period each unit shall be kept constantly watered or preferably be completely immersed in water if the size of the unit so permits. Otherwise curing practice as given in clause D 1.29 shall be followed.
iv)
1.35. SLOTS OPENING ETC. Slots, openings, or holes, pockets etc. shall be provided in the concrete work in the positions indicated in the drawings or as directed by ENGINEER. Any deviation from the approved drawing shall be made good by CONTRACTOR at his own expense without damaging any other work. Sleeves, bolts, inserts etc. shall also be provided in concrete work where so specified. 1.36. INSPECTION i) All materials workmanship and finished construction shall be subject to the continuous inspection and approval of ENGINEER. ii) All materials supplied by CONTRACTOR and all work or construction performed by CONTRACTOR rejected as not in conformity with the specifications and drawings shall be immediately replaced at no additional expense to the OWNER. iii) Approvals of any preliminary materials or phase work shall in no way relieve the CONTRACTOR from the responsibility of supplying concrete and or producing finished concrete in accordance with the specifications and drawings. iv) All concrete shall be protected against damage until final acceptance by OWNER or his representative. v) CLEAN-UP a) Upon the completion of concrete work, all forms, equipment construction tools, protective covering and any debris resulting from the work shall be removed from the premises.
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b) c)
All debris i.e., empty containers, scrap wood etc. shall be removed to "Dump" daily or as directed by ENGINEER. The finished concrete surfaces shall be left in a clean condition satisfactory to ENGINEER.
1.37. ACCEPTABLE CRITERIA Any concrete work shall satisfy the requirements given below individually and collectively for it to be acceptable. a) Properties of constituent materials b) Characteristic compressive strength c) Specified mix proportions d) Minimum cement content e) Maximum free water /cement ratio f) Workability g) Temperature h) Density of fully compacted concrete i) Curing j) Tolerances in dimensions k) Tolerances in levels l) Durability m) Surface finishes n) Special requirements such as o) Water tightness p) Resistance to aggressive chemicals q) Resistance to freezing and thawing r) Improved fire resistance s) Wear resistance t) Resistance to early thermal cracking The ENGINEER s decision as to the acceptability or otherwise of any concrete work shall be final and binding on the CONTRACTOR. For work not accepted, the ENGINEER may review and decide whether remedial measures are feasible so as to render the work acceptable. The ENGINEER shall in that case direct the CONTRACTOR to undertake and execute the remedial measures. These shall be expeditiously and effectively implemented by the CONTRACTOR. Nothing extra shall become payable to the CONTRACTOR by the OWNER for executing the remedial measures.
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1.38 MODE OF MEASUREMENT AND PAYMENT i) The unit rate for concrete work under various categories shall be all inclusive and no claims for extra payment on account of such items as leaving holes, embedding inserts, etc. shall be entertained unless separately provided for in the schedule of quantities. No extra claim shall also be entertained due to change in the number, position and/or dimensions of holes, slots or openings, sleeves, inserts or on account of any increased lift or scaffolding etc. All these factors should be taken into consideration while quoting the unit rates. Unless consideration while quoting the unit rates. Unless provided for in the schedule of quantities the rates shall also include fixing inserts in all concrete works, whenever required. ii) Payments of concrete will be made on the basis of unit rates quoted for the respective items in the schedule of quantities. No deduction in the concrete quantity will be made for the reinforcement, inserts etc. and opening less than 1/20 of a sq.m. in area where concrete is measured in sq.m and 1/150 cu.m. Where concrete is measure in cu, Metres. Where no such deduction for concrete is made, payment for shuttering work provided for such holes, pockets etc. will not be made. Similarly the unit rates for concrete work shall be inclusive or exclusive of shuttering as provided for in the schedule of quantities. Where formwork is paid for separately, it shall be very clearly understood that payment for formwork is inclusive of form work, shuttering, shoring, propping, scaffolding etc. complete. Payment for beams will be made for the quantity placed on the depth being reckoned from the underside of the slabs and length measured as the clear distance between supports. Payments for columns shall be made for the quantity based on height reckoned upto the underside of slabs. The unit rate for precast concrete members shall include form work, mouldings, finishing, hoisting and setting in position including setting mortar, provision of lifting arrangement etc. complete. Only if reinforcement is used it shall be measured and paid for separately under item rate.
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D.2 2.1.
SPECIFICATION FOR GENERAL BUILDING WORKS SCOPE: This specification covers the general requirement for brick masonry, plastering, flooring, doors, windows, ventilators, wood work, water proofing, false ceiling, painting and such other related work forming a part of this job which may be required to be carried out though not specifically mentioned above. The work under this specification shall consist of furnishing of all tools, plants, labour, materials, any and everything necessary for carrying out the work.
2.2.0 APPLICABLE CODES AND SPECIFICATIONS : 2.2.1 This specification covers standards and specifications and are made a part of this specification. All standards, tentative specifications, specifications, codes of practices referred to herein shall be the latest edition including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, this specification shall govern: IS.1077 Common burnt clay building bricks. IS.3102 Classification of burnt clay solid bricks IS.2180 Burnt clay building bricks, heavy duty IS.3495 Method of tests for burnt clay building bricks IS.2691 Burntclayfacingbricks IS.2212 Code of practice for brick work. IS.2645 Integral cement water proofing compounds IS.1443 Code of practice for laying and finishing of cement concrete flooring tiles IS.2114 Code of practice for laying in situ Terrazzo floor Finish IS.777 Glazed Earthenware tiles. IS.4021 Timber door, window and ventilator frames IS.2202 Wooden flush shutters (solid, core type) Part II IS.1003 Timber aneled and glazed shutters (Part-I& II) IS.4020 Methods of tests for wooden flush doors:
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Type tests. IS.1761 IS.4351 IS.1038 IS.1081 -
IS.5807 IS.1477
IS.2338 IS.427 IS.428 IS.2395 IS.3384 IS.1580 IS.1322 IS.1346
Transparent sheet glass for glazing and framing purposes. Steel door frames. Steel doors, windows and ventilators. Code of practice for fixing and glazing of metal (steel aluminium) doors, windows and ventilators. Method of test or clear finishes for wooden Furniture (Part-I to III) Code of practice for painting of ferrous metals in buildings and allied finishes (Part I & II) Code of practice for finishing of wood and wood- based materials (Part-I). Distemper, dry, colour as required. Distemper, oil emulsion, colour as required. Code of practice for painting concrete, masonry and plaster surfaces. Bitumen primer for use in water proofing and damp proofing. Bituminous compound for water-proofing and caulking purposes. Bitumen felts for water-proofing and damp proofing. Code of practice for water-proofing of roofs with Bitumen felts.
2.3.0. BRICKWORK: 2.3.1 Bricks used in works shall conform to the relevant Indian Standards. They shall be sound, hard, homogenous in texture well burnt in kiln without being vitrified, table moulded, deep red, cherry or copper coloured, of regular shape and size and shall have sharp and square edges and parallel faces. The bricks shall be free from pores chics, flaws of humps of any kind, bricks containing unground particles and/or which absorb water more than 1/6th of their weight when soaked in water for twenty-four hours shall be rejected. Over-burnt or under-burnt bricks shall be liable to rejection. The bricks shall give a clear ringing sound when struck and shall have a minimum crushing strength of 50 Kg./Sq.cm. unless otherwise noted in drawings. The classes and quality requirements of bricks shall be as laid down in IS.3102.
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2.3.2 The size of the brick shall be 22.86 x 11.43 x 7.62 cm. Unless and otherwise specified, but tolerance upto +/- 3mm in each direction shall be permitted. However bricks conforming in size to IS 1077 could be used. Bricks shall be provided with frogs. Only full size bricks shall be used for masonry work. Brick bats shall be used only with the permission of the ENGINEER to make up required wall length or for bonding. Sample bricks shall be submitted to the ENGINEER for approval and bricks supplied shall confirm to approved samples. If demanded by ENGINEER, brick sample shall be got tested as per IS 3495 by CONTRACTOR at no extra cost to OWNER. Bricks rejected by ENGINEER shall be removed from the site of works within 24 hours. 2.3.3.0 MORTAR 2.3.3.1.Mortar for brick masonry shall be prepared as per IS : 2250. Mix for cement mortar shall be as specified in the respective items of work. Gauge boxes for sand shall be of such dimensions that one completed bag of cement containing 50kgs of cement forms one unit. The sand shall be free from clay, shale, loam, alkali, organic matter and shall be of sound, hard, clean and durable particles. Sand shall be approved by ENGINEER. If so directed by the ENGINEER, sand shall be thoroughly washed till it is free of any contamination. 2.3.3.2 For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry condition. Water shall then be added and mixing continued to give a uniform mix of required consistency. Cement mortar shall preferably be machine mixed, though hand mixing in a thorough manner may be allowed. The mortar so mixed shall be used within twenty five (25) minutes of mixing. The mortar left unused in the specified period shall be rejected. 2.3.3.3The CONTRACTOR shall arrange for test on mortar samples if so directed by the Engineer. Re-tempering of mortar shall not be permitted. 2.3.4. WORKMANSHIP 2.3.4.1 All bricks shall be thoroughly soaked in clean water for at least one hour immediately before being laid. The cement mortar for brick masonry work shall be as specified in the respective item of work. Brick work 230mm thick and over shall be laid in English Bond unless otherwise specified. 115mm thick wall shall be laid with stretchers. For laying bricks a layer of mortar shall be spread over the full width of
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suitable length of the lower course. Each brick shall be pressed into the mortar and shoved into final position so as to embed the brick fully in mortar. Bricks shall be laid with frogs upper-most. 2.3.4.2 All brick work shall be plumb, square and true to dimensions shown. Vertical joints in alternate courses shall come directly one over the other and be in line. Horizontal course shall be levelled. The thickness of brick courses shall be kept uniform. For walls of thickness greater than 230mm both faces shall be kept in vertical planes. All interconnected brickwork shall be carried out at nearly one level (so that there is uniform distribution of pressure on the supporting structure) and no portion of the work shall be left more than one course lower than the adjacent work. Where this is not possible, the work shall be raked back according to bond (and not saw toothed) at an angle not exceeding 45 Degree. But in no case the level difference between adjoining walls shall exceed 1.25m. Workmanship shall conform to IS : 2212. 2.3.4.3 Bricks shall be so laid that all joints are well filled with mortar. The thickness of joints shall not be less than 6mm and not more than 10mm. The face joints shall be raked to a minimum depth of 12mm by raking tools daily during the progress of work when the mortar is still green, so as to provide a proper key for the plaster or pointing to be done. When plastering or pointing is not required to be done, the joints shall be uniform in thickness and be struck flush and finished at the time of laying. Face of brickwork shall be cleaned daily and all mortar droppings removed. The surface of each course shall be thoroughly cleaned of all dirt before another course is laid on top. If the mortar in the lower course has begun to set, the joints shall be raked out to a depth of 12mm before another course is laid. 2.3.4.4 All brick work shall be built tightly against columns, floor slabs or other structural members. 2.3.4.5 Where drawings indicate that structural steel columns are to be fire proofed with brick work, the brick shall be built closely against all flanges and webs with all spaces between the steel and brick work filled solid with mortar. Steel members partly embedded in brick work and not indicated to be fire proofed with concrete, shall be covered with not less than 12mm thick mortar unless directed otherwise by Engineer.
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2.3.5 Miscellaneous inserts in masonry, e.g sleeves, wall ties, anchors, conduits, structural steel, steel lintels etc shall be installed by the CONTRACTOR at no extra cost to the OWNER. Furnishing of any of these inserts by the CONTRACTOR, will be paid for separately. Openings, arches, etc. shall be provided as on the drawings. Chases, pockets etc. shall be provided as shown in the drawings to receive windows, louvers, doors, frames etc. Wall ties and flashings shall be built into the brickwork in accordance with the drawings and specifications. It shall be clearly understood that the rates quoted by the CONTRACTOR include for fixing of inserts, leaving openings, cutting chases in brickwork for various trades etc. 2.3.6. FACING BRICK WORK : 2.3.6.1 Facing bricks of the type specified shall be laid in the positions indicated on the drawings and all facing brickwork shall be well bonded to the backing bricks. No facing brickwork shall at any time be more than 600mm above the backing brickwork. 2.3.6.2. All facing brickwork shall be pointed as the work proceeds and internal faces of the brickwork shall be pointed with neat flush joint to give a fair face. 2.3.6.3 Faced work shall be kept clean and free from damage, discolouration etc. at all time. The CONTRACTOR shall fill carefully all holes with bricks similar to the surrounding brickwork and point brick as required. 2.3.6.4.For facing brickwork, double scaffolding shall be used. No holes in brickwork for scaffolding shall be permitted. 2.3.7. The green work shall be protected from rain by suitable covering. Bricks shall be kept constantly moist on all faces for a minimum period of ten days. Brick work shall not be raised more than one metre per day. 2.3.8. The rates quoted by the CONTRACTOR are exclusive of transoms and mullions. CONTRACTOR shall provide the same as shown or indicated in the drawings. These shall be generally provided only in half and full brick walls. Dimensions of the transoms and mullions shall conform to the thickness of the wall. Concrete work for transoms and mullions shall conform to the specifications for concrete and shall be of grade M25.
