government of india - department of atomic...

Government of IndiaDepartment of Atomic Energy

Indira Gandhi Centre for Atomic ResearchCIVIL ENGINEERING GROUP

Tender forCONSTRUCTION OF RR COMPOUND

WALL AND FORMATION OF PERIPHERAL ROAD FROM SUBSTATION

PDC-5 TO CMPL IN IGCAR, KALPAKKAM.

Tender No. : CEG/IGC/830/2011



Name of work : Construction of RR compound wall and formation of peripheral road from Substation PDC-5 to CMPL in IGCAR, Kalpakkam.


INDEX Section Title Page No.I Notice Inviting Tenders 2 - 14

II Form of Agreement and General rules and directions for guidance of the contractor 15 – 19

III Special conditions 20 – 35 III - A Safety code for contractors 36 – 63IV General conditions of contract 64 – 113

Schedule - F 114 – 118IVA Power and Electrical Safety 119 – 120V Technical Specifications 121 – 354VA Schedule of construction 355VI Schedule of drawings 356VII Schedule of supply of materials 357 – 359

Annexure A-G 360 – 376VIII Instructions to contractors 377

Schedule of Quantities 378 - 389

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SECTION – I : NOTICE INVITING TENDERGovernment of India

Department of Atomic EnergyIndira Gandhi Centre for Atomic Research

CIVIL ENGINEERING GROUP

1.0 Sealed tenders are invited on behalf of the President of India by the Director, ESG Kalpakkam 603 102, Kancheepuram District, Tamilnadu from reputed and experienced Civil Engineering Contractors with proven technical and financial capabilities, possessing the required construction equipments and who have executed major civil works costing not less than 80 % of Estimated cost under a single contract or two similar works each costing not less than 60 % of Estimated cost or three similar works each costing not less than 40 % of Estimated cost during past seven years (atleast one work shall be of similar nature) and who are on the approved list of the appropriate class of Central Public Works Department, State Public Works Department, Railways, Military Engineer Services for the following work:

The value of executed works shall be brought to current costing level by enhancing the actual value of work at simple rate of 7% per annum, calculated from the date of completion to last date of receipt of applications for tenders.

Firms satisfying the eligibility conditions can also download the tender document by clicking the Tender document download button from our website www.igcar.gov.in and submit the completed tender by Courier (OR) Speed post as per the Instructions to Tenderers downloading the tender document from website. These instructions are available as part of the tender document also.

TENDER No.: CEG/IGC/830/2011

Name of workConstruction of RR compound wall and formation of peripheral road from Substation PDC-5 to CMPL in IGCAR, Kalpakkam.

Estimated Cost ` 195.67 LakhsEarnest Money Deposit ` 3,91,340/-Security Deposit 5% of tendered valuePerformance Guarantee 5% of tendered valueCost of Tender Document ` 1,040/- (including VAT)Note:(i) For tenderers desiring to purchase the tender in person this cost of tender shall be paid in cash to P&AO, IGCAR, Kalpakkam.

[OR](ii) For tenderers desiring to download the tender from the website this cost of tender document shall be submitted as Demand draft from any scheduled bank drawn in favour of

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http://www.igcar.gov.in/

Pay & Accounts Officer, IGCAR, Kalpakkam 603 102 payable at Kalpakkam.

Time Allowed 12 [Twelve] MonthsLast date for receipt of tenders Upto 3:30 PM on 25-4-2011

Time of opening of Tenders3:35 PM on 25-4-2011 for Envelope (1) and 3.35PM on 5-5-2011 for Envelope (2) & (3)

(#)Similar work means, tenderers who have successfully executed any of the following works as specified below:

Large road projects involving filling in embankments, Asphaltic Concrete, Granular sub base formation, wet mix macadam, bituminous concrete and semi dense bituminous macadam, using paver finisher & other machineries for road works, RCC cuvert structures, RR compound walls etc.

2.0 The security deposit at 5% of the gross amount of the bill shall be deducted from each running bill of the contractor till the sum along with the sum already deposited as earnest money, will amount to security deposit of 5% of the tendered value of the work. In addition the contractor shall be required to deposit of 5% of the tendered value of the contract as performance security in the prescribed form (as specified in the Annexure) within a period of fifteen days of issue of letter of intent.

3.0 Tender documents can be had on written request, duly recommended by Associate Director/CEG or his authorised representative on any working day from 4-4-2011 to 15-4-2011 on payment of the cost of tender document in cash in person (this amount is not refundable) from the Pay & Accounts Officer, IGCAR, Kalpakkam 603 102.

[OR]

Firms satisfying the eligibility conditions can also download the tender document by clicking the Tender document download button from our website www.igcar.gov.in from 4-4-2011 to 15-4-2011 and submit the tender by Courier (OR) Speed post to the address mentioned below as per the Instructions to Tenderers downloading the tender document from website. These instructions are available as part of the tender document. Please refer relevant page of tender document. (If the tender is received beyond the time and period specified for its receipt then it will not be considered as it will be ‘LATE TENDER’. Department will not be held responsible for any courier or postal delay).

Associate Director,Civil Engineering Group,

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CDO building,Indira Gandhi Centre for Atomic Research,Kalpakkam 603 102

4.0 (i) Tenderers shall furnish evidence in original for verification, of their past experience in execution of large road projects involving filling in embankments, Asphaltic Concrete, Granular sub base formation, wet mix macadam, bituminous concrete and semi dense bituminous macadam, using paver finisher & other machineries for road works, RCC culvert structures, RR compound walls etc with their average annual turnover during the past five years duly certified by registered chartered Accountant and details of construction equipments, works experiences and other requisites along with their application for tender forms.

(ii) In case of tenderers downloading the tender from website they need to submit evidences of their eligibility criteria as prescribed in NIT in the form of Xerox copies duly attested by Gazetted officer and they need to produce all original to department for verification during the period as mentioned in the NIT.

5.0 Firms who have purchased the tender in person shall fill up and submit the tender as per following procedure:

The tenderer shall be required to place the Earnest Money and the tenders in separate sealed envelopes marked `Earnest Money' and `Tender' in separate envelopes placed in another envelope marked as Tender respectively and these two envelopes shall then be placed in another sealed envelope and submitted. The envelope containing the EMD shall be opened first. If the EMD is found to be in order, then only the envelope containing the tender will be opened.

6.0) The firm who quotes on the tender document downloaded from website shall strictly follow the following procedure.

6.1) The tender shall be submitted in Three envelops;

i) First envelope shall contain tender application (if tender downloaded from web) tender fee, attested document providing fulfillment of eligibility criteria as per the tender notice. The said documents shall be attested by a Gazetted officer. In cases where it is not possible to obtain the attestation of Gazetted officer, then the agency shall submit the same with self attestation and shall furnish the entire original at the time of tender opening, failing which his second envelope containing the tender document shall not be opened. One Demand draft for tender cost drawn as per prescribed form should be enclosed along with credentials.

ii) Second envelope shall contain EMD in the form as prescribed in the tender document or Notice Inviting Tender.

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iii) Third envelope shall contain the tender document.

6.2) The First envelope containing tender fee, attested document proving fulfillment of eligibility criteria shall be opened first.

In case;

i) Tender cost is not submitted in proper form and / or the

ii) Firm fails to fulfill eligibility criteria on the basis of document submitted in the first envelope.

The second and third envelopes will not be opened and the offer will not be considered.

Important Note: The envelopes shall be clearly superscribed on top as

FIRST ENVELOPE – TENDER COST AND ATTESTED COPIES OF CREDENTIALS

SECOND ENVELOPE – EMD IN PRESCRIBED FORMTHIRD ENVELOPE – TENDER DOCUMENT

ALL THESE THREE ENVELOPES SHALL BE WAX SEALED AND PLACED IN A COMMON SINGLE ENVELOPE AND SUBMITTED.

7.0) Tenders will be received up to 3.30 PM on 25-04-2011 (or the next working day if 25-04-2011 happens to be a holiday) by the Associate Director/CEG, at Central Design Office, IGCAR, Kalpakkam (Office Phone No. 044-27480092) and the FIRST ENVELOPE containing the Eligibility criteria and Tender document cost alone will be opened on the same day at 3:35 PM in the presence of attending tenderers [Only for those who have downloaded the tender from website and submitted by post].

8.0) In case of tenderers downloading the tenders from website and are submitting through courier/speed post, the originals supporting the eligibility criteria will be verified on 29-4-2011, 2-5-2011 and 3-5-2011 during which they should come in person and produce the originals for verification at office address mentioned above para 7.0.

If the tenderers fail to come in person and get the eligibility criteria verified by showing the originals, within the prescribed period as mentioned in the Notice Inviting Tender such of those tenders will be summarily rejected. After verification of the original for eligibility criteria, the names of tenderer

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who are found eligible for opening of the tender will be uploaded in the website (www.igcar.gov.in) on 4-5-2011.

TENDER will be opened on 5-5-2011 at 3.35 PM in the presence of attending tenderers.

9.0) TENDERS NOT ACCOMPANYING THE FOLLOWING ARE LIABLE TO BE SUMMARILY REJECTED

a) Earnest Money Deposit can be submitted as follows

In the form Deposit at Call receipt or Demand Draft/Bankers Cheque in favour of P&AO, IGCAR, Kalpakkam for the full EMD amount.

Note: - CASH & CHEQUES FOR EARNEST MONEY DEPOSIT WILL NOT BE ACCEPTED.

b) In the case of contractors in the approved list of public works Department, Central Public Works Department or Military Engineering Services shall be required to submit the copy of evidence showing the appropriate and eligible class to which they belong. Incase of reputed contractors they are required to submit the detailed list of works carried out by them during the last five years along with solvency certificate and the list of machines and manpower they posses. List of projects under execution or awarded shall be submitted.

c) Performance report of works referred in Point (b).

d) PAN Certificate in the latest approved form - Details of sales tax registration including details of commercial tax office with which they are remitting this tax.

e) Tenderer may please intimate their Bank Account Number, IFSC code, Branch details so as enable the department for payments through Bank.

f) The tenderer purchasing the tender submitting the same in person shall be required to place the Earnest Money and the tender in separate sealed envelopes marked `Earnest Money' and `Tender' respectively and both these envelopes shall then be placed in another sealed envelope and submitted. The envelope containing the EMD shall be opened first. If the EMD is found to be in order then only the envelope containing the tender will be opened. Tenderers downloading the tender from website and submitting through courier / speed post shall follow the instructions prescribed in Sl.No.(6).

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g) In case of successful tenderer, the tenderer is required to deposit an amount equal to 5% of the tendered value of the contract as irrevocable performance guarantee in the form of bank guarantee from any of the scheduled bank or by demand draft from State bank of India or Canara Bank drawn in favour of Pay & Accounts Officer, IGCAR, Kalpakkam payable at Kalpakkam within a period of 15 days of issue of letter of intent. The letter of award of work will be issued only after the above said performance guarantee in any one of the prescribed forms is received and accepted failing which the Government shall without prejudice to any other right or remedy available in law, be at liberty to forfeit the earnest money absolutely.

h) In addition to the above, the successful tenderer is required to remit security deposit amounting to 5% of the tendered value, which shall be deducted at 5% of the gross amount of the bill from each running bill, till such amount along with the sum already deposited as earnest money, shall amount to security deposit as specified above.

i) Tenderer to note that tenders with any condition including that of conditional rebate shall be rejected forthwith.

j) Bidders shall not be under a declaration of ineligibility for tender quoting and fraudulent practice.

k) Documentary evidence of adequate financial standing.

l) Information regarding projects in hand, current litigation, orders regarding exclusion, expulsion or block entry if any to be furnished.

m) The capacity of the contractor to take up a new project under consideration in addition to his present commitments must be clearly brought out. He should also furnish the details referring as to have both physically and financially capable of executing this contract in the stipulated time as per milestones projected in addition to executing the other commitments.

n) Copies of original documents detailing the constitution or legal status place of regulation and principle place of business, written power of attorney of the regulatory of the bond to commit the bidders.

o) Qualification and experience of key site management and technical personnel proposed for the contract.

p) Evidence of adequacy of working capital for this contract. Access to lines of credit and availability of other financial resources.

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q) Information regarding any litigation, current or during the last five years, in which the bidder is involved, the parties concerned and disbursed amount.

r) Proposals for sub-contracting components of the works including the qualification and experience of the identified sub-contractor in the relevant field.

s) The proposed methodology and program of construction, backed with equipment planning and deployment duly supported with broad calculation and quality control procedures proposed to be adopted, justifying their capability of execution and completion of the work as per technical specifications within the stipulated period of completion as per milestones.

Note: Original documents substantiating the eligibility criteria all mentioned should be produced for verification at the time of requisition of tender document in person.

10.0 Director / ESG on behalf of President of India does not bind himself to accept the lowest or any other tender and reserves to himself the authority to reject any or all of the tenders or to allot parts of the works to different agencies without assigning any reasons there for. All tenders, in which any of the prescribed conditions is not fulfilled shall be summarily rejected.

Director, ESG Indira Gandhi Centre for Atomic Research

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Annexure – I

IMPORTANT INSTRUCTIONS TO TENDERERS DOWNLOADING THE TENDER DOCUMENT FROM WEBSITE

11.1. The Tenderers, who have downloaded the tenders from the website, shall read the following important instructions carefully before quoting the rates and submitting the tender documents.

11.2 The tenderer should see carefully and ensure that the tender document containing all the pages as per the index has been downloaded for making required entries.

11.3 A clear print out of tender document shall be taken on good quality A4 size paper and the printer settings, etc. shall be such that the document is printed as appearing in the web and without any change in format, number of pages, etc. and shall also ensure that no page is missing. Only original computer printout of the document shall be used. Photocopy shall not be accepted..

11.4 In case of any doubt in the downloaded tender, the same shall be got clarified from the Engineer-in-charge or authorities calling the NIT before submission of tenders.

11.5 The name of the tenderer shall be filled on the relevant pages of the tender form and all the pages shall be invariably signed and seal affixed including drawings attached (if any).

11.6 The tenderer shall ensure that the downloaded tender document is properly stitched and sealed with sealing wax on covers before submitting the document. Loose / spiral bound tenders shall not be accepted. Sealing of the tenders with adhesive tapes is not acceptable and the tenders are liable to be summarily rejected.

11.7 There shall be no correction / addition / alteration /omission made in the text of the downloaded tender document. If found otherwise, the same shall be treated as non responsive and summarily rejected.

11.8 The tenderer shall sign the declaration enclosed before submitting the tender.

11.9 Application for request for tender as per enclosed format vide Annexure VI and submit it alongwith eligibility criteria in first envelope.

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Annexure – II

UNDERTAKINGS TO BE FURNISHED BY THE TENDERER

1. Undertaking – A

“I ……………………………………………………………… Son of …………………………………………… Residing at …………………………………………………………………………………………………… ……………………………………….………………………….. hereby give an undertaking that I have read and I am aware of all the clauses and sub clauses of tender forms and I confirm that I will abide by all the terms and conditions available in original standard IGCAR tender. My Income tax Permanent Account Number (PAN) is ………………………………Note: The standard tender document is available in the website www.igcar.gov.in

(Seal of the Firm) (Dated Signature of Contractor

or his authorized Power of Attorney)

2. Undertaking – B

“I ……………………………………………………………… Son of …………………………………………… Residing at ……………………………………………………………………… ………………………………… ……………………………………….………………………….. hereby give an undertaking that I have give an undertaking that none of my relative(s) as defined below is/are employed in DAE as per details given in tender document. In case at any stage, it is found that the information given by me is false / incorrect, IGCAR shall have the absolute right to take any action as deemed fit without any prior intimation to me”

The near relatives for this purpose are defined as;1. Members of a Hindu undivided family2. They are husband and wife3. The one is related to the other in the manner as father, mother,

son(s) son’s wife (daughter-in-law), daughter(s) daughter’s husband (son-in-law), brother(s) and brother’s wife, sister(s) and sister’s husband (brother-in-law)

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(Seal of the Firm) (Dated Signature of Contractor

or his authorized Power of Attorney)

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Annexure – III

Declaration by Contractor(To be given by tenderers downloading the tender document from the web)

This is to certify that;

1) I / We have submitted the tenders in the proforma as downloaded directly from the websites which are same as available in the website and there is no change in the format, number of pages, etc.

2) I / We have not made any modifications / corrections / additions etc., in the tender documents downloaded from web by me / us.

3) I / We have checked that no page is missing and all pages as per the index are available and that all pages of tender document submitted by us are clear and legible.

4) I / We have signed (with stamp) all the pages of tender document before submitting the same.

5) I / We have stitched and covers wax sealed the tender documents properly before submitting the same.

6) I / We have submitted the cost of the tender in the first cover as prescribed.

7) I / We have submitted requisite EMD in the prescribed form in the second cover.

8) I / We have read carefully and understood the ‘Important instructions to contractors’, ‘Important instructions to tenderers downloading the tender documents from website’ and entire standard clauses and proforma forms displayed in website.

9) In case at later stage, it is noticed that there is any difference in my / our tender documents with the original documents, IGCAR shall have the right to cancel the tender / work, forfeit the Earnest Money, Performance Guarantee / Security Deposit, take appropriate action as per the prevailing rules in force and IGCAR shall not be bound to pay any damages to me / us on this account.

Dated …………………. (Contractor)

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(Signature with seal)

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Annexure – IV

Checklist for Tenderers to be filled and submitted

Name of work:

Construction of RR compound wall and formation of peripheral road from Substation PDC-5 to CMPL in IGCAR, Kalpakkam.

S.No.

Description Status

1. Experience in executing similar nature of work

Enclosed / Not enclosed

2. Average annual turnover statement certified by Registered Charted Accountant

Enclosed / Not enclosed

3. Annual turnover 30% of estimated cost during the past three year.

Available / Not available

4. Loss for more than 2 years during last five years ending previous financial year

Incurred / Not incurred

5. Solvency of 40% of estimated cost. Solvent / Not solvent6. Performance report from Clients. Enclosed / not

enclosed7. Details regarding organization. Enclosed / Not

enclosed8. Evidence to Registration in PWD / CPWD / etc. Attached / Not

attached9. Information regarding project in hand /

litigation. Enclosed / Not enclosed

10. Cost of tender document [As per N.I.T] Enclosed / Not enclosed

The information provided above is correct to my knowledge. If the same is found not correct at later stage I agree for departmental action, whatsoever it may be.

Signature of candidate

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Annexure – V Government of India

Department of Atomic EnergyIndira Gandhi Centre for Atomic Research

Civil Engineering GroupESTIMATES & CONTRACT SECTION

APPLICATION FOR REQUEST FOR TENDER

1) a] Name of work for whichTender is requested

:

b] Notice Inviting Tender No. :

c] Estimated cost put to tender :

2) Name of Tenderer Address

:

3) Whether belonging to :(a) Registered contractor in CPWD / PWD / Highways / MES:

[Copy of Registration certificate to be enclosed]

(b) DAE local contractor category [Copy of work order of maximum work executed during recent past shall be enclosed]

(c) Other categories, specify details

4) Eligibility criteria: :(a) Annual Turnover : Required 30% of estimated cost. Available Rs. …………

(Copy of Profit & Loss statement for the last 5 years duly certified by Registered Charted Accountant (or) Copies of ITCC showing the turnover must be enclosed)

Certified by: ___________________________________________________________

(b) Solvency Required 40% of estimated cost Available Rs. _________________ (Copy of solvency to be enclosed)

Issued by: ____________________________________________________________

(c) Work executed [Copies of work order and completion certificate to be enclosed]:

One work of 80% Two work of 60% Three work of 40%

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(d) Similar nature of work executed :

Details ………………………………………………………………………………………(List of similar works in hand and similar works carried out by tenderer for the last 7 years indicating (i) agency for work executed (ii) value of work (iii) completion time as stipulated and actual (or) present position of work must be enclosed).

(e) Whether executed on own name (or) on sub contract(f) Tender purchased and not quoted :

in previous occasion details(g) Current commitments, i.e. work :

on hand details(h) List of Technical staff they possess :(i) List of construction plant, machinery,

equipment, accessories & infrastructurefacilities possessed by the agency tocomplete the work in time. :

(j) Performance certificate :WCT registration certificate : Available / Not Available PAN (Permanent Account No.) : Available / Not Available TIN (Tax Identification No.) : Available / Not Available

Signature of Contractor

For Office Use:-1) Credentials verified by : __________________________________ Engineer / E&CS

2) Recommendation as per eligibility norms : ELIGIBLE / NOT ELIGIBLE

3) Recommendation for issue of tenderSignature: ____________________

Head, E&CS

4) Approval of Competent Authority : To Issue / Not to Issue

Signature: ____________________ Associate

Director/CEG

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SECTION – II : FORM OF AGREEMENT AND GENERAL RULES AND DIRECTIONS FOR GUIDANCE OF THE

CONTRACTORGovernment of India


ITEM RATE TENDER & CONTRACT FOR WORKS

FORM OF TENDER AND GENERAL RULES ANDDIRECTIONS FOR THE GUIDENCE OF CONTRACTOR

General Rules and Directions

1. All works proposed for execution by contract will be notified in a form of invitation to tender posted in public places and signed by the Chief Engineer / Associate Director, CEG / Engineer-in-Charge.

This form will state the work to be carried out as well as the date for submitting and opening tenders and the time allowed for carrying out the work, also the amount of earnest money to be deposited with the tender, and the amounts of Security Deposit to be deposited by the successful tenderer and the percentage, if any, to be deducted from the bills, Performance Security to be deposited before commencement of the work. Copies of the specifications, designs and drawings any other documents required in connection with the work designed for the purpose of identifications by the Chief Engineer / Associate Director, CEG / Engineer-in-Charge shall also be open for inspection by the contractor at the office of the Chief Engineer / Associate Director, CEG / Engineer-in-Charge, during office hours. 2. In the event of the tender being submitted by a firm, it must be signed separately by each member, thereof, or in the event of the absence of any partner, it must be signed on his behalf by a person holding a power-of-attorney authorizing him to do so, such power of attorney to be produced with the tender and it must disclose that the firm is duly registered under the Indian Partnership Act.3. Receipts for payments made on account of work when executed by a firm must also be signed by the several partners. Except where the contractors are described in their tender as a firm, in which case the receipts must be signed in the name of the firm by one of the partners or by some other person having due authority to give effectual receipts for the firm.4. Any person, who submits a tender, shall fill up the usual printed form, stating at what rate he is willing to undertake each item of the work. Tenders, which proposes any alteration in the work specified in the said form of invitation to tender, or in the time allowed for carrying out the work, or which contain any other condition of any sort including conditional rebates, will be summarily rejected. However, tenders with unconditional rebate(s) is acceptable. No single tender shall include more than one work, but contractors who wish to tender for two or more works shall submit separate tender for each. Tenders shall have the name and number of the works to which they refer, written on the envelopes.

The rate(s) and / or amount must be quoted in decimal coinage both in words and figures.

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5. The Chief Engineer / Associate Director, CEG / Engineer-in-Charge, or his duly authorized assistant will open tenders in the presence of any intending tenderers who may be present at the time, and will enter the amounts of the several tenders in a comparative Statement in a suitable form. In the event of a tender being accepted, a receipt for the earnest money forwarded therewith shall thereupon be given to the tenderer who shall thereupon for the purpose of identifications sign copies of the specifications and other documents mentioned in Rule 1. In the event of a tender being rejected, the earnest money forwarded with such unaccepted tender shall thereupon be returned to the tenderer without any interest.6. The officer inviting tenders shall have the right of rejecting all or any of the tenders and will not be bound to accept the lowest tender or any other tender.7. The receipt of an accountant or clerk for any money paid by the tenderer will not be considered as an acknowledgment of payment to the Chief Engineer / Associate Director, CEG / Engineer-in-Charge, and the contractor shall be responsible for seeing that he procures a receipt signed by the Chief Engineer / Associate Director, CEG / Engineer-in-Charge or by Accounts Officer or by a duly authorized cashier.8. The memorandum of work tendered for and the schedule of materials to be supplied by the India Gandhi Centre for Atomic Research and their issue rates shall be filled in and completed in the office of the Chief Engineer / Associate Director, CEG / Engineer-in-Charge before the tender form is issued. If a form is issued to an intending tenderer without having been so filled in and completed, he shall request the office to have this done before he completes and delivers his tender.9. The tenderers shall sign a declaration under the Officials Secret Act 1923, for maintaining secrecy of the tender documents drawings or other records connected with the work given to them. The unsuccessful tenderers shall return all the drawings given to them.10. Rates quoted by the contractor in Item Rate tender in figures and words shall be accurately filled in so that there is no discrepancy in the rates written in figures and words, However, if discrepancy is found the rate which correspond to the amount worked out by the contractor shall be taken as correct.11. If the amount of Item is not worked out by the contractor or it does not correspond with the rate written either in figures or in words, then the rate quoted by the contractor in words shall be taken as correct and not the amount.12. Incase of any tender where unit rate of any item / items appear unrealistic, such tender will be considered as unbalanced and incase the tenderer is unable to provide satisfactory explanation, such a tender is liable to be disqualified and rejected.13. Whether the rates quoted by the contractor in figures and in words tallies, the amount is not worked out correctly the rate quoted by the contractor shall be taken as correct and not the amount.14. In event no rate has been quoted for any items(s) then rate for such item(s) will be considered as zero.

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15. If it is found that the tender is not submitted in proper manner or contains too many corrections and/or absurd rates, or amount, it will be open for the Government to take suitable disciplinary action against the Contractor.

16. The contractor shall give a list of both gazetted and non-gazetted IGCAR employees related to him.

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ITEM RATE TENDER FOR WORKSI/We have examined the notice inviting tender, Schedule of supply of

material, drawings, Specifications applicable, Drawings & Designs, General Rules & Directions, Conditions of contract, clauses of contract, Special Conditions, Schedule of Quantities & other documents and Rules referred to in the conditions of contract and all other contents in the tender document for the work.

I/We, hereby tender for the execution for the President of India of the work specified in the underwritten memorandum within the time specified in such memorandum at the rates specified therein, and in accordance in all respects with the specifications, designs, drawings and instructions in writing referred to in Rule-1, hereof and in Clause-11 of the conditions of contract and with such materials as are provided for, by and in all respects in accordance with, such conditions so far as applicable.

MEMORANDUMa.

General Description

: Construction of RR compound wall and formation of peripheral road from Substation PDC-5 to CMPL in IGCAR, Kalpakkam.

b.

Estimated cost : ` 195.67 Lakhs

c.

Earnest money : ` 3,91,340/-

d.

Security Deposit : 5% of the tendered value of the work.

e.

Performance Security

: 5% of the tendered value of the work.

The security deposit equal to 5% (five percent) of the contract value will be collected by deductions from the running bills of the contractor at the rate of 5% of the gross amount of the bill and earnest money, deposited at the time of tender, will be treated as part of security deposit. The security deposit will also be accepted in the form of Government Securities or Fixed Deposit Receipt of Scheduled Banks or State Bank of India. The security deposit as deducted above can be released against bank guarantee issued by a scheduled bank, on its accumulations to a minimum of ` 5 lakhs subject to the condition that amount of such bank guarantee, except last one shall not be less than ` 5 lakhs.

The performance security equal to 5% (five percent) of the contract value is required to be deposited with in 15 days from the date of LOI, in the form of fixed deposit receipts or Guarantee bonds of any Scheduled Bank or State Bank of India.

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The Security Deposit / performance Security shall be endorsed in favour of the Pay and Accounts Officer, IGCAR, Kalpakkam – 603102.

a. Time allowed for the work:

12 Month(s) (Including monsoon period) from 15th day after the date of written order to commence the work.

Should this tender be accepted in whole or in part, I/We, hereby agree:

i) to abide by and fulfill all the terms and provisions of the said conditions annexed hereto and all terms and provisions contained in notice inviting tenders so far as applicable and/or in default thereof to forfeit and pay to the President of India or his successor in office, the sum of money mentioned in the said conditions. A sum of ` 3,91,340/- is hereby forwarded by Deposit at Call Receipt of a Scheduled Bank Guaranteed by the Reserve Bank of India (or) Demand draft of a scheduled bank (or) by Banker’s Cheque of a scheduled bank. If I/We fail to furnish the prescribed performance guarantee within the prescribed period, I/We agree that the said President or his successors in office shall without prejudice to any other right or remedy be at liberty to forfeit the said Earnest Money absolutely. Further, if I/We fail to commence the work specified in the above Memorandum, I/We agree that the said President or his successors in office shall without prejudice to any other right or remedy available in law, be at liberty to forfeit the said Earnest Money and performance guarantee absolutely, otherwise the said Earnest Money shall be retained by him towards Security Deposit mentioned against Clause (d) of the above mentioned memorandum.

ii) to execute all the works referred to in the tender documents upon the terms and conditions contained or referred to therein and to carry out. Such deviations as may be ordered up to a maximum of percentage mentioned, at the rates quoted in the tender document and those in excess of the limit at the rates to be determined in accordance with the provisions contained in Clause 12.2 & 12.3 of the Tender form.

Further, I/We agree that in case of forfeiture of earnest money or both Earnest Money & Performance Guarantee as aforesaid, I/We shall be debarred for participation in the re-tendering process of the work.

DECLARATIONI/We, hereby declare that I/We shall treat the tender documents,

drawings and other records connected with the work as Secret/Confidential documents and shall not communicate information/derived there from to any person other than a person to whom I/We am/are authorized to communicate the same or use the information in any manner prejudicial to the safety of the state.Dated the ………………………………day of 2011

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TENDERER (S)

*SIGNATURE+ Witness……………………………….Address………………………................………………………………………….

Occupation……………………………...

ACCEPTANCE The above tender is hereby accepted by me for and on behalf of the President of India.Dated the ………………………………..day of 2011

@SIGNATURE

* Signature of contractor before submission of tender.+ Signature of witness to contractor’s signature.@ Signature of the Officer by who accepted.

ADDITIONAL RULES AND DIRECTIONS FOR THE GUIDANCE OF TENDERERS

1) The tender shall be valid for a minimum period of 120 (One hundred and twenty) days from the date of opening of tenders.

2) The tender document including the drawings shall be signed by the tenderer and returned along with his offer for this work.

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SECTION – III : SPECIAL CONDITIONS

1. LOCATION:The proposed site for this work is near Sadhurangapattinam. The site is

accessible by road from Madras via Chengalpattu - Thirukalikundram and also via Mahabalipuram.

2. SITE INVESTIGATION:The contractor acknowledge that he has satisfied himself as to the

nature and location of the work, the general and local conditions, particularly those bearing upon transportation, disposal, handling and storage of materials, availability of labour, water, electric power, roads and uncertainties of weather, or similar physical conditions of the site, the confirmation and conditions of the ground the character, the quality and qualities of surface and sub-surface materials to be encountered, including the subsoil water levels, the character of equipment facilities needed preliminary to and during the progress of the work, and all other matters upon which information is reasonably obtainable and which can in any way affect the work or his cost there of under this contract. Any failure of the contractor to acquaint himself with all the available information concerning these conditions will not relieve him from responsibility for estimating properly the difficulty or cost of successfully performing the work. Non-familiarity with the site conditions will not be considered a reason either for extra claims or for not carrying out the work in strict conformity with drawings and specifications. The contractor shall note that any clarifications regarding specifications, conditions of contract, schedule of quantities, scope of work, etc., are required, he should contact the office of the Engineer. No claim on account of ambiguity in any respect will be entertained.

3. SCOPE OF WORK:The tenderer should also note that other contractor will be working in

the vicinity and this work will have to be carried out in proper co-ordination with them. The tenderers shall also note that they shall have to clear the site of vegetation, debris etc. before commencement of the work and that no extra payment is permissible on account of clearance of site, removal of debris etc. coming in the way of construction work.

The work to be done under those specifications consists of furnishing all labour, materials, tools, equipment and services and performing all work (except work, equipment and materials specified to be performed or furnished by the Department) required to execute the work specified in the tender, and all other work required to satisfactorily complete construction in strict accordance with the specifications and drawings enclosed. It is intended that the drawings and specifications include everything requisite and necessary to finish the entire work properly. Notwithstanding the fact that every item necessarily involved may not be specifically mentioned. All work when finished shall be delivered in a complete and undamaged state.

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4. LAYOUT AND STAKING OUT BASE LINES AND LEVELS:The contractor shall layout his work from base lines and grades

established by the Department, and shall be responsible for all measurements in connection therewith. The contractor shall, at his own expense furnish all stakes, templates, platforms, equipments, ranges and labour that may be required in setting and cutting or laying out any part of the work. The contractor shall be held responsible for the proper execution of the work to such lines and grades as may be established or indicated on the drawings and specifications. The contractor shall take benchmarks, lines and levels. The contractor is to construct and maintain proper benches at the intersections of all main walls, columns, etc. in order that the lines and levels may be accurately checked at all times, theodolite, levels, prismatic compass, chain, steel and metallic tapes and all other surveying instruments found necessary for the work shall be provided by the contractors for use at site in connection with this work.

5. DRAINAGE ARRANGEMENTS AROUND PROPOSED SITE OF CONSTRUCITON:

The contractor shall control the grading in the vicinity of the buildings and trenches, so that surface water is prevented from running into excavated areas. The contractor shall also be responsible to see that no area around his works becomes flooded during rainy season because of his piles up materials, etc., and subsequently flood other buildings. At the discretion of the Engineer the contractor shall take steps to prevent flooding. It shall be the contractor’s responsibility to keep areas around his work dry. The cost of repairing damages, if any, to the work under execution or to any Government property in and around the site shall be entirely borne by the contractor when such damages are due to non-compliance with the above conditions.

6. APPROACH ROAD:The contractor will be required to construct suitable approach roads

leading to the construction site from the main road and maintain the same at his own cost.

Contractor shall be permitted to use the existing roads in the establishment area for the purpose of transporting labourers and materials etc. The Engineer-in-charge, however, will not undertake to provide any approach roads to the site of work. It shall be entirely the responsibility of the contractor to provide and maintain such temporary approach roads at his own cost for the purpose of movement of men, materials and equipment. Layout of such approach road shall be submitted to Engineer-in-charge for his approval before undertaking the construction of the same. Such approach roads shall be made available to other agencies carrying out the work in the same area in consultation with Engineer-in-charge of the works without any extra cost.

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7. SPECIFICATION AND DRAWING:a) The work shall conform to the contract specifications enclosed.b) The work shall also conform to the enclosed drawings, and to such other drawings relating thereto as may be furnished from time to time during construction by the Engineer in explanation of details of modifications, including such modifications as the Engineer may consider necessary to meet conditions found during the progress of the work.c) It shall be understood that drawings furnished to the contractor shall be interpreted by the use of given dimensions, and nomenclature only, and that the drawing shall not be scaled.d) Prior to the execution of the work, the contractor shall check all drawings and shall immediately report all errors, discrepancies and/or omissions discovered therein to the Engineer. All such errors discrepancies and/or omissions will be adjusted by the Engineer. Any adjustment made by the contractor without prior approval of the Engineer shall be at his own risk and the settlement of any complications arising from such adjustment shall be made by the contractor at his own expenses.

In case of difference between drawings and specifications, the specifications shall govern. Anything mentioned in the specifications, and not shown on the drawings, or shown on the drawings and not mentioned in specifications, shall be of like effect as if shown or mentioned in both.e) In the absence of any specification for any work or material, relevant Indian Standard specifications will apply. In the case of any class of work for which no specifications have been given, such works shall be carried out in accordance with the specification and requirement given by the Engineer.

8. SHOP DRAWINGS:a. The drawings consisting of such detailed drawings as are not included in the contract drawing or larger scale details of certain parts of the work indicated on the contract drawings, shall be complete and shall contain all required detailed information as may be reasonably required for satisfactory prosecution of the work.b. Drawings to be furnished by the contractor shall be included in the bid price of this work. Approval of the shop drawings shall not be construed as authorizing additional work or increased costs to the department. Adjustment in the bid price or any extension of time to cover required charges in the shop drawings to comply with the requirements of the contract specifications shall not be permitted.c. Prior to submittal for approval, the contractor shall be responsible for thoroughly checking all drawings whether prepared by him or by his sub-contractors to ensure that they comply with the intend and the requirements of the contract specifications and that they fit in with the overall building layout. Drawings found to be inaccurate or otherwise in error will be returned for correction by the contractor to his sub-contractors prior to submittal.

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d. The Engineer-in-charge will review and return three copies of each drawings to the contractor, marked either ‘APPROVED NOT REQUIRED’. Then approved, each copy of the drawings will be identified as having received such approval by being stamped and dated. If the drawings are approved as noted, the contractor shall make the indicated corrections immediately and may proceed with the work as though the drawings had been approved. If unapproved, the contractor shall make all required corrections, immediately and resubmit drawings as above until they are approved or approved as noted.e. After the contractor has made the corrections to unapproved drawings, the contractor shall submit six copies of each drawings to the Engineer who will return three approved copies to the contractor.f. The approval of the drawings by the Engineer shall not be considered as a complete dimensional check, but will indicate only that the general method of construction and detailing is satisfactory. Approval of such drawings will not relieve the contractor of the responsibility for any errors or compliance with requirements of the contract plans and specifications, nor will any discrepancy between shop drawings and contract plans and specifications. The contractor shall be responsible for the dimensions and design of adequate connections, supports details and satisfactory construction of the work, any fabrication, erection setting or other work done in advance of the receipt of approved drawings shall be done entirely at the contractor’s risk.

9. PROGRESS AND COMPLETION:The entire work shall be completed within the period as specified in the

Tender schedule elsewhere including monsoon period from fifteenth day after the date on which the written order to commence the work is issued.a) The contractor shall furnish sufficient forces, construction plant and equipment, and shall work such hours, including night shifts and overtime operations, as may be necessary to ensure the progress of the work in accordance with the attached construction schedule and its completion within the time specified in this contract. If in the opinion of the Engineer, the contractor refuses or fails to comply with his obligations set forth in the preceding sentence, the contractor shall take such steps as may be necessary to improve this progress and the Engineer may require him to increase the number of shifts and/or overtime operations, days of work, size of forces and/or the amount of construction plant. All such action taken by the contractor pursuant to the direction of the Engineer shall be without additional cost to the department.

Failure of the contractor to meet his obligations set-forth in the paragraph above, under this provision shall be ground for determination by the Engineer that the contractor is not progress the work with such diligence as will ensure completion within the time specified. Upon such determination the Engineer shall take necessary steps to increase the labour forces, amount of construction plant, etc., as he deems fit to ensure completion of works in accordance with the schedule at the contractor’s expense.

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b) It shall be the responsibility of the contractor to mark the actual progress of the works in progress report from at the end of every two weeks, and the calculated progress for the job as a whole, and shall submit three copies to the Engineer.The time allowed for carrying out the work as entered in the tender shall be strictly observed by the contractor and shall be deemed to be of the essence of the contract on the part of the contractor and shall be reckoned from the fifteenth day of the date on which the work order to commence the work is issued to the contractor and all work shall be completed in accordance with the construction schedule attached to the specifications. Monsoon or inclement weather will not be considered reason for extension of time. The contractor shall submit a time schedule keeping the phasing of the work generally in line with the construction schedule for the approval of the Engineer and such an approved programme shall be strictly adhered to by the contractor.

10. SEQUENCE OF WORK:The contractor shall execute the finishing work as per the sequence given

by the Engineer from time to time. It shall be the contractor’s responsibility to transport all equipment and materials to the job site at his own expenses. The contractor shall use only established roadways for construct and use such temporary roadways or necessary and approved by the Engineer. When it is necessary to cross kerbs or sidewalks, protection against damage shall be provided by the contractor. Any damage caused to roads, kerbs, sidewalks, or other load bearing facilities shall be repaired by the contractor at his own expenses.

11. CO-OPERATION WITH OTHER CONTRACTORS:The contractor shall afford all facilities and give complete co-operation

for the execution of various other works, if required to be carried out simultaneously by other agencies while his own work is in progress. The co-ordination will be effected in consultation with the Engineer-in-charge of the work. Other contractors are also likely to be authorized by the owners to work in the same area during the construction stage for work such as (i) Electrical (ii) Air-conditioning (iii) Services and (iv) Public health and other miscellaneous works.

The contractor shall afford all facilitiesa) For the installation of embedded parts, sleeves with its accessories in

slabs, beams or walls by the other agencies, before the reinforcement is placed. Necessary outlets in the shuttering will have to be provided by the civil contractor for this purpose for which no extra payment will be admissible.

b) For the installation of various service lines in the walls, floors, slabs ducts etc.,

c) The contractor shall afford all facilities for using scaffolding etc., by the other contractors.

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No extra claims on account of facilities provided for carrying out the work mentioned above will be entertained.

12. INSPECTION:The work shall be conducted under the general discretion of the Engineer

and is subject to inspection by his appointed Inspectors to ensure strict compliance with the terms of the contract. No failure of the Engineer or his designated representative during the progress of the work to discover or to reject materials or work not in accordance with the requirement of this contract shall be deemed an acceptance thereof, or a waiver of defects therein, and no payment by the Engineer, or partial/entire occupancy of he premises, shall be construed to be an acceptance of work or materials which are not strictly in accordance with the requirement of this contract. No change whatsoever to any provision of the specifications shall be made without written authorization from the Engineer.

13. SUPPLY OF MATERIALS:The materials to be supplied by the department and their issue rates are

given in schedule of supply of materials and the contractors have to make their own arrangements for the carriage of the same from departmental stores to the work site. While every attempt will be made to supply sizes as detailed in the drawings other suitable sections may be offered to suit the design. No extra payment would be admissible for the use of alternative sections. Materials not covered by the Schedule of supply of materials and available for issue which the Department may be supplied at the discretion of the Engineer at rates to be fixed by him and inclusive of storage and supervision charges.

14. DELAY IN PROCUREMENT OF MATERIALS:Although every effort will be made by the Department to secure the

permits and authorization for controlled materials, including cement and steel, yet with delay in the supply of these materials will not entitle the contractor to any compensation whatsoever. In case the materials included in schedule of supply of materials are not supplied by the Department and in case the use of such materials is required in the works, the contractor with prior orders of the Engineer, for the use of each of such materials/sections, etc., from his own stocks or sources, may use of such materials of approved and tested quality. In all such cases the contractor shall produce the details of these materials such as quality, quantities including testing certificates and shall be entitled to claim extra payment for such use. The extra payment would be difference between the actual price (to be supported by vouchers) and the issue price.

15. SUBSTITUTE OF MATERIALS:a) In any section of these specifications where items of material or equipment are specified by brand name, catalogue number or by name of manufacturers the reference is intended to be descriptive and got restrictive

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and is solely for the purpose of indicating type or quality of item that will be acceptable. An approved equal shall be acceptable whether so specifically stated or not at the discretion of Engineer.b) The engineer reserves the right to have certain tests and/or analysis made of any proposed substitute material or equipment to determine its acceptability for the purpose specified.i) Samples of the proposed substitute material or equipment certified by

the manufacturer, shall be submitted to the Engineer for test and/or analysis. The quantities of the items in question required for these tests and/or analysis shall be determined by Engineer.

ii) During the progress of the work, the Engineer may, should be deem it advisable, take samples of the substitute item for check test for analysis.

iii) All costs of the tests, check tests and/or analysis made shall be borne by the contractor, except that where more than two check tests, are requested that the cost of additional tests and/or analysis shall be borne by the department.

iv) No proposed substitute for a specified item shall be used in the work of the contract prior to written authorization by the Engineer, such written authorization to state the amount of the adjustment, if any to be made in favour of the department.

v) Should the use of authorised substitute materials and/or equipment proposed by the contractor, require, in the opinion of the Engineer changes or modifications in the design, engineering drawing, specifications or work to be performed under the contract in any way, all of the cost of making such changes or modifications, whether or not considered at the time of the substitute was approved shall be borne by the contractor. Said costs shall include, but not be limited to, the finishing installation by the contractor or any additional materials or equipment which in the opinion of the Engineer may be deemed necessary to accommodate the substitute materials and/or equipment in the work.

16. a) ANY SAMPLES AND DESCRIPTIVE DATA REQUIRED SHALL:1) Be submitted within the time specified in these specifications or if no time specified, within a reasonable time as determined by the Engineer before use to permit inspection and testing.2) Be shipped prepaid and delivered as specified in these specifications, or as directed by the Engineer.3) i) be properly marked to show the name of the materials trade name or manufacturer, place of origin name and location of the work where the materials represented by the sample is to be used, and the name of the contractor submitting the sample.

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ii) Failure of any sample to pass the specified requirements for a particular use will be sufficient cause for refusal to consider further for the same use any sample from the same manufacturer whose materials failed to pass the tests.

17. TESTING MATERIALS:It shall be the responsibility of the contractor to provide number of

concrete cube moulds and arrange to cast the cube specimens as per specifications and as directed by the Engineer. After initial curing, the test specimens shall be delivered to the concrete testing laboratory at Kalpakkam for further curing and testing by the Government. The contractor shall also provide necessary equipment and labour for sampling and conducting other field tests like slump tests etc., as directed by the Engineer at no extra cost to the Government.

18. MODE OF MEASUREMENT:Mode of measurement when not specified in the tender shall be in

accordance with the relevant Indian Standard specifications and where not spelt out in I.S.S., the Engineer’s decision shall be final and biding on the contractor.

19. ASSISTANCE FOR TAKING MEASUREMENT:The contractor shall provide necessary labour and assistance to the

Engineer for checking layout, alignments, levels and other survey works connected with the excavation of work and also for taking measurement for finished works at no extra cost to the Government.

20. SCHEDULE OF QUANTITIES:The schedule of quantities is to be read in conjunction with this special

conditions, general conditions of contract, specifications, drawings and schedule of supply of materials, detailing materials to be supplied by the Department.

The quantities stated are to be considered approximate only and the unit prices entered in the schedule of quantities shall apply to the actual quantities in the completed work, up to a Deviation of as specified elsewhere in the contract value of the work.

Each tender should contain not only the rates but also the value of each item of work entered in a separate column and all the items should be totalled up in order to show the aggregate value of the entire tender. All corrections in the tender schedule shall be duly attested by the dated initials of the tenderer. Corrections which are not attested may entail the rejection of the tender. The tender document should be signed and returned without, detaching any part of the document.

21. SCHEDULE OF RATES:

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Rates quoted shall include labour, materials, tools, plant, appliances, transport, equipment, taxes, duties, octroi levies water and power supply, metering and consumption charges, temporary plumbing, cost of storage sheds for materials, contractor’s supervision, overheads and profit, general risks of liabilities and all that is necessary for the satisfactory completion of the job, other than services and materials supplied free by the Government. The rates quoted by the tenderer in the schedule shall be inclusive of sales tax on contract materials. Sales tax on contract turnover as levied by the local state Government authorities, Octroi duty and or other duties levied by the Government or other public bodies. Unless otherwise stated in the schedule of quantities rates for all items shall be for the complete work including supplying and fixing of all materials etc. The contractor when called for by the Department, should furnish detailed analysis in support of the rates quoted by him against each item of the tender. The Department reserves the right to utilize the analysis thus supplied in settling any deviations or claims arising on this contract. The rates shall be firm and shall not subject to the exchange variations, labour conditions or any conditions whatsoever other than what is provided in the contract.

22. PLAN OF OPERATION & CO-OPERATION:The contractor for work under the contract shall be required to co-

ordinate his work with that of other contractors performing work at the site and also in the same area. So far as practicable all contractor shall have equal rights to use all roads, ground and facilities made available for the joint use of the contractors. In case of disagreement regarding such use, the decision of the Engineer shall govern.

The contractor shall afford all facilities and give complete co-operation for the execution of various other works, if required to be carried out simultaneously by other agencies while his own work is in progress. The co-ordination will be effected in consultation with the Engineer-in-Charge of the work. Other contractors are also likely to be authorized by the owners to work in the same area during the construction stage for work such as (i) Electrical (ii) Air-conditioning (iii) Services and (iv) Public Health and other miscellaneous works.

The contractor shall afford all facilitiesa) For the installation of embedded parts, sleeves with its accessories in slabs, beams or walls by the other agencies, before the reinforcement is placed. Necessary outlets in the Shuttering will have to be provided by the civil contractor for this purpose for which no extra payment will be admissible.b) For the installation of various service lines in the walls, floors, slabs ducts etc.c) The contractor shall afford all facilities for using scaffolding etc. by the other contractors.

No extra claims on account of facilities provided for carrying out the work mentioned above will be entertained.

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It is envisaged that other works such as installation of sanitary, water supply and electrical arrangements, equipment, piping and other works not covered in this contract may have to be carried out by the other agencies in the completed/partial completed portion of the building along with this work. The tenderer shall permit such works to be carried out without any hindrance and fully co-ordinate his activities with other agencies. No compensation or claim for such contingencies shall be entertained.

23. TRAFFIC INTERFERENCE:The contractor shall conduct his operations so as to interfere as little as

possible with the use of existing roads at or near locations where the work is being performed, when it is necessary to excavate a trench across an existing road, store materials thereon or perform other work which would obstruct traffic, notification of the start of such work or storage of materials, and details of the proposed methods of providing the required facilities for safe and continuous use of roads shall be submitted to the Engineer atleast 48 hours in advance, thereof, and the contractor shall at his own expense, marks such approved temporary provisions as are required to maintain atleast one lane of traffic by bridging the excavation, providing ramps over surface obstructions or providing suitable temporary by-pass around the obstructions. This contract to provide and erect, before construction, substantial barricades, bridging over trenches, ramps side walks, guard rails and warning signs, furnish, place and maintain adequate lights and warning signals and provide flag man, watchman as directed by the Engineer.

24. GOVERNMENT LABOUR LAWS:The contractor has to follow strictly the Government labour acts which

are in force at present and all necessary facilities and arrangements for labour will have to be made by the contractor.

25. EARNEST MONEY DEPOSIT:The amount of the earnest money, which a contractor should deposit

with the tender, is regulated by the following scales. In case of petty works costing ` 5,000/- or less the Executive Engineer may, at his discretion, dispense with the condition for calling for earnest money.

(i) For works estimated to cost upto ` 10.00 Crores 2% (Two percent) of the estimated cost.

(ii) For works estimated to cost more than ` 10.00 Crores ` 20.00 lakhs plus 1% (One percent) of the estimated cost in excess of over ` 10.00 Crores.

The earnest money may be accepted in the following forms:(i) Deposit at call receipt of a scheduled bank guaranteed by

the Reserve Bank of India.(ii) Banker’s Cheque.(iii) Demand draft.(iv) FDR.

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When amount of earnest money is more than ` 5 lakhs, part of earnest money is acceptable in the form of bank guarantee also. In such case, minimum 50% of earnest money or ` 20.00 lakhs, whichever is less, will have to be deposited in shape prescribed above and balance can be accepted in form of, bank guarantee issued by a scheduled bank.

It should be ensured that the FDR is valid for a period of six months or more after last date of receipt of tenders and that it is pledged in favour of the tender inviting authority.

If the banks are closed on the day of opening of tenders the date of opening of tender shall be postponed suitably.

26. SECURITY DEPOSIT:A sum @ 5% of the gross amount of the bill shall be deducted from

each running bill of the contractor till sum along with the sum already deposited as earnest money, will amount to security deposit of 5% of the tendered value of the work. In addition the contractor shall be required to deposit an amount equal to 5% of the tendered value of the contract as performance security within the period prescribed for commencement of work in letter of award issued to him. However, security deposit may be released against bank guarantee issued by a scheduled bank of its accumulation to a minimum amount of Rs.5 lakhs subject to the condition that amount of any bank guarantee except last one, shall not be less than Rs.5 lakhs.

27. WITHDRAWAL OF TENDER:If any tenderer withdraws his tender within the validity period or makes

any modification in the terms and conditions of the tender which are not acceptable to the Department, then the Government shall without prejudice to any other right or remedy be at liberty, to forfeit 50% (fifty percent) of this earnest money absolutely. Further the tenderer shall not be allowed to participate in the re-tendering process of the works.

28. SUB CONTRACTORS:The contractor shall within fifteen days, after the date of award of this

contract notify the Engineer in writing of the names of all subcontractors proposed for the work and the extent and character of the work to be done by each. If, for sufficient reason, at any time during the progress of the work, the Engineer determines that any sub-contractor is incompetent or undesirable, who will notify the contractor accordingly and the contractor shall take steps immediately to cancel such sub-contract. Subletting by contractors shall be subject to the same regulations. Nothing contained in this contract shall create any contractual relations between any subcontractor and the department.

29. SECURITY RULES:

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The contractor shall follow at site all security rules as may be framed by the department from time to time regarding removal of materials from site, issue of Identity cards control of entry of personnel and all similar matters.

30. RETURN OF CONTAINERS:301. The contractor shall sell and serviceable empty cement bags except those which are used on bonafide works as approved by the Engineer, to the authorized bag collecting agents of cement suppliers at the rates fixed from time to time by the DCS&D and produce evidence to that effect to the Engineer. For every empty cement bag not so returned, he will be levied a penalty of ` 1/- (Rupee one only) per bag. The paper bags need not be returned.30.2. Containers of all other materials listed in schedule of supply of materials of this document issued to the contractor shall be returned unless otherwise stated elsewhere in good condition to the Government stores and in any case of dispute, the decision of the Engineer will be final.

31. ACCOMMODATION:The Engineer will not provide any quarters for the accommodation of

contractor’s personnel. No land will be made available within the project area for the construction of staff and labour quarters for the contractor. The contractors will make his own arrangement for leasing suitable land for housing his personnel and the cost on this account should be included in his rate structures. The contractor shall make his own arrangements at his cost for water supply, sanitation, access roads, electrification and general cleanliness of his camps, as required by labour laws in force. All arrangements regarding sanitation, water supply, electric supply and cleanliness shall be tidy and workman like and shall be not approved by the Engineer prior to the construction of the camps, warehouse, shed, shop and office facilities as required by the contractor shall be provided by him at his own expenses, and shall be approved by the Engineer.

After the work is over, all these temporary facilities shall be removed by the contractor at his own expense to the satisfaction of the Engineer, within 30 days from the date of completion of work.

32. TEMPORARY BUILDINGS:Warehouse, shed, workshop and office facilities as required by the

contractor shall be provided by him at his own expenses. Prior approval of the Engineer-in-charge shall be obtained in respect of location layout and details, of these buildings. After the work is over these temporary facilities shall be removed by the contractor at his own expenses to the satisfaction of the Engineer-in-charge within 10 days from the date of completion. No land for erecting temporary huts for housing the contractors Labourers will be made available by the Department. The contractor will have to make his own arrangements for the same.

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33. STORAGE:All materials shall be stored as to prevent deterioration or

contamination by foreign matters and to ensure the preservation of their quality and fitness for the work. If the storage arrangement is not to the Engineer’s satisfaction, the Engineer may direct the contractor to make such arrangements as he considers necessary and in the event of non-compliance, he would reserve the right to make proper arrangements departmentally or through other agencies at contractor’s cost. All materials shall be stored in adequate quantities well in advance to meet the construction schedule.

34. PAST EXPERIENCES:Contractors shall submit along with the tender details of their past

experience in execution of large works, including value of each work and name of clients, place of execution and other relevant information.

35. SITE ORGANISATION:The contractor shall furnish a list of plant and equipment that he

proposes to bring to site for the execution of the work. He shall also furnish full details of Engineering and Managerial Organisation along with the names and experience of Senior Engineers and supervisors who will be posted by him for this work.

36. RUBBLE STONE AND AGGREGATES:The contractor shall select good quality of rock approved by the

Engineers for the purpose of producing aggregates and rubble stone for construction work. Any machine crushed graded stone aggregate conforming to IS will be permitted for all concrete works. It is the responsibility of the tenderer to obtain good quality material to the satisfaction of the Engineer. If the quality of rock is not upto the required standard from one quarry, the tenderer will have to obtain the rock from other sources. The tenderer is not entitled for any extra payment on account of extra lead if any involved.

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37. ADDITIONAL SECURITY RULES:The contractors may please not that the identify cards shall have the

photo’s of the personnel concerned control of entry of personnel and all similar matters. The contractor and his personnel shall abide by all security measures imposed by the Engineer or his duly authorised representative from time to time.

38. EMPLOYEES:It is to be ensured that all the employee and workers employed by the

contractor and also by the sub-contractor are law abiding citizens, with clean record. Anti-social elements rowdies and persons with adverse police records should not be employed as far as possible on the works at Kalpakkam.

It is to be ensured by the contractor that the correct personnel particulars and addresses of the employees and workers employed by the contractor and sub-contractors are available with them.

39. EMERGENCY PREPAREDNESS:It may be noted that the Government as a part of the emergency

preparedness for any eventual site emergency civil defense which/would require the entire or part of the contractors personnel and labour to be evacuated from the site without any advance notice as and when deemed necessary. This may result in temporary stoppages of work with possible loss of time and productivity not likely to exceed 1 day. This aspect shall be taken into account while quoting their rates and the department will not uncertain any claim/compensation on this account. However, the department may grant suitable extension of time only.

40. ENTRY TIMING FOR TRUCKS:All the trucks transporting materials for the works should have valid

permit for running inside Kalpakkam area. The materials have to be transported only during 09.00 hours and 18.00 hours within the Kalpakkam area.

41. WATER:The contractor should make his own arrangement for the supply of

water required for the works. Water supply if available, shall be made available to the contractor at one point from the existing water mains and the contractor shall arrange for installing water meter as approved by the Engineer and lay all further piping to the various work sites at his own cost. The charges for water supply shall be metered and recovered from the contractor from the running bills at the rate of ` 28/- per 10,000 litres.

42. ELECTRIC POWER:

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Electric power if required shall be made available to the contractor for construction purposes only at one point near the work site at 50 cycles single phase 230 volts or 3 phase 400 volts and recoveries will be made at the rate of ` 5/- [Rupees five only] per KWh from the contractor’s running bill. The contractor shall make his own arrangements for the distribution of the power to all of his works from the point of supply. The contractor will be liable to pay ` 50/- [Rupees fifty only] per month towards the rent for meter. (The contractor shall note that the rates for water supply, electrical consumption for department power supply and meter rent mentioned above are as per the prevailing rates intimated by Civil / Electrical section and the same will be made based on the amendments being made by Civil/Electrical section from time to time, and recoveries will be effected accordingly).

43. BREAKUP OF COMPONENTS FOR ESCALATION:For the purpose of arriving at the amount of escalation referred to in

Clause 10 CC of the General Conditions of Contract (Section IV) the component of cement, steel, materials, labour and POL as indicated in Schedule - F.

43(A) Provided always that the provision of clause 10 CA shall not be applicable for contracts where provisions of clause 10 CC are applicable, but in cases where provisions of clause 10 CC are not applicable, the provisions of Clause 10 CA will become applicable.

44. TENDER RATES INCLUSIVE OF WORKS CONTRACT TAX:The rates quoted by the tenderer shall also be inclusive of works

contract tax, if any on the transfer of property in roads involved in execution of Work Contract Act 1983 (in other words turn over tax) which is to be paid by the tenderer to the Government from time to time during the execution of the contract/works. No separate claim on this account will be entertained by the Department.

44.1. Works Contract Tax – Provisions for works contract after taking into account TNVAT act 2006Tamil Nadu Government has enacted the “The Tamil Nadu Value Added Tax Act 2006 (TNVAT) which has come into force in the State, with effect from 01-01-2007. Following are the provisions relating to work contracts being executed in IGCAR/GSO etc.

Works Contract Tax will be levied as under:-

(i) For major civil works : 2% of the total amount payable to the contractor

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(ii) For civil maintenance : 2% of the total amount payable to the works contractor

(iii) Other works contracts : 4% of the total amount payable to the contractor

Works Contract Tax Exemption Certificate issued under TNGST is not valid with effect from 01-01-2007. “No Liability Certificate” in Form-S under TNVAT has to be obtained afresh by all the contractors for availing exemption. The certificate is issued for each contract separately and the original is required to be submitted to Accounts (Works) / IGCAR

45. DEDUCTION OF INCOME TAX:As per Section 194 (C) of Income Tax Act, as amended by letter No.

275/9₤, 72/9- TJ (Circular No.86) dated 19-5-1972 received from Ministry of Finance (Department of Revenue and Insurance), New Delhi, the Income Tax @ 2% (two percent only) and 2.5% (Two point five percent only) surcharge and 2% education cess on IT and surcharge on income tax as applicable on the gross value of the work done will be recovered from the bills. A certificate for the amount so recovered will be issued by the Department to the contractor.

46. CONDITIONAL TENDER WITH CONDITIONAL REBATE SHALL BE SUMMARILY REJECTED (APPLICABLE FOR SINGLE PART TENDERS ONLY):

Any person who submits a tender shall fill up the usual printed form, stating at what rate he is willing to undertake each item of the work. Tenders, which propose any alteration in the work specified in the said form of invitation to tender or in the time allowed for carrying out the work, or which contain any other condition of any sort including conditional rebate will be summarily rejected. No single tender shall include more than one work, but contractors who wish to tender for two or more works shall submit separate tender for each. Tender shall have the name and number of the works to which they refer, written on the envelopes. The rate(s) must be quoted in decimal coinage. Amounts must be quoted in full rupees by ignoring fifty paise and considering more than fifty paise as rupee one.

47. LIST OF WORKS CARRIED OUT BY TENDERERS:The tenderer shall also submit along with a tender “a list of works” and

also the appropriate cost of each work carried out by him in the past for different Government Department or Public bodies.

48. PLANT ETC. TO BE EXCLUSIVE USE FOR THE WORK:All painting equipment scaffolding ladders and materials provided by

the contractors shall when brought on to site to be deemed to be exclusively / intended for the construction and completion of the works, and the contractor

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shall not remove the same or any part thereof (save for the purpose of moving it from one part of the site to another) without the consent in writing of the Engineer-in-charge such shall not be unreasonably withheld.

49. DEPARTMENT NOT LIABLE FOR DAMAGES TO PLANT ETC.:a. The Department shall not at any time be liable for the loss of or injury to any of the said construction plant and temporary work of materials.b. If any plant or equipment or machinery purchased out of advances taken from the Department, such plant, equipment or machinery shall have to be issue by the contractor at least to the extent of such advance and pledged in the name of the Department until all such advances shall have been paid to the Department.

50. URGENT REPAIRS:If by reason of any accident or failure or other event occurring to, in

connection with the works or any part thereof either during the period of maintenance any remedial or other work on repair shall in the opinion of the Engineer-in-Charge be urgently necessary for security and the contractor is unable or unwilling, Engineer-in-charge at once to do his own or other workmen to such work or repair as may consider necessary. If the work or repair so done is work which in the opinion of the Engineer-in-charge, the contractor was liable to do at his own expenses under the contract, all the costs and charge properly incurred by the Engineer-in-charge in doing so, shall on demand, be paid by contractor or may be deducted from any moneys due to which may become due to the Contractor provided always that the Engineer-in-charge shall be soon after the occurrence of any such emergency as may be reasonably practicable notify the contractor thereof in writing.

51. GOVERNMENT LABOUR ACTS/LAWS:The contractor has to follow strictly the Government Labour Acts, which

are in force at present and introduced from time to time, such as, Acts enforced by Regional Provident Fund Commissioner. Directorate of ESIS and Enforcement Officer of Contract Labour Act, and all necessary arrangement for labour, security insurance will have to be made by the Contactor at his own cost.

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SECTION – IIIA : SAFETY GUIDE FOR WORKS CONTRACT

1. INTRODUCTION

Many of the works of Department of Atomic Energy at its various sites are executed by the contractors. During these works, contractors personnel are likely to the exposed to different types of hazards. Similarly, unsafe acts of contractors personnel may generate hazards for Departmental staff and/or workmen of other contractors working at the site. Such unsafe acts may also pose danger to the existing installations and even to members of public. This guide is prepared to facilitate safe working during execution of contract works.

2. GENERAL SAFETY PROVISIONS

The Contractor shall take all safety precautions during the execution of awarded work and shall maintain and leave the site safe at all times. At the end of each working day and at all times when the work is temporarily suspended, he shall ensure that all materials, equipment and facilities will not, cause damage to existing property, personal injury or interfere with the other works of the project or Station. The contractor shall comply with all applicable provisions of the safety regulations, clean up programme and other measures that are in force at the site.

The Contractor shall provide and maintain all lights, guards, fencing, warning signs, caution boards and other safety measures and provide for vigilance as and where necessary or as required by the Engineer-in-charge or by any duly constituted authority for the protection of workers or for the safety of others. The caution boards shall also have appropriate symbols.

Adequate lighting facilities such as flood lights, hand lights and area lighting shall be provided by the Contractor at the site of work, storage area of materials and equipment and temporary access roads within his working area.

The contractor shall obtain written approval of the Engineer-in-charge to the lighting scheme and place of tapping prior to its installation.

The contractor shall plan his operations so as to avoid interference with the other Departmental works, other contractors or Sub-Contractors at the site. In case of any interference, necessary coordination shall be sought by the contractor from the Department for safe and smooth working.

The Contractor and his sub-contractor, if any shall comply with the instructions given by the Safety Engineer or his authorized nominee

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regarding safety precautions, protective measures, house keeping requirements, etc. The Safety Engineer with due intimation to Engineer-in-Charge shall have the right to stop the work of the Contractor, if in his opinion proceeding with the work will lead to an unsafe and dangerous condition. Engineer-in-Charge shall get the unsafe condition removed or provide protective equipment at the contractors cost. The contractor can employ his own safety Engineer or nominate one of his officers for liaison with Departmental Safety Engineer for ensuring compliance of all safety rules. Contractor shall ensure that all his workmen are aware about the nature of risk involved in their work and have adequate training for carrying out their work safely.

The contractor shall be held responsible for non-compliance of any of the safety measures and delays, implications, injuries, fatalities and compensation arising out of such situations of incidents.

3. TRAFFIC

The contractor shall conduct his operations so as to interfere as little as possible with the use of existing roads at or near locations where the work is being performed.

When interference to traffic is inevitable, notice of such interference shall be given to the Engineer-in-charge well in advance (at least 48 hours) with the details of start of the work and time required, storage of materials, and details of the proposed methods of providing the required facilities for safe and continuous use of roads and obtain his clearance.

The contractor shall, at his own expense, make such approved temporary provisions as are required to maintain atleast one lane of traffic by bridging the excavation, providing ramps over surface obstructions or providing suitable temporary bye-pass around the obstructions. The Contractor shall exercise full care to ensure that no damage is caused by him or his workmen, during the operation, to the existing water supply, sewerages, power or telecommunication lines or any other services or works. The contractor shall be required to provide and erect before construction, substantial barricades, guard-rails, and warning signs. He shall furnish, place and maintain adequate warning lights, signals, etc., as required by Engineer-in-charge. 4. SAFE MEANS OF ACCESS

Adequate and safe means of access and exit shall be provided for all work places, at all elevations. Using of scaffolding members (avoiding a ladder) for approach to high elevations shall not be permitted.

Suitable scaffolds shall be provided for workmen for all works that cannot safely be done from the ground, or from solid construction except

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such short duration work as can be done safely from ladders. Ladder shall be of rigid construction having sufficient strength for the intended loads and made either of good quality wood or metal and all ladders shall be maintained well for safe working condition. An extra mazdoor shall be engaged for holding the ladder if ladder is not securely fixed. If the ladder is used for carrying materials as well, suitable foot holds and hand holds shall be provided on the ladder. The ladder shall be given an inclination not steeper than 1 in 4 (1 horizontal and 4 vertical). Ladders shall not be used for climbing carrying materials in hands. While climbing both the hands shall be free.

Scaffolding or staging more than 3.5m above the ground or floor, swung or suspended from an overhead support or erected with stationary support shall have a standard guard rail properly attached, bolted, braced or otherwise secured at least 1.0m high above the floor or platform of such scaffolding or staging. The guard rail shall extend along the entire exposed length of the scaffolding with only such opening as may be necessary for the delivery of materials. Standard railing shall have posts not more than 2m apart and an intermediate rail halfway between the floor or platform of the scaffolding and the top rail. Such scaffolding or staging shall be so fastened as to prevent it from swaying from the building or structure. Scaffolding and ladder shall conform to relevant IS specification (IS: 3696-1966). Timber/Bamboo scaffolding shall not be used.

Working platforms of scaffolds shall have toe boards at least 15cm in height to prevent materials from falling down.

A sketch of the scaffolding proposed to be used shall be prepared and approval of the Engineer-in-Charge obtained prior to start of erection of scaffolding. All scaffolds shall be examined by Engineer-In-Charge before use.

Working platform, gangways and stairways shall be so constructed that they shall not sag unduly or unequally and if the height of the platform or gangway or stairway is more than 3.5m above ground level or floor level, they shall be closely boarded, shall have adequate width for easy movement of persons and materials and shall be suitably guarded as described in 3.3 above.

The Planks used for working platform shall not project beyond the end supports to a distance exceeding four times the thickness of the planks used. The planks shall be rigidly tied at both ends to prevent sliding and slippage. The thickness of the planks shall be adequate to take load of men and materials and shall not collapse.

Every opening in the floor of a building or in a working platform shall be provided with suitable means to prevent fall of persons or materials by providing suitable fencing or railing, the minimum height of which shall be 1.0m, along with 15 cm high sheet obstruction at floor level along the railing.

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Safe means of access shall be provided to all working platforms and other elevated working places. Every ladder shall be securely fixed. No single portable ladder shall be over 9m in length. For ladders upto 3m in length the width between side rails in the ladder shall in no case be less than 300mm. For longer ladders this width shall be increased by at least 20mm for each additional metre of length. Step spacing shall be uniform and shall not exceed 300 mm.

Adequate precautions shall be taken to prevent danger from electrical lines and equipment. No scaffolding, ladder, working platform, gangway runs, etc. shall exist within 3 metres of any uninsulated electric wire. Whenever electric power and lighting cables are required to run through, (pass on) the scaffolding or electrical equipments are used, such scaffolding structures shall have minimum two earth connections with earth continuity conforming to IS code of practice.

5. EXCAVATION, TRENCHING AND EARTH REMOVAL

All Trenches 1.2 m or more in depth shall at all times be supplied with at least one ladder for each spacing of 30m in length or fraction thereof. Ladder shall be extended from bottom of the trench to at least 1m above the surface of the ground.

The sides of the trench which are 1.2m or more in depth shall be stepped back to give suitable slope (angle of repose) or securely held by timber bracing, so as to avoid the danger of sides from collapsing. The excavated material shall not be placed within 1.5m of the edges of the trench or half of the depth of the trench, whichever is more. Cutting shall be done from top to bottom. Under no circumstances mining or under-cutting shall be done.

The Contractor shall ensure the stability and safety of the excavation, adjacent structures, services and the works.

Open excavations shall be fenced off by suitable railing and warning signals installed at night at well lit places so as to prevent persons slipping or falling into the excavations.

All blasting operations shall be carried out on the basis of procedures approved by Inspector of Explosives. All works in this connection shall be carried out as per IS code of Practice. Barricades, Warning Signs etc. shall be placed on the roads/open area. Prior approval of such operation shall be obtained from Safety Engineer Engineer-In-Charge of works.

a) For removal of earth from an earth mound a written permission shall be obtained from the Engineer- In-Charge of the work and the Engineer-In-Charge of the earth mound.

b) As far as practical, earth shall be removed mechanically. c) Wherever manual removal of earth is involved, earth shall be

removed from the top by maintaining the proper slope equal to the angle of re-pose of the earth.

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d) Such work shall be constantly supervised by the contractor’s responsible person and frequently inspected by the departmental representative to ensure that no under-cutting is done.

6. CONCRETNG

Shuttering and supporting structures shall be of adequate strength and approved by Engineer-in-Charge. This shall be ensured before concrete is poured. The procedure approved by Engineer-in-Charge shall be followed for mixing, transporting and pouring of concrete.

7. DEMOLITION Before any demolition work is commenced and also during the

progress of the work:

a) All roads and open area adjacent to the work site shall either be closed or suitably protected. Appropriate warning signs shall be displayed for cautioning approaching persons.

b) Before demolition operations begin, the Contractor shall ensure that the power on all electric service lines is shut off and the lines cut or disconnected at or outside the demolition site. If it is necessary to maintain electric power during demolition operation, the required service lines shall be adequately protected against damage. Persons handling heavy materials/equipments shall wear safety shoes.

c) No floor, roof or other part of the building shall be overloaded with debris or materials as to render it unsafe.

d) Entries to the demolition area shall be restricted to authorized persons only.

8. PERSONAL PROTECTIVE EQUIPMENT:

All necessary personal protective equipment as considered necessary by the Engineer-in-charge shall be kept available by contractor for the use of the persons employed on the site and maintained in a condition suitable for immediate use. Also the contractor shall take adequate steps to ensure proper use of equipment by those concerned. The personal protective equipments are to be provided by the contractor.

a) All persons employed at the construction site shall use safety helmets. For other types of works, persons working in that area shall also use safety helmets, if advised by safety Engineer/Engineer-in-charge.

b) Workers employed on mixing asphaltic materials, cement and lime mortars shall use protective goggles, protective foot wear and hand gloves. Use of proper respirators shall be an advantage.

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c) Persons engaged in welding and gas cutting works shall use suitable welding face shields. The persons who assist the welders shall use suitable goggles. Protective goggles shall be worn while chipping and grinding.

d) Stone breakers shall use protective goggles. They shall be seated at sufficiently safe intervals of distance.

e) Persons engaged in or assisting in shot blasting operations and cleaning the blasting chamber shall use suitable gauntlets, overalls, dust-proof goggles, boots and protective hood supplied with fresh air at the minimum rate of 9 m3/hr.

f) All persons working at heights more than 4.5m above ground or floor and exposed to risk of falling down shall use safety belts, unless otherwise protected by cages, guard railings, etc. In places where the use of safety belts is impractical, suitable net of adequate strength fastened to substantial supports shall be employed.

g) All powered two-wheeler motorcycle and scooter drivers and their pillion riders shall wear crash helmets inside the project/plant sites.

h) When workers are employed in sewers and inside manholes which are in use, the contractor shall ensure that the man-holes are opened and are adequately ventilated atleast for an hour. After it has been well-ventilated, the atmosphere inside the space shall be checked for the presence of any toxic gas or oxygen deficiency and recorded in the get register before the workers are allowed to into the man-holes. The man-holes opened shall be cordoned off with suitable railing and provided with warning signals or caution boards to prevent accidents. There shall be proper illumination in the night.

9. PAINTING

The Contractor shall not employ women on the work of painting with products containing lead in any form. Only men above the age of 18 years shall be employed on the work with lead paint. The following precautions shall be taken during the work.

Supplied air respirators shall be provided for use by the workers when paint is applied in the form of spray, or a surface having lead paint is dry rubbed or scraped.

Overalls shall be supplied by the contractors to the workmen and adequate facilities shall be provided to enable the painters to wash at the cessation of work.

All painting jobs, especially those in which lead paints are used shall be kept under industrial hygiene surveillance.

Smoking, open flames or sources of ignition shall not be allowed in places where paints and other flammable substances are stored, mixed or used. A caution board, with the instructions written in national/regional language, “SMOKING IS STRICTLY PROHIBITED” shall be displayed in the vicinity where

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painting is in progress or where paints are stored. Symbols shall also be used for caution boards.

Suitable fire extinguishers/sand buckets shall be kept available at places where flammable paints are stored, handled or used.

When painting work is done in a closed room or in a confirmed space, adequate ventilation shall be provided. If adequate ventilation cannot be provided, workers shall wear suitable respirators.

Epoxy resins and their formulations used for painting shall not be allowed to come in contact with the skin. The workers shall use plastic gloves and/or suitable barrier creams.

Adequate ventilation shall be provided especially when working with hot resin mixes.

Increased personal hygiene shall be practiced to control inadvertent contract with the resin and eliminate its effects.

Workers shall thoroughly wash hands and feet before leaving the work. Work clothes be changed and laundered frequently.

10. LIFTING MACHINES AND TACKLES

Use of lifting machines and tackles including their attachments, anchorage and supports shall conform to the following standards or conditions.

a) Lifting machines and tackles shall be of good mechanical construction, sound material and adequate strength and free from any defects and shall be kept in good repair and in good working order. Every rope used in hoisting or lowering materials or as a means of suspension shall be of good quality and adequate strength and free from any defect.

b) Every crane operator or lifting appliance operator shall be properly qualified. No person under the age of 21 years shall be in charge of any hoisting machine or give signal to operator of such machine.

c) In case of every lifting machine (and of every chain, ring, hook, shackle, swivel and pulley block used in hoisting or as means suspension) the safe working load shall be ascertained and clearly marked. In case of a lifting machine having a variable safe working load, each safe working load and the conditions under which it is applicable shall be clearly indicated. No part of any machine or any gear referred to above in this paragraph shall be loaded beyond the safe working load except for the purpose of testing. This shall be approved by the Safety Engineer.

d) In case of departmental machines, the safe working load shall be notified by the Engineer-in-charge. As regards Contractor’s machines, the contractor shall notify the safe working load of the machine to the Engineer-in-charge whenever he brings any machinery to site of work and get it verified by the Engineer-in-

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charge, supported by a valid test certificate by the competent person.

e) Thorough inspection and load testing of lifting machines and tackles shall be done by a competent person atleast once every 12 months and records of such inspection and testing shall be maintained.

Motors, gearing transmission, couplings, belts, chain drives and other moving parts of hoisting appliances shall be provided with adequate safeguards. Hoisting appliances shall be provided with such means as will reduce to the minimum the risk of any part of a suspended load becoming accidentally displaced or lowered. 11. WELDING AND GAS CUTTING

Welding and gas cutting operations shall be done only by qualified and authorized persons and as per IS Specifications and code of Practice.

Welding and gas cutting shall not be carried out in places where flammable or combustible materials are kept and where there is danger of explosion due to presence of gaseous mixtures.

Welding and gas cutting equipment including hoses and cables shall be maintained in good condition.

Barriers shall be erected to protect other persons from harmful rays from the work. When welding or gas cutting is done in elevated positions, precautions shall be taken to prevent sparks or hot metal falling on persons or flammable materials.

Suitable type of protective clothing consisting of fire resistant gauntlet gloves, leggings, boots and aprons shall be provided to workers as protection from heat and hot metal splashes. Welding shields with filter glasses of appropriate shade shall be worn as face protection.

Adequate ventilation shall be provided while welding in confined space or while brazing, cutting or welding zinc, brass, bronze, galvanized or lead coated materials.

Welding and gas cutting shall not be done on drums, barrels, tanks or other containers unless they have been emptied, cleaned thoroughly and it is made certain that no flammable material is present.

Fire extinguisher shall be available near the location of welding operations. Fire safety permit shall be obtained for working at volnearable areas and operating areas before flame cutting/welding is taken up.

For electric (Arc) welding the following additional safety precautions shall be taken:

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I) When electrical welding is undertaken near pipe lines carrying flammables, such pipe lines shall not be used as part of earth conductor but a separate earth conductor shall be connected to the machine directly from the job.

II) Personnel contact with the electrode or other live parts of electric welding equipment shall be avoided.

III) Extreme caution shall be exercised to prevent accidental contact of electrodes with ground.

IV) The welding cables shall not be allowed to get entangled with power cables. It shall be ensured that the cables are not damaged by movement of materials.

12. GRINDING:

All portable grinders shall be used only with their wheel guards in position to reduce the danger from flying fragments should the wheel break during the use.

Grinding wheels of specified diameter only shall be used on a grinder-portable or pedestal-in order not to exceed the prescribed peripheral speed.

Goggles shall be used during grinding operation.

13. ELECTRICITY Guide lines for providing temporary power supply at the site and

general safety procedures for using electricity are given in the enclosed Annexure. 14. HOUSE KEEPING

The contractor shall at all times keep his work spot, site office and surroundings clean and tidy from rubbish, scrap, surplus materials and unwanted tools and equipment.

Welding and other electrical cables shall be so routed as to allow safe traffic by all concerned.

No materials on any of the sites of work shall be so stacked or placed as to cause danger or inconvenience to any person or the public. The Engineer-in-charge may require the contractor to remove any materials which are considered to be of danger or cause inconvenience to the public. If necessary, the Engineer-in-charge may cause them to be removed at the contractor’s cost.

At the completion of the work, the Contractor shall have removed from the work premises all scaffoldings, surplus materials, rubbish and all huts and sanitary arrangements used/installed for his workmen on the site.

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The Engineer-in-charge has the right to stop work if the Contractor fails

to improve upon the housekeeping after having been notified.

15. FIRE SAFETY

All necessary precautions shall be taken to prevent outbreak of fires at the construction site. Adequate provisions shall be made to extinguish fires should they still break out.

a) Quantities of combustible materials like timber, bamboos, coal, paints, etc., shall be the minimum required in order to avoid unnecessary accumulation of combustibles at site.

b) Containers of paints, thinners and allied materials shall be stored in a separate room which shall be well ventilated and free from excessive heat, sparks, flame or direct rays of the sun. The containers of paint shall be kept covered or properly fitted with lid and shall not be kept open except while using.

c) Fire extinguishers as approved by the Engineer-in-charge shall be located at the construction site at appropriate places.

d) Adequate number of contract workmen shall be given education and training in fire fighting and extinguishing methods.

16. SAFETY WORK PERMIT In order to ensure safety of work for hazardous operation (such

as entry into confined spaces, welding/cutting on equipment/pipes where explosion hazard is present, works on high voltage and main medium voltage lines, blasting etc.,)

Special Safety work permits (SWP) shall be raised. The SWP’s shall also to be obtained for any other work as recommended by Safety Engineer.

The Contractor shall strictly ensure all the safety conditions and requirements stipulated in the Safety work permit. The decision of the Safety Engineer shall be final in this regard.

17. WORK IN RADIATION AREA The contractor shall follow the stipulated procedure regarding

work in the radiation area and other works related with radiography.

18. WORK IN AND AROUND WATER BODIES When the work is done near any place where there is risk of

drowning, all necessary rescue equipment such as life buoys and life jackets shall be provided and kept ready for use and all necessary steps taken for prompt rescue of any person in danger and adequate provision shall be made for prompt first-aid treatment of all injuries likely to be

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sustained during the course of the work. Persons who do not know swimming shall not be engaged alone for any work where risk of drowning exists. Sufficient number of life buoys or life jackets shall be provided.

19. MEDICAL FACILITIESThe contractor shall arrange adequate facilities for medical aid

and treatment for his staff and workers engaged on the work site including the first-aid facilities if they are not available at the project site.

First-aid appliances including sterilized dressing, cotton wool and antiseptic cream shall be made available at a readily accessible places at every work site. These shall be maintained in good order under the charge of a responsible person.

At large work places where hospital facilities are not available within easy reach of the works, first-aid posts shall be established and be manned by a trained compounder. An ambulance shall be available during the entire period of work for attending to injury cases.

20. SAFETY OFFICER/SAFETY COORDINATOR

The contractor shall have a Safety Officer or a supervisor to be designated as a Safety Coordinator in order to specifically look into the implementation of different safety requirements of the contract work. The person thus designated will in general co-ordinate with the Engineer-in-charge on matters of safety and in particular ensure that the Safety Guide is complied with fully. His name shall be displayed on the Notice Board at a prominent place at the work site.

21. REPORTING OF ACCIDENT

All accidents leading to property damage and/or personnel injuries shall be reported to the Engineer-in-charge immediately who shall inform SARCOP to be followed up with detailed accident reports in prescribed form. Contractor shall also submit a monthly statement of accidents to Engineer-in-charge by 4th of every month showing details of accident, nature of injury including disability, days lost, treatment required, etc., and the extent of property damage.

22. PUBLIC PROTECTION The Contractor shall make all necessary provisions to protect the public.

He shall be bound to bear the expenses for defence of every action or other proceedings at law that may be brought by any person for injury sustained owing to neglect of any precaution required to taken to be protect the public. He shall pay any damage and cost which may be awarded in any such suit, action or proceeding to any such person, or the amount which may be fixed as a compromise by any such person.

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23. OTHER STATUTORY PROVISIONS Notwithstanding the above clauses from 1 to 21 there is nothing in

these to exempt the Contractor from the provisions of any other Act or Rules in force in the Republic of India. In particular all operations involving the transport, handling, storage and use of explosives shall be as per the standing instructions and conform with the Indian Explosives Act, 1884 and the explosive Rules, 1983. Handling, transport, storage and use of compressed gas cylinders and pressure vessels shall conform with the Gas Cylinder Rules 1981 and Static and Mobile Pressure Vessels (Unfired) Rules 1981. In addition, The Indian Electricity act 1910 and Indian Electricity Rules 1956, the Atomic Energy Act, 1962, the Radiation Protection Rules, 1971, Radiation Protection Manual of Nuclear Facilities and the Atomic Energy (Factories) Rules, 1988 and various rules and Act related to mining shall also be strictly complied with.

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HEIGHT PASSHeight pass for all workers & supervising staff engaged by contractor shall be obtained which includes a medical test by qualified doctor by contractor and physical test by department safety officer for all works where these worker/supervisors need to be work above a height of +/-3.5m, which is mandatory as per safety requirement.

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ANNEXURE GUIDELINES AND GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT SITE

1. GENERAL Following safety requirements shall be complied with before the contractor uses the power supply.

1.1The Contractor shall submit a list of licenced electrical staff to be posted at site.

1.2 It shall be the responsibility of the Contractor to provide and maintain complete installation on the load side of the supply point with regard to the safety requirements at site. All cabling and installation shall comply with the appropriate statutory requirements given below and shall be subject to approval of the Departmental Engineer-in-charge/Electrical Engineer.

a) Indian Electricity Act, 1910. b) Electricity (Supply) Act, 1948. c) Indian Electricity Rules, 1956. d) National Electric Code, 1985. e) Other relevant rules of Local Bodies and Electricity Boards.

After installation of the electrical power wiring works by the contractor, form of completion certificate as per IS:732 (Form SGCW-1) shall be submitted by the contractor duly signed by the authorized valid licenced electrical contractor and /or supervisor along with one copy of the contractor’s license and/or competency certificate of supervisor issued by the Electricity Board/Government Electricity Organisations as per the enclosure.

The power supply shall be regulated as per the terms and conditions of the supply of the respective electricity boards.

1.3 (a) For purposes of electrical load and power planning by the electrical section, the contractor shall furnish along with the tender, the estimated load requirement of electric power for the execution of the contract works in terms of maximum Kilo Watt or KVA demand during various periods/months of the contract period along with the details of the construction electrical equipment/machinery with their individual load details and location/locations of power supply required for availing temporary electric power supply in the standard proforma enclosed (form SGCW -2).

(b) The electric power supply will be generally made available at one point in the works site of the Contractor by the department.

(c) Where distribution boards are located at different places the Contractor shall submit schematic drawing indicating all details like size of wires, Over Head or cable feeders, earthing etc., The position and location of all equipments and switches shall be given.

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1.4 The Contractor shall make his own arrangements for main earth electrode and tappings thereof. The existing earth points available at site can be used at the discretion of the Departmental Electrical Engineer with prior permission. Method of earthing, installation and earth testing results shall conform to relevant I.S. Specifications (IS-3043).

1.5 All three phase equipment shall be provided with double earthing. All light fixtures and portable equipment shall be effectively earthed to main earthing.

1.6 All earth terminals shall be visible. No gas pipes and water pipes shall be used for earth connection. Neutral conductor shall not be treated as earth wire.

1.7 The Contractor shall not connect any additional load without prior permission of Departmental Electrical Engineer. For obtaining additional power required, test reports of the tests mentioned in (d) of Form SGCW-1 shall be submitted.

1.8 Joints in earthing conductors shall be avoided. Loop earthing of equipment shall not be allowed. However tappings from an earth bus may be done.

1.9 The entire installation shall be subjected to the following tests before energisation of installation including portable equipment.

a) Insulation resistance test. b) Polarity test of switches. c) Earth continuity test. d) Earth electrode resistance.

The test procedures and their results shall conform to relevant IS Specifications. The contractor shall submit a test report for his complete installation every 2 months or after rectifying any faulty section in the specimen test report. One such test report for the complete installation shall be submitted before onset of monsoon.

2. The following are provided for general guidance of the Contractor and shall be read as specific requirement, in addition to complying with Indian Electricity Act, Indian Electricity Rules and IS Specifications.

2.1 Installation

a) Only persons having valid wireman’s licence/competency certificate shall be employed for carrying out electrical work and repair of electrical equipment, installation and maintenance at site. The job shall be supervised by a qualified licenced Supervisor. b) Electrical equipment and installations shall be installed and maintained as to prevent danger from contact with live conductors and to prevent fires originating from electrical causes like short circuits, overheating etc. Installation shall not cause any hindrance to movement of men and materials.

