TECHNICAL SPECIFICATIONS

VOLUME-III

Issued By: Project Director (UP)

Telecommunications Consultants India Limited

5th Floor, TCIL Bhawan, Greater Kailash-1

New Delhi-110048 Email: atuljain@tcil-india.com

Visit us at http://www.tcil-india.com

Telecommunications Consultants India Ltd.

(A Govt. of India Enterprise) TCIL Bhawan, Greater Kailash-I

New Delhi – 110048 (India) Telephone no.:011-26202020, Fax:011-26241865

website: www.tcil-india.com Email:tcil@tcil-india.com

CIN No.:U74999DL1978GOI008911

TENDER DOCUMENT

FOR “CONSTRUCTION OF GHAT STEPS, PATHWAYS, SOLID WASTE ENCLOSURES, SOLAR ILLUMINATION AND LANDSCAPING AT

PRATAPGARH GHUSIER NATH, DISTRICT-PRATAPGARH, UTTAR PRADESH UNDER DEVELOPMENT OF SPIRITUAL CIRCUIT-I OF

SWADESH DARSHAN SCHEME”

Tender No: TCIL/CIVIL/PD(UP)/SC-1/2017/02

Issued on: November 08, 2017

Development of Spiritual Circuit - I in Uttar Pradesh under Swadesh Darshan Scheme of Ministry of Tourism

INDEX

S.NO.

DESCRIPTION

PAGE

1. INTRODUCTION 1-2

2. PERTICULAR SPECIFICATIONS 3-3

3. TECHNICAL SPECIFICATIONS 4-145

4. LIST OF APPROVED MAKES 146-150

PARTICULAR SPECIFICATIONS

CIVIL WORKS

1. General: The work shall be carried out strictly in accordance with particular specifications and drawings. The drawings, specifications BOQ etc. shall be taken complementary and also supplementary to each other and shall form part this contract. Any work or material shown on drawings and not specifically included in BOQ/specification or vice versa shall be executed and deemed to be included in the scope of work for lump sum rate. However, the steel for reinforcement work shall be TMT-BARS of Fe-500D.

2. In case there are no specifications for items shown on the drawings or where items are not exhaustively described, the general specifications of CPWD shall be followed for which nothing extra shall be paid. In case, no details are available even in CPWD specification, then decision of owner/TCIL is final & binding on the contractor.

3. Scope of works : The scope of work for building & development works under this

contract includes for full & final and entire completion of all works including all internal and external services in all respects described in particular specification Part-I and as shown on drawings forming part of the contract.

4. Although all the details of construction have been by an large covered in these

documents, any item or details of construction not specifically covered but obviously implied and essential to consider Civil works and all internal and external services complete and functional, shall be deemed to have been covered in the lump sum quoted. The cost of external development works pertaining to a particular contract shall also be carried out on a final lump sum price based on the rates quoted for each item. The tend erer may however, consider a minimum level of specifications conforming to IS code or National Building Code to cover any missing details.

5. Sample of Materials: The Contractor shall produce samples of all materials and

shall obtain approval of these in writing from Architect/ Project Engineer before he places bulk order for the materials for incorporation in the works. The samples must be produced atleast six week before they are to be incorporated in sample dwelling units. Materials to be incorporated in the work shall conform to latest relevant ISI. The items should be ISI marked where manufactured.

6. Slopes : Adequate slope shall be provided in areas where there is likelihood of

ingress of water such as toilets, balconies, verandah, kitchens, terraces, top of chajjas, window cills, plinth protections etc. though these may not be expressly shown in drawings.

7. Curing: Exposed surfaces of all cement works viz. cement concrete, brick work,

flooring, plastering, pointing and the like shall be cured by keeping the surface adequately and continuously wet as directed by Architect and Project Engineer for at least seven days where ordinary portland cement has been used. Approved curing compound may be used in lieu of moist curing with the permission of Architect and Project Engineer. Such compound shall be applied to all exposed surface of cement works as soon as possible after the initial setting of cement. This shall be without extra cost.

Note: - The work shall in general conform to the specifications for Civil, Electrical and all other works with up to date CPWD correction slips for all sub heads of work as applicable, and, Technical Specifications included in the tender documents, wherever applicable. Wherever any aspect of design / construction / material standards is not covered under the above mentioned specification, relevant standards shall be referred to in the order of precedence which shall be as follows. In the case of discrepancy between the Schedule of Quantities, the Specifications and /or the Drawings, the following order of preference shall be observed –

a. Description of Schedule of Quantities

b. Particular specification and Specific Condition, if any.

c. Drawings

d. CPWD / PWD Specifications

e. Indian Standard Specifications of B.I.S/ IRC/ BS/ ASTM/ DIN/ NBC.

DETAILS TECHNICAL SPECIFICATIONS AND CONDITIONS- CIVIL WORKS

1. EARTH WORK: As per relevant CPWD specifications.

Irrespective of the stipulations in the relevant CPWD Specifications, any surplus excavated earth

which is beyond the requirement it shall be disposed of by the contractor at his own cost to the

place as permitted by the local authority after obtaining written permission of the Engineer – in-

charge and no payment will be made by the Department for disposal of this surplus excavated

earth. Also the Contractor shall, at his own expense and without extra charges, make provision for

all shoring, pumping, dredging or bailing out water, encountered from any sources such as

rains, floods, springs, subsoil water table being high or due to any other cause

whatsoever. The foundation trenches shall be kept free from water while all the works below

ground level are in progress without any extra payment. Filling in plinth shall be consolidated with

water and compacted with pneumatic rammers, to achieve 90% relative density on testing. One

test is to be carried out for 1000 sq.m of compacted area.

2. PLAIN CEMENT CONCRETE AND REINFORCED CEMENT CONCRETE WORK:

a) STONE AGGREGATE:

i) Stone aggregate used in the work shall be of hard broken stone to be obtained from approved source (Quarries to be approved by the Engineer in charge) and shall conform to relevant provision in the Latest CPWD Specifications for works.

b) SAND

i) Sand to be used for the work shall be of as specified in CPWD specifications 2009. Sand shall be obtained from the source to be got approved by the Engineer in charge and washed if required, with appropriate equipment to bring down the chemical, inorganic and organic impurities within the permissible limits as per the direction of the Engineer in charge. The same shall consist of hard siliceous materials.

Note: Where only one variety of sand is available the sand will be sieved for use in finishing

work as directed by the Engineer – in – charge in order to obtain smooth surface and nothing

extra will be paid on this account.

c) Nothing extra shall be paid for screening or washing the sand as prescribed above.

d) CENTERING SHUTTERING AND SCAFFOLDING:

i) All Scaffolding centering for RCC shall be with properly designed system and brought to site well in advance so that the progress of the work is not hampered for non-availability of the same.

ii) All shuttering for RCC work except soffits of slab shall be in water proof shuttering

Ply. Shuttering for slab and soffits shall be in water proof shuttering ply or in good quality mild steel plates free of dents, bends or warping and rusting as approved by the Engineer in charge.

iii) Contractor should deploy complete one set of shuttering materials for minimum one complete floor and the shuttering material for beam bottom shall be minimum for two complete floors.

e) DESIGN MIX CONCRETE (DMC)

i) The batching and mixing plant shall be fully automatic.

ii) The contractor has to arrange to erect batching plant for the design mix concrete on his own.

iii) The concrete shall be transported to the site in specially made Transit Mixers & shall have suitable retarders so that it should not set before placing in position. It should have sufficient flow so that at height the concrete shall be placed by pumping only.

iv) Each Transit Mixer reaching site shall invariably have manufacturer‟s certificate containing details like truck number Grade of mix, time of leaving the plant, time of reaching a site etc. A copy of the same shall be handed over to Engineer- in – Charge or his authorized representative.

v) However samples for testing etc. shall be taken as per the mandatory tests prescribed in latest CPWD specifications.

vi) In respect of projected balconies, projected slabs at roof level and projected verandah, the payment for the RCC work shall be made under the items of RCC slabs. Nothing extra shall be paid for the side shuttering at the edges of these projected balconies and projected verandah. All the exposed edge shall however be finished as per specifications and nothing extra shall be paid for this.

vii) In the items of RCC walls, railings and roofs etc. nothing extra shall be paid for making designs as per patterns given by Architects or for thickness of sections.

viii) The water will be tested with regard to its suitability for use in CC work and nothing extra will be paid for on this account.

ix) To receive anchor bolt / foundation for machines to be installed at later date, pocket of size minimum 110x100x300 mm shall be kept while concerting of RCC/ CC members and shall be filled with CC 1:1:2 with plasticizer and as per the direction of Engineer in charge.

REINFORCEMENT:

TMT reinforcement steel shall be used shall be as per design and conforming to IS: 1786

pertaining to Fe 500D OR Fe 500D grade of steel.

3. BRICK WORK

a. Bricks used in the work shall be FPS to be obtained from kilns to be got approved from the Engineer in charge and shall be best quality well burnt ground moulded bricks as available in the locality. They shall have a compressive strength of not less than 75 Kgs/sq.cm and an absorption percentage of not more than 15(Fifteen) % of its dry weight when immersed in water for 24 hours. In all other respects they shall conform to the provision in Latest CPWD Specifications for works.

b. Both the face of wall of thickness more than 23cm shall be kept in the proper plane. Walls of half brick thickness or less shall be measured separately and paid in sqm.

c. Half brick thickness has to be taken as 115mm. Bricks wall beyond half brick thickness shall be measured in multiple of half brick (ie.115mm) which shall be deemed to be inclusive of mortar joints. In all other respects they shall conform to the provision in CPWD specification 2009.

4. WOOD WORK:

a. Timber required for manufacture of chowkhats and shutters for doors, windows, ventilators,

partitions etc shall be Forest Stewardship council (FSC) certified wood and it shall be seasoned and preservative treated.

b. The moisture contents of the wood used in the work shall not be more than that stipulated in the relevant clause of Latest CPWD Specifications for works. The rate quoted for various items shall be inclusive of kiln seasoning and preservative treatment of wood. In all other respects the wood used in the work shall conform to the provision in latest CPWD specification for works.

c. The sample of species to be used shall be deposited by the contractor with the Engineer-in – charge before commencement of the work. The contractor shall produce cash voucher and certificate from standard kiln seasoning plant operator about the timber section to be used on the work having been kiln seasoned by them failing which it would not be so accepted as kiln seasoned.

d. Transparent sheet glass (Float glass) conforming to IS 1761 – 1970 shall be used.

e. Minimum thickness shall be governed as under unless otherwise specified in the item.

AREA of Glazing Max. Unsupported

length Thickness

For glazing area up to 0.5 Sgm 120 cm 4 mm

For glazing area more

than0.5 sqm

120 cm 5.5 mm

f. Glazing for toilet and in fixed ventilators shall be of frosted type.

I) Factory made shutters, as specified shall be obtained from factories to be approved by the Engineer – in - charge and shall conform to IS 2202 (Part –1977. The contractor shall inform well in advance to the Engineer – in – charge the name address of the factory from where the contractor intends to get the shutters manufactured.

g. The contractor will place order for manufacture of shutters only after written approval of Engineer – in – charge in this regard is obtained. The contractor is bound to abide by the decision of the Engineer – in-charge. In case the factory already proposed by the contractor is not found competent to manufacture quality shutters, the Engineer – in – charge will recommend the name of another factory from the approved list.

h. The contractor will also arrange stage wise inspection of the shutters at factory with the Engineer in charge or his subordinate authorized representatives. Contractor will have no claim, if the shutters brought at site are rejected by the Engineer in charge in part or in full lot due to bad workmanship / quality or damages caused during their shifting from factory to site. Such shutters will not be measured and paid and the contractor shall remove the same from the site of work within 7 days after the written instruction in this regards are issued by the Engineer in charge or his authorized representatives.

5. STEEL WORK:

a. All steel grills shall be according to the Architect’s detailed drawings and obtained from approved suppliers. These shall conform to Latest CPWD Specifications for works.

b. In case of grills an approved quality priming coat of zinc chromate shall be applied over and above a shop coat of primer. Nothing extra shall be payable for providing shop coat primer, but the zinc chromate primer will be paid for separately.

c. All welded steel works shall be tested for quality of weld as laid in IS 822- 19780 before actual erection.

6. ALUMINIUM WORKS

a) Scope: - (Work to be carried out as per latest CPWD specifications of works)

The scope of the work is the fabrication, supply and erection at site of all types of glazed

doors, windows and ventilators in accordance with the drawings and specifications.It is the

responsibility of the tenderer to inspect the site and obtain for himself all relevant information

and details in respect of the work including access facilities for stacking and storage field work

in making connections with self-tapping screw assembling etc and take into account all such

things in working out his rates for the finished work.

b) The supply and erection will include all parts such as but not restricted to frames, tracks, guides, mullions, styles, rails, couplers, transoms, rails, plates glazing bars, glass, hinges, arrangement, spring catches, cord and pulley arrangements, spring catches, cord and pulley arrangements door closers floor springs etc., required for the whole work whether the parts/ items are individually and specifically referred to in the schedules/ specifications/drawings or not provided that the supply and installation of such parts can be inferred there from and are necessary to make the work complete, unless separate provision is made in the bills of quantities for supply to such parts/items.

c) The doors, windows, ventilators, will be fabricated to suit the finished clear openings in the building/structure which the tenderer will himself measure.

d) Materials:-

i) The members will be made out of aluminum alloy corresponding to IS:733 and will consist of extruded sections and of other shapes, and to sized gauges as shown in the drawings/ described in accordance with the relevant IS codes. The members shall be chosen to provide strength/ stability and maximum resistance to wear and tear.

ii) The Sections will be as per approved makes, extruded sections. As indicated in the drawings the tenderer should specifically mention which sections he is using.

iii) The weight of sections and the corresponding catalogue numbers are mentioned. The IS specifications are to be strictly adhered.

iv) The alloy of extruded aluminum should be BS or IS old HE9, Alcon 50 SWP. to this effect test certificate has to be provided for the extruder.

e) Finishing:

i. The extruded aluminum section has to be mechanically finished to remove all scratches; extrusion marks etc and subsequently thoroughly cleared in all alkali baths prior to anodizing.

ii. The polyester powder coating should be of desired shade with minimum average thickness to 50 microns or other shades as required and to this effect the tenderer must have to produce test certificate from authorized institutions Bureau of Indian Standard.

iii. The polyester powder coated material should be properly wrapped in gummed tape before fabrication to avoid scratches during fabricated and erection shall be kept protected till handing over.

f) Fabrication:

i. Before commencing the fabrication the contractor shall submit to client for their approval detailed shop drawings, based on the Architects drawings and corresponding specification showing junctions, fittings, accessories such as hinges flush bolts, locks, latches, latching arrangements, peg stays, rotor arms, anodize pivots gaskets rubber packing door felts, mastic, sealant etc., including fixing and sealing arrangements . Type and method of scaffolding he intends to use, Fabrication is to be taken up only after approval by client/EIC and in accordance with the approved drawings .Sections for fabrication of door/ window/ventilators etc shall be as per architectural drawings or as approved by the EIC. A sample of finished door/windows/ ventilator/ fire check door / railing etc. shall be fabricated as per the shop drawings approved by EIC/client for final approval before under taking mass production/ fabrication,

ii. The doors, window, ventilators and partitions shall as per thickness given in the BOQ item / specifications, Polyester Powder coating shall be as specified in the item specifications.

iii. All materials shall conform to relevant IS. Codes and in the absence of IS code, they

should correspond to the best engineering practice; decision of the EIC/Consultant shall be final and binding on the contractor.

iv. Fabrication shall be done true to the drawing/ sample approved and in correspondence to the finished openings at the site. All joints shall be mitered at the corners, true right angles, and joints to be finished neatly to hairlines, with concealed fasteners, wherever possible joints shall be made in concealed locations.

v. All fabricated/finished items shall be packed and carted properly to site to prevent any damage in transit. On receipt at site they shall be carefully stacked in protected storage to avoid distortion/damage.

vi. Site installation shall be with concealed screws, self-tapping or other approved fasteners or may be by welding, due precautions shall be taken to avoid any distortion/discoloration/damage to the finished items.

vii. Wood work faces/parts coming in contact with masonry shall before shifting to the site be given a heavy coat of alkali resistance bitumen paint. Steel items coming in contact with other incompatible materials shall be given a thick coat of zinc chromate primer.

g) Glazing:

Glazing shall be done with flawless sheet glass of best approved quality without

waviness, distortion, coloration / discoloration, of specified thickness in sizes as shown in

the drawings, fixed as required with special glazing clips, putty, neoprene/PVC gaskets.

All glass shall be cleaned thoroughly before they are fixed in position. Unless otherwise

specified the minimum thickness shall be 5.5 mm thick.

7. GLASS ENTRANCES AND GLAZING WITH PATCH FITTING

a) SCOPE OF WORK

i) The contractor shall be responsible for design, fabrication, supply, installation, test and guarantee of all items including taking all measures that may be required to complete the work asper Architectural concept drawings and specifications details.

ii) The specialist agency engaged to carry out the external glazing installation and supply shall have at least 5 years of relevant experience and have completed external glazing systems of similar nature and equivalent scale of works as shown in the tender documents.

iii) The specialist contractor shall submit an outline of recent comparable works (illustrated by appropriate drawings, sketches, photographs, brochures) by the firm / it's technical partner to illustrate the competence, experience and suitability of the firm.

b) The brief scope of work is:

i) Design, preparation of shop drawings, calculations, engineering data and test reports.

ii) Fabrication and installation of Glass Entrances and Glazing with Patch Fittings system.

iii) All anchors, fixings, attachments, reinforcements, steel reinforcing for mullions and transoms required for a complete installation, except those specifically indicated as being provided by other trades.

iv) Exposed Architectural mullions and other support members.

v) Finishes, protection coatings and treatments.

vi) Sealing with approved sealants within and around the perimeter.

vii) All thermal insulation, firesafing etc. including supports and/or backing.

viii) All caulking, sealing, electrometric and metal flashing, and gaskets including sealing at junctions with roof, ground-floor waterproofing and building expansion joints between structures.

ix) Electrical bonding and ear thing of all metal cladding elements.

x) Provisions to receive electrical outlets and cutouts for conduits and other electrical

work.

xi) Glass and glazing.

xii) Transportation, storage, handling, protection and cleaning.

c) SUBMITTALS

i) Product Data: Include construction details, material descriptions, and dimensions of individual components, profiles and finishes.

ii) Shop Drawings

d) FABRICATION AND INSTALLATION DETAILS, INCLUDING FOLLOWINGS

i) Plans, elevations and sections.

ii) Details of fittings and glazing.

iii) Hardware quantities, locations and installation requirements.

iv) Sample for verification, for each type of exposed finish required for

1. Metal finish: 150mm long section of patch fittings, rails and other items.

2. Glass: 150mm square, showing exposed edge finish.

e) MATERIALS

i) Glass

1. Glass shall be as specified in drawing or BOQ or as per design requirement. It shall be Indian / imported hard coated reflective bronze and heat strengthened glass. It shall be of approved amke.

2. In toughening of Glass rolling direction shall be parallel to the width of the glass panel such that waviness if any is parallel to the horizontal and no waviness parallel to the vertical and to ensure that such waviness is of negligible order.

ii) Components

1. Patch fittings: Stainless steel clad aluminium

2. Floating Transom Bar: Steel cladded in metal matching fittings and in sizes recommended by manufacturer for application indicated. Include stainless steel support rods, lateral adjustment and ceiling channel. Support fins to be metal, finished to match transom bar.

3. Rails: Stainless steel clad aluminium.

4. Accessory Fittings : Matching with patch fittings and rails metal and finish for overhead door stop, Centre hosing lock, glass support fin brackets and other as shown in drawing.

5. Anchors and fastenings: Concealed

6. Weather stripping: Sweep type

iii) Hardware

1. Hardware should be heavy duty in matching finish

2. Concealed Floor Closer and Top Pivots

a. Centre hung; BHMA A156.4, Grade 1; including cases, bottom arm, top walking beam pivots, plates, and accessories required for complete installation.

b. Swing : Double acting; Positive dead stop, concealed with hold open angle

c. Delayed action closing Concealed Overhead Holder: Grade 1, with dead stop setting coordinated with concealed floor closer.

d. Push-pull set : Stainless steel finish

3. Lock set of approved make.

f) FABRICATION

1. Provide holes and cutouts in glass to receive hardware, fittings, rails and accessories before tampering glass. Fully temper glass using horizontal (roller-hearth) process and fabricate so, when installed, roll wave distortion is parallel with bottom edge of door or tile.

2. Factory assembled components and factory installed hardware to greatest extent possible.

g) EXECUTION

1. Examine areas and condition for compliance with requirements for installation tolerances and other conditions affecting performance of work.

2. Install all glass system and associated components according to manufacturer‟s written instructions.

3. Set units in level and plumb.

4. Maintain uniform clearances between adjacent components.

5. Lubricate hardware and other moving parts according to manufacturer‟s written instructions.

6. Set, seal and grout floor closer cases as required suiting hardware and substrate indicated.

h) CLEANING

1. The Contractor shall ensure that all actions are taken during installation to eliminate the effects of corrosive substances on the finishes.

2. The Contractor shall clean both internal and external surfaces to remove corrosive substances, dust or cement/mortar dropping during the installation as may be directed and instructed by the ENGINEER IN CHARGE.

3. The internal surfaces of glass and aluminum frame are to be cleaned with compatible cleaning agents prior to the installation of the internal protective sheeting.

4. The Contractor shall provide written verification that cleaning agents are compatible with aluminum, stainless steel, glass coatings, granite, glazing materials and sealants. In no case shall alkaline or abrasive agent be used to clean the surface. Care shall be taken during cleaning to avoid scratching of the surface by grit particles.

5. Prior to snagging inspections the Contractor shall, remove the internal protection sheets and carry out a thorough cleaning of all glass and aluminum.

6. The Contractor shall also make good any physical damage to the structure including scratches, dents, abrasions, pitting, etc. to the satisfaction of the ENGINEER IN CHARGE.

7. Manufacturer's delivery or job markings on glass and adhesive for manufacturer's labels shall be either a neutral or slightly acidic material. In no case shall such material be alkaline; any staining of glass by alkaline material will be cause for rejection of the glass.

8. After the installation of each pane of glass all markings and labels shall be carefully and completely removed from the panes. Thereafter no markings or labels of any sort shall be placed on the glass.

9. Glazed openings shall be identified by suitable warning tapes or flags attached with a non-staining adhesive or other suitable means to the framing of the opening. Tapes or flags shall not be in contact with glass.

10. As soon as it is practically possible after the issuance of the occupation Permit for the Building, the Contractor is to carry out a complete cleaning of the external face.

i) PERFORMANCE GUARANTEE:

i) The contractor shall offer a minimum of 10 year Performance Warranty for the entire installation carried out.

j) MEASUREMENTS

Measurements shall be in Sq m of actual area covered.

k) RATE

Rate shall include all required labour, material, designing, drawing conveyance,

testing at approved laboratory breakage, wastage, supervision, protection till hand

over and free maintenance during defect liability period etc. complete.

8. FLOORING:

i) The flooring in the building shall be as per the approved floor finish drawings and laid in

such a way that limits in floor levels would not exceed the limits provided in the latest CPWD specifications or manufactures specifications.

ii) Wherever Tile flooring is done it shall be with 1st. Quality tiles only.

iii) Slope in floors shall be provided as per architectural drawings, else the levels at any place when checked over a distance of one meters in any direction should not show variation in floor level more than 3 mm.

iv) Rate for the items of flooring is inclusive of provision of sunken flooring and finishing edges of the same in bath kitchen, toilets, cutting holes for traps / pipes etc., and nothing extra shall be paid on this account unless otherwise specified.

9. FALSE CEILING

a) False ceiling items in general are carried out as per the description of the item in the Bill of quantities and also as per the manufacturer‟s specifications / as directed by the Engineer – in – Charge. Location of particular type of false ceiling shall be as per relevant drawing, in its absence written approval of EIC shall be obtained.

10. ALUMINIUM COMPOSITE PANELS (ACP) CLADDING

a) Providing and fixing Aluminium Composite panel cladding including framing as per the elevation, section and the plan drawings provided, fabricated out of heavy duty Aluminium extruded profiles conforming to alloy 643900 WP with chemical composition and mechanical properties as per IS-733 and as per specifications.

b) The contractor must design the cladding as per the prevalent site conditions and building elevations profiles. No extra claims shall be entertained at any stage for aluminum profile/ wall thickness and size dimensions. The Contractor must quote rates accordingly.

c) The anchoring / bracing of the wall cladding to the RCC beams/ columns shall be done with non-corrosive galvanized brackets of approved design, (Galvanizing to be done conforming to IS 4759-1996 up to 610 gms. Per Sq. M. (80- 90 micron thickness).

d) The framework shall be aligned for the entire height of each Mullion and of the entire width of each Transform by laser beam equipment to ensure 100 percent „X‟ axis and „Y‟ axis alignment.

e) The system should also provide for pressure equalization. The details for pressure equalization to be submitted by the contractor and got approved by the Engineer-in-charge.

f) EPDM Gaskets of suitable profiles (to accommodate shall be provided including the labour element for fixing in appropriate locations is to be included in the rate).

g) The Periphery of the framework shall be sealed both from inside and outside with silicon weather sealant to make the cladding watertight.

h) Cost of Aluminium composite panel consisting of a core of polyethylene sandwiched between two aluminium skins of 0.5mm thickness with a mild edge. 4 mm total thickness with surface finish of PVDF coating as approved by the Engineer-in-charge, as shown in the elevation, plan and cross section drawings along with labour element for cutting stacking, carrying to heights and fixing to appropriate locations is included in the rates.

i) All the vertical and horizontal section grooves are to be sealed non staining silicon sealant of make as specified in the list of approved make to make the entire system synchronies with the basic structural glazing/curtain wall structure and also make the system air tight and watertight. The fixing details should be got approved by the Engineer- in-charge. The peel off foil should be removed at the time of handing over as may be required by the Engineer-in-charge.

j) Product

i) ACP shall be as approved with high fiber filled sandwiched panel 4mm install on Aluminium framing and Galvanised brackets. Aluminium cladding panel to be PVDF fluorocarbon coated factory applied colours. Reverse side to be in mill finish. All the joints shall be sealed with silicon sealant of approved make. The colour of sealant to be decided by Engineer-in-Charge.

ii) A sample of panels and installation methods to be submitted to the Engineer-in-Charge for approval.

k) Manufacture

i) The panels must be visually flat. Any stiffener applied to compensate for wind load must not read through.

l) Installation

i) The panels shall be fixed in accordance with manufacture‟s recommendations.

ii) Technical Properties of Aluminium Composite Panels

iii) All cladding shall be of 4.0 mm thick aluminium composite panel comprising of high mineral filled core sandwiched between two skins of aluminium alloy.

1. Mechanical Properties : Tensile strength >130 N / mm2 : 0.2 % proof stress 90 N / mm2

: Elongation 5 %

: Modules of elasticity 70,000 N/mm2

2. Vibration and Noise :Average airborne–Sound Damping

Transmission loss R/N 25db (DIN 4109)

3. Thermal Transmittance‟s: 0.014 m2 ˚C/W

4. Moment of Inertia :0.347 cm4/m

5. Panel Weight :5.5 Kg/m2

6. Finish :PVDF stove lacquered (Fluoro carbon) on one side and reverse side in mill finish.

7. Colour :Colour to be selected by Engineer-in-Charge Representative using standard PVDF colour chart from manufacturer.

m) Protection Protection should not be removed until after installation.

n) Warranties

The Contractor shall provide a data to confirm compliance with specific requirements

for resistance and fire properties. The guarantee should be for a 20 salt spray

resistance and fire properties. The guarantee should be for a 20 year period against

peeling chalking (No. 8 rating), fading, blistering, flaking, chipping and cracking.

o) Measurement: The measurement shall be for exposed actual surface area with grooves cladded on plain/ curved surface excluding the concealed trims.

11. SAMPLES OF MATERIALS:

a) Sample of all materials/ fittings and fixture to be used in the work such as doors, windows, tiles, sanitary, water supply, drainage fittings and fixtures shall be submitted well in advance by the contractor for approval from the Engineer-in charge of work in writing before placing orders for the entire quantity required for completion of work. Samples approved by the Engineer-in charge / Client shall be kept in Sample Room under the charge of Engineer-in charge and shall retain till completion of work.

b) Finished items in respect of typical portion of works of repetitive nature such as typical room, toilet, railing, door, window or any other work desired by the engineer-in- charge shall be prepared by the contractor to the satisfaction of Engineer-in – charge and got

approved from him in writing before the commencement of these items for the entire work.

c) The requirements for preparation of samples shall be observed and fulfilled by the contractor well in advance to avoid any detriment to the general progress of work. In other words, this will not be allowed to have any effects on the general progress of work or on any of the terms and conditions of the contract. No claims of any kind whatsoever including the claims of extension of time will be entertained due to the incorporation of this requirement.

12. STAINLESS STEEL RAILINGS

a) The scope of the work includes preparation of the shop drawings (based on the architectural drawings), fabrication, supply, installation and protection of the stainless steel railing till completion and handing over of the work.The stainless steel work shall be got executed through specialized fabricator having experience of similar works. The Contractor shall submit the credentials of the fabricator for the approval of the Engineer-in- Charge.

b) The Contractor shall submit shop drawings, for approval of the Engineer- in-Charge, for fabricating stainless steel railing with detailing of M.S. stiffener frame work backing along with the fixing details of the M.S. frame work to the R.C.C columns. The details of the joints in the stainless steel railing including location, etc. shall also be shown in the shop drawings.

c) The Contractor shall procure and submit to the Engineer-in-Charge, samples of various materials for the railing work, for approval. After approval of samples, the Contractor shall prepare a mock up for approval of Engineer-in-Charge / Consultant. The material shall be procured and the mass work taken up only after the approval of the mock up by the Engineer-in-Charge / Consultant. The mock-up shall be dismantled and removed by the contractor as per the directions of the Engineer-in- Charge. Nothing extra shall be payable on this account.

d) The stainless steel shall be of grade 304 with brushed steel satin finish and procured from the approved manufacturer. It shall be without any dents, waviness, scratches, stains etc.

e) The required joints in the railing provided as per the architectural drawings, shall be welded in a workmanlike manner including grinding, polishing, buffing etc. all complete and compacted. The temporary clamps provided and fixed to hold the stainless steel railing, in position shall be removed after the concrete has set properly. The junction of the flooring and the cladding shall be neatly filled with weather silicone sealant of approved colour and shade. Nothing extra shall be payable on this account.

f) One test (three specimens) for each lot shall be conducted for the stainless steel pipe in the approved laboratory. Therefore, the material shall preferably be procured in one lot from one manufacturer.

g) The finished surface shall be free of any defects like dents, waviness, scratches, stains etc. and shall have uniform brushed steel satin finish. Any defective work shall be rejected and redone by the Contractor at his own cost. The finished surface shall therefore be protected using protective tape which shall be removed at the time of completion of the work. The surface shall then be suitably cleaned using nonabrasive approved cleaner for the material. Nothing extra shall be payable on this account.The item includes the cost of all inputs of labour, materials (including stainless steel pipes, welding, brazing, concrete, protective film, weather silicone sealant etc including cost of providing and fixing M.S. frames), T & P other incidental charges, wastages etc. The items also included providing and fixing stainless steel anchor fasteners for fixing railing.

h) The railing shall be fixed in position using stainless steel pipes, stainless steel posts of required diameters and thickness as shown on drawing and polished to satin finish including cutting, welding, grinding, bending to required profile and shape, hoisting, butting, polishing etc.

i) The item includes the cost of all inputs of labour, materials, T&P, other incidental charges, wastage etc. The entire work shall be carried out to the satisfaction of Engineer-In-Charge.

13. GLASS:

a) All glass and glazing material shall be verified and coordinate with the applicable Performance requirement.

b) All glass shall be cut to require size and ready for glazing. All glass shall be accurate sizes with clear undamaged edges and surfaces which are not disfigured. Any panel which does not fit any section of the curtain wall and shop front will be rejected and a replacement made at the Contractor‟s expense.

c) Glass shall conform to the quality, thickness and dimensional requirement specified in US Federal specifications DD – G0415C.

d) Heat strengthened glass shall not deviate in surface flatness by more than 0.23 mm within 260mm of leading or trailing edge, or 0.076mm in centre. Direction of ripple shall be consistent and is acceptable to Architect. Distortion of glass shall be controlled as much as possible during heat strengthening. Sag distortion shall be unidirectional and surface compression shall be in the range of 320-450 Kg/cm². All glass shall be delivered to site with the manufacturer’s label of identification attached.

e) The glass glazed panel / structural glazing frames for the structural glazing system shall be designed to withstand lateral imposed loads and comply with requirement of local building codes.

f) Glass shall be free from defect or impurities detrimental to its performance. Defects such as bubbles, waves, spots scratches, spalls, discoloration, visibly imperfect coating, chipping, and bubbles delaminating of pacifier film shall be limited in accordance with the Manufacturer‟s / trade guidelines. The glass is to be produced in such a way that the rollers will be parallel to what will be the horizontal position of the glass. Glass be consistent in colour.

g) Double glazed units shall be procured only from approved manufacturer. Quality control tests shall be performed for mixing, curing, adhesion and dew point. The unit shall be guaranteed against condensation and dirt between the panes, failure of seal and damage to internal coating.

h) All glass breakage caused by the Contractor or his sub-contractor because of negligence or caused by the installation of faulty work by him shall be replaced by the Contractor at his own expense without delay to the project completion.

14. WATER PROOFING TREATMENT:

a) All the items for water proofing treatment with cement based water proofing treatment for roof slab and sunken portion in schedule of quantities shall be guaranteed for TEN YEARS the case of cement based treatment by the contractor as per Performa prescribed. The water proofing treatment work should be got done through specialized agency approved by Engineer-in-charge.

15. INTEGRAL CEMENT BASED WATER PROOFING TREATMENT FOR ROOF /SUNKEN FLOORS OF W.C`S ETC.

a) The proprietary water proofing compound shall conform to I.S.2645 – 1975 in cement based water proofing treatment, stone aggregate shall be used instead of brick aggregate without any extra cost wherever required by the Engineer- in – charge.

b) The finished surface after water proofing treatment shall have required slope.

c) While treatment of sunken floors is done it shall be ensured that the „S‟ or „P‟ traps as the

case may be have been fixed / eased and rounded off properly the work shall be carried

out as per relevant CPWD specifications.

d) GURANTEE:

The above water proofing, treatment shall be guaranteed for TEN YEARS against any

leakage etc. the contractor shall have to execute a bond, 10% of cost of items executed

for water proofing shall be retained for 10 years as security ( Refer GCC provisions)

16. BORE WELLS

a) Scope of Work

The general character and the scope of work to be carried out under this contract are

illustrated in the following specifications. It gives only general guidance as regards design,

drilling and construction of tube wells. Before selecting the method of construction to be

adopted, the contractor shall give due consideration to site condition and Geological data

of the site. The construction and testing of tubewells shall be as per IS 2800- 1979 (Part 1

and 2). This contract is an item rate contract. All payments shall be made for the actual

work executed. The Contractor shall ensure the required minimum yield.

b) Selection of Site

The site where the tubewell is proposed shall be examined by tenderer, and changes if

required shall be discussed with the engineer prior to start of work. Any previous data

available with the Contractor regarding nearby tubewells should be made use of to evolve

suitable procedure for drilling, developing, testing etc.

c) Geological Data

During the drilling operation, contractor shall collect the samples of different strata from

suitable intervals or where change in strata is met with. It shall be carefully examined and

analysed and the data shall be preserved carefully and handed over to Engineer. The

contractor shall make one drilling time log during the execution of work for the bore well.

d) Design and lowering of pipe assembly

The length and diameter of the housing pipe shall be selected on the basis of static water

level, the draw down and the discharge expected from the well and the size of the pump

to be installed. The size and length of blind pipes and the slotted/ strainer pipes shall be

selected according to the expected discharge and the depth of tubewell. The size and

distribution of the slots shall be as per IS 8110. After completion of the bore hole the

contractor shall assemble the tube well assembly according to the water bearing strata

met during boring, after getting the same approved from the Engineer and shall lower in

to the drilled hole the same keeping the slotted strainer opposite to water bearing strata

from which the water is to be extracted . The bail plug shall rest on firm ground. Before

the bail plug is lowered, about one metre depth of the bore hole shall be packed with the

gravel to avoid sinking of the assembly. In case part of a bore hole is not proposed to be

utilized, it shall be filled with gravel before lowering the assembly. The slotted pipe and

other pipes shall be provided with proper guides to keep them in the centre of the bore to

ensure uniform gravel packing all around.

Gravel Packing

All gravel shall consist of hard rounded particles reasonably uniform in diameter and shall

be of size, determined after analyzing the character of the water bearing formation

tapped. The gravel shroud around the screen shall be uniform. It should be free from

dust, dirt and other vegetable matters. Gravel packing once started shall be carried out

continuously until it is completed. Pea gravel/Stone Chips shall be thoroughly washed.

e) Development of Borewell

The well shall be developed either by surging and agitating or by over pumping and back

washing with an air lift and high velocity jetting. The tube well shall be developed as per

IS 2800 -1979 or latest by air compressor to be arranged by the contractor as required

and stipulated in BOQ to obtain the maximum discharge available from the completed

tubewell. Another acceptable method may also be adopted. This development process

shall be continued until the stabilization of sand and gravel particles has taken place. The

development shall continue until the gravel should stop sinking, discharge of depression

ceases to improve and the sand content is not more than 20parts per million. A record of

the hours of working of Air compressor shall be maintained by Employer Engineer which

will be signed by the contractor or his authorized representative. Payment for

development of tubewell shall be made at the hourly rate indicated in the schedule of

quantities for the actual period during which the Air-Condition has worked. A statement

showing the quantity of gravel initially filled in the bore and the quantity added during

development should be prepared by the contractor and got signed by the representative

of the Engineer.

f) Disinfection

The well shall be disinfected after completion of test for yield. All the exterior parts of the

pump coming in contact with the water shall be thoroughly cleaned and dusted with

powdered chlorine compound. In fact it shall be disinfected every time a new pump is

installed or the one installed is replaced after repairs.

The stock solution of chlorine may be prepared by dissolving fresh chlorinated lime. For

obtaining an applied standard concentration of 50 ppm, 1 litre of the stock solution shall

be used to treat 300 liters of water.

g) Grouting and sealing

Grouting and sealing of tubewell may be done, if required depending upon the site

conditions and the quality of the discharge of the strata encountered. To ensure that the

grout shall be provided a satisfactory seal, it shall be applied in one continuous operation.

Sealing of the tube well may be done by grouting the annular space between bore and

the housing pipe, with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 : coarse

aggregate 20 mm nominal size) to a depth of 5m below the grouted level.

h) Handing over of the borewell.

The tubewell shall be handed over in complete shape. The housing pipe shall be

closed by a well cap for the period between the completion of the tube well and the

installation of the pump set.

The following information shall be furnished by the drilling agency on completion of

the tubewell :

i) Strata chart of the tube well indicating the different types of soils met with, at different depths.

ii) Samples of strata collected , neatly packed and correctly marked in sample bags.

iii) Chart of actual pipe assembly lowered indicating the size of pipes, depth ranges, where slotted/ strainer pipes have been used, depth and diameter of housing pipe, reduced level of the top of the housing pipe and the diameter and depth of the bore hole.

iv) Position of every joint in the well assembly.

v) Hours of development done by the compressed air, pump sets or by other means.

vi) Pumping water level at the developed discharge.

vii) Two copies of test certificates of the water samples results from approved testing agency.

viii) Results of development along with levels of static subsoil water and depth of draw for steady discharge.

ix) Results of mechanical (sieve) analysis of samples of aquifer materials wherever applicable.

x) Yield analysis and recommendation on the safe pumping yield, pump settings

and specifications for suitable pumps etc.

xi) Verticality tests results to be recorded in accordance with IS:2800- 1979

xii) TUBEWELL DATA: - Shall be decided by the Engineer-in-charge.

i) Water for drilling – Contractor shall make his own arrangement for water required for drilling purposes as well for development purposes.The design for the tube well indicating the depth range of the aquifer zones to be tapped shall be given after a detailed study of the data collected during drilling operations.

j) The slotted pipes should have an effective open area of at least 15% and the slotted size should be 1.6 mm. All pipes shall be painted fresh before lowering. The pipes shall be welded thoroughly all round to prevent leakage and breakage. Centering guides may be used to maintain the verticality of the tube wells which shall be tested.

k) The annular space between the bore well and tube well assembly shall be packed with well-graded pea gravel of good quality, durability and high sphericity.