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2.3.9. Where shown on the structural drawings bricks for partition walls shall be stacked adjacent to the structural member to pre-deflect the structural member before the wall is built. 2.4.0. All joints in masonry shall be raked to a depth of 12mm with a hooked tool made for the purpose when the mortar is still green and in any case within 48 hours of its laying. The surface to be rendered shall be washed with fresh, clean, water free from all dirt, loose material, grease, etc .and thoroughly wetted for 6 hours before plastering work is commenced. Concrete surfaces to be rendered will however be kept dry. The wall should not be too wet but only damp at the time of plastering. The damping shall be uniform to get uniform bond between the plaster and the wall. 2.4.1. The proportion of the mortar shall be as specified under the respective items of work. Cement shall be mixed thoroughly in dry condition and then just enough water added to obtain a workable consistency. The quality of water, sand and cement shall be as per I.S. Standards. The mortar thus mixed shall be used immediately and in no case shall the mortar be allowed to stand for more than 25minutes after mixing with water. 2.4.2. Curing of plaster shall be started as soon as the applied plaster has hardened enough so as not to be damaged. The decision as to when the plaster has hardened, will be given by the ENGINEER. Curing shall be done by continuously applying water in a fine spray and shall be carried out for at least 7 days. 2.4.3. Whenever the specification or the item of work calls for water proofing, the CONTRACTOR shall provide the percentage of water-proofing compound as specified in the items of work. 2.4.4. Where lath plaster is specified, it shall be paid for at the same rate as for plaster work without metal lath except that separate payment for metal lath will be made. 2.4.5. Ceiling plaster shall be done before wall plaster and wall plaster shall commence at top and work downwards. 2.4.6. Interior and Exterior plaster This plaster shall be laid in a single coat of 12mm thickness. The mortar shall be dashed on the prepared
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surface with a trowel and finished smooth by trowelling on the surface with neeru (lime cream). Neeru shall be properly slaked fat lime. The standard of finish expected is high and shall conform to IS:2394. Interior plaster shall be carried out on jambs, lintel and sill faces, top and undersides, etc. as shown in the drawing or as directed by the ENGINEER. Rate quoted for plaster work shall be deemed to include plastering of all those surfaces. However, if the item of work includes plaster finish, no separate payment would be made under Plastering work. 2.5.0. WATERPROOFING ADMIXTURE If directed by the ENGINEER, the CONTRACTOR shall use approved water proofing admixtures made by reputed manufacturer in the mortar for plaster work. The quantity to be used etc, shall be in accordance with the manufacturers instructions subject however to the approval of the ENGINEER. These admixtures shall not contain calcium chloride unless specifically allowed by Engineer and shall conform to IS: 2645. Payment shall be made for actual quantity of such admixture used unless it is already covered in the rates for the work concerned. 2.6.0 CERAMIC TILED WORK IN FLOORING The type, quality, size, thickness, colour, etc. of the tiles for flooring and skirting work shall be of test quality approved by the ENGINEER. For this purpose, the CONTRACTOR shall provide the ENGINEER with necessary samples for his selection. 2.6.1. Before the tiling work is commenced, the sub-surface shall be thoroughly cleaned and washed of all loose materials, dirt, and scum or laitance and then well wetted without forming water pools on the surface. 2.6.2 The tiles shall be laid on mortar bedding of about 20mm thick. The proportion of mortar shall be one part of cement and 3 parts of sand. The tiles shall be fixed on this bed one after another, each tile being gently tapped with a wooden mallet till it is properly bedded and in level with the adjoining tiles. The joints shall be perfectly straight and uniform in thickness. The tiles shall be laid perfectly in level unless otherwise specified or required or desired by the ENGINEER. After laying the tiles the joints shall be finished with white cement or cement of approved colour.
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2.6.3. For lime mortar, lime from burnt stone shall be used. It shall be free from ash and impurities and be in the form of lumps and not powder when brought to site. Lime which is damaged due to rain, soaking, moisture or air slaking will be rejected. 2.6.4. Floor tiles laid adjoining the wall project 12mm under the plaster, skirting or dado as may be required by the ENGINEER. Half tiles and pieces shall be avoided as far as possible. After laying, the flooring shall be allowed to cure undisturbed for seven days. Design traffic shall not be allowed on the floor at least 14 days after laying the tiles. 2.6.5. About a week after laying the tiles, each and every tile shall be lightly tapped with a small wooden mallet to find out if it gives a hollow sound. If it does, such tiles along with any other cracked or broken tiles shall be removed and replaced with a new tile to proper line and level. The same procedure shall be followed again after the tiles are finally laid. For the purpose of ensuring that such replaced tiles match with those earlier laid, it is necessary that the contractor order enough extra tiles from the factory to meet this contingency. 2.6.6. For dado and skirting work, the vertical surface shall be thoroughly cleaned and wetted. Thereafter it shall be evenly and uniformly covered with about 12mm thick cement mortar. For this work the tiles as obtained from the factory shall be of the size required and practically fully polished. The back of each tile to be fixed shall be covered with a thin layer of neat cement paste and the tile shall then be gently tapped, against the wall with a wooden mallet. This shall be done from the bottom of the surface upwards. The joints shall be as close as possible and the work shall be truly vertical and flush. After the work has set, hand polishing with carborandum stones shall be done so that the surface attains a high glossy finish corners and junctions shall be finished true. True workmanship shall conform to IS:1443. 2.6.7. The work is subject to the approval of the ENGINEER. If any portion of the work is rejected by the ENGINEER, the same shall be removed and redone by the CONTRACTOR to the satisfaction of the ENGINEER at no extra cost to the OWNER.
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2.7.0. GLAZED TILE WORK : The glazed tiles in paving and dado shall be of the best available first class quality approved by the ENGINEER and they should be laid on a base of 12mm thick cement mortar.The tiles shall be of standard size without warp and with straight edges true and even in shape and size and of uniform colour. They shall be laid truly vertical on walls and truly horizontal on floors or to slopes as directed. The joint shall be very thin, uniform and perfectly straight. The joint shall be floated with white cement as approved by the ENGINEER. At the top of dado work, a coloured glazed tile border 75mm deep shall be provided as approved by ENGINEER. The rate quoted for paving and dado work shall be inclusive of angles, corner pieces and approved colour border on top. Glazed tiles shall conform to IS:771. 2.8 INTEGRAL CEMENT FINISH ON CONCRETE FLOOR : In all case where integral cement finish on a concrete floor has been specified, the top layer of concrete shall be screeded off to proper level and tamped with tamper having conical projections so that the aggregate shall be forced below the surface. The surface shall be finished with a wooden float and a trowel with pressure. The finish shall be continued till the concrete reaches its initial set. No cement or cement mortar finish shall be provided on the surface. Where specified, a floor hardener as approved by the ENGINEER shall be supplied and used as recommended by the manufacturer. 2.9 WOOD WORK IN DOORS, WINDOWS, PARTITIONS, LOUVERS, RAILINGS ETC: Wood used for all work shall be the best of the respective class specified and properly seasoned by at least 6 months air drying, suitable for joiners work, should be of natural growth, uniform in texture, straight grained, free from sapwood, dead knots, open shakes, boreholes, rot, decay and any and all other defects and blemishes.
2.9.1
2.9.2 The thickness specified for joiners wrought timbers are unless otherwise specified, prior to planning and 3mm will be allowed from the thickness stated for each wrought faces. 2.9.3 All joining shall be wrought on all faces and finished off by hand with sand paper, with slightly rounded arises.
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2.9.4 The joints shall be pinned with hard wood pins and put together with white lead. Jointing shall be by means of mortice and tennon or dovetailed joints as approved. 2.9.5 Any joiners work which shall split, fracture, shrink, or show flaws or other defects due to unsoundness, inadequate seasoning or bad workmanship, shall be removed and replaced with sound material at the CONTRACTORs expense. 2.9.6 Doors, windows, and ventilator frames, transoms and mullions shall be rebated. All dimensions shall be as per drawings. The top framing member of doors and top and bottom framing of windows and ventilators shall project about 150mm in brickwork. The verticals of door frames shall project about 50mm below finished floor. Surface coming in contact with brick work shall be painted with bitumen as directed by the ENGINEER. Each of the door and window frames shall be provided with 3 Nos. M.S.230 x 50 x 5mm flat split hold-fasts on each side. These hold fasts shall be embedded in masonry or concrete work. The work shall conform to IS:4021. 2.9.7 The doors shall be panelled or solid flush doors as described in the item of work. All flush doors shall be supplied with approved fittings such as hinges, lock of approved make with handles on both sides, anodised aluminium tower bolts, aldrop and latch arrangements, door stoppers etc. and as detailed in schedule. Panelled doors shall have the same fittings except lock, shall be provided. Each door leaf shall have two 200mm tower bolts, two anodised aluminium or oxidised brass handles, rubber bush and one door stopper mounted near the bottom of door. External flush doors shall be made of weather-proof plywood. Flush doors shall conform to IS:2202 (Part-I) 2.9.8. Doors will generally have no sills but if a few have to be provided, the CONTRACTOR shall do so at no extra cost to the OWNER. 2.9.9. The type of window shall be as specified. Each shutter shall have minimum one pair of hinges, two tower bolts, one handle and peg stay. Ventilators shall have two M.S. hold fasts and hinges, one handle at each and one small tower bolt in the centre, where so directed by the ENGINEER.
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2.9.10. The workmanship of all door and window shutters shall conform to the requirements of IS:1003 (Part I & II) and IS:2203 (Part I). If required, flush door panels shall be got tested as per IS: 4020. 2.9.11. Cupboards, almirahs and shelves shall be provided as shown in drawings. 2.9.12. The finish expected is of a very high order and the work shall be all inclusive whether or not all detailed specifications have been spelt out and the work shall be free from blemish. 2.9.13. Iron bars or grills are proposed to be provided in the windows or ventilators. Glass louvered ventilators where specified shall be provided. 2.9.14. Glazed windows, louvers, ventilators and doors shall be provided with either clear or pin headed glass 4mm thick which shall be free from all blemishes and shall conform to IS:1761. It should be clearly understood that glass which does not have uniform refractive index or which is wavy, will be rejected. 2.9.15 Wood work shall not be painted, oiled or otherwise treated before it has been approved by the ENGINEER. 2.10 ALUMINIUM DOORS, WINDOWS AND FITTINGS The aluminium doors, windows and fittings shall conform to IS:1948-1961. 2.11. PAINTING/POLISHING WOOD WORK AND IRON WORK. 2.11.1.Paint / Polish to be used for various items of work shall be of best quality and shall be obtained ready mixed in sealed containers from approved manufacturer. The CONTRACTOR shall obtain the ENGINEERs approval for the make and colour of the paint he proposed to use. If required, polish for wood work shall be tested as per IS:5807 (PART I & III) 2.11.2 All surfaces shall be thoroughly cleaned of all dirt, loose particles and rust and approved, prior to application of paint. For wood surfaces, a priming coat without colouring matter shall be first applied after which all holes, cracks, etc. shall be made good with putty and all knots
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properly filled with quicklime. Workmanship shall conform to IS:1477 (Part I & II) and 2330 (Part I) 2.11.3. Specified number of coats shall be applied and at least 24 hours shall elapse between the application of successive coats. No painting shall be carried out on exterior work in wet weather or on surfaces which are not entirely dry. 2.11.4.Painting / polishing rate shall include all necessary scaffolding, cradles and plant. Measurements will be on the basis of sq.m for doors and windows, only the projected area will be measured. If such painting / polishing is not already a part of the item, without deducting for the glazed portions though not painted. The CONTRACTORs rate should take this into account. 2.12. DISTEMPERING, WHITE, COLOUR WASHING AND PAINTING OF WALLS. 2.12.1. DISTEMPERING The surface to be treated shall be thoroughly cleaned of all dirt and loose particles etc. Inequalities and holes shall be filled with gypsum, which should be allowed to set hard before distemper is applied. Distemper shall be of well known brands of approved make. It shall be applied by a broad stiff brush in two coats over a coat of primer. The first and second coat shall be applied only after the primer coat has thoroughly dried. The first coat shall be of a lighter tint. The shade of the distemper shall be got approved by the ENGINEER. Water bound and oil bound distemper shall conform to the requirements of IS:427 and 428 respectively. 2.12.2.WHITE WASH Walls to be thoroughly cleaned before white wash is applied. White wash shall be of ordinary fat lime and of good quality. It shall be slaked with an excess of water to the consistency of a cream and allowed to remain under water for 2 days. It shall then be strained through a cloth and 2kg of clean gum added for every cubic metre of lime ready for white washing. Each coat is to be applied with a brush. It shall be laid with a stroke of the brush from the top, downwards, another from bottom upwards over the first stroke and similarly, one stroke from the right and