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c) Materials for all electrical equipment shall be selected with regard to working voltage, load and working environment. Such equipment shall conform to the relevant standards. d) The minimum clearance to be maintained for all overhead lines along roads and across roads shall be as per the statutory requirements as listed in clause 1.2 of Annexure. e) Grounding conductor of wiring system shall be of copper or other corrosion-resistant material. An extra grounding connection shall be made in appliances/equipment where chances of electric shock is high. f) Electric fuses and/or circuit breakers installed in equipment circuits for short circuit protection shall be of proper rating. It is also recommended that high rupturing capacity (HRC) fuses be used in all circuits. For load of 5 KW or more earth leakage circuit breaker shall be provided in the circuits. g) Wherever cables or wires are laid on poles, a guard wire of adequate size shall be run along the cables/wires and earthed effectively. Metallic poles as a general rule shall be avoided and if used shall be earthed individually. Anticlimbing guards and danger notices shall be provided on poles. Each equipment shall have individual isolating switches. h) Wires and cables shall be properly supported and an approved method of fixing shall be adopted. Loose hanging of wires & cables shall be avoided. Lighting and power circuits shall be kept distinct and separate. i) Reinforcement rods or any metallic part of structure shall not be used for supporting wires and cables, fixtures, equipment, earthing etc. j) All cables and wires shall be adequately protected mechanically against damages. In case the cable is required to be laid under ground, it shall be adequately protected by covering the same with bricks. Plain cement Concrete (PCC) tile or any other approved means. k) All armoured cables shall be properly terminated by using suitable cable glands. Multistranded conductor cables shall be connected by using cable lugs/sockets. Cable lugs shall preferably be crimped. They shall be of proper size and shall correspond to the current rating and size of the cable. Twisted connections will not be allowed. l) All cable glands, armouring and sheathing of electric cables, metal circuits and their fittings, metallic fittings and other non-current carrying parts of electrical equipment and apparatus shall be effectively grounded. m) All the Distribution Boards, Switch Fuse units, Bus bar chambers, ducts, cubicles etc. shall have MS enclosures and shall be dust, vermin and water proof. The Distribution Boards, switches etc. shall be so fixed that they shall be easily accessible. Changes shall be done only after the approval of the Departmental Electrical Engineer. n) The contractor shall provide proper enclosures/covers of approved size and shape for protection of all the switch board, equipment etc. against rain. Exposed live parts of all electrical circuits & equipment shall be enclosed permanently. Crane trolley wires and other conductors which cannot

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be completely insulated shall be placed such that they are inaccessible under normal working conditions.o) Iron clad industrial type plug outlets are preferred for additional safety. p) Open type Distribution Boards shall be placed only in dry and ventilated rooms; they shall not be placed in the vicinity of storage batteries or otherwise exposed to chemical fumes. q) Isolating switches shall be provided close to equipment for easy disconnection of electrical equipment or conductors from the source of supply when repair or maintenance work has to be done on them. r) In front of distribution boards a clear space of 90 cm shall be maintained in order to have easy access during an emergency. s) Adequate working space shall be provided around electrical equipment which require adjustment or examination during operation. t) As far as possible electrical switches shall be excluded from a place where there is danger of explosion. All electrical equipment such as motors, switches and lighting fittings installed in work room where there is possibility of explosion hazard shall be explosion proof. u) All connections to lighting fixtures, starters or other power supplies shall be provided with PVC insulated, PVC sheathed twin/three/four core wires to have better mechanical protection for preventing possible damage to equipment or injury to personnel. Taped joints shall not be allowed and the connections may be made in looping system. Electric starter of motors, Switches shall not be mounted on wooden boards. Only sheet steel mounting or iron frame work shall be used. v) All the lighting fixtures and lamp holders shall be of good quality and in good condition. Badly repaired or broken holders, etc. shall not be used. w) Only PVC insulated and PVC sheathed wires or armoured PVC insulated and sheathed cables shall be used for external power supply connections of temporary nature. Weather proof rubber wires shall not be used for any temporary power supply connections. Taped joints in the wires shall not be used. x) The bulbs/lamps used for illumination and testing purpose shall have cover or guard to protect them from accidental breakages. Only 24 V supply system shall be used for hand lamps etc, while working inside metallic tanks or conducting vessels. y) After installation of new electric system and or other extensive alterations to existing installations, thorough inspection shall be made by Departmental Electrical Engineer before the new system or new extension is put in use. z) Contractor shall ensure that power factor for their loads shall be maintained at 0.85. In case the power factor falls below 0.85, necessary capacitor units shall be provided by the contractor.

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2.2 Operation & Maintenance

a) All persons who work with electrical installation/equipment shall be aware of the electrical hazards, use of protective devices and safe operational procedures. They shall be given training in fire fighting, first aid and artificial resuscitation techniques. b) The supervisor shall instruct the proper procedure, specify and enforce the use of necessary protective equipment such as adequately insulated pliers, screw drivers, fuse pullers, testing lamps and similar hand tools. Only wooden ladders shall be used to reach the heights in electrical work. c) No material or earth work shall be allowed to be dumped below or in the vicinity of the bare overhead line conductors. d) Separate work permits shall be issued for individual group leaders working on the same system which shall be returned after the completion of the work to Safety Supervisor and no system shall be energised without the clearance of Safety supervisor. e) Before any maintenance work is commenced on electrical installations/equipment, the circuits shall be de-energised and ascertained to be dead by positive test with an approved voltage testing device. Switches shall be tagged or the fuse holders withdrawn before starting the work. Adequate precautions shall be taken in two important aspects viz.

I) That there shall be no danger from any adjacent live parts and II) That there shall be no chances of re-energisation of the

equipments on which the persons are working f) While working on or near a circuit, whenever possible the use of one hand may be practiced even though the circuit is supposed to be dead. The other hand may preferably be kept in pocket. g) When it is necessary to touch electrical equipment (for example when checking for overload of motors) back of the hand may be used. Thus, if accidental shock were to cause muscular contractions one would not ‘freeze’ to the conductor. h) Operation of electrical equipment shall be avoided when standing on wet floor or when hands are wet. i) Before blown fuses are replaced, the circuit shall be locked out and an investigation shall be made for the cause of the short circuit or overload. j) When two persons are working within reach of each other, they shall never work on different phases of the supply. k) When structural repairs, modification or painting work are to be undertaken, appropriate measures shall be taken for the protection of persons whose work may bring them into the proximity of live equipment/circuit.

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l) It shall be ensured that the insulation and wire size of extension cords are adequate for the voltage and current to be carried. m) While tapping electricity from the socket, plug top must be used. It shall be ensured that no extension boards are over loaded while tapping. Only standard three pin plugs shall be used for tapping electricity. Broken sockets/plugs shall be replaced immediately with good ones. Only joint free cables shall be used for connecting equipment/apparatus.n) Floors shall be kept free from trailing electrical cables to avoid tripping hazard. o) Power supply to all the machines and lighting fixture shall be switched off when not in use. p) Temporary electrical connections shall be removed as soon as the stipulated work is over. After completion of the works, the contractor shall dismantle the distribution boards and the other facilities he may have erected. q) Unauthorised tapping of power by others from distribution boards under the control of the contractor shall be prohibited at all circumstances. r) No flammable materials shall be stored in any working area near the switch boards. s) Safety work permits shall be used for switching off the main feeder and equipment by the contractor. t) “MEN ON LINE” “ DO NOT SWITCH ON” “DANGER” or “CAUTION” board as applicable shall be used during maintenance works on the electrical equipment.2.3 Portable electrical equipment a) Portable electrical equipment shall be regularly examined, tested and maintained to ensure that the equipment and its leads are in good order. Register shall be maintained for inspection recording, the testing dates and results of the equipments. b) All portable appliances shall be provided with three core cable and three pin plug. The third pin of the plug shall invariably be earthed. It shall be ensured that the metal part of the equipment shall be effectively earthed. c) All connections to portable equipment or machines from the panel/distribution board/extension board shall be taken using 3 core double insulated PVC flexible copper wire in one length. No joints shall be allowed in this flexible wire. In case single length of wire is not sufficient for a particular location then the supply can be tapped by providing another extension board comprising of switch and socket. d) Flexible cables for portable lamps, tools, and apparatus shall be regularly examined, tested periodically and maintained to ensure safety.

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FORM NO. SGCW -1FORM FOR COMPLETION CERTIFICATE

(Prescribed under Cl.1.2 of Annexure)

I/We certify that the installation detailed below has been installed by me/us and tested and that to the best of my/our knowledge and belief, it complies with Indian Electricity Rules, 1956 as well as IS:732-963 code of practice for Electrical Wiring Installations. (System voltage at exceeding 650 Volts (Revised).

Electric Installation at …………………………………………………………. Voltage and system of supply ………………………………………………………….

Particulars of work Number

Total Load

Type of system of wiring

i) Light Points ii) Fan Points iii) Plug points (3 pin) iv) Motors

If the work involves installation of overhead lines and/or underground cableEarthing: Description of earthing electrode, size of earth wire and number of electrodes provided: Test results: 1. Insulation resistance for the whole installation.

I) Between conductors II) Between each conductor and earth

2. Resistance of earthing electrode or earthing system. 3. Maximum earthing resistance of installation __________________________

Signature of Supervisor Name and addressof Supervisor.

Signature of ContractorName and address

of Contractor.

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FORM NO.SGCW-2‘A’ APPLICATION FOR SERVICE CONNECTION BY CONTRACTOR

(Prescribed under Cl.1.3 of Annexure)(to be filled in triplicate)

1 Name & Address of Contractor :2 Reference to Tender & Work Order :3 Completion period :4 Connected load details (please attach

Details in a separate sheet):

5 Max. demand anticipated :6 Nature of service connection required

(Whether single or three phase):

7 Place where service requireda) Works :b) Colony :

8 If supply of electricity is free or chargeable (Please enclose extract of conditions from the tender)

:

9 Details of meter provideda) If meter required from the Department whether SD is paid

:

b) Details of SD (Security Deposit) :c) Whether meter is tested or not, if tested, attach test report, if not, Details of testing fee deposited

:

10 Name of Supervisor/Electrician in Charge of installation and maintenance

:

11 Electrical licence No. of person mentioned Against col.10

:

12 Electrical safety appliances available for use

:

13 Fire extinguishers available for use :14 First Aid facility/box available for use,

if any:

(Signature of the Contractor) Date: Name:

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‘B’ CERTIFICATE BY THE CONTRACTOR

Certified that my/our installations have been carried out in accordance with I.E. Rules and that I/We have employed competent persons to handle the installations.I/we am/are agreeable to the bills, in respect of this service connections being raised on the basis the connected load furnished above, in case the actual consumption falls below the one stipulated by the tender conditions.

(Signature of the contractors) Name:Address:

Date: ……………………………………………………………………………………..

………………………………….

‘C’ CERTIFICATE BY THE CONTRACT CONTROL ENGINEER

Verified the particulars and forwarded to the Engineer In Charge.

(Signature of Contract control Engineer)Name:Section: Civil/Electrical/Mechanical

………………………………………………………………………………………………………………………….

‘D’ CERTIFICATE BY THE ENGINEER IN CHARGE Certified that the particulars furnished by the contractor are true to the best of my knowledge and belief and that I have satisfied myself as to the safe conditions of electrical installations for which the service connection is applied for.

Signature: Name:

Designation with section:

Date: ………………………………………………………………………..

………………………………………………….

‘E’ CERTIFICATE BY THE SAFETY ENGINEER Certified that I have inspected the electrical installations referred herein and after satisfying myself about the safe conditions of the installation, I hereby recommended that the service connection be given to the contractor.

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Signature of Safety Engineer.Name:

Date:………………………………………………………………………………………………………

……………………

‘F’ AUTHORISATION BY THE ELECTRICAL ENGINEER

Service connection may be/may not be given for the reasons noted hereunder.

Signature of Electrical Engineer.Name:Designation:

Date:…………………………………………………………………..

…………………………………………………

‘G’ ‘REPORT OF COMLIANCE’

Service connection is give by me ona) Meter Nos. 1.

2.3.

b) Initial readings: 1.2.3.

c) Locations: 1.2.3.

d) Mater sealings

Signature of Electrical Engineer (Metering and Billing)

Name:Designation:

Date:

Note:1st copy to Contract Control Engineer

2nd copy to Safety Engineer

and 3rd copy to Electrical Engineer

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After all the formalities are completed and Report of Compliance(G) are filled up by the Electrical Engineer after power supply is given

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Procedure for Safe Working at heights1.0 SCOPE:1.1 For work at height of 3.5mts. and above from the ground floor, where a

person is likely to fall from a height of 3.5mtrs., unless otherwise protected by rail or other means.

2.0 OBJECTIVE:2.1 To ensure personnel working at heights are fit to work at such hazardous locations.2.2 Safe working conditions at height exist i.e. strong working platform,

handrail, toe guard, etc.2.3 Personnel not to adopt unsafe practice while working at heights2.4 To ensure use of appropriate personal protective equipment for safe

working.

3.0 APPLICABILITY:3.1 This procedure is applicable for work at height of 3.5mts and above

from the ground floor, where a person is likely to fall from a height of 3.5mts unless otherwise protected by rail other means; this procedure shall be adopted by all the department staffs and all the contract workers executing works at IGCAR.

4.0 RESPONSIBILITY:4.1 Responsibility for implementation of this procedure lies with the

concerned person executing the work.

5.0 PRE-REQUISTE:5.1 The concerned person executing the work and his supervisor shall

check the entire work place (height more than 3.5mtrs.) with respect to safety. He shall take necessary guidance from Environmental & Industrial Safety Section (E&ISS) for ensuring the applicability and implementation of the procedure.

6.0 EQUIPMENTS AND ACCESSORIES:6.1 Ladder, Safety Belts, Safety net and other PPE’s.

7.0 IMPORTANT DEFINITION:Fall Protection – It means items, which can;

7.1 Prevent a person form falling i.e. guard, railing, etc.7.2 Arrest the falling of person i.e. safety belt.7.3 Hold the falling person above the ground i.e. safety net.

8.0 PROCEDURE FOR OBTAINING HEIGHT PASS CERTIFICATE:8.1 Departmental person shall undergo medical test as per listed test in the

format enclosed (Annexure-1-Height Pass) by the Certifying Surgeon / Doctor at occupational health centre, IGCAR.

8.2 Contractor’s personnel shall obtain the certificate in the format enclosed (height pass) from Certifying Surgeon / MBBS Doctor.

8.3 Person medically fit to work at heights shall be given safe work training and shall have undergo the physical test as per the format (annexure-1-height pass).

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8.4 Medically and physically fit persons shall be issued height pass certificate and a registration number shall be assigned on the form and the same recorded in the height pass register.

8.5 The pass will be valid for 1 year from the date of issue. In case the individual wants to continue the work at height beyond this period he has to obtain a fresh height pass certificate.

9.0 SAFETY PRACTICE WHILE WORKING AT HEIGHT:9.1 Apply for a height work permit (Annexure-2)9.2 The concerned supervisor shall ensure that safe work

environment exists, safe work methods followed (refer AERB notification, Annexure-4) and personnel working at height have valid height pass certificate.

9.3 Concerned Engineer in charge or contractor as applicable shall provide all necessary resources to achieve all objects as stated above.

9.4 Access to work area at height shall be ensured by providing portable ladders (Refer annexure-3 - ladder safety).

9.5 Safety net shall be fixed under the work spot so as to prevent fall of material and personnel to ground /floor to cause damage/injury if other fall protection means are not practicable.

9.6 Safety training of fall prevention shall be given to all workmen involved in such operations.

9.7 Hand tools used by the workmen at height shall be secured with static line / with body of the user (tool bag).

10.0 REFERENCES:1. Atomic Energy (Factories) Rules, 1996.2. AERB Notification (Refer AERB/IPSD/PKG/2004/8274 dt.29.11.2006)

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Annexure-1

HEIGHT PASS(Working at heights more than 3.5 m above ground or floor)

Ref. No. Valid upto:

(Valid only for 1Year from issue unless cancelled/withdrawn earlier by the issuing authority. It can be revalidated free of cost on due application to Head, IS. In case of loss, applicant must apply and appear for the practical test again.)

1. Full Name of applicant (Block letters)& Desgn. :

2. Present address :

3. Permanent Address :

4. Age and Sex:

5. Height and weight:________ cm and ______ kg.

6. IC No. / Gate pass No. and Date :

7. Name of Contractor with whom engaged at present :

8. Contract work order No. :

9. Description of present Job :

10. Previous experience of working at heights:Name of employer

Duration of employment

Work experience

Declaration:I here by declare that the above informations furnished by me is true and correct. I shall always wear the safety belt and tie the life line whenever working at height above 10 feet or in depth. I shall not misuse the height pass issued to me or transfer it to any other person. I shall never come to duty or work at height / depth under influence of alcohol.

Date: Signature and Name of the applicant

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FILLED BY USER

MEDICAL TEST

Blood pressure:

Flat foot :

Epilepsy :

Mental depression :

Frequent headache or reeling sensation:

Limping gait :

Vertigo

Any other height related illness :

Date of Medical Test: Name and Signature of Medical Officer

Registration No. and seal

PHYSICAL TEST Date of physical Test:

(The above applicant has appeared at the following practical test conducted by Head, IS and the results are given below)

Walking freely over a horizontal bar at 1 ft. height:

Wearing a safety belt and tying the knot:

Walking freely over a horizontal structure at 10 ft. height:

General physique:

Climbing of rope

:PASS/FAIL

:PASS/FAIL

:PASS/FAIL

:PASS/FAIL

:PASS/FAIL

The above applicant’s performance in the above tests has been satisfactory / un-satisfactory. He has been issued a height pass bearing Sl. No._______________(If found un-satisfactory mention reason):

Date of issue: Name and Signature of Issuing Authority ( E&ISS) with seal

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Annexure-2

HEIGHT WORK PERMIT (More than 3.5 m)

Permit No.: ______________Date of issue_______________ Validity____________

Location: Date:

Name of contractor: Work Order No.:

Name of Dept. Engineer In-charge :

Ladder for access and safe working platform

Check tightness of scaffolds and lending

Check for handrails

Yes / No

Yes / No

Yes / No

All openings protected / guarded against fall hazard Yes / No

Check for the need of safety net at all openings Yes / No

Personnel working at height has obtained height pass certificate and provided with safety belt. Option to tie belt exist

Yes / No

Fire Safety measures, if hot work is carried out at height Yes / No

Area lighting for height works Yes / No

Safe work procedure is available or not Yes / No

Supervisor is available to supervise the job Yes / No

Contractor Supervisor/ Engineer Contractor Safety Supervisor / Officer

Contractor Site / Engineer In- chargeIndustrial Safety The work is permitted / Not Permitted :Reason for rejection :

Industrial Safety

Revalidation of work permit(to be re-validated weekly till work completes and area is clear)Date / TimeName of issuerIssuer initial

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FILLED BY USER

Annexure-3LADDER SAFETY

ATOMIC ENERGY (F) RULES, 1996

Rule no. 52. LADDERS.- (1) Every ladder shall be of good construction, sound material and of adequate strength for the purpose for which it is used. The rungs shall be parallel, level and uniformly spaced at 30 cm.

(2) Ladders shall be inspected regularly and repaired immediately. No ladder with defective or missing rungs shall be used. Wooden ladders shall not be painted. For preserving the material from deterioration linseed oil or clear varnish shall be

(3) No portable single ladder shall be over 9 m in length the width between side rails in rung ladder shall in no case be less than 28 cm for ladder upto and including 3 m in length. For longer ladders this width shall be increased atleast 20mm for each additional metre of length. Uniform step spacing shall not exceed 30 cm.

(4) All ladders with spreading bases such as step and trestle ladders shall be equipped with rigid spreads or some other means to prevent their premature opening or closing.

(5) Ladders shall be in a safe position before being climbed. The best angle for a ladder is 75 with the horizontal ie the distance of the base of the ladder from the wall, pole structure etc., as the case may be shall be ¼ th its length.

(6) A ladder shall be stored upon brackets and in sheltered locations.

(7) A ladder shall not be placed upon a box, barrel, or other moveable insecure object and against a round or annular pillar such as pipe or narrow steel section etc.

(8) Two ladders must not be spliced together as far as possible. When it is inevitable they shall be tied together properly to ensure rigidity. Extra parallel members at the point of splicing may be added to each of the main members of the ladders. Two ladders shall not be spliced together to provide access to greater height than when a single ladder is used.

(9) Bamboo ladders shall be provided with twisted wire loops enclosing both longitudinal members to prevent them from opening outwards. However, such ladders where longitudinal members are reinforced with metal/wire loops shall not be used when working on electrical circuits.

(10) Metal ladders with insulating rubber shoes shall only be used for working with electrical lines or in places where they may come in contact with such wires.

(11) No worker shall work from a plank placed on the rungs of ladders.

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(12) All permanently installed vertical ladders above a height of 3m shall have manguards provided.

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Annexure-4

AERB Notification (Refer AERB/IPSD/PKG/2004/8274 dt. 29.11.2004)WORKING AT HEIGHT

All open side of a structure above a height of 3.5 m from which worker might fall and openings into which a worker might fall should be adequately covered or barricaded. Every opening in the floor of a building, or in a working platform shall be provided with suitable fencing/railing of 1 m.

Where barricades cannot be installed, a safety net should be installed close to the level at which there is a danger of a fall. During erection of tall buildings/ structures, above 3.5 m height nylon nets shall be provided to ensure safety of men if there is a fall from height in case it is not possible to provide barricades.

Where a secure foothold is impracticable, safety belts or harnesses with secure anchorage points should be provided at the working place as well as access to the access path to the working spot. All persons working at heights more than 3.5 m above ground or floor and exposed to the hazard of falling down shall use safety belts

At elevated places, secure access and foothold should be provided. Adequate and safe means of access shall be provided at all work places for all elevations. Means of access may be portable or fixed ladder, ramp or a stairway. The use of cross braces or framework a means of access to the working surface shall not be permitted.

Scaffolding or staging 3.5m above the ground floor shall have guardrail properly attached, bolted, braced or otherwise secured at least 1m height above the floor and platform.

Where the platform is more than 3.5 m above ground floor for working standing on the platform, the width should be minimum 1 m.

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SECTION – IV : CONDITIONS OF CONTRACT

GENERAL

DEFINITIONS:

1. The ‘Contract’ means the documents forming the tender and acceptance thereof and the formal agreement executed between the President of India and the Contractor together with the documents referred to therein including these conditions, the specifications, designs, drawings and instructions issued from time to time by the Chief Engineer / Associate Director, CEG / Engineer-in-Charge and all these documents taken together shall be deemed to form one contract and shall be complementary to one another.

2. In the contract the following expression shall unless the context otherwise requires, have the meanings hereby respectively assigned to them.

a. The expression ‘Works’ or ‘Work’ shall unless there be something either in the subject or context repugnant to such construction be construed and taken to means the works by or by virtue of the contract contracted to be executed whether temporary or permanent and whether original, altered, substituted or additional.

b. The ‘Site’ shall mean the land and/or other places on, into or through which work is to be executed under the contract or any adjacent land, path or street through which work is to be executed under the contract or any adjacent land, path or street which may be allotted or used for the purpose of carrying out the contract.

c. The ‘Contractor’ shall mean the individual or firm or company whether incorporated or not undertaking the works and shall include the legal personnel representative or such individual or the persons composing such firm or company or the successors of such firm or company and the permitted assignees of such individual or firm or firms or company.

d. The ‘President’ means the President of India and his successors.e. The ‘Chief Engineer’ means the Chief Engineer or the Director of

Engineering Service Group, Indira Gandhi Centre for Atomic Research, Kalpakkam. The ‘Engineer-in-Charge’ means the authorized representative of Chief Engineer or Associate Director, CEG or, Head as the case may be of the Civil Engineering Division, Engineering Service Group, Indira Gandhi Centre for Atomic Research, Kalpakkam who shall supervise and be in charge of the work and who shall sign the contract on behalf of the President.

f. ‘Government’ or ‘Government of India’ shall mean the President of India.g. The term C.E. represents Chief Engineer, of the Engineering Service Group,

Indira Gandhi Centre for Atomic Research, Kalpakkam.h. Market Rate shall be the rate as decided by the Engineer-in-Charge on the

basis of the cost of materials and labour at the site where the work is to be executed plus the percentage to cover, all overheads and profits.

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i. ‘Contract Price’ means the sum named in the Tender subject to such additions there to or deductions there from as may be made under the provisions herein before contained.

j. ‘Temporary Work’ means all temporary works of every kind required in or about the execution, completion and maintenance of the works.

k. Words imparting the singular number includes the plural number and vice versa according to the context.

l. ‘Tendered Value’ means the value of the entire work as stipulated in the letter of award.

3. Where the context so requires, words imparting the singular only also include the plural and vice versa. Any reference to masculine gender shall whenever required include feminine gender and vice versa.

4. Headings and Marginal notes to these General Conditions of Contract shall not be deemed to form part thereof or be taken into consideration in the interpretation or construction thereof or of the contract.

5. The contractor shall be furnished, free of cost one certified copy of the contract documents except standard specifications, Schedule of Quantities and such other printed and published documents, together with all drawings as may be forming part of the tender papers. None of these documents shall be used for any purpose other than that of this contract.

6. The work to be carried out under the contract shall, except as otherwise provided in these conditions, include all labour, materials, tools, plants, equipment and transport which may be required in preparation of and for and in the full and entire execution and completion of the works. The descriptions given in the schedule of Quantities shall, unless otherwise stated, be held to include wastage on materials, carriage and cartage, carrying and return of empties, hoisting, setting, fitting and fixing in position and all other labours necessary in and for the full and entire execution and completion of the work as aforesaid in accordance with good practice and recognized principles.

7. The contractor shall be deemed to have satisfied himself before tendering as to the correctness and sufficiency of his tender for the works and of the rates and prices quoted in the Schedule of Quantities, which rates and prices shall, except as otherwise provided, cover all his obligations under the Contract and all matters and things necessary for the proper completion and maintenance of the works.

8. The several documents forming the Contract are to be taken as mutually explanatory of one another, detailed drawings being followed in preference to small scale drawing and figured dimensions in preference to scale and special conditions in preference to General Conditions.

8.1 In the case of discrepancy between the schedule of quantities, the Specifications and/or the Drawings, the following order of preference shall be observed.i) Description of Schedule of Quantities.ii) Particular Specification and Special Condition, if any.iii) Drawings.

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iv) Specifications.v) Indian Standard Specifications of B.I.S.

8.2 If there are varying or conflicting provisions made in any one document forming part of the contract, the Accepting Authority shall be the deciding authority with regard to the intention of the document and his decision shall be final and binding on the contractor.

8.3 Any error in description, quantity or rate in Schedule of Quantities or any omission there from shall not vitiate the Contract or release the Contractor from the execution of the whole or any part of the works comprised therein according to drawings and specifications or from any of his obligations under the contract.

9. The successful tenderer/contractor, on acceptance of his tender by the Accepting Authority shall, within 15 days from the stipulated date of start of work sign the contract consisting of:-i) The notice inviting tender, all the documents including drawings, if any,

forming the tender as issued at the time of invitation of tender and acceptance thereof together with any correspondence leading thereto.

ii) Standard form as mentioned in Tender consisting of:a) Various standard clauses with corrections up to the date along with

annexure thereto.b) Specification for various items of work.c) IGCAR safety code for contract works.d) Model Rules for the protection of health, sanitary arrangements for

workers employed by IGCAR or its contractors.e) DAE contractor’s Labour Regulations.

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CONDITIONS OF CONTRACT

CLAUSE 1: PERFORMANCE GUARANTEE

i) The contractor shall submit an irrevocable Performance Guarantee of 5% (Five percent) of the tendered amount in addition to other deposits mentioned elsewhere in the contract for his proper performance of the contract agreement, (not withstanding and/or without prejudice to any other provisions in the contract) within period specified in Schedule ‘F’ from the date of issue of letter of acceptance. This period can be further extended by the Engineer-in-charge upto a maximum period as specified in Schedule ‘F’ on written request of the contractor stating the reason for delays in procuring the Performance Guarantee, to the satisfaction of the Engineer-in-charge. This guarantee shall be in the form of Government Securities or fixed deposit receipts or Guarantee Bonds of any Scheduled Bank/Banker’s cheque of any scheduled bank/ or the State Bank of India in accordance with the form annexed as Appendix-‘A’ hereto. In case a fixed deposit receipt of any Bank is furnished by the contractor to the Government as part of the performance guarantee and the Bank is unable to make payment against the said fixed deposit receipt, the loss caused thereby shall fall on the contractor and the contractor shall forthwith on demand furnish additional security to the Government to make good the deficit.

ii) The Performance Guarantee shall be initially valid upto the stipulated date of completion plus 60 days beyond that. In case the time for completion of work gets enlarged, the contractor shall get the validity of performance Guarantee extended to cover such enlarged time for completion of work. After recording of the completion certificate for the work by the competent authority, the performance guarantee shall be returned to the contractor, without any interest.

iii) The Engineer-in-charge shall not make a claim under the Performance guarantee except for amounts to which the President of India is entitled under the contract (notwithstanding and/or without prejudice to any other provisions in the contract agreement) in the event of :

iv) In the event of the contract being determined or rescinded under provisions of any of the clause /condition of the agreement, the performance guarantee shall stand forfeited in full and shall be absolutely at the disposal of the President of India.

(a) Failure by the contractor to extend the validity of the Performance Guarantee as described herein above, in which event the Engineer-in-charge may claim the full amount of the Performance guarantee.

(b) Failure by the contractor to pay President of India any amount due, either as agreed by contractor or determined under any of the Clauses/Conditions of the agreement, within 30 days of the service of notice to this effect by Engineer-in-charge.

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(c) APPENDIX-‘A’

FORM OF PERFORMANCE SECURITY BANK GUARANTEE BOND

In consideration of the President of India (hereinafter called “The Government”) having agreed under the terms and conditions of agreement No...........................Dated...............made between............................... and ................................... (hereinafter called “the said contractor(s)”) ..........For the work .........................………………………………………………………............................................. (hereinafter called “the said agreement”) having agreed to production of a irrevocable Bank Guarantee for Rs.................(Rupees ..........……………………………………………...........only) as a security / guarantee from the contractor(s) for compliance of his obligations in accordance with the terms and conditions in the said agreement.

1. We (indicate the name of the bank).....(hereinafter referred to as the “the Bank”) hereby undertake to pay to the Government an amount not exceeding Rs..........................................................................only on demand by the Government.

2. We (indicate the name of the bank) do hereby under take to pay the amounts due and payable under this Guarantee without any demure, merely on a demand from the Government stating that the amount claimed is required to meet the recoveries due or likely to be due from the said contractor(s). Any such demand made on the Bank shall be conclusive as regards the amount due and payable by the Bank under this Guarantee. However, our liability under this guarantee shall be restricted to an amount not exceeding Rs.................. (Rupees...................…………………………………………………………....only).

3. We, the said bank further undertake to pay to the Government any money so demanded notwithstanding any dispute or disputes raised by the Contractor(s) in any suit or proceeding pending before any court or Tribunal relating thereto, our liability under this present being absolute and unequivocal.

The payment so made by us under this bond shall be a valid discharge of our liability for payment there under and the contractor(s) shall have no claims against us for making such payment.

4. We...........……………………………....(Name of Bank)...…………………………….. further agree that the Guarantee herein contained shall remain in full force and effect during the period that would be taken for the performance of the said agreement and that it shall continue to be enforceable till all the dues of the Government under or by virtue of the said agreement have been fully paid and its claims satisfied or discharged or till Engineer-in-Charge on behalf of the Government certifies that terms and conditions of the said agreement have been fully and properly carried out by the said contractor(s) and accordingly discharges this Guarantee.

5. We……………………….................(Name of Bank)....………………………………. further agree with the Government that the Government shall have the fullest liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the terms and conditions of the said agreement or to extend time of performance by the said contractor(s) from time to time or to postpone for any time or from time to time any of the powers exercisable by the Government against the said contractor(s) and forbear or enforce any of the

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terms and conditions relating to the said agreement and we shall not be relieved from our liability by reason of any such variation, or extension being granted to the said contractor(s) or for any forbearance, act of omission on the part of the Government or any indulgence by the Government to the said contractor(s) or by any such matter or thing whatsoever which under the law relating to sureties would, but for this provision, have effect of so relieving us.

6. This Guarantee will not be discharged due to the change in the constitution of the Bank or the contractor(s).

7. We.....………………………...........(Name of Bank)……………………....... lastly undertake not to revoke this Guarantee except with the previous consent of the Government in writing.

8. This Guarantee shall be valid up to ................... unless extended on demand by Government. Notwithstanding anything mentioned above, our liability against this guarantee is restricted to Rs................. (Rupees……………………………………………………......................only) and unless a claim in writing is lodged with us within six months of date of expiry or the extended date of expiry of this guarantee all our liabilities under this guarantee shall stand discharged. Dated the ........................ day of ...................... for.…………………….……..……………............ (Indicate the name of the Bank)

CLAUSE 1-A: RECOVERY OF SECURITY DEPOSIT:The person/ persons whose tender(s) may be accepted (hereinafter

called the contractor) shall permit Government at the time of making any payment to him for work done under the contract to deduct a sum at the rate of 5% of the gross amount of each running bill till the sum along with the sum already deposited as earnest money, will amount to security deposit of 5% of the tendered value of the work. Such deductions will be made and held by Government by way of Security Deposit unless he has / they have deposited the amount of Security at the rate mentioned above in cash or in the form of Government Securities or Fixed Deposit Receipts. In case a fixed deposit receipt of any bank is furnished by the contractor to the Government as part of the security deposit and the bank is unable to make payment against the said fixed deposit receipt, the loss caused thereby shall fall on the contractor and the contractor shall forthwith on demand furnish additional security to the Government to make good the deficit.

All compensation or the other sums of money payable by the contractor under the terms of this contract may be deducted from, or paid by the sale of a sufficient part of his security deposit or from the interest arising there from, or from any sums which may be due to or may become due to the contractor by Government on any account whatsoever and in the event of his Security Deposit being reduced by reason of any such deductions or sale as aforesaid, the contractor shall within 10 days make good in cash or fixed deposit receipt tendered by the State Bank of India or by scheduled banks or Government Securities (if deposited for more than 12 months) endorsed in favour of the Pay & Accounts Officer, IGCAR, any sum or sums which may have been deducted from, or raised by sale of his security deposit or any part thereof. The security deposit

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shall be collected from the running bills of the contractor at the rates mentioned above and the Earnest Money if deposited in cash at the time of tenders will be treated a part of the Security Deposit.

The security deposit as deducted above can be released against bank guarantee issued by a scheduled bank, on its accumulations to a minimum of Rs.5 lakhs subject to the condition that amount of such bank guarantee, except last one, shall not be less than 5 lakhs.NOTE 1 : Government papers tendered as security will be taken at 5% (five per cent) below its market price or at its face value, whichever is less. The market price of Government papers would be ascertained by the Engineer-in-charge at the time of collection of interest and the amount of interest to the extent of deficiency in value of the Government paper will be withheld if necessary.NOTE 2 : Government Securities will include all forms of securities mentioned in Rule No. 274 of the G.F. Rules except fidelity bond. This will be subject to the observance of the condition mentioned under the rule against each form of security.NOTE 3 : Note 1 & 2 above shall be applicable for both Clauses 1 & 1A

CLAUSE 2 : COMPENSATION FOR DELAYIf the contractor fails to maintain the required progress in terms of Clause 5

or to complete the work and clear the site on or before the contract or extended date of completion, he shall, without prejudice to any other right or remedy available under the law to the Government on account of such breach pay as agreed compensation the amount calculated at the rates stipulated below as the authority specified in Schedule F (whose decision in writing shall be final and binding) may decide on the amount of tendered value of the work for every completed day/month (as applicable) that the progress remains below that specified in Clause 5 or that the work remains incomplete. This will also apply to items or group of items for which a separate period of completion has been specified.i) Compensation for delay of work - @1.5% per month of delay to be computed on per day basis.Provided always that the total amount of compensation for delay to be paid under this Condition shall not exceed 10% of the Tendered Value of work or of the Tendered Value of the item or group of items of work for which a separate period of completion is originally given.The amount of compensation may be adjusted or set-off against any sum payable to the Contractor under this or any other contract with the Government. In case, the contractor does not achieve a particular mentioned milestone in schedule F, or the re-scheduled milestone (s) in terms of Clause 5.4, the amount shown against that milestone shall be with held, to be adjusted against the compensation levied at the final grant of Extension of Time. Withholding of this amount on failure to achieve a milestone, shall be automatic without any notice to the contractor. However, if the contractor catches up with the progress of work on the subsequent milestone(s) the withheld amount shall be released. In case the contractor fails to make up for the delay in subsequent milestone(s) amount mentioned against each milestone missed subsequently also shall be withheld. However, no interest, whatsoever shall be payable on such withheld amount.

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CLAUSE 2A : INCENTIVE FOR EARLY COMPLETIONIn case the contractor completes the work ahead of scheduled completion

time, a bonus @ 1% (one percent) of the tendered value per month computed on per day basis, shall be payable to the contractor, subject to a maximum limit of 5% (five percent) of the tendered value. The amount of bonus, if payable, shall be paid along with final bill after completion of work. Provided always that provision of the Clause 2A shall be applicable only when so provided in “Schedule F”.

CLAUSE 3 : DETERMINATION OF CONTRACT: POWERS OF ENGINEERS-IN-CHARGE:

Subject to other provisions contained in this clause, the Engineer-in-Charge may, without prejudice to his any other right or remedy against the contractor in respect of any delay, inferior workmanship, otherwise or to any claim for damage and / or any other provisions of this contract or otherwise and whether the date for completion has or has not elapsed, by notice in writing absolutely determine the contract in any of the following cases:i) If the contractor having been given by the Engineer-in-Charge a notice in writing to rectify, reconstruct or replace any defective work or that the work is being performed in an inefficient or otherwise improper or un-workman like manner shall omit to comply with the requirements of such notice for a period of seven days thereafter.

ii) If the contractor has, without reasonable cause, suspended the progress of the work or has failed to proceed with the work with due diligence so that in the opinion of the Engineer-in-Charge (which shall be final and binding) he will be unable to secure completion and continues to do so after a notice in writing of seven days from the Engineer-in-charge.

iii) If the contractor fails to complete the work with in the stipulated date or items of work with individual date of completion, if any stipulated, on or before such date(s) of completion and does not complete them within the period specified in a notice given in writing in that behalf by the Engineer-in- Charge.iv) If the contractor persistently neglects to carry out his obligations under the contract and/ or commits default in complying with any of the terms and conditions of the contract and does not remedy it or take effective steps to remedy it with in 7 days after a notice in writing is given to him in that behalf by the Engineer-in- Charge.

v) If the contractor shall offer or give or agree to give to any person in Government service or to any other person on his behalf any gift or consideration of any kind as an inducement or reward for doing or forbearing to do or for having done or forborne to do any act in relation to the obtaining or execution of this or any other contract for Government;

vi) If the contractor shall enter into a contract with government in connection with which commission has been paid or agreed to be paid by him or to his knowledge,

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unless the particulars of any such commission and the terms of payment thereof have been previously disclosed in writing to the Engineer-in-charge;

vii) If the contractor shall obtain a contract with government as a result of wrong tendering or other non-bonafide methods of competitive tendering; orviii) If the contractor being individual, or if a firm, any partner thereof shall at any time be adjudged insolvent or have a receiving order or order for administration of his estate made against him or shall take any proceedings for liquidation or composition (other than a voluntary liquidation for the purpose of amalgamation or reconstruction) Under any insolvency Act for the time being inforce or make any conveyances or assignment of his effects or composition or arrangement for the benefit of his creditors or purport so to do or if any application be made under any Insolvency Act for the time being in force for the sequestration of his estate or if a trust deed be executed by him for benefit of his creditors.ix) If the contractor being a company shall pass a resolution or the court shall make an order that the company shall be wound up or if a receiver or a manager on behalf of a creditor shall be appointed or if circumstances shall arise which entitle the court or the creditor to appoint a receiver or a manager or which entitle the court to make a winding up order.

x) If the contract shall suffer an execution being levied on his goods and allow it to be continued for a period of 21 days.

xi) If the contractor assigns, transfers, sublets (Engagement of labour on a piece – work basis or of labour with materials not to be incorporated in the work, shall not be deemed to be subletting) or otherwise parts with or attempts to assign, transfer, sublet or otherwise parts with the entire works or any portion thereof without the prior written approval of the Engineer-in-charge.xii) If the work is not started by the contractor within 1/8th of the stipulated time.

When the contractor has made himself liable for action under any of the cases aforesaid, the Engineer-in-Charge on behalf of the President of India shall have powers:a) To determine or rescind the contract as aforesaid (of which termination or rescission notice in writing to the contractor under the hand of the Engineer-in-Charge shall be conclusive evidence). Upon such determination or rescission the earnest money deposit, security deposit already recovered and performance guarantee of the contractor shall be liable to be forfeited and shall be absolutely at the disposal of Government.b) After giving notice to the contractor to measure up the work of the contractor and to take such whole, or the balance or part thereof as shall be un-executed out of his hands and to give it to another contract to complete the work. The contractor, whose work is determined or rescinded as above, shall not be allowed to participate in the tendering process for the balance work.

In the event of above courses being adopted by the Engineer-in-Charge the contractor shall have no claim to compensation for any loss sustained by him by reasons of his having purchased or procured any materials or entered into any engagements or made any advances on account or with a view to the execution of the work or the performance of the contract. And in case action is taken under any of the provisions aforesaid, the contractor shall not be entitled to recover or

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be paid any sum for any work thereof or actually performed under this contract unless and until the Engineer-in-Charge has certified in writing the performance of such work and the value payable in respect thereof and he shall only be entitled to be paid the value so certified.

CLAUSE 3A : WORK CANNOT BE STARTED EITHER PARTY MAY CLOSE THE CONTRACT

In case the work cannot be started due to reasons not within the control of the contractor within 1/8th of the stipulated time for completion of work, either party may close the contract. In such eventuality, the Earnest Money Deposit and the Performance Guarantee of the contractor shall be refunded, but no payment on account of interest, loss of profit or damages etc. shall be payable at all.

CLAUSE 4 : CONTRACTOR LIABLE TO PAY COMPENSATION EVEN IF ACTION NOT TAKEN UNDER CLAUSE 3.

Contractor liable to pay compensation even if action not taken under Clause 3, Powers to take possession of or require removal of or sell contractor’s plant.

In any case in which any of the powers conferred upon the Engineer-in-Charge by clause 3 thereof, shall have become exercisable and the same shall not be exercised, the non-exercise thereof shall not constitute a waiver of any of the conditions hereof and such powers shall notwithstanding be exercisable in the event of any future case of default by the contractor and the liability of the contractor for compensation shall remain unaffected. In the event of the Engineer-in-Charge putting in force all or any of the powers vested in him under the preceding clause he may, if he so desires after giving a notice in writing to the contractor, take possession of or (at sole discretion of the Engineer-in-Charge which shall be final( and binding on the contractor) use as on hire (the amount of the hire money being also in the final determination of the Engineer-in-Charge) all or any tools, plant, materials and stores, in or upon the works, or the site thereof, belonging to the contractor, or procured by the contractor and intended to be used for the execution of the work or any part thereof, paying or allowing for the same in account at the contract rates, or, in the case of these not being applicable, at current market rates to be certified by the Engineer-in-Charge whose certificate thereof shall be final and binding on the contractor, otherwise the Engineer-in-Charge by notice in writing may order the contractor, or his clerk of the works, foreman or other authorised agent to remove such tools, plant, materials, or stores from the premises (within a time to be specified in such notice); and in the event of the contractor failing to comply with any such requisition, the Engineer-in-Charge may remove them at the contractor’s expense or sell them by auction or private sale on account of the contractor and at his risk in all respects and the certificate of the Engineer-in-Charge as to the expense of any such removal and the amount of the proceeds and expense of any such sale shall be final and conclusive against the contractor.

CLAUSE 4A: CLAIM FOR IDLE LABOUR - DELETED

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CLAUSE 5 : TIME AND EXTENSION FOR DELAYThe time allowed for execution of the Works as specified in the Schedule

“F” or the extended time in accordance with these conditions shall be the essence of the Contract. The execution of the works shall commence from such time period as mentioned in Schedule “F” or from the date of handing over of the site whichever is later. If the Contractor commits default in commencing the execution of the work as aforesaid, Government shall without prejudice to any other right or remedy available in law, be at liberty to forfeit the earnest money & performance guarantee absolutely.5.1 As soon as possible after the Contract is concluded the Contractor shall submit a Time and Progress Chart for each milestone and get it approved by the Department. The Chart shall be prepared in direct relation to the time stated in the Contract documents for completion of items of the works. It shall indicate the forecast of the dates of commencement and completion of various trades of sections of the work and may be amended as necessary by agreement between the Engineer-in-Charge and the Contractor within the limitations of time imposed in the Contract documents, and further to ensure good progress during the execution of the work, the contractor shall in all cases in which the time allowed for any work, exceeds one month (save for special jobs for which a separate programme has been agreed upon) complete the work as per mile stones given Schedule “F”.5.2 If the work(s) be delayed by:

I. force majeure orII. abnormally bad weather orIII. serious loss or damage by fire, orIV. civil commotion, local commotion of workmen, strike or lockout, affecting

any of the trades employed on the work, orV. delay on the part of other contractors or tradesmen engaged by Engineer-

in-Charge in executing work not forming part of the Contract, orVI. non-availability of stores, which are the responsibility of Government to

supply orVII. non-availability or break down of tools and plant to be supplied or supplied

by Government orVIII. any other cause which in the absolute discretion of the Engineer-in charge

is beyond the Contractor’s control.Then upon the happening of any such event causing delay, the Contractor

shall immediately give notice thereof in writing to the Engineer-in-Charge but shall nevertheless use constantly his best endeavors to prevent or make good the delay and shall do all that may be reasonably required to the satisfaction of the Engineer-in-Charge to proceed with the works.5.3 Request for rescheduling of mile stones and extension of time to be eligible for consideration, shall be made by the Contractor in writing within fourteen days of the happening of the event causing delay on the prescribed form. The Contractor may also, if practicable, indicate in such a request the period for which extension is desired. 5.4. In any such case the Engineer-in-charge may give a fair and reasonable extension of time and reschedule the mile stones for completion of work. Such extension shall be communicated to the Contractor by the Engineer in-Charge in

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writing, within 3 months of the date of receipt of such request. Non application by the contractor for extension of time shall not be a bar for giving a fair and reasonable extension by the Engineer-in-Charge and this shall be binding on the contractor.

CLAUSE 6 : MEASUREMENTS OF THE WORK DONEEngineer-in-Charge shall, except as otherwise provided, ascertain and

determine by measurement the value in accordance with the contract of work done.

All measurement of all items having financial value shall be entered in Measurement Book and/or level field book so that a complete record is obtained of all works performed under the contract.

All measurements and levels shall be taken jointly by the Engineer-in-Charge or his authorized representative and by the contractor or his authorised representative from time to time during the progress of the work and such measurements shall be signed and dated by the Engineer-in-Charge and the contractor or their representatives in token of their acceptance. If the contractor objects to any of the measurements recorded, a note shall be made to that effect with reason and signed by both the parties.

If for any reason the contractor or his authorized representative is not available and the work of recording measurements is suspended by the Engineer-in-Charge or his representative, the Engineer-in-Charge and the Department shall not entertain any claim from contractor for any loss or damages on this account. If the contractor or his authorized representative does not remain present at the time of such measurements after the contractor or his authorized representative has been given a notice in writing three (3) days in advance or fails to countersign or to record objection within a week from the date of the measurement, then such measurements recorded in his absence by the Engineer-in-Charge or his representative shall be deemed to be accepted by the Contractor.

The contractor shall, without extra charge, provide all assistance with every appliance, labour and other things necessary for measurements and recording levels.

Except where any general or details description of the work expressly shows to the contrary, measurements shall be taken in accordance with the procedure set forth in the specifications notwithstanding any provision in the relevant Standard Method of measurement or any general or local custom. In the case of items which are not covered by specifications, measurements shall be taken in accordance with the relevant standard method of measurement issued by the Bureau of Indian, Standards and if for any item no such standard is available then a mutually agreed method shall be followed.

The contractor shall give not less than seven days notice to the Engineer-in-Charge or his authorized representative in-charge of the work before covering up or otherwise placing beyond the reach of measurement any work in order that the same may be measured and correct dimensions thereof be taken before the same is covered up or placed beyond the reach of measurement and shall not cover up and place beyond reach of measurement any work without consent in writing of the Engineer-in-Charge or his authorized representative in-charge of the work who shall within the aforesaid period of seven days inspect the work, and if any work shall be covered up or placed beyond the reach of measurements without such notice having been given or the Engineer-in-Charge’s consent being

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obtained in writing the same shall be uncovered at the Contractor’s expense, or in default thereof no payment or allowance shall be made for such work or the materials with which the same was executed.

Engineer-in-Charge or his authorized representative may cause either themselves or through another officer of the department to check the measurements recorded jointly or otherwise as aforesaid and all provisions stipulate herein above shall be applicable to such checking of measurements or levels.

It is also a term of this contract that recording of measurements of any item of work in the measurement book and/or its payment in the interim, on account or final bill shall not be considered as conclusive evidence as to the sufficiency of any work or material to which it relates nor shall it relieve the contractor from liabilities from any over measurement or defects noticed till completion of the defects liability period.

CLAUSE 6A : COMPUTERIZED MEASUREMENT BOOK:Engineer-in-charge shall, except as otherwise provided, ascertain and determine by measurement the value of work done in accordance with the contract.All measurements of all items having financial value shall be entered by the contractor and compiled in the shape of the Computerized Measurement Book having pages of A-4 size as per the format of the department so that a complete record is obtained of all the items of works performed under the contract.All such measurements and levels recorded by the contractor or his authorized representative from time to time, during the progress of the work, shall be got checked by the contractor from the Engineer-in-charge or his authorized representative as per interval or program fixed in consultation with Engineer-in-charge or his authorized representative. After the necessary corrections made by the Engineer-in-charge, the measurement sheets shall be returned to the contractor for incorporating the corrections and for resubmission to the Engineer-in-charge for the dated signatures by the Engineer-in-charge and the contractor or their representatives in token of their acceptance.Whenever bill is due for payment, the contractor would initially submit draft computerized measurement sheets and these measurements would be got checked/test checked from the Engineer-in-charge and/or his authorized representative. The contractor will, thereafter, incorporate such changes as may be done during these checks/test checks in his draft computerized measurements, and submit to the department a computerized measurement book, duly bound, and with its pages machine numbered. The Engineer-in-charge and/or his authorized representative would thereafter check this MB, and record the necessary certificates for their checks/test checks.The final, fair, computerized measurement book given by the contractor, duly bound, with its pages machine numbered, should be 100% correct, and no cutting or over-writing in the measurements would thereafter be allowed. If at all any errors is noticed, the contractor shall have to submit a fresh computerized MB with its pages duly machine numbered and bound, after getting the earlier MB cancelled by the department. Thereafter, the MB shall be taken in the Divisional Office records, and allotted a number as per the Register of Computerized MBs. This should be done before the corresponding bill is submitted to the Divisional Office for payment. The contractor shall submit two spare copies of such

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computerized MBs for the purpose of reference and record by the various officers of the department.The contractor shall also submit to the department separately his computerized Abstract of Cost and the bill based on these measurements, duly bound, and its pages machine numbered along with two spare copies of the bill. Thereafter, this bill will be processed by the Division Office and allotted a number as per the computerized record in the same way as done for the measurement book meant for measurements.The contractor shall, without extra charges, provide all assistance with every appliance, labour and other things necessary for checking of measurements/levels by the Engineer-in-charge or his representative.Except where any general or detailed description of the work expressly shows to the contrary, measurements shall be taken in accordance with the procedure set forth in the specifications notwithstanding any provision in the relevant Standard Method of measurement or any general or local custom. In the case of items which are not covered by specifications, measurements shall be taken in accordance with the relevant standard method of measurement issued by the Bureau of Indian Standards and if for any item no such standard is available then a mutually agreed method shall be followed.The contractor shall give not less than seven days notice to the Engineer-in-charge or his authorized representative in charge of the work before covering up or otherwise placing beyond the reach of checking and/or test checking the measurement of any work in order that the same may be checked and/or test checked and correct dimensions thereof be taken before the same is covered up or placed beyond the reach of checking and/or test checking measurement and shall not cover up and place beyond reach of measurement any work without consent in writing of the Engineer-in-charge or his authorized representative in-charge of the work who shall within the aforesaid period of seven days inspect the work, and if any work shall be covered up or placed beyond the reach of checking and/or test checking measurements without such notice having been given or the Engineer-in-charge’s consent being obtained in writing the same shall be uncovered at the Contractor’s expense, or in default thereof no payment or allowance shall be made for such work or the materials with which the same was executed.Engineer-in-charge or his authorized representative may cause either themselves or through another officer of the department to check the measurements recorded by contractor and all provisions stipulated herein above shall be applicable to such checking of measurements or levels.It is also a term of this contract that checking and/or test checking the measurements of any item of work in the measurement book and/or its payment in the interim, on account of final bill shall not be considered as conclusive evidence as to the sufficiency of any work or materials to which it relates not shall it relieve the contractor from liabilities from any over measurement or defects noticed till completion of the defects liability period.

CLAUSE 7: PAYMENT ON INTERMEDIATE CERTIFICATE TO BE REGARDED AS ADVANCES.

No payment shall be made for work, estimated to cost Rs. Twenty thousand or less till after the whole of the work shall have been completed and certificate of

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completion given. For works estimated to cost over Rs. Twenty thousand the interim or running account bills shall be submitted by the contractor for the work executed on the basis of such recorded measurements on the format of the Department in triplicate on or before the date of every month fixed for the same by the Engineer-in-Charge. The contractor shall not be entitled to be paid any such interim payment if the gross work done together with net payment/adjustment of advances for material collected, if any, since the last such payment is less than the amount specified in Schedule “F”, in which case the interim bill shall be prepared on the appointed date of the month after the requisite progress is achieved. Engineer-in-Charge shall arrange to have the bill verified by taking or causing to be taken, where necessary the requisite measurements of the work. In the event of the failure of the contractor to submit the bills, Engineer-in-Charge shall prepare or cause to be prepared such bills in which event no claims whatsoever due to delays on payment including that of interest shall be payable to the contractor. Payment on account of amount admissible shall be made by the Engineer-in-Charge certifying the sum to which the contractor is considered entitled by way of interim payment at such rates as decided by the Engineer-n-Charge. The amount admissible shall be paid by 10th

working day after the day of signing of contractor on the measurements prepared by department together with the account of the material issued by the department or dismantled materials, if any. In the case of works outside the headquarters of the Engineer-in-Charge, the period of ten working days will be extended to fifteen working days.

All such interim payments shall be regarded as payment by way of advances against final payment only and shall not preclude the requiring of bad, unsound and imperfect or unskilled work to be rejected, removed, taken away and reconstructed or re-erected. Any certificate given by the Engineer-in-Charge relating to the work done or materials delivered forming part of such payment may be modified or corrected by any subsequent such certificate(s) or by the final certificate and shall not by itself be conclusive evidence that any work or materials to which it relates is/are in accordance with the contract and specifications. Any such interim payment, or any part thereof shall not in any respect conclude, determine or affect in any way powers of the Engineer-in-Charge under the contract or any of such payments be treated as final settlement and adjustment of accounts or in anyway vary or affect the contract.

Pending consideration of extension of date of completion, interim payments shall continue to be made as herein provided without prejudice to the right of the department to take action under the terms of this contract for delay in the completion of work, if the extension of date of completion is not granted by the competent authority.

The Engineer-in-Charge in his sole discretion on the basis of a certificate from the Asst. Engineer to the effect that the work has been completed up to the level in question make interim advance payments without detailed measurements for work done (other than foundations, items to be covered under finishing items) up to lintel level (including sunshade etc.) and slab level for each floor working out at 75% of the assessed value. The advance payments so allowed shall be adjusted in the subsequent interim bill by taking detailed measurements thereof.

CLAUSE 8: COMPLETION CERTIFICATE AND COMPLETION PLANSWithin ten days of the completion of the work, the contractor shall give

notice of such completion to the Engineer-in-Charge and within thirty days of the

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receipt of such notice the Engineer-in-Charge shall inspect the work and if there is no defect in the work, shall furnish the contractor with a final certificate of completion, otherwise a provisional certificate of physical completion indicating defects (a) to be rectified by the contractor and/or (b) for which payment will be made at reduced rates, shall be issued. But no final certificate of completion shall be issued, nor shall the work be considered to be complete until the contractor shall have removed from the premises on which the work shall be executed all scaffolding, surplus materials, rubbish and all huts and sanitary arrangements required for his/their work people on the site in connection with the execution of the works as shall have been erected or constructed by the contractor(s) and cleaned off the dirt from all wood work, doors windows, walls, floor or other parts of the building in upon or about which the work is to be executed or of which he may have had possession for the purpose of the execution thereof, and not until the work shall have been measured by the Engineer-in-Charge. If the contractor shall fail to comply with the requirements of this Clause as to removal of scaffolding, surplus materials and rubbish and all huts and sanitary arrangements as aforesaid and cleaning off dirt on or before the date fixed for the completion of work, the Engineer-in-Charge may at the expense of the contractor remove such scaffolding, surplus materials and rubbish etc., and dispose of the same as he thinks fit and clean off such dirt as aforesaid, and the contractor shall have no claim in respect of scaffolding or surplus materials as aforesaid except for any sum actually realized by the sale thereof.

CLAUSE 8A: CONTRACTOR TO KEEP SITE CLEANWhen the annual repairs and maintenance of works are carried out, the

splashes and droppings from white washing color washing, painting, etc., on walls, floor, windows, etc. shall be removed and the surface cleaned simultaneously with the completion of these items of work in the individual rooms, quarters or premises etc. where the work is done without waiting for the actual completion of all the other items of work in the contract. In case the contractor fails to comply with the requirements of this clause, the Engineer-in-Charge shall have the right to get this work done at the cost of the contractor either departmentally or through any other agency. Before taking such action, the Engineer-in-Charge shall give ten days notice in writing to the contractor.

CLAUSE 8B: COMPLETION PLANS TO BE SUBMITTED BY THE CONTRACTOR

The contractor shall submit completion plan as required vide General Specifications for Electrical works (Part-1 internal) 2005 and (Part-II external) 1994, as applicable within thirty days of the completion of the work.

In case, the contractor fails to submit the completion plan as aforesaid, he shall be liable to pay sum equivalent to 2.5% of the value of the work subject to a ceiling of ` 15,000 (Rs. Fifteen thousand only) as may be fixed by the Superintending Engineer concerned and in this respect the decision of the Superintending Engineer shall be final and binding on the contractor.

CLAUSE 9 : PAYMENT OF FINAL BILL

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The final bill shall be submitted by the contractor in the same manner as specified in interim bills within three months of physical completion of the work or within one month of the date of the final certificate of completion furnished by the Engineer-in-Charge whichever is earlier. No further claims shall be made by the contractor after submission of the final bill and these shall be deemed to have been waived and extinguished. Payments of those items of the bill in respect of which there is no dispute and of items in dispute, for quantities and rates as approved by Engineer-in-Charge, will, as far as possible be made within the period specified herein under, the period being reckoned from the date of receipt of the bill by the Engineer-in-Charge or his authorized Asstt. Engineer, complete with account of materials issued by the Department and dismantled materials..

i) If the Tendered value of work is up to `15 Lakhs - 3 monthsii) If the Tendered value of work exceeds `15 Lakhs - 6 months

CLAUSE 9A : PAYMENT OF CONTRACTOR’S BILLS TO BANKPayments due to the contractor may if so desired by him be made to his

bank instead of direct to him provided that the contractor furnishes to the Engineer-in-Charge (1) an authorization in the form of a legally valid document such as a power of attorney conferring authority on the bank to receive payments and (2) his own acceptance of the correctness of the account made out as being due to him by Government or his signature on the bills or other claim preferred against Government before settlement by the Engineer-in-Charge of the account or claim by payment to the bank. While the receipt given by such banks shall constitute a full and sufficient discharge for the payment, the contractor should wherever possible present his bills duly receipted and discharged through his bankers.

Nothing herein contained shall operate to create in favour of the bank any rights or equities vis-à-vis the President.

CLAUSE 10 : MATERIALS SUPPLIED BY GOVERNMENT Materials which Government will supply are shown in Schedule ‘A’ which

also stipulates quantum, place of issue and rate(s) to be charged in respect thereof. The contractor shall be bound to procure them from the Engineer-in-Charge.

As soon as the work is awarded, the contractor shall finalise the programme for the completion of work as per clause 5 of this contract and shall give his estimates of materials required on the basis of drawings/or schedule of quantities of the work. The contractor shall give in writing his requirement to the Engineer-in-Charge which shall be issued to him keeping in view the progress of work as assessed by the Engineer-in-Charge, in accordance with the agreed phased programme of work indicating monthly requirements of various materials. The contractor shall place his indent in writing for issue of such materials at least 7 days in advance of his requirement.

Such materials shall be supplied for the purpose of the contract only and the value of the materials so supplied at the rates specified in the aforesaid schedule shall be set off or deducted, as and when materials are consumed in items of work (including normal wastage) for which payment is being made to the contractor, from any sum then due or which may therefore become due to the

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contractor under the contract or otherwise or from the security deposit. At the time of submission of bills, the contractor shall certify that balance of materials supplied is available at site in original good condition.

The contractor shall submit along with every running bill (on account or interim bill) material-wise reconciliation statements supported by complete calculations reconciling total issue, total consumption and certified balance (diameter/section-wise in the case of steel) and resulting variations and reasons therefore. Engineer-in-Charge shall (whose decision shall be final and binding on the contractor) be within his rights to follow the procedure of recovery in clause 42 at any stage of the work if reconciliation is not found to be satisfactory.

The contractor shall bear the cost of getting the material issued, loading, transporting to site, unloading, storing under cover as required, cutting assembling and joining the several parts together as necessary. Not withstanding anything to the contrary contained in any other clause of the contract and (or the CPWA code) all stores/materials so supplied to the contractor or procured with the assistance of the Government shall remain absolute property of Government and the contractor shall be the trustee of the stores/materials, and the said stores/materials shall not be removed/disposed off from the site of the work on any account and shall be at all times open to inspection by the Engineer-in-Charge or his authorized agent. Any such stores/materials remaining unused shall be returned to the Engineer-in-Charge in as good a condition in which they were originally supplied at a place directed by him, at a place of issue or any other place specified by him as he shall require but in case it is decided not to take back the stores/materials the contractor shall have no claim for compensation on any account of such stores/materials so supplied to him as aforesaid and not used by him or for any wastage in or damage to in such stores/materials.

On being required to return the stores/materials, the contractor shall hand over the stores/materials on being paid or credited such price as the Engineer-in-Charge shall determine having due regard to the condition of the stores/materials. The price allowed for credit to the contractor, however, shall be at the prevailing market rate not exceeding the amount charged to him, excluding the storage charge, if any. The decision of the Engineer-in-Charge shall be final and conclusive. In the event of breach of the aforesaid condition, the contractor shall in addition to throwing himself open to account for contravention of the terms of the licenses or permit and/or for criminal breach of trust, be liable to Government for all advantages or profits resulting or which in the usual course would have resulted to him by reason of such breach. Provided that the contractor shall in no case be entitled to any compensation or damages on account of any delay in supply or non-supply thereof all or any such material and stores provided further that the contractor shall be bound to execute the entire work if the materials are supplied by the Government within the original schedule time for completion of work plus 50% thereof or schedule time plus 6 months whichever is more if the time of completion of work exceeds 12 months, but if a part of the materials only has been supplied within the aforesaid period, then the contractor shall be bound to do so much of the work as may be possible with the materials and stores supplied in the aforesaid period. For the completion of the rest of the work, the contractor shall be entitled to such extension of time as may be determined by the Engineer-in-Charge whose decision in this regard shall be final and binding on the contractor.

The contractor shall see that only the required quantities of materials are got issued. Any such material remaining unused and in perfectly good/original condition at the time of completion or determination of the contract shall be

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returned to the Engineer-in-Charge at the stores from which it was issued or at a place directed by him by a notice in writing. The contractor shall not be entitled for loading, transporting, unloading and stacking of such unused material except for the extra lead, if any involved, beyond the original place of issue.

CLAUSE 10A : MATERIALS TO BE PROVIDED BY THE CONTRACTORThe contractor shall, at his own expense, provide all materials, required for

the works other than those which are stipulated to be supplied by the Government.

The contractor shall, at his own expense and without delay, supply to the Engineer-in-Charge samples of, materials to be used on the work and shall get these approved in advance. All such materials to be provided by the Contractor shall be in conformity with the specifications laid down or referred to in the contract. The Contractor shall, if requested by the Engineer-in-Charge furnish proof, to the satisfaction of the Engineer-in-Charge that the materials so comply. The Engineer-in-Charge shall within thirty days of supply of samples or within such further period as he may require intimate to the Contractor in writing whether samples are approved by him or not. If samples are not approved, the Contractor shall forthwith arrange to supply to the Engineer-in-Charge for his approval fresh samples complying with the specifications laid down in the contract. When materials are required to be tested in accordance with specifications, approval of the Engineer-in-Charge shall be issued after the test results are received.

The contractor shall at his risk and cost submit the samples of materials to be tested or analyzed and shall not make use of or incorporate in the work any materials represented by the samples until the required tests or analysis have been made and materials finally accepted by the Engineer-in-Charge. The Contractor shall not be eligible for any claim or compensation either arising out of any delay in the work or due to any corrective measures required to be taken on account of and as a result of testing of materials.

The contractor shall, at his risk and cost, make all arrangements and shall provide all facilities as the Engineer-in-Charge may require for collecting and preparing the required number of samples for such tests at such time and to such place or places as may be directed by the Engineer-in-Charge and bear all charges and cost of testing unless specifically provided for otherwise elsewhere in the contract or specifications. Engineer-in-Charge or his authorized representative shall at all times have access to the works and to all workshops and places where work is being prepared or from where materials, manufactured articles or machinery are being obtained for the works and the contractor shall afford every facility and every assistance in obtaining the right to such access.

The Engineer-in-Charge shall have full powers to require the removal from the premises of all materials which in his opinion are not in accordance with the specifications and in case of default, the Engineer-in-Charge shall be at liberty to employ at the expense of the contractor, other persons to remove the same without being answerable or accountable for any loss or damage that may happen or arise to such materials. The Engineer-in-Charge shall also have full powers to require other proper materials to be substituted thereof and in case of default, the Engineer-in-Charge may cause the same to be supplied and all costs which may attend such removal and substitution shall be borne by the Contractor.

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CLAUSE 10B: CLAUSE 10B(i): SECURED ADVANCE ON NON-PERISHABLE MATERIALS

The contractor, on signing an Indenture in the form to be specified by the Engineer-in-charge, shall be entitled to be paid during the progress of the execution of the work upto 90% of the assessed value of any materials which are in the opinion of the Engineer-in-charge non-perishable, non-fragile and non-combustible and are in accordance with the contract and which have been brought on the site in connection therewith and are adequately stores and/or protected against damage by weather or other causes but which have not at the time of advance been incorporated in the works. When materials on account of which an advances has been made under this sub-clause are incorporated in the work, the amount of such advance shall be recovered/deducted from the next payment made under any of the clause or clauses of this contract.

Such secured advance shall also be payable on other items of perishable nature fragile and combustible with the approval of the Engineer-in-charge provided the contractor provides a comprehensive insurance cover for the full cost of such materials. The decision of the Engineer-in-charge shall be final and binding on the contractor in this matter. No secured advance, shall however, be paid on high-risk materials such as ordinary glass, sand, petrol, diesel, etc.

CLAUSE 10B(ii) : MOBILISATION ADVANCE Mobilization advance not exceeding 10% of the tendered value may be

given, if requested by the contractor in writing within one month of the order to commence the work. In such a case, the contractor shall execute a Bank guarantee bond from a scheduled nationalized bank as specified by the Engineer-in-charge for the full amount of such advance is released. Such advance shall be in two or more installments to be determined by the Engineer-in-charge at his absolute discretion. The first installment of such advance shall be released by the Engineer-in-charge to the contractor on a request made by the contractor to the Engineer-in-charge in this behalf. The second and subsequent installments shall be release by the Engineer-in-charge only after the contractor furnishes a proof of the satisfactory utilization of the earlier installment to the entire satisfaction of the Engineer-in-charge.Provided always that provision of clause 10B (ii) shall be applicable only when so provided in schedule “F”

CLAUSE 10B(iii) : PLANT MACHINERY & SHUTTERING MATERIAL ADVANCE

An advance for plant, machinery & shuttering material required for the work and brought to site by the contractor may be given if requested by the contractor in writing within one month of bringing such plant and machinery to site. Such advance shall be given on such plant and machinery, which in the opinion of the Engineer-in-charge will add to the expeditious execution of work and improve the quality of work. The amount of advance shall be restricted to 5% of the tender value. In the case of new plant and equipment to be purchased for the work, the advance shall be restricted to 90% of the price of such new plant

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and equipment paid by the contractor for which the contractor shall produce evidence satisfactory to the Engineer-in-charge. In the case of second hand and used plants and equipment, the amount of such advance shall be limited to 50% of the depreciated value of plant and equipment as may be decided by the Engineer-in-charge. The contractor shall, if so required by the Engineer-in-charge, submit the statement of value recognized by the Central Board of Direct Taxes under the Income-Tax Act, 1961. No such advance shall be paid on any plant and equipment of perishable nature and on any plant and equipment of a value less than Rs.50,000/- seventy five percent of such amount of advance shall be paid after he plant & equipment is brought to site and balance twenty five percent successfully commissioning the same.

Leasing of equipment shall be considered on par with purchase of equipment and shall be covered by the tripartite agreement with the following:

1. Leasing company which gives certificate of agreeing to lease equipment to the contractor.

2. Engineer-in-charge and3. The contractor

This advance shall further be subject to the condition that such plant and equipment (a) are considered by the Engineer-in-charge to be necessary for the work; (b) and are in and are maintained in working order (c) hypothecated to the Government as specified by the Engineer-in-charge before the payment of advance is released. The contractor shall not be permitted to remove from the site such hypothecated plant and equipment without the prior written permission of the Engineer-in-charge. The contractor shall be responsible for maintaining such plant and equipment in good working order during the entire period of hypothecation falling which such advance shall be entirely recovered in lump sum. For this purpose, steel scaffolding and form work shall be treated as plant and equipment.

The contractor shall insure the plant and machinery for which mobilization advance is sought and given, for a sum sufficient to provide for their replacement at site. Any amounts not recovered from insurer will be borne by the contractor.

CLAUSE 10B(iv) : INTEREST & RECOVERY The mobilization advance and plant and machinery advance in (ii) & (iii)

above bear simple interest at the rate of 10 percent per annum and shall be calculated from the date of payment to the date of recovery, both days inclusive, on the outstanding amount of advance. Recovery of such sums advanced shall be made by the deduction from the contractor’s bills commencing after first ten percent of the gross value of the work is executed and paid, on pro-rata percentage basis to the gross value of the work billed beyond 10% in such a way that the entire advance is recovered by the time eighty percent of the gross value of the contract is executed and paid, together with interest due on the entire outstanding amount upto the date of recovery of the installment.If the circumstances are considered reasonably by the Engineer-in-charge, the period mentioned in (ii) and (iii) for request by the contractor in writing for grant of mobilization advance and plant and equipment advance may be extended in the discretion of the Engineer-in charge. The said bank guarantee for advances shall initially be made for the full amount and valid for the contract period, and be kept renewed from time to time to cover the balance amount and likely period of complete recovery together with interest

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CLAUSE 10C : PAYMENT OF ACCOUNT OF INCREASE IN PRICES / WAGES DUE TO STATUTORY ORDER(S) DELETED

CLAUSE 10CA: PAYMENT DUE TO VARIATION IN PRICES OF MATERIALS AFTER RECEIPT OF TENDER

If, after submission of the tender, the price of material specified in Schedule “F” increases/decreases beyond the price(s) prevailing at the time of the last stipulated date for receipt of tenders (including extensions, if any) for the work, then the amount of the contract shall accordingly be varied and provided further that any such variations shall be effected for stipulated period of contract including the justified period extended under the provisions of clause 5 of the contract without any action under clause 2.

However for the work done/during the justified period extended as above, it will be limited to indices prevailing at the time of stipulated date of completion or as prevailing for the period under consideration, whichever is less.

The increase / decrease in prices shall be determined by the All India Wholesale Price Indices of materials as published by Economic Adviser to Government of India, Ministry of Commerce and Industry and base price for cement and/or steel reinforcement bars as issued under authority of Engineer-in charge as valid in the last stipulated date of receipt of tender, including extension, if any, and for the period under consideration incase, price index of a particular material is not issued by Ministry of Commerce & Industry, then the price index of nearest similar materials is indicated in Schedule “F” shall be followed.

The amount of the contract shall accordingly be varied for cement and/or steel reinforcement bars and will be worked out as per the formula given below for individual material:

a) Adjustment for component of individual material:

Where, V: Variation in material cost i.e. increase or decrease in the amount in rupees to be paid or recovered.P: Base price of material as issued under authority of Engineer-in charge, valid at the time of the last stipulated date of receipt of tender including extensions, if any.Q: Quantity of material used in the works since previous bill.Clo: All India whole sale price index for material as Published by the Economic Advisor to Government of India, Ministry of Industry and Commerce as valid on the last stipulated date of receipt of tenders including extensions, if any.

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Cl: All India whole sale price Index for material for period under consideration as published by Economic Advisor to Government of India, Ministry of Industry and Commerce.

(In respect of the justified period extended under the provisions of clause 5 of the contract without any action under clause 2, the index prevailing at the time of stipulated date of completion or the prevailing index of the period under consideration, whichever is less, shall be considered)

CLAUSE 10 (CC): PAYMENT DUE TO INCREASE / DECREASE IN PRICES / WAGES AFTER RECEIPT OF TENDER FOR WORKS

If the prices of materials (not being materials supplied or services rendered at fixed prices by the department in accordance with clause 10 & 34 thereof) and/or wages of labour required for execution of the work increase; the contractor shall be compensated for such increase as per provisions detailed below and the amount of the contract shall accordingly be varied, subject to the condition that such compensation for escalation in prices and wages shall be available only for the work done during the stipulated period of the contract including the justified period extended under the provisions of clause 5 of the contract without any action under clause 2. However, for the work done during the justified period extended as above, the compensation as detailed below will be limited to prices/wages prevailing at the time of stipulated date of completion or as prevailing for the period under consideration, whichever is less. No such compensation shall be payable for a work for which the stipulated period of completion is equal to or less than the time as specified In schedule “F”. Such compensation for escalation in the prices of materials and labour, when due, shall be worked out based on the following provisions:-

(i) The base date for working out such escalation shall be the last stipulated date of receipt of tenders including extension, if any.(ii). The cost of work on which the escalation will be payable shall be reckoned as below: a) Gross value of work done upto this quarter …………… (A)b) Gross value of work done upto the last quarter...................... (B)c) Gross value of work done since previous quarter (A-B) : ......... (C)d) Full assessed value of Secured Advance fresh paid in this quarter (D)e) Full assessed value of Secured Advance recovered in this quarter:(E)f) Full assessed value of Secured Advance for which escalation is

payable in this quarter (D-E)…………. (F)g) Advance payment made during this quarter...........................(G)h) Advance payment recovered during this quarter .............. (H)i) Advance payment for which escalation is payable in this quarter (G-H)................. (I)

(I)j) Extra items/deviated quantities of item paid as per Clause 12

based on prevailing market rates during this quarter...(J)

Then, M = C + F + I –JN = 0.85 x M

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k) Less cost of material supplied by the Department as per Clause 10 and recovered during the quarter. (K)

l) Less cost of services rendered at fixed charges and recovered as per clause 34 and recovered during the quarter. (L)

Cost of work for which escalation is applicable

W = N - (K + L)

(iii) Components of CEMENT, STEEL, materials, labour, P.O.L., etc. shall be pre-determined for every work and incorporated in the special conditions of contract attached (to the tender paper) here-in-after. The decision of the Engineer-in-Charge in working out such percentages shall be binding on the contractors.(iv) The compensation for escalation for CEMENT, STEEL, materials and P.O.L. shall be worked as per the formulae given below:

a) Adjustment for component of “Cement”

Vc: Variation in cement cost i.e. increase or decrease in the amount in rupees to be paid or recovered.W: Cost of work done, worked out as indicated in sub para (ii) of clause

10CC.Xc: Component of cement expressed as percent of the total value of work. CI: All India Wholesale price Index for cement for the period under consideration as published by the Economic Advisor to Government of India, Ministry of Industry & Commerce. (In respect of the justified period extended under the provisions of clause 5 of the contract without any action under clause2, the index prevailing at the time of stipulated date of completion or the prevailing index of the period under consideration, whichever is less, shall be considered).CI0: All India Whole Sale Price Index for Cement as published by the Economic Adviser to Government of India, Ministry of Industry and Commerce as valid on the last stipulated date of receipt of tenders including extension, if any.

b) Adjustment for component of “Steel”

VS: Variation in steel cost i.e. increase or decrease in the amount in rupees to be paid or recovered.W: Cost of work done, worked out as indicated in sub para (ii) of above.XS: Component of steel expressed in percent to the total value of work.

(as indicated under Para 21 of special conditions of contract).

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SI: All India Wholesale Price Index for steel (bars & rods) for the period under consideration as published by Economic Advisor to the Government of India, Ministry of Industry & Commerce. However, the Price Index shall be minimum of the following:-(i) Index for the month when the last consignment of steel reinforcement for

the stipulated contract period is over.(ii) Index for the month by which half of the stipulated contract period is over.(iii) Index for the period under consideration.

For the justified period extended under the provisions of clause 5 of the contract, without any action under clause 2, the same principle as for the period within stipulated period of completion, will apply.

a) For the month when the last consignment of steel reinforcement for the work is procured orb) For the month in which half of the stipulated contract period is over. Whichever of these two is earlier. SI0: All India Whole Sale Price Index for Steel (Bar & Rods) published by the Economic Adviser to Government of India, Ministry of Industry and Commerce New Delhi, as valid on the last stipulated date of receipt of tender including extension, if any.

c) Adjustment for component of “Material” (except cement & steel / electrical component of construction material)

VM: Variation in Materials cost i.e. increase or decrease in the amount in rupees to be paid or recovered.

W: Cost of work done, worked out as indicated in sub Para (ii) of above.XM: Component of Materials expressed as percent of the total value of work. MI: All India Wholesale Price Index for civil component/electrical component of construction material as worked out on the basis of All India Wholesale Price Index for individual Commodities/Group items for the period under consideration as published by Economic Advisor to Government of India, Ministry of Industry & Commerce and applying weightages to the individual Commodities/Group items.

(In respect of the justified period, extended under the provisions of clause 5 of the contract without any action under clause 2, the index prevailing at the time of stipulated date of completion or the prevailing index of the period under consideration, which ever is less, shall be considered).

MI0: All India Whole Sale Price Index for civil component / electrical component of construction materials as worked out on the basis of All India whole sale Price Index for Individual Commodities/ group items valid on the last stipulated date of receipt of tender including extension, if any, as published by the Economic Adviser to Government of India, Ministry of Industry and Commerce, and applying weightages to Individual Commodities / group Items

d) Adjustment for component of “POL”

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VF: Variation in cost of Fuel, Oil and Lubricant i.e. increase or decrease in the amount in rupees to be paid or recovered.

W: Value of work done, worked out as indicated in sub Para (ii) of clause 10CC.Z: Component of Fuel, Oil and Lubricant expressed as percent of the total

value of work. FI: All India Wholesale Price Index for Fuel, Oil & Lubricant for the period under

consideration as published by Economic Advisor to Government of India, Ministry of Industry & Commerce, New Delhi.(In respect of the justified period extended under the provisions of clause 5

of the contract without any action under clause 2, the index prevailing at the time of stipulated date of completion or the prevailing index of the period under consideration, whichever is less, shall be considered).

FI0: All India Whole Sale Price Index for Fuel, Oil and Lubricant as published by the Economic Adviser to Government of India, Ministry of Industry and Commerce, New Delhi. valid on the last stipulated date of receipt of tender including extension, if any. v) The following principles shall be followed while working out the indices mentioned in para (iv) above.(a) The compensation for escalation shall be worked out at quarterly intervals and shall be with respect to the cost of work done as per bills paid during the three calendar months of the said quarter. The first such payment shall be made at the end of three months after the month (excluding) in which the tender was accepted and thereafter at three months interval. At the time of completion of the work, the last period for payment might become less than 3 months, depending on actual date of completion.(b) The index (MI / FI etc.) relevant to any quarter / period for which such compensation is paid shall be the arithmetical average of the indices relevant to the three calendar months. If the period up to date of completion after the quarter covered by the last such installment of payment, is less than three months, the index MI & FI shall be the average of the indices for the months falling within that period.vi) The compensation for escalation for labour shall be worked out as per the formula given below:

VL: Variation in labour cost i.e. amount of increase or decrease in rupees to be paid or recovered.W: Value of work done, worked out as indicated in sub-Para (ii) above.Y: Component of labour expressed as a percent of the total value of the workLl0: Minimum daily wage in rupees of an unskilled adult male mazdoor, fixed under any law, statutory rule or order as on the last stipulated date of receipt of tender including extension, if any.

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Ll: Minimum wage in rupees of an unskilled adult male mazdoor, fixed under any law, statutory rule or order as applicable on the last date of the quarter previous to the one under consideration. (In respect of the justified period extended under the provisions of clause 5 of the contract, without any action under clause 2, the minimum wage prevailing on the last data of quarter previous to the quarter pertaining to stipulated date of Completion or the minimum wage prevailing on the last date of quarter previous to the one under consideration, whichever is less, shall be considered.)vii) The following principles will be followed while working out the compensation as per sub para (vi) above.a) The minimum wage of an unskilled Male Mazdoor mentioned in sub para (vi) above shall be the higher of the wage notified by Government of India, Ministry of Labour and that notified by the local administration, both relevant to the place of work and the period of reckoning.b) The escalation for labour also shall be paid at the same quarterly intervals when escalation due to increase in cost of materials and/or P.O.L. is paid under this clause. If such revision of minimum wages takes place during any such quarterly intervals, the escalation compensation shall be payable at revised rates only for work done in subsequent quarters.c) Irrespective of variation in minimum wages of any category of labour, for the purpose of this clause, the variation in the rate for an unskilled adult Male Mazdoor alone shall form the basis for working out the escalation compensation payable on the labour component.viii) In the event the price of materials and/or wages of labour required for execution of the work decrease(s), there shall be a downward adjustment of the cost of work so that such price of materials and/or wages of labour shall be deductable from the cost of work under this contract and in this regard the formula herein before stated under this clause 10 CC shall mutatis-mutandis apply, provided that:(a) No such adjustment for the decrease in the price of materials and/or wages of labour aforementioned would be made in case of contracts in which the stipulated period of completion of the work is equal to or less than the time as specified in Schedule “F”.(b) The Engineer-in-Charge shall otherwise be entitled to lay down the procedure by which the provision of this sub-clause shall be implemented from time to time and the decision of the Engineer-in-Charge in this behalf shall be final and binding on the contractor.ix) Provided always that the provision of the preceding 10 CA shall not be applicable for contracts where provisions of this clause are applicable, but in cases where provisions of this clause are not applicable, the provisions of Clause 10 CA will become applicable.

CLAUSE 10D : DISMANTLED MATERIALS GOVT. PROPERTY: The contractor shall treat all materials obtained during dismantling of a

structure, excavation of the site for a work etc. as Governments property and such materials shall be disposed off to the best advantage of Government according to the instructions in writing issued by the Engineer-in-Charge.

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CLAUSE 11 : WORK TO BE EXECUTED AS PER SPECIFICATIONS, DRAWINGS, ORDERS, ETC.

The contractor shall execute the whole and every part of the work in the most substantial and workman like manner and both as regards materials and otherwise in every respect in strict accordance with the specifications. The contractor shall also conform exactly fully and faithfully to the designs, drawings and instructions in writing in respect of the work signed by the Engineer-in-Charge and the contractor shall be furnished free of charge one copy of the contract documents together with specifications, design, drawings and instructions as or not included in the standard specifications of DAE, CPWD,BIS, Indian standards specified in Schedule “F” or in any Bureau of Indian Standard or any other, public standard or code or schedule of rates or any other printed publications referred to elsewhere in the contract.

The contractor shall comply with the provisions of the contract and with the care and diligence execute and maintain the works and provide all labour and materials, tools and plants including for measurements and supervision of all works, structural plans and other things of temporary or permanent nature for such execution and maintenance in so for as the necessary for providing these, is specified or is reasonably inferred from the contract. The contractor shall take full responsibility for adequacy, suitability and safety of all the works and methods of construction

CLAUSE 12 : DEVIATIONS / VARIATIONS : EXTENT AND PRICINGThe Engineer-in-Charge shall have power (i) to make alteration in, omissions from, additions to or substitution for the original specifications, drawings, designs and instructions that may appear to him to be necessarily advisable during the progress of the work and (ii) to omit a part of the works in case of non-availability of a portion of the site or for any other reasons and the contractor shall be bound to carry out the works in accordance with any instructions given to him in writing signed by the Engineer-in-Charge and such alterations, omissions, additions, substitutions shall form part of the contract as if originally provided therein and any altered, additional or substituted work which the contractor may be directed to do in the manner specified above as part of the works shall be carried out by the contractor on the same conditions in all respects including price on which he agreed to do the main work except as hereafter provided.12.1: The time for completion of the work shall, in the event of any deviations resulting in additional cost over the tendered value sum being ordered, be extended, if requested by the contractor as follows:(i) In the proportion which the additional cost of the altered, additional or substituted work, bears to the original tendered value, plus (ii) 25% of the time calculated in (i) above or such further additional time as may be considered reasonable by the Engineer-in-Charge.12.2: DEVIATION, EXTRA ITEMS AND PRICING

In the case of extra item(s), the contractor may within fifteen days of receipt of order or occurrence of the item(s) claim rates, supported by proper analysis, for the work and the engineer-in-charge shall within one month of the receipt of the claims supported by analysis, after giving consideration to the analysis of the rates submitted by the contractor, determine the rates on the basis

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of the market rates and the contractor shall be paid in accordance with the rates so determined.In the case of substituted items, the rate for the agreement items (to be substituted) and substituted item shall also be determined in The manner as mentioned in the aforesaid para:

a) DEVIATION, SUBSTITUTED ITEMS PRICING If the market rate for the substituted item so determined is more than the

market rate of the agreement item (to be substituted), the rate payable to the contractor for the substituted item shall be the rate for the agreement item (to be substituted) so increased to the extent of the difference between the market rate of substituted item and the agreement item (to be substituted).b) If the market rate for the substituted item so determined is less than the market rate of the agreement item (to be substituted), the rate payable to the contractor for the substituted item shall be the rate for the agreement item (to be substituted) so decreased to the extent of the difference between the market rate of substituted item and the agreement item (to be substituted).

DEVIATION, DEVIATED QUANTITIES, PRICING In the case of contract items, substituted items, contract cum substituted

items, which exceed the deviation limit mentioned below, the contractor may within fifteen days of receipt of order or occurrence of the excess, claims revision of the rates, supported by proper analysis, for the work in excess of the above mentioned limits, provided that if the rates so claimed are in excess of the rates specified in the schedule of quantities, the Engineer-in-Charge shall within one month of receipt of the claims supported by analysis, after giving consideration the analysis of the rates submitted by the contractor, determine the rates on the basis of the market rates and the contractor shall be paid in accordance with the rates so determined.12.3: The provisions of the preceding paragraph shall also apply to the decrease in the rates of items for the works in excess of the deviation limits as given below, and the Engineer-in-Charge shall after giving notice to the contractor within one month of occurrence of the excess and after taking into consideration any reply received from him within fifteen days of the receipt of the notice, revise the rates of the work in question within one month of the expiry of the said period of fifteen days having regard to the market rates.12.4: The contractor shall send to the Engineer-in-Charge once every three months an upto date account giving complete details of all claims for additional payments to which the contractor may consider himself entitled as an all additional work ordered by the Engineer-in-Charge, which he has executed during the preceding quarter failing which the contractor shall be deemed to have waived his right. However, the Engineer-in-Charge may at consideration of such claims on merits. 12.5: For the purpose of operation of Schedule “F”, the following works shall be treated as works relating to foundations:i) For buildings, compound walls, plinth level or 1.2 metres (4 feet) above ground level whichever is Lower than excluding items of flooring and D.P.C but including base concrete below the floors.

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ii) For abutments, piers, retaining walls of culverts and bridges, walls of water reservoirs: the bed of floor level.iii) For retaining walls where floor level is not determinate: 1.2 metres above the average ground level or bed level.iv) For roads: All items of excavations and filling including treatment of sub-base.12.6: Any operation incidental to or necessarily has to be in contemplation of tenderer while filling tenders, necessary for proper execution of the item included in the Schedule of Quantities or in the schedule of rates mentioned above, whether or not, specifically indicated in the description of the item and the relevant specifications, shall be deemed to be included in the rates quoted by the tenderer or the rate given in the schedule of rates, as the case may be, Nothing extra shall be admissible for such operations.

CLAUSE 13: FORECLOSURE OF CONTRACT DUE TO ABANDONMENT OR REDUCTION IN SCOPE OF WORK

If at any time after acceptance of the tender Government shall decide to abandon or reduce the scope of the work for any reason whatsoever and hence not require the whole or any part of the works to be carried out, the Engineer-in-charge shall give notice in writing to that effect to the contractor and the contractor shall act accordingly in the matter. The contractor shall have no claim to any payment of compensation or otherwise whatsoever, on account of any profit or advantage which he might have derived from the execution of the works in full but which he did not derive in consequence of the foreclosure of the whole or part of the works.

The contractor shall be paid at contract rates full amount for works executed at site and in addition, a reasonable amount as certified by the Engineer-in-charge for the items hereunder mentioned which could not be utilised on the work to the full extent in view of the foreclosure.i) Any expenditure incurred on preliminary site work, e.g. temporary access roads, temporary labour huts, staff quarters and site office, storage accommodation and water storage tanks.ii) Government shall have the option to take over contractor’s materials or any part thereof either brought to site or of which the contractor is legally bound to accept delivery from suppliers (for incorporation in or incidental to the work) provided however, Government shall be bound to take over the materials or such portions thereof as the contractor does not desire to retain. For materials taken over or to be taken over by Government cost of such materials as detailed by Engineer-in-charge shall be paid. The cost shall, however, take into account purchase price, cost of transportation and deterioration or damage which may have been caused to materials whilst in the custody of the contractor.iii) If any materials supplied by Government are rendered surplus, the same except normal wastage shall be returned by the contractor to Government at rates not exceeding those at which these were originally issued less allowance for any deterioration or damage which may have been caused whilst the materials were in the custody of the contractor. In addition, cost of transporting such materials from site to Government stores, if so required by Government, shall be paid.

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iv) Reasonable compensation for transfer of T & P from site to contractor’s permanent stores or to his other works, whichever is less. If T & P are not transported to either of the said places, no cost of transportation shall be payable.v) Reasonable compensation for repatriation of contractor’s site staff and imported labour to the extent necessary.