17. GRIHA requirements

Materials shall be procured by the contractor keeping in view the recycled content to conform

the GRIHA requirements as detailed in SCC and elsewhere.

18. VARIATION IN CONSUMPTION OF MATERIALS:

The variation in consumption of material shall be governed as per CPWD specification and

clauses of the contract to the extent applicable.

19. MISCELLANCEOUS:-

Materials manufacture by reputed firms and approved by Engineer – in charge shall only be used.

Only articles classified as “First Quality” by the manufactures shall be used unless otherwise

specified. Preference shall be given to those articles which bear ISI certification marks. In case

articles bearing ISI certification marks are not available the quality of sample brought by the

contractor shall be judged by the standards laid down in the latest CPWD specifications. For

items not covered by the latest CPWD specification, relevant ISI standards shall apply.

20. TESTS:

a. Materials brought at site of work shall not be used in the work before getting satisfactory test results for Mandatory tests as per relevant provisions in Latest CPWD Specifications for works. Normally, part rate payment shall be allowed in the running account bills only if the materials are tested and test results are found to be satisfactory to by the Engineer-in-charge. These tests shall be got done from laboratories certified and approved by competent central/state Governments or the laboratory set up by the contractor at site as per directions of EIC/ Consultant.

b. The Engineer-in - charge of work shall check the test results and satisfy himself before allowing any payment in the running /final bill.

TECHNICAL SPECIFICATIONS HORTICULTURE WORKS:

1. General Requirements

a. Scope of work

i. The work shall in general conform to the Latest CPWD Specifications for works. Work under this Contract shall consist of furnishing all labour, materials, equipment and appliances necessary and required. The Contractor is required to completely furnish all the plumbing and other specialized services as described hereinafter and as specified in the schedule of quantities for Horticulture works.

ii. Without restricting to the generality of the foregoing the work shall include the following:

1. GRASSING

a. PREPARATION

i. During period prior to planting the ground shall be maintained free from weeds.

ii. Grading and final leveling of the landscaping shall be completed at least three weeks prior to the actual sowing. Clods of excavated earth shall then be broken upto the size not more than 75mm in any direction. The area shall then be flooded with water and after 10 days and within 15 days of flooding, weeds that re-germinate shall be uprooted carefully. The rubbish arising from this operation shall be removed and disposed of in a manner directed by Engineer. Regular watering shall be continued until sowing by dividing the lawn area into portion or approx 5 mts. Square by constructing small bunds to retain water. These „bunds‟ shall be level just prior to sowing of grass plants. At the time of actual planting of grass, it shall be ensured that he soil has completely settled.

iii. Slight unevenness, ups and downs and shallow depressions resulting from the settlement of the flooded ground, in drying and from the subsequent weeding operations, shall be removed by fine dressing the surface to the final levels by adding suitable quantities of good earth brought from outside, if necessary as directed by the Engineer. In fine dressing, the soil at the surface and for 40mm depth below shall be broken down to particles of size not exceeding 6mm in any direction.

b. SOIL :

i. The soil itself shall be ensured to satisfaction of Engineer to be a good, fibrous loam, rich in humus.

c. SOWING THE GRASS ROOTS :

i. Grass roots (Cynodon dectylon or a local approved by the Engineer) shall be obtained from a grass patch, seen and approved beforehand.

ii. The grass roots stock received at site shall be manually cleaned of all weeds and water sprayed over the same after keeping the stock in a place protected from sun and dry winds.

d. Grass stock received at site may be stored for a maximum of three days. In case grassing for some areas is scheduled for a later date fresh stock of grass roots shall be ordered and obtained.

e. EXECUTION :

i. Small roots shall be dabbled about 15 cms (or at other spacing‟s as per BOQ item) apart into the prepared grounds. Dead grass and weeds shall not be planted.

ii. Grass areas will only be accepted as reaching practical completion when

germination has proved satisfactory and all weeds have been removed.

iii. All planting is to be done in moderately dry to moist (not wet ) soil and at times when wind does not exceed a velocity of 8 kilometer per hours.

f. MAINTENANCE OF LAND SCAPING WORK

i. As soon as the grass is approximately an inch high it shall be rolled with a light wooder, roller in fine, dry weather and when it has grown to 2 to 3 inches above the ground, weeds must be removed and regular cutting with the scythe and rolling must be begun. A top dressing of announce of guano to the square yard on well decomposed well broken sludge manure will help on the young grass. The scythe must continue to be used for several months until the grass is sufficiently secure in the ground to bear the mowing machine. It should be possible to use the inch above the normal level of the first two or three cuttings. That is today the grass should be cut so that it is from 1 to 2 inches in length, instead of the ½ to ¾ of an inch necessary for mature grass.

ii. In absence of rain the lawn shall be watered every ten days heavily, soaking the soil through to a depth of at least 25 cms.

iii. Damage failure or dying back of grass due to neglect of watering especially for seeding out of normal season shall be the responsibility of the contractor.

iv. Any shrinkage below the specified levels during the contract or defects liability period shall be rectified at the contractor‟s expense.

v. The contractor is to exercise care in the use of rotary cultivator and mowing machines to reduce to a minimum the hazards of flying stones and brickbats. All rotary mowing machines are to be fitted with safety guards.

g. ROLING :

i. A light roller shall be used periodically, taking care that the lawn is not too wet and sodden. Rolling should not be resorted to, to correct the levels in case certain depressions are formed due to watering

h. EDGING :

i. The contractor shall establish a neat edge where planting areas meet grass areas with spade or edging tool immediately after all planting, including lawn planting, is completed. Particular care shall be exercised in edging to establish good flowing curves as shown on the plans or as directed by the Engineer. Edging must be cut regularly and shall be maintained by the contractor.

i. FERTILIZING :

i. The lawn shall be fed once a month with liquid manure prepared by dissolving 45 grams of ammonia sulphate in 5 litres of water.

j. WATERING :

i. Water shall be applied daily during dry weather. Watering whenever done should be thorough and should wet the soil at least upto a depth of 20 cms to eliminate air pockets and settle the soil.

k. WEEDING :

i. Prior to regular mowing the contractor shall carefully remove rank and unsightly weeds.

2. MAINTENANCE

a. The landscape contractor shall maintain all planted area within the landscape 1contract boundaries until the period of one year after the complete plantation. Maintenance shall include replacement of dead plants. Watering, weeding, cultivating, control of insects, fungicide and other disease by means of spraying with an approved insecticide or fungicide, pruning and other horticulture operations necessary for the proper growth of the plants and for keeping the landscape sub- contract area neat in appearance.

b. PRUNING & REPAIRS

c. Upon completion of planting work on the landscape sub-contract all trees should be pruned and all injuries repaired where necessary. The amount of pruning shall be limited to the minimum necessary to remove dead or injured twigs and branches and to compensate for the loss of roots and the results of transplanting operations. Pruning shall be done in such a manner as not to change the natural habit or special shape of the trees. In general, one third to one fourth branching structure of the plants to be removed to compensate the loss of roots during transplantation by thinning or shortening branches but no leaders shall be cut. All pruning shall be done with sharp tools in accordance with instructions of the consultant. Pruning cuts shall be painted with recommended paints.

3. TREE GUARDS :

a. Where tree guards are necessary, care should be taken to ensure that they do not impede

movement or restrict growth.

4. NURSERY STOCK :

a. Planting should be carried out as soon possible after reaching site. Where planting must, of

necessity, be delayed, care should be taken to protect the plants from pilfering or damage from people or animals. Plants with bare roots should be healed in as soon as received or otherwise protected from dying out, and others set closely together and protected from the wind. If planting should be unpacked, the bundles opened up and each group of plants heeled in separately and clearly 37abeled. If for any reason the surface of the roots becomes dry the roots should be thoroughly soaked before planting.

5. PROTECTIVE FENCING :

a. According to local environment shrubs may have to be protected adequately from vandalism

until established.

6. COMPLETION :

a. On completion the ground should be formed over and left tidy.

7. RATE:

The rates quoted for the horticulture items listed in BOQ shall provide for the cost

involved in all the operations described above.

TECHNICAL SPECIFICATIONS

NON SCHEDULE ITEMS

CIVIL WORKS

1.1 Flush Pointing:

The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence if any shall be removed by brushing and scraping. The surface shall then be thoroughly washed with water, cleaned and kept wet before pointing is commenced. In case of concrete surface if a chemical retarder has been applied to the form work, the surface shall be roughened by wire brushing and all the resulting dust and loose particles cleaned off and care shall be taken that none of the retarders is left on the surface.

The joints shall be raked to such a depth that the minimum depth of the new mortar measured from either the sunk surface of the finished pointing or from the edge of the brick shall not be less than 12 mm.

The mortar shall be pressed into the joints and shall be finished off flush and level with the edges of the bricks, tiles or stones so as to give a smooth appearance. The edges shall be neatly trimmed with a trowel and straight edge.

Flush pointing on exposed surface of Brick or Stone masonry surface with Lime, Surkhi and sand/stone dust mortar in the ratio of 1:1:1 {One lime : 1 Surkhi (100% dark red Surkhi) : 1 sand/stone dust}.

1.2 Signage:

Signage is the design or use of signs and symbols to communicate a message to a specific group. Stainless Steel (SS) alloy should be SS 304 grade. This offers excellent corrosion resistance and effectively combats tarnishing under most circumstances.

Metal Etching (by Chemical Etching Machine) are most popular in corporate & Industries, because of its long life and impressive quality.

Some features are:

Rust resistance Sturdy Long Life Any Size / Accurate dimensions Attractive look Compact design

1.3 Stone:

All the stone work is carried out as per CPWD specification Volume I 2009. unless specified in the specification & drawings. All required test of stone shall be as per Indian Standard (IS) codes.

1.3.1 Course Rubble (CR) Stone Masonry - First Sort:

Stone shall be hard, sound, durable and free from weathering decay and defects like cavities, cracks, flaws, sand holes, injurious veins, patches of loose or soft materials and other similar defects that may adversely affect its strength and appearance. As far as possible stones shall be of uniform colour, quality or texture. Generally stone shall not contain crypst crystalline silica or chart, mica and other deleterious materials like iron-oxide organic impurities etc.

The stone shall be red or white or any other stone as specified in the description of item in the BOQ. The stone shall be hard, sound, tough, free from cracks, decay & weathering. In case of red sand stone, white patches or streaks shall not be allowed. However scattered spots upto 10 mm diameter will be permitted. Before starting the work the contractor shall get samples of stone approved by the Project-in-Charge.

Stones with round surface shall not be used.

Size of Stones:

Normally stones used should be small enough to be lifted and placed by hand. Unless otherwise indicated, the length of stones for stone masonry shall not exceed three times the height and the breadth on base shall not be greater than three-fourth of the thickness of wall, or not less than 150 mm. The height of stone for rubble masonry may be upto 300 mm.

Dressing:

Every stone shall be dressed to the required size and shape chisel dressed on all beds and joints so as to be free from waviness and to give truly vertical and horizontal joints.

In exposed masonry, the faces that are to remain exposed in the final position and the adjoining faces to a depth of 6 mm shall be the fine chisel dressed so that when checked with 60 cm straight edge, no point varies from it by more than 1 mm.

The top and bottom faces that are to form the bed joints shall be chisel dressed so that variation from 60 cm straight edge at no point exceeds 3 mm. Faces which are to form the vertical joints should be chisel dressed so that variation at any point with 60 cm straight edge does not exceed 6 mm.

Any vertical face that is to come against backing of masonry shall be dressed such that variation from straight edge does not exceed 10 mm. All angles and edges that are to remain exposed in the final position shall be true, square and free from chippings.

A sample of dressed stone shall be prepared for approval of Project-in-Charge. It shall be kept at the worksite as a sample after being approved.

Mortar:

Mortar shall be use in cement mortar 1: 4 ( 1 cement : 4 Course sand) as as specified in the description of item in the BOQ.

Laying of Stone:

All stones shall be wetted before use. The walls shall be carried up truly plumb or to specified batter. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. The height of each course shall not be less than 15 cm nor more than 30 cm.

The walls and pillars shall be carried up truly plumb or battered as shown in drawings. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical.

Face stones shall be laid alternate headers and stretchers. No pinning shall be allowed on the face. No face stone shall be less in breadth than its height and at least one third of the stones shall tail into the work for length not less than twice their height.

The hearting or the interior filling of the wall strictly is not allowed in any case of wall.

The masonry in a structure shall be carried up uniformly but where breaks are unavoidable, the joints shall be raked back at angle not steeper than 45°. Toothing shall not be allowed.

Bond Stones :

Though bond stones shall be provided in walls upto 600 mm thickness, a set of two or more bond stones overlapping each other by at least 150 mm shall be provided in a line from face to back. In case of highly absorbent types of stones (porous lime stone and sand stone etc.) the bond stone shall extend about two-third into the wall, as through stones in such walls a set of two or more bond stones overlapping each other by at least 150 mm shall be provided. Each bond stone or a set of bond stones shall be provided for every 0.5 m2 of the wall surface and shall be provided at 1.5 m to 1.8 m apart clear in every course.

Quoins:

The quoins shall be of the same height as the course in which these occur. These shall be at least 450 mm long and shall be laid stretchers and headers alternatively. These shall be laid square on the beds, which shall be rough-chisel dressed to a depth of at least 100 mm. In case of exposed work, these stones shall have a minimum of 25 mm wide chisel drafts at four edges, all the edges being in the same plane.

Joints:

All bed joints shall be horizontal and all side joints vertical. All joints shall be fully packed with mortar, face joints shall not be more than one cm thick.

Pointing:

All exposed joints shall be pointed with mortar as specified. The pointing when finished shall be sunk from stone face by 5 mm or as specified. The depth of mortar in pointing work shall not be less than 15 mm.

TECHNICAL SPECIFICATION

PLUMBING/SANITARY WORKS

1.0 GENERAL:

1.1 The work shall be carried out in the accordance with the drawings and design as would be issued to the Contractor by the Engineer-in-charge / Architect/Consultant.

1.2 The work shall be executed and measured as per metric dimensions given in the Bill of

Quantities, drawings etc.

2 MEASUREMENTS:

All measurements shall be taken in accordance with relevant IS codes, unless otherwise specified.

3. STANDARDS AND CODE OF PRACTICE

The work shall be carried out as per the enclosed Specifications of work and the construction drawings to be issued from time to time. These specifications shall be read in conjunction with CPWD specifications 2009 with up to date CPWD correction slips, National Building Code (latest amendment), Relevant Codes of Practices and Standards as issued by BIS (all with the latest amendments).

In case of any deviation, ambiguity, omissions, variations, confusion and dispute over specification the consultant’s decision shall be final and binding on contractor. All the clause of above codes and specifications of sanitary installation, water supply, drainage & miscellaneous items shall be applicable on the project and binding on the contract whether specifically mentioned in these specifications or not.

List of Indian Standards –

a) SP : 35 : 1987 – Hand Book on Water Supply & Drainage

b) Manual on Water Supply & Treatment

c) Manual on Sewerage & Sewage Treatment

d) IS : 651 – 1992 : S W Pipes and fittings

e) IS : 458 – 2003 : Precast concrete pipes

f) IS : 784 – 2001 : Pre stressed concrete pipes

g) IS : 780 – 1984 : Sluice valves for water works

h) IS : 783 – 1985 : Laying of Concrete pipes

i) IS : 1172 – 1993 : Basic requirement for water supply, drainage & sanitation

j) IS : 1239 (I & II) – 1982 : G I Pipes and fittings

k) IS : 2065 – 1983 : Water supply in buildings

l) IS : 1742 – 1983 : Building drainage

m) IS : 2800 – 1991 : Tubewells / Borewells

n) IS : 5329 – 1983 : Sanitary pipe work above ground

o) IS : 4127 – 1983 : Laying of S W Pipes

p) IS : 4985 – 2000 : UPVC pipes for water supply

TECHNICAL SPECIFICATIONS WATER

SUPPLY

GENERAL REQUIREMENTS

(a) Any damage caused to the building, or to electric, sanitary water supply or other installations etc. therein either due to negligence on the part of the contractor, or due to actual requirements of the work, shall be made good and the building or the installations shall be restored to its original condition by the contractor.

Nothing extra shall be paid for it, except where otherwise specified.

(b) All water supply installation work shall be carried out through licensed plumbers.

(c) It is most important to ensure that wholesome water supply provided for drinking and culinary purposes, is in no way liable to contamination from any less satisfactory water. There shall, therefore, be no cross connection whatsoever between a pipe or fitting for conveying or containing wholesome water and a pipe or fitting for conveying or containing impure water or water liable to contamination or of uncertain quality of water which has been used for any purpose. The provision of reflux or non return valves or closed and sealed valves shall not be construed a permissible substitute for complete absence of cross-connection.

(d) No piping shall be laid or fixed so as to pass into, through or adjoining any sewer,

scour outlet or drain or any manhole connected therewith nor through any ashpit or manure-pit or any material of such nature that would be likely to cause undue deterioration of the pipe.

(e) Where the laying of any pipe through fouled soil or previous material is unavoidable, the piping shall be properly protected from contact with such soil or material by being carried through an exterior cast iron tube or by some other suitable means. Any piping or fitting laid or fixed, which does not comply with the above requirements, shall be removed and re-laid in conformity with the above requirements.

(f) All pipes shall be so laid and fixed and maintained as to be and to remain completely water tight, thereby avoiding waste of water, damage to the property and the risk of contamination of the water conveyed.

(g) The change in diameter and in direction shall preferably be gradual rather than

abrupt to avoid undue loss of head. No bend or curve in piping shall be made so as to alter the cross section.

LAYING AND JOINTING OF WATER SUPPLY PIPES AND FITTINGS

GENERAL SPECIFICATIONS of UNDER GROUND WORKS

1. UNLOADING:

(a) The pipes shall be unloaded where they are required.

(b) Unloading (except where mechanical handling facilities are available) – pipes weighing upto 60 kg shall be handled by two persons by hand passing. Heavier pipes shall be unloaded from the lorry or wagon by holding them in loops, formed with ropes and sliding over planks set not steeper than 45 degree. The planks shall be sufficiently rigid and two ropes shall always be used to roll the pipes down the planks. The ropes should be tied on the side opposite the unloading. Only one pipe shall be unloaded at a time.

(c) Under no circumstances shall be the pipes be thrown down from the carriers or

be dragged or rolled along hard surfaces.

(d) The pipes shall be checked for any visible damage (such as broken edges, cracking or spalling of pipe) while unloading and shall be sorted out for reclamation. Any pipe which shows sufficient damage to preclude it from being used shall be discarded.

2. STORING:

(a) The pipes and specials shall be handled with sufficient care to avoid damage to them. These shall be lined up on one side of the alignment of the trench socket facing upgrade when line runs uphill and upstream when lines run on level ground.

(b) Each stack shall contain pipes of same class and size, consignment or batch

number and particulars of the suppliers, wherever possible, shall be marked on the stack.

(c) Storage shall be done on firm, level and clean ground. Wedges shall be provided

at the bottom layer to keep the stack stable.

3. CUTTING:

(a) Cutting of pipes may be necessary when pipes are to be laid in lengths shorter than the lengths supplied, such as while replacing accessories like tees, bends, etc. at fixed position in the pipe lines.

(b) A line shall be marked around the pipe with a chalk piece at the point where it is

to be cut. The line shall be so marked that the cut is truly at right angle to the longitudinal axis of the pipe.

TRENCHES:

(c) The trenches shall be so dug that the pipes may be laid to the required alignment and at required depth.

(d) Cover shall be measured from top of pipe to the surface of the ground. In general

the cover should be 1000 mm unless specified in drawings.

(e) The minimum width of the trench should be “D + 400 mm”, where, D is outer diameter of the pipe.

(f) For pipes with diameter less than 1200 mm, the bed of the trench shall be

excavated to the pipe grades so that uniform support is assured for the full length of the pipe.

(g) The bed of the trench, if in soft or made up earth, shall be well watered and

rammed before laying the pipes and the depressions, if any, shall be properly filled with earth and consolidated in 20 cm layer.

(h) If the trench bottom is extremely hard or rocky or loose stony soil, the trench shall

be excavated at least 150 mm below the trench grade. Rocks, stone or other hard substances from the bottom of the trench shall be removed and the trench brought back to the required grade by filling with selected fine earth or sand (or fine moorum if fine soil or sand is not available locally) and compacted so as to provide a smooth bedding for the pipe or provide lean cement concrete as required and specified..

(i) After the excavation of the trench is completed, hollows shall be cut at the

required position to receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the barrels of the pipes shall rest throughout their entire length on the solid ground and that sufficient spaces left for jointing the underside of the pipe joint. These socket holes shall be refilled with sand after jointing the pipe.

(j) Roots of trees within a distance of about 0.5 meter from the side of the pipe line

shall be removed or killed.

(k) The excavated materials shall not be placed within 1 meter or half of the depth of

the trench, whichever is greater, from the edge of the trench. The materials excavated shall be separated and stacked so that in refilling that may be re-laid and compacted in the same order to the satisfaction of the Engineer-in-charge.

(l) The trench shall be kept free from water. Shoring and timbering shall be provided

wherever required. Excavation below water table shall be done after dewatering the trenches.

(m) Where the pipe line or drain crosses an existing road, the road crossing shall be

excavated half at a time, the 2nd half being commenced after the pipes have been laid in the first half and the trench refilled. Necessary safety measures for traffic as directed shall be adopted. All types, water main cables, etc. met within the course of excavation shall be carefully protected and supported. Care shall be taken not to disturb the electrical and communication cable met with during course of excavation, removal of which, if necessary, shall be arranged by the Engineer-in-charge.

4. When pipes are laid under road and pavements, subjected to heavy traffic loads, the trench may be covered with RCC slabs of suitable dimensions.

5. LAYING:

(a) The pipes shall be lowered into the trench by means of suitably pulley blocks, sheer legs chains ropes etc. In no case the pipes shall be rolled and dropped into the trench. One end of each rope may be tied to a wooden or steel peg driven

into the ground and the other end held by men which when slowly released will lower the pipe into the trench. After lowering, the pipes shall be arranged so that the spigot of one pipe is carefully centered into the socket of the next pipe, and pushed to the full distance that it can go. The pipe line shall be laid to the levels required. Specials shall also be laid in their proper position as stated above.

(b) Where so directed, the pipes and specials may be laid on masonry or concrete

pillars. The pipe laid on the level ground, shall be laid with socket facing the direction of flow of water.

(c) In unstable soils, such as soft soils and dry lumpy soils it shall be checked

whether the soils can support the pipe lines and if required suitable special foundation shall be provided.

6. THRUST BLOCKS:

(a) Thrust blocks are required to transfer the resulting hydraulic thrust from the fitting of pipe on to a larger load bearing soil section.

(b) Thrust blocks shall be installed wherever there is a change in the direction / size

of the pipe line or the pressure line diagram, or when the pipe line ends at a dead end. If necessary, thrust blocks may be constructed at valves also.

(c) Thrust blocks shall be constructed taking into account the pipe size, water

pressure, type of fitting, gravity component shell when laid on slopes and the type of soil.

7. BACK FILLING AND TAMPING:

(a) Back filling shall follow pipe installation as closely as possible to protect pipe from falling boulders, eliminating possibility of lifting of the pipe due to flooding of open trench and shifting pipe out of line by caved in soil.

(b) The initial back fill material used shall be free of large stones and dry lumps.

(c) The initial back fill shall be placed evenly in a layer of about 100 mm thick. This

shall be properly consolidated and this shall be continued till there is a cushion of at least 300 mm of cover over the pipe.

(d) If it is desired to observe the joint or coupling during the testing of mains they

shall be left exposed. Sufficient back fill shall be placed on the pipe to resist the movement due to pressure while testing.

8. HYDROSTATIC TESTS:

(a) After a new pipe has been laid, jointed and back filled (or any valved section thereof), it shall be subjected to the following two tests :

(b) (m) Pressure test: At a pressure of at least double the maximum working

pressure-pipe and joints shall be absolutely water tight under the test.

(ii) Leakage test: (To be conducted after the satisfactory completion of the

pressure test) at a pressure to be specified by the authority for a duration of two hours.

(c) Hydrostatic Tests: The portions of the line shall be tested by subjecting to

pressure test as the laying progresses before the entire line is completed. In this

way any error of workmanship will be found immediately and can be corrected at a minimum cost. Usually the length of the section to be tested shall not exceed 500m.

(d) Where any section of a main is provided with concrete thrust blocks or

anchorages, the pressure test shall not be made until at least five days have elapsed after the concrete is cast. If rapid hardening cement has been used in these blocks or anchorages, test shall not be made until atleast two days have elapsed.

(e) Prior to testing, enough back fill shall be placed over the pipe line to resist

upward thrust. All thrust blocks forming part of the finished line shall have been sufficiently cured and no temporary bracing shall be used.

(f) The open end of the section shall be sealed temporarily with an end cap having

an outlet which can serve as an air relief vent or for filling the line, as may be required. The blind face of the end cap shall be properly braced during testing by screw jacks and wooden planks or steel plate.

(g) The section of the line to be tested shall be filled with water manually or by a low

pressure pump. Air shall be vented from all high spots in the pipe line before making the pressure strength test because entrapped air gets compressed and caused difficulty in raising the required pressure for the pressure strength test.

PROCEDURE FOR PRESSURE TEST:

1. Each valved section of the pipe shall be slowly filled with water and all air shall be expelled from the pipe through hydrants and blow offs. If these are not available at high places, necessary tapping may be made at points of highest elevation before the test is made and plugs inserted after the tests have been completed.

2. If the trench has been partially back-filled the specified pressure based on the elevation of the lowest point of the line or section under test and corrected to the elevation of the test gauge, shall be applied by means of a pump connected to the pipe in a manner satisfactory to the Engineer-in-charge. The duration of the test shall not be less than 5 minutes.

3. Examination under Pressure: All exposed pipes, fittings, valves, hydrants and

joints should be carefully examined during the open-trench test. When the joints are made with lead, all such joints showing visible leaks shall be recaulked until tight. When the joints are made with cement and show seepage or slight leakage, such joints shall be cut out and replaced as directed by the authority. Any cracked or defective pipes, fittings, valves or hydrants discovered in consequence of this pressure test shall be removed and replaced by sound material and the test shall be repeated until satisfactory to the Engineer-in- charge.

4. If the trench has been back-filled to the top, the section shall be first subjected to

water pressure normal to the area and the exposed parts shall be carefullyexamined. If any defects are found, they shall be repaired and the pressure test repeated until no defects are found. The duration of the final pressure tests shall be at least one hour.

PROCEDURE FOR LEAKAGE TEST:

5. Leakage is defined as the quantity of water to be supplied into the newly laid pipe, or any valved section thereof, necessary to maintain the specified leakage test pressure after the pipe has been filled the water and the air expelled.

No pipe installation shall be accepted until the leakage is less than the number of cm3/h determined by the formula :

ql = ND P / 3.3

Where ql = the allowable leakage in cm3/h. N = number of joints in the length of the pipe line. D = diameter in mm, and

P = the average test pressure during the leakage testing kg/cm2.

6. Variation from Permissible Leakage: Should any test of pipe laid in position discloses leakage greater than the specified in para 5 the defective joints shall be repaired until the leakage is within the specified allowance.

LAYING AND JOINTING UNPLASTICISED P.V.C. PIPES (EXTERNAL WORK)

1. HANDLING AND STORAGE:

Unplasticized P.V.C. pipes are light in weight material. Reasonable care shall be taken in handling and storage of these to prevent damages. On no account the pipes shall be dragged along the ground. Pipes shall be given adequate support at all times. They shall not be stacked in large piles, especially under warm temperature conditions as the bottom pipes may distort, thus giving rise to difficulty in pipe alignment and jointing.

For temporary storage in the field, where racks are not provided care shall be taken that the ground is level and free from loose stones. Pipes stored thus shall not exceed three layers and shall be so stacked as to prevent movement, the pipes shall preferably be stored under shade.

For satisfactory service performance of plastic pipes under conditions of use, the following points must be kept in view while undertaking installation of plastic piping system:

a) The plastic materials are ‘thermoplastic’ in nature, and must not be used in

contact with hot surfaces (or hot water) ;

b) They must be supported at regular intervals for above ground installation ;

c) Allowance must be made, during installation for their expansion, particularly by using loose clips / clamps ;

d) A range of specials, and matching fittings must be identified and their

manufactures / suppliers listed.

2. TRENCHES:

The trench bottom shall be carefully examined for the presence of hard objects such as flints, rock projections or tree roots etc. pipes shall be bedded in sand or soft soil free from rock and gravel. Back fill 15 cm above the pipe shall also be of fine sand or soft soil. Pipes shall not be painted. The width of trench shall be not less than outside dia meter of pipe plus 30 cm in case of gravel soils. Pipes shall be laid at least 90 cms below the ground level (measured from surface of the ground to the top of the pipe).

3. JOINTING:

(a) Solvent welded joints : Non heat application Method :

In this method, instead of forming a socket on one pipe and an injection moulded socket fitting or coupler is used, with a provision to take in the pipes at both ends, the solvent cements are applied on the surfaces to be jointed and the joint is made at ambent temperature. Injection moulded fittings only shall be used in preference to fabricated fittings, only solvent recommended by the manufacturers of the pipes shall be used and full load on the joints applied only after 24 hours. The pipe shall be cut perpendicular to the axis of the pipe length with a metal cutting saw or an ordinary hand saw with small teeth. Pipe ends have to be beveled slightly with a beveling tool (Reamer) at an angle of about 30 degree. The total length of insertion socket (injection moulded socket or couplet) shall be marked on the pipe and checked how far the pipe end could be insertedinto the fitting socket. Attempt shall be made to push the pipe to the marked distance if not possible it shall at least be pushed for 2/3 of this distance.Dust, oil, water

grease etc. shall be wiped cut with a drycloth from the surface. Further the grease should be throughly removed with a suitable solvent, such as methylene chloride or as an alternative the outside surface of the pipe and the inside of the fitting may be roughened with emery paper.

Generous coating of solvent cement shall be evenly applied on the inside of the fitting alround the circumference for the full length of insertion and on the outside of the pipe end upto the marked line with non synthetic brush of suitable dimension. The pipe shall be pushed into the fitting socket and held for 1 or 2 minutes as otherwise the pipe may come out of the fitting due to the slippery quality of cement and the tapering inside bore of the fitting. The surplus cement on the pipe surfaces shall be wiped out. If the solvent cement has dried up too much or the tapering of the socket is too steep, jointing will not be proper and pipe will come out of the fitting.

In summer months joints shall be made preferable early in the morning or in the evening when it is cooler. This will prevent joint from pulling apart when the pipe cools off at night. Heat application method for jointing shall not be allowed.

(b) Flanged Joints:

For jointing P.V.C. pipes particularly of larger sizes to valves and vessels and larger size metal pipes where the tensile strength is required the joint is made by the compression of a gasket or ring seal set in the face of C. I. flange. Flanges solvent welded to the P.V.C. pipes shall be supplied by the manufacturers.

4. CROSSING ROAD OR DRAIN:

Where the pipe line crosses a road or a drain, it shall be through R.C.C. pipe.

5. SUPPORTS FOR VALVE AND HYDRANT:

Valve and hydrant tees shall be supported, so that the torque applied in operating a valve is not transmitted to the pipe line.

6. INSPECTION AND TESTING:

Solvent welded pipe shall not be pressure tested until at least 24 hours after the last solvent cemented joint has been done.

All control valves shall be positioned open for the duration of the test and open end closed with water tight fittings. The testing pressure on completion of the work shall not be less than one and a half time the working pressure of the pipes.

Pressure shall be applied either by hand pump or power driven pump. Pressure gauges shall be correctly positioned and closely observed to ensure that at no time are the test pressure exceeded. The systems shall be slowly and carefully filled with water to avoid surge pressure or water hammer. Air vents shall be open at all high points so that air may be expelled from the system during filling.

When the system has been fully charged with water and air displaced from the line air vent shall be closed and the line initially inspected for seepage at joints and firmness of supports under load. Pressure may then be applied until the required test pressure is reached.

Without any additional requirement of make-up-water the test pressure should not fall

more than 0.2 kg/sq.cm. at the end of one hour test duration.

7. MEASUREMENTS:

The length shall be measured in running meter correct to a cm for the finished work which shall include P.V.C. fittings such as bends, tees, elbows, reducer, crosses, plugs, sockets, nipples and nuts, but exclude taps, valves, etc. All pipes and fittings shall be classified according to their outside diameters and pressure ratings. Fitting of unequal outside diameter shall be measured along with the larger diameter pipe.

P.V.C. Pipes Service Connection

Either metal or P.V.C. saddles, as specified, shall be used for the off take of service connections from larger bore pipes (50 mm diameter and above). The saddle consists of two half round sections of metal or P.V.C. which are bolted together or held round the pipe by wedge grips. A seal is formed between the saddle and the pipe and the under surface of the upper section. The service connection is taken from a boss on the upper section.

Conventional equipment for tapping under pressure may be used with these service connections using a special trapanning cutter to pierce the pipe wall. Ferrules shall not be screwed directly into pipes without the introduction of saddle piece. A typical illustration of a ferrule connection 20.11.2

Measurements

Connections shall be enumerated.

Rate

The rate shall include the cost of labour and materials involved in all the operations described above.

P.V.C. Pipe-Repairs

While temporary or emergency repairs may be made to the damaged pipes, permanent repairs should be made by replacement of the damaged section. In case of damage by external blows, the extent of the damage may be greater on the inner-surface.

Sometimes, pipes are damaged accidentally due to trenching operation in street repairs. Shell split or chipout occur in the wall of the pipe, a short piece of pipe of sufficient length to cover the damaged portion of the pipe is cut. The sleeve is cut longitudinally and heated sufficiently to soften it so that it may be slipped over the damaged pipe. I

Measurements

Repairs shall be enumerated.

Rate

Rate shall include the cost of all materials and labour involved in all the operations described above.

Laying and Jointing P.V.C. Pipes (Internal Work)

Clamping

The pipes shall be laid and clamped to wooden plugs fixed above the surface of the wall. Alternatively plastic clamps of suitable designs, wherever manufactured, shall be preferred. Provision shall be made for the effect of thermal movement by not gripping or districting the pipe at supports between the anchors for suspended pipes. The supports shall allow the repeated longitudinal temperature movement to take place without abrasion. Line or point contact with the pipe shall be avoided. Heavy components such as metal valves shall be individually supported.

Supports

P.V.C. pipes require supports at close interval. Recommended support spacings for unplasticised P. V.C. pipes are given in Table 2. This spacing may be increased by 50% for vertical run support.

TABLE 2

Pipe Dia mm Support spacing mm

20

700

25 750

32 825

40 975

50 975

It is essential that P.V.C pipes shall be aligned properly before fixing them on the wooden plugs with clamps. Even if the wooden plugs are fixed using a plumb line, P.V.C. pipe shall also be checked for its alignment before clamping. The pipe line will be wavy if the clamps are not fixed keeping the pipe plumb.

Connection to a Water Tap

Connection to the water tap shall be made by means of a G.I. adopter. G.I. adopter shall preferably be supplied by the same manufacturer as that of P.V.C. pipe. In any threaded coupling between P.V.C. and G.I. it is preferable that P.V.C. is fitted inside the G.I. fitting. If however greater projection is desired, same shall be achieved by joining a short piece of a G.I. pipe (Nipple)

Connection from Masonry/Concrete Water Tank

Solvent cement shall be coated on the section of the pipe to be embedded in concrete. Fine dry sand and cement mixture shall be sprinkled uniformly around the pipe. This shall give a rough surface which can be safely embedded in concrete; water proofing cement shall be used to close the gap properly.

Measurements

The length shall be measured in running metre correct to a cm for the finished work which shall include P.V.C. fittings such as bends, tees, elbows, reducer, crosses plugs, sockets, nipples and nuts, but exclude, taps, valves, etc. All pipes and fittings shall be classified according to their outside diameters and pressure ratings. Fittings of unequal outside diameter shall be measured along with the larger diameter pipe.

Rate

The rate shall include the cost of labour and material in all the operation described above, except metal pipe used for encasing P.V.C. pipe and anchor blocks, unless otherwise specified.

CPVC PIPES FOR COLD & HOT WATER SUPPLY DISTRIBUTION NETWORK

The scope of this specifications cover pipes & fittings using CPVC Compound. The CPVC compound shall confirm to NSF certification for use in drinking / portable water. It also covers general & technical properties of the CPVC pipes, fittings, the basic compound, installation procedures, cement solvent details, special fittings, Concealed & external plumbing etc.

STANDARDS & SPECIFICATIONS

IS: 15778: 2007 -Specification for Chlorinated Poly Vinyl Chloride (CPVC) Pipes for Potable Hot & Cold water distribution systems.

ASTM D1784 - Standard Specification for Rigid Poly Vinyl Chloride (PVC) and Chlorinated Poly

Vinyl Chloride (CPVC) Compounds.

ASTM D2846 - Specification for Chlorinated Poly Vinyl Chloride (CPVC) Plastic Hot & Cold water distribution systems.

ASTM F493 - Standard Specification for Solvent Cements for Chlorinated Poly Vinyl Chloride

(CPVC) Plastic Pipe & Fittings.

Technical Details of CPVC {Abbreviations: OD Outer Dia., ID Inner Dia., WT Wall Thickness.}

General Properties:

Specific Gravity ASTM D 792 23oC 1.55 Specific Volume ASTM D 570 23oC 0.645cm2/g Water Absorption ASTM D 785 23oC +0.03%

100OC +0.55%

MECHANICAL

Izod Impact ASTM D 256 23oC 80J/mo.n Tensile Strength ASTM D 638 23oC 55N/mm2 Flexural Strength ASTM D 790 23OC 104N/mm2

Compressive Strength ASTM D 695 23OC 70N/mm2

TECHNICAL DETAILS

Outside Diameter and Wall Thickness for CPVC SDR 11 Plastic Pipe

Nominal Size (MM)

Avg. OD MM (SDR II)

Tolerance (MM)

Min. Wall Thickness MM (SDR II)

Tolerance (MM)

15 15.90 +/- 0.08 1.70 + 0.51

20 22.20 +/- 0.08 2.00 + 0.51

25 28.60 +/- 0.08 2.59 + 0.51

32 34.90 +/- 0.08 3.18 + 0.51

40 41.30 +/- 0.10 3.76 + 0.51

50 54.00 +/- 0.10 4.90 + 0.58

CPVC SDR 11 Pipe Pressure Rating vs Temperature Table

Operating Temperature Working Pressure Rating (kg/cm2)

SDR II

15 TO 50 MM DIA

23°C 28.10

27°C 28.10

32°C 25.57

38°C 23.05

43°C 21.64

49°C 18.27

54°C 17.42

60°C 14.05

66°C 13.21

71°C 11.24

77°C 8.99

82°C 7.03

93°C 5.62

JOINING CPVC PIPES & FITTINGS

CUTTING –

In order to make a proper and neat joint, measure the pipe length accurately and make a small mark. Ensure that the pipe and fittings are size compatible. Cut the pipe with a plastic pipe cutter or hacksaw blade. Cutting tubing as squarely as possible provides optimal bonding area within a joint.