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another from the left over the first brush before it dries. Three such coats shall be applied. 2.12.3.COLOUR WASH Colour wash shall be applied the same way as white wash. Necessary and approved colouring matter shall be added to the white wash which has been strained. Only wash sufficient for the days work shall be prepared each morning. If the finished surface is powdery and comes off easily or the general appearance is streaky, the work shall be rejected. 2.12.4.PAINTING Paint to be used for the various items of work should be of approved make and colour. It is imperative that the CONTRACTOR should obtain ENGINEERs permission in regard to the make and colour of paint that he proposes to use for the various items of work. The painting work shall be carried out as directed by the ENGINEER, keeping however, in view the recommendations of the manufacturers. Where painting with plastic emulsion is specified all uneven surfaces shall be made up by use of putty of appropriate quality, after the surface has been thoroughly cleaned of all dust, dirt and sand papered. One primer coat and two coats of emulsion paint shall be applied. Workmanship shall conform to the requirements of IS:2395. 2.13.0 EXPANSION JOINTS, WATER STOPS, PREMOULDED JOINT FILLERS, FLASHINGS 2.13.1 EXPANSION JOINTS Expansion joints shall be provided with 20gauge copper strips/mild steel hot dip galvanised strips of 250mm width at locations shown on drawings or as approved by ENGINEER. The strips shall be bent to the shape indicated on the drawing and embedded properly in masonry. The joint width shall be uniform throughout and special care shall be taken to ensure proper bending at expansion joints. Expansion joints shall be continuous and where two or more strips meet, they shall be lapped to the extent of 75mm and joints properly soldered. The expansion joints shall be filled with premoulded joint fillers and sealed with mastic compound. For purposes of measurement, the laps provided will be neglected. Wherever an expansion joint between the existing part and new part is proposed the rate quoted shall be inclusive of making necessary connections with existing part.
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2.13.2 WATER STOPPERS : Water stops shall be of rubber or PVC Bars of approved make. These shall be provided at locations indicated on drawings. Water stops shall be lapped 100mm and heat sealed to obtain continuity. Water stops shall be cleaned thoroughly of all concrete and mortar coating as directed before resuming concrete work. Water stops shall be in long lengths to avoid joints as far as possible. 2.13.3 JOINT FILLER : Premoulded joint fillers shall be of a non-deteriorating and resilient type. A sample of material shall be approved by the ENGINEER before being brought to site. Installation shall be carried out properly and as directed. 2.13.4 FLASHINGS : Metal or tar felt flashings shall be fixed as directed by the ENGINEER. Metal flashings where provided shall be welded / soldered to obtain continuity. Tar felt flashings shall be lapped for a minimum length of 150mm. Flashings shall be measured and paid for in linear metres for the specified width disregarding laps or joints. 2.14.0.WATER PROOFING WORK : All surfaces to be water proofed shall be dry, clean, smooth and free from dust and loose particles. 2.14.1TAR FELT TYPE : For a five layer treatment, bitumen primer conforming to IS:3394 shall be applied. Over this primer coat, hot bitumen conforming to IS:1580 shall be applied at the rate of 1.2 kg./Sq.m. Hessian based felt type-3 Grade-2 conforming to IS:1322 shall be spread and embedded in the previously laid bitumen while hot. Hot bitumen will again be applied over the felt at the rate of 1.2 Kg./Sq.m. Pea size gravel or grit shall be uniformly spread at the rate of 0.008cu.m./sq.m. The end and side laps of each sheet shall not be less than 100 and 175mm respectively and shall be firmly bonded with bitumen. The extreme ends shall be taken up about 100 150mm along parapet wall and embedded in chases made in the wall and brick masonry and made good in plaster. The standard of water proofing shall comply with IS:1346. For seven layer treatment, one additional layer of bitumen shall be laid before gravel layer in a manner described above for five layer treatment.
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D.3. SPECIFICATION FOR WATER SUPPLY AND SANITARY WORKS 3.1.0. SCOPE : This specification covers the general requirements for supplying and laying of water supply pipe line with necessary fittings and fixtures for buildings / structures tapping off from potable water supply distribution system, supplying and laying sewage pipe line with disposal works including provision of all fittings and fixtures of sanitary works and such other related items of work forming a part of the job, which may be required to be carried out though not specifically mentioned above. The work under this specification shall consist of furnishing of all tools, plants, labour, materials and any and everything necessary for satisfactorily carrying out the work. 3.2.0 APPLICABLE CODES : 3.2.1. The following standards and codes are made part of this specification. All standards, codes of practice referred to herein shall be the latest editions including all official amendments and revisions. a. b. c. d. e. f. g. h. i. j. k. l. m. IS.458 IS.554 IS.651 IS.774 IS.775 IS.781 IS.783 IS.1068 IS.1239 IS.1536 IS.1626 IS.1703 IS.1726 Concrete Pipes (with and without reinforcements). Dimensions for pipe threads where pressure tight joints are required on the threads. Salt glazed stoneware pipes and fittings. Flushing cisterns for water closets and urinals (valve-lesssiphonic type). Cast iron brackets and supports for wash basins and sinks. Sand cast brass screw-down bib taps and stop taps forwater services. Code of practice for laying of concrete pipes. Electroplated coatings of nickel and chromium on iron and steel. Mild steel tubes (Part-I) and Mild steel tubulars and other wrought steel pipe fittings (Part-II) Centrifugally cast (Spun) iron pressure pipes for water, gas and sewage. Asbestos cement building pipes, gutters and fittings (spigot and socket types). Ball valves (horizontal plunger type) including floats for water supply purposes. Cast iron manhole covers and frames.
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n. o. p. q. r. s. t. u. v.
IS1729 IS.1742 IS.2326 IS.2470 IS.2556 IS.2963 IS.3311 IS.5329 IS.5434
Sand cast iron spigot and socket soil,waste and ventilating pipes, fittings, and accessories. Code of practice for building drainage. Automatic flushing cisterns for urinals. Code of practice for design and construction of septic tanks. Vitreous sanitary appliances (Part-I to Part-XV) Non-ferrous waste fittings for wash basins and sinks. Waste plug and its accessories for sinks and wash basins. Code of practice for sanitary pipe work above ground for buildings Non-ferrous alloy bottle traps for marine use.
3.3.0 DRAWINGS 3.3.1. Drawings released for construction showing locations of sanitary and water supply fixtures will be furnished to the CONTRACTOR and all drawings so furnished shall form a part of this specification. Drawing will also furnish the details of one/or more supply points outside the building for the water supply system and disposal points/schemes for sanitary works. The CONTRACTOR shall refer to these drawings for all information contained therein which pertains to as required for this work. CONTRACTOR shall submit to OWNER/ENGINEER for his approval, detailed working drawings showing layout of water supply and sanitary works with necessary fittings and fixtures before the actual construction is undertaken. 3.3.2 All Civil works will be measured and paid under respective items of work. 3.4.0. SANITARY INSTALLATION : 3.4.1. The work shall be carried out complying in all respect with any specific requirements of the Local Body in whose jurisdiction the work is situated and as approved by the OWNER/ENGINEER. 3.4.2. Any damage caused to the building, or to installations therein, either due to negligence on the part of the CONTRACTOR or due to actual requirements of the work, shall be made good and the building or the installation shall be restored to its original condition by the CONTRACTOR. No extra payments shall be made for such works
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except when there is an item specifically included for such work in the schedule. 3.4.3. All sanitary and plumbing work shall be carried out by licensed plumbers. 3.4.4. On completion of the work, the site shall be cleaned and all rubbish disposed off as directed by the ENGINEER. 3.4.5. All sanitary appliances including sanitary fittings, fixtures, toilet requisites shall be of size and design as specified in the item of work and as per sample approved by the ENGINEER. 3.4.6. All sanitary fittings and fixtures shall be acceptable to the ENGINEER/ OWNER and if there are any variations, they shall satisfy the permissible tolerances in dimensions/slope/contour as specified in relevant IS Codes /Standards. 3.4.7. All white glazed porcelain fixtures, such as wash basin sink, drain board, water closet pan, urinal P trap etc., shall have hard durable white glazed finish. They shall be free from cracks, indentations or other glazing defects. No chipped porcelain fixtures shall be used. Joints between iron and earthenware pipes shall be made perfectly air and water tight by chaulking with near cement mortar. 3.4.8. INDIAN TYPE WATER CLOSET (I.W.C) This shall be the long pan pattern with separate foot-rests made of white glazed earthenware, white glazed vitreous china or white glazed fire clay. The general requirements shall conform to IS:2556 (Part III and Part-X). Each pan shall have an integral flushing rim of suitable type. It shall also have an inlet or supply horn for connecting the flush pipe. The flushing rim and inlet shall be of self-draining type. It shall have a weep hole at the flushing inlet to the pan. The flushing inlet shall be in the front unless otherwise specified or ordered by the ENGINEER. The inside of the bottom of the pan shall have sufficient slope from the front towards the outlet and the surface shall be uniform and smooth to enable easy and quick disposal while flushing. The exterior surface shall be unglazed and sufficiently rough or grooved at right angle to the axis of the outlet. Pans shall be provided with a trap P or S type with a minimum 50mm water seal and 50mm diameter vent horn. Pan shall be laid at the correct location and level over a bed of lime concrete using brick aggregates (1 part lime mortar
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to 2 parts brick bats with lime mortar of 1 part lime to 2 parts of sand) or cement sand admixture as specified in the drawings. 3.4.9 WASH BASINS 3.4.9.1 Wash basins shall be of quality colour glazed earthenware, colour glazed vitreous China or Hi-lites colour glazed fire clay as specified and conforming to IS:2556 (Part IV). TYPE Corner wash basin Flat Back SIZE 400 x 400mm 550 x 400mm
3.4.9.2 Wash basin shall be of one piece construction, including as combined overflow. All internal angles shall be designed so as to facilitate cleaning. Each basin shall have a rim sloping inside towards the bowl on all sides except sides in contact with the walls and shall have skirting at the back. Basins shall be provided with single or double tap holes as specified. The tap holes shall be square. A suitable tap hole button shall be supplied if one tap hole is not required in installations. Each basin shall have a circular waste hole to which the interior of basin shall drain. The waste hole shall be either rebated or levelled internally with diameter of 65mm at top and a depth of 10mm to suit a waste plug having 64mm diameter. Each basin shall be provided with a non-ferrous 32mm waste fitting. Stud slots to receive the brackets on the underside of the wash basins shall be suitable for a bracket with stud not exceeding 13mm diameter, 5mm high and 305mm from the back of basin to the centre of the stud. The stud slots shall be of depth sufficient to take 5mm stud. Every basin shall have an integral soap holder recess or recesses which shall fully drain into the bowl. The position of the chain stay-hole shall not be lower than the over flow slot. A slot type of overflow having an area of not less than 5sq.cm shall be provided and shall be so designed as to facilitate cleaning of the overflow. The specifications for waste plug, chain and stay shall be the same as given for sinks. 3.4.9.3 All the waste fittings shall be chromium plated. Bottle trap shall conform to IS:5434. The chromium plating shall be of service grade No.2 conforming to IS:1068.
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3.5.0 CAST IRON SOIL WASTE AND VENT PIPES AND FITTINGS : 3.5.1. All cast iron pipes and fittings shall be of uniform thickness with strong and deep socket, free from flaws, air-holes, cracks, sand-holes and other defects and conform to IS:1536. The diameter specified shall be internal diameter of pipe. The pipes and fittings shall be true to shape, smooth and cylindrical and shall ring clearly when struck over with a light hand hammer. All pipes and fittings shall be properly cleaned of all foreign material before being fixed. 3.5.2. All plug bends of drainage pipes shall be provided with inspection and cleaning caps, covers which shall be fixed with nuts and screws. Pipes shall be fixed to the wall by C.I. or MS holder bat clamps, unless projecting ears with fixing holes are provided at socket end of pipe. The pipes shall be installed, truly vertical or to the lines and slopes as indicated. The clamps shall be fixed to the walls by embedding their hooks in cement concrete blocks (1:2:4) 10cm x 10cm by making necessary holes in the walls at proper places. All holes and breakages shall be made good. The clamps shall be kept 25mm clear of the finished face of the walls to facilitate cleaning and painting of pipes. 3.5.3. The annular space between the socket and spigot shall be filled with a gasket of hemp or spun yarn soaked in neat cement slurry. The joint shall then be filled with stiff cement mortar 1:2 (1 cement : 2 find sand) well pressed with caulking tool and finished smooth on top at an angle of 450. The joint shall be kept wet for not less than 7days by tying a piece of gunny bag kept moist. Joints shall be perfectly air and water tight. 3.5.4. C.I. Pipes and fittings which are exposed shall be first cleaned and then painted with a coat of red lead primer. Remaining two coats of paint shall be white zinc base and approved colour. 3.5.5. The thickness of fittings and their socket and spigot dimensions shall conform to the thickness and dimensions specified for the corresponding sizes of straight pipes. 3.5.6. The connection between the main pipe and branch pipes shall be made by using branches and bends with access for cleaning. Floor traps shall be provided with 25mm dia. puff pipe where the length of the waste is more than 1800mm or the floor trap is connected to a waste stack through bends.
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3.5.7. C.I. Pipe shall be measured along the centre lines of pipes including fittings such as branches, plug bends, etc. 3.5.8. All cast iron pipes and fittings including joints shall be tested by a smoke test to the satisfaction of the ENGINEEER and left in working condition after completion. The smoke test shall be carried out as stated under. Smoke shall be pumped into the pipe at the lowest end from a smoke machine which consists of bellows and burner. The materials usually burnt is greasy cotton waste which gives out a clear pungent smoke which is easily detectable by sight as well as smell if there is a leak at any point of the pipe line. 3.5.9. Water test and air test shall be conducted as stipulated in IS:5329. 3.6.0 ASBESTOS CEMENT PIPES AND FITTINGS : 3.6.1 All A.C. soil waste vent pipes and fittings shall conform to IS:1626. The pipes shall have spigot and socket ends. These shall be composed of an inert aggregate consisting of clean asbestos fibre cemented together by ordinary Portland cement conforming to IS:269 or Portland blast furnace slag cement conforming to IS:455. No organic materials shall be added to the composition. 3.6.2 The pipes shall be straight and the ends of the pipes and fittings shall be finished square to their axes. The finished pipes and fittings shall be true and smooth, their inner and outer surfaces being as nearly as procurable, concentric. They shall be in all respects, homogenous and free from impurities or other imperfections. 3.6.3. The permissible tolerances on the thickness and external dimensions of pipes and fittings including hydraulic test pressure of the pipes and fittings shall conform to IS:1626. 3.6.4. All A.C. pipes and fittings shall be of approved make and with necessary accessories, wherever required. The diameter wherever specified for pipes and fittings shall be clear internal diameter. All gaps between pipes and fittings and walls shall be filled with cement mortar 1:3 neatly finished for which no extra payment will be made. All pipes and fittings shall be supported with standard fixing brackets.