The contractor shall, if required by the Engineer-in-charge furnish to him books of account, wage books, time sheets and other relevant documents and evidence as may be necessary to enable him to certify the reasonable amount payable under this condition.The reasonable amount of items on (i), (iv) and (v) above shall not be in excess of 2% of the cost of the work remaining incomplete on the date of closure, i.e. total stipulated cost of the work as per accepted tender less the cost of work actually executed under the contract and less the cost of contractor’s materials at site taken over by the Government as per item (ii) above `Provided always that against any payments due to the contractor on this account or otherwise, the Engineer-in-charge shall be entitled to recover or be credited with any outstanding balances due from the contractor for advance paid in respect of any tool, plants and materials and any other sums which at the date of termination were recoverable by the Government from the contractor under the terms of the contract.

CLAUSE 14 : CANCELLATION OF CONTRACT IN FULL OR PART

Deleted ( Merged with clause 3)

CLAUSE 15: SUSPENSION OF WORKi) The contractor shall, on receipt of the order in writing of the Engineer-in-Charge,(whose decision shall be final and binding on the contractor) suspend the progress of the works or any part thereof for such time and in such manner as the Engineer-in-Charge may consider necessary so as not to cause any damage or injury to the work already done or endanger the safety thereof for any of the following reasons:(a) on account of any default on the part of the contractor or;(b) for proper execution of the works or part thereof for reasons other than the default of the contractor; or(c) for safety of the works or part thereof. The contractor shall, during such suspension, properly protect and secure the works to the extent necessary and carry out the instructions given in that behalf by the Engineer-in-Charge.ii)If the suspension is ordered for reasons (b) and (c) in sub-Para (i) above:(a) the contractor shall be entitled to an extension of time equal to the period of every such suspension PLUS 25%, for completion of the item or group of items of work for which a separate period of completion is specified in the contract and of which the suspended work forms a part, and;

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(b) If the total period of all such suspensions in respect of an item or group of items of work for which a separate period of completion is specified in the contract exceeds thirty days, the contractor shall, in addition, be entitled to such compensation as the Engineer-in-Charge may consider reasonable in respect of salaries and/or wages paid by the contractor to his employees and labour at site, remaining idle during the period of suspension, adding thereto 2% to cover indirect expenses of the contractor. Provided the contractor submits his claim supported by details to the Engineer-in-Charge within fifteen days of the expiry of the period of 30 days.iii) If the works or part thereof is suspended on the orders of the Engineer-in-Charge for more than three months at a time, except when suspension is ordered for reasons (a) in sub-para (i) above, the contractor may after receipt of such order serve a written notice on the Engineer-in-Charge requiring permission within fifteen days from receipt by the Engineer-in-Charge of the said notice, to proceed with the work or part thereof in regard to which progress have been suspended and if such permission is not granted within that time, the contractor, if he intends to treat the suspension, where it affects only a part of the works as an omission of such part by Government or where it affects whole of the works, an abandonment of the works by Government, shall within ten days of expiry of such period of 15 days give notice in writing of his intention to the Engineer-in-Charge. In the event of the contractor treating the suspension as an abandonment of the contract by Government, he shall have no claim to payment of any compensation on account of any profit or advantage which he might have derived from the execution of the work in full but which he could not derive in consequence of the abandonment. He shall, however, be entitled to such compensation, as the Engineer-in-Charge may consider reasonable, in respect of salaries and/or wages paid by him to his employees and labour at site, remaining idle in consequence adding to the total thereof 2% to cover indirect expenses of the contractor provided the contractor submits his claim supported by details to the Engineer-in-Charge within 30 days of the expiry of the period of 3 months.

Provided, further, that the contractor shall not be entitled to claim any compensation from Government for the loss suffered by him on account of delay by Government in the supply of materials in schedule ‘B’ where such delay is covered by difficulties relating to the supply of wagons, force majeure including non-allotment of such materials by controlling authorities, acts of God, acts of enemies of the state/country or any reasonable cause beyond the control of the Government.

CLAUSE 16 : ACTION IN CASE WORK NOT DONE AS PER SPECIFICATIONS :

All works under or in course of execution or executed in pursuance of the contract shall at all times be open and accessible to the inspection and supervision of the Engineer-in-Charge, his authorised subordinates in charge of the work and all the superior officers, officer of the Quality Assurance Unit of the Department or any organization engaged by the Department for Quality Assurance and of the Chief Technical Examiner’s Office, and the contractor shall, at all times, during the usual working hours and at all other times at which reasonable notice of the visit of such officers has been given to the contractor, either himself be present to receive orders and instructions or have a responsible agent duly accredited in writing, present for that purpose. Orders given to the

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Contractor’s agent shall be considered to have the same force as if they had been given to the contractor himself.

If it shall appear to the Engineer-in-Charge or his authorised subordinates incharge of the work or to the Chief Engineer in charge of Quality Assurance celll or his subordinate officers or the officers of the organization engaged by the Department of Quality Assurance or to the Chief Technical Examiner or his subordinate officers, that any work has been executed with unsound, imperfect, or unskillful workmanship, or with materials or articles provided by him for the execution of the work which are unsound or of a quality inferior to that contracted or otherwise not in accordance with the contract, the contractor shall, on demand in writing which shall be made within twelve months (Six months in the case of work costing Rs.10Lakh and below expect road work) of the completion of the work from the Engineer-in-Charge specifying the work, materials or articles complained of notwithstanding that the same may have been passed, certified and paid for forthwith rectify, or remove and reconstruct the work so specified in whole or in part, as the case may require or as the case may be, remove the materials or articles so specified and provide other proper and suitable materials or articles at his own charge and cost. In the event of the failing to do so within a period specified by the Engineer-in-Charge in his demand aforesaid, then the contractor shall be liable to pay compensation at the same rate as under clause 2 of the contract (for non-completion of the work in time) for this default.

In such case the Engineer-in-Charge may not accept the item of work at the rates applicable under the contract but may accept such items at reduced rates as the Schedule “F” may consider reasonable during the preparation of on account bills or final bill if the item is so acceptable without detriment to the safety and utility of the item and the structure or he may reject the work outright without any payment and/or get it and other connected and incidental items rectified, or removed and re-executed at the risk and cost of the contractor. Decision of the Engineer-in-Charge to be conveyed in writing in respect of the same will be final and binding on the contractor.

CLAUSE 17 : CONTRACTOR LIABLE FOR DAMAGES, DEFECTS DURING MAINTENANCE PEIROD

If the contractor or his working people or servants shall break, deface, injure or destroy any part of building in which they may be working, or any building, road, road kerb, fence, enclosure, water pipe, cables, drains, electric or telephone post or wires, trees, grass or grassland, or cultivated ground contiguous to the premises on which the work or any part of it is being executed, or if any damage shall happen to the work while in progress, from any cause whatever or if any defect, shrinkage or other faults appear in the work within 12 months (6 months in the case of work costing ` 10,00,000/- and below except road work) after a certificate final or otherwise of its completion shall have been given by the Engineer-in-Charge as aforesaid arising out of defect or improper materials or workmanship, the contractor shall upon receipt of a notice in writing on that behalf make the same good at his own expense, or in default, the Engineer-in-Charge cause the same to be made good by other workmen and deduct the expense from any sums that may be due, or at any time thereafter may become due to the contractor, or from his security deposit, or the proceeds of sale thereof or of a sufficient portion thereof. The security deposit of the contractor shall not be refunded before the expiry of 12 months (6 months in the case of work costing ` 10,00,000/- and below except road work) after the issue of the certificate final or

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otherwise, of completion of work, or till the final bill has been prepared and passed whichever is later. Provided that in the case of road work, if in the opinion of the Engineer-in-Charge, half of the security deposit is sufficient to meet all the liabilities of the contractor under this contract, half of the security deposit will be refundable after 6 months and the remaining half after 12 months of the issue of the said certificate of completion or till the final bill has been prepared and passed whichever is later. Performance Security shall be refunded to the contractor after completion of the work and recording the completion certificate.

In case of maintenance and operation of E&M services, the security deposit deducted from contractors shall be refunded within one month from the date of final payment or within one month from the date of completion of the maintenance contract, whichever is earlier

CLAUSE 18: CONTRACTOR TO SUPPLY TOOLS & PLANTS ETC.The contractor shall provide at his own cost all materials (except such special

materials, if any, as may in accordance with the contract be supplied from the Engineer-in-Charge’s stores), machinery, tools & plants as specified in schedule “F”. in addition of this other plant, tools, appliances, implements, ladders, cordage, tackle, scaffoldings and temporary works requisite or proper for the proper execution of the work, whether original, altered or substituted and whether included in the specification or other documents forming part of the contract or referred to in these conditions or not, or which may be necessary for the purpose of satisfying or complying with the requirements of the Engineer-in-Charge as to any matter as to which under these conditions he is entitled to be satisfied, or which he is entitled to require together with carriage therefore to and from the work. The contractor shall also supply without charge the requisite number of persons with the means and materials, necessary for the purpose of setting out works, and counting, weighing and assisting in the measurement or examination at any time and from time to time of the work or materials. Failing his so doing the same may be provided by the Engineer-in-Charge at the expense of the contractor and the expenses may be deducted, from any money due to the contractor, under the contract and/or from his security deposit or the proceeds of sale thereof, or of sufficient portions thereof.

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CLAUSE 18A: RECOVERY OF COMPENSATION PAID TO WORKMAN In every case in which by virtue of the provisions of section 12 sub-section

(1) of the Workmen’s Compensation Act. 1923, Government is obliged to pay compensation to a workman employed by the contractor, in execution of the works, Government will recover from the contractor the amount of the compensation so paid; and, without prejudice to the rights of the Government under Section 12, sub-section (2) of section 12 the said Act, Government shall be at liberty to recover such amount or any part thereof by deducting it from the security deposit or from any sum due by Government to the contractor whether under this contract or otherwise. Government shall not be bound to contest any claim made against it under section (1) of 12, sub-section the said Act, except on the written request of the contractor and upon his giving to Government full security for all costs for which Government might become liable in consequence of contesting such claim.

CLAUSE 18B: ENSURING PAYMENT AND AMENITIES TOWORKERS IF CONTRACTOR FAILS TO DO SO

In every case in which by virtue of the provisions of the Contract Labour (Regulation and Abolition) Act, 1970 and of the contract labour (Regulation and Abolition) Central Rules, 1971, Government is obliged to pay any amounts of wages to a workman employed by the contractor in execution of the works, or to incur any expenditure in providing welfare and health amenities required to be provided under the above said Act and the Rules, under Clause 19 H or under the DAE Contractor’s Labour Regulations, or under the rules framed by Government from time to time for the protection of health and sanitary arrangements for workers employed by Department of Atomic Energy contractors, Government will recover from the contractor the amount of wages so paid or the amount of expenditure so incurred; and without prejudice to the rights of the Government under Section 20, sub-section (2) and Section 21, sub-section (4) of the contract labour (Regulation and Abolition) Act, 1970, Government shall be at liberty to recover such amount or any part thereof by deducting it from the security deposit or from any sum due by Government to the contractor whether under this agreement or otherwise. Government shall not be bound to contest any claim made against it under Section 20, sub-section (1) and section 21, sub-section (4) of the said Act, except on the written request of the contractor and upon his giving to the Government full security for all costs for which Government might become liable in contesting such claim.

CLAUSE 19: LABOUR LAWS TO BE COMPLIED BY THE CONTRACTORThe contractor shall obtain a valid license under the Contract Labour (R &

A) Act, 1970 and the Contract Labour (Regulation and Abolition) Central Rules, 1971, before the commencement of the work, and continue to have a valid license until the completion of the work. The contractor shall also abide by the provision of the Child Labour (Prohibition & Regulation) Act-1986.

The contractor shall also comply with the provisions of the building and other Construction Workers (Regulation of Employment & Conditions of Service) Act, 1996 and the building and other Construction Workers Welfare Cess Act, 1996.

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Any failure to fulfill these requirements shall attract the penal provisions of this contract arising out of the resultant non-execution of the work.

CLAUSE 19A: NO LABOUR BELOW 14 YEARS No labour below the age of 14 (fourteen) years shall be employed on the work.

CLAUSE 19B : PAYMENT OF WAGESi) The contractor shall pay to labour employed by him either directly or through sub-contractors, wages not less than fair wages as defined in the DAE, Contractor’s Labour Regulations or as per the provisions of the Contract Labour (Regulation and Abolition) Act, 1970 and the Contract Labour (Regulation and Abolition) Central Rules, 1971, wherever applicable. ii) The contractor shall notwithstanding the provisions of any contract to the contrary, cause to be paid fair wage to labour indirectly engaged on the work, including any labour engaged by his sub-contractors in connection with the said work, as if the labour had been immediately employed by him.iii) In respect of all labour directly or indirectly employed in the works for performance of the contractor’s part of this agreement, the contractor shall comply with or cause to be complied with the DAE Contractor Labour Regulations made by Government from time to time in regard to payment of wages, wage period, deductions from wages, recovery of wages not paid and deductions unauthorized made, maintenance of wage books or wage slips, publication of scale of wages and other terms of employment, inspection and submission of periodical returns and all other matters of the like nature or as per the provisions of the Contract Labour (Regulation and Abolition) Act, 1970 and the Contract Labour (Regulation and Abolition) Central Rules 1971, wherever applicable.iv-a) The Engineer-in-Charge concerned shall have the right to deduct from the moneys due to the contractor any sum required or estimated to be required for making good the loss suffered by a worker or workers by reasons of non-fulfillment of the conditions of the contract for the benefit of the workers, non-payment of wages or of deduction made from his or their wages which are not justified by their terms of the contract or non-observance of the regulations.iv-b) Under the provisions of the minimum wages (Central) Rules, 1950, the contractor is bound to allow to the labours directly or indirectly employed in the works one day’s rest for six days continuous work and pay wages at the same rate as for duty. In the event of default, the Engineer-in-Charge shall have the right to deduct the sum or sums not paid on account of wages for weekly holiday to any labourer, and pay the same to the persons entitled thereto from any money due to the contractor by the Engineer-in-Charge.v) The contractor shall comply with the provisions of the payment of wages Act 1936, Minimum Wages Act, 1948, Employees Liability Act, 1938, Workmen’s Compensation Act, 1923, Industrial Disputes Act, 1947, Maternity Benefit Act, 1961 and the Contractor’s Labour (Regulation and Abolition) Act, 1970 or the modifications thereof or any other laws relating thereto and the rules made there under from time to time.

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vi) The contractor shall indemnify Government against payments to be made under and for the observance of the laws aforesaid and the D.A.E. Contractor’s Labour Regulations without prejudice to his right to claim indemnity from his sub-contractors.vii) The regulations aforesaid shall be deemed to be a part of this contract and any breach thereof shall be deemed to be a breach of this contract.viii) Whatever is the minimum wages for the time being, or the wage payable is higher than such wages, such wage shall be paid by the contractor to the workman directly without the intervention of Jamadar and that Jamadar shall not be entitle to deduct or recover any amount from the minimum wage payable to the workman as and by way commission or otherwise.ix) The contractor shall ensure that no amount by way of commission or otherwise is deducted or recovered by the Jamadar from the wage of workman.CLAUSE - 19B (1) : Additional Liabilities if any in complying with the provisions of clause 19( B) – ( i ) to ( viii ) shall be entirely to the contractor’s account.

CLAUSE-19C : SAFTY PROVISIONS FOR LABOUR & PENALTY ON DEFAULT In respect of all labour directly or indirectly employed in the work for the

performance of the contractors part of this agreement, the contractor shall at his own expense arrange for the safety provisions as per DAE safety code framed from time to time and shall at his own expense provide for all facilities in connection therewith. In case the contractor fails to make arrangements and provide necessary facilities as aforesaid, he shall be liable to pay a penalty of Rs. 200/- for each default and in addition the Engineer-in-Charge shall be at liberty to make arrangement and provide facilities as aforesaid and recover the costs incurred in that behalf from the contractor.

CLAUSE 19D : The contractor shall submit, by the 4th and 19th of every month, to the

Engineer-in-Charge a true statement showing, in respect of the second half of the preceding month and the first half of the current month respectively.1. The number of labourers employed by him on the work.2. Their working hours.3. The wages paid to them.4. The accidents that occurred during the said fortnight showing the circumstances under which they happened and the extent of damage and injury caused by them, and5. The number of female workers who have been allowed Maternity Benefit, according to clause 19 F and the amount paid to them.

Failing which the contractor shall be liable to pay to Government a sum not exceeding Rs. 200/- for each default or materially incorrect statement. The decision of the Engineer-in-Charge shall be final in deducting from any bill due to the contractor the amount levied as fine and be binding on the contractor.

CLAUSE 19E: HEALTH AND SANITARY ARRANGEMENTS FOR WORKERS

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In respect of all labour directly or indirectly employed in the works for the performance of the contractors part of this agreement, the contractor shall comply with or cause to be complied with all the rules framed by Government from time to time for the protection of health and sanitary arrangements for workers employed by the Department of Atomic Energy and its contractors.

CLAUSE 19F: Leave and pay during leave shall be regulated as follows:1) LEAVE i) In case of delivery : maternity leave not exceeding 8 weeks, 4 weeks upto and including the day of delivery and 4 weeks following that day.ii) In the case of miscarriage : upto 3 weeks from the date of miscarriage.2) PAY i) In the case of delivery : leave pay during maternity leave will be at the rate of the women’s average daily earnings, calculated on the total wages earned on the days when full time work was done during a period of 3 months immediately preceding the date on which she gives notice that she expects to be confined or at the rate of Rs.1/- only a day whichever is greater.ii) In case of miscarriage : leave pay at the rate of average daily earnings calculated on the total wages earned on the days when full time work was done during a period of 3 months immediately preceding the date of such miscarriage.3) CONDITIONS FOR THE GRANT OF MATERNITY LEAVE No maternity leave benefit shall be admissible to a woman unless she has been employed for a total period of not less than 6 (six) months immediately preceding the date on which she proceeds on leave.4) The contractor shall maintain a register of maternity (Benefit) in the prescribed from as shown below and the same shall be kept at the place of work.

REGISTER OF MATERNITY BENEFITS(Clause 19 F of the conditions of contract)

Name and address of the contractor(s) :___________________________Name and location of the work :__________________________________

Name of the

employee

Father’s / Husband’s

Name

Nature of employment

Period of actual

appointment

Date on which notice of

confinement given1 2 3 4 5

Date of delivery /

miscarriage

Date on which maternity leave commenced and endedIn case of Delivery In case of Mis-carriage

Commenced Ended Commenced Ended6 7 8 9 10

Leave pay paid to the employee

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SPECIMEN FORM OF THE REGISTER, REGARDING MATERNITY BENEFIT ADMISSIBLE TO THE CONTRACTOR’S LABOUR IN D.A.E. WORKS.Name of the work :______________________________________Name of the contractor :___________________________1. Name of the woman and her husband’s Name :2. Designation :3. Date of appointment :4. Date with months and years in which she is employed :5. Date of discharge/dismissal, if any :6. Date of production of certificates in respect of pregnancy :7. Date on which the woman informs about the expected delivery :8. Date of delivery/Miscarriage/death :9. Date of production of certificate in respect of delivery/miscarriage :10. Date with the amount of maternity/death benefit paid in advance of expected delivery:11. Date with the amount of subsequent payment of maternity benefit :12. Name of the person nominated by the woman to receive the payment of the

maternity benefit after her death :13. If the woman dies, the date of her death, the name of the person to whom maternity benefit amount was paid, the month thereof and

the date of payment :14. Signature of the contractor authenticating entries in the register :15. Remarks column for the use of Inspecting Officer :

CLAUSE 19G : In the event of the contractor(s) committing a default or breach of any of the

provisions of the D.A.E. Contractor’s Labour Regulations and Model Rules and provisions of Contract Labour (R&A) Act 1970,and Central Labour (R&A) Central Rules, 1971, for the protection of health and sanitary arrangements for the workers as amended from time to time or furnishing any information or submitting or filing any statement under the provisions of the above Regulations and Rules which is materially incorrect, he/they shall, without prejudice to any other liability, pay to the Government a sum not exceeding Rs. 200/- for every default, breach or furnishing, making, submitting, filling such materially incorrect statements and in the event of the contractor(s) defaulting continuously in this respect, the penalty may be enhanced to Rs. 200/- per day for each day of default subject to a maximum of 5% of the estimated cost of the work put to tender. The decision of the Engineer-in-Charge shall be final and binding on the parties.

Should it appear to the Engineer-in-Charge that the Contractor(s) is/are not properly observing and complying with the Model rules and the provisions of the Contract Labour (Regulation and Abolition) Act, 1970 and the contract Labour (R&A) Central Rules 1971 for the protection of health and sanitary arrangements for work people employed by the contractor(s) (hereinafter referred as “the said Rules”) the Engineer-in-Charge shall have power to give notice in writing to the contractor(s) requiring that the said Rules be complied with and the amenities prescribed therein be provided to the work-people with in a reasonable time to be specified in the notice. If the contractor(s) shall fail within the period specified in the notice to comply with and/or observe the said Rules and to provide the

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amenities to the work-people as aforesaid, the Engineer-in-Charge shall have the power to provide the amenities here-in-before mentioned at the cost of the contractor(s).

The contractor(s) shall erect, make and maintain at his/their own expense according and to approved standards all necessary huts and sanitary arrangements required for his/their work-people on the site in connection with the execution of the works, and if the same shall not have been erected or constructed, according to approved standards, the Engineer-in-Charge shall have power to give notice in writing to the contractor(s) requiring that the said huts and sanitary arrangements be remodeled and/or reconstructed according to approved standard, and if the contractor(s) shall fail to remodel or reconstruct such huts and sanitary arrangements according to approved standards within the period specified in the notice, the Engineer-in-Charge shall have the power to remodel or reconstruct such huts and sanitary arrangements according to approved standards at the cost of the contractor(s).

CLAUSE 19H: The contractor(s) shall at his/their own cost provide his/their labour with

a sufficient number of huts (hereinafter referred to as the “camp”) of the following specifications on a suitable plot of land to be approved by the Engineer-in-Charge.

1. a) The minimum height of each hut at the eaves level shall be 2.10 m. and the floor area to be provided will be at the rate of 2.7 Sq.m. for each member of the worker’s family staying with the labourer.

b) The contractor(s) shall in addition construct suitable cooking places having a minimum area of 1.80 m. x 1.50 m adjacent to the hut for each family.

c) The contractor(s) shall also construct temporary latrines and urinals for the use of the labourers each on the scale of not less than four per each one hundred of the total strength, separate latrines and urinals being provided for women.

d) The contractor(s) shall construct sufficient number of bathing and washing places, one unit for every 25 persons residing in the camp. These bathing and washing places shall be suitably screened.

2. a) All the huts shall have walls of sun-dried or burnt-bricks laid in mud mortar or other suitable local materials as may be approved by the Engineer-in-Charge. In case of sun dried bricks, the walls should be plastered with mud gobri on both sides. The floor may be katcha but plastered with mud gobri and shall be at least 15 cm. above the surrounding ground. The roofs shall be laid with thatch or any other materials as may be approved by the Engineer-in-Charge and the contractor shall ensure that throughout the period of their occupation the roofs remain water-tight.

b) The contractor(s) shall provide each hut with proper ventilation.c) All doors, windows and ventilators shall be provided with suitable leaves

for security purposes.d) There shall be kept an open space of at least 7.2 m between the rows of

huts which may be reduced to 6 m according to the availability of site with approval of the Engineer-in-Charge. Back to back construction will be allowed.

3. Water Supply : The contractor(s) shall provide adequate supply of water for the use of labourers. The provision shall not be less than 10 Ltrs. of pure and wholesome water per head per day for drinking purposes and 15 Ltrs. of clean

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water per head per day for bathing and washing purposes. Where piped water supply is available, supply shall be at stand posts and where the supply is from wells or rivers, tanks, which may be of metal or masonry, shall be provided. The contractor(s) shall also at his/their own cost make arrangements for laying pipe lines for water supply to his/their labour camp from the existing mains wherever available and shall pay all fees and charges therefore.

4. The site selected for the camp shall be high ground, removed from jungle.

5. Disposal of Excreta : The contractor(s) shall make necessary arrangements for the disposal of excreta from the latrines by trenching or incineration which shall be according to the requirements laid down by the Local Health Authorities. If trenching or incineration is not allowed, the contractor(s) shall make arrangements for the removal of the excreta through the Municipal Committee/authority and inform it about the number of labourers employed so that arrangements may be made by such committee/authority for the removal of the excreta. All charges on this account shall be borne by the contractor and paid direct by him to the Municipality/authority. The contractor shall provide one sweeper for every 8 seats in case of dry system.

6. Drainage : The contractor(s) shall provide efficient arrangements for draining away sullage water so as to keep the camp neat and tidy.

7. The contractor(s) shall make necessary arrangements for keeping the camp area sufficiently lighted to avoid accidents to the workers.

8. Sanitation : The contractor(s) shall make arrangements for conservancy and sanitation in the labour camps according to the rules of the Local Public Health and Medical Authorities.

CLAUSE 19I : The Engineer-in-Charge may require the contractor to dismiss or remove from

the site of the work any person or persons in the contractors employ upon the work who may be incompetent or misconduct himself and the contractor shall forthwith comply with such requirements.

CLAUSE 19J :

It shall be the responsibility of the contractors to see that the building under construction is not occupied by anybody unauthorised during construction and to hand over to the Engineer-in-Charge vacant possession of complete building. If such building though completed, is occupied illegally, then the Engineer-in-Charge will have the option to refuse to accept the said building/buildings in that position and delay in acceptance on this account will be treated as delay in completion and for such delay levy upto 5% of tendered value of work may be imposed by the Chief Engineer/ Engineer-in-charge whose decision shall be final both with regard to the justification and quantum and be binding on the contractor.

However the Chief Engineer may require the contractor through a notice to remove the illegal occupation any time on or before construction and delivery.

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CLAUSE 19K : EMPLOYMENT OF SKILLED/SEMI-SKILLED WORKERS. The contractor shall, at all stages of work, deploy skilled/semi-skilled

tradesmen who are qualified and possess certificate in particular trade from CPWD Training Institute/Industrial Training Institute/National Institute of construction Management and Research (NICMAR)/National Academy of Construction, CIDC or any similar reputed and recognized Institute managed/certified by State/Central Government. The number of such qualified tradesmen shall not be less than 20% of total skilled/semi-skilled workers required in each trade at any stage of work. The contractor shall submit number of man days required in respect of each trade, its scheduling and the list of qualified tradesmen along with requisite certificate from recognized Institute to Engineer in charge for approval. Notwithstanding such approval, if the tradesmen are found to have inadequate skill to execute the work of respective trade, the contractor shall substitute such tradesmen within two days of written notice from Engineer-in-charge. Failure on the part of contractor to obtain approval of Engineer-in-charge or failure to deploy qualified tradesmen will attract a compensation to be paid by contractor at the rate of Rs.100 per such tradesman per day. Decision of Engineer in Charge as to whether particular tradesman possesses requisite skill and amount of compensation in case of default shall be final and binding.

Provided always, that the provisions of this clause, shall not be applicable for works with estimated cost put to tender being less than Rs.5 Crores.

CLAUSE 20 : MINIMUM WAGES ACT TO BE COMPILED WITH :The contractor shall comply with all the provisions of the Minimum Wages

Act, 1948, Contract Labour (Regulation and Abolition) Act, 1970, and rules framed there under and other labour laws affecting contract labour that may be brought into force/amended from time to time.

CLAUSE 21 : WORK NOT TO BE SUB-LET / ACTION IN CASE OF INSOLVANCY

The contract shall not be assigned or sub-let without the written approval of the Engineer-in-Charge. And if the contractor shall assign or sub-let his contract, or attempt to do so, or become insolvent or commence any insolvency proceedings or make any composition with his creditors or attempt to do so, or if any bribe, gratuity, gift, loan, perquisite, reward or advantage pecuniary or otherwise, shall either directly or indirectly, be given, promised or offered by the contractor, or any of his servants or agent to any public officer or person in the employ of Government in any way relating to his office or employment, or if any such officer or person shall become in any way directly or indirectly interested in the contract, the Engineer-in-Charge on behalf of the President of India shall have power to adopt the courses specified in Clause 3 hereof in the interest of Government and in the event of such courses being adopted the consequences specified in the said Clause 3 shall ensue.

CLAUSE 22 : SUMS PAYABLE BY WAY OF COMPENSATIONAll sums payable by way of compensation under any of these conditions shall

be considered as reasonable compensation to be applied to the use of Government without reference to the actual loss or damage sustained, and whether or not any damage shall have been sustained.

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CLAUSE 23 : CHANGES IN FIRM'S CONSTITUTION TO BE INTIMATED Where the contractor is a partnership firm, the previous approval in writing of

the Engineer-in-Charge shall be obtained before any change is made in the constitution of the firm. Where the contractor is an individual or a Hindu undivided family business concern such approval as aforesaid shall likewise be obtained before the contractor enters into any partnership agreement where under the partnership firm would have the right to carry out the work hereby undertaken by the contractor. If previous approval as aforesaid is not obtained, the contract shall be deemed to have been assigned in contravention of Clause 21 hereof and the same action may be taken, and the same consequence shall ensue as provided in the said Clause 21.

CLAUSE 24: WORKS TO BE UNDER DIRECTION OF ENGINEER-IN-CHARGE

All works to be executed under the contract shall be executed under the direction and subject to the approval in all respects of the Engineer-in-Charge who shall be entitled to direct at what point or points and in what manner they are to be commenced, and from time to time carried on.

CLAUSE 25 : SETTLEMENT OF DISPUTES & ARBITRATIONExcept where otherwise provided in the contract, all questions and disputes

relating to the meaning of the specifications, design, drawings and instructions here-in before mentioned and as to the quality of workmanship or materials used on the work or as to any other question, claim, right, matter or thing whatsoever in any way arising out of or relating to the contract, designs, drawings, specifications, estimates, instructions, orders or these conditions or otherwise concerning the works or the execution or failure to execute the same whether arising during the progress of the work or after the cancellation, termination, completion or abandonment thereof shall be dealt with as mentioned hereinafter :ii) If the contractor considers any work demanded of him to be outside the requirements of the contract, or disputes any drawings, record or decision given in writing by the Engineer-in-Charge on any matter in connection with or arising out of the contract or carrying out of the work, to be unacceptable, he shall promptly within 15 days request the Superintending Engineer in writing for written instruction or decision. Thereupon, the Superintending Engineer shall give his written instructions or decision within a period of one month from the receipt of the contractor’s letter.

If the Superintending Engineer fails to give his instructions or decision in writing within the aforesaid period or if the contractor is dissatisfied with the instructions or decision of the Superintending Engineer, the contractor may, within 15 days of the receipt of Superintending Engineer’s decision, appeal to the Chief Engineer who shall afford an opportunity to the contractor to be heard, if the latter so desires, and to offer evidence in support of his appeal. The Chief Engineer shall give his decision within 30 days of receipt of contractor’s appeal. If the contractor is dissatisfied with this decision, the contractor shall within a period of

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30 days from receipt of the decision, give notice to the Chief Engineer for appointment of arbitrator failing which the said decision shall be final binding and conclusive and not referable to adjudication by the arbitrator.iii) Except where the decision has become final, binding and conclusive in terms of Sub Para (i) above disputes or difference shall be referred for adjudication through arbitration by a sole arbitrator appointed by the Director, IGCAR / Secretary, DAE. If the arbitrator so appointed is unable or unwilling to act or resigns his appointment or vacates his office due to any reason whatsoever another sole arbitrator shall be appointed in the manner aforesaid. Such person shall be entitled to proceed with the reference from the stage at which it was left by his predecessor.

It is a term of the contract that the party invoking arbitration shall give a list of disputes with amounts claimed in respect of each such dispute along with the notice for appointment of arbitrator and giving reference to the rejection by the Chief Engineer of the appeal.

It is also a term of this contract that no person other than a person appointed by such Director, IGCAR / Secretary, DAE, as aforesaid should act as arbitrator and if for any reason that is not possible, the matter shall not be referred to arbitration at all.

It is also a terms of the contract that if the contractor does not make any demand for appointment of arbitrator in respect of any claims in writing as aforesaid within 120 days of receiving the intimation from the Engineer-in-Charge that the final bill is ready for payment the claim of the contractor shall be deemed to have been waived and absolutely barred and the Government shall be discharged and released of all liabilities under the contract in respect of these claims.

The arbitration shall be conducted in accordance with the provisions of the Arbitration and Conciliation Act, 1996, (26 of 1996) or any statutory modifications or re-enactment thereof and the rules made there under and for the time being in force shall apply to the arbitration proceeding under this clause.

It is also term of this contract that the arbitrator shall adjudicate on only such disputes as are referred to him by the appointing authority and give separate award against each dispute and claim referred to him and in all cases where the total amount of the claims by any party exceeds Rs.1,00,000/- the arbitrator shall give reasons for the award.

It is also a term of the contract that if any fees are payable to the arbitrator, these shall be paid equally by both the parties.

It is also a term of the contract that the arbitrator shall be deemed to have entered on the reference on the date he issues notice to both the parties calling them to submit their statement of claims and counter statement of claims. The venue of the arbitration shall be such place as may be fixed by the arbitrator in his sole discretion. The fees, if any, of the arbitrator shall, if required to be paid before the award is made and published, be paid half and half by each of the parties. The cost of the reference and of the award (including the fees, if any, of the arbitrator) shall be in the discretion of the arbitrator who may direct to any by whom and in what manner, such costs or any part thereof shall be paid and fix or settle the amount of costs to be so paid.

CLAUSE 25A : NO ARBITRATION FOR DECISION ON SUB-STANDARD WORK

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CLAUSE 26 : CONTRACTOR TO INDEMNIFY GOVT. AGAINST PATENT RIGHTS

The contractor shall fully indemnify the President of India against any action, claim or proceeding relating to infringement or use of any patent or design or any alleged patent or design rights and shall pay any royalties which may be payable in respect of any article or part thereof included in the contract. In the event of any claims made under an action brought against Government in respect of any such matters as aforesaid the contractor shall be immediately notified thereof and the contractor shall be at liberty, at his own expense, to settle any dispute or to conduct any litigation that may arise there from. Provided that the contractor shall not be liable to indemnify the President of India in the infringement of the patent or design or any alleged patent or design right is the direct result of an order passed by the Engineer-in-Charge in this behalf.

CLAUSE 27: LUMPSUM PROVISION IN TENDER:When the estimate on which a tender is made include lump sums in respect

of parts of the work the contractor shall be entitled to payment in respect of the items of work involved or the part of the work in question at the same rates, as are payable under this contract for such item, or if the part of the work in question is not, in the opinion of the Engineer-in-charge payable of measurement, the Engineer-in-Charge may at his discretion pay the lump sum amount entered in the estimate, and the certificate in writing of the Engineer-in-Charge shall be final and conclusive against the contractor with regard to any sum or sums payable to him under the provisions of the clause.

CLAUSE 28: ACTION WHERE NO SPECIFICATIONS ARE SPECIFIEDIn the case of any clause of work for which there is no such specification as

referred to in Clause XI, such work shall be carried out in accordance with the Bureau of Indian Standard specification. In case there are no such specification in Bureau of Indian standards, the work shall be carried out as per manufacturer’s specifications, if not available then as per District specification. In case there are no such specification as required above, the work shall be carried out in all respects in accord with the instructions and requirements of the Engineer-in-charge.

CLAUSE 29 : WITH HOLDING AND LIEN IN RESPECT OF SUMS DUE FROM CONTRACTOR

1) Whenever any claim or claims for payment of a sum of money arises out of or under the contract against the contractor, the Engineer-in-Charge of the Government shall be entitled to withhold and also have a lien to retain such sum or sums in whole or in part from the security, if any deposited by the contractor and for the purpose aforesaid, the Engineer-in-Charge or the Government shall be entitled to withhold the security deposit, if any, furnished as the case may be and also have a lien over the same pending finalisation or adjudication of any such claim. In the event of the security being insufficient to cover the claimed amount

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or amounts or if no security has been taken from the contractor, the Engineer-in-Charge or the Government shall be entitled to withhold and have a lien to retain to the extent of such claimed amount or amounts referred to above, from any sum or sums found payable or which at any time thereafter may become payable to the contractor under the same contract or any other contract with the Engineer-in-Charge or the Government or any contracting person through the Engineer-in-Charge pending finalisation or adjudication of any such claim.

It is an agreed term of the contract that the sum of money or moneys so withheld or retained under the lien referred to above, by the Engineer-in-Charge or Government will be kept withheld or retained as such by the Engineer-in-Charge or Government till the claim arising out of or under the contract is determined by the Arbitrator, (if the contract is governed by the arbitration clause) by the competent court, as the case may be, and that the contractor will have no claim for interest or damages whatsoever on any account in respect of such withholding or retention under the lien referred to above and duly notified as such to the contractor. For the purpose of this clause, where the contractor is a partnership firm or a limited company, the Engineer-in-Charge or the Government shall be entitled to withhold and also have a lien to retain towards such claimed amount or amounts in whole or in part from any sum found payable to any partner/limited company as the case may be, whether in his individual capacity or otherwise.2) Government shall have the right to cause an audit and technical examination of the works and the final bills of the contractor including all supporting vouchers, abstract, etc. to be made after payment of the final bill and if as a result of such audit and technical examination, any sum found to have been over paid in respect of any work done by the contractor under the contract or any work claimed by him to have been done by him under the contract and found not to have been executed, the contractor shall be liable to refund the amount of over-payment and it shall be lawful for Government to recover the same from him in the manner prescribed in sub-clause (1) of this clause or in any other manner legally permissible, and if it is found that the contractor was paid less than what was due to him under the contract in respect of any work executed by him under it, the amount of such under-payment shall be duly paid by Government to the contractor.

Provided that Government shall not be entitled to recover any sum over-paid, nor the contractor shall be entitled to payment of any sum paid short where such payment has been agreed upon between the Superintending Engineer or Executive Engineer on the one hand and the contractor on the other under any terms of the contract permitting payment for work after assessment by the Executive Engineer.

CLAUSE 29A : LIEN IN RESPECT OF CLAIMS IN OTHER CONTRACTSAny sum of money due and payable to contractor (including the security

deposit returnable to him) under the contract may be withheld or retained by way of lien by the Engineer-in-Charge or the Government or any other contracting person or persons through Engineer-in-Charge against any claim of the Engineer-in-Charge or Government or such other person or persons in respect of payment of a sum of money arising out of or under any other contract made by the contractor with the Engineer in-charge or the Government or with such other person or persons.

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It is an agreed term of the contract that the sum of money so withheld or retained under this clause by the Engineer-in-Charge or the Government will be kept withheld or retained as such by the Engineer-in-Charge or the Government or till his claim arising out of in the same contract or any other contract is either mutually settled or determined by the arbitration clause or by the competent court, as the case may be, and that the contractor shall have no claim for interest or damage whatsoever on this account or on any other ground in respect of any sum of money withheld or retained under this clause and duly notified as such to the contractor.

CLAUSE 30 : EMPLOYMENT OF COAL MINING OR CONTROLLED AREA LABOUR NOT PERMISSIBLE

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CLAUSE 31 : SUPPLY OF UNFILTERED WATER The contractor(s) shall make his/their own arrangements to water required

for the work and nothing extra will be paid for the same. This will be subject to the following conditions:

i) That the water used by the contractor(s) shall be fit for construction purposes to the satisfaction of the Engineer-in-charge.

ii) The Engineer-in-charge shall make alternative arrangements for supply of water at the risk and cost of contractor(s) if the arrangements made by the contractor(s) for procurement of water are in the opinion of the Engineer-in-charge, unsatisfactory.

CLAUSE 31 A : DEPARTMENTAL WATER SUPPLY, IF AVAILABLEWater if available may be supplied to the contractor by the department

subject the following conditions:-i) The water charges shall be recovered as specified in special conditions. ii) The contractor(s) shall make his/their own arrangement of water

connection and laying of pipeline from existing main of source of supply.iii) The Department do not guarantee to maintain uninterrupted supply of

water and it will be incumbent on the contractor(s) to make alternative arrangements for water at his/their own cost in the event of any temporary breakdown in the Government water main so that the progress of his/their work is not held up for want of water. No claim of damage or refund of water charges will be entertained on account of such breakdown.

CLAUSE 32 : ALTERNATE WATER ARRANGEMENT i) Where there is no piped water supply arrangement and the water is taken

by the contractor from the wells or hand pump constructed by the Government, no charge shall be recovered from the contractor on that account. The contractor shall, however, draw water at such hours of the day that it does not interfere with the normal use of which the hand pumps and wells are intended. He will also be responsible for all damage and

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abnormal repairs arising out of his use, the cost of which shall be recoverable from him. The Engineer-in-charge shall be the final authority to determine the cost recoverable from the contractor on this account and his decision shall be binding on the contractor.

ii) The contractor shall be allowed to construct temporary wells in Government land for taking water for construction purposes only after he has got permission of the Engineer-in-charge in writing. No charges shall be required to provide necessary safety arrangements to avoid any accidents or damage to adjacent buildings, roads and service lines. He shall be responsible for any accidents or damage caused due to contribution and subsequent maintenance of the wells and shall restore the ground to its original condition after the wells are dismantled on completion of the work.

CLAUSE 33 : RETURN OF SURPLUS MATERIALS Not-withstanding anything contained to the contrary in any or all of the

clauses of this contract, where any materials for the execution of the contract are procured with the assistance of Government either by issue from Government stocks or purchase made under orders or permits or licenses issued by Government, the contractor shall hold the said materials economically and solely for the purpose of the contract and not dispose of them without the permission of the Government and return, if required by the Engineer-in-Charge, all surplus or unserviceable materials that may be left with him after the completion of the contract or at its termination for any reason whatsoever on being paid or credited such price as the Engineer-in-Charge shall determine having due regard to the condition of the materials. The price allowed to the contractor however, shall not exceed the amount charged to him excluding the element of storage charges if any. The decision of the Engineer-in-Charge shall be final and conclusive. In the event of breach of the aforesaid condition the contractor shall in addition to throwing himself open to action for contravention of the terms of the licenses or permit and/or for criminal breach of trust, be liable to Government for all moneys, advantages or profits resulting or which in the usual course would have resulted to him by reason of such breach.

CLAUSE 34 : HIRE OF PLANT AND MACHINERY DELETED

CLAUSE 35 : USE OF ASPHALTIC MATERIALS DELETED

CLAUSE 36 : EMPLOYMENT OF TECHNICAL STAFF AND EMPLOYEES

The contractor shall provide all necessary superintendence during execution of the work and as along thereafter as may be necessary for proper fulfilling of the obligations under the contract.

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The contractor shall immediately after receiving letter of acceptance of the tender and before commencement of the work, intimate in writing to the Engineer-in-Charge the name, qualifications, experience, age, address and other particulars along with certificates, of the principal technical representative to be in charge of the work and other technical representative(s) who will be supervising the work. Minimum requirement of such technical representative(s) and their qualifications and experience shall not be lower than as specified in Schedule “F”. The Engineer-in-Charge shall within 3 days of receipt of such communication intimate in writing his approval or otherwise of such a representative to the contractor. Any such approval may at any time be withdrawn and in case of such withdrawal, the contractor shall appoint another such representative according to the provisions of this Clause. Decision of the tender accepting authority shall be final and binding on the contractor in this respect. Such a principal technical representative and other technical representative(s) shall be appointed by the contractor soon after receipt of the approval from Engineer-in-Charge and shall be available at site before of start of work.

All the provisions applicable to the principal technical representative under the Clause will also be applicable to other technical representative(s). The principal technical representative and other technical representative(s) shall be present at the site of work for supervision at all times when any construction activity is in progress and also present himself/themselves, as required, to the Engineer-in-charge and/or his designated representative to take instructions. Instructions given to the principal technical representative or take instructions. representative(s) shall be deemed to have the same force as if these have been given to the contractor. The principal technical representative and other technical representative(s) shall be actually available at site fully during all stages of execution of work, during recording/checking/test checking of measurements of works and whenever so required by the Engineer-in-charge and shall also note down instructions conveyed by the Engineer-in-charge designated representative(s) in the site order book and shall affix his/their signature in token of noting down the instructions and in token of acceptance of measurements/checked measurements/test checked measurements. The representative(s) shall not look after any other work. Substitutes, duly approved by Engineer-in-charge of the work in similar manner as aforesaid shall be provided in event of absence of any of the representative(s) by more than two days.

If the Engineer-in-Charge, whose decision in this respect is final and binding on the contractor, is convinced that no such technical representative or agent is effectively appointed or is/are effectively attending of fulfilling the provision of this clause a recovery non refundable shall be effected from the contractor as specified in Schedule F and the decision of the Engineer-in-Charge as recorded in the site order book and measurement recorded in Measurement Books shall be final and binding on the contractor. Further if the contractor fails to appoint a suitable technical representative and if such appointed persons are not effectively present or are absent by more than two days without duly approved substitute or do not discharge their responsibilities satisfactorily, the Engineer-in-Charge shall have full powers to suspend the execution of the work until such date as a suitable other technical representative(s) is /are appointed and the contractor shall he held responsible for the delay so caused to the work. The contractor shall submit a certificate of employment of the technical representative along with every on account bill/final bill and shall produce evidence if at any time so required by the Engineer-in-Charge.

The contractor shall provide and employ on the site only such technical assistants as are skilled and experienced in their respective fields and such

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foremen and supervisory staff as are competent to give proper supervision to the work.

The contractor shall provide and employ skilled, semiskilled and unskilled labour as is necessary for proper and timely execution of the work.

The Engineer-in-Charge shall be at liberty to object to and require the contractor to remove from the works any person who in his opinion misconducts himself, or is incompetent or negligent in the performance of his duties or whose employment is otherwise considered by the Engineer-in-Charge to be undesirable. Such person shall not be employed again at works site without the written permission of the Engineer-in-Charge and the persons so removed shall be replaced as soon as possible by competent substitutes.

CLAUSE 37 : LEVY/TAXES PAYABLE BY CONTRACTORi) Sales Tax/VAT or any other tax on materials in respect of this contract shall

be payable by the contractor and Government shall not entertain any claim whatsoever in this respect.

ii) The contractor shall deposit royalty and obtain necessary permit for supply of the red bajri, stone, kankar etc. from local authorities.

iii) If pursuant to or under any law, notification or order any royalty, cess or the like becomes payable by the Government of India and does not any time become payable by the contractor to the State Government. Local authorities in respect of any material used by the contractor in the works then in such a case, it shall be lawful to the Government of India and it will have the right and be entitled to recover the amount paid in the circumstances as aforesaid from dues of the contractor.

CLAUSE 38: CONDITIONS FOR REIMBURSEMENT OF LEVY/TAXES IF LEVIED AFTER RECEIPT OF TENDERS

(i) All tendered rates shall be inclusive of all taxes and levies payable under respective statutes. However, pursuant to the Constitution (46th

Amendment) Act, 1982, if any further tax or levy is imposed by Statute, after the last stipulated date for the receipt of tender including extensions, if any and the contractor thereupon necessarily and properly pays such taxes/levies, the contractor shall be reimbursed the amount so paid, provided such payments, if any, is not, in the opinion of the Superintending Engineer (whose decision shall be final and binding on the contractor) attributable to delay in execution of work within the control of the contractor.(ii) The contractor shall keep necessary books of accounts and other documents for the purpose of the condition as may be necessary and shall allow inspection of the same by a duly authorized representative of the Government and/or the Engineer-in-Charge and further shall furnish such other information/document as the Engineer-in-Charge may require from time to time.(iii) The contractor shall within a period of 30 days of the imposition of any such further tax or levy pursuant to the Constitution (46 th Amendment) Act, 1982, give a written notice thereof to the Engineer-in-Charge that the same is given pursuant to this condition, together with all necessary information relating thereto.

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CLAUSE 39: TERMINATION OF CONTRACT ON DEATH OF CONTRACTORWithout prejudice to any of the rights or remedies under this contract, if

the contractor dies, the Engineer-in-Charge on behalf of the President of India shall have the option of terminating the contract without compensation to the contractor.

CLAUSE 40 : IF RELATIVE WORKING IN DAE, THEN CONTRACTOR NOT ALLOWED TO TENDER :

The contractor shall not be permitted to tender for works in the Indira Gandhi Centre for Atomic Research, (Responsible for award and execution of contracts) in which his near relative is posted as AO/AAO or as an officer in any capacity between the grades of Engineer-in Charge to Assistant Engineer.( Both inclusive) (SO/C and above.) He shall also intimate the names of persons who are working with him in any capacity or are subsequently employed by him and who are near relatives to any gazetted officer in the Department of Atomic Energy. Any breach of this condition by the contractor would render him liable to be debarred from tendering in this Department.NOTE : By the term ‘near relative’ is meant wife, husband, parents and grand parents, children and grand children, brothers and sisters, uncles, aunts and cousins and their corresponding in-laws.

CLAUSE 41 : NO GAZETTED ENGINEER TO WORK AS CONTRACTOR WITHIN ONE YEAR OF RETIREMENT.

No Engineer of gazetted rank or other gazetted officer employed in Engineering or administrative duties in an Engineering Department of the Government of India is allowed to work as a contractor for a period of One years of his retirement from Government Service without the previous permission of Government of India. This contract is liable to be cancelled if either the contractor or any of his employees is found at any time to be such a person who had not obtained the permission of Government of India as aforesaid, before submission of the tender or engagement in the contractors service as the case may be.

CLAUSE 42: RETURN OF MATERIALS AND RECOVERY FOR EXCESSISSUED

i) After completion of the work and also at any intermediate stage in the event of non reconciliation of materials issued, consumed and in balance – (see Clause 10), theoretical quantity of materials issued by the Government for use in the work shall be calculated on the basis and method given hereunder:a) Quantity of cement and bitumen shall be calculated on the basis of quantity of cement and bitumen required for different items of work as shown in the Schedule of Rates mentioned in Schedule ‘F’. In case any item is executed for which standard constants for the consumption of cement or bitumen are not available in the above mentioned schedule/statement or cannot be derived from the same shall be calculated on the basis of standard formula to be laid down by the Engineer-in-charge.

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b) Theoretical quantity of steel reinforcement or structural steel sections shall be taken as the quantity required as per design or as authorized by Engineer-in-charge, including authorized lappages, chairs etc. plus 3% wastage due to cutting into pieces, such theoretical quantity being determined and compared with the actual issues each diameterwise, sectionwise and categoriwise separately.c) Theoretical quantity of G.I. & C.I. or other pipes, conduits, wires and cables, pig lead and G.I./M.S. sheets shall be taken as quantity actually required and measured plus 5% for wastage due to cutting into pieces (except in the case of G.I./M.S. sheets it shall be 10%), such determination & comparison being made diameterwise & categoriwise.d) For any other material as per actual requirements.ii) Over the theoretical quantities of materials so computed a variation shall be allowed as specified in Schedule ‘F’. The difference in the net quantities of material actually issued to the contractor and the theoretical quantities including such authorized variation, if not returned by the contractor or if not fully reconciled to the satisfaction of the Engineer-in-charge within fifteen days of the issue of written notice by the Engineer-in-charge to this effect shall be recovered at the rates specified in Schedule ‘F’ without prejudice to the provision of the relevant conditions regarding return of materials governing the contract. Decision of Engineer-in-charge in regard to theoretical quantities of materials, which should have been actually used as per the Annexure of the standard schedule of rates and recovery at rates specified in Schedule ‘F’, shall be final & binding on the contractor.For no scheduled items, the decision of the Superintending Engineer regarding theoretical quantities of materials which should have been actually used, shall be final and binding on the contractor.iii) The said action under this clause is without prejudice to the right of the Government to take action against the contractor under any other conditions of contract for not doing the work according to the prescribed specifications.

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CLAUSE 43 : COMPENSATION FOR DAMAGE TO WORKS DURING WAR LIKE SITUATIONS :

The work (whether fully constructed or not) and all materials, machines, tools and plants, scaffolding, temporary buildings and other things connected therewith shall be at the risk of the contractor until the work has been delivered to the Engineer-in-Charge and a certificate from him to that effect obtained. In the event of the work or any materials properly brought to the site for incorporation in the work being damaged or destroyed in consequence of hostilities or war like operations, the contractor shall, when ordered in writing by the Engineer-in-Charge, remove any debris from the site, collect and properly stack (or remove) in store all serviceable materials salvaged from the damaged work and shall be paid at the contract rates in accordance with the provision of this agreement for the work of clearing the site of debris, stacking or removal of serviceable materials and for the reconstruction of all works ordered by the Engineer-in-Charge, such payments being in addition to compensation up to the value of the work, originally executed before being damaged or destroyed and not paid for. In case of works damaged or destroyed but not already measured and paid for, the compensation shall be assessed by the Engineer-in-Charge up to Rs. 5,000/- and by the Chief Engineer for a higher amount. The contractor shall be paid for the damage/destruction suffered and for the restoring the materials at the rate based on the analysis of rates tendered for in accordance with the provisions of this agreement. The certificate of the Engineer-in-Charge regarding the quality and quantity of materials and the purpose for which they were collected shall be final and binding on all parties to this contract.

Provided always that no compensation shall be payable for any loss in consequence of hostilities or war-like operations (a) unless the contractor had taken all such precautions against Air Raid as are deemed necessary by the A.R.P. Officers or the Engineer-in-Charge, (b) for any materials etc. not on the site of the work or for any tools and plant, machinery, scaffolding, temporary buildings and other things not intended for the work.

In the event of the contractor having to carry out reconstruction as aforesaid, he shall be allowed such extension of time for its completion as is considered reasonable by the Engineer-in-Charge.

CLAUSE 44 : APPRENTICES ACT - PROVISIONS TO BE COMPLIED WITH The contractor shall comply with the provisions of the Apprentices Act,

1961 and the rules and orders issued there under from time to time. If he fails to do so, his failure will be a breach of the contract and the Chief Engineer may, in his discretion, cancel the contract. The contractor shall also be liable for any pecuniary liability arising on account of any violation by him of the provisions of the said Act.

CLAUSE 45 : REFUND OF SECURITY DEPOSIT AFTER LABOUR CLEARANCE

– DELETED -

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SCHEDULE ‘F’Reference to General Conditions of Contract.Name of work : Construction of RR compound wall and

formation of peripheral road from Substation PDC-5 to CMPL in IGCAR, Kalpakkam.

Estimated cost of work : ` 195.67 Lakhsi) Earnest Money : ` 3,91,340/-ii) Performance Guarantee : 5% of the tendered value of the work.iii) Security Deposit : 5% of the tendered value of the work.

GENERAL RULES & DIRECTIONS

: Officer inviting tender Associate Director, CEG / IGCARMaximum percentage of quantity of all items of work to be executed beyond which rate are to be determined in accordance with Clauses 12.2 & 12.3 See below

Definitions : 2(v) Engineer-in-charge : As intimated in the work order.

2(viii) Accepting authority Chief Engineer, CEG/ Associate Director, CEG

2(x) Percentage on cost of materials and labour to cover al overheads and profits :

15% (For arriving rate for extra item)

2(xi) Standard schedule of rates : CEG, IGCAR Schedule of Rates (SOR)

2(xii) Department : DAE, Government of India9(ii) Standard CPWD contract form : CPWD form 7/8 as modified and

corrected upto 2005

Clause - 1i) Time allowed for submission of

Performance Guarantee from the date of issue of letter of Intent, in days :

15 (Fifteen) days

ii) Maximum allowable extension beyond the period provided in (i) above in days :

7 days

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Clause - 2Authority for fixing compensation under clause 2 : Chief Engineer / Associate

Director, CEG

Clause – 2AWhether clause 2A shall be applicable : No.

Clause - 5Number of days from the date of issue of work order for reckoning date of start :

15 (Fifteen) days

Mile stone(s) as per table given below:Table of Mile Stones(s)

Sl.No. Description of Milestone (Physical)

Time allowed in days (from date

of start)

Amount to be with-held in case of non

achievement of milestone

1.2.

(OR)

Sl.No. Financial progressTime allowed in

days (from date of start)

Amount to be with-held in case of non achievement

of milestone1. 1/8th (of whole work) 1/4th (of whole

work) In the event of not achieving the necessary progress as assessed from the running payments, 1.5% of the tendered value of work will be withheld for failure of each milestone.

2. 3/8th (of whole work) ½ (of whole work)

3. 3/4th (of whole work) 3/4th (of whole work)

4. Full Full

Time allowed for execution of work: 12 Month(s) including monsoon period

Clause – 6 or 6AClause applicable –(6 or 6A) Clause 6A is applicable

Clause – 7

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Gross work to be done together with net payment/adjustment of advances for material collected, if any, since the last such payment for being eligible to interim payment

-

Clause – 10B(ii)Whether Clause 10B(ii) shall be applicable (yes or No) : No

Clause – 10CAMaterials Covered under this clause Nearest Material for which All

India Wholesale Price index is to be followed

1.Base price of the Cement (P) – Nil 1.Cement

2.Base price of the Steel Reinforcement (P) – Nil

2.Steel (bars and rod)

3.Structural steel (P) – Nil 3.Steel sheets ,Plates & strips4.Bitumen (P) - Nil 4.Bitumen

Clause – 10CCClause 10CC to be applicable in contracts with stipulated period of completion exceeding the period shown in next column. (for breakup of components of escalation, refer clause 43, of section-III, special condition).ComponentsCement – 4.4%Steel – NilMaterials – 75.6%Labour – 15 %POL – 5%

6 (Six) Months

Clause – 11Specifications to be followed for execution of work

DAE & CPWD, BIS, Indian Standard ‘Special publication’.

Clause – 1212.2 & 12.3 Deviation limit beyond which clauses 12.2 &

12.3 shall apply for building work30%

12.5 Deviation limit beyond which clause 12.2 & 12.3 100%

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shall apply for foundation work

Clause – 16Competent Authority for deciding reduced rates :

Chief Engineer/Associate Director, CEG

Clause – 17Whether Clause 17 shall be applicable (Yes or No):

Yes

Clause – 36(i)

Requirement of Technical Representative(s) and recovery Rate

Cost of work(` In Lakh)

Requirement of Technical Staff Minimum Experience

(years)Qualification Number

More than 1000

i) Project Manager with degree in corresponding discipline of Engineering ii) Graduate Engineeriii) Graduate Engineer

(or)Diploma Engineer

1

12

2

10

5Nil

5

500 to 1000

(i) Graduate Engineer

(ii) Graduate Engineer Or

Diploma Engineer

1

2

2

5

Nil

5

200 to 500

(i) Graduate Engineer

(ii) Graduate Engineer Or

Diploma Engineer

1

1

1

5

Nil

550 to 200 Graduate Engineer 1 5

10 to 50Graduate Engineer

OrDiploma Engineer

1

1

Nil

5

Sl.No. Qualification Experience ( years) Rate of recovery

i Project Manager with Degree 10 `20,000/- p.m

ii Graduate Engineer 5 `15,000/- p.miii Graduate Engineer or

Diploma Engineer Nil5 `10,000/- p.m

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Clause – 42

i) (a) Schedule / statement for determining theoretical quantity of cement & bitumen on the basis of Delhi Schedule of Rates (Latest Revision) printed by CPWD

ii) Variations permissible on theoretical quantities.

(a) Cement for works with estimated cost put to tender not more than ` 2 lakhs

5% plus / minus

for works with estimated cost put to tender more than ` 2 lakhs but upto ` 5 lakhs

4% plus / minus

for works with estimated cost put to tender more than ` 5 lakhs

3% plus / minus

(b)Bitumen all works 2.5% plus only &

Nil on minus side

(c) Steel reinforcement and structural steel sections for each diameter, section and category

5% plus / 4% minus

(d) All other materials Nil

iii) Recovery rate of Steel Reinforcement – ` 48,000 / M.T.--------

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SECTION – IVA : POWER AND ELECTRICAL SAFETY

1. The Department will provide 415V, 3 phase, 4 wire supply at one location as indicated in the drawing. The energy consumption will be metered and charged as specified.

2. The Contractor will make arrangements for receiving the power supply. He will have a distribution switchboard with one number incomer switch with HRC fuses and sufficient number of outgoing feeders, properly with HRC fuse protection. Sub-distribution boards may be provided and wired from the distribution board by the Contractor. Cabling from the meter and supply point to the distribution board will be done by the Contractor. The distribution board and other locations shall be provided with danger boards with skull mark.

3. Single phase loads will be connected such that the loads and the 3 phases are balanced.

4. All distribution boards and sub-distribution boards will be properly grounded with 2 ground connections and each board will have one independent pipe earth electrodes.

5. All electrical equipment like switches, motors and power outlets shall be properly grounded and shall be well protected from weather (rain and dust).

6. Equipment with electric prime movers will be installed in permanent manner as far as possible with fixed cabling. Insulated wires in metallic conduits can substitute for armoured cables, if required.

7. Portable lights and equipment (limited to unavoidable tools like vibrators, drills and polishing machine) will be connected using metal clad sockets and plugs to avoid mechanical damage.

8. Insertion of wires in sockets will not be permitted.9. All portable appliances shall be properly grounded.10. All portable electrical tools will be tested and certified by authorized

staff. Contractor’s Electrical Supervisor may be authorized for the work by the Department at its discretion.

11. Cabling and wiring will be run underground with proper mechanical protection of overhead beyond normal human reach so as to avoid hindrance to movement of men and materials. Cable route indicators shall be provided as directed by Engineer-in-Charge wherever cables are run underground.

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12. For temporary connections 3 Core insulated and sheathed cables will be used for single phase and 4 core insulated and sheathed cables will be used for 3 phase wiring, Armoured cables will be preferred.

13. Unarmoured cables will not be tied to metal supports using metal wires.

14. All wires used shall be healthy and joints shall be minimum. The joints shall be properly insulated and shall be approved by Departmental Engineer. Joints shall be properly supported and positioned above normal human reach. Joints shall not be permitted in wet areas. Loose wiring will not be allowed over floor. Extra length of wires and cables shall be properly coiled and kept in safe position.

15. Electrical work including temporary connections and extensions will be carried out by licensed electricians only. All electrical installations will be energized only after approval by the Department.

16. List of electrical staff to be posted at site will be furnished by the Contractor before the commencement of Contract.

17. Adequate area lights will be provided by the Contractor to ensure safe working.

18. Departmental electrical staff will be available at site for rectification of faults upto metered point during normal working hours on normal working days. Contactor’s qualified staff will maintain the Contactor’s electrical installations.

19. The Contractor will allow free access to departmental safety engineers for inspection of electrical connections and distribution systems and abide by their decisions in the interest of safety of personnel. The contractor also will avail the industrial safety and related training being provided by the department free of cost and ensure that most of the field staff are trained adequately.

20. DEPARTMENT WILL PROVIDE ELCB PROTECTION AT THE METERING POINT FOR ESTIMATED LOAD UPTO 25 HP. WHEREVER THE CONNECTED LOAD EXCEEDS 25 HP. THE CONTRACTOR WILL PROVIDE ELCB FOR ALL 3 PHASE AND SINGLE PHASE LOADS AT HIS MAIN DISTRIBUTION BOARD. THE ELCBS WILL HAVE A SENSITIVITY OF 100 MILLI AMPS.

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SECTION – V : TECHNICAL SPECIFICATIONS

General:

The detailed specifications given hereinafter are for the items of works described in the schedule of quantities attached herein, and shall be guidance for proper execution of work to the required standards. It may also be noted that the specifications are of generalized nature and these shall be read in conjunction with the description of item in schedule of quantities and drawings. The work also includes all minor details of construction which are obviously and fairly intended and which may not have been referred to in these documents but are essential for the entire occupation in accordance with standard Engineering practice.

Unless specifically otherwise mentioned, all the applicable codes and standards published by the Indian Standard Institution and all other standards which may be published by them before the date of receipt of tenders, shall govern in all respects of design, workmanship, quality and properties of materials and methods of testing, methods of measurements etc. Wherever any reference to any Indian Standard Specifications occurs in the documents relating to this contract, the same shall be inclusive of all amendments issued thereto or revision thereof, if any, up to the date of receipt of tenders. In case there is no I.S.I. specification for the particular work, such work shall be carried out in accordance with the instructions in all respects, and requirements of the Engineer-in-Charge. The work shall be carried out in a manner complying in all respects with the requirements of relevant bye-laws of the Municipal Committee/Municipal Corporation/Development Authority / Improvement Trust under the jurisdiction of which the work is to be executed or as directed by the Engineer-in-Charge and, unless otherwise mentioned, nothing extra shall be paid on this account.

Samples of various materials, fittings, etc. proposed to be incorporated in eh work shall be submitted by the contractor for approval of the Engineer-in-charge before order for bulk supply in placed.

The contractor shall take instructions from the Engineer-in-charge regarding collection and stacking of materials in any place. No excavated earth or building materials shall be stacked on areas where buildings, roads, services, compound wails etc. are to be constructed.

The contractor shall maintain in perfect condition all works executed till the completion of the entire work allotted to him. Where phased delivery is contemplated, this provision shall apply to each phase.

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

The contractor shall clear the site thoroughly of all scaffolding materials and rubbish etc. left out of his work and dress the site around the building to the satisfaction of the Engineer-in-charge before the work is considered as complete.

The Director, Engineering Services Group (OR) Associate Director, Civil Engineering Group shall be the sole deciding authority as to the meaning, interpretations

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and implications for various provisions of the specifications and his decision in writing shall be final and binding on all concerned.

In case any difference or discrepancy between the specifications and the description in the schedule of quantities, the schedule of quantities all take precedence. In case of any difference or discrepancy between specifications and drawing, the specifications shall take precedence.

Read 'Department' as 'CEG/ESG/IGCAR

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CLEARING AND EARTHWORK

1. Scope:

1.1 This specification covers the general requirements of earthwork in excavation in different materials, site grading, filling in areas as shown in drawing, filling back around foundations and in plinths, conveyance and disposal of surplus soils or stacking them properly as shown on the drawings and as directed by the Engineer and all operations covered within the intent and purpose of this specification.

2. Applicable Codes:

2.1 The following Indian Standard Codes, unless otherwise specified herein, shall be applicable. In all cases, the latest revision of the codes shall be referred to.

IS 783 Code of practice for laying of concrete pipes.IS 1200 Method of measurement of building and civil engineering works.

Part 1 EarthworkPart 27 Earthwork done by mechanical appliancesExcavation work-code of safety.

IS 2720 Methods of test for soils:Part 1 Preparation of dry soil samples for various tests.Part 2. Determination of water contentPart 4 Grain size analysisPart 5 Determination of liquid and plastic limitPart 7 Determination of water content dry density relation using light compaction.Part 9 Determination of dry density moisture content relation by constant weight of soil methodPart 14 Determination of density index (relative density) of cohesion less soilsPart 28 Determination of dry density of soils In place, by the sand replacement method. Part 33 Determination of the density in place by the ring and water replacement methodPart 34 Determination of density of soil in place by rubber balloon method.Part 38 Compaction control test (Hilf Method).

3. Drawings:

The Engineer will furnish drawings wherever, in his opinion such drawings are required to show areas to be excavated/ filled, grade level, sequence of priorities etc. The Contractor shall follow strictly such drawings.

4. General

4.1 The Contractor shall furnish all tools, plants, instruments, qualified supervisory personnel, labour, materials any temporary works, consumables, any and everything necessary, whether or not such items are specifically stated herein for completion of the job in accordance with the specification requirements.

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4.2 The Contractor shall carry out the survey of the site before excavation and set properly all lines and establish levels for various works such as earthwork in excavation for grading, basement, foundations, plinth filling, roads, drains, cable trenches, pipelines etc. Such survey shall be carried out by taking accurate cross sections of the area perpendicular to established reference grid lines at 8m intervals or nearer as determined by the Engineer based on ground profile. These shall be checked by the Engineer and thereafter properly recorded.

4.3 The excavation shall be done to correct lines and levels. This shall also include, where required, proper shoring to maintain excavations and also the fabricating, erecting and maintaining of substantial barricades around excavated areas and warning lamps at night for ensuring safety .

4.4 The rates quoted shall also include for dumping of excavated materials in regular heaps, blinds, riprap with regular slopes as directed by the Engineer, within the lead specified and levelling the same so as to provide natural drainage. Rock/soil excavated shall be stacked properly as directed by the Engineer. As a rule, all softer material shall be laid along the centre of heaps, the harder and more weather resisting materials forming the casing on the sides and the top.

5.0 Clearing and Earthwork

5.1 a) Clearing the site: All the area upon which the construction is to be carried out and areas which are required by the Contractor for his construction facilities are to be cleared of all rubbish and other objectionable matter. Trees if any, shall not be uprooted or cut without the prior approval of the Engineer. All spoils and unserviceable materials and rubbish shall be burnt and removed from the site.

5.1 b) Precious objects, Relics Objects of Antiquity: All gold, silver, oil, minerals, archaeological and other findings of importance, trees cut or other materials of any description and all precious stones, coins, treasures, relics, antiquities and other similar things which may be found in or upon the site shall be the property of the owner and the contractor shall duly preserve the same to the satisfaction of the Owner and from time to time, the same to such person or persons as the Owner may from time to authorize or appoint to receive the same.

5.1 c) Payment: The cost of clearing the areas is deemed to have been included in the rates furnished in the Schedule of Quantities and Rates and no separate payment will be made for the clearing work.

5.2 Earthwork

a) General: The earth work shall consist of all works involved in site grading, excavation, shoring, filling around foundations, disposal of soils as directed by the Engineer, and such other relevant items. The area to be excavated or filled with the excavated materials shall be clearly demarcate din the filed by the Contractor. Excavation shall be done to lines and levels as shown in relevant drawings. The earthwork shall also include, where required, temporary bracing and shoring to maintain excavation, maintenance without interruptions

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to service. of all cables, duct banks, pipe lines etc. All excavation work shall be inspected and approved by the Engineer before any further works in excavation are allowed to commence.

b) Classification: All materials to be excavated shall be classified by the Engineer, into one of the following classes and shall be paid for at the rate tendered for that particular class of material. No distinctions hall be made whether the material is dry, moist or wet. The decision of the Engineer regarding the classification of the material shall be final and binding on the Contractor and not be a subject matter of any appeal or arbitration.

Any earthwork will be classified under any of the following categories.

i) Ordinary and Hard Soil: These shall include all kinds of soils containing kankar, sand, silt, murrum and/or shingle, gravel, clay, loam, peat, ash, shale, etc., which can generally be excavated by spade, pick, axes and shovel, and which is not classified under "Soft and Decomposed Rock" and and "Hard Rock" defined below. This shall also include embedded rock boulders not longer than 1 metre in anyone direction and not more than 200mm in anyone of the other two directions.

ii) Soft and Decomposed Rock: This shall include rock, boulders, slag, chalk, slate, hard micaschist, laterite and all other materials which in the opinion of Engineer is rock, but does not need blasting chiseling and could be removed with picks, hammer, crow bars, wedges, and pneumatic breaking equipment The mere fact that the Contractor resorts to blasting/chiseling for reasons of his own, shall not qualify for classification under- 'Hard Rock'

This shall also include excavation in macadam and tar-red roads and pavements This shall also include rock boulders not longer- than 1 metre in any direction and not more than 500 mm in anyone of the other two directions Masonry to be dismantled will also be measured under this item.

iii) Hard Rock: This shall include all rock occurring in large continuous masses which cannot be removed except by chiseling for-loosening it. Harder varieties of rock with or without veins and secondary minerals which, in the opinion of the Engineer require chiseling shall be consider-ed as hard rock. Boulders of rock occurring in such sizes and not classified under (a) and (b) above shall also be classified as hard rock, Concrete work both reinforced and un-reinforced to be dismantled will be measured under- this item, unless a separate provision is made in the Schedule of Quantities.

c) Limits of Excavation: Excavation shall be carried out to such widths, lengths, depths and profiles as axe shown on the drawings or such other outlines and grades as may be specified by the Engineer. Where the blasting is resorted to for excavation, the last 150mm above final level will be excavated by barring and wedging to avoid any over cut and the Contractor is not eligible for any extra payment on this account. Should cutting be taken deeper than required levels such extra excavation shall not be measured for payment. The Contractor shall at his own expense fill up such extra depth with the concrete of same mix as the mud mat concrete.

d) Excavation in open cuts: Unless otherwise indicated on the drawings, trench excavation shall be by open cut .Bottom of trenches for piping shall be accurately graded so that the pipe is uniformly supported along its entire length.

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e) Stability of Excavation: The methods of excavation shall in every case be subject to the approval of the Engineer and the Contractor shall ensure that stability and safety of the excavation, adjacent structures, services and the works.

f) Timber Shoring: Whenever the Engineer directs, the sides of the excavation shall be timbered and shored by a proper method previously approved by the Engineer The Contractor shall have full responsibility for the stability of the excavations and safety workmen.. If any slip occurs, the Contractor shall remove all the slipped material from the excavated pit, without payment. Also if any damage to the built up structure occurs because of the slip, the Contractor shall make it good without any payment.

6. Excavation:

6.1 All excavation work shall be carried out by mechanical equipment unless in the opinion of the Engineer, the work involved and time schedule permit manual work.

6.2 Excavation for permanent work shall be taken out to such widths, lengths, depths and profiles as are shown on the drawings or such other lines and grades as may be specified by the Engineer. Rough excavation shall be carried out to a depth 150.mm above the final level The balance shall be excavated with special care. Soft pockets shall be removed even below the final level and extra excavation filled up as directed by the Engineer. The final excavation if so instructed by the Engineer, should be carried out just prior to laying the mudmat.

6.3 The contractor may, for facility of work or similar other reasons excavate, and also backfill later, if so approved by the engineer, at his own cost outside the lines shown on the drawings or directed by the Engineer. Should any excavation be taken below the specified elevations, the Contractor shall fill it up, with concrete of the same class as in the foundation resting thereon, upto the required elevation. No extra shall be claimed by the contractor on this account.

6.4 All excavation shall be done to the minimum dimensions as required for safety and working facility. Prior approval of the Engineer shall be obtained by the Contractor in each individual case, for the method he proposes to adopt for the excavation, including dimensions, side slopes, dewatering, disposal, etc. This approval, however, shall not in any way relieve the Contractor of his responsibility for any consequent loss or damage. The excavation must be carried out in the most expeditious and efficient manner. Side slopes shall be as steep as will stand safely for the actual soil conditions encountered. Every precaution shall be taken to prevent slips. Should slips occur, the slipped material shall be removed and the slope dressed to a modified stable slope. Removal of the slipped earth will not be paid for if the slips are due to the negligence of the contractor.

6.5 Excavation shall be carried out with such tools, tackles and equipment as described herein before. Other methods like chiseling may be resorted to in the case of hard rock; however not without the specific permission of the Engineer.

7. Stripping Loose Rock

All loose boulders, semi detached rocks (along with earthy stuff which might move

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therewith) not directly in the excavation but so close to the area to be excavated as to be liable, in the opinion of the Engineer, to fall or otherwise endanger the workmen, equipment, or the work, etc., shall be stripped off and removed away from the area of the excavation. The method used shall be such as not to shatter, or render unstable or unsafe the portion which was originally sound and safe. Any material not requiring removal as contemplated in the work, but which, in the opinion of the Engineer, is likely to become loose or unstable later, shall also be promptly and satisfactorily removed as directed by the Engineer. The cost of such stripping will be paid for at the unit rates accepted for the class of materials in question.

8. Backfilling around foundations in Pits, Trenches, Plinth and Under floors

i) Earth: All clods of earth shall be broken or removed. Material for backfilling shall generally be obtained from the spoil of excavation The Employer shall have the option, in case of shortage of good selected earth obtained from excavation to direct the contractor- to get the filling materials from approved borrow pits.

ii) Filing in pits and around Structures: As soon as the work in foundations has been accepted and measured, the spaces around the foundation structure in pits and trenches shall be cleared of all debris, brick bats, mortar dropping etc .. And filled with earth in layers not exceeding 150mm, watered -and - compacted with mechanical compaction machines to 95% modified proctor density. The Engineer may however permit manual compaction by hand tampers in case he is satisfied that mechanical compaction is not possible. When filling reaches the finished level, the surface shall be flooded with water, unless otherwise directed, for atleast 24 hours allowed to dry and then the surface again compacted as specified above to avoid settlements at a later stage. The finished level of the filling shall be trimmed to the level slope specified.

iii) Plinth filling: Plinth filling shall be carried out with approved material as described herein before in layers not exceeding 150mm, watered and compacted with mechanical compaction machines to 95% modified proctor density. The Engineer may however permit manual compaction by hand tampers in case he is satisfied that mechanical compaction is not possible. When filling reaches the finished level, the surface shall be flooded with water, unless otherwise directed, for atleast 24 hours allowed to dry and then the surface again compacted as specified above to avoid settlements at a later stage. The finished level of the filling shall be trimmed to the level slope specified.

9. Back filling excavated earth in trenches for water pipes and drains

i) General: All clods, lumps etc. shall be broken or removed.

ii) Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipes and drains have been tested and passed Where the trenches are excavated in soil, the filling shall be done with earth on the sides and top of pipes in layers not exceeding 15 cm watered, rammed and consolidated, taking care that no damage is caused to the pipe.

iii) Sand in plinth and other places: When directed by the Employer, backfilling shall be carried out with sand. The filled in sand shall be flooded with water for sufficient time to ensure maximum consolidation. The surface of the consolidated sand shall be dressed to

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the required level or slope. Construction of floors or other structures shall not be started until the Engineer has inspected and approved the fill.

10. Reinstatement of Damaged Surface: All materials, structure, foundations, surfaces etc affected or damaged during excavation shall be made good by Contractor at no extra cost to the Company.

11. Clearing of Excavation: Excavation shall be cleaned, trimmed to exact shape and all disturbed material and other debris shall be removed before any further work with concrete or backfilling commenced the Contractor shall inform the Engineer and get the area approved by him. Cost of this work is deemed to have been included in the unit rate for excavation.

12. Disposal of Surplus: AII surplus materials shall be carried away from the Site and dumped at dumping site selected by the Engineer. The Engineer may ask the Contractor to dump the excavated materials in regular heaps, bunds, blankets, riprap with regular slopes as directed by the Engineer and leveled so as to provide natural drainage. As a rule, all softer material shall be laid along the Centre of heaps, the harder and more weather resisting materials forming the casing on the sides and the top.

All such works as mentioned above are seemed to have been taken into account while quoting for the excavation and no extras shall he claimed by the contractor for the above works.

13. Dewatering: The Contractor shall provide, maintain and operate sufficient pumping equipment of the required capacity to keep the area of construction free from water during construction period and paid under the relevant item

14. Measurement and Payment: The measurement of excavation of soil, soft rock and hard rock shall be taken as the net volume of the voids formed by removal of the materials. The net volume for this purpose shall be taken as follows:

It shall be equal to the volume formed by the measurement lines as shown in tile excavation drawing. If the excavation carried cut is short of payment lines, the measurement will be restricted to actual Excavation performed beyond the required payment lines, shall not be measured for payment. Where suitable bearing materials is not encountered at the elevations shown on the drawings, the. Employer may direct in writing that the excavation be carried to elevations below those shown on the drawings.

In case of isolated pockets where -materials of different categories are intermixed and in the opinion of the Employer are impracticable to measure such pockets may be ordered to be excavated and the soft rock and hand rock stacked separately After measurements of the stacks 20% in respect of soils and 40% in respect rock from the corresponding stack measurements deducted for voids. Stacking will be done by the Contractor free of cost. Volume of hard rock and soft rock so arrived at will be deducted from the total Volume excavated and remaining volume will be paid for at the rates, quoted for soil.. The employer may direct the excavated material to be dumped in areas which require

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filling and level the disposed earth at no extras cost over the quoted rate within the lead and lift specified in the schedule of quantity.

Shoring, pumping/baling out water, removal of slips refilling the space between the building wall and sides of the trenches with the excavated soil laid in 150mm layers watered, cost of cleaning the construction site shall be included in the Contractor's rate structure. No extra payment whatsoever shall be made for the same.

The rate of excavation shall also include drilling and muffling arrangements for blasting operations Where called for, for excavation in soil, soft rock and hard rock and disposal - of the spoil within the specified lead as per specifications, and schedule of quantities.

In the case of hard rock payment for blasting and removing hard rock will be restricted to stacked quantity less 40% deduction for voids or quantity measured as para above whichever 'is less. No extra payment will be made for stacking and disposal (after measurement) as per schedule of quantity.

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EMBEDMENT PARTS (RE-STEEL, CIVIL, MECHANICAL & ELECTRICAL)

1.0 Reinforcement, Splicing and Mechanical Fasteners & Couplers

1.1 Scope:

The work covered under this section shall include supplying, cleaning, cutting, bending, placing, binding and securing of reinforcement in position for all structures. This shall also include welding, splicing and mechanical fasteners for reinforcement bars.

1.2 Material:

1.2.1 Mild Steel and TMT

Mild steel bars shall conform to IS: 432 (Grade -1) and TMT bars of Fe 415 shall conform to IS: 1786 and as specified in the drawing/Bar bending schedule. All steel shall be of weldable quality and shall be procured from main steel manufacturers and not from re-rollers. Only Thermo-mechanically treated reinforcing bars of grade Fe415 shall be used in the works. In addition to the requirements of IS 1786 the TMT bars should meet the following requirements.

Yield stress (0.2% proof stress) of any individual bar SHALL NOT BE HIGHER than 10% of the specified characteristic strength of 500Mpa. This is to ensure that extra high plastic moments are not developed at the supports because of extra high strength of rebars. Otherwise it may lead to shear failure of the members under the condition of plastic hinge formation.

The ratio of ultimate to yield stress shall not be less than 1.2. This is to ensure adequate length of yield plateau to ensure ductile behaviour.

Minimum percentage elongation shall be 14% on a gauge length of 200mm. This is again to ensure enough ductility.

1.2.2 Anti-corrosive Treatment to TMT Reinforcement Bars with Fusion Bonded Epoxy Coating (FBEC)

1.0 Reinforcing Bars

The reinforcing bars to be provided with Fusion Bonded Epoxy Coating shall conform to the tender specifications and relevant I.S. Specifications. Inspite of producing test certificates by contractor for the proper quality of reinforcing bars, the quality of steel could also be tested by the FBE coating firm at plant site for bend test before doing coating and that if the reinforcing bar fails in bend test, then it shall not be provided with FBEC and in that case, cost of conveyance of such steel to plant and removing form plant shall be of the contractor. The rechecking quality of steel, for bend test will be done by the coating agency in the presence of contractor provided the contractor choose to remain present.

Reinforcing bars to be coated shall be fresh from rolling mills as far as possible. If the bars are very much rusted in quality before providing FBEC, such bars shall have a loss of weight at contractor's risk.

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To ascertain the loss in weight of reinforcing bars on account of removal of rust during coating, random weighment before and after coating shall be done and that loss in weight shall be borne by the contractor.

2.0 Coating Bars with FBEC

The FBEC coating shall be done confirming to LS. Code 13620: 1993 with additional stipulations as under.

2.1 The Fusion Bonded Epoxy Coating shall be carried out by an authorised FBE coating agency approved by Department.

2.2 Patch-up materials shall be procured in sealed containers with certificates from coating agency for supply of such patch-up materials.

2.3 The tender rate for FBE coating shall include using PVC coated G.I. Binding Wires of 18G.

3.0 Tests for FBE coating on Reinforcing Bars

3.1 The contractor shall produce certificate from.the FBE. coating agency that the quality of powder epoxy material and other components of FBEC conform to LS. 13620: 1993. Such certificates shall accompany each delivery challan of coated bars while leaving the plant. The contractor may also carry out such tests at plant jointly or separately of the coating agency to confirm use of proper quality of coating material.

3.2 The coated reinforcement bars shall be tested at plant by the contractor. Test reports shall be jointly signed by authorised representatives of contractor and the coating agency. The tests on coated bars shall be as per LS. for the following tests:

(a) Thickness (b) Continuity (c) Adhesion

The frequency of tests shall be for the thickness of coating minimum two bars of each size from each production shifts.

Random tests shall be made for continuity of coating.

3.3 Inspite of above tests and test certificates produced by the contractor and coating agency, the Department/Owner reserves the rights to carry out independent tests at coating plant for cross checking. The contractor's agreement with coating agency shall include the provisions for Department's/Owner's cross checking and that if the coating quality is not approved by the Department/Owner the decision of the Department/Owner to reject or repair the coating shall be final and binding on all parties.

3.4 Thickness of Fusion Bonded Epoxy Coating shall be 200 to 250 microns.

3.5 Holidays in coating shall not be more than two holidays per linear foot (six holidays per meter) of coated bar.

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4.0 Handling

4.1 The coated bars shall be carefully handled in order not to drop them, not to rub them on hard surface or against another coated bar while conveying, stacking, placing or stacking of fabricated bars and that for this purpose, wooden packing batons shall be used at spacing of not more than 60 cms. The coated bars shall be tied to make bundles with PVC binding material to avoid damages to coating.

4.2 The coated bars shall be stacked with separation gap between ground and bars with wooden batons between rows of bars or bundles of such tied bars. Such wooden or padded contact shall be at spacing of not more than 60 cms.

4.3 The cut ends of bars shall be touched ·up with special touch up materials of specifications as provided by coating agency. There shall be minimum time gap to repair the cut ends and damaged portions with touch up materials and that failure to do so may cause complete rejection of the coated bars. The cut ends and damaged portions shall be touched up with repair patch-up material within four hours time gap. All damages to coating in handling etc. shall be repaired irrespective of their size. This stipulation supersedes provision of I.S. Code.

4.4 No payment will be made for coated bars which are not used in the work and that if they were paid either on account of coating of the rejectable part of bars or doing extra fabrication etc., the amount paid will be recovered from contractor. The contractor will be paid for the same quantity of steel bars used in the work and paid under relevant item. . 4.5 While bending the bars, the pins of workbenches shall be provided with PVC or plastic sleeves. It is preferable that contractor install bar bending machines suitable for FBE coated bars and that each bending operation is done in a time of not less than 90 sees.

4.6 The coated steel shall not be directly exposed to sun rays and rains and shall be protected with opaque polythene sheets or such other approved materials.

4.7 While doing concreting, the workmen or trolleys shall not directly move on coated bars but can move on wooden planks placed on the bars by contractor.

4.8 In spite of all test certificates, if the coated bars are roughly handled by contractor either during transport, fabrication, stacking, placing and concreting etc. or handled in such a manner as to damage the coating for area or portion more than reasonable, the Engineer-in-charge or Department/Owner reserve the right to reject the FBE coated bars and that if rejected then such rejected bars shall be removed by contractor from work site within three days. The decision of Engineer-in-charge will be final as to reject the bars with damage coating or to allow repairing the coating, or to get it recoated entirely at contractor's cost.

5.0 Transportation:

5.1 The trailers shall have wooden spacers on the deck with a spacing of two feet between each other.

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5.2 The side poles of the trailors may ideally be protected by covering hassein clothes or any similar material to prevent abrasion against the coated bars and the side poles have to be pipes and not angles/channels.

5.3 To tie the bars with the trailor preferably use nylon wires and in case metal strings are used kindly insulate them by providing hassein cloth or by PVC pipe.

5.4 The bars have to be transported in 40 feet trailors, so that there shall not be any sagging of bars at the ends.

6.0 Stacking:

6.1 The bars are to be stacked at least ten inches above ground with necessary drainage provided below the stacks to prevent water logging. Wooden spacers shall be kept at the bottom with a distance of two feet from each other or any appropriate spacing to prevent coated bars touching the ground. .

6.2 Higher diameter bars i.e. 20mm and above shall be kept in layer by layer with wooden spacers separating each layer of the stack. The smaller diameter bars have also to be kept in similar form in bundles not necessarily be kept in single layers.

6.3 The stacks are to be covered with opaque polythene cover to prevent rain or sun directly falling on it.

6.4 In case coated bars are to be stacked for a long period it is advisable to have them stacked under covered area.

7.0 Cutting:

The coated bars can be cut mechanically or manually by using chisel, but the area here the cutting bench is placed has to be leveled and wooden spacers are to be permanently installed. This would enable the bars to be supported even while they are adjusted for positioning on the cutting benches.

8.0 Bending:

8.1 If the bending is not by machine the bending bench shall be with a wooden platform and in case the bench is of concrete or metal they have to be protected with plywood or wooden covers.

8.2 The mandrel has to be protected against abrasion while the coated bars are bent.

8.3 If the bending is by a bending machine the mandrel may have tufflon/nylon cover so that the coating shall not be damaged.

8.4 In case the bending is carried out by a manual method the mandrel (pins) have to be covered with PVC pipes of appropriate diameter. The pins have to be even (like an MS Round); if tor steel is used as pins that could damage the coating, which may thus be

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avoided.

8.5 Any nails or other such bare metal objects should be removed from the bench so that the coating may not damage with those contact areas.

8.6 The chairs, bars supports, etc. may be plastic or coat at bars.

Note: May you require diameter for mandrels you may kindly follow IS:13620-93 clause 8.3 Table 1.

9.0 Repair & Sealing of cut ends using Liquid Epoxy Patch-up material:

9.1 The two compound patch-up material supplied to you in two packs of epoxy and catalyst or hardner. The mixing has to be in the same proportion. (See the Guidelines as in attachment).

9.2 The cut ends have to be sealed immediately after the cuts are made. In case it isdelayed the ends have to be properly cleaned by using an emery paper and a cloth and then apply the epoxy patch-up.

9.3 All damages visible to the naked eye may be touched up by using epoxy patch-up.

9.4 Always apply touch-up only to a dry bar. It should not be applied in wet condition as it may affect adhesion.

10.0 General cares for fixing bars and while pouring concrete:

10.1 The PVC coated binding wire should be used for tying the bars to eliminate any damage to the coating as well as to prevent corrosion to these wires.

10.2 No metallic shuttering, bare pipes, metallic staging material, cutting/bending tools, etc. should be dropped or dragged on the coated bars.

10.3 Wooden spacers may be used for bar supports so that the coating shall not get damaged.

10.4 . The bars after the bending shall also be placed on wooden or rubber and shall not be thrown on the ground.

10.5 It s ideal to have minimum stock ofstee1 required at job site to minimize handling damages.

Recommended Procedure for repair & Sealing cut ends of FBECR using Liquid Epoxy Patch-up Material (for clause 9.1)

(1) The two compound patch-up material supplied to you in two packs of epoxy and catalyst or hardener. The mixing has to be in the same proportion.