DEBURRING / BEVELING –

Burrs and fillings can prevent proper contact between tube and fitting during assembly and should be removed from the outside and inside of the pipe. Debarking tool, pocket knife or file is suitable for this. A slight bevel on the end of the tubing will ease entry of the tubing into the fitting socket.

FITTING PREPARATION -

Using a clean, dry rag, wipe dirt and moisture from the fitting sockets and tubing end. The tubing should make contact with the socket wall 1/3 to 2/3 of the way into the fitting socket.

SOLVENT CEMENT APPLICATION –

Use only CPVC cement or an all – purpose cement conforming to ASTM F 493 or joint failure may result. When making a joint, apply a heavy, even coat of coat of cement to the pipe end. Use

the same applicator without additional cement to apply a thin coat inside the fitting socket. Too much cement can cause clogged water ways.

ASSEMBLY –

Immediately insert the tubing into the fitting socket, rotate the tube ¼ to ½ turn while inserting. This motion ensures and even distribution of cement within the joint. Properly align the fittings. Hold the assembly for approximately 10 seconds, allowing the joint to set-up.

SET AND CURE TIMES –

Solvent cement set and cure times are a function of pipe size, temperature and relative humidity. Curing time is shorter for drier environments, smaller sizes and higher temperatures. It requires 10 to 20 minutes for perfect joint.

MINIMUM CURE TIME PRIOR TO PRESSURE TESTING AT 150 PSI(10 BAR)

Ambient Temperature During Cure Period

Pipe Sizes

15 to 25 mm dia 32 to 50 mm dia

Above 15°C 1 Hour 2 Hours

4 - 15°C 2 Hours 4 Hours

Below 4°C 4 Hours 8 Hours

TESTING

Once an installation is completed and cured as per these recommendations. The system should be hydrostatically pressure tested at10 bar for one hour is recommended. When pressure testing, the system should be filled with water and all air bled from the highest and farthest points in the run. If a leak is found, the joint must be cut out and discarded. A new section can be installed using couplings. During sub-freezing temperatures, water should be blown out of the lines after testing to eliminate potential damage from freezing. Air testing is not recommended.

HANDLING AND STORAGE

Reasonable care should be exercised in handling CPVC tubing and fittings. They should not be dropped, stepped on, or have objects thrown on them. If improper handling or heavy impact results in cracks, splits or gouges, the damaged section should be discarded. CPVC tubing should be covered with a non-transparent material when stored outdoors for long periods of time. When installing CPVC pipe and fitting in an area that is exposed to direct sunlight for an extended period of time, protect the pipe with insulation or an acrylic water based white paint.

HANGER AND SUPPORTS

For vertical / horizontal runs, support at 1 meter intervals for all diameter is desired. Piping should not be anchored tightly to supports, but rather secured with smooth straps or hangers that allow for movement caused by expansion and contraction.

SAFE HANDLING OF SOLVENT CEMENT

When using solvent cements, primers and cleaners there are some basic safety measures all users should keep in mind.

Avoid prolonged breathing of solvent vapors. When pipe and fittings are being joined in enclosed areas, the uses of ventilating devices are advised.

Keep cements, primers and cleaners away from all sources of ignition, heat, sparks and open flame.

Keep containers of cements, primers and cleaners tightly closed except when the product is being used.

Dispose of all rags used with solvents in a proper outdoor waste receptacle.

Avoid eye and skin contact. In case of eye contact, flush with plenty of water for 15 minutes and call a physician.

PVC (Sch40 & sch80) PIPES FOR COLD WATER SUPPLY DISTRIBUTION NETWORK

PRODUCT FEATURES

General –

PVC sch 40 / 80 plumbing system is suitable for all cold water plumbing and drinking water applications. The pipes are manufactured by extrusion process and fittings are manufactured by injection moulding process.

Raw Material –

The rigid PVC (Polyvinyl Chloride) compound used in the manufacture of pipes and fittings is Type 1, i.e. Grade 1 PVC 1120 as identified in ASTM D 1784. The compound contains specified amounts of pigment, stabilizers and other additives to facilitate extrusion.

Product Specifications –

The system is made as per ASTM (American Society for Testing of Materials) standards. The Pipes are made as per ASTM D 1785 and Fittings are made as per ASTM D 2466 (for SCH 40 Fittings) and ASTM D 2467 (for SCH 80 Fittings). The pipes are plain ended in lengths of 3 meters in SCH 40 and SCH 80 pressure classes.

PRESSURE RATING – PVC SCHEDULE 40

Norm Size (mm) Max. Work Pre. at 23°C (kg/cm2)

15 42.19

20 33.75

25 31.64

32 26.01

40 23.20

50 19.69

65 21.09

80 18.28

100 15.47

150 12.66

PVC SCHEDULE 40 & 80 PRESSURE PIPES AND FITTINGS INSTALLATION PROCEDURES

1. CUT PIPE

Cut pipe square. As joints are sealed at the base of the fitting socket. An angled cut result in joint failure.

Acceptable tools include miter saw, mechanical cut off saw or wheel cutter. Wheel type cutters must employ a blade designed for plastics.

2. REMOVE BURR AND BEVEL

Remove all burrs from inside and outside of pipe with a knife-edge, file, or deburring tool. Chamfer (bevel) the end of the pipe 10° - 15°.

CLEAN

Remove surface dirt, grease, or moisture with a clean dry cloth.

3. DRY FIT

With light pressure, pipe should go one third to one half of the way into the fitting socket. Pipes and fittings that are too tight or too loose should not be used.

4. APPLICATOR

Use an applicator that is one half the pipe diameter.

Too large an applicator will force excessive cement into the inside of small diameter fittings. Too small an applicator will not apply sufficient cement to large diameter systems.

5. CEMENT

Apply a full even layer of cement to the outside of a pipe and medium layer of cement to the inside of a fitting.

6. JOIN PIPE AND FITTINGS

Assemble pipe and fitting socket till it contacts socket bottom. Give pipe a quarter turn. Hold pipe and fitting together until the pipe does not back out.

Remove excessive cement from the exterior. A properly made joint will show a

continuous bead of cement around the perimeter.

PVC cement for SCH 40 and interference fit Pipe Size (In.) Cement Type Min. Vis. (CP) IPS-weld On

15 – 50 mm Medium bodied 500 705

65 – 150 mm Heavy bodied 1600 717

PVC SCHEDULE 40 & SCHEDULE 80 PRESSURE PIPES AND FITTINGS SUPPORT SPACING FOR PVC PIPE -

SUPPORT AND SPACING

All piping should be supported with an approved hanger at intervals sufficiently close to maintain correct pipe alignment and to prevent sagging or geode reversal. Pipe should also be supported at all branch ends and at all changes of direction. Support traps arms as close as possible to the trap. In keeping with good plumbing practices support and brace all closet bends and fasten closet flanges.

1. Concentrated load should be supported directly so as to eliminate high stress concentrations.

Should this be impractical then the pipe must be supported immediately adjacent to the load.

2. In system where large fluctuations in temperature occur, allowances must be made for

expansion and contraction of the piping system. Since changes in direction in the system are usually sufficient to allow for expansion and contraction hangers must be placed so as not to restrict this movement.

3. Hangers should provide as much bearing surface as possible. To prevent damage to the

pipe, file smooth any sharp edges or burrs on the hungers or supports.

Schedule – 40

Recommended Support spacing (in mm)

Nom. Pipe Size (mm)

Support Spacing (mm)

15 750

20 750

25 900

32 900

40 1000

50 1000

63 1200

75 1200

100 1350

150 1500

PVC SCHEDULE 40 & SCHEDULE 80 PRESSURE PIPES AND FITTINGS –

JOINT CURING -

Recommended initial set times

Temperature Pipe Size Pipe Size Pipe Size

Range 15 – 32 mm 40 – 80 mm 100 – 150 mm

15.5°C – 37.7°C 15 min. 30 min. 1 hour

4.4°C – 15.5°C 1 hour 2 hours 4 hours

Recommended initial cure times

Temperature Pipe Size Pipe Size Pipe Size

Range 15 – 32 mm 40 – 80 mm 100 – 150 mm

15.5°C – 37.7°C 6 hours 12 hours 24 hour

4.4°C – 15.5°C 12 hour 24 hours 48 hours

TESTING PRESSURE SYSTEM

1. Conduct pressure testing with water. DO NOT USE AIR OR OTHER GASES for pressure testing.

2. The piping system should be adequately anchored to limit movement. Water under pressure exerts thrust forces in piping systems. Thrust blocking should be provided at changes of direction, change in size and at dead ends.

3. Refer tables given for initial set & cure times before pressure testing.

4. The piping system should be slowly filled with water, taking care to prevent surge and air entrapment. The flow velocity should not exceed 1 feet per second.

5. All trapped air must be slowly released. Vents must be provided at all high points of the piping system. All valves and air relief mechanisms should be opened so that the air can be vented while the system is extremely dangerous and it must be slowly and completely vented prior to testing.

6. The piping system can be pressurized to 125% of its designed working pressure. However care must be taken to ensure the pressure does not exceed the working pressure of the lowest rated component in the system (valves, unions, flanges, threaded parts etc.)

7. The pressure test should not exceed one hour. Any leaking joints or pipe must be cut out and replaced and the line recharged and retested using the same procedure.

UNDERGROUND INSTALLATION

PVC pipes and fittings can be installed underground, since these piping systems are flexible systems, proper attention should be given to burial conditions. The stiffness of the piping system is affected by sidewall support, soil compaction, and the condition of the trench, Trench bottoms should be smooth and regular in either undisturbed soil or a layer of compacted backfill. Pipe must lie evenly on this surface throughout the entire length of its barrel.

TRENCHING The following trenching and burial procedures should be used to protect the piping system.

1. The trench should be excavated to ensure the sides will be stable under all working

conditions.

2. The trench should be wide enough to provide adequate room for the following –

Jointing the pipe in the trench.

Snaking the pipe from side or side to compensate for expansion and contraction.

Filling and compacting the side fills.

The space between the pipe and trench wall must be wider than the compaction equipment used in the compaction of the backfill. Minimum width shall not be less than the greater of either the pipe outside diameter plus 16 inches or the pipe outside diameter times 1.25 plus 12 inches. Trench width may be different if approved by the design engineer.

3. The trench bottom should be smooth, free of rocks and debris, continuous, and provide uniform support. If ledge rock, hardpan or large boulders are encountered, the trench bottom should be padded with bedding of compacted granular material to a thickness of at least 4 inches. Foundation bedding should be installed as required by the engineer.

4. Trench depth is determined by the pipe’s service requirements. Plastic pipe should

always be installed at least below the frost level. The minimum cover for lines subject to heavy overhead traffic is 24 inches.

5. A smooth, trench bottom is necessary to support the pipe over its entire length on firm

stable material. Blocking should be used charge pipe grade or to intermittently support pipe over low sections in the trench.

BEDDING AND BACKILLING

1. Even though sub-soil conditions vary widely from place to place, the pipe backfill should be stable and provide protection for the pipe.

2. The pipe should be surrounded with a granular material which is easily worked around

the sides of the pipe Backfilling should be performed in layer of 6 inch. With each layer being sufficiently compacted to 85% to 95% compaction.

3. A mechanical tamper is recommended for compacting sand and gravel backfill which

contain a significant proportion of fine grained material, such as silt and clay. If a tamper is not available, compacting should be done by hand.

4. The trench should be completely filled. The backfill should be placed and spread in fairy uniform layers to prevent any unfilled spaces or voids. Large rocks, stones, frozen clods, or other large debris should be removed. Heavy tampers or rolling equipment should only be used to consolidate only the final backfill.

5. HANDLING

The pipe should be handled with reasonable care. Because thermoplastic pipe is much lighter in weight than metal pipe. There is sometimes a tendency to throw it around. This should be avoided.

The pipe should never be dragged or pushed from a truck bed. Pallets for pipe should be removed with a fork lift. Loose pipe can be rolled down timbers, as long as the pieces do not fall

on each other or on any hard or uneven surface.

In all cases, severe contact with any sharp objects (rocks, angle irons, forks on forklifts, etc.) should be avoided.

STORING

If possible, pipe should be stored inside. When this is not possible, the pipe should be stored on level ground which is dry and free from sharp objects. If different schedules of pipes are stacked together, the pipe with the thickest walls should be at the bottom.

The pipe should be protected from the sun and be in an area with proper ventilation. This will lessen the effects of ultraviolet rays and help prevent heat built-up.

If the pipe is stored in racks, it should be continuously supported along its length. If This is not possible, the spacing of the supports should not exceed three feet (3’).

POLYETHYLENE WATER STORAGE TANKS

1. MATERIAL: Polyethylene used for manufacture of tanks and manhole lids shall be high density (HDPE); and shall conform to IS: 10146. Polyethylene shall be compounded with carbon black so as to make the tank resistant to ultra violet rays from the sun. The percentage of carbon black content in polyethylene shall be 2.5 ± 0.5 percent and it shall be uniformly distributed. The materials used for the manufacture of tank, manhole lid and fittings shall be such that they neither contaminate the water nor impart any taste, colour, odour or toxity to water.

2. MANUFACTURE AND FINISH:

The tanks shall be manufactured by rotational moulding process. Each tank and the manhole lid shall be single piece having arrangement for fixing and locking the manhole lid with the tanks. Excess material at the mould parting line and near the top rim shall be neatly cut and finished. The internal and external surface of the tanks shall be smooth, clean and free from didden internal defects like air bubbles, pit and metallic or other foreign material inclusion. Capacity of the tank, minimum weight of the empty tank (without manhole lid) and the manufacture brand name shall be embossed on the top surface of the tank near manhole.

3. SHAPE, SIZE AND CAPACITY:

The tank shall be cylindrical vertical with closed top having a manhole. Diameter and height of the tank of various capacities shall be as per manufacturer’s specifications and a clearance of ±3 percent shall be permitted on these dimensions.

4. WEIGHT AND WALL THICKNESS:

Minimum weight of the empty tank (exclusive of manhole lid fittings) and the minimum wall thickness of top, bottom and sides shall be specified in Table below. Wall thickness shall be checked beyond 150 mm of the edge where the direction the plane of tank surface changes.

TABLE

S.No. Capacity (liters)

Minimum Wall thickness (mm)

Minimum Weight of empty Tank (kg)

(1) (2) (3) (4)

1. 200 4.4 7.8

2. 300 4.4 9.0

3. 400 5.5 15.0

4. 500 6.0 18.0

5. 700 6.6 23.5

6. 1000 7.0 33.0

7. 1250 7.0 40.0

8. 1500 7.0 47.0

9. 1700 7.0 54.0

10. 2000 8.2 64.0

11. 2500 8.2 81.0

12. 3000 8.8 96.0

13. 4000 10.0 138.0

14. 5000 10.7 191.0

15. 6000 10.7 209.0

16. 7500 10.7 250.0

17. 10000 11.5 363.0

18. 15000 11.5 550.0

19. 20000 13.2 814.0

5. INSTALLATION AND FITTINGS :

The flat base of the tank shall be fully supported over its whole bottom area on a durable rigid flat and level platform sufficiently strong to stand without deflection the weight of the tank when fully filled with water. Depending upon the capacity and location tanks may be suitably anchored as per the directions of the Engineer-in-charge. For inlet, outlet and other connections fully threaded G. I. HDPE or PVC connections with hexagonal checknuts and washerson either side of the tank wall shall be provided. Holes for threaded connections shall be drilled and not punched. Pipes entering of leaving the tank shall be provided with unions and suitably supported on a firm base to avoid damage to the tank walls.

6. MANHOLE LID:

The lid shall rest evenly and fit over the rim of the manhole so as to prevent the ingress of any foreign mater into the tank. The lid shall be provided with suitable arrangement for locking it with the tank.

SOIL, WASTE, VENT AND RAIN WATER PIPES AND FITTINGS

(PVC PIPES)

1 SCOPE OF WORK

The scope of this section comprises the supply, installation, testing and commissioning of internal soil, waste, vent and rain water disposal pipes.

2 BASIC PIPING SYSTEM

Soil, waste, vent and rain water pipes of 75 / 110 / 160 mm dia in shafts, ducts and in concealed areas i.e. sunken slab etc. shall consist of UV stabilized uPVC SWR pipes as per type B of IS:13592 & fittings as per IS:14735. The pipes and fittings shall be suitable for rubber ring joint. All fittings shall be of injection moulded type. The rubber rings shall confirm to IS : 5382. The waste pipes of 65 mm and smaller dia shall be of rigid uPVC as per IS:4985 of min 6 kg / sq cm, suitable for solvent cement joints.

The wall thickness of Pipes shall be as follows –

75 mm diameter - wall thickness 3.2 to 3.8 mm

110 mm diameter - wall thickness 3.2 to 3.8 mm

160 mm diameter - wall thickness 4.0 to 4.6 mm

Pipes shall be fixed by means of clamps in two sections, bolted together, built into the walls, wedged and neatly jointed as directed and approved by the Engineer. All bends, branches, swan neck and other parts shall conform to the requirement and standards as described for the pipes. Pipes shall be rested against the walls on suitable wooden cradles. Local authority regulations applicable to the installations shall be strictly followed.

Where indicated, the soil pipes shall be continued upwards without any diminution in its diameter, without any bend or angle to the height shown in the drawings. Joints throughout shall be made with rubber ring method for 75/110/160 mm dia and solvent cement for 65 mm and lower dia pipes. The soil pipes shall be covered on top with cowl as directed and approved. All vertical soil pipes shall be firmly fixed to the walls with properly fixed clamps, and shall as far as possible be kept 50mm clear of wall.

Every waste pipe shall connected to the floor trap through the PVC hopper pipe / height raiser and branch saddle strip or to a multi floor trap. No waste pipe shall be discharged over the grating. The contractor will ensure that this requirement is adequately met with. Wherever floor traps are provided, it shall be ensured that at least one wash is connected to such floor traps to avoid drying of water seal in the trap. Ventilating pipes shall be of UPVC SWR pipes, conforming to the requirements laid down earlier.

Where soil, waste and ventilating pipes are accommodated in shafts ducts, adequate access to cleaning eyes shall be provided.

The internal and external pipe surfaces shall be smooth and clean. They shall be free from grooves, obstructions or other defects. All pipe ends shall be cut cleanly and shall be perpendicular to the axis of pipes.

All fittings used in UPVC piping systems shall be of similar characteristic and same make as those of the pipes. All uPVC fittings shall be factory fabricated suitable for jointing to pipes with rubber rings for 75 / 110 / 160 mm dia and with solvent cement for 65 mm dia and below. Appropriate solvents as recommended by the pipe manufacturer shall be used for installing the pipes at site. Solvents shall be supplied to site in original manufacturer's container.

All Water closets shall be connected through WC connectors of suitable type as per site requirements.

The water seal of all floor traps which are connected into the pipe and manholes shall be minimum 50 mm as per IS : 5329. For other traps used as branch connections may have lesser water seal.

All pipes and fittings shall be stored, handled, cut, laid and installed in position strictly as per manufacturer's recommendations.

As soon as uPVC pipes and fittings are received at site, they shall be examined for their wall thickness and pressure rating. Only pipes and fittings and solvents of approved manufacture shall be used.

UPVC pipes require supports at close intervals. Recommended support spacing for unplasticised PVC pipes is 1400 mm for pipes 50 mm dia and above. Pipes shall be aligned properly before fixing them on the wooden plugs with clamps. Even if the wooden plugs are fixed using a plumb line, pipe shall also be checked for its alignment before clamping, piping shall be properly supported on or suspended from clamps, hangers as specified and as required. The Contractor shall adequately design all the brackets, saddles, anchors, clamps and hangers and be responsible for their structural sufficiency. Pipe supports shall be primer coated with rust preventive paint.

3 INSTALLATION OF SOIL, WASTE & VENT PIPES

All Horizontal pipes running below the slab and along the ceiling, shall be fixed on structural adjustable clamps, sturdy hangers of the design as called for. The pipes shall be laid in uniform slope and proper levels. All vertical pipes shall be truly vertical fixed by means of stout clamps in two sections, bolted together, built into the walls, wedged and neatly jointed. The branch pipes shall be connected to the stack at the same angle as that of fittings. All connections between soil, waste and ventilating pipes and branch pipes shall be made by using pipe fittings with inspection doors for cleaning. Pipes shall be fixed in a manner as to provide easy accessibility for repair and maintenance and shall not cause obstruction in shafts. Where the horizontal run off the pipe is long or where the pipes cross over building expansion joints etc.

Use WC connectors for the connection of WC to the soil pipes. Apply rubber lubricant on WC connector ring as well as on the outer side of WC pan.

4 JOINTING

(a) Make sure the spigot end and inside of socket is clean and the sealing ring is placed evently in the socket.

(b) When cutting pipes, make sure they are cut square. Chamfer the end cut to angle of 15° with a medium file.

(c) A correct depth of entry of the spigot into the socket is required to allow thermal movement. To achieve this, push spigot fully into the socket (remove sealing ring at this time) and make a mark on the spigot. Withdraw the spigot by 10 mm & mark the spigot with a bold line. This bold mark indicates the correct depth of entry to allow the necessary expansion gap.

(d) Smear rubber lubricant evently on the chamfered spigot and the sealing ring. Then insert the spigot into socket with light twisting motion. Pull out the pipe to allow 10 mm expansion gap.

(e) The joint is now complete and required no additional mastics, tape or cement or any other jointing sealants.

5 CUTTING AND MAKING GOOD

Pipes shall be fixed and tested as building proceeds. The contractor shall provide all necessary holes, cutouts and chases in structural members as building work proceeds. Wherever holes are cut or left originally they shall be made good with cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 stone aggregate 20 mm nominal size) or cement mortar 1:2 (1 cement : 2 coarse sand) Cured and the surface restored to original condition.

Since, the toilet and kitchen floor are not sunken. Hence, provision should be made in

slab during its casting, for holes for soil and waste pipes. For this purpose a brick may be placed at slab at exact location of pipe, so that the cutting and making good the slab becomes easy and there shall be no requirement of slab cutting at later stage.

110/160 mm dia PVC sleeve should be left in beams, retaining wall or any other place before its casting for passing of soil/waste pipe. The contractor should prepare shop drawing for the exact location of sleeve and get it approved from the consultant. Cutting of structural member will not be permitted at later stage

6 PIPE PROTECTION

Where pipes are embedded in floors, slabs, columns, beams etc., they shall be given a protection by encasing them with 75 mm thick 1:2:4 cement concrete all round the pipes and fittings as specified in Bill of Quantity.

SANITARY FIXTURES & CP FITTINGS

1. SCOPE

The scope of this section consists supply, installation, testing and commissioning of following items.

a. Sanitary appliances and fixtures for toilets.

b. Chromium plated brass fittings

c. Stainless steel sinks in kitchen area

d. Accessories e.g. towel rods, toilet paper holders, soap dish, towel rails, coat hooks etc.

Whether specifically mentioned or not the Contractor shall provide for all appliances and fixtures all fixing devices, nuts, bolts, screws, hangers as required.

All exposed pipes within toilets and near appliances/fixtures shall be of chromium plated brass or copper unless otherwise specified.

All sanitary fixtures and bathroom fittings will be strictly as per the Make and model catalogue number mentioned in the BOQ or desired by the owner / architect / consultant / Employer as an alternative to the mentioned model with all accessories related to the model.

2 GENERAL REQUIREMENTS

All glazed Vitreous China Sanitary Ware fixtures shall conform to Bureau of Indian Standards IS: 2556. The details make and type of the fixtures shall be as provided in the Bill of Quantities. The Vitreous China Sanitary ware shall be of one of the makes specified in the document. They shall be of non-porous and fully vitreous, with all the visible portions perfectly glazed and shall absolutely be free from hairline cracks pinholes and local depressions. It shall be perfectly symmetrical, uniform and with smooth curves. All sanitary fixtures and fittings shall be stored under covered roof and handled carefully to prevent any damage.

All materials shall be new and of quality conforming to specifications and subject to the approval of the Engineer. Wherever particular makes are mentioned, the choice of selection shall remain with the Architect/Consultant.

All appliances, fixtures and fittings shall be provided with all such accessories as are required to complete the item in working condition whether specifically mentioned or not in the Bill of Quantities, specifications, drawings. Accessories shall include proper fixing arrangements, brackets, nuts, bolts, washers, screws and required connection pieces.

The sanitary fixtures and fittings shall be installed at the correct assigned position as shown on the drawings and as directed by the Engineer and shall fully meet with the aesthetic and symmetrical requirements as demanded by the Engineer.

All fixtures and accessories shall be fixed in accordance with a set pattern matching the tiles or interior finish as per Architect requirements. Wherever necessary, the fittings shall be centered to dimensions and pattern as called for.

Fixing screws shall be half round head chromium plated (CP) brass screws, with CP brass washers unless otherwise specified. Chromium plated fittings shall be cast brasschromium plated of the best quality as detailed in the Bill of Quantities and shall be approved by Engineer prior to installation.

Fixtures shall be installed by skilled workman with appropriate tools according to the best trade practice. Manufacturer's instructions shall be followed for the installation of fixtures. Fixtures in all toilets shall be standard height mounting as called for on the drawings. Fixtures shall be mounted rigid, plumb and true to alignment.

All appliances, fittings and fixtures shall be fixed in a neat workmanlike manner true to level and to heights shown on the drawings and in accordance with the manufacturers' recommendations. Care shall be taken to fix all inlet and outlet pipes at correct positions. Faulty locations shall be made good and any damage to the finished floor; tiling, plaster, paint, insulation or terrace shall be made good by the Contractor at his own cost.

All materials shall be rust proofed; materials in direct or indirect contact shall be compatible to prevent electrolytic or chemical (bimetallic) corrosion.

Wall flanges shall be provided on all walls, floors, columns etc. wherever supply and disposal pipes pierce through them. These wall caps shall be or chromium plated brass snugly fittings and the receiving pipes and shall be large enough to cover the punctures properly.

Sanitary appliances, subject to the type of appliance and specific requirements, shall be fixed in accordance with the relevant standards and the following:

Contractor shall, during the entire period of installation and afterwards, protect the appliances by providing suitable cover or any other protection so as to absolutely prevent any damage to the appliances until handing over (The original protective wrapping shall be left in position for as long as possible)

The appliances shall be placed in correct position or marked out in order that pipe work can be fixed or partially fixed first.

The appliance shall be fixed in a manner such that it will facilitate subsequent removal if necessary.

The appliance shall be securely fixed. Manufacturer's brackets and fixing methods shall be used wherever possible. Compatible rust proofed fixings shall be used. Fixing shall be done in a manner that minimize noise transmission.

Appliances shall not be bedded (e.g. WC pans, pedestal units) in thick strong mortar that could crack the unit (e.g. ceramic unit)

Pipe connections shall be made with demountable unions. Pipe work shall not be fixed in a manner that it supports or partially supports and appliance.

Appliances shall be fixed true to level firmly fixed to anchor or supports provided by the manufacturer and additional anchors or supports where necessary.

Sizes of sanitary fixtures given in the Specifications or in the Bill of Quantities are for identification with reference to the catalogues of make considered. Dimensions of similar models of other makes may very within +_ 10% and the same shall be provided and no claim for extra payment shall be entertained no shall any payment be deducted on this account.

Samples of Sanitary appliances and fixtures for toilets, chromium plated brass fittings, stainless steel sinks, accessories like towel rods, toilet paper holders, soap dish, liquid soap dispensers, towel rails coat hooks, hand driers, drinking water fountains etc as listed in the relevant items in the Bill of Quantities shall be approved by the Architect /Consultant / Engineer prior to installation. The Contractor shall quote his rates for the items in the Bill of Quantities accordingly. The rates shall be inclusive of accessories (in such case) required for installation. Bottle traps (for wash basins, sinks, urinals etc) shall be deep seal (Min. 6 cm seal) cast brass bottle traps, heavy chromium plated. All bottle traps shall be two piece construction to enable removal of the bottom portion for cleaning purpose. VITREOUS CHINA SANITARY WARE

3.1.1 Indian Type Water Closet

Squatting pans shall be of white vitreous china conforming to IS: 2556 Part – I for General Requirements and relevant I.S. codes for each pattern as described below :

i) Long pattern – conforming to IS: 2556 (Part – III).

ii) Orissa pattern – conforming to IS: 2556 (Part – III).

The flushing rim and inlet shall be of the self draining type. It shall have weep hole at the flushing inlet to the pan. The flushing inlet shall be in the front, unless otherwise specified or ordered by the Engineer-in-charge. The inside of the bottom of the pan shall have sufficient slope from the front towards the outlet and the surface shall be uniform and smooth to enable easy and quick disposal while flushing. The exterior surface of the outlet below the flange shall be an unglazed surface which shall have grooves at right angles to the axis of the outlet. In all cases a pan shall be provided with a (100 mm) S.C.I. trap ‘P’ or ‘S’ type with approximately 50 mm water seal and 50 mm dia vent horn, where required by the Engineer-in-charge or 110 mm dia UPVC WC Connector.

3.1.2 European Type Water Closet

Water closets shall be of white vitreous china conforming to IS: 2556 (Part-I) and 2556 (Part-II). The closets shall be of one piece construction. Water Closet shall be siphonic wash down type floor or wall mounted set, as per bill of quantities or as shown in the drawings. Wall hung WC shall be supported by C. l. floor mounted chair, which shall be fixed in a manner as approved by the Engineer.

Each WC set shall be provided with approved quality of seat, rubber buffers and chromium-plated hinges. Seat shall be so fixed that it remains absolutely stationary in vertical position without falling down on the WC.

The WC for the disabled toilet shall be complete with grab rail and other accessories as required and directed.

3.2 Urinals

Urinals shall be lipped type half stall with glazed vitreous China of size as called for in the Bill of Quantities.

Half stall urinals shall be provided with 15mm dia CP spreader, CP domical waste and CP cast brass bottle trap with pipe and wall flange and shall be fixed to wall by Cl brackets, Cl wall clips and CP brass screws as recommended by manufacturer complete as directed by the Engineer.

Flush pipes shall be Gl pipes concealed in wall chase but with chromium-plated bends at inlet and outlet.

Gl / PVC waste pipes shall be provided for urinals. Waste pipes may be exposed on wall or concealed in chase as directed by the Engineer.

3.3 Urinal Partitions

Urinal partitions shall be white glazed vitreous china of size specified in the Bill of Quantities or as specified by the Architect in the Architectural drawings.

Porcelain partitions shall be fixed at proper heights with CP brass bolts, anchor fasteners and MS clips as recommended by the manufacturer and directed by the Engineer.

3.4 Wash Hand Basin

Washbasins shall be white glazed vitreous china of size, shape and type specified in the Bill of Quantities.

Each basin shall be provided with painted MS angle or Cl brackets and clips and the basin securely fixed to wall/counter slab. Placing of basins over the brackets without secure fixing shall not be accepted. The MS angle shall be provided with two coats of red oxide primer and two coats of synthetic enamel paint of make, brand and colour as approved by the Engineer.

Each basin shall be provided with 32mm dia CP waste with overflow, pop-up waste or rubber plug and CP brass chain as specified in the Bill of Quantities, 32mm dia CP brass

bottle trap with CP pipe to wall flange. Basins shall be fixed at proper heights as shown on drawings. If heights are not specified, the rim level shall be 800 mm from finished floor level or as directed by the Engineer.

Where oval shape or round shape wash basins are required to be fixed these shall be fixed preferably in RCC platform with local available stone topping either fully sunk in stone top or flush with the stone topping as directed by Engineer-in-charge.

White glazed pedestals for wash basins, where specified shall be provided. The quality of the glazing of the pedestal shall be exactly the same as that of the basin along with which it is to be installed. It shall be completely recessed at the back to accommodate supply and waste pipes and fittings. It shall be capable of supporting the basin rigidly and adequately and shall be so designed as to make the height from the floor to top of the rim of basin 75 to 85 cm.

3.5 Sinks

Sinks shall be stainless or any other material as specified in the Bill of Quantities.

Each sink shall be provided with painted MS or Cl brackets and clips and securely fixed.

Counter top sinks shall be fixed with suitable painted angle iron brackets or clips as recommended by the manufacturer. Each sink shall be provided with 40mm dia CP waste and rubber plug with CP brass chain as given in the Bill of Quantities.

The MS angle shall be provided with two coats of red oxide primer and two coats of synthetic enamel paint of make, brand and colour as approved by the Engineer.

Supply fittings for sinks shall be deck mounted or wall mounted CP swivel faucets with or without hot and cold water mixing fittings as specified in the Bill of Quantities. These shall be measured and paid for separately.

3.6 Toilet Paper Holder

Toilet paper holder shall be glazed vitreous china (Colour of the unit shall match with the other fixtures or wall tile) or chrome plated of size, shape and type specified in the Bill of Quantities.

Porcelain toilet paper holder shall be fixed in walls and set in cement mortar 1:2 (1 cement: 2 coarse sand) and fixed in relation to the tiling work.

In case of chrome plated ones the same shall be fixed by means of screws/capping having finish similar to the sanitary fixtures or wall/partitions. When fixed on timber partition, it shall be fixed on a solid wooden base member provided by the Project Manager.

3.7 Towel Rail

Tower rail shall be chromium plated brass or of stainless steel or powder coated brass of size, shape and type specified in the Bill of Quantities.

Tower rail shall be fixed with screws/capping having finish similar to the towel rail in wall with rawl plugs or nylon sleeves and shall include cutting and making good as required or directed by the Engineer.

3.8 Accessories

Porcelain accessories shall be fixed in walls and set in cement mortar 1:2 (1 cement: 2 coarse sand) and fixed in relation to the tiling work.

Joints/gaps between all sanitary appliances/fixtures and the floor/walls shall be caulked with an approved mildew resistant sealant, having ant fungal properties, of colour and shade to match that of the appliances/fixture and the floor/wall to the extent possible.

3.9 FITTING

All C P bathroom fittings and accessories will be supplied as per the make and model number specified in the BOQ or specified by Architect/Employer.

INSTALLATION OF SANITARY FIXTURES AND FITTINGS

a) General

All setting and bedding of sanitary fittings shall be done carefully to suit the required levels. Mortar drops, paint splashes etc. shall be removed from fittings, walls and floors immediately before these get dry.

b) Fixing Water Closet Squatting Pan (Indian Type W.C. pan)

The pan shall be sunk into the floor and embedded in a cushion of average 15 cm cement concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate/ brick aggregate 40 mm nominal size) as specified. This concrete shall be left 115 mm below the top level of the pan so as to allow for flooring and its bed concrete. The floor should be suitably sloped so that the wastewater is drained into the pan. The pan shall be provided with a 100 mm `p' or s trap as required in the item with a approximately 50 mm seal. The joint between the pan and the trap shall be made leak proof with cement mortar 1:1 (1 cement :1 fine sand).

c) Fixing Wash down Water Closet (European Type W.C. pan)

The closet shall be fixed to the floor by means of 75 mm long 6.5 mm diameter counter sunk bolts and nuts embedded in the floor concrete using rubber or fiber washers so as not to allow any lateral displacement. The joint between the trap of W.C. and soil pipe shall be made with cement mortar 1:1 (1cement : 1 fine sand).

d) Fixing Foot rest

After laying the floor, as specified, a pair of foot rest of size 250mm X 130mm X 30mm of white vitreous china shall be set in cement mortar 1 : 3 (1 cement : 3 coarse sand). The footrest shall be fixed at a distance of 175mm from the inner edge of the back side of the pan and shall be fixed at convenient angle.

e) Fixing flushing Cistern

The cistern shall be fixed on two C.I. or mild steel brackets which shall be firmly embedded in the wall in cement mortar 1 : 4 (1 cement : 4 fine sand).

The height of the bottom of the cistern from the top of the pan shall be 2 meters for high level and 30cm. for low level cistern.

f) Fixing over flow pipe

The cistern shall be provided with 25mm nominal bore galvanized mild steel over flow pipe with fittings, which shall terminate into a brass perforated mosquito proof cap and at 6" above flow level of the W.C. room.

g) Fixing flush pipe and its connection

Low level flushing cistern

In case of low level flushing cistern it shall be connected to the closet by means of 40mm dia white porcelain enameled flush bend using Indian rubber adapters joint. The other specification shall be the same as described at (i) above.

h) Fixing plastic seat and cover

The seat shall be fixed to the pan by means of two 8mm dia corrosion resistant hinge bolts with a minimum length of shank of 65mm and threaded to within 15mm of the head. Each bolt shall be provided with two suitably shaped washers of rubber or other similar material for adjusting the level of the seat while fixing it to the closet. In addition one 8mm nonferrous metal or stain- less steel washer shall be provided with each bolt. The maximum diameter of the washers fixed on the under side of the pan shall not be greater than 25mm. One arm of the hinge in each bolt shall be fixed to the under site of the seal by three nos. 20mm long No.6 gauge wood screws. The other arm of the hinge shall be fixed to the under side of the cover flush with the surface by means of 3 nos. 10mm long No. 6 gauge wood screws.

i) Fixing bowl pattern urinals

Urinals shall be fixed in position by using wooden plugs and screws, and shall be at a height of 65cm. From the floor level to the top of the lip of urinal, unless otherwise directed. The wooden plugs shall be fixed in the wall in cement mortar 1:3 (1 cement : 3 fine sand).

j) Fixing wash basins and kitchen sink

The basin shall be supported on a pair of R.S. or C.I. brackets fixed in cement mortar 1:3 (1 cement : 3 coarse sand). The R.S. or C.I. brackets shall conform to IS 775-1962. The wall plaster on the rear shall be cut to rest over the top edge of the basin. After fixing the basin plaster shall be made good and surface finished to match with the existing one.

The C.P. brass trap and unions shall be connected to 32mm dia waste pipe which shall be suitably bent towards the wall and which shall discharge into an open drain leading to a gully trap or direct into the gully trap, on the ground floor and shall be connected to a waste pipe stack through a floor trap on the upper floors. C.P. brass trap and union may not be provided where the surface drain or a floor trap is placed directly under the basin and the waste is discharged in to it vertically.

k) Fixing Mirror

The mirror shall be mounted on asbestos sheet or plywood sheet and shall be fixed in position by means of 4 C.P. brass screws and C.P. brass washers over rubber washers and wooden plugs firmly embedded in the wall.

The height of the bottom edge of the mirror shall generally be 120cm above the floor level unless otherwise specified or shown in drawing. Unless otherwise specified the longer sides shall be fixed horizontally. Fixing glass shelf unit

The bracket of the unit shall be fixed with C.P. brass screws to wooden plugs firmly embedded in the wall with cement mortar 1 : 3 ( 1 cement : 3 coarse sand).

The height of the glass shelf above the floor level shall 115cm unless otherwise specified or shown in drawings.

l) Fixing towel rail

The brackets of the wall rail shall be fixed by means of C.P. brass screws to wooden plugs firmly embedded in the wall with cement 1 : 3 ( 1 cement : 3 coarse sand).

The height of the towel rail above the floor level shall be 75cm unless otherwise specified or shown in drawings.

m) Fixing toilet paper holders

It shall be fixed in a position by means of screws and wooden plugs embedded in the wall with cement mortar 1:3 (1 cement : 3 coarse sand).

a) FITTING

Contractor shall install all chromium plated, stainless steel or powder coated brass fittings as shown on the drawings or as directed by the Engineer and given in the Bill of Quantities.

All CP accessories shall be fixed with CP brass half round head screws and cup washers if required in wall with rawl plugs or nylon sleeves and shall include cutting and making good as required or as directed by the Engineer.

The fittings shall be supplied complete with chromium plated matching flanges, wall cover plates, nuts and extension pieces of required lengths. Metallic washers where required shall also be of chromium plated brass. All bib cocks and stopcocks shall conform to Indian Standard IS: 781. Brass screw down pillar taps shall conform to IS: 1701 and all other fittings shall match the supply fitting in construction and appearance. All fixing accessories and screws shall be similar to fittings. All washers shall conform to Indian Standard IS: 4346.

All waste fittings (Waste, Chain, Overflow, Spreader Caps etc.) shall be of brass / copper heavy chromium plated of the make and design specified and match the supply fittings. They shall conform to Indian Standard IS:2963.

