LIST OF APPROVED MAKES ( Electrical Items)

i. Flexible Copper wires : Finolex/ Havell’s/ Polycab wires. ii. Switch & Sockets : Legrand/ Anchor/ Havells. iii. Distribution board : Legrand/ Hager/ Havell’s iv. 4. MCCB, MCB, RCCB : Legrand/ Hager/ Havell’s/ L&T. v. Lug : Dowells vi. Casing caping/Conduit : Berlia/ Polypack/ Pestoplast/ Richa vii. Cable gland : Commet viii. Exhaust fan : Bajaj/ Crompton Greaves/ Havells/ Usha/Orient ix. Lighting fixture : Phillips/ Bajaj/ Crompton Greaves/Havells x. Ceiling fan : Bajaj/ Crompton Greaves/ Havells/ Usha/Orient

LIST OF APPROVED MAKES (CIVIL WORKS) Sl. No. Material Approved Make/ Manufacturers 1 Plywood/ Flush Door Kutty, Kitply, Century, Greenply, Mayur, Gattani2 Laminate Green Laminate Century, Neo Nuxe, For Mica3 Adhesive Fevicol, Pidilite4 Pre‐laminated particle board Anchor, Durian, Novappan 5 Aluminium building hardware IPSA, Everite, EBCO, ECIE, Hardwin Traders 6 Locks Godrej, Harrison, Yale 7 PVC door/ shutter Rajshri8 Ceramic tiles Regency, Kajaria, Somani, H&R Johnson, Bell, Orient 9 Vitrified tiles Regency, Kajaria, Somani, H&R Johnson, Bell, Naveen, RAK, Asian, Marbito 10 Pre‐coated iron galvanized profile sheet and accessories Lloydeck, Trackdeck, Multiclad, TATA Bluescope, Dyna Roof 11 Water proofing compound FOSROC, SIKA, CICO12 Wall putty JK Wall putty, Birla putty 13 Paint Asian, Berger, Nerolac, ICI paints 14 Aluminium sections Jindal, Hindalco, Indalco, Mahaveer15 White Cement ACC Birla, Ultra‐Tech 16 Glass (float/ sheet) Modiguard, Saint Gobian, TATA Continantal17 Pressed Steel door frame Senharvic, AGEW, Steel Flast, Rajender Steel18 Vitreous china sanitary ware Paryware, Hindustan Sanitary ware, CERA19 Plastic WC cover Hindustan Sanitary ware, Commander20 Stainless Steel sink Nilkanth, Nirali, Jayna, Crysil 21 G.I pipes Jindal, TATA, Prakash Surya 22 G.I fittings Unik, ZOLOTO‐M, DRP‐M, Kent 23 CPVC pipe Astral, Ashirwad, SFMC 24 Rain water & PVC pipes & fittings Prince, Supreme, Finolex, SFMC 25 Gunmetal valves Leader, Sant26 Upvc pipes & fittings Supreme, Finolex, SFMC 27 Stoneware Pipes, Gully Traps (IS 651) Pragati, Perfect, Burn, C&R 28 C.I covers & Manhole covers RIF, NICO

29 CP Brass Fittings & Accessories Jaquar, Gem, Ess‐ess, Aquaplus 30 Floor Drain Fixture & Channel Gratings Chilly, Neer, ACO31 C.P. Grating for Floor Trap Chilly Cockroach Trap, GMGR 32 Cast Iron Pipes & Fittings Manhole covers and frames‐ As per IS:3989 (Pipes & Fittings) NECO, KAPILANSH 33 Cast Iron Pipes & Fittings Manhole covers and frames‐ As per IS:1729 (Manhole covers and frames) NECO, Raj iron Foundry, BIC Calcutta, Kajeco, SKFBC, K.K.,SRIF, RIF 34 Cast Iron Pipes & Fittings Manhole covers and frames‐ As per IS:1536 (CILA pipe) Electro Steel Calcutta, Kesoram Calcutta 35 Electro Steel Calcutta, Kesoram Calcutta, Kartarvalves & fittings 36 Drip Seal Vinod Cement Co. Chandigarh (PJS‐43)37 GI pipe Sealant Henkel – LOCTITE 55 38 Pipe clamp & supports Chilly, Euro Clamp, Hi tech 39 Clean Out Plug Neer, GMGR 40 GM / Forged Brass Ball Valves Zoloto, DRP, Sant / Leader 41 Wafer Type Check Valve Audco, Zoloto, Advance 42 Butterfly Valve Audco, Zoloto, Advance 43 Air Release Valve Zoloto, OR, Arco44 Ball Float Valve Zoloto, HBD, Esseti 45 MH / Water Tank Plastic Steps KGM, Patel, Pranali Industries 46 Insulation for Hot Water Pipes Thermoflex, K‐Flex, Armacell 47 Water Tanks Sintex, Rotoplast48 SFRC MH cover & frame and gratings KK Manholes & Gratings, SFP/Steel Fibre ProductPragati 49 Anticorrosive Tape for Pipe Protection PYPKOTE50 Anticorrosive Bitumastic Paint Shalimar51 Epoxy Paint Asian, Berger, J&N 52 Pressure Gauge H Guru, Fiebig, Dwyer 53 Water Meter (Mechanical Type) Kaycee Kranti, Capstan, Actaris 54 Fastener Fisher, Hilti, Canon55 Fire Sealant Hilti, Promat, Birla 3 M 56 Sealant & Additives Asian paints, Foscroc, Pidilite 57 Concrete Additives SIKA, Fosroc, CICO, Sunanda Roff 58 Polymer sealant for expansion joint SIKA, CICO, Pidilite, G.E.Silicon. 59 RCC pipe Ashok Cement pipe, Indian Hume pipe, KK 60 APP membrane Lloyd Insulation, Builtech Products Pvt. Ltd., CICO technologies Ltd., FOSROC chemicals, STP Ltd., SIKA, IWL India Ltd., Pure Leathers Ltd. 61 Paver Tiles Endura, Marbonite

Note: Incase of non-availability/shortage, contractor will take approval from Owner to procure alternative brands as per approved make list .

TECHNICAL SPECIFICATIONS FOR

CIVIL AND OTHER ALLIED WORKS

PROJECT: Extension of Laboratory building at NRL site

CONTENTS Sub-Head No. Content / Description 1. ------------------ 2. REFERENCE STANDARDS 3. EARTH WORK 4. ANTI-TERMITE TREATMENT 5. SAND FILLING 6. STONE FILLING 7. UPVC PIPE 8. PEA GRAVEL 9. PLAIN AND REINFORCED CONCRETE WORK 10. STEEL REINFORCEMENT 11. FORM WORK 12. STRUCTURAL STEEL WORK 13. ALUMINIUM DOORS, WINDOWS & VENTILATORS 14. FLOORING AND PAVING 15. PLASTERING 16. WHITE WASHING AND CEMENT PAINTING 2.0 REFERENCE STANDARDS

Wherever reference of BIS Specifications or BIS Codes of Practice are made in

the Specifications/Schedule of Rates or Preambles, reference shall be to the latest edition of BIS (Bureau of Indian Standards).

IS: 109 Ready mixed paint, brushing, priming, plaster to Indian Standard colour

No. 631 and 361 white and off-white.

IS: 248 Sodium bisulphite, technical (Sodium metabisulphite ).

IS: 383 Coarse and Fine aggregates from natural sources for concrete.

IS: 419 Putty, for use on window frames.

IS: 427 Distemper, dry, colour as required.

IS: 432 Mild Steel and Medium tensile steel bars.

IS: 456 Code of Practice for Plain and Reinforced Concrete.

IS: 459 Corrugated & Semi-corrugated asbestos cement sheets.

IS: 515 Natural and Manufactured aggregate for use in mass concrete.

IS: 730 Hook bolts for corrugated sheet roofing. IS: 800 Code of Practice for General Construction in Steel

IS: 814 Covered electrodes for manual metal arc welding of carbon and carbon manganese steel.

IS: 815 Classification coding of covered electrodes for metal arc welding of structural steels.

IS: 816 Metal Arc Welding for General Construction of Mild Steel.

IS: 817 Code of practice for training and testing of metal arc welders.

IS: 883 Code of practice for structural timber in building.

IS: 1038 Steel doors, windows and ventilators.

IS:1079 Hot rolled carbon steel sheets and strips.

IS: 1081 Code of practice for fixing and glazing of metal (steel and aluminium) doors, windows and ventilators.

IS: 1161 Steel tubes for structural purposes.

IS: 1285 Wrought aluminium and aluminium alloy extruded round tube and hollow sections.

IS: 1361 Steel windows for industrial buildings.

IS: 1363 Hexagon head bolts, screws and nuts of product grade C : Part-I Hexagon head bolts ( size range M-5 to M-64 ).

IS: 1367 Technical supply conditions for threaded steel fasteners.

IS: 1566 Hard - Drawn steel wire fabric for concrete reinforcement.

IS: 1786 High strength deformed steel bars and wires for concrete reinforcement.

IS: 2062 Steel for general structural purposes.

IS: 2116 Sand for masonry mortars.

IS: 2212 Code of practice for brickwork.

IS: 2386 Methods of test for aggregates.

IS: 2553 Safety glass : Part-I General purpose.

IS: 2835 Flat transparent sheet glass.

IS: 3007 Code of practice for laying of asbestos cement sheets.

IS: 4021 Timber door, window and ventilator frames.

IS:- 4923 Hollow steel sections for structural use.

IS: 4925 concrete batching and mixing plant.

IS: 5410 Cement Paint.

IS: 6477 Dimensions for wrought aluminium and aluminium alloys, extruded hollow sections.

IS: 7318 Fusion welding of steel.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 2720(PART- XXVIII) - Determination of dry density of soil, in-place, by the Sand

Replacement Method

IS: 2720(PART- XXIX) - Determination of dry density of soil, in-place, by the Core

Cutter Method

IS: 2076 Specification for unsupported flexible vinyl film & sheeting

IS: 4985 Specification for unplasticised polymer of vinyl chloride pipe

IS: 13162 (PART-III - Method of test for determination of thickness at specified

pressure for Geo – textile sheet.

IS: 13162(PART IV) - Method of test for determination of puncture resistance by falling

cone method

IS: 14293 Method of test for trapezoid tearing strength for Geo-textile sheet

IS: 14294 Method of test for determination of apperent opening size by dry sieving

technique for Geo-textile sheet

IS: 14324 Method of test for determination of water permeability-permittivity for Geo- textile sheet

3.0 EARTHWORK 3.1 EXCAVATION 3.1.1 Excavation shall be carried out in soil of any nature and consistency, in

the presence of water or in the dry, met on the site to the lines, levels and contours shown on the detailed drawings and Contractor shall remove all excavated materials to soil heaps on site or transport for use in filling on the site or stack them for reuse as directed by the Owner.

3.1.2. Surface dressing shall be carried out on the entire area occupied by the

buildings including plinth protection as directed without any extra cost. The depths of excavation shown on the drawings are the depths after surface dressing.

3.1.3 The site around all buildings and structures to a width of 3 metres

beyond the edge of plinth protection, ramps, steps, etc., shall be dressed and sloped away from the buildings.

3.1.4 Black cotton soil, and other expansive or unsuitable soil excavated shall

not be used for filling in foundations, and plinths of buildings or in other structures including manholes, septic tanks etc., and shall be disposed off within the contract area marked on the drawings, as directed, levelled and neatly dressed.

3.1.5 In case of trenches exceeding 2.0 metres depth or where soil is soft or

slushy, the sides of trenches shall be protected by timbering and shoring. The Tenderer shall be responsible to take all necessary steps to prevent

the sides of trenches from caving in or collapsing. The extent and type of timbering and shoring shall be as directed by the Owner.

3.1.6 Where the excavation is to be carried out below the foundation level of

adjacent structure, the precautions to be taken such as under pinning, shoring and strutting etc., shall be determined by Owner. No excavation shall be done unless such precautionary measures are carried out as per directions of Owner.

3.1.7 Specification for Earth work shall also apply to excavation in rock in

general. The excavation in rock shall be done such that extra excavation beyond the required width and depth as shown in drawings is not made. If the excavation done in depth greater than required / ordered. The Contractor shall fill the extra excavation with concrete of mix 1:5:10 as the foundation concrete at his own cost.

3.1.8 The Contractor shall make all necessary arrangements for

dewatering/defiling as required to carry out proper excavation work by bailing or pumping out water, which may accumulate in the excavation pit from any cause / source whatsoever.

3.1.9 Contractor shall provide suitable draining arrangements at his own cost

to prevent surface water entering the foundation pits from any source. 3.1.10 The Contractor is forbidden to commence the construction of structures

or to carry out concreting before Owner has inspected, accepted and permitted the excavation bottom.

3.1.11 Excavation in disintegrated rock means rock or boulders including

brickbats which may be quarried or split with crow bars. This will also include laterite and hard conglomerate.

3.1.12 Excavations in hard rock - meant excavation made in hard rock to be

done manually, or by blasting using only explosives and / or pneumatic hammers. In case of blasting, control blasting should be adopted depending on site conditions. For using explosives, Contractor shall follow all provisions of Indian Explosive Act/Rules 1983, corrected/ revised upto date.

3.1.13 In case of hard rock excavation to be carried out using explosive the

Contractor shall obtain the written approval in advance. 3.1.14 The measurements for excavations shall be restricted and limited to

minimum excavation line as per drawing for payment purposes. 4.0 ANTI-TERMITE TREATMENT MEASURES 4.1 SCOPE This specification specifies the requirement for the chemical treatment of

soils for the protection of buildings and plant buildings from attack by subterranean termites. This includes usages of anti-termite chemicals,

minimum rates of application, procedures to be adopted for pre-constructional measures.

4.2 CODE OF PRACTICES 4.2.1 The following Indian Standard Code of Practices of latest edition only shall

be followed and wherever references of the same has been taken, it shall be of latest edition only :

IS : 6313 Code of Practice for Anti-termite Measures in Buildings : (Part- I) Constructional Measures. (Part- II) Pre-Constructional Chemical Treatment Measures. (Part-III) Treatment For Existing Buildings.

IS : 8944 Specification for Chlorpyriphos Emulsified Concentrate.