(2) The cut ends have to be sealed immediately after the cuts are made. In case it is

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delayed the ends have to be properly cleaned by using an emery paper and a cloth and then apply the epoxy patch-up.

(3) All damages visible to the naked eye may be touched up by using epoxy patch-up.

(4) Always apply touch-up only to a dry bar': It should not be applied in wet condition as it may affect adhesion.

How to apply Epoxy Patch-up compound in the field to repair on FBE coated bars:

Epoxy Patch-up is supplied in two parts:

A = Epoxy resinB = Catalyst of Hardner

Empty contents of the containers A & B, stir with a wooden stirrer for five minutes; wait five minutes to allow chemical reaction between epoxy and catalyst to form the patching material.

Use small brush and apply (after removing the rust, if-any, by sand paper) on damaged area or cut ends. With one coat it is possible to achieve 150 microns DFT. But if used with big brushes it may achieve higher thickness.

Please use the mixed patch-up within four to five hours after mixing. If kept separate and stored in dry cool area the epoxy patching has a shelf life of 12 months.

1.3 Quality:

Whenever demanded by the Engineer, the contractor shall submit the manufacturers test certificate for steel. Random tests on steel supplied by contractor may be performed by Owner as per relevant Indian Standards. All costs incidental to such tests shall be at contractor's expense. Steel not conforming to specification shall be rejected. All reinforcement shall be clean, free from grease, oil, paint, dirt, loose mill, scale, loose rust; dust, bituminous material or any other substances that will destroy or reduce the bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used: All bars shall be rigidly held in position before concreting. No welding of rods to obtain continuity shall be allowed unless approved by the Engineer. In all cases of important connections, tests shall be made to prove that the joints are of the full strength of bars welded. Special specifications, as specified by the Engineer, shall be adhered to in the welding of cold worked reinforcing bars and other mild steel.

1.4 Fabrication:

The reinforcement shall be cold bent without the use of heat to the shapes as mentioned in the Drawings! bar bending schedule as per IS 2502. Bars having cracks or splits on the bends shall be rejected. In case of mismatch/discrepancies in the drawings, Engineer's decision shall be final. The high strength deformed steel bars shall not be re-bent or

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straightened without the approval of the Engineer. Crossing bars shall not be tack welded. Bars shall, be properly tagged for easy identifications .. No welding/splicing of rods to obtain continuity shall be allowed unless it is shown in the drawings or approved by the Engineer.

Where reinforcement bars are bent aside at construction joints and afterwards bent back into their original position, care should be taken to ensure that at no time the radius of the bend is less than 4 times the dia of bar for MS and 6 times the dia for HYSD bars.

1.5 Storage:

The reinforcement steel shall not be kept in direct contact with ground but stacked on top of an arrangement of timber sleepers. Fabricated reinforcement shall be carefully stored to prevent damage, distortion, corrosion and deterioration.

Reinforcement shall be stored under cover, if desired by the Engineer. If necessary, the reinforcement steel shall be coated with cement wash before stacking, to prevent scale and rust. Such coating, rust, scale if any shall be removed before fabrication of the bar. The stacks shall be easily measurable. Steel needed for immediate use shall only be removed from storage. Any reinforcement, which has deteriorated or has been damaged or is otherwise considered defective by the Engineer, shall not be used in the works.

1.6 Bending / Fixing / Placing:

Rough handling, shock loading (prior to embedment) and the dropping of reinforcement from a height shall be avoided. Reinforcement shall be accurately bend, placed and fixed by any approved means to maintain the correct position of bars as shown on the drawings for this purpose. They shall be bent gradually by machine. The contractor shall use cover blocks, spacers and chairs as per IS: 2502 to prevent displacement during placing & compaction of concrete. Cover blocks shall be cast with the same grade of concrete as that of the concrete in which the same is getting embedded. Casting of cover blocks using cement mortar shall not be permitted. Use of PVC cover blocks may be permitted at the discretion of the Engineer. Bars intended to be in contact at crossing joints shall be securely bound together at all such points with 16 gauge annealed soft Iron wire (Binding wire). The vertical and horizontal distance required between successive layers of bars in beams, walls or similar members shall be maintained by the provisions of spacer bars at such intervals that the main bars do not perceptibly sag between adjacent spacer bar. Arrangements for placing concrete shall be such that reinforcement in position does not have to bear extra load and get disturbed. The diameter of such spacer bar shall not be less than the diameter of the main bar. Normally all reinforcement bars placed in concrete shall be straight. Bars shall be so placed that cover to the reinforcement is maintained as shown in the drawing. No personnel and equipment shall be allowed to rest directly on the steel reinforcement. If the movement of personnel becomes necessary and allowed by the Engineer, proper and safe walkways shall be provided. Top layer of reinforcement shall be supported to avoid bending of the bars. Reinforcing bars shall not be straightened and re-bent in a manner that is detrimental to the materials. No reinforcement shall be bent when in position in the work, without the approval of the Engineer whether or not it is partially embedded in concrete. Bends and shapes shall comply strictly with the dimensions corresponding to the approved bar

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bending schedules. Bar bending schedule shall be checked by the contractor, if required, before any bending is done. In-situ bending of embedded bars using Oxy-Acetylene flame shall not be resorted to, however, unless and until if it can be proved that cold bending is not possible the same may allowed at the discretion of the Engineer. Erected and secured reinforcement shall be inspected and approved by Engineer prior to placement of concrete.

When specified diameter of reinforcement is not available, Contractor may be allowed to replace such diameters with available diameters calculated to provide the equivalent steel area as shown on the drawings and such alterations shall be carried out only after obtaining the written approval of the Engineer.

Exposed ends of dowel bars for under ground structures shall be protected if necessary by encasing the same in lean concrete at no extra cost. For structures above ground, exposed ends of dowel bars shall be given adequate coat of cement wash and if additional protection is needed as per the Engineer, shall be wrapped with plastic tape, at no extra cost.

Exposed portions of Reinforcement bars must not be subjected to impact or rough handling and workmen will not be permitted to climb on bar extensions until concrete has sufficient strength so that no movement of bars in concrete is possible.

Whenever necessary/as directed by the Engineer before placing the reinforcement in congested areas full scale mock-ups shall be carried out and approval from Engineer shall be obtained. Such mock-ups will be paid as per the relevant items of the tender.

1.7 Tolerance on placing of reinforcement

Unless otherwise specified in the drawings reinforcement shall be placed in accordance with IS:456-2000.

1.8 Cover to reinforcement

Unless otherwise specified in the drawings the cover to reinforcement shall be as per IS:456-2000 or as directed by Engineer.

1.9 Splicing of Reinforcement Bars:

1.9.1 Lap splicing:

Lapping of reinforcement bars shall be done at locations as shown in the drawings or as directed by the Engineer. However not more than 50% of the splices shall be provided in one location. The lap length shall not be less than that specified in the drawings. If not specified, the lap length shall be decided by the Engineer. Splices in adjacent bars shall be staggered and the locations of all splices, except those specified on the drawings' shall be approved by the Engineer. The bars shall not be lapped

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unless the length required exceeds the maximum available lengths of bars. At such locations, whereby providing lap splice is giving rise to congestion of reinforcement or wherever required as per Engineer, such splice shall be replaced with welding/mechanical splicing at the discretion of the Engineer.

1.9.2 Splices by Threaded Couplers (Bartech Couplers)

This type of splicing shall be of standard threaded mechanical splice coupler. Splicing procedure and qualification, testing shall be done as per ASME, Section -III, division-2. The cutting, cold forging and threading of reinforcement bars shall be done as per manufacturers specifications. Reduction of the nominal cross section area of the parent bar is not allowed. This type of splicing shall be carried out using necessary type threaded couplers including locking arrangements wherever required of M/s BARTEC, Dextra Splice Ltd, Bangkok or equivalent. The Coupler shall be such that there should not be any requirement of rotating the rebars for connection. The nominal cross section of the bar at the root of the thread shall not be less than nominal cross section of the parent bar. Actual performance of the coupler joint shall be at least equivalent to the characteristic strength of the parent bar i.e. tensile failure should occur in the bar and shall be sufficiently away from the joint. Elongation after failure must be equivalent to the parent bar. Permanent Elongation after loading upto 0.6 fy shall not exceed 0.1 mm

1.9.3 Procedure for Splicing

The reinforcement rod to be spliced shall be cut by a hacksaw to get a perfectly plane end surface. The portion of the bar being engaged with the splice sleeve shall be cleaned with a power brush. The inner surface of the sleeve shall be cleaned with acetone or any other approved solvent.

The splicing shall be carried out either by manufacturer's technician or personnel of Contractor having been trained by the manufacturer. In case of Contractor's technician, he shall be qualified for the operation. Operator qualification procedure shall be as per acceptable norms of QA & QC of IGCAR.

1.10 Mechanical Fasteners for Reinforcement Bars

Mechanical fasteners may to be provided at locations where the reinforcement bars are splayed in the RC wall around the air lock openings. Mechanical fasteners are used to fasten the outer and inner reinforcement bars to prevent them from moving outward thus avoiding cracking of concrete.

Mechanical fasteners may consist of a pair of20mm or higher dia. High Yield Strength deformed bars, threaded at both ends. MS clamps made out of flats, pressed in a die shall be used to clamp the reinforcement bars. The entire set of the fasteners shall be fabricated as shown in the drawings or as directed by the Engineer. The length of the fasteners required may vary and actual length for each location shall be determined by the Contractor from the drawings or will be specified by the engineer as the case may be.

Samples from all materials required for the fabrication of the mechanical fasteners shall

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be tested as per the relevant standards and test certificates shall be provided at no extra cost. System shall be qualified as detailed in the drawing.

1. The system involves cold forging of the ends of the bar for enlarging the size, cutting square threads such that root thread diameter is slightly bigger than parent bar. The bars are joined at site with a coupler. In this system, coupler is to be rotated by adopting B type threads the sides of the joint.

2. The system should be capable in using effectively for following elements of the structure locations:

a. Main column / wall reinforcement bars. b. Column beam junction-column can be taken up independent of beam by

providing L - bars with threaded couplers. c. Shear wall slab junction - shear wall can be taken up independent of

beam by providing L - bars with threaded couplers. d. Creating temporary access for final cleaning of pour. e. Avoiding laps in slab pours / raft pours / circumferential reinforcement and

thereby reducing congestion of reinforcement.

3. The system should be capable for joining bars from diameter 16mm to 36mm.

4. Reducers/couplers are to be used for joining bars of different diameters.

5. No specific approval from designer / site engineer is required for converting lap / weld / mechanical splice shown on the drawing to bartec couplers. However, the contractor has to prepare bar bending schedule duly approved after deciding locations of couplers at no extra cost to IGCAR.

6. Instructions for preparing joints at site are as under:

a) Only hand tightening of couplers to be done. No wrench to be used. Use of wrench may damage the threads and weaken the joint.

b) The bars are to be aligned properly by holding the bar by two labourers and then coupler is to be hand tightened.

c) Inspection to be visual i.e to ensure that all the threads are covered by a coupler. However, there is adequate margin in designing the joints and even if 4 ( four) threads are covered by coupler, guaranteed bat break is ensured.

d) Ensure that same type joints are not provided fully at any joint. For example at joint B-type thread is to be only on one side and A-type thread is on other side.

e) This guaranteed bar breaking system even if there is no staggering of joints.

f) For mixed construction where reinforcement bars are to be welded to steel structure, bartec weldable couplers are to be used.

7. QA in making threads and making joint:

a) Double forging is not allowed. In case of improper forging, such as buckling, recut

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the bar and repeat forging.

b) Check the threaded end of the bar with 'go' and 'no go ' gauge. The' go' gauge must go over the full thread length. The 'no-go' gauge must not go over more than half of the full thread length. However, this check is required to be done after every setting of machine for a particular

c) Tensile test of joint is to be conducted on minimum 3 specimens per diameter at start of project. Then minimum one specimen is to be tested per 100 joints for that particular diameter up to 1000 jointed. Afterwards, one specimen is to be tested per 1000. joints for that particular diameter. However the Engineer at his discretion can change the number of samples for. testing to ensure better QA at no extra cost to IGCAR. Acceptance criteria is that the bar break to be away from coupler and also away from forged area.

1.11 Welding of Reinforcement Bars:

Normal bond laps in reinforcement may be replaced by lap or butt welding if asked by the Engineer, under certain conditions.

Both shop and Site welding shall conform to ASME section III division -2. Electrode shall be E-70 18, 3.15mm dia. electrode shall be used for root pass and 4mm dia. shall be used for subsequent and final pass. Weld procedure qualification (WPQ) and welder qualification (WQ) shall be done as per ASME section -III. Tension test and macro etch test shall be done on the test specimen for both WPQ and WQ. Acceptance criteria for above test specimen shall conform to ASME section III division 2 for tensile test and for macro etch test respectively.

1.11.1 Welding procedure:

Length of the reinforcement bars shall be cut and trimmed to the required size. Edge preparation shall be done as per the approved procedure. Pre-heating of bars shall be done at 100° by Oxy-Acetylene flame and temperature

shall be checked with a 'Thermo Chalk' (surface temperature sensing crayon). Electrode E-70 18 shall be properly baked before using. Welding shall be done as per the approved procedure. The inter pass temperature shall be maintained between 90° to 250°C.

1.11.2. Testing of production joints (shop weld)

a) 100% visual inspection of all joints. b) Die Penetration Test on root & final pass for 10% of total number of joints. c) 1800 bend test on completed weld joints with DP test of bent portion lout

of 100 joints. _ d) Frequency of sampling for tension test on weld joints shall be

i) lout of the first 10 joints, ii) lout of the next 90 joints. iii) 2 out of the next and each subsequent unit of 100 joints.

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e) Radiography test (on butt weld) shall be conducted on lout of25 joints.

Testing and acceptance criteria/rejection criteria shall meet the requirements of ASME section III division – 2.

1.12 Inspection:

The placing reinforcements shall be completed well in advance of concrete pouring. Immediately before pouring the concrete, the reinforcement shall be examined by the Engineer for accuracy of placement and cleanliness. Necessary corrections as directed by him shall be carried out.

1.13 Rate:

a) The rate quoted against the items of reinforcement work shall include supply, fabrication and placement of reinforcement rods in position, providing necessary cover blocks, binding wires, tools and plant and labour , all testing etc complete for satisfactory completion of the job.

b) No payment shall be made for binding wires, cover block, temporary supports, hangers, etc. required for keeping the steel in position. For supporting horizontal reinforcement at heights larger than 300 mm, support drawings will be prepared by the Contractor and approved by the Engineer. Reinforcement chairs, laps, spacers embedded in concrete as mentioned in drawing or specified by the Engineer will be measured and paid for.

c) No extra Quantity will be paid for the modification of embedded reinforcement or for the faulty fabrication or placement.

d) Dowels neither shown on the drawings nor instructed by the Engineer, but required for construction facilities and/or sequence, shall not be measured.

e) The rate quoted against the item of welding shall include cutting, cleaning and welding of reinforcement bars including qualification of welders, materials, all testings as per specifications, providing of welding electrodes, welding machine, jig for welding, other tools and plants, consumbles and labour etc complete for the satisfactory completion of the job.

The rate quoted against the item of mechanical splicing (Bartee) shall include qualification of the system, cutting and cleaning of reinforcement, threading of reinforcement bars, Supplying and placing of couplers including thread protection caps and plastic caps on coupler, all testing as per specifications, providing jig for splicing and necessary tools and plant for Bartee Couplers threaded splices (Bartee or equivalent) rate quoted shall also include. cold forging of bars, connection of the bars as per manufacturers specifications. The rate shall also include providing jig for splicing and necessary tools and plant and including testing as per specifications and labour etc complete for the satisfactory completion of the job. The quoted rate shall be for a single joint all-inc

1.14 Mode of Measurement:

The mode of measurement for various items of work covered under this specification is as follows:

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Reinforcement bars (both mild steel and TMT and Fusion Bonded Epoxy coated) shall be measured as length of the rod as specified in the approved bar bending schedule and converted into theoretical weight in Metric tons. The theoretical weight to be used for the purpose of calculating the weight of the reinforcement rod are as follows:

Sl. No. Diameter of Rod Weight in Kg/m1 6mm 0.2222 8mm 0.3953 10mm 0.6174 12mm 0.8885 16mm 1.5786 20mm 2.4667 22mm 2.9848 25mm 3.8539 28mm 4.834

10 32mm 6.31311 36mm 7.99012 45mm 12.485

Welding of reinforcement rods shall be measured as number of joints welded, which has been incorporated in the work. The joints that are required for testing and qualification of welds/ welders will not be paid separately.

Mechanical splicing of reinforcement rods shall be measured as number of joints spliced, which has been incorporated in the work. The joints that are required for testing and qualification of splices / splicers will not be paid separately.

Mechanical fasteners for the reinforcement rods shall be measured in weight in metric tonnes, which are incorporated in the work.

Only such laps which are shown in the drawings or as directed by the Engineer shall be measured and paid for.

All testing of different joints as specified in drawings or as directed by Engineer will be at contractor's cost.

For Fusion Bonded Epoxy coating the measurement will be taken in MT of steel in the relevant item.

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Specifications for Fabrication, Erection of Structural Steel works

1.0 Scope

This specification covers the technical requirements for supply of all steel items required for the work as per drawings including design of connections, preparation of fabrication drawings, fabrication, inspection, testing and painting after necessary surface preparation, transporting and erection at site at desired location of:

a) Main Structural steelworkb) Miscellaneous structural steelworkc) Embedded parts

All the works shall be carried as per approved QA procedures.

1.1 Main Structural Steel

a) Beams, girders, monorails made of rolled section and / or rolled sections with cover plates, and/or compound girders, and/or plate girders, and / or box type sections.

b) Columns made of rolled sections with or without cover plates and / or compound sections battened / laced and / or built up sections from plates with or without grinding at ends and at splice locations,

c) Roof structure such as roof trusses, purlins, bracings, etc. d) Base plates for columns including grinding (where specified)on top of base plates

and underside of column shafts. e) Any other item of structural steel framing, though not -specifically mentioned but

required for the building(s). f) Liner plates and supporting framework. g) Steel chimney(s). h) Top shield platform structure. i) Any other structures as shown in the drawings for fabrication

1.2 Miscellaneous Steelwork

a) Platforms and walkways with chequered plates / gratings. b) Ladders with or without cages. c) Handrails. d) Miscellaneous equipment supports, rails for equipment movement and their

associated connections. e) Steel enclosures for equipment or electrical instrument panels, rooms etc. f) Any other miscellaneous. Structures shown in the drawings for fabrication.

1.3 Embedded parts

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a) Anchor bolts of different sizes and types, including necessary accessories like nuts, washers, etc.

b) Pipe sleeves with circumferential baffle plates of various diameters in carbon steel, including Micro alloy steel.

c) Rectangular hatch frames fabricated out of structural shapes and plates. d) Door frames. e) All other embedded parts as shown on drawings released for fabrication.

The scope of work does not include following:

I) For embedded parts: Anchor fasteners, erection of EPs.II) For miscellaneous structures: Interior doors for buildings and associated

hardwares.

2.0 Applicable codes, Specifications

The pertinent clauses and sections of the following codes, standards and specifications (latest revision), shall apply to the material, design, detailing, fabrication and inspection of the work covered by this specification as specified in the other sections of this specification

IS:102 Ready mixed paint, brushing, and red lead. non-setting, primingIS:800 Code of Practice for general construction in steel.IS:806 Code of practice for use of steel Tubes in General Building

Construction.IS:808 Dimensions for Hot Rolled Steel Beams, Channels and Angle

Sections.IS:875 Code of practice for Design loads, For buildings & Structures (Part 1

to 5)IS:919 ISO system of limits and fits. (Parts 1 & 2) IS:1161 Steel Tubes for Structural Purposes - Specification IS:1200 Method of Measurement in Building Civil Engineering WorksIS:1239 Mild steel Tubes, Tubulars and other wrought steel fittings. (Parts 1 &

2)IS:1363 Hexagon Head Bolts, Screws and Nuts of product Grade C.IS:1364 Hexagon Head Bolts, Screws and Nuts of product Grade A & B.IS:1367 Technical supply conditions for threaded fasteners.IS:1477 Code of practice for painting of ferrous metals in buildings. (Part 1 &

2)IS:1852 Rolling and cutting tolerances for hot rolled steel products.IS:1893 Criteria for earthquake resistant design of structures.IS:1977 Low tensile Structural Steels - Specification.IS:1978 Line pipeIS:2002 Steel plates for pressure vessels for intermediate and high

temperature service including boilers. IS:2016 Specification for Plain washers.IS:2062 Steel for general structural purposes - SpecificationIS:2074 Ready mixed paint, Air drying, red oxide zinc chromes priming -

Specification IS:3589 Steel Pipes for water and sewage - Specification

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IS:3757 Specification for high strength structural boltsIS:4000 Code of practice for high strength bolts in steel structuresIS:5372 Taper washer for channels (ISMC)IS:5374 Taper washer for I beams (ISMB)IS:5620 Recommendation for structural design criteria for low head slide

gates.IS:5624 Foundation BoltsIS:6533 Code of practice for design and construction of steel

chimney Part 2- Structural Aspects IS:6639 Specification for Hexagon Bolts for steel structuresIS:7215 Tolerances for fabrication of steel structures.IS:8500 Structural steel - micro alloyed (medium and high strength

qualities)- Specification IS:11855 General requirements for Rubber Seals for hydraulic gatesIS:12843 Tolerances for erection of steel structuresSP:6(1) ISI Hand Book for structural engineers -1, Structural Steel Section BS:3139 High strength friction grip bolts for structural engineering.BS:4395(1) High strength friction grip bolts and associated nuts and washers for

structural engineering.BS:4604 The use of high strength friction grip bolts in structural steel work. AWS D1.1. Structural Welding Code-Steel AERB/SS/CSE-2 Design, Fabrication and Erection of Steel Structures

Important to Safety of Nuclear Facilities ASME Sec II, Part C

Specification for Welding Rods, Electrodes and Filler Material

ASME Sec V Non -destructive ExaminationASME Sec VIII, Div 1

Rules for Construction of Pressure Vessels.

ASME Sec IX Welding and Bracing Qualification.ASTM A-36 Specification for Structural SteelASTM A 167 Standard specification for Stainless and Heat Resisting Chromium

Steel Plates, Sheet, StripASTM A 262 Standard practice for Detecting Susceptibility to Intergranular attack

in Austenitic Stainless SteelsASTM A 380 Standard Practice for Cleaning and descaling Stainless Steel Plates,

Equipment and SystemsASTM A 516 Standard specification for Pressure Vessel Plates, Carbon Steel for

Moderate and lower Temperature Service. ASTM E 94 Standard Guide for Radiographic TestingASTM E 165 Standard test method for Liquid Penetrant Examination ASTM E 709 Standard Guide for Magnetic Particle Examination

In the event of the conflict of certain requirements of this specification with the details shown in drawings, the decision of the Engineer shall be final.

3.0 Drawings

3.1 Engineer’s Drawing

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3.1.1 Engineer shall issue to Contractor I Vendor such drawings and data as specified by Contract which may include, depending on Contract:

a) Preliminary Drawings and Data along with Tender I Enquiry. b) Any additional basic engineering details to enable detailed engineering by

Contractor I Vendor, as required by Contract. c) Interface particulars with other Contracts and d) Detailed engineering drawings in Engineer's Scope.

3.1.2 Detailed drawings of structures and systems will be issued to Contractor in a phased manner to suit construction schedule. Contractor shall intimate in writing, his projected date of requirement of drawings. The Schedule of release of drawings shall be mutually agreed to, based on project schedules, unless such dates of drawing release are specified in Contract.

Engineer reserves the right to make changes, revisions to drawings even after release for preparation of shop drawings, which are to be made to reflect additional data / details received and updated requirements. Revisions to drawings and any new drawings made to include additional work by Contractor shall be considered as part of this specification contract without additional cost implication to the Engineer.

3.1.3 Engineer shall have the authority to issue to the Contractor from time to time, such supplementary drawings I data as may be necessary to enable the Contractor to meet his obligations adequately.

3.1.4 In case of variations in drawings and specifications, the decision of the Engineer shall be final. Should the Contractor find discrepancies in the information furnished by the Engineer, he shall refer such discrepancies to the Engineer before proceeding with such work.

3.1.5 If Contractor suffers delay by reason of Engineer's failure to issue within a reasonable time such drawings, for which a notice is given by Contractor stating that his Works are likely to be delayed, unless such. drawings are issued, Engineer may, in consultation with Owner, determine and notify Contractor, any proportionate extension of Contract, consequent to such delays not attributable to Contractor.

3.1.6 Unless otherwise specified, the drawings and specifications are intended to include everything obviously requisite and necessary for proper and entire completion of the work and shall be carried out accordingly for completeness as required.

3.1.7 Design drawings by the Engineer will show all the dimensions and if necessary, clearances of the structure, forces where necessary, size of each member, definite location of openings, to various levels, and all other information necessary to enable the Contractor to prepare drawings for fabrication and erection.

3.1.8 It shall be clearly understood that Engineer's drawings are design drawings and are not intended to show connection details, cuts, notches, bends and other such details.

3.1.9 Shop Drawings For Embedded Parts: The Engineer shall supply fabrication drawings for items outlined in clause 1.3 of this specification, giving full details to the Contractor and there will not be any need for the Contractor to prepare shop drawings. For items outlined in clauses 1.1 and 1.2 .the Engineer will supply only design drawings

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and the Contractor shall prepare the shop drawings in accordance with AERB code, IS: 800 and wherever these are not applicable, AISC Manual should be used.

3.2 Fabrication Drawings

3.2.1 Contractor shall prepare all fabrication and erection drawings in metric units for the entire work based on the design drawings supplied by the Engineer. Shop detail drawings shall show all shearing, punching, drilling, bevel cutting, bending, and all welding in complete detail. All connections and splices shall be designed and detailed by the Contractor and clearly shown on the drawings. Bill of material shall show number, size, length, weight and assembly work of each erection piece. Bill of material for each drawing shall include fasteners/bolts, nuts, washers and other accessories complete with specification, size, length, numbers, etc for each erection mark and proper identification for each joint. . Bill of material shall be prepared erection mark wise, showing weight of each component part and total weight of each erection mark. All revisions after initial issue of a drawing shall be clearly indicated with issue number and date of revision. Details shown in the drawings shall be clear and legible.

3.2.2 Each drawing submitted by the Contractor shall be clearly marked with the following details.

a) Name of the Owner. b) Name of the Consultant. c) Project Title including (if applicable) number of units and unit numbers. d) Purchase Order No./Contract Number e) Title of the Drawing clearly identifying the system, equipment or part. f) Drawing, Revision Number and Date. g) Space for Consultant's Drawing Number. h) Name of the Contractor.i) In case of Sub-contractor or Manufacturer's drawing, name of the Contractor and

Sub-Contractor or Manufacturer shall be incorporated. j) Drawings duly signed in "checked" and "approved" columns. k) Scale to which the drawing is drawn. l) Cross-references to all relevant drawings. m) All notes relevant to the drawing: n) All notes necessary for understanding and execution of work shown on a drawing

shall be presented on the same drawing. o) All legends to all notations. p) Details of revisions carried out. q) Bill of materials shall be tabulated, wherever required. r) All titles, noting, markings and writings on the drawing shall be in English. s) All the dimensions shall be in metric units. t) If standard catalogues are submitted, the applicable items shall be highlighted

therein.

Drawings, which do not meet the above standards specified, will not be accepted.

3.2.3 Contractor shall not commence shop detailing from information on Engineer's design drawings unless such drawings or part of such drawings are officially released with the stamp bearing "Released for Construction". Contractor shall be responsible for the correctness of all shop drawings. Six (6) prints. shall be submitted to the Engineer· for

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scrutiny and approval. The fabrication drawings shall be revised by the Contractor to reflect all revisions - in design drawings as and when such revisions are made by Engineer. Six (6) prints of the revised fabrication drawings shall be submitted to the Engineer for approval.

3.2.4 No detailed shop drawings will be accepted for examination by the Engineer unless they are complete and checked and approved by Contractor's qualified Structural Engineer and accompanied by an erection plan showing the location of all pieces detailed.

3.2.5 Contractor should check for erection clearance and ensure that detailing of connections is carefully planned to obtain ease in erection of structures including field-welded connection and bolting. Field connections/splices may be welded or bolted type, as specified in drawings.

3.2.6 Fabrication shall not be started until Contractor has received copies of such drawings upon which Engineer has endorsed his approval. Approval by Engineer of any of the drawings shall not relieve Contractor from the responsibility for correctness of engineering, design of connections, workmanship, fit of parts, details, material, errors or omissions of any and all work shown thereon. Any work done prior to approval of shop drawings will be at the Contractor's risk. The Contractor shall make such changes in the design when so directed, which are considered necessary to make the structures conform to the provisions and intent of the specifications, without any additional cost to the Owner. Engineer's approval shall not invalidate any claim for damages of any kind for incorrectly detailed / fabricated steel, notwithstanding any approval of such drawings by Engineer.

3.2.7 Contractor shall submit design calculations for each and every connection detail proposed by him and also for any substitution for members, desired by him and approved by the Engineer. Fabrication drawings not accompanied by calculations for the connection design are liable to be rejected.

3.2.8 Each lot of drawings sent by Contractor for approval shall contain a limited number of drawings and shall be in an order and manner which follows erection sequence or as required by Engineer based on priorities allocated.

3.2.9 Engineer will return one copy of Contractor's drawing marked with Engineer's approval/comments. Contractor shall furnish the Engineer Six (6) prints of all approved final drawings for field use and record purpose. Contractor shall also furnish the Engineer with one reproducible of each drawing. These reproducible shall incorporate all modifications, field changes substitutions etc. affected and shall reflect the status "as built". It should be noted that so-called sepia or similar process reproducible are not acceptable. All these reproducible are not acceptable. All these reproducible shall be submitted rolled (not folded) on the outside of regular mailing tubes.

3.2.10 All these drawings will remain the property of the Engineer (IGCAR). Engineer reserves the right to use them in any manner whatsoever.

3.2.11 Two sets of soft copies of all final approved Contractor's drawings in the form of CDs shall be furnished by the Contractor for Owner's use after incorporating the as built status.

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3.2.12 Time consumed by the Contractor in securing approval of drawings should not be added to the time allowed for completion of contract. A period of four (4) weeks from the dates of receipt of drawings by the Engineer should be anticipated for this item of procedure in the schedule.

4.0 Materials

4.1 Steel Supply

All steel shall be procured and supplied by the Contractor, from reputed sources as approved by Engineer and shall conform to the following:

4.1.1 Contractor shall use materials for fabrication as specified in the approved drawings. All materials supplied by the Contractor shall be in sound condition, of recent manufacture, free from defects such as loose mill scales, slag intrusions, laminations, pitting, flaky rust etc. The lengths/sizes of steel sections and plates shall be as supplied by the steel mills and conform to the latest issue of the relevant IS /ASME specification.

4.1.2 All materials required for the work shall be correlated with manufactures test certificates. In the absence of test certificates, materials shall be tested by Contractor through an approved laboratory for establishing specification requirements at Contractor's cost, and as directed by the Engineer. All tests shall be witnessed by Owners' representative.

4.1.3 The Contractor shall supply the mill test certificate for the materials being supplied by him.

4.1.4 Material supplied against these Test Certificates (TCs) should have identification stamped or stencilled on them. All such identification markings shall be authenticated by the inspection agency, which has inspected and approved the material.

4.1.5 The Engineer shall have the right to test random samples to prove authenticity of the test certificates produced by the Contractor at the Contractor's cost. Any material found not meeting the specification requirement would be rejected.

4.2 Substitutions:

Whenever the Contractor desires to substitute structural members, shown on the drawings, due to non-availability of requisite materials, such substitutions shall be made only after authorisation in writing by the Engineer.

Engineer may also direct to make substitution, when he considers such substitution is necessary.

5.0 Fabrication

5.1 GeneralAll workmanship and finish shall be of the best quality and shall conform to good engineering practice and the best-approved method of fabrication. All materials shall be finished straight and shall be machined true and square where so specified. All holes and

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edges shall be free of burrs. Shearing and chipping shall be neatly and accurately done and all portions of work exposed to view shall be neatly finished. Standard fabrication clearances as detailed in American Institute of Steel Construction Manual and IS Codes shall generally be followed unless otherwise directed/approved. Materials at the shop shall be kept clean and protected from weather. In addition

a) All care should be taken to avoid undue welding distortions. b) Complete layout shall be prepared and got approved by the Engineer before

actual fabrications are started. If needed mock-ups may also be prepared. c) All fit ups shall be got approved from the Engineer. d) Standard tolerances as per relevant IS specifications shall be followed.

5.1.A Electrodes:

All Electrodes and welding shall be of low hydrogen type conforming to ASME Sec II Part C. Brands approved by IGCAR shall only be used.

5.2 Connections

5.2.1 All connections shall be designed for forces indicated on the design drawings. The contractor shall be responsible for selection of standard connections from AISC Manual of Steel Construction "unless specified in drawings. Where standard joints are not available, contractor shall design connections and shall get Engineer's approval prior to fabrication

5.2.2 Connections shall be effected either by welding or bolting or as specified on the drawings. Type and quality of weld/ bolts shall be in accordance with relevant IS Codes and as specified on the drawings.-

5.2.3 Where necessary, tapered washers, flat washers or spring washers shall be used with bolts. The length of the bolt shall be such that at least one thread of bolt projects beyond the nut, except in case of high strength friction grip bolts where this projection shall be at least three times the thread pitch.

5.2.4 In all cases where bearing is critical, the unthreaded portion of bolt shall bear on the members assembled. A washer of adequate thickness may be provided to exclude the threads from the bearing thickness, even if a longer grip bolt has to be used for this purpose.

5.2.5 All connections and splices shall be designed for full strength of members or loads indicated unless otherwise approved. Column splices shall be designed for the full tensile strength of the minimum cross section at the splice. Unless otherwise specified, beam end connections shall be designed for 60% of the shear capacity of rolled sections and 80% of shear capacity for built-up sections plus additional axial forces, if any.

5.2.6 All members likely to collect rainwater shall have drain holes provided.

5.2.7 Shop connections shall be generally welded. Field connections shall be made with

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bolts or HSFG bolts or welding as specified on the drawings.

5.2.8 Not more than one shop splice shall be provided to make up the full length of a member. Shop splices to make the full member lengths shall be of full penetration butt-welded type and radiographically tested.

5.2.9 Transportation or the Contractor's erection methods may require additional splices not shown on the drawings. The Contractor shall be responsible for the design and detailing of such splices or joints, and shall submit these for the Engineer's approval.

5.3 Straightening

5.3.1 Rolled material, before being worked, shall be straightened, unless otherwise required/specified. If straightening or flattening is necessary, it shall be done by methods that will not injure the material. Long plates shall be straightened by passing through a mandrel or levelling rolls and structural shapes by the use of mechanical or hydraulic bar/section straightening machines. Heating or forging shall not be resorted to without the prior approval of the Engineer in writing. In case of site fabrication, the Engineer shall approve the straightening methods in writing before commencing the work.

5.3.2 Checking of the straightness of the structural members. like angles, channels, beams etc. shall be done by using the thread. For checking of the straightness-of ·the-column sections piano wire shall be used. The sections, which are twisted beyond repairs, shall not be used for fabrication. Heating or hammering shall not be permitted. After removal of bends structural members shall be submitted for inspection and approval of Engineer.

5.4 Cutting

5.4.1 Cutting may be done by shearing, chopping, sawing or machine flame cutting. All re-entrant corners shall be shaped notch free to a radius of at least 12-mm. Sheared or cropped edges shall be dressed to a neat workmanlike finish and shall be free from distortion and burrs.

5.4.2 Hand flame cutting shall be undertaken, only if so permitted by the Engineer and shall only be carried out by an expert in such work. Hand flame cut edges shall be ground smooth and straight.

5.4.3 Edges of flange cover plates and plates used to form any sections shall be ground smooth/planed.

5.5 Punching and Drilling

5.5.1 Holes for all connections shall be drilled accurately and the burrs removed effectively. Where several parts are to be connected, such parts shall be first assembled, tightly clamped together and drilled through. Holes in secondary members such as purlins, girts, lacing bars etc. may be punched full size through material not over 12mm

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thick. Holes should be clean cut, without burr or ragged edges.

5.5.2 Sub-punching may permitted before assemble, provided the holes are punched 3 mm smaller in diameter than the required size and reamed after assembly to the full diameter. The thickness of material punched shall not in such cases exceed 16 mm.

5.5.3 When match drilling is carried out in one operation through two or more separate parts, these parts shall be separated after drilling and the burrs removed.

5.5.4 Holes for turned and fitted bolts shall be drilled to a slightly smaller diameter and reamed to a diameter equal to the nominal diameter of the shank or barrel subject to HB tolerance specified in IS: 919.

5.5.5 Where reamed members are taken apart for transporting or handling ,the respective pieces reamed together shall be so marked that they may be reassembled in the same position in the final setting up. No interchange of reamed parts will be permitted. Poor matching, over drilling and ovality in holes shall be a cause for rejection. Burning holes with gas is strictly prohibited.

5.5.6 Holes may be required to be drilled by the Contractor at site for installing equipment or steel furnished by other agencies. The information for this will be supplied to the Contractor by the Engineer before or after erection of the steel. Holes should be by drilling or other machining process and not by gas cutting sets.

5.6 Rolling and forming

Plates, channels, RSJ, etc., for circular bins, bunkers, chimneys, gantry girders etc shall be accurately laid off and rolled or formed to required profile/shape as called for on the drawings. Adjacent sections shall be match-marked to facilitate accurate assembly, welding and erection in the field.

5.7 Grinding

Column ends bearing on each other, resting on base plates, compression joints designed for bearing, base plates coming in contact with column end and cap plates shall be ground smooth to ensure 90% contact with local gap not exceeding 0.10 mm (filler gauge shall be used to check this gap). AII ground surfaces shall be protected from dirt and mechanical damages till the assembly is completed. However the underside of base plate bearing on cement grout need not be ground smooth.

5.8 Gratings

All gratings shown and/or listed on the drawings shall be fabricated as a complete unit as detailed or as necessary for connections to structural steel framing. The gratings shall be capable of sustaining a safe live load of 500 kg/sq.metre of plan area and shall have a minimum thickness of 25mm unless otherwise specified on the Engineer's design drawings. Treads and landings shall be suitable for the prescribed loading and be

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furnished complete with a one-piece standard non-slip abrasive nosing of approved type.

5.8.1 M.S. Gratings

The maximum spacing of the spacer bars shall not exceed 100mm and that of main bars, 40mm. The minimum thickness of main flats shall be 5mm. The normal span of gratings shall not generally exceed 1.5 metres. Gratings shall be painted with 2 coats of approved paint (shop / site) as specified by the Engineer. The Engineer shall also approve the grating pattern.

5.8.2 Electroforged gratings

The electroforged gratings shall be of make "INDIANA" or other equivalent. These are manufactured by pressing round or twisted cross bars into solid bearing bars and obtaining perfectly homogeneous weld at every intersection without any air gaps using the process of electroforging. The gratings shall be hot dip galvanised as per IS 2629 where provided outside the building. The gratings provided inside the building shall be finished as per schedule of finishes.

5.9 Handrails

Handrails shall be provided on open sides of platform, stairways and around all openings as shown on drawings. Handrails shall be of mild steel pipe of flush welded construction, ground smooth, using 32mm nominal bore medium class pipe provided with double rail, top rail about 1 metre above platform / walkway level and the intermediate rail 450 mm below top rail and pipe posts spaced not more than 1.5 metres apart and 150 mm high 6mm thick toe plate. All handrails shall be painted as per requirement. Smooth uniform curves and bends shall be provided at stair returns and also where so ever required /specified. Posts connected to curb plates shall have a neat closure at the bottom and a 6mm thick plate nearly welded to posts for attachments to curb plate/ toe guards. All necessary fittings including inner dowels at splices, brackets, bolts, bends, flanges and chains, shoes for removable type handrails where required shall be furnished by the Contractor. Open ends of all the pipe posts shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction changes in the handrail. The rate quoted for handrails shall be per Metric Tonne of completed hand railing including posts, all fittings etc.

5.10 Chequered Plate

Chequered plates used shall be 6mm o/p thick or as indicated on drawings and shall be capable of carrying a minimum live load of 500 kg/sq.metre unless otherwise specified on design drawings. Chequered plate shall be fixed by 8mm diameter cadmium plated M.S.

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screws with countersunk heads at a maximum spacing of 400mm. Members supporting the chequered plate shall have matching holes tapped in them. Chequered plates may also be required to be welded to the structural steel framing. The decision in this regard will be given by the Engineer wherever required/specified.

6.0 Welding

6.1 General

6.1.1 Welding procedure specification (WPS) shall be established and Qualification of weld procedure (QWP) shall be done in accordance with the requirements of ASME Sec IX, or AWS D 1.1 as and where specified. Welders employed shall also be qualified as per above standards prior to taking up fabrication.

Following pre-qualified welding process shall be employed for fabrication, erection and repair by :

a) Submerged Arc Welding (SAW). b) Shield Metal Arc Welding (SMAW). c) Gas Metal Arc Welding (GMAW). d) Gas Tungsten Arc Welding (GTAW)

6.1.2 All welds shall be free from defects like blowholes, lack of penetration, undercutting, cracks etc. All welds shall be cleaned of slag or flux and show sections, smoothness of weld metal, featheredges without overlap and freedom from porosity.

6.1.3 50mm on either side of the surfaces on which weld metal is to be deposited shall be smooth, uniform, free from fins, tears burrs cracks and absolutely free from grease, paint, loose scale, moisture or any other substance which would adversely affect quality and strength of weld

6.1.4 Machining, thermal cutting or grinding may be employed for joint preparation or removal of unacceptable work or metal. The weld edges shall be smooth & regular surface free from cracks & notches. Flame cut material above 50mm thick shall be pre-heated to 100°C prior to flame cutting.

6.1.5 All weld fit-up shall comply with tolerances specified in the design drawing. The parts to be joined by fillet welds shall be brought into close contact as practicable. The root gap in no event shall be greater than 3 mm for SMAW process and 1.5mm for SAW process. If the separation is greater than 1.6mm the leg of the fillet weld shall be increased by the amount of root opening. This shall apply only in the case of continuous welds. Abutting parts to be butt-welded shall be carefully aligned and correct root gap shall be maintained through out the weld operation. The fit up of joints at contact surfaces that are not completely sealed by welds shall be close enough to exclude water after painting. The separation between laying surfaces of lap joint and butt joints with backing plate shall not exceed 1.5mm. Abutting parts to be butt-welded shall be carefully aligned and the correct root gap maintained throughout the welding operation. Misalignments greater than 25% of the thickness of the thinner plates or 3mm, whichever is smaller, shall be corrected and .in making the correction, the parts shall not be drawn into a slope sharper than 2 degrees.

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6.1.6 All tack welds shall be made using qualified procedure and qualified welders. Any preheat requirement specified in the welding procedure shall also apply to tack welds. All tack welds shall be examined visually for defects and if found defective, shall be removed.

6.1.7 Welding of temporary attachment/fixtures to retain fit up is allowed in case the parts have a nominal thickness of at least 6mm. Temporary attachments are welded to at the distance of at least 30 mm from the weld seam for construction of CS and least 60mm for welding austenitic steel. Welding of temporary attachments/fixtures into the joint slot is not allowed. All temporary fixtures to be removed after welding by grinding them to weaken the welded portion and hammering thereafter, followed by grinding the portion of any weld remaining on the base metal. A dye check at the discretion of the quality surveyor shall be done to detect any crack/defect at the point of fixture temporary weld. .

6.1.8 It is not allowed to turn over and carry over heavy assemblies in tacking condition in order to control the geometric dimensions to the requirements of the drawings.

6.1.9 Non-flatness of the facing sheets being assembled into the subassemblies in the longitudinal and transverse direction is allowed within 10mm for 1m of the length.

6.1.10 During the installation of the structural steel members care shall be taken to prevent damage of the sheets and of the welding seams. The work shall be positioned for flat welding wherever practicable and overhead weld shall be avoided as far as possible.

6.1.11 In the joints of the parts with dissimilar thickness smooth transition of one part to the other must be provided by way of the gradual decreasing of the thickness of the thicker part with the slope of the surface not exceeding 15 degree.

6.1.12 Welding shall not be done when the surface of the members are wet or exposed to rain. or high wind velocities unless the welding operator and the work are properly protected. In joints connected only by fillet welds. the minimum size of fillet weld to be used shall be as shown in the following table unless otherwise specified in the drawing.

Material thickness of Thicker part joined (mm)

Minimum size of fillet weld (leg dimension of fillet weld)

(mm)Up to 6 3

Over 6 to 12 5 Over 12 to 18 6

Over 18 8

6.1.13 Fillet welds 5 mm or larger in size for SMAW and 10mm for SAW shall be made with two or more passes. Welding rods shall be 3.15 in diameter maximum for root passes. and 4mm and above in diameter for subsequent passes. Complete penetration butt weld shall be terminated at the ends of the joint in a manner that will insure their soundness. Where abutting parts are 20mm or more in thickness. suitable run-on and run-off plates with similar edge preparation and having a width not less than the thickness of the thicker part shall be used. These extension pieces shall be removed after completion of .weld and the end of the weld made smooth and flush with the abutting parts.

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6.1.14 In case of full penetration butt welds without backing. root weld shall be back gouged to sound metal before second side welding for complete fusion throughout the entire cross section. However. in case of square butt welds done in flat position from both sides and with thickness of parts joined less than 8mm and root opening not less than half the thickness of the thinner part, gouging can be dispensed with. .

6.1.15 Welding rods shall be limited to 3.15mm in diameter for root passes, and 4mm and above in diameter for subsequent passes. Complete penetration butt weld shall be terminated at the ends of the joint in a manner that will insure their soundness. Where abutting parts are 20mm or more in thickness. suitable run-on and run-off plates with similar edge preparation and having a width not less than the thickness of the thicker part shall be used. These extension pieces shall be removed after completion of weld and the end of the weld made smooth and flush with the abutting parts.

6.1.16 All welded shop splices in each component part of covered plate beam or built up member shall be made before the component part is welded to other parts of the member. Long girders or girder section may be made by welding sub assemblies each made in accordance as explained above. When making these sub assembly splices, whether in the shop or field, the welding sequence should be reasonably balanced between web and flange welds. Where weld reinforcement interferes with the proper fit-up between components to be assembled for welding, these welds shall be ground flush prior to assembly.

6.1.17 Preheating for welding of steel shall conform to ASME Section VIII Div 1

6.1.18 Post weld heat treatment shall conform to ASME Section VIII, Div 1. No stress relief using oxyacetylene flame is permitted.

6.1.19 In assembling & joining parts of a structure or a built-up members and in reinforcing parts to members, the procedure and sequence shall be such as to minimise distortion and shrinkage. The fabricator shall prepare a welding sequence for a member or structure which in conjunction with WPS and overall fabrication method, will produce members or structure meeting the quality requirement specified The welding sequence and distortion control programme shall be submitted to Engineer for comments and information before start of welding Such programme shall include, besides other appropriate details, full particulars in regard to the following:

a) Proposed pre-bending in components such as flanges and flange cover plates and pre-setting of joints to offset expected distortion.

b) Make up of sub-assemblies proposed to be welded before incorporation in fined assembly.

c) Proposed joint forms, classification of wire and flux or covered electrodes, welding process including fit up and welding sequence with directions in which freedom of movement is to be allowed.

d) Proposed number, spacing and type of storage backs and details of jigs and fixtures for maintaining proper fit up and alignment during welding.

e) Any other special features like assembling similar members back to back or stress relieving procedure.

f) If so desired by the Engineer, mock up welding shall be carried out at Contractor's cost to establish the efficiency of the proposed programme, with any modification suggested by the Engineer in limiting distortion or land residual

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stress to acceptable levels. g) For sections made of rolled sections with cover plates, the ends of the plate

shall be seal welded or alternatively flange cover plate terminated 25mm short of the full length and welded across to the beam for proper end sealing and/or as directed by the Engineer.

6.1.20 Welds shall be defect free and surfaces shall be thoroughly cleaned to remove all visible weld defects and extra material. All welds shall be stamped/identified with System/Joint No/Welder punch etc. as per approved procedure at a distance of 30-35 mm from the weld seam.

6.2 Welding Consumables

6.2.1 Electrodes, filler wires and flux used for welding shall be from approved manufacturers/Suppliers. When requested by the engineer, the contractor shall furnish certification that electrode or electrode flux combination will meet the requirements of classification. The classification and size of electrode, arc length, voltage & amperage shall be suited to type and thickness of material, type of groove, welding positions and other circumstances attending work.

6.2.2 Electrodes, filler wire and consumables shall conform to the requirements of ASME Sec. II Part C .

6.2.3 Only low hydrogen electrodes shall be used for welding. These electrodes shall be purchased in hermetically sealed containers or baked by the user as recommended by electrode manufacturer. Electrode flux coating shall be sound and unbroken. Broken or damaged coating shall cause the electrodes to be discarded. SMAW electrodes shall be properly stored. Before welding, the electrodes shall de dried in an holding oven as per manufacturer's recommendations. Only limited quantity shall be issued to the welders. The electrodes shall be kept in "carry ovens" and shall not be exposed to the atmosphere.

6.2.4 The filler wire and flux combination for submerged arc welding shall conform to the requirements of ASME Section II, Part C. The weld metal deposited by the submerged arc process shall have mechanical properties not less than that of base material specification. The flux used for SAW process shall be dry and free of contamination from dirt, mill scale or foreign material. The flux purchased in packages shall be stored in dry place. Flux shall be dried in case of damaged package at a temperature of 260°C for 1 hour prior to welding operation. Flux shall be placed in dispensing system immediately upon opening a package.

6.2.5 Welding plants and accessories shall be of adequate capacity and shall satisfy appropriate standards and be of the approved make and quality. Proper safety rules shall be followed and adequate means to measure the current shall be provided.

6.3 Inspection

Fit ups shall be examined by the quality surveyor as per the approved QA plan prior to

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welding the joint. All welds shall be inspected for flaws by the method described under the Clause 11.3 (Inspection of welds).

a) Raw material with cracks, seams, laps, lamination and heavy pitting are not acceptable. Ultrasonic testing of plates above 50 mm thick or as per the material specification shall be carried out for the soundness of material.

b) Flame cut edges of plates more than 38 mm for fillet weld, greater than 25 mm for butt welds, fillet welds when both the plates exceed 25 mm, fillet welds between tension flanges and webs 100 % MPTI OPT shall be carried out. For full penetration welds, OPT shall be carried out after back gouging before second side welding. 100% MPT shall be carried out on low alloy steel, flame cut edges for thickness greater than 12mm.

c) The dimensions of the fit ups shall be maintained as specified in the fabrication drawings.

d) Welding shall be carried out as per approved WPS and QWS by qualified welders.e) Macro etch test on welds shall be carried out 1 per structures for built up girders,

columns and other heavy structures for penetration. f) 100% MPT I OPT for thickness greater than 25mm and less than 32 mm for butt

welds.g) 100 % RT shall be carried out for thickness greater than 32mm. 100% RT for butt

welds of rolled sections having a depth greater than 600mm shall be carried out.h) Minimum 10 % of Fillet welds for plate thickness less than 25 mm or less than

10mm fillet size, MPT/DPT shall be carried out. i) 100 % MPT/DPT shall be carried out for fillet welds for plate thickness greater

than 25mm and more than 10 mm fillet size.j) Dimensions of all the assembles and sub-assemblies shall be as per fabrication

drawings within the tolerances specified in IS 7215.

Sl. No. Type of defect Acceptance criteria Remarks

1. Cracks Not acceptable (NA)2. Incomplete or lack of fusion NA3. Mis alignment of butt welds 0.25 x T maximum of 3mm T: Thickness of

thinner plate4. Reinforcement Max reinforcement of

2mm for t<10mm3mm for t>10mm <15mm4mm for 15mm and greater

5. Undercut 0.25mm deep max6. Sharp edges Min radius of 2mm

6.4 Weld Repairs

Whenever weld repair is required, Contractor shall give prior intimation to the Engineer and permission before the repairing is taken up. When a defect is detected in a weld, it shall be removed by cutting/grinding and smooth blending of the area with parent metal without sharp edges, corners. If welding is required, the same shall be done using the qualified procedure/welder and stage inspection as per the original weld. Correction of defect in the same portion of the weld shall not be allowed more than two( 2) times. Portion of the welding seams, which have been subjected to repair, must be indicated in

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the weld inspection reports.

7.0 Erection

7.1 General

7.1.1 The Contractor shall supply all erection bolts, permanent bolts and electrodes as required for the job. At all times the Contractor shall be responsible for the safety and protection of fabricated material, from loss or damage of any nature until the completion of erection work.

7.1.2 Structural steel work will involve the erection of columns, beams, bracing, crane girders, purlins, trusses, monorails, ladders, platforms, gratings, chequered plates, liners, chimneys etc.

7.1.3 The Contractor shall complete all preliminary works at site, including post concrete survey wherever required well before the arrival of fabricated structural steel, such as keeping in readiness electrical winches, mobile cranes, gin poles, compressors, all 'tools and tackles, welding sets, torque wrenches, impact wrenches, etc., as part of this contract" and any other work that may be necessary so as to start erection immediately after the arrival of fabricated steel at site.

7.1.4 The Contractor shall arrange for such quantum of erection equipment, supervision staff, labour and other arrangements so as to carry out the work efficiently. The equipment and services provided by Contractor shall include but not be limited to, the supply of labour, transport vehicles, crane derricks, gin poles, winches, welding equipment and tools, compressed air if required, blocking, scaffolding, locked storage for tools, welding rods, positioners, cables etc required for site fabrication assembly and erection of the structure. If found necessary the Contractor shall also provide at his own cost arrangements for inspection and testing of material used-in-erection. He shall satisfy the Engineer regarding arrangements for various types of work to be undertaken by him.

7.1.5 No dragging of fabricated structural steel shall be permitted.

7.1.6 All fabricated structural steel shall be stored 150mm above ground on suitable packing, to avoid damage during the monsoon. Steel shall be stored in the order of erection with erection/identification marks visible. Storage areas shall be prepared and maintained by the Contractor. Any steel stored near excavations shall be removed immediately to a safe distance to avoid burial under debris.

7.1.7 The Contractor shall protect all existing plants, embedded parts, all permanent and temporary structures, piping, conduits, equipment and facilities against damage during erection. The Contractor shall perform his work in a manner, which in no way endangers the operations of any existing plant or structures or hinders other construction activities.

7.1.8 The Contractor shall arrange at his own expense, the necessary non-inflammable staging and hoisting materials or equipment required for the erection work and shall remove and take them away after the completion of the job. The Contractor shall also provide necessary passageways, fences, safety belts, helmets, safety shoes, lights and other fittings to the satisfaction of the Engineer and for protection of his men and materials.

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7.1.9 All structures shall be erected as shown in drawings. The Contractor shall carry out all erection work in the sequence required/ approved by the Engineer. The methods of erection and complete erection scheme shall be subject to the approval of the Engineer and shall be modified wherever required by the Engineer. This, however, will not relieve the Contractor of the responsibility for safe and expeditious completion of the work, its quality and accuracy.

7.1.10 Drifts should be used only for drawing the members into position and must not be used to such an extent so as to destroy the holes. Drifts of a larger size than the nominal diameter of the hole shall not be allowed. Any damaged holes or burrs must be rectified to the satisfaction of the Engineer. Correction of minor misfits and reasonable amount of reaming, if any, shall be considered as a part of erection. Any error in shop work, which prevents proper fit even after a moderate amount of reaming and slight chipping or cutting shall be immediately reported to the Engineer. The Contractor's work shall also include straightening and repairing of materials slightly damaged and drilling some holes in members where required. This is deemed to have been included in the unit rate quoted and nothing extra shall be payable for the above operations. Design Concession Request (OCR) shall be raised and got approved for all repairs and modification required.

7.1.11 In case of any faulty erection, all such dismantling and re-erection required will be at the Contractor's cost. Shim stock of mild steel plates, required for erection will be set, levelled and prepared for grouting / dry packing.

7.1.12 Where flat bearing beams occur, bearing plates shall be set, leveled and prepared for grouting/dry packing.

7.1.13 Structural Steel frames shall be erected plumb and true to tolerance indicated in the relevant clause. All steel columns and beams shall be checked for plumb and level individually before and after connections are made. Temporary bracing shall be introduced wherever necessary to take care of all loads to which the structures may be subjected including erection equipment and the operation thereof. Such bracings shall be left in place as long as may be required for safety. Proper size steel cables, slings etc shall be used to avoid any damage due to accidents.

7.1.14 As erection progresses, the work shall be securely bolted to take care of all dead load, wind and erection stresses. No final welding or bolting shall be done until the structure has been properly aligned and approved by the Engineer.

7.2 Code

Unless specified in the relevant drawing and specification, all erection work shall be arried out in accordance with the latest edition of Indian Standard Code of Practice for use of Structural Steel in General Building Construction IS-800 & AISC code herever applicable.

7.3 Anchor Bolts & Foundations

7.3.1 The Contractor shall carefully check the location and layout of anchor bolts

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embedded in foundation constructed to ensure that the structures can be properly erected as shown on the drawings. Any discrepancy in the anchor bolts/foundation shall be reported to the Engineer.

7.3.2 Anchor bolts shall be provided with two nuts on upper threaded portion, one of which may be used for levelling the column base to the required elevation and one will be a lock nut. 'All shim stock, required for keeping the specified thickness of grout and in connection with erection of structures on foundations, crane brackets or at any other locations shall be of good MS plates and shall be supplied by the Contractor at his cost.

7.3.3 A certain amount of cleaning of foundations and preparing the area is considered normal and shall be carried out by the Contractor at no extra cost.

7.3.4 Where beams bear in pockets or on walls, bearing plates shall be set and levelled as part of the work. The Contractor shall carry out all grouting under column base plates or beam bearing plates, unless the grouting is specifically excluded from the scope of work.

7.4 Erection Procedures

7.4.1 The structures shall be erected by assembling in sections on the ground and hoisting successive sections into place, or they may be built up in place by individual members at the option of the Contractor. The staging in different sections already erected shall be self sufficient in stability for all conditions or stresses including those caused by wind. If erected by assembling in sections, not less than 50% of all bolting in place shall be done in each section before starting another section.

7.4.2 All bolts shall be drawn up tight but not to such a degree as to endanger the strength of the bolts and nuts shall be locked in place with lock nuts. Only wrenches approved by the Engineer shall be used on the work and the use of any wrench, which may deform the nut, will not be permitted. At least ten percent of the bolts in each connection as directed by Engineer shall be tested for tightness by calibrated wrenches or other approved methods free of charges. If any bolt in any connection is found to be not sufficiently tightened, all bolts in that connection shall be re-tightened and tested again without claiming any extra.

7.4.3 The Contractor shall take all precautions for the safety of labourers at the time of erection. Safety belts shall be provided to workers while working at all levels for the erection of tower. The erected structure shall be well secured and protected at the close of the day to avoid any damage to the structure and workman.

8.0 Tolerances

The dimensional and weight tolerance for rolled shapes shall be in accordance with IS: 1852 for indigenous steel. The tolerances for fabrication of structural steel shall be as per IS: 7215. Tolerances mentioned below shall be achieved after the entire structure or part thereof is in line, level and plumb. The tolerances specified below do not apply to steel structures where the deviations from true position are intimately linked with and directly

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influence technological process. In such cases, the tolerances of process technologists/suppliers which will be indicated in the drawing.

8.1 Columns

Deviation of column axes at foundation top level with respect to true axes

a) In longitudinal direction + 5mm

b) In lateral direction + 5mm

Deviation in the level of bearing surface of columns at foundation top with respect to true level: +5mm

Out of plumbness (verticality) of column axis from true vertical axis, as measured at column top:

(a) For column upto and including height in 15 metres in height

: + 1/1000 of column mm

(b) For columns exceeding 15 column height in height in metres in height mm whichever is less

: + 1/1000 of mm or + 20

Deviation in straightness in longitudinal and transverse planes of column at any point along mm the height.

: + 1/1000 of column height in mm or + 10 whichever is less

Difference in erected position of adjacent pairs of columns along length or across width of building prior to connecting trusses / beams with respect to true distance

+ 10mm

Deviation in any bearing or seating level with respect to true level

+ 5mm

Deviation in differences in bearing levels of a member on adjacent pair of columns both across and along the building

+ 10mm

8.2 Connection of Members

Beam to beam, beam to column connections - Where the abutting parts are to be jointed by butt welds, permissible deviation from the squareness of the end is

Beams upto 600mm in depth -1.5mm

Beams over 600mm in depth - 1.5mm every 600mm depth to a maximum of 3mm

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Where abutting parts are to be jointed by bolting through cleats or end plates, the connection require closer tolerance. Permissible deviation from the squareness of the end is

For Beams 1 mm per 600 mm of depth up to a max. of 1.5 mm.

8.3 Depth of Members:

Acceptable deviation from the specified overall depth is

For depth of 900mm and under + / - 3mm

For depth over 900mm and under 1800mm

+ / - 5mm

For depth of 1800mm and over +8mm / -5mm

8.4 Trusses and Beams

Shift at the centre of span of top chord member with respect to the vertical plane passing through the centre of bottom chord

+ 1/250 of height of truss in mm or + 15mm

Lateral shift of top chord of truss at the centre of span from the vertical plane passing through the centre of supports of the truss

+ 1/1500 of span of truss in mm or + 15mm whichever is less

Lateral shift in location of purlin true position + 5mm

Deviation in difference of bearing levels of trusses or beams from the true difference

i) + 20mm for trussesii) for beams:Depth <1800mm : + 6mmDepth >1800mm : + 10mm

Deviation in sag in chords and diagonals of truss between node points

1/1500 of length in mm or 10mm whichever is smaller

Deviation in sweep of trusses, beams etc. in the horizontal plane

1/1000 of span in mm subject to a maximum of 10mm

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8.5 Crane Gantry Girders & Rails

Shift in the centre line of crane rail with respect to centre line of web of crane gantry girder

+ 5mm

Shift in plan of alignment of crane rail with respect to true axis of crane rail at any point

+ 5mm

Difference in alignment of crane rail in plan measured between any two points 2 metres apart along rail

+ 1mm

Deviation in crane track with respect to true gaugea) For track gauges upto and including 15metres:

+ 5mm

b) For track gauges more than 15 metres + [5 + 0.25 (S-15)]Where S in metres in true gauge

Deviation in the crane rail at any point from true level

1/1200 of the gauge distance or + 10mm whichever is less

Difference in the crane rail actual levels between any two points 2 metres apart along the rail length

+ 2mm

Deviation in levels between crane track rails ata) Supports of crane girders + 15mmb) Mid span of crane girders + 20mm

Relative shift of crane rail surfaces at a joint in plan and elevation

2mm subject to grinding of surfaces for smooth transition

Relative shift in the location of crane stops (end buffers) along the crane tracks with track gauge S in mm

1/1000 of track gauge S in mm subject to maximum of 20mm

8.6 Chimneys and Towers:

Out of plumbness (verticality) from the true vertical axis

1/1000 of the height of the chimney or tower in mm

9.0 Marking of Members:

9.1.1 After checking and inspection, all members shall be marked for identification during erection. This mark shall correspond to distinguishing marks on approved erection drawings and shall be legibly painted and stamped on it The match mark shall be punched on both sides of the member and the erection mark on the face of the member.

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The erection mark shall be stamped with a metal dye with figures at least 20mm high and to such optimum depth as to be clearly visible.

9.1.2 All erection marks shall be on the outer surface of all sections and near one end, but clear of bolt holes. The marking shall be so stamped that they are easily discernible when sorting out members. The stamped marking shall be encircled boldly by a distinguishable paint to facilitate easy location.

9.1.3 Erection marks on like pieces shall be in identical locations. Members having lengths of 7.0 m or more shall have the erection mark at both ends.

9.1.4 In case of embedded parts, identification mark shall be visible on the exposed surface after embedding in place.

10.0 Storage

10.1.1 The Contractor shall have proper arrangements for storage. He shall identify the storage area where raised. platform will be constructed by him. The materials will be identified area-wise and quantity-wise with proper identification marks.

10.1.2 Covered storage (Storage of fabricated materials): The Contractor shall make storage arrangements category-wise for storing fabricated materials and these materials shall be available for erection whenever called for. Fabricated materials should be stored separately according to different categories viz. embedded parts, pipe sleeves, angle frames, gratings and fabricated structural shapes. All the above materials when stacked should have proper access for inspection either by the Engineer or his authorised representatives.. The fabricated materials should be properly identified by giving identification marks. Similar precautions shall be taken to prevent the above material from rusting or any damage during the storage. Any fabricated EPs/material damaged/rusted during storage shall be rectified/repaired at Contractor's own cost.

10.1.3 The rates quoted by the Contractor for fabrication shall deemed to have included cost for storage facilities, handling, fabrication, labour, tools, plants, transport, testing, painting, hardware like bolts nuts, and all other incidentals to complete the item etc. for which no separate payment will be made.

11.0 Inspection, Testing & Reports

11.1 General

11.1.1 Contractor shall give due notice to Engineer in advance of the materials or workmanship getting ready for inspection. All rejected material shall be promptly removed from the shop and replaced with new material for Engineer's approval/inspection. The fact that certain material has been accepted at Contractor's shop shall not invalidate final rejection at site by Engineer if it fails to be in proper condition or has fabrication inaccuracies which prevents proper assembly. No material shall be painted or dispatched to site without the inspection and approval by Engineer unless such inspection is waived in writing by the Engineer.

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11.1.2 Shop inspection by Engineer or his authorised representative or submission of test certificates and acceptance thereof by Engineer shall not relieve Contractor from the responsibility of furnishing material conforming to the requirements of these specifications, nor shall it invalidate any claim which the Engineer may make because of defective or unsatisfactory material or workmanship.

11.1.3 Contractor shall provide all the testing and inspection services and facilities for shop work except where otherwise specified. Contractor's inspection work shall be under the control of competent Chief Inspector whose primary responsibility is inspection (reporting to Management) and not to production department.

11.1.4 For fabrication work carried out in the field the same standard of supervision and quality control shall be maintained as in shop fabricated work. The inspection and testing shall be conduced in a manner satisfactory to Engineer. The inspection and testing on structural steel members shall be as set forth below:

11.2 Material Testing

11.2.1 All materials conforming to a particular Indian/ASTM or any other standard as called for shall be tested as required by such standard. Proof in the form of certified test reports or mill certificates indicating the required tests have been carried out as per specification at the source as acceptable. In case these are not available, then the Contractor at his cost shall perform these tests.

11.2.2 Engineer has option to specify additional inspection or testing as he deems necessary and the additional cost of such testing will be borne by the Engineer.

11.2.3 The Contractor shall maintain records of all inspection and tests, which shall be made freely available to the Engineer and shall be submitted to the Engineer at completion of each stage of work.

11.2.4 If mill test reports are not available for any steel materials, the same shall be got tested by Contractor to Engineer's satisfaction to demonstrate conformity with the relevant specification at his own cost.

11.3 Inspection of Welds

The following methods are used for the quality control of welded joints. All weld shall be grinded and thoroughly cleaned before taking up the inspection

11.3.1 Visual Inspection Visual inspection shall be performed prior to and during and after non-destructive testing. The completed welds should be checked for correct size and profile. All weld surfaces shall be free from slag, creators, abrupt ridges and vallies, arc strikes. Prior to fabrication proper included angle, route opening , route face, alignment and c1eaness of joint shall be checked and ensured . All weld shall be visually inspected to ensure the welding performed are within the acceptable limits specified in CI 6.4

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11.3.2 Magnetic Particle Test(MPT) For fillet welds of size 10mm and above and lor critical areas, the root and final passes shall be tested using MPT. The Engineer shall however decide the requirements of any additional testing. For Complete penetration butt welds, the root and final passes shall be tested using MPT. All MPT shall be as per ASTM- E709. Defects if found, shall be repaired and retested. The cost of demagnetising after testing shall also deemed to be included in the quoted rates of the Contractor.

11.3.3 Liquid Penetrant Inspection MPT may be substituted by Liquid Penetrant Inspection where the former is not feasible due to configuration. All surfaces of the welds to be inspected by ~PT shall be free from scale, flux, ridges etc. The testing should be in accordance with ASTM-E165. Defects if found, shall be repaired and retested. The cost of demagnetising after testing shall also deemed to be included in the quoted rates of the Contractor.

11.3.4 Radio-graphic Examination Full penetration butt welds shall be fully radio-graphed or spot radiographed as shown in drawings IQA plans in accordance with ASTM: E-94.

11.3.5 Ultrasonic Testing Wherever built up sections for crane runways girders are fabricated, the T-joints of the sections shall be subjected to ultrasonic testing as per ASME,Sec-V,Article 5, Ultrasonic examinations for welds to be performed by the Contractor at his own cost.

11.4 Acceptance Standard The acceptable standards for weld inspection shall be as per ASME Sec VIII-Div I.

11.5 Dimensions, Workmanship and Cleanliness

All the fabricated embedded parts of Structural Steel members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment and surface finish are in accordance with the requirements shown ·on the approved Contractor's shop drawings and/or Engineer's drawings.

11.6 Inspection of Test Failure

In the event of any failure of structural, steel members to meet inspection or test requirements, the Contractor shall notify the Engineer or his authorised representative. A design concession request has to be made and got approved from the Engineer or his representative before repair is undertaken. The quality control procedures to be followed to ensure satisfactory repair shall be subject to approval by Engineer. Contractor shall maintain records of all inspection and testing which shall be made available to the Engineer or his authorised representative, for three years from the date of completion of the contract.

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12.0 Painting

12.1 General

The plant is located near the seacoast in a corrosive atmosphere. Contractor shall follow the best method of surface preparation and painting system.

12.1.1 In order to achieve the maximum durability, one or more of the following methods of surface preparation shall be followed, depending on condition of steel surface and as instructed by Engineer. Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system:

a) Manual or hand tool cleaningb) Mechanical or power tool cleaningc) Blast cleaning

12.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standards in case of manual or hand tool cleaning shall be St2 or equivalent, in case of mechanical or power tool cleaning it shall be St3 or equivalent, in case of blast cleaning it shall be Sa 2 ½ or equivalent as per Swedish Standard SIS-055900 / ISO-8501-1.Where highly corrosive condition exists, then the blast cleaning shall be Sa3 as per Swedish Standard. Prior to surface preparation all other contaminants, oil, grease etc. Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity exceeding 85%. Engineers reserve the right to instruct the type of surface preparation depending upon the condition of material.

12.1.3 Irrespective of the method of surface preparation, the first coat of primer must be applied on dry surface immediately and in any case within 4 hours of cleaning of surface. However at times of unfavourable weather conditions, Engineer shall have the liberty to control time period, at his sole discretion andlor to insist on recleaning, as may be required, before primer application is taken up. In general during unfavourable weather conditions, blasting and painting shall be avoided as far as possible.

12.1.4 Surfaces shall not be coated in rain, wind or in environment where injurious airborne elements exist, when the steel surface temperature is below 5Degree C and the humidity is greater than 85%.

12.1.5 To the maximum extent each coat of material shall be applied as a continuous film uniform thickness free of probes. Any spot or areas missed in the application shall be recoated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness.

12.1.6 Paint manufacturer's instructions shall be followed strictly at all times. Particular attention shall be paid to the following.

a) Instructions for storage to avoid exposure as well as extremes of temperature b) Surface preparation prior to painting c) Mixing and thinning d) Application of paints and the recommended limit on time intervals between coats.

12.1.7 Painting shall be carried out preferably by spraying. Brushes may be used

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sparingly at certain locations only and the brushes used for painting shall be of a style and quality that will enable proper application of paint. Type of brush shall be chosen according to its application and there shall be a minimum of brush marks left in the applied paint. Engineer reserves to instruct type of application of paint.

12.1.8 Portions of steel members embedded I to be encased in concrete shall not be painted. Joints to be site welded shall have no shop paint for at least 50 mm from the welding zone. Similarly steel surfaces shall not panted in areas where connection is by use of friction grip bolts. On completion of joint the surfaces shall receive the painting as specified.

12.1.9 Primer and finish paints shall be compatible with each other to avoid cracking and wrinkling. As such it is recommended that the primer and finish paint shall be from the same manufacturer.

12.1.10 Contractor shall furnish all the characteristics of paint material along with the test certificates. All paint material shall be of first quality.

12.1.11 All Structural steel surfaces except EPs shall be given the first coat of primer at shop and the second coat after it is erected in position. Further, any abraded surface of the first coat during transport from shop to site and during erection shall be provided with a touch-up coat of the primer. The field primer shall be compatible with the shop primer.

12.1.12 The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter by grit blasting to white metal in accordance with IS 1477 -Parts I & II / Swedish Standard SIS 05-5900. At places where grit blasting is not feasible, one coat of suitable approved anti-corrosive paint shall be applied.

12.1.13 The paint treatment specified shall be applied soon after completion of pre-cleaning or pre-treatment in order to prevent contamination of the surfaces in any way, either by brushing or by spraying on the thoroughly cleaned and dry surface as desired by the Engineer. Airless spraying shall be carried out if so specified by the Engineer.

Area Description Painting system Minimum DFTAT Shop – After Fabrication but before erection

1 coat of Epoxy primer 50 Microns

After erection 1 coat of Epoxy primer 50 MicronsImmediately after erection

1 coat of Micaceous Iron Oxide

75 Microns

Finish Paint 2 coat of Chlorinated Rubber based finishing paint @ minimum 50 Microns per coat

100 Microns

Total DFT 275 Microns

12.2 Acceptance Criteria

a) All painted surfaces shall be uniform & pleasing appearance.b) All epoxy and enamel painted surfaces wherever finish paint is specified shall be

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of uniform texture and high glossy finish.c) All storms, splashes & spatters of paints shall be removed.d) Surfaces shall meet the minimum specified DFT for their respective systems.

13.0 Fire Protection for Structural Steel

Wherever specified on the drawings, fire protection for structural steel shall be adopted, as per this specification.

Fire protection coating shall be used for fire protection of structural steel members like angles, beams and columns. Cementetious, inorganic, vermiculite-free formulation fire proofing system shall be used as given below.

13.1 Appointment of Specialised agency

Fire protection of structural steel is considered as specialised activity. The Bidder should appoint such specialists or specialised agencies who have experience of such system. The Bidder should indicate along with the bid name of the agency who carries out this special work. The Bidder should also submit with his bid, the list of personnel to be deployed with their experience, list of equipment to be used and list of similar works carried out previously or under progress by the specialist agency. This information is required in order to establish the capacity of the Bidder to the satisfaction of the Engineer. The Contractor's attention is brought to the fact that though "fire protection" may be carried out by or under guidance of nominated sub-contractors/suppliers the overall responsibility for all aspects of these works rests with the Contractor.

13.2 Materials

Cementetious inorganic vermiculite-free formulation. It is a single powder component mixed with water prior to application. Shall have high impact strength, non-flammable during or after application and shall be hard and durable.

13.3 Surface preparation

Prior to the application of fireproofing material, the substrate coating shall be free of oil, grease, direct condensation or other contamination.

13.4 Lathing

Galvanized or painted metal lath shall be installed prior to applying the fireproofing compound. Lath shall be secured by bending around flange and/or securing through use of stud welding, beam furring clips or tie wire.

13.5 Mixing

Potable water shall be added to the mortar mixer and with the mixer running slowly, the

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fireproofing compound shall be added and mixed for 5 to 10 minutes until a homogeneous mortar like consistency is achieved.

13.6 Application

The mortar shall be applied by spray or trowel finish. Thickness of coating shall be adequate for 3-hour fire rating.

13.7 Curing

In low humidity, high temperature, or direct sun or wind, the finished surface shall be kept damp for at least 12 hours after application. Freshly applied fireproofing compound shall be protected from rain, condensation or running water for 24 hours after application to prevent leaching of catalyst.

13.8 Guarantee

The Contractor shall give minimum 40 years guarantee for the system.

13.9 Details to be given by the Specialised agency

Complete details of the fire protection system proposed including results of the test conducted should be submitted to the Engineer for approval.

13.10 Rate

Contractor shall be paid, on the actual area (sq.m.) of application of fire protection system. No separate payment will be made for scaffolding, bracing and propping etc. necessary for safe and efficient execution of the various items of work. Cost of all such temporary work as required is deemed to have been included in the individual item rates quoted by the Contractor.

14.0 Co-ordination

The Contractor shall plan his work so as to avoid interference with work being done by other agencies. He shall permit the Engineer and/ or other agencies working on the project in restricted use of his scaffolding.

15.0 Safety Precautions:

a) The Contractor shall take all safety precautions to ensure that no damage is done to existing construction, equipment and facilities.

b) The Contractor shall comply with all safety regulations and follow other precautionary measures, which the Engineer may indicate from time to time. The decision of the Engineer shall be binding on the Contractor.

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c) Contractor shall submit methodology for adopting safety measures, which he proposes to follow at site for approval of the Engineer at no extra cost.

16.0 Sub Contracting

The contractor shall not sub-contract any work without a written approval from the Engineer. The contractor shall be responsible to the Engineer for all the work sub-contracted by him.

17.0 Embedded parts

17.1 General

The details furnished below are in addition to general requirements of material supply, fabrication, inspection, testing etc. specified in the earlier clauses of this specification.

17.2 Electrodes:

All electrodes and welding wire shall be low hydrogen type conforming to ASME Sec II Part C. Brands approved by IGCAR shall only be used.

17.2.1 Material test certificate shall be in original.

17.2.2 Material supplied against these TC’s should have identification stamped or stenciled on them which can be correlated with the TC’s

17.2.3 All such identification markings shall be authenticated by the inspection agency which has inspected and approved the material.

17.2.4 The contractor shall furnish to the Engineer duplicate copies of all purchase order copies covering the material ordered by him for this project and also test reports.

17.2.5 The Engineer shall have the right to test random samples to prove authenticity of the test certificates produced by the Contractor at the Engineer's cost. Any material found not meeting the required specification will be rejected and expenditure on test with 30% over head will be deducted from the contractor's bill.

17.2.A Fabrication of EPs

Fabrication of EPs shall be done as per the relevant drawings and specification to avoid any possible damage to the threading on the anchor bolts before erection of the equipment, suitable protective plugs are inserted. In some cases, internally threaded sockets are embedded with top of the socket kept flush with the concrete face.

17.3 Inspections And Testing

All fabricated EP's shall be inspected as per approved QA plan. The inspection shall cover visual examination, MPT, LPT, RT and UT such that these EP's are free from burrs,

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cracks, nicks and surface irregularities as per previous clauses of this specification.

17.4 Air hold test

All pipe and sleeve EPs of safety systems meant for sustaining pressure or otherwise specified shall be tested for leak tightness. The test pressure/holding time shall be as per the approved Drawings. Air pressure shall be held minimum for 10 minutes to detect leakage and pin holes.

17.5 Painting and Preservation

17.5.1 All carbon steel sleeve EPs higher than 350mm NB size shall be grit blasted/pickled and painted both inside and outside by zinc chrome primer. In case of painting on inside surface has practical difficulties, and then the pipes shall be closed by airtight covers till the erection of piping.

17.5.2 All the EPs shall be cleaned of dirt, rust, weld spatters and loose mill scale by hand brush / power brush and to be given with two coats of approved brand of zinc silicate primer of minimum OFT of 75 micron per coat.

17.5.3 All the embedded pipe sleeves and drain hubs shall be properly covered using suitable end caps to avoid choking by the entry of foreign materials.

17.6 Rectification

Any rework / rectification on the EP's required due to improper placement after concreting shall be carried out by the Contractor to the satisfaction of Engineer without any extra cost. This shall also include any additional inspection requirements as decided by Engineer.

18.0 Quality Surveillance

18.1 General

18.1.1 The Engineer shall subject all works and materials covered by this specification to inspection.

18.1.2 The Contractor shall provide free access in his shop during working hours for the inspection staff, designated by the Engineer, at all phases of the work and assist them where necessary in conducting the inspection. The Contractor shall expeditiously furnish all gauges, instruments and other necessary measuring equipment required for inspection of the work in the shop. The shop inspection by the inspector is intended to ensure that the material and workmanship are in accordance with this specification, but it will be not relieve the Contractor of any of his responsibilities for the product. The inspector's inspection will include, but not be limited to, the following:

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18.2 Material

The inspector will ascertain that only materials conforming to the requirements of this specification are used.

18.3 Dimension and Tolerances

The Engineer will ensure and check that the structural members conform to the dimensions and tolerances as set out on the drawings and as required by the specification.

18.4 Welding Procedure

The Engineer will witness the welding and testing of any procedure qualification tests that are required by this specification. The Engineer will also check that welding procedure (including the electrode, flux, current, arc voltage, speed of travel) used are in accordance with the approved welding procedures.

18.5 Welding Equipment

The Engineer will check the welding equipment to be used for the work to ensure that it is in such condition as to enable qualified welders to follow the procedures. .

18.6 Welder & Welding Operator Qualifications

18.6.1 The Engineer will permit welding to be performed only by welders and welding operators who are qualified by tests in accordance with ASME - Section IX

18.6.2 When the quality of a welder-or-welding operators' work, appears to be below the requirements, the Engineer may require testing of his qualifications by necessary tests.

18.7 Welds

18.7.1 The Engineer will ascertain that the sizes, length and the location of all welds conform to the requirements of this specification and the approved fabrication drawings. Temporary welds used for the works shall be removed and ground flush with the original surface.

18.7.2 The Engineer will identify with a distinguishing mark of all parts of the joints that he has inspected and accepted.

18.7.3 The Contractor shall comply with all the demands of the Engineer to correct improper workmanship and to remove and replace, or correct as instructed, all welds found defective or deficient.

18.7.4 ln the event of faulty welding or its removal for rewelding results in damage to the base metal in the judgement of the Engineer, or its retention is not in accordance with the

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intent of the plans and specification, the Contractor shall remove and replace the damaged materials at his own cost.

19.0 Rate

The rate quoted against the following item of works shall include.

19.1 Fabrication and Erection of Structural Steel

Supply, fabrication, cleaning using grit blasting, marking cutting, machining, aligning, supporting, welding including all consumables, inspection, shop painting using two coats of approved primer, inclusive of all raw materials such as MS plates, sections, pipes etc, transporting the fabricated parts to site, hoisting and erecting to required tolerances with temporary supports, inclusive of all labour, tools and equipment, scaffoldings, etc complete all as per drawings and specifications. Necessary jigs and fixtures will not be measured and paid separately, i.e. the price quoted shall include all these expenses. Providing erection bolts shall not be paid separately. NOT, if any, as specified in drawings will be measured and paid separately. Bending of monorails shall include dye check after bending.

19.2 Fabrication and Erection of Embedded Parts

Supply, fabrication, inspection, cleaning using grit blasting, marking, cutting, machining, aligning, supporting, welding including all consumables, painting using two coats of approved zinc silicate primer on all surfaces not in contact with concrete, inclusive of all raw materials such as MS plates, sections, pipes etc, transporting the fabricated parts to site, inclusive of all labour, tools and equipment, scaffoldings, etc complete all as per drawings and specifications. Necessary jigs and fixtures provided only for erection and which can be retrieved after concreting will not be measured and paid separately, i.e. the price quoted shall include all these expenses. However, jigs and fixtures required to be embedded in concrete will be measured and paid separately. NOT, if any, as specified in drawings will be measured and paid separately.

19.3 Painting of Structural Steel and Embedded Parts

Supply and application of paint according to specifications including cleaning using wire/power brush and sand paper and grit blasting wherever carried out.

20.0 Method of measurement

20.1 Structural steel shall be measured on weight basis by calculating the theoretical weight using unit weight, as per relevant IS codes based on approved fabrication drawings without deducting for holes, notches, bevel cuts etc. Wherever a component consists of a cut joist or channel, the full weight of the rolled section shall be considered only if more than half the depth of the section is used. Otherwise only half the section unit weight shall be considered for the weight of the component. Deductions shall be made in

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the weight of plates for skew cuts and notches of 900 sq cm or larger. The weight of any built-up member shall be separated into the weight of each component. No extra shall be paid for rolling margin of structural members, welding, galvanizing, painting, surface treatment in stainless steel and connection bolts, nuts, washers etc.

20.2 Embedded Parts shall be paid as per approved fabrication drawings. No extra shall be paid for welding and rolling margins, coating.

20.3 The measurement of NDT e.g. DPT, LPT shall be measured in meter length of weld.

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CONCRETE WORKS, FORM WORK & WATER PROOFING WORKS

1.0 Scope

This specification covers the proportioning, mixing and placing of plain, reinforced and pre-cast concrete. Included herein, are

i) Requirements for pre-qualification, purchase, testing and storage of concrete making materials, design of concrete mixes, sampling, testing and batching.

ii) Preparation and placement of concrete including chilling, mixing, conveying, depositing and curing, finishing, grouting, inspection, clean-up and miscellaneous works.

iii) Generation of records and other miscellaneous works. All information pertaining to plain, reinforced, pre-cast/heavy concrete shown and noted on the drawings shall be considered part of this specification and shall supersede this specification where information thereon is contrary to the contents of this specification.

iv) The Specification also covers installation and maintenance of dewatering system in good working condition and running for the entire period of contract to keep the area dry for further work.

It shall be noted that the major portion of placement of normal concrete will be carried out by using concrete pumps. Special provisions with regard to materials and their properties, equipment and pipe accessories, field practices, field control relevant to concrete pumping have been highlighted under clause 31.0

2.0 Standards & Specifications

The provision of the latest revisions with amendments if any of the following Indian Standards codes and other relevant codes shall form a part of this specification to the extent they are relevant. Where the Indian Standards are in conflict with the stipulations of this specification, these specifications shall supersede the Indian Standards.

2.1 Bureau of Indian Standards:

IS-269 Specification for Ordinary and Low Heat Portaland cementIS-383 Specification for coarse and fine Aggregates from natural source

for concreteIS-432 Indian Standard Specification for Mild Steel and Medium Tensile

Steel Bars and Hard Drawn Steel Wire for concrete Reinforcement - Part 1 and 2

IS-456 Code of practice for Plain and Reinforced Concrete for General Building Construction.

IS-457 Code of practice for Plain and Reinforced Concrete for General Building Construction.

IS-460 Specification for Test Sieves (Part 1 II & III)

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IS-515 Specification for natural and manufactured aggregates for use in mass concrete.

IS-516 Methods of tests for strength of concrete IS-650 Specification for standard sand for testing of cementIS-1190 Methods of sampling and analysis of concreteIS-1200 Method of measurement of building and civil engineering works;

Piling (Part 23) IS-1322 Specification for bitumen felts for waterproofing and damp

proofing IS-1489 Specification for Portland Pozzolana Cement (Parts 1 & 2)IS-1536 Centrifugally Cast (Spun) Iron Pipes for water gas and Sewage IS-1537 Vertically Cast Iron Pressure Pipes for Water, Gas and Sewage IS-1538 Cast Iron Fittings for Pressure Pipes for water, gas and sewage IS-1566 Specification for hard drawn steel wire fabric for (Parts I & II)

concrete reinforcementIS-1786 Specification for high strength deformed steel bars and wires for

concrete reinforcement.IS-1742 Code of Practice for Building drainageIS-1791 Code of practice for batch type concrete mixersIS-1893 Criteria for earthquake resistant design of structuresIS-2386 Methods of test for aggregates for concrete (Parts 1 to 8)IS-2395 Code of practice for painting concrete, masonry and plastering

surface (Part I & II)IS-2430 Method of sampling of aggregates for concreteIS-2438 Specification for roller pan mixerIS-2502 Code of practice for bending and fixing of bars for concrete

reinforcementIS-2505 General Requirements for concrete vibrators: Immersion typeIS-2506 General Requirements for Screed board concrete vibratorsIS-2514 Specifications for Concrete vibrating tablesIS-2571 Code of Practice for Laying In-situ Cement Concrete FlooringIS-2645 Specification for integral cement waterproofing compoundsIS-2722 Specification for portable swing weigh batcher. (Single & Double

bucket type)IS-2750 Specifications for steel scaffoldingsIS-2751 Code of practice for welding of mild steel plain and deformed

bars used for reinforced concrete constructionIS-2770 Methods of testing bond in reinforced concreteIS-3025 Methods of sampling and test (physical and chemical) water

used in industryIS-3085 Method of tests for permeability of cement mortar & concreteIS-3366 Specification for pan vibratorsIS-3370 Code of Practice for Concrete Structures for Storage of Liquids

(Part 1 to 3)IS-3414 Code of practice for design and installation of joints in buildings

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IS-3558 Code of practice for use of immersion vibrators for consolidating concrete.

IS-3559 Pneumatic concrete breakersIS-3696 Safety code scaffolds and ladders (Part 1 & 2)IS-4014 Code of practice for steel tubular scaffolding (Parts 1 & 2)IS-4031 Method of physical tests for hydraulic cement (Parts 1 to 15)IS-4032 Method of chemical analysis of hydraulic cementIS-4078 Code of practice for indexing and storage of drill cores.IS-4082 Recommendation on stacking and storage of construction

materials at siteIS-4326 Code of practice for earthquake resistant design and

construction of buildingIS-4634 Method of testing performance of batch type concrete mixersIS-4656 Specification for form vibrators for concreteIS-4845 Definitions & terminology relating to hydraulic cementIS-4900 Specification for plywood for concrete shuttering workIS-4925 Concrete batching and mixing plantIS-4926 Ready mixed concreteIS-4984 Specification for high density Polyethylene pipes for potable

water supply (fourth revision)IS-4985 Specification for Unplasticized PVC pipes for potable water

suppliesIS-4998 Criteria for design of reinforced concrete chimneysIS-5329 Code of Practice for Sanitary Pipe Work above Ground for

BuildingsIS-5525 Recommendation for detailing of reinforcement in reinforced

concrete worksIS-5892 Concrete transit mixers & agitatorsIS-6066 Recommendations for Pressure Grouting of Rock Foundations in

River Valley Projects.IS-6461 Glossary of terms relating to cement concrete (Part I to XII)IS-6925 Methods of test for determination of water soluble chlorides in

concrete admixturesIS-7242 Specification for Concrete SpreadersIS-7251 Specification for concrete finishersIS-7320 Concrete slump test apparatusIS-7325 Apparatus for determining constituents of fresh concreteIS-7861 Code of Practice for Extreme Weather Concreting (Parts 1 & 2)

recommended Practice for hot weather concreting, and for cold weather concreting.