The flushing system of the EWC shall be with 32 mm control cock and elbow set complete with adjustable sleeves and wall flanges. The flush valve for EWC shall be in conformity with IS: 6249.

p) TESTING

All appliances, fixtures and fittings shall be tested before and after installation. Water seals of all appliances shall be tested.

q) MOCKUP AND TRIAL ASSEMBLY

The installation of the Sanitary fixtures and fittings shall be as per the shop drawings approved by the Engineer.

The contractor shall make a mock up toilet in consultation with the Engineer. The sanitary fixtures and fittings shall be got approved by the Engineer prior to the procurement. On completion of the mock up, changes if any required shall be carried out to the satisfaction of the Engineer. Relevant instructions from manufacturers shall be followed as applicable. This trial assembly shall be developed to determine the location of cut outs in the building structure, holding devices etc. which will be required for final installation of all sanitary fixtures and fittings.

The fixtures in the trial assembly can be re-used for final installation without any additional payments for fixing or dismantling of the fixtures.

The contractor shall provide all the necessary supporting and fixing devices to install the sanitary fixtures and fittings securely in position. The fixing devices shall be rigidly anchored into the building structure. The devices shall be rust resistant and shall be so fixed that they do not present an unsightly appearance in the final assembly. Where the location demands, the Engineer may instruct the contractor to provide chromium plated or other similarly finished fixing devices. In such circumstances the contractor shall arrange to supply the fixing devices and shall be installed complete with appropriate vibration isolating pads, washers and gaskets.

r) FINAL INSTALLATION

The contractor shall install all sanitary fixtures and fittings in their final position in accordance with approved trial assemblies and as shown on drawings. The installation shall be complete with all supply and waste connections. The connection between building and piping system and the sanitary fixtures shall be through proper unions and flanges to facilitate removal/replacement of sanitary fixtures without disturbing the built in piping system. All unions and flanges shall match in appearance with other exposed fittings.

Fixtures shall be mounted rigid, plumb and to alignment. The outlets of water closet pans and similar appliances shall be examined to ensure that outlet ends are butting on the receiving pipes before making the joints. It shall be ensured that the receiving pipes are clear of obstruction. When fixtures are being mounted, attention shall be paid to the possibility of movement and settlement by other causes. Overflows shall be made to ensure that necessary anchoring devices have been provided for supporting water closets, washbasins, sinks and other appliances.

s) PROTECTION AGAINST DAMAGE

The contractor shall take every precaution to protect all sanitary fixtures against damage, misuse, cracking, staining, breakage and pilferage by providing proper wrapping and locking arrangement till the completion of the installation. At the time of handing over, the contractor shall clean, disinfect and polish all the fixtures and fittings. Any fixtures and fittings found damaged, cracked chipped stained or scratched shall be removed and new fixtures and fittings free from defects shall be installed at his own cost to complete the work.

t) MEASUREMENT AND RATES

Sanitary fixtures (Vitreous China ware and CP fittings) shall be measured by numbers.

Rate of providing and fixing of sanitary fixtures, accessories, shall be include all items, and operations stated in the respective specifications and Bill of Quantities and nothing extra is payable.

Rates of all items under specification clauses above shall be inclusive of cutting holes and chases and making good the same, CP brass screws, nuts, bolts and any other fixing arrangements required and recommended by manufacturers, testing and commissioning etc. complete.

LAYING AND JOINTING OF SEWER AND DRAIN PIPES AND FITTINGS

GENERAL SPECIFICATIONS

UNLOADING:

(e) The pipes shall be unloaded where they are required.

(f) Unloading (except where mechanical handling facilities are available) – pipes weighing upto 60 kg shall be handled by two persons by hand passing. Heavier pipes shall be unloaded from the lorry or wagon by holding them in loops, formed with ropes and sliding over planks set not steeper than 45 degree. The planks shall be sufficiently rigid and two ropes shall always be used to roll the pipes down the planks. The ropes should be tied on the side opposite the unloading. Only one pipe shall be unloaded at a time.

(g) Under no circumstances shall be the pipes be thrown down from the carriers or

be dragged or rolled along hard surfaces.

(h) The pipes shall be checked for any visible damage (such as broken edges, cracking or spalling of pipe) while unloading and shall be sorted out for reclamation. Any pipe which shows sufficient damage to preclude it from being used shall be discarded.

STORING:

(d) The pipes and specials shall be handled with sufficient care to avoid damage to them. These shall be lined up on one side of the alignment of the trench socket facing upgrade when line runs uphill and upstream when lines run on level ground.

(e) Each stack shall contain pipes of same class and size, consignment or batch

number and particulars of the suppliers, wherever possible, shall be marked on the stack.

(f) Storage shall be done on firm, level and clean ground. Wedges shall be provided

at the bottom layer to keep the stack stable.

CUTTING:

(c) Cutting of pipes may be necessary when pipes are to be laid in lengths shorter than the lengths supplied, such as while replacing accessories like tees, bends, etc. at fixed position in the pipe lines.

(d) A line shall be marked around the pipe with a chalk piece at the point where it is to be cut. The line shall be so marked that the cut is truly at right angle to the longitudinal axis of the pipe.

(e) TRENCHES :

(a) The trenches shall be so dug that the pipes may be laid to the required alignment and at required depth.

(b) The minimum width of the trench should be “D + 400 mm”, where, D is outer

diameter of the pipe.

(c) The bed of the trench, if in soft or made up earth, shall be well watered and rammed before laying the pipes and the depressions, if any, shall be properly filled with earth and consolidated in 20 cm layer.

(d) If the trench bottom is extremely hard or rocky or loose stony soil, the trench shall

be excavated at least 150 mm below the trench grade. Rocks, stone or other hard substances from the bottom of the trench shall be removed and the trench brought back to the required grade by filling with selected fine earth or sand (or fine moorum if fine soil or sand is not available locally) and compacted so as to provide a smooth bedding for the pipe or provide lean cement concrete as required and specified..

(e) After the excavation of the trench is completed, hollows shall be cut at the

required position to receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the barrels of the pipes shall rest throughout their entire length on the solid ground and that sufficient spaces left for jointing the underside of the pipe joint. These socket holes shall be refilled with sand after jointing the pipe.

(f) Roots of trees within a distance of about 0.5 meter from the side of the pipe line

shall be removed or killed.

(g) The excavated materials shall not be placed within 1 meter or half of the depth of the trench, whichever is greater, from the edge of the trench. The materials excavated shall be separated and stacked so that in refilling that may be re-laid and compacted in the same order to the satisfaction of the Engineer-in-charge.

(h) The trench shall be kept free from water. Shoring and timbering shall be provided

wherever required. Excavation below water table shall be done after dewatering the trenches.

(i) Where the pipe line or drain crosses an existing road, the road crossing shall be

excavated half at a time, the 2nd half being commenced after the pipes have been laid in the first half and the trench refilled. Necessary safety measures for traffic as directed shall be adopted. All types, water main cables, etc. met within the course of excavation shall be carefully protected and supported. Care shall be taken not to disturb the electrical and communication cable met with during course of excavation, removal of which, if necessary, shall be arranged by the Engineer-in-charge.

(j) When pipes are laid under road and pavements, subjected to heavy traffic loads, the trench may be covered with RCC slabs of suitable dimensions.

LAYING:

(d) The pipes shall be lowered into the trench by means of suitably pulley blocks, sheer legs chains ropes etc. In no case the pipes shall be rolled and dropped into the trench. One end of each rope may be tied to a wooden or steel peg driven into the ground and the other end held by men which when slowly released will lower the pipe into the trench. After lowering, the pipes shall be arranged so that the spigot of one pipe is carefully centered into the socket of the next pipe, and pushed to the full distance that it can go. The pipe line shall be laid to the levels required. Specials shall also be laid in their proper position as stated above.

(e) Where so directed, the pipes and specials may be laid on masonry or concrete

pillars. The pipe laid on the level ground, shall be laid with socket facing the direction of flow of water.

(f) In unstable soils, such as soft soils and dry lumpy soils it shall be checked

whether the soils can support the pipe lines and if required suitable special foundation shall be provided.

BACK FILLING AND TAMPING:

(e) Back filling shall follow pipe installation as closely as possible to protect pipe from falling boulders, eliminating possibility of lifting of the pipe due to flooding of open trench and shifting pipe out of line by caved in soil.

(f) The initial back fill material used shall be free of large stones and dry lumps.

(g) The initial back fill shall be placed evenly in a layer of about 100 mm thick. This

shall be properly consolidated and this shall be continued till there is a cushion of at least 300 mm of cover over the pipe.

(h) If it is desired to observe the joint or coupling during the testing of mains they

shall be left exposed. Sufficient back fill shall be placed on the pipe to resist the movement due to pressure while testing.

GLAZED STONE WARE PIPES & FITTINGS

a) MATERIAL:

(i) STONE WARE PIPES AND FITTINGS :

All pipes with spigot and socket ends and fittings shall conform to IS: 651. These shall be sound, free from visible defects such as fire cracks or hair cracks. The glaze of the pipes shall be free from crazing. The pipes shall give a sharp clear tone when struck with a light hammer. There shall be no broken blisters. The thickness of pipes shall be as given in the Table below :

TABLE

Internal diameter Mm

Thickness of the barrel and socket mm

100 12

150 16

200 17

The length of pipes shall be 60, 75, 90 cm exclusive of the internal depth of socket. The pipes shall be handled with sufficient care to avoid damage to them.

b) TRENCHES:

(i) The trenches shall be so dug that the pipes may be laid to the required alignment and at required depth.

(ii) Cover shall be measured from top of pipe to the surface of the ground.

(iii) The width of the trench shall be D+400 mm with a minimum of 750 mm. (D=

External diameter of pipe). Note: The width should not be more than the mentioned for structural safety of the pipes.

(iv) The bed of the trench, if in soft or made up earth, shall be well watered and

rammed before laying the pipes and the depressions, if any, shall be properly filled with earth and consolidated in 20 cm layer.

(v) If the trench bottom is extremely hard or rocky or loose stony soil, the trench shall

be excavated at least 150 mm below the trench grade. Rocks, stone or other hard substances from the bottom of the trench shall be removed and the trench brought back to the required grade by filling with selected fine earth or sand (or fine moorum if fine soil or sand is not available locally) and compacted so as to provide a smooth bedding for the pipe.

(vi) After the excavation of the trench is completed, hollows shall be cut at the

required position to receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the barrels of the pipes shall rest throughout their entire length on the solid ground and that sufficient spaces left for jointing the underside of the pipe joint. These socket holes shall be refilled with sand after jointing the pipe.

(vii) Roots of trees within a distance of about 0.5 meter from the side of the pipe line

shall be removed or killed.

(viii) The excavated materials shall not be placed within 1 meter or half of the depth of the trench, whichever is greater, from the edge of the trench. The materials excavated shall be separated and stacked so that in refilling that may be re-laid and compacted in the same order to the satisfaction of the Engineer-in-charge.

(ix) The trench shall be kept free from water. Shoring and timbering shall be provided

wherever required. Excavation below water table shall be done after rewatering the trenches.

(x) Where the pipe line or drain crosses an existing road, the road crossing shall be

excavated half at a time, the 2nd half being commenced after the pipes have been laid in the first half and the trench refilled. Necessary safety measures for traffic as directed shall be adopted. All types, water main cables, etc. met within the course of excavation shall be carefully protected and supported. Care shall be taken not to disturb the electrical and communication cable met with during course of excavation, removal of which, if necessary, shall be arranged by the Engineer-in-charge.

c) CONCRETE SUPPORT:

i) BEDDING :

Bedding shall be rectangular in section and shall extend laterally at least 15cm beyond and on both sides of the projection of the barrel of the pipe. The thickness of the concrete below the barrel of the pipe shall be 10cm for pipes under 150mm diameter and 15cm for pipes 150mm and over in diameter. Where bedding is used alone the concrete shall be brought up at least to the invert level of the pipe to form a cradle and to avoid lime contact between the pipe and the bed.

The width of the bedding shall be external diameter of the pipe plus

(a) 30cm upto trench depth of 1.2 meter.

(b) 40cm for trench depth more than 1.2 meter.

ii) HAUNCHING

Concrete haunching shall consist of:

a) Concrete bed as described for bedding in (i) above.

b) The full width of the bed carried upto the level of the horizontal level of the

pipe; and

c) Splays from this level carried up on both sides of the pipe; from the full width of

the bed to meet the pipe barrel tangentially.

iii) SURROUND OR ENCASING

Surround or encasing shall be similar to haunching upto the horizontal diameter of the pipe and top portion over this shall be finished in a semi circular form to give a uniform encasing for the top half of the pipe.

d) LAYING:

The pipe shall be laid accurately and perfectly true to line, levels and gradients. Great care shall be taken to prevent sand etc. from entering the pipes. The pipes between two manholes shall be laid truly in a straight line without vertical or horizontal undulation. All junction and changes in direction and diameter shall be made inside manholes by means

of curves tapered channels formed in cement concrete finished smooth and benched on both sides. The body of the pipe shall, for its entire length, rest on an even level of concrete, grips being made or left in the bed to receive the sockets of the pipes. Normally the sockets ends should face the upstream. When the line runs up hill the socket ends should face the upgrade.

All pipes shall be laid on a bed of cement or lime concrete with thickness and mix as specified, projecting on each side of the pipe to the specified width of the trench. The pipes with their crown level at 1.20 m depth and less from ground shall be covered with 15 cm thick. Concrete above the crown of the pipe and sloped off to meet the outer edges of the concrete, to give a minimum thickness of 15 cm all – around the pipe. Pipes laid at a depth greater than 1.20 m at crown shall be concreted at the sides upto the level of the center of the pipe and sloped off from the edges to meet the pipe tangentially.

e) JOINTING GLAZED STONE WARE PIPES:

Tarred gasket or yarn soaked in neat cement slurry shall first be placed round the spigot of each pipe and spigot shall then be placed well home into the socket of pipe previously laid. The pipe shall then be adjusted and fixed in the correct position and the gasket caulked tightly home so as to fill not more than one forth of the total depth of the socket.

The remainder of the socket shall be filled with a stiff mixture of cement mortar proportion of 1 part of cement and 1 part of fine sand. When the socket is filled, a fillet shall be formed round the joint with a trowel, forming an angle of 45 degree with the barrel of the pipe.

Mortar shall be mixed as necessary for immediate use and no set mortar shall be beaten up and used before it has begun to set.

After the joint is made, any extraneous material shall be removed from the inside of the joints with a suitable scrapper or '. The newly made joints shall be protected, until set, from the sun, dry winds, rain or frost. Sacking or other suitable materials, which shall be kept damp, may be used for the purpose.

The approximate quantity of cement required for each joint for following sizes of pipes are given below for guidance.

Nominal dia of pipe (mm) Cement (Kg)

100 1.00

150 1.50

200 2.00

250 2.50

f) JOINTING CAST IRON PIPES WITH STONE WARE PIPES :

Where any cast iron soil pipe, waste pipe, ventilating pipe or trap is connected with a stone ware pipe or drain communicating with a sewer, the bedded spigot end of such cast iron soil pipe, waste pipe ventilating pipe or trap shall be inserted into a socket of such stone ware pipe or drain and the joint made with mortar consisting of 1 part of Portland cement and 1 part of clean sharp sand after placing a tarred gasket or hemp yarn soaked in neat cement slurry round the joint and inserted in it by means of a caulking tools.

g) CURING:

The mortar joints shall be cured at least for 7 days before testing.

h) TESTING OF JOINTS:

HYDRAULIC TEST:

The pipes shall be subjected to a pressure of at least 2.5meter head of water at the highest point of the section under test. The test shall be carried out by suitably plugging the low end of the drain and the ends of the connection, if any and filling the system with water. A knuckle bend shall be temporarily jointed in at the top end and a sufficient length of vertical pipe jointed to it so as to provide the required test head; or the top end may be plugged with a connection to a hose ending in a funnel which could be raised or lowered till the required head is obtained and fix suitably for observation. Subsidence of the test water may be done to one or the more of the following causes:-

i) Absorption by pipes and joints;

ii) Sweating of pipes or joints;

iii) Leakage at joints or from defective pipes and

iv) Trapped air.

Allowance shall be made for (i) above by adding water until absorption has ceased after which the proper test should commence if any leakage is visible the defective part of the work should be made good. A slight amount of sweating which is uniform may be over looked but excessive sweating from a particular pipe or joint shall be watched for as taken as indicating a defect to be made good.

RECTIFICATION OF FAULTY JOINTS:

Any joint leaking or sweating shall be rectified or embedded into into 150mm layer of cement concrete (1:2:4) 300mm in length and the section retested.

S. W. GULLY TRAP

a) MATERIAL:

S.W. Gully Trap:

Gully traps shall conform to IS: 651. These shall be sound, free from visible defects such as fire cracks, or hair cracks. The glaze of the traps shall be free from crazing. They shall given a sharp clear tone when struck with light hammer. There shall be no broken blisters.

Each gully trap shall have one C.I. grating of square size corresponding to the dimensions of inlet of gully trap. It will also have a water tight C.I. cover with frame inside dimensions 300 x 300 mm the cover weighing not less than 4.50 kg and the frame not less than 2.70 kg. The grating, cover and frame shall be of sound and good casting and shall have truly square machined seating faces.

b) EXCAVATION:

The excavation for gully traps shall be done true to dimensions and levels as indicated on plans or as directed by the Engineer-in-charge.

c) FIXING:

The gully trap be fixed over cement concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal size) foundation 650 mm square and 100 mm thick. The jointing of gully outlet to the branch drain shall be done similar to jointing of S.W. pipes as described above.

d) BRICK MASONRY CHAMBER:

After fixing and testing gully and branch drain, a brick masonry chamber 300 mm x 300 mm (in side) with bricks in cement mortar 1:5 ( 1 cement : 5 fine sand) shall be built with a 100 mm brick work round the gully trap from the top of the bed concrete upto ground level. The space between the chamber walls and the trap shall be filled with cement concrete 1:5:10 ( 1 cement : 5 fine sand : 10 graded stone aggregate 10 nominal size). The upper portion of the chamber i.e. above the top level of the trap shall be plastered in side with cement mortar 1:3 ( 1 cement : 3 sand), finished with a floating coat of neat cement. The corners and bottoms of the chamber shall be rounded off so as to slop towards grating.

C.I. cover with frame 300 mm x 300 mm (inside) size small then be fixed on the top of the brick masonry with cement concrete 1:2:4 ( 1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) 40 mm thick and rendered smooth. The finish top of the cover shall be left about 40 mm above the adjoining ground level so as to exclude the surface water from entering the gully trap.

MANHOLES

i) GENERAL:

Manholes of different types and sizes specified shall be constructed in the sewer line at such places and to such levels and dimensions as shown in the drawing or as directed by the Engineer-in-charge. The size specified shall indicate the inside dimensions (between wall faces) of the manholes. The branch sewer should deliver sewage in the manhole in direction of main flow and the junction must be made with case so that flow in the main is not impeded.

No drain from house fitting i.e. gully taps or soil pipes etc. to manholes shall normally exceed a length of 6 meter unless it is unavoidable.

At every change of alignment, gradient or diameter of a drain, there shall be a manhole or inspection chamber. Bends and junctions in the drains shall be grouped together in manhole as far as possible. The maximum distance between manholes shall be 45 m for up to 300 mm dia, 75 meter for 350 to 500 mm dia and 90 meter for 600 mm dia and above.

Where the diameter of the drain is increased, the crown of the pipe shall be fixed at the same level and necessary slope given in the invert of the manhole chamber.

Manholes shall be built to the following specifications:-

a) Bed concrete:

The manhole shall be built on a bed of cement concrete 1:4:8 (1 cement : 4 coarse sand: 8 graded stone aggregate 40 mm nominal size) The thickness of Bed Concrete shall be 150 mm upto 0.90 meter depth, 200 mm thick for manholes from 0.90 meter to 2.25 meter depth and 30 mm for manholes of above 2.25 meter depth.

b) Walls:

The walls of the manholes shall be of brick masonry. The brick masonry shall be with bricks in cement mortar 1:4 (1 cement : 4 coarse sand) of brick work shall be carefully built in English bond. The jointing face of each brick being well buttered with cement mortar before laying so as to ensure a full joint. The thickness of wall shall not be less than 230mm upto 2.25 meter in depth, 345 mm thick for depth 2.25 to 3.0 meter, 460 mm thick for depths 3.0 m to 5.0 meter and 575 mm thick for 5.0 to 8.0 meter depth. For greater depths and for subsoil water conditions the exact thickness of wall shall

be governed by the structural design & site conditions.

c) Plaster:

The inside of wall shall be plastered by 12 mm thick with cement mortar 1:3 (1 cement : 3 coarse sand) and finished with a floating coat of neat cement. All angle shall be rounded to 7.5 cm. radius and all rendered internal surfaces shall have impervious finish obtained by using a steel trowel.

Where the saturated soil is met with, also the external surface of the walls of the manhole shall be plastered with 12 mm thick cement plaster 1:3 (1 cement : 3 coarse sand) finished smooth upto 30 cm above the highest sub-soil water level with the approval of the Engineer-in-charge. The plaster shall further be water proofed with addition of approved water proofing compound in a quantity as per manufacturer’s specifications. Channels and benching:

Channels shall be semi circular in the bottom half and of diameter equal to the sewer. Above the horizontal diameter, the sides shall be extended vertically to the same level as the crown of the out going pipe and the top edge shall be suitably rounded off. The branch channels shall also be similarly constructed with respect to the benching but at their junction with the main channel on appropriate shall suitably rounded off in the direction of flow in the main channel shall be given.

The channels and benching shall be done in cement concrete 1:2:4 (1cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size) rising at a slope of 1 in 6 from the edges of channel. The channels of the bottom of the chamber shall be finished with the floating coat of neat cement.

d) Foot Rests:

All manholes deeper than 0.8 m shall be provided with C. I. foot rests. These shall be embedded 20 cm deep in 20 x 20 x 10 cm blocks of cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 20 mm nominal size). The concrete block with C.I. foot rest placed in its center shall be cast in situ along with the masonry and surface finished with 12 mm thick cement plaster 1:3 (1 cement : 3 coarse sand) finished smooth.

Foot rests which shall be of 20 x 20 sq. C.I. bars shall be fixed 30 cm apart vertically and staggered laterally and shall project 10 cm beyond the surface of the wall. The top foot rest shall be 45 cm below the manhole cover.

Foot rests shall be painted with coal tar, the portion embedded in the cement concrete block being painted with thick cement slurry before fixing.

e) Cover slabs:

These shall be of R.C.C. 1:1.5:3 (1 cement :1.5 coarse sand : 3 graded stone aggregate 20 mm nominal size) 15 cm thick with surface and edge finished fair. Full bearing equal to the width of the wall shall be given to the slab on all sides. The frame of the man hole cover shall be embedded firmly in the R.C.C. slab so that the top of the frame remains flush with the top of the R.C.C. slab. Where the opening of manhole is only 560 mm dia, the MH cover shall be fixed in 150 mm thick PCC (1:2:4).

ii) TESTING:

Manholes shall be tested by filling with water to a depth not exceeding 1.2 meter as directed by the Engineer-in-charge.

After completion of the work manhole covers shall be sealed by means of thick grease.

iii) CONNECTION TO A EXISTING SEWER:

The connection to an existing sewer shall, as far as possible, be done at the manholes. Where it is unavoidable to make connection in between two manholes, the work of breaking into the existing sewer and forming the connection shall be carried out under the supervision Administrative Authority.Breaking of sewer shall be effected by the cautions enlargement of sewer hole and every precaution shall be taken to prevent any material from entering the sewer. No connection shall be former in such a way so as to constitute a projection into the sewer or to cause any diminutions in its effective size.

iv) DROP CONNECTIONS:

Where it is uneconomic or impracticable to arrange the connection within 600 mm height above the invert of the manhole, the connection shall be made by constructing a vertical shaft outside the manholes chamber. If the difference in the levels between the incoming drain and the sewer does not exceed 600 mm and there is sufficient room in the manhole, the connection pipe may be directly brought through the manhole wall and the fall accommodated by constructing a ramp in the benching of the manhole. PRECAST CONCRETE MANHOLE COVERS & FRAMES

Precast reinforced cement concrete manhole covers intended for use in sewerage, drainage and water works shall generally conform to IS: 12592 - 2002. Detailed specification are as under :

1. GRADES: TYPES & USES

Manhole covers and frames shall be of the following four grades and types:

Grades Grade Designation Type / shape of cover

Light Duty LD – 2.5 Rectangular, Square, Circular

Medium Duty MD – 10 Rectangular, Circular

Heavy Duty HD – 20 Circular-Square, Rectangular,

Extra Heavy Duty EHD – 35 Circular, Square, Rectangular,

2. The different grades and types of manhole covers may be used as follows :

a) LD – 2.5 Rectangular, Square or Circular types:

These are suitable for use within residential and institutional complexes / areas with pedestrian but occasional LMV traffic. These covers may also be used for inspection chambers.

b) MD – 10:

These are suitable for use in service lanes / roads, car parking areas etc.

c) MD – 20:

Suitable for use in institutional/commercial areas / carriage ways with heavy duty vehicular traffic like buses, trucks, etc. for a wheel load between 50 to 100 KN.

d) EHD – 35: Circular, square, or rectangular (scrapper manhole) types -

These are suitable for use on carriage way in commercial industrial / port areas / near warehouses / godowns where frequent loading and unloading of trucks / trailers are common, with slow to fast moving vehicular traffic of the types having wheel loads upto 115 KN, irrespective of the location of the manhole chambers.

3. MATERIAL:

(i) Cement :

cement used for the manufacture of precast concrete manhole covers shall conform to IS : 269 or 455 or 1489 or 6909 or IS : 8041 or IS : 8043 or IS : 8112.

(ii) Aggregate:

he aggregates used shall be clean and free from deleterious matter and shall conform to the requirements of IS: 383–1970.The aggregates shall be well graded and the nominal maximum size of coarse aggregate shall not exceed 20 mm.

(iii) Concrete:

The mix proportions of concrete shall be determined by the manufacturer and shall be such as will produce a dense concrete without voids, honey combing etc. (IS : 456) The minimum cement content in the concrete shall be 360 kg/m3 with a maximum water cement ratio of 0.45. Concrete weaker than grade M-30 (design mix) shall not be used. Compaction of concrete shall be done by machine vibration.

(iv) Reinforcement:

a) The reinforcement steel shall conform to Grade A of IS: 2062 or IS 432 (Part I) or IS : 432 (Part 2) or IS : 1786 as appropriate.

Reinforcement shall be clean and free from loose mills scale, loose rust, and mud, oil, grease or any other coating which may reduce or destroy the bond between the concrete and steel. A light film of rust may not be regarded as harmful but steel shall not be visibly pitted by rust.

b) Fibers steel: In association with in the main steel bars reinforcement

steel fibers of appropriate types and forms may also be used as secondary reinforcement (upto 0.5% by volume).

4. SHAPES AND DIMENSIONS:

(i) Shapes :

The shapes of precast concrete manhole covers shall be square, rectangular or circular as specified.

(ii) Dimensions:

Dimensions of precast concrete manhole covers shall be as given in Table below, the minimum clearance at top between the frame and cover shall be 5 mm.

TABLE

S. No.

Description Heavy / Extra duty HD / EHD

Heavy Medium duty M.D.

Light duty L.D.

1. Clear opening matching the top opening of manhole

560 mm dia or 600 mm dia or square or 560 mm

450 mm dia. 480 mm dia. 500 mm dia. dia or square

600 x 450 mm (rectangular) 450 mm dia or 350 mm dia or square

2. Precast slab with integral frame (D/T)

900 mm dia x 180 mm or square corners cut 1000 mm dia x 200 mm or square corner cut

800 mm. dia x 130 mm 800 mm dia x 150 mm

850mmx700mmx100mm 625mm dia x 100 mm or 575 mm dia x 100 mm or square

3. Thickness of cover depth of frame (T1)

100 mm or 110 / 120 mm

70 / 80 mm 50 mm

4. Matching Manhole Cover (B)

685 / 660 mm or 735 / 710 mm dia or square

585 mm dia or 645 mm dia or square

685 x 535 mm 515 mm dia or square 435 mm dia or square

5. Edge protection of covers/lifting facility

Precast manhole covers are designed and provided with MS rims of 2.5 mm thickness welded around with provision of two lifting hooks welded at appropriate locations.

6. Chequered pattern on operative Surface

The MS rims along with the edges of precast manhole covers and their operative surface are suitably coated/finished using corrosion resistant paint.

7. Marking covers

On the Precast manhole covers/precast slabs are suitably marked on the operative surface with the following letters, unless specified otherwise

Name of the Department/Sewer or SWD/Grade/Date of MFR/Trade Name etc.

8. Performance requirements

Test load

When tested for ULTIMATE breaking load using 300 mm dia block as per the method described in IS : 12592 (Part I) manhole covers shall be within the following range :

Light duty - 2.5 tones (L.D. – 2.5) Heavy duty – 20 tones (HD – 20) Medium duty - 10 tones (MD – 10) Extra heavy duty - 35 tones (EHD – 35).

5. LIFTING DEVICE :

The minimum diameter of mild steel rod used as lifting device shall be 10 mm for light and 12 mm for medium duty covers and 16 mm for heavy and extra heavy duty covers. The lifting device shall be protected from corrosion by not galvanizing or epoxy coating or any other suitable.

6. FINISHING AND COATING:

To prevent any possible damage from corrosion of steel the underside of the covers shall be treated with anticorrosive paint. The top surface of the covers shall be given a chequered finish.

In order to protect the edges of the covers from possible damage at the time of lifting and handling it is necessary that the manhole covers shall be cast with a protective mild steel

sheet of minimum 2.5 mm thickness around the periphery of the covers. Exposed surface of mild steel sheet shall be given suitable treatment with anticorrosive paint or coating.

7. PHYSICAL REQUIREMENTS:

a) General :

All units shall be sound and free from cracks and other defects which interface with the proper placing of the unit or impair the strength or performance of the units. Minor chipping at the edge / surface resulting from the customary methods of handling during delivery shall not be deemed for rejecting.

b) Load test:

The breaking load of individual units when tested in accordance with the method described in IS: 12592 shall be not less than the values specified in Table below.

TABLE

Grade of cover

Type Load in Tones Diameter of Blocks in mm

EHD – 35 Circular, Square or Rectangular

35 300

HD – 20 Circular, Square or Rectangular

20 300

MD – 10 Circular, or Rectangular

10 300

LD – 2.5 Rectangular, Square or Circular

2.5 300

8. FIXING :

The frames of manhole shall be firmly embedded to correct alignment and level in RCC slab or plain concrete as the case may be on the top of masonry which shall be paid as extra unless specified otherwise.

TECHNICAL SPECIFICATIONS

INTERNAL ELECTRICAL WORKS

Internal & External electrical works will be carried out as per CPWD specifications and will be paid accordingly.

A. CABLES

MEDIUM VOLTAGE 1.1 kV GRADE XLPE INSULATED / PVC INSULATED CABLES

1. GENERAL

The MV cables shall be supplied, inspected, laid, tested and commissioned in accordance with drawings, Specifications, relevant Indian Standard and cable manufacturer's instruction.

2. MATERIAL

Specifications of PVC insulated, sheathed aluminum / copper conductor cable shall be as follows:

a. Conductor

Stranded compacted circular conductor shall be of electrical grade high conductivity aluminum/ copper conductor as per IS: 8130 / 84.

b. Insulation

The insulation shall be compounded PVC, application shall be by extrusion process insulation type C (85deg.C) conforming to IS: 5831-1984. The thickness of insulation will be as per the relevant Indian codes.

c. Laying-up

Insulated conductors of multi core cables shall be with thermoplastic fillers in the interstices. The phase identification of cores shall be by colored strips.

d. Inner Sheath

Cores shall be surrounded either by a wrapped or an extruded PVC sheath. The thickness of the inner sheath shall be as per relevant Indian codes.

e. Armouring

The armouring shall be provided over the inner sheath. Single core cable shall have non- magnetic armouring. Multi core cables shall have either galvanized round steel wires or flat steel strip armouing. Steel wires and strips for armouring confirm to IS: 3975. The direction of lay of armouring shall be opposite to that of cores.

f. Outer Sheath

Single and multi core cables are provided with an extruded PVC outer-sheath. The thickness of the sheath shall be as per IS: 1554-1988. The PVC compound for the outer- sheath shall confirm to Type ST1 of IS 5831. The colour of the outer sheath shall be black.

3. Specifications for XLPE insulated HR PVC sheathed aluminum / copper conductor cable shall be as follows:

a. Conductor

Stranded compacted circular conductor shall be of electrical grade high conductivity aluminum / copper conductor per IS: 8130/84.

b. Insulation

The insulation shall be of natural unfilled chemically cross linked polyethylene conforming to IS: 7098. The thickness of insulation shall be as per the relevant Indian codes.

c. Laying-up

Insulated conductors of multi core cables shall be with plastic fiber in the interstices. The phase identification of cores shall be by colored strips.

d. Inner Sheath

The cores shall be surrounded by either a wrapped or by an extruded PVC sheath. The thickness of the inner sheath shall be as indicated in the relevant codes.

e. Armouring

The armouring shall be provided over the inner sheath. Single core cable shall have non- magnetic armouring. Multi core cables shall have either galvanized round steel wires or flat steel strip. Steel wires and strips for armouring confirm to IS: 3975. The direction of lay of armouring shall be opposite to that of cores.

f. Outer Sheath

Single and multi core cables are provided with an extruded PVC outer-sheath. The thickness of the sheath shall be as per IS: 1554-1988. The PVC compound for the outer- sheath shall confirm to Type ST2 of IS: 5831. The colour of the outer sheath shall be black.

4. CABLE LAYING AND HANDLING

It should be ensured that both ends of the cable are properly sealed to prevent ingress / absorption of moisture.

5. CABLE HANDLING

When cable drums have to be moved over short distance, they should be rolled in the direction of the arrow marked on the drum.

While removing cables, the drums shall be properly mounted on jacks or on a cable wheels or any other suitable means, making sure the spindle, jack etc. are strong enough to take the weight of the drum.

The cables shall not be given a sharp bend to a small radius. The minimum safe bending radius for all types of PVC/XLPE cables shall be taken as 12 times the overall diameter of the cable. Wherever practicable, larger radius should be adopted. At joints and terminations, the bending radius of individual cores of a multicore cable shall not be less than 15 times its overall diameter.

Cable with kinks and straightened kinks, or with similar apparent defects like defective armoring etc. shall not be installed / laid.

Cables of different voltages as well as power and control cables should be kept in different trenches/racks with adequate separation. Where available space is restricted, LV/MV cable shall be laid above HV cables.

Where cables cross over cannot be avoided, the cable of higher voltage shall be laid at a lower level than the cable of lower voltage.

Installation of cables including jointing shall be carried out as per IS: 1255 amended and revised to date.

Power and communication cables shall, as far as possible cross at right angles. Where power cables are laid in proximity to communication cables, the horizontal and vertical clearances shall not normally be less than 60 cm.

Cables shall be laid direct in ground, in pipes / closed ducts, in open ducts or on surface depending on environmental conditions, and as required in schedule of quantities.

During the preliminary stages of laying the cable, consideration should be given to proper location of the joint position so that when the cable is actually laid, the joints are made in the most suitable places and as approved by Consultant. As far as possible, water logged locations, carriage ways, pavements, proximity to telephone cables, gas or water mains, inaccessible places, ducts, pipes, racks, etc. shall be avoided.

The cable shall not in any circumstances be bent so as to form an abrupt right angle but must be rounded off at the corners to a radius not less than 12 times the overall diameter of the cable.

In case, where there are chances of any damage to the wiring/cables, such wiring/cables shall be covered with a sheet metal protective covering (not less than 16 SWG), the base of the covering being flush with the plaster or brickwork as the case may be, or the wiring /cables shall be drawn through a heavy gauge metal conduit pipe by complying with all the requirements of conduit wiring system.

Such protective covering shall, in all cases, be fitted on all down drops within 1.5 m from the floor or from floor level upto the switch board, whichever is less.

While cutting and stripping of the outer sheathing of the cable, care shall be taken that the sharp edge of the cutting instrument does not touch the inner insulation of the conductors. The protective outer covering of the cable shall be stripped off near

connecting terminal and this protective covering shall be maintained upto close proximity of connecting terminals. The cables laid near junction boxes shall be made moisture proof with a plastic compound.

6. CABLE JOINTING & TERMINATION

Jointing shall be as per the manufacturer’s recommendations using standard kits. Cable joints shall be made in suitable, approved cable joint boxes, jointing of cables in the joint boxes and filling of compound shall be done as per manufacturer’s recommendations. Heat shrinkable joints shall be made.

Cables shall be terminated onto the terminals of switchgear through crimping lugs of proper size and of heavy duty. Cable lugs shall be fitted onto the cable by crimping or compression jointing.

Continuity of cable armouring is to be maintained. Double compression glands to be used. Proper crimping tools to be used.

7. TRENCHING & CABLE LAYING

The minimum width of trench shall be 45 cm and depth shall be 75cm for laying of cable. Where more than one cable is to be laid in the same trench in horizontal formation, the width of trench shall be increased such that the minimum gap between the cables is one diameter of the cable unless specified otherwise.

The clearance between axis of the end cables and the sides of the trench shall be minimum 1.5 D (diameter) of the end cable.

The trenches shall be excavated in reasonably straight lines. Wherever there is a change in direction, suitable curvature shall be provided.

Where gradients and changes in depth are unavoidable, these shall be gradual.

The bottom of the trenches shall be level and free from stone, brick bats etc. The trench shall then be provided with a layer of clean, dry sand cushion of not less than 9 cm in depth.

Cable laid in trenches in a single tier formation shall have a covering of clean, dry sand of

not less than 20 cms. above the base cushion of sand before the protective cover is laid.

In the case of vertical multi-tier formation, after the first cable has been laid, a sand cushion of 30 cms shall be provided over the initial bed before second tier is laid. If additional tiers are formed, each of the subsequent tiers shall have a sand cushion of 30 cms as stated above. The top-most cable shall have final sand covering not less than 17 cms before the protective cover is laid.

Unless otherwise specified, the cables shall be protected by second class bricks of not less than 20 cm x 10 cm x 10 cm (nominal size) as per CPWD building specification, or protection covers placed on top of the sand, (brick to be laid breadth wise) for the full length of the cable to satisfaction of the owner. Where more than one cable is to be laid in the same trench, this protective covering shall cover all the cables and project at least 5 cm over the sides of and cables.

The trenches shall be then back filled with excavated earth free from stone or other sharp-edged debris and shall be rammed and watered, if necessary, in successive layers not exceeding 30 cm. Unless otherwise specified, a crown of earth not less than 50 mm in the center and tapering towards the sides of the trench shall be left to allow for subsidence. The crown of earth, however, should not exceed 10 cms.

Where road bends or lawns have been cut or kerb stones displaced, the same shall be repaired to the satisfaction of the architect and all surplus earth or rock removed to places as specified.

In locations such as road crossing, entry to building in paved areas etc. cables shall be laid in pipes or closed ducts.

All cable entry/exit points into the building through pipe sleeves shall be properly sealed with water and fire safe sealants in an approved manner to avoid any seepage of water into the building.

Manholes of adequate size, as decided by the Architect, shall be provided to facilitate of adequate strength feeding/drawing in of cables and to provide working space for persons. Suitable manhole covers with frame of proper design shall cover Manholes.

CABLE LOOPS: Sufficient cable loop length shall be left.

8. CABLES ON HANGERS OR RACKS / TRAYS

The contractor shall provide and install all iron hangers racks, or racks with die-cast cleat, with fixing rag bolts or girder clamps or other specialist fixing as required.

Where hangers or racks are to be fixed to wall sides ceiling and other concrete structures, the contractor shall be responsible for cutting away, fixing and grouting in rag bolts and making good the damages as required.