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3.6.5. The annular space between the socket and spigot shall be filled with a gasket of hemp or spun yarn soaked in tar. The joint shall then be filled with stiff cement mortar 1:2 (1 cement : 2 fine sand) well pressed with caulking tool and finished smooth on top with neat cement paste at an angle of 450. The joint shall be kept wet for not less than 7days by tying a piece of gunny bag kept moist. Joints shall be perfectly air and water tight. 3.6.6 A.C. Pipes shall be measured along with centre lines of pipes including fittings such as junctions, bends, etc. 3.6.7 Pipes and fittings shall be tested with a smoke test as specified in Clause 7.5.8 3.7.0 STONEWARE PIPES AND FITTINGS : 3.7.1 All pipes with spigot and socket ends shall conform to IS: 651 and shall be of Grade A as specified. These shall be sound, free from visible defects such as fine cracks or hair cracks. The glaze of the pipes shall be free from crazing. The pipes shall give a sharp clear note, when struck with a light hammer. There shall be no broken blisters. The pipe shall be handled with sufficient care to avoid damage to them. 3.7.2. Pipes shall be laid to the correct grade and alignment shown in the plan / sections with their sockets up the gradient. Laying and jointing shall conform to the general requirements specified in IS:651. 3.7.3. Stoneware pipe used for sewers shall be subjected to a test pressure of 1.5m head of water at the highest point of the section under test. The test shall be carried out suitably by plugging the low end of the drain and the ends of the connection if any and filling the system with water. A buckle bend shall be temporarily joined in at the top end and sufficient length of vertical pipe joined to it so as to provide the required test head or the top may be plugged with a connection to a hose ending in a funnel which could be raised or lowered till the required head is obtained and fixed suitably for observation. Where leakage will be visible, the defective part of the work shall be removed and made good. 3.7.4. In measuring the length of sewer pipes, laid length between faces of manholes shall only be measured omitting lengths of channels between inside faces of walls of manholes or chambers.
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3.8.0 P.V.C. PIPES AND FITTINGS : 3.8.1 All pipes with spigot and socket ends shall conform to IS:651 and shall be of grade A as specified. These shall be sound, free from visible defects such as fine cracks or hair cracks. The glaze of the pipes shall be free from crazing. There shall be no broken blisters. The pipe shall be handled with sufficient care to avoid damage to them. 3.8.2. Pipe shall be laid to the correct grade and alignment shown in the plan/sections with their sockets up the gradient. Laying and jointing shall conform to the general requirements specified in IS. 3.8.3 P.V.C. pipes used for sewers shall be subjected to a test pressure of 40m head of water at the highest point of the section under test. The test shall be carried out suitably by plugging the low end of the drain and the ends of the connections if any and filling the system with water. A buckle bend shall be temporarily joined in at the top and a sufficient length of vertical pipe joined to it so as to provide with a connection to a hose ending in a funnel which could be raised or lowered till the required head is obtained and fixed suitably for observation. Where leakage is visible, the defective part of the work shall be removed and made good. 3.8.4. In measuring the length of sewer pipes, laid length between faces of manholes shall only be measured omitting lengths of channels between inside faces of walls of manholes or chambers. 3.9.0 STOP COCK AND BIB COCK : 3.9.1. A Bib cock (Bib tap) is a draw-off tap with a horizontal inlet and free outlet and stop cock (stop tap) is a valve with a suitable means of connections for insertions in a pipe line for controlling of stopping the flow. They shall be of specified size and shall be of the screw down type. The closing device should work by means of a disc carrying a renewable non-metallic washer, which shuts against water pressure on a seating at right angles to the axis of the threaded spindle. The cocks shall open in anti-clockwise direction. When the bib cocks and stop cocks are required to be chromium plated, the chromium plating shall be of service Grade No.2 conforming to IS:1068. In finish and appearance, the plated articles shall be free from plating defects such as blisters, pits, roughness and shall not be stained or discoloured.
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3.9.2. These fittings shall be of brass heavy class, chromium plated (C.P.) and of approved manufacture and pattern with screwed or flanged ends as specified. The fittings shall in all respects comply with the requirements of IS:781. The standard size of brass fittings shall be designed by the nominal bore of the pipe to which fittings are attached. A sample of each kind and all supplies made according to the approved samples. 3.9.3. All cast fittings shall be sound and free from laps, blow-holes and fittings. Both internal and external surfaces shall be clean, smooth, etc. Boring, plugging, stopping or patching of the casting shall not be permitted. The bodies, bonnets, spindles and other parts shall be axial, parallel, and cylindrical with surfaces smoothly finished. The area of the water way of the fittings shall not be less than the area of the nominal bore. 3.9.4. The fittings shall be fully examined and cleared of all foreign matter before being fixed.The fittings shall be fitted in the pipe line in a workman-like manner.The joint between fittings and pipes shall be made leak-proof.The joints and fittings shall be leak proof when subjected to a pressure test specified by the ENGINEER and the defective fittings and joints shall be replaced or redone. 3.10.0 GUARANTEE FOR WATER SUPPLY, SOIL VENT SYSTEM : 3.10.1 The CONTRACTOR shall deliver to the OWNER / ENGINEER upon completion of his work under this CONTRACT, a written GUARANTEE. i. That for a period of five (5) years after acceptance by the ENGINEER, plumbing and drainage work shall be free from defective material and workmanship. That for a period of five (5) years after acceptance by the ENGINEER, the CONTRACTOR shall be responsible for the water / air tightness of all joints. That he will, at his own expense, repair, replace all such defective work and all other works damaged thereby, during the terms of GUARANTEE.
ii.
iii.
3.10.2 After completion of the work, the CONTRACTOR shall obtain and hand over to the ENGINEER necessary certificates.
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D.4.TECHNICAL SPECIFICATION - SPECIFIC REQUIREMENTS Cement IS : 269 -
Specification for 43 grade ordinary Portland cement.Material Storage IS:4082 Recommendations on stacking and storing of Construction materials at site. Construction Safety IS:7969 Safety code for handling and storage of building materials. Concrete Mix Design : IS:10262 Recommended guidelines for concrete mix de SP:23 (S&T)- Handbook on concrete mixes. Measurement IS : 3385 - Code of practice for measurement of Civil Engineering works 4.1. STORING OF MATERIALS All materials shall be stored in a manner so as to prevent its deterioration and contamination which would preclude its use in the works. Requirement of IS:4082 shall be complied with. CONTRACTOR will have to make his own arrangements for cement and the storage of adequate quantity of cement. If such cement is not stored properly and has deteriorated, the material shall be rejected. Cement bags shall be stored in dry weather proof shed with a raised floor, well away from the outer walls and insulated from the floor to avoid moisture from ground. Not more than 15 bags shall be stacked in any tier. Storage arrangement shall be approved by ENGINEER. Storage under tarpaulin shall not be permitted. Each consignment of cement shall be stored separately and consumed in its order of receipt. Each size of coarse and fine aggregate shall be stacked separately and shall be protected from leaves and contamination with foreign material. The stacks shall be on hard, clear, free draining bases, draining away from the concrete mixing area. CONTRACTOR shall make his own arrangements for water at site for construction. The reinforcement shall be stacked on top of timber sleepers to avoid contact with ground/water. Each type and size shall be stacked separately.
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4.2 CONCRETE 4.2.1 General Concrete grade shall be designated on drawings. In concrete grade M25, the number represents the specified characteristic compressive strength of 150mm cube at 28 days, expressed in N/Sq.mm as per IS: 456. Concrete in the works shall be DESIGN MIX CONCRETE or NOMINAL MIX CONCRETE. All plain cement concrete works shall be nominal mix concrete and reinforced cement concrete works of M25 grade and above of Design mix concrete. 4.2.2 DESIGN MIX CONCRETE : Mix Design & Testing : For Design Mix concrete, the mix shall be designed according to IS:10262 and SP:23 to provide the grade of concrete having the required workability and characteristic strength not less than appropriate values given in IS:456. The design mix shall in addition be such that it is cohesive and does not segregate and should result in a dense and durable concrete and also capable of giving the finish as specified. For liquid retaining structures, the mix shall also result in water tight concrete. The CONTRACTOR shall exercise great care while designing the concrete mix and executing the works to achieve the designed result. The minimum cement content for Design Mix Concrete shall be as given below. Grade of concrete Minimum Cement Content in Kg/cu.m of concrete M25 400 The minimum cement content stipulated above shall be adopted irrespective of whether the contractor achieves the desired strength with less quantity OF CEMENT. The CONTRACTORs quoted rates for concrete shall provide for the above eventuality and nothing extra shall become payable to the CONTRACTOR in this account. Even in the case where the quantity of cement required is higher than that specified above to achieve desired strength based on an approved mix design, nothing extra shall become payable to the CONTRACTOR. It shall be CONTRACTORs sole responsibility to carry out the mix designs at his own cost. He shall furnish to ENGINEER at least 30days before concrete operations, a statement of proportions proposed to be used for the various concrete mixes and the strength results obtained. The strength requirements of the concrete mixes
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ascertained on 150mm cubes as per IS:516 shall comply with the requirements of IS:456. 4.3 Superstructure : Brick work in CM 1:6 of chamber burnt II class bricks of size 9 x 41/2 x 3 of bearing walls plastered with CM 1:5, 12mm thick inside and outside shall be provided. All main walls shall be 230mm (1Brick) thick. The partition walls will be in brick work in CM 1:4, 115 mm thick will have to be provided with reinforcement bars as indicated in the drawing.
4.3.1 RCC lintels : A continuous RCC lintel in M25 mix of 150mm thick using 20mm graded hard granite stone shall be provided for the entire building except for the portion of grill in service verandah. Necessary reinforcement for the drop in service verandah shall be taken from the roof slab. The lintel beam shall be for full width of the walls even on partition walls. 4.3.2. RCC Sunshade : RCC sunshade in M25 mix using 20mm graded HBG stone shall be 600mm wide and shall be cast along with the continuous lintel beam as per drawing. 4.4. ROOFING AND FLOORING : The roof slab shall be of RCC M25 mix using 20mm graded hard machine broken granite stone, 125 mm thick and reinforcement as shown in drawing. The top of the roof slab will be provided with weathering course consisting of one course of pressed tiles of size 200 x 200 x 20mm embedded in CM 1:3 mixed with crude oil as specified in Tamil Nadu Building Practice of Tamil Nadu Public Works department and pointed at top with CM 1:3 mixed with crude oil, over a bed of brick jelly concrete in lime (proportion being 32:12.5 of 80 mm average thickness). The underside of the roof shall be plastered with cement mortar 1:3, 12mm thick. Ceramic tiled floorings shall be provided in the rooms detailed in clause 4.6 of this section. The floor level of the above rooms should be suitably depressed to allow for laying of tiles and mortar. The floor level of all rooms shall be maintained uniform on completion of flooring works.
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Flooring for bath and F.O.L. shall be anti-skid ceramic tile of size 200mmx200mm with C.M 1:3,20mm thick immediately after the concrete is laid. Necessary water proofing compound should be added for all flooring in F.O.L. and Bath. The floor level in bath room and F.O.L. in all floors should be depressed by 50mm below the level of the general floor area. The sunken portion of slab, if needed, below floor level in toilet rooms to receive Indian type water closets (orissa pan type) shall be plastered with CM 1:3, 12mm thick with admixture of approved water proofing compound and painted with two coats of asphaltic paint. 4.5 M.S. sheets for centering for RCC slab works to be adopted instead of wooden planks. The entire centering arrangements for the RCC slabs and beams should be checked and approved by the Boards Engineer before concrete is laid. All centering and props shall be properly braced and cross braced in two directions and well stayed or strutted on all sides enough to resist storm or sudden high winds or any other unforeseen impact during execution. All RCC concrete shall be vibrated with suitable vibrators depending on depth/ thickness of concrete . The concrete for the entire building should be mixed only by using diesel or electricity operated concrete mixers. Hand mixing by manual labour is not permitted. Necessary hooks for fixing fan may be provided at suitable locations in floor / roof slabs while concreting for which no extra payment will be made. PVC conduits, junction boxes and accessories should be laid before concreting wherever necessary for concealed wiring. 4.6 FLOORING : CERAMIC TILED FLOORING: Ceramic tiled flooring using rectified tile of size400mmx400mm in CM 1:3, 20mm thick bedding shall be provided in the room. Pointing to be done with the same colour cement. Necessary samples of tile shall be provided by the contractor for approval of the Engineer. The floor level should be suitably depressed to allow for laying tiles and mortar so as to maintain uniform level for all rooms.
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4.7.