IS-7989 Safety code for handling and storage of building materials.IS-8112 Specification for 43 grade ordinary Portland cementIS-8142 Method of test for determining setting time of concrete by

penetration resistance.IS-8989 Safety code for erection of concrete framed structuresIS-9103 Concrete Admixtures - Specifications

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IS-9284 Method of test for abrasion resistance of concreteIS-9417 Specification for welding cold worked bars for reinforced

concrete construction.IS-10262 Recommended guidelines for concrete mix designIS-11993 Code of practice for use of screed board concrete vibratorsIS-12330 Specification for sulphate resisting Portland CementIS-12269 Specification for 53 grade ordinary Portland CementIS-12436 Specification for Preformed Rigid Polyurethane and

Polysocyanureate Foams for Thermal InsulationIS-13920 Ductile Detailing of Reinforced Concrete StructuresIS-14687 Guidelines for False work for Concrete StructuresSP-23 Handbook on Concrete Mixes

2.2 ASTM Standards:

ASTM C-33 Standard specification for concrete aggregateASTM C-260 Standard specification for Air-entraining admixtures for ConcreteASTM C-494 Standard Specification for Chemical Admixtures for ConcreteASTM C-295 Standard guide for petrographic examination of aggregates for

concreteASTM E-11 Standard specification for wire cloth sieves for testing purpose.ASTM D-75 Sampling of aggregates

2.3 ACI Codes and Specifications:

ACI 203 Vacuum dewatered concreteACI 211.7-70 Recommended practice for selecting proportions for normal

weight concreteACI C 234 R-96

Standard specification for wire cloth sieves for testing purpose

ACI 304.2-68 Placing concrete by pumping method.

2.4 Other Standards

Railway Specifications

Tests for chloride & caliphate contents of aggregates

BS-8081 BS Code of Practice For Ground AnchoragesBS-8204 Vacuum dewatered concrete

ASME Section-III Div-2

3.0 Concrete – General:

The Contractor shall supply the concrete and concrete materials as specified herein and department shall hold the contractor solely responsible for supplying concrete and/or concrete materials in accordance with this specification.

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4.0 Material

4.1 Source and Approval

All materials shall be procured only from approved sources only. The Engineer will give such approval only after tests have been carried out to ensure that all materials are as per this specification and that concrete of acceptable quality can be made from the materials procured. The Engineer, however reserves the right to reject the materials and also disapprove the source even without conducting any tests on materials, if in his judgment, he considers that the materials are unsuitable.

4.2 Inspection Facilities and Sampling

The contractor shall provide all facilities, manpower, material etc. to the Engineer for Inspection, Sampling and Testing of various materials as specified herein under without any financial implications to department.

5.0 CementThe Contractor shall make necessary arrangements to the satisfaction of the Engineer for the following.

5.1 PurchaseThe cement should be purchased from renowned and well established manufacturer. The contractor shall have minimum two independent sources of supply throughout the period of contract for uninterrupted supply of cement. The sources shall be pre-qualified and approved by the Engineer with respect to quality of the final product, testing requirements and the capability to supply the approved cement in required quantity to meet the construction schedules. The above evaluation shall be done by the Contractor at his own cost.

5.2 SpecificationThe cement supplied to the site shall meet all the physical and chemical requirements as specified in IS 8112 (latest revision) I IS 12269 (latest revision) for 43/53 grades of Ordinary Portland Cement (OPC).

It shall be noted that all the types and brands of cement, which are being used at site, shall be subjected to the Engineer's approval.

For underground structures exposed to sub-soil and ground water, OPC with C3A content from 5 to 8 percent shall be used.

5.3 Pre dispatch testsCement released for the site shall have undergone following tests for each lot of 50 MT or part thereof or whenever batch changes. All the test results shall meet the requirement of 43/53 grade OPC as specified in IS 8112/1S 12269

The Contractor shall satisfy himself that the cement conforms to the requirements as specified in pre-dispatch tests. He shall produce the list of certificates for each batch from

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the manufacturer as soon as a new consignment arrives at site or immediately upon its storage at Site and before sampling for testing in-house or at laboratory approved by the Engineer. The Engineer shall have free access at any time to witness tests on any sample stored at manufacturer yard for dispatch to work site.

5.4 Tests at siteOn production of the test certificate by the Contractor, he shall arrange for site testing at department site laboratory or else .at any outside laboratory approved by Quality Assurance' group of department. Sampling in presence of department Quality Assurance Group for such tests shall be free of cost. Cement shall be accepted based on fulfilling the following test requirements as per IS 8112.

(1) Setting time Initial & Final - One per 250MT silo capacity.(2) Strength - One per 250MT silo capacity.(3) Soundness

Le-Chatelier method - One per 500 MT Autoclave method - One per 500 MT

(4) Specific gravity - One per 500 MT(5) Specific surface - One per 500 MT(6) Chemical test each brand for

(i) 43 Grade: each brand and one per 3 months (ii) 53 Grade: each brand and one per 3 months

At any time, if felt necessary the Engineer can insist on chemical analysis of the cement in addition to above.

The Contractor shall provide every facility to the Engineer including manpower etc. for the sampling, testing and inspection of cement at the site of the work at his own cost.

Contractor shall have procedures approved by the Engineer for all the tests to be conducted on cement.

In case all or any of the above mentioned tests are conducted in any of the outside laboratories approved by department, cost of complete testing shall be borne by the Contractor. Contractor shall ensure that the construction schedule is not affected because of testing of materials at outside laboratories.

Test results either in department site laboratory or at approved outside laboratories shall be taken as final and conclusive for the purpose of release of payment on supply of cement.

5.5 StorageThe contractor shall make necessary arrangements to the satisfaction of the Engineer for the storage of cement to prevent deterioration due to moisture and/or intrusion of foreign matter. If the storage arrangement is not to the satisfaction of Engineer, he may direct the Contractor to make such arrangements as he considers necessary, and in the event of non- compliance, he would reserve the right to make proper arrangements departmentally or through other agencies at the Contractor's risk & cost.

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The Contractor shall have adequate, weatherproof storage capacity for storing of cement required for a period of one month. Bulk cement shall be stored in approved waterproof bins or silos. Bagged cement shall be stored in a suitable weather tight warehouse, in a manner to provide easy access for identification, inspection and withdrawal of each consignment. During monsoon, if necessary, like warm dry air blast be circulated intermittently inside warehouses to keep the surrounding air free from moisture. Storage buildings shall have a capacity for the storage of sufficient quantity of cement to allow sampling at least two weeks before the cement is used. In any event, the storage capacity shall be adequate to stock enough quantity of cement to ensure uninterrupted work in accordance with the construction schedule. Stored cement shall also meet the test requirements as per relevant IS codes and any other specific requirement at work site at any time after storage, when a retest is ordered by the Engineer. Each consignment shall be stacked separately with the date of receipt flagged on it, not more than 12 bags being stacked in height, the bags being arranged with headers and stretchers and each stack to be of 1000 bags with number of the stack flagged. There should be sufficient space between two stacks for easy access for sampling, inspection and withdrawal.

One sample from each stack of 1000 bags/capacity of the silo shall be taken and tested as per relevant Indian Standards/specified requirements. Cement may be released for use in site only upon it's passing the standard tests as per Clause No 5.4 of this specification. Normally consignments shall be used in the order of receipt at site unless otherwise directed. In the case of large concrete pours, the Engineer will decide on the batch of cement to be used taking into consideration the quantity of cement with particular reference to the concerned concrete pours. Any additional work in handling and storage of cement above this requirement shall be to the contractor's account and no extra claim will be entertained. At the beginning of each day's work the Contractor shall transport cement to different work sites in quantities depending on the day's requirement. Cement shall be protected from exposure to moisture in transit, in storage at the works site until it is used on the work.

Cement which has remained in bulk storage at the factory for more than three months, or which has remained in bags either in dealer's storage or at work site for more than 3 months or even before this period whenever suspected during and after rainy season shall be invariably retested by contractor to see that it conforms to the specified requirements. For high performance concrete cement older than 3 months after its 'manufacture shall not be used. Cement shall be rejected if it fails to conform to any of the specified requirements. On rejection, it shall be promptly removed from the site of work at the cost of Contractor.

Contractor shall depute a qualified and experienced storekeeper for maintaining stock position. Record shall be maintained at all the time indicating the status of consumption, stock, opening balance, closing balance, test certificates from manufacturer's department site laboratory or at approved outside lab. This record shall be subjected to frequent verification by Contractor and check measured by the Engineer. Details in the record being maintained should be identified by the manufacturer, stack No at store yard, testing status along with certificates, date of manufacture, source of cement, Location for which the cement being released, Issue voucher No etc., along with date and time of release of cement from store.

Contractor shall have a procedure approved by the Engineer for the periodic inspection of

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stored cement to detect any deterioration & separation of deteriorated material. The contractor at his own cost shall remove such rejected/deteriorated cement from work site.

Contractor shall be responsible for testing including physical and chemical tests as per relevant IS code to the test requirements at any stage before the cement being put into use.

6.0 Aggregates6.1 Source and approvalThe Contractor shall make necessary arrangements to the satisfaction of the Engineer for supply of approved quality fine and coarse aggregate of normal & heavy density to the work site from. approved sources.

Note: The contractor is deemed to have made his own investigation and also bound by the stipulations under relevant section.

For all other manufactured construction materials such as bricks, timber or any other materials the contractor is deemed to have made his own survey and included in the unit rates.

All local factors involved in arriving at the rates shall deem to have been considered, from local material suppliers.

Prevailing royalty charges and taxes are to be borne by the Contractor and deemed to have been included in rates quoted".

Any new source shall be prequalified as per the relevant Indian Standards/other specifications as noted in this specification and approved by the Engineer without any additional claim to department. Contractor shall be responsible for ascertaining the yield of sand / identifying new source if necessary. Department is not responsible for non-availability of sand.

6.2 Inspection facilitiesThe Contractor shall, at his own cost, provide all facilities, manpower, material etc to the Engineer, both at the source and at the site of work, for sampling, inspection and testing for carrying out tests which cannot be carried out at department site laboratory, throughout the contract period.

6.3 Samples Approval of the Engineer shall be obtained before bringing aggregates (coarse & fine) from any quarry/source. Samples of materials, proposed to be used shall be submitted free of charge in sufficient quantities to the Engineer for his approval. Approved samples shall be identified and preserved by the Contractor for future reference. This approval shall not, in any way, relieve the Contractor of his responsibility for ensuring supply of materials in strict conformity with this specification.

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6.4 Damaged materials Any material considered damaged, deteriorated and/or not conforming to specifications or considered defective shall be immediately removed by the Contractor from the site of work at his cost. If the contractor fails to remove the material within 48 hours of notice given by the Engineer, the Engineer reserves the right to have the materials removed from the site and charge the Contractor, the expenditure incurred.

6.5 Storage All materials shall be stored at work site in adequate quantities (minimum four weeks storage) well in advance to meet the construction schedule. Coarse & fine aggregates shall be stacked separately in such a manner to prevent contamination by foreign material. All aggregates shall be stored on concrete or masonry platform. Rock ladder shall be provided to avoid segregation during free fall of aggregates from conveyor belt while loading the aggregates in the bins. Each size shall be kept separate with wooden, steel, concrete Or masonry bulkheads or shall be stored in separate stacks, taking care to prevent the materials at the edges of the stock piles from getting intermixed. Stacks of fine and coarse aggregates shall be stored in easily measurable stacks of suitable heights as may be directed by the Engineer. Reclamation tunnel shall be provided below the stacks of coarse & fine aggregates and the transportation of the aggregates shall be such that the grading is not affected. Manual handling is permitted only on specific approval of Engineer. If the storage arrangement is not to the Engineer's satisfaction, the Engineer may direct the Contractor to make such arrangements as he considers necessary and in the event of non-compliance, he reserves the right to make proper arrangement departmentally or through other agencies at Contractor's risk and cost. High density fine aggregates shall be suitably stored in covered sheds to prevent them being washed off by rains. Storage shall be done at locations acceptable to the Engineer.

6.6 SpecificationAII the tests required for pre-qualification shall be carried out by the Contractor at his own cost well in advance in consultation with Engineer. Following specifications shall serve as guidance for testing and acceptance. IS 383, IS 2386, ASTM C-295, ASTM D1411, SP -23, Railway Specifications and any other relevant Specifications. The code I standard to be used for any particular test shall be decided by the Engineer based on requirement at work site.

6.7 Fine AggregatesNatural or manufactured fine aggregates shall be of following types:

6.7.1 Normal Fine AggregatesNormal fine aggregates shall consist of natural sand, manufactured sand, or an approved combination' thereof. Fine aggregates shall be graded within the limits of Zone II specified in Table-I. The sand shall be of siliceous material, sharp, hard, strong and durable and shall be free from adherent coating, clay, dust, alkali, organic material, deleterious matter, lumps, etc. The sand lots falling in the Zones I & III or Zones I, III & IV shall be proportioned suitably to obtain the combined grading fulfilling the limits of Zone II specified in Table 1. However Zone IV of Table I should not be used.

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Table – 1Grading limits for Fine Aggregates

IS SIEVE PERCENTAGE PASSING BY WEIGHT DESIGNATION ZONE-1 ZONE -II ZONE -III ZONE-IV

10m 100 100 100 100 4.75mm 90 -100 90 -100 90 -100 95 -100 2.36mm 60-95 75 -100 85 -100 95 -100 1.18 mm 30-70 55-90 95 -100 90 -100 600 micron 15-34 35-59 60-79 80 -100 300 micron 5-20 8-30 12-40 15-50 150 micron 0-10 0-10 0-10 0-15

6.7.2 High Density Fine AggregatesHigh-density fine aggregates shall consist of sand manufactured from hematite ore or from other iron-ore approved by the Engineer. High- density fine aggregates shall be graded to the required zone within the limits specified in Table-1( Zonal and Zone II). For this purpose the fine aggregates shall be suitably fractioned into coarse, medium and fine varieties.

6.7.3 Special Heavy Fine AggregatesThese shall be made up of well graded steel shots suitably introduced in the concrete mix as replacement to fine aggregates to achieve the required density and workability of super heavy concrete.

All these steel aggregates shall be free from rust and/or oil coatings.

Special heavy fine aggregates shall be graded to the required zone within the limits specified in Table-lB.

Table – IB : Grading for Special Heavy (Steel Shots) Fine Aggregates

Steel Shots size in mm

Percentage by Weight Remarks

5 - 4.5 10 Note:A suitable proportion if hematite fine aggregate shall be used to obtain proper combined gradation, such that concrete of the required workability, density and strength is achieved, which shall be derived by conducting concrete trial study series in the laboratory

4.5 – 4.0 124.0 – 3.5 123.5 – 3.0 123.0 – 2.5 122.5 – 2.0 122.0 – 1.0 12

0.5 18Total 100 %

6.7.4 Note:For crushed stone the permissible limit on 150 micron IS sieve is to be increased to 20%. This shall not affect the 5 percent allowance permitted on clause 4.3 of IS - 383.(latest edition) applying to other sieve size.

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Fine aggregate complying with the requirement of both grading Zone-I & II of Table-I is suitable for concrete production but the quality of concrete produced will depend upon a number of factors including proportions.

In addition to above grading, the fine aggregate shall be so graded that concrete of the required workability, density and strength can be produced using the specified water cement ratio. The method of determining gradation by sieve analysis shall be according to 1S: 2386 latest edition.

6.8 StandardsExcept as otherwise called for in this specification, the aggregates shall conform to latest Indian Standard Specifications.

6.9 Screening and washingEither natural or manufactured sand shall be prepared for use by such screening, washing or both, as necessary to remove all objectionable foreign matter while separating the sand grains to the required size fractions. Natural sand shall be washed, unless the Engineer gives specific written permission, to use the sand that meets the specification and standards of cleanliness without washing. The Contractor at work site shall provide the requisite washing facilities at his own cost.

6.10 Foreign materials limitationsThe fine aggregate shall be free from injurious amounts of dust, clay lumps, pyrites, coal, lignite, soft or elongated or flaky particles, shale, alkali, organic matter, loam, mica and other deleterious substances. It should not contain impurities or material which may affect strength and durability of concrete or which are liable to attack steel reinforcement. The percentage of deleterious substances in the fine aggregates, as delivered to the mixer shall not exceed the values given in Table-2, when tested in accordance with IS: 2386.

Table – 2

Fine aggregateNormal (% by weight) High density

(% by weight)River sand Crushed sanda) Material passing 75 micron 3.00 (max.) 15.00 (max.) 5.00 (max.)**b) Shale 1.00 (max.) Nil Nilc) Coal and Lignite 1.00 (max.) Nil Nild) Clay lumps 1.00 (max.) 1.00 (max.) Nile) Total of other deleterious substances such as alkali, Mica coated grains, soft and flaky particles and loam

2.00 (max.) 2.00 (max.) 1.00 (max.)

f) Total of all above substances

5.00 (max.) 2.00 (max.)* 3.00 (max.)

* Excluding (a)

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** Depending on actual workability and w/c, maximum limit shall be reduced.

6.11 Organic impuritiesAggregate, when tested in accordance with IS: 2386- Latest edition, The method of test for organic impurities in sand", producing a colour darker than the standard, shall be rejected. However such sand, when tested for mortar-making properties, and the mortar develops a compressive strength at 7 and 28 days of not less than 95% of that developed by a similar mortar made from another portion of same sample which has been washed in 3 % solution of sodium hydroxide followed by thorough rinsing in water, then the Engineer may permit use of such sand on works.

For sand, which is used after washing, the washed water from the sand shall be free from water-soluble chloride and sulphate content. The presence of chloride & sulphate content can be checked with silver nitrate and barium chloride respectively. Approval of the Engineer shall be taken before bringing sand from a sand quarry.

6.12 GradationThe fine aggregates shall be so graded that concrete of the required workability, density and strength can be produced using the specified water cement ratio. The method of determining gradation by sieve analysis shall be according to IS 2386 latest edition. A rod mill impact or any other suitable crushing system shall also be installed by the contractor for production of crushed sand of the requisite quality to mix with natural sand as may be required to obtain the specified gradation and the fineness of fine aggregates. The layout of the crushing, washing, batching, and chilling plants and transport system will be subject to the approval of Engineer.

6.13 Specific gravity Normal sand having a specific gravity below 2.60 (saturated surface-dry basis) shall not be used without special permission of the Engineer. High Density fine aggregate having an average specific gravity (saturated surface dry basis) below 4.65 shall not be used. Three nos. of samples per 10 Tonnes of high density aggregate shall be taken and an average specific gravity of all the samples shall only be considered for working out an average. Sampling of aggregates shall be in accordance with ASTM D-75 and IS 2430 (latest).

Specific gravity of fine steel aggregates shall not be less than 7.5.

6.14 Frequency of testing & other characteristics The fine aggregate shall be tested for physical, chemical and mechanical properties and impurities content as per schedule given in Table No. 5. .

6.15 Coarse aggregates Coarse aggregates shall be of following types.

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6.15.1 Normal coarse aggregates Normal coarse aggregate shall consist of hard, strong, durable particles of crushed stone aggregates shall be angular & nearly cubical and shall be free from thin elongated soft pieces, vegetable or other deleterious matter. It shall have no adherent coating.

Elongation and flakiness index of the processed aggregate shall not be more than 15% each when tested as per relevant Indian Standard.

6.15.2 High density coarse aggregates

High density coarse aggregates for making heavy concrete shall consist of stone manufactured from hematite ore or any other approved iron ore. The aggregate shall be free from an excess of thin elongated soft pieces, vegetation and other deleterious matter.

High-density coarse aggregates shall be manufactured by crushing iron ore obtained from a quarry approved by the Engineer. The ore shall not be of the laminated variety. The iron ore boulders (lumps) shall be uniformly compact, dense and strong and shall be free from laterite or other coverings/coatings. .

The iron ore boulders shall be of size above 75 mm and shall be kept in stacks of about 10 tonnes capacity or as specified by the Engineer for sampling at the site of crushing. The samples shall be collected and tested free of cost as per the directions of the Engineer. The stacks shall be identified by proper numbering and a statement showing the arrivals and stock position shall be submitted to the Engineer regularly. Minimum 3 numbers of samples shall be collected from stacks of 10 tonnes each and tested as directed by the Engineer. Such of the stacks as are found defective shall be removed forthwith from the site by the Contractor at his own cost.

A stack is declared to have been approved for crushing when:

The average value of the specific gravity of minimum 10 boulder samples is 4.65 or above and no single value is less than 4.50. If any value is found less than 4.5 then 2 more samples shall be tested from the same lot after proper sorting out and removal of such visible objectionable boulders (lumps) and both of the samples shall meet above requirement.

The average specific gravity of the finished coarse and fine aggregates shall not less than 4.65.

Elongation and flakiness index-of the processed aggregate shall not be more than 15% when test as per relevant Indian Standard.

6.15.3. Special Heavy Coarse Aggregates

The special heavy coarse aggregates for making Super Heavy Concretes shall consist of artificial heavy aggregates, well graded steel punching or sheared steel bars of suitable size as replacement of coarse aggregates. The maximum size of these aggregates shall not exceed 20 mm in order to maintain uniform good workability and to achieve satisfactory homogeneity in the finished concrete. The lid ratio shall be nearly one. The

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quality of these aggregates shall be the same as that of the steel bars used as reinforcement in the structure.

All these steel aggregates shall be free from rust and/or oil coatings.

Concrete mixes using these heavy aggregates shall be carefully designed to avoid segregation during handling, placing, compaction.

6.16 StandardsNormal coarse aggregate shall conform to IS:383.

6.17 WashingCoarse aggregate shall be washed if necessary to remove all vegetable and other perishable substances and objectionable amounts of other foreign matter. Contractor shall have washing facility at site of work for everyday washing. He shall establish a procedure for washing to prove that the aggregates, coarse and fine, after washing, fulfill the specified requirements.

6.18. Grading The. size of normal and nigh density coarse aggregates shall· be selected from the standard sizes given in Table- 3A, 38, 3C, 3D, 3E and 3F and as per IS:383. The method of determining grading by sieve analysis shall be according to IS:383.and IS:2386 latest edition. The stones shall be crushed by the Contractor in primary and secondary crushers to yield the aggregates as per specification and sizes as required for the concrete as described under various items of schedule of quantities contained in relevant section of - the document. In certain areas where there is congestion of reinforcement and embedment’s, appropriate size of aggregates required shall be used without any additional cost to department for screening off the necessary quantity of the required aggregate from the stock piles.

In addition to above, high density coarse aggregates shall be separated into two sizes/fractions;

a) bet 20mm and 10 mm -Table 3A b) bet 10mm and 4.75mm -Table 38

When combined in proper proportion, it shall fit in the grading limits as in Table 3C.

Table – 3ACombined Grading Requirement for High Density Heavy Coarse Aggregates

(between 20mm and 10mm)

IS SIEVE size in mm Percent passing by weight25 10020 95-1010 0-10

4.75 0

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Table – 3BCombined Grading Requirement for High Density Heavy Coarse Aggregates

(between 10mm and 4.75mm)IS SIEVE size in mm Percent passing by weight

20 10010 60-100

4.75 0-10

Table – 3CCombined Grading Requirement for High Density 20mm Coarse Aggregates

IS SIEVE size in mm Percent passing by weight25 10020 95-10010 30-50

4.75 0-10

Table – 3DGrading Requirements for High Density Heavy 12.5mm Coarse Aggregates

IS SIEVE size in mm Percent passing by weight16 100

12.5 95-10010 45-80

4.75 0-10

Table – 3EGrading Requirement for High Density Heavy 10mm Coarse Aggregates

IS SIEVE size in mm Percent passing by weight12.5 10010 85-100

4.75 0-10

Table – 3FGrading Requirement for Special Heavy (Steel Cuttings) 20mm Coarse Aggregates

Steel Bar Dia in mm

Percentage by Weight

Length of Pieces to be cut in mm Remarks

20 5 20 A suitable proportion of Hematite coarse aggregate shall be used to obtain proper combined gradation, such that concrete of the required workability, density and strength is achieved, which shall be derived by conducting concrete trial study series in the laboratory

18 15 1816 15 1612 15 1210 15 108 15 86 20 6

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6.19 Specific gravity

Normal coarse aggregate shall have a specific gravity (saturated surface dry basis) not less than 2.7. High density coarse aggregate shall have an average specific gravity (saturated surface dry basis) not less than 4.65. .

Specific gravity of special heavy coarse (steel) aggregates shall not be less than 7.5.

6.20 Foreign materials

The amount of deleterious substances for coarse aggregates shall not exceed the following limits as given in Table No. 4 below.

Table No. 4

Deleterious Substances Maximum percent by weight of total sample

Normal High densityCoal and Lignite 1.0 NilShale Nil NilClay lumps 1.0 NilSoft Fragments Nil NilMaterial finer than 75 micron 3.0 2.0Total of other deleterious substances such as alkali, mica coated grain, soft fragments and loam etc.

0.5 0.5

Sum of percentage of all deleterious materials

5.0 2.5

6.21 Frequency of testing and other characteristicsThe coarse aggregate shall be tested for physical, mechanical and chemical properties and impurities content as per the schedule given in the Table No. 5.

Table No. 5Aggregate Testing Schedule

Sl. No.

Activity / TestRequirement Frequency Applicable

code Remarks

1. Petrographic analysis

New Source or change in quality of aggregates observed, one sample per source

IS:383/ASTM C-295IS:2386(Part – VIII)

Strained quartz < 20%

2 Alkali reqctivity (by both of the following)

New Source or change in quality of aggregates observed, one

IS:383/SP23/IS:2386(Part – VIII)

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sample per source

a] Chemical method Once in 6 months during progress of work

b] Mortar bar test One per source IS:2386ASTM C1260

Six months 0.05% maxOne year 0.10% max

3 Chloride content One per source Railway Spec. ASTM D-1411

0.02% by wt max*

4 Sulphate content One per source Railway Spec. ASTM D-1411

0.04% by wt max

5 Crushing value Once in 3 months one sample per source

IS:2386 IS:383 30% max.

6 Abrasion value Once in 6 months IS:2386 IS:383 30% max.7 Impact value Once in 3 months

one sample per source

IS:2386 IS:383 30% max.

8 Specific gravity(SSD condition)

Once in 3 months one sample per source

IS:2386 2.70 (For C.A)21.60 (For F.A)4.65 (For H.A)7.5 (For S.H.A)

9 Size and Gradation One sample per shift or **

IS:383/ASTM C33

Refer Table No. 1&3

10 Flakiness & elongation index

One sample for 2500cu.m. of concrete or once in a week whichever is earlier or **

IS:2386 15% Each max.

11 Absorption/moisture content

One sample daily or **

IS:2386 3% max.

12 Deleterious material One sample per 6 months

BHAVANI Spec / IS:2386 / IS:383

Ref Table 2&4

13 Organic impurity (only for F.A.)

Once in 6 months or ** or change in quality of aggregate One sample per source

BHAVANI Spec / IS:2386 / IS:383

NO impurity

14 Iron content for heavy density aggregate

Well in advance of commencement of work and once sample for 2000 MT or part therof. Or **

BHAVANI Spec 60.0% min.

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* However the total amount of chloride contributed from all the ingredients in one cubic meter of concrete shall not exceed 600 g/cum for reinforced concrete and 400 g/cu., for prestressed concrete. ** Whenever visual inspection demands, Engineer will instruct.

Note: River sand shall be screened through 6 mm square hole mesh and sand passing

shall be washed prior to using for concrete works. Crushed sand is not a by-product. It is specially crushed from aggregate. Silt content shall be checked for each truckload of river sand and dust content

shall be checked for each truck load of crushed stone. All the above tests shall be conducted to qualify the quarry or source of

aggregates.

7.0 WATER

7.1 Water For Concreting Water for concreting shall meet the following requirements.

Water used for both mixing and curing shall be clean & free from injurious amounts of oils, acids, alkalis, salt, sugar, organic materials or other substances that may be deleterious to the concrete or steel. Potable water is generally considered satisfactory for mixing and curing the concrete. Engineer shall approve the sources and treatment of water for concrete. As a guide, the following concentrations represent the maximum permissible values:

To neutralize 100 ml sample of water, using phenolphthalein as an indicator, it should not require more than 5 ml. of 0.02 normal NaOH. The details of test shall be given in IS: 3025 (Part 22).

To neutralize 100 ml sample of water, using methyl orange as an indicator, it should not require more than 25 ml of 0.02 normal H2SO-. The details of test shall be as given in IS: 3025 (Part 23).

Permissible limits of solids when tested shall be in accordance with IS:3025

In case of doubt regarding development of strength, the suitability of water for making. concrete shall be ascertained by the compressive strength and initial setting time tests specified in Clause 5.4.

The sample of water taken for testing shall represent the water proposed to be used for concreting, due account being paid to seasonal variation. The sample shall not receive any treatment before testing other than that envisaged in the regular supply of water proposed for use in concrete. The sample shall be stored in a clean container previously rinsed out with similar water.

Average 28 days compressive strength of at least three 15 cm concrete cubes prepared with water proposed to be used shall not be less than 90 percent of the average of strengths of three similar concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested in accordance with the requirements of IS: 516.

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The initial setting time of test block made with the appropriate cement and the water proposed to be used shall not be less than 30 minutes and shall not differ by +30 minutes from the initial setting time of control test block prepared with the same cement and distilled water. The test blocks shall be prepared and tested in accordance with the requirements of IS: 4031.

The pH value of water shall generally be not less than 6.

The water found satisfactory for mixing is also suitable for curing concrete. However water used for curing should not produce any objectionable stain or unsightly deposits on the concrete surface.

7.2 Temperature Mixing water shall be kept cool by storing it under cover. Water shall be transported to the mixing plant in such a way that there is no rise in temperature. If chilled water, flakes or crushed ice is used as part of the mixing water to achieve the specified temperature of water, it is recommended that the Contractor shall install and maintain in good working condition the adequate refrigeration facility to produce chilled water at temperature not exceeding 8 C. The Contractor shall also build and maintain well-insulated adequate capacity storage tanks for cold water with insulated connecting piping. To supplement this refrigeration facility, the Contractor may use ice plant or commercial ice manufactured from water meeting the requirements of clause 7.0 & Table 6, subject to approval of the Engineer. The full quantity of crushed ice shall be stored in cold storage 24 hrs in advance of start of concreting. The temperature in the cold storage shall not be more than -2°C. Contractor shall arrange flake icemakers of required capacity. The Contractor should however, study the placing temperature condition and workout a plant capacity commensurate with the construction schedule and concrete placing equipment indicated therein and submit his scheme and obtain the approval of Engineer before the actual commencement of work.

7.3 Pre-Qualification & Testing Pre-qualification shall be done by the Contractor in consultation and close co-ordination with Engineer well in advance of commencement of work in line with the requirements as mentioned in the various clauses of this specification- In addition to this, Contractor shall arrange for testing of one water sample every three months or as directed by the Engineer at contractor's own cost.

Note: Storage tank shall be cleaned once in a month or whenever the Engineer in his judgment feels that tank need to be cleaned.

7.4 Supply Pressure Clean water in pipes under press-ure shall be provided by the Contractor with all necessary equipment for giving adequate nozzle pressure (2 kg/sq.cm) as required even at the highest elevation, for convenient and effective jetting on concrete surfaces, for cooling aggregate required for concrete, for curing concrete and other requirements.

8.0 Ice

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Ice if used as replacement for a portion or all of the mixing water, it shall be produced from water, which meets the requirements of clause 7.0. Ice when used shall be crushed/flaky condition and such ice shall have thickness less than 3 mm. The Contractor shall make his own arrangement for storing adequate quantity of ice.

9.0 ADMIXTURES

9.1 General All types of Admixtures, minerals and chemical admixtures etc shall be used in concrete only with the 'approval of the Engineer. Admixtures shall be used in concrete only with the approval of the Engineer. admixtures shall be added to the mix by an approved automatic dispenser, which shall be directly controlled by the batching plant operator. The contractor shall procure all chemical admixtures required for the works. Contractor shall arrange for pre-qualification of such admixtures to fulfill the requirements as specified in ASTM C-494, at his own cost. With the passage of time, neither the compressive strength nor durability of concrete shall be reduced lesser than that permitted by Indian standard.

Other properties of concrete and steel shall not be impaired by the use of admixtures. Chloride of an admixture shall be such that the total amount in the concrete at the time of placing shall be limited to 600 gm/rn3 for RCC works. In the case of air entraining agent a reference of approved quality shall be used in the controlled concrete to entrain identical amount of air. Admixtures shall be used in the manner and with the control specified by the Engineer. Chemical admixtures shall be used to suit the requirements of the work. Material shall be procured only after qualification in accordance with these codes/specifications. Type of admixture to be used shall be decided only on approval of Engineer.

Admixtures shall be tested as per ASTM C 494 / IS 9103 / SP23. The admixtures shall be accompanied by a manufacturer's certificate indicating the utilization limit date. The product concerned shall not be used after this date.

Admixtures shall be mixed into the mixing water except for the liquefiers, which are placed in barrel of mixer trucks, at the end of transport at the site.

Utilization and storage conditions shall conform to those specified by the manufacturer in the corresponding technical documentation.

9.2 Air Entraining AgentsWhere specified, approved by the Engineer, entraining agents conforming to the requirements of ASTM C-260 (Air entraining admixtures for concrete) may be used to entrain the specified amount of air in the concrete mix. The recommended total air content of the concrete at the mixer is as follows.

Maximum aggregate size Total air %20mm 5 +/- 140mm 4 +/- 1

Method of measuring air content will be as per IS 1199.

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9.3 High Range Water Reducing AdmixturesWhere specified and approved by the Engineer high range water reducing admixtures shall be added in quantities specified by the Engineer in the form of solution.

9.4 High Range Water Reducing and Retarding AdmixturesWhere specified and approved by the Engineer, an admixture which is high range water reducing and delays the setting of concrete mixture shall be used in quantifies specified by Engineer. ,

9.5 Accelerating Admixtures (Type C or Type E) Where specified and approved by the Engineer, an admixture when added to concrete, mortar or gout, increases the rate of hydration of a hydraulic cement, shortens the time of set, or increases the rate of hardening or strength development, shall be used in quantities specified by the Engineer.

All the above admixtures shall be added to the required quantities which shall be established after carrying out different mix trials and shall be aimed to achieve the required properties of fresh and hardened concrete.

9.6 Water Proofing Admixtures Where specified and approved by the Engineer, waterproofing agents conforming to IS:2645, shall be added in quantities specified by the Engineer.

9.7 Surface Retarders Approved brand of surface retarding (set retarding) agents shall be used for preparation of construction joint by green cutting of concrete after final setting time of concrete. Such retarder shall be able to expose the aggregates uniformly by removing the cement sand matrix for 5 to 7 mm after S hours of concrete placement or final setting time, whichever is earlier when water is sprayed with a pressure of 7 Kg/sq.cm from distance of 500mm (approximately).

9.8 Acceptance and Storage Contractor shall produce test certificates as per relevant codes for each batch of material received at Site. The contractor shall have sufficient storage space to store the material after acceptance of the material by the Engineer on production of tests certificates as well as the certificates issued by in house testing facility or any approved laboratory.

Admixture shall be used as per manufacturer's instruction and with the control specified by the Engineer. The admixture shall be tested as per ASTM C-494. The admixture shall be accompanied by manufacturer's certificate indicating the utilization limit date. The product shall not be used after this date.

a)

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Tests on chemical analysis and infrared spectroscopy shall be conducted for every batch or part thereof.

All Admixtures shall meet the physical requirements as per ASTM C 494.

The cost towards all admixtures, minerals shall be included in the item rate of concrete.

No separate payment will be made on account of any admixtures/minerals.

All the expenditure for all of the tests mentioned above shall be borne by the Contractor.

10.0 AGGREGATE CRUSHING AND PROCESSING PLANT Aggregate crushing and processing plant to be provided by the Contractor shall conform to the following.

10.1 Type of plant Except where aggregates are required in small quantities and can meet the requirements from an approved single commercial source, a modem and dependable aggregate plant capable of producing satisfactory concrete aggregates in sufficient quantities and the rate necessary to meet the requirements of the construction schedule without interruption shall be provided by the Contractor at a location acceptable to the Engineer. The crushing plant of minimum capacity of 3SO cu.m. per day shall comprise of jaw crushers, cone crushers, gyro sphere and rod mill or any other type of crusher approved by the Engineer. All aggregates produced in the primary crusher shall pass through secondary crushers before being taken to final screening and loading in bins. Complete facilities shall be provided for proper washing, classifying, storing, reclaiming and delivering the aggregates to the mixing plant. The Contractor shall install rock ladders when free fall of aggregate is more than 2m, to avoid breakage of aggregates and reduce production of undersize during production as well as storage of coarse aggregates. Aggregate taken to storage bins over the batching plant shall be free from under-sizes.

Option lies with the Contractor as regards provisions of coarse/fine aggregates from the approved quarry as specified in Clause 6.1. However in case he desires he can obtain necessary quarry permits from local Government bodies. All the necessary royalty and license fees shall be paid by him directly to the local Government body without any claim made from the owner on this account.

The crushing plant shall not make the area dusty and dust level shall be lower that specified by Environmental pollution control authority. To achieve this the crushing plant should have dust collection arrangements and the boulders should be wetted with water sprinkling before loading in to crushing plant.

10.2 Test run The aggregate plant shall be operated for a sufficient time in advance of the dates set for first placement of concrete to permit the development of procedures which result in high capacity production of aggregates proven by tests to meet all the requirements of this specification.

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10.3 Fines in sand The facilities for fine aggregate production shall be so designed and operated as to retain the necessary quantity of finer fractions. An excess of fines will not be permitted. All crushing, washing, screening, classifying, blending, batching or other properties of fine aggregate necessary to meet these specifications shall be performed so as to produce acceptable gradation complying with this specification.

10.4 Drainage of sand Aggregates shall not be added directly from the washing or classifying operation to the aggregate bins in the concrete mixing plant, but shall be stored as required, to permit drainage of excess water and in such a manner as to avoid contamination by foreign materials. Sand shall remain in free-draining storage for at least 48 hours prior to use.

10.5 SegregationThe stock piles for aggregates shall be formed so as to prevent segregation and as approved by the Engineer. The deposition and removal there from shall be done in a manner to maintain the uniformity of grading. The side slopes of stock piled aggregates shall be kept flatter than the angle of repose to prevent accumulation of coarser material at the bottom of the slope.

Unless otherwise specified, coarse aggregate shall be supplied in separate stockpiles in the following sizes.

4.75mm to 10mm 10mm to 20mm 20 mm to 40mm

Sufficient quantity of stockpile proportionate to requirement as per construction schedule, for each aggregate size shall be maintained for normal aggregate. Heavy aggregate shall be processed so that complete stockpiles are available prior to placing.

10.5.1 Stock Piling

If aggregates are to be stock piled, they shall be on a proper base made out of rubble soling or plain cement concrete flooring to avoid contamination of ground soil, and if required at surrounded on three sides by masonry wall dividers for each type/size of aggregates or as directed and approved by the Engineer.

10.6 Volume of storage The contractor shall study the construction schedule and workout the volume of storage required to meet the maximum rate of concreting per hour.

Sufficient live storage of all size fractions of processed aggregates shall be maintained at all times to permit continuous placing of concrete at the rate commensurate with schedule

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requirements. The Contractor may also plan to store sufficient quantity of coarse and fine aggregates so that concreting during monsoon can proceed without hindrance, as the collection of the same during monsoon may be difficult.

10.7 Approval of aggregate plant layout The contractor shall submit the details of plant and scheme for crushing and processing aggregate including description and capacities of crushers, details of processing equipment, conveyors, electric motors etc. and flow chart of the scheme giving the rates -of flow of materials at various crushing and separation point. The contractor shall store all the three sizes of aggregates, sand separately in the covered cylindrical bins of minimum 600 tons capacity each, to keep the same free from foreign materials. The contractor shall provide rock ladders to avoid segregation during free fall of aggregate from conveyor belts. The contractor shall crush the aggregate at site near batching and mixing plant. However, due to certain circumstances, crushers had to be installed far away from storage bins then aggregate transported from crushing plant shall pass through the final screening plant. The contractor shall submit detailed arrangement of layout and take written approval of the Engineer before starting erection of crushing plant.

11.0 CONCRETE BATCHING PLANT A modem dependable batch-type mixing plant capable of producing concrete of specified quality and at the rate of output required to meet the schedule requirements shall be established by the Contractor. Two mixers of 60 m3/hr and one 30 m3/hr capacity preferably pan type shall be installed by the Contractor at location finalised by the Engineer. A balanced complement of transporting, handling and placing equipment shall be provided by the contractor at locations and in a manner approved by the Engineer. The concrete batching and mixing plant shall be completely installed with preliminary operation for a sufficient length of time prior to scheduled date for placement of first concrete, to enable the Engineer to make the necessary physical tests (to assess the performance of plant) prior to use of the plant for the production of concrete. Batching plants shall be fully automatic with computer control along with the facility of automatic moisture correction for fine aggregate. Batching plants shall have the facility of recording and printing the details of each ingredient per batch.

11.1 Type of plant The type of plant to be furnished shall be automatic and fully computer controlled. The term 'automatic' is used to define a plant in which:

Plant should have the facility to provide the computer printouts of each batch of concrete i.e. its ingredients in detail.

Batch weights are set on a mix selector manually.

Mixes are batched in weigh hopper by operation of electric switch in one operation automatically.

Mixes are charged in a mixer; 'concrete is mixed and unloaded in a hopper in one operation by selecting mix number and operating a push button. Two 60 m3/hr and one 30 m3/hr capacity of fully automatic and computerized batching

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plants will be required for mixing and batching of concrete. The batching plant shall be equipped to measure moisture content in sand and adjust the water cement ratio of the mix accordingly automatically. Each plant shall be capable of producing the concrete according to the recipe of mix fed into computer with the desirable accuracy/tolerances specified for each of the ingredient with different combination of mixing sequence to produce normal concrete of different grades with the help of single command. Plant software shall be capable of giving the batch weight records for each batch along with mixing cycle time in a format specified by the Engineer. Contractor shall provide full details about the batching plants to be employed at site during tendering stage itself.

11.2 Weighing Units Every delivery point of aggregates and cement into the mixer charging hopper shall have a weighing unit and each weighing unit shall include a visible, spring-less direct reading dial which shall indicate the scale load at all stages of the weighing operation from zero to full capacity. As far as practicable, the scale dials and the weighing equipment shall be in full view of the operator, so that he may conveniently observe the operation of the batcher gates and the discharge of the materials. Provision shall be made for adjustment and change in weights of materials being charged into the hopper.

11.3 Measuring water and ice Water shall be measured by weight except in situations for which written approval is obtained from the Engineer to measure by volume. The mechanism for measuring and delivering water to the mixers shall not permit leakage when the valves are closed. Ice shall be measured by weight. The filling and discharge valves for the water tank shall be so interlocked that the discharge valves cannot be opened before the filling valve is fully closed.

11.4 Dispenser for admixture The concrete plant shall include a dispensing device to accurately measure and deposit the full quantity of admixture into each mix at one time. The dispenser shall be interlocked with the batching and discharging controls of the water so that the batching and discharge of the admixtures will be automatic. The device shall be capable of ready adjustment to permit varying the quantity of the admixtures to be batched. The equipment spall be kept in a clean and fully operating condition.

11.5 Tolerance in batching weighment errorsWeighing devices shall be capable of measuring the various ingredients to the following accuracy.

Material Accuracy percentCement +/- 1 (by weight)

Water/Ice +/- 1 (by weight)Aggregate smaller than 20mm size +/- 2 (by weight)

Admixtures +/- 1 (by weight or volume)

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Also overall weight variation in a batch + 1 %

The contractor in consultation with the Engineer shall check at least once in a fortnight or any time felt necessary by the Engineer, that all the compositions of materials leaving the scales actually comply with the specified composition within the tolerance specified above. If this is not the case the Contractor shall immediately make necessary corrections required and shall check the equipment by calibrating the equipment.

11.6 Records and chartsThe Contractor shall maintain an accurate record at the batching plant for the following:

a) The weight of the cement, water and admixture. b) The weight of the aggregate for each size recorded separately.c) Temperature of the concrete immediately after mixing. d) Mixing time of each batch when all the materials are loaded into the mixer. e) Time when the concrete is delivered from the mixer.

This record will be maintained either by automatic recorder or manually. In case batching plant is provided with automatic recorder it shall comply with the following.

11.7 MixersMixers may be stationary mixers of either the tilting or non-tilting type of approved design.

11.7.1 Maintenance The mixers shall be maintained in satisfactory operating condition, and mixer drums shall be kept free of hardened concrete. Mixer blades shall be replaced when worn down more than 10 percent of their depth. Should any mixer at any time produce unsatisfactory results, leak mortar or cause waste of materials, its use shall be promptly discontinued until it is repaired.

11.7.2 Stationary Mixers Mixers, which have a rated capacity not exceeding 200 litres of mixed concrete, may be tilting type. Mixers, that have a rated capacity of 200 litres or more of mixed concrete, shall be non-tilting types. Mixers shall not be charged in excess of the capacity recommended by the manufacturer. Mixers shall be capable of combining the materials into a uniform mixture and of discharging this mixture without segregation. The mixers of mixing plant shall include a device for counting the total number of batches of concrete mixed. The mixers shall be operated at the drum speed designated by the manufacturer on the nameplates.

11.7.3 Mixing time The mixing periods specified herein are to ensure proper quality control. The mixing time will be increased when such increase is necessary to secure the required uniformity and consistency. Excessive over mixing requiring addition of water will not be permitted. Mixing time shall be in accordance wit the recommendation of the batching plant

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manufacturer.

11.8 Provision of inspection The complete plant assembly shall include provisions to facilitate the inspection of all operations at all times.

11.9 Maintenance of records All records and charts of the batching and mixing operations shall be prepared as specified herein and promptly handed over to the Engineer.

11.10 Sampling facilities Suitable facilities shall be provided for readily obtaining representative samples of aggregate from each of the batchers, and suitable devices for obtaining representative samples of concrete for slump tests, unit weight, air content and uniformity tests shall be made by the Engineer. All necessary platforms, tools and equipment for obtaining samples shall be furnished at the start of work.

11.11 Concrete specimen Concrete specimen shall be prepared from the mixes used in the work and tested to determine the adequacy and accuracy of control for the materials entering into the concrete mix. The Contractor shall perform preparation, storage and testing of the specimen, in presence of the Engineer to his entire satisfaction.

11.12 Test weights Standard test weights and any other auxiliary equipment required for checking the operating performance of each scale or other measuring device shall be provided by the contractor. Periodic tests shall be made in presence of Engineer in such a manner at such intervals as may be directed by the Engineer. Upon completion of such test and before further use of the measuring, weighing or recording devices, such adjustments, repairs or replacements shall be' made' to secure satisfactory performance.

11.13 Approval of concrete plant layout Plans and technical data for the concrete plant proposed for use to produce the quantities and quality of concrete for completion of the concrete works under this specification shall be submitted to the Engineer for approval along with the tender.

11.14 Truck mixing Truck mixing unless otherwise authorized by the Engineer, shall be of the revolving drum type, watertight and so constructed that the concrete can be mixed to ensure a uniform distribution of materials throughout the mass. All solid materials for the concrete shall be accurately measured in accordance with clause 11.6 and charged into the drum at the proportioning plant. Except and as subsequently provided, the truck mixer shall be

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equipped with a device by which the quantity of water added can be readily verified. The mixing water may be added directly to the batch, in which case a tank will not be required. Truck mixers may be required to be provided with means by which the mixing time can be readily verified by the Engineer.

The maximum size of batch in truck mixers shall not exceed the maximum rated capacity of the mixer as stated by the manufacturer and stamped in metal on the mixer. Truck mixing shall be continued for not less than 50 revolutions after all ingredients, including the water are in the drum. The speed shall neither be less than 4 RPM, nor more than a speed resulting in a peripheral velocity of the drum of 68 m per minute. Not more than 100 revolutions of mixing shall be at a speed in excess of 6 RPM. Mixing shall begin within 30 minutes after the cement has been added either to the water or aggregate.

When cement is charged into a mixer drum containing water or surface wet aggregate and when the ambient temperature is about 32 Deg. C, this limit shall be reduced to 15 minutes. The limitation on time between the introduction of the cement to the aggregate and the beginning of the mixing may be waived, when in the judgment of the Engineer, the aggregates are sufficiently free from moisture, so that there will be no harmful effects on the cement.

12.0 CLASSES OF CONCRETE Unless otherwise specifically stated as "Ordinary Concrete"; all concrete· proposed under this specification shall be taken to mean Controlled concrete. For mix design, IS: 10262 shall be used.

12.1 Controlled concrete Controlled concrete means that the mix proportions are determined by preliminary mix designs and laboratory tests. These shall be carried out at frequent intervals and also whenever the Engineer has reasons to believe that there has been a change in the quality/properties/grading etc. of any of the constituents of concrete, which in his opinion would impair its strength and/or durability. Under this head, two types of concrete are proposed. They are "Normal Concrete", and "Heavy Concrete", a prefix and two numbers shall identify each class of concrete. Prefix 'N' would denote Normal concrete and prefix 'H' would denote heavy concrete. The two numbers e.g. 30/20 would denote the crushing strength of concrete cubes (characteristic strength) at 28 days age in N/sq.mm and maximum size of coarse aggregate in sq.mm respectively.

The characteristic compressive strengths on 15 cm cubes at 28 days for all the types of concrete as mentioned above shall be same as given in tables for respective types of concrete. The only difference shall be in their densities achieved by using Normal/ Heavy aggregates.

Note: Compressive strength tests may with the approval of the Engineer shall be conducted on 15 cm. diameter and 30cm high cylinders in accordance with IS:516 instead of on cubes. Where cylinder strength figures are adopted, the compressive strength figures given in respective table below for every grade of concrete shall be modified according to the formula.

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Minimum cylinder compressive Strength required for 15cm. cubes

= 0.8 times compressive strength specified

The Contractor shall supply and place normal/heavy/super heavy grout consisting of an approved mixture of cement, normal/heavy/super heavy fine aggregates, water and when specified, a non-shrink agent. Grout shall be placed as shown on the drawings or as specified by the Engineer.

12.2 Normal concreteUnless otherwise specified on drawings or called for in the schedule of quantities, the class of normal concrete to be used shall generally be selected from Table no. 8.

Table No. 8 (Characteristic Strength)

ClassCharacteristic Compressive

strength on 15cm cubes at 28 days in N/sq.mm

Maximum aggregate size in mm

N / 15 / 20 15 20N / 20 / 20 20 20N / 25 / 20 25 20N / 30 / 10 30 10N / 30 / 20 30 20N / 35 / 10 35 10N / 35 / 20 35 20N / 40 / 10 40 10N / 40 / 20 40 20N / 45 / 10 45 10N / 45 / 20 45 20N / 50 / 10 50 10N / 50 / 20 50 20

When requirement arises, the grade of concrete such as N/32.5, N37.5, N42.5 etc. and varying size aggregate to 12.5mm shall be accommodated with the approval of the Engineer.

Normal concrete shall have a net unit weight of not less than 2450 Kilograms per cubic metre.

12.3 Plum Concrete General requirements for normal concrete work shall apply for Plum concrete further supplemented by the stipulations as given below.

Plum concrete shall be normal concrete with normal aggregates and batched by volume in the proportion of 1:5:10. The normal maximum size of coarse aggregate shall be 40mm and down graded, with plums upto 150mm size and upto 20% by volume of concrete mix. The plums shall be distributed evenly in the concrete mix and shall not be closer than 150mm from the surface of finished work.

Plum concrete shall be provided in the following manner.

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Plum concrete work shall be. started on kraft paper on top of basement raft. Plum concrete shall be constructed to such profiles as to allow provision of 50mm

thick expanded polystyrene between all other concrete surfaces and plum concrete.

12.4 Heavy Concrete Heavy concrete shall have a net unit weight of not less than 3600 kilograms per cubic metre, weight being taken after stripping the test specimen. The class of concrete to be used shall generally be selected from the table 9 below. Wherever concrete need to be pumped, slump shall be varied with the approval of the Engineer. In such events, contractor shall carry out fresh trial studies to establish desired properties.

Table 9

Class RangeCompressive

strength in N/sq.mm

Maximum Aggregate size Slump

H/30/10 30 10 The slump or flow of grout shall be decided based on pouring condition and mix design with the approval of the Engineer.

H/30/20 30 20

H/Grout 45 Fine aggregate

When requirement arises, the grade of concrete such as H/35, H/40 etc. and varying size aggregate to 12.5mm shall be accommodated with the approval of the Engineer.

13.0 THEORETICAL CONSUMPTION OF CEMENT The minimum cement content in kg/cu. m of concrete shall be as specified in tables of IS: 456-2000 for severe exposure condition or as per the approved mix design whichever is higher.

The rates quoted by the Contractor for all normal and heavy concrete of grades N/30,N/45,H/30, H/45, are deemed to have been based on optimum use of the cement as required for the approved design mix.

Any upward variation required to obtain the specified strength shall be provided by the contractor at no extra cost.

Errors due to permitted inaccuracies in actual weighing over designed mixes shall not be paid.

The rate of the concrete is inclusive of all type of ingredients such as aggregates, cement, all types of admixtures , minerals, chemical admixtures etc.

14.0 MINIMUM CEMENT CONTENTS For any particular mix, minimum cement content mix and water cement ratio shall be elected so that strength, workability and durability requirements are met for specified work. Reference shall be made to Table 5 and 6 of IS- 456: 2000 unless specified

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otherwise

15.0 TRIAL CONCRETE MIXESThe proportions of cement, fine aggregate, coarse aggregate)e, additives and water necessary to produce a concrete mix which will fulfill the requirements of this specification for each class of concrete shall be determined on the basis of trial mixes conducted with the samples of the material as used in the work site in presence of the Engineer in field laboratory by the Contractor.

16.0 CONCRETE MOCK UP A representative full scale mock up for any part of the structure incorporating various intricate embedment’s and reinforcing steel shall be made, if so directed by the Engineer, to study the construct ability aspects. Payment for such mock-ups shall be made under the corresponding items in the schedule of quantities.

17.0 TEMPERATURE CONTROL The placement temperature of concrete shall be as indicated on the relevant drawings or as directed by the Engineer.

18.0 TEMPERATURE CONTROL OF CONCRETE INGRADIENTS 18.1 Cement Cement shall not be stored outside and open to sky.

18.2 Aggregates The stockpiles of the aggregates shall be protected from direct sunlight to avoid aggregate being heated up. Wherever water is sprayed, suitable correction for W/C shall be applied so that the intent of the mix design is not altered. Water shall be sprayed on the aggregate pile every 300mm or 450mm height as the piles are built up. The piles thereafter shall be kept cool by use of water sprays. Fine aggregate may be stored under shelter if the contractor so chooses. Heavy fine aggregates shall be stored in a shed on hard flooring protecting it from rain, wind and sunlight. Heavy coarse aggregates shall be stacked in bins with three-sided masonry walls of sufficient height and with hard flooring. These bins shall be protected from direct heat from sun.

There shall be convenient and quick method or arrangement of drawing and transportation of sufficient quantity of aggregates for stand by batching plants, directly from the main stacks/bins kept at Main Batching plants, at any time.

18.3 Chilling of Aggregates for Cooling If necessary, the coarse aggregates shall be taken into the bins and chilled water at temperature not more than 8oC shall be sprayed on it through perforated pipe and aggregates shall be cooled and allowed to be drained through screen fixed at the bottom.

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Draining screen shall remove excess water from the aggregate in order to provide coarse aggregate with minimum and uniform moisture content. The capacity and arrangements of the bins shall be such as to supply moisture free cooled aggregate to the top of the batching plant so that continuous supply of concrete shall be maintained. For the quantity of aggregates to be used by standby mixer, a days quantity of aggregate shall be separated from the main stock pile 24 hours before use and sprinkled with water every 300mm to 450mm layer during transfer and then maintained at the temperature as low as possible.

18.4 Concrete Placing During hot-weather and rains the concrete shall be covered with tarpaulins, transported in as short a time as possible, placed in the forms and consolidated to final state. Adequate precautions shall be taken to cover the transit mixer and water sprayed on the mixer to maintain the temperature if required at no extra cost.

18.5 Hot Weather Conditions When concrete is to be placed under hot weather conditions, special provision shall be made in the handling, placing methods and in protection during such period, to ensure that concrete of frill strength and free from damage will be obtained. For obtaining the desired objective, means such as concreting during cooler hours of the. day, use of chilled water etc., as set forth hereunder shall be adopted.

18.6 Suspension of Day Time Placing As far as possible concrete will be placed during cool hours and even after sunset. If placed after sunset, sufficient lighting to the satisfaction of the Engineer shall be made for placing the concrete.

18.7 Inclement Weather Commencement of concrete pour shall be avoided during heavy rains, storms and high winds.

19.0 MIX DESIGN OF CONCRETE The Contractor shall carry out mix design of concrete for various grades such as N15, N30, H30, etc. using different sizes of aggregates as directed by the Engineer to produce concrete of the required strength, workability, durability and other properties. Concrete shall be proportioned to obtain workable mixes for the purpose intended and to adequately meet the strength and finish requirements.

Primary mix design shall be established through several trial studies by the contractor well in advance so as to meet the time schedule of the work. This activity shall be done in consultation and close co-ordination with the Engineer. The test schedule shall be as decided by the Engineer. The test schedule and plan of testing shall be as indicated in Table 1 of Annexure 1 to this specification and shall be used as guidance.

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During mix design/trial studies, contractor shall use the ingredients, which are qualified/approved for actual work at work site.

19.1 Reworking of Mix Design Whenever there is a change of cement brand or its strength, the grading of aggregates are found to have changed or if there is a change in the type or quality of the admixtures used, then mix design shall be reworked to obtain the specified parameters. This also should be done without any extra cost to the owner and without affecting the schedule.

19.2 Proportioning for Maximum Density Suitable proportions of sand and the several sizes of coarse aggregates for each class of concrete shall be selected to give as nearly as practicable, the maximum density. This is to be determined by mathematical means, laboratory tests, field trials or other means. If necessary. the gradation of the aggregates shall be corrected by changes in the aggregate plant and the processing methods so that maximum density and good workable concrete can be produced to comply with the requirements of the jobs ..

19.3 Proportioning by W/C Ratio Once a mix, including its water cement (W/C) ratio has been determined and specified after trial studies & approved by the Engineer, that W/C ratio shall be maintained. The Contractor shall determine the water content of the aggregate frequently as the work progresses and the amount of mixing water entering the mixer shall be changed to compensate for the water content in aggregates so as to maintain specified W/C maintained at all the time.

19.4 W/C Ratio Values The actual W/C ratio to be adopted shall be determined in each instance by the Contractor, so as to have workable mix without affecting the specified/required properties of concrete in its fresh and hardened state. Permissible tolerance in w/c ratio shall be maintained to + 0.02 of the specified value. In case of any change in any of the properties, mix design shall be redone and tested for its specified properties.

a)19.5 Consistency and Slump

The concrete shall have a consistency such that it will be workable in the required position. It shall be of such consistency that when properly vibrated, will flow around reinforcing steel, and all embedded parts. The slump for concrete as determined by slump tests as per IS 1199 shall not exceed the maximum slumps indicated below for each type of construction unless otherwise approved or directed by the Engineer. Whenever concrete is needed to be pumped, slump shall be varied with the approval of the Engineer. In such events, contractor shall carry out fresh trial studies to establish the desired properties.

Table 10

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Sl.No. Workability Slump in mm Type of ConstructionMin. Max.1. Self leveling 150 200 Raft where reinforcement layout is

congested2. Medium 25 75 Plain footings, caissons, sub structure

walls etc.3. Medium 50 100 Reinforced beams, columns, wall etc.4. Medium 40 80 Reinforced foundation, wall and footings5. Low 25 50 Pavements6. Very low 15 50 Heavy mass construction7. High 100 150 Trench fill, Insitu piling and Tremie

concrete

The contractor shall not place concrete having a slump outside the limits specified without the approval of the Engineer. The slump results shall not differ by + 25mm or +1/3 of the required value whichever is less.

Slump tests shall be conducted immediately in the first mix of every grade of concrete and necessary correction shall be made. In addition the same test shall be carried out during the following circumstances:

a) At least one test in each grade per shift. b) At the time of molding the cubes for compressive strength. c) At least one test for every 50 cu. m concrete or part thereof d) Whenever the visual inspection demands e) More frequently, if there is distinct change in job condition f) If required by the engineer at least one test per air content test

19.6 Air Content Test Not less than one air content determination shall be made for each 50 cubic metres of air entrained concrete placed and no ease shall the be less than one-air content test for each class of concrete placed on one week or whenever necessity arises.

20.0 TESTS ON CONCRETE Sampling and testing of concrete shall be conducted in accordance with the following schedule and the specifications mentioned against each activity.

Sampling of the product shall be done during actual production and placement of the concrete for use at work site as given in Table I of Annexure I to this specification, for fresh and hardened concrete.

20.1 Cube Tests During the progress of construction, compression tests shall be made to determine whether the concrete being produced complies with the strength requirements specified. The tests will be made in accordance with IS: 516.

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Six or more 15 cut. control specimens shall be made for each 50 cubic metres or portion there of or for each pour per class of concrete. This number may be increased, at the option of the Engineer, when additional tests appear necessary. A set of six or more specimens from random mixer batches shall constitute a test, three being tested for 7 days strength and thee being tested for 28-day strength.

The strength test result shall be the average strength of the thee companion test specimens, tested at 28 days, except that, if one specimen in a test shows manifest evidence of improper sampling, moulding or testing, the result shall be discarded and the remaining two strengths averaged. Separate procedures shall be established when cements other than Portland cement are used.

20.2 Use of 7 Days Test Normally 7th day 28th day tests shall be made on specimens. For any mix, a correlation between 7 day and 28 day strengths may be made in the laboratory. Soon after a job starts, a similar correlation will evolve for samples of concrete taken from the mixer. After that correlation has been established, the results of the 7 day tests may be used as an indicator of the -compressive strengths, which should be expected at 28-days, provided such results are consistent. If 7 -day tests show compressive strengths that are too low, measures shall be taken at once, at the Engineer's direction, without waiting for the results of the 28-day tests.

20.3 Acceptance Criteria Acceptance criteria shall be as per Clause No. 16.0 of IS 456-2000.

20.4 Failure to meet Strength RequirementIn the event that concrete tested fails to meet the specification, the Engineer shall have the right to insist on anyone or all of the following and the contractor at his own expense shall carry out all such measures as directed by the Engineer.

Changes in the concrete mix proportions for the remainder of the work Coring and testing of the concrete represented by the tests that failed as per

IS:456 (Clause No.17.0). Extended curing of the concrete represented by the specimen Load tests on part of structures as per IS: 456 (Clause No.17.0) Replacement of any such portions of the structure. NDT of such concrete which indicates a low strength

20.4.1 Details of Load TestsThe Engineer shall instruct the Contractor to make a loading test on the works or any part thereof if in the Engineer's opinion such a test is necessary. Such load tests may be required when the strength of the job control tests falls below the required strength as per the 'Acceptance Criteria' stated earlier or for any other reason due to defective work the structure does not meet requirements of this specification. Such load tests shall be conducted in accordance with the provisions of IS: 456, unless otherwise stated herein after. If the member shows evident failure, such changes as necessary to make the structure adequately strong shall be made by the contractor free of cost to department. If on the other hand, the failure becomes apparent, the Engineer, under special

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circumstances can retain the portion of the structure under test, provided suitable strengthening and I or load dispersion arrangement is feasible. Cost of such strengthening or load dispersion arrangement shall be borne by the contractor.

The member shall be deemed to have passed the test if the maximum deflection at the end of 24 hours does not exceed the deflection given as per IS: 456-2000.

= 40 L2/d Where = deflection in mm L = effective span in m d = overall depth of the section in mm

If the deflection exceeds '' and the member does not recover at least 75 percent of the observed deflection within 24 hours of removal of superimposed load, the test loading shall be repeated after a lapse of atleast 72 hours and the member shall be considered to have failed to pass the test, if the recovery after the second test loading is not at least 80% of the maximum deflection shown during the second test.

Load test shall not be made until the expiry of 28 days of effective hardening. of the concrete.

If the test be instructed to be made solely or in part for the reason that the site-made concrete cubes fail to attain the specified strength or due to defective workmanship, the test shall be made at the Contractor's own cost. If still, in the opinion of the Engineer, the work is found to be defective the contractor shall conduct such tests as required at his own cost to satisfy the Engineer. If the result of the tests is satisfactory, no payments shall be made to the contractor.

If the result of the test is not satisfactory, the Engineer shall instruct that the part of the works concerned shall be dismantled or cut out and reconstructed to comply with this specification, or that other measures shall be taken to make the works secure at contractor's cost.

21.0 TRANSPORTATION All concrete shall be conveyed from the mixing plant to the place of final deposit in suitable leak tight buckets, dampers, containers, truck mixers or conveyors. All means of conveyance shall be adopted to deliver concrete of the required consistency and plasticity without segregation.

The concrete shall be transported from the mixing plant to the place of placement as rapidly as possible by method, which will prevent the segregation, loss of any of ingredients, and before any appreciable increase in the temperature of mixed concrete has taken place. During hot/cold weather, the concrete shall be transported in deep container. Other suitable methods to reduce loss of water by evaporation in hot weather and heat loss in cold weather shall also be adopted.

No water shall be added during transport or before the pouring of the concrete, except as may be specified in advance and approved by the Engineer. In the case of liquefied concrete, the concrete truck shall be fitted with a special container. Liquefier insertion

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conditions and complimentary mixing conditions shall be precisely specified following the acceptance test and shall be subject to the approval of the Engineer.

To make the concrete as homogeneous as possible, it shall be mixed in the transporter, before being poured into the hopper.

When concrete is transported in buckets, whether by rail car or trucks, the buckets shall be covered by tarpaulin, damp sacking or other approved covers at the time the buckets are filled at the central plant and shall remain covered until the concrete is ready to be deposited in hoppers or buggies at the forms.

21.1 Time interval between Mixing and Placing Concrete shall be placed and compacted in its final position in forms within 90 (ninety) minutes or initial setting time of the cement used whichever is less after the addition of water to the cement and aggregate. However, the above time limit may be relaxed at the discretion of Engineer, provided that the concrete can still be placed and effectively compacted without addition of further water.

21.2 Re-Tempered Concrete Concrete that has been left standing and which has become stiff so that it cannot be placed in satisfactory condition shall not be deposited in the work and shall be withdrawn from the place of work immediately.

21.3 Cleaning Equipment All equipment used for transporting and placing of concrete shall be maintained in clean condition. All buckets, hoppers, chutes, dampers and other equipment shall be thoroughly cleaned after each period of placement.

22.0 RE-DOSING OFADMIXTURES Concrete mix shall be designed for suitable workability as per site condition and to 'fulfill the other specified requirements. For easy placing and proper placement of concrete, especially for pumped concrete, slump adjustment may have to be done to bring the concrete to required consistency in the event of drop of slump below the required limit for pumping, due to the prevailing atmospheric conditions at the time of concreting. Re-dosing of admixture (super plasticizer) shall be resorted to with the approval of the Engineer.

Basis for re-dosing shall be established by conducting several trials to find out the percentage of re-dosing required for various slumps measured before re-dosing, to bring the concrete to suitable consistency (within specified limits). Consequences of re-dosing on the strength or any other significant parameter of the concrete shall also be tested before taking the permission for re-dosing of admixtures.

Re - dosing shall be done only at the worksite and not at the batching plant. Suitable arrangements for re-dosing, including a structure, dispensing unit for admixture etc., shall be made such that accurate re-dosing, mixing and testing for consistency is done with minimum time duration.

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Records need to be maintained for each re-dosing and shall be incorporated in batch weight records of relevant mix at the batching plant.

23.0 PLACING OF CONCRETE The procedure for placing of concrete shall be as follows:

23.1 Engineers approval for Equipment and Methods of Delivery Before any concrete is placed, the entire placing programme consisting of equipment, layout, proposed procedures and methods shall be submitted to the Engineer for his approval and no concrete shall be placed until the Engineer's approval has been received. On each occasion that the Contractor intends to place concrete, he shall give the Engineer at least 24 hours prior notice in writing. Engineer's approval for pouring concrete shall be taken as conveyed when the concrete pour card is signed. Sufficient plant capacity and transporting apparatus shall be available to ensure continuous delivery at the average rate of 35 to 40 cubic meters per hour. The rate of delivery of concrete, during concreting operations shall, however, be such as to provide for proper handling, placing and finishing of the concrete and to ensure that there will be a minimum rate of rise of the concrete to avoid formation of "cold joints" during the longest continuous \hours even in the warmest weather. Adequate protection to the green concrete during transport and placement shall be ensured during rains also. If there is any sign of washing of cement and sand, the concrete shall be entirely removed immediately.

The methods of delivering and handling the concrete shall be such as to facilitate placing with minimum of re-handling and without damage to the structure or the concrete.

23.2 Items Cast in Concrete All items to be embedded in concrete shall be correctly positioned and securely held in the forms, well in advance of placing of concrete.

23.3 Details of Placing The control of placing shall begin at the mixer discharge. Concrete shall be discharged by the vertical drop into the middle of the bucket, damper or hopper and this principle of vertical discharge of concrete shall be adhered to, throughout all stages of delivery until the concrete comes to rest in the forms. Struts, stays and braces sewing temporarily to hold the forms in correct shape and alignment, during the placing of concrete at their locations, shall be removed only when the concrete placing has reached an elevation rendering their service unnecessary. These temporary members shall be entirely removed from forms and not buried in the concrete.

In preparation for the placing of concrete, all sawdust, wood chips and other construction debris and extraneous matter shall be removed from the interior of forms. Prior to placing concrete on a rock surface, the rock surface must be thoroughly cleaned and the concrete placing must be preceded by a 12 mm to 25 mm thick layer of cement mortar with sand and cement in the same proportion as the mortar in the concrete is to be placed.

No concrete shall be used which does not reach its final position in the form within the

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time stipulated as the initial setting time for the cement used.

23.4 Placing Concrete using Chutes Concrete shall be placed so as to avoid segregation of the materials and the displacement of the reinforcement and embedment’s. The use of long troughs, chutes and pipes for conveying concrete from the mixer to the forms shall be permitted only on written authorisation from the Engineer. In case the above methods are observed to be unsatisfactory in terms of quality of concrete, the Engineer may order discontinuance of their use. Open troughs and chutes shall be of metal or metal lined. No corrugated sheets shall be allowed as chutes or troughs. Chutes will be supported on steel or wooden members, no bend will be accepted in the chute. The chutes! trough shall be covered at the top and there shall be no sharp corners and the joint shall be such that no leakage of slurry or fines would occur. The concrete shall be prevented from spreading at the drop point by the provision of the vertical plate at the end of the chute. Where steep slopes exist, the chutes shall be equipped with baffles or be in short lengths to adjust the direction of movement. The addition of water at any point in the system of transportation, to facilitate the movement of concrete shall strictly be not permitted. All chutes, troughs and pipes, shall be kept clean and free from coatings of hardened concrete by thoroughly flushing them with water after each run; water used for flushing shall be discharged clear of the structure. Concrete shall not be permitted to fall freely from a height of more than 1.5 m or to strike the forms at an angle. Where drop chutes are used, a sufficient number must be provided so that the concrete discharged from the chute is not required to flow laterally more than 1.0 m. Where a drop chute is swung from the vertical, the bottom two sections must be maintained in a vertical position to avoid segregation. Flushing water quality shall be same as that of the water, which is being used, in the concrete mix. However, based on the work urgency, if lift height is to be increased beyond 1.5 m, methods shall be worked out by the way of trials and mock up such that intended properties of the concrete both in fresh and .hardened state in situ are not altered. This methodology shall be adopted only after the approval of the Engineer.

23.5 Clean-Up Concrete shall not be placed into the forms, until the cleaning of concrete surfaces and the placement of reinforcing steel and embedded parts have been inspected and approved by the Engineer.

23.6 Removing Surface Water

Storm water or water from the concrete which may accumulate on the surface of the bedding layer shall be removed by suitable means before start of placement. No concrete shall be placed on a water-covered surface. However the surface must have been sufficiently soaked and shall be moistened before placement of concrete begins.

23.7 Bonding Mortar Immediately before concrete placement, surface of previously placed concrete, which will be in contact with the concrete to be placed, shall be covered with a bonding mortar grout. The bonding medium shall be a coat of cement-sand mortar of thickness 5 to 10 mm. The mortar shall have the same cement-sand ratio as the concrete, which will be placed on it. The water cement ratio shall be determined by placing conditions and as

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approved by the Engineer If directed so by the Engineer, the Contractor may arrange to mix the bonding mortar at the site of concreting itself by using suitable mechanical mixer. The cost of the bonding mortar to be used shall be deemed to have been included in the general rate structure for works and nothing extra shall be payable. When green cuffing is employed as instructed by the Engineer, bonding mortar application need not be done.

23.8 Avoiding Segregation Concrete placed by barrows, buggie cars, short chutes or hand shovelling in restricted forms 'shall be subjected to the requirement for vertical delivery of limited height to avoid segregation. Concrete shall be deposited as nearly as practicable in its final position to avoid segregation due to re-handling or flowing. For locations where direct placement is not possible and in narrow forms, suitable drop chutes and "elephant trunks" shall be provided to confine the concrete in movement.

23.9 Thickness of Layers Concrete shall be placed in successive layers ranging in thickness not exceeding 300 mm or as directed by the Engineer. Generally the pour height for columns and walls shall be about 1.5m. Any deviation from this shall be subjected to approval the Engineer. For other locations the Engineer shall decide the height of pour. The bucket loads or other units of deposit shall be spread progressively along the face of the layer with such overlap as will facilitate spreading the layer of uniform depth and texture with a minimum of hand shovelling. Any tendency to segregation shall be corrected by shovelling stones into mortar rather than mortar on to stones. Such a condition shall be corrected by redesign of mix, change in processes or other means as directed by the Engineer.

When less than a complete layer is placed in one operation, it shall be terminated at a vertical bulkhead. Each layer of concrete shall be placed and compacted before the preceding layer of concrete has been set initially to prevent injury to the green concrete and avoid surface of separation between the layers.

23.10 Bedding of Layer Bedding planes shall be approximately horizontal and special care shall be taken to ehsure that cold joints are not developed.

23.11 placement Interval Each placement of concrete shall be' allowed to set for 48 hours and longer when required before the start of a subsequent placement.

23.12 Special Provisions in Placing When placing concrete in walls with openings, in floors of integral slab and beam construction and other similar condition, the placing shall stop when the concrete reaches the top of the opening, or bottom horizontal surface of the slab, as the case may be. Placing shall be resumed before the concrete in place takes initial set, but not until it has had time to settle as determined by the Engineer. The fresh concrete shall be vibrated in place to avoid cold joints.

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To' avoid visible joints as far as possible upon exposed faces, the top surface of the concrete adjacent to the forms shall be smoothened with a trowel. Where a feather edge might be produced at a construction joint, as in the sloped top surface of a wing wall, an inset form-work shall be used to produce a blocked out portion in the preceding layer which shall produce an edge thickness normal to the slope of not less than 75 mm in the succeeding layer.

Immediately following the discontinuation in placing of concrete, all accumulations of mortar splashed upon the reinforcing steel and the surface of the forms shall be removed. Dried mortar chips and dust shall not be puddle into the unset concrete. If the accumulations are not removed prior to the concrete getting set,: care shall be exercised not to damage or break the concrete steel bond at or near the surface of the concrete while cleaning the reinforcing steel. The sequence of placing concrete shall be as instructed by the Engineer or as shown on the drawings.

In placing concrete through reinforcing steel, care shall be taken to prevent segregation of the coarse aggregate. Where the congestion of steel makes placing difficult, it may be necessary to move top steel aside to get proper placement

24.0 COMPACTION Each layer of concrete shall be worked with suitable types of equipment until the concrete has been consolidated to the maximum practicable density, is free of pockets of coarse aggregate and fits tightly against all form surfaces and embedded materials.

24.1 Type of Vibrators The operator/mason handling the Vibrator shall have been qualified for the job by the Engineer. The concrete shall invariably be compacted by mechanical vibrating equipment, supplemented by hand spading and tamping. The vibrators shall be internal-immersion type high frequency vibrators with speed of not less than 7000 rpm when immersed in the concrete. Vibrators shall be used in sufficient number of units and power of each unit to properly consolidate all concrete in each layer immediately after it has been .placed in the forms.

24.2 Use of Vibrators Vibrators shall be manipulated so as to thoroughly work the concrete around the reinforcement and embedded fixtures, and into corners and angles of the forms. Sufficient numbers of vibrators with standby arrangement should be kept ready at site of work depending upon size and duration of pour before start of work.

Internal vibrators shall be inserted in a vertical position only, at intervals of about 450 to 700mm depending upon the mix, the equipment used, the type of structure and continued experience on job. The vibrators shall be withdrawn slowly, approximately at the rate of 75 mm/sec. The spacing shall provide some overlapping of the area vibrated at each insertion. In no case shall vibrators be used to move concrete laterally inside the forms. Vibration needle shall be kept clear of forms at least by 100 mm. Over-vibration shall not be permitted. Hand tamping in some cases may be allowed subject to the approval of the Engineer.

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Vibrators shall not be applied directly or through the reinforcement to sections or layers of concrete, which have hardened to the extent, the concrete ceases to be plastic state.

24.3 Melding Successive Batches In placing concrete in layers, which are advancing horizontally as the work progresses, great care shall be exercised to ensure adequate vibration, blending and melding of the concrete between the succeeding batches.

24.4 Vibrator Penetration of Under-Layer The vibrator shall penetrate lull in the layer being placed and also penetrate the layer below by about 50 mm while it is still plastic, to ensure good bond and homogeneity between the two layers and prevent the formation of cold joints.

24.5 Vibrating against Reinforcement Care shall be taken to prevent contact of vibrators against reinforcement steel. Vibrators shall not be brought in contact with reinforcement steel after start of initial set. Vibrators shall not be allowed to come in contact with forms or finished surfaces and embedment’s.

24.6 Use of Form Attached Vibrators The form-attached vibrators shall be used only after specific authorisation of the Engineer.

24.7 Use of Surface Vibrators The use of surface vibrators shall not be permitted for consolidation of concrete under ordinary conditions. However, for thin slabs, surface vibration by specially designed vibrators may be permitted upon approval of Engineer.

24.8 Stone Pocket and Mortar Pondages The formation of stone pockets or mortar pondage in corners and against face of forms shall not be permitted. Should these occur, they should be dug out, reformed and refilled to sufficient depth and shape for thorough bonding as directed by the Engineer. Concrete that is of excessive slump, segregated or unworkable shall not be placed in the forms or, if placed, shall be removed as directed by the Engineer.

25.0 CONSTRUCTION JOINTS AND KEYS When the work is to be interrupted, horizontal and vertical construction joints and bonding keys shall be located and shall conform in detail to the requirements of the plans unless otherwise directed by the Engineer. In the case of water retaining structures, containment structures and other structures water stops of approved material shall be provided if so specified on the drawing or desired by the Engineer. Construction joints shall be provided in positions as shown or described in the drawings.

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In a column, the joint shall be formed about 75mm below the lowest soffit of the beams framing in to it. Concrete in a beam shall be placed throughout, without a joint but if the provision of a joint is unavoidable, the joint shall be vertical and at the middle of the span. Before fresh concrete is placed, the cement skin or any loose or porous material of partially hardened concrete shall be thoroughly removed and cut back until the solid face is exposed and surface made rough by hacking using a pneumatic tool, or any other method as directed by the Engineer. The rough surface shall be thoroughly wetted for about two hours and shall be dried and coated with 1:1 freshly mixed cement sand slurry, immediately before placing the new concrete. Special care shall be taken to see that the first layer of concrete is placed after a construction joint is thoroughly rammed against the existing layer.

25.1 Construction Joint Treatment The entire construction joint shall be treated by green cutting using air/water jet at suitable pressure to remove the laitance from the green concrete surface to receive. subsequent pour over it. Suitable, approved brand of surface retarder shall be used to retard the setting time of green concrete to a depth of 5 to 8 mm. Green cutting shall be done only after the final setting of concrete, so that the additional water available from the air water jet used for green cutting on the surface does not harm the quality of the concrete. As a pre-qualification, field mock-ups shall be conducted to check the adequacy of the material and method employed on the job before adopting the green cutting. One mock-up for each grade of concrete, concrete with different types of cement and different kinds of exposure of the proposed construction joint in consultation with the Engineer shall be conducted. In case of change in material (surface retarder) or methodology of green cuffing, pre qualification shall be repeated.

25.2 Application of surface retarder & green cutting at construction joint of concrete

25.2.1 Scope Work under this procedure covers application of surface retarder over the green concrete and green cutting the exposed surface of concrete after final setting time to expose the aggregate, for proper bonding with fresh concrete of successive pours.

25.2.2 Material Qualification The surface retarder shall be qualified for use based on number of site trials/mock-ups for achieving the desired surface after green cutting during different ambient conditions.

25.2.3 Qualification of Workman Workman qualification for surface retarder and green cutting operation shall be done, and record of qualification survey maintained. .

25.2.4 Application Surface retarder shall be applied uniformly with the help of agricultural spray machine at the rate of 5 to 6 sq. ml.litre

Form panel at construction joint :- where ever the side of a particular pour is to receive concrete at a later date, a bulk head of such sides will be coated with surface retarder at

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least one hour before the receipt of concrete. For horizontal construction joints:- wherever the concrete is to be placed above a particular pour, surface retarder shall be applied on the finished top surface of the said' pour within half an hour of finishing.

25.2.5 Green Cutting Green cutting shall be started after final setting time of concrete to expose the aggregate, for proper bonding with fresh concrete of successive pours. The surface of concrete shall be green cut using air-water jet. Air pressure of 4 to 6 kg/sq.cm. and water pressure of 1 to 2 kg/sq.cm. shall be provided in the nozzle for generating required air-water jetting effect for effective green cuffing of concrete surface as established during various mockups at site. The inclination of nozzle-tip to the concrete surface shall be 45° to 60° and its distance from the concrete surface be kept at 100-150 mm. Bunds shall be made using cement mortar at convenient locations and cut out shall be made in the side shutter to drain off excess water. All the laitance and green cut material shall be removed from the green cut surface simultaneously.

The time of green cuffing shall be displayed on Tags, which will be placed at appropriate locations so that said activity can be controlled in the proper way.

26.0 TREATMENT ON SUSPENSION OF WORK DURING CONCRETING Whenever work is suspended on any section for more than one hour, the horizontal edges of the concrete next to the forms on surfaces, which will be exposed, shall be brought to a horizontal plane perpendicular to the plans of the forms and treated so that the finished work will show smooth straight lines.

27.0 EXPANSION JOINTS Expansion joints in concrete structures shall be provided at specified places as indicated on the drawings. The materials shall be as specified by the Engineer or as detailed in the specifications.

28.0 SEPARATION JOINTS Separation joint shall be obtained by using a high-density polystyrene sheet I neoprene sheet as specified. High-density polystyrene sheet, if used shall be wrapped in heavy-duty polythene sheet as specified, stuck on the surface against which concrete will be placed. Adequate care should be taken to cause no damage to the sheet.

29.0 WASH WATER Wash water shall be removed in a manner to prevent running down and staining of concrete surfaces, which will be exposed at the completion of the job. Should unsightly wash-water streaks develop on the exposed surface, they shall be removed to obtain a uniform colour and texture satisfactory to the Engineer.

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30.0 PLACEMENT OF CONCRETE AROUND LARGE OPENINGS IN WALLS While placing concrete around large openings in the walls, adequate care shall be taken to ensure proper flow and compaction of concrete at the underside of such openings. A list of such openings is as below, but shall not be limited to the following.

Pipe penetrations larger than 500 mm in diameter. Rectangular canister embedded duets in various walls Material airlock barrel.

Adequate size and numbers of openings (window) shall be provided as directed by the Engineer in the form work, around and in particular the underside of such large openings to allow escape of entrapped air and for insertion of vibrator needle if necessary. Once the concrete reaches the level of the window provided in the form work, the same shall be closed and sealed by suitable means temporarily. Permanent sealing shall be done after hardening of the concrete or as advised by the Engineer.

The Contractor at his own cost shall repair any pockets or defects found in the concrete around large openings after removal of form work.

31.0 PLACING OF CONCRETE BY PUMPING METHODS

31.1 General Placing of concrete by pumping will be as specified or authorised by Engineer to achieve the required speediness of construction and maintain targeted schedules.

Pumping of concrete shall be done only after conducting pumpability trials to ascertain the performance of fresh concrete on pumping in presence of the Engineer as per approved procedure. During pumping, concrete shall be conveyed either through rigid pipe or through flexible hose and discharged directly into the desired area. A steady supply of pumpable concrete is necessary for satisfactory pumping. A pumpable concrete requires properly graded aggregates, material uniformity, consistent batching and thorough mixing. Concrete pumps used shall be able to deliver concrete over a horizontal distance of about 400 m or of about 100 m in a vertical direction, (with intermediate figures for a combination of horizontal and vertical movements). They shall be used for concreting densely reinforced structures, internal structural elements of buildings and for large pours of concrete.

Placement of normal concrete by pumping will be permitted as specified or authorised by the Engineer. The decision, whether or not to pump any particular mix shall rest entirely with the Engineer and no extra claims for payment on this account will be entertained. The pumping equipment, pipelines and accessories as well as proportioning of pumpable concrete shall generally confirm to the recommendations of ACI-304.2 (latest revision) - Placing of concrete by pumping method. The final selection of mix shall be obtained after careful mix designs for pumpable concrete mixes and shall have the approval of the Engineer.

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31.2 Pumping Equipment Requisite numbers of modern dependable concrete pumps capable of pumping concrete of specified quality at a rate required to meet the construction schedules, together with a balanced complement of placer booms and pipelines, accessories, spare parts, power controlled placing booms, and experienced pump operators and maintenance staff shall be provided at locations and in a manner approved by the Engineer.

The pumping plant shall be completely installed on each occasion, with preliminary mock operation for a sufficient length of time prior to scheduled placement of a particular concrete pour, to enable the Engineer to conduct pumpability tests and necessary adjustments for the concrete mix, prior to use of the pumping for placement of concrete.

31. 3. Type of Pump The individual piston pumps shall have a net horizontal pumping capacity of not less than 30 Cu.m. per hour at a horizontal distance of 400 m and capable of generating a minimum pressure of 80 bars. These pumps shall consist of a receiving hopper with a bolted grill at top of capacity not less than 600 litres. The hoppers shall be provided with hydraulically driven re-mixing blades or other agitating devices to keep the concrete mixed continuously and maintain consistency and uniformity. The pumps shall of manufacturer's specification for the above mentioned requirement. Care shall be taken by the Contractor to ensure uninterrupted operation of the pumps during the entire period of concreting by providing adequate standby arrangements. The primary power and pump equipment shall be either truck or trailer mounted, and not skid mounted.

31.4 Pipelines and Accessories Pipelines, couplings etc. should meet the above requirements and as per manufacturer's specification approved by the Engineer.

31.5 Flexible conduit (hose) Flexible conduit shall be made of rubber, or spirally wound flexible metal, and plastic flexible conduits generally present greater resistance to movement of concrete and their performance is not the same as that of a rigid pipe and also larger sizes (100mm to 125mm) have a tendency to leak. Flexible conduits provided, shall be interchangeable with rigid pipes and their use restricted to curves, difficult placement areas, and as connection to moving cranes or to water borne lines.

31.6 Trial mixes and Mix Design The trial mixes for pumping shall be prepared and tested in the Site laboratory by contractor in accordance with clause 31.15 of this specification. The contractor shall also check the ingredients, particularly the coarse and fine aggregates for the conformance to the desired properties described. Experience with the use of local aggregate and their uniformity shall also be considered in the proportioning concepts.

31.7 Mix Design for concrete by pumping

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a) Taking the above factors into account, the concrete shall first be designed for normal placement conditions and then modified as necessary to suit pumping. The following procedure shall be adopted.

b) Design the mix for specified characteristic strength and workability.

c) Check and ensure combined grading of aggregates i.e. as uniform grading as possible. This requirement is vital as gaps or partial gaps are the basic reasons for poor water retention property and segregation under pressure.

d) Determine the optimum sand content for the required workability and increase sand content by reducing volume of coarse aggregate per unit volume of concrete by about 10 % as a degree of protection against under sanding due to batch variations.

e) Recheck the minimum cement content for durability.

f) Examine the total fines content i.e. cement and fine aggregates passing through 300 micron sieve and readjust the mix, if necessary. A very rich mix with fine sand will be as problematic as coarse sand with lean mix.

g) Re-appraise the grading if the particle shape of any particular fraction is such-as may-cause-excessive voids. Re-adjust as required. lf necessary examining the void ratio of various combinations, using void meter to achieve minimum voids at the expense of 'sufficient fines' content.

h) If dissatisfied with the results as obtained from steps above, consider what remedial action may be taken to overcome the troublesome factor. For example, the following two situations may occur:

i) If the sand has coarser fraction it is worth considering the addition of a proportion of finer sand, or alternately if the sand has finer fraction, the addition of coarse fraction may be considered. Addition or reduction of cement may help, but the correct solution is to overcome the gap in overall grading as stated above.

j) In a 20 mm aggregate maximum size, if there is an excess of 10 to 4.75mm fraction, and this fraction is flaky with unduly large surface area, either increase the, sand content to reduce the possibility of segregation and to reduce the inter-practical stresses, or (better) re-grade using single sized aggregates.

k) At the trial mix stage small variations can be made preferably in the light of the pressures registered and observed performances through the pump. In certain cases admixtures may be economically and beneficially used to improve or eliminate circumstances that cannot readily be overcome by other means.