IS : 4015 Guide for Handling cases of Pesticide Poisoning :

(Part- I) First- Aid Measures. (Part-II) Symptoms, Diagnosis and Treatment.

4.3 TERMINOLOGY 4.3.1 Chemical Barrier - The layer of chemically treated soil in immediate

contact with the foundation and floor structure of a building and plant building forms a barrier and is impervious to termite entry.

4.3.2 Soil Treatment - The application of chemicals (toxicants) to the soil

adjacent to and under a building and plant building to form a chemical barrier which is lethal or repellent to termites.

4.3.3 Pre-construction Chemical Treatments - This is a process in which soil

treatment is applied to buildings or plant buildings during its construction. 4.3.4 Treatments For Existing Buildings - The application of chemical

termiticides to existing building or plant building to eliminate existing termite infestation and to make them resistant to termite attack.

4.4 SITE PREPARATION 4.4.1 The trees, stumps, logs or roots shall be removed from the building or

plant building site area to reduce the hazards from subterranean termites. Similarly, the sub-floor area shall be kept free from all debris. In order to ensure uniform distribution of the treating solution and to assist penetration, the following site preparation may be necessary.

a. On clays and other heavy soils where penetration is likely to be slow and

on sloping sites where run off of the treating solution is likely to occur, the surface of the soil shall be scarified to a depth of at least 75 mm.

b. On loose, sandy or porous soils where loss of treating solution through piping or excessive percolation is likely to occur, preliminary moistening to fill the capillary spaces in the soil shall be done.

c. All sub-floor levelling and grading shall be completed. All cutting, trenches

and excavations shall be completed with back-filling in place. Borrowed fill must be free from organic debris and shall be well compacted.

d. All concrete form work, levelling pegs, timber off cuts and other builders’

debris shall be removed from the area to be treated. 4.5 CHEMICALS 4.5.1 Chlorpyriphos emulsified concentrate 1% concentration, toxic to sub-

terraineean termites, shall be use to check termite infestation in the soil. This is useful in the treatment of new building / plant building sites and shall also be used to eradicate existing infestation in building and plant buildings and to prevent reinfestation. The above chemical emulsion is required to be dispersed uniformed in the soil so as to form an effective chemical barrier.

4.5.2 Chlorpyriphos 20% emulsifiable concentrate conforming to IS : 8944 of

approved brand and manufacturer shall be purchased directly either from the manufacturer or from the reputed and authorised dealers in sealed original containers which shall be clearly levelled with the concentration of emulsifiable concentrate. The containers of the above chemical concentrate shall be kept in safe custody of the Contractor or his authorised representatives and storage shall be done in a dry and cool place under shed away from any fires source or flame. The above chemical concentrate shall be issued for use to meet the day’s requirement. Empty container, after proper washing and container with concentrated chemical with left unused at the end of the days’ work shall be returned to the storage place.

4.5.3 1 litre of Chlorpyriphos 20% emulsified concentrate should be mixed with

19 litres of water for getting Chlorpyriphos emulsifiable of 1% concentration. Graduated containers shall be used for the above dilution of Chlorpyriphos chemical.

4.5.4 Application of the chemical shall be done using hand operated

compressed air sprayer of water can to facilitate uniform dispersal of the chemical emulsion. For large jobs, power sprayer shall be used to save labour and time. Proper check shall be kept to ensure that the specified quantity of chemical is used for the required area during the operation.

4.6 PRE-CONSTRUCTION CHEMICAL TREATMENT 4.6.1 Pre-construction treatment of soils for the protection of buildings or plant

building from the sub-terraineean termites shall be done as per IS : 6313 (Part-II).

4.6.2 Soil treatment shall start when foundation trenches and pits are ready to take bed concrete / levelling course in foundations. Laying of bed concrete / levelling course should start when the chemical emulsion has been absorbed by the soil and the surface is quite dry. In the event of water logging of foundation pit, the water shall be pumped out and the chemical emulsion shall be applied when the soil is absorbent. The treatment shall not be carried out during rains or soil is wet. The treatment to the surface of earth filling within the plinth shall also be done in the same manner laying the sub-grade for flooring.

4.6.3 The treated soil barrier shall not be disturbed. If , for the some reasons,

the treated soil barriers are disturbed, immediate step shall be taken to restore the continuity and completeness of the barrier system.

4.6.4 The Chlorpyriphos emulsified 1% concentration shall be applied uniformly

at the prescribed rate in all the stages of the treatments given below : 4.6.4.1 Treatment for Masonry Foundations and Basements a. The bottom surface and the sides (upto a height of 300 mm ) of the

excavations made for masonry foundation and basements shall be treated with the chemical at the rate 5.0 litres per square metre surface area.

b. After the masonry foundation and the retaining wall of the basements

come up the back fill in the immediate contact with the foundation structure shall be treated at the rate of 7.5 litres per square metre of the vertical surface of the sub-structure of each side. If water is used for ramming the earth fill, the chemical treatment shall be carried out after the ramming operation is done by rodding the earth at 150 mm centres close to the wall surface and spraying the chemicals with the above doses.

4.6.4.2 Treatment for RCC Foundations and Basements The treatment shall start at the depth of 500 mm below ground level

except when such ground level is raised or lowered by filling or cutting after the foundations have been cast. In such cases the depth of 500 mm shall be determined from the new soil level resulting from the filling or cutting mentioned above, and soil in immediate contact with the vertical surfaces of RCC foundations shall be treated at the rate of 7.5 litres per square metre.

4.6.4.3 Treatment of Top Surface of Plinth Filling

The top surface of the consolidated earth within the plinth walls shall be

treated with chemical emulsion at the rate of 5.0 litres per square metre of the surface before the sand bed or sub-grade is laid. If the filled earth is well rammed and the surface does not allow the emulsion to seep through, holes upto 50 to 75 mm deep at 150 mm centres both ways shall be made with 12 mm diameter mild-steel rod on the surface to facilitate saturation of the soil with the chemical emulsion.

4.6.4.4 Treatment at Junction of the Walls and the Floor

Special care shall be taken to establish continuity of the vertical chemical

barrier on inner wall surfaces from ground level (where it had stopped with the treatment described in 6.4.1b) upto the level of the filled earth surface. To achieve this, a small channel 30 x 30 mm shall be made at all the junction of walls and columns with the floor (before laying the sub-grade). The rod holes shall be made in the channel upto the ground level 150 mm apart and the iron rod moved backward and forward to break-up the earth. The chemical emulsion shall be poured along the channel at the rate of 7.5 litres per square metre of the vertical wall or column surface so as the soak the soil to the right to the bottom. The soil should be tamped back into place after this operation.

4.6.4.5 Treatment of Soil Along External Perimeter of Building

a. After the building or plant building is completed, 300 mm deep holes shall

be made in made in the soil with iron rods along the external perimeter of the building/plant building at intervals of 150 mm. The rods should be moved backward and forward in-side the holes to break up the earth and these holes shall be filled with chemical emulsion at the rate of 7.5 litres per square metre of the vertical surfaces. After the treatment, the earth should be tamped back in to place.

b. In the event of filling is more than 300 mm, the above external perimeter

treatment shall be extended to the full depth of earth filling upto the ground level.

4.6.4.6 Treatment of Soil under Apron (Plinth protection) along External Perimeter

of Building Top surface of the consolidated earth over which the apron is to be laid

shall be treated with chemical emulsion at the rate of 5.0 litres per square metre of the surface. If consolidated earth does not allow the emulsion to seep through, holes upto 50 to 75 mm deep at 150 mm centres both ways shall be made with 12 mm diameter mild steel rod on the surface to facilitate saturation of the soil with chemical emulsion.

4.6.4.7 Treatment of walls Retaining soils above Floor Level Retaining walls such as basement walls or outer walls above the floor

level retaining soil shall be protected by providing chemical barrier by treatment of retained soil in the immediate vicinity of the walls. The soil retained by the walls shall be treated at the rate of 7.5 litres per square metre of the vertical surface, in continuation of the one formed under 6.4.1.

4.6.4.8 Treatment of Soil Surrounding Pipes, Wastes and Conduits When pipes, wastes and conduits enter the soil inside the area of the

foundation, the soil surrounding the points of entry shall be loosened around each such pipe wastes or conduit for a distance of 150 mm and to a depth of 75 mm before treatment is commenced. When they entered the

soil external to the foundations, they shall be similarly treated for a distance of over 300 mm unless they stand clear of the walls of the buildings by about 75 mm.

4.6.4.9 Treatment of Expansion Joints The soil beneath the Expansion joints should be given special attention

when the treatment under 6.4.3 above is carried out. This treatment should supplemented treating through the expansion joints after the sub-grade has been laid, at the rate of 2.0 litres per linear metre of expansion joints.

4.6.5. Measurements All dimensions shall be measured correct to a cm. The measurements for

all the operations described above shall be plinth area of the building or plant building in square-metres at floor 1 level (Ground floor). Nothing extra shall be measured for payment.

4.7 TREATMENT FOR EXISTING BUILDING 4.7.1 Anti-termite measures described below shall be necessary for the

eradication and control of termites in existing buildings/plant buildings. Chemical treatment for the eradication and control of sub-terraineean termites in existing buildings or plant buildings shall be done as per IS : 6313 (Part-III).

4.7.2 The Chlorpyriphos emulsified 1% concentration shall be applied uniformly

at the prescribed rate in all the stages of the treatments given below : 4.7.2.1 Treatment Along Outside of Foundations a. The soil in contact with the external wall of the building/plant building shall

be treated with chemical emulsion at the rate of 7.5 litres per square-meter of vertical surface of the sub-structure for each side. To facilitate this treatment, trenches shall be excavated with help of a shovel exposing the wall surfaces upto a depth of 500 mm and holes 150 mm apart shall be made with an iron rod close to the wall face and the same shall be extended from the bottom of the trench to the top of the footing of the foundation or upto a depth at least 500 mm. Half the total quantity of the chemical emulsion shall be poured into these holes and the rest shall be sprayed on the back filled earth as it is return on to the trench, directing the spray against the wall surface.

b. If there is a concrete or masonry apron around the building, approximately

12 mm diameter holes shall be drilled as close as possible to the plinth wall about 300 mm apart, and deep enough to reach the soil below. The chemical emulsion shall be poured in to these holes to soak the soil below at rate of 2.25 litres per linear metre.

c. In case of RCC framed structure, the soil (back-fill earth) in contact with the column sides and plinth beams along the external perimeter of the building / plant building shall be treated with chemical emulsion at the rate of 7.5 litres per square metre of the vertical surfaces of the structures. To facilitate this treatment, trenches shall be excavated with the help of a shovel exposing the sides of the column and plinth beams upto a depth of 500 mm or upto the bottom of the plinth beam, if this level is less than 500 mm. The chemical emulsion shall be sprayed on the back-fill earth as it is returned into the trench, directing the spray against the concrete surfaces of the beams or columns as the case may be.

4.7.2.2 Treatment of Soil Under Floors. Chemical treatment shall be done by drilling 12 mm diameter holes at the

junction of the floor and walls along the cracks on the floors and along the construction joints at the interval of 300 mm to reach soil below. Chemical emulsion shall be squirted into these holes using a hand operated pressure pump to soak the soil below until refusal or upto a maximum of 1.0 litre per hole. The hole shall then be sealed properly with cement mortar 1 : 2 ( 1 cement : 2 coarse sand) finished to match the existing floors. The above cement mortar applied shall be cured for atlas 10 days as per the direction of Engineer-in-Charge.

4.7.2.3 Treatment of Voids in Masonry

The movement of termites through the existing masonry wall should be arrested by drilling holes in masonry wall at plinth level and squirting chemical emulsion into the holes to soak the masonry. The hole shall be drilled at an angle of 45o from both sides of the plinth wall at 300 mm intervals and the chemical emulsion shall be squirted through these holes to soak the masonry using a hand operated pressure pump. This treatment shall also be done to internal walls having foundations in the soil. Holes shall also be drilled at wall corners and where doors and window frames are embedded in the masonry or floor at the ground. Emulsion shall also be squirted through these holes till saturation or to a maximum 1.0 litre per hole. Care shall be taken to seal these holes after the treatment.

4.7.2.4 Treatment at Points of Contact of Wood Work All the existing wood work in the building / plant building which is in

contact with floor or walls and which is infested by termite shall be treated by spraying the chemical emulsion at the points of contacts with the adjoining masonry by drilling 6 mm diameter holes at downward angle of about 45o at the junction of wood work and masonry walls. The squirting of chemical emulsion into these holes shall be till refusal or to a maximum of half a litre per hole. The treated holes shall then be sealed properly.

4.7.3 Measurements All dimensions shall be measured correct to a cm. The measurement shall

be made of the surface actually provided with anti-termite treatment.

Measurement shall be done separately for treatment of foundations, soil under floors, voids in masonry and wood work as detailed below :

a. Treatment along out side of foundations : The measurements shall

be made in running metres taking lengths along the plinth of the building.

b. Treatment of soil under floors : The measurements shall be made in Square metres. Inside the clear dimensions of rooms, verandah etc., shall be taken.

c. Treatment of voids in masonry : The measurements shall be made in

running metres along the plinth of the building.

d. Treatment to wood work : The measurements shall be made in running metres for chowkhats, joists, purlins, beams etc.

4.8 STORAGE AND DISPOSAL OF CONTAINERS Containers with chemical shall be kept in a cool, dry and well ventilated

room under lock and key. It shall be kept away from food and food stuffs, children and animals and any fire source or flame. Empty containers instead of reusing shall be destroyed or buried in soil at safer place away from inhabitation. Containers shall never be kept open.

4.9 SAFETY PRECAUTIONS a. Precautions for health hazards and safety measures shall conform to

Appendix- B of IS: 6313 (Part- II).

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

c. The concentrates are oil solutions and will cause fire hazard owing to the

use of petroleum solvents. Flames shall not be allowed during mixing.

d. In case of poisoning, suitable measures shall taken for protection in accordance with IS: 4015 (Part- I) and IS: 4015 (Part- II).

5.0 FILLING 5.1 Back filling of excavations in trenches, foundations and elsewhere shall

consist of one of the following materials approved by Owner. i . Soil ii. Sand iii. Moorum iv. Hard-core v. Stone / gravel. All back filling materials shall be approved by the Owner /Consultant.