DOORS, WINDOWS & VENTILATORS : All doors except toilet doors shall be of CW hollow core flush door with frame of size 100x65mm and shutter using 75x30mm CW scantlings for frame work and fixing 4mm thick commercial plywood on both sides, TW lipping on edges, fixing 1mm thick lamination of approved quality & design on both sides, Brass butt hinges, Brass parallel bolt, Brass handles on both sides, Brass door stopper etc and as per the specification and sizes mentioned in the drawing and painted with two coats of approved brand enamel paint over a coat of primer. The fixtures to be provided as per the schedule of items for all doors. Toilet doors shall be of PVC door with frame, Forex or equivalent, the frame made out of hollow core door frame of size 50x47mm with a wall thickness of 5mm rigid foam sheet, mitre cut at two corners and joined with 2Nos of 150mm long brackets of 15x15mm MS square tube & reinforced with 19x19mm MS square tube of 19G and fixed to thr wall by drilling 100mm long MS screws using PVC fasteners and PVC shutter made out of 30mm thick PVC rigid foam panel door and PVC shutter made out of 30mm thick PVC rigid foam panel door and shutter made from MS tubular frame of 19 G of size 19x19mm for styles and 15x15mm for top & bottom rails and covered with 5mm thick heat moulded PVC 'C' channel of size 50x30mm for styles with 5mm thick PVC sheet [width 75mm for lock rail, bottom rail, top rail on either side]. The inner panelling should be inserted with 5mm thick PVC sheet sealed with solvent cement adhesive to the styles and rails with 5x25mm PVC sheet beading on either side and as per the specification and sizes mentioned in the drawing . All windows shall be of aluminium glazed windows with 5mm thick plain glass and as per the specification & of sizes noted in the drawing. The fittings and furniture shall be provided as per the specification MS grills for windows using MS flats 25x5mm painted with one coat red oxide primer and of design approved by the Engineer at site shall be provided inside. All Ventilators are of Anodized aluminum fixed type ventilator, Zig-Zag type, using Aluminium Box section 63x38xmmx0.85kg/m, 4mm thick machine frosted glass, aluminium mesh fixed with aluminium beading clip 17.15x17.27x0.178kg/m, fixing rubber lining etc.
4.8
PLASTERING WITH CEMENT MORTAR : Plastering with CM 1:5, 12 mm thick to be laid for the interior and exterior faces of walls. Plastering with CM 1:3, 12 mm thick as shown in the drawing to be provided. Plastering specification laid down in
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IS:1661-1972 shall apply. For external rendered finishes, the specification laid down in IS:2402-1963 shall apply. 4.8.1 PROPORTIONING : The material used in the preparations of plastering mixer may be measured by volume using gauge boxes. 4.8.2 QUANTITY OF WATER : For general cement plaster work, the quantity of water required is about 70% by weight of cement. IS:2250 1965 may be followed. 4.8.3 MIXING : Cement and sand IS:1543-1960 shall be mixed only in the required proportion to obtain a uniform colour. Water shall then be added to get the required consistency for the plaster. Mixing may be done either manually or mechanically. Hand mixing shall be carried out on a clean, water tight platform. During mixing, the mortar shall be heed back and forth for 10 to 15minutes, after the water is added. In machine mixing, the mixer shall run atleast 5minutes after placing all the ingredients in the drum. The thickness of plaster work for single coat, both internal and external shall 12mm. For single coat plaster, the fineness modulus of sand should be as far as possible, 1.5 and confirming to grading zone IV of IS:383-1970. Where only fine sand is available, the fineness modulus of sand may be improved by mixing the required percentage of coarse sand. The strength of plaster mix gets reduced with the reduction in the fineness modulus of sand. Should mortar crack or perish through neglect of watering or other fault of the contractor, the work shall be removed and redone at the contractors expense or should the contractor fail to water the work to the satisfaction of the Engineer-in-charge of the work, the later may supply the requisite men to water the work properly and charge the cost to the contractor. 4.9 COLOUR WASHING : The outside of the walls and the entire building to be colour washed with two coats using supercem pigments over a coat of primer. The
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inside of the walls to be colour washed with two coats using Oil Bound Distemper over a coat of primer 4.10 PAINTING : All the wood work and M.S. grills to be painted with two coats of approved brand/ colour enamel paint. Painting has to be carried out as per the specification. STAIR CASES The stair-case shall be with RCC M25 mix waist slabs with flat intermediate landing. The steps will be with brick work in cement mortar 1:5. MS hand Rails for staircase using MS square 20x20mm and MS Pipe 40mm dia, painted with one coat red oxide primer as per approved design and as directed by Engineer at site, painted with one coat red oxide primer The width of flight should be as indicated in the drawing. DRAINS : Suitable down-fall pipes 100mm dia of P.V.C. pipes (6kg/sq.cm) with necessary clamps of plastic with screws of brass shall be provided and taken outside the building up to basement level and finally connected to the outside drain. SANITARY FITTINGS : Lavatory shall be provided with Indian water closet of Orissa pan type and European water closet in the places shown in the drawing. The pan of Indian water closet set shall be of Hi-lites colour of 580x420mm size. In order to clean the portion between the trap in the flush out latrine, and pipe, suitable specials with eye should be provided. The cleaning of the section will be done when necessary arises through this eye. The plumbing shall be of best workmanship and the whole apparatus shall be handed over in good condition after testing them to the satisfaction of the Engineer. The sewer connections shall be taken to the outside sewer line or to a distance of 3metre from the outer face of the building, if the outside main sewer is not within 3metre.
4.11
4.12
4.13
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The quantities given in schedule and for drainage and sewage arrangements are only tentative. These items of work have to be executed as per the decision and direction of the Engineer at site according to site condition. 4.14 WATER SUPPLY : The bath room, lavatory and the kitchen should be fitted with a 15mm C.P. brass screw down bib cock tap connected to the PVC distribution main including necessary bib-cock, collars, reducers, bends, elbows, connecting special pipe. The rates quoted should be for the complete work including the labour for cutting, and should be done to the entire satisfaction of the Engineer at site. The exact size of distribution main valves and bib cock will however be decided by the Engineer at site to suit site conditions. The quantities indicated in the schedule for water supply items are tentative and are for tender comparison purposes All PVC used for water supply should be of heavy duty and approved make with necessary specials conforming to relevant I.S.S. 4985/1988 or latest editions with working pressure 15kgf/cm2 . In all bathrooms, C.P. showers with shower arm 300mm, necessary pipe line with suitable wheel valve shall be provided. Necessary RCC brackets have to be provided in the bathroom. Necessary floor trap using 150mm dia brass grating to be provided as instructed by the Engineer at site. 4.15 STEPS Steps shall be of brickwork in CM 1:6 shall be provided wherever necessary. ENDURA step/landing Tiles of approved colour/ design for steps set in CM 1:3,20mm thick with contrast colour shall be provided. The tread and rise of each step shall be as indicated in the drawing. 4.16 FINISH OF THE BUILDING : The building is to be finished to the high standard and neat in all respects as directed by the Engineer at site. 4.17 SAMPLES FOR APPROVAL Samples of all sanitary fittings, water supply fittings, such as bib-cocks, valves, etc. shall be provided for the approval of the Engineer-incharge before installation. Sample of all furniture fittings for doors, windows, aluminium sections for windows and joinery fittings in
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ventilator, cupboard, country wood shutters shall be produced for the approval of the Engineer-in-charge before fixing. 4.18 GENERAL The buildings shall be executed generally as per the approved drawings and specification. BORED CAST-IN-SITU CONCRETE PILES
D5.
5.1. SCOPE 5.1.1. This specification covers the furnishing of all materials, plant, labour, equipment, tools and services for the complete and proper installation of vertical concrete piles, as shown on the drawings or specified, including all surveying and setting out necessary for correct location of piles, furnishing everything necessary for forming working piles, test piles and anchor piles (if required), excavations for pile cut-off of all piles to a true plane at the elevation specified, load test of single pile and/or pile groups designated for that purpose or as directed during the progress of the work (unless otherwise specified) and clean-up of the working area. Contractor shall also exhume test piles, before/after load tests, as directed by Engineer, if so specified, for checking the quality of the pile shaft in case of cast-in-situ piles. Contractor shall provide everything requisite and necessary exhume the pile as instructed. 5.1.2. Access to the work areas be kept unobstructed and clear at all times so as not to hamper the work of other trades. 5.1.3. Contractor shall, prior to submitting a proposal, acquaint himself fully in regard to the scope of the work in accordance with the intent and meaning of the borings and soil investigation report, where such bore hole data and soil investigation report, are available, and drawings and specifications, examine the premises sufficiently to compare them with the drawings and specifications and satisfy himself as to the condition of the site, obstructions, accessibility, etc. required in connection with the work. Failure to comply with this requirement shall in no way relieve Contractor of his responsibility to completely perform the work in accordance with the specification. 5.1.4. Contractor shall on award of the contract, install test piles as directed by Engineer and load test the same as per this specification and as directed by Engineer. In the case of cast-in-situ piles, Engineer may
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direct contractor to completely exhume some or all test piles, before or before load testing, to examine the quality of the pile shaft. This shall be done either by excavating around the pile or by pulling out or by a combination of both methods. 5.1.5. If the quality of the pile shaft does not satisfy the requirements of this specification and / or if the pile fails to attain the specified safe pile capacity and if this can be attributed to defective workmanship and / or negligence on the part of Contractor, all costs of mobilization, Installation and testing of test piles, exhuming or test piles and any other work in connection with the test piles shall be to the cost of Contractor. 5.1.6. In the event of test piles not satisfying the requirements of this specification, Owner reserves the right to terminate the contract and to award the contract to other parties. 5.1.7. The information given in the bore logs and soil investigation report, where such bore logs and soil investigation report are available, is given to Bidders / Contractor in good faith and Owner / Engineer will not be responsible for any inaccuracies or discrepancies therein and shall not entertain any claim whatsoever from Bidders / Contractor on this account. 5.1.8. Nothing contained in the contract documents shall relieve Contractor from the responsibility of obtaining approval from Engineer for all pile installation criteria. 5.1.9. Scope of this Specification covers bored cast in situ piles of circular cross section. These piles shall be formed by boring to the specified depth as shown and called for on the drawings or as directed by Engineer. Execution on pile bore shall be any one of the methods outlined below. a) Using percussion type of boring technique and bentonite slurry to stabilise the hole, with temporary guide casing through unstable strata only upto a maximum of 5m below working ground level. Using Direct Mud Circulation or Reverse Mud Circulation method with bentonite slurry as drilling mud and appropriate equipment and with temporary guide casing through unstable strata, only upto a maximum of 5m below working ground level.
b)
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c)
Using permanent rigid liners of steel or any other material approved by the ENGINEER. Temporary casings of length exceeding 5m below working ground level shall not be used for forming the pile bores. Concrete piles formed shall be free of any necking and excessive bulging. Contractor shall not proceed with the work before obtaining instruction / clarification from the Owner / Engineer.
5.2. APPLICABLE CODES AND SPECIFICATIONS 5.2.1. All applicable documents, including standards, codes, rules, laws, regulations of regulatory bodies referred to herein shall be of latest issue or edition and shall be considered part of this specification, except as may otherwise be stated herein. 5.2.2. Unless otherwise stated herein and in specific technical requirements. the design, materials and workmanship shall conform to the following standards: IS : 2911 a) Part I b) Part -4-1985 IS : 2131 1981 IS : 456 2000 IS : 455 IS : 269 1989 IS: 1489 1991 IS:8112 1989 IS : 383 1970 IS : 2386 1963 IS : 432 1982 : : : : : : : : : : : : Code of practice for design and construction of pile foundations. Part I concrete piles, Section-2 (SEC.2-1979) Bored cast in situ piles. Part 4 Load test on piles Method of standard penetration test for soils Code of practice for plain and reinforced concrete. Portland slag cement Specification for ordinary, Rapid hardening and low heat portland cement Portland Pozzolana cement High Strength ordinary Portland cement Specifications for coarse and fine aggregates from Natural sources for concrete Methods of Test for aggregates for concrete Specification for Mild steel and medium Tensile steel bars and hand drawn steel wire for concrete reinforcement Specification for cold twisted steel bars for concrete reinforcement Safety code for excavation work
IS : 1786 1985 IS : 3764 1992
: :
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IS : 1200 1988
Method of measurement of building works Part-XXIII
5.3. MATERIALS 5.3.1. CONCRETE 5.3.1.1.All concrete work shall conform to IS 456 unless otherwise stated herein. All aspects of concrete work including materials specifications, preliminary mix designs, workability, inspection, testing etc. shall be as specified Section D of this specification. 5.3.1.2.Cement used shall be ordinary port land cement of not less than 43 grade conforming to I.S. 269. Where port land Pozzolana Cement is specified to be used, only such cement which does not contain fly ash as Pozzolans, shall be approved. 5.3.1.3.In case of piles where concrete is to be placed through tremie pipe, coarse aggregates, as per I.S. 383, are preferable to crushed aggregates for better workability. 5.3.1.4.Maximum size coarse aggregate shall be 20mm. 5.3.1.5 Concrete shall be M25 grade as per specification for concrete work unless otherwise called for. Concrete, for piles in alkali soil/alkaline water, shall have a minimum 28 days 15cm works cube compressive strength of 250 kg/cm2 (25 N/mm2 ) and shall not contain less than 400kgs. of cement per cum. of concrete in piles. 5.3.1.6.Concrete, for piles formed in-situ, shall have sufficient slump (125 to 175m) to drop into place properly. The water-cement ratio including the water contained in the aggregates, shall be limited to 0.5, unless otherwise stipulated. Special plasticizing admixtures, if approved by Engineer, shall be added to the concrete as per manufacturers instructions to improve the slump, without impairing the specified strength. 5.3.1.7.Atleast one test shall be made for every 25 piles cast and not less than one test shall be made for any one days concreting operation. Each test shall consist of three works test cubes field cured. One cube shall be tested at 7 days and the other two at 28 days. Records of all cube test results shall be communicated to Engineer.