32.0 FINISHING, GENERAL

Unless otherwise specified, all minimum concrete finishes shall conform to the U2 and F2 finishes.

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Finish F2 and F3 shall describe formed surfaces. Finish U2 and U3 shall describe unformed surfaces.

Offsets or fins caused by displaced or misplaced form sheathing, lining or form section or by defective form timber shall be referred to as ‘abrupt irregularities'. All other irregularities shall be referred to as 'Gradual irregularities'. Gradual irregularities shall be measured as deviation from a plane surface with a template 1.5 m for long formed surfaces and 3.0 m long for unformed surfaces. Curing of the finished surfaces shall be continued for a period of ten days.

32.1 Formed Surface

Finish F2 - shall apply to all formed surfaces for which finish F3 or any other special finish which is not specified in the drawing or by the Engineer. Finish F2 - shall include filling all form tie holes repair of gradual irregularities exceeding 3 mm, removal of ridges and fins and abrupt irregularities by grinding using mechanical grinders with corborandum stone.

F1 and F2 have been deemed to be considered in the item rate of form work Finish F3 - shall apply to formed surfaces wherever specified in the drawings or specified by the Engineer.

Finish F3 - shall include all measures specified for finish F2 and in addition, filling air holes with mortar and treatment of the entire surface

with sack rubbed finish. It shall also include clean up of loose and adhering debris. Where a sack rubbed finish is specified, the surfaces shall be prepared within two days after removal of the forms.

The surfaces .shall be wetted and allowed to dry slightly before mortar is applied by sack rubbing. The mortar used shall consist of one part cement to one and one half parts by volume of fine (IS No 16 mesh) sand. Only sufficient mixing water to give the mortar a workable consistency shall be used. The mortar shall then be rubbed over the surface with a fine burlap or linen cloth so as to fill all the surface voids. The mortar in the voids shall be allowed to stiffen and solidify after which the whole surface shall be cleaned with burlap so that the entire surface presents a uniform appearance without air holes and irregularities.

32.2 Unformed Surfaces

Finish U2 shall apply to all unformed surfaces for which finish U3 or any other special finish is not specified.

Finish U2 shall include:Screeding and applying a wood 'float finish to the surface of the concrete to the required slopes and grade; Repair of abrupt irregularities unless a roughened texture is specified. Repair of gradual irregularities exceeding 6mm.

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Finish U3 -shall apply to unformed surfaces for which a high degree or surface smoothness is required, where shown on the drawings or as specified by the Engineer

Finish U3 shall include: Screeding, floating and applying a steel trowel finish to the surface of the concrete to the required slopes and grade; Repair of gradual irregularities exceeding 6 mm, finishing joints and edges of concrete with edging tools.

The rates quoted by the Contractor include the cost of finishes F1, F2 and U1, U2. For F3 and U3 finish -separate rates as indicated in the respective schedule of quantities shall apply.

33.0 CURING, PROTECTION, REPAIRING AND FINISHINGAll concrete shall be cured by keeping it moist for the period of time specified herein to ensure that complete hydration and hardening take place. Certain types of finish or preparation for overlying concrete must be done at certain stages of the curing and special treatment may be required for specified concrete surface finishes.

33.1 Continuous spraying Curing shall be assured by use of an ample water supply under pressure in pipes, with all necessary appliances of hose, sprinkles and spraying devices with 'a terminal pressure of 2 Kg/sq.cm. Continuous fine-mist spraying or sprinkling shall be used, unless otherwise specified or .approved by the Engineer.

33.2 Membrane curing Surface coating type curing compound may be used only with permission of the Engineer. No curing compound shall be used on surfaces where future blending with concrete, waterproof or acid proof membrane or painting is specified.

33.3 Alternate curing methods Whenever, in the judgment of the Engineer it may be necessary, the continuous spray methods may be omitted. A method covering approved material such as wet burlap and' other- method as approved by the Engineer may be used. Type of covering, which would stain, disfigures or damages the concrete during and after curing period shall not be used. Approved covering shall be kept continuously wet during the specified curing period.

33.4 CuringConcrete shall be maintained in moist condition for at least the first 10 days after placing. For concrete containing high early strength cement, the. curing time can be reduced to minimum 7 days. For concrete containing pozzolana, the curing time shall not be less than 14 days.

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33.5 Ponding For curing of concrete in pavements, sidewalks, floors, flat roofs, or other level approved surfaces the ponding method of curing is preferred. Special attention shall be given to edges and corners of the slabs to ensure complete and proper protection to these areas. The ponded areas shall be kept continuously filled with water and leaks shall be promptly repaired.

33.6 Commencement of curing Curing of concrete shall start after 8 hours of placement and in hot weather, within 4 hours of placement. During the first 24 hours, the concrete shall be cured by use of wet burlap or such other means to cover the concrete surfaces. The formwork shall also be kept wet by sprinkling of water.

During the period of high ambient temperatures (t >30oC) the Contractor shall take all required measures to prevent any adverse effect on fresh concrete like very fast setting, fast water evaporation, rapid decrease in plasticity, cracking after concreting (plastic cracking) or after hardening (due to rise in concrete temperature, resulting in reduced final strength and cracking).

When necessary, the contractor shall formulate procedures for curing the fresh concrete. The Engineer shall approve such procedure.

34.0 PROTECTING FRESH CONCRETE Newly placed concrete shall be protected by approved means from rain, sun and wind. Concrete placed below the ground level shall be protected from falling earth during and after placing. Concrete placed in ground containing deleterious substances shall be kept free from contact with such ground or with water draining from such ground during placing of concrete and for a period of at least 3 days unless otherwise directed by the Engineer. The ground water around newly poured concrete shall be maintained at an approved level by pumping or other approved means of drainage and adequate steps shall be taken to prevent floatation and flooding, fresh concrete shall be protected by leaving the forms in place for stipulated period; by prevention of disturbing shocks and vibrations and by avoidance of premature stressing until the concrete has attained sufficient strength to sustain the dead and live loads. For the length of time that the forms must be left in place after placement of concrete see clause entitled 'Removal of Forms.

Workmen shall be warned against and prevented from disturbing green concrete during its setting period. If it is necessary that workmen enter the area of freshly placed concrete, the Engineer may require in order to minimize undesirable effects, that bridges be placed over the work area. Steps shall be taken to protect green concrete from damage by debris, loading, vibration, and abrasions, mixing with deleterious materials that may in the opinion of the Engineer impair the strength and/or durability of the concrete.

35.0 REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE

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The procedure approved by the Engineer shall be available with the contractor for inspection of the concrete including repair and replacement of unsatisfactory concrete. Concrete, which is unsatisfactory, shall be repaired by cutting out the unsatisfactory material and by replacing it with new concrete. Voids to be so filled shall be provided with anchors, keys or dovetail slots whenever necessary to attach the new material securely in place. Surface of prepared voids shall be wetted for 24 hours immediately before the patching material is placed. Skilled workmen shall make repair of concrete. Repairs shall be made as soon as practicable after removal of forms and in a manner to meet the requirements for the finish specified for the particular location. The portion of the concrete to be repaired may be .reinforced with steel mesh if directed by the Engineer. Nothing extra shall be charged for such repairs on any accounts.

All materials, procedures and operations used in the repair of concrete & also the finished work shall be subjected to the approval of Engineer. All fillings shall be tightly bonded to the concrete & shall be sound, free from shrinkage cracks or dummy areas after the fillings have been cured and dried.

35.1 Use of Epoxy in Repairs The use of an epoxy for bonding fresh concrete for repairs will be permitted Epoxies shall be applied in accordance with the instructions of the manufacturer. For repair of the concrete works, the contractor shall use epoxy as a bonding agent prior to placing fresh concrete. The Contractor for this job shall arrange approved material. The use of epoxy for the repair work will be at the discretion of the Engineer.

Epoxy is a two-pack system containing base and hardeners. The shelf life of the unmixed cans is about one year or more when stored under climatically controlled atmosphere as specified by the manufacturer. The base and hardener(s) shall be mixed in the correct proportions recommended by the manufacturer. The blend, after mixing intimately, shall have a pot life of one hour and the material shall be applied over the old concrete in a thin film. Fresh concrete shall be deposited immediately prior to the film drying up so as to ensure proper bonding between both concretes.

35.2 Use of Dry Pack in Repairs Where the dry pack method of repair is used, pockets shall be sharp and square at the surface edges, but corners within pocket shall be rounded. The perimeter of the pocket shall be under cut in several places. Pockets for dry pack shall have a minimum depth of 25 mm. The pockets to be repaired shall be scrupulously clean and slightly wet with no free water on the surface. The surface shall then be dusted lightly with cement by means of dry brush. Under no conditions shall the pockets be painted with neat cement grout.

The dry pack mix shall be proportioned by weight; I part cement to 2.5 parts of sand that will pass a No. 16 screen. Only enough water shall be used to produce a mortar, which will stick together when moulded into a ball by a slight pressure of the hands and will not extrude water but will leave the hands just damp. Dry pack material shall be placed and packed in layers having a compacted thickness of about 10 mm. Each layer shall be solidly compacted over its entire surface by use of hardwood stick and hammer. The stick is normally about 300 mm to 460 mm long and not over 30 mm in diameter. Most of the tamping should be directed at a slight angle and towards the side of the pocket to ensure maximum compaction and bond. Water shall not be used to facilitate finishing.

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35.3 Matching of Patch Surfaces Filling material used in repair of surfaces which will be exposed after completion of the project shall be made with cement from the same sources as that used in concrete and blended with a sufficient amount of white Portland cement to produce the same colour as m the adjoining concrete. Patched surfaces shall be given a final treatment as required to make the texture of the patch to match that of the surrounding material.

35.4 Curing of Patched Work Immediately after patching is completed, the patched area shall be covered with an approved non-staining, water-saturated material, which shall be kept wet and protected against sun and wind for a period of 12 hours. Thereafter, the patched area shall be kept continuously wet by a fine spray or sprinkling as required for the duration of minimum curing time or as decided by the Engineer.

35.5 Approval by Engineer All materials, finished work procedures and operations used in the repair of concrete and also the shall be subject to the approval of the Engineer. All fillings shall be tightly bonded to, the concrete and shall be sound, free from shrinkage cracks or dummy areas after the fillings have been cured and dried. The Contractor at his own cost shall do all repair works.

36.0 Concrete Topping to Floors36.1 General

Where concrete topping is to be laid over the structural slab, then this slab shall be screeded to the proper temporary elevation and the top mortar shall be chipped so as to expose the aggregate.

36.2 Surface treatment The surface to which the concrete topping is to be applied shall be thoroughly cleaned of the laitance, scale and all foreign material. The cleaning will normally include chipping by pneumatic chippers or sand blasting, particularly if there is any oil or grease film. Just prior to placing the topping, a mortar paste shall be scrubbed thoroughly into the surface of existing concrete. This mortar paste shall be composed of one part cement to one part fine, well washed sand (preferably No. 16 screen). This mortar paste shall have medium consistency and should not exceed thickness of 2 mm after application.

Care shall be exercised in placing the mortar paste to ensure that it is not placed too far in advance of the topping since the latter must be applied before the coat has stiffened and set. This mortar thus placed shall not be paid for.

36.3 Screeds

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Screeds shall be set as guides for a straight edge to bring the surface of the floor concrete to the required elevation. They must be sufficiently rigid to resist distortion during spreading and levelling of the concrete. All floors shall be free of pockets or depressions and shall be finished level, excepting where floor drains occur, in which case they should be sloped to the same, and screeds shall not be removed until the topping is sufficiently stiff to retain the desired level or slope

36.4 Mix Unless otherwise specified, mix proportions for concrete floor topping shall be I part cement, 1 'A part of sand and 2 parts crushed coarse aggregate (not exceeding 12 mm in size) by weight based on dry materials. The mix proportions shall be subject to minor variations by the Engineer to suit actual conditions. This mix shall be a "no slump concrete" of the driest consistency that can be worked and the net water cement ratio shall not be greater than 0.40.

All concrete topping shall be vibrated using screed-mounted vibrators, the screed being designed to suit the surface levels and locations etc.

The work shall consist of 40 mm thick flooring comprising 28 mm thick under bed topped with 12mm thick wearing course.

36.5 Application The topping shall be spread evenly with rakes and compacted thoroughly by screed mounted vibrators, the screed being designed sufficiently heavy for thorough compaction. After being compacted, the topping shall be trimmed to grade with a straight edge followed by wood floating. Where the area is sufficient to justify their use, preliminary finishing or floating shall be carried with a power driven float equipped with vibrating devices. The final compaction and smoothening to a fine texture shall be done with a steel power trowel. Initial wood floating shall not begin until the concrete is sufficiently set so that finishing does riot bring water to the surface and until the topping has hardened sufficiently to bear the weight of a man without leaving an indentation. Finishing with steel power trowels may be commenced as soon as the floated topping has hardened enough to prevent excess fine material from working to the surface. This operation shall be performed with heavy pressure to produce a dense, smooth, watertight surface free from blemishes. Sprinkling cement or a mixture of sand and cement on the surface to absorb excess moisture or to facilitate trowelling shall not be permitted.

36.6 CuringThe finished floor surface shall be adequately protected from damage and as soon as it is sufficiently hard to support workmen, a light fog spray shall be applied and it shall then be completely covered with airtight non-staining waterproof curing paper with edges lapped and sealed or it may be covered with non-staining sand, cotton or burlap mats provided they are kept continuously and completely moist. The said covering shall be kept in place for the curing period specified in the specification. Under certain conditions, and only with the approval of the Engineer, the Contractor may apply a colour-less curing compound in accordance with the manufacturer's instructions. The use of curing compound if approved would be at the cost of contractor and nothing extra shall be

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payable.

However, under no conditions shall the curing compound be applied until after the topping has been cured by soaking with water continuously for 24 hours.

36.7 Monolithic floorsThe above requirements in respect of screeds, finishing and curing floors for concrete topping shall also apply where monolithic concrete floors are specified.

36.8 Floor hardenersThe work shall consist of 40 mm thick flooring, comprising 28mm underbed topped with 12 mm thick wearing course of hardonite or approved equivalent. All material shall conform to specification and the hardonite powder shall be brought to the site in original sealed containers bearing the manufacturer's name.

36.9 Base preparation The base cement concrete slab or masonry surface shall be cleaned of all dirt with water and hard brush. The base surface shall be hacked or otherwise roughened to obtain a good bond. The surface shall be clean, free from grease, oil, dust, loose particles, etc and thoroughly soaked with water to prevent absorption of mixing water from the base course. Before placing the underbed, any excess standing water shall be mopped out. Before laying the flooring, approval of the Engineer shall be obtained as to the acceptability of the base.

36.10 Underbed The underbed shall consist of cement concrete with 10 mm clean, well graded, and hard approved stone chips and clean, sharp, coarse sand. Elongated or thin flake like fragments of stone. shall be avoided. The proportion of the mix shall be of grade N25. Water content shall be minimum, sufficient to give workable consistency. Generally water cement ratio of 0.4 should suffice.

Prior to commencement of the laying of underbed a thick coat of cement slurry shall be given on the cleaned surface. This shall not be paid for separately. Underbed floor shall be cast in panels not exceeding 5 sq.m. in area and no side more than 2.5 m long. The casting sequence shall be in a chequer board fashion, no two adjacent panels being cast before the contraction of the previous one has taken place. Flat bars of steel or wood duly oiled to prevent sticking shall support the edge of each panel into which the floor is divided. The bars shall be removed before filling in adjoining panels. At least 48 hours shall elapse before concreting in the adjacent bay is commenced. After laying, the underbed shall be leveled, compacted and brought to proper grade with a screed or float.

Alternatively the contractor may cast the underbed floor continuously in one pour after getting his scheme approved by the Engineer.

36.11 Special Topping

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Proportion of the metallic hardener shall be as specified or as indicated by the manufacturer, suitable for heavy-duty floor.

However in absence of any such direction, one part of metallic hardener shall be mixed dry with 4 parts of cement, by weight. To this mixture 6mm down nominal size stone chips shall be added in proportion of 1:2 by volume and machine mixed. Minimum quantity of water shall be added to make it workable with a water cement ratio not greater than 0.4.

36.12 Laying The hardonite mixture shall be laid on the underbed concrete base and shall be properly compacted by screed vibration or heavy wooden battens and trowelled smooth to give a hard and even surface. The placing of the 12 mm thick topping shall be carried out within 2 hours of laying of the underbed. Curing shall be carried out for a period of 10 days during which time the entire finish surface shall be kept constantly wet.

36.13 Hardonite flooring by Vacuum Dewatered Concrete To lay 50mm thick N25 grade PCC over the existing concrete surface, after the floor is properly screeded by using double beam screed vibrators, the surface shall be subjected to the vacuum dewatering treatment to remove the additional water. The water cement ratio shall be 0.43 after the application of vacuum dewatering.

After the vacuum dewatering treatment, Rockite or equivalent metallic dry shake mixed with cement as per manufacturer's specification (generally at the rate of 4.5 Kg per sq.m.) and shall be spread over the green concrete and the procedure as per the guide lines detailed in ACI 203 or BS 8204 shall be followed.

36.14 Protection After floors have been completed to final elevation and cured, they shall be protected from damage for the time of the contract during the period of construction and equipment erection. Protection shall be in the form of timber decking, tarpaulins or other forms of covering as approved by the Engineer.

37.0 FOUNDATION BEDDING, BONDING AND JOINTING All surfaces or concrete beds shall be prepared by suitable shaping, thorough cleaning, washing and de-watering the surface as may be indicated in the plans, or as the Engineer may direct to meet the various situations encountered in the work.

37.1 Preparation of earth All soil surfaces upon which or against which concrete is to be placed shall be well compacted and free from standing water, mud or debris. Soft or yielding soil shall be removed and replaced, with lean concrete or with selected soil and compacted to the same density as the surrounding area. The surface of absorptive soil against which concrete is to be placed shall be moistened thoroughly so that moisture will not be drawn

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from the freshly placed' concrete.

37.2 Preparation of concrete surface other than bedding The preparation of concrete surfaces upon which additional concrete is to be placed shall preferably be done by scarifying and cleaning while the concrete is between its initial and final set. This method shall be used wherever practicable and shall consist of cutting the surface with picks and stiff brooms and by use of any approved air and water jet combination as directed by the Engineer. Great care shall be taken in performing this work to avoid removal of too much mortar and the weakening of the surface by loosening of aggregate. When it is not practicable to follow the above method it will be necessary to employ air tools to remove laitance and roughen the surface and clean the surface by air water jet. The final required result shall be a pitted surface from which all dirt; unsound concrete, laitance and glazed mortar have. been removed. Wet sand blasting shall be done, if necessary in the opinion of the Engineer, to accomplish the above requirements. Water and/or air jet pressure at the point of concrete contact surface shall not exceed 4-kgf/sq cm

37.3 Bonding treatment (Mortar) After the concrete surfaces upon which new concrete is to be placed have been scarified, cleaned and wetted as specified herein, they shall receive a bonding treatment, immediately before placement of the concrete. The bonding medium shall be a coat of cement sand mortar. The mortar shall have the same cement-sand ratio as the concrete, which will be placed on it. The water cement ratio shall be determined by placing conditions, and as approved by the Engineer. Bonding mortar shall be placed in sufficient quantity to completely cover the surface about. 6mm thick. It shall be brushed or broomed over the surface and worked thoroughly into all cracks, crevices, and depressions. Accumulations or puddles of mortar shall not be allowed to settle in depression and shall be brushed out to a satisfactory degree, as determined by the Engineer. Concrete shall be placed immediately upon the fresh mortar. Mortar shall be placed at a rate that it can be brushed over the foundation just in advance of placement of concrete. Only as much area shall be covered with mortar as can be covered with concrete before initial set in mortar takes place. The amount of mortar that will be permitted to be placed at anyone time, or the area that it is to cover, shall be in accordance with the Engineer's direction. No extra claim shall be allowed on this account to the Contractor.

37.4 Cleaning and bonding formed construction joints Vertical construction joints shall be thoroughly cleaned by methods approved by the Engineer. In placing concrete against formed construction joints, the surface of the joints, where accessible and as directed by the Engineer, shall be coated thoroughly with the specified bed-joint bonding mortar immediately before they are covered with concrete. Where it is impracticable to apply such a mortar coating special precautions shall be taken to ensure that the new concrete is brought into intimate contact with the surface of the joint by careful puddling and spading with the aid of suitable tools.

38.0 WORKMANSHIP OF CONCRETE All workmanship shall be according the latest IS standards and modem and good

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engineering practices, Contractor shall obtain complete instruction about the material, proportions and manner of incorporation and application in the work from the Engineer from time to time.

The proportions of fine and coarse aggregate, cement and water shall always be as approved by the Engineer. The quantities of all ingredients of concrete shall always be determined by weight.

The entire contents of the drum of a mixer shall be discharged before the ingredients for the next batch are fed into the drum, Partly set, re-mixed or excessively wet concrete shall not be used and it shall be immediately removed from the Site. Each time the work stops, the mixer shall be thoroughly cleaned. When the next mixing commences, the first batch shall have 10% additional cement to allow for loss in the drum. No extra claims for such additional quantity of cement shall be entertained.

39.0 RATES AND MODE OF MEASUREMENT The unit rate for concrete work under various categories shall be all inclusive and no claims for extra payment on account of such items as leaving holes, embedding inserts, etc. shall be entertained unless separately provided for in the Schedule of Quantities. No extra claim shall also be entertained due to change in the number, position and/or dimensions of holes, slots or openings, sleeves, inserts or on account of any increased pour heights etc. All these factors should be taken into consideration while quoting the unit rates.

Payments for concrete will be made on the basis of unit rates quoted for the respective items in the Schedule of Quantities. No deduction in the concrete quantity will be made for reinforcements, cover blocks and individual opening less than 0.100 of a Sq.m. in areas where concrete is measured in sq.m. and 0.010.Cu.m. where concrete is measured in cubic metres of trusses, which shall be spanned from the near by walls/ columns.

The Contractor shall. prepare, before commencement of actual shuttering work, design and drawings for formwork and centering and get them approved by the Engineer well in advance before the fabrication and erection of formwork. Formwork shall be designed to fulfill the following requirements:

1. Sufficiently rigid and tight to prevent loss of grout or mortar from the concrete at all stages and appropriate to the methods of placing and compacting.

2. Made of suitable materials.

3. Capable of providing concrete of the correct shape and surface finish within the specified tolerance limits.

4. Capable of withstanding without deflection the worst combination of self weight, reinforcement and concrete weight, all loads and dynamic effects arising from construction. and compacting activities, wind and weather forces.

5. Capable of easy striking without shock, disturbance or damage to the concrete.

6. Soffit forms capable of imparting a camber if required.

7. Soffit forms and supports capable of being left in position if required.

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8. Capable of being cleaned and/or coated if necessary immediately prior to casting the concrete; design temporary openings where necessary for these purposes and to facilitate the preparation of construction joints.

Unless otherwise specified all forms in contact with concrete having F-3 finish shall be plywood panel formworks. Forms will be firmly bolted to previous pour of concrete. No through bolts embedded in concrete will be permitted in any structures. Threaded mild steel sleeves designed for holding in concrete or standard coil nut anchors may however be embedded upto a depth of 225mm from each face. The forward end of such sleeves or coil nuts shall be retained at least 25mm within the concrete to permit complete enclosure by subsequent dry packing side. The contractor should finish all the coil nuts by dry packing. The recesses, if any, formed by the removable timber wedges shall be filled with polysulphide caulking compound or Epoxy mortar if depth is less at contractor's own cost.

In the items of work of concrete, minimum cement contents to be used in the works have been specified. No extra payment shall be made to the contractor for the use of extra cement more than these values to achieve the required strengths, workability etc.

The unit rate for precast concrete members shall include formwork, moulding, finishing, hoisting and setting in position including setting mortar, provision of lifting arrangement etc. complete. Reinforcement and inserts shall be measured and paid for separately under respective item rates.

Unit rate of concrete is deemed to have include the following

1. Supply and storage of cement, fine and coarse aggregate, water, batching plants, aggregate crushing plant, aggregate washing plant, ice plant, batching, mixing, conveying, placing, compacting etc at all levels complete inclusive of all labour, supervisory staff, sampling, all testing’s, maintaining records, obtaining approval of Engineer etc. all inclusive for satisfactory completion of the job.

2. Admixtures, minerals, chemical admixtures and additives etc. required to produce concrete of required fresh and hardened properties and workability.

3. Trial mixes and all related mix design activities and testing.4. Tests for pumpability.5. Curing. 6. F2 and U2 finishes 7. Making good of defective and unsound works as per specifications. 8. Any other testing as required by the Engineer.

40.0 FORM WORK The work covered under this section shall include the providing, erection and removal of formwork for normal, heavy and super heavy concretes in walls, columns, foundations, slabs, beams including climbing formwork/slip form if required, formwork etc, including its supporting members.

40.1 General

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The form work shall consist of. but not limited to shores, bracings, sides of beams, columns, walls, rafts and bottom of slabs including ties, anchors, inserts, hangers, false work, wedges etc., complete, which shall be properly planned for the work. For the floors, supports can be taken from the down below floors with prior permission of the Engineer. Wherever required provision shall be made to support the floor shuttering by means

40.2 Materials Materials for the Formwork shall be of formed steel plates, Plywood, timber form work covered with steel sheets, oil tempered hard board. Sliding forms', and slip forms may be used with the approval of the Engineer. The supporting system shall be either adjustable props made of mild steel pipes for heights upto 6 m or composite columns fabricated using M.S. Structural steel members.

Forms shall conform to the shapes, lines, grades and dimensions including camber of the concrete as called for on the drawings. Ample struts, walers, braces, etc., shall be used to hold the forms in proper position without any distortion whatsoever until the concrete has set sufficiently to permit removal of forms. Formwork shall be rigid and strong enough to withstand effect of vibration practically without any deflection, bulging, distortion or loosening of its supports and shall be such as to prevent loss of slurry from the concrete. The contractor shall use either foam strips or any suitable sealing tape to prevent loss of slurry through the joints of formwork. Forms shall be braced, strutted, propped and so supported that it shall not deform under weight and pressure of the concrete and also due to construction facilities. The form work shall be designed and fixed to meet the tolerances in various areas specified in this specification or as specified in the relevant drawings. Formwork for removable hatchways and plugs shall be installed in place wherever possible. Back form for sloping concrete surfaces shall be provided as decided by the Engineer at no extra cost.

Unless prior approval in writing has been received from the Engineer all vertical wall fonns shall be constructed for the pressure as per the provisions given in ACI.

All horizontal forms shall be constructed for pressures from the dead load of the concrete and embedment’s and a minimum live load of 200 Kg/sq.m. For any additional loads, the formwork shall be suitably designed and got approved.

Forms constructed for retaining heavy concrete of net dry density 3650 Kg/cum after curing shall be built for pressures which have been increased by the ratio of the Unit Weight of heavy concrete to normal concrete.

Further, the formwork shall be designed to withstand all the pressures arising out of placement of concrete using pumps.

Temporary openings, which can be conveniently closed, shall be provided at the base of columns and wall forms and other places necessary to facilitate cleaning, inspection and vibration of concrete. Immediately before concrete is placed, the forms shall be made sufficiently rigid and tight, thoroughly cleaned, properly treated and free from foreign material. When forms appear to be unsatisfactory in any way, either before or during the placing of concrete, the Engineer shall order the work to be stopped until the defects have been corrected.

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40.3 Centering requirements Centering using steel tubular props, H frames, built-up sections, with provisions to adjust the heights of the props shall be used and they shall be to true levels and rigid. They shall be adequately braced horizontally and vertically. For faster constructions, quick strike decking systems I Acro I Doka systems shall also be used for shuttering supported on floors below, vertical props shall be so supported on wedges or other measures shall be taken whereby the props can be gently lowered vertically while striking the shuttering. Bamboos and wooden poles shall not be used as props or cross bearers. Centering supported on structural steel work shall also be designed for the conditions mentioned above. Wherever required additional trestles required to support the embedded parts resting on the soffits of the floor shall be provided without any additional cost.

40.4 Tie rods As far as possible MS tie rods left in type shall be used for supporting all forms. Retrievable type can also be used with the prior approval of Engineer. Tie rods shall have provision for removal of a section of each rod at surface of the concrete to a depth of approximately 50 mm. All holes left by the removal of conical nuts or other removable fixtures embedded in the face of the concrete shall be filled and finished with cement sand mortar in a manner specified in the finishing specification. Use of internal through ties for Spent Sub-assembly Storage Pool walls and the structures below ground level shall not be permitted. Threaded inserts embedded on each face of the wall shall be cut for attaching the forms to previously placed concrete.

No tie rods shall be directly welded onto the wall liners.

Through Tie rods shall, be permitted only upon approval of the Engineer and when permitted shall be cut off flush with the face of the concrete, or the countersunk, filled and finished, as required by the Engineer, in the manner specified under the finishing specification, Measures shall be taken to prevent rust stains on concrete.

40.5 Form oil In general use of form oil shall not be permitted on the surfaces which require painting. If form oils are used by the contractor, a non-staining mineral oil or other approved oil may be used provided it is applied before placing reinforcing steel and embedded parts. Such form oil shall be insoluble in water and not injurious to concrete and shall not become flaky or be removed by rain or wash water. Form oils that retard the setting of concrete shall not be used.

All excess oil on the form surface and any oil on metal or other parts to be embedded in the concrete shall be carefully removed. Before treatment with oil, forms shall be thoroughly cleaned of dried splatter of concrete from placement of previous lift.

The contractor shall clean the concrete surfaces from any leftover form oil at his own cost if form oils are used.

40.6 Self supporting shutter In certain areas, as identified by the Engineer, metal decking! conventional form ply and supported on structural steel on removable structural steel framework shall be used as self supporting shuttering as an alternative to the conventional shuttering in places where

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the area below has to be kept free of scaffolding and centering works. The fixing of metal sheets to structural steel members shall be by bolting or welding as advised and nothing extra shall be paid for such bolting and/or welding.

Plate inserts may be embedded in the side walls during concreting, from which bracket supports can be obtained. Structural steel built-up sections or trusses shall be used for supporting the formwork. The Contractor shall submit the design and detailed drawings for the above scheme for the approval of the Engineer. The scope of work shall include design, fabrication, erection and dismantling of the supporting structure.

The supporting structure for the formwork shall not be paid separately.

40.7 Chamfers and FilletsUnless shown on drawings or elsewhere to the contrary, all corners and angles shall be formed with 450 mouldings to form chamfers and fillets on the finished concrete. The standard dimensions of chamfers and fillets, unless otherwise detailed or specified shall be 25mnX2Snmi. For heavy concrete work, chamfers or fillets may be 40-50mm. Care shall be exercised to ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced to the same texture as the forms to which it is attached. Unit rates quoted shall include providing such chamfers as specified or shown in the drawings.

Vertical construction joints or faces, which will be exposed at the completion of the project shall be chamfered as above except where not permitted by the Engineer.

40.8 Joints Joints in forms shall be truly horizontal or vertical unless otherwise specified and shall be sufficiently tight to prevent any leakage of cement slurry to avoid formation of fine or blemish. Faulty joints shall be sealed as directed by the' Engineer. Suitable devices shall be used to hold adjacent edges together in accurate alignment. The contractor shall use sealing tapes to avoid leakage of slurry though the formwork joints. On the removal of forms the contractor shall finish marks left by sealing tapes so as to merge with other concrete surface. The contractor shall also take care to maintain symmetry in formwork in slabs, walls, columns etc. so as to give a pleasant appearance to finish concrete surface. All forms shall be so made that they can be removed without hammering or prying against the concrete.

40.9 Reuse of forms Before reuse, all forms shall be thoroughly scrapped, cleaned, examined and when necessary, repaired and re-oiled before resetting. Formwork shall not be used/reused, if declared unfit or unserviceable by the Engineer.

40.10 Clean out provisions Form with limited working space within, shall be provided with temporary clean-out doors or openings for cleaning, washing, blowing and removal of water, wood chips, trash etc.

40.11 Working platformThe Contractor shall provide safe working platform for workmen, when working above

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ground level. Safe method of approach shall be provided to reach locations above ground level. Handrails shall be provided for all working platforms. Hanging platforms shall have safety net provisions. All ladders shall have handrails and shall not be kept vertical. All platforms, ladders handrails etc. shall be firmly secured to ground or on supports. No loosely supported ladders or platforms shall be used in the works. All ladders and platforms shall have a kick plate 150mm high either MS or wooden board for safety of personnel. Ladders and platforms shall be periodically cleaned of loose debris etc.

40.12 Removal of formsIn the determination of time for removal of forms, consideration shall be given to the location and character of the structure, the weather and other conditions including the setting and curing of the concrete and materials used in the mix.

Forms and their supports shall not be removed without the approval of the Engineer. Improper methods of removal of formwork likely to cause overstressinq or damage to the concrete shall not be used. Supports shall be removed in such a manner as to permit the concrete to uniformly and gradually take the stresses due to its own weight.

The supports can be reinstated in anticipation of abnormal conditions. Re-propping of beams shall not be done except with the approval of the Engineer.

The minimum period for removal of forms shall be as mentioned below. However, the seven day test results shall be as per IS: 456 (latest revision). If the strength requirements are not met with, the formwork shall be removed as per the instruction of the Engineer.

Sl. No. Class of StructureEarliest age of concrete at

stripping for placement temperature not less than 20 Deg. C using Ordinary Portland Cement

1 Walls, Columns & vertical sides of beams

24 to 48 hours or as decided by the Engineer

2 Slabs (props left under) 3 days3 Beam soffits

(Props left under)7 days

4 Removal of probs to slabi) Spanning upto 4.5mii) Spanning over 4.5m

7 days14 days

5 Removal of probs to Beami) Spanning upto 6mii) Spanning over 6m

14 days21 days

6 Cantilever construction Not until adequate fixity is developed subject to minimum of 10 days

Striking shall be done slowly with utmost care to avoid any damage to concrete surfaces or any projections on it and without shock or vibrations, by gently easing the wedges/jacks. If after removing the formwork, it is found that timber has been embedded in the concrete, it shall be removed and made good as approved.

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Tie rods, clamps form bolts etc., which must be entirely removed from the walls or similar structure shall be loosened not sooner than 24 hours after the concrete was deposited. Works damaged due to premature or careless removal/withdrawal/loosening/striking of form's shall be re-constructed at contractor's cost.

40.13 REQUIREMENT OF FORM WORK FOR VARIOUS STRUCTURES

40.13.1. Stopper formwork Stopper formwork (Bulkh9ad) shall be provided at all vertical construction joints. Such formwork shall be leak tight and shall not allow leakage of cement slurry. Wherever specified in the drawings, gas barrier/ water stopper shall be provided in the stopper shutter. In addition to the erected stopper shutter, emergency stopper formwork shall be kept ready before starting large concrete pours, with provision for gas barrier/ water stopper if required. All stopper formwork shall be measured and paid in the item of wall formwork only.

40.13.2. Pockets for foundation bolts Pockets for foundation bolts shall be made out of plywood or timber. These shall be made slightly tapered for ease of removal. The bottom of such formwork shall be necessarily closed so as not to allow entry of concrete from bottom. The timber pocket may have to be broken to withdraw after concreting and the rate quoted shall include for loss of timber during such an eventuality. The rate for the pocket shall include provision of templates wherever required or as directed by the engineer.

40.13.3 Formwork for Heavy/Super Heavy concrete Wherever Heavy/Super Heavy concrete is specified in the drawings, formwork shall be designed to achieve the specified tolerances and carry load from the concrete of density not less than 3650 Kg/Cu.m. Special care shall be taken to cut and plug the through tie rods if permitted to avoid streaming of radiation.

40.13.4 Curved formwork This shall cover all such formwork, which is curved in plan. The formwork shall be fabricated to the required curvature at shop before use. Mismatch if any at site, shall be rectified by cutting or replacing the panel/members.

40.13.5 Form work for pre cast concrete works All pre-cast units shall be east in a suitable yard, bed or platform with firm foundation and free from wind. The platform shall have a smooth plaster finish. The yard shall be fenced and shall have a curing tank of adequate size and capacity. The Contractor shall be responsible for the accuracy of the level and shape of the bed or platform. A suitable serial number and the date of casting shall be impressed or printed on each unit. Each unit shall be concreted in one operation. Reinforced concrete members shall be marked to indicate the upper surface.

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The form shall be of steel sheets with only rigid steel frames. All components of formwork shall be so held that during casting there is no deformation of the form resulting in the concrete units not confirming to dimensions indicated in the drawings. The shuttering shall be made with a tolerance of ( ±) 3 mm in all directions.

The side shutters shall not be struck in less than 24 hours for ordinary Portland cement and 72 hours for Port] and pozzolana cement after concreting and no pre-cast unit shall be lifted during striking the form.

The cost of formwork for Hatch blocks, Hatch beams etc shall be inclusive of deshuttering wherever required and is deemed to have been included in the item rate for precast concrete hatch blocks I beams.

40.13.6 Tolerances The following tolerances are permitted unless otherwise mentioned in the relevant drawings. The tolerances shall be taken as the departure from the true position at any point after completion of the structure.

Sectional dimensions: (±) 3 ruin for cast-in-situ concrete.Plumb: 2.5 mm in 5 meters but not cumulative. Tolerances in various sections should be compensatory and not cumulative.Levels: ± 2 mm before any deflection has taken place for both cast-in-sib and pre-cast works. For Fuel Cooling pool, Reactor Vault second stage wall concrete, the tolerance shall be (+) 0mm and (-) 2 mm. Tolerances for climbing type of form work. Variation in walls: Not more than (-f-) 3 mm. Total deviation at any point of climbing form I other formwork measured in horizontal plane with respect to the projection of a corresponding reference point at the base of the structure. (Total deviation consists of translational and rotational components.) : 3 mm per 6m height. Variation for plumb: Not more than 100mm for structure height taken at vertical axis of vessel. Variation from true circular section: Not more than 75 mm in radius from vertical axis of vessel. Latest computerized survey instruments shall be used for checking the verticality and alignment of the form work.

40.14 Submission of Contractor's Scheme Bidder shall submit along with his tender the scheme for shuttering, centering, scaffolding for dome and containment wall and other important elements. These should be supported by preliminary drawing arid design calculations. Final drawing shall be submitted before start of work.

The scheme submitted by the contractor should be for all the different type of centering and shuttering schemes proposed and should be so elaborate keeping in mind the entire cross-section of the HEF in general. The scheme should be such that the construction of one part of the building should not hinder the work on the other parts and keeping in mind the construction schedule.

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For centering and shuttering of walls all the working drawings, details of erection methods calculation of stress and of deflections shall be supplied to the Engineer for approval at least 3 months in advance of erection.

40.16 Alteration and Maintenance Any modification that the Engineer may require shall be made by the Contractor. Notwithstanding the approval of or alteration suggested by the engineer in the submitted design for any of the temporary work etc. the Contractor shall remain wholly and entirely responsible until the final acceptance of works, for the efficiency, security, safety and maintenance and for all obligations and risks in regard to such work specified or implied in the contract. He shall reinstate the same at his own cost, should any mishap or accident occur causing damage or injury thereto, subject however to such provisions of the conditions of contract as may be applicable in the case of such damage or injury.

40.17 Rate The rate for formwork in general shall include providing of all labour, and formwork along with cost of all necessary backing and supporting members including all temporary fixtures and consumables, including staging in case of suspended floors and dismantling after use. The rate shall also include cutting and finishing of through tie rods, The rate shall also include damage to form work while fixing inserts, cut - outs and fixing and removal of cut outs as well as finishing the same in proper line and level and location.

No Separate payments shall be made for any permanent embedment’s left in the concrete.

40.18 Mode of Measurement The mode of measurement for all form work in general shall be for area of form work in contact with concrete in Square meters.

Payments for form work will be made on the basis of unit rates quoted for the respective items in the Schedule of Quantities. No deduction in the form work quantity will be made for individual opening less than 0.1 sq.m.

No extra payment shall be done for F1 and F2 finish. Contractor shall be paid for F3 finish only for undulations more than 3mm.

Where the formwork is paid for separately, it shall be very clearly understood that payment for formwork is inclusive of form work, shuttering, shoring, propping, scaffolding, etc. complete.

For precast concrete no form work will be paid separately. The item rate is inclusive of all shuttering, finishing, curing, storing, transporting, lifting, placing in position with specified tolerances, al labour tools / tackles, plant & equipment, supervision etc. . .

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41.0 GROUT/DRY PACK 41.1 General Grout / Dry Pack shall be provided as specified on the drawings. The 'proportion of Grout shall be such as to produce a flowable mixture consistent with minimum water content and shrinkage.

Concrete surfaces to be grouted / dry packed shall be thoroughly roughened and cleaned of all foreign matter and laitance. Anchor bolts, anchor bolt holes and the' bottom of equipment and column base plates shall be cleaned of all oil, grease, dirt and loose material. The use of hot strong caustic solution for this purpose may be permitted.

Prior to grouting/dry packing, the hardened concrete surfaces shall be saturated with water.

Forms around base plates shall be reasonably tight to prevent leakage of grout/dry pack. Adequate clearance shall be provided between formwork and base plate, to permit grout/dry pack to be worked properly into place.

Grouting, once started, shall be done expeditiously and continuously to prevent segregation, bleeding and within the initial setting time. Grout shall be worked from one side to the other, to prevent entrapment of air.

Water in anchor bolt holes shall be removed before grouting is started.

Forms and shims shall not be removed and the anchor bolts shall not be tightened for at least 24 hours after placing the grout. After the removal of forms and peripheral shims, area occupied by shims shall be filled and the area between the base and the edge of the foundation shall be finished smooth to allow drainage away from the base. Interconnecting piping and machinery shall not be attached to the machinery before anchor bolts are tightened. It is desirable to make these connections at least after a minimum of seven days from the date of grouting. During this period, the grout shall be properly cured.

41.2 Dry Pack The dry pack shall consist of 1 : 2.5 (Cement : Sand), sand passing through 1.18 mm square hole opening standard sieve. Only enough water shall be added to produce a mortar, which will stick together when moulded into a ball by a slight pressure of hand and will not extrude water but will leave the hands just damp. Dry pack material shall be placed and packed in layers having a compacted thickness of about 10mm. Each layer shall be solidly compacted over the entire surface by use of hardwood stick and hammer. Sand for this job shall be as pure as specified for concrete making.

42.3 Grout 41.3.1 Normal Grout The contractor shall supply and place normal grout consisting of an approved mixture of cement, normal fine aggregate, water, admixture and when specified by the Engineer, a non-shrink agent. Normal grout shall be placed as shown on the drawings or specified by the Engineer.

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Grouting through holes in base plates shall be, by pressure grouting. The pressure to be used for grouting shall be as directed by the Engineer. The grout proportions shall be as follows:

Mix proportion W/C Ratio (max)Mix 1: 1 Cement: Sand grout with anti shrink compound

0.44

Mix 1:2 Cement: Sand grout with anti shrink compound

0.44

Mix 1: 1:2 cement: sand with 6mm down stone chips and. anti shrink compound

0.44

Note: If the requirement arises, mixes other than the specified above, such as mix 1 : 1.5, 1 : 1.75, 1 : 2.25 etc. shall be used with the approval of the Engineer. The WIC ratio shall be as per the manufacturer's recommendation and in no case shall exceed the values specified above.

Special Grout The contractor shall supply and place heavy grout consisting of approved high strength cementatious ready mix non-shrink grout 'Conbextra GP-2' (M/s Fosroc make) or equivalent shall be provided at equipment bases, areas specified in the drawing

The grout shall be prepared only to the extent it can be used within the specified pot life by the manufacturer. Any left over grout or grouts not consumed within the time limits of pot life, shall not be used and shall be discarded. The shelf life of the grout shall also be checked before they are used. Expired date grouts shall not be used under any circumstances.

The grouts shall be chloride free.

They shall be used following strictly the manufacturer's specification.

41.3.3 Heavy Grout The contractor shall supply and place heavy grout consisting of an approved mixture of cement, heavy fine aggregate, water, and when specified by the Engineer, a water reducing agent and a non-shrink agent. The heavy grout / dry pack of density not be less than 3200 Kg/cum shall be provided at equipment bases, areas specified in the drawing

41.4 Inspection All materials, workmanship and finished construction shall be subject to the continuous inspection and approval of Engineer

All materials supplied by Contractor and all works or construction performed by Contractor and rejected - as not in conformity with the specifications and drawings shall be immediately replaced at no additional expense to IGCAR. .

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Preliminary approvals of any materials or phase of work shall in no way relieve the Contractor from the responsibility of supplying grouting materials and or producing finished grout in accordance with the specifications and drawings.

All grouting, shall be protected against damage until final acceptance by IGCAR or his representative.

Upon the completion of grouting work, all forms, equipment, construction tools, protective coverings and any debris shall be removed from the area as directed by the Engineer.

41.5 Rate Rate quoted shall include

1. All man power and materials 2. All scaffolding, ladder, platform etc 3. Fixing of nozzles prior to concreting, damage to shutter, fixing of nozzles after

concreting including drilling holes. 4. Cutting of nozzles after grouting, making good by dry pack and finishing the

surface to suit the surroundings. 5. All tools and tackles, grouting pump, mechanical grout mixer etc.

Supply, placing, compacting and curing

41.6 Mode of Measurement Payment will be made for cum of grout actually consumed and not the quantity mixed, which includes fixing of nozzles if any.

42.0 INJECTIQN GROUTING

42.1 Scope The scope of work covered under this specification is injection grouting at following locations.

i) Where the required impermeability of concrete is not achieved. ii) Where defective concrete is suspected and observed. iii) Where water seepage is observed.

The grouting shall be carried out to achieve the leak tightness of concrete at Contractor's cost.

The grouting shall also be carried out at specified locations in the drawing or as directed by the Engineer for which payment will be made as per schedule of items.

42.2. General

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The injection grouting shall be carried out through threaded GI nozzles of suitable length fixed in the area to be grouted. The nozzle length, diameter and spacing shall be as specified in the drawing or as directed by the Engineer. The diameter of the nozzle shall be as per site conditions and generally 16 mm dia may be adopted for cement grouts and 12mm for epoxy grouting. The entire scheme shall be duly approved by the Engineer before commencing the work.

42.3 Materials The grouting material shall be epoxy or cement based with non-shrink additive as specified in the drawings, specifications or as directed by the Engineer.

42.3.1 Epoxy Grout The epoxy grout shall comprise of an injectable solvent free, aggregate free, low viscosity, free flowing, two-component epoxy injection resins, which shall be pumped through the nozzles (fixed prior to concreting or drilled after concreting) under pressure and rapidly cure to a high strength materials. It shall comply with ASTM C-881-1987 Type I - Grade I Class (B+C). It shall be suitable for application in both dry and damp conditions.

Selection of injecting resin system:

The generic name 'epoxy resin' covers a very diverse range of chemically and physically different polymers. To achieve durable repairs, careful selection of the resin composition appropriate to the application and service condition is essential.

The proposed resin injection system is required to have following characteristics. The material should comply with the requirement of ASTM C 881 Type I Grade I Class (B+C).

a) It should be two component (resin/hardener), low viscosity, solvent free, aggregate free, injection liquid based on high strength epoxy resin and suitable for deep impregnation. The epoxy 'and hardener system shall be able to cure in moist/wet conditions also.

b) It should rapidly cure to a- high strength, shrinkage free hardening and without embrittlement.

c) It shall possess anti corrosion, good adhesiveness and bond with the concrete with adhesive strength both under dry and damp conditions and should be capable for use under extreme ambient conditions and remain fluid during applications.

The proposed resin to be used shall be of two parts preferably supplied in different containers according to the manufacturers recommended proportions indicating identifications such as base hardener, recommended proportion, batch no, shelf life, date of manufacturing grade, type, class, quantity etc. Each batch shall invariably carry test certificates for tests conducted in IGCAR approved laboratory. The Engineer may at his discretion, appoint his representative to witness these tests at the laboratory. No separate payment will be made for testing. The chemical composition of epoxy resin constituent of component 'A' shall have an epoxy equivalent of 160-275 g/g mole and physical requirements shall be in line with ASTM C-881. A sample of proposed material intended to be used shall be supplied by the contractor to Engineer to verify the required

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parameters. The material shall be generally used within 6 months from the date of manufacture.

List of tests to be conducted as per ASTM C-881.

Property Tested as per ASTM No.

Requirement

Viscosity D-2393 20 poise (Max)Bond Strength2 days (moist cured)14 days (moist cured)

C-882C-882

6.9 N/mm2 (Min)10.3 N/mm2 (Min)

Water absorption (24 hours) D-570 1.0% (Max)Shrinkage D-883 Shall pass the testCompressive strength 7 days D-693 55.2 N/mm2 (Min)Tensile strength 7 days D-638 34.5 N/mm2 (Min)Elongation at break D-638 1.0% (Min)Gel time As per manufacturer’s specification

42.3.2 Cement based grout

42.3.2.1 Cement and waterThe cement shall be ordinary Portland cement 42 grade conforming to IS:8112. It shall be mixed with water to achieve required consistency for pumping. The quality standards of water to be used shall be same as that of RCC works.

42.3.2.2 SandSand shall be such as to produce a flowable grout without any tendency to segregate. Sand for general grouting purposes, shall be graded within the following limits.

Passing IS 2.36mm sieve 95 to 100%Passing IS 1.18mm sieve 65 to 95%Passing IS 300 micron sieve 10 to 30%Passing IS 150 micron sieve 3 to 10%

Sand for fluid grouts, shall have the fine material passing the 300 and 150 micron sieves at the upper limits specified above. Sand, for stiff grouts, shall meet the usual grading specifications for concrete.

43.3.2.3 Admixture To achieve high consistency with low water cement ratio, suitable water reducing admixture as approved by the Engineer may be used. Suitable anti shrinkage compound shall be added in the mix if specified or as directed by the Engineer.

Proportion or admixture quantity or water and type of mixing shall be as per manufacturer's instructions. Compatibility of admixture with the type of cement used shall be ascertained before use of any admixture with cement.

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42.4 Grouting Operations Grouting operations shall normally begin after 6 weeks of the last concrete poured. A high speed mechanical mixer shall be used to mix the epoxy grout as per manufacturer's recommendation. The grouting shall be done by using hand and pressure shall vary between 2 kg/cm2 to 4 kg/cm2 or as directed by the Engineer. The grouting range can be achieved by injecting the grout with initial low pressure proceeding further with increasing the pressure gradually. Slow and steady increase in pressure shall be followed to produce uniform impregnation of the zone under treatment. The injection pump shall be connected to the lowest tube and the injection allowed to proceed at gradually increasing pressures until grout appears at the adjacent / higher point or refusal of further grout entry at the operating pressure. Cement grouting shall be done normally starting with lean mix and slowly increasing the richness of mix. Cubes shall be cast to test the strength of the cement grout as directed by the Engineer. After successful completion of grouting the nozzles shall be cut and ground properly and finished with dry packing. Wherever specified in the drawing, contractor has to make suitable arrangements for placement of nozzles prior to concreting for its rigidity, thoroughness etc complete with or without piercing through formwork. Contractor has to arrange adequate equipment/manpower required for the work to carryout in different areas simultaneously. Contractor at his cost may appoint a specialized agency to carry out the grouting works. Detailed procedure of grouting shall be prepared by the contractor and submitted to the Engineer for approval before commencement of work.

a)42.5 Special note on Grouting around EPs, Penetrations EPs having Diameter above 300mm Grouting is required to be done around penetration EPs having diameter above 300mm and some special EP's. Procedure for grouting shall be generally same as above with the grouting pressure not exceeding the specified value in the drawing. The nozzles for grouting may be placed prior to concreting or may be permitted to drill after the concreting and the length and diameter of the nozzles shall be as given in the drawing.

42.6 Rates for Grouting Applicable to only those grouting operations as specified in the drawings/directed by the Engineer. Rate quoted shall include:

All labour and man power All scaffolding, ladder, platform etc Supply and fixing of nozzles prior to concreting, damage to shutter, supply and

fixing of nozzles after concreting including drilling holes. Cutting of nozzles after grouting, making good by dry pack / epoxy mortar and

finishing the surface to suit the surroundings. All tools and tackles, grouting pump, mechanical grout mixer etc. Supply of all required materials, injection, and curing.

42. 7 Mode of Measurement For epoxy grout, payment will be made for Kgs. of grout actually consumed and not the quantity mixed. Nozzles shall be paid in numbers, regardless of length. For cement grout, payment will be made for Kgs. of cement actually consumed, which

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includes fixing of nozzles also.

44.0 EMBEDDED PARTS This specification covers placement of Embedded Parts to be provided and kept secured in position until concrete has set completely. Specifications for fabrication of Embedded Parts are given elsewhere in specifications for Structural Steel Fabrication Works.

Material and workmanship Embedded Parts shall consist of anchor bolts, metal shapes, inserts, hangers, opening frames, floor clips, sleeves, conduits, flashing plates with lugs and anchors and fittings which are required to be embedded monolithically, either wholly or partly, in concrete structures but shall not include reinforcing steel, form ties or embedded piping.

All types of rounds and structural sections required for supporting of Embedded Parts shall be supplied by contractor. The contractor will be paid for these supports under relevant items of fabrication and erection of Embedded Parts in the schedule.

Embedded Parts shall be clean and free from contaminations such as mud, oil, paint, laitance, loose rust, mill scale and all other foreign substances.

The contractor shall leave all openings, pockets, grooves, chases etc. in concrete as shown on drawings.

Setting of Embedded Parts Embedded Parts shall be accurately placed in positions shown on the drawings and firmly held during the placing and setting of concrete. Templates shall be used for aligning and securing all Embedded Parts as specified by the Engineer or shown on the drawings. In the case of partial embedment’s the length projecting from the concrete shall be protected from damage and build up of rust.

Unless otherwise specified, form ties, reinforcing steel, concrete platforms, runways and the like shall not be attached in any way to Embedded Parts.

Vibrator shall not come in contact with Embedded Parts during the placing of concrete and Embedded Parts shall be free from undue vibration from other operations of the contractor.

Except as noted hereunder or specified on the drawings all Embedded Parts shall be set to a tolerance of + 6mm at no extra cost. Embedded Parts requiring stringent tolerance in certain locations shall be set to the required tolerance at no extra cost.

Description of Extent of Work

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Embedded Parts to be erected by the contractor shall include all steel members partially or entirely embedded in the concrete.

The contractor shall take all precautions in the fabrication shop, during transport/handling to site and final erection at the proper location to avoid any distortion of fabricated Embedded Parts.

45.0 EMBEDDED PIPING This clause of specification shall apply to steel and cast iron pipe work system of nominal diameter not exceeding 30 cm.

All works under this section shall conform to IS 1742 and IS 5329. The contractor shall clean the piping by flushing of all the loose material prior to handing over to Engineer.

Cast Iron Fittings And Joints Unless otherwise specified, cast iron pipes and fittings shall have bell and spigot joints. Cast iron fittings for soil and drainage system shall conform to IS 1536,1537,1538 specifications. Bell and spigot joints shall be lead filled or cement mortar filled as specified.

Lead Filled Socket and Spigot Joints Lead filled Socket and spigot joints shall be made with best quality braided yarn or jute of proper thickness, wound twice around the pipe and tightly caulked with best quality lead wool to a depth of not less than 5 cm.

Alternatively, lead filled Socket and spigot joints shall be sealed with cast lead following the preparation of joint base with yarning material. Sufficient braided yarn or jute shall be wound around the spigot to properly centre the spigot in the Socket of each joint. Each thread of yarn shall be cut longer than the circumference of the pipe so that ends will overlap and overlapped ends of successive laps shall be staggered. Each strand of yarn shall be thoroughly placed and hammered home into the joint with suitable yarning tools.

Each joint shall be sealed with cast lead in one pour so that the joint space is filled to a depth of not less than 60 mm. After the lead has cooled to the temperature of the pipe, the lead joints shall be caulked tight by means of power or hand tools so that the joints are water tight, care being taken that the bells are not overstrained.

Concrete Encased Socket and Spigot Joints Where cast iron pipes and fittings are specified to be encased in concrete, each joint shall be sealed with yarn as specified, on lead filled, to properly align the joint and prevent entry of cement mortar into the pipe. Care should be taken while placing concrete not to disturb the alignment of the pipe. This type of joint shall only be permitted for drain pipes not subjected to pressure and will not be permitted for soil pipes or pipes carrying sewage.

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Floor Drains Floor drains, either cast iron or other metal types, will be provided for installation in the floors of the buildings, as shown on the drawings. The drains will be cast iron, stainless steel or copper or any other type. The drain pipe shall have a slope of at least 1 :50 away from the floor drain or as shown in the relevant drawings.

Roof Drains and Piping Sumps Roof drains and down-take piping to sumps will be installed in the buildings. The embedded down-take piping from roof drains shall be erected by the contractor.

Patent Couplings Where Patent Couplings are specified to be used or permitted by the. Engineer, the materials used and the method of installation and standard of workmanship shall comply with the recommendations of manufacturer.

Testing All embedded piping provided and erected by the contractor shall be subjected to smoke test as per IS 1742 or any other test as desired by the Engineer to check the integrity of joints. The cost of testing shall be borne by the contractor.

Materials and Workmanship The contractor shall ensure that the pipe work and fittings are accurately aligned to correct lines and elevations before being embedded in concrete and that all guides, supports or hangers are accurately fitted so that the alignment of pipes is maintained. The contractor shall install the guides, supports or hangers in such a manner as to restrict and effectively prevent vertical or lateral movement of the piping during placing of concrete. Unless otherwise specified, all piping shall be located to a tolerance of ±10mm.

Cleaning of Pipes and Fittings The contractor shall ensure that all the pipes, fittings and every component of the piping are clean and free from loose mill scale, rust and other foreign matter when erected. Plugs shall be used to protect temporary open ends of pipe work so that no mortar or concrete enters and chokes the pipe.

Description of Extent of Work All pipes and fittings shall be supplied by the contractor. The contractor shall erect the piping to be embedded in the concrete of the structures covered under this contract.

Pipes Jointing in Forms

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The carbon steel pipe laying, welding and testing shall be done by contractor as part of embedded piping. The contractor shall place pipes in the form and align to an accuracy of ±12mm or as specified in the relevant drawings. Final alignment after welding and ensuring that no misalignment takes place during concreting shall be the responsibility of the contractor.

Mode of measurement The embedded parts and embedded piping shall be measured and paid for as per relevant items mentioned in the "schedule of Quantities and Rates". The actual weight of full length of anchor bolts, embedded parts, sleeves, miscellaneous steel members and shapes, etc. handled by the Contractor irrespective of their actual length of insertion, shall be measured and allowed for payment. Where the theoretical weight cannot be assessed satisfactorily the actual weight shall be followed under certification of the Engineer. The protection of the material with proper anti-corrosive painting/greasing and covering with gunny bags against damage till the structure is handed over shall be the responsibility of the contractor and cost of such measures for protection shall be deemed to be included in the unit rates quoted by the Contractor in the schedule. Any "boxing" left for inserts and penetrations during construction for facility of the contractor's work and later on grouted by the same contractor after placing the insert/shall be considered for the measurement purpose as if the inserts and penetrations were placed before the concreting. This boxing shall be placed only with the approval of the Engineer.

46.0 PRECAST CONCRETE All concrete for precast concrete work shall comply with specifications for general concrete work and with the following additional requirements.

Tolerances All units shall be cast as per detailed drawings furnished by the Engineer and to the tolerances indicated thereon. In the absence of any such indication the dimensions shall not vary by more than +3mm.

Platform All precast units shall be cast on a suitable yard, bed or platform with firm foundation and free from wind. The platform shall be fenced and shall have a curing tank of adequate size. The contractor shall be responsible for the accuracy of the level or shape of the bed or platform. A suitable serial number and the date of casting shall be impressed or printed on each unit. Each unit shall be concreted in one operation.

Forms The forms shall be steel forms with rigid steel frames or plywood forms if specifically approved by the Engineer. All component parts of formwork shall be so held that during concreting, there is no deformation of the form resulting in the concrete units not conforming to dimensions indicated on the drawings.

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Striking Forms Side shutters shall not be struck in less than 24hours for ordinary Portland cement and 72 hours for Portland pozzolana cement after depositing concrete or as specified by the Engineer.

Identification Marks The surface of the underside or upper side, which is reinforced, shall be distinctly marked.

Curing The blocks shall be kept at not less than 90 % humidity immediately after manufacture, for 24 hours and thereafter wet cured for a period of 14 days at a temperature of not less than 160 C. Rapid drying at the end of curing period shall not be permitted. Therefore they shall be stored under a safe and shaded enclosure/area. During this period, the blocks shall be handled carefully without causing any damage to corners, edges, surfaces etc.

Hoisting The lifting and removal of precast units shall be undertaken without causing shock, vibration or undue bending stresses to or in the units. Before lifting and removal takes place, the contractor shall satisfy the Engineer or his representative that the methods he proposes to adopt for these operations will not overstress or otherwise affect seriously the strength of the precast units. Lifting hooks shall be embedded in correct position of the unit as shown in the drawings to facilitate erection. These shall be burnt off and finished after erection if directed so, by the Engineer. The units shall be incorporated in the work in accordance with details shown on drawings or as directed by the Engineer. Cracked or damaged precast pieces, during, before or after erection shall be removed and replaced with good ones at the contractor's expense.

Jointing The joints shall be filled in with cement mortar 1:3 unless otherwise specified on the drawings. After jointing, the joint shall be cured for minimum of 10 days. All sharp and abrupt ridges and marked depressions shall be removed by grinding or filling with cement mortar properly bonded to the concrete.

47.0 PRECAST CONCRETE HATCH COVERS

All concrete for hatch covers shall comply with specifications for general concrete work and with following additional requirements.

a) All hatch covers shall be cast as per detailed drawings furnished by the Engineer and to suit the openings as built. The tolerances in dimensions shall be +0 or-3mm unless otherwise noted on drawings. No two adjacent hatch covers shall differ by 2mm in elevation. However, before concreting hatch covers, site measurements of actual openings at the final location of hatches

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shall be taken. Clearance around hatch covers shall be maintained, if required, by adjusting their overall dimensions to suit actual size of opening.

b) As far as possible these hatch covers shall be cast very near to their final locations to minimise handling of these hatch covers.

c) Each hatch cover cast for a particular location/opening shall be properly identified by use of metal plates as indicated in drawings.

d) Each hatch cover shall have MS edge protection angle frame along its perimeter, and vertical connecting angles, as given in detailed drawings. The frame shall be fabricated taking into consideration, the actual size of opening at its final location.

e) Care shall be taken while concreting to ensure that this framework does not get distorted during/after concreting.

f) All formed surfaces of the hatch cover shall have F3 finish and unformed surfaces shall have U3 finish.

g) The hatch covers/blocks will have to be transported and placed in final location by the contractor. Rectification of hatch covers or blocks will have to be carried out by the contractor if tolerances as specified are not achieved. The unit rate for this item shall include casting, curing, transporting to final location, erection, rectification and re-erection after painting at final location. Hoisting shall be done as per relevant clause for precast concrete given above.

48.0 HEAVY CONCRETE BLOCKS This specification covers the supply of heavy concrete blocks of densities as specified by the Engineer viz. 3600kg/m3 required for removable shielding walls at different locations.

48.1 FormsAll forms for heavy concrete precast blocks shall be machine finish steel moulds machined to an accuracy of 1.5mm and shall be subjected to Engineer's approval.

48.2 Dimension, Tolerances, Shape, Weight and Surface FinishingThe block shall have nominal dimensions of 100mm X 200mm X 400mm generally and other dimensions and shapes as specified in the drawings. The dimensions of blocks shall not deviate more than +3 mm from nominal dimensions. The blocks shall be solid and be of rectangular shape. The surface of the blocks shall be finished smooth and free from voids, imperfections etc.

Curing The blocks shall be kept at not less than 90 % humidity immediately after manufacture, for 24 hours and thereafter wet cured for a period of 14 days at a temperature of not less than 16oC. Rapid drying at the end of curing period shall not be permitted. Therefore they shall be stored under a safe and shaded enclosure/area. During this period, the blocks shall be handled carefully without causing any damage to corners, edges, surfaces etc.

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Sampling, Testing and Strength Prior to manufacture trial mixes shall be prepared. When suitable mixes have been established, a sufficient number of blocks shall be cast to permit the Engineer to check the density and surface finish. If accepted these shall be standard for all blocks to be manufactured. IS 1199 method of sampling and analysis of concrete shall apply in addition to the requirement of this specification. The compressive cube strength of cured concrete blocks shall not be less than 25 N/mm2 at 28 days after casting.

Mode of measurement for Precast Actual volume of work shall be measured in cubic metres unless otherwise specified in the schedule of quantities. Deductions or openings, conduits, pipes, ducts shall be made but no deductions shall be made for openings up to .1 sq.m in area each . No additions or deductions be made for embedded fixtures.

No separate payment shall be made for formwork, shuttering, curing, handling, placing in position and jointing wherever required as per specification, drawings and schedule of quantities.

49.0 UNDERGROUND WATERPROOFING USING ACRYLIC BASED MODIFIED POLYMER AND APP POLYMER, MODIFIED BITUMINOUS MEMBRANE

49.1 Scope This specification covers providing of waterproofing of underground structures and basements using Acrylic based modified polymer and polymer modified bituminous membrane treatment. These are provided below the raft and along the outer walls and top slabs of underground tunnels.

The specification describes the basement waterproofing treatment using Acrylic based modified polymer treatment and APP polymer modified bituminous membrane, mode of preparation of surface and mode of application. The work shall be executed with the best good engineering practice, special instruction of the material manufacturer and to the complete satisfaction of the Engineer.

Before commencing the work, the contractor shall obtain the approval of the Engineer in writing regarding the schedule of work. He shall undertake precautions to prevent damage to the already carried out work.

49.2 Material

Cement, aggregate, sand and water

Cement, sand, aggregate and water required for bed concrete, levelling layer cement - sand mortar, protective layer of cement - sand mortar etc. shall conform to specification given under concrete and plastering.

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Underground waterproofing membrane ( APP polymer modified bituminous membrane).

The technical specifications of the waterproofing membrane shall be as given in table below:

Sl.No. Property Result Test method

1. Softening point, oC 155 ASTM D362. Penetration, d mm @ 25 oC 25 ASTM D 53. Breaking strength

- Longitudinal N/5 cm 850 UEAtc- Transverse N/5 cm 750 ASTM D 412

4. Elongation %- Longitudinal 55 UEAtc- Transverse 55 ASTM D 412

5. Puncture resistance- static indentation 13 UEAtc- dynamic indentation 13

6. Water absorption, % wt7. Water tightness8. Heat resistance, oC9. Tear strength, N

- Longitudinal 60 ASTM D 5147- Transverse 100

10. Thickness Min 4.00mm11. Weight Min 4.5 kg/sqmt12. Flexibility at low temperature 10 oC D.A.E - C13. Impermeability of membrane to

waterAbsolute UNI 8202

All the basement rafts shall be provided below them with polymer modified membrane waterproofing and all vertical surfaces shall also be provided with the same.

The membrane must be durable and keep its physical and mechanical properties during 60 years.

The material must have the following certificates:

Compliance certificate with respect Sanitary Hygiene Fire safety certificate Physical health certificate

Certification must be carried out according to the established norms and rules as per Indian practice.

The choice of the water proofing material for reinforced concrete base slabs and building underground part must be carried out with account of aggressive ground water influence. Information on the chemical composition of the ground water must be obtained by the contractor.

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49.3 Safety and Environmental Requirements The waterproofing material must be blast proof, i.e. It should not explode Harmful content in the material must not exceed the norms set by the physical health norms. The material must burn only when put into the fire source. The material must have minimum inflammability and minimum characteristics as to flame spreading. In the technical conditions of the material's manufacturer there must be the requirements to safety and to environmental safety.

49.4 Acceptance Criteria The materials shall be sent to site only after the approval of the Engineer. The acceptance shall be carried out batch wise and each batch shall have the same properties. The contractor shall carryout necessary analysis/tests from random samples as directed by the Engineer at his own cost. In case of materials failing to satisfy the requirements, the same shall be replaced and fresh supply obtained at his own cost.

The acceptance for APP membrane shall be carried out according to the acceptance control of the following characteristics:

Blanket appearance in a roll and out of the roll. Material dimensions in a roll Weight of 1 M2 of the material Weight of the binder from the application side

Relative elongation at tension Breaking force at tension Flexibility at a stud Heat-resistance

The acceptance is carried out through sampling of 10 items out of a batch. The products dispatched to the consumer must be accompanied by the certificates in which the following are indicated:

Name of the manufacturing enterprise Name of the material, its conventional name Batch number and production date Quantity (M2) of the material Test results and confirmation of quality compliance

49.5 Testing Methods The testing methods shall be as described in ASTM 06222-98 for Atactic Polypropylene (APP) polymer modified bituminous sheet material.

49.6 Packing, Marking, Transportation and Storage Packing, marking, transportation and storage requirements are fulfilled according to the technical conditions of manufacturing enterprise.

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49.7 Manufacturer's Guaranties The manufacturer must guarantee compliance of the material with the present technical requirements when meeting the transportation and storage conditions of the customer.

The contractor shall provide the guarantee for the water proofing for a period of 10 years in Rs 100 non judicial stamp paper.

49.8 Requirements to the Presented Data The choice of the waterproofing materials for base slab and embedded parts of buildings and facilities must be made based on the data presented as follows:

Physical and mechanical characteristics and properties of the material in accordance with Section 2 of this specification.

Chemical composition of the materials Compliance certificate Fire safety certificate Physical health certificate Technological guide for carrying out waterproofing, including the requirements to

the base surface, adhesive composition, methods of control and quality estimation of the works being done.

Rates The rates shall be for the unit rates for the complete work as detailed out in this specifications above inclusive of supply of materials, equipment, labour, consumables etc. unless any particular portion is specifically excluded. The levelling course of PCC will be paid as per the relevant item in the schedule of quantity.

Mode of Measurement The measurement for the waterproofing membrane shall be in area covered, the deductions of all openings and shall be measured in square metres to the nearest three decimals unless otherwise specified in the schedule of quantities.

No separate payment will be made for over laping and for the provision of extra lambs at junctions as shown in the drawings

49-A Specifications for only acrylic based polymer modified cementious coating. 100% acrylic based milky white polymer like Armoucrete or other approved equal acts as a protective coating to the toilets, bathroom basements and other surfaces etc. along with cement. It is used in the form of slurry with cement. The normal proportion for slurry coat is 2:1 (cement: polymer) by weight. To protect slurry coat one more coat is to be applied with 2:1:1 (cement: Polymer: silica sand) By weight before applying first coat of slurry. surface shall be cleaned thoroughly by brush and no undulations/depositions of materials shall be allowed. It shall be free from laitances, dust etc. If any deprenion/undulation/air holes or observed, the same to be plugged/filled by polymer paste in ratio 10: 1 (cement: polymer). Mix preparation shall be as follows: two parts of cement and one part of

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polymer to be mixed in mechanical agitator for two to three minutes and then mix is allowed for another two minutes to released entrapped air.

The mix shall then be applied on prepared surface by brush. During brush application, no area shall be left. on the .prepared surface allowed to air.

After slurry coat, area to be for 5 to 6 hours and then lightly water cured for 5 - 6 hours. Then second and final coat is applied by brush to protect the first coat. 5-6 hours after application, surface to be lightly water cured for 5-6 hours. After this period the surface is ready to receive back fill material etc.

50.0 P.V.C WATERSTOPS

50.1 Scope of work The work to be done under this specification comprises the supply and delivery of plastic polyvinyl chloride water stops, and accessories, all in accordance with the requirements of this specification.

50.2 References Reference is made in this specification to the following:

Standards of the American society for testing materials: D 412-66 Tentative method of Tension Testing of Vulcanised Rubber. D624-54 Standard method of Test for Tear Resistance of Vulcanmsed Rubber D2240-64 T Tentative method of test for Indentation Hardness of Rubber by means of a durometer.

50.3 MaterialThe waterstops shall be fabricated from a plastic compound, the basic resin of which shall be polyvinyl chloride. The compound shall contain any addition resin, plasticizers, inhibitors or other material such that, when the material is compounded, it shall meet the performance requirements given in this specification.

Single-pass reworked material of the same composition generated from the fabricator's waterstop production may be used. No reclaimed polyvinyl chloride shall be used. All waterstop shall be moulded or extruded in such a manner that any cross section will be dense, homogeneous, and free from porosity and other imperfections.

50.4 Qualification Samples The supplier shall furnish a sample of the material for each of the types of waterstop on which he tenders and which is in sheet form having a uniform thickness of from 1 .5 to 3mm (1/16 to 1/8 inch) and having a total area of not less than 0.2 sq. m (2 sq.ft.). Each sample shall be accompanied by an affidavit from the supplier to the effect that the sample is of the same material and all respects as that to be used in the manufacture of the finished waterstop.

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In addition, the supplier shall furnish a 300mm (1 ft) length of each type of waterstop he intends to supply.

All qualification samples shall be supplied free of cost to the purchaser.

All samples shall be clearly marked and labeled (in such a manner that the sample will not be damaged) showing the supplier's name, the date, the type of waterstop it represents and the supplier of the plastic materials.

50.5 Physical Requirements

The waterstop or material from which the waterstops are fabricated shall meet the following physical requirements:

Test & Characteristic Ref. Section Unit RequirementTensile Strength 6.2 (a) Kg/cm2 122.50 min (1750 psi)Ultimate Elongation 6.2 (b) % 350 minTest Resistance 6.2 (c) Kg/cm2 19.25mm (275 psi)Stiffness in flexure 6.2 (d) Kg/cm2 24.5 min (350 psi)Accelerated Extraction : Elongation

6.2 (e) Kg/cm2 105 min (1500 psi) 250 min

Effect of Alkali in 7 daysWt. IncreaseWt increase

6.2 (f) % 0.25 max.0.10 max.

Hardness changes on shores durometer (type A)

Point +/- 5

30 days – Wt. Increase - wt. Increase- dimension change

%%%

0.40 max.0.30 max.+1

50.6 Method of Test

Test specimens:

Specimens for all test, except as otherwise specified, shall be cut from sheets 1.5mm (1/16 inch) to 3.0mm (1/8 inch) thick, supplied by the manufacturer. Specimens shall be of the shape and dimension specified in the individual test methods.

Test shall be conducted in a standard laboratory atmosphere of 70.75° F & 50 ± 2 percent, relative humidity, unless otherwise specified in the testing methods or in this specifications. (a) Tensile strength and (b) Ultimate Elongation:

The tensile strength and ultimate elongation shall be carried out on both the samples as received and also on sample which has been subjected to the Accelerated Extraction Test described in (c) below in accordance with ASTM D 412-66 "Tentative Method of Tension Testing of vulcanised Rubber" using die "C". The result shall be based and reported on the average of a minimum of five tests.

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(c) Tear Resistance:

The standard method of test for Tear resistance of Vulcanised Rubber (ASTM designation 0 624.54), using either die "A" or "8" shall be followed.

(d) Stiffness in Flexure:

A specimen 2.54 cm (1 inch) width and 5.08 (2 inches) in. length shall be fixed in the vice, having jaws of the smooth flat type, with one half of the length of the specimen free of jaws. The vice shall be fixed to a suitable base and placed in a universal testing machine. The specimen shall be subjected to loading as a cantilever beam with the point of loading at a position 6 mm (1/4 inch) from the face of the vice jaws. A loading head of greater width than the specimen and suitable length shall be used to apply the load. The loading head should be 3mm (1/8 inch) material and shall be braced to prevent any flexure under load. The loading face of the head shall be ground to one side to form a knife-edge and. sufficiently rounded to prevent gripping of the specimen material by the head. The stiffness in flexure shall be determined from the material load deflection characteristic, using the following formula:

WhereE = Stiffness in flexure (kg/gm") P = applied load (kg) L = Span length (6mm)

' = deflection under applied load (mm) I = moment of inertia for specimen section (m 4)

(e) Accelerated extraction:

Five tensile test specimen conforming to the shape and the dimension given in ASTM designation d-412-66 using die"c" shall be cut from the sample submitted and the group weighed to nearest milligram. The specimens shall be placed in one-litre tall-form beaker with spout. The beaker shall be filled within dissolving 5.0 grams of chemically pure sodium hydroxide and 5.0 grams of chemically pure potassium hydroxide in one litre of distilled water. The specimen shall be completely immersed and the top of the beaker covered by a clock-glass. The beaker shall then be placed in a constant temperature bath, which shall maintain the temperature of the solution between-140-150o F, a 6mm ( ... 'inch) diameter glass tube shall be inserted into the spout of the beaker to within 12mm (I inch) of the bottom of the beaker. Air shall then be gently bubbled throughout the solution at the rate of about one bubbled per second. The solution shall be changed every 24 hours, the new solution being warmed to 1500 f before replacing the old.

Once daily, each of the five specimens shall be removed from the beaker (preferably at the time of renewing the solution) and shall be rinsed lightly in distilled water. Each specimen shall be superficially dried by means of clean cloth. Ten minutes after the specimens have been thus dried, the group of five specimens shall be weighed and the

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weight recorded. The sequence of testing shall be carried out continuously for a period of not less than 14 days, after which, provided they have reached constant weight, they shall be tested for tensile strength and elongation. Under no circumstances, however, shall the specimens be tested for tensile strength until they have reached constant weight which is assumed to have been obtained when three successive daily readings do not differ from one another by more than 0.05% of the original weight

(f) test on the effect of alkalies:

A specimen not more than 6mm (…inch) thick weighing about 150 grams shall be cut from the sample supplied. Its dimension to the nearest 0.25mm (0.001 inch) and weight to the nearest milligram shall be recorded. The durometer reading using the shore durometer (type a) shall be taken in accordance with ASTM 0-2240-64 T.

The specimen shall be completely immersed in a freshly made solution containing 0.5 grams of chemically pure sodium hydroxide and 0.5 grams of chemically pure potassium hydroxide per 100 ml of distilled water, kept at 70-75° F. The solution shall be replaced every 7 days with fresh solution at the same temperature. At the end of 7 days the specimen shall be removed, rinsed with distilled water and the surface dried with a clean cloth. The specimen shall be re-immersed for a further period of 23 days at the end of which time the dimensions, weight and durometer hardness shall again be measured. At the age of 7 and 30 days and changes either in weight and dimension shall be recorded as percentage of the weight and dimensions of the original sample.

50.7 Non -Standard Test The supplier is advised that the purchaser on the finished waterstop may, also carry out certain additional tests that cannot be described as standards. This particular test is intended to further evaluate the water tightness in concrete under various hydrostatic heads and at various joint openings.

50.8 Packaging The waterstop shall be shipped in coils and wrapped or created as necessary to ensure acceptance and safe delivery by common or other carriers at the lowest rate to the point of delivery called for in the contract. .

Each coil shall be single length of waterstop and shall be 25 to 30 meters in length. The inside diameter of the coil shall be not less than 300mm (12 inch).

50.9 Splices The supplier shall furnished complete instructions on the manner in which they suggest splices could expediently be made in the filed to ensure the following.

(a) that the material is not damaged by heat sealing or by application of cementing materials. (b) that the splices have a tensile strength not less 80 percent of the unspliced

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materials. (c) that the ribs and centre bulb match up exactly and are continuous.

50.10 Inspection The Inspector shall have a free entry to those parts of the company's and any subcontractor's works that concern the manufacture of the material ordered at all times while work on the contract is being performed. The company shall afford the Inspector, without charge, all reasonable facilities to satisfy him that the material is being furnished in accordance with the contract.

The purchaser reserves the right to require sheet samples of material at any time during the contract to determine conformance to this specification.

50.11 Rejection Failure of the qualification sample to meet all the requirement of this specification shall constitute cause for excluding consideration any bid on this product.

50.12 Patents: The supplier must satisfy himself concerning the existence of patent rights covering this material or any part thereof and make necessary licensing arrangement with relation thereto.

50.13 Rate Only actual length after jointing as placed shall be measured. All laps provided for shall not be measured separately. The rate quoted shall include all labour, equipment, jigs and fixtures required for providing and retaining the water stops in position, jointing etc. 100% liquid penetration or vacuum box tests and nothing extra shall be paid for.

50.14 Mode of Measurement Mode of measurement shall be in running meters. Payments for this will be made on the basis of unit rates quoted for the respective items in the Schedule of Quantities.

51 DEWATERING DURING EXECUTION OF WORK

51.1 GeneralDue to presence of ground water level close to finished grade level, the Excavation pits are expected to be full of ground water. The bidder should study carefully the conditions existing at site regarding ground water. It is Contractor's responsibility to install and maintain suitable dewatering system in good working condition at site to ensure that all the excavations are in dry condition.

The dewatering shall be continued till the same is required and shall be stopped after the

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prior approval of the Engineer.

51.2 Extent of Work During the period of construction, the Contractor is responsible for dewatering of all structures arid excavations under his scope of work.

The Contractor shall use adequate Diesel Pumps or D.G. Sets, so that there shall be continuous dewatering pumping to keep the area dry. The Contractor shall be paid for this work under relevant item in the Schedule of Quantities and Rates. The site shall not be allowed to flood and the Contractor shall take all precautions to ensure sufficient standby pumping capacity at all times, particularly in case of power failure.

51.3 Site Condition The Geotechnical investigations carried out so far at this site indicate that the area has Charnockite suit of rocks and Pyroxene granulites of Archaean age as a basement overlain by recent coastal alluvium with an unconformity. Geotechnical investigations shows that ground water was encountered at a depth varying from 2.0m to 5.0m below ground level. So it will be necessary to resort to· de-watering so that construction work can be carried out in dry condition.

51.4 The Dewatering Scheme At Kalpakkam monsoon period normally occurs from middle of September to end of December every year and it normally rains intermittently. 'During the period of monsoon there may be two or three cyclones in and around the area. The Bidders are advised to get further data about maximum rainfall etc from relevant departments of Government if necessary before quoting. The construction is to be carried out very near i.e. about 500 to

600 metres from the High Tide Line of the sea. In rainy season, Ground Water Level will be just at General Ground Level.

51.5 Requirements of Dewatering SystemThe requirements of dewatering system for proposed construction works are as follows:

a) Lowering the water table and intercepting the seepageb) Increasing the stability of the excavated slopesc) Preventing the loss of material from beneath the slopes or bottom of the excavationd) Prevent rupture I heave at the bottom ,of the excavatione) Provide absolute dry surface at the bottom of excavation. It is expected that

elaborate well point system together with all necessary pumps, pipe lines, spares etc will be required to be installed by the Contractor at site. The layout and details of this system will have to be submitted to the Engineer for his approval before installation. The Bidder however should study the local conditions, subsoil data etc. and formulate his own scheme and submit along with his tender.

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TABLE – 1PLAN, SCHEDULE AND TESTING REQUIREMENTS FOR CONCRETE

Sl.No. Material Test or inspection Frequency @

(Normal)Reference Document

Acceptance document

Responsible agencies forPerformance Verification

1 Cement Normal consistency One per 250 MT and part thereof

IS 4031 IS 8112 / 12269

Contractor’s Lab located in IGCAR site

Contractor’s QA Surveillance IGCAR - QAPhysical

propertiesFineness (Specific surface)

One per 500 MT IS 4031 IS 8112 / 12269

Soundness One per 500 MT IS 4031 IS 8112 / 12269

Compressive Strength at ages i.e. 3, 7 & 28 Days

One per 250 MT and part thereof

IS 4031 IS 8112 / 12269

Specific gravity One per 500 MT IS 4031 IS 8112 / 12269

Initial / Final setting time

One per 250 MT and part thereof

IS 4031 IS 8112 / 12269

Chemical properties

Alkali content One per batch IS 4032 IS 8112 / 12269

3rd party inspection by Contractor

Contractor’s QA Surveillance IGCAR - QA

Chemical composition At least once in 3 months per each brand and each grade

IS 4032 IS 8112 / 12269

Heat of Hydration One sample for each grade each brand & each factory

IS 4032 IS 8112 / 12269

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Acceptance document


2 Fine Aggregates 1. Grading – sieve analysis

Daily 1 sample per shift

IS 2386 IGCAR Specification

Contractor at IGCAR Lab

Contractor’s QA Surveillance IGCAR - QAPhysical

properties2. Deleterious material Inspection everyday IS 2386 IGCAR

Specification3. Silt content Inspection everyday IS 2386 IGCAR

Specification

4. Specific gravity Once in 6 months & 1 sample / source


5. Soundness test Once in 6 months & 1 sample / source


6. Moisture content / absorption

Daily three times IS 2386 IGCAR Specification

Batching plant

Chemical properties

1. Chloride & Sulphate Once in 6 months ASTM D 1411

IGCAR Specification



2. Iron content (Heavy) One for each source & 1 per 5000 MT

IS 1493


Once per source or one sample whenever change in quality of aggregate is observed

IS 2386

4. Alkali aggregate reactivity

- Do – and once in 6 months


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Sl.No. Material Test or inspection Frequency @ (Normal) Reference

DocumentAcceptance document


3 Coarse Aggregates

1. Sieve analysis At least 1 sample per shift IS 2386 IGCAR Specification



Physical property

2. Elongation index & flakiness index

One sample per every 2500 cum of concrete or one sample / week whichever is early.

IS 2386

3. Deleterious material

One sample / week and daily inspection

IS 2386

4.Specific gravity Once in 6 months for normal density aggregates (for high density, each 10 MT of iron ore lumps (boulders) stack & for aggregate product from these shall be one sample per 1000MT or part thereof for special heavy.

IS 2386

5. Soundness Once per source IS 2386

6. Moisture content Daily 3 times IS 2386 Batching plant

7. Absorption Daily 3 times IS 2386

8. Organic impurities One sample per Month IS 2386

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Acceptance document


3. (contd)

Mechanical properties

1. Crushing value Once in 3 months IS 2386 IGCAR Specification



2. Impact value Once in 3 months IS 2386

3. Abrasion value Once in 6 months IS 2386

Geological properties


One / source or one sample wherever change in quality of aggregates is observed.



Chemical properties 1. Alkali Reactivity One / source or one sample wherever change in quality of aggregates is observed and once in six months.




2. Chloride & Sulphate content

- do - IS 2386

3. Iron content (Heavy) One for each source & 1 per 5000 MT

IS 1493

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Acceptance document


4 Water Physical and Chemical properties

Once in 3 months IS 456 & IS 3025

IGCAR Specification



5 AdmixturePerformance evaluation

1) Water reduction, setting time, workability and compressive strength

Prequalification of brand and batch qualification per 25 MT

ASTM C-494

ASTM C-494

Contractor at batching plant


2) Specific gravity at 23oC

One sample per day ASTM C-494

ASTM C-494

Contractor at batching plant

Physical properties Chemical analysis

1) Infrared spectroscope

For pre-qualification of admixture and for 125 MT of batch qualification

ASTM C-494

ASTM C-494



2) PH % - do - - do - - do -

3) Solid content - do - - do - - do -4) Chloride content - do - - do - - do -

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Acceptance document


6 Mix design of concrete

i) Design of concrete mix in accordance with IGCAR specification / drawings

For every grade of concrete

IGCAR approved procedure

IGCAR Specification

Contractor IGCAR-QA

ii) Conducting trial study to checka) Compatibility of admixture with

cement.b) Workability at different intervals

to determine slump loss.c) Setting time of concrete at

different atmospheric temperature.

d) Bleeding of concrete.

- do - - do - - do - - do - Contractor’s QA Surveillance IGCAR - QA

iii) Conducting tests on hardened concrete for acceptance.

For all grades of concrete

IGCAR Specification

IS 456 and IGCAR Specification

- do - Contractor’s QA Surveillance IGCAR - QAiv) Performing pumpability trials of

concrete to ensurea) Insitu compressive & split

tensile strength of concrete by curing the sample at site by continuous sprinkling water or identical curing of structure and by laboratory in curing tank.

b) Wet sieve analysis of concrete to ensure uniformity of mix before and after pumping.

- do - - do - IGCAR Specification

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Acceptance document


7 CONCRETE at Batching plant / Production point.

i) Inspection of all concrete making material like cement, water, ice admixture, coarse and fine aggregate for its quality and verifying its relevant test certificate / report for acceptance before starting the concrete.

Daily 1 sample per shift IGCAR Specification

IGCAR Specification

Contractor Contractor’s QA Surveillance IGCAR - QA

ii) Calibration of batching plant including servicing.

Once in 15days or after major pours or after repair of B/P whichever is early.

IGCAR Specification

IGCAR Specification

Contractor

iii) Verifying the recipe of mix design used for production of concrete.

Before starting of concrete and at regular intervals during concrete production.

IGCAR approved mix design

IGCAR approved mix design

Contractor

Workability of concrete All the mixes visual inspection. From every fourth transit mixer and at demand testing

IS-1199 IS-1199 Contractor Contractor’s QA Surveillance IGCAR - QA

Temperature of concrete mix.

From the first production of concrete and at regular interval as situation demands.

IGCAR Specification

IGCAR Specification


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7. (contd)

Air content of concrete One sample per day for each grade of concrete when any admixture is used or as situation demands.

IGCAR Specification

IGCAR Specification


Air content of Air entrained concrete.

Min. one per 50 M3

Density At the time of casting specimens or one per 50 cu.m.

IS - 1199 IS - 1199 Contractor Contractor’s QA Surveillance IGCAR - QA

Setting time test One sample for each pour where green cutting is involved. Minimum one test per hour


Bleeding test. For every big pours or wherever required. Optional at the discretion of Engineer.


Casting of specimen for compressive strength for 7 and 28 days

One sample per 500 M3 of concrete or part thereof

IGCAR Specification

IGCAR Specification


Additional samples to determine compressive strength at various ages

Whenever required IS - 516 IGCAR Specification


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7. (contd)

Split tensile strength @ 28 days (casting)

One sample per 500 M3

of concrete or one set per pour of Walls of RCB or as situation demands for other structures.

IS - 5816 IGCAR Specification


Casting of specimen for modulus of elasticity.


of concrete or one set per pour of Walls of RCB or as situation demands for other structures.