5.1.1 Soil filling - Soil material shall be free from rubbish, roots, hard lumps

and any other foreign organic material. Filling shall be done in regular horizontal layers each not exceeding 20 cm. Depth.

5.1.2 Back filling around completed foundations, structures, trenches and in

plinth shall be done to the lines and levels shown on the drawings. 5.1.3 Back filling around pipes in the trench shall be done after hydrotesting is

done. 5.1.4 Back filling around liquid retaining structures shall be done only after

leakage testing is completed and approval of Owner is obtained.

5.1.5 Sand filling - Sand shall be coarse, clean, strong, free from dust, organic

and foreign matter and shall be approved by the owner / consultant.

The filling shall be done in layers not exceeding 20 cm in thickness

including consolidating and dressing each deposited layer by flooding with

water, compacting with Mechanical contractor and properly consolidated.

The density to be achieved for each layer shall not be less than 90% of

the density obtained in the laboratory. The compaction should be tested

as per I.S. 2720 (Part – 28 & 29). Care shall be taken to see that the

compaction equipment does not hit or come too close to the Bullet so as

to cause any damage to it.

The top and slope surface of consolidated sand filling shall be dressed to

required level, slope, lives and grades and shall be protected from

damage and maintained till the works are completed in all respects.

Sand filling shall not be covered till the Engineer-in-charge inspects the

job, satisfied and approved.

5.1.6 Stone filling – Stone shall be broken stone of 90 mm to 10 mm size suitable for providing a dense and compacted layer. Stone shall be sound, durable, free from flakes, dust, other impurities, decay, weathering, salt, alkali and adherent coatings.

Broken stone shall be spread and leveled in layers of 15 cm thick, watered i/c hand packing wherever required as per direction of Engineer-in-charge. The thickness of broken stone layer shall remain same as it exists in other areas.

5.1.7 Stone pitching - The size of pitching stone shall not be less than 15 cm

in either direction. It should be sound, durable, free from dust, other impurities, weathering, salt, alkali and adherent coatings. Stone shall be laid in proper line, slope and set with cement mortar 1 : 6 (1 cement : 6 coarse sand) including cement mortar pointing 1 : 3 (1 cement : 3 fine

sand) after racking out of joints upto 12 mm depth and shall be cured properly as per direction of Engineer-in-charge.

6.0 UPVC Pipe - Unplasticised polymer of Vinyl Chloride (UPVC) pipe shall

conform to I.S. 4985 and shall be of standard manufacture. Pipe shall be tested as per I.S. 4985 (latest). All test clearance certificates shall be produced to the client for approval. 150 mm dia perforated UPVC pipe shall be laid over sand filling of mound at the top of bullet as shown in the drawing and as per direction of Engineer-in-charge.

Pipe shall be laid to collect all percolated water / moisture deposited over UPVC sheet and drain out the same in outside. The pipe shall be laid in slope so that all collected water can be drained out effectively.

Pipe shall be supplied along with all related accessories required for fillings, connections and installation of pipe.

Pipe shall be covered with layer of pea gravel 150mm thick all along the pipe as shown in the drawing and as per direction of Engineer-in-charge.

All work shall be subject to inspection by the client and the contractor must satisfy the client.

7.0 Pea Gravel - Pea gravel shall be clean, strong, free from dust, organic and

foreign matter and its size shall remain same as it exists on other side of mound. It shall be approved by the client before laying.

Pea gravel of 150 mm (min) thick, after hand packing, shall be laid all round and all along UPVC perforated drainage pipe as per drawing and as per direction of Engineer-in-charge.

The thickness of gravel layer shall remain same as it exists on the other sides of mound. Care shall be taken so that filled-up sand cannot enter into the perforated pipe.

The contractor shall guarantee that the pea gravel layer shall remain in position, level and thickness as specified in the drawing for at least one year after commissioning. It shall be the responsibility of the contractor to replace the gravel layer if it is damaged during guarantee period.

8.0 PLAIN AND REINFORCED CONCRETE WORK This specification deals with cement concrete, plain or reinforced, for

general use, and covers the requirements for concrete materials, their storage, grading mix design, strength and quality requirements, pouring at all levels, reinforcements, protection, curing, form work, finishing, painting, admixtures, inserts and other miscellaneous works.

8.1 MATERIALS 8.1.1 Cement : Any of the following cements may be used as required. IS - 269 Ordinary Portland Cement, 33 Grade.

IS - 455 Portland Slag Cement.

IS - 6909 Specifications for Super Sulphate cement.

IS - 8041 Rapid Hardening Portland Cement.

IS - 8112 43 Grade Ordinary Portland cement.

IS - 12330 Sulphate Resistant Ordinary Portland cement.

IS - 12269 53 Grade Ordinary Portland cement.

8.1.2 Water : Water used for mixing and curing concrete and mortar shall

conform to the requirements as laid down in clause 4.3 of IS: 456. Sea-water shall not be used for concrete work.

8.1.3 Aggregates : Coarse and fine aggregates for cement concrete plain and reinforced shall conform to the requirements of IS : 383 and / or IS : 515. Before using, the aggregates shall be tested as per IS : 2386.

Coarse aggregate: Coarse aggregate for all cement concrete work shall

be broken or crushed hard stone, black trap stone obtained from approved quarries or gravel.

Sand : Fine aggregate for concrete work shall be coarse sand from

approved sources. Grading of coarse sand shall be within grading zones I, II or III laid down in IS : 383, table-4. If required the aggregates (both fine and coarse) shall have to be thoroughly washed and graded as per direction of Owner.

8.2 MIXING All cement concrete plain or reinforced shall be machine mixed. Mixing

by hand may be employed where quantity of concrete involved is small, with the specific prior permission of the Owner , 10 % extra cement shall be added in case of hand mixing as stipulated in IS - 456.

8.3 WATER CEMENT RATIO Once a mix, including its water-cement ratio, has been determined and

specified for use by the Owner that water cement ratio shall be maintained.

8.4 LAYING Concreting shall be commenced only after the Owner has inspected and

passed the sub-base / base or the centering, shuttering and reinforcement. Concrete in slab, beams, columns, footings etc., shall be laid gently in layers not exceeding 15 cm and shall be properly consolidated by means of approved mechanical vibrators.

8.5 CURING

a. After the concrete has begun to harden, it shall be protected with moist

gunny bags, sand or any other material approved by the Owner /Consultant against quick drying. After 24 hours of laying concrete, the surface shall be cured by flooding with water or by covering with wet absorbent materials for 7 days as per the direction of Owner.

b. Approved curing compounds may be used in lieu of moist curing with the permission of the Owner /Consultant. Such compounds shall be applied to all exposed surfaces of the concrete as soon as possible after the concrete has set. No extra payment shall be made for the same.

8.6 GRADES OF CONCRETE 8.6.1 Grades of Cement concrete shall be as given below :

Grade Specified Characteristic compressive strength at 28 days

(N / mm2)

1. 2. 3 4. 5. 6.

M - 7.5 M - 10 M - 15 M - 20 M - 25 M - 30

07.5 ( 75 Kg / cm2 ) 10.0 ( 100 Kg / cm2 ) 15.0 ( 150 Kg / cm2 ) 20.0 ( 200 Kg / cm2 ) 25.0 ( 250 Kg / cm2 ) 30.0 ( 300 Kg / cm2 )

8.6.2 Grades lower than M-15 shall not be used in reinforced concrete. 8.6.3 M-7.5 grades of concrete may be used for lean concrete bases and

simple foundation for masonry walls. 8.6.4 A sieve analysis test of aggregates shall be carried out as and when the

source of supply is charge without extra charge notwithstanding the mandatory test required to be carried out as per CPWD Specification.

8.6.5 All test in support of mix design shall be maintained as a part of records

of the contract. Test cubes for mix design shall be prepared by the Contractor under his own arrangements and at his costs, but under the supervision of the Owner .

8.7 NOMINAL MIX CONCRETE 8.7.1 All concrete work (P.C.C. / R.C.C.) shall be with nominal mix concrete

unless specified otherwise. The proportions of materials used for concrete of grades M-5, M-7.5, M-10, M-15 and M-20 shall be as per the following table.

Proportions for Nominal Mix of Concrete

Grade of

Concrete

Total Quantity of Dry Aggregate by Mass per 50 Kg of Cement (as sum of Fine and Coarse

Proportion of Fine Aggregate to

Coarse aggregate

Quantity of water per

50 Kg of cement

Aggregates). In Kg. Max.

( by Mass ) Maximum in Liters.

M - 5

M-7.5

M - 10

M - 15

M – 20

M- 25

800

625

480

350

250

Generally 1.2 subject to an upper limit of 1 : 1.5 and a lower limit of 1: 2

.5

-do-

-do-

-do-

-do-

60

45

34

32

30

Notes : 1. The proportions of the fine aggregates should be adjusted from upper

limit to lower limit progressively as the grading of the fine aggregates become finer and the maximum size of coarse aggregate becomes larger. Graded coarse aggregate as per IS: 383 may be used.

2. This Table envisages batching by weight. Volume batching when done,

the nominal mixes would roughly be 1: 3: 6, 1 : 2.5 : 5 and 1 : 1.5 : 3 for M-10, M-15 and M-20 respectively.

3. For under-water concreting the quantity of coarse aggregate, either by

volume or mass, shall not be less than 1.5 times and not more than twice that of the fine aggregates.

8.7.2 The cement content of the mix specified for any nominal mix shall be

proportionately increased if the quantity of water in a mix has to be increased to overcome the difficulties of placement and compaction, so that water-cement ratio is not exceeded. In case of vibrated concrete, the limits specified, above may suitably be reduced to avoid segregation.

8.7.3 If the nominal mix concrete is made in accordance with the proportion

given for a particular grade does not yield the specified strength, such concrete shall be classified as belonging to lower grade. However, if the strength results of test are higher than those specified for the grade in the nominal mix of concrete it shall not be placed in a higher grade.

8.8. TESTING OF CONCRETE 8.8.1 Testing of concrete, sampling and acceptance criteria shall be in

accordance with Clauses 14 and 15 of IS :456. 8.8.2 A slump test shall be taken at each mixer at least once in every fifty

batches mixed. Any batch for which a slump test is being made shall not be transferred to the place of laying until the slump test has been completed. Any batch which gives a slump in excess of that described at the time of preliminary tests shall be rejected and removed from the site.

8.8.3 The minimum frequency of sampling of concrete of each grade shall be

in accordance with the provision in IS-456 (Cl.No.-15.2.2) 8.8.4 If a test for particular work does not meet the specified requirements, the

Owner in his absolute discretion may accept the work at a correspondingly reduced rate provided the average strength at 28 days is not less than 85% of the specified strength.

8.8.5 If the results are poorer than 85% of the specified strength, the Owner

may order further testing of any kind as may be deemed necessary in his opinion, including load tests. The load tests shall be carried on the portion of the structure involving concrete represented by the unsatisfactory works test and such other adjoining elements of a building as the Owner may decide.

If the results of the load tests are not satisfactory, the Contractor shall at

his own cost undertake remedial measures including dismantling and reconstruction according to the directions and to the satisfaction of the Owner / Consultant. If the load test is successful, the Owner/ Consultant may

exercise his judgement before accepting or rejecting the work and shall still have the power to apply a reduction in rate as herein stated before, in case the work in question is accepted.

8.9 PROPORTIONING Mixes of cement concrete shall be as ordered. Where the concrete is

specified by grade, it shall be prepared by mixing cement, sand and coarse aggregate by weight as per mix design. In case the concrete is specified as volumetric mix, then dry volume batching shall be done, making proper allowances for dampness in aggregate and bulking in sand. Equivalent volume batching for concrete specified by grade may however be allowed by the Owner at his discretion.

9.0 STEEL REINFORCEMENT

9.1 Steel reinforcement shall comprise :

i. Mild steel bars conforming to IS: 432, Part-I.

ii . TISCON CRS bars.

iii . Hard drawn steel wire fabric conforming to IS: 1566.

iv . Cold twisted bars conforming to IS: 1786.

v. TMT bars.

9.2 All joints in reinforcement shall be lapped adequately to develop the full strength of the reinforcement, unless reinforcement are as per provision of IS: 456 as per instruction of Owner.

Following procedure shall be followed for welding of Tor steel reinforcement bars :

i. Welding of Tor steel reinforcement bars shall be taken up only after

specific approval by Owner / Consultant.

ii. Lap welding with longitudinal beads shall only be adopted. iii. The thickness of weld bead should be 0.2 x diameter of bar and the

length of the longitudinal bead required shall be 10 x diameter of bar, however, the maximum length of continuous bead shall be limited to 5 x diameter of bar with intermediate gap. When welding is done on both sides bead length shall be 5 x diameter of bar on each side.

iv. Stripper at closer spacing shall be provided in the lap welded joints as

directed by Owner

9.3 M.S. round bars shall be hooked at ends as specified. Ribbed Tor-steel shall be bent at right angles at ends as indicated or directed.

10.0 FORM WORK 10.1 The shuttering or form work shall conform to the shape, lines and

dimension as shown on the drawings and be so constructed as to remain sufficiently rigid during placing and compacting of the concrete and shall be sufficiently tight to prevent loss of liquid from the concrete. The surface that becomes exposed on the removal of forms shall be examined by Owner or his authorised representative before any defects are made good. Work that has sagged or bulged out or contains honey combing, shall be rejected. All shuttering shall be plywood or steel shuttering.

10.2 The Contractor shall be responsible for sufficiency and adequacy of all

form work. Centering and form work shall be approved by the Owner before placing of reinforcement and concreting.

11.0 STRUCTURAL STEEL WORK This specification covers the technical requirements for the preparation

of shop drawings, supply, fabrication, protective coating, painting and erection of all structural steel rolled sections, built up sections, plates and miscellaneous steel required for the completion of the work.

11.1 STRUCTURAL STEEL All structural steel used in construction within the purview of this contract

shall comply with one of the following Bureau of Indian Standard Specifications, whichever is appropriate or as specified.

IS: 2062 Hot Rolled Sections and Plates.