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5.3.1.8.Owner reserves the right to reject piles of deficient concrete General Body Meeting of the Society on 28.9.06 at 5.30 PM. strength. Such rejected piles (installed or to be installed) shall be replaced by Contractor, by new or additional piles and the cost of such replacement shall be wholly borne by Contractor. 5.3.1.9.Engineer reserve the right to order a change in the mix or in the water-cement ratio to obtain the specified strength and / or workability. 5.3.2. REINFORCEMENT 5.3.2.1.All reinforcement for use within the pile shaft, shall be as per drawings and be associated and tied and or welded together and made up into cages sufficiently rigid to withstand handling without damage and distortion. 5.3.2.2.Joints in longitudinal bars, if unavoidable, shall be made by lapping and the laps shall be tack-welded to prevent distortion of the reinforcing cages except for driven precast piles where they shall be butt-welded. 5.3.2.3.The projecting lengths of the longitudinal bars beyond the pile cut-off level shall be equal to a minimum of 50 times bar diameter or such other length as shown on drawings. 5.3.2.4.For precast driven piles, all the longitudinal bars shall be of the same length and be fitted into the pile shoe. Shorter bars, to resist local bending moments near the middle point of the pile or any other location, may be added but shall be carefully arranged as sudden discontinuity of bars may lead to cracks under heavy driving. 5.3.2.5.The lateral links / helix shall fit tightly against the longitudinal bars and be fixed to them by welding or soft annealed 16 gauge black iron wire, the free ends of which shall be turned into the interior of the pile. 5.3.2.6.The spacing of lateral reinforcement shall be such as to permit free flow of concrete around it. For precast driven piles, the transition between closer spacing and maximum spacing, shall be gradual over a length of three times the diameter / side. 5.3.2.7.Concrete cover over all reinforcement including lateral links or helix, shall be 50mm unless other wise shown on drawing. Care shall be
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taken to preserve the correct over and alignment of reinforcement free from any twist, throughout the whole operation of placing the reinforcing cage into the bore hole and concreting the pile. The inside the dimension of the reinforcing cage shall be adequate for operation of the tremie pipe when used. 5.3.3. STEEL CASING 5.3.3.1.Temporary steel castings, used for driven cast-in-situ piles and for bored piles using casings, shall be straight and shall have sufficient wall thickness and strength to withstand without damage, distortion, etc. the handling stresses and driving stresses set up in obtaining the specified depth and set (in the cast of the former piles)and to resist harmful distortion of buckling due to soil pressures developed during installation of pile or adjacent piles. Joints shall be welded or lock seamed. Screwed joints shall be permitted for casings for bored piles. Casings and their joints shall be sufficiently water - tight. 5.3.3.2Casings shall be of such diameter as to give the specified nominal diameter of the pile. Casing lengths shall be the maximum consistent with standard practice, transport, handling and driving facilities. 5.3.3.3Detachable shoes used with the temporary steel casings for driven cast-in-situ piles shall be of cast iron and for requisite strength of the standard sizes used with the respective steel castings and the shoe shall be coaxial with the steel casing. 5.3.3.4Casings distorted from true and uniform shape, whether caused by driving or earth and water pressure, resulting in a reduction of the cross sectional area of the pile in excess of 10%, shall not be used on the work. 5.4. PILE CAPACITY, QUALITY AND TOLERANCES
5.4.1. Piles individually and in groups, installed in place, shall safely sustain the load specified on the drawings. The capacity of the piles in place, shall be tested by conducting routine tests as decided by Engineer on one or more working piles. The safe load i.e pile capacity shall be assessed as defined under Routine Tests on Working Piles herein after.
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5.4.2. In the case of cast-in-situ piles, Contractor shall guarantee 90% of full cross sectional area of the pile and also guarantee against occurrence of necking or wasting, bulging, spelling of pile shaft concrete, exposure of pile shaft reinforcement, honey combed/porous pile shaft concrete and similar defects which will impair the strength and durability of the pile. 5.5. SETTING OUT
5.5.1. The CONTRACTOR will be furnished with one reference benchmark and with two mutually perpendicular reference axes. The CONTRACTOR shall locate accurately the position of piles and install stakes as directed or as required by drawings with reference to the reference bench mark and axes furnished. The CONTRACTOR shall make good to the satisfaction of the ENGINEER, defective or in fructuous work arising out of error in field layout, notwithstanding that such layout and staking may have been checked and approved by the ENGINEER. 5.5.2. The CONTRACTOR shall check the co-ordinates of initial guide casing or permanent liner position for each pile during and immediately after placing the casing on the ground prior to its driving and confirm the same with the co-ordinates of that pile as shown on the drawing. 5.6. CONTINUITY OF CONSTRUCTION
5.6.1. Any pile that is taken up for execution from boring to final concreting shall be executed at a continuous stretch without interruption, stoppage of work in between shifts will be permitted only during boring stage of the pile execution if further boring is pending. Thereafter right from boring or chiseling of the final portion of the length of the pile, through subsequent activities of flushing, lowering of reinforcement cage, lowering of tremie, preconcrete flushing and upto concreting, no halt whatsoever in the execution of the pile will be permitted. 5.6.2. In case there is a halt of work during any of these activities except concreting the CONTRACTOR shall take steps to bore an extended length of further 300mm or as decided by the ENGINEER, or adopt any other measure as decided by the ENGINEER. 5.6.3. If there is any stoppage of work during concreting, this pile shall be abandoned altogether.
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5.6.4. Cost of remedial measures and their consequences shall be borne by the CONTRACTORs act of commission or omission. 5.7. BENTONITE DRILLING MUD
5.7.1. The bentonite powder shall be mixed thoroughly with clean, potable water to make a suspension of density as specified. The temperature of the water used and that of the bentonite fluid supplied to the pile bore shall not be lower than 5C. where saline or chemically contaminated ground water occurs, special precautions shall be taken as approved by the ENGINEER to modify the bentonite suspension or pre-hydrate the bentonite with fresh, potable water so as to render the fluid suitable for construction of piles. The PH of the fluid shall range from 9.5 to 12. The density freshly prepared bentonite suspension should be between 1.03 to 1.1gm/ml. The density of the bentonite suspension after mixing with deleterious material in the bore hole may go upto 1.25gm/ml. The marsh viscosity when tested by a marsh cone shall be between 30 to 60 second. The differential free swell shall be more than 540%. The bentonite suspension fluid shall be continuously circulated and agitated using circulating pumps to prevent deposition of suspension and coagulation. 5.7.2. The suspension fluid shall be regularly tested to ensure its suitability for use as drilling mud. The frequency of testing the fluid and the method of sampling shall be proposed by the CONTRACTOR for approval prior to the commencement of the work. The frequency may subsequently be varied as deemed necessary by the ENGINEER. These tests shall ensure consistency of the fluid properties, after the mixing process, blending of freshly mixed bentonite suspension and previously used betonite suspension and any pricess which may be adopted to remove impurities from previously used bentonite suspension. 5.8. PILE BORING:
5.8.1. Formation of pile bores: 5.8.1.1.Pile bores for bored cast in situ concrete piles shall be executed upto a minimum depth specified in the Drawings or as modified by the ENGINEER in writing during progress of boring. The pile shall achieve its required capacity to take downward and upward force and horizontal forces in combination as specified.
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5.8.1.2.Pile bores shall be executed by any of the following methods: a) using the Direct Mud Circulation or Reverse Mud Circulation Methods with bentonite slurry as drilling Mud and appropriate equipment. Using percussion type of drilling and bentonite slurry to stabilize the hole. Using permanent rigid liners of steel or any other material approved by the ENGINEER and boring through the liners The BIDDER shall indicate along with his Bid which of the above methods he proposes to adopt for this work. However the decision of the ENGINEER regarding the method to be adopted for executing the bores shall be binding on the CONTRACTOR.
b)
c)
5.8.1.3.Use of temporary guide casings through unstable strata is permitted only upto a maximum of 5 m below ground level. 5.8.1.4. The CONTRACTOR shall ensure that bores formed are true to a cylindrical shape to the extent possible and over cutting is minimized. The CONTRACTOR shall also ensure that water cavities behind temporary casings are altogether avoided so as to ensure quality concrete for the pile shaft. 5.8.1.5.Boring shall not be carried out within a distance of five times the diameter of the pile from a pile which has been freshly concreted within the past forty-eight hours.
5.8.2. Direct mud circulation method: 5.8.2.1.The initial boring of about 1.5 m shall be done by bailer and the guide casing shall then be lowered into the bore hole. The bore shall be filled with bentonite slurry fed from bentonite installation. 5.8.2.2.The centre-line of the guide casing shall be checked with respect to the reference points before proceeding with further boring. Further boring shall proceed with the use of direct mud circulation chisel upto the founding strata.
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5.8.2.3.The chisel used to bore the hole, shall be of diameter appropriate for the specified nominal diameter of the hole to be bored. The chisel shall be connected to API rods of adequate diameter and thickness through which bentonite slurry shall be pumped. 5.8.2.4.Bentonite slurry shall be pumped through the chisel rods by means of high pressure pumps. The chisel shall have suitable ports for the bentonite slurry to flow out at high pressure. The bentonite slurry and the cuttings, which are carried to the surface by the rising flow of slurry shall pass through a setting tank of adequate size to remove the cuttings and spoils from the slurry before the slurry is re-circulated to the pile bore. A suitable bentonite slurry mixing and re-circulation plant shall be designed and installed. 5.8.3. Reverse mud circulation method 5.8.3.1.The CONTRACTOR shall adopt Reverse Mud circulation Method only where strata encountered are such that there is no danger of loosening of the sub-soil during the boring operations and the subsoil gradually becomes denser and more compact with progressive depth, or where bedrock is being penetrated at shallow depths. This methods shall be adopted only if approved by the ENGINEER 5.8.3.2.The Method is essentially the same as the Direct Mud Circulation Method except that the bentonite slurry shall be sucked through the chisel instead of being pumped through it. Except for this, the specifications for Direct Mud Circulation Method apply here also. 5.8.4. Bailer boring using bentonite slurry. 5.8.4.1.This process is essentially the same as the Mud Circulation Method except that all boring shall be done by flap value bailer or flap valve bailer and chisel upto the founding stratum, using bentonite slurry. Bentonite slurry shall be allowed to flow into the guide casing through pipes or channels, so that the guide casing is always kept filled with bentonite. The material extracted by the bailer shall be left alongside the boring if so directed by ENGINEER. Fresh bentonite slurry shall be allowed to flow into the casing so that the top level of the bentonite is kept the same at all times. 5.8.4.2. Except as modified herein above, the specification for Direct Mud Circulation Method shall apply to Bailer Boring also.
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5.8.4.3. Loss of drilling mud while boring: In the event of a rapid loss of drilling mud in a pile bore, the CONTRACTOR shall immediately draw the attention of the ENGINEER and take necessary action as approved by the ENGINEER. 5.8.5 Auger boring Augers are used cohesive and other soft soils above water table. Hand augers are used for depths upto about 6 metres. Mechanically operated augers are used for greater depths and they can also be used is gravelly soils. Samples recovered from the soil brought up by auguers are badly disturbed and are useful for identification purpose only. 5.8.5.1.Auger and shell boring Cylindrical auguers and shells with cutting edge on teeth at the lower end can be used for making deep borings. Hand operated rings are used for depths upto 25m and the mechanical rigs upto 50m . Auguers suitable for soft to stiff clays, shells for very stiff and hard clay and shells or sand pumps for sandy soils, small boulders thin soft strata or rock, or cemented gravel can be broken by chisel bits attached to drill rods. The hole usually requires a casing. 5.8.5.2Percussion boring In this methods, soil and rock formation are broken by repeated blows of heavy chisel or bit suspended by a cable or drill rod. Water is added to the hole during boring if not already present, and the slurry of pulverised material is bailed out at intervals. 5.8.6. Final post-bore flushing and cleaning: On completion of the total length of the pile bore, the bore shall be thoroughly cleaned and flushed. 5.8.6.1.If the pile bore has been executed by either of the mud circulation methods, fresh bentonite slurry shall be pumped through the chisel resting at the base of the bore to completely remove all currings and other loose material from the base. During the flushing, the speed of the bentonite circulation pump shall be raised to maintain high
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pressure. Such flushing shall be continued for at least 20 minutes while occasionally agitating the chisel. Flushing shall be continued beyond 20 minutes if the return slurry indicates presence of cuttings still within the bore. 5.8.6.2.In case the pile bore has been executed by Bailer Boring with Bentonite Slurry the bore shall be initially cleaned of loose material by light tampering of the flap-valve bailer. Thereafter the bailer shall be withdrawn and a string of AP1 rods shall be lowered up to the base of the bore and bentonite slurry shall be pumped through under high pressures in the case of the Mud Circulation Method. Agitation shall be effected by circular movement of the string of rods around the pile bore. Flushing shall be thus continued for at least 20 minutes. Flushing shall continue beyond 20 minutes till the return wash indicates that the bore is clean to the satisfaction of the ENGINEER. 5.8.6.3 Where permanent liners have been used, the bore shall be filled with water that has been certified for concreting and a flap valve bailer shall be used to remove the loose material light tamping. The bailer shall then be withdrawn and a string of API rods shall be lowered down to the base of the bore. The certified water shall then be pumped through the string of rods at high speed for atleast 20 minutes. Agitation shall simultaneously be effected by a gentle vertical movement and vigorous circular movement to the rods. Flushing shall continue thus beyond 20 minutes till the return wash indicates that the bore is clean to the satisfaction of the ENGINEER. The water from within may be pumped out with approval of the Engineer. However no pumping out shall be done if the ground water table is above the bottom of the pile bore and/or if the subsoil around the bottom of the pile bore is likely to be disturbed by pumping out the water. 5.9. PLACEMENT OF REINFORCEMENT CAGE:
5.9.1. Immediately after successful completion of final post-bore flushing and cleaning, the reinforcement cage shall be lowered into the pile bore. All care shall be taken during transporting, lifting and lowering of the cage that the cage does not twist or distort out of alignment. 5.9.2. The cage shall be lowered into the pile bore by gravity and shall not be forced linto the bore. Care shall be exercised that no collapse of any portion of the unlined bore occurs while lowering. In case the total length of the pile is such that handling of the entire length of the
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cage becomes unwieldy, the cage shall be fabricated in two lengths. The location of such jointing shall however be got approved by the ENGINEER in writing. After the first section of the cage is lowered and held with the top of the bars adequately outside the bore, the upper cage section shall be lifted, held vertical and gradually lowered over the lower cage section so that the main longitudinal reinforcement bars of the two cage sections are aligned bar for bar. Jointing of the respective bars of the two cages shall be effected as per Clause 5.3.2 above. The internal cage shall then be lowered into the pile bore and into final position and held in place by slings or suitable devices approved by the ENGINEER. 5.9.3. Longitudinal reinforcement above the ground level shall not be arbitrarily bent for seating the concrete tremie hopper. If the reinforcement cage has been fabricated longer than that required on the Drawing (in view of a shorter pile bore than that envisaged earlier), the excess lengths shall be cut. Outward flaying of the main reinforcement bars of the cage shall not exceed 5 degrees with the vertical to avoid breaking of the bars while rebending the reinforcement back into position after the concreting. In any case, the internal radius of the bend shall not be less than five times the bar diameter. While flaying the reinforcement cage outwards, it shall be ensured that the cover to reinforcement within the pile bore to be concreted is maintained. 5.10 FINAL PRE-CONCRETING FLUSHING: 5.10.1 Immediately after the reinforcement cage is positioned, the concrete tremie pipe shall be lowered into the pile bore concentrically within the reinforcement cage, with the bottom of the tremie pipe just above the bottom of the bore. The top of the tremie pipe shall be connected to a high speed bentonite pump and flushing with bentonite slurry shall be resumed. If concreting of the pile bore is to be done by concrete pump, flushing shall be done through a string of API rods lowered into the pile bore concentrically within the reinforcement cage with the bottom of the string of rods just above the bottom of the pile bore. 5.10.2 The procedure for flushing shall be the same as that indicated in clause 5.8.6 above. At the end of such flushing the CONTRACTOR shall ensure that heavy contaminated bentonie suspension, which could impair free flow of the concrete from the tremic pipe or concrete pump trunk, has not accumulated in the
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bottom of the pile bore. The suspension shall be sampled from the pile bore bottom by a suitable device approved by the ENGINEER and the density of the suspension checked by a calibrated hydrometer. The density of the sampled suspension shall not exceed 1.2gm/cc. In case this value is exceeded, flushing shall be resumed as per Clause 5.8.6 till the suspension is within the desired density range. 5.11. PILE CONCRETING 5.11.1. GENERAL 5.11.1.1Concreting of pile bores shall be executed only through a tremle system of concrete pump over the entire length of the pile. Tipping in of concrete from ground level or above into the pile bore is prohibited even if the pile bore is dry (as may perhaps be the case for pile bores with permanent liners). 5.11.1.2. Only freshly mixed concrete shall be used. Placement of the concrete shall be a continuous operation. The CONTRACTOR shall ensure that concrete mixers of adequate capacity are provided at the site with standby. If concrete pump is to be used for concreting a standby pump shall be provided. The pile shall be abandoned if concreting operations are suspended due to any reason by more than 20 minutes. It shall also be ensured that there are no air pockets created within the concrete shaft. 5.11.2.TREMIE CONCRETING SYSTEM 5.11.2.1. Tremie pipe concreting shall be done as per IS.456 and IS:2911 (Part I/Sec.2). The minimum diameter of the tremie pips shall be 200mm. The steel hopper at the top of the tremie pipe shall have a volume in excess of the total volume of the tremie pipe below. The neck of the hopper shall be fitted with a steel plate covering the entire opening. Suitable arrangements shall be made to remove the steel plate and uncover the hopper neck aperture when the hopper is full of concrete. The hopper and the entire length of the tremie pipe shall be thoroughly clean and free of any encrusted concrete or internal protrusions such a sleeves, collars etc. or any soil or debris. The entire tremie pipe-hopper system shall be water tight. 5.11.2.2. After the final pre-concreting flushing has been successfully executed, the tremie pipe shall not be extracted but shall continue to remain upto the bottom of the pile bore. Suitable ramps or staging
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shall be provided to facilitate easy and smooth feeding of the hopper with concrete either manually or by mechanised means, The ramps of staging shall be flexible enough to allow concrete feeding if the hopper is raised during concreting. 5.11.2.3 A sliding plug of polystyrene for similar material lighter than water and approved by the ENGINEER shall be placed in the tremie pipe to prevent direct contact between the first charge of concrete in the tremie and the bentonite slurry. At the commencement of concreting, the steel plate shall first cover the hopper neck while the hopper iscompletely filled with concrete. The steel plate shall then be removed and the concrete in the hopper allowed to flow into the tremie pipe.Subsequent charges of concrete shall be maintained as continuous as possible until the pile bore is concreted as specified in Clause 5.11.5 below. The tremie pipe shall at all times penetrate the concrete by minimum two meters after placing of the concrete has commenced and shall not be withdrawn from within the concrete until completion of concreting. Care shall be exercised when vertical movement is imparted on the tremie pipe to force the concrete down the tremie pipe. Such movements shall be limited. The CONTRACTOR shall note that the pile shall be abandoned if in the opinion of the ENGINEER, the tremie pipe bottom has been raised above the concrete level within the pile bore. While raising the tremie pipe, care shall be exercised that the reinforcement cage is not disturbed from its position. 5.11.3.Concrete pump : 5.11.3.1.If the concrete pump is used to feed the hopper of a tremie concreting system Clause 5.11.2 shall apply. 5.11.3.2.If the concrete pump is used for placing concrete directly into the pile bore, the trunk of the pump shall be placed upto the bottom of the pile bore immediately after the string of AP1 rods used for final preconcreting flushing have been removed after successful flushing. The trunk shall at all times penetrate the concrete after commencement of concreting by at least two metres and shall not be withdrawn from within the concrete until the completion of concreting. The CONTRACTOR shall note that the pile shall be abandoned if in the opinion of the ENGINEER, the trunk has been raised above the concrete level within the pile bore. While raising the trunk, care shall
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be exercised that the reinforcement cage is not disturbed from its position. 5.11.4. Lifting of temporary casing : 5.11.4.1.The temporary casing shall be carefully withdrawn only after the concrete surface in the pile bore has risen to not less than three metres above the bottom of the casing or not less than one metre above the level of ground water whichever is higher. The casing shall be lifted only to the extent that there is minimum one metre of concrete above the casing bottom. The level of concrete shall be checked vis a vis the casing bottom and ground water level by suitable methods as approved by the ENGINEER. 5.11.4.2 While withdrawing the temporary casing, care shall be exercised that the reinforcement cage is not pulled out along with the casing. It shall also be ensured that no voids or ground water pockets are formed around the pile shaft during withdrawal. Adequate precautions shall be exercised to ensure that the concrete is not lifted up along with the casing and that no necking or waisting occurs in the pile shaft. Special care shall be exercised when the ground water level is high. During withdrawal, the movement of the temporary casing shall be maintained in an axial direction relative to the pile. 5.11.5.Completion of concreting: Irrespective of the specified pile cut-off level, concrete shall be poured into the pile bore until all the contaminated concrete at the top of the bore overflows the top of the pile bore and beat concrete appears continuously as overflow. Concreting shall then be terminated after permission of the ENGINEER. 5.12 PILE CUT OFF AND EXTENSION : 5.12.1.Excavation for pile cut-off shall be done by the CONTRACTOR unless indicated otherwise in Data Sheet A. The extent of excavation shall not exceed the minimum necessary for the required pile cut-off. The CONTRACTOR shall provide adequate side slopes / shoring at no extra cost to the OWNER. In order to provide safe working space for pile cut-off, Excavated material shall not be stacked near the edge of any excavation. The material shall be stacked at spots designated by the
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OWNER near the excavation within the plant limits at no extra cost to the OWNER. Dewatering if required, will not be paid separately. 5.12.2. Pile cut-off to specified levels shown on the Drawing shall be done by the CONTRACTOR for all piles at no extra cost. The CONTRACTOR shall station an adequate work force at site for the same. 5.12.3.When cutting off and trimming piles to the specified cut-off level, the contractor shall take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and the pile repaired in an approved manner to provide a full and sound section at the cut-off level. 5.12.4.Minimum chipping of the pile shall be 600 mm or till sound concrete is met with or specified cut-off level, whichever is greater. While chipping the concrete, care shall be taken to ensure that the reinforcement is not damaged in any way. If the reinforcement is damaged while chipping or bending back, the CONTRACTOR shall rectify the same as directed by the ENGINEER at no extra cost to the OWNER. If the specified cut-off level is less than 600 mm below the ground level (which is the concrete overflow level after all temporary casings are withdrawn) or if the cutoff level is above the ground level, the concrete shaft shall be chipped by minimum 600mm or till sound concrete is met with, whichever is greater. Thereafter, if found necessary, additional reinforcement shall be jointed as specified earlier in Clause 5.3.2 above. The pile shall then built up to the specified cut-off level using suitable circular formwork & concrete of grade specified for the pile shaft. 5.12.5 If due to any defective concreting, honey-combing, exposure of reinforcement, snapping of reinforcement bars etc., stripping of pile concrete is required to be done to a level lower than the specified cutoff level to obtain dense and sound concrete, the pile shall be built up with the good concrete of specified grade for the pile shaft upto the specified cut off level by the CONTRACTOR at no extra cost to the OWNER. Such building up including excavation, concreting, form work and compacted backfiring shall be at CONTRACTORs cost. 5.12.6. On completing pile cut-off for any pile, all exposed reinforcement surface shall be coated with cement wash at no extra cost to the OWNER.
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5.12.7.The CONTRACTOR shall backfill all excavation done by him for pile cutoff to levels specified by the ENGINEER or as shown on the Drawing, These levels shall be lower that or at least equal to the original working level. 5.12.8. Any over-excavation and backfilling of the same with consolidation shall be at no extra cost to the OWNER. 5.13. TOLERANCES; 5.13.1 Positional: 5.13.1.1. For a pile cut off at or above ground level, the maximum permitted deviation of the pile centre from the centre-point shown on the Drawing shall be 75 mm in any direction. An additional tolerance for the pile head, cut off below ground level will be permitted as below. 5.13.2. Vertical: Tolerance of verticality shall be with in 1 in 75 for the completed pile shaft. 5.13.3. Rake: The equipment governing alignment of the inclined permanent casing and boring tool shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The maximum deviation of the finished pile from the specified rake shall be 1 in 25 for piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6. 5.13.4. Corrective measures: 5.13.4.1. No forcible corrections to piles to overcome errors of position or alignment shall be attempted. 5.13.5 If after excavation for pile cut off, any pile or piles are found to exceed the specified positional and/or alignment tolerances, these shall be replaced or supplemented by the CONTRACTOR by additional pile(s) as directed by the ENGINEER at no extra cost to the OWNER. Also if as a result of pile(s) exceeding the specified permissible positional deviations, and/or the consequent addition of any replacement pile(s), any pile cap is required to be enlarged, the extra cost of such pile cap enlargement shall be to the CONTRACTORs account.
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5.14 BANDONED PILE BORES AND REJECTED PILES : 5.14.1 Abandoned pile bores shall be filled with sand which constitutes fine aggregate used for making concrete. If a permanent liner has already been driven, the same shall be withdrawn progressively as the sand is poured in. However no attempts shall be made to extract the liner if, in the opinion of the ENGINEER, this can damage or set out of alignment any other pile in the vicinity.
5.14.2.No attempt shall be made to forcibly extract a rejected pile shaft. Rejected piles shall be cut off as directed by the ENGINEER. The CONTRACTOR shall install replacement pile or piles in lieu of rejected piles as directed by the ENGINEER. 5.14.3.Piles / casing / borings that are defective or exceed the tolerance specified, shall be left in place or pulled out as directed by the Engineer, without adversely affecting the performance of adjacent piles. In case piles/casings can not be extracted, that shall be cut off as directed by the Engineer. 5.14.4.The CONTRACTOR shall not be paid any additional amount for filling up abandoned pile bores or cutting off rejected piles, provision of extra piles, enlargement of pile cap etc., necessitated due to faulty work of the CONRACTOR, filling of voids, etc. 5.15. PILE CAPACITIES : 5.15.1.Safe structural capacity of the pile shall be taken as the load calculated on the basis of permissible concrete stresses and permissible steel stresses as per IS : 456. 5.15.2.The total load carrying capacity shall be determined by conducting initial load tests on piles installed to full length. 5.15.3.Pile load tests on both initial piles as well as working piles shall be carried out to establish and prove these capacities. 5.16. PILE LOAD TESTS : 5.16.1.General : Any number of test piles and working piles as specified in the schedule of items or at the discretion of the ENGINEER shall be subjected to load