The hangers or racks shall be designed to leave at least 25 mm clearance between the cables and the face to which it fixed. Multiple hangers shall have two or more fixing holes. All cables shall be saddled at not more than 500 mm intervals. These shall be designed to keep provision of some spare capacity for future development. Minimum spacing between the cables shall be one diameter of the cable or as specified.

9. CABLE TRAY

a) The MS cable trays should have undergone rigorous rust proofing process, which should

comprise of alkaline, degreasing, descaling in diluted sulpharic acid and a recognized phosphating process. The sheet work shall then be given two coats of oxide primer before two coats of final painting. Cable trays shall be either painted (Stove enameled) or hot dip galvanized as called for in the schedule of quantities.

b) Cable trays shall be complete with bends, joints, coupler plates and accessories as may be required for joining the cable trays.

c) Cable trays shall be either perforated or ladder type as called for in the schedule of quantities.

10. PERFORATED CABLE TRAYS

Standard Technical details of perforated cable tray shall be as follows:

S.

No. Description Thickness

1. 150mm to 450mm width 2mm thick & 40mm collar

2. 600mm to 750mm width 2mm thick & 50mm collar

3. 900mm to 1200mm width 3mm thick & 75mm collar

Minimum 10mm dia GI rod suspender shall be used @ 1500mm intervals.

11. LADDER TYPE CABLE TRAYS

Standard technical details of ladder type

cable

trays

shall

be as follows:S. No.

SIZE OF TRAY (Width)

SIZE OF MAIN CHANNEL

SIZE OF RUNG & SPACING

BETWEEN RUNGS

SIZE OF ANGLE FOR SUPPORT

1. 900mm to 1500mm 25 x100 x 25 x 3mm 20 x 50 x 20 x 3mm @ 250C/C

50x50x5mm @150mm C/C

2. 600mm to 750mm 25 x 75 x 25 x 2.5mm 20 x 40 x 20 x 2.5mm @ 250C/C

40X40x5mm @180mm C/C

3. 150mm to 450mm 5 x 75 x 25 x 2mm 20 x 30 x 20 x 2.5mm @ 250C/C

32X32x4mm @180mm C/C

Fixing arrangement shall be as approved by the Consultant / Owner / PMC

Hardware to be used in cable tray system shall be galvanized or zinc passivated.

a. Quality of Zinc

Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS: 209- 1992.

b. Coating Requirement

Minimum weight of zinc coating for mild steel flats with thickness upto 6 mm in accordance with IS:6745-1972 shall be 400 g/sqm.

The weight of coating expressed in grams per square meter shall be calculated by dividing the total weight of Zinc by total area (both sides) of the coated surface.

The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash and dross inclusions, bare patches black spots, pimples, lumpiness, runs; rust stains bulky white deposits, blisters.

Mild steel flats / wires shall undergo a process of degreasing, pickling in acid, cold rinsing and then galvanizing.

12. TESTING OF CABLES

The Meggar value in normal dry weather shall be 50 mega ohm for 1.1 kV grade cable. Cables shall be tested at works for the following tests before being dispatched to site by the project team:

a. Insulation Resistance Test. b. Continuity resistance test. c. Sheathing continuity test. d. Earth test.(in armoured cables) e. Hi Pot Test.

Test shall also be conducted at site for insulation between phases and between phase and earth for each length of cable, before and after jointing. On completion of cable laying work, the following tests shall be conducted in the presence of the Owner’s site representative:

a. Insulation Resistance Test( Sectional and overall) b. Continuity resistance test. c. Sheathing continuity test. d. Earth test.

All tests shall be carried out in accordance with relevant Standard Code of Practice and Electricity Rules. The Contractor shall provide necessary instruments, equipment and labour for conducting the above tests and shall bear all expenses in connection with such tests. All tests shall be carried out in the presence of the Employer / Owner representative.

13. CABLE TAGS

Cable tags shall be made out of 2mm thick aluminum sheets. Each tag shall be 2” in dia or 3” x 3” square with one hole of 2.5mm dia, 6 mm below the periphery, or as approved by Consultant. Cable designations are to be punched with letters / number punches and the tags are to be tied to cables with piano wires of approve quality & size. Tags shall be tied inside the panels beyond the glanding as well as above the glands at cable entries. Along trays tags are to be tied at all bends. On straight lengths, tags shall be provided at every 5 meters.

Cables shall be secured to cable trays with 3mm thick x 25mm wide aluminum strips/suitable GI clamp, or as approved by Consultant, at 1000 mm intervals and screwed by means of rust proof screws, washers and bolts, of adequate but not excessive lengths. Cable trays for horizontal runs suspended from the ceiling will be supported with mild steel straps or brackets, at 1000 mm intervals and the overall tray arrangement shall be of a rigid construction. External cabling route marker with GI plate marked with “DANGER 1.1 kV CABLE” with 1 meter long GI angle iron grouting bracket including 1:3:6 ratio cement concrete base block of minimum size 200 x 200 x 350 mm to be provided or as approved by Elect. Supply Company.

B. EARTHING

1. SYSTEM OF EARTHING

The system shall be TNS with 4 wires supply system (R, Y, B, N and 2 Nos. E) brought from the main LT Panel.

All non-current carrying metal parts of the electrical installation shall be earthed as per IS: 3043 – 1987 with latest amendment. All metal conduits, cable sheath, switchgear, DBs, light fixture, equipment and all other parts made of metal shall be bonded together and connected to earth electrodes. Earthing shall be in conformity with provisions of rules 32, 61, 62, 67 and 68 of Indian Electricity Rules, 1956.

All earthing conductors shall be of high conductivity copper or GI, as specified in the schedule of quantities & shall have protection against mechanical damage. The cross- sectional area of earth conductors shall not be smaller than half that of the largest current carrying conductor.

Main earthing conductors shall be taken from the earth connections at the main L T panel to an earth electrode with which the connection is to be made. All joints in tapes shall be with four rivets and shall be brazed in case of copper and by welding bolting in case of GI. Wires shall be connected with crimping lugs, all bolts shall have spring washers. Sub- mains earthing conductors shall run from the main distribution panel to the sub distribution panel. Final distribution panel earthing conductors shall run from sub- distribution panel.

Circuit earthing conductor shall run from the exposed metal of equipment and shall be connected to any point on the main earthing conductor, or its distribution panel. Metal conduits, cable sheathing and armouring shall be earthed at the ends adjacent to distribution panel at which they originate, or otherwise at the commencement of the run by an earthing conductor in effective electrical contact with cable sheathing. Where equipment is connected by flexible cord, all exposed metal parts of the equipment shall be earthed by means of an earthing conductor enclosed with the current carrying conductors within the flexible cord. Switches, accessories, lighting fitting etc. which are rigidly secured in effective electrical contact with a run of metallic conduit shall not be considered as a part of the earthing conductor for earthing purposes, even though the run of metallic conduit is earthed.

a. All Lighting fixtures, sockets outlets, fans, switch boxes and junction boxes etc.

shall be earthed with copper wire as specified in schedule of quantities. The earth wire ends shall be connected with solderless/bottle type copper lugs.

All the earth wires in switch boxes, sockets outlets, DB’s and light fixtures shall be of green Colour (PVC insulated).

Main earth bus shall be taken from the L.T. switch board to earth electrodes. The electrical resistance of earthing conductors shall be low enough to permit passage of fault current necessary to operate fuse or circuit breaker, and it shall not exceed 1 ohm.

2. SIZING OF EARTHING CONDUCTORS

The cross sectional area of earthing conductor shall not be smaller than half of the largest current carrying conductor subject to an upper limit of 80 Sq.mm. If the area of the largest current carrying conductor or bus bar exceeds 160 sq.mm then two or more earthing conductors shall be used in parallel, to provide at least half the cross sectional area of the current carrying conductor or bus bars. All fixtures, outlet boxes, junction boxes and power circuits upto 15 amps shall be earthed with PVC insulated copper wire.

All 3 phase switches and distribution panels upto 60 amps rating shall be earthed with 2 Nos. distinct and independent 4 mm dia copper / GI wires. All 3 phase switches and distribution panels upto 100 amps rating shall be earthed with 2 Nos. distinct and

independent 6 mm dia copper / GI wires. All switches, bus bar, ducts and distribution panels of rating 200 amps and above shall be earthed with minimum of 2 nos separate and independent 25 mm x 3 mm copper / GI tape. Earthing details given in Table – A & B shall be referred to as a general guidance. Exact sizes to be worked out by the contractor as per relevant IS Codes.

Table - A

Size of earth leads

(a) For Transformer/Generator Neutral Point Earthing:

Transformer/ DG Set Rating

Electrolytic Bare copper Conductor Wire or strip

Galvanized Iron Conductor wire or strip

50kVA & below/4mm dia 4mm dia 25mm x 6.0mm 75 kVA 25mm x 3.0mm 25mm x 6.0mm 100 kVA 25mm x 6.0mm 32mm x 6.0mm 150 kVA 25mm x 6.0mm 40mm x 6.0mm 200 kVA 25mm x 6.0mm 40mm x 6.0mm 250 kVA 25mm x 6.0mm 40mm x 6.0mm 300 kVA 25mm x 6.0mm 40mm x 6.0mm 500 kVA 40mm x 6.0mm 40mm x 6.0mm 750 kVA 40mm x 6.0mm 50mm x 6.0mm 1000 kVA 40mm x 6.0mm 50mm x 6.0mm 1250 kVA 50mm x 6.0mm 50mm x 6.0mm 1500 kVA 50mm x 6.0mm 75mm x 6.0mm 2000 kVA 50mm x 6.0mm 75mm x 6.0mm

NOTE: - EXACT SIZE OF EARTH LEAD TO BE DETERMINED AS PER LATEST IS CODES.

TABLE – B

(b) For Equipment Earthing (Applicable to Transformer, Generators, Switchgears, Panels, DB’s, Motors etc.)

Rating of 400-V, 3ph 50 cy. Equipment In kVA

Bare Electrolytic Copper conductor Wire / Strip

Galvanised Iron Wire / Strip

upto 5 2mm dia 2mm dia 6 to 15 3mm dia 3mm dia 16 to 30 4mm dia 4mm dia 31 to 50 6mm dia 6mm dia 51 to 100 25mm x 3.0mm 25mm x 6.0mm 101 to 125 25mm x 3.0mm 32mm x 6.0mm 126 to 150 25mm x 3.0mm 32mm x 6.0mm 151 to 200 25mm x 6.0mm 40mm x 6.0mm 201 to 300 25mm x 6.0mm 50mm x 6.0mm 301 to 500 32mm x 6.0mm 50mm x 6.0mm 501 to 800 40mm x 6.0mm 50mm x 6.0mm Above 800 50mm x 6.0mm 50mm x 6.0mm

NOTE: EXACT SIZE OF EARTH LEAD TO BE DETERMINED AS PER LATEST IS CODES.

NOTE: ALL THREE PHASE EQUIPMENT SHALL BE DOUBLE EARTHED

3. PROHIBITED CONNECTIONS

Neutral conductor, sprinkler pipes, or pipes conveying gas, water, or inflammable liquid, structural steel work, metallic enclosures, metallic conduits and lighting protection system conductors shall not be used as a earthing conductor.

4. CONNECTION/JOINTS

The earthing connections/joints should be bolted, riveted, welded, brazed type.

In case of bolted joints, GI/Passivated hardware’s of adequate size/nos. should be used for firm connections. The minimum contact area should be equal to the width of the strip or cross-sectional area of earthing lead. Welded/brazed joints should be smooth and continues. All welded/brazed joints should be treated with anti-corrosive paints to protect it from corrosion/rusting.

All bolted connections/joints of Cu strip should be tinned.

Wherever, flexible earthing connection is must, it should be hydraulically crimped lugs of Copper/Aluminum. The effective earthing connection surface should be smooth & free from paints and oxide coatings.

5. EARTHING

The following must always be ensured in earthing system:

All earths must be interconnected. This includes transformer neutrals, Transformer body, HT Panels, LT Panels, lightning protection system earths, UPS earths etc and provision for interconnection with other services earthing grid etc. shall be made. All earth pits should be at equi - potential.

Extraneous conductive parts such as gas pipes, other service pipes and ducting risers and pipes of fire protection equipment and exposed metallic parts of the building structure.

The Contractor shall get the soil resistivity test done at his own cost of the area where earthing pits are to be located before starting the installation.

6. RESISTANCE TO EARTH

The resistance of earthing system shall not exceed 1 ohm.

SPECIFICATION FOR HOT DIP GALVANIZING PROCESS FOR MILD STEEL USED FOR EARTHING FOR ELECTRICAL INSTALLATION

7. GENERAL REQUIREMENTS

a. Quality of Zinc

Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS: 209- 1992.

b. Coating Requirement

Minimum weight of zinc coating for mild steel flats with thickness upto 6 mm in accordance with IS:6745-1972 shall be 400 g/sqm.

The weight of coating expressed in grams per square meter shall be calculated by dividing the total weight of Zinc by total area (both sides) of the coated surface.

The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash and dross inclusions, bare patches black spots, pimples, lumpiness, runs; rust stains bulky white deposits, blisters. Mild steel flats / wires shall undergo a process of degreasing pickling in acid, cold rinsing and then galvanizing. Jointing of earthing tape shall be by welding. All joints and cut ends shall be properly painted with aluminum paint.

8. MAINTENANCE FREE CHEMICAL EARTHING:

Maintenance Free Chemical Earthing shall be done strictly as per manufacturer’s recommendations. It shall be completely maintenance free, long life close to 25 years, environmentally safe, non corrosive & electrically conductive. The earth resistance results shall be less than one ohm.

C. MV PANELS: 1.0 GENERAL

Medium voltage power control centres (generally termed as switchboard panels) shall be in sheet steel clad cubicle pattern, free floor standing, totally enclosed, compartmentalized design having multitier arrangement of the incomers and feeders as per details given in the schedule of quantities. All panels shall conform to the requirements of the latest addition of IS and shall be suitable for 415 V, 3 phase AC supply or 230 V single phase AC supply as required. The drawing of panel mmay got approved from Engineer En-charge before placing order.

2.0 CONSTRUCTIONAL FEATURES

The Switch Boards shall be totally enclosed, sheet steel cubicle pattern, extensible on either side, dead front, floor mounting type (wall mounting if specifically asked for in BOQ) and shall have a bus bar chamber at the top and the cable entry from the bottom. (For panel requiring top cable entries if any, refer to BOQ). The cable terminations should be in side the feeder compartment only.

The Switch Boards shall be completely dust and vermin proof. Synthetic rubber gaskets between all adjacent units and beneath all covers shall be provided to render the joints dust and vermin proof to provide a degree of ingress protection of IP 43. All doors and covers shall also be fully gasketed with synthetic rubber. All the live parts shall be properly shrouded with FRP sheets.

The Switch Board shall be fabricated with CRCA Sheet Steel of thickness not less than 2.0mm and shall be folded and braced as necessary to provide a rigid support for all components. The doors and covers shall be constructed from CRCA sheet steel of thickness not less than 1.6 mm. Joints of any kind in sheet metal shall be seam welded and all welding slag ground off and welding pits wiped smooth with plumber metal. Base channel shall be fabricated from ISMC 75 and door shall be provided at the bottom with arrangement for fixing bolts in the foundation.

All panels and door covers shall be properly fitted and square with the frame. The cutouts in the panel shall be correctly positioned.

Lifting lugs of adequate strength shall be provided on each transport section of the panels. Fixing screws shall enter holes tapped into an adequate thickness of metal or provided with hank nuts. Self threading screws shall not be used in the construction of the Switch Boards.

3.0 SWITCHBOARD DIMENSIONAL LIMITATIONS

A base channel 75 mm x 5 mm thick shall be provided at the bottom.

The overall height of the Switch Board shall be limited to 2200 mm

The height of the operating handle, push buttons etc shall be restricted between 300 mm and 1900 mm from finished floor level.

4.0 BUS BARS

The bus bars shall be suitable for 4 wire, 415 volts, 50 Hz, system. The main bus bar shall be made of high conductivity electrolytic grade AL 91E Aluminium. The bus bars shall have uniform cross section throughout the panel. The bus bars shall be capable of carrying the rated current at 415 volts continuously. The bus bar will run in a separate busbar chamber using bus insulators made of non-deteriorating, vermin proof, non hygroscopic materials such as epoxy fiber, reinforced polyester or moulding compound (min. 25mm clearance between phase to phase & phase to neutral busbars shall be provided). The interval between the two insulators will be designed after considering the

following: a) Strength and safe load rating of the insulator, b) The vibrating force generated during a fault, c) A Factor of safety of 1.25 d) A set of insulators at both ends of the bus.

Bus bars shall be sized considering maximum current density of 1 Amps/ cross section Sq.mm area. The size of the bus bar calculations must be approved by the consultants.

The bus bars shall be designed to withstand a temperature rise of 45oC above the ambient. To limit the temperature rise in the bus bar chamber a set of louvers can be provided at strategical places considering the air circulation. All the bus bars shall be insulated with PVC heat shrinking sleeves throughout (except at joints) the length of the panel. The electro-galvanised high tensile steel nuts, bolts, plain or spring washers of suitable size will be used in connecting the various section of the bus bars.

5.0 SWITCH BOARD INTERCONNECTIONS

All connections between the bus bars/Breakers terminations shall be through solid Aluminium strips of adequate size to carry full rated current which shall be PVC/fibre glass insulated. For switch unit ratings upto 63A PVC insulated copper conductor wires of adequate size to carry full load current can be used. The terminations of all such interconnections shall be properly crimped.

6.0 CABLE TERMINATIONS

Knockout holes of appropriate size and number shall be provided in the Switch Board in conformity with the location of incoming and outgoing conduits/cables. All cable entries shall be from bottom until & unless specifically asked for in the BOQ.

The cable terminations of the circuit breakers shall be brought out to terminal cable sockets suitably located in the panel.

All outgoing links for FSU\MCB feeders shall be in the feeder compartment only. The Switch Boards shall be complete with tinned brass cable sockets, tinned brass compression glands, gland plates, supporting clamps and brackets etc for termination of 1100 volt grade aluminium conductor PVC cables.

7.0 EARTHING

The panels shall be provided with an aluminium earth bus of suitable size running through out the length of the switchboard. Suitable earthling eyes/bolts (at min. two points) shall be provided on the main earthing bus to connect the same to the earth grid

at the site. Sufficient number of star washers shall be provided at the joints to achieve earth continuity between the panels and the sheet metal parts.

8.0 INTERLOCKING

The panels shall be provided with the following interlocking arrangement.

a) The door of the switch-fuse compartments is so interlocked with the switch drive or

handle that the door can be opened only if the switch is in `OFF' position. De- interlocking arrangement shall also be provided for occasional inspection.

b) It shall not be possible for the breaker to be withdrawn when in `ON' position.

c) It shall not be possible for the breakers to be switched on unless it is either in fully

inserted positions or for testing purposes in fully isolated position.

d) The breaker shall be capable of being raked in to `testing' `isolated' and `maintenance' positions and kept locked in any of these position.

e) A safety latch to ensure that the movement of the breaker as it is withdrawn, is

checked before it is completely out of the cubicle shall be provided.

9.0 WIRING All wiring for relays and meters shall be with PVC insulated copper conductor wires. The wiring shall be coded and labeled with approved ferrules for identification. The minimum size of copper conductor control wires shall be 1.5 sq.mm except for the circuits related to current transformers or circuits with current carrying capacity more than 5 Amps (for which min. 2.5 Sq.mm copper conductor wires shall be used).

10.0 SHEET STEEL TREATMENT AND PAINTING

Sheet Steel materials used in the construction of these units should have undergone a rigorous rust proofing process comprising of alkaline degreasing, descaling in dilute sulfuric acid and a recognised phosphating process. The steel work shall then receive two coats of oxide primer before final painting. Castings shall be scrupulously cleaned and fettled before receiving a similar oxide primer coat. All sheet steel shall after metal treatment shall be powder coated with shade RAL 7032 (Siemens Gray) on the outside of the panel and mounting plates shall be of orange shade . Each coat of paint shall be properly stoved and the paint thickness shall not be less than 50 microns (shade of paint may be changed if the Engineer In charge so desires).

11.0 NAME PLATES AND LABELS

Suitable engraved white on black name plates and identification labels of metal for all Switch Boards and Circuits shall be provided. These shall indicate the feeder number and feeder designation.

12.0 INSTALLATION

Installation shall be done by erection Contractor.

13.0 TESTING AND COMMISSIONING

Copies of type tests and routine test as per relevant specification, carried out at manufacturer’s work shall be submitted to the ENGINEER IN CHARGE as required.

Wiring and connections including earthing shall be checked for continuity and tightness.

Insulation shall be measured with a 500 V megger and insulation resistance shall not be less than 100 Mega ohms

Interlocking operation to be checked as per requirement.

Tests shall be performed in presence of authorized representative of the ENGINEER IN CHARGE for which the contractor shall give due prior notice.

14.0 HIGH VOLTAGE TEST

A high voltage test with 2.5 KV for one minute shall be applied between the poles and earth. Test shall be carried out on each pole in turn with the remaining poles earthed, all units raked in position and the breakers closed. Original test certificate shall be submitted along with panel.

15.0 PRE-COMMISSION TESTS:

Panels shall be commissioned only after the successful completion of the following tests. The tests shall be carried in the presence of Architect's/Consultant's or their representatives.

i) All main and auxiliary bus bar connections shall be checked and tightened.

ii) All wiring termination and bus bar joints shall be checked and tightened.

iii) Wiring shall be checked to ensure that it is according to the drawing.

iv) All wiring shall be tested for insulation resistance by a 1000 volts meggar.

v) Phase rotation tests shall be conducted

vi) All relays and protective devices shall be tested for correctness of settings and operation by introducing a current generator and an ammeter in the circuit.

16.0 CLIMATIC CONDITIONS:

The panels & switch gear components shall be suitable for following climatic conditions:

Maximum Minimum

DBT 45OC 3OC RH 90% 20%

17.0 HEATING ARRANGEMENT:

The panel shall be provided with a thermostatically controlled heating arrangement

for monsoon (200 Watt) to take care of high humidity conditions. A 6/16A service

socket outlet (single phase) shall be provided in one of the compartments in all the

panels.

18.0 METERING, INSTRUMENTATION AND PROTECTION

1.0 The specifications hereinafter laid down shall cover all the meters, instrumentation and protective devises required for the electrical work. The ratings, type and quantity of meters, instruments and protective devices shall be as per the schedule of quantities and drawings.

Measuring Instruments

General

Direct reading electrical instruments shall be in conformity with IEC-51, BS: 89 or IS: 1248. The accuracy of direct reading shall be 1.0 for voltmeters and 1.5 for ammeters. Other type of instruments shall have accuracy of 1.5. The error due to variations in temperature shall be limited to a minimum. The meter shall be enclosed in a dust tight housing. The housing shall be of steel or phenolic mould. The design and manufacture of the meters shall ensure the prevention of fogging of instrument glass. Instrument meters shall be sealed in such a way that access to the measuring element and to the accessories within the case shall not be possible without removal of the seal. The meters shall be provided with white dials and black scale marking. The pointer shall be black in colour and shall have zero position adjustment device which could be operated from outside. The direction of deflection shall be from left to right. Suitable selector switches shall be provided for all ammeters and voltmeters intended to be used on three phase supply.

a) Ammeters

Ammeters shall be moving iron type. The moving part assembly shall be with jewel bearings. The jewel bearing shall be mounted on a spring to prevent damage to pivot due to vibrations and shocks. The ammeters shall be manufactured and calibrated as per the latest edition of IS 1248 or BS 89. Ammeters shall be instrument transformer operated, and shall be suitable for 5 A. Secondary of instrument transformer. The scales shall be

calibrated to indicate primary current, unless otherwise specified. The ammeters shall be capable of carrying sustained overloads during fault conditions without damage or loss of accuracy.

b) Voltmeters

Voltmeter shall be of moving iron type. The range for 400 volts, 3 phase voltmeters shall be to 0 to 500 volts. Suitable selector switch shall be provided for each voltmeter to read voltage between any two lines of the system. The voltmeter shall be provided with protection fuse of suitable capacity.

2.0 INSTRUMENT TRANSFORMERS

Current Transformers

Current transformers shall be in conformity with IS: 2705 (Part-I, II, & III) in all respects. All current transformers to be used in the L.T. Electrical panels shall be low tension, ring type resin cast current transformer with the requisite currents ratio having secondary of the current transformers selected will be based on the following;

1. For energy measuring: 1.0 class of accuracy. 2. For other metering: 1.5 class of accuracy. 3. For protects on: 3.0 class of accuracy. Where a common CT is used for different

functions the CT accuracy class will be equal to the best class required by any of those function.

Current transformers shall be capable of withstanding without damage, magnetic and thermal stresses due to short circuit fault of 35 MVA on medium voltage system. Terminals of the current transformers shall be marked permanently for easy identification of poles. Current transformers shall be provided with earthing terminals for earthing chassis frame work and fixed part of the metal casing (if any). Each CT shall be provided with rating plate indicating the following:

1. Name and make 2. Serial Number 3. Transformation ratio 4. Rated burden 5. Rated voltage

6. Accuracy class

The current transformers to be selected for this panel will have at least 20% extra VA capacity available over the normal capacity based on the following details ;

1. For ammeters : 3 VA 2. For current coils of KW & KWHR, PF, KVAR meters or for all recorders : 5 VA. 3. For normal wiring: 2 VA. 4. For current coil of protection relays: 10 VA under; no circumstances the VA rating of

the CT's will be less than 15 VA.

Current transformers shall be mounted such that they are easily accessible for inspection, maintenance and replacement. The wiring for CTs shall be copper conductor, PVC insulated wires with proper termination lugs and wiring shall be bunched with cable straps and fixed to the panel structure in a neat manner.

3.0 CONTROL DEVICES

a) Push Buttons

The push buttons used in the panels will be rated for more than 415 volts and 2 amps. All the push buttons will be mounted on the front door and the assembly will be in two parts. All the push buttons will be mounted on the front door of the cubicle in regular symmetrical fashion as per the general norms being practiced. Only one make of push buttons will be used in the assembly of all the panels. The selection of the colour of the

push buttons will be as follows

Function Colour Starting/Switching ON Green Stopping/Switching OFF Red Resetting Black Forward ON Yellow Reverse ON Blue Emergency OFF Red/Mushroom

b) Indicating Lights

The indicating lights used in the panel will be pleasant looking and round shape having the following features;

1. A separate front lens for it's easy replacement. 2. Facility to replace the bulb from the front. 3. Baynet pin cap bulbs of standard size to be used. 4. The shape of the lens to allow viewing from sides. 5. Series resistance with use of low voltage bulb for longer life. 6. Clear and distinct indication for light ON and OFF with differences of brightness of the

lens.

The selection of the colours of the indicating lamps will be as follows: - Red for system in operation - Amber for system ready for operation. - Green for system being put off. - Red, yellow and blue for incoming supply.

5.0 TESTING

5.1 Instrument transformers shall be tested at factory as per IS: 2705 & IS: 3156. The test

shall incorporate the following:

a) Type tests b) Routine tests

Original test certificates in triplicate shall be provided.

5.2 Meters shall be tested as per IS: 1248. The tests shall include both type tests and routine

tests. Original test certificate in triplicate shall be furnished.

5.3 a) Suitable injection tests shall be applied to the secondary circuit of every instrument to establish the correctness of calibration and working order.

b) All relays and protective devices shall be tested to establish correctness of setting and operation by introducing a current generator and an ammeter in the circuit.

19.0 MINIATURE CIRCUIT BREAKERS

The MCB's shall be of the completely moulded design suitable for operation at 240/415 Volts 50 Hz system. MCB’s shall be quick make and break type conforming to relevant IS. Housing shall be heat resistant and have a high impact strength. MCB’s shall be flush mounting type and shall be provided with trip free manual operating liver with ON/OFF indications

MCB’s shall be provided with magnetic thermal releases for overcurrent and short circuit protection. The overload or short circuit device shall have a common trip bar in case of DP and TPN MCB’s. The MCB's shall have inverse time delayed thermal overload and instantaneous magnetic short circuit protection. The MCB time current characteristic shall coordinate with H.R.C. fuse/PVC cable characteristic.

The MCB's shall have a minimum breaking capacity of 10 kA at 230/415 volts in accordance with IEC: 898 - 1995 and IS: 8828 – 1996

20.0 MOULDED CASE CIRCUIT BREAKERS

1.0 GENERAL

Moulded case circuit breakers shall be incorporated in the switch board wherever specified. MCCB shall conform to IEC: 947-II or IS: 13947-II in all respects. MCCB shall be suitable for three phase 415 volts AC. Suitable discrimination shall be provided between upstream and down stream breakers in the range of 10-20 milli seconds. All MCCBs will have earth fault module (if specifically asked) and front operated. All four pole MCCB shall be suitable for three phase four wire system, with the neutral clearly identified and capable of first make last break feature.

2.0 CONSTRUCTION

The MCCB cover and case shall be made of high strength heat-resistant and flame retardant thermosetting insulating material, operating handle shall be quick make/quick break. The operating handle shall have suitable `ON' `OFF' and `TRIPPED' mechanical indicators notable from outside. All MCCBs shall have a common operating handle for simultaneous operation and tripping of all the three phases. The MCCB should be suitable for disconnection and isolation with marking on front name plate.

Suitable arc extinguishing device shall be provided for each contact. Tripping unit shall be thermal-magnetic type provided on each pole and connected by a common trip bar such that tripping of any one pole operates all three poles to open simultaneously. Thermal magnetic tripping device shall have IDMT characteristics for sustained over load and short circuits. All MCCBs above 250 Amps will also have short circuit magnetic pickup level adjustment.

MCCBs

All MCCBs shall have variable thermal overload releases which can be adjusted at site. 3.0 Contact tips shall be made of suitable arc resistant, sintered alloy for long electrical life. Terminals shall be of liberal design with adequate clearances. All MCCBs of higher ratings above 250 Amps, shall be provided with separate extended arcing contacts.

4.0 INTERLOCKING

Moulded case circuit breakers shall be provided with the following interlocking devices for interlocking the door of a switch board.

a) Handle interlock to prevent unnecessary manipulations of the breaker.

b) Door interlock to prevent the door being opened when the breaker is in ON or OFF

position.

c) Defeat-interlocking device to open the door even if the breaker is in ON position.

5.0 BREAKING CAPACITY

The moulded case circuit breaker shall have a rated service. Short circuit breaking capacity of not less than 25 KA rms at 415 volts AC. Wherever required, higher breaking capacity breakers to meet the system short circuit fault shall be used.

6.0 ACCESSORIES

All the accessories like shunt, undervoltage contact blocks shall be of snap fitting possible at site.

7.0 TESTING

a) Original test certificate of the MCCB shall be furnished.

b) Pre-commissioning tests on the switch board panel incorporating the MCCB shall be done as per standard specifications.

21.0 MEDIUM VOLTAGE AIR CIRCUIT BREAKER

1.0 GENERAL

Air circuit breakers shall be incorporated in the panels wherever specified. ACB shall conform to IEC 947-II or IS: 13947-II in all respects. ACBs shall be suitable for operation on 415 volts, 3 Phase, 50 Hz, AC supply. All air circuit breakers using in the panel will be mounted in separate cubicles and will be of the same make to maintain the uniformity.

2.0 TYPE AND CONSTRUCTION

Air circuit breakers shall be of enclosed pattern, dead front air break type with trip free operating mechanism. All ACBs will be thermal magnetic type. Air Circuit breakers shall be of with drawable type and will be mounted on a rigid steel frame. The ACBs shall be strong and robust in construction with suitable arrangement for anchoring when in fully engaged or fully drawn out positions. There shall be no dependence upon the panel board frame for any critical alignment. The withdrawal arrangement shall be such as to allow smooth and easy movement. The ACB shall have minimum four positions service, test , isolated and maintenance.

All the current carrying parts of the circuit breakers shall be silver plated. Suitable arcing contacts shall be provided to protect the main contacts. The contacts shall be of spring loaded design. The sequence of operation of the contacts shall be such that arcing contacts `make before' and break after the main contacts. Arcing contacts shall be provided with efficient are chutes on each pole. The contact tips and arc chutes shall be suitable for ready replacement. Self aligning isolating contacts with automatic shutters to screen the live parts shall be provided. The design of the breaker shall be such that all the components are easily accessible for inspection, maintenance and replacement.

Operating Mechanism

Air circuit breaker shall be provided with a quick-make, trip free operating mechanism. The operating mechanism shall be strain-free spring operated. The system will have horizontal, self aligning, isolating pairs of moving and stationary power and control contracts. The unit will have three horizontal positions corresponding to:

a) Plugged in Position

Here both the power and control contacts are in made position and the breakers gets mechanically locked in this position. The breaker can go in ON position only after being locked in this position.

b) Test Position

Here the power contacts gets isolated where as the control contacts can be kept in made status. The breakers can be mechanically locked in this position and made ON and off for testing purposes.

c) With drawn Position

In this position the power and control connections are in isolated status and the moving portion of the breaker can be dismantled from the panel.

An isolating shutter or set of shutters are to be provided for the automatic coverage of live power and control fixed isolating contacts in the withdrawn position.

All the breakers with remote closing arrangement will have a spring charging motor of single phase 230 V and a closing coil. In case of power failure the spring charging can be done manually with the help of button or lever. The circuit breaker should switch on only when the spring is charged fully which should be able to store energy

for one closing and one tripping operation. The spring will also get fully charged when the breaker is in closed position. In this case the spring should store enough energy to make first tripping, one re-closing and the second tripping. The ACB should have an anti pumping feature.

The breaker will have quick making trip free closing mechanism. The operation of the mechanism will be independent of the speed of the closing lever or the duration of the closing signal.

The breaker will have following indications distinctly not able from out side :-

- Mechanical indicator for spring fully charged. - Mechanical indicator for spring discharged. - Electrical indication of breaker ON status. - Electrical indication of breaker OFF status. - Electrical indication of trip circuit healthy.

- Separate trip indication for overload and short circuit.

All breakers will have switching ON and OFF time of less than 4 cycles and will have the following interlocks for the safe operation of the equipment. Breakers to ON only when mechanically locked many of the three horizontal isolation position.

When the breaker is in plugged in position it will ON only with the front door closed. The breakers will be provided with 6 Nos. each of type NO and NC auxiliary contacts rated for 10 Amps AC at 415 V and 6 Amps DC at 48 V. These contacts are in addition to the ones already in use for the operation of the breaker and will be required for subsequent interlocks incorporated in near future.

Whenever requested mechanical positive inter locks will be provided between the operation of different breakers with the help of individually unique and matched castle key locks.

Rating The rating of the circuit breaker shall be as per the drawings and schedule of quantities. The rated breaking capacity of the breakers shall be minimum 50 KA or as specified at 415 volts AC. The rated making capacity shall be as per relevant standard.

Accessories

Circuit breakers shall be provided with the following Accessories. a) Under-voltage relay for the incoming ACB. b) Overload release with IDMT characteristics. c) Instantaneous over current relays. d) Alarm switches (if specifically asked for) e) Auxiliary switches f) Circuit breaker position indicators ON/OFF/TEST/ ISOLATED.

Testing

Testing of each circuit breaker shall be carried out at the works as per IS:13947-II and the original test certificate shall be furnished in triplicate. The tests shall incorporate at least the following: a) Impulse withstand test b) Power frequency withstand test c) Short circuit test d) Temperature-rise test under rated conditions.

9.1 ADDITIONAL REQUIREMENTS

1 The contractor shall submit the original manufacturer’s test certificates in respect of ACB,

Pumping Sets, Motors, Starters, Main switches etc.

2 The aluminium copper conductor cable (heavy) should be ISI marked PVC insulated,

armored and should be confirming to relevant IS-Specifications, codes with latest

amendments.

3 Test Certificate:-

A test certificate from the manufacturers shall be handed over to the department before

installation of the equipment specifying that the equipment conforms to relevant I.S.

S/P.W.D. specifications.

4 Wiring Diagram:-

After completion of the work a complete drawing showing connections to the various

equipments is to be prepared by the tenderer and to be submitted to the department

along with final bill of the work.

5 Connections:-

Inter connections from the bus-bar chamber to the different main switches/Air circuit

breakers should be through solid copper bars of the required capacity duly insulated for

which no extra payment will be made.

6 The rates quoted should be F.O.R. at site of work including cost of installation, freight,

octroi taxes and other charges. Nothing extra over and above rates will be admissible.

7 Superflous conditions and conditional tender will be rejected.

8 Telegraphic tenders and tenders without earnest money in shape of deposit at call will

not be accepted.

9 The machinery will be installed as per standard P.W.D. specifications and to the entire

satisfaction of the Engineer-in-charge.

10 The quantity of electrical equipments and pumping sets can be increased/ decreased by

the department.

11 The tender submitted by the firms shall be valid for 90 days (3 months) from the date of

opening of Price Bid.

12 In case any mistake is found in the N.I.T. the same shall be rectifiable even after the

opening of the tender and execution of contract agreement as per requirement and site

conditions.

13 Pump, Motor, Generator, Starters, ACB shall be inspected by Department officers at the

factory premises before being transported to the store or agency/work place.

9.2 OPERATION & MAINTENANCE

9.2.1 The contractor shall maintain all Independent Feeders erected under this contract for a

period of 12 months during the Defect Liability Period. Details of staff to be deputed

during the maintenance period shall be submitted to the Engineer-in-Charge and prior

approval shall be taken.

FIRE FIGHTING

TECHNICAL SPECIFICATION

SECTION- I: FIRE PROTECTION SYSTEM

1. SCOPE

The scope of this section consists of following but is not limited and required as per site conditions, to supply, installation, testing and commissioning of the fire protection system. The philosophy of the system is as follows :

a. The Fire Suppression System shall comprise the Fire Hydrants System, and Hand

Appliances.

i. Fire Hydrant System (Pressurised) for the internal landing valves and the hose reels at

landings.

b. The Hydrant System under normal conditions shall be pressurized by means of the electric motor driven Jockey Pump.

c. The Hydrant shall be provided with two pump sets, one of which will be diesel engine driven

and the other electric motor driven.

d. The starting and stopping of the Jockey pump shall be automatic based on the pressure switches at preset low and high pressure.

e. Terrace Pump

f. The electric motor driven Hydrant starts automatically at a preset pressure by means of a

pressure switch. As soon as the Hydrant Pump starts, the Jockey Pump Stops. If for any reason or electric failure the electric motor driven Hydrant Pump does not start at the preset pressure or is unable to maintain the pressure, the diesel engine driven Hydrant Pump starts at the preset pressure.

g. The Hydrant Pump, whether electric motor driven or the diesel engine driven shall be

stopped only manually.

h Tenderer shall ensure Hydro Testing of the complete system.

i The Tenderer shall obtain the necessary approval of the drawings and the schemes from

the local authority / Fire Depptt. as per the requirement at his own cost. The tenderer shall also take care of any other requirement so that insurance cover can be obtained, if required at minimum premium at later date. After completion of work completion certification for fire officer /local authority.

j. The tenderer shall design and after approval of Services Consultant/ Engineer In Charge/

Engineer-In-Charge display a glass covered framed floor plan clearly showing the locations of all landing valves, hose reels, hand appliances, as well as the DO’s and DON’T’s near each stair case landing for the personnel and the exit direction in case of an emergency. The dimensions of the floor plan, its scale, lettering size, colour scheme etc shall be as directed by the Services Consultant/Engineer In Charge/Engineer-In-Charge.

k. Cost for getting Approval of Fire Hydrant and Sprinkler system from local fire authority and any other relevant statutory authority at initial and various other stages of work, including preparation of report/drawings as per fire authority shall be included. Contractor shall include cost of all liason work which are not explicity mentioned above but are mandatory to have fire authority approval.

2. PIPE WORK

2.1 GENERAL REQUIREMENTS

All materials shall be of the best quality conforming to the specifications and subject to the approval of the Consultants.

Pipes shall be fixed in a manner as to provide easy accessibility for repair and maintenance and shall not cause obstruction in shafts, passages etc.