IS: 1079 Cold Formed Light Gauge Sections. IS: 1161 Tubular Sections. IS: 4923 Hollow Sections ( rectangular or square )

11.2 SMITHY WORKS All smithy work shall be accurately made as shown in the drawings and

shall be clean and sound. The metal shall not be burnt or injured in any way.

11.3 FABRICATION Fabrication of steel structure shall be carried out in conformity with the

best modern practices and with due regard to speed with economy in fabrication and erection and shall conform to IS: 800. All members shall be so fabricated as to assemble the members accurately on site and erect them in correct positions. Before despatch to site the components shall be assembled at shop and any defect found shall be rectified. All members shall be free from kind, twist, buckle, bend, open joints etc., and shall be rectified before erecting in position. Failure in this respect will subject the defective members to rejection.

11.4 WELDING 11.4.1 Welding shall be adopted in most of the cases for fabrication of steel

structure. Welding work shall be carried out as shown in relevant drawings as per IS-816 or as required and approved by the Owner /Consultant. Welding of joints shall be so arranged that the resulting tensile and compressive stresses produced by each part of weld tend to balance each other.

11.4.2 The step back method of welding shall be adopted for continuous runs.

Members which offer greater resistance to compression shall be welded first. The work shall be securely held in position by means of tack weld, clamps or jig before commencing of welding work so as to prevent relative movement due to distortion or other cause. All welds with blow holes, slag-intrusion and other defects must be removed from each run before another run is super imposed and also from the final run. Any defects in the work shall be rectified by the Contractor at his own expense. Bends, twists or distortion caused in any member due to faulty workmanship and method adopted during welding or in transit will be rejected and will have to be replaced / rectified by the Contractor at his own expense. According to the size of electrodes used, the Contractor is expected to adjust the current rating in the welding generators.

11.5 The Owner /Consultant reserves the right to have test done at any time

for any welding and the cost of the test shall be borne by the Contractor.

11.6 Wherever continuous plates are used in built up member such as girders, columns, etc., the continuity of such plates shall be first ensured by full strength butt joints before welding such plates with the main member to form part of the built up member.

11.7 All connection / joints made in shop shall wherever possible be welded

connections and connections / joints made at site shall be bolted connections /site welded connections. Continuous welding shall be done for all box members even if it is not required from design point of view.

11.8 Electrodes: Electrodes used for welding shall comply with IS: 814 or

IS: 815 or any specification provided to the Contractor from time to time. No electrodes remaining in open containers for more than 72 hours shall be used.

11.9 No welder shall be employed to carry out welding in any position except

those who are fully qualified to weld in that position as per IS: 7318, Part-1 Qualifying tests for metal arc welders. Welders employed shall be required both before commencing work and at intervals during the progress of work to make test pieces as laid down in IS: 817 and IS: 7318, Part-1 for the purpose of grading of welders and according to the said grading, welders will be employed on jobs. Welders are to be got approved by Owner / Consultant before engaging on work.

11.10 MS BLACK / HIGH STRENGTH BOLTS AND NUTS MS Black / High Strength Bolts and Nuts and washers etc., shall be as

per IS: 800, IS: 1363 and IS:- 1367. Manufacturer’s test certificate shall be made available to the Owner /Consultant or his representative, when called for. For bolted joints, shanks and threaded bolts are to be used to ensure that threaded length do not encroach within the thickness of connected members of dimension beyond the following limit :

a) 1.5 mm for connected members of thickness below 12 mm and

b) 2.5 mm for connected member of thickness 12 mm and above

and that adequate shearing and bearing values required as per design are achieved.

11.11 Every portion work shall have its erection mark or number stencilled on

the member for guidance in erection and bear all necessary marks of erections as directed by the Owner.

11.12 No part of the work is to be oiled, painted (except contact surfaces )

packed, bundled, crated or despatched until it has been finally inspected and approved by the Owner or his authorised representative. The whole steel work before being despatched from the Contractor’s shop shall be dry and after being thoroughly cleaned from dust, mills scale, rust etc., and shall be given two coats of primer and one coat of final paint as per painting specification attached in this enquiry. Unless otherwise specified, all surfaces inaccessible after welding shall be given

two coats of primer and two coats of paints as per painting specification attached in this enquiry.

11.13 The Owner or his authorised representative shall have free access at all

reasonable time to all places where the work is being carried out, and shall be provided by the Contractor at his own expenses all necessary facilities for inspection during fabrication and erection. The Owner or his authorised representative shall be at liberty to reject the work in whole or in part if the workmanship or materials do not conform to the terms of the specifications mentioned herein. The Contractor shall remove, replace or alter any part of the work as ordered by the Owner or his authorised representative.

12.0 PAINTING ON STRUCTURAL STEEL The following specification shall be used for painting of structural steel

work : 12.1 SCOPE This specification shall be used in non coastal area. Surface Preparation The surfaces to be painted shall be sand blasted to Sa - 2.5 as per

Swedish Standard SIS 05 - 59 - 00. Air used for sand blasting must be dry and oil free. Sand used for sand blasting shall be good quality river sand suitable for achieving the required surface finish. For optimum results pressure of sand blasting gun should be maintained at around 7.0 kg/cm2 and maximum height of profile should be kept around 50 microns. Sand blasted surfaces must be coated with primer within 4 hrs. In dry climate. Moreover it is not advisable to carry out sand blasting when humidity exceeds 85% (R.H).

12.1.1 Painting system to be used are indicated below:

a. Epoxy Painting

Primer P 1-2 coats + finish paint FP1 ( 2 coats ) where P1 is epoxy polyamide cured zinc chromate primer having DFT of 35 micron per coat and FP1 is epoxy polyamide cured finish paint having DFT ( Dry Film Thickness ) of 35 micron per coat.

b. For Chlorinated Rubber Paint Primer P2 - 2 coats + finish paint FP2 - 2 coats. Where P2 is high chlorinated zinc phosphate primer having DFT of 50 microns per coat and FP2 is chlorinated rubber based paint having DFT of 50 microns per coat.

12.1.2 Equivalent product chart for approved paint manufactures for primer P1 and P2 and finish paint FP1 and FP2 indicated above is enclosed.

12.1.3 All the surfaces must be sand blasted and 2 coats of prime plus 1 coat of finish paint applied in the shop before the same are shifted to site for erection. All the members must be suitably match marked for facilitating proper assembly.

After erection is over all surfaces shall be washed up as follows :

a. Washing with clean water ( pressure 7 kg/cm2 ) using suitable nozzles. During washing broom corn brushes shall be used to remove foreign matters.

b. Solvent washing if required to remove traces of oil grease etc.

After washing the surface as indicated above, the surfaces shall be

suitably touched up to the extent required so that all the damages to the primed surfaces caused during erection are taken care off. The surfaces affected by welding and / or gas cutting during erection shall also be suitably touched up. Before touch up is taken up surfaces shall be prepared by mechanical means such as grinding, power brushing etc., to achieve surface finish to ST-3.

After touch up work is over as indicated above all the surface shall

be given one coat of finish paint to the required specification.

12.1.4 The following points must be observed for painting work :

a. Primer and paint shall be compatible to each other and should be from the same manufacturer.

b. The recommendation of the paint manufacturer regarding mixing,

matching and application must be followed meticulously.

c. Technical representative of paint manufacturer should be available at site as and when required by Owner for their expert advice as well as to ensure that the painting work is executed as per the instruction of paint manufacturers.

Paints and primers shall be supplied at site in original container with

factory seal otherwise such paints and primers shall not be allowed to be used.

Mode of application i.e., by spray, brush or roller shall be strictly as per

recommendation of paint manufacturers.

Painting materials must be used before the expiry date indicated on the containers.

Number of coats and DFT per coat must be strictly followed as indicated

above. If the desired DFT is not achieved for primer and finish paints in two coats (each), Contractor shall be required to apply extra coat (s) to achieve the desired DFT without any extra cost to Owner.

Colour shade for each coat of primer and finish paint must be different

to identify the coats without any ambiguity. Shade for the final finish coat shall be decided by Owner at site. All painting materials must be accompanied by manufactures test

certificates. However, if Owner has any doubt regarding quality of materials, he shall have the right to direct Contractor to get the doubtful material tested or and provide ( by the Contractor ) testing agencies for which no extra payment shall be made to the Contractor and the charges shall deemed to be covered in the unit rates quoted for fabrication and erection of structural work.

DFT for paint shall be measured on at least 20 points and mean DFT

shall not vary by more than 10% than specified in DFT. Instrument for measurement of DFT shall be arranged and provided by Contractor at his cost. Thickness of each coat shall also be checked regularly to ensure uniformity in DFT.

12.1.5 Measurement

Structural work so painted shall be measured on MT basis. The weight

for this item shall be taken from any of the following documents in the following order of priority:

i. Weights mentioned on the approved drawings.

ii. Weights for actual structural fabrication work.

12.1.6 Sand blasting and painting works, being a specialised job, must be

carried out through the approved agencies only.

12.1.7 Equivalent Chart for various paint manufacturers

CODE

ASIAN G & N SHALIMAR J & N BERGER BOMBAY

P1 APCODUR

- EPOXY ZINC

CHROME PRIMER

AMERCOAT-71

EPIGARD-4 ZINC

CHROMATE PRIMER

EPILAC ZINC CHROMATE

PRIMER

EPILUX-4 ZINC

CHROMATE PRIMER

PENTA-DUR PRIMER

1532

P2 ASIOCHLO

R HB ZINC

PHOSPHATE PRIMER

NEROLAC PHOSPHATE PRIMER

CHLORO- KOTE ZINC PHOSPHATE PRIMER

JENSOLAC CR PRIMER

LINSOL HB ZINC

PHOSPHATE PRIMER

KANGAR-OD HB ZINC PHOSPHAT

E OR HEMPATEX

PRIMER 1632

FP1

APCODUR CF 692

NEROLAC TWO COMP

EPOXY

EPIGARD XL FINISH

EPILAC 974 ENAMEL

EPILUX - 4 ENAMEL

PENTADUR ENAMEL

5534

GRAY

FP2

ASIOCHLOR CF

625

NEROLAC CR

PAINT

CHLOROKOTE

FINISH

JENSOLAC CHLORINATE

D RUBBER PAINT

LINSOL CHLORINATE

D RUBBER PAINT

PENTA-CHLOR GP

ENAMEL 5638

12.2 SCOPE This specification shall be used for the painting of structural steel in

coastal area in saline atmosphere. 12.2.1 SURFACE PREPARATION Surface preparation for all items to be painted shall be done by sand

blasting to SA 2.5 as per Swedish Specification SIS 05-59-00. Air used for sand blasting must be dry and oil free. Sand used for sand blasting must be of good quality river sand suitable for achieving required surface finish. For optimum results, pressure at sand blasting gun should be maintained at around 7 kg/cm2 and maximum height of profile should be kept around 50 microns. Sand blasted surface must be coated with primer within 2 hrs. In dry climate. Moreover it is not advisable to carry out sand blasting when humidity exceeds 50% RH.

12.2.2 Painting systems to be used are as indicated below:

a. For unpainted surfaces.

i. P1 - One coat of Ethyl silicate inorganic zinc primer having DFT of 70

microns per coat.

ii. IP1 - One coat of Epoxy MIO having DFT of 70 microns per coat.

iii. FP1 - One coat of finish epoxy paint using two pack Polyamide cured epoxy having DFT of 40 microns per coat.

iv. FP-2 - One coat of Aliphatic Acrylic Polyurethane paint having DFT of 40

microns per coat.

12.2.3 The following points must be observed for painting work:

a. Only the approved paints / primers as indicated in the equivalent product chart (attached herewith) are to be used.

b. All the surfaces must be sand blasted and one coat of primer including

one coat of MIO are to be applied in the fabrication shop at project site before lifting the components for erection. After erection is over all the surfaces must be washed as indicated below:

i. Wash with clean water (pressure approx. 7 kg /cm2) using suitable nozzles. During washing, broom corn brushes to be used to remove foreign matter, if any.

ii. Solvent washing if felt necessary to remove traces of oil, grease etc.

iii. After washing surfaces as indicated above, shall be suitably touched up

to the extent required, so that all the damages to the primed surfaces caused during erection are taken care off.

c. Surfaces effected by welding and/or gas cutting or handling during erection shall also be suitably touched up after preparing the damaged surfaces by mechanical means such as grinding, power brushing etc., to achieve surface finish to ST-3.

d. Application of ethyl silicate inorganic zinc primer must be undertaken by

spray method. Other application methods such as brush / roller application is not permitted.

e. Primers and paints for a particular system must be purchased from

same manufacturer for compatibility.

f. Recommendation of the paint manufacturer regarding mixing, maturing, application (except as indicated specially in this specification ) must be followed meticulously.

g. Technical representative of the paint manufacturers at site must be

made available as and when required by Owner / Consultant for their expert advice as well as to ensure that painting work is executed as per instructions of paint manufacturer.

h. All paints, primers must be supplied to site in original containers with

factory seal. Otherwise paints, primers shall not be allowed to use.

i. Mode of application for other primers and paints except ethyl silicate inorganic zinc primer shall be strictly as per recommendation of paint manufacturer.