Casting of specimen for flexural modulus test

One sample per pour for walls and top slab of RCB or as desired by the Engineer



Water permeability test to decide grade of concrete


of RCB concrete or as desired by the Engineer for any other concrete.


Casting of specimen for cylinder compression strength.

For every 500 M3 or one set per pour of concrete of RCB structure or as desired by the Engineer.



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Acceptance document


7. (contd)

Inspection the batch weight records of concrete produced for different grades and field concrete data records.

For every pour or as situation demands.

IGCAR Specification

IGCAR Specification


Consistency Each pour, for first three transit mixers, subsequently for every 5th transit mixer.

IGCAR Specification

IGCAR Specification


8 CONCRETE at Pumping / pouring point.

Consistency Each pour, for first three transit mixers, subsequently for every 5th transit mixer.

IGCAR Specification

IGCAR Specification


Temperature For each Transit Mixer

Casting of Cubes For Pours of RCB, 1 set of cubes for every 50 cu.m.

IGCAR Specification

IGCAR Specification


Casting of Cylinders For Pours of RCB, 1 set of cubes for every 50 cu.m.

IGCAR Specification

IGCAR Specification


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52.0 ROOFING INSULATION, WATER PROOFING ETC .

52.1 Scope The work under this specification shall cover all insulation and water proofing necessary for the roofing work as shown on the drawings.

52.2 Inspection of Surfaces Prior to start of the work, the surfaces on which insulation is to be applied shall be inspected by the Contractor and any defects found in the surfaces shall be reported in writing. Failure to report such defects shall be considered as acceptance of the surfaces as a satisfactory base for roofing. The surface shall be cleaned and dried before the laying of roofing is started.

52.3 Mortar Screeding of Precast Roofing Cement sand mortar comprising one part cement and 4 parts clean, sharp, coarse sand of uniform thickness 12mm (minimum) shall be laid on top of the precast concrete roof units. After curing for seven days and on approval by the Engineer, proper insulation work shall be taken in hand.

52.4 Grading a) Low-sloped Roof The precast concrete plank roofing and some cast-in-situ roof areas have been provided with a general slope of 1 in 80. Any local re-grading, as and where necessary shall be done by varying the thickness of foam concrete on top of insulation, prior to application of water proofing treatment, and run-off gradient of not less than 1 in 120 shall be ensured by such re-grading.

b) Flat Roof The grading shall be provided by an underbed prepared properly to the satisfaction of the Engineer and as specified under 'Schedule of Quantities. Unless otherwise specified, the grading shall be done by foam concrete so as to ensure a run-off gradient of not less than 1 in 120. The minimum thickness at low points and/or valleys shall not fall below 18 mm. After curing for 7 days and on approval of the underbed by the Engineer, the insulation work shall be taken in hand

52.5 Foam Concrete This shall be light weight aerated or foam concrete of uniform thickness of 100mm over sloping roofs or average 200mm thickness over flat roofs as specified in the ‘Schedule of Quantities’ suitable for application as heat insulating material for roofs. The material shall have a unit weight between 0.35 and 0.45 gm/cm3. These insulating properties shall be such that the thermal conductivity shall not exceed 0.100 Kcal transmitted per hour per Sq. Metre per Degree centigrade per metre thickness. The foam concrete may be laid in-situ in suitable panels or in precast blocks. Before starting the laying of foam concrete samples shall be prepared at site and tested for approval of the Engineer at no extra cost. Foam concrete shall conform to IS: 6598.

52.5.1 Laying The foam concrete shall be sufficiently strong to take the usual work loads and standard loads expected on the roof. Any damaged portion shall be removed and replaced forthwith. Approval of the Engineer shall be taken before laying the water proofing over the insulation. For in-situ work, the coating shall be in the form of panels and a high degree of homogeneity shall be achieved in its structure. The shrinkage shall be reduced by proper control on mixing and curing methods.

For laying of precast blocks nominal bed mortar of cement sand mix shall be used. Hot bitumen primer of grade 80/100 at 1.2 kg/m2 minimum, shall be applied on the concrete roof before laying foam concrete to provide a vapour barrier.

The foam concrete surface shall be finished with mortar screed to provide a hard surface for receiving the waterproofing treatment as specified below.

The insulation surface shall be finished with a mortar screed to provide a hard surfacing for receiving water proofing treatment. The mortar screed shall be of cement-sand comprising 1 part cement and 4 parts clean, sharp coarse sand and of average thickness 25 mm or as per manufacturer's specifications. If required by the manufacturer chicken wire mesh shall be used for applying the mortar screed. In carrying out local re-grading for drainage purpose care should be taken that thickness of the screed does not fall anywhere below the minimum thickness specified by the manufacturer. The screed shall be properly cured for 7 days and should be absolutely dry before starting the water proofing treatment.

While laying the foam concrete, samples from each batch of the mix shall be kept for test if so desired by the Engineer.

52.6 Water ProofingWater proofing shall be made for extra heavy treatment - courses for very severe conditions as per IS - 5246. The bidder shall give in his tender the particular manufacturer's specifications he proposes to use regarding the bituminous felts, bitumen layers, pea size gravels, etc. and also alternatively the particulars of chemical base water proofing membrane he proposes to use.

52.6.1 Bituminous Felt Water Proofing 52.6.2 Materials The felts shall be hessian base self finished felt type 3, grade 1 and with a minimum total weight of 22.3 Kg. per Ten Sq. m. as per IS-5222. The bonding materials shall consist of blown type bitumen conforming to IS: 702 - or residual bitumen conforming to IS: 73 - or a mixture thereof, selected to withstand local conditions of prevailing temperature and gradient of roof surfaces. The penetration of bitumen shall be limited to 40 when tested in accordance with IS: 1203. The pea size gravel shall be dry, clean, hard, durable and free from dirt, clay or any other foreign material.

The contractor shall submit samples of bituminous felts and pea size gravel he proposes to use to the Engineer- in-charge and after approval of the same the bulk material shall be brought to the site.

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52.6.3 Laying Water proofing treatment shall be laid by a specialist firm. The work, in general shall be done in accordance with IS: 5246 - latest edition and as per the following specification.

The felts shall be laid in lengths at right angles to the direction of the run-off gradient, commencing at the lowest level and working upward. Minimum overlaps of 75mm shall be provided at the sides of strips of felt. End laps shall be 100 mm minimum and shall be staggered at least 600 mm. All work shall be carried out as per standard practice and/or as approved by the Engineer.

a) With InsulationWhere insulation is used, the screeding on top of it with local re-grading, if required, shall be cured, cleaned and dried perfectly as specified earlier prior to application of water proofing treatment. Insulation shall not be used at drain mouths, rain water gutters, vertical faces like parapet walls, curbs, projecting pipes etc. where the water proofing treatment will be laid and built as shown in drawings and/or as specified elsewhere.

b) Without InsulationFor laying water proofing without roof insulation, the roof surface having general slope may be re-graded locally, if and where necessary, by screeding with cement mortar (1 part cement and 4 parts clean sharp, coarse sand) to ensure everywhere a run-off gradient of not less than 1 in 120. After curing the local screeding for seven days, the surface shall be cleaned and water proof treatment shall be started, after the surface is perfectly dried. The following shall be the procedure for laying the water proofing.

Primer shall, first of all, be applied to the roof, and then the following layers shall be laid:

1) Hot applied bitumen at 1.2 Kg./sq.m. minimum 2) Hessian base, self-finished felt type 3, grade 1 3) Hot applied bitumen at 1.2 Kg./sq.m. minimum 4) Hessian base, self-finished felt, type 3, grade 1 5) Hot applied bitumen at 1.2 Kg.Sq.m., minimum. 6) Hessian base, self-finished felt, type 3, grade 1. 7) Hot applied bitumen at 1.2 Kg/Sq.m. minimum. 8) Finishes with pea-sized gravel at 0.006 Cu.m./Sq.m

The roof surface shall be perfectly cleaned after the completion of the whole operation.

52.7 FlashingFlashing shall be done unless otherwise specifically stated, in the same way as the water proofing in 8 courses, except the last layer, where instead of finishing with pea sized gravel, flashing shall be finished with two coats of bituminous primer. The flashing shall be extended up the vertical surfaces as shown on drawings. The flashing shall end in grooves in vertical walls at a minimum height of 150mm above the roof level. Insulation fillets shall be provided of size 150mm x 150mm. at the junction of the wall with the roof. Angle fillets with cement concrete of 1:2:4 shall be providing over which the water proofing treatment is to be taken. The grooves shall be at least 65mm deep, wedge shaped, and caulked with water proof mastic cement after the flashings are properly bonded. The grooves filling shall be cured by watering for at least 4 days. Where specified in drawings or directed by the Engineer, metal flashing shall be provided. The metal flashing shall be done as shown on

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the drawings. The material shall be 18 g. GI sheets as specified in the drawings and l or as directed by the Engineer with not less than 600 grams of zinc coating per square meter of double surfaces.

52.8 Projecting Pipes When a pipe passes through a roof on which water proofing treatment is to be laid, a cement concrete angle fillet shall be built around it and the water proofing treatment taken over the fillet in the manner shown in drawings. The bitumen used as grout shall conform to IS:702 . If shown on drawings the pipe shall be surrounded with a separate sheet metal flanged collar. The flange of the collar shall be 150 mm wide and bonded to the layer of felt.

52.9 Expansion Joints Water proofing treatment of expansion joints shall be carried out in accordance with drawings.

52.10 Gutters The gutters shall have a minimum gradient of 1 in 60 for rapid run off. The grading shall be done with cement mortar (1. part cement and 4 parts clean, sharp, coarse sand) at the invert appropriately sloped which shall be properly cured, cleaned and dried prior to start of water proofing treatment.

The gutter shall be provided with one extra layer of roofing felt. A priming coat shall be first applied over which the first layer of felt shall be bonded with hot bitumen followed by successive layers of felt securely bonded together and finally painted with a coat of hot bitumen at not less than 1.5Kg/Sq.m. The felt layers laid separately in the gutters shall be overlapped with the corresponding layers on the roof.

The felt treatment in the gutters shall be carried down into the outlet pipes to a minimum depth of 100 mm.

52.11 Surface Finish A surface finish of pea sized rounded gravel has been provided generally as a measure of protection to the treatment and to increase its durability. On flashings, drain mouths, gutters, etc. the gravel shall be omitted and finished with two coats of bituminous primer for flashings and drain mouths and one coat of hot bitumen at the rate of minimum 1.5 Kg./sq.m. for gutters.

52.12 Supervision by Manufacturer's Representatives The Contractor shall arrange at his own cost the supervision of the work on insulation, water proofing and flashing by the manufacturer's representative to ensure that the work is being executed as per manufacturer's specifications and instructions.

52.13 Guarantee The Contractor shall give in writing supported by the manufacturers of insulation. Felt and Bitumen a guarantee for 10 years as the life of the work. An amount equal to 10% of the cost of the work shall be held as security deposit for this purpose or otherwise' contractor may provide bank guarantee for the above mentioned

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amount.

The Contractor shall make periodical inspection specially before start of rainy season and repair the waterproofing treatment for any apparent defects to ensure complete waterproofing during the guarantee period.

52.14 Polymer Based Water Proofing Membrane Alternative to the bitumen felt water proofing; water proofing can also be done by any of the following chemical based water proofing systems.

a) Polymer modified bituminous membrane. b) Monomer based synthetic membrane. c) Neoprene modified polymer based membrane.

52.14.1 Polymer Modified Bituminous Membrane Waterproofing treatment for flat roof slab shall be based on polymer modified Bituminous membrane treatment shall be as given below:

The property of polymer modified bituminous membrane treatment shall be as given below:-

Sl.No. Property Result Test Method

1. Softening Point, oC 155 ASTM D 362. Penetration, dmm @ 25oC 25 ASTM D 53. Cold Temperature Flexibility, oC -10 to -15 UEA tc4. Breaking Strength,

- Longitudinal N/5 cm- Transverse N/5 cm

850750

UEA tc ASTM D 412

5. Elongation, %- Longitudinal - Transverse

4545

UEA tc ASTM D 412

6. Puncture Resistance- Static- Dynamic

L3L3

UEA tc

7. Water absorption, % Wt. < 0.12 ASTM D 570ASTM D 471

8. Heat Resistance, oC > 120 UEA tc9. Tear Strength, N

- Longitudinal - Transverse

60100

ASTM D 5147

10. Water tightness >60 KPa UEA tc

The procedure shall be given below:

Clean the entire surface with the help of wire brush so as to make it free from loose dust, dirt etc.

Apply a coat of bituminous primer at the rate of 0.2 Kg/sq.m.

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Lay 4 mm thick polyester reinforced polymer modified bituminous membrane by torch-on-method using LPG torch flame. The joints at the overlaps shall be sealed by thermofusion method using LPG torch flame and a Thapi (Trowel)

Apply a coat of Bituminous aluminium paint on entire surface of the membrane (where the roof is inaccessible)

To protect polyster reinforced polymer modified bituminous membrane provide 25mm thick plaster in cement mortar 1:4 with chicken mesh as reinforcement (where the roof is accessible)

52.14.2 Monomer Based Synthetic Membrane The membrane should be based on propylene diene menomer such as SIKALENE - EPDM or equivalent

52.14.3 Application The roof surface should be in good condition, clean and free from oil, grease and other contamination. The surface irregularities of the roof must be remedied before applying the covering. Single component slow curing adhesive is to be poured directly from the container and spread evenly with a brush or roller. The sheet is then unrolled over the fresh adhesive and the sheet is roller worked until it is flat and free from wrinkles. Adjoining sheet is overlapped at least 3" and splice tape is used on overlap area. The membrane is fixed at the perimeter by mechanical fasteners.

52.14.4 Surface Preparation The concrete surface should be thoroughly abraded to remove all laitance. Any trace of loose plaster, oil grease and any other materials that might affect adhesion are to be removed by wire brushing the surface. The entire surface shall then be washed thoroughly with plenty of water and then allowed to dry.

52.14.5 Coving Coving is done at all junctions of horizontal and vertical surfaces with polymer modified 1:3 cement mortar.

52.14.6 Neoprene Modified Polymer Based Membrane The entire surface shall be coated with spray applied neoprene modified polymer based water proofing membrane using a specifically designed application equipment. Polymer base water proofing membrane shall be applied to provide the specified nominal dry film thickness (dft) of 2 mm. Application to a wet film thickness (wft) of 3mm shall be achieved in a single coat. It shall be overlaid by a non-woven needle punched bonded 200gm/m2

weight geo-textile fabric to provide a total system thickness of 3.5mm.

Geo-textile is to be applied to the surface of the Proofex SM within five minutes of application and whilst the surface is still wet and the geo-textile can absorb moisture.

The cured membrane shall meet the following testing requirements.

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Property Test MethodUltimate elongation ASTM D 412-90Recovery from 350% elongation ASTM D 412-90Modulus ---Tear Resistance ASTM D 624-73Puncture resistance (At max. displacement)

ASTM 154

Crack bridging capability FTM 153Water pressure resistanceNegativePositive

FTM 181

Water absorption @ 9 months continual immersion

ASTM D 471

Curing Efficiency ASTM X 156ASTM C 309

Chloride ion Diffusion Taywood test method

All areas of finished waterproofing work shall be protected from tearing and abrasion till the time of finishing.

52.15 Finishing The coated surface should then be protected with concrete screed containing water proofing admixtures laid to slope with the spaces between the bricks filled with water proofing cement mortar. The surface then shall be plastered and finished smooth with a steel trowel and cured for minimum of 5 days.

52.16 Manufacturers Supervision and GuaranteeThe above mentioned water proofing system shall be adopted as per manufacturers instructions and the manufacturers shall arrange for supervision by his representative as mentioned in above 13.12. The Contractor shall give in writing supported by the manufacturer, a guarantee for 10 years as the life of the work.

An amount equal to 10% of the cost of the work shall be held as security deposit or otherwise contractor may provide bank guarantee for the above amount

53. Cement based water proofing53.1 This item relates to the cement based water proofing treatment using broken bricks and cement mortar mixed with water proofing compound laid over RCC slabs. The work shall be executed as per instruction of Engineer.

53.2 a) Cement: ISI Portland cement will be used for this work.

b) Sand: Sand shall meet the requirements specified for concrete works.

c) Brick bat: First class bricks, new, well burnt (full, half, quarter and smaller broken brick bats upto 25mm down grade) according to requirements as per IS: 3068.

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d) Water proofing compound: Dry and powdered condition of manufacturers patented material.

e) Water: Free from impurities and potable water.

Preparation of surface: All loose plaster, dust and debris shall be removed and joints (construction, expansion and plumbing) shall be raked, cleaned and washed with water to provide a good key for water proofing treatment.

53.3 Water proofing treatment by broken bricks: Before starting water proofing treatment, the surface is to be cleaned as explained in above. The flat terraces, gutters etc. will be treated by surface method, which starts directly over RCC slab and includes the brick bat coba to provide the necessary gradient for easy flow of rain water. The coba is finally covered with plaster mixed with water proofing compound at the rate as specified by the manufacturer, finished smooth with trowel in cement colour with false marking of 300mm or more as required at site in the shape of round vata. The slope for flat terraces would be 1:120 with the minimum of 50mm thick near outlets. But as per the site requirement and as per the direction of Engineer-in-charge, this may vary. The average thickness should not be less than 75mm.

In gutters, sloped roof and folded plates, it is not necessary to vary the thickness and 40mm thick treatment will be sufficient for this. The water proofing compound shall be added to mortar as per manufacturer’s recommendation.

53.4 Curing: The water proofing have to be cured continuously for seven days as per normal practice.

53.5 Guarantee: A performance guarantee for a period of 8 (Eight) year is to be given after completion of water proofing works by the Contractor.

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4. MASONRY AND ALLIED WORKS

1.1 ScopeThis shall include all brick, concrete block and stone masonry, in walls and foundations, plastering and all other wall finishes as shown on drawings and as specified below for use in structures and locations covered under the scope of work.

1.2 Brick Masonry Where applicable, the code of Practices for Brick works: IS: 2212 shall be followed.

1.2.1 Materials a) Bricks

Bricks shall conform to the requirements of IS: 1077. All bricks shall be hand or machine moulded and of good quality (minimum 50 kg/cm2 compressive strength) sound, hard, well burnt throughout but not over burnt, of regular and uniform size, shapes and colour(generally deep red or copper), homogeneous in texture and free from flaws and cracks. They shall have plane rectangular faces with parallel sides and square, straight and sharply defined edges. A fractured surface shall show a compact, fine grained, uniform and dense texture free from lumps of lime, laminations, cracks, air holes, grits, soluble salts causing efflorescence, or other defects which may in any way impair the strength, durability, appearance and usefulness of the brick. A clear metallic ringing sound shall be emitted when two bricks are struck together. After 24 hours immersion in cold water, water absorption by weight shall not exceed 20% of the dry weight of the brick. They shall not break when thrown on the ground on their flat face in saturated condition from a height of 1600 mm.

Bricks shall be of local standard size. The tolerance permitted in the accepted size of bricks shall be plus or minus 1 mm in any dimension. Only bricks of one standard size shall be used on one work unless specially permitted by the Engineer. Each brick shall have the manufacturer's identification mark or initial marked clearly in, the frog, Three representative samples of full size bricks shall be submitted with the bid and the approved samples shall remain with the Engineer for future comparison and references. All bricks proposed to be used shall conform to the approved samples in all respects. Any brick found not upto the specification shall be removed immediately from the site at the Contractor's own cost.

b) Cement Portland cement shall conform to: IS: 8112, or IS: 12269.

c) Sand Sand for masonry mortars shall have the quality and particle size grading conforming to IS: 2116 . The grading of sand for use in mortar for un reinforced and reinforced brick work shall be within the specified limits for respective works. The fineness modulus of sand for mortar in un reinforced brick work shall be between 2.4 and 1.0 and the same for reinforced brickwork shall be between 2.4 and 2.9. Sand whose grading falls outside the

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specified limits due to excess or deficiency of coarse or fine particles may be processed to comply with the standard-by screening and/ or blending.

d) Water Water shall be clean and free from oil, acid, salt, and other injurious materials. Water fit for drinking will generally be found suitable. Water shall be obtained from sources approved by the Engineer.

1.2.2 Storage and Handling of Materials

a) Bricks Bricks shall not be dumped at site. They shall be stacked in regular tiers, even as they are unloaded, to minimize breakages and defacement of bricks. The supply of bricks shall be so arranged that at least three days requirements of bricks are available at site at any time. Bricks selected for different situations of use in the work shall be stacked separately.

b) Cement, Sand Cement, sand etc. shall be stored as stated under relevant clause of Specifications for Concrete.

1.2.1 Mortar

a) Mortar for brickwork except for half brick partition walls and parapet shall be1 part cement and 6 parts sand by volume.

b) Mortar for half brick walls and parapet shall be 1 part cement and 4 parts sand by volume.

c) The proportion s for mortar shall be different from those specified above when shown on drawings and or schedule of items . The cement and sand shall be mixed dry in specified proportions and than thoroughly mixed to proper consistency. No mortar that has stood for more than half and hour shall be used mortar that shows a tendency to become dry before this time shall have water added to it and remixed.

1.2.4 Laying and Workmanship Bricks of different dimensions will not be used on the same work except when specially permitted by the Engineer. All bricks shall be sufficiently soaked, but not, excessively wet, before laying. All bricks shall be soaked in water for a period of two hours before use, and no bricks shall be used until there is complete cessation of bubbles when immersed in water.

All dirt and dust shall be removed from the brick and the surfaces shall be moist at the time of laying.

No bats or cut bricks shall be used in the work unless absolutely necessary around

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irregular openings or for adjusting the dimensions of different courses and for closers, in which case full brick shall be laid at corners, the bats being placed in middle of the courses.

The bricks shall be laid on a full bed mortar and to line, level and shapes shown on the drawings, when laying, the bricks shall be slightly pressed so that mortar can get into all the pores of the bricks surface to ensure proper adhesion. Cross joints and wall joints shall be properly flushed and packed with mortar so that no hollow spaces are left. Bricks shall be handled carefully so as not to damage their edges. They should not also be thrown from any height to the ground but should be put down gently. All courses shall be laid truly horizontal and all vertical joints made truly vertical. Vertical joints in one course and the next below shall not come over one another and shall not normally be nearer than % of brick length. Fixture, plugs, frames etc. if any, shall be built in at places shown in the drawing, while laying courses only and not later by removal of the bricks already laid. All the work shall be carried out as per IS: 2212.

Prior to commencement of the brick work, all concrete surface, on which brick work is to be commenced I butted such as floor slab, column sides, beam sides I bottom top ,shall be closely hacked, wire brushed and well wetted so as to remove all laitance and loose particles and obtain a hard and rough surface. After the preparation, the surface shall be well cleaned and then only work shall commence. Cost of hacking, cleaning etc. shall be included in the unit rate for brick work and no separate measurement and payment shall be made on this account

Bricks with 20 mm deep frog shall be used frog down. Bricks with 10mm deep frog shall be used either frog up or frog down. Care shall be taken during construction to see that edges of bricks at quoins, sills, heads etc. are not damaged. All brick work shall be tightly built against columns, floor slabs, or other structural members around door and window frame with proper distances to permit caulked joints. In case of very dry weather, the surface of the brick shall be kept wet to prevent drying of mortar. At the end of day's work, provision shall be made to keep the top surface of brick work wet with water. Brick work shall be added uniformly throughout so that no portion of the work shall be left more than 900mm lower than other. Verticality of the walls and horizontality of the courses shall be checked very often with plumb bob and spirit level respectively.

Brick work shall be so laid out and arranged that a minimum of cutting and shaping is required. Where necessary, to trim brick work units, they shall be cut, trimmed or broken where required to a neat, true line without chips on exposed faces. Brick work one and half bricks thick or more shall have both faces in true plane. Brick work of lesser thickness shall have one selected face in true plane. Bonds used shall be English and shall be carried throughout the work. At all corners, alternate courses of brick work shall be laid header and stretcher wise as seen on the face, so as to secure good bond. The arrangements of bonds at quoins shall be symmetrical.

Bricks shall be laid in joints not exceeding 10mm in thickness and this thickness shall be uniform throughout. Joints shall be struck flush with the face at the time of laying. All joints on face shall be raked to minimum 10mm depth while the mortar is still green to provide bond for plaster or pointing. The rate of laying masonry may be upto a height of 1000mm per day or as approved by the Engineer.

All sash and door frames, louvers, and other connections requiring weatherproofing, shall

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be built in and the outside joints at the perimeter of exterior doors and window frames shall be cleaned out to a uniform 20mm depth and filled solidly with an approved elastic caulking compound applied with a caulking gun. Scaffolding will generally be single but may be double if warranted for the particular work as approved by the Engineer. Scaffolding shall be generally erected with steel pipes. The contractor shall take all measures to ensure safety of work and the working people.

Steel wire fabric shall be provided at the junction of brick masonry and concrete to overcome reasonably the differential drying shrinkage/thermal movement.

Contractor shall be entirely responsible for any damage to property or injury to persons resulting from defective scaffolding, ladders and materials, or otherwise arising out of default in this respect. Proper scaffolding shall be provided to allow easy approach to every part of the work. Overhead work shall not be allowed.

1.2.5 Encasing of Structural Members Where drawings show that structural steel columns and spandrel beams are to be partly or wholly covered with brick work, the bricks shall be built tightly against all flanges and webs with all spaces between the steel and the brick work filled solid with setting mortar and this mortar shall not be less than 12mm thick.

1.2.6 Reinforcement and Anchorage For the walls, anchors in the form of MS flats or rods from columns and/or beams and any other anchoring and reinforcements, shown on drawings, shall be adequately embedded in the brickwork.

For reinforced brick work, the reinforcements shall be 8mm HYSD bars to be placed at every 1 layers or as specified on the drawing. All reinforcements shall be thoroughly cleaned and fully embedded in the mortar. The thickness of the joints in brick work containing steel bars shall be increased so as to have a minimum mortar cover of 6mm around the bar interposed between the brick and the reinforcement. Overlap in the reinforcement, if any, shall not be less than 10mm. The reinforcements shall be lapped with dowels left in R.C. columns or welded to steel stanchions. Where transoms and mullions are provided in the brick walls, such bands shall be to the full width of the wall and the concrete grade not lesser than N/20/20. Such band will be measured separately under respective item of miscellaneous concrete in the Schedule of Quantities.

All half-brick partition walls shall have MS reinforcing bars at every fourth course of the brick work or at 100 mm interval and they shall be securely anchored at their ends where the partitions bond.

Dowels, left for brick work from columns, in case are found broken, the contractor has to weld the existing bars instead of lapping with the broken bars near the column faces. Such welding shall be paid under the relevant item of work.

1.2.7 Exposed Brick Work Exposed brick work in superstructure where shown on drawing shall be executed by

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specially skilled masons. They shall be built with bricks, which have high durability, resistance to abrasion and moisture penetration. Courses shall be truly horizontal and vertical joints truly vertical. Wooden straight edges with brick course graduations shall be used to control uniformity of brick courses. Where curvatures and other architectural features are to be provided, bricks specially made to required shape for this purpose shall be used, if possible, otherwise, selected bricks rubbed and ground to correct shape and size may be used. If face bricks are specified in drawing or schedule of Quantities, the brick work shall be in composite bricks, with face bricks on the exposed face and balance in normal bricks, but maintaining the bond fully. Such burnt clay facing bricks shall have physical properties and other requirements conforming to IS: 2691. Where face bricks are not specified, bricks for the exposed face shall be specially selected from routine bricks. All the exposed brick work shall be cleaned at the end of day's work and on completion of work shall be rubbed down, washed clean and painted as specified. Where face bricks are used, Carborundum stone shall be used for rubbing down.

1.2.8 Curing All brick work shall be kept constantly wet for at least 7 days from the date of laying of brick work.

1.2.9 Embedment of Fixtures All fixtures shall generally be embedded in mortar and masonry units shall be cut as required. Iron & steel members, partially embedded in brick work shall be given a bituminous protective coating for the portion to be embedded. All embedment in the brick work shall be surrounded by concrete of N/20/20 not less than 100 mm all around and to the full portion of the wall.

1.2.10 Cleaning Upon completion of the masonry installation, all exposed brick surface shall be cleaned of all mortar and cement grout encrustation and concrete stains. Protruding mortar joints shall be chipped off. As the cleaning progresses, all masonry work shall be examined and all imperfect jointings, nail holes, cracks, etc. shall be carefully pointed up and filled with mortar where required and the horizontal rakings left tooled and clean.

Cleaning of surfaces of exposed brick work, after completion, shall be done by giving a thorough wash with a 10% solution of muriatic acid followed by a complete rinse with clean water. On completion of the work, all equipment and surplus materials shall be removed and the floors left broom clean.

1.3 Concrete Block Masonry 1.3.1Scope This specification covers construction of walls using normal concrete blocks required for shielding I non-shielding walls in the main plant buildings.

1.3.2 Forms All forms for normal concrete precast blocks shall be machine finished steel moulds

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machined to an accuracy of 1.5 mm and shall be subject to Engineer's approval.

1.3.3 Dimension, Tolerances, Shape, Weight, Surface Finishing The concrete block shall be machine made precast blocks of the required strength density and water absorption as described below The blocks shall have nominal dimensions of 200 mm x 100 mm x 100 mm or any other suitable size as approved by the engineer to suit the requirement of the wall. The Dimension of the blocks shall not deviate more than (+0mm, -3mm) from the nominal dimensions. The blocks shall be of rectangular shape and shall be fully solid type blocks or grade D block as per IS 2185. The water absorption for the concrete block shall not be more than 10%. The cured concrete blocks shall have block density of 2300 kg/cu m. for fully solid blocks. The block density of the grade D blocks shall be of 1800 kg/cu m. The tolerance for density of concrete blocks shall be +25 kg/cu m. The surface of the blocks shall be finished smooth, and free from voids, imperfections etc.

1.3.4 Curing The blocks shall be wet cured for a period of 10 days immediately after manufacture, at a temperature of not less than 16°C. Rapid drying at the end of curing period shall not be permitted.

1.3.5 Sampling, Testing and Strength Prior to manufacture, trial mixes shall be prepared. When suitable mixes have been established, a sufficient number of blocks shall be cast to permit the Engineer to check the density strength and water absorption and surface finish. If accepted, these shall be the standard for all blocks to be manufactured. ASTM specification C-140 Standard Methods of sampling and Testing Units or I.S. 1199 shall apply in addition to the requirement of this specification. The compressive strength of the cured concrete blocks shall not be less than 50 kg/cm2 at 28 days after casting.

1.3.6 Materials a) Cement Portland cement shall conform to IS:269,IS:8112,IS:12269, and latest edition.

b) Sand Sand for masonry mortars shall have the quality and particle size grading conforming to IS:2116 latest edition. The grading of sand for use in mortar shall be within the specified limits for respective works. The fineness modulus of sand for mortar in brick work shall be between 2.9 and 2.3 and the same for reinforced brickwork shall be between 2.9 and 2.1. A sand whose grading falls outside the specified limits due to excess or deficiency of coarse or fine particles may be processed to comply with the standard by screening and/ or blending. Any deviation may be allowed at the discretion of the Engineer.

c) Water Water shall be Clean and free from oil, acid, salt, and other injurious materials. Water fit for drinking will generally be found suitable. Water shall be obtained from sources approved by the Engineer.

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1.3.7 Laying and Workmanship Concrete Block masonry in superstructure shall be laid in mortar of proportions as indicated in 'Schedule of Quantities & Rates'. The mortar shall be spread over the entire top surface of the block including the front and rear shells, as well as the webs to a uniform layer of 1 cm. thickness. Full mortar bedding shall be obtained for complete utilisation of load carrying capacity of the blocks. For the vertical joints the mortar shall be applied on the vertical edges and the slight depression on the vertical sides to secure proper lateral 3.4.6to position the vertical joints will be required to be compacted by addition of mortar and compacted with jointing tools.

The first course of concrete masonry shall be laid with great care to ensure proper alignment, level and plumb. To facilitate this the alignment of the wall shall be marked on the existing foundation/ slab. The construction of the wall shall be started from one end proceeding in the other direction. Each course shall be checked for alignment and plumb. All mortar joints shall be 10 mm thick. In building concrete masonry for jambs of doors and windows the hollows within one block length around the opening will be required to be filled with concrete of grade N-10. The concrete should be laid in the hollows properly tamped and consolidated, ensuring proper adhesion to the webs and sides of the blocks. The rate for the laying of the .concrete block masonry should include cost of the filler concrete stipulated above.

The mortar joint shall be raked out in order to have a key for plaster.

Door and window hold-fasts should be at block course level and their ends are to be embedded in a hollow, which shall be filled up with concrete of grade M-20. The filling concrete should be properly done with adequate tamping so as to obtain a finished surface nearly as good as the precast block used for the masonry work.

The Concrete Blocks used should be laid dry except slightly moistening the surface on which mortar is to be applied to prevent absorption of water from the mortar. During the curing of mortar joints, the walls should only be slightly moistened and shall not be allowed to become excessively wet until the wall has been plastered/ painted. As the frequent wetting & drying of the concrete blocks is to be avoided before final rendering of wall surface is done, the surfaces are to be protected from excessive wetting from monsoon and other causes.

1.4 Stone Masonry

1.4.1 Stone The stone shall be approved one, free from decay and weathering. The stone shall be obtained from approved quarry. Discoloured or distorted stones with boulder skin or earthy or porous matter, or stones with round surface shall not be used. The stones should be clean, flat bedded. The crushing strength of the rubble for use in the stone masonry should not be less than 150 kg/sq.cm. They should be properly cleaned of dirt and dust and all weathered portions should be skinned off before use. Rubbles having a weight of 20-10 kg per piece should not be less than 70% of the total and other pieces should not have a weight less than 10-15 kgs per piece.

The stones shall be hammer-dressed on the face, the sides and the bed to enable them to

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come into close proximity with each other. The stones may be laid at random without being brought upto any level course and with lamination perpendicular to the thrust with a suitable proportion of small stones and chips to fill up interstices.

1.4.2 Mortar The mortar used for jointing shall be 1 part of cement and 6 parts of sand by volume and conform to requirement as indicated in case of brickwork elsewhere.

1.4.3 Laying and Workmanship All stones shall be thoroughly wetted before use. Every stone shall be carefully fitted to the adjacent stone so as to form neat and close joints. Face stone shall tail back and bond well into the backing. Stones shall be arranged to break joint as much as possible. Long vertical lines of joints shall be avoided. Their height shall not be greater than the breadth of the face or the length of tail into the wall.

The masonry shall be carried out regularly. When the masonry of one part has to be delayed, the work shall be raked back at an angle not exceeding 40deg. Toothing in masonry shall not be allowed.

Bond or through stones running right through the walls shall be provided in walls upto 600mm thick. If the walls are more than 600 mm thick, a line of these which overlap each other at least 150 mm, shall be laid from face to back. At least through or bond stone shall be inserted for every Sq.m of surface.

1.4.4 Joints Stones shall be so laid that all joints are full or mortar joints shall not be more than 25 mm thick.

When plastering or pointing is not required to be done, joints shall be struck flush and finished at the time of laying.

1.4.5 Curing Green work shall be protected from the effects of sun, rain etc, by suitable covering. It shall be kept constantly moist on all the faces for a period of at least 10 days from the date of laying.

1.4.6 Measurement Measurement shall be made for the actual volume of work done and as per the relevant Indian Standards. Deductions shall be made for all openings, lintels, sills, conduits, ducts, pipes etc., but no deductions shall be made when measurement of opening is less than 0.1 sq.m.

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1.5 Plastering Plastering on brick work or concrete surfaces at various locations shall be done as described in relevant drawings and specifications. The contractor shall take prior approval of the "Engineer" as regards to the location where plastering to be taken up.

1.5.1 Materials a) Water and Cement Water and Portland cement shall be as specified for brick work.

b) Sand Sand shall consist of natural sand, crushed stone sand or crushed gravel sand, from an approved source. The sand shall be hard, durable, clean, and free from adherent coatings and organic matter, and shall not contain any appreciable amount of clay balls or pellets.

The sand shall not contain any harmful impurities such as iron pyrites, alkalies, salts, coal, mica, shale or similar laminated or other in such form or in such quantities as to affect adversely the hardening, the strength, the durability, or the appearance of the plaster or applied decoration, or to cause corrosion of any metal in contact with the plaster. Total of all deleterious substances shall not exceed 5% by weight. The sand shall be properly graded and of medium size with a fineness modulus of 2.0 to 2.2. Sand shall conform to IS: 181 and grading shall conform to IS: 1542.

1.5.2 Storage of Materials Cement and sand shall be stored as specified in relevant clauses under specifications for concrete.

1.5.3 Mixing Unless otherwise specified on drawings and or schedule of items, the mortar for plastering shall be mixed in the proportion of 1 part of cement and 5 parts of sand by volume mixed in a dry state and then wetted and mixed thoroughly to obtain the required consistency, including machine mixing if desired by the employer. The mortar shall be consumed within half an hour of mixing. Any mortar for plaster, which is partially set, shall be rejected and removed from the site. Machine mixed mortar shall be prepared in an approved mixer, approved by the employer Mixing for 1.5 to 2 minutes is normally sufficient. Plastering on which epoxy based protective coating is to be applied shall not have any lime in its mortar. This shall have a mix in the proportion of 1 part of cement and 3 parts of sand by volume.

1.5.4 Preparation of Surface All joints in the masonry shall be raked out to a depth of at least 10mm with a hooked tool made for the purpose while the mortar is still green. Surface on which plastering is to be done shall be clean and free from all dust, loose materials, grease etc. and be well wetted for at least 6 hours before plastering. Brick work shall be brushed down with a steel wire brush to remove all loose dust from the joints and thoroughly washed with water. All laitance shall be removed by Chipping and roughening from concrete surfaces, which are to be plastered. Preparation of surface shall generally conform to the requirements

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specified in IS: 1661 and IS: 2402.

The concrete surface to be plastered shall be closely hacked with chipping hammer and the face should be left as rough as possible to form a key. This surface preparation shall be approved by the "Engineer" before the application of plaster. The chipped concrete surface shall then be thoroughly soaked with water and wire brushed to remove all loose particles and then cleaned by water spraying. Cost of hacking, cleaning etc. shall be included in the unit rate for plastering and no separate payment shall be made on this account.

On hard smooth surfaces (such as high grade concrete) or other surfaces presenting an inadequate key, an adhesive of approved make and brand shall be applied. The adhesive shall be applied by spraying and thin coat of rendering done while the adhesive is still tacky. Providing a bonding coat shall be deemed to be included in the rate.

Lath plaster shall be provided at the junctions of dissimilar materials such as concrete / brick / stone / steel/non-ferrous metals / wood etc. Where lath plaster is specified, it shall be paid for at the same rate as for plasterwork except that separate payment for metal lath will be made.

15.5 Application of Plaster For external plaster, the plastering operations shall commence from the top floor and carried downwards. For internal plaster, the plastering operations for the walls shall commence at the top and carried downwards. Plastering shall be carried out to the full length of the wall or to natural breaking points like doors/windows etc. Ceiling plaster shall be completed before commencing wall plastering. Double scaffolding in accordance with the requirements stipulated in IS: 2750 and IS: 3696 shall be used for the works.

To overcome the possibility of development of cracks in the plastering work, plastering work shall be deferred as much as possible so that fairly complete drying shrinkage in concrete and masonry work takes place.

In all plasterwork, mortar shall be done with somewhat more than the required thickness and well pressed into the joint and on the surface and rubbed and leveled with a flat wooden rule to give required thickness. Plaster, when more than 15 mm thick, shall be done in two coats, a base coat followed by the finishing coat. Thickness of the base coat shall be just sufficient to fill up all unevenness in the surface. No single coat, however, shall exceed 12 mm in thickness. The lower coat shall be thicker than the upper coat. The overall thickness of the coats shall not be less than the minimum thickness shown on the drawings. The undercoat shall be allowed to dry and shrink before applying the second coat of plaster. The under coat shall be scratched or roughened before it is fully hardened to form a mechanical key. The method of application shall be "thrown on" rattier than "applied by trowel".

To ensure even thickness and true surface, patches of plaster about 100mm to 150mm square or wooden screen 75 mm wide and or the thickness of the plaster shall be fixed vertically about 2000mm to 3000mm apart, to act as gauges. The finished wall surface shall be true to plumb, and the Contractor shall, without any extra cost to IGCAR, make up any irregularity in the brick work with plaster. All vertical edges of brick, pillars, door jambs etc. shall be chamfered or rounded off as directed by the Engineer. After the plastering

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work is completed all debris shall be removed and the area left clean. All corners must be finished to their true angles or rounded. Any plastering that is damaged shall be repaired and left in good condition at the completion of the job.

1.5.6 Curing All plastered surface after laying, shall be cured for a minimum period of seven days, by an approved method, and shall be protected from excessive heat and sunlight by suitable approved means. Moistening shall commence as soon as the plaster has hardened sufficient and is not susceptible to damage. Each individual coat of plaster shall be kept damp continuously, for at least two days, and then dried thoroughly, before applying the next coat.

1.5.7 Finish In any continuous face of a wall, finishing treatment of any type should be carried out continuously and day break shall be made to coincide 'with architectural break in order to avoid unsightly patches at junctions.

Generally, the standard finish shall be used unless otherwise shown on drawing or directed by the Engineer. Wherever any special treatment to the plastered surface is indicated, the work shall be done exactly as shown on the drawings, to the entire satisfaction of the Engineer regarding the texture, colour and finish.

a) Standard Finish Wherever punning is indicated, the interior plaster shall be finished rough, otherwise the interior plaster shall generally be finished to a smooth surface. The exterior surface shall generally be finished with a wooden float.

b) Neat cement FinishImmediately after achieving a true plastered surface with the help of a wooden straight edge, the entire area shall be uniformly treated with a paste of neat cement at the rate of one (1) kg. per Sq.m. and rubbed smooth with a trowel.

1.6 Decorative Wall Finishes 1.6.1 Materials a) Cement Cement shall be ordinary Portland cement conforming to IS: 8112 - latest edition or white cement of approved quality.

Coloured cement shall be either ready mixed material or may be obtained by mixing pigments and cement at site, as approved by the Engineer. The pigments to be mixed with cement shall conform to Appendix 'A' of BS: 1014. Samples of colouring material shall be submitted to the Engineer for approval and material procured shall conform in all respects to the approved samples, which shall remain with the Engineer. All coloured cement and/or pigments shall be stored in an approved manner in order to prevent deterioration.

b) Aggregates

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All aggregates other than sand shall conform to IS: 181 latest edition.

c) Sand Sand and water shall be as specified under "Plastering".

1.6.2 Finishing Treatment

a) Coloured Plaster This shall be done in the same way as specified under plastering clause 1.5 but using coloured cement in place of ordinary cement. When coloured plastering is specified in more than one coat, the top coat only shall be made with coloured cement.

b) Pebble Dash Finish Mortar of required thickness consisting of 1 part cement and 1 parts sand by volume shall be applied to form a base coat in the usual manner of thickness 12 mm. While the mortar is still plastic. small pebbles or crushed stone of size generally from 10mm to 12mm, as approved by the Engineer, shall be thrown to the plastered surface. The aggregate shall be lightly tapped into the mortar with a wooden float or the flat end of a trowel, in order to ensure satisfactory bond between the dashing and the mortar.

For pebble dash finish the base course shall be 12mm thick and top course shall be 8mm thick. Necessary water proofing compound shall be added in the base coat for external walls to make surface water proof.

c) Rough Cast Finish The plaster shall be laid in two coats. The first coat shall consist of one part of cement and four parts of clean sharp sand. The thickness of the first coat shall be just sufficient to fill up all unevenness in the surface under treatment but shall not exceed 12 mm. The plaster shall be laid by throwing the mortar by using a strong whipping motion on the prepared surface with a trowel in a uniform layer and pressed to form a good bond. The surface shall not be smoothened. The second coat shall consist of one part of cement and 1 parts of gravel or crushed stone of size 6 mm to 12 mm or Hard Blue Granite of size 6 to 10 mm or as approved by the Engineer. The thickness of this coat shall be 7 mm to 8mm. The cement and aggregate shall be mixed dry in the proportion by volume as specified. Water shall be added to form a plastic mix easily workable. The second coat shall be applied while the first coat is still soft and plastic. The plastic mix shall be thrown on to the first coat by means of trowel and left in the rough condition. If it is desired to colour the surface, the colour may be mixed with the second coat, in the proportion required by the Engineer to give the desired effect. As the colour fades on drying, a deeper shade than is desired should be applied. Alternatively, coloured cement may be used. The work shall conform to relevant clauses of IS: 1661.

d) Sand Faced Finish The plaster shall be applied in two coats consisting of an under coat of cement mortar (1:5) 12mm thick and a finishing coat with cement mortar (1:1) 8mm thick. The sand used in the finishing coat shall pass through 4.75 mm sieve and be retained on 2.16mm sieve. Key should be formed on the surface of base coat by thoroughly combing it in many horizontal

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lines about 12mm apart and 1mm deep when the mortar is still plastic.

The surfaces of the finishing coat shall be treated to obtain a uniform fine-grained texture with the help of sponges, felt pads, etc. Care shall be taken to see that the cement used is of the same shade throughout the work.

Whenever more than 20mm thick plaster has been specified, which is intended for purpose of providing beading, bands, etc. those works shall be carried out in two or three coats as directed by the Engineer duly satisfying the requirements of curing each coat (rendering/floating) for a minimum period of 2 days and curing the finished work for at least 7 days.

e) Scrapped Finish Ordinary plaster as described under clause 1.4 after being leveled and allowed to stiffen for a few hours, shall be scrapped with a steel straight edge to remove the surface skin. The pattern shall be as approved by the Engineer.

f) Textured Finishes Mortar consisting of 1 part cement and 1 parts sand by volume shall be applied in a manner as specified under "Plastering" .. Ornamental treatments in the form of horizontal or vertical rib texture, fan texture etc. shall be applied by means of suitable tools to the freshly applied plastered surface, as approved by the "Engineer".

g) Cement Wash The cement wash shall be slurry made of cement and water (about 14 kg/100 sq.m.) and shall be applied with a white wash brush. Before applying the cement wash, the concrete surface must be cleaned and free from oil, grease, dust or loose material and shall be well wetted. The cement washed area shall be adequately cured for complete hydration of cement.

Alternatively water proof cements like 'Snowcem' or equivalent can also be used for better finish. The mode of application shall be as per manufacturer instructions.

1.7 Metal lath and Wire fabric Welded steel wire fabric shall conform to IS:4948. Expanded metal shall conform to IS:412 Galvanized wire mesh shall be of approved quality. Chicken mesh of 22 gauge shall be of approved quality

Laying and WorkmanshipThe type and details of the steel material to be used for metal lath plastering work and at the junctions of brick masonry/concrete before wall plastering shall be as specified in the respective items of work.

For metal lath plastering work, the weight of steel material shall be not less than 1.6 kg/sq m.

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Steel material for use at the Junction of brick masonry/ concrete shall have the mesh dimensions not greater than 50mm.

Steel material shall be obtained in maximum lengths as manufactured to restrict joints to the minimum. Overlap at the joints shall be minimum 25mm which shall be securely tied with wires of diameter not less than 1.25mm at spacing not more than 100mm for lath plastering work. Nailing to wall shall be at spacing not exceeding 200mm. The material shall be straightened, cut and bent to shape if required for fixing as per the details indicated in the drawings.

1.8 Pointing to Masonry All joints of brick work/block work shall be raked out to a depth of 10mm with a hooked tool made for the purpose while the mortar is still green. The brick work shall then be brushed down with a stiff wire brush, so as to remove all loose dust from the joint and thoroughly washed with water. Mortar consisting of 1 part cement and 1 parts clean, sharp, well graded sand by volume shall be pressed carefully into the joints and finished with suitable tools to shape as shown on the drawings. Any surplus mortar shall be scrapped off the wall face leaving the surface clear.

The pointed surface shall be kept wet for at least seven days for curing.

1.9 Granite Stone Facing Granite stone facing where specified shall be done as shown on drawings and shall conform to IS: 4101 (Part I). The stone shall be as specified on drawings and/or schedule of items. Sample of stone shall be submitted to the Engineer for approval and then bulk purchase made.

The thickness of facing stone shall not be less than 12mm unless otherwise specified on drawings.

The stone slabs shall be cut and finished to sizes as per pattern shown on drawings. They shall be fastened to wall with suitable anchorage as approved by the Engineer. The base course plaster shall be of proportion 1: 1. The stones shall be pasted to the base course with cement slurry of 12mm thick at least.

Where pointing is specified on drawings, it shall be done by mortar as specified on drawings/ or schedule of items.

1.10 Rubble Soling for Floors on Grade The rubble shall be of approved quality. Thickness of soling shall be as shown on the drawings/schedule of quantities. The rubble soling shall be carefully hand packed as close as possible and bedded firmly with their largest side place vertical, the broader faces downward, the smaller surface at top and voids and interstices filled in solidly by wedging with hard chips and small stones but of largest size possible to fit interstices finished with cement sand mortar 1: 1 0 min and thickness as indicated on drawing.

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No stone shall be less than 80mm in thickness or less than 2.8 kg in weight or more than the depth of soling in thickness and not to exceed in length or breadth twice its thickness.

When a sufficient length of soling has been laid, this shall be compacted with a three wheeler power roller and the surface shall be evened by binding uniformly with sand not exceeding 10% silt during rolling. Places inaccessible to the roller may be compacted by hand with log hammer or mechanical tampers or by hand rollers subject to the approval of the Engineer.

. 2.0 BUILDING JOINTS

2.1 Expansion Joint Filler Standard heavy density expanded polystyrene of minimum density 20 kg / cum. and conforming to IS: 2671 shall be procured and used in accordance with drawings. The thickness of the material shall be as indicated on drawing. Adhesive if any required to fix expansion joint filler to all forms of structure shall be supplied by the Contractor. A sample of material shall be approved by the Engineer before it is used on site. Installation shall be carried out as directed by the Engineer. The polythene sheet used for wrapping shall be of minimum 250 micron thick and shall be got approved by the Engineer.

Bitumen Impregnated fiber boards conforming to IS: 1838 shall be procured and used in accordance with drawings. Adhesive if any, required to fix expansion joint filler to all forms of structure shall be supplied by the Contractor. The thickness of the material shall be as required. A sample of material shall be approved by Engineer before its use on site. Installation shall be carried out as shown in drawings or as directed by the Engineer.

2.2 Expansion Joint Sealing Expansion joint shall be provided with copper strips conforming to IS: 1972, hot dip galvanized strips fabricated in accordance with IS: 277 with class 2 zinc coating of width and thickness as stated in the schedule of quantities are as shown on drawings or as approved by the Engineer. The strips shall be bent to shape indicated on the drawings and connected properly to the structure. Expansion joints shall be continuous and where two or more strips meet they shall be lapped 75 mm and brazed or welded as the case may be. Brazing or welding shall be carried out by qualified brazer/welder. Brazing/welding shall be subject to non-destructive testing by the Contractor as directed by the Engineer. For the purpose of measurement the laps provided shall not be considered and only finished length shall be considered.

2.3 Bitumastic Joint Sealing Compound Bitumastic Joint Sealing Compound conforming to Grade A (normal) of IS:1834 shall be supplied and used in accordance with the manufacturers instructions and as shown on the drawings. The size of groove to be sealed shall be shown on the drawings/ schedule of quantities. A sample of material shall be got approved by the Engineer before use.

2.4 Bitumastic Paint for Isolation Joint

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Bitumastic Paint Confirming to IS: 9862 shall be supplied applied by the Contractor. Two coats of paint shall be applied over - surfaces to form isolation joints. Painting shall be performed in accordance with the manufacturer's instruction or/and as directed by the Engineer. A sample of material shall be approved by the Engineer before it's used on site.

2.5 Neoprene Sheet Neoprene sheet shall conform to the following specifications and a sample of material shall be got approved by the Engineer before use.

2.5.1 Neoprene – Normal Physical Properties

Grade (Ourometer) 60 Hardness ASTM 0-676 60 ±5 Tensile Strength (Min) ASTM-0-212 175 kg/sq.cm.

Elongation at Break (Min) ASTM-0-212 350% Young's Modulus (derived from shear Modulus) 350 PSI

2.5.2 Accelerated Tests to determine Long Term Ageing Characteristics (Over aged 70 hrs / 100 deg C ASTM – D-573)

Change in Hardness (Points) max 0 to 15Tensile Strength, maximum change + 15 %Elongation at Break, Maximum change 0 to -20%Compression set (22 grs/70 deg C 750 kg/sq.cm.ASTM – D – 395 Method – B max 25%Low temperature stiffness at -20 deg CYoungs Modulus, max (ASTM – 0 – 797) 750 kg/sq.cm.

Tear test (ASTM – D – 622) Min ozone(1 PPM in Air by volume, 20% strain38 deg +/- 1 deg C-ASTM-D-1129)100 hrs., samples to be IGCARed before test toRemove any traces of impurities. No cracks

Neoprene sheet shall be placed and cut suitably to shapes and sizes mentioned in/shown on the drawings. Brazing shall be carried out as per manufacturer's specifications and by qualified persons, subject to testing as directed by Engineer.

2.6 Polyethylene Sheet Polyethylene sheets 250 micron thick conforming to IS: 2508 shall be supplied and used to form separation joints. A sample material shall be approved by Engineer before its use at site.

2.7 Kraft Paper Kraft paper shall be supplied and used to cast new concrete against old concrete wherever

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specified on drawings and schedule of quantities. It shall conform to IS: 1397 and be approved by the Engineer before its use at site.

2.8 Paper Joint Paper joint where specified shall be standard water proof paper (two layers of paper with a layer of bitumen in between) as approved by the Engineer.

2.9 Sliding Cover Strip At the expansion joints, members like columns and beams are duplicated on either side of the separation joints and provided with embedded parts for installing the sliding type cover strip to accommodate any building block movement. The cover strip shall be provided both at vertical and horizontal points in according with details shown on drawings. The strip element shall be mild steel/aluminium, plain or chequered as indicated, and of size and thickness shown on drawings and schedule of quantities and rates.

The fixed edge shall be suitably attached to the embedded bearing plate, by plug weld or tap screw as shown or as instructed by the Engineer. At the sliding edge, the sliding surfaces of the embedded plate provided and underside of the cover strip shall be machined smooth. Adequate care shall be taken not to cause any damage to the strip

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10. METHOD OF MEASUREMENTS OF BUILDING WORKS AND PAYMENT

1.1 General The method of measurement for various items of works shall be in general as per IS 1200 and in particular, as specified below. Measurements shall be entered according to the dimensions given on the drawings and/or as per actual measurement of work in case of variations from drawings at the instructions of the Engineer. In case the contents of these clauses are contrary to what is specified in Indian Standards then this Specification will supersede the relevant IS standard.

1.2 Brick Masonry/Concrete Block Masonry

a) Wall thickness shall be measured in terms of nominal brick/concrete block size, which shall be deemed to be inclusive of mortar joints.

b) Actual volume of work done shall be measured in Cu.m. and deductions for openings, lintels, sills, conduits, ducts, pipes, etc. shall be made for openings upto 0.1 Sq.m. in area each. No deductions shall be made for insert and embedded fixtures nor any extra be made for the mortar used for fixing or for necessary cutting of bricks/blocks.

c) For encasing of steel beams, columns, etc. the sizes as shown on drawings shall be measured, and no deductions shall be made for the volume of steel beams, columns etc.

d) No extra payment shall be made for any cutting of bricks/blocks for encasing of beams, columns, etc. and/or bricks cut for any other purposes.

e) Half brick thick walls shall be measured in Sq.m. and deductions made for all openings, lintels, sills, conduits, ducts,pipes etc., but no deduction shall be made for openings upto 0.1 Sq.m. in area each. No additions or deductions shall be made for embedded fixtures.

f) Stone masonry : The measurement of work shall be the product of length, height and thickness and deductions shall be made as for brick work. .

g) Reinforced brickwork /blockwork shall be measured separately from general brickwork /blockwork and reinforcements shall be measured separately under relevant item in the Schedule of Quantities unless included in the items for masonry work. Laps - in wire mesh reinforcements shall be considered for measurement. Reinforcing bars shall be measured on actual area basis. Reinforcing bars shall be measured by weight. No extra shall be paid for modifications to existing dowels if necessary, to tie up brickwork/blockwork.

h) Exposed brickwork using selected ordinary bricks or wire cut bricks for the exposed faces as specified in the item, shall be measured separately for composite brickwork in cubic metres for actual volume of work done.

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Deductions for openings etc. shall be made as described in (b) and (c) above.

1.3 False Ceiling a) The actual area of work done shall be measured in square metres. b) No separate payment shall be made for hangers, supports, rails, fixtures, etc. c) No deduction shall be made for openings, inserts, etc. upto 0.1 Sq.m. in area

each. d) No separate payment shall be made for arrangements for lighting fixtures, air

conditioning diffusers, grills, etc.

1.4 Plastering, Punning, Pointing, etc.

a) All plastering, punning, pointing etc. shall be measured on the area finished in Sq. m.

b) For measurement of openings whose jambs, sills, soffits, reveals, etc. are plastered, the following procedures shall be followed:

1) For openings upto 0.5 Sq.m. each, no deductions shall be made and no additions shall be made for reveals, soffits, jambs, sills, etc.

2) For openings exceeding 0.5 Sq.m. but not exceeding 3.0 Sq.m. each, deductions shall be made for half the area of the openings and no additions shall be made for reveals, soffits, jambs, sills, etc.

3) For openings exceeding 3.0 Sq.m. each, deductions shall be made for the whole area and additions shall be made for reveals, soffits, jambs, sills etc.

c) For openings, sleeves, pipes, etc. whose sides are not plastered, no deductions shall be made for openings upto 0.1 Sq.m. in area each and full deduction shall be made for openings above 0.1 Sq.m. each.

d) No extra shall be paid for finishing around openings, sleeves, pipes, ducts, inserts etc.

e) Sides of Plasters, projections, etc. shall be measured for actual size.

f) No measurements shall be made for rounding and chamfering junctions, corners, etc.

g) Grooves, patterns, designs, etc. in plastering shall be measured separately either in R.M. and/or in Sq.m. as specified in the 'Schedule of Quantities'.

h) Bidder may note that he may have to do plastering work on the existing brick work done by other agencies and he may have to do the surface finishes required for the plastering work at no extra cost to IGCAR.

1.5 Metal Doors, Windows, Ventilators, Louvres etc.

a) Supply of metal doors, windows, ventilators, louvres etc. with fittings shall be measured for each unit of respective sizes of openings, unless otherwise specified. Metal glazing beads when specified under Schedule of Quantities shall not be paid separately.

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b) Separate payment shall not be made for fixing the frames, shutters, etc. grouting, mastic, caulking etc. (excluding glass and glazing).

c) Mastic filling for the frames of all metal doors, windows, ventilators, louvres, etc. shall not be measured separately. This shall be included under the respective item wise rates of fixing, grouting frames.

d) All glass and glazing for the doors, windows, etc. shall be paid separately under respective items.

e) Automatic door closer shall be measured separately for actual numbers used.

1.6 Glass and Glazing

a) All glass and glazing shall be measured for actual area of work done in Sq.m.

b) No separate payment shall be made for clips, bolts, and nuts, mastic cement, putty, beads etc. that may be required for fixing the glass.

c) No separate payment shall be made for cleaning the glass after erection.

d) No separate payment shall be made for cutting the glass panes to required sizes.

1.7 Rolling Shutters

a) Rolling shutters shall be paid for each unit of respective sizes of opening as specified in the 'Schedule of Quantities'.

b) Where shown on the drawings and/or specified in the 'Schedule of Quantities', electric drive with accessories shall be provided and no separate payment shall be made for this. Payment for the rolling shutter unit shall be inclusive of all such accessories.

1.8 Miscellaneous Metal The actual weight of the fabricated metal shall be paid in Metric Tonnes irrespective of the nature and location of work, unless otherwise specified in the 'Schedule of Quantities'. Where the fabricated materials are supplied by IGCAR and the Contractor has to installandembed the same in masonry, the payment shall likewise be made on the basis of the actual weight of such fabricated material. No separate payment shall be made for welding, if required, or for cleaning of material for proper bonding in concrete.

1.9 Flooring, Skirting, Dado etc . a) All flooring, skirting, dado etc. shall be measured on actual area laid in Sq.m. No

deductions shall be made for openings, pipes, sleeves, etc. upto 0.1 sq.m. in area each.

b) No separate payment shall be made for the underbed, which shall be included in the flooring rates.

c) No separate payment shall be made for fillers, rounding and chamfering, etc. done on junctions, corners etc ..

d) No separate payment shall be made for the metal or PVC/glass dividing strips,

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when specified in 'Schedule of Quantities'.

e) No separate payment shall be made for rubbing, polishing etc.

f) No separate payment shall be made for the form work for the construction joints, sides of openings, sleeves, pipes etc.

g) Floor finish on steps shall be measured separately as specified in the 'Schedule of Quantities'.

h) No separate payment shall be made for additions of patented applications on surfaces, if specified.

1.10 Painting a) The contractor will be paid for painting in accordance with the rate quoted by him

for the relevant items of work in the Schedule of Quantities. The rates shall be inclusive of all items of work such as cleaning, wire brushing, washing the surface with detergent or by water jet as specified in the specifications.

b) All structural steel work, whose all or any faces are painted, shall be paid in weight of the steel in Metric Tonnes unless otherwise specified in the 'Schedule of Quantities'.

c) All other painting except (b) above shall be measured on the actual area finished in Sq.m. For measurements of openings whose jambs, sills, soffits, reveals etc. are painted, the following procedure shall be followed:

i. For openings upto 0.5 Sq.m. each, no deductions shall be made and no additions shall be made for jambs, sills etc.

ii. For openings, exceeding 0.5 Sq.m. but not exceeding 3.0 Sq.m. each, deductions shall be made for half the area of openings, and no addition shall be made for jambs, sills etc.

iii. For openings exceeding 3.0 Sq.m. each, deductions shall be made for the whole area, and additions shall be made for the jambs, sills, soffits, reveals etc.

d) For openings, pipes, sleeves, etc. whose sides are not finished, no deductions shall be made for openings etc. upto 0.1 Sq.m. in area each and full deductions shall be made for all openings, above 0.1 Sq.m. in area each.

e) No extra shall be paid for painting, etc. done around openings, sleeves, pipes, doubts, inserts etc.

f) No extra payment shall be made for painting, etc. on features such as grooves, ducts, beads, projections, cornices, etc. unless given different finish or otherwise specified in the 'Schedule of Quantities'. The actual area of the features shall be girthed and included in the measurements.

g) For painting of uneven surfaces in doors, windows, ventilators, louvers, gratings, railing, gates, etc. equivalent plain areas shall be measured as given in IS: 1200 - latest edition.

h) No extra will be paid for preparation of surface, sand papering, cleaning etc.

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i) All glass shall be cleaned after painting and no extra shall be paid for this.

j) For painting pipes for sanitary and plumbing work, measurement shall be made on actual workdone in R.M. for different diameters. Measurement shall be along the central lines of pipes laid. No deductions or additions shall be made for valves, fittings etc.

1.11 Scaffolding etc. No separate payment will be made for scaffolding, bracing, propping, etc. necessary for safe and efficient execution of the various items of works. Cost of all such temporary work as required is deemed to have been included in the individual item rates quoted by the Contractor.

1.12 Roofing, Insulation, Water Proofing, Flashing, Etc. a) These shall be measured on actual area laid in square metres. No deductions shall

be made for openings, pipes, sleeves, etc. upto 0.1 Sq.m. in area each.

b) If cast-in-situ insulation (foam concrete) is done, no separate payment shall be made for form work etc.

c) No separate payment shall be made for laps in water proofing, flashing etc.

d) No separate payment shall be made for finishing round roof drains.

e) No separate payment shall be made for rounding, chamfering etc. of junctions, corners etc.

f) No separate payment shall be made for cutting grooves, and keying the flashing in the groove.

g) Metal flashing shall be measured in square metres of actual area done.

h) No payment shall be made for cutting wastages, materials left over etc. which shall be the property of the Contractor.

i) Fillets shall be measured for actual work done in running metres.

1.13 Pipes 1) Cast iron pipes shall be measured along the centre lines of pipes including all

fittings such as 'Y' junctions, plug bends, etc.

2) GI pipes with fittings completely fixed in position shall be measured and paid for the finished centre line lengths, including all fittings such as tees, bends, couplings etc.

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1.0 QUALITY MANAGEMENT REQUIREMENTS 1.1 Scope This chapter specifies requirements to be incorporated in a contractor's quality assurance programme for construction. The contractor is responsible for planning and developing a programme that assures that all his management, design and technical responsibilities for quality are incorporated and executed effectively. The programme is aimed primarily at ensuring an efficient quality management in construction and taking corrective actions, when necessary.

1.2 Quality Assurance Assuring reliability and quality of work carried out under this package is the primary responsibility of the contractor. The contractor shall have a documentation quality system addressing the mechanism to achieve the required quality level and the work carried out conforming to be the best manufacturing and work practices prevailing at the time of execution of contract

The contractor shall have a well-structured organization of personnel and resources to specify, achieve, verify and document all work. This should also include the approval from IGCAR wherever required. Quality system can be in line with national / international standards / models and shall address following areas:

a) Design/Engineering whenever applicable.

b) Procurement of consumable materials and equipment.

c) Construction

d) Subcontracting

e) Special processes

f) Measuring and testing equipment

g) Inspection and test including non-destructive testing and other examination of the material and equipment.

h) Handling, storing, preservation, packaging and shipping

i) Item identification and traceability

j) Documentation and quality records.

k) Disposition of non-conformance and corrective action and demonstrate conformance of the work carried out meeting specified requirements.

1.3 Applicability The requirements of this chapter apply to the construction activities when specified in a contract.

1.4 Contractor's Responsibilities

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The contractor / vendor / sub vendors shall have an independent quality control inspection and testing organization .. They should also make provision for setting up a test facility wherever required. Personnel working in this group shall not have any other responsibility such as planning, safety and production. This department shall work in close co ordination with the quality assurance department of IGCAR and abide by their instructions in all aspects of work. The quality personnel performing all the package works are to be. suitably academically qualified to have suitable professional experience in their relevant field. For example: nde, welding technology, metrology as applicable.

The contractor shall furnish along with this bid an organization chart which includes the structure and size of the manpower of the quality department for detailed scrutiny I approval and acceptance of IGCAR. Contractor's quality personnel shall be evaluated by IGCAR. Contractor personnel found not suitable for performing the works shall be replaced immediately with efficient quality performers to ensure speedy execution of works without sacrificing quality.

Wherever found essential the contractor may have to provide for hiring outside inspection agency.

Following are the procedures to be developed to fulfil the above requirements.

a) To develop and implement the controls and quality assurance procedures, that will promptly detect and dispose of, or prevent, non- conformance to contractual requirements.

b) To comply with the IGCAR's requirements as specified in the contract.

c) To prepare a quality assurance manual which shall be submitted for the Engineer's concurrence before the contract is awarded or at the latest before the work starts.

d) To prepare a quality plan which shall be submitted to the engineer before the work starts.

e) To update and resubmit the quality assurance manual and quality plan to reflect current practices when significant changes occur in the contractor's programme or organisation in order to improve its effectiveness or to prevent recurrence of non conformances.

f) To initiate corrective measures promptly when any quality problems are identified or deviations from established requirements are noticed.

1.5 Quality Assurance Programme The contractor shall plan, establish, implement and maintain a quality assurance programme that complies with the requirements of this chapter.

1.6 Organisation The contractor shall:

a) Clearly define management policies, objectives and responsibilities for quality assurance, including the responsibility of each division within a multi divisional organization. The responsibility and authority for quality of those managing and

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performing the work and of those auditing and verifying conformance to quality requirements shall be defined and their relationships shown on organization charts.

b) Provide for the review by management of the status and adequacy of the quality assurance programme.

c) Define the responsibility and authority of personnel who are primarily responsible for quality assurance and their organisational independence during audits and define the responsibility and authority of personnel who are primarily responsible for quality control and their organisational independence to

i) identify and record quality problems ii) initiate or recommend or provide solutions through designated channels. iii) verify the implementation of dispositions iv) control further processing, delivery or installation of a non- conforming

item or service until the deficiency or unsatisfactory condition has been resolved.

Note that, generally, audit personnel shall not be within the pattern of daily activities.

When inspection I quality control is to be performed by personnel other than authorized inspectors then such a provision should be made in the concerned quality plans and should also be got approved from IGCAR.

1.7 Quality Assurance Documents A) Quality Assurance Manual i) The contractor shall: .

Prepare a quality assurance manual, approved and signed by a senior management official, and subject it for the engineer's concurrence before the contract is awarded or at the latest before the work starts. A quality assurance manual submitted under a previous contract or tender may be referred to.

Review and update the manual to reflect current quality assurance policies and procedures and resubmit the resulting manual.

Implement the programme according to the provisions specified in the manual.

ii) The quality assurance manual shall deal as appropriate with the following:

Organization - the manual shall define the organisational measures

Quality plan - the manual shall identify the group responsible for the quality plan and define its main principles and features in adequate procedures.

Quality assurance procedures - documented quality assurance procedures shall be included or shall be outlined and cross-referenced. Referenced QA procedures shall be made available to the quality assurance representative.

Manual review - a statement shall be incorporated for reviewing and updating the manual.

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B) Quality Plan i) The contractor shall

Plan the inspection and test activities.

Identify in the quality plan the inspection and tests to be performed on the items listed in the contract, in compliance with contractual and/or technical requirements.

Submit the plan for the engineer's concurrence/approval following the award of the contract and before the work starts. Referenced inspection and test specification and/or procedures shall be made available to the quality assurance representative during the implementation of the quality plan. This quality plan shall identify at appropriate stage witness points and hold points and also give clearly the acceptance standards for all inspections, tests and examinations performed.

Update the plan during the life of the contract to reflect current conditions of manufacturing, construction, inspection and testing and resubmit the plan to the engineer.

ii) The quality plan shall be on a format to be approved by the engineer. The quality plan shall deal as appropriate with:

identification of the characteristics or items to be inspected and tested.

Identification of the required inspection, test and special process operations and their relative location in the construction cycle. The contractor may include additional "in process" inspection points for his own evaluation of quality, which will not be subject to acceptance and witness by the quality assurance representative.

Reference to inspection, test and special process procedures, standards, acceptance criteria and sampling plan, if any. Indications of hold points beyond which the activity shall not proceed until the required inspections or tests have shown satisfactory results and have been documented.

Provisions for engineer to insert witness points at which activities are to be observed. The activity may nevertheless proceed beyond a witness point should the engineer fail to attend in spite of due notification.

The quality plans for subcontracted items, when concurred with by the Contractor, shall be submitted to the engineer as applicable, for concurrence and insertion of witness and hold points.

C) Quality Assurance Procedures The contractor shall have procedures for the following specific requirements should they apply to the contract:

a) Document control

b) Procurement

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c) Measuring and testing equipment

d) Inspection and test

e) In-process inspection

f) Final inspection

g) Inspection status

h) Identification and traceability

i) Preservation, handling and storage during construction

j) Special processes

k) Quality records

l) Non-conformances

m) IGCAR-supplied items, if any

n) Corrective actions.

Each QA procedure shall define, as applicable, such things as: its purpose and scope; who is responsible for what; how all steps are to be performed; what materials, equipment and documentation are to be used; how it is all controlled. Forms used shall be registered after approval

QA procedures shall be updated when necessary.

1.8 Special Requirements The Contractor shall

a) Establish measures to-ensure that all quality related documents are reviewed for adequacy and approved for release by authorized agency.

b) Establish distribution lists for the above mentioned documents, update and maintain them in the current form to assure that the proper personnel are issued with all the documents necessary to perform the work.

c) Make the applicable issues of these documents available at areas where these activities are performed.

d) Establish and update lists of applicable documents for construction and' distribute them systematically. Controlled distribution is required for these lists only.

e) Ensure that changes to documents receive the authorizations by the same organizations as the initial documents unless other organizations are specifically designated. Maintain a record of changes as they are made, written notes or documents are acceptable provided that they are made by authorized persons according to established procedures. Documents shall be revised and issued after a practical number of changes have been issued.

f) Control shall be established for disposition and removal of obsolete drawings, procedures and other documents so that they may not be inadvertently used for

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works.

1.9 Procurement a) Selection of Sub-Contractors. The Contractor shall identify items to be procured. He shall undertake the following.

i) Determine for these subcontracted items the applicable quality Management Requirements. Classification of these quality Management Requirements shall be in such a way that the overall quality is not impaired. The classification list shall be submitted to the engineer for acceptance.

ii) Evaluate and select Sub-Contractors in accordance with the applicable quality Management Requirements with regard to their ability to meet subcontract and quality requirements and the process of selection should be informed to IGCAR. IGCAR reserves the right to reject such Sub-Contractors who are not found suitable to carry out intended works.

iii) When off the shelf items are to be procured, evaluation of Sub-Contractor may not necessarily be required. The Contractor shall nominate to the quality assurance representative those materials, parts and components that belong to this category.

b) Subcontract Requirements. The Contractor shall include in subcontracts the following, as applicable:

i) A clear description of the items or services to be procured including technical data and inspection and test requirements by reference to standards, technical specifications, drawings, etc.

ii) A designation of the applicable quality Management Requirements to be applied to the items and exceptions, if any.

iii) A designation of the Contractor's QA procedures to be implemented by the Sub-Contractor, if applicable.

iv) lnstructions for the submission, retention and disposition of quality records.

v) Requirements for packaging and shipping, where applicable.

vi) A statement related to the right of access to the Sub-Contractor's premises and records for audit and! or surveillance by the Contractor or the Engineer.

vii) instructions for notification of witness points and hold points.

viii) Requirement for the Sub-Contractor to report non-conformances.

ix) Applicable requirements to be extended to lower tier sub-Contractor, if any Subcontract documents shall be reviewed and approved by the Engineer

x) AII un-priced subcontracts and associated reference data shall be made available on request for review by the quality representative.

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c) Amendments to Subcontracts. The Contractor shall process amendments to subcontracts in the same way as initial subcontract and reference the initial subcontract number in the amendments.

a) Verification of the Quality Management System Implemented by the sub-Contractor (Refer Applicable Quality Management Requirements).

b) Receiving Inspection to the extent that is practical, receiving inspection shall be specified. in the quality plan .

The Contractor shall

i. Identify and inspect items on receipt to ascertain that they comply with contractual requirements. In determining the amount or nature of receiving inspection, consideration shall be given to the surveillance exercised at source and documented evidence of quality conformance. Receiving inspection shall cover as a minimum verification of deterioration or damage during transport, identification control, and review of required documentation.

ii. Hold incoming items until the required inspection and / or test have been completed or the necessary inspection and/or test reports have been received and verified except when items are released under positive recall.

1.10 Measuring and Testing Equipment All measuring and testing equipment and devices used to verify characteristics that can affect item quality should be controlled and maintained. At prescribed intervals, or prior to use, they shall be calibrated and adjusted against certified equipment having a known valid relationship to nationally recognized standards. Where no national standards exist, the basis employed for calibration shall be documented.

No special calibration and control measures are necessary on rulers, tape measures, levels and other such devices, if normal commercial practices provide for adequate accuracy and/or if large tolerances are allowed for the corresponding measurements.

The Contractor shall

a) Include in calibration procedures, equipment type, frequency of checks, and description of check method, acceptance criteria and action to be taken when results are unsatisfactory. Exception will be allowed for measuring and testing equipment for which calibration is simple and does not require a specific detailed procedure. The Contractor shall identify those types of measuring equipment for which he has not provided calibration procedures.

b) Identify measuring and testing equipment with a tag, sticker, or other suitable indicator to show the calibration status.

c) Maintain calibration records for measuring and testing equipment.

d) Assess and document the validity of previous inspection and test results when measuring and testing equipment are found to be out of calibration.

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For concreting and earthwork activities:

The above mentioned requirements are mandatorily applicable only to the following equipment and instruments:

i. Laboratory scaleii. Compression test machineiii. Tensile test machineiv. Batching Plantv. Grout batching machine

For all other equipment and instruments, the requirements are non-mandatory but they may be used as a guide.

1.11 Inspection and Test a) The Contractor shall provide for the performance of inspections and tests as

specified in the quality plan. These inspections and tests shall be carried out in accordance with written procedures that define the acceptance/rejection criteria. The Contractor shall amend the selected inspection methods in cases where their unsuitability is demonstrated.

b) Inspections and tests shall be documented in inspection and test reports that identify as a minimum, the item inspected or tested, applicable drawings, specifications or procedures, the date of inspection or test, the inspector, tester or data recorder, the type of observation, the results, the acceptability and the action taken in connection with any deficiencies identified.

1.12 In-Process Inspection The Contractor shall

a) Identify, inspect and/or test items as required by the quality plan.

b) Monitor process methods, where inspection is not feasible.

c) Hold items until the required inspections and/or tests have been completed or necessary reports have been received and verified except when items are released under positive recall. Release under positive recall shall not preclude (a) above.

For concreting activities: i) The Contractor shall establish adequate measures for pre-concreting, in process

and post concreting inspections to be performed as applicable.

ii) A part of these inspections and the 'documentation thereof may be delegated to the works personnel. In such cases, the independent inspections can be reduced to an extent to be defined in the quality plan or in the inspection procedures only after the approval of Engineer - in - charge.

iii) Such measures do not preclude complete independent inspections to be performed on a programmed basis or as consequence of results obtained.

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1.13 Final inspection The Contractor shall

a) Identify, inspect and/ or test the completed item as required by the quality plan.

b) Verify that the item has been inspected at all points shown in the quality plan and that the records are adequate and completed.

1.14 Inspection Status The Contractor shall

a) Provide means for assuring that required inspection and tests are performed and that the acceptability of items with regard to inspections and tests - performed is known throughout manufacturing and construction.

b) Establish and maintain a system for identifying the inspection/acceptance status by means of tags, stamped impressions, or other physical means to be affixed to the item or its container or by means of inspection records.

c) Show the identity of the Contractor and his inspector on any inspection marking used.

d) Provide for measures for controlling status indicators including the authority for application and removal of tags, stamps or other marking.

e) Identify non-conforming items until their conformity is established.

1.15 Identification and Traceability The Contractor shall establish and maintain an adequate system to

Identify each item (lot, component or part) to the applicable drawing, specification or other technical documents, throughout the whole construction process.

a) Assign to each item a unique identification where specific tractability is required by the contract.

b) Record this identification on all process, inspection and test records, where traceability is specified.

c) List the items that do or do not require traceability concerning concrete activities.

1.16 Preservation, Handling and Storage The Contractor shall

a) Establish, maintain and document a system for the preservation, storage and handling of all items from the time of receipt through the entire construction process and subsequent storage to prevent abuse, misuse, damage, deterioration or loss.

b) Periodically inspect stored items for condition and shelf life expiry.

c) Inspect and test special handling tools and equipment at specific times to verify that

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the tools and equipment are adequately maintained and will not damage the items and will ensure safe and adequate handling. .

d) Use specific written procedures and trained personnel for lifting of critical or high value items.

1.17 Construction a) The Contractor shall clearly define the responsibilities for the documented

preparation of works. This written preparation shall consist of instructions or work assignments. It shall be established in accordance with the construction schedules and be available to the works and inspection personnel prior to commencement of work. This work instruction will document the following.

- Work methods

- Sequence of operations

- Workmanship criteria

- Type of equipment needed

- Special working environment, if any.

b) For concreting and other common civil work activities, these instructions may be included in drawings, specifications or other design documents.

c) The Contractor shall insure that prior to release for construction all jigs, fixtures, tooling masters, templates, and patterns used for verifying quality are controlled. The extent and frequency of tool control shall be defined.

1.18 Special Processes The Contractor shall

a) Identify those special processes subject to the requirements of this clause. Special processes shall include welding, heat-treating and non-destructive examination, as applicable.

b) Establish documented procedure to assure that these processes are accomplished under controlled conditions by qualified personnel using qualified documented procedures and suitable equipment in accordance with applicable codes, standards, specifications, criteria and- contractual requirements.

c) Maintain documentation for currently qualified personnel and processes according to the requirement of pertinent codes and standards.

d) Define the necessary qualifications of personnel and procedures for special processes not covered by existing codes or standards, or where item or service quality requirements exceed the requirements of established codes or standards.

e) Not consider concreting as a special process. However, the Contractor shall ensure that foremen and vibrator operators are properly selected from experienced or trained personnel prior to assignment of works and are given regular training by concrete placement experts as needed.

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1.19 Quality Records The Contractor shall

a) Maintain quality records as evidence that

i) The quality assurance programme meets the requirements of these Quality Management Requirements (manual, procedures, and quality plan).

ii) The items or services meet contractual or other applicable technical requirements (specifications, drawings, calculations, manufacturing, inspection and test procedures)

iii) Personnel and procedures for special processes are qualified.

iv) Measuring and testing equipment is calibrated.

v) The procurements meet the requirements.

vi) Corrective actions are being taken and are effective as required

vii) Audits are performed as required.

b) Maintain final performance quality records which include as appropriate

i) As built records.

ii) Material test reports or certificates

iii) Non-destructive examination records or certificates.

iv) Inspection and test records.

v) Non-conformance reports.

vi) Concrete batch plant printout.

Items iii) and iv) apply to those operations performed after receipt of materials from the supplier.

c) Identify, index and file quality records for easy retrieval.

d) Retain quality records for the time specified in the contract. If not specified, final performance quality records shall be retained for 10 years.

e) Provide a suitable environment for storing of records to minimize deterioration or damage and to prevent loss (the use of a double filing system is an acceptable method)

f) Construction completion certification is an important part of this contract package. In order to give full meaning to this requirement all quality records shall be generated, got authorised by all agencies at appropriate stages, documented and preserved. Periodic audits by competent authority shall be performed on these documents to establish the efficiency. These audits reports are to be submitted to the Engineer to provide an effective feedback so that corrective action can be initiated on time.

g) Construction completion document has to be prepared incorporating all the

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essential requirements and records, giving justification that all the requirements of drawings, specification are met and the design intent is met and this document shall be made available to the Engineer-in-charge at the time of completion.

The Contractor shall:

a) Investigate the causes of significant or recurring non-conformances and take appropriate action to prevent repetition.

b) Document and have reported to appropriate levels of the Contractor's management causes of significant conditions that adversely affect quality and the corrective action taken.

1.22 Quality Assurance Programme, Facilities and Physical Resources Prior to the award of a contract, and to the performance of the activity, the Engineer shall evaluate the Contractor's quality assurance programme, manufacturing facilities and resources to determine whether the requirements of this section can be met.

In the event of the Contractor not fulfilling all applicable requirements, IGCAR may award the contract provided that he takes the responsibility for those QA requirements that will not be met by the Contractor. In such a case, the exceptions shall be clearly defined in the contract. .

1.23 Quality Plan IGCAR shall evaluate the quality plan and all revisions thereto in order to determine its acceptability. . .

IGCAR shall indicate his witness points and hold points on the accepted quality plan. In addition, IGCAR shall perform surveillance according to the accepted quality plan.

1.24 Access The Contractor shall provide for reasonable access of the competent authorities and of IGCAR to his premises and records for audit and surveillance purposes.

1.25 Audit There shall be provision for having periodic internal audits conducted on the Quality Assurance System and the activities affecting quality of this package. These audits may be carried out once in six months by independent group of the Contractor.

The Contractor shall agree to have periodic Audits conducted by Site Audit Group and Corporate Audit Group of IGCAR. Construction of HEC is governed by the Atomic Energy Regulatory Board regulations and the activities are subject to regulatory inspections periodically. The Contractor shall be bound to provide corrective actions and responses when some non-conformances are reported at these audits.

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SPECIFICATION FOR ROAD WORKS

201. CLEARING AND GRUBBING

This work shall consist of cutting, removing and disposing of all materials such as trees, bushes, shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150mm in thickness, rubbish etc., which in the opinion of the Engineer are unsuitable for incorporation in the works, from the area of road land containing road embankment, drains, cross-drainage structures and such other areas as may be specified on the drawings or by the Engineer. It shall include necessary excavation, backfilling of pits resulting from uprooting of trees and stumps to required compaction, handling, salvaging, and disposal of cleared materials. Clearing and grubbing shall be performed in advance of earthwork operations and in accordance with the requirements of these Specifications.

201.2. Preservation of Property/Amenities

Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings, pipelines, sewers and all highway facilities within or adjacent to the highway which are not to be disturbed shall be protected from injury or damage. The Contractor shall provide and install at his own expense, suitable safeguards approved by the Engineer for this purpose.

During clearing and grubbing, the Contractor shall take all adequate precautions against soil erosion, water pollution, etc., and where required, undertake additional works to that effect vide Clause 306. Before start of operations, the Contractor shall submit to the Engineer for approval, his work plan including the procedure to be followed for disposal of waste materials, etc., and the schedules for carrying out temporary and permanent erosion control works as stipulated in Clause 306.3.

201.3. Methods, Tools and Equipments

Only such methods, tools and equipment as are approved by the Engineer and which will not affect the property to be preserved shall be adopted for the Work. If the area has thick vegetation/roots/trees, a. crawler or pneumatic tyred dozer of adequate capacity may be used for clearance purposes. The dozer shall have ripper attachments for removal of tree stumps. All trees, stumps, etc., falling within excavation and fill lines shall be cut to such depth below ground level that in no case these fall within 500mm of the subgrade. Also, all vegetation such as roots, under-growth, grass and other deleterious matter unsuitable for incorporation in the embankment / subgrade shall be removed between fill lines to the satisfaction of the Engineer. On areas beyond these limits, trees and stumps required to be removed as directed by the Engineer shall be cut down to 1 m below ground level so that these do not present an unsightly appearance.

All branches of trees extending above the roadway shall be trimmed as directed by the Engineer.

All excavations below the general ground level arising out of the removal of trees, stumps, etc., shall be fi11ed with suitable material and compacted thoroughly so as to make the surface at these points conform to the surrounding area.

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Ant-hills both above and below the ground, as are liable to collapse and obstruct free subsoil water flow shall be removed and their workings, which may extend to several metres, shall be suitably treated.

201.4. Disposal of Materials

All materials arising. from clearing and grubbing operations shall be the property of Government and shall be disposed of by the Contractor as hereinafter provided or directed by the Engineer.

Trunks, branches and stumps of trees shall be cleaned of limbs and roots and stacked. Also boulders, stones and other materials usable in road construction shall be neatly stacked as directed by the Engineer. Stacking of stumps, boulders, stones etc., shall be done at specified spots with all lifts and upto a lead of 1000 m.

All products of clearing and grubbing which, in the opinion of the Engineer, cannot be used or auctioned shall be cleared away from the roadside in a. manner as directed by the Engineer. Care shall be taken to see that unsuitable waste materials are disposed of in such a manner that there is no likelihood of these getting mixed up with the materials meant for embankment, subgrade and road construction.

201.5. Measurements for Payment

Clearing and grubbing for road embankment, drains and cross-drainage structures shall be measured on area basis in terms of hectares. Clearing- and grubbing of borrow areas shall be deemed to be a part of works preparatory to embankment construction and shall be deemed to have been included in the rates quoted for the embankment construction item and no separate payment shall be made for the same. Cutting of trees upto 300 mm in girth including removal of stumps and roots, and trimming of branches of trees extending above the roadway shall be considered incidental to the clearing and grubbing operations. Removal of stumps left over after trees have been cut by any other agency shall also be considered incidental to the clearing and grubbing operations.

Cutting, including removal of stumps and roots of trees of girth above 300 mm and backfilling to required compaction shall be measured in terms of number according to the sizes given below:-

i) Above 300mm to 600mm ii) Above 600mm to 900mm iii) Above 900mm to 1800mm iv) Above 1800mm

For this purpose, the girth shall be measured at a height of 1 metre above ground or at the top of the stump if the height of the stump is less than one metre from the ground.

201.6. Rates

201.6.1. The Contract unit rates for the various items of clearing and grubbing shall be

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payment in full for carrying out the required operations including full compensation for all labour, materials, tools, equipment and incidentals necessary to complete the work. These will also include removal of stumps of trees less than 300mm in girth as well as stumps left over after cutting of trees carried out by another agency, excavation and back-filling to required density, where necessary, and handling, salvaging, piling and disposing of the cleared materials with all lifts and upto a lead of 1000m.

201.6.2. The Contract unit rate for cutting (including removal of stumps and roots) of trees of girth above 300 mm shall include excavation and backfilling to required compaction, handling, salvaging, piling and disposing of the cleared materials with all lifts and upto a lead of 1000 m.

201.6.3. Where a Contract does not include separate items of clearing and grubbing, the same shall be considered incidental to the earthwork items and the Contract unit prices for. the same shall be considered as including clearing and grubbing operations.

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301. EXCAVATION FOR ROADWAY AND DRAINS

301.1. Scope

This work shall consist of excavation, removal and satisfactory disposal of all materials necessary for the construction of roadway, side drains and waterways in accordance with requirements of these Specifications and the lines, grades and, cross-sections shown in the drawings or as indicated by the Engineer. It shall include the hauling and stacking of or hauling to sites of embankment and subgrade construction, suitable cut materials as required, as also the disposal of unsuitable cut materials in specified manner, trimming and finishing of the road to specified dimensions or as directed by the Engineer.

301.2. Classification of Excavated Material

301.2.1. Classification: All materials involved in excavation shall be classified by the Engineer in the following manner:

(a) Soil

This shall comprise topsoil, turf, sand. silt, loam, clay, mud, peat, black cotton soil. soft shale or loose moorum, a mixture of these and similar material which yields to the ordinary application of pick, spade and/or shovel, rake or other ordinary digging implement. Removal of gravel or any other nodular material having dimension in anyone direction not exceeding 75 mm occurring in such strata shall be deemed to be covered under this category .