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tests. The CONTRACTOR shall provide everything,necessary including equipment, measuring devices, jacks, structural framework, kentledges etc. This includes installation of test piles also and concreting of pile cap either temporary or permanent over single or group of piles for testing the piles. The pile cap concreting will not be paid for separately. 5.16.1.1 Load tests shall in general be carried out as per IS : 2911(Part4) except as modified herein or directed otherwsie by the ENGINEER. 5.16.1.3.Piles to be load tested shall either be so designated on the Drawings or specified / selected by ENGINEER in the field. 5.16.1.4.Test load shall be applied to the piles by any suitable means preferably by a properly calibrated hydraulic jack with a remote control pump. Test load applied to the piles shall be such that a constant load is maintained under increasing settlement. 5.16.1.5.The required reaction may be derived from either a loaded platform or anchor piles. Anchor piles shall not be closer than 6 times the pile diameter on either side. Working piles shall not be used anchor piles. Anchor piles, if provided, shall be at CONTRACTORS cost. 5.16.1.6.Load tests shall in general be carried out not earlier than 28 days from the time of casting the pile and may be performed concurrently with the pile installation operations if permitted by the ENGINEER. 5.16.1.7.The design and arrangement of application of loading etc. for all types of load tests, shall be submitted by the CONTRACTOR to the ENGINEER for his approval. 5.16.1.8.All load tests shall be conducted under the supervision of the ENGINEER. All responsibilities for conducting the tests safely and properly shall rest with the CONTRACTOR. 5.16.1.9.Arrangements shall be made to cast the test piles and conduct initial load test on the same. On conformation of load test results, further testing of piles shall be done. 5.16.1.10 Calibration of equipment The CONTRACTOR shall ensure, that all the equipment / instruments are properly calibrated, at the start of the tests, to reflect the correct values. If so demanded by the ENGINEER, the CONTRACTOR shall
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have all or such specific instruments tests at an approved testing laboratory at the CONTRACTORS cost and the test report shall be submitted to the ENGINEER. If the ENGINEER desires to witness / inspect such tests, the CONTRACTOR shall arrange for this and also provide such access and facilities for inspection as are required. 5.16.2 Initial load tests 5.16.2.1 Immediately on mobilisation to site, the CONTRACTOR shall prepare to install piles for conducting initial vertical load (downward and pull-out) tests. 5.16.2.2 In case the cut off is below ground level, a suitable excavation shall be made to provide access to the level after breaking off the unsound concrete as specified earlier in Clause 5.12. 5.16.2.3 For the compression type of test, the pile head shall be cut off level and capped by a R.C. cap to provide a horizontal plane bearing surface upon which a steel plate shall be placed. Earth from under the pile cap shall be scooped out so that pile cap has no soil support. Thereafter, the kentledge and all other accessories outside the pit pertaining to and necessary for conducting the test shall be set up. An easy access to the pile test head shall be provided. 5.16.2.4 If the pile test head is below the ground water level, the CONTRACTOR shall provide suitable sumps and dewater the pit so as to render the pit dry enough to enable conducting the test. Any dewatering will be considered as part of the test and the CONTRACTOR shall not be separately paid for the same. 5.16.2.5 The test load shall be so applied that it reaches the pile in a static manner. The loading may be applied directly by kentledge or jacking against a reaction system provided by means of kentledge, tension piles or ground anchors. Where kentledge is used it shall be supported on a properly designed frame or gantry such that there is no possibility of the load tilting or collapsing. The foundations of this frame or gantry should be sufficiently far way from the test pile so as not to affect its behaviour to any significant extent. Where tension piles or ground anchors are used, they shall be located a minimum distance of three times the test pile size from the centre of the test pile to the centre of the pile / anchor.
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5.16.2.6 The displacement of the test pile shall be related to a fixed datum. This may consist of a reference beam (datum bar) supported by two foundations positioned outside the zones of influence of the reactions support area. The deflection measuring equipment must be set up in such a way that any tilting of the test pile will not cause errors in the measurements. Dial gauges shall be used for measuring deflection. The least count of the dial gauges shall be at least 0.01mm. At least two but preferably four dial gauges shall be used and shall be placed at diagonally opposite corners. 5.16.2.7 The reference bars for the strain gauges shall be adequately rigid and on firm supports. The supports for the reference bars shall be so located that they are beyond the zone of influence of the loaded test pile (equal to three times the pile size from pile edge) and the zone of influence of kentledge supports. The bars shall be adequately stiffened and placed on supports in a manner such that any effect due to ambient temperature variations and vibrations due to traffic etc. are minimised. The reference bars and strain gauges shall not be exposed to direct sun and the pit shall be protected by tarpaulin sheets while the test is in progress. 5.16.2.8 The total test load shall be three (3) times the estimated safe loadcarrying capacity of the pile. Percentage of the above load shall be applied in equal increments of 20 percent of the estimated safe load. Unloading may however be in higher decrements with total number not less than five. At each load increment, pile deflection shall be observed accurate to 0.02mm at an interval of 2, 4, 8, 15, 30,60 and 120 minutes as the case may be upto a time when the rate of deflection of the pile top reduces to 0.1mm in first half an hour or 0.2mm in one hour or till 2hours whichever occurs first. The load increment in any case shall be maintained for 1 hour atleast. The design load as well as the final load shall be maintained for 24 hours. At these load increments, after the first hour, deflection readings shall be taken at every one hour interval. 5.16.2.9 During the release stage, each load decrement shall be maintained at least for 30 minutes & readings of deflection noted. When the load is fully released to zero, measurements of rebound shall be continued till the deflection of the pile top is not more than 0.1mm per half hour.
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5.16.3. If the initial test pile (s) which is (are) load tested fails (fall) to attain the specified safe structural capacity of piles and if this can be attributed to defective workmanship and / or negligence on the part of the CONTRACTOR, the OWNER reserves the right to terminate the contract and to award the contract to other parties. In such an event, all costs of mobilization, installation and testing of test pile(s) and any other work in connection with the test piles, shall be borne entirely by the CONTRACTOR. 5.16.3.1.While executing the pile bore for all test piles, a record of bore log and Standard Penetration Tests shall be maintained over the continuous length of boring in an approved format. Sub soil samples and rock cuttings shall be collected and systematically preserved. A complete log of the sub surface profile shall be maintained during execution of boring for each and every pile shaft and a copy of such log shall be maintained to the owner for scrutiny prior to commencement of lowering of reinforcement cage 5.17. Load tests on working piles : 5.17.1. These tests shall be carried out on poles selected by the ENGINEER after they have been cast. Tests to be carried out on working piles shall essentially be ordinary compression type. 5.17.2. The working pile shall be considered to have stood the test satisfactorily if total settlement under final test load is not more than 12 mm and as stated in IS 2911 Part IV. 5.17.3. If the pile does not satisfy these requirements and if this can be attributed to defective workmanship or negligence on the part of CONTRACTOR, all costs of the load test, the cost of providing and installing additional piles, cost of additional or enlarged pile caps and other work necessitated because of the defective pile, shall be at the cost of CONTRACTOR. 5.17.4 Records of load test results: Within 48 hours of completion of each test, the CONTRACTOR shall furnish a copy of all recorded test data to the ENGINEER. Upon completion of pile load tests, the CONTRACTOR shall furnish the ENGINEER at no extra cost with a pile test report in triplicate and this shall include the following information where applicable. a) Identification of working pile/test as per Drawing.
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b) c) d) e) f) g) h) i)
Co-ordinate axes of pile, elevation of bottom of pile, cut-off Level of pile, type of pile, pile size. Pile Bore log Records. SPT Results Deviation from designated location / alignment. Jack gauge calibration curves from approved Test House. Tabulation of loads and settlement readings during the loading and unloading of the pile. Graphic representations of the test results in the form of time-loadsettlement curves. Graphic analysis of Initial Cyclic test results to separate skin friction and end bearing as set out in IS : 2911 (Part-IV)
Remarks concerning any unusual occurrences during installation or test loading of the working piles / test piles. 5.18 INDIRECT INTEGRITY TESTS FOR PILES : The ENGINEER may desire to get bored cast in situ piles subject to integrity tests by indirect methods through another agency. The CONTRACTOR shall give all cooperation in getting such tests conducted. The ENGINEER reserves the right to give due weightage and consideration to results of these tests which will affect the integrity of the installed piles.
5.19. INSTALLATION RECORDS : 5.19.1. The CONTRACTOR shall submit each working day, detailed pile installation records in duplicate for each pile installed in the enclosed formats. The ENGINEERS piling plans will show all piles serially numbered as per the piling layout plans. The cost of all labour, materials and services called for herein shall be included in the CONTRACTORs unit rates. 5.19.2 The details of the record shall include but not be limited to the list below : PILE INSTALLATION RECORD : A. Basic data : 1) Piling Layout Drawing No. 2) Pile Number 3) Location Co-ordinates 4) System / Structure
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5) Pile Location vis-a vis Pile Group (Draw dimensioned sketch with reference axes and shade the pile) 6) Pile Type : Vertical / Raker 7) Pile Nominal Diameter 8) Pile Tip Elevation 9) Pile Cut-off Elevation 10)Ground Level at Pile Location. 11)Grade of Concrete Specified 12)Reinforcement Details (Draw sketch if complex) 13)Safe Capacity of Pile Specified. B. Pile bore data : 1. Date and Time of Start 2. Date and Time of Completion 3. Method of Boring 4. Inner Nominal Diameter of Temporary Casing / Permanent Liner 5. Length of Temporary Casing / Permanent Liner 6. Material of Permanent Liner. 7. Method of Jointing Temporary Casing / Permanent Liner 8. Treatment to Permanent Liner 9. Length Bored in Soil 10. Length Bored in Rock 11. Bore Log (Draw sketch or refer to separate sheet) 12. Details of Standard Penetration Test 13. Number of Subsoil Samples / Rock cuttings collected. 14. Ground Water Elevation 15. Any Artesian Conditions 16. Any Bore Collapse and Details 17. Any Loss of Drilling Mud and Details 18. Any other Details or Phenomena Observed. C. Flushing Record : 1) Date and Time of Start of Final Post-bore Flushing. 2) Date and Time of Completion of Final Post-bore Flushing. 3) Remarks on inspection of Wash of Post-bore Flushing. 4) Date and Time of Start of Final Pre-concreting Flushing. 5) Date and Time of completion of Final Pre-concreting Flushing. 6) Remarks on Inspection of Wash of Pre-concreting Flushing.
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D. Concreting Record : 1. Date and Time of Start of Concreting. 2. Date and Time of Completion of Concreting. 3. Grade of Cement and Name of Manufacturer 4. Date of Manufacture of Cement 5. Date of Concrete as mixed 6. Grade of Concrete Specified 7. Slump of Mixed Concrete at pile Head 8. Cube-Test Results 9. Method of Concrete Placement in Pile Bore. 10. Theoretical Volume of Concrete : (Pile Tip to Top Pile as Cast) 11. Actual Volume of Concrete : (Pile Tip to Top of Pile as Cast) 12. Ratio of Actual Volume to Theoretical Volume of Concrete : (Express as Percentage) 13. Any Delays during Concreting and Reasons. 14. Overflow Quantity 15. Any other details 5.20. CLEAN-UP: 5.20.1. All throughout the work, the CONTRACTOR shall take all steps to prevent spillage of bentonite slurry on the site in areas outside the immediate vicinity of boring. The slurry shall not be allowed to flow into any water courses, nallahs, site drains or any public drains. 5.20.2. Any discarded and / or used bentonite shall be removed from the site without any undue delay. 5.20.3. Upon completion of piling work, all casings, equipment, construction tools, protective coverings and any debris resulting from the work shall be removed from the premises. 5.20.4. All debris, empty containers, scrap timber etc. shall be removed as directed by the ENGINEER / OWNER. 5.20.5. Exposed and finished concrete and dowel surfaces shall be left in a clean condition satisfactory to the ENGINEER.
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Bid Ref. No: CE/D/CNR//R-APDRP (Part-B)/Specn. No: E-1069/ 2013-14

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DESIGN AND DESIGN LOADINGS

Wind Loads shall be considered as per IS:875 part (3)

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10. 11. 12. 13. 14. (b) 1. 2. 3. (c) 1. 2. 3. 4. 5. 6. 7. 8. 9.

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Zone-IV 100 95-100 95-100 90-100 80-100 15-50 0-15

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Percent by weight Crushed 3.00 1.00 ----

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Inorganic Sulphates (as SO4) Alkali Chlorides (as Cl) 1.5. i)

0.30 0.05 0.20

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Medium High Very high

50-100 75-100 100-150 See 5.6.c below

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i) ii) iii) iv) v) vi) vii)

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i) ii) iii) iv) v) vi)

i) ii) iii) iv) v) vi) vii)

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1.12 PROCEDURE FOR PLACING OF CONCRETE: APPROVAL OF EQUIPMENT & METHODS a)

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scrapped, cleaned, plugged and joints

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