J. All painting materials should be consumed within expiry date indicated

by manufacturers on the containers.

k. Number of coat & DFT per coat must be strictly followed as indicated in the specification above and if the desired DFT is not achieved in the specified number of coat, Contractor shall be required to apply extra coat (s) to achieve desired DFT without any additional cost to Owner / Consultant. It may be noted here that multi-coat is not allowed for ethyl silicate inorganic zinc primer and therefore extreme care is to be taken for assuring desired DFT in single coat. Unless it is not practical to do so, colour shades for primer, intermediate coat and finish paints must be different to identify each coat without any ambiguity.

l. All painting materials must be accompanied by manufacturers test

certificate. However, if Owner / Consultant has any reasonable doubt

regarding quality of the materials then, Contractor shall be required to get doubtful materials tested by Owner / Consultant approved testing agencies and nothing extra shall be paid for carrying out above testing

and testing charges shall be deemed to be included in the rates quoted

for painting work.

m. DFT for painting shall be measured on at least 20 points and mean DFT shall not vary by more than 10% of the specified DFT. Reliable and calibrated instrument for measurement of DFT shall be arranged and provided by Contractor at his cost at site.

n. Sand blasting, painting work being a specialised job, must be carried out through approved agencies only. List of approved agencies is as indicated below :

12.2.4 EQUIVALENT CHART FOR VARIOUS PAINT MANUFACTURERS

CODE

ITEM DFT PER COAT

(MICRONS)

ASIAN G & N SHALIMAR J & N

BERGER BOMBAY

P1 ETHYL

SLILICATE INORGA-

NIC ZINC

PRIMER

70

APCOSIL

601

DYMET -

COTE - 9

TUFFKOTE

ZILICATE

J&N INORGA-

NIC ZINC

SILICATE PRIMER

ZINC

ANODE

304

HEAPELS

GALVO-SIL

1570

IP1 EPOXY

MIO 70

APCO-DUR

MIO

AMER COAT

385

EPIGUARD

HB MIO

EPILAC HB

MIO

EPILUX-4

HB MIO

PENTA-DUR

HB MIO 4567

FP1 TWO PACK

POLYA-MIDE

CURED EPOXY

40 APCO-DUR

CF-692

NERO-LAC

TWO COMP

EPOXY

EPIGUARD

XL

EPILAC

974

EPILUX-4

ENAMEL

PENTA-DUR

ENAMEL

5534

FP2 ALIPHA-

TIC ACRYLIC

POLYURE- THANE PAINT

40 APCO-THANE

674

AMER-COAT

450 GL

SHALI-THANE

JN 992

PU FINISH

PAINT

BERGA-

THANE

ENAMEL

PENTO-

THANE

4513

13.0 ALUMINIUM DOORS, WINDOWS & VENTILATORS 13.1 Aluminium doors, windows and ventilators shall be as per the specification

of CPWD Specifications 2009 Volumes II (Sub Head 21.0) and manufactured from wrought aluminium and aluminium alloy extruded round tube and/or hollow rectangular / square sections conforming to IS: 1285 and IS: 6477 or equivalent as approved by Owner / Consultant..

14.0 FLOORING AND PAVING 14.1 Sub base of Floor 14.1.1 The area to be paved shall be divided into suitable panels. Form work

shall be provided. The boarding / battens shall be fixed in position with their toe at proper level, giving slope where required. Alternatively base concrete may be deposited in the whole area at a stretch.

14.1.2 Before placing the base concrete the sub-base shall be properly wetted

and rammed. The concrete of the specified mix shall then be deposited between the forms where provided, thoroughly tamped and the surface finished level with the top edge of the forms. The surface of base concrete shall be spread uniformly. The surface shall be finished rough to provide adequate bond for the topping. Two or three hours after concrete has been laid the surface shall be brushed with wire brush to remove any scum or latinate and swept clean so that coarse aggregate is exposed.

14.2 Cement Concrete Floor Finish 14.2.1 The surface of base concrete shall be thoroughly cleaned by scrubbing

with coir or steel wire brush. Before laying the topping, the surface shall be soaked with water at least for 12 hours and surplus water mopped up immediately before the topping is laid.

14.2.2 The forms shall be fixed over the base concrete dividing into suitable

panels. Where glass dividing strips are provided, thickness of glass dividing strips shall be 4 mm or as indicated. Before placing the concrete topping, neat cement slurry at the rate of 2 Kg/Sq.m. shall be then thoroughly brushed into the base concrete just ahead of the finish. The topping shall then be laid, thoroughly compacted by using screed board/plate vibrator. The surface floated with a wooden float to a fair and even surface shall be left for some time till moisture disappears from it. Junctions with skirting / dado on wall surfaces shall be rounded off using cement mortar 1:2. Curing shall be carried out for a minimum of 7 days.

15.0 PLASTERING

15.1 Sand for plastering shall conform to IS-1542. 15.2 Preparation of surface shall be done as per CPWD Specifications. 15.3 Cement mortar shall be of the mix as indicated in the items and shall be

mixed as specified in the CPWD Specifications. 15.4 Joints in walls etc. shall be raked to a depth of 12 mm, brushed clean

with wire brushes dusted and thoroughly washed before starting the plaster work.

15.5 The surface shall be thoroughly washed with water cleaned and kept wet to saturation point before plastering is commenced.

15.6 Cement mortar as indicated, shall be firmly applied to the masonry walls in a uniform layer to the thickness specified and will be pressed into the joints. On concrete surfaces rendering shall be dashed to the roughened surface to ensure adequate bond. The surface shall be finished even and smooth. Hectoring wherever required shall be done as per directions of Owner / Consultant. Nothing extra shall be paid on this account.

15.7 All plaster work shall be cured for at least 7 days. 15.8 Integral water proofing compound shall be mixed with cement in the

proportion recommended by the manufacturer. Care shall be taken to ensure that the water proofing material gets well and integrally mixed with cement. All other operations are the same as for general plaster work.

15.9 For sand face plaster, undercoat of cement plaster 1:4 ( 1 cement : 4

sand ) of thickness not less than 12 mm shall be applied similar to one coat plaster work. Before the under coat hardens the surface shall be scared to provide for the top coat. The top coat also of cement mortar 1:4 shall be applied to a thickness not less than 8 mm and brought to an even surface with a wooden float. The surface shall then be tapped gently with a wooden float lined with cork to retain a coarse surface texture, care being taken that the tapping is even and uniform.

16.0 WHITE WASHING AND CEMENT PAINTING 16.1 White Washing 16.1.1 Where white wash is indicated, 3 coats of white wash shall be applied.

The surface shall present a smooth and uniform finish. 16.1.2 White wash shall be prepared from lime slaked at site and mixed and

stirred with 5 litres of water for 1 Kg. of unslaked lime to make a thin cream. The cream shall be screened through a clean,coarse cloth and suitable adhesive such as DDL or equivalent as per manufacturer specification shall be added. About 1.3 Kg of sodium chloride in hot water shall also be added for every 10 Kg. Of lime for making the coat hard and rule resistant. Indigo shall also be mixed @ 3 gm/Kg of lime. Each coat shall be allowed to dry before next coat is applied. When dry the wash should show no sign of cracking, One coat consists of application with brushes in horizontal stroke followed by vertical stroke.

16.2 Cement Painting 16.2.1 Cement paint: Cement paint shall comply with IS: 5410 specification for

cement paint of colour as required.

16.2.2 Where shown on drawings for external surfaces of sand faced plaster, or any other surface, two coats of cement paint shall be applied of tint and shade as approved by the Owner.

16.2.3 On external plastered surfaces, sand faced or plain plastered and

concrete surfaces, cement paint shall be vigorously scrubbed on to work the paint into the voids and provide a continuous paint film free from pin holes and other openings. Curing shall be done between the coats and for at least 2 days following the final coat.

QUALITY ASSURANCE PLAN

3.1 Purpose: Purpose of this “Quality Assurance Plan” is to provide guidelines & procedure for ensuring proper quality for the jobs to be executed within the contract based on the item description & specifications as per Tender document. However, this document is for guidance only and should not be considered as exclusive. There may be some more tests which are required to be done by the contractor during various stages of execution as relevant standards/ specifications/ direction of EIC.

3.2 Scope: Scope of this Manual is to define the procedure for Quality Assurance & Quality Control for construction activities.

3.3 Site Organogram : To achieve proper control over quality of work, a site organization/ organogram has been framed and provided in Annexure V of the tender document, which requires deployment of two (2) numbers of lead quality officers‐ one each for civil jobs and electrical works. 3.4 General:

3.4.1 The contractor shall be required to produce samples of all materials sufficiently in advance to obtain approval of the Engineer‐in‐Charge. Subsequently the materials to be used in the actual execution of the work shall strictly conform to the quality of samples approved. In case of variation, such materials shall be liable to rejection. 3.4.2 All the materials used in the work shall comply with the requirement of Engineer‐in‐ Chargeand shall pass all the tests and analysis required by him as per particular specifications as applicable or such recognized specifications as acceptable to the Engineer‐in‐Charge. 3.4.3 The contractor shall be required to provide appliances at site, such as weighing scale, graduated cylinder, standard sieves, thermometer, slump cones etc. as per Annexure X in order to enable the Engineer‐in‐Charge to conduct field tests to ensure that the quality is consistent with the prescribed specifications and nothing extra shall be paid on this account. 3.4.4 The contractor shall at his cost, make all arrangement and shall provide such facilities as may be require for collecting, preparing and forwarding the required number of samples for tests and for analysis at such time and to such places, as directed by NRL. Nothing extra shall be paid for the above and including the cost of material to be tested. 3.4.5 The necessary tests shall be conducted in the laboratories approved by the NRL. The testing charges, if any, shall be borne by the contractor. 3.4.6 The contractor or his Lead Quality Officer shall associate in collection, preparation, forwarding and testing of such samples. In case he or his authorized representative is not present or does not associate himself, the results of such tests and consequences thereon shall be binding on the contractor.

3.4.7 The contractor shall give a performance test of the entire installations as per standard specifications before the work is finally accepted and nothing extra whatsoever shall be payable to the contractor for the test.

3.4.8 Contractor arrange for various construction material tests as per details provided in Annexure‐XI. The tests mentioned in this list are indicative only. Some more tests may be required to be done from time to time, during the progress of work. Contractor shall arrange for such tests at field or laboratories at no extra cost. 3.4.9 Contractor has to maintain and regularly update the following machine printed site registers, formats of which are enclosed in Annexure‐XII. These registers shall be updated and submitted to NRL for further checking. a) Material Issue & Stock Register (for materials issued by NRL) b) Site Measurement Register c) Site Instruction Register d) Site inspection Register e) Cube Test Register f) Equipment Deployment Record g) Material Test Register 3.4.10 Hindrance Register: This register shall be kept in custody of NRL. Hindrance, if any, shall be reported in person by the contractor or his representative maximum within the next day of hindrance. In case of failure in reporting within the next day of hindrance, the same shall not be recorded by NRL.

3.5 Inspection & Test Plan General Note: The enclosed ITP’s shall be followed for the work to be performed by the contractor. The provisions indicated for stage wise inspection by Engineer‐in‐charge are the minimum and the Engineer‐in‐charge may decide to increase Witness points. Activities for which ITP’s are not given, contractor has to develop and get the same approved by Engineer‐in‐charge well before start of the work. Contractor has to carry our 100% examination of all activities.

Legend: WC : 100 % Examination by Contractor. W : Witness Point : An activity which requires witnessing by Engineer‐in‐charge / NRL when the activity is performed after proper notification has been provided. Rm : Random / Surveillance Inspection by Engineer‐in‐charge. : Monitoring of making observation to verify whether or not material/ item or services conform to specified requirement. Surveillance activities may include audit, inspection, witness of testing, review of quality documents & records, Personnel qualification etc. Note : Responsibility of execution of the inspection / testing is with the contractor. Engineer‐in‐charge / NRL only verifies examination of testing done by the contractor at important stages. Abbreviations: AFC : Approved For Construction BM : Bench Mark PCC : Plain Cement Concrete

RCC : Reinforced Cement Concrete WBM : Water Bound Macadam PVC : Poly Vinyl Chloride OMC : Optimum Moisture Content FGL : Finished Ground Level GL : Ground Level PL : Plinth Level Inspection Test Plan

Sl. No.

Inspection & Test Plan Responsibility Contractor NRL

1.0 SURVEYING 1.1 Grid pillars WC Rm 1.2 Survey equipment inspection WC Rm 1.3 R.L transfer from permanent B.M W 1.4 Initial levels of area, contour plans etc. WC Rm 1.5 Protection of Control points, Permanent Bench Mark WC Rm 2.0 SITE GRADING 2.1 Initial levels of area WC W 2.2 Filling material test WC W 2.3 Compaction test (Core cutter test‐ format attached) WC Rm 2.4 Final levels of area WC W 3.0 EARTH WORK 3.1 Initial levels of area WC W 3.2 Layout, Excavation WC Rm 3.3 Obstacles‐ underground pipes, cables etc. WC W 3.4 Sub‐soil water, shoring, strutting WC Rm 3.5 Final level of excavation & filling, compaction WC W 4.0 BACK FILLING/ SAND FILLING/ EARTH FILLING 4.1 Sub‐grade formation/ compaction WC Rm 4.2 Filling material test WC W 4.3 Treatment of soil (if any) WC W 4.4 Filling in layers, consolidation, watering WC Rm 4.5 Compaction tests on filling WC Rm 4.6 Filling to required level WC Rm 5.0 ANTI-TERMITE TREATMENT 5.1 Chemical details WC W 5.2 Surface preparation WC W 5.3 Safety precautions WC Rm 5.4 Chemical application WC W 6.0 SHUTTERING 6.1 Layout & Cover check WC Rm 6.2 Shuttering material inspection WC Rm 6.3 Water tightness, Line, level and alignment check WC Rm 6.4 Staging, scaffolding, walkway etc. WC Rm 6.5 Surface cleanliness check WC Rm 6.6 Removal time for shuttering WC Rm 7.0 PLAIN CEMENT CONCRETE 7.1 Layout & Surface preparation WC Rm 7.2 Material inspection, Mix proportion WC Rm 7.3 Shuttering, concreting, compaction WC Rm

