technical specification civil, structural, part-a,b

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TECHNICAL SPECIFICATION

Name of work: “WORKSHOP FOR UNIT 3 AND 4 EXPANSION PROJECT AT IB THERMAL POWER STATION OF OPGC”

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CONTENTPARTA:TECHNICALSPECIFICATIONFORCIVILANDROADWORKSPARTB:TECHNICALSPECIFICATIONFORSTRUCTURALANDCLADDINGWORKSPARTC:TECHNICALSPECIFICATIONFORELECTRICALWORKSPARTD:TECHNICALSPECIFICATIONFOREOTCRANES

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TECHNICALSPECIFICATION

Nameofwork:“WORKSHOPFORUNIT3AND4EXPANSIONPROJECTATIBTHERMALPOWERSTATIONOFOPGC

1) TheconstructionmaterialssuchasCement,sand,chipsetc. if feltnecessarywillbesubjectedto

testatthecostandriskoftheagency.2) Any defective material brought to site should be removed by the agency at the instance of

department.3) AgencyhastoarrangeallconstructionmaterialssuchasCement,Sand,Chips,MSreinforcement

bars,colours,paintsetcrequiredfortheworkaspertheitemspecifications.4) The quantity mentioned in the schedule of quantities is purely tentative. At any point of time

agencymaybeaskedtoexecuteanyquantityofworkasperthesiterequirement.5) All the itemsmentioned indetail itemsof theworkmaybeexecutedatany locationandatany

height.6) AllthematerialsaretobeapprovedbyconcernedEngineer‐in‐chargeinwrittenbeforeuse.7) Allworkistobecarriedoutwithoutcausinghindrancetoday‐to‐dayactivityofpeople.8) Agency has to make his own arrangement of construction water for the works from available

pointsonly.9) Contractorhastomakehisownarrangementdewateringtoreachtherequiredlevelofexcavation.10) Electricity if requiredby theagency is tobearrangedbydeployingaDGset..Contractorhas to

makeallnecessaryarrangementforsafesupplyofelectricity.11) Ordinary Portland Cement of Ultratech, Konark, ACC make of 53 grade, confirming to

correspondingIScodeshallbeutilizedintheworkbeforetheexpirydate.12) TMT reinforcement and structural steel must be of TATA/SAIL/JINDAL make conforming to

correspondingIScode.13) Constructionmaterialssuchassand,bricks,chips,bazrietc.shouldbestackedandkeptsufficient

in stock at theConstruction site. The area is to be fencedproperly by the contractorwith besthousekeeping.

14) Fly Ash Bricks will be supplied free of cost from OPGC Ash Brick Manufacturing Plant. Thecontractorhastomakehisownarrangementfortransportationofbrickstotheconstructionsite.BalanceAshBricksaftercompletionofworkmusthavetobereturnedbackattheAshBrickPlant,failingwhichdoubletheprevailingcostoftheflyashbrickwillbedeductedfromtheParty’sFinalBill.

15) Properscaffolding(MSscaffolding)asperOPGCstandardmustbedonewhileworkingatheight.

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16) The contractormust have to keep sufficient steel scaffoldingmaterial for work at heights and

stagingforroofshutteringwork.17) ConstructiondebrismusthavetobedisposedtoadesignatedplaceasallowedbyEIC.ThePlace

willbeleveledanddressedtimetotimebythecontractorinthisowncost.18) Parties have to deploy minimum two number full time Supervisors (Minimum Qualification‐

Matriculate)havingminimum5yearsofworkingexperience insupervisingCivilConstruction/Maintenance jobs and one number civil engineer (Diploma engineer.) having minimum 5yr ofexperienceincivilandstructuralworks.

19) Enclosedwithalltherelevantdrawingrelatedtotheaforementionedjob.

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A.TechnicalSpecification–Civil

SECTION–1‐GENERAL

1.0 GENERAL1.1 ApplicationofSpecification This specification shall be read in conjunction with other

documentsformingtheContract.1.2 The construction work shall be carried out in such a

manner that where some existing features/structures are to be integrated with thenewwork,work shall proceedwithoutupsetting the existing situation. Constructionshallbecarriedoutinacoordinatedmannerwiththeworkofothercontractorsinthearea.

1.3 Duringworkonand/or in thevicinityofexistingrail tracks theContractorshall take

all necessary precautionary measures. Watchmen shall be engaged with redlights/flags on either sideof theworkingplacewith cautionboardduring theperiodof working to caution the men working regarding approaching of any rolling stock.Warning signals during day and red lamps during night shall be provided to thewatchman.

1.4 Available soil Investigation report for the site shall be deemed to be studied by the

Contractor prior to submission of his tender. Additional soil investigation work, ifrequiredforthepurposeofthework,shallbedonebytheContractoroftheirown.

1.5 TheContractor,beforesubmittinghistendershallvisitthesiteandascertainthelocal

conditions, labour rules, availability of constructionmaterials, traffic restrictions, allobstructions in the area and also ascertain all site conditions including sub‐soilconditions and shall allow for any extras likely to be incurred due to all suchconditionsinhisquotedprices. NoclaimshallbeentertainedfromtheContractoronanysuchaccountunderanycircumstanceswhatsoever.

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1.6 SettingOutandLeveling The Contractor shall set out and level the works and will be responsible for the

accuracyofthesame. Heistoprovideall instrumentsandproperqualifiedstaffwithlabourforgettinghisworkcheckedbytheEngineer/Consultant.Suchchecking,ifanyshallnot, however, relieve theContractor inanywayofhis responsibility for correctsettingout.