Pipes shall be securely fixed to walls and ceilings by suitable clamps and supports (galvanised after fabrication) at intervals specified. Only approved type of anchor fasteners shall be used for RCC slabs and walls / floors etc.

Valves and other appurtenances shall be so located that they are easily accessible for operations, repairs and maintenance.

Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required in a neat workman like manner.

Pipe accessories such as gauges, meters, control devices, etc. shall have the same working pressure rating as the associated pipework. All pipework shall be free from burrs, rust and scale and shall be cleaned before installation. All personnel engaged on welding operations must possess a certificate of competence issued by an acceptable / recognized authority.

2.2 PIPING

Pipes of following types are to be used:

Sprinkler and Hydrant system pipes shall be Mild Steel black pipes as per IS: 1239 heavy grade (for pipes of sizes 150 mm N.B. and below) and IS: 3589 heavy grade (for pipe sizes above 150 mm NB). M.S. pipes buried below ground shall be primered by anticorrosive pyp kote primer and suitably wrapped with bitumin base 4 mm pyp kote wrapping ang coating.

All pipe clamps and supports shall be fabricated from MS steel sections and shall be factory galvanised before use at site. Welding of galvanised clamps and supports shall not be permitted.

Pipes shall be hung by means of expandable anchor fastener of approved make and design. The hangers and clamps shall be fastened by means of galvanised nuts and bolts. The size/diameter of the anchor fastener and the clamps shall be suitable to carry the weight of water filled pipe and dead load normally encountered.

Hangers and supports shall be throughly galvanised after fabrication. The selection and design of the hanger & support shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipeline movements as necessary. All guides, anchor braces, dampener, expansion joint and structural steel to be attached to the building/structure trenches etc. shall be provided. Hangers and components for all piping shall be approved by the Consultants.

The piping system shall be tested for leakages at 2 times the operating pressure or 1.5 time shut-off pressure, which ever is highest including testing for water hammer effects.

Flanged joints shall be used for connections for vessels, equipment, flanged valves and also on two straight lengths of pipelines of strategic points to facilitate erection and subsequent maintenance work.For pipes under ground installation the pipes shall be buried at least one meter below ground level and shall have 230 mm x 230 mm masonry or concrete supports at least 300 mm high at 3m intervals. Masonry work to have plain cement concrete foundation (1 cement: 4 coarse sand: 8 stone aggregate) of size 380x380x75 thick resting on firm soil.

Mains below ground level shall be supported at regular intervals not exceeding 3.0 metres and shall be laid at least 2.0 metre away from the building.

2.3 PIPING INSTALLATION & SUPPORT

Tender drawings indicate schematically the size and location of pipes. The Contractor, on the award of the work, shall prepare detailed working drawings, showing the cross-sections, longitudinal sections, details of fittings, locations of isolating and control valves, drain and air valves, and all pipe supports. He must keep in view the specific openings in buildings and other structure through which pipes are designed to pass.

Piping shall be properly supported on, or suspended from, on stands, clamps, hangers as specified and as required. The Contractor shall adequately design all the brackets, saddles, anchor, clamps and hangers, and be responsible for their structural stability.

Pipe work and fittings shall be supported by hangers or brackets so as to permit free expansion and contraction. Risers shall be supported at each floor with Galvanised steel clamps. To permit free movement of common piping support shall be from a common hanger bar fabricated from Galvanised steel sections.

Pipe hangers shall be provided at the following maximum spacings:

Pipe Dia (mm)

Hanger Rod Dia (mm)

Spacing between Supports (m)

Up to 25 6 2

32 to 50 10 2.7

80 to 100 12 2.7

125 to 150 16 3.6

200 to 300 19 5.3

The end of the steel rods shall be threaded and not welded to the threaded bolt.

All pipe work shall be carried out in a proper workman like manner, causing minimum disturbance to the existing services, buildings, roads and structure. The entire piping work shall be organized in consultation with other agencies work, so that area can be carried out in one stretch.

Cut-outs in the floor slab for installing the various pipes area are indicated in the drawings. Contractor shall carefully examine the cut-outs provided and clearly point out wherever the cut-outs shown in the drawings, do not meet with the requirements.

Pipe sleeves, larger diameter than pipes, shall be provided wherever pipes pass through walls and slab and annular space filled with fibreglass and finished with retainer rings.

The contractor shall make sure that the clamps, brackets, saddles and hangers provided for pipe supports are adequate or as specified / approved by Consultants. Piping layout shall take due care for expansion and contraction in pipes and include expansion joints where required.

All pipes shall be accurately cut to the required sizes in accordance with relevant BIS codes and burrs removed before laying. Open ends of the piping shall be closed as the pipe is installed to avoid entrance of foreign matter. Where reducers are to be made in horizontal runs, eccentric reduces shall be used for the piping to drain freely. In other locations, concentric reduces may be used.

Automatic air valves shall be provided at all high points in the piping system for venting. All valves shall be of 15mm pipe size and shall be associated with an equal size gate valves. Automatic air valves shall be provided on hot water risers.

Discharge from the air valves shall be piped through a pipe to the nearest drain or sump. All pipes shall be pitched towards drain points.

Pressure gauges shall be provided as shown on the approved drawings. Care shall be taken to protect pressure gauges during pressure testing.

2.4 PIPE FITTINGS

Pipe fittings mean tees, elbows, couplings, unions, flanges, reducers etc and all such connecting devices that are needed to complete the piping work in its totality.

Fabricated fittings shall not be permitted for pipes diameters 50mm and below.

When fabricated fittings are used, they shall be fabricated, welded in workshops. They shall be inspected by Engineer-In-Charge before dispatch from the workshop. The welding procedures of the workshop should have been approved by the rules for sprinkler system and applicable to hydrant and sprinkler system. For “T” connection, pipes shall be drilled and reamed. Cutting by gas or electrical welding shall not be permitted.

2.5 JOINTING

2.5.1 WELDED JOINTS :

Joints between MS pipes and fittings shall be made with the pipes and fittings having “V” groove and welded with electrical resistance welding in an approved manner. But welding without “V” groove shall not be permitted.

All joints in the pipe line with screwed fittings shall be seal welded after testing and the weld plus the adjoining portion shall be given two coats of zinc rich primer.

2.5.2 FLANGED JOINTS (65 MM DIA AND ABOVE)

Flanged joints with flanges conforming to IS: 6392 shall be provided on

A. Straight runs at intervals not exceeding 25-30m on pipe lines of 50 mm dia and above

and as directed by the Engineer-In-Charge.

B. For jointing all types of valves, appurtenances, pumps, connections with other type of pipes, to water tanks and other places necessary and as required for good engineering

practice and as shown/noted on the drawings.

C. Flanges shall be with GI bolts and nuts and 3mm insertion gasket of natural rubber conforming to IS: 11149.

2.5.3 UNIONS (UPTO 50 MM DIA)

Approved type of dismountable unions shall be provided on pipe lines of 40 mm dia and smaller dia, in locations similar to those specified for flanges.

3. AIR VESSEL

The air vessel shall be provided to compensate for slight loss of pressure in the system and to provide an air cushion for counter-acting pressure, surges, whenever the pumping sets come into operation. Air vessel shall conform to IS:3844. It shall be normally half full of water, when the system is in normal operation. Air vessel shall be fabricated with 8 mm thick M.S. plate with dished ends and suitable supporting legs. It shall be provided with one 100 mm dia flanged connection from pump, one 25 mm drain with valve, one water level gauge and 25 mm sockets for pressure switches. The air vessel shall be tested to pressure for 12 hours at 2 times the operating pressure or 1.5 times the shut-off.

4. AIR CUSHION TANK

Every wet riser shall be provided with an air cushion tank at its top most point. The air cushion shall be provided with an automatic air release cock, 20 mm dia drain pipe, drain valve and shut off valve.

5 SYSTEM DRAINAGE

The system shall be provided with suitable drainage arrangement with drain valves complete with all accessories.

6 VALVE CHAMBERS

Provision of suitable brick masonary chambers in cement mortar 1:5 (1 cement: 5 coarse sand) on cement concrete foundations 150 mm thick 1:5:10 mix (1 cement: 5 fine sand: 10 graded stone aggregate 20 mm nominal size) with 15 mm thick cement plaster inside and outside finished with a plaster inside and outside finished with a floated coat of neat cement inside with cast iron surface box approved by fire brigade including excavation, back-filling complete shall be made.

7. VALVES

7.1 SLUICE VALVES

Sluice valves shall be double flanged valves with cast iron body. The spindle, wall seat and wedge nuts shall be of bronze. They shall generally have non-rising spindle and shall be of the particular duty and design called for.

The valves shall be supplied with suitable flanges, non- corrosive bolts and asbestos fibre gaskets. Sluice valves shall conform to Indian Standard IS: 780-1969 and IS: 2906.

7.2 BUTTERFLY VALVE

The butterfly valve shall be suitable for waterworks and rated for 300 P.S.I

The body shall be of cast iron to IS: 210 in circular shape and of high strength to take the water pressure. The disc shall be heavy duty cast iron with anti corrosive epoxy or nickel coating.

The valve seat shall be of high grade elastomer or nitrile rubber. The valve is closed position shall have complete contact between the seat and the disc throughout the perimeter. The elastomer rubber shall have a long life and shall not give away on continuous applied water pressure. The shaft shall be EN 8 grade carbon steel.

The valve shall be fitted between two flanges on either side of pipe flanges. The valve edge rubber shall be projected outside such that they are wedged within the pipe flanges to prevent leakages.

7.3 BALL VALVE

The ball valve shall be made forged brass and suitable for test pressure of pipe line. The valve shall be internally threaded to receive pipe connections.

The ball shall be made from brass and machined to perfect round shape and subsequently chrome plated. The seat of the valve body-bonnet gasket and gland packing shall be of Teflon.

The handle shall be provided with PVC jacket. The handle shall also indicate the direction of ‘open’ and ‘closed’ situations. The gap between the ball and the Teflon packing shall be sealed to prevent water seeping.

The handle shall also be provided with a lug to keep the movement of the ball valve within 90°. The lever shall be operated smoothly and without application of any unnecessary force.

7.4 GUN METAL VALVES

Gun metal Valves shall be used for smaller dia pipes, and for threaded connections. The Valves shall bear certification as per IS: 778

The body and bonnet shall be of gun metal to IS: 318. The stem gland and gland nut shall be of forged brass to IS: 6912. The hand wheel shall be of cast iron to IS: 210.

The Hand wheel shall be of high quality finish to avoid hand abrasions. Movement shall also be easy. The spindle shall be non rising type.

7.5 NON-RETURN VALVE

Non-Return valves shall be cast iron double flanged with cast iron body and gunmetal internal parts conforming to IS: 5312.

7.6 PRESSURE RELIEF VALVE

Each System shall be provided with a Pressure Relief Valves. The Valve shall be spring actuated and set to operate as per field requirement. The Valve shall be constructed of bronze and provided with an open discharge orifice for releasing the water. The Valve shall be open lift type.

8. PRESSURE SWITCH

The pressure switches shall be employed for starting and shutting down operation of pumps automatically, dictated by line pressure. The Pressure Switch shall be diaphragm type. The housing shall be die cast aluminium, with SS 316 movement, pressure element and socket. The set pressure shall be adjustable.

The Switch shall be suitable for consistent and repeated operations without change in values. It shall be provided with IP: 55 water and environment protection.

9 PRESSURE GAUGE

Pressure gauge shall be provided near all individual connections of the hydrant system with isolation valves and near each flow switch assembly of the sprinkler system. Pressure gauge shall be 50 mm dia gunmetal bourdon type with gunmental isolation ball valve, tapping and connecting pipe and nipple. The gauge shall be installed at appropriate height for easy readability.

10 PAINTING

All Hydrant and Sprinkler pipes shall be painted with post office red colour paint. All M S pipes shall first be cleaned thoroughly before application of primer coat. After application of primer coat two coats of enamel paint shall be applied. Each coat shall be given minimum 24 hours drying time. No thinners shall be used. Wherever required all pipe headers shall be worded indicating the direction of the pipe and its purpose such as "TO RISER NO.1" etc.

Painting shall be expertly applied; the paint shall not over run on surfaces not requiring painting such as walls, surfaces etc. Nuts and bolts shall be painted black, while valves shall be painted blue.

11. FIRE HYDRANTS 11.1.1 INTERNAL HYDRANTS

A. Contractor shall provide on each landing and other locations as shown on the drawings double headed gunmetal landing valve with 100 mm dia inlet as per IS:5290, with shut off valves having cast iron wheels as shown on the drawings. Landing valve shall have flanged inlet and instantaneous type outlets as shown on the drawings.

B. Instantaneous outlets for fire hydrants shall be standard pattern and suitable for fire hoses.

C. Contractor shall provide for each internal fire hydrant station two numbers of 63 mm dia. 15 m long ruberized fabric lined hose pipes with gunmetal male and female instantaneous type coupling machine would with GI wire (hose to IS:636 type 2 and couplings to IS:903 with IS certification), fire hose reel, gunmetal branch pipe with nozzle to IS:903. This shall be measured and paid for separately.

D. Contractor shall provide standard fire hose reels of 20mm dia high pressure dunlop rubber hose 36.5 m long with gunmetal nozzle, all mounted on a circular hose reel of heavy duty mild steel construction having cast iron brackets. Hose reel shall be connected directly to the wet riser with an isolating valve. Hose reel shall conform to IS:884 and shall be mounted vertically . This shall be measured and paid for separately.

E. Each internal hydrant hose cabinet shall be provided with a drain in the bottom plate. The drain point shall be lead away to the nearest general drain.

F. Each internal hydrant hose cabinet containing items as above shall also be provided with a nozzle spanner and a Fireman’s Axe. The cabinet shall be recessed in the wall as directed. This shall be measured and paid for separately.

G. Each hose cabinet shall be conspicuously painted with the letters “FIRE HOSE”.

11.1.2 HOSE REEL

Hose reel shall conform to IS : 884, heavy duty, 20 mm dia length shall be 36 metre long fitted with gun metal chromium plated nozzle, mild steel pressed reel drum which can swing upto 170 degree with wall brackets of cast iron finished with red and black enamel complete. 11.1.3 FIRE HOSE

All hose pipes shall be of 63 mm diameter RRL/ CP as required, conforming to IS : 636 or IS : 8423. The hose shall be provided with copper alloy delivery coupling. The hose shall be capable of withstanding a bursting pressure of 35.7 Kg/Sq.cm without undue leakage or sweating. Hose shall be provided with instantaneous spring-lock, type couplings.

11.1.4 BRANCH PIPE, NOZZLE

Branch pipes shall be of gun metal with loaded tin bronze ring at the discharge and to receive the nozzle and provided at the other with a leaded tin bronze ring to fit into the instantaneous coupling. Nozzle shall be of spray type of diameter of not less than 16 mm and not more than 25 mm. Nozzle shall be of loaded tin bronze branch pipe and nozzle shall be of instantaneous pattern conforming to Indian Standard - 903.

11.1.5 HOSE CABINET

Hose cabinet shall be provided for all internal and external fire hydrants. Hose cabinets shall be fabricated from 16 gauge MS powder coated sheet of fully welded constrcution with hinged double front door partially glazed (3 mm glass panel) with locking arrangement, stove enamelled fire red paint (shade No. 536 of IS:5) with “FIRE HOSE” written on it prominently (size as given in the schedule of quantities). Cabinet surfaces in contact with the walls shall not be powder coated but instead given two coats of anti-corrosive bitumastic paint.

11.1.6 INTERNAL HOSE CABINET

Hose cabinet shall be of glass fronted with hinged door & lock. The cabinet shall be made of 16 gauge thick MS sheet and spray painted to shade No. 536 of IS: 5. The hose cabinet shall be of size to accommodate the following:

A. Landing Valves (Single/double headed) B. Hose pipe

C. Hose reel (36.5 mtr.) D. Branch pipes, nozzles (2 sets)

E. Fire man's axe and hand appliances

TECHINAL SPECIFICATIONS

EXTERNAL ELECTRICAL WORKS

SYSTEM DESCRIPTION

1.0 GENERAL INFORMATION

1.1 Ambient air temperature shall be taken as 50 deg. C for the purpose of designing

of electrical equipment.

1.2 This specification shall be read and constructed in conjunction with the drawings and

annexure to determine the scope of work.

1.3 All equipment shall be capable of continuous operation satisfactorily under the following

conditions:

a) voltage variation : ± 10%

b) frequency variation : ± 5%

c) combined voltage & frequency variation : ± 10%

1.4 Nominal system supply available shall be as follows:

a) Incoming : 11 kV, 3 Ph., 50 Hz, with fault level of 350 MVA.

b) Distribution : 415V, 3 Ph., 4 wire, 50 Hz with fault level of 35 kA.

2.0 CODES AND STANDARDS

2.1 All equipment and materials specified herein or not, shall be designed, manufactured and

tested with the latest applicable standards & bureau of Indian standards.

2.2 All electrical equipment shall also conform to the latest electricity rules as regards safety

and other essential provisions.

2.3 All electrical installation work shall comply with the requirements of the following Act /

rules / codes as amended up to date:

a) Indian electricity act.

b) Indian electricity rules.

c) National electric code published by BIS.

d) All relevant Is codes of practice.

e) Regulations published by tariff advisory committee.

3.0 SYSTEM DESCRIPTION

3.1 GENERAL

a) One independent radial feeder is envisaged from State Electricity Board for

receiving incoming supply on 11 kV.

b) 11 KV incoming supply shall be connected to Metering Panel through 11 kV XLPE

cable.

c) 11 kV XLPE cable shall be buried in ground

d) 11 KV Panel shall have each outgoing shall feed power to the Transformer.

e) 415V L T panel shall receive power from Distribution Transformer I DG

synchronization panel and shall feed power to various Blocks & Common Services

as per enclosed single line diagram.

f) There shall be different metering for State Electricity supply and for DG power

supply through the same energy meter. For this purpose, a control cable shall run

from substation to different energy meters.

g) Further routing of cables and Power Distribution shall be as per Single Line

Diagram.

4.0 DESIGN CRITERIA

4.1 GENERAL

a) The equipment shall be used in high voltage system having characteristics as listed

in this specification.

b) The equipment shall be installed in a hot, dusty, humid and tropical atmosphere.

c) here shall be no radio interference when the equipment are operated at maximum

service voltage.

d) The max. temp. in any part of the equipment at specified rating shall not exceed

the permissible limits as stipulated in the relevant standards.

e) The equipment shall be capable of withstanding the dynamic and thermal stresses

of listed short circuit current without any damage or deterioration.

f) All equipment, accessories and wiring shall have tropical protection, involving

special treatment of metal and insulation against fungus, insects and corrosion.

g) The safety clearances of all live parts of the equipment shall be as per relevant

standards.

h) All equipment/components of identical rating shall be physically and electrically

interchangeable.

i) All outdoor equipment shall be suitable to mount on steel structure. Connectors

shall be bimetallic conductor.

j) Wherever single core cables are terminated in any equipment, gland plate shall be

of Aluminium (3-4 mm thick).

k) There shall be no straight through joints in power & control cables.

l) All cable terminations shall be with Double compression cable gland with armour

holding system.

m) The lighting fixture shall have loop in & loop out facility.

GENERAL& TECHNICAL

1 POINT WIRING:-

1.1. DEFINITION :-

A point (other than socket outlet point shall include all work necessary in complete wiring to the various outlets from the controlling switch or MCB.

1.2. SCOPE:-

Following shall be deemed to included in point wiring.

i. Conduit/casing and capping/channels as the case may be, accessories for the same and wiring cables between the switch box and the point outlet, loop protective earthing of each fan / light fixture.

ii. All fixing accessories such as clips, nails, screws, Phil plug, rawl plug etc as

required.

iii. Metal / PVC switch boxes for control switches, regulators, sockets etc, recessed

or surface type of modular type or piano type with sheet as required and as mentioned in BOQ.

iv. Outlet boxes, junction boxes, pull-through boxes etc, but excluding metal boxes if any, provided with switchboards for loose wires/conduit terminations.

v. Any special block required for neatly housing the connector.

vi. Control switch or MCB, as specified in BOQ / drawings.

vii. 3 / 5 pin or 6 pin socket, ceiling rose or connector as required.

viii. Connections to ceiling rose, connector, socket outlet, lamp holder, switch etc.

xi. Bushes conduit or porcelain tubing where wiring cables pass through wall etc.

1.3 MATERIAL:-

i The system of wiring shall consist of ISI marked single core, PVC insulated, FRLS, 1100 volt grade, stranded, flexible copper conductor wires as per IS : 694 amended up to date.

ii The Conduit and accessories shall be of mild steel of ISI marked (IS: 9537)

ERW black, stove enameled, screwed type. The wall thickness of conduits shall be 16 SWG for 20, 25 and 32 mm dia conduits and 14 SWG for 40 and 50 mm dia conduits.

1.4. CONDUCTOR SIZE :-

Wiring shall be carried out with following sizes of wires –

a. Light/fan/call bell/ exhaust fan point - 1.5 sq mm.

b. 5 amp plug points - 1.5 sq mm..

c. Light circuit - 1.5 sq mm.

d. 5 amp plug points for computers - 2.5 / 1.5 sq mm.

e. General / Primary Power point - 4.0 sq mm.

f. Secondary Power point - 2.5 sq mm.

g. Power point for AC - 4.0 / 6.0 sq mm.

1.5 Size of Earth wires shall be as per following table -

Size of point/ circuit / submain wires Earth wire

2x1.5 sqmm. - 1x1.0 / 1.5 sqmm.

2x2.5 sqmm. - 1x1.5 sqmm.

2x4 sqmm. - 1x2.5 sqmm.

2x6 sqmm. - 1x4 sqmm.

2x10 sqmm. - 1x6 sqmm.

2x16 sqmm. - 1x6 sqmm.

4x6 sqmm. - 2x4 sqmm.

4x10 sqmm. - 2x6 sqmm.

4x16 sqmm. - 2x6 sqmm.

2. MEASUREMENT:-

2.1. POINT WIRING :-

i. Unless and otherwise specified, there shall be no linear measurement for point wiring for light points, fan points, exhaust fan points and call bell points. These shall be measured on unit basis by counting.

ii. No separate measurement will be made for interconnections between points in

the same distribution circuit and for the circuit protective (loop earthing) conductors between metallic switch boxes.

2.2 POINT WIRING FOR SOCKET OUTLET POINTS :-

i. The light plug (5A/6A) point and power (5A/15A) point shall be measured on unit basis by counting. The submain / circuit wiring to socket outlets is included in the item, from the respective tapping point of live cable, namely switch box, another socket outlet point, or the sub distribution board as the case may be, up to the socket outlet.

ii. The metal box with cover, switch/MCB socket outlet and other accessories shall

also be included in the above item.

2.3 GROUP CONTROL POINTS WIRING :-

i. In the case of points with more than one point controlled by the same switch,

such point shall be measured in parts i.e.(a) from the switch to the first point outlet as one point (Primary point), and (b) for the subsequent points each shall be treated as separate point (additional/secondary).

ii. No recovery shall be made for non-provision of more than one switch in such

cases.

2.4 TWIN CONTROL LIGHT POINT WIRING:-

i. A light point controlled by two numbers of two way switches shall be measured as two point.

ii. No recovery shall be made for non-provision of more than one ceiling rose /

connector in such cases.

2.5 MULTIPLE CONTROLLED CALL BELL POINTS WIRING:-

g. In the case of call bell points with a single call bell outlet, controlled from more than one place, the point shall be measured in parts i.e. (a) from the call bell outlet to one of the nearest ceiling roses meant for connection to bell push, treated as one point and (b) from that ceiling rose to the next one and so on, shall be treated as separate point(s).

ii. No recovery shall be made for non-provision of more than one ceiling rose or

connector for connection to call bell in such cases.

3. CIRCUIT AND SUBMAIN WIRING:-

3.1. CIRCUIT WIRING :-

Circuit wiring shall mean the wiring from the distribution board up to the first tapping point inside the switch board.

3.2. SUB MAIN WIRING :-

Sub main wiring shall mean the wiring from one main/distribution switchboard to another board / panel and from Distribution Board to Power Outlet / AC Outlet.

4. MEASUREMENT OF SUBMAIN / CIRCUIT WIRING :-

i. Sub main wiring shall be measured on linear basis along the run of the wiring. The measurement shall include all length from end to end of conduit or casing and capping as the case may be, exclusive of interconnections inside the switch board etc. The increase on account of diversion or slackness shall not be included in the measurement.

ii. The length of circuit wiring shall be measured from the distribution board to the nearest

switch box from which the point wiring starts. Looping of switch box also will be counted towards circuit wiring, measured along the length of conduit / channel.

5. SYSTEM OF DISTRIBUTION AND WIRINGS :-

i. Main distribution board shall be controlled by the circuit breaker. Each outgoing circuit shall be controlled by a circuit breaker on the phase or live conductor.

ii. The branch distribution board shall be controlled by a circuit breaker. Each

outgoing circuit shall be provided with a MCB of specified rating on the phase or live conductor.

iii. The load of the circuits shall be divided, as far as possible, evenly between the

number of ways of the distribution boards, leaving at least one spare circuit for future extension.

iv. The neutral conductors (incoming and outgoing) shall be connected to a common

link (multi way connector) in the distribution board and be capable of being disconnected individually for testing purposes.

i. Wiring shall be separate for essential loads (ie those fed through stand by

supply) and non-essential loads throughout.

6. BALANCING OF CIRCUIT:-

The balancing of circuits in three wire or poly phase installations shall be arranged up to the satisfaction of the Engineer-in-charge.

7. WIRING SYSTEM:-

a) The wiring shall be done only by the “Looping system”. Phase or live conductors shall be looped at the switch boxes. For point wiring neutral / earth wire looping for the first point shall be done in the switch box, and neutral / earth looping of subsequent point will be made from point outlet.

b) Lights, fans and call bells shall be wired in the ‘lighting’ circuits. 15A/16A socket

outlets and other power outlets shall be wired in the ‘Power’ circuits. 5A/6A socket outlets shall also be wired in the “Lighting” circuit unless mentioned otherwise.

c) The wiring throughout the installation shall be such that there is no break in the

neutral wire except in the form of a linked switch gear.

d) Surface wiring shall run, as far as possible, along the walls and ceiling so as to be

easily accessible for inspection.

e) In all types of wiring, due consideration shall be given for neatness, good appearance and safety.

f) Colour coding :

Phase : Red / Yellow / Blue (three phase wiring)

Live : Red (single phase wiring)

Neutral : Black

Earth : Green

8. PASSING THROUGH WALLS OR FLOORS:-

i. When wiring cables are to pass through a wall, these shall be taken through a protection (steel/PVC) pipe or porcelain tube of suitable size such that they pass through in a straight line without twist or cross in them on either end of such holes. The ends of metallic pipe shall be neatly bushed with porcelain, PVC or other approved material.

ii. Where a wall pipe passes outside a building so as to be exposed to weather, the

outer end shall be bell mouthed and turned downwards and properly bushed on the open end.

iii. All floor openings for carrying any wiring shall be suitably sealed after installation.

9. JOINTS IN WIRING:-

i. No bare conductor in phase and/or neutral or twisted joints in phase, neutral, and/or protective conductors in wiring shall be permitted.

ii. There shall be no joints in the through-runs of cables. If the length of final circuit or sub main is more than the length of a standard coil, thus necessitating a through joint, such joints shall be made by means of approved mechanical connectors in suitable junction boxes.iv. Termination of multi stranded conductors shall be done using suitable crimping type thimbles.

10. CONFORMITY TO I.E. ACT, I.E. RULES AND STANDARDS:-

i. All electrical works shall be carried out in accordance with the provisions of the Indian Electricity Act, 1910 and Indian Electricity Rules 1956 amended up to date.

ii. The work shall also conform to relevant Indian Standard codes of practice for the

type of work involved.

iii. In all electrical installation works, relevant safety codes of practice shall be

followed.

iv. The complete wiring installation shall confirm to IS : 732 amended up to date.

11. GENERAL REQUIREMENTS OF COMPONENTS :-

11.1 QUALITY OF MATERIALS :-

All materials and equipment supplied by the contractor shall be new. They shall be of such design, size and material as to satisfactorily function under the rated conditions of operation and to with stand the environmental conditions at site.

11.2 RATING OF COMPONENTS:-

i. All components in a wiring installation shall be of appropriate ratings of voltage, current and frequency, as required at the respective sections of the electrical installation in which they are used.

ii. All conductors, switches and accessories shall be of such size as to be capable

of carrying the maximum current which will normally flow through them, without their respective ratings being exceeded.

11.3 CONFORMITY OF STANDARD:-

All components shall conform to relevant Indian Standard specification, wherever existing. Materials with ISI certification mark shall be preferred. However for conduits, wiring cables, piano/tumbler switches and socket outlets, ISI marked materials shall only be permitted.

11.4 INTERCHANGEABILITY:-

Similar parts of all switches, lamp holders, distribution fuse boards, switch gears, ceiling roses, brackets, pendants, fans and all other fittings of the same type shall be interchangeable in each installation.

SWITCHES & RECEPTACLES (Piano Type)

1. CONTROL SWITCHES FOR POINTS:-

i. The switch box or regulator box shall be hot dipped galvanized, factory fabricated. The wall thickness shall not be less than 1.2 mm (18 gauge) for boxes up to a size of 20 cm x 30 cm, and above this size 1.6 mm (16 gauge) thick boxes shall be used. The metallic boxes shall be duly painted with anticorrosive paint before erection.

ii. Where a large number of control switches and/or fan regulators are required to be installed at one place, these shall be installed in more than one outlet box adjacent to each other for ease of maintenance.

iii. An earth terminal with stud & 2 metal washers shall be provided in each box for termination of protective conductors and for connection to socket outlet/metallic body of fan regulator etc.

iv. Clear depth of the box shall not be less than 50 mm, and this shall be increased

suitably to accommodate mounting of fan regulators in flush pattern.

v. The fan regulators can also be mounted on the switch box covers, if so directed

by the Engineer-in-charge.

vi. Control switches (single pole switches) carrying not more than 16 A shall be of piano type, as specified, and the switch shall be "ON" when the nob is down.

vii. Only MCB' s shall be used for controlling industrial type socket outlets.

viii. Control switch shall be placed only in the live conductor of the circuit. No single pole switch or fuse shall be inserted in the protective (earth) conductor, or earthed neutral conductor of the circuit.

ix. All switches, regulators, outlets & other accessories shall be white colour with

matching white cover plate. In no case ivory or off white switches shall be accepted.

x. All switches shall be as per IS 3854 amended up to date.

2. SOCKET OUTLETS:-

i. Socket outlet shall be of the same type, white piano type as their control switches. These shall be rated either for 5A/6A or 15A/16A. Combined 5A/15A or

6A/16A six pin socket outlet shall be provided in `power' circuits.

ii. In an earthed system of supply, socket outlets and plugs shall only be of 3 pin

type, the third pin shall be connected to earth through protective (loop earthing) conductor. 2 pin or 5 pin sockets shall not be permitted to be used.

iii. Every socket outlets shall be controlled by a switch or MCB, as specified. The

control switch/MCB shall be connected on the `live' side of the line.

iv. Outlet boxes for socket outlets (both15A/16A and 5A/6A) points shall be of size 175 mm x 100mm.

v. Unless and other wise specified, the control switches for the 5A/6A and 15A/16A

socket outlets shall be kept along with the socket outlets.

xi. All sockets shall be as per IS 1293 amended up to date.

3. SWITCH BOX COVERS:-

Phenolic laminated sheets of approved white shade (same as switches and sockets) shall be used for switch box covers. These shall be of white 3 mm thick synthetic phenolic resin bonded laminated sheet as base material and conforming to grade P-I of IS:2036-1974, Secured to the box with counter sunk C.P. Brass Screws. The corners of cover plates shall be at right angle.

SWITCHES & BOXES (Modular Type)

i. The switch box or regulator box shall be made of metal on all sides, except on the front. The boxes shall be used of the same make and model as of modular switches. In no case the locally manufactured switch boxes will be accepted. The size of box shall be governed by the number of switches/outlets/regulators on the respective board. The boxes shall be with zinc plating and yellow passivation to complies with the rust test as per IS 3854. The boxes should have slotted holes for level adjustments. The boxes shall be fitted with riveted brass earth terminals for earth connections.

ii. Clear depth of the box shall not in a range of 50 mm to 65 mm depending upon

the size of board and manufacturer.

iii Control switch shall be placed only in the live conductor of the circuit. No single pole switch or fuse shall be inserted in the protective (earth) conductor, or earthed neutral conductor of the circuit. The switches shall be provided with silver contacts. The neutral should make first and breaks last.

iv. Socket outlet shall be rated either for 5A/6A or 15A/16A. 5/6 Amp sockets shall be of 5 pin type with shutters. Combined 5A/15A or 6A/16A six pin shuttered socket outlet shall be provided in `power' circuits. The earth pin shall be connected to earth through protective (loop earthing) conductor. All sockets shall be provided with safety shutters to allow easy entry of two pin plugs without the need to force the earth terminal by unsafe means. All sockets shall confirm to IS:1293.

v. Every socket outlet shall be controlled by a switch, as specified. The control

switch shall be connected on the `live' side of the line.

Vi The switches and sockets shall be manufactured using engineering plastic to

make it fire retardant and highly resistant to impact.

vii. The fan speed regulators shall be of electronic and stepped type

viii. The RJ-45 data socket shall be suitable for cat5/cat 6 data cables.

ix. Gold plated contacts shall be provided in all communication jacks to enhance data and voice transmission.

SWITCHGEAR AND CONTROLGEAR

1. GENERAL ASPECT:-

i. All items of switchgear and distribution boards (DB' s) shall be metal clad type.

ii. The types, rating and/or categories of switch gear and protective gear shall be as specified in the tender schedule of work.

iii. RCCB’s and RCBO’s where specified, shall conform to the requirements of

current rating, fault rating, single phase or three phase configuration and sensitivity laid down in the tender documents.

iv. While each outgoing way of distribution board (D.B.) shall be of miniature circuit

breaker (MCB) as specified, and of suitable rating on the phase conductor, the corresponding earthed neutral conductor shall be connected to a common neutral terminal block and shall be capable of being disconnected individually for testing purpose.

v. Independent earth terminal block.

Every distribution board (single phase as well as three phase) shall have an earth terminal block identical to, but independent from neutral terminal block, to enable termination of protective (loop earthing) conductors (incoming as well as out goings) individually by screwed connection and without twisting.

vi. Earthing terminal (1 for single phase and 2 for three phase) shall be provided on

the metal cladding of switches and D.B.'s for body earthing. These shall be suitably marked.

vii. Knock out holes, with or without end plates as per standard design of

manufacturers, shall be provided in the metal cladding of switches and D.B.’ s for termination of conduits/cables.

viii. Each distribution board shall be provided with a circuit list giving details of each

circuit which it controls and the current rating of the circuit, and the size of the fuse element.

2. MCB TYPE DISTRIBUTION BOARDS (MCB DB) :-

i. MCB DB' s may be of single phase, three phase (horizontal type) suitable for feeding single phase loads or 3 phase (vertical type) suitable for feeding single phase as well as three phase loads, each phase isolation type three phase DB in which each phase can be isolated by a separate circuit breaker or RCCB, as specified. These shall be complete with accessories, but without MCB’ s, which shall be specified as a separate item in the tender documents.

ii. The current ratings and the number of ways shall be as specified. Blanking plates

shall be provided to close unused ways. These shall be indicated as a separate item in the Schedule of work.

iii. MCB DB' s shall be of surface/flush mounting pattern according to the

requirement of their location, and shall be suitable to accommodate MCB' s and MCB type isolators and RCCB (ELCB) at incoming in single pole or multi pole configuration, as required.

ii. MCB DB's shall be double door type, dust and vermin proof conforming to IP 43 or as per BOQ, and shall be fabricated out of CRCA sheet steel, minimum 1.2 mm thick, with stove enameled paint finish.

v. In case of Concealed / Recessed D.B.’s, the DB should have metallic collar for

zero error installation, however, cutting of brick work, providing suitable lintel, making good the wall including plastering etc. with necessary civil work including all Civil material shall be included in contractor’s scope for proper completion of work.

vi. MCB DB's shall have removal type end plates with knock-outs at the bottom and

top, and shall have hinged covers with locking arrangement.

vii. Only the knobs of the MCB's shall protrude out of the front covers through

openings neatly machine made for the purpose.

viii. The bus bars used shall be solid electrolytic copper of appropriate sections.

ix. Din bar(s) shall be provided for mounting the MCB's.

x. The complete board shall be factory fabricated and shall be duly pre-wired in the

works, ready for installation at site.

xi. The board shall be fully pre wired with single core PVC insulated copper

conductors/insulated solid copper links, and terminated on to extended type terminal connectors, suitable for connections to the sizes of the respective conductors.

xii. All incoming and outgoing wiring to the pre wired MCBDB' s shall be terminated

only in the extended terminal connectors to be provided within the DB. The terminal connectors shall therefore be so provided as to facilitate easy cable connections and subsequent maintenance.

3. MCCB TYPE DISTRIBUTION BOARDS (MCCB DB) :-

i. All MCCB DB' s shall be of three phase suitable for feeding single phase loads or 3 phase loads through SP/TP MCB’s, IP 43 enclosure, sheet steel, double door with tinned copper bus bar, neutral bar, earth bar, knock outs etc. The DB’s shall be original factory fabricated of approved make.

ii. The current ratings of Incomer MCCB shall be upto 250 amp and the number of

ways shall be as specified. Blanking plates shall be provided to close unused ways.

iii. MCCB DB shall be of surface/flush mounting pattern according to the

requirement of their location, and shall be suitable to accommodate Four pole MCCB at incomer and SP/TP MCB’s at outgoings, as required.

iii. MCCB DB's shall be dust and vermin proof conforming to IP 43, and shall be fabricated out of CRCA sheet steel, minimum 1.3 mm thick, with stove enameled paint finish.

v. In case of Concealed / Recessed D.B.’s, the DB should have metallic collar for

zero error installation, however, cutting of brick work, providing suitable lintel, making good the wall including plastering etc. with necessary civil work including all Civil material shall be included in contractor’s scope for proper completion of work.

vi. MCCB DB's shall have removal type end plates with knock-outs at the bottom and top, and shall have hinged covers with locking arrangement.

viii. The bus bars used shall be solid electrolytic copper of appropriate sections.

ix. Din bar(s) shall be provided for mounting the MCB's.

4. WORKMANSHIP:-

i. Good workmanship is an essential requirement to be complied with. The entire work of manufacture/fabrication, assembly and installation shall conform to sound engineering practice.

ii. The work shall be carried out under the direct supervision of a first class licensed

foreman, or of a person holding a certificate of competency issued by the state Government for the type of work involved, employed by the contractor, who shall rectify then and there the defects pointed out by the Engineer-in-charge during the progress of work.

5. COMMISSIONING ON COMPLETION:-

Before the workman leaves the work finally, he must make sure that the installation is in commission, after due testing.

6. COMPLETION PLAN AND COMPLETION CERTIFICATE :-

i. For all works completion certificate after completion of work shall be submitted to the Engineer-in-charge.

ii. Completion plan drawn to a suitable scale in tracing cloth with ink indicating the

following, along with three blue print copies of the same shall also be submitted.

a) General layout of the building.

b) Locations of main switch board and distribution boards, indicating the circuit

numbers controlled by them.

c) Position of all points and their controls.

d) Types of fittings, viz. fluorescent, pendants, brackets, bulkhead, fans and

exhaust fans etc.

e) Name of work, job number, accepted tender reference, actual date of completion,

names of Division/Sub-Division and name of the firm who executed the work with their signature.

7. ADDITION TO AN INSTALLATION:-

An addition, temporary or permanent, shall not be made to the authorised load of an existing installation until it has been definitely ascertained that the current carrying capacity and the condition of the existing accessories, conductors, switches etc affected, including those of the supply Authorities, are adequate for the increased load.