7.4 Top level / Thickness of PCC WC Rm 7.5 Curing WC Rm 8.0 REINFORCED CEMENT CONCRETE 8.1 Material Tests WC W 8.2 Material Inspection, Layout & Surface preparation WC Rm 8.3 Design Mix WC W 8.4 Form work/ Water stoppers/ Cover WC Rm 8.5 Reinforcement WC Rm 8.6 Mix proportion, W/C ratio, Slump test WC Rm 8.7 Inserts, Foundation bolts, templates WC W 8.8 Pour card (format attached) WC W 8.9 Concreting, compaction, test cubes WC Rm 8.10 Curing WC Rm 8.11 Testing of cubes WC W 9.0 BRICK WORK 9.1 Layout WC Rm 9.2 Material tests WC W 9.3 Soaking of bricks WC Rm 9.4 Thickness of joints/ bond/ closers WC Rm 9.5 Line, level, plumb WC Rm 9.6 Raking out joints, Keys in brick work, if any WC Rm 9.7 Curing WC Rm 10.0 PLASTERING 10.1 Scaffolding WC Rm 10.2 Mix proportion WC Rm 10.3 Hacking, cleaning of surface, removing of loose particles WC Rm 10.4 Watering of surface prior to plastering WC Rm 10.5 Thickness of plaster, plumb, even surface WC Rm 10.6 Grooves, opening etc. WC Rm 10.7 Curing WC Rm 11.0 STRUCTURAL STEEL (During fabrication)11.1 Material test WC W 11.2 Fabrication drawings WC W 11.3 Welder’s performance qualification WC Rm 11.4 Welding machines, tools, tackles WC Rm 11.5 Filler material, baking of electrodes, sequence of welding, interpass cleaning WC Rm 11.6 Surface cleaning, application of primer, paint WC W 11.7 Checking as per drawing WC W 12.0 STRUCTURAL STEEL (During Erection) 12.1 Safety of workmen, scaffolds WC W 12.2 Final coat of paint WC Rm 13.0 PAINTING WORKS 13.1 Colour brand/ shade WC W 13.2 Material inspection WC W 13.3 Surface cleaning & preparation WC Rm 13.4 Application WC Rm 14.0 ROOFING SHEETS 14.1 Material as per specification‐ check WC W 14.2 Type of hooks‐ J/ L or self tapping screws WC Rm 14.3 Layout & level of truss/ purlin WC Rm 14.4 Lapping WC Rm

14.5 Fixing of hooks, washers/ self tapping screws WC Rm 14.6 Wind ties WC Rm 14.7 Barge boards (is any) WC Rm 15.0 TILES FLOORING/ SKIRTING/ WALL TILES 15.1 Material inspection WC W 15.2 Base surface preparation WC Rm 15.3 Layout/ pattern WC Rm 15.4 Level/ slope in floor WC W 15.5 Base plaster mix WC Rm 15.6 Soaking of tiles in water WC Rm 15.7 Cutting of tiles as per design & room layout WC Rm 15.8 Finishing & cleaning WC Rm 16.0 CEMENT CONCRETE FLOORING/ SKIRTING 16.1 Base surface preparation WC Rm 16.2 Layout/ pattern WC Rm 16.3 Glass strips, (if any) WC Rm 16.4 Level/ slope in floor WC W 16.5 Thickness of floor WC Rm 16.6 Concrete mix WC Rm 16.7 Curing WC Rm 17.0 INER-LOCKING PAVER BLOCKS 17.1 Material inspection WC W 17.2 Layout/ Pattern WC Rm 17.2 Base preparation WC Rm 17.4 Sand filling – compaction, thickness WC Rm 17.5 Laying & Fixing WC Rm 18.0 TERRAZO FLOORING 18.1 Material inspection WC W 18.2 Base surface preparation WC Rm 18.3 Mix proportions & laying WC Rm 18.4 Curing WC Rm 18.5 Polishing WC Rm 19.0 KOTA STONE/ MARBLE/ GRANITE FLOORING 19.1 Material inspection WC W 19.2 Base surface preparation WC Rm 19.3 Base plaster mix WC Rm 19.4 Layout & Fixing WC Rm 19.5 Polishing WC Rm 20.0 INTERNAL PLUMBING 20.1 Material inspection WC W 20.2 Layout WC Rm 20.3 Painting of pipes (if any) WC Rm 20.4 Installation testing WC W 20.5 Sanitary fixtures & fittings WC W 20.6 Sunken slab treatment WC W 21.0 EXTERNAL PLUMBING 21.1 Material inspection WC W 21.2 Layout WC Rm 21.3 Painting of pipes (if any) WC Rm 21.4 Bed concrete of pipes WC Rm 21.5 Hooking up with manhole/ septic tank WC Rm 21.6 Road crossings, if any WC Rm 21.7 Installation testing WC W

22.0 WATER PROOFING 22.1 Surface preparation WC W 22.2 Chemical WC W 22.3 Execution by specialised agency WC Rm 23.0 PVC- Doors & Windows 23.1 Material inspection WC W 23.2 Embedment of members in wall/ floors WC Rm 23.3 Alignment of frames WC Rm 23.5 Hold fasts WC Rm 23.6 Fittings WC Rm 24.0 WOOD WORKS- Doors/ Windows/Ceiling & Frames 24.1 Material inspection WC W 24.2 Thickness of members as per requirement WC Rm 24.3 Clearance prior to painting/ oiling as well as fixing in place WC Rm 24.4 Wood preservative WC Rm 24.5 Polishing/ primer & painting WC Rm 24.6 Embedment of members in wall/ floors WC Rm 24.7 Alignment of frames WC Rm 24.8 Hold fasts WC Rm 24.9 Fittings WC Rm 24.10 Wire gauge WC Rm 24.11 Glass panes WC Rm 25.0 ALUMINIUM WORKS 25.1 Material inspection WC W 25.2 Glass panes WC Rm 25.3 Fixing WC Rm 26.0 ROAD WORKS 26.1 Excavation/ grading depth WC W 26.2 Bed level compaction tests WC W 26.3 Slope, camber WC Rm 26.4 Material Inspection WC W 26.5 GSB WC Rm 26.6 Side shoulder construction in advance for confinement of aggregates WC Rm 26.7 Scarifying, if any WC Rm 26.8 WBM WC Rm 26.9 Tack coat application WC Rm 26.10 Premix carpeting WC Rm 26.11 Embankment‐ compaction tests WC W 27.0 FENCING WORKS 27.1 Posts‐ RCC/ angles WC Rm 27.2 Base & Spacing of posts WC Rm 27.3 Alignment of posts WC Rm 27.4 Galvanized chain link‐ dia & wire mesh size WC W 27.5 Fixing & straightening of chain link, keeping it tight, erect WC Rm 27.6 Painting on posts, if any WC Rm

POUR CA Name of woName of thWork Orde INS1 DES2 APP3 GRA4 CEM5 QUA6 QUA 7 QUA 8 DET 9 FOR 10 PRO11 CUB12 MAC 13 TIM

14 SLU15 WAT16 TOTSKIL The aboveMr. present duconcreting

SIGNCON

ARD FOR CON

ork e Contractor er No. PECTIONS SCRIPTION AND LPROX. QUANTITY ADE OF CONCRETMENT QUANTITY ALITY AND SOURALITY OF COARSE

ALITY OF FINE AGTAILS OF REINFO

RM WORK

OPOSED FINISH LBE SAMPLES TO BCHINERIED DEPLE OF POURING MP TER CEMENT RATAL NUMBER OF WLLED e structure woruring g.

NATURE OF NTRACTOR

In

NCRETE WOR LOCATION OF WOOF CONCRETE TTE REQUIRED CE OF WATER E AGGREGATE A. CLEANLINB. GRADATIOC. CRUSHINGGGREGATE A. SILT CONTB. GRADATIORCEMENTS A. DIA. OF MAB. DIA. OF STC. C/C DIST. OD. C/C DIST OE. LAPS (NosF. CHAIRS (NG. COVERAGEA. SURFACE CB. CLEAN & WC. ALIGNMEND. SUPPORT E. WATERTIGEVEL BE TAKEN LOYED TIO WORKERS

rk have been ch

nspection T

RKS

ORK O BE POURED

NESS ON G STRENGTH TENT ON AIN BARS TIRRUPS OF BARS OF STIRRUPS s) Nos) E CHECK CONDITION WELL OILED NT TO FROMWORK GHTNESS

ecked and foun

Test Plan (

/ RIGIDITY

UNSKnd ready for con

S

(contd.)-

: : : : : : : : NO.S

: : : : KILLED : ncreting. from t

SIGN. OF NRL

SL No.

:

WO O

the contractor w FIEL

ORKING CONDITIBSERVATIONS FODURING CASTIN

will be LD INSPECTION R

ON OUND NG

REPORT

Inspection Test Plan (contd.)-

CORE CUTTER TEST

Name of work Name of the Contractor Work Order No.

SL. NO.

DESCRIPTION TEST POINT No. 1 2

1 Mass of core cutter (gm) 2 Mass of core cutter + wet soil (gm) 3 Volume of core cutter (cc) 4 Bulk density (gm/cc) 5 Mass of wet soil (gm) 6 Mass of oven dried soil (gm) 7 Moisture content (%) 8 Dry density = BD/ (1+MC/100), (gm/cc) 9 Lab control density (gm/cc) 10 % of compaction

Field Inspection Report Sign: Contractor NRL

ANNEXURE X List of Laboratory Equipments

A. For Building & Road works: 1. Sieves‐ as per IS 460‐1962 (i) IS Sieves – 450mm internal dia., of sizes 100mm, 80mm, 63mm, 50mm, 40mm, 25mm, 20mm, 12.5mm, 10mm, 6.3mm, 4.75mm, complete with lid and pan. (ii) IS Sieves‐ 200mm internal dia. (brass frame), consisting of 2.36mm, 1.18mm, 600 microns, 425 microns, 300 microns, 212 microns, 150 microns, 90 microns, 75 microns, with lid and pan.

2. Sieve shaker capable of 200mm and 300mm dia. Sieves, manually operated with timing switch assembly. 3. Ovens‐ electrically operated, thermostatically controlled upto 110° C –sensitivity 1°C. 4. Equipment for slump test‐ Slump cone, steel plate, tamping rod, steel scale, scoop. 5. Cube moulds‐ 150cm X 150cm X 150 cm‐ 50 no.s 6. 100 tonnes compression testing machine, electrically‐cum manually operated. 7. Graduated measuring cylinders 200ml. capacity 8. Balances‐ (i) 7 kg. to 10 kg. capacity, semi‐self indicating type‐ accuracy 10 gm. (ii) 500 gm. Capacity, semi‐self indicating type‐ accuracy 1hm. (iii) Pan balance‐ 5 kg. capacity accuracy 10 gms. (iv) Chemical balance, 100 gm capacity‐ accuracy 0.1 gm 9. Aggregate Crushing strength apparatus 10. Aggregate Impact value appartaus 11. Los Angeles Test apparatus 12. Rapid Moisture meter 13. Core cutter apparatus 14. Temperature gun, Temperature Range ‐ 0 to 750F 15. Theodolite 16. Dumpy Level with staffs 17. Electrical moisture meter for timber 18. Digital Elcometer (0‐125 microns for steel & 0‐100 microns for non ferrous base with accuracy of 1 micron) B. Miscellaneous: 1. Vernier Callipers 2. Steel measuring tapes‐ 3. Rebound hammer for testing concrete

ANNEXURE XI Material Tests

Freq

uen

cy (

7)

• Water

from each sour

ce shall be

got tested

before the

commenceme

nt of work

and thereafter

once in

every 3 month

s till the

completion of

the work.

Number of Tes

ts for each

source shall b

e 3. For all

quantities

• 50 cum

or part

thereof and o

n each change

of source.

10 cum or par

t thereof

Min

m.

Qty

. for

te

stin

g

As per requireme

nt 50 cum

10 cum

Fiel

d

(F)/

La

bor

at L F or L

Tes

t p

roce

du

re

(4) IS 3025

IS: 2386, part

II Append

ix B IS: 238

6, part II

IS: 2386

Tes

ts (

3)

(i) pH Value (ii) Lim

its of Acidity

(iii) Limits of A

lkality (iv) Pe

rcentage of so

lids (a) Ch

lorides

(b) Suspende

d matter

(c) Sulphates

(d) In

organic solids

(e) Org

anic solids

Percentage of

soft or

deleterious m

aterial Particl

e size Estima

tion of Organi

c Impurities

Surface moistu

re Determ

ination of 10%

fine value

Specific Gravi

ty Bulk D

ensity Aggreg

ate Crushing S

trength

Aggregate Imp

act value

Mat

eria

l (2

) Water Coarse

Aggregates

Sl. N

o.

(1)

1

2

Material Tests (contd.)

Fre

qu

ency

(7

)

40 cum or par

t thereof or

change of sour

ce

• 50 cum

for R.C.C work

includi

ng in all other

small locatio

n.

• In case

, R.C.C. done in

a day is

less than 50 cu

m test may be

carried

out as require

d by EIC

• 50 cum

or 10 batches

of 5‐7 cum ea

ch for R.C.C wo

rk in all

location taken

together.

•

In case, R.C.C.

done in a day i

s less tha

n 50 cum test

may be

carried out as

required by

EIC. •

Every 1 cum or

part therof

Min

m. Q

ty. f

or

test

ing

(6)

40 cum

20 cum

20 cum

1 cum

Fiel

d (

F)/

Lab

orat

ory

(L)

(5) F F F F or L F F/ L F / L

Tes

t p

roce

du

re

(4) Append

ix A Append

ix C Append

ix D Append

ix B Append

ix G

Appendix H

Appendix M

Tes

ts (

3)

Organic Impu

rities Silt Con

tent Bulkin

g of Sand

Particle size

distribution Slump

test

Cube test

Moisture Cont

ent

Mat

eria

l (2

) Sand Concrete Timber

Sl. N

o.

(1) 3 4. 5.

Material Tests (contd.)

Freq

uen

cy (

7)

NA NA ‐ ‐

Min

m. Q

ty. f

or t

esti

ng

(6)

• For lot

size, 2001‐10

000, 20 no.s

• For lot

size, 10001‐3

5000, 32 no.s

• For lot

size, 35001‐5

0000, 50 no.s

• For lot

size 2000 or le

ss bricks, as pe

r decisio

n of EIC

• For lot

size 2001‐100

00, 5 no.s of

bricks •

For lot size, 1

0001‐35000, 1

0 no.s of

bricks •

For lot size, 3

5001‐50000, 1

5 no.s of

bricks •

For lot size 20

00 or less brick

s, as per

decision of EIC

•

From 26‐50 sh

utters, 8 no. s

amples

• From 5

1‐100 shutters

, 13 no. sampl

es •

From 101‐150

shutters, 20 n

o. samples

• From 1

51‐300, 32 no

. of samples

• From 3

01‐500, 50 no

. of samples

• From 5

01 and above,

80 no. of sam

ples •

For 25 and le

sser no.s, as pe

r decision

Of EIC

‐ ‐

Fiel

d (

F)/

Lab

orat

ory

(L)

(5) L L F/L F/L

Tes

t p

roce

du

re

(4) Append

ix I

Appendix J

Appendix K

Appendix L

IS: 2202/

Appendix N

IS 2

72

0,

MO

RST

& H

IS 2

38

6,

MO

RST

&H

Tes

ts (

3)

Dimensional t

est

Compressive

Strength

Water Absorp

tion Efflore

scence

• End Im

mersion

Test •

Knife test

Adhesion test

Gra

dat

ion

, Den

sity

of

Com

pac

ted

laye

r

Gra

dat

ion

, A

bra

sion

& Im

pac

t va

lue,

Fla

kin

ess

&

Elon

gati

on

Mat

eria

l (2

) Bricks Flush Door Granular

Sub base WBM

Sl. N

o.