1.7 Safety The Contractor shall take adequate precautions to ensure

complete safety and prevention of accidents at site. The safety precautions shallconformtothefollowingIScodeswhereverapplicable.

IS:3696 .. Safetycodeforscaffoldsandladders (Part‐1&2) IS:3764..SafetyCodeforExcavationWork IS:4014 .. Codeofpracticeforsteeltubularscaffolding. (Part‐1) IS:4014..SafetyRegulationsforScaffolding. (Part‐2) IS:4082 .. Recommendationsonstackingand storageofconstructionmaterialsatsite IS:4130..SafetyCodeforDemolitionofBuildings IS:4138..SafetyCodeforWorkinginCompressedAir IS:5121.. Safetycodeforpilingandotherdeepfoundations IS:7293 ..SafetyCodeforWorkingwithConstruction Machinery

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The Contractor shall also abide by the safety regulations of the Employer and otherdirectivesgivenbytheEngineer/Consultantfromtimetotime.

1.8 KeepingWorksFreefromWater The Contractor shall provide and maintain at his own cost, pumps and other

equipmenttokeeptheworksfreefromwaterandcontinuetodosountil thehandingoveroftheWorks.

1.9 Rubbish TheContractorshallclearalltrees,rubbish,vegetation,sod,brickbatsetcanddispose

themsuitablyinallottedareasathisowncost.1.10 BenchMarks,ReferencePillarsetc The Contractor shall protect surveyor’s bench marks and reference lines, ground

water gauges and control points fromdamage ormovement duringwork. In case ofanydamage,theContractorshallhavetorestorethemtooriginalconditionathisowncost.

1.11 Standards(Latestedition) Unlessspecificallymentionedotherwise,allapplicablecodesandstandardspublished

bytheBureauofIndianStandards,IRC(IndianRoadCongress)Codes,specificationforroad and bridge works under Ministry of Road. Transport and Highways (MORTH),(4thRevision), IndianRailwayStandardSpecificationbyMinistry ofRailwaysandallother such documents as published on the date of award of contract shall governdesign, workmanship, quality and properties of materials, method of field andlaboratory testing, method of measurement for different items of work and otherpertinentfeaturesetc.

In case of variance between this specification and the various standards mentioned

above, the provisions of this specification shall prevail upto the extent of suchvariance,exceptasmentionedinspecificsection.

1.12 SecrecyofInformation

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The Contractor shall not divulge any information that he may obtain regarding thisprojecttoanyotherparty.

1.13 All obligations of the Contractor as specified shall be carried out by the Contractor

withincontractpriceandnoadditionalpaymentwillbeduebeyondthecontractpricefor carrying out all such work. Wherever it is stipulated in the specification thatContractorwillcarryoutaworkathisowncostorexpenseorwithoutanyextracostto the Employer or similar, it must be clearly understood that such stipulation hasbeenmadeonly for thesakeofemphasisbutsuchstipulationwillnot inconstruedtomean that any additional amount will be payable for carrying out any work asspecifiedwherenosuchstipulationhasbeenmade.

1.14 All the civil work shall be carried out as per the drawings, Bill of Quantities,

specificationandasdirectedbyEngineer/Consultant.

SECTION‐2‐DISMANTLING/DEMOLITIONWORK

2.1 Planning Before starting the actual dismantling work, the Contractor shall carefully study the

structures/ buildings/equipment to be dismantled/demolished and of themanner inwhichvariouspartsaresupportedandalsohowfarthestagebystagedemolitionwillaffectthesafetyoftheadjoiningstructures,ifany.TheContractorshallthenprepareadefinite plan of the procedure for systematic demolition and submit to theEngineer/Consultant for his approval. The plan of procedure as approved by theEngineer/Consultant shall be rigidly followed in actual execution of the demolitionwork.

2.2 WorkingCondition Thedismantlingoperationsifrequiredtobecarriedoutinanoperatingplantshallbe

donewithoutanyhindrancetotheplantoperationactivities. All dismantling work shall be carried out in a phased manner as approved by the

Engineer/Consultant.2.3 Safety The Contractor shall take adequate precautions to ensure complete safety of all

installations and theoperational personnelworking in the region,while carryingoutthedismantlingworkandtransportation.

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All safety codes as prescribedby theEmployer forworking in theplant area and thesafety codes prescribed by other mandatory bodies shall be followed by theContractorwhiledismantling.

Onalldemolitionworks,safetysignalslikedangerboards,redlights,safetynetetcas

neededand/orasdirectedshallbeconspicuouslyexhibitedandtheareaofdemolitionshall be kept barricaded or kept manned to prevent trespassing by unauthorisedpersons.

First‐aidequipmentshallbekeptat thesiteofdemolitionworkofanymagnitude for

emergencyuse. Personalsafetyequipmentasmentionedhereundershallbemadeavailablefortheuse

ofpersonsemployedonthedemolitionworkandmaintainedingoodcondition.

i) Safetyhelmetsandshoestoworkmenenteringintodismantlingsite.

ii)Gogglespreferablymadeofcelluloidlenstoworkmenemployedondemolitionofwalls,floors,etctoprotecttheeyesfromflyingpieces,dirt,dustetc,

iii)GlovestoworkmenengagedondemolishingRCCwork,removingsteelworketc.

iv) Safetybelts,fallarrestortoworkmenworkingatheight.2.4 ToolsandTackles2.4.1 All tools and tackles and equipment viz diamond sawing machine for cutting floor

panels,chippingguns