(b) Ordinary Rock (not requiring blasting)This shall include:

i) rock types such as laterites, shales and conglomerates, varieties of limestone and sandstone etc., which may be quarried or split with crow bars. also including any rock which in dry state may be hard, requiring' blasting but which, when wet, becomes soft and manageable by means other than blasting; .

ii) macadam surfaces such as water bound and bitumen/tar bound; soling of roads. paths etc. and hard core; compact moorum or stabilised soil requiring grafting tool or pick or both and shovel. closely applied; gravel and cobble stone having maximum dimension in anyone direction between 75 and 300 mm;

iii) lime concrete, stone masonry in lime mortar and brick work in lime/Cement mortar below ground level, reinforced cement concrete which may be broken up with crow bars or picks and stone masonry in cement mortar below ground level; and

iv) boulders which do not require blasting having maximum dimension in any direction of more than 300mm, found lying loose on the surface or embedded in river bed, soil, talus, slope wash and terrace material of dissimilar origin.

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(c) Hard Rock (requiring blasting) This shall comprise:

i) any rock or cement concrete for the excavation of which the use of 'mechanical plant and/or blasting is required;

ii) reinforced cement concrete (reinforcement cut through but not separated from the concrete) below ground level; and

iii) boulders requiring blasting.

(d) Hard Rock (blasting prohibited)

Hard rock requiring blasting as described under (c) but where blasting is prohibited for any reason and excavation has to be carried out by chiselling. wedging or any other greed method.

(e) Marshy Soil

This shall include soils like soft clays and peats excavated below the original ground level of marshes and swamps and soils excavated from other areas requiring continuous pumping or bailing out of water.

301.2.2. Authority for classification : The classification of excavation shall be decided by the Engineer and his decision shall be final and binding on the Contractor. Merely the use of explosives in excavation will not be considered as a reason for higher classification unless blasting is clearly necessary in the opinion of the Engineer.

301.3. Construction Operations

301.3.1. Setting out: After the site has been cleared as per Clause 201, the limits of excavation shall be set out true to lines, curves, slopes, grades and sections as shown Oil the drawings or as directed by the Engineer. The Contractor shall provide all labour, survey instruments and materials such as strings, pegs, nails, bamboos, stones, lime, mortar, concrete, etc., required in connection with the setting out of works and the establishment of bench marks. The Contractor shall by responsible for the maintenance of bench marks and other marks and stakes as long as in the opinion of the Engineer, they are required for the work.

301.3.2. Stripping and storing topsoil : When so directed by the Engineer, the topsoil existing over the sites of excavation shall be stripped to specified depths constituting Horizon "A" and stockpiled at designated locations for re-use in covering embankment slopes, cut slopes, berms and other disturbed areas where re-vegetation is desired. Prior to stripping the topsoil, all trees, shrubs etc. shall be removed along with their roots, with approval of the Engineer.

301.3.3. Excavation - General: All excavations shall be carried out in conformity with the directions laid here-in-under and in a manner approved by the Engineer. The work ,shall be so done that the suitable materials available from excavation are satisfactorily utilized as decided upon beforehand.

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While planning or executing excavations, the Contractor shall take all adequate precautions against soil erosion, water pollution etc. as per Clause 306, and take appropriate drainage measures to keep the site free of water in accordance with Clause 311.

The excavations shall conform to the lines, grades, side slopes and levels shown on the drawings or as directed by the Engineer. The Contractor shall not excavate outside the limits of excavation. Subject to the permitted tolerances, any excess depth/ width excavated beyond the specified levels/dimensions on the drawings shall be made good at the cost of the Contractor, with suitable material of characteristics similar to that removed and compacted to the requirements of Clause 305.

All debris and loose material on the slopes of cuttings shall be removed. No backfilling shall be allowed to obtain required slopes excepting that when boulders or soft materials are encountered in cut slopes, these shall be excavated to approved depth on instructions of the Engineer and the resulting cavities filled with suitable material and thoroughly compacted in an approved manner.

After excavation, the .sides of excavated area shall be trimmed and the area contoured to minimise erosion and ponding, allowing for natural drainage to take place. If trees were removed, new trees shall be planted, as directed by the Engineer. The cost of planting new trees shall be deemed to be incidental to the work.

301.3.4. Methods, tools and equipment: Only such methods, tools and equipment as approved by the Engineer shall be adopted/used in the work. If so desired by the Engineer, the Contractor shall demonstrate the efficacy of me type of equipment to be used before the commencement of work.

301.3.7. Excavation of road shoulders/verge/median for widening of pavement or providing treated shoulders : In works involving widening of existing pavements or providing treated shoulders, unless otherwise specified, the shoulder/verge/median shall be removed to their full width and to levels shown on drawings or as indicated by the Engineer. While doing so, care shall be taken to see that no portion of the existing pavement designated for retention is loosened or disturbed. If the existing pavement gets disturbed or loosened, it shall be dismantled and cut to a regular shape with sides vertical and the disturbed/loosened portion removed completely and relaid as directed by the Engineer, at the cost of the Contractor.

301.3.8. Excavation for surface/sub-surface drains: Where the Contract provides for construction of surface/sub-surface drains to Clause 309, excavation for these shall be carried out in proper sequence with other works as approved by the Engineer.

301.3.9. Slides: If slips, slides, over-breaks or subsidence occur in' cuttings during the process of construction, they shall be removed at the cost of the Contractor as ordered by the Engineer. Adequate precautions shall be taken to ensure that during construction, the slopes are not rendered unstable or give rise to recurrent slides after construction. If finished slopes slide into the roadway subsequently, such slides shall be removed and paid for at the Contract rate for the class of excavation involved, provided the slides are not due to any negligence on the part of the Contractor. The classification of the debris material from the slips, slides etc. shall conform to its condition at the time of removal and payment

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made accordingly regardless of its condition earlier.

301.3.10. Dewatering: If water is met with in the excavations due to springs, seepage, rain or other causes, it shall be removed by suitable diversions, pumping or bailing out and the excavation kept dry whenever so required or directed by the Engineer. Care shall be taken to discharge the drained water into suitable outlets as not to cause damage to' the works, crops or any other property. Due to any negligence on the part of the Contractor, if any such damage is caused, it shall be the sole responsibility of the Contractor to repair/restore to the original condition at his own cost or compensate for the damage.

301.3.11. Disposal-of excavated materials: All the excavated materials shall be the property of the Employer. The material obtained from the excavation of roadway, shoulders, verges, drains, cross drainage works etc., shall be used for filling up of (i) roadway embankment, (ii) the existing pits in the right-of-way and (iii) for landscaping of the road as directed by the Engineer, including levelling and spreading with all lifts and lead upto 1000 m and no extra payment shall be made for the same.

All hard materials, such as hard moorum, rubble, etc., not intended for use as above shall be stacked neatly on specified land as directed by the Engineer with all lifts and lead upto 1000 m.

Unsuitable and surplus material not intended for use within the "lead specified above shall also, if necessary, be transported with all lifts and lead beyond initial 1000 m, disposed of or used as directed by the Engineer.

301.3.12. Backfilling: Backfilling of masonry /concrete/hume pipe drain excavation shall be done with approved material after concrete/masonry/hume pipe is fully set and carried out in such a way as not to cause undue thrust on any part of the structure and/or not to cause differential settlement All space between the drain walls and the side of the excavation shall be refilled to the original surface making due allowance for settlement, in layers generally not exceeding 150 mm compacted thickness to the required density, using suitable compaction equipment such as mechanical tamper, rammer or plate compactor as directed by the Engineer.

301.4. Plying of Construction Traffic

Construction traffic shall not use the cut formation and finished subgrade without the prior permission of the Engineer. Any damage arising out of such use shall be made good by the Contractor at his own expense.

301.5. Preservation of Property

The Contractor shall undertake all reasonable precautions for the protection - and preservation of any or all existing roadside trees, drains, sewers or. other sub-surface drains, pipes, conduits and any other structures under or above ground, which may be affected by construction operations and which, in the opinion of the Engineer, shall be continued in use without any change. Safety measures taken by the Contractor in this respect, shall be got approved from the Engineer. However, if any of these objects is damaged by reason of the Contractor's negligence, it shall be replaced or restored to the

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original condition at his expense. If the Contractor fails to do so, within the required time as directed by the Engineer or if, in the opinion of the Engineer, the actions initiated by 'the Contractor to replace/restore the damaged objects are not satisfactory, the Engineer shall arrange the replacement/restoration directly through any other agency at the risk and cost of the Contractor after issuing a prior notice to the effect.

301.6. Preparation of Cut Formation

The cut formation, which serves as a subgrade, shall be prepared to receive the sub-base/base course as directed by the Engineer.

Where the material in the subgrade (that is within 500 mm from the lowest level of the pavement) has a density less than specified in Table 300-2, the same shall be loosened to a depth of 500 mm and compacted in layers in accordance with the requirements of Clause 305.

Any unsuitable material encountered in the subgrade level shall be removed as directed by the Engineer and replaced with suitable material compacted in accordance with Clause 305.

In rocky formations, the surface irregularities shall be corrected and the levels brought up to the specified elevation with granular base material as directed by the Engineer, laid and compacted in accordance with the respective Specifications for these materials. The unsuitable material shall be disposed of in accordance with Clause 301.3.11. After satisfying the density requirements, the- cut formation shall be prepared to receive the subbase/base course in accordance with Clauses 310 and 311 to receive the sub-base/base course.

301.7. Finishing Operations

Finishing operations shall include the work of properly shaping and dressing all excavated surfaces.

When completed, no point on the slopes shall vary from the designated slopes by more than 150 mm measured at right angles to the slope, except where excavation is in rock (nard or soft) where no point shall vary more than 300 mm from the designated slope. In no case shall any portion of the slope encroach on the roadway.

The finished cut formation shall satisfy the surface tolerances described in Clause 902.

Where directed, the topsoil removed earlier and conserved (Clauses 301.3.2 and 305.3.3) shall be spread over cut slopes, where feasible, berms and other disturbed areas. Slopes may be roughened and moistened slightly, prior to the application of topsoil, in order to provide satisfactory bond. The depth of topsoil shall be sufficient to sustain plant growth, the usual thickness being from 75 mrn. to 100 mm.

301.8. Measurements for Payment

Excavation for roadway shall be measured by taking cross-sections at suitable intervals in

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the original position before the work starts and after its completion and computing the volumes In cu. m. by the method of average end areas for each class of material encountered. Where it is not feasible to compute volumes by this method because of erratic location of isolated deposits, the volumes shall be computed by other accepted methods.

At the option of the Engineer, the Contractor shall leave depth "indicators during excavations of such shape and size and in such positions as directed so as to indicate the original ground level as accurately as possible. The Contractor shall see that these remain intact till the final measurements are taken

301.9. Rates

301.9.1. The Contract unit rates for the items of roadway and drain excavation shall be payment In full for carrying out the operations required for the individual items including full compensation for

i) setting out; ii) transporting the excavated materials and depositing the same on sites of

embankments, spoil banks or stacking as directed within all lifts and lead upto 1000 m or as otherwise specified;

iii) trimming bottoms and slopes of excavation; iv) dewatering; v) keeping the work free of water as per Clause 311; and vi) all labour, materials, tools, equipment, safety measures, testing and incidentals

necessary to complete the work to Specifications. --------

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305. EMBANKMENT CONSTRUCTION

305.1. General

305.1.1. Description: These Specifications shall apply to the construction of embankments including subgrades, earthen shoulders and miscellaneous backfills with approved material obtained from roadway and drain excavation, borrow pits or other sources. All embankments, subgrades, earthen shoulders and miscellaneous backfills shall be constructed in accordance with the requirements of these Specifications and in conformity with the lines, grades, and cross-sections shown on the drawings or as directed by the Engineer.

305.2. Materials and General Requirements

305.2.1. Physical requirements:

305.2.1.1. The materials used in embankments, sub grades , earthen shoulders and miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any other material approved by the Engineer. Such materials shall be free of logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or affect the stability of the embankment/subgrade.

The following types of material shall be considered unsuitable for embankment:a) Materials from swamps, marshes and bogs;b) Peat, log, stump and perishable material; any soil that classifies as OL, OI,

OH or Pt in accordance with IS:1498;c) Materials susceptible to spontaneous combustion;d) Materials in a frozen condition;e) Clay having liquid limit exceeding 70 and plasticity index exceeding 45; and f) Materials with salts resulting in leaching in the embankment.

305.3.5. Spreading material in layers and bringing to appropriate moisture content

305.3.5.1. The embankment and subgrade material shall be spread in layers of uniform thickness not exceeding 200mm compacted thickness over the entire width of embankment by mechanical means, finished by a motor grader and compacted as per Clause 305.3.6. The motor grader blade shall have hydraulic control suitable for initial adjustment and maintain the same so as to achieve the specific slope and grade. Successive layers shall not be placed until the layer under construction has been thoroughly compacted to the specified requirements as in Table 300-2 and got approved by the Engineer. Each compacted layer shall be finished parallel to the final cross-section of the embankment.

305.3.5.2. Moisture content of the material shall be checked at the site of placement prior to commencement of compaction; if found to be out of agreed limits, the same shall be made good. Where water is required to be added in such constructions, water shall be

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sprinkled from a water tanker fitted with sprinkler capable of applying water uniformly with a controllable rate of flow to variable widths of surface but without any flooding. The water shall be added uniformly and thoroughly mixed in soil by blading, discing or harrowing until a uniform moisture content is obtained throughout the depth of the layer.

If the material delivered to the roadbed is too wet, it shall be dried, by aeration and exposure to the sun, till the moisture content is acceptable for compaction. Should circumstances arise, where owing to wet weather, the moisture content cannot be reduced to the required amount by the above procedure, compaction work shall be suspended.

Moisture content of each layer of soil shall be checked in accordance with IS: 2720 (part 2), and unless otherwise mentioned, shall be so adjusted, making due allowance for evaporation losses, that at the time of compaction it is in the range of 1 per cent above to 2 per cent below the optimum moisture content determined in accordance with IS:2720 (part 7) or IS:2720 (Part 8) as the case may be. Expansive clays shall, however, be compacted at moisture content corresponding to the specified dry density, but on the wet side of the optimum moisture content obtained from the laboratory compaction curve.

After adding the required amount of water, the soil shall be processed by means of graders, harrows, rotary mixers or as otherwise approved by the Engineer until the layer is uniformly wet.

Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when being placed in the embankment and a maximum size of 50 mm when being placed in the subgrade.

305.3.5.3. Embankment and other areas of fill shall, unless otherwise required in the Contract or permitted by the Engineer, be constructed evenly over their full width and their fullest possible extent and the Contractor shall control and direct construction plant and other vehicular 'traffic uniformly over them. Damage by construction plant and other vehicular traffic shall be made good by the Contractor with material having the same characteristics and strength as the material had before it was damaged.

Embankments and other areas of unsupported fills shall not be constructed with steeper side slopes, or to greater widths than those shown in the Contract, except to permit adequate compaction at the edges before trimming back, or to obtain the final profile following any settlement of the fill and the underlying material.

Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks face including embankments, cuttings, other fills and excavations steeper than 1 vertical on 4 horizontal, such faces shall be benched as per Clause 305.4.1 immediately before placing the subsequent fill.

All permanent faces of side slopes of embankments and other areas of fill formed shall, subsequent to any trimming operations, be reworked and sealed to the satisfaction of the Engineer by tracking a tracked vehicle, considered suitable by the Engineer, on the slope or any other method approved by the Engineer.

305.3.6. Compaction: Only the compaction equipment approved by the Engineer shall be employed to compact the different material types encountered during construction. Smooth wheeled, vibratory, pneumatic tyred, sheepsfoot or pad foot rollers, etc. of suitable size and

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capacity as approved by the Engineer shall be used for the different types and grades of materials required to be compacted either individually or in suitable combinations.

The compaction shall be done with the help of vibratory roller of 80 to 100 kN static weight with plain or pad foot drum or heavy pneumatic. tyred roller of adequate capacity capable of achieving required compaction.

The Contractor shall demonstrate the efficacy of the equipment he intends to use by carrying out compaction trials. The procedure to be adopted for these site trials shall first be submitted to the Engineer for approval.

Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a lighter category of plant to provide any preliminary compaction to assist the use of heavier plant be taken into account.

Each layer of the material shall be thoroughly compacted to the densities specified in Table 300-2. Subsequent layers shall be placed only after the finished layer has been tested according to Clause 903.2.2 and accepted by the Engineer. The Engineer may permit measurement of field dry density bya nuclear moisture/density gauge used in accordance with agreed procedure and the gauge is calibrated to provide results identical to that obtained from tests in accordance with IS: 2720 (Part 28). A record of the same shall be maintained by the Contractor.

When density measurements reveal any soft areas in the embankment / subgrade / earthen shoulders, further compaction shall be carried out as directed by the Engineer. If in spite of that the specified compaction is not achieved, the material in the soft areas shall be removed and replaced by approved material, compacted to the density requirements and satisfaction of the Engineer.

305.3.7. Drainage : The surface of the- embankment/subgrade at all times during construction shall be maintained at such a cross fall (not flatter than that required for effective drainage of an earthen surface) as will shed water and prevent ponding.

305.3.8. Repairing of damages caused by rain/spillage of water: The soil in the affected portion shall be removed in such areas as directed by the Engineer before next layer is laid and refilled in layers and compacted using appropriate mechanical means such as small vibratory roller, plate compactor or power rammer to achieve the required density in accordance with Clause 305.3.6. If the cut is not sufficiently wide for use of required mechanical means for compaction, the same shall be widened suitably to permit their use for proper compaction. Tests shall be carried out as directed by the Engineer to ascertain the density requirements of the repaired area. The work of repairing the damages including widening of the cut, if any, shall be carried out by the Contractor at his own cost, including the arranging of machinery/equipment for the purpose.

305.3.9. Finishing operations : Finishing operations shall include the work of shaping and dressing the shoulders/verge/roadbed and side slopes to conform to the alignment, levels, cross-sections and dimensions shown on the drawings or as directed by the Engineer subject to .the surface tolerance described in Clause 902. Both the upper and lower ends of the side slopes shall be rounded off to improve appearance and to merge the embankment with the adjacent terrain.

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The topsoil, removed and conserved earlier (Clause 301.3.2 and 305.3.3) shall be spread over the fill slopes as per directions of the Engineer to facilitate the growth of vegetation. S lopes shall be roughened and moistened slightly prior to the application of the topsoil in order to provide satisfactory bond. The depth of the topsoil shall be sufficient to sustain plant growth, the usual thickness being from 75mm to 150mm.

Where directed, the slopes shall be turfed with sods in accordance with Clause 307. If seeding and mulching of slopes is prescribed, this shall be done to the requirement of Clause 308.

When earthwork operations have been substantially completed, the road area shall be cleared of all debris, and ugly scars in the construction area responsible for objectionable appearance eliminated.

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401. GRANULAR SUB-BASE

401.1. Scope

This work shall consist of laying and compacting well-graded material on prepared subgrade in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as necessary according to lines, grades and cross-sections shown on the drawings or as directed by the Engineer.

401.2. Materials

401.2.1. The material to be used for the work shall be natural sand, moorum, gravel, crushed stone, or combination thereof depending upon the grading required. Materials like crushed slag, crushed concrete, brick metal and kankar may be allowed only with the specific approval of the Engineer. The material shall be free from organic or other deleterious constituents and conform to one of the three gradings given in Table 400-1.

While the gradings in Table 400-1 are in respect of close-graded granular sub-base materials, one each for maximum particle size of 75mm, 53mm and 26.5mm, the corresponding gradings for the coarse-graded materials for each of the three maximum particle sizes are given at Table 400·2. The grading to be adopted for a project shall be as specified in the Contract.

401.2,2. Physical requirements: The material shall have a 10 percent fines value of 50 kN or more (for sample in soaked condition) when tested in compliance with BS:812 (part 111). The water absorption value of the coarse aggregate shall be determined as per IS : 2386 (Part 3); if this value is greater than 2 per cent, the soundness test shall be carried out on the material delivered to site as per IS: 383. For Grading II and III materials, the CBR shall be determined at the density and moisture content likely to be developed in equilibrium conditions which shall be taken as being the density relating to a uniform air voids content of 5 percent.

401.3. Strength of sub-base: It shall be ensured prior to actual execution that the material to be used in the sub-base satisfies the requirements of CBR and other physical requirements when compacted and finished.

When directed by the Engineer, this shall be verified by performing CBR tests in the laboratory as required on specimens remoulded at field dry density and moisture content and any other tests for the "quality" of materials, as may be necessary.

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TABLE 400-1. GRADING FOR CLOSE GRADED GRANULAR SUB-BASE MATERIALS

IS Sieve Percent by weight passing the IS sieve

Designation Grading I Grading II Grading III75.0 mm 100 - -53.0 mm 80-100 100 -26.5 mm 55-90 70-100 1009.50 mm 35-65 50-80 65-954.75 mm 25-55 40-65 50-802.36 mm 20-40 30-50 40-650.425 mm 10-25 15-25 20-350.075 mm 3-10 3-10 3-10

CBR value (Minimum) 30 25 20

TABLE 400-2. GRADING FOR CLOSE GRADED GRANULAR SUB-BASE MATERIALS

IS Sieve Percent by weight passing the IS sieve

Designation Grading I Grading II Grading III75.0 mm 100 - -53.0 mm 10026.5 mm 55-75 50-80 1009.50 mm4.75 mm 10-30 15-35 25-452.36 mm0.425 mm0.075 mm <10 <10 <10

CBR value (Minimum) 30 25 20

Note : The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS : 2720 (part 5) shall have liquid limit and plasticity index not more than 25 and 6 per cent respectively.


401.4.1. Preparation of subgrade : Immediately prior to the laying of sub-base, the subgrade already finished to Clause 301 or 305 as applicable shall be prepared by removing all vegetation and other extraneous matter, lightly sprinkled with water if necessary and rolled with two passes of 80 -100 kN smooth wheeled roller.

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401.4.2. Spreading and compacting : The sub-base material of grading specified in the Contract shall be spread on the prepared subgrade with the help of a motor grader of adequate capacity, its blade having hydraulic controls suitable for initial adjustment and for maintaining the required slope and grade during the operation or other- means as approved by the Engineer.

When the sub-base material consists of combination of materials mentioned in Clause 40l.2.1, mixing shall be done mechanically by the mix- in-place method.

Manual mixing shall be permitted only where the width of laying is not adequate for mechanical operations, as in small-sized jobs. The equipment used for mix-in-place construction shall be a rotavator or similar approved equipment capable of mixing the material to the desired degree. If so desired by the Engineer, trial runs with the equipment shall be carried out to establish its suitability for the work.

Moisture content of the loose material shall be checked in accordance with IS:2720 (Part 2) and suitably adjusted by sprinkling additional water from a truck mounted or trailer mounted water tank and suitable for applying water uniformly and at controlled quantities to variable widths of surface or other means approved by the Engineer so that, at the time of compaction, it is from 1 per cent above to 2 per cent below the optimum moisture content corresponding to IS:2720 (part 8). While adding water, due allowance shall be made for evaporation losses. After water has been added, the material shall be processed by mechanical or other approved means like disc harrows, rotavators until the layer is uniformly wet.

Immediately thereafter, rolling shall start. If the thickness of the compacted layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For a compacted single layer upto 225mm the compaction shall be done with the help of a vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required compaction. Rolling shall commence at the lower edge and proceed towards the upper edge longitudinally for portions having unidirectional crossfall and super-elevation and shall commence at the edges and progress towards the centre for portions having crossfall on both sides.

Each pass of the roller shall uniformly overlap not less than one- third of the track made in the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots or depressions, which become apparent, corrected by removing or adding fresh material. The speed of the roller shall not exceed 5 km per hour.

Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry density for the material determined as per IS:2720 (Part 8). The surface of any layer of material on completion of compaction shall be well closed, free from movement under compaction equipment and from compaction planes, ridges, cracks or loose material. All loose, segregated or otherwise -defective areas shall be made good to the full thickness of layer and re-compacted.

401.5. Surface Finish and Quality Control of Work: The surface finish of construction shall conform to the requirements of Clause 902.

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Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900.

401.6. Arrangements for Traffic: During the period of construction, arrangement of traffic shall be maintained in accordance with Clause 112.

401.7. Measurements for Payment: Granular sub-base shall be measured as finished work in position in cubic metres.

The protection of edges of granular sub-base extended over the full formation as shown in the drawing shall be considered incidental to the work of providing granular sub-base and as such no extra payment shall be made for the same.

401.8. Rate: The Contract unit rate for granular sub-base shall be payment in full for carrying out the required operations including full compensation for

(i) making arrangements for traffic to Clause 112 except for initial treatment to verges, shoulders and construction of diversions;

(ii) furnishing all materials to be incorporated in the work including all royalties, fees, rents where necessary and all leads and lifts;

(iii) all labour, tools, equipment and incidentals to complete the work to the Specifications;

(iv) carrying out the work in pan widths of road where directed; and

(v) carrying out the required tests for quality control.

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406. WET MIX MACADAM SUB-BASE / BASE

406.1. Scope

This work shall consist of laying and compacting well-graded material on prepared

This work shall consist of laying and compacting clean, crushed, graded aggregate and granular material, premixed with water, to a dense mass on a prepared subgrade/sub-base/base or existing pavement as the case may be in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as necessary to lines, grades and cross-sections shown on the approved drawings or as directed by the Engineer.

The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm. When vibrating or other approved types of compacting equipment are used, the compacted depth of a single layer of the sub-base course may be increased to 200 mm upon approval of the Engineer

406.2. Materials

406.2.1. Aggregates

406.2.1.1. Physical requirements: Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used, not less than 90 percent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall conform to the physical requirements set forth in Table 400-10 below.

TABLE 400-10. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WET MIX MACADAM FOR SUB-BASE/BASE COURSES

Test Test Method Requirements1 * Los Angles Abrasion

value orIS:2386 (Part-4) 40 percent (Max.)

* Aggregate Impact value

IS:2386 (Part-4)or IS:5640

30 percent (Max.)

2 Combined flakiness and Elongation indices

(Total)IS:2386 (Part-1) 30 percent (Max.)**

* Aggregate may satisfy requirements of either of the two tests.** To determine this combined proportion, the flaky stone from a representative

sample should first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only the elongated particles be separated out from the remaining (non-flaky) stone metal. Elongation index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and elongation index so found are added up.

If the water absorption value of the coarse aggregate is greater than 2 percent, the soundness test shall be carried out on the material delivered to site as per

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IS:2386(part-5).

406.2.1.2. Grading requirements : The aggregates shall conform to the grading given in Table 400-11.

TABLE 400-11. GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX MACADAM

IS Sieve Designation

Percent by weight passing the IS sieve

53.0 mm 10045.0 mm 95-10026.5 mm -22.40 mm 60-8011.20 mm 40-604.75 mm 25-402.36 mm 15-30600.00 micron 8-2275.00 micron 0-8

Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.

The final gradation approved within these limits shall be well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa.


406.3.1. Preparation of base: Clause 404.3.1. shall apply.

406.3.2. Provision of lateral confinement of aggregates: While constructing wet mix macadam, arrangement shall be made for the lateral confinement of wet mix. This shall be done by laying materials in adjoining shoulders along with that of wet mix macadam layer and following the sequence of operations described in Clause 407.4.l.

406.3.3. Preparation of mix: Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity having provision for controlled addition of water and forced/positive mixing arrangement like pugmill or pan type mixer of concrete batching plant. For small quantity of wet mix work, the Engineer may permit the mixing to be done in concrete mixers.

Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size. While adding water, due allowance should be made for evaporation losses. However, at the time of compaction, water in the wet mix should not vary from the optimum value by more than agreed limits. The mixed material should be uniformly wet and no

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segregation should be permitted.

406.3.4. Spreading of mix : Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the prepared subgrade/sub- base/base in required quantities. In no case should these be dumped in heaps directly on the area where these are to be laid nor shall their hauling over a partly completed stretch be permitted.

The mix may be spread either by a paver finisher or motor grader. For portions where mechanical means cannot be used, manual means as approved by the Engineer shall be used. The motor grader shall be capable of spreading the material uniformly all over the surface. Its blade shall have hydraulic control suitable for initial adjustments and maintaining the same so as to achieve the specified slope and grade.

The paver finisher shall be self-propelled, having the following features:

(i) Loading hoppers and suitable distribution mechanism

(ii) The screed shall have tamping and vibrating arrangement for initial compaction to the layer as it is spread without rutting or otherwise marring the surface profile.

(iii) The paver shall be equipped with necessary control mechanism so as to ensure that the finished surface is free from surface blemishes.

The surface of the aggregate shall be carefully checked with templates and all high or low spots remedied by removing or adding aggregate as may be required. The layer may be tested by depth blocks during construction. No segregation of larger and fine particles should be allowed. The aggregates as spread should be of uniform gradation with no pockets of fine materials.

406.3.5. Compaction: After the mix has been laid to the required thickness, grade and crossfall/camber the same shall be uniformly compacted, to the full depth with suitable roller. If the thickness of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 to 100 kN weight may be used. For a compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory roller of minimum static weight of 80 to 100 kN or equivalent capacity roller. The speed of the roller shall not exceed 5 krn/h,

In portions having unidirectional cross fall/superelevation, rolling shall commence from the lower edge and progress gradually towards the upper edge. Thereafter, roller should progress parallel to the centre line of the road, uniformly over-lapping each preceding track by at least one third width until the entire surface has been rolled. Alternate trips of the roller shall be terminated in stops at least I m away from any preceding stop.

In portions in camber, rolling should begin at the edge with the roller running forward and backward until the edges have been firmly compacted. The roller shall then progress gradually towards the centre parallel to the centre line of the road uniformly overlapping each of the preceding track by at least one-third width until the entire surface has been rolled.

Any displacement occurring as a result of reversing of the direction of a roller or from any other cause shall be corrected at once as specified and/or removed and made good.

Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be

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thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of an area without scarifying the surface to permit proper bonding of the added material shall not be permitted.

Rolling should not be done when the subgrade is soft or yielding or when it causes a wave-like motion in the sub-base/base course or subgrade. If irregularities develop during rolling which exceed 12 mm when tested with a 3 metre straight edge, the surface should be loosened and premixed material added or removed as required before rolling again so as to achieve a uniform surface conforming to the desired 'grade and crossfall. In no case should the use of unmixed material be permitted to make up the depressions.

Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density [or the material as determined by the method outlined in IS: 2720 (Part-8)

After completion, the surface of any finished layer shall be well-closed, free from movement under compaction equipment or any compaction planes, ridges, cracks and loose material. All loose, segregated or otherwise defective areas shall be made good to the full thickness of the layer and recompacted.

406.3.6. Setting and drying: After final compaction of wet mix macadam course, the road shall be allowed to dry for 24 hours.

406.4. Opening to Traffic : Preferably no vehicular traffic of any kind should be allowed on the finished wet mix macadam surface till it has dried and the wearing course laid.

406.5. Surface Finish and Quality Control of Work

406.5.1. Surface evenness: The surface finish of construction shall conform to the requirements of Clause 902.

406.5.2. Quality control : Control on the quality of materials and works shall be exercised by the Engineer in accordance with Section 900.

406.6. Rectification of Surface Irregularity: Where the surface irregularity of the wet mix macadam course exceeds the permissible tolerances or where the course is otherwise defective due to subgrade soil getting mixed with the aggregates, the full thickness of the layer shall be scarified over the affected area, re- shaped with added premixed material or removed and replaced with fresh premixed material as applicable and recompacted in accordance with Clause 406.3. The area treated in the aforesaid manner shall not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and ungraded material or fines.

406.7. Arrangement for Traffic : During the period of construction, arrangement of traffic shall be done as per Clause 112.

406.8. Measurements for Payment Wet mix macadam shall be measured as finished work in position in cubic metres.

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406.9. Rates : The Contract unit rate for wet mix macadam shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8.

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502. PRIME COAT OVER GRANULAR BASE

502.1. Scope

This work shall consist of the application of a single coat of low viscosity liquid bituminous material to a porous granular surface preparatory to the superimposition of bituminous treatment or mix.

502.2. Materials

502.2.1. Primer: The choice of ,a bituminous primer shall depend upon the porosity characteristics of the surface to be primed as classified in IRC:16. These are:

(i) Surfaces of low porosity; such as wet mix macadam and water bound macadam(ii) Surfaces of medium porosity; such as cement stabilised soil base,(iii) Surfaces of high porosity; such as a gravel base.

502.2.2. Primer viscosity: The type and viscosity of the primer shall comply with the requirements of IS 8887, as sampled and tested for bituminous primer in accordance with these standards. Guidance on viscosity and rate of spray is given in Table 500-1.

TABLE 500·1. VISCOSITY REQUIREMENT AND QUANTITY OF LIQUID BITUMINOUS PRIMER

Type of surface Kinematic Viscosity of Primer at 60oC (Centistokes)

Quantity of Liquid Bituminous Material per 10 Sq.m. (kg)

Low porosity 30 – 60 6 to 9Medium porosity 70 – 140 9 to 12High porosity 250 – 500 12 to 15

502.2.3. Choice of primer: The primer shall be bitumen emulsion, complying with IS 8887 of a type and grade as specified in the Contract or as directed by the Engineer. The use of medium curing cutback as per IS 217 shall be restricted only for sites at sub-zero temperatures or for emergency applications as directed by the Engineer.

502.3. Weather and Seasonal Limitations : Bituminous primer shall not be applied to a wet surface (see 502.4.2) or during a dust storm or when the weather is foggy, rainy or windy or when the temperature in the shade is less than 10oC. Surfaces which are to receive emulsion primer should be damp, but no free or standing water shall be present.

502.4. Construction

502.4.1. Equipment: The primer distributor shall be a self-propelled or towed bitumen pressure sprayer equipped for spraying the material uniformly at specified rates and temperatures. Hand spraying of small areas, inaccessible to the distributor, or in narrow strips shall. be sprayed with a pressure hand sprayer, or as directed by the Engineer.

502.4.2. Preparation of road surface: The surface to be primed shall be prepared in

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accordance with Clauses 501.8. and 902 as appropriate. Immediately prior to applying the primer the surface shall be carefully swept clean of dust and loose particles, care being taken not to disturb the interlocked aggregate. This is best achieved when the surface layer is slightly moist (lightly sprayed with water and the surface allowed to dry) and the surface should be kept moist until the primer is applied.

502.4.3. Application of bituminous primer: The viscosity and rate of application of the primer shall be as specified in the Contract, or as determined by site trials carried out as directed by the Engineer. Where a geosynthetic is proposed for use, the requirements of Clauses 703.3.2 and 703.4 shall apply. The bituminous primer shall be sprayed uniformly in accordance with Clause 501. The method for application of the primer will depend on the type of equipment to be used, size of nozzles, pressure at the spray bar and speed of forward movement. The Contractor shall demonstrate at a spraying trial, that the equipment and method to be used is capable of producing a uniform spray, within the tolerances specified.

502.4.4. Curing of primer and opening to traffic: A primed surface shall be allowed to cure for at least 24 hours or such other period as is found to be necessary to allow all the volatiles to evaporate before any subsequent surface treatment or mix is laid. Any unabsorbed primer shall first be blotted with an application of sand, using the minimum quantity possible. A primed surface shall not be opened to traffic other than that necessary to lay the next course. A very thin layer of clean sand may be applied to the surface of the primer, to prevent the primer picking up under the wheels of the paver and the trucks delivering bituminous material to the paver.

502.4.5. Tack coat: Over the primed surface, a tack coat should be applied in accordance with Clause 503.

502.5. Quality Control of Work: For control of the quality of materials supplied and the works carried out, the relevant provisions of Section 900 shall apply.

502.6. Arrangements for Traffic: During construction operations, arrangements for traffic shall be made in accordance with the provisions of Clause 112.

502.7. Measurement for Payment: Prime coat shall be measured in terms of surface area of application in square metres.

502.8. Rate: The contract unit rate for prime coat with adjustments as described in Clause 502.7 shall be payment in full for carrying out the required operations including full compensation for all components listed in Clause 401.8 (i) to (v) and as applicable to the work specified in these Specifications. Payment shall be made on the basis of the provision of prime coat at an application rate of 0.6 kg per square metre, with adjustment, plus or minus, for the variation between this amount and the actual amount approved by the Engineer after the preliminary trials referred to in Clause 502.4.3.

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503. TACK COAT

503.1. Scope

This work shall consist of the application of a single coat of low viscosity liquid bituminous material to an existing bituminous road surface preparatory to the superimposition of a bituminous mix, when specified in the Contract or instructed by the Engineer.

503.2. Materials

503.2.1. Binder: The binder used for tack coat shall be bitumen emulsion complying with IS 8887 of a type and grade as specified in the Contract or as directed by the Engineer. The use of cutback bitumen as per IS 217 shall be restricted only for sites at sub-zero temperatures or for emergency applications as directed by the Engineer.

503.3. Weather and Seasonal Limitations : Bituminous material shall not be applied to a wet surface or during a dust storm or when the weather is foggy, rainy or windy or when the temperature in the shade is less than 10°C. Where the tack coat consists of emulsion, the surface shall be slightly damp, but not wet. Where the tack coat is of cutback bitumen, the surface shall be dry.

503.4. Construction

503.4.1. Equipment: The tack coat distributor shall be a self propelled or towed bitumen pressure sprayer, equipped for spraying the material uniformly at a specified rate. Hand spraying of small areas, inaccessible to the distributor, or in narrow strips, shall be sprayed with a pressure hand sprayer, or as directed by the Engineer.

503.4.2. Preparation of base: The surface on which the tack coat is to be applied shall be clean and free from dust, dirt, and any extraneous material, and be otherwise prepared in accordance with the requirements of Clauses 501.8 and 902 as appropriate. Immediately before the application of the tack coat, the surface shall be swept clean with a mechanical broom, and high pressure air jet, or by other means as directed by the Engineer.

503.4.3. Application of tack coat: The application of tack coat shall be at the rate specified in the Contract, and shall be applied uniformly. If rate of application of Tack Coat is not specified in the contract then it shall be at the rate specified in Table 500-2. The normal range of spraying temperature for a bituminous emulsion shall be 20°C to 70°C and for a cutback, 50°C to 80°C if RC-70IMC-70 is used. Where a geosynthetic is proposed for use, the provisions of Clauses 703.3.2 and 703.4.4 shall apply. The method of application of the tack coat will depend on the type of equipment to be used, size of nozzles, pressure at the spray bar, and speed of forward movement. The Contractor shall demonstrate at a spraying trial, that the equipment and method to be used is capable of producing a uniform spray, within the tolerances specified.

Where the material to receive an overlay is a freshly laid bituminous layer that has not been subjected to traffic, or contaminated by dust, a tack coat is not mandatory where the overlay is completed within two days.

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TABLE 500-2. RATE OF APPLICATION OF TACK COAT

Type of SurfaceQuantity of Liquid

Bituminous Material in Kg. per Sq.m. area

i) Normal bituminous surfaces 0.20 to 0.25ii) Dry and hungry bituminous surfaces 0.25 to 0.30

iii) Granular surfaces treated with primer 0.25 to 0.30

iv) Non bituminous surfaces

a) Granular base (not primed) 0.35 to 0.40

b) Cement concrete pavement 0.30 to 0.35

503.4.4. Curing of tack coat: The tack coat shall be left to cure until all the volatiles have evaporated before any subsequent construction . is started. No plant or vehicles shall be allowed on the tack coat other than those essential for the construction.

503.5. Quality Control of Work: For control of the quality of materials supplied and the works carried out, the relevant provisions of Section 900 shall apply.

503.6. Arrangements for Traffic: During the period of construction, arrangements for traffic shall be made in accordance with the provisions of Clause 112.

503.7. Measurement for Payment : Tack coat shall be measured in terms of surface area of application in square metres.

503.8. Rate: The contract unit rate for tack coat shall be payment in full for carrying out the required operations including for all components listed in Clause 401.8 (i) to (v) and as applicable to the work specified in these Specifications. The rate shall cover the provision of tack coat at 0.2 kg per square metre, with the provision that the variance in actual quantity of bitumen used will be assessed and the payment adjusted accordingly.

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507. DENSE GRADED BITUMINOUS MACADAM

507.1. Scope

This clause specifies the construction of Dense Graded Bituminous Macadam, (DBM), for use mainly, but not exclusively, in base/binder and profile corrective courses. DBM is also intended for use as road base material. This work shall consist of construction in a single or multiple layers of DBM on a previously prepared base or sub-base. The thickness of a single layer shall be 50mm to 100mm.

507.2. Materials

507.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration Grade complying with Indian Standard Specifications for "Paving Bitumen" IS: 73, and of the penetration indicated in Table 500- 10 for dense bitumen macadam, or this bitumen as modified by one of the methods specified in Clause 521, or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade of bitumen is given in The Manual for Construction and Supervision of Bituminous Works.

507.2.2. Coarse aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained on the 2.36mm sieve. They shall be clean, hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other deleterious substances. Where the Contractor's selected source of aggregates have poor affinity for bitumen, as a condition for the approval of that source, the bitumen shall be treated with an approved anti-stripping agent, as per the manufacturer's recommendations, without additional payment. Before approval of the source, the aggregates shall be tested for stripping. The aggregates shall satisfy the physical requirements specified in Table 500-8, for dense bituminous macadam.

Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of the crushed material retained on the 4.75 mm sieve shall have at least two fractured faces.

507.2.3. Fine aggregates: Fine aggregates shall consist of crushed or naturally occurring mineral material, or a combination of the two, passing the 2.36mm sieve and retained on the 75 micron sieve. They shall be clean, hard, durable, dry and free from dust, and soft or friable matter, organic or other deleterious matter.

The fine aggregate shall have a sand equivalent value of not less than 50 when tested in accordance with the requirement oflS:2720 (Part 37).

The plasticity index of the fraction passing the 0.425 nun sieve shall not exceed 4. when tested in accordance with IS: 2720 (Part 5)

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TABLE 500-8. PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR DENSE GRADED BITUMINOUS MACADAM

Property Test SpecificationCleanliness (dust) Grain size analysis1 Max 5% passing

0.075mm sieveParticle shape Flakiness and Elongation

Index (Combined)2Max 30%

Strength* Los Angeles Abrasion Value3 Aggregate Impact Value 4

Max 35%Max 27%

Durability Soundness:5

Sodium SulphateMagnesium Sulphate

Max 12%Max 18%

Water Absorption Water absorption 6 Max 2%

Stripping Coating and Stripping of Bitumen Aggregate Mixtures7

Minimum retained coating 95%

Water Sensitivity** Retained Tensile Strength 8 Min 80%

Notes: 1. IS: 2386 Part 1 5. IS:2386 Part 52. IS: 2386 Part 1 6. IS:2386 Part 3 (the elongation test to be done only on non-flaky aggregates in the sample)3. IS: 2386 Part 4* 7. IS:62418. IS: 2386 Part 4* 8. AASHTO T283**

* Aggregate may satisfy requirements of either of these two tests.** The water sensitivity test is only required if the minimum retained coating in the

stripping test is less than 95 %

507.2.4. Filler: Filler shall consist of finely divided mineral matter such as rock dust, hydrated lime or cement approved by the Engineer.

The filler shall be graded within the limits indicated in Table 500-9.

TABLE 500-9. GRADING REQUIREMENTS FOR MINERAL FILLER

IS Sieve (mm) Cumulative percent passing by weight of total aggregate.

0.6 1000.3 95 – 100

0.075 85 – 100

The filler shall be free from organic impurities and have a Plasticity Index not greater than 4. The Plasticity Index requirement shall not apply if filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by weight of total aggregate, shall be Portland cement or hydrated lime and the percentage of fine aggregate reduced accordingly.

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Cement or hydrated lime is not required when the limestone aggregate is used. Where the aggregates fail to meet the requirements of the water sensitivity test in Table 500-8, then 2 per cent by total weight of aggregate, of hydrated lime shall be added without additional cost.

507.2.5. Aggregate grading and binder content: When tested in accordance with IS:2386 Part 1 (wet sieving method), the combined grading of the coarse and fine aggregates and added filler for the particular mixture shall fall within the limits shown in Table 500-10, for dense bituminous macadam grading 1 or 2 as specified in the Contract. The type and quantity of bitumen, and appropriate thickness, are also indicated for each mixture type.

TABLE 500-10. COMPOSITION OF DENSE GRADED BITUMINOUS MACADAM PAVEMENT LAYERS

Grading 1 2

Nominal aggregate size 40mm 25mm

Layer Thickness 80 – 100mm 50 – 75mm

IS Sieve1 (mm) Cumulative % by weight of total aggregate passing

45 10037.5 95-100 10026.5 63-93 90-10019 - 71-9513.2 55-75 56-809.5 - -4.75 38-54 38-542.36 28-42 28-421.18 - -0.6 - -0.3 7-21 7-210.15 - -0.075 2-8 2-8

Bitumen content % by mass of total mix2 Min 4.0 Min 4.5

Bitumen grade (pen) 65 or 90 65 or 90

Notes: 1 The combined aggregate grading shall not vary from the low limit on one sieve to the high limit on the adjacent sieve.2. Determined by the Marshall method.

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507.3. Mixture Design

507.3.1. Requirement for the mixture: Apart from conformity with the grading and quality requirements for individual ingredients, the mixture shall meet the requirements set out in Table 500-11.

TABLE 500-11. REQUIREMENTS FOR DENSE GRADED BITUMINOUS MACADAM

Minimum stability (kN at 60°C) 9.0Minimum flow (mm) 2Maximum flow (mm) 4Compaction level (Number of blows)

75 blows on each of the two faces of the specimen

Per cent air voids 3-6Per cent voids in mineral aggregate (VMA)

See Table 500-12 below.

Per cent voids filled with bitumen (VFB)

65 – 75

The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in Table 500-12

TABLE 500-12. MINIMUM PER CENT VOIDS IN MINERAL AGGREGATE (VMA)

Nominal Maximum Particle size 1 (mm)

Minimum VMA, Percent Related to Design Air Voids, Percent 2

3.0 4.0 5.09.5 14.0 15.0 16.0

12.5 13.0 14.0 15.019.0 12.0 13.0 14.025.0 11.0 12.0 13.037.5 10.0 11.0 12.0

Notes: 1. The nominal maximum particle size is one size larger than the first sieve to retain more than 10 per cent. 2. Interpolate minimum voids in the mineral aggregate (YMA) for design air voids values between those listed.

507.3.2. Binder content: The binder content shall be optimised to achieve the requirements of the mixture set out in Table 500-11 and the traffic volume specified in the Contract. The Marshall method for determining the optimum binder content shall be adopted as described in The Asphalt Institute Manual MS-2, replacing the aggregates retained on the 26.5 mm sieve by the aggregates passing the 26.5 mm sieve and retained on the 22.4 mm sieve, where approved by the Engineer.

Where 40 mm dense bituminous macadam mixture is specified, the modified Marshall

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method described in MS-2 shall be used. This method requires modified equipment and procedures; particularly the minimum stability values in Table 500-11 shall be multiplied by 2.25, and the minimum flow shall be 3mm.

507.3.3. Job mix formula: The Contractor shall inform the Engineer in writing, at least 20 days before the start of the work, of the job mix formula proposed for use in the works, and shall give the following details:

i) Source and location of all materials;

ii) Proportions of all materials expressed as follows where each is applicable:

a) Binder type, and percentage by weight of total mixture.

b) Coarse aggregate/Fine aggregate / Mineral filler as percentage by weight of total aggregate including mineral filler.

iii) A single definite percentage passing each sieve for the mixed aggregate;

iv) The individual gratings of the individual aggregate fractions, and the proportion of each in the combined grading.

v) The results of tests enumerated in Table 500-11 as obtained by the Contractor.

vi) Where the mixer is a batch mixer, the individual weights of each type of aggregate, and binder per batch,

vii) Test results of physical characteristics of aggregates to be used;

viii) Mixing temperature and compacting temperature.

While establishing the job mix formula, the Contractor shall ensure that it is based on a correct and truly representative sample of the materials that will actually be used in the work and that the mixture and its different ingredients satisfy the physical and strength requirements of these Specifications.

Approval of the job mix formula shall be based on independent testing by the Engineer for which samples of all ingredients of the mix shall be furnished by the Contractor as required by the Engineer.

The approved job mix formula shall remain effective unless and until a revised Job Mix Formula is approved. Should a change in the source of materials be proposed, a new job mix formula shall be forwarded to the Engineer for approval before the placing of the material.

507.3.4. Plant trials - permissible variation in job mix formula: Once the laboratory job mix formula is approved, the Contractor shall carry out plant trials at the mixer to establish that the plant can be set up to produce a uniform mix conforming to. the approved job mix formula. The permissible variations of the individual percentages of the various ingredients in the actual mix from the job mix formula to be used shall be within the limits as specified in Table 500- 13. These variations are intended to apply to individual specimens taken for quality control tests in accordance with Section 900.

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TABLE 500-13. PERMISSIBLE VARIATIONS FROM THE JOB MIX FORMULA

DescriptionPermissible variation

Base/Binder course

Wearing course

Aggregate passing 19mm sieve or larger + 8% + 7%

Aggregate passing 13.2mm, 9.5mm + 7% + 6%

Aggregate passing 4.75mm + 6% + 5%

Aggregate passing 2.36mm, 1.18mm, 0.6mm + 5% + 4%

Aggregate passing 0.3mm, 0.15mm + 4% + 3%Aggregate passing 0.075mm + 2% + 1.5%Binder content + 0.3% + 0.3%Mixing temperature + 10oC + 10oC

Once the plant trials have demonstrated the capability of the plant, and the trials are approved, the laying operation may commence. Over the period of the first month of production for laying on the works, the Engineer shall require additional testing of the product to establish the reliability and consistency of the plant.

507.3.5. Laying Trials: Once the plant trials have been successfully completed and approved, the Contractor shall carry out laying trials, to demonstrate that the proposed mix can be successfully laid, and compacted all in accordance with Clause 501. The laying trial shall be carried out on a suitable area which is not to form part of the works, unless specifically approved in writing, by the Engineer. The area of the laying trials shall be a minimum of 100 sq.m. of construction similar to that of the project road, and it shall be in all respects, particularly compaction, the same as the project construction, on which the bituminous material is to be laid.

The Contractor shall previously inform the Engineer of the proposed method for laying and compacting the material. The plant trials shall then establish if the proposed laying plant, compaction plant, and

methodology is capable of producing satisfactory results. The density of the finished paving layer shall be determined by taking cores, no sooner than 24 hours after laying, or by other approved method.

Once the laying trials have been approved, the same plant and methodology shall be applied to the laying of the material on the project, and no variation of either shall be acceptable, unless approved in writing by the Engineer, who may at his discretion require further laying trials.

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507.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.

507.4.2. Preparation of base: The base on which Dense Graded Bituminous Material is to be laid shall be prepared in accordance with Clauses 50 I and 902 as appropriate, or as directed by the Engineer. The surface shall be thoroughly swept clean by a mechanical broom, and the dust removed by compressed air. In locations where-mechanical broom cannot access, other approved methods shall be used as directed by the Engineer.

507.4.3. Geosynthetics: Where Geosynthetics are specified in the Contract this shall be in accordance with the requirements stated in Clause 703.

507.4.4. Stress absorbing layer: Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance with the requirements of Clause 522.

507.4.5. Prime coat: Where the material on which the dense bituminous macadam is to be laid is other than a bitumen bound layer, a prime coat shall be applied, as specified, in accordance with the provisions of Clause 502, or as directed by the Engineer.

507.4.6. Tack coat: Where the material on which the dense bituminous macadam is to be placed is a bitumen bound surface, a tack coat shall be applied as specified, in accordance with the provisions of Clause 503, or as directed by the Engineer.

507.4.7. Mixing and transportation of the mixture: The provisions as specified in Clauses 501.3 and 501.4 shall apply.

507.4.8. Spreading: The provisions of Clauses 501.5.3 and 501.5.4. shall apply.

507.4.9. Rolling: The general provisions of Clauses 501.6 and 501.7 shall apply, as modified by the approved laying trials. The compaction process shall be carried out by the same plant, and using the same method, as approved in the laying trials, which may be varied only with the express approval of the Engineer in writing.

507.5. Opening to Traffic

The newly laid surface shall not be open to traffic for at least 24 hrs after laying and completion of compaction, without the express approval of the Engineer in writing.

507.6. Surface Finish and Quality Control of Work

The surface finish of the completed construction shall conform to the requirements, of Clause 902. All materials and workmanship shall comply with the provisions set out in Section 900 of this Specification.

507.7. Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance

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with the provisions of Clause 112

507.8. Measurement for Payment

Dense Graded Bituminous Materials shall be measured as finished work either in cubic metres, tons or by the square metre at a specified thickness as detailed on the Contract drawings, or documents, or as directed by the Engineer.

507.9. Rate

The contract unit rate for Dense Graded Bituminous Macadam shall be payment in full for carrying out the all required operations as specified, and shall include, but not necessarily limited to all components listed in Clause 501.8.8.2 (i) to (xi). The rate shall include the provision of bitumen, at 4.25 percent by weight of the total mixture.

The variance in actual percentage of bitumen used will be assessed and the payment adjusted, up or down, accordingly.

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508. SEMI-DENSE BITUMINOUS CONCRETE

508.1. Scope

This clause specifies the construction of Semi Dense Bituminous Concrete, for use in wearing/binder and profile corrective courses. This work shall consist of construction in a single or multiple layers of semi dense bituminous concrete on a previously prepared bituminous bound surface. A single layer shall be 25mm to 100mm in thickness.

508.2. Materials

508.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration grade complying with Indian Standard Specification for Paving Bitumen, IS: 73 and of the penetration indicated in Table 500-15, for semi dense bituminous concrete, or this bitumen as modified by one of the methods specified in Clause 521, or as otherwise specified in the Contract. Guidance on the selection of an appropriate grade of bitumen is given in The Manual for Construction and Supervision of Bituminous Works.

508.2.2. Coarse aggregates: The coarse aggregates shall be generally as specified in Clause 507.2.2, except that the aggregates shall satisfy the physical requirements of Table 500-14.

508.2.3. Fine aggregates: The fine aggregates shall be all as specified in Clause 507.2.3.

508.2.4. Filler: Filler shall be generally as specified in Clause 507.2.4. Where the aggregates fail to meet the requirements of the water sensitivity test in Table 500-14 then 2 per cent by total weight of aggregate, of hydrated lime shall be added without additional cost.

508.2.5. Aggregate grading and binder content: When tested in accordance with 1S:2386 Part 1 (Wet sieving method), the combined grading of the coarse and fine aggregates and added filler shall fall within the limits shown in Table 500-15 for gradings 1 or 2 as specified in the Contract.

508.3. Mixture Design

508.3.1. Requirements for the mixture: Apart from conformity with the grading and quality requirements for individual ingredients the mixture shall meet the requirements set out in Table 500-16.

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TABLE 500-14. PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR SEMI DENSE BITUMINOUS CONCRETE PAVEMENT LAYERS

Property Test SpecificationCleanliness (dust) Grain size analysis1 Max 5% passing

0.075mm sieveParticle shape Flakiness and Elongation

Index (Combined)2Max 30%

Strength* Los Angeles Abrasion Value3 Aggregate Impact Value 4

Max 35%Max 27%

Polishing Polished Stone Value5 Min 55

Durability Soundness:6

Sodium SulphateMagnesium Sulphate

Max 12%Max 18%

Water Absorption Water absorption 7 Max 2%

Stripping Coating and Stripping of Bitumen Aggregate Mixtures9

Minimum retained coating 95%

Water Sensitivity** Retained Tensile Strength 8 Min 80%

Notes: 1. IS: 2386 Part 1 6. IS:2386 Part 52. IS: 2386 Part 1 7. IS:2386 Part 3 (the elongation test to be done only on non-flaky aggregates in the sample)3. IS: 2386 Part 4* 8. AASHTO T283**4. IS: 2386 Part 4* 9. IS: 62415. BS: 812 Part 114

* Aggregate may satisfy requirements of either of these two tests.** The water sensitivity test is only required if the minimum retained coating in the

stripping test is less than 95 %

The requirements for minimum per cent voids in mineral aggregate (VMA) are set out in Table 500-12

508.3.2. Binder content: The binder content shall be optimised to achieve the requirements of the mixture set out in Table 500-16 and the traffic volume as specified in the Contract. The Marshall method for determining the optimum binder content shall be adopted as described in the Asphalt Institute Manual MS-2, replacing the aggregates retained on the 26.5mm sieve and retained on the 22.4mm sieve, where approved by the Engineer.

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TABLE 500-15. COMPOSITION OF SEMI DENSE BITUMINOUS CONCRETEPAVEMENT LAYERS

Grading 1 2

Nominal aggregate size 13mm 10mm

Layer Thickness 35 – 40mm 25 – 30mm

IS Sieve1 (mm) Cumulative % by weight of total aggregate passing

4537.526.519 10013.2 90-100 1009.5 70-90 90-1004.75 35-51 35-512.36 24-39 24-391.18 15-30 15-300.6 - -0.3 9-19 9-190.15 - -0.075 3-8 3-8

Bitumen content % by mass of total mix2 Min 4.0 Min 4.5

Bitumen grade (pen) 65* 65*

Notes: 1 The combined aggregate grading shall not vary from the low limit on one sieve to the high limit on the adjacent sieve.2. Determined by the Marshall method.* Only in exceptional circumstances, 80/100 penetration grade may be used, as approved by the Engineer.

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TABLE 500-16. REQUIREMENTS FOR DENSE GRADED BITUMINOUS MACADAM

Minimum stability (kN at 60°C) 8.2Minimum flow (mm) 2Maximum flow (mm) 4Compaction level (Number of blows)

75 blows on each of the two faces of the specimen

Per cent air voids 3-5Per cent voids in mineral aggregate (VMA)

See Table 500-12

Per cent voids filled with bitumen (VFB)

65 – 78

508.3.3. Job mix formula: The procedure for formulating the job mix formula shall be generally as specified in Clause 507.3.3 and the results of tests enumerated in Table 500-16 as obtained by the Contractors.

508.3.4. Plant trials - permissible variation in job mix formula:The requirements for plant trials shall be all as specified in Clause 507.3.4, and permissible limits for variation as shown in Table 500-13.

508.3.5. Laying trials: The requirements for laying trials shall be all as specified in Clause 507.3.5.


508.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.

508.4.2. Preparation of base: The surface on which the Semi Dense Bituminous material is to be laid shall be prepared in accordance with Clauses 501 and 902 as appropriate, or as directed by the Engineer. The surface shall be thoroughly swept clean by mechanical broom and dust removed by compressed air. In locations where a mechanical broom cannot access, other approved methods shall be used as directed by the Engineer.

508.4.3. Geosynthetics: Where Geosynthetics are specified in the Contract this shall be in accordance with the requirements stated in Clause 703

508 4.4. Stress absorbing layer: Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance with the requirements of Clause 522

508.4.5. Tack coat: Where specified in the Contract, or otherwise required by the Engineer, a tack coat shall be applied in accordance with the requirements of Clause 503.

508.4.6. Mixing and transportation of the mixture: The provisions as specified in Clauses 501.3.and 501.4 shall apply.

508.4.7. Spreading: The general provisions Of Clauses 501.5.3 and 501.5.4 shall apply.

508.4.8. Rolling: The general provisions of Clauses 501.6 and 501.7 shall apply, as

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modified by the approved laying trials. The compaction process shall be carried out by the same plant, and using the same method, as approved in the laying trials, which may be varied only with the express approval of the Engineer in writing.

508.5. Opening to Traffic

The newly laid surface shall not be open to traffic for at least 24 hours after laying and the completion of compaction, without the express approval of the Engineer in writing.

508.6. Surface Finish and Quality Control

The surface finish of the completed construction shall conform to the requirements of Clause 902. All materials and workmanship shall comply with the provisions set out in Section 900 of this Specification.

508.7. Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with the provisions of Clause 112

508.8. Measurement for Payment

The measurement shall be all as specified in Clause 507.8.

508.9. RateThe contract unit rate shall be all as specified in Clause 5.07.9, except that the rate shall include the provision of bitumen at 4.75 per cent, by weight of total mixture. The variance in actual percentage of bitumen used will be assessed and the payment adjusted up or down, accordingly.

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SECTION – VA : SCHEDULE OF CONSTRUCTION

First Month: 10 % of the total value of work

Second Month: 20 % of the total value of work

Third Month: 30 % of the total value of work

Fourth Month: 40 % of the total value of work

Fifth Month: 50 % of the total value of work

Sixth Month: 60 % of the total value of work

Seventh Month: 70 % of the total value of work

Eighth Month: 80 % of the total value of work

Ninth Month: 85 % of the total value of work

Tenth Month: 90 % of the total value of work

Eleventh Month: 95 % of the total value of work

Twelveth Month: 100 % of the total value of work

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SECTION – VI : SCHEDULE OF DRAWING

The following drawings will form part of the Tender document.

Sl.No. Drawing No. Title

1. Sketch Layout of proposed road

2. Sketch Cross section of Road

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SECTION – VII : SCHEDULE OF SUPPLY OF MATERIALS

(To be supplied by the Government)

Sl.No.

Particulars of Materials Unit

Approx. Quantit

y

Rate at which

materials will be

supplied to Contractor

Place of issue

1. Reinforcement Steel M.T. 24 M.T. Free issue

Department Stores, IGCAR,

Kalpakkam.

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1. Quantities shown in the schedule are approximate quantities to the issued to contractors at Departmental stores. It will be the responsibility of the contractor to draw from Departmental stores correct requirement of quantities required for the job.

2. The cost on account of taking delivery, loading, transporting from stores to work spot, unloading returning excess materials drawn and other incidental expenses will be entirely to contractor’s account.

3. The contractor will have to submit an account of all materials issued by the Department and used on the job along with the final bill for the purpose of interim checks, contractors will submit account of materials as and when required by the Engineer.

4. (a) Reinforcing steel to be issued shall include steel bars required for concrete reinforcement, 115mm thick brick work, standard books cranks, bends, authorized laps, dowels and all authorized chairs / separators clips, pins. Binding wire will be arranged by the contractor and will be entirely at his own cost. It shall be noted that the reinforced steel 10mm dia. and below if any issued in coils shall be straightened by the contractor at no extra cost to the Government.

4. (b) Reinforcing steel bars in available lengths will be issued to the contractor and received back from him by actual weighing of the same by suitable weighing device provided by the Engineer. For the purpose of arriving at an average weight per unit length of any individual size of the bar, a few bars of the same size selected at random from each consignment shall be weighed, their lengths accurately measured and average weight per unit length found out. Unit weights thus found out for each size and each consignment shall be approved by the Engineer. Bars measured as used in works shall be converted into weight by adopting unit weights referred to above. This weight shall be considered only for the final account of the steel issued by department to the contractor so as to establish the wastage and unaccountable quantity of steel etc. payment made to the contractor for the work involved under relevant items pertaining to placing of reinforcing steel except 6mm and 8mm dia (nominal size) M.S rods included in the schedule of quantities will be as follows and not be affected by the above procedure.

For the purpose of payment, weight will be calculated on the basis of bar bonding schedule and weights of bar given under wherever actual lengths placed differed from bar bending schedule actual length will only be measured.

Bar Dia (mm) Weight Kg/ Metre5 0.1546 0.2228 0.395

10 0.61712 0.88816 1.5818 2.0020 2.4722 2.9825 3.8528 4.8332 6.3136 7.99

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However the payment for 6mm and 8mm dia (Nominal size) M.S. rods will be based on the weight as arrived at by the procedure under 4(b) above.

4.(c) Account of reinforcement steel issued for 115mm brickwork / concrete reinforcement will have to be rendered by the contractor along with the final bill adopting the unit weights referred to in (b) above for quantity of steel measured in lengths. Theoretical quantity of steel for the purpose shall be taken as the quantity required as per design/ bar bending schedule or as specially authorized by the Engineer with above unit weights including authorized lappages plus 3% wastage due to cutting into pieces. Over this theoretical quantity arrived at plus 5% and minus 4% shall be allowed as variation due to wastage being more or loss as would be approved by the Engineer. Any wastage over and above this percentage or steel outright unaccounted for, shall be charged to contractor at double the recovery rate indicated in schedule of supply of material or schedule ‘F’ per metric tonne. Steel returned in full length bars or in lengths of two meters and above in conditions equally serviceable as at the time of issue, shall be taken as reduction in the quantity of issue, to arrive at net quantity issued to the contractor for the purpose of accounting.

4.(d) Account of structural steel issued free of cost will have to be rendered by the contractor along with the final bill, adopting the unit weights as per the I.S. Structural Engineers hand book for quantity of steel measured in lengths. Theoretical quantity of steel for this purposes shall be taken as the quantity required as per design or as specially authorized by the Engineer with above unit weight plus 3% wastage due to cutting into pieces (non – returnable), welding, grinding etc., over this theoretical quantity arrived at plus 5% and minus 4% shall be allowed as variation due to wastage due to cutting into short lengths (These cut, pieces are however to be returned to the department) as would be approved by the Engineer. Any wastage over and above this percentage or steel outright unaccounted for, shall be charged for the contractor at double the recovery rate indicated in schedule of supply of materials or schedule ‘F’ per metric tonne. Steel returned in full length or in lengths or two meters and above in condition equally serviceable as at the time or issue shall be taken as reduction in the quantity of issue to arrive at net quantity issued to the contractor for the purpose of accounting.

5. For all other materials other than those indicated in foot, notes 1 to 5 above reasonable wastage as decided by the Engineer will be allowed. Any excess wastage as well as the materials outright unaccountable will be charged for, at departmental issue rates or market rates whichever is higher plus 15%.

6. Periodical check may be exercised by the Engineer on materials issued to the contractor and for cement for which all assistances will be given by the contractor. To enable this contractor will maintain Registers. records, etc., which will show quantities received by the contractor, quantities used quantities remaining balance. The materials in the contractor’s stores should be arranged in such a way so as to enable physical check. a Register with columns as desired by the Engineer will be maintained by the contractor and will be produced daily for check.

7. All materials to be returned to the government, by the contractor will be returned at his own cost. No payment on account of loading carting and unloading as directed etc., will be made to the contractor.

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ANNEXURE - A

STATEMENT OF MEN AND MACHINERY



Sl. No. DescriptionManpower to be

deployed by tenderer

1. Have the tenderer visited the site

2. Manpower deployment:

a. Masonsb. Carpenterc. Fitter / Bar bendingd. Welderse. Laboursf. Semiskilled for Carpenter /

Fitterg. Electricianh. Mechanical Operation

3. Technical Staff Deployment

a. Graduate Engineersb. Diploma Engineersc. Supervisorsd. Quality Control Engineer

Date ……………………. Signature of Tendererwith seal

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SL No. Description

Machineries to be deployed by

tenderer4. Machinery Deplovment:

a. Concrete Manufacturing Plant.b. Concrete Mixers.c. Vibrators.d. Dewatering pumps.e. Hoist I Tower Crane.f. JCB I Poclain.g. Compression Testing Machine.h. Concrete Workability Test

Equipment.i. Formwork Materials.j Trucks I Dumpers.k. Scaffolding Materials.I. Transit Mixers.m. Compressors.n. Mechanical Rammer.o. Welding Machines.p. Gas Cutting Sets.q. Survey Instruments.r. Curing pumps.s. Material Testing Lab.

Equipments.

NOTE : It is noted that the above deployment is minimum. After detailed programming and actual condition at site, additional deployment shall be done as necessary for completion of the work within the stipulated time period.


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ANNEXURE - BLIST OF PROPOSED MANUFACURER OF BUILDING MATERIALS



Sl.No.

Description of Materials

Manufacturers Recommended by the

Department

Proposed to be incorporated

by the tenderer.

1. Ordinary Portland Cement of Grade 43

M/s. ACC M/s. Ultratech CementsM/s. Zuari CementsM/s. Priya CementsM/s. Coromandel KingM/s. Penna Super

2. TMT (Thermo Mechanically Treated) Bars

M/s. TATA Iron & Steel Co. M/s. SAILM/s. RINLM/s. IISCO

3. Structural Steel Section

M/s. SAILM/s. TISCO

4. Structural Steel Plates

M/s. SAILM/s. TISCO M/s. ESSAR

5. Anti-Termite Chemical

M/s. Pest Control India M/s. Peecopp Chloro-pyrifos chemical

6. Tilesa] Ceramic Tiles M/s. Asian Tiles

M/s. H.R. Johnson (I) Ltd. M/s. Spartex Ceramics (I) Ltd.M/s. Somani-PilkingtonM/s. Orient tiles M/s. Kajaria Ceramics Ltd.M/s. Regency.

b] Vitrified Tiles M/s. H.R. Johnson (I) Ltd.M/s. Asian TilesM/s. Bell Ceramics Ltd.M/s. Regency.


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Sl.No.


Manufacturers Recommended by the Department

Proposed to be

incorporated by the

tenderer.c] Glazed Tiles M/s. H.R. Johnson (I)

Ltd. M/s. Somani-Pilkington

c] FRP Doors M/s. Forex Doors.7. PVC Flooring M/s. LG Industries

M/s. Armstrong M/s. Krishna Vinyl Ltd.

8. Wooden Doorsa] Flush Door Shutters M/s. Diamond Industries

M/s. Kutty flush doors M/s. Oswin Industries

b] Factory made Panelled Door Shutters

M/s. Diamond Industries M/s. Kutty flush doors M/s. Oswin Industries

c] FRP Doors M/s. Forex Doors.9. Plywoods M/s. Assam Plywood

M/s. Indian Plywood M/s. Anchor Plywood.

10. Steel Doors / Windows

M/s. Godrej M/s. NCL seclor

11. Aluminium Grills / Aluminium sections.

M/s. Windoors M/s. Decogrille M/s. Zindal M/s. Hindal co.

12. Fittings & Fixtures. M/s. Everite M/s. Diamond M/s. Ebco M/s. Jhal M/s. Classic M/s. Dyna M/s. Godrej M/s. Hardwyn M/s. LinkM/s. GargM/s. Bharat

13 (a).

Waterproofing Treatment

M/s. Structural waterproofing company (p) Ltd. M/s. Dugar water proofing co. M/s. Fosroc Chemicals.

Date ……………………. Signature of

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Tendererwith seal

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Sl.No.


Manufacturers Recommended by the

Department

Proposed to be

incorporated by the

tenderer.(b). Integral

Waterproofing Compound

M/s. Accoproof M/s. CICO M/s. Impermo M/s. Fosroc Chemicals M/s. Pidilite IndustriesM/s. Roff Chemicals.

14. Cement Based Paint M/s. Snowcem India Ltd.M/s. AerocemM/s. Asian paintsM/s. Good Neraloc Paints Ltd. M/s. ICI PaintsM/s. Berger Paints India Ltd.M/s. Shalimar paints M/s. Dulux Paints.

15. Glass for Doors / Windows

M/s. Modi GuardM/s. Saint GobainM/s. Asahi Glass.

16 (a).

Synthetic Enamel Paint

M/s. Asian paintsM/s. Good Neraloc Paints Ltd. M/s. ICI PaintsM/s. Berger Paints India Ltd.M/s. Shalimar paints M/s. Dulux Paints.

(b). Epoxy Paints M/s. Asian paints M/s. ShalimarM/s. Carboline M/s. Ameron paints.

17. Expansion Joint fiber Boards

M/s. S.T.P. Ltd. M/s. Lloyd InsulationM/s. Sanfilled.

18. Sanitary wares M/s. HindwareM/s. Parryware

19. C.P. Brass Fittings & Fixtures

M/s. JaguarM/s. EsscoM/s. MetroM/s. Parryware.

20. PVC Flushing Cistern M/s. Parryware (Slimline)M/s. Hindware

21. Plain Glass Mirror M/s. Modi Float GlassM/s. Saint GobainM/s. Asahi

22. EWC Seat Cover M/s. Commander

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M/s. Parryware M/s. Hindware


Sl.No.



Proposed to be

incorporated by the

tenderer.23. S.S. Sink M/s. Diamond

M/s. Nirali24. G.I. Pipes M/s. TATA

M/s. Zindal25. G.I. Fittings M/s. Star

M/s. ZindalM/s. TataM/s. R-brand ISI mark

26. GM Gate Valves M/s. HimsonM/s. LeaderM/s. SKE

27. Ball Valve M/s. PeacoM/s. HawaM/s. Leader

28. Sluice Valve M/s. KirloskarM/s. KartharM/s. LeaderM/s. SKE

29. C.I. Pipes / D.I. pipes M/s. Electrosteel M/s. ZindalM/s. Lanco.M/s. Swastik

30. C.I. Frames & Covers M/s. Ashok,M/s. DiamondM/s. Swastik

31. SW Pipes & Gully Trap

M/s. AshokM/s. DalmiaM/s. Neycer

32. RCC Hume Pipes M/s. Karthik pipes33. PIG LEAD M/s. Hindustan Zinc Ltd.34. PVC Pipes M/s. Finolex

M/s. TruboreM/s. Varun

35. Paving Tiles, Cement Tiles

M/s. UltraM/s. Eurocon M/s. Hindustan

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Sl.No.



Proposed to be

incorporated by the

tenderer.36. Bricks M/s. EBW

M/s. SNB37. False ceilinga] Ceiling tiles

(particle board)M/s. Anchor

b] Bison Board M/s. NCLc] Calcium silicate

BoardM/s. Ramco (Hilex)

d] Mineral Fibre Board M/s. Armstrong,M/s. Diakon

e] Aluminium Premould M/s. Luxalon or equivalent

38. Ready Mix Concrete M/s. L&TM/s. ACCM/s. RamcoM/s. Coramendal


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ANNEXURE - CSTATEMENT OF CASH FLOW FOR THE WORK



Sl.No. Months Cash Flow %

1.1 s t

%

2. 2nd %3. 3 rd %4. 4 t h %5. 5 t h %6. 6 t h %7. 7 t h %8. 8 t h %9. 9 t h %10. 10 t h %11. 11 t h %12. 12 t h %13. 13 t h %14. 14 t h %15. 15 t h %


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ANNEXURE - D

FORM OF BANK GUARANTEE BOND FOR PERFORMANCE SECURITY / SECURITY DEPOSIT

In consideration of the President of India (hereinafter called "The Government") having agreed under the terms and conditions of Agreement No ……..………………………...…………………………….. dated………..………… made between ……………………………..……….... and ………………………………………………… (hereinafter called" the said Contractor{s}" ) for the …………………………………………………………. work

………………………………………………………………………………………….………………….. ................ .. ... ... ... (hereinafter called " the said Agreement") having agreed to production of a irrevocable bank Guarantee for ………………………….. Rs. ……………… (Rupees ………………………………………………………..…………….. only), as a security / guarantee from the contractor(s) for compliance of his obligations in accordance with the terms and conditions in the said agreement, we ……………………………….………….. (Indicate the name of the Bank) (hereinafter referred to as "the Bank") hereby undertake to pay to the Government an amount not exceeding Rs. ..........….. (Rs………………….………………………………….... …………………………………………..only) on demand by the Government.

2. We …………………………………………………………………………. (indicate the name of Bank) dohereby undertake to pay the amounts due and payable under this guarantee without any demur, merely on a demand from the Government stating that the amount claimed is required to meet the recoveries due or likely to be due from the said Contractor(s). Any such demand made on the bank shall be conclusive as regards the amount due and payable by the Bank under this guarantee. However, our liability under this guarantee shall be' restricted to an amount not exceeding Rs…………… (Rupees ……………..……………………………………….. only).

3. We, the said bank, further undertake to pay to the Government any money so demanded notwithstanding any dispute or disputes raised by the Contractor(s) in any suit or proceeding pending before any Court or Tribunal relating thereto, our l iabil ity under this present being absolute and unequivocal.

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The payment so made by us under this bond shall be a valid discharge of our l iabil ity for payment thereunder and the Contractor(s) shall have no claim against us. for making such payment.

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4. We ……………………………………………... (indicate the name of Bank) further agree that the guarantee herein contained shall remain in full force and effect during the period that would be taken for the performance of the said Agreement and that it shall continue to be enforceable til l all the dues of the Government under or by virtue of the said Agreement have been fully paid and its claims satisfied or discharged or til l Engineer-in-charge on behalf of the Government certifies that the terms and conditions of the said Agreement. have been fully and properly carried out by the said Contractor(s) and accordingly discharges this guarantee.

5. We ………………………………………………… (indicate the name of Bal1k) further agree with the Government that the Government shall have the fullest .liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the terms and conditions of the said Agreement or to extend time of performance by the said Contractor(s) from time to time or to postpone for any time or from time to time any of the powers exercisable by the Government against the said Contractor(s) and to forbear or enforce any of the terms and conditions relating to the said Agreement and we shall not be relieved from our liability by reason of any such variation, or extension being granted to the said Contractor(s) or for any forbearance, act of omission on the part of the Government or any indulgence by the Government to the said Contractor(s) or by any such matter or thing whatsoever which under the law relating to sureties would, but for this provision, have effect of so relieving us.

6. This guarantee will not be discharged due to the change in the constitution of the Bank or the Contractor(s).

7. We ……………………………………………………………………………… (indicate the name of Bank) lastly undertake not to revoke this guarantee except with the previous consent of the Government in writing.

8.. This guarantee shall be valid up to ……………………., unless extended on demand by Government. Notwithstanding anything mentioned above, our l iabil ity against this guarantee is restricted to Rs…………….. (Rupees …….……. .…………………………..………..…. ... . only) and unless a claim in writing is lodged with us within six months of the date of expiry or the extended date of expiry of this guarantee, all our l iabil ities under this guarantee shall stand discharged

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Signed and sealed

Dated the ------------------- day of ------------------- for------------------------------------------ (indicate the name of Bank)

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ANNEXURE - E

PROFORMA FOR GUARANTEE TO BE EXECUTED BY THE CONTRACTORS FOR REMOVAL OF DEFECTS AFTER COMPLETION IN RESPECT OF WATERPROOFING WORKS.

Name of work :

Work Order No. :

Agreement No. :

This agreement made this _________________ day of ________________ two thousand and ____________ between ____________________ (hereinafter called the Guarantor of the other part) and the PRESIDENT OF INDIA ___________________ (hereinafter called the Government of the one part)

WHEREAS this agreement is supplementary to a contract (hereinafter called the Contractor dated and .made between the GUARANTOR OF THE ONE PART AND GOVERNMENT of the other part, whereby the Contractor, inter alia, undertook to render the buildings and structures in the said contract recited completely water and leak proof.

AND WHERE THE GUARANTOR agreed to give a guarantee to the effect that the saids structures. will remain water and leak proof for ____________ years from the date of _________ .

NOW THE GUARANTOR hereby guarantees that waterproofing treatment given by him will render the structures completely leak proof and the minimum life of such waterproofing treatment shall be 10 years to be reckoned from the date after the maintenance period prescribed in the contract

Provided that the guarantor will not be responsible for leakage caused by earthquake or structural defects or misuse / alteration of structures and for such purpose:

(a)Misuse shall mean operation which will damage treatment, like

(b) Alteration shall mean construction of an additional structure or apart or construction adjoining to existing structure whereby treatment is removed in parts

(c) the decision of the Chief Engineer with regard to cause of

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leakage shall be final

During this period of guarantee the guarantor shall make good all defects and incase of any defect being found render the building waterproof to the satisfaction of the Engineer-in-Charge at his cost arid shall commence the work for such rectification within seven days from the date of issue of the notice from the Engineer-in-Charge call ing upon him to rectify the defects failing which the work shall be got done by the Department by some other contractor at the guarantor's cost & risk. The decision of the Engineer-in-Charge as to the cost payable by the Guarantor shall be final and binding.

That if the Guarantor fails to execute the waterproofing or commits breach there-under then the Guarantor will. indemnify the Principal and his successors against all loss, damage, cost expense or otherwise which may be incurred by him by reason of any default on the part of the Guarantor in performance and observance of this supplemented agreement. As to the amount of loss and/or damage and cost incurred by the Government the decision of Engineer-in-Charge will be firia1 & binding on the parties.

IN WITNESS WHEREOF these presents have been executed by the Obligator (Guarantor) __________________________________________ and _________________________ by _____________________ for and on behalf of the President of India on the day, month and year first above written.

SIGNED SEALED AND DELIVERED BY (Obligator / Guarantor) in the presence of:

1.

2.

Signed for and on behalf of the President of India in the presence of

1.

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ANNEXURE - FINDENTURE FOR SECURED ADVANCE

(For use in cases in which the contract is for finished work and the contractor has entered in an agreement for the execution of a certain specified quantity of work in given time)


State : TamilnaduAdministration : Department of Atomic EnergyGROUP : Civil Engineering GROUP, IGCAR

THIS INDENTURE made the ……………………… day of ……………. 19……. BETWEEN expression shall where the context so admits or implies be deemed to include his executors, administrators and assigns) of the one part and the President (hereinafter called the President which expression shall where the context so admits or implies be deemed to include his successors in office and assigns) of the other part.

WHEREAS by an agreement dated ……………………………………………………… (hereinafter called the said agreement) the contractor has agreed.

AND WHEREAS the President has agreed to advance to the contractor the sum of Rs……………….. on the security of materials, the quantities and other particulars of which are detailed in Part-II of a Running Account Bill (B) for the said works signed by the contractor on ………………………………….. and President has reserved t himself the option of making any further advances on the security of other materials brought by the contactor to the site of the said works.

NOW THIS INDENTURE WITHNESSETH that in pursuance of the said agreement and in consideration of the sum of Rs…………………. on or before the execution of these presents paid to the contractor by the President (the receipt where of the contractor both hereby acknowledge and of such further advance, if any, as may be made to him as aforesaid the contractor both hereby convenient and agree with the President and declare as fol lows:

1) That the said sum of Rupees ……………………………. so advanced by the President to the contractor as aforesaid and all or any further sum or sums advanced as aforesaid shall be employed by the contractor in or towards expenditure the execution of the said works and for no other purpose whatsoever.

2) That the materials detailed in the said Running Account Bil l (B) which claims to any materials in respect of which an advance has been made to him as aforesaid.

3) That the materials detailed in the said Running Account Bil l (B)

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and all other materials on 'the security of which any further advance or advances may hereafter to be made as aforesaid (hereinafter called the said materials) shall be used by the contractor solely in the execution of the said works in accordance with the directions of the Divisional Officer of the said works, Civi l Engineering Group (hereinafter cal led "the Divisional Officer) and in the terms of the said agreement.

4) That the contractor shall make at his own cost al l necessary and adequate arrangements for the proper watch, safe-custody and protections against all risks of the said materials and that until used in construction as aforesaid said materials shall remain at the site of the said works in the contractor's custody and on his own responsibi l ity and shall at all times be open to inspection by the Divisional Officer or any officer authorised by him. In the event of the materials or any part thereof being stolen, destroyed or damaged or becoming 'deteriorated in a greater degree that is due to reasonable use and wear thereof the contractor will forthwith replace the same with other materials of l ike quality or repair and make good the same as required by the Divisional Officer.

5) That the said materials shall not on any account be removed from the site of the works except, with the written permission of the Divisional Officer or an 'officer authorised by him on that behalf

6) That- the advance shall be repayable in full when or before contractor receives payment from the President of the price payable to him for the said works .under the terms and provisions of the said agreement. Provided that if, any intermediate payments are made to the contractor on account of work done thereon the occasion of each such payment the President will be at l iberty to make a recovery from the contractor's bi l l for such payment by deduction there from the value of the said materials than actually used in the construction and in respect of which recovery has not been made previously the value for this purpose being determined in respect of the 'each description of materials at the rates at which the amounts of the advances made under these presents were calculated

7) That if the contractor shall at any time make any default in the performance or observance in any respect of any of the terms and provisions of the 'said agreement or of these presents the total amount of the advance or advances what may sti l l be owing to the President shall immediately on the happening of such default be repayable by the contractor to the President together with interest thereon at twelve percent per annum from the date of respective dates of such advance or advances to the date of repayment and with all costs, charges, damages and expenses incurred by the President in or for the recovery thereof or the enforcement of this security or otherwise by reasons of the default of the contractor and contractor hereby convenants and agrees with the President to repay and pay the same respectively, to him accordingly.

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8) That the contractor hereby charges al l the said materials with the re-payment to the President of India ………………… the said sum of Rs………………………………………………………………… and any further sum of sums advanced as aforesaid and al l cost, charges, damages and expenses payable under these presents PROVIDED ALWAYS and it is hereby agreed to declared that notwithstanding anything in the said agreement and without prejudice to the powers contained therein if and whenever:

a) Seize and util ise the said materials or any part thereof in the completion of the said works on behalf of the contractor in accordance with the provisions in that behalf contained in the said agreement debiting the contractor with the actual cost of effecting such completion and the amount due in respect of advances under these present and crediting the contractor with the value of work done as if he had carried it out in accordance with the said agreement and at the rates thereby provided. If the balance is against the contractor he is to pay same to the President on demand

b) Remove and sell by public auction the' seized materials or any part thereof and out of the moneys arising from the sale retain all the sum, aforesaid repayable or payable to the President under these presents and pay over the surplus (if any) to the contractor.

c) Deduct all or any' part of the money owing out of the security deposit or any sum due to the contractor under the said agreement.

9) That except in the event of such default on the part of the contractor as aforesaid interest on the said advances shall not be payable.

10) That in the event of any conflict between the provisions of these presents and the said 'agreement the provisions of these presents shall prevail and the event of any dispute or difference arising over the construction or effect of these . presents the settlement of which has not been herein before expressly provided for the same shall be referred to the Chief Engineer, Engineering Services Group, time being in force shall apply to any' such reference.IN WITNESS thereof the said ………………………….. and

……………………. by the order under the direction of the President have hereinto set their respective hand the day and year first above written.

Signed, sealed and delivered by the said contractor in the present of

SignatureNameAddress

Witness

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Signed byby the order and direction of the President in the presence of

SignatureNameAddress

Witness********

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ANNEXURE - G

GUARANTEE BOND FOR ANTITERMITE TREATMENT

(For Guarantee to be executed by contractors for removal of defects after completion of Antitermite treatment works)

This agreement made this …………..….. day of ………….……… two thousand ………….……………..…….. between M/s ……………………….……………… (hereinafter called “the Guarantor of the one part) and the PRESIDENT OF INDIA (hereinafter called “the Government” of the other part).

Whereas this agreement is supplementary to a contract (hereinafter called “the contract”) dated ……………….. and made between the Guarantor of the one part and the Government of the other part whereby the contractor inter-allia undertook to render the buildings and structure completely termite proof.

AND WHEREAS THE GUARANTOR agreed to give a guarantee to the effect that the said structure will remain termite proof for ten years from the date of handing over of the building and or completion date of contract whichever is later.

NOW THE GUARANTOR hereby guarantees that the anti-termite treatment provided by him will render the structures completely termite proof and the minimum life of such anti-termite treatment shall be ten years to be reckoned from the date of handing over of the building and/or completion of the building whichever is later.

Provided that the Guarantor will not responsible for damages caused due to structural defects or misuse of premises/area.

a) Misuse of premises shall mean any operation which will disturb the chemical barrier like excavation under floors, breaking of walls at G.L. disturbing the treatment already carried out.

The decision of the Engineer-in-charge with regard to cause of damage shall be final.

During this period of guarantee the guarantor shall make all the arrangements to do the post constructional anti-termite treatment in all the buildings in case of any termite nuisance being found in the building, to the satisfaction of the Engineer-in-charge at the cost of guarantor and shall commence the work for such treatment within seven days from the date of call ing upon him to rectify the defects, by the Engineer-in-charge, fail ing which the work shall be got done by the Department by some other contractor at the GUARANTOR’s COST and risk. The decision of the Engineer-in-

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charge as to the cost payable by the Guarantor shall be final and binding.

That if the Guarantor fails to execute the anti-termite treatment or commits breach there under then the Guarantor will indemnify the principal and his successors against all loss, damage, cost, expense or otherwise which may be incurred by the Department by reason of any default on the part of the GUARANTOR in performance and observance of this supplementary agreement. As to the amount of loss and/or damage and/or cost incurred by the Government the decision of the Engineer-in-charge will be final and binding on the parties.

IN WITNESS WHEREOF these presents have been executed by the Obligator ……………… and by ………………………….. and for and on behalf of the PRESIDENT OF INDIA on the day, month and year first above written.

SIGNED, sealed and delivered by (OBLIGATOR) in the presence of :

1.

2.

SIGNED FOR AND ON BEHALF OF THE PRESIDENT OF INDIA BY …………………………………………..

in the presence of :

1.

2.

****************

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SECTION VIII – SCHEDULE OF QUANTITIES

GENERAL INFORMATION FOR GUIDANCE OF TENDERERS

1. The schedule of quantities is to be read for the purpose of pricing in conjunction with the special conditions, general rules for the guidance of contractors, conditions of contract, specifications, drawings, schedule of supply of materials and the appendices.

2. The prices inserted in the schedule of quantities shall be inclusive of value of the work described including all cost and expenses, which may be required in and for the construction of the work described together with the general risks, liabilities and obligations not forth or implied in the documents on which the tender is to be based.

3. The quantities stated are to be considered approximate only and the unit prices entered in the schedule of quantities and prices shall apply only to the actual quantities measured in the completed work in accordance with the specifications.

4. All the materials other than those shown in schedule of supply of materials in section VII are to be arranged by the contractor and his rates should account for the same.

5. Rates quoted for all items in this tender shall include cost of all materials including cement. Department will not supply any materials other than materials stipulated in Part VII of the tender and as such the rates quoted must be all inclusive.

6. The contractor shall be responsible for supply of cement and procure Ordinary Portland Cement 43 Grade conforming to IS: 8112 and use it on works. Since the supply of cement by the department has been dispensed all the clauses relevant to supply of cement by department in this tender document stands cancelled. The contractor shall purchase cement from the approved manufacturers only. Secured advances on cement up to 90% of purchase price shall be paid to the contractor after indemnifying the Government and through insurance cover. The quantity of cement on which secured advance shall be paid will be restricted to the consignment of cement tested and passed in the test in department laboratory. The secured advance on cement shall be regulated as per Clause 10-B of conditions of contract. Prior approval to be obtained from the Engineer for the quantities proposed to be purchased.

7. Compensation for escalation in the prices of materials and labour when due is permissible as per provisions in Clause 10CC of conditions of contract.

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8. If contractors need any clarification they are required to contact the Associate Director, CEG, Indira Gandhi Centre for Atomic Research, Central Design Office, Kalpakkam 603 102, Kancheepuram District, Tamilnadu. (Telephone STD Code: 044 – 27480092)

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