(1) 6. 7. 8. 9.

Annexure XII Register Formats a) Material Issue & Stock Register (for materials issued by NRL)

MATERIAL STOCK & ISSUE RECORDS

Page No:

Name of work: Contractor: W.O No.:

SOR Item No.

Brief Item Description

Executed on Rate of Consumption

Consumed Qty.

Material Requisition Details

Signature

Date Qty. Contractor NRL

b) Site Measurement Register SITE MEASUREMENT REGISTER

Name of work:

Page No:

Contractor: W.O No.: Date of Measurement: Sl. No.

Item No.

Item description(in brief) and location Unit L B D/ H No. Qty. Remarks

c) Site Instruction Register SITE OBSERVATION REGISTER

Name of work: Page No: Contractor: W.O No.:

Date Site Instruction in detail Signature &

Name (NRL) Accepted by (contractor)

Complied by contractor on

Cross checked by NRL with remarks

d) Site Inspection Register INSPECTION CLEARANCE REGISTER

Name of work: Page No: Contractor: W.O No.: Sl. No.

Item / Activity offered for Inspection

Location Offered by (contractor)

Inspected & accepted by

(NRL)

Next activity

Remarks

f) Equipment Deployment Record EQUIPMENT DEPLOYMENT RECORD (Page No.)

Name of work: Contractor: W.O No.: Sl.No. Date Equipment

Details Deployment Reference gate

pass Signature

Date Purpose Contractor NRL

e) Cube Test Register

CUBE TESTING REGISTER Page No: Name of work: Contractor: W.O No.:

28

DA

YS

CO

MPT

ESSI

VE

STR

ENG

TH

(kg/

cm2)

NR

L SIG

N

CO

NTR

AC

TO

R

SIG

N

AV

G.

ST RE

NG

TH

ST RE

NG

TH

TO TA L LO AD

D

AT

E (TES

TED

)

7 D

AY

S C

OM

PTES

SIV

E ST

REN

GTH

(kg/

cm2)

NR

L SI

GN

CO

NT

RA

CT

OR

SI

GN

.

AV

G.

ST RE

NG

TH

STR

ENG

TH

TOTA

L LOA

D

DA

TE (T

ESTE

D)

CU

BE

MA

RK

DA

TE

OF

PO UR

IN

G

LO CA

TI ON

O

F C

ON

CR

ETE

GR

D.

OF

CO

NC

RE

TE

SL.

NO

.

g) Material Test Register Page No: Name of work: Contractor: W.O No.:

Rem

arks

Sign

atur

e

NR

L

Con

tract

or

Stat

us o

f te

st

resu

lts

Ref

eren

ce

Doc

.

Dat

e of

te

stin

g

Sam

ple

take

n on

Lot

size

/ Q

ty.

(fro

m

whi

ch

sam

ple

is

take

n)

Freq

uenc

y of

te

st

as

per

BIS

/ co

ntra

ct

Mat

eria

l de

scrip

tion

Sl.

No.

APPENDIX ‘A’ TEST FOR ORGANIC IMPURITIES The aggregate must also be checked for organic impurities such as decayed vegetation humus, coal dust etc. What is called the colour test is reliable indicator of the presence of harmful organic matter in aggregate, except in the area where there are deposits of lignite. Fill a 350 ml clear glass medicine bottle upto 70 ml mark with a 3% solution of caustic soda or sodium hydroxide. The sand is next added gradually until the volume measured by the sandy layer is 125 ml. The volume is then made upto 200 ml by addition of more of solution. The bottle is then stoppered and shaken vigorously and allowed to stand for 24 hours. At the end of this period, the colour of the liquid will indicate whether the sand contains a dangerous amount of matter. A colourless liquid indicates a clean sand free from organic matter. A straw coloured solution indicates some organic matter but not enough to be seriously objectionable. Darker colour means that the sand contains injurious amounts and should not be used unless it is washed, and a retest shows that it is satisfactory. Add 2.5 ml of two per cent solution of tannic acid in 10 per cent alcohol, to 97.5 ml of three per cent sodium hydroxide solution. Place in a 350 ml bottle, fix the stopper, shake vigorously and allow to stand for 24 hours before comparison with the solution above the sand.

Note: A three per cent solution of caustic soda is made by dissolving 3 g of sodium hydroxide in 100 ml of water, preferably distilled. The solution should be kept in a glass of bottle tightly closed with a rubber stopper. Handling sodium hydroxide with moist hands may result in serious burns. Care should be taken not to spill the solution for it is highly injurious to clothing, leather, and other materials.

APPENDIX ‘B’ TEST FOR PARTICLE SIZE (SIEVE ANALYSIS)

Apparatus: Perforated plate sieves as per IS designation should be used. The balance or scale shall be such that it is readable and accurate to 0.1 per cent of the weight of the test sample. Sample: The weight of sample available shall not be less than the weight given in the table below. The sample of sieving shall be prepared from the larger sample either by quartering or by means of a sample divider.

TABLE SHOWING MINIMUM WEIGHTS FOR SAMPLING Maximum size present in substantial proportions (mm) Minimum weight of sample for sieving (Kg) 10 0.5 4.75 0.2 2.36 0.1

Test Procedure: The sample shall be brought to an air‐dry condition before weighing and sieving. This may be achieved either by drying at room temperature or by heating at a temperature of 100 degree to 110 degree centigrade. The air dry sample shall be weighed and sieved successively on the appropriate sieves starting with the largest. Care shall be taken to ensure that the sieves are clean before use. Each sieve shall be shaken separately over a clean tray until not more than a trace passes, but in any case for a period of not less than two minutes. The shaking shall be done with a varied motion, backwards and forwards, left to right, circular clockwise and anti‐clockwise, and with frequent jarring, so that the material is kept moving over the sieve surface in frequently changing directions. Materials shall not be forced through the sieve by hand pressure, but on sieves coarser than 20 mm, placing of particles is permitted, Lumps of fine material, if present may be broken by gentle pressure with fingers against the side of the sieve. Light brushing of underside of the sieve with a soft brush may be used to clear the sieve openings. Light brushing with a fine camel hair brush may be used on the 150 micron IS sieve to prevent segregation of powder and blinding of apertures. Stiff or worn out brushes shall not be used for this purpose and pressure shall not be applied to the surface of the sieve to force particles through the mesh. On completion of sieving the material retained on each sieve, together with any material cleaned from the mesh, shall be weighed. Reporting of Results: The results shall be calculated and reported as: (a) The cumulative percentage by weight of the total sample passing each of the sieves, to the nearest whole number: Or (b) The percentage by weight of the total sample passing one sieve and retained on the next smaller sieve, to the nearest 0.1 percent. In order that the sieves shall not be overloaded, care must be taken to ensure

that the maximum sieve loads shown in Table (below) are not exceeded at the completion of sieving. I.S. Sieve Designation Maximum weight for

45 cm dia sieve kg 30 cm dia sieve kg 45 mm 10 4.5 40 mm 8 3.5 31.5 mm or 22.1 mm 6 2.5 20 mm 4 2.0 16 mm or 12.5 mm 3 1.5 10 mm 2 1.0 5.6 mm 1.5 0.75 4.75 mm 1.0 0.50 3.35 mm ‐ 0.30

APPENDIX ‘C’ TEST FOR SILT CONTENT The sand shall not contain more than 8% of silt as determined by field test with measuring cylinder. The method of determining silt contents by field test is given below: A sample of sand to be tested shall be placed without drying in a 200 ml measuring cylinder. The volume of the sample shall be such that it fills the cylinder upto 100 ml mark. Clean water shall be added upto 150 ml mark. Dissolve a little salt in the water in the proportion one tea spoon to half a litre. The mixture shall be shaken vigorously, the last few shakes being sidewise direction to level off the sand and the contents allowed to settle for three hours. The height of the silt visible as settled layer above the sand shall be expressed as a percentage of the height of sand below. The sand containing more than the above allowable percentage of silt, shall be washed so as to bring the silt contents within allowable limits.

APPENDIX ‘D’ BULKING OF FINE AGGREGATES/SAND (FIELD METHODS) Two methods are suggested for determining the bulking of sand/fine aggregate. The procedure may be suitably varied, if necessary. Both depend on the fact that the volume of inundated sand/fine aggregate is the same if the sand/fine aggregate were dry.

Method -1: Put sufficient quantity of sand loosely into a container until it is about two‐third full. Level off the top of the sand and push a steel rule vertically down through the sand at the middle to bottom, measure the height. Suppose this is ‘X’ cm. Empty the sand out of the container into another container where none of it is lost. Half fill the first container with water. Put back about half the sand and rod it with a steel rod, about 6 mm in diameter, so that its volume is reduced to a minimum. Then add the remainder and level the top surface of the inundated sand. Measure its depth at the middle with the steel rule. Suppose this is ‘Y’ cm. The percentage of bulking of the sand due to moisture shall be calculated from the formula: Percentage bulking = (X/Y ‐1) X 100 Method-2: In a 250 ml measuring cylinder, pour the damp sand, consolidate it by staking until it reached the 200 ml mark. Then fill the cylinder with the water and stir the sand well (the water shall be sufficient to submerge the sand completely). It will be seen that the sand surface is now below its original level. Suppose the surface is at the mark of Yml, the percentage of bulking of sand due to moisture shall be calculated from the formula. Percentage bulking= (200/Y – 1) x 100

APPENDIX E TEST FOR SURFACE MOISTURE Take a sample of wet aggregate and weigh it (A). Then place it in a frying pan and gently apply heat, meanwhile stirring with a glass rod until the surface moisture disappears. This is apparent when the aggregate loses its shining wet appearance and becomes dull, or when it just attains a free funning condition. The saturated surface dry material is then weighed (B). Continue the heating thereafter until the moisture is evaporated and weigh the dry sample (C). The surface moisture is then calculated as follows: Surface moisture = 100 x A ‐ B C It is expressed as a percentage of dry aggregate.

APPENDIX F DETERMINATION OF TEN PER CENT FINE VALUE

Apparatus: The apparatus for the standard test shall consist of the following: (a) A 15 cm diameter open‐ended steel cylinder, with plunger and base‐plate, as shown in Fig. in the end of this appendix. The surfaces in contact with the aggregate shall be machined and case hardened or otherwise treated so as to have a diamond (VH) pyramid hardness number of not less than 650 VH. (b) A straight metal tamping rod of circular cross‐section 16 mm in diameter and 45 to 60 cm long, rounded at one end. (c) A balance of capacity 3 Kg, readable and accurate to one gram. (d) I.S. Sieve of sizes 12.5, 10 and 2.36 mm. (d) A compression testing machine capable of applying a load of 50 tonnes and which can be operated to give a uniform rate of loading so that the maximum load in any test is reached in 10 minutes. This load may vary from 0.5 to 50 tonnes. (e) For measuring the sample, a cylindrical metal measure of sufficient rigidity to retain its form under rough usage and of the following internal dimensions: Diameter 11.5 cm Height 18.0 cm (f) Means of measuring the reduction in the distance between the plates of the testing machine to the nearest one millimeter during the test (for example, dial gauge). Test Sample: Material for the test shall consist of aggregate passing a 12.5 mm I.S. Sieve and retained on a 10 mm I.S. Sieve. The aggregate shall be tested in a surface dry condition. If dries by heating the period of drying shall not exceed four hours, the temperature shall be 100ºC to 110ºC and the aggregate shall be cooled to room temperature before testing. The quantity of aggregate shall be such that the depth of material in the cylinder, after tamping as described below, shall be 10 cm. The weight of material comprising the test sample shall be determined (weight A) and the same weight of sample shall be taken for the repeat test. Note: About 6.5 kg of natural aggregate is required to provide the two test samples. Less of light weight aggregate is required. The measuring cylinder is filled in three layers of approximately equal depth with aggregate passing a 12.5 mm I.S. Sieve and retained on 10 mm I.S. Sieve. Each layer is subjected to 25 strokes from the tamping rod (16 mm dia and 45 to 60 cm long) rounded to one end, care being taken in case of weak materials not to break the particles. The surface of the aggregate shall be carefully leveled and the plunger inserted so that it rests horizontally on this surface. Test Procedure: The apparatus, with the test sample and plunger in position, shall then be placed in the compression testing machine. The load shall be applied at a uniform rate so as to cause a total penetration of a plunger in 10 minutes of about: 15.0 mm for rounded or partially rounded aggregates (for example uncrushed gravel) 20 mm for nominal crushed aggregate & 24 mm for honey combed aggregate (for example expanded shales and slags). These figures may be varied according to the extent of the rounding or honey combing. After reaching the required maximum penetration, the load shall be released and the whole of the material removed from the cylinder and sieved on a 2.36 mm I.S. Sieve. The fines passing the sieve shall be weighed, and this weight expressed as a

6.3

130

to 1

40

percentage of the weight of the test sample. Normally, this percentage will fall within the range 7.5 to 12.5, but if it does not, a further test shall be made at a load adjusted appropriately, to bring the percentage fines within the range of 7.5 to 12.5. A repeat test shall be made at the load that gives as percentage fines within the range 7.5 to 12.5. Calculations: The mean percentage fines from the two tests at this load shall be used in the following formula to calculate the load required to give 10 percentage fines. Load required for 10 percent fines = Where X = Load in tonnes and 14 × X Y + 4 Y= mean percentage fines from two test at X tonnes load. Reporting of Results: The load required to produce 10 percent fines shall be reported to the nearest whole number for loads of 10 tonnes or more, the nearest 0.5 tonne for loads of less than 10 tonnes. The value expressed to the nearest 0.5 tonne should be as follows: (a) For normal concrete, not less than 5 tonnes. (b) For wearing surfaces, not less than 10 tonnes. (c) For granolithic concrete, not less than 15 tonnes.