PVC CONDUIT WIRING SYSTEM

1. SCOPE:-

This chapter covers the detailed requirements for wiring work in non-metallic conduits. This chapter covers both surface and recessed types of wiring work.

2. APPLICATION:-

1. Recessed conduit work is generally suitable for all applications. Surface conduit work may be adopted in places like workshops etc. and where recessed work may not be possible to be done. The type of work shall be as specified in individual works.

2. Flexible non-metallic conduits shall be used only at terminations, wherever

specified.

3. Special precautions :-

i. If the pipes are liable to mechanical damages, they should be adequately protected.

ii. Non-metallic conduit shall not be used for the following applications :-

a) In concealed/ inaccessible places of combustible construction where ambient temperature exceeds 60oC.

b) In places where ambient temperature is less than 5oC.

c) For suspension of fluorescent fittings and other fixtures.

d) In areas exposed to sunlight.

3. MATERIAL:-

3.1 CONDUITS :-

i. All non-metallic conduit pipes and accessories shall be of suitable material complying with IS: 2509-1973 and IS : 3419-1988. for rigid conduits and IS : 9537(V)-2000 for flexible conduits. The interior of the conduits shall be free from obstructions. The rigid conduit pipes shall be ISI marked.

ii. The conduit shall be circular in cross-section. The conduit shall be designated by

their nominal outside diameter. The dimensional details of rigid non-metallic conduits are given in Table-1a.

iii. No non-metallic conduit less than 20 mm in diameter shall be used.

iv. WIRING CAPACITY :-

The maximum number of PVC insulated aluminium/copper conductor cables of 650/1100 V grade conforming to IS: 694-1990 that can be drawn in one conduit of various sizes is given in table-2a. Conduit sizes shall be selected accordingly.

3.2 CONDUIT ACCESSORIES:-

i. The conduit wiring system shall be complete in all respect including accessories.

ii. Rigid conduit accessories shall be normally of grip type.

iii. Flexible conduit accessories shall be of threaded type.

iv. Bends, couplers etc. shall be solid type in recessed type of works, and may be

solid or inspection type as required, in surface type of works.

v. Saddles for fixing conduits shall be heavy gauge non-metallic type with base.

vi. The minimum width and the thickness of the ordinary clips or girder clips shall be

as per Table-3a.

vii. For all sizes of conduit, the size of clamping rod shall be 4.5mm (7 SWG) diameter.

4. INSTALLATION:-

1. COMMON ASPECTS FOR BOTH RECESSED AND SURFACE CONDUIT WORKS.

i. The erection of conduits of each circuit shall be completed before the cables are drawn in.

ii. CONDUIT JOINTS:-

a) All joints shall be sealed/cemented with an approved cement. Damaged conduit

pipes / fittings shall not be used in the work. Cut ends of conduit pipes shall have no sharp edges nor any burrs left to avoid damage to the insulation of conductors while pulling them through such pipes.

b) The Engineer-in-charge, with a view to ensuring that the above provision has

been Carried out, may require that the separate lengths of conduit etc. after they have been prepared, shall be submitted for inspection before being fixed.

iii. BENDS IN CONDUITS :-

a) All bends in the system may be formed either by bending the pipes by an

approved method of heating, or by inserting suitable accessories such as bends, elbows or similar fittings, or by fixing non-metallic inspection boxes, whichever is most suitable. Where necessary, solid type fittings shall be used.

b) Radius of bends in conduit pipes shall not be less than 7.5 cm.

c) Care shall be taken while bending the pipes to ensure that the conduit pipe is not

injured, and that the internal diameter is not effectively reduced.

iv. PAINTING:-

After installation, all accessible surface of metallic accessories shall be painted.

i. ADDITIONAL REQUIREMENTS FOR SURFACE CONDUIT WORK:-

ii. Conduit pipe shall be fixed by heavy gauge non-metallic saddles with base, secured to suitable approved plugs with screws in an approved manner, at an interval of not more than 60 cm, on either side of couplers or bends or similar fittings, saddles shall be fixed at a closer distance from the center of such fittings. Slotted PVC saddles may also be used where the PVC pipe can be pushed in through the slots.

iii. Where the conduit pipes are to be laid along the trusses, steel joists etc. the

same shall be secured by means of saddles or girder clips as required by the Engineer-in-charge. Where it is not possible to use these for fixing, suitable clamps with bolts and nuts shall be used.

5. ADDITIONAL REQUIREMENTS FOR RECESSED CONDUIT WORK :-

i. MAKING CHASE :-

a) chase in the wall shall be neatly made, and of ample dimensions to permit the conduit to be fixed in the manner desired.

b) In the case of buildings under construction, the conduits shall be buried in the

wall Before plastering, and shall be finished neatly after erection of conduit.

ii. In case of exposed brick/rubble masonry work, special care shall be taken to fix the conduit and accessories in position along with the building work.

iii. NG CONDUITS IN CHASE :-

a) The conduit pipe shall be fixed by means of staples, or by means of non-metallic saddles, placed at not more than 60 cm apart, or shall be fixed by any other approved means of fixing.

b) At either side of the bends, saddles/staples shall be fixed at a distance of 15 cm

from the center of the bends.

iv. ERECTION IN RCC WORK:-

a) The conduit pipes shall be laid in position and fixed to the steel reinforcement bars

by steel binding wires before the concreting is done. The conduit pipes shall be fixed firmly to the steel reinforcement bars to avoid their dislocation during pouring of cement concrete and subsequent tamping of the same.

b) Fixing of standard bends or elbows shall be avoided as far as practicable, and all

Curves shall be maintained by bending the conduit pipe itself with a long radius which will permit easy drawing of conductors.

c) Location of inspection/junction boxes in RCC work should be identified by

suitable means to avoid unnecessary chipping of the RCC slab subsequently to locate

these boxes.

v. FIXING INSPECTION BOXES:-

a) Suitable inspection boxes to the minimum requirement shall be provided to permit

inspection, and to facilitate replacement of wires, if necessary.

b) These shall be mounted flush with the wall or ceiling concrete. Minimum 65 mm Depth junction boxes shall be used in roof slabs.

c) Suitable ventilating holes shall be provided in the inspection box covers.

vi. FIXING SWITCH BOXES AND ACCESSORIES:-

Switch boxes shall be mounted flush with the wall. All 137 outlets such as switches, socket outlets etc. shall be flush mounting type, unless otherwise specified in the additional specification.

vii. FISH WIRE:-

To facilitate subsequent drawing of wires in the conduit, GI fish wire of 1.2 mm (18 SWG) shall be provided along with the laying of the recessed conduit.

6. BUNCHING OF CABLES:-

a) Cable carrying alternating current, installed in metal conduit, shall always be bunched so that the outgoing and return cables are drawn into the same conduit.

b) Where the distribution is for single phase loads only, conductors for these phases

shall be drawn in one conduit.

c) In case of three phase loads, separate conduits shall be run from the distribution boards to the load points, or outlets as the case may be.

7. EARTHING REQUIREMENTS:-

i. A protective (earth) conductor shall be drawn inside the conduit in all distribution circuits to provide for earthing of non-current carrying metallic parts of the installation. These shall be terminated on the earth terminal in the switch boxes, and/or earth terminal blocks at the DB's.

ii. Protective conductors of large size which may not be possible to be carried

inside the conduits (as in the case of some sub mains etc.) may be laid external to the conduits and clamped thereto suitably.

iii. Gas or water pipes shall not be used as protective conductors (Earth medium).

TABLE – 1a.

DIMENSIONAL DETAILS OF RIGID NON-METALLIC (PVC) CONDUITS.

(All dimensions in mm)

S.No. Nominal outside diameter

( In mm )

Maximum outside diameter

( In mm )

Minimum inside diameter

( In mm )

Maximum permissible eccentricity ( In mm )

Maximum permissible

ovality ( In mm )

1. 20 20 +0.3 17.2 0.2 0.5

2. 25 25 +0.3 21.6 0.2 0.5

3. 32 32 +0.3 28.2 0.2 0.5

4. 40 40 +0.3 35.8 0.2 0.5

5. 50 50 +0.3 45.0 0.4 0.6

TABLE – 2a

MAXIMUM NUMBER OF PVC INSULATED 650/ 1100 VOLT GRADE COPPER CONDUCTOR CABLE THAT CAN BE DRAWN INTO RIGID PVC CONDUIT.

Nominal cross sectional area of conductor in Sqmm.

20 mm

25 mm

32 mm

40 mm

1.50 5 10 14 -

2.50 5 8 12 -

4.00 3 8 10 -

6.00 2 5 8 -

10.00 - 3 5 6

16.00 - - 3 6

25.00 - - 2 4

Note :-

The above table shows the maximum capacity of conduits for a simultaneous drawing of cables.

TABLE – 3a.

ORDINARY CLIPS OR GIRDER CLIPS.

S.No. Size of conduit Width Thickness

1. 20 mm & 25 mm 19 mm 20 SWG ( 0.9144 mm )

2. 32 mm & above 25 mm 18 SWG ( 1.219 mm )

TRUNKING CABLE MANAGEMENT SYSTEM

SCOPE

1. This chapter covers the requirements of mini trunking (casing wiring) and adaptable metallic or PVC trunking ("otherwise also called wire ways").

Adaptable trunking shall be used for power cables and data cables to run parallel in two different compartments with partition.

2. Mini Trunking is suitable for surface wiring work indoors where necessitated,

either due to aesthetics or technical requirements, such as case of extension of existing wiring, avoidance of recessed wiring in RCC columns etc. PVC insulated cables and / or other approved insulated cables to IS: 694- 1990 shall be used in this type of work.

Wherever data cables are used for information outlets. Adaptable trunking shall be used.

3. (i) This system using PVC trunking shall be adopted in residential buildings,

or office building where there is a need of tidy wiring system.

(ii) PVC Trunking for distribution of Voice, Data and Power should be used for cable management and should accept RJ45 Data socket and Power socket or other wiring accessory like switches, indicators etc.

(iii) Trunking should be equipped with rail on its surface on which clip-on

partition can be clipped which should accept frames/plates for wiring devices upto 6/8 modules.

(i) Trunking should have insulation rating of 5 mega Ohm. Trunking should

have the following fire resistance characteristics.

- Operating temperature between - 40 Deg to 60 Deg.

MATERIAL

1. The mini trunking and adaptable trunking shall be of the same material, viz. either PVC or anodized aluminium in extruded sections.

2. The mini trunking shall have a square or rectangular body. The trunking cover

shall be "CLIP-ON" type with double grooving in the case of PVC wire-ways, and CLIP-ON type for the metallic wire ways. All surfaces shall have smooth finish inside and outside. The top of the side walls of the body shall be suitable for the above types of fixing arrangement of trunking. PVC trunking or Aluminium trunking should have uniform thickness throughout its length and shall be of factory finish.

3. PVC trunking shall be of good quality PVC, free from defects like deformation,

unevenness, blisters, cavities etc.

Dimensions

(i) The sizes of mini trunking for the various sizes of cables and the maximum number of 650/1100 V grade PVC insulated aluminium / copper

conductor cables that can be carried in one trunking are given size wise in Table given later.

(ii) The thickness of the mini trunking & adaptable trunking shall be 1 mm minimum.

(iii) When mini trunking cover is clipped onto the trunking body, cover should completely overlap on the base (casing),

Outlet Boxes

The outlet boxes such as switch boxes, regulator boxes and their phenolic laminated sheet covers shall be as per requirements.

INSTALLATION

1. Attachment to wall and ceiling

(i) The mini trunking and adaptable tmnking shall be fixed by means of suitable screws to approved type of asbestos or fiber fixing plugs, at intervals not exceeding 60 cm for all sizes for mini trunking. In case of Adaptable tmnking, the screwing distance shall be such that the weight of the trunking & cable hold firmly on the wall or ceiling. On either side of the joints, the distance of the fixing arrangement shall not exceed 15 cm from, the joint.

(ii) All trunking body shall be fixed directly on wall or ceiling as above.

(iii) Trunking shall be used only on dry walls and ceiling, avoiding outside walls as far as possible and shall not be buried in walls not fixed in proximity to gas, steam or water pipes or immediately below the heater.

(iv) Adaptable trunking shall be with pill off cover for protection against dust. Pill off cover shall be removed only on completion of painting of walls.

2. Passing through floors or walls

When conductors pass through floors, the same shall be carried in an approved PVC conduit, or heavy gauge steel conduit properly bushed at both ends. The conduit shall be carried 20 cm above floor level and 2.5 cm below ceiling level and neatly terminated into the casing. Steel conduit pipes wherever accessible shall be securely earthed.

3. Joints in casing and capping

(i) The wire ways in straight runs should be in single piece as far as possible so as to avoid joints. Trunking shall be of 2m or 3m standard length for the ' ease of installation.

(ii) All joints shall be scar-fed or cut diagonally in longitudinal section, and shall

be smoothed down by filing to make the joints a very close fit as far as possible and without burrs. They shall be screwed at joints with two or more screws as would be necessary.

(iii) Joints arising out of bends or diversion shall be done using standard accessories like Internal angle. External angle, Flat angle (elbows). Flat junction (T) and end caps. For the separation of data and power cables there shall be partition in both trunking and accessories. Internal and external angle shall have variable angle for the alignment at

the wall comers. In no case the radius of curvature of the cables inside a bend shall be less than 6 times their overall diameter.

4. Trunking should be of white colour in case of PVC trunking and of white

or grey colour in case of Aluminium trunking.

(i) Mini Trunking attached to ceiling shall be carried completely across the ceiling/wall whenever required by the engineer in charge, instead of being stopped at an outlet location and in all such cases, dummy mini trunking must be provided.

5. Attachment of capping

(i) Wherever required by the Engineer in Charge, capping shall not be fixed until the work has been inspected with the wires in position and approved. The inspection will be done from time to time as the work progresses.

(ii) Cover shall be attached to body after all the insulated wires are laid inside. (iii) No screws or nails shall be used for fixing PVC cover to the body.

(iv) Aluminium cover shall be fixed by using cadmium plated flat head / round head screws with an axial spacing not exceeding 30 cm.

6. Installation of Cables

(i) For ease of maintenance, cables carrying direct current or alternating current shall always be bunched so that the outgoing and return cables are drawn in the same trunking.

(ii) Mini trunking shall be of such a design that it holds the wires inside the trunking body (casing) at suitable intervals, so that at the time of opening ' of the trunking cover (capping), the wires may remain in position in the trunking body (casing) and do not fall out.

7. Earth Continuity

(i) A protective (earth continuity) conductor shall be drawn inside for earthing of all metallic boxes of the installations as well as for connections to the earth pin of the socket outlets.

(ii) In the case of metallic trunking there shall be a metallic link

between adjacent trunking covers with screw connections, and also connections from the end casing to the earth terminal of metallic boxes / outlets / switch boards as per the case may be, for the complete body earthing of the system.

TABLE

Maximum number of PVC insulated 650/1100 Volt Grade Aluminium / Copper conductor cable conforming to IS: 694-1990

Nominal

10/15

20/15

25/15

32 mmx

40 mmx

40 mmx

cross sectional

area

mmx 10 mm

mmx 10 mm

mmx 16 mm

16mm 25 mm 40 mm

1.5

3

5

6

8

12

18

2.5

2

4

5

6

9

15

4

2

3

4

5

8

12

6

2

3

4

6

9

10

1

2

3

5

8

16

1

2

4

6

25

1

3

5

35

2

4

50

1

3

70

1

2

Note: Dimensions shown above are outer dimensions of mini trunking.

CIRCUIT BREAKERS

A. MINIATURE CIRCUIT BREAKERS (MCB):-

Miniature Circuit Breakers (MCBs) are to be used in final power distribution and branch circuits, as well as control circuits for effective protection against overload and short- circuit protection. These shall conform to latest Indian and / or International Standards,

IS: 8828-1996, IEC: 60898-1995

Miniature circuit breakers shall be quick make and break type for 240/415 V AC, 50 Hz application with magnetic thermal release for over current and short circuit protection.

The breaking capacity shall not be less than 10kA at 415V AC.

MCBs shall be C-curve type and DIN mounted.

The offered MCBs should be ‘ISI’ marked. ‘ISI’ marking on the MCB should be clearly displayed (printed) on the MCB. It should not be displayed by pasting stickers or printing. Name of the manufacturer shall also be printed clearly on body of MCB. Also make and brand shall be clearly identified on each MCB.

Technical Features

Isolation : to ensure complete electrical Isolation of downstream circuit or equipment , when the MCB is switched OFF ( to be marked on the MCB in symbolic form)

IP 20 Degree of Protection: to prevent electrical shocks by accidental touch to any live

parts, by providing finger touch proof terminals.

Positive Contact Indication: In accordance with IEC-60947-2, MCBs for this characteristic shall have positive contact indication, so that in the event of accidental contact welding during faults, MCB knob does not show OFF position. This is essential to prevent any serious accidents during maintenance.

Energy Limitation Class-3: to ensure minimum let through energy in the event of a fault, for safety of downstream circuit equipment. ( to be mentioned on the MCB as per standards )

Low Power Loss: MCBs should have low power loss, in any case not more than prescribed limits of standards. Energy efficient MCBs having lesser power loss than prescribed in relevant standards will be preferred.

Line-Load Reversibility: to allow line or load connections from top or bottom terminals without any risk of unsafe operation or protection performance of MCB.

Ease of Installation: MCBs should have design to help easy & fast installation on DIN rail, with provision of dual position bistable clips for secured mounting.

Large Terminal Design: MCBs to have minimum 25 sq.mm. terminals for ratings below 32A, and 35 sq.mm. for ratings of 32A and above, to ensure perfect termination of connections. Terminals of MCBs shall have captive screws.

Ease of Identification: Basic technical parameters, rating, operating voltage, etc. shall

be printed on front face of MCB for ease of identification.

Mechanical Life shall be 20000 operations and Service life at rated load for In below 32A shall be 20000 and for In above 32A shall be 10000 operations.

B. Earth Leakage Circuit Breaker / Residual Current Circuit Breaker - Current Operated Type (ELCB / RCCB / RCBO)

Residual Current Circuit Breakers shall conform to IEC 61008.& IS12640. ISI marking is compulsory on RCCB. The RCCBs shall have sensitivities of 30 mA, 100mA, 300 mA as per the requirement / as per BOQ. For People Protection the sensitivity must not be more than 30mA.

A 100/300mA RCCB is recommended for Protection against fire

The RCCBs shall have disconnection facility with suitability for Isolation and Positive Contact Indication, and shall be immune towards nuisance tripping due to Transient overvoltages.

The RCCBs shall have trip indication facility on the front face.

System of operation

ELCB/ RCCB/RCBO shall work on the principle of core balance transformer. The

incoming shall pass through torroidal core transformer. As long as the currents in the

phase and neutral shall be the same, no electro motive force shall be generated in

the secondary winding of the transformer. In the event of a leakage to earth, an

unbalance shall be created which shall cause a current to be generated in the

secondary winding, this current shall be fed to a highly sensitive miniature relay,

which shall trip the circuit if the earth leakage current exceeds a pre-determined

critical value. ELCB/RCCB/RCBO shall be current operated independent of line

voltage. Current sensitivity shall be of 30mA at 240/415V AC or as specified in BOQ /

drawings and shall have a minimum of 10000 electrical operations. The RCBO shall

also provide over load and short circuit protection in addition to the earth leakage

protection.

Mechanical Operation

The moving contacts of the phases shall be mounted on a common bridge, actuated by a rugged toggle mechanism. Hence, the closing/opening of all three phases shall occur simultaneously. This also shall ensure simultaneous opening of all the contacts under tripping conditions.

Neutral Advance Feature

The neutral moving contact shall be so mounted on the common bridge that, at the time of

closing, the neutral shall make contact. First before the phases; and at the time of

opening, the neutral shall break last after allowing the phases to open first. This is an

important safety feature which is also required by regulations.

Testing Provision

A test device shall be incorporated to check the integrity of earth leakage detection

system and the tripping mechanism. When the unit is connected to service, pressing

the test knob shall trip the ELCB/RCCB/RCBO and the operating handle shall move

to the “OFF” position.

C. MOULDED CASE CIRCUIT BREAKER (MCCB's)

The rated normal current should be specified at 40°C

The present specification applies to moulded-case circuit breakers (MCCB) from

16A to 800 Amp for AC (50/60Hz) low voltage electrical installation from 220V to

415V. MCCB shall be equipped with a trip Unit that offers the appropriate level of

performance to fit to the application.

MCCBs shall be designed for both vertical and horizontal mounting, without any adverse

effect on Electrical performance. It shall be possible to supply power either from the

upstream or downstream side.

For a MCCB rating frame given, MCCBs dimensions shall be the same whatever

the ultimate breaking capacity.

MCCB shall have a rated operational voltage of 415 V and insulation voltage of 600 V (AC

50/60 Hz),

The breaking capacity performance certificates shall be available for category A to

the above mentioned standards. The MCCBs shall have a rated service breaking

capacity (Ics) equal to the ultimate breaking capacity (Icu) at defined operational

voltage.

The moulded case circuit breaker shall have a breaking capacity as mentioned against each in Schedule of Quantity at 415 volts. Wherever required, higher breaking capacity breakers to meet the system short circuit fault shall be used. In absence of any capacity specifically mentioned in the bill of quantities and drawings, following breaking capacities shall be used –

100 / 125 Amp : 25 KA

160/200/250/300 Amp : 35 KA

400/630/800 Amp : 50 KA

Circuit breaker design

Safety

For maximum safety, the power contacts shall be insulated in an enclosure made

of a thermosetting material from other functions such as the operating mechanism, the

case, the trip unit and auxiliaries (ON/OFF/Trip Contact, Shun t, Under Voltage etc.)

All poles shall operate simultaneously for circuit breaker opening, closing and tripping.

Isolation

In order to ensure suitability for isolation complying with IEC 60947-2 § 7-27:

MCCBs shall be actuated by a toggle or handle that clearly indicates the three positions:

ON, OFF and TRIPPED.

MCCB should clearly indicate the suitability for isolation in the name plate identified by

the symbol.

The operating mechanism shall be designed such that the toggle or handle can

only be in OFF position (O) if the power contacts are all actually separated, in

OFF position, the toggle or handle shall indicate the isolation position.

MCCBs shall be able to receive a device for locking in the “isolated” position,

with up to 3 padlocks, Ø8 maximum.

MCCBs shall be equipped with a “push to trip” button in front to test operation and the

opening of the poles.

MCCB rating, “push to trip” button, performances and contact position indication must be

clearly visible and accessible from the front, through the front panel or the door of the

switchboard.

Class II Front Face

MCCBs shall be designed to prevent access to live parts when the cover is removed ,

means main current path of the circuit breaker should be isolated from auxiliary section

i.e MCCB shall offer class –II front face.

Current limitation, durability

From 16 A to 800 A rating frame, MCCBs shall equip a double breaking type rotary

contact

mechanism, having current- limiting feature to limit let through energy on the installation.

The electrical durability of MCCBs, as defined by IEC 60947-2 standard, shall be at least

equal to 3 times the minimum required by the standard (8000 operations up to 250A &

4000 operations up to 800A).

Auxiliaries and accessories

MCCBs shall be designed to enable safe on-site installation of auxiliaries such as voltage

releases (shunt & under voltage releases) and indication switches as follows:

Field installable auxiliary contacts for signalising different functions, as: open/ closed

position, fault signal, electrical fault (including earth fault) signal, all auxiliaries shall

be common for the entire range,

They shall be separated from power circuits,

All electrical auxiliaries shall be of the snap-in type and fitted with terminal blocks,

Auxiliary function and terminals shall be permanently engraved on the case of the

circuit breaker and the auxiliary itself.

The addition of auxiliaries shall not increase the volume of the circuit breaker.

Rotary handle, shall not mask or block device settings, and should indicate three

positions O (OFF),I (ON)and tripped.

Rotary handle should have push to trip button.

Rotary handle should have provision to install lock and key arrangement for

interlocking purpose (Example: 2 lock 1 key ,3 lock two key etc.)

Rotary handle shall ensure IP40 for direct type and IP 55 for extended Rotary handle.

Protections requirements

General

MCCBs shall comprise a device, designed to trip the circuit-breaker in the event of

high-value short-circuit currents. This device shall be independent of the thermal

magnetic or electronic trip unit.

MCCBs up to 250A shall be equipped with Thermal magnetic trip unit.

MCCBs with ratings over 250A shall be equipped with electronic trip units.

Thermo-magnetic trip unit should have:

Adjustable thermal protection from 75 – 100% times the current rating

Protection setting shall apply to all circuit breakers pole thru single knob from the front of

MCCB without opening the front cover of the MCCB.

Fixed magnetic protection for current ratings up to 250 A.

Electronic trip units should have:

Adjustable over load protection from 50 -100% times the current rating

Variable short circuit protection from 2 to 10 Ir.

Protection setting shall apply to all circuit breakers pole thru single knob from the front of

MCCB without opening the front cover of the MCCB

In case of 4 pole MCCB neutral should be adjustable as a Neutral unprotected or Neutral Protection.

Earth protection

Earth Fault protection,Where ever specified, MCCB should have Earth fault protection as

provision. MCCB earth fault protection should have following settings.

Selection of Ir MCCB rating.

Earth fault sensitivity selection from 10 – 60% In

Time delay selection in case of Earth Fault with instantaneous feature.

Installation

It should be possible to terminate Aluminium cable of required size for the defined current

carrying capacity. The requisite size should be made available by means of extended

terminals (as a standard offer) in case the direct terminals are not of adequate size.

Adequate phase to phase clearance has to be ensured in case of extended terminations.

The circuit breaker should provide the flexibility of terminating line and load from any

direction. Manufacturers should test the circuit breaker for this condition and requisite test

certificate should be available.

Phase barrier should be provided as a standard feature.

Testing

a) Original test certificate of the MCCB as per IEC/IS 60947 - 2 shall be furnished.

D. Pre-commissioning tests on the switchboard panel incorporating the MCCB shall be done as per standard specifications.

E. AIR CIRCUIT BREAKER

General:

Circuit breakers shall be of 3pole or 4pole, air break, moulded case, horizontal draw-out type fully interlocked or fixed type as specified and designed to deliver performances without periodical maintenance.

Air circuit breakers (ACB) shall comply with standards IS/IEC 60947-1 & 2. The breakers shall be tested & certified at CPRI/ERDA.

Air circuit breakers shall have a rated operational voltage of 600 V AC (50/60Hz).

The rated insulation voltage should be atleast 1000V AC (50/60Hz) & impulse voltage of 12 kV.

Circuit breakers shall be capable of carrying the full load current defined for 50o C without any derating.

Circuit breaker main contacts shall be silver plated high grade copper with each pole encased in a reinforced polyester casing completely insulated from each other internally and offer double insulation for the operators on the breaker front face.

Circuit breakers shall be of single frame having uniform “height x width x depth” with common door cut-outs.

Performances:

The ACB breaking capacity performance certificates shall be available for category B according to IEC 60947-2 standard.

The tests shall be carried out with a breaking performance during operation (Ics) and admissible short time withstand (Icw) equal to the ultimate breaking capacity (Icu). i.e. Icu = Ics = Icw = 50KA for 1 Sec. or as specified in BOQ.

All Air circuit breakers can be reverse fed without reduction in performance.

The Circuit Breaker shall have higher Mechanical life i.e. 20000 operations up to 1600A & 16000 operations for ratings >1600A.

The breakers shall have high electrical life i.e. 5000 operations up to 1600A & 5000

operations for ratings 1600A without maintenance

The operating mechanism shall be of the Open/Closed/Open stored-energy spring type. The closing time shall be less than or equal to 70 milliseconds to ensure faster closing.

The operating mechanism shall be of fast opening type with opening time of breaker should be <40ms & spring charging time of less than 5 seconds.

All 4 Pole ACBs shall have fully rated neutral equal to rating of the breaker & shall be protected against over-load & short-circuit with provisions for settings at neutral for protection, half protection or no protection.

Accessories & Auxiliaries:

Electrical operated Circuit Breakers shall be operated with remote operation function combined with spring charging motor, closing coil & shunt trip coil having control voltage of 240 VAC. The electrical operated breaker shall also be provided with operating handle for manual closing, mechanical ON/OFF indicator, spring charged indicator, etc.,

Shunt trip and closing coil shall be of typical design and both should be accessible from the front of ACB after opening the cover, without disturbing any other part/release.

Circuit breaker shall be provided with under-voltage trip release which shall automatically trip the breaker for voltages in the range of 35% to 70% of the system voltage.

The ACB design shall be modular in construction that is it shall be possible to mount the coils from the front without removing the breaker from Cradle.

All electrical auxiliaries including the motor spring charging mechanism shall be field adaptable and should not require any calibration at site or the necessity for any tool (except a screwdriver).

The Circuit Breaker shall have minimum 6 changeover auxiliary contacts rated at 10 A 240/380V volts 50 Hz. There should exist facility to add one more set of 4 contacts as required.

Option for fixing Ready-to-close contact shall exist for indicating that all safety parameters are checked & enabling closure of breaker, ensuring at-most safety for the user.

All accessories & auxiliaries should be common for entire range of circuit breakers.

Safety:

It shall be possible to connect all auxiliary wiring from the front face of the air circuit breaker. This wiring shall be taken through a set of disconnecting contacts, so that all auxiliary wiring is automatically disconnected in the isolated position.

There exists clear indication of the following parameters in the front panel of the circuit breakers:

ON - Circuit breaker closed OFF - Circuit breaker open Spring Charged – Ready-to-close Spring charged – Not ready-to-close Spring discharged

circuit breaker in "service" position (drawout only)

circuit breaker in "test" position (drawout only)

circuit breaker in "isolated" position (drawout only)

Mechanical and electrical anti-pumping devices shall be incorporated in the circuit breakers as required.

The circuit breaker shall be fitted with arc chutes on each pole designed to permit rapid dispersion, cooling and extinction of the arc. Arc Chute cover should be integral part of breaker to safeguard persons from arc during extinction & it shall be removable on site.

The automatic shutters should be integral part of breaker & locking arrangement should be provided as per standards.

The with-drawable circuit breaker shall have the following three distinct and separate positions, which shall be indicated on the face of the panel.

"Service" -- Both main and auxiliary circuits are connected "Test" – All auxiliary circuits are connected & main circuits are

disconnected "Isolated" -- Both main and auxiliary circuits are disconnected

The circuit breaker shall be suitable for moving out to Maintenance Position with the telescopic rails extended and with the cubicle door opened. The routine maintenance shall be capable of being carried out in this position.

There should be a positive locking at these positions while racking out or racking in for clear & confirmative indications as the position is reached. A push button shall be available to release the lock.

Interlocks:

It shall not be possible to with-draw the breaker from the cubicle in "ON" condition. To achieve this, suitable mechanism shall be provided to trip the breaker before the Breaker is isolated.

It shall not be possible to switch “ON” the breaker until it is either in the fully inserted position or for testing purposes it is in the fully isolated position.

It shall not be possible for the Circuit Breaker to be plugged in unless it is in the OFF position.

A safety catch shall be provided to ensure that the movement of the breaker, as it is withdrawn, is checked before it is completely out of the cubicle, thus preventing its accidental fall due to its weight.

A door interlock shall be provided so that it shall not be possible to open the door until the air circuit breaker moving part is in the disconnected position.

A mis-match interlocking shall be provided to prevent insertion of a draw-out type circuit breaker having a rating higher than the current rating of the fixed part.

The racking handle shall be stored on the air circuit breaker in such a manner as to be accessible without defeating the door interlocking.

Provision should exist for fixing key lock to have secured interlocking with the other circuit

breakers.

The breaker shall be locked in disconnected position using key lock or padlock to avoid

accidental charging of the breaker during maintenance phase.

Terminations:

All circuit breakers shall be fully tropicalized as standard & suitable for terminating copper or aluminium bus bars.

Both fixed & draw-out circuit breakers shall have single pole-pitch to ensure sufficient & safer clearances between phases.

Provision shall exist to change the orientation of rear terminations from to horizontal to vertical connection or vice-versa at installation to enable ease of bus bar/cable terminations.

Protections:

The Circuit breaker protection shall be through micro processor based trip units.

The micro processor release should be self powered type without any auxiliary power supply during normal operation of the breaker.

The circuit breaker control unit shall measure the true r.m.s value of the current.

The protection release shall have following protections as standard.

Adjustable over load current (Ir) settings from 40% to 100% of rating of ACB (In).

Over load time setting (tr) from 0.5s, 1s, 2s, 4s…….24s as field selectable curves

Short circuit setting (Isd) from 1.5 to 10 times of Ir setting Short circuit time delay adjustable from 0 to 400 msec. Instantaneous (Ii) protection with an adjustable pick-up and an OFF

position. Earth fault setting adjustable in absolute Ampere with time delay

settings from 0 to 400 ms.

I2t ON / I2t OFF options shall be available for short-circuit & earth fault protections to enhance discrimination with downstream devices.

Individual fault trip LED indications shall be available on the trip unit for easy & faster identifying the cause of fault.

The trip unit shall have integral test facility to verify the healthiness and to avoid external calibration.

The release shall be self diagnostic with separate indication in case of mal functioning.

It shall be possible to change the protection settings on line and the circuit breaker need not be switched of while adjusting the setting.

Circuit breakers shall conform to Electromagnetic compatibility tests (EMC) as specified in

IEC60947-2.

The Circuit breaker control unit shall be interchangeable on site for adaptation to changes in the installation.

The control unit shall have thermal memory throughout the range to store temperature rise data in case of repetitive overload or earth fault for protecting the cables and loads.

Circuit breakers in the outgoing feeders shall be provided with micro processor / Thermo magnetic based trip units (as per BOQ) offering protection against over load (Long time) & Instantaneous protection ensuring total discrimination.

Testing

Testing of each circuit breaker shall be carried out at the works as per IEC:60947 and the original test certificate shall be furnished in triplicate. The tests shall incorporate atleast the following:

i) Impulse withstand test

ii) Insulation test

iii) Di-electric rigidity /Insulation test

iv) Mechanical operation checking

v) Thermal protection with a current of 3ith starting from cold conditions.

SAFETY PROCEDURE

1. While the Indian Electricity Rules 1956, as amended upto date, are to be followed in their entirety, particular attention is drawn to the various clauses indicated in Appendix 'C'. Any installation or portion of installation, which does not comply with these rules, should be got rectified immediately.

2. The detailed instructions on safety procedures given in B.I.S. Code No. 5216-1982 "Code

of Safety Procedures and Practices in Electrical Works" shall be strictly followed.

3. a) Schematic diagram All such boards are to be duly marked and numbered.

Similarly, for each campus consisting of substation/substations and a number of buildings, a comprehensive power distribution schematic diagram for the entire campus shall be prepared.

Based on additions/alterations such diagrams should be updated from time to time.

b) Keep premises clean

Premises like substations, switch rooms, pump house, generating rooms etc. shall be kept clean. Such premises should not be used to store broken furniture, dismantled materials, waste material, parking boxes etc.

c) Keep all electrical shafts clean and locked

Such shafts should not be used for dumping floor malwa etc.

d) Protected premises

All premises like substation, pump house etc. to be maintained as protected area, admission allowed to authorized persons only.

e) Also, the frontage of such areas shall be kept free and parking etc. in front shall

not be allowed.

4. No inflammable materials shall be stored in places other than the rooms specially

constructed for this purpose in accordance with the provisions of Indian Explosives Act.

5. Rubber or insulating mats should be provided in front of the main switchboards or any

other control equipments of medium voltage and above.

6. Protective and safety equipments such as rubber gauntlets or gloves, earthing rods,

linemen's belt, portable artificial respiration apparatus etc. should be provided in each sub-station, service center/enquiry office and important installations. Where electric welding or such other nature of work is undertaken, goggles shall also be provided.

7. Necessary number of caution boards such as "Man on Line, Don't switch on" should be

readily available in each sub-station, enquiry office and important installations.

8. Standard first aid boxes containing materials as prescribed by the St. John Ambalance Brigade or Indian Red Cross should be provided in each sub-station, enquiry office and important installations and should be readily available.

9. Periodical examination of the first aid facilities and protective and safety equipments provided at the various installations shall be undertaken for their adequacy and effectiveness and a proper record shall be maintained.

10. Charts (One in English and another one in the regional language) displaying methods of giving artificial respiration to a recipient of electrical shock should be prominently displayed at appropriate places.

11. A Chart containing the names, addresses and telephone numbers of nearest autheorized

medical practitioners, hospitals, fire brigade and also of the officers in executive charge shall be displayed prominently along with the First Aid Box.

12. Executive Engineers should take immediate steps to train supervisory and authorized

persons of the Engineering staff viz. A.Es., J.Es, Head Electricians, Foremen, Electricians and Wiremen in the First Aid Practices, including various methods of artificial respiration with the help of local authorities such as Fire Brigade, St. John Ambulance Brigade, Indian Red Cross or other recognized institutions equipped to impart such training, as prompt rendering of artificial respiration can save life at times of electric shock.

13. All new recruits should be given such First Aid Training immediately after

appointment.

14. All Supervisory and authorized persons of the Engineering staff should be deputed for

refresher course in First Aid Training after every two years.

15. Details of preventive maintenance to be undertaken shall be in accordance with the chapter 14 of these specifications. All preventive maintenance works shall be preplanned as far as possible and names of persons who are assigned to this work should be entered in a logbook.

16. Electrical wiring and control switches should be periodically inspected and any

defective wiring, broken parts of switches which will expose live parts, should be replaced immediately to make the installations safe for the user.

17. Reports indicating details of preventive maintenance works done should be kept in a

register by each Junior Engineer (E) and should bear signatures of Assistant Engineer and Executive Engineer by way of checks.

18. No work shall be undertaken on live installations, or on installations, which could be

energized unless another person is present to immediately isolate the electric supply in case of any accident and to render first aid, if necessary.

19. No work of live L.T. switch board in the sub-stations should be handled by a person

below the rank of a Wireman and such a work should preferably be done in the presence of the Junior Engineer (E) in charge of the work.

20. When working on or near live installations, suitably insulated tools should be used, and

special care should be taken to see that those tools accidentally do not drop on live terminals causing shock or dead short.

21. The electrical switchgears and distribution boards should be clearly marked to indicate

the areas being controlled by them.

22. Before starting any work on the existing installation, it should be ensured that the electric supply to that portion in which the work is undertaken is preferably cut off. Precautions like displaying "Men at Work" caution boards on the controlling switches, removing fuse carrier from these switches, and these fuse carriers being kept with the person working on the installation, etc. should be taken against accidental energisation. "Permit to Work" should be obtained from the Junior Engineer-in-Charge. No work on H.T. main should be undertaken unless it is made dead and discharged to earth with an earthing lead of appropriate size. The discharge operation shall be repeated several times and the installation connected to earth positively before any work is started.

23. Before energizing on an installation after the work is completed, it should be ensured that all tools have been removed and accounted, no person is present inside any enclosure of the switch board etc. any earthing connection made for doing the work has been removed, "Permit to Work" is received back duly signed by the person to whom it was issued in token of having completed the work and the installation being ready for re- energising and "Men at Work" caution boards removed.

24. In case of electrical accidents and shock, the electrical installation on which the accident

occurred should be switched off immediately and the affected person should be immediately removed from the live installation by pulling him with the help of his coat, shirt, wooden rod, broom handle or with any other dry cloth or paper. He should be removed from the place of accident to a nearby safe place and artificial respiration continuously given as contained in B.I.S. Code and Standard prescribed by St. John Ambulance Brigade or Fire Brigade.

25. While artificial respiration on the affected person is started immediately, help of Fire

Brigade and Medical Practitioner should be called for and artificial respiration should be continued uninterrupted until such help arrives.

26. These instructions should be explained in Hindi/local language to those staff that does

not understand English.

27. Executive Engineers should take particular care to ensure that these instructions are imparted to the existing staff and as well as to the new entrants.

TESTING OF INSTALLATION

SCOPE

This chapter describes the details of tests to be conducted in the completed internal electrical installations, before commissioning.