All dim ensions in m illim etres

Internal Diameter of Cylinder = 152.0± 0.5

Fig.: Apparatus for Determination of Ten per cent Fine Value

100 to 150 φ20 φ

152.≠0.5

25

K 16K 16 200 to 230

APPENDIX G

SLUMP TEST Apparatus: Mould shall consist of a metal frustum of cone having the following internal dimensions: Bottom diameter……………………………………………………..20 cm Top diameter…………………………………………………………10 cm Height…………………………………………………………………30 cm The mould shall be of a metal other than brass and aluminium of at least 1.6 mm (or 16 BG) thickness. The top and bottom shall be open and at right angles to the axis of the cone. The mould shall have a smooth internal surface. It shall be provided with suitable foot pieces and handles to facilitate lifting it from the moulded concrete test specimen in a vertical direction as required by the test. A mould provided with a suitable guide attachment may be used. Tamping rod shall be of steel or other suitable material 16 mm in diameter 60 mm long and rounded at one end. Procedure: The internal surface of the mould shall be thoroughly cleaned and free form superfluous moisture and any set concrete before commencing the test. The mould shall be placed on a smooth horizontal, rigid and non-absorbent surface viz. leveled metal plate. The operator shall hold the mould firmly in place while it is being filled with test specimen of concrete. The mould shall be filled in four layers, each approximately one quarter of height of mould. Each layer shall be tamped with twenty five strikes of the rounded end of the tamping rod. The strokes shall be distributed in a uniform manner over the cross section of the mould and for the second and subsequent layers shall penetrate into the under- lying layer. The bottom layer shall be tamped through out its depth. After the top layer has been rodded, the concrete shall be struck off level with trowel or the tamping rod, so that the mould is exactly filled. Any mortar which shall leak out between the mould and the base plate shall be cleaned away. The mould shall be removed from the concrete immediately after filling by raising it slowly and carefully in a vertical direction. The moulded concrete shall then be allowed to subside and the slump shall be measured immediately by determining the difference between the height of the mould and that of the highest point of specimen.

The above operations shall be carried out at a place free from vibration or shock, and within a period of two minutes after sampling. Result: The slump shall be recorded in terms of millimeters of subsidence of the specimen during the test. Any slump specimen which collapses or shears off laterally give incorrect result. If this occurs, the test shall be repeated with another sample. The slump test shall not be used for very dry mixes as the results obtained are

APPENDIX H

CUBE TEST FOR COMPRESSIVE STRENGTH OF CONCRETE - MANDATORY LAB TEST

H-0 One sample (consisting of six cubes 15x15x15 cm shall be taken for every 20 cum or part thereof concrete work ignoring any part less than 5cum or as often as considered necessary by the Engineer- in-Charge. The test of concrete cubes shall be carried out in accordance with the procedure as described below. A register of cubes shall be maintained at the site of work in Appendix C. The casting of cubes, concrete used for cubes and all other incidental charge, such are curing, carriage to the testing laboratory shall be borne by the contractors. The testing fee for the cubes, if any, shall be borne by the department.

H-1 Test Procedure

H-1.1 Mould The mould shall be of size 15 cmx15 cmx15 cm for the maximum nominal size of aggregate not exceeding 40 mm. For concrete with aggregate size more than 40 mm size of mould shall be specified by the Engineer-in-charge, keeping in view the fact that the length of size of mould should be about four times the size of aggregate.

The moulds for test specimens shall be made of non-absorbent material and shall be substantially strong enough to hold their form during the moulding of test specimens. They shall not vary from the standard dimensions by more than one percent. The moulds shall be so constructed that there is no leakage of water from the test specimen during moulding. All the cube moulds for particular site should, prior to use, be checked for accuracy in dimensions and geometric form and such test should at least be made once a year.

Each mould shall be provided with a base plate having a plane surface and made of non-absorbent material. This plate shall be large enough in diameter to support the moulds properly without leakage. Glass plates not less than 6.5mm thick or plain metal not less than 12mm thick shall be used for this purpose. A similar plate shall be provided for covering the top surface of the test specimen when moulded.

Note: Satisfactory moulds can be made from machine or steel castings, rolled metal plates or galvanized.

H-1.2 Sample of Concrete

Sample of concrete for test specimen shall be taken at the mixer or in the case of ready mixed concrete from the transportation vehicle discharge or as directed by Engineer-in-Charge. Such samples shall be obtained by repeatedly passing a scoop or pail through the discharge stream of concrete. The sampling operation should be spread over evenly to the entire discharging operation. The samples thus obtained shall be transported to the place of moulding of the specimen to counteract segregation. The concrete shall be mixed with a shovel until it is uniform in appearance. The location in the work of the batch of concrete this sampled shall be noted for further reference. In case of paving concrete, samples shall be taken from the batch immediately after deposition of the sub grade. At least five samples shall be taken from different portion of the pile and these samples shall be thoroughly mixed before being used to form the test specimen.

The sampling shall be spread as evenly as possible throughout the day. When wide changes occur during concreting, additional sample shall be taken if so desired by the Engineer-in-Charge.

H-1.3 Preparation of Test Specimens

The interior surfaces of the mould and base plate shall be lightly oiled before the concrete is placed in the mould. The samples of concrete obtained as described under the test specimen shall be immediately moulded by one of the following methods as indicated below:-

When the job concrete is compacted by manual methods, the test specimen shall be moulded by placing the fresh concrete in the mould in three layers, each approximately one third of the volume of the mould. In placing each scoopful of concrete the scoop shall be moved around the top edge do the mould as the concrete there sided from it, in order to ensure a uniform distribution of concrete within the mould. Each layer shall be rodded 35 times with 16 mm rod, 60 cm in length, bullet pointed at the lower end. The strokes shall be distributed in uniform manner over the cross section of the mould and shall penetrate into underlying layer. The bottom layer shall be rodded through its depth. After the top layer has been rodded, the surface of the concrete shall be struck off with a trowel and covered with a glass plate at least 6.5 mm thick or a machined plate. The whole process of moulding shall be carried out in such a manner as to preclude the change of the water cement ratio of the concrete, by loss of water either by leakage from the bottom or over flow from the top of the mould.

When the job concrete is placed by vibration and the consistency of the concrete is such that the test specimens cannot be properly moulded by hand rolling as described above, the specimens shall be vibrated to give a compaction corresponding to that of the job concrete. The fresh concrete shall be placed in mould in two layers, each approximately half the volume of the mould. In placing each scoopful of concrete the scoop shall be moved around the top edge of the mould as the concrete there slides from it, in order to ensure a symmetrical distribution of concrete within the mould. Either internal or external vibrators may be used. The vibration of each layer shall not be continued longer than is necessary to secure the required density. Internal vibrators shall only be used when the concrete is required to be compacted in layers. In compacting the first layer, the vibrators shall not be allowed to rest on the bottom of the mould. In placing the concrete for top extent that there will be no mortar loss during vibrations. After vibrating the second layer enough concrete shall be added to bring level above the top of the mould. The surface of the concrete shall then the struck off with a trowel and covered with a glass or steel plate as specified above. The whole process of moulding shall be carried out in such a manner as to preclude the alteration of water-cement ratio of the concrete by loss of water, either by leakage for the bottom or over flow from the top of the mould.

H-1.4 Curing and Storage of Test Specimen In order to ensure reasonably uniform temperature and moisture conditions during the

first 24 hours for curing the specimen and to protect them from damage, moulds shall be covered with wet straw or gunny sacking and placed a storage box so constructed and kept on the work site that its air temperature when containing concrete specimens shall remain 22ºC to 33ºC. Other suitable means which provide such a temperature and moisture conditions may be used.

Note:- It is suggested that the storage box be made of 25 mm dressed tongued and grooved timber, well braced with battens to avoid warping. The box should be well painted inside and outside and should be provided with a hinged cover and padlock.

The test specimen shall be removed from the moulds at the end of 24 hours and stored in a moist condition at a temperature within 24ºC to 30ºC until the time of test. If storage in water is desired, a saturated lime solution shall be used.

H-1.5 Testing The specimens shall be tested in accordance with procedure as described below:

(a) The tests shall be made at an age of concrete corresponding to that for which the strengths are specified.

(b) Compression tests shall be made immediately upon removal of the concrete test specimen from the curing room i.e. the test specimen shall be loaded in damp condition. The dimensions of the test specimens shall be measured in mm accurate to 0.5 mm.

(c) The metal bearing plates of the testing machine shall be placed in contact with the ends of the test specimens. Cushioning materials shall not be used. In the case of cubes, the test specimen shall be placed in the machine in such a manner that the load is applied to sides of the specimens as cast. An adjustable bearing block shall be used to transmit the load to the test specimen. The size of the bearing block shall be the same or slightly larger than that of test specimen. The upper or lower section of the bearing block shall be kept in motion as the head of the testing machine is brought to a bearing on the test specimen.

(d) The load shall be applied axially without shock at the rate of approximately 140 kg. per sq.cm. per minute. The total load indicated by the testing machine at failure of test specimen shall be recorded and the unit compressive strength is calculated in kg per sq. cm. using the area computed from the measured dimension of the test specimen. The type of failure and Appearance of the concrete shall be noted.

PAsuleomTTth MLWH NFLWH FLWH CAto 'A 'B 'C

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APPENDIX J TEST FOR COMPRESSIVE STRENGTH

Specimen Five whole bricks shall be taken from the samples as specimens for this test. Length and width of each specimen shall be measured correct to 1 mm. Apparatus The apparatus consists of compression testing machine, the compression plate of which shall have a ball seating in the form of portion of a sphere the centre of which shall coincide with the centre of the plate. Procedure (a) Pre-conditioning: The specimen shall be immersed in the water for 24 hours at 25º to 29ºC. Any surplus moisture shall be allowed to drain at room temperature. The frog of the bricks should be filled flush with mortar 1:3 (1 cement : 3 clean coarse sand of grade 3 mm and down) and shall be kept under damp jute bags for 24 hours, after that these shall be immersed in clean water for three days. After removal from water, the bricks shall be wiped out of any traces of moisture. (b) Actual Testing: Specimen shall be placed with flat faces horizontal and mortar filled face upward between three 3 ply plywood sheets each of thickness 3 mm and carefully centred between plates of the testing machine. Plaster of Paris can also be used in place of plywood sheets to ensure a uniform surface. Load shall be applied carefully axially at uniform rate of 14 N/mm2 per minute till the failure of the specimen occurs. Reporting the Test Results The compressive strength of each specimen shall be calculated in N/mm2 as under :

Compressive Strength = Maximum load at failure (in N) Area of Specimen (in sq mm) In case the compressive strength of any individual brick tested exceeds the upper limit of the average compressive strength specified for the corresponding class of brick, the same shall be limited to the upper limit of the class specified in 6.1.2 for the purpose of calculating the average compressive strength. Compressive strength of all the individual bricks comprising the sample shall be averaged and reported. Criteria for Conformity A lot shall be considered having satisfied the requirements of average compressive strength if the average compressive strength specified in 6.1.2 for the corresponding class of brick tested is not below the minimum average compressive strength specified for the corresponding class of bricks by more than 20 per cent.

APPENDIX K TEST FOR WATER ABSORPTION

No. of Specimen Five whole bricks shall be taken from samples as specimen for this test. Apparatus A balance required for this test shall be sensitive to weigh 0.1 percent of the weight of the specimen. Procedure (a) Pre-conditioning: The specimen shall be allowed to dry in a ventilated oven at a 110°C to 115°C till it attains a substantially constant weight. If the specimen is known to be relatively dry, this would be accomplished in 48 hours, if the specimen is wet, several additional hours may be required to attain a constant weight. It shall be allowed to cool at room temperature. In a ventilated room, properly separated bricks will require four hours for cooling, unless electric fan passes air over them continuously in which case two hours may suffice. The cooled specimen shall be weigh (W1) a warm specimen shall not be used for this purpose. (b) Actual Testing: Specimen shall be completely dried before immersion in the water. It shall be kept in clean water at a temperature of 27°C ± 2°C for 24 hours. Specimen shall be wiped out of the traces of water with a damp cloth after removing from the water and then shall be weighed within three minutes after removing from water (W2). Reporting the Test Results The water absorption of each specimen shall be calculated as follows and the average of five tests shall be reported. Water Absorption W2 – W1 x 100 W1

Criteria for Conformity A lot shall be considered having satisfied the requirements of water absorption if the average water absorption is not more than 20% by weight.

APPENDIX L

TEST FOR EFFLORESCENCE No. of Specimen Five whole bricks shall be taken as specimen for this test. Apparatus Apparatus required for this test shall be a shallow flat bottom dish containing distilled water. Procedure (actual testing) The brick shall be placed vertically in the dish with 2.5 cm immersed in the water. The room shall be warm (18ºC to 30ºC) and well ventilated. The bricks should not be removed until it absorbs whole water. When the whole water is absorbed and the brick appears to be dry, place a similar quantity of water in that dish and allow it to evaporate as before. The brick shall be examined after the second evaporation. Reporting the Test Results The rating to efflorescence in ascending order shall be reported as ‘NIL’, ‘SLIGHT’, ‘MODERATE’, ‘HEAVY’ or ‘SERIOUS’ in accordance with the following : (a) NIL: When there is no perceptible deposit of efflorescence. (b) SLIGHT: When not more than 10 per cent of the area of the brick is covered with a thin deposit of salts. (c) MODERATE: When there is heavier deposit and covering upto 50% of the area of the brick surface but unaccompanied by powdering or flaking of the surface. (d) HEAVY: When there is a heavy deposit of salts covering 50% or more of the brick surface but unaccompanied by powdering or flaking of the surface. (e) SERIOUS: When there is heavy deposit of salts, accompanied powdering and/or flaking of the surface and tending to increase in the repeated wetting of the specimen. Criteria for Conformity A lot be considered having satisfied the requirements of efflorescence if for 4 out of the specimen of 5 bricks, the rating of efflorescence is not beyond “Moderate”.