1.0 GENERAL

1.1 TESTS On completion of installation, the following tests shall be carried oul:-

1) Insulation resistance test. 2) Polarity test of switch. 3 ) Earth continuity test. 4) Earth electrode resistance test.

1.2 Witnessing of tests

Testing shall be carried out for the completed installations, in the presence of and to the satisfaction of the Engineer-in-charge by the contractor. All test results shall be recorded and submitted to the Department.

1.3 Test instruments

All necessary test instruments for the tests shall be arranged by the contractor if so required by the Engineer-in-charge.

2.0 INSULATION RESISTANCE

2.1 The insulation resistance shall be measured by applying between earth and the whole system of conductors, or any section thereof with all fuses in place, and all switches closed, and except in earthed concentric wiring, all lamps in position, or both poles of the installation otherwise electrically connected together, a direct current pressure of not less than twice the working pressure, provided it need not exceed 500 volts for medium voltage circuits. Where the supply is derived from a three wire D.C., or a polyphase A.C. system, the neutral pole of which is connected to earth either directly or through added resistance, the working pressure shall be deemed to be that which is maintained between the phase conductor and the neutral.

2.2 The insulation resistance shall also be measured between all the conductors

connected to one pole, or phase conductor of the supply, and all the conductors connected to the neutral, or to the other pole, or phase conductors of the supply with all the lamps in position and switches in "off position, and its value shall be not less than that specified in sub-clause 16.2.3.

2.3 The insulation resistance in mega ohms measured as above shall not be less

than 12.5 mega ohms for the wiring with PVC insulated cables, subject to a minimum of 1 mega ohm.

2.4 Where a whole installation is being tested, a lower value than that given by the

formula, subject to a minimum of 1 mega ohm, is acceptable.

2.5 A preliminary and similar test may be made before the lamps etc. are installed,

and in this event the insulation resistance to earth should not be less than 25 mega ohms for the wiring with PVC insulted cables, subject to a minimum of 2 mega ohms.

2.6 The term "outlet" includes every point along with every switch, except that a switch combined with a socket outlet, appliance or lighting fitting is regarded as one outlet.

2.7 Control rheostats, heating and power appliances and electric signs may, if

required, be disconnected from the circuit during the test, but in that event the insulation resistance between the case or frame work, and all live parts of each rheostat, appliance and sign, shall be not less than that specified in the relevant Indian Standard Specifications, or where there is no such Specification, shall be not less than one mega ohm.

3.0 POLARITY TEST OF SWITCH

3.1 In a two wire installation, a test shall be made to verify that all the switches in every circuit have been fitted in the same conductor throughout, and such conductor shall be labeled or marked for connection to the phase conductor, or to the non-earthed conductors of the supply.

3.2 In a three wire or a four wire installation, a test shall be made to verify that every

non-linked single pole switch is fitted in a conductor which is labeled, or marked for connection to one of the phase conductors of the supply.

3.3 The installation shall be connected to the supply for testing. The terminals of all

switches shall be tested by a test lamp, one lead of which is connected to the earth. Glowing of test lamp to its full brilliance, when the switch is in "on" position irrespective of appliance in position or not, shall indicate that the switch is connected to the right polarity.

4.0 TESTINGOFEARTHCONTCNUITYPATH

The earth continuity conductor, including metal conduits and metallic envelopes of cables in all cases, shall be tested for electric continuity. The electrical resis- tance of the same along with the earthing lead, but excluding any added resistance, or earth leakage circuit breaker, measured from the connection with the earth electrode to any point in the earth continuity conductor in the completed installation shall not exceed one ohm.

5.0 MEASUREMENT OF EARTH ELECTRODE RESISTANCE

5.1 Two auxiliary earth electrode, besides the test electrode, are placed at suitable distance from the test electrode (see figure 14). A measure current is passed between the electrode 'A' to be tested and an auxiliary current electrode 'C', and the potential difference between the electrode 'A' and auxiliary potential 'B' is measured. The resistance of the test electrode 'A' is then given by:

Where,

R = V

I

R - Resistance of the test electrode in ohms,

V - Reading of the voltmeter in volts. I - Reading of the ammeter in amps.

5.2 (i) Stray current flowing in the soil may produce serious errors in the

measurement of earth resistance. To eliminate this, hand driven generator is used.

(ii) If the frequency of the supply of hand driven generator coincides with the frequency of stray current, there will be wandering of instrument pointer. An increase or decrease of generator speed will cause this to disappear.

5.3 At the time of test, the test electrode shall be separated from the earthing

system.

5.4 The auxiliary electrodes shall be of 13 mm diameter mild steel rod driven upto 1

m into the ground.

5.5 All the three electrodes shall be so placed that they are independent of the

resistance area of each other. If the test electrode is in the form of a rod, pipe or plate, the auxiliary current electrode 'C' shall be placed at least 30 m away from it, and the auxiliary potential electrode 'B' shall be placed mid-way between them.

5.6 Unless three consecutive readings of test electrode resistance agree, the test

shall be repeated by increasing the distance between electrodes A and C upto 50m, and each time placing the electrode B midway between them.

5.7 On these principles, "Megger Earth Tester", containing a direct reading ohm

meter, a hand driven generator and auxiliary electrodes are manufactured for direct reading of earth resistance of electrodes.

6.0 TEST CERTIFICATE

On completion of an electrical installation (or an extension to an installation), a certificate shall be furnished by the contractor, countersigned by the certified supervisor under whose direct supervision the installation was carried out. This certificate shall be in the prescribed form as given in Appendix 'E' in addition to the test certificate required by the local Electric Supply Authorities.

1.0 ERECTION & COMMISSIONING GENERAL

1.1 EQUIPMENT ERECTION

a) The equipment in disassembled condition shall be received at site by the

contractor.

b) The contractor shall unpack, assemble all parts, mount and wire up loose

equipment, fitting and accessories and complete all connections.

c) The contractor shall mount the equipment on respective foundation/ supports, level

& align the same & arrange for necessary grouting/anchoring.

d) The erection work shall be carried out in compliance with manufacturer's instruction

and shall include all adjustments, checks and measurements.

e) The contractor shall record results of all erection tests and measurements and

furnish copies of the same to the owner for his reference and record.

f) Any internal wiring of the equipment, which has been left incomplete because of

shipping, split or which requires minor modifications shall be carried out by the

contractor. This includes mounting of items like relays, meters etc. and connecting

the same as per wiring scheme diagram furnished by the original manufacturers.

1.2 CONSUMABLES AND HARDWARE

The contractor shall furnish all erection materials, hardware and consumables required

for the completion of the installation. The materials shall include but not limited to the

following:

a) Consumables : welding rods & gas, oil & grease, cleaning fluids, paints,

electrical tape, soldering materials etc.

b) Hardware : bolts, nuts, washers, screws, brackets, supports,

clamps, hangers, saddles, cleats, sills, shims etc.

c) Materials : junction boxes, terminal blocks, connectors, ferrules,

lugs, brass glands, rigid/flexible conduits, cables, ground

wires etc.

Supply of cement, sand, stone etc. required for the execution of the contract shall be

responsibility of the contractor.

1.3 ERECTION TOOLS & TACKLES

a) The contractor shall provide all tools, tackle, implements, module equipment such

as chain pulley block, trailers etc. which are required for transportation, handling

and erection of equipment.

b) Special erection tools, if any, furnished by the Manufacturer along with the

equipment may be used by the contractor. such tools and equipment, however,

shall be returned in good working conditions to the owner on completion of the job.

c) The contractor shall also arrange for major testing equipment as list below:

Insulation Tester : Motor operated Megger 1000V & 10KV grade.

Hand operated Megger 1000V.

Hand driven earth resistance megger, range 0-1/3/30 ohms.

Tong testers of suitable ranges.

Contact resistance measuring set for micro-ohms.

Torque wrench.

Primary / secondary injection set and relay testing kit.

Multi meters, test lamp, field telephone with buzzer sets, different gauges etc.

Streamline filter.

Chain pulley block, cable jacks & spindle, cable, collars, electricians tool kit,

jointer's tool kit, fitters tool kit, welding transformer, phase sequence meter,

HV testing kit, primary & secondary injection kit.

other test equipment as required for testing and commissioning of the equipment

shall have to be arranged by the contractor.

1.4 METHODS AND WORKMANSHIP

a) All work shall be installed in a first class, neat workman like manner by mechanics /

electricians skilled in the trade involved.

b) The erection work shall be supervised by competent supervisors holding relevant

supervisory license from the Government.

c) All details on installation shall be electrically and mechanically correct.

d) The installation shall be carried out in such a manner as to preserve access to

other equipment installed.

e) If in the opinion of the contractor any work is insufficiently specified or require

modification, the contractor shall refer the same in writing to the owner and obtain

his instruction / approval before proceeding with the work.

f) If the contractor fails to refer such instances, any excuse for the faulty erection,

poor workmanship or delay in completion shall not be entertained.

g) Equipment and material, which are wrongly installed shall be removed and re-

installed to comply with the design requirement at the contractor's expense, to the

satisfaction of the owner/consultant.

h) All scaffolding pipes and frames shall be of tubular steel. Bamboo's/ balliesl timer

frames are not permitted under any circumstances. All vertical & horizontal

scaffolds shall be of MS pipes of adequate size to withstand the loads & pressures.

The working platforms shall be either of conduit pipes or MS bars.

1.5 ALLOWABLE WASTAGE

a) The erection contractor shall make every effort to minimize wastage during erection

work. In any case, the wastage shall not exceed 1 %

b) Measurement shall be taken at site jointly by contractor and owner's

representative.

c) If the actual wastage be more than the quoted figure then equivalent price of the

balance amount will be deducted from contractor's bills.

d) The contractor shall submit a detailed account of materials issued to him after

completion of work. The excess materials after completion of job shall be returned

back to the owner's store.

1.6 FOUNDATION AND CIVIL WORK

a) The contractor shall check the foundations provided by owner before

commencement of erection to ensure their suitability.

b) All final adjustments of foundation levels, chipping and dressing of foundation

surfaces, drilling holes on foundation channels to suit the equipment setting and

grouting of anchor bolts, sills, inserts and fastening devices shall be carried out by

the contractor including minor modification of civil work as may be required for

erection.

c) Any cutting of masonry work which is necessary shall be done by the Contractor at

his own cost and shall be made good to match the original work. The contractor

shall obtain approval of owner/ consultant before proceeding with any cutting of

masonry / concrete work.

1.7 EXCAVATION AND BACK FILLING

a) The contractor shall perform all excavation and back filling as required for the

scope of work pecified.

b) The contractor shall make his own arrangement for pumping out any water that

may accumulate in the excavation.

c) All excavation shall be back filled to the original level with good consolidation.

1.8 REPAIR OF DAMAGE SUBSTAINED DURING TRANSIT

The contractor shall repair minor damages sustained during transit or subsequent

storage in purchaser's store. The repair charges shall be paid to the contractor on the

basis of extra work.

1.9 INSPECTION

a) After completion of erection / installation, each piece of equipment shall be

thoroughly tested as per approved procedure and inspected in presence of the

owner/consultant for correctness and completeness of erection and acceptability

for start up.

b) A check list in triplicate will be furnished by the owner/consultant wherein all details

to be checked and necessary instruction shall be listed. the inspection and

checking shall strictly follow the checklist.

c) on completion of the inspection (2) copies of the check list duly filled-in shall be

handed over to the owner/consultant.

d) This check list shall be jointly signed by the contractor and the owner/consultant.

Such endorsement, however, shall not relieve the contractor of his obligations

under the contract.

2.0 11 KV SWITCHGEARS

2.1 11 KV HT Switchgears shall be installed in accordance with IS:3072 and manufacturer's

instructions. The contractor shall be required to install and align any channel sills

whichform part of the foundation. The HT Switchgears shall be made absolutely vermin

proof.

2.2 Control wiring (if any) between 11 KV HT switchgears & other electrical equipment shall

be carried out as per the instructions of the manufacturers & site-in-charge.

3.0 TRANSFORMER

3.1 Installation of the transformer shall be in accordance with the IS : 1886, manufacturer's

instructions and as per the enclosed drawings.

3.2 Care shall be taken during handling of insulating oil to preventing ingress of moisture or

foreign material. Testing and sampling of oil shall be in accordance with manufacturer's

instructions and related IS. If oil filtration is required the same shall be carried out at site

by the Contractor.

3.3 Control wiring between Transformer & other electrical panels shall be carried out as per

the manufacturer's drawings and as per the instructions of site - in - charge.

4.0 415 V BUS DUCT

4.1 Bus duct will be received in transportable pieces. The Contractor shall erect the bus duct

including bends, wall seating copper flexible at both ends and complete all connections in

accordance with Manufacturer's drawings. The work also includes erection of steel

hangers / supports for these bus ducts wherever necessary.

4.2 All steel structure / support / hardware for supporting bus duct shall be calculated by the

contractor.

5.0 MAIN PCC / CAPACITOR PANELS

5.1 All above panels & DBs will be available in split - up - sections for ease of transportation

and handling. However in some cases, breakers, busbars relays, meters and control

switches may be supplied loose to be mounted and connected at site as per the relevant

drawings.

5.2 All alignments leveling, grouting, anchoring and adjustments shall be carried out in

accordance with manufacturer's instructions and/or as directed by the Engineer. All

boards shall be cleaned by using blower before installation.

5.3 All connections in the panels shall be completed, checked and adjusted to ensure safety

and satisfactory operation of the equipment. This includes the following activities:

a) Functional test on circuit breakers.

b) Setting of protective relays and thermal over load relays.

c) Adjustment of zero error of various indicating instruments.

d) Testing of thermal overload relays by primary injection and protective relays by

secondary injection.

5.4 In some cases, minor modifications may have to be carried out at site in the wiring of an

equipment to meet the requirements of the desired control scheme and the Contractor

shall have to do the same at no extra cost.

6.0 MISC. ITEMS AND LOCAL PANEL INSTALLATION

6.1 The contractor shall install miscellaneous items such as local control station, start-stop

push button stations, and local starter units. control panels, misc. panel etc.

6.2 These equipment will be generally wall or column mounted excepting a few which are

floor mounted. The exact locations will be as decided by the Engineer at site.

6.3 All supports or brackets need for installation shall be fabricated by the Contractor.

6.4 All welding, cutting, chipping and grinding as and when necessary shall be carried out by

the Contractor at no extra cost.

7.0 CABLING SYSTEM

7.1 CABLE TRAYS AND RACKS

a) The contractor shall install the cable racks, trays, risers, shafts and supports.

b) Cable trays and risers shall be aligned and leveled correctly. All runs shall be

installed parallel to the trench/building walls and floors except otherwise noted on

the drawings.

c) The contractor shall provide embedded steel inserts/supports on wall, ceiling or

floor by suitable anchoring & shall secure racks and supports by welding these to

inserts.

d) The trays in general shall be supported at a distance of 1.5 to 2 meters on

horizontal and vertical run.

e) Cable trays shall be installed as per drawings furnished to the Contractor. Any

deviation in routes shall have the prior approval of the Engineer In charge.

f) Prefabricated cable trays and accessories shall be assembled and erected at site

as per instructions of Manufacturer. Alternately, the Contractor shall fabricate and

install all cable trays, risers, shafts and supports as agreed upon during finalization

of the award.

g) Sufficient spacing not less than 250 mm shall be provided between trays and

maintained to permit adequate access for installing and maintaining the cables.

h) Contractor shall co-ordinate with other contractors (such as for piping etc.) where

there is a common support for cable trays and for other services.

i) All necessary steel & all consumables as specified elsewhere shall be provided by

the contractor.

7.2 STORAGE AND HANDLING

a) Cable drums shall be stored on hard and well drained surface so that they may not

sink. In no case the drum shall be stored on the flat Le. with flange horizontal.

b) Rolling of drum shall be avoided as far as practicable. For short distance, the

drums may be rolled provided they are rolled slowly and in proper direction as

marked on the drum.

c) In absence of any indication the drums may be rolled in the same direction as it

was rolled during taking up the cable.

d) For unreeling the cable, the drum shall be mounted on jacks or on cable wheel.

The spindle shall be strong enough to carry the weight without bending.

e) The drum shall be rolled on the spindle slowly so that cable should come out over

the drum and not below the drum.

f) While laying cable, cable rollers shall be used at an interval of 2000 mm. The cable

shall be pushed over the roller by a gang of people positioned in between rollers.

g) Cable shall not be pulled from the end without having intermediate pushing

arrangement. Bending radius of the cable shall not be less than that is specified by

the manufacturer.

h) All possible care shall be taken during unreeling and laying to avoid damage due to

twist, kink or sharp bends.

7.3 CABLE LAYING

a) Cable shall generally be installed in ladder type / perforated trays in trenches or

buried in ground except for some short runs in conduit for protection or crossings

the roads etc.

b) Each length of run shall be physically measured at site before cutting the cable.

Contractor shall furnish cable cutting the schedule to engineer in charge with

respect to able drum length available at site and runs of cables & sizes of cables.

c) Cable may also be laid through hume pipes in road crossings etc. The hume pipes

shall be supplied and placed in position by the Contractor.

d) Cable laid on trays and risers shall be neatly dressed and clamped at an interval of

3000 mm and 900 mm for horizontal and vertical cable run respectively and at

each bend of cable.

e) All power cables shall be clamped individually and control cables shall be clamped

in groups of three or four cables.

f) Clamps for multicore cables shall be fabricated of 25 x 3 mm G.I. flats. Single core

power cables shall be laid in trefoil formation and clamped with trefoil clamps made

of Fiber glass/PVC.

g) Cable openings etc. in walls/floor made by the Contractor or by others shall be

sealed by the Contractor suitably by Hessian tape and bitumen compound or by

any other proven method to prevent ingress of water.

h) Directly buried cables shall be laid as per detail shown in drawing. These cables

shall be laid on and covered with sand/raddle earth and protected by brick barriers

as sides and precast concrete slab brick on top. Job also involve

digging/excavation of earth and refilling the same after laying of cables. For cables

laid underground a loop of diameter of 3 meters shall be provided near each

terminating ends.

i) After completion of installation and prior to connection, all High Voltage Power

cables shall be given a high potential test. The contractor shall provided this Hipot

Test set having provision of leakage current measurement.

j) Laying cost shall include all above activities including supply and fixing of clamps

etc.

k) Cables for machines in clean area shall be laid in suitable size of stainless steel

conduit.

7.4 CABLE TAGS AND MARKERS

a) Each cables and conduit run shall be tagged with numbers that appear in the cable

schedules. Cables and conduits shall be tagged at every thirty (30) meters. Cables

and conduits shall also be tagged on either side of a floor/wall passage.

b) The tags shall be of PVC or Aluminium with the number engraved on it and

securely attached to the cable by not less than two turns of G.!. wire.

c) Location of cables laid directly underground shall be indicated clearly by cable

marker made of cast iron.

d) The location of cable joints, if any, shall be clearly indicated with cable marked with

an additional inscription "Cable Joint".

e) The marker shall project 100 mm above ground and shall be spaced at an interval

of 30 meters at every change of direction.

f) Where cables are cut from the drums the ends of the cables at the drums shall be

properly sealed.

g) The power and control cable shall be laid with a provision of extra length at one of

the end terminations. This length shall be confirmed by the Engineer in charge

before laying.

h) Cost of laying shall also include supply and fixing of tags, cable markers etc.

7.5 TERMINATIONS JOINTS AND CONNECTION

a) The termination, Joints and connections of cables shall be done by qualified

jointers strictly in accordance with manufacturer's instruction drawings and/or as

directed by the Engineer.

b) The work shall include all clamping, fittings, fixing, plumbing, soldering, taping,

compound filling, epoxy cable jointing, crimping, connecting, shorting and earthing

as required for all such operations should be available with concerned contractor.

For all size of L T termination, crimping tool (Hydraulic type) shall be used. Further,

inhibiting compound shall be provided before termination.

c) The equipment will be generally provided with blank plates for cable/conduit entry

and cable end box for power cables.

d) The Contractor shall perform all drilling, cutting on the blank plates and any minor

modification work required to complete the job.

e) If the cable-end box or terminal enclosure provided on the equipment is found

unsuitable and requires major modification, the same shall be carried out by the

Contractor as extra work item.

f) Control cable cores entering control panel/switch gear / MCC etc. shall be neatly

bunched and served with nylon cord or PVC perforated tape to keep in position at

the terminal block.

g) The contractor shall provide oil resistance ferrules for all control cable cores at all

terminations including at all junction boxes. and at all terminations. The ferrules

shall carry terminal numbers as per drawing. The ferrules shall be of interlocked

plastic type or approved equal.

h) Spare cores shall be similarly tagged, crimped with lug and taped on the ends.

Spare cores shall be tagged with individual cable number.

i) Terminations and connections shall be carried out in such a manner as to avoid

strain on the terminals.

j) All cable entry points shall be sealed and made vermin and dust proof. Unused

opening, if any shall be effectively closed.

k) Termination kits for HT cables, Straight through joint kits for HT & L T cables, cable

of all glands lugs shall be arranged by the Contractor, which includes furnishing

consumable materials such as plumbing and soldering material, electrical tape

including bitumen compound/resin if not a part of kit shall be included in the

erection rates.

8.0 IMPORTANT NOTES FOR ERECTION ACTIVITIES

8.1 CABLES AND CONDUITS

a) Approximate lengths of cables and conduits runs will be given in the cable

schedule. Before commencement of work the Contractor shall take actual

measurements and prepare his own cable cutting schedules to reduce wastage to

a minimum.

b) During the erection period the Contractor shall furnish weekly / fortnightly report on

cable position in an approved proforma so as to keep the Engineer In Charge

apprised of the position and to enable him to intimate any procurement action in

time.

c) The Contractor shall also maintain and submit when requested, a record of cable

insulation value when drawn from store, after laying, before and after

termination/jointing.

8.2 EXCAVATION AND BACK FILLING

a) The Contractor shall perform all excavation and back filling as required for the

scope of work specified.

b) The Contractor shall make his own arrangement for pumping out any water that

may accumulate in the excavation.

c) All excavation shall be back filled to the original level with good consolidation.

8.3 FOUNDATION AND CIVIL WORK

a) The contractor shall provide foundations wherever required & in case same has

been provided by the employer earlier, same shall be checked for correctness

before commencement of erection to ensure their suitability.

b) All final adjustments of foundation levels, chipping and dressing of foundation

surfaces, drilling holes on foundation channels to suit the equipment setting and

grouting of anchor bolts, sills, inserts and fastening devices shall be carried out by

the Contractor including minor modification of civil work as may be required for

erection.

c) Any cutting of masonry work which is necessary shall be done by the Contractor at

his own cost & shall be made good to match the original work.

The Contractor shall obtain approval of Engineer before proceeding with any

cutting ,of masonry /concrete work.

8.4 STRUCTURAL FABRICATION WORKS

a) All chequered plate covers, cable racks, trays, supports, hangers and brackets

wherever necessary shall be supplied/fabricated by the Contactor. Steel for

fabrication shall be straightened and cleaned of rust and grease. All fabrication

shall be free of sharp edge.

b) Every effort shall be made to minimize the wastage of steel as far as practicable

during fabrication. The wastage in no case shall exceed as specified else where in

this specification.

8.5 TESTING AND COMMISSIONING

a) On completion of erection work, the Contractor shall request the Engineer, for

inspection and tests with minimum of fourteen (14) days' advance notice.

b) The Engineer shall arrange for joint inspection of the installation for completeness

and correctness of the work. Any defect pointed out during such inspection shall be

promptly rectified by the Contractor.

c) The installation shall be then tested and commissioned in presence of the

Engineer.

d) The Contractor shall provide all men, material and equipment required to carry out

the tests.

All rectification, repairs or adjustment work found necessary during inspection,

testing and commissioning shall be carried out by the Contractor, without any extra

cost. The handing over of the installation shall be effected only after the receipt of

written instruction from the Purchaser/his authorized representative.

9.0 SCHEDULE OF PRE-COMMISSIONING TESTS

9.1 CIRCUIT BREAKER

a) Insulation resistance test on each pole by Meggar.

b) Insulation resistance test on control circuit.

c) Checking of all joints for leakage in breaker.

d) Measurement of contact resistance for all the Three Phases.

e) Checking the auxiliary circuits associated with circuit breaker.

f) Functional check of breaker operation electrically at 70% and 110% of rated D.C.

supply voltage.

g) Checking of interlock provided in Control Circuits and tripping through simulated

protective relay contacts. Auto-reclosing duty cycle check wherever auto-reclosing

is required.

h) Measurement of resistance of closing and tripping coils.

9.2 CURRENT TRANSFORMER

a) Insulation Resistance test on each winding by Megger to earth and between

windings.

b) Checking of all ratios on all cores by Primary injection set.

c) Polarity check on each winding.

d) Continuity test.

e) Check for connection to correct taps.

f) Oil level check.

9.3 EARTHING

a) Continuity of earthing connection.

b) Testing of Earth Resistance of Individual Electrode.

c) Testing of Earth Resistance of the combined earthing system.

9.4 SWITCHBOARDS / MCC / DISTRIBUTION BOARD / PANELS

a) Measurement of insulation Resistance of Bus-bar System.

b) Measurement of I. R. of Control Circuit.

c) Functional check of circuit components

d) Continuity check of different circuits.

e) Calibration test of Relays and Meters.

f) Space heater operation.

g) Annunciations.

9.5 RELAYS & METERS

a) Calibration test.

b) Operation I performance test.

NOTE

Tests required for some of the major items are indicated for Bidder's reference. Apart from the

tests listed herein and also as mentioned elsewhere in this specification, any other test as

necessary per relevant standards, recommendations, Code of Practice, Manufacturer's

recommendations etc., shall have to be carried out by the Contractor without any implication

within the quoted price and time schedules.

LIGHTING FIXTURES AND FANS

(i) The lighting fixtures and fans shall be assembled and installed in position complete and ready for service in accordance with the details drawings, manufacturer's instructions and to the satisfaction of the Architect/consultant. Fixtures shall be suspended true to alignment plumb level and capable of resisting all lateral and vertical forces and shall be fixed as required.

All ceiling fans shall be provided with suspension arrangement in the concrete slab/roof members. It is the duty of the contractor to make these provisions at the appropriate stage of construction. Exhaust fans shall be fixed at locations shown on the drawings. All switch and outlet boxes, fan and light fittings shall be bonded to earth through connector blocks. Wires brought out from junction boxes shall be encased in GI flexible pipes for connecting to fixtures concealed in suspended ceiling.

All lighting fixtures and fans shall be supplied as per the make and catalogue numbers mentioned in the bill of quantities or drawings in the original packing along with all standard accessories & control gears as per manufacturers specifications against that item number. All fans and exhaust fans shall also be provided with the guarantee or warrantee cards as the case may be.

(ii) a) Lighting fittings: - Lights, fans and socket outlet shall be so located as to provide maximum comfort to the occupant and to enable him to utilise the electricity in the most economical manner. Every lighting fitting shall be controlled by a switch which shall be in live conductor of the circuit. Where control of the fitting at more than one point is necessary. It shall be done by as many two way and intermediate switches as there are control points.

b) Fittings Wires: - These wires shall be of copper and shall be used only for internal wiring of fittings and shall be carried up to the termination of the light point.

c) Fluorescent tube fittings: - These fittings shall be high power factor type i.e. shall consist of necessary power factor improvement capacitor. The fittings shall be standard models complete with necessary number of tubes. These shall be complete with all components supplied as original components with standard models and shall be assembled and wired by the manufactured at the factory. The fluorescent tube shall be of the same make as the fitting. In cases where tubes are not manufactured by the fittings, manufactures the fluorescent tube of any approved make as directed by the Engineer-in- charge shall be used.

d) High Pressure mercury / sodium vapour lamps:- These fittings shall be complete with necessary vapour lamp, lamp holder, fittings with reflector, condensor, choke and starter etc. of appropriate size and quality complete in all respects with electric connections.

(iii) CEILING FANS:-

a) ceiling fans including their suspension shall conform to relevant Indian Standards.

b) All ceiling fans shall be wired to ceiling roses or to special connector boxes, and

suspended from hooks or shackles, with insulators between hooks and suspension rods. There shall be no joint in the suspension rod.

c) For existing concrete roofs, a 12 mm dia. MS rod in the shape of ‘U’ with their

vertical legs bent horizontally at the top at least 19 cm on either side, and bound

to the top reinforcement of the roof shall be used.

d) The leading in wire shall be of nominal cross sectional area not less than 1.5 sq.

mm. And shall be protected from abrasion.

e) Unless otherwise specified, all ceiling fans shall be hung 2.75 m above the floor.

f) In the case of measurement of extra down rod for ceiling fan including wiring, the

same shall be measured in units of 10 cm. Any length less than 5 cm shall be ignored.

g) The wiring of extra down rod shall be paid as supplying and drawing cable in

existing conduit.

(iv) EXHAUST FANS:-

a) Exhaust fans shall conform to relevant Indian Standards.

b) Exhaust fans shall be erected at the places indicating by the Engineer-in-charge. Exhaust fan may be fixed in a window panel provided for this purpose or in masonry. For fixing an exhaust fan in masonry a circular hole shall be provided in the wall to suit the size of the frame, which shall be fixed by means of rag bolts embedded in the wall. The hole shall be neatly plastered to the original finish of the wall. The exhaust fan shall be connected to the exhaust fan point, which shall be wired as near to the hole as possible, by means of a flexible cord, care being taken to see that the blades rotate in the proper direction.

c) Exhaust fans for installation in corrosive atmosphere, shall be painted with

special PVC paint or chlorinated rubber paint.

d) Installation of exhaust fans in kitchens, dark rooms and such other special locations need careful consideration; any special provisions needed shall be specified.

LIST OF APPROVED MAKES / BRANDS / AGENCIES

The Owner/Consultant reserves the right to select any of the brands indicated in the list of approved

makes without any extra claim from the contractor. Following makes/ brands are also approved in

addition to those mentioned in the item of works as described in BOQ & Specifications.

1. CIVIL WORKS

SL. No.

ITEM MAKE

1 GREY CEMENT ACC, LARSEN & TOUBRO, GUJARAT AMBUJA, J.K, BIRLA; ULTRA TECH, JAYPEE.

2 WHITE CEMENT JK, BIRLA, WHITE

3 WALL PUTTY BIRLA, J.K

4 REINFORCEMENT/STRUCTURAL STEEL

SAIL, TATA STEEL, TISCO, RATHI UDYOG,

5 ANTI-TERMITE TREATMENT PEST CONTROL INDIA LTD, PEST CON INDIA, PEST CONTROL INCORPORATED.

6 CONCRETE ADDITIVE KRYTON, CICO, FAIRMATE, PIDILITE

7 FLUSH DOOR/ SHUTTERS GREEN, DURO, CENTURY, GODREJ, MAYUR.

8 PLYWOOD / BLOCK BOARD / SOFT BOARD

DURO, GREEN, CENTURY, MAYUR.

9 PRELAMINATED PARTICLE BOARD

NOVAPAN, ANCHOR, GREEN LAM, MAYUR.

10 LAMINATES CENTURY, GREEN LAM, DURO, EURO, MAYUR.

11 ADHESIVE FOR WOOD WORK DUNLOP, FEVICOL, VAMICOL, PIDILITE.

12 POLYRETHANE SEALANT KRYTON, PIDLITE, FAREMATE,

13 POLYETHELENE BOARD/ BACK UP ROD

DUTRON SUPREME INDUSTRIES.

14 ALUMINIUM SECTIONS JINDAL, HINDALCO, INDAL, INDOALUSIS (MAHAVIR.)

15 STAINLESS STEEL OZONE, DORMA.

16 EXPANSION/ FASTNERS FISHER, HILTI, ANCHOR

17 FLOAT GLASS/ TOUGHENED GLASS

SAINT GOBAIN, AIS GLASS.

18 CERAMIC TILES SOMANY, KAZARIA,. VARMORA

19 VITRIFIED PORCELINE TILES KAJARIA, VARMORA, SOMANY.

20 INTERLOCK TILES/GRASS PAVER BLOCKS

NIMCO PREFAB, UNISTONE, MODERN.

21 TERRAZZO TILES NITCO, MODERN, HINDUSTAN.

22 CEMENT CONCRETE TILES ULTRA, EUROCON, NITCO, DURACRETE.

23 SYNTHETIC ENAMEL PAINTS BERGER (LUXOL GOLD), ASIAN (APCOLITE), ICI DULUX (GLOSS)

24 OIL BOUND DISTEMPER ASIAN (TRACTOR), BERGER (BISON), NEROLAC.

25 CEMENT PAINT SNOWEEM PLUS, BERGER (DUROCEM EXTRA), ULTRATECH

26 PLASTIC EMULSION PAINT ICI, ASIAN, MAS PAINT (ULTRATECH), NEROLAC.

27 OTHER PAINTS/PRIMERS ICI DULUX, ASIAN, BERGER, NEROLAC, ULTRATECH

28 PAINT BERGER, ASIAN PAINTS, ICI, ULTRATECH, NEROLAC.

29 SURFACE TEXTURE ULTRATECH, HERITAGE, SPECTRUM

30 DOOR/ WINDOWS /PATCH FITTINGS

EBCO, GODREJ, HETTICH, DORMA, OZONE.

31 LOCKS EBCO, GODREJ, HARRISON.

32 WARDROBE/ CUBBOARDS EBCO, GODREJ, HETTICH

33 NON METALLIC HARDENER COMPOUND

CICO, RECRON, FAIRMATE.

34 POLYSULPHIDE SEALANT PIDLITE, FORROC.

35 PAVEMENT TILES PAVIT, ASIAN, ULTRA DESIGNER TILES

37 MS PIPE JINDAL (HISAR), PRAKASH, SURYA.

38 LAMINATION GREENLAM , EURO ,CENTURY

39 HINGES DORMA,GARG,HETICH

40 DOOR CLOSER DORMA, INDOBRASS

41 FALSE CEILING ARMSTONG, DAIKEN

42 POLYCORBONATE ROOF SHEETING

GE, DANPALON

43 SHEET ROOFING TATA BLUESCOPE.

44 GLASS MOSAIC TILE CORAL, BISAZZA.

45 FRP DOORS FIBERWYS TECHNOLOGY / PLYMOLDS/ECHON INDUSTRIES LIMITED / SYNTAX

2. PLUMBING WORKS:

S.NO

.

DESCRIPTION

MANUFACTURER'S NAME

1. VITREOUS CHINA SANITARYWARES PARRYWARE / CERA / HINDUSTAN

2. C. P. FITTINGS / MIXTURES JAQUAR / MARC

3. URINAL / W C FLUSHING SYSTEM JAQUAR / MARC

4. FIRE CLAY SINK SANFIRE / JOHNSON PEDDER

5. STAINLESS STEEL SINK NIRALI / PARRY / FRANKE

6. BALL VALVES / NRV / STRAINER / PRV CIM / LEADER / AUDCO / ZOLOTO / FESTO / ADVANCE / AIP

7. G.I.PIPES - IS : 1239 JINDAL (Hissar) / Bharat / Prakash Surya

8. G.I.FITTINGS - IS : 1239 UNCO / R BRAND / UNIK / ZOLOTO

9. S.W.PIPES / GULLY TRAPS - IS : 651 BURN / PERFECT OR I. S. I. MARKED

10. EWC PLASTIC SEAT COVERS PARRYWARE / CERA / HINDUSTAN / COMMANDER

11. PVC LOW LEVEL FLUSHING CISTERN PARRY - SLIM LINE / HINDUSTAN / CERA

12. OVER HEAD TANKS SINTEX / ATUL

13. S S FLOOR GRATING / FLOOR CLEAN OUT CHILLY / Hightech

14. S S LIQUID SOAP DISPENSOR / HAND DRIER

IMPULSE / TOSHI / UTEC

15. UPVC Soil/waste/rain water pipes and fittings - IS:13592

SUPREME / PRINCE / FINOLEX

16. UPVC water supply pipes and fittings - IS:4985 SUPREME / PRINCE / FINOLEX

17. CPVC water supply pipes and fittings ASTRAL / AJAY

18. PVC sch 40 / 80 water supply pipes and fittings ASTRAL / AJAY / Supreme

19. WATER LEVEL INDICATOR / Level controllers Elegant / Unison / Technika / Sigma

20.

21. Anchor Fastener / U clamp / Pipe hangers

Hilti / Intello Tech / Chilli / Hightech / Fisher

22 R.O.Plant BRISANZIA / ENWECO / AQUA GREEN WATER.

23. ANY OTHER ITEMS ON APPROVAL OF ARCHITECT / CONSULTANT OR ENGINEER-IN-CHARGE

3. ELECTRICAL WORKS:

S.NO. DESCRIPTION MANUFACTURER'S NAME

1. MCB / RCCB / RCBO / DB L&T (Hager) / ABB / LEGRAND (Lexic) / HPL/ Schneider (M9)

2. Industrial outlet L&T (Hager) / ABB / LEGRAND (Lexic) / HPL/ Schneider (M9)

3. MCCB (Medium) ABB (TMA) / L & T (D sine / DNX) / Schnieder (Compact) / Siemens (VL) / Legrand/HPL

4. MCCB (Economical) ABB (TMD) / L & T (DH) / Schnieder (NS) / Siemens (VT)/HPL

5. SWITCH FUSE UNIT WITH HRC FUSES L. & T. / ABB / Schnieder / Siemens

6. CONTACTORS / RELAYS L & T / SIEMENS / ABB / Schneider

7. Current Transformers Kappa / Pragati / AE / G&M

8. Voltage Transformers Kappa / G & M / AE

9. Ammeters / Voltmeters and metering equipments

L & T / SIEMENS / Automatic Electric / Neptune / enercon

10. Selector Switches Kaycee / Salzar / L&T

11. LED lights L&T / Vaishno/Philips/HPL/Bajaj

12. Change Over Switches GE / L&T / HH ELCON / ABB

13. PVC insulated Copper conductor wires FINOLEX / RR / RPG / Polycab / Rallison / Bonton / Batra Henley

14. Telephone Wires and cables FINOLEX / RR / RPG / Polycab / Bonton / HPL

15. Television Coaxial cable FINOLEX / RR / RPG / Polycab / Bonton / HPL

16. Switchs and Sockets outlets (Conventional piano type)

ANCHOR / SSK /HPL

17. Switchs and Sockets outlets (Modular type) Clipsal (Opal) / MK (wraparound) / Legrand (Mosaic) / ABB / Siemens / Crabtree (Piccadly) / Wipro (North West)/HPL

18. PVC / XLPE INSULATED 11 KV / 1.1 KV CABLES

FORT GLOSTER / NICCO / RPG / FINOLEX / POLYCAB / RALLISON

19. CONTROL CABLES / WIRES FORT GLOSTER / NICCO / RPG / FINOLEX / POLYCAB / RALLISON

20. H.V. CABLE TERMINAL JOINTS RAYCHEM / 3 M / Mseal

21. LUGS DOWELLS / 3D / C.C.I. / 3 M

22. PVC Conduits and accessories AKG / BEC / CAP / SEIKO / POLY PACK

23. Fluorescent Tube Fitting PHILIPS / WIPRO / SHEREDER / HPL

24. Incandescent Light Fitting DECON / ANKUR / WIPRO

25. HPMV / HPSV / Halogen Lamp Fitting PHILIPS / WIPRO / SHEREDER

26. Ceiling Fans / Exhaust Fans / Air Circulators

CROMPTON / BAJAJ / USHA / ALMONARD / HAVELLS

26. Solar System BAJAJ / TATA POWR SOLAR (Veena Enterprises) / PRIMO TECH

28. Any Other Items On approval of consultant or Engg in charge

Note for all makes:

1. Wherever makes have not been specified for certain terms as equivalent makes referred, the same shall be as per BIS and as per approved by Engineer- in-charge / Consultant.

2. Contractor shall be required to get the finishing items/products approved in respect of

their make, finish, texture, color & such parameters, which are essential.

3. The samples or Cat. No. of all type of items should be approved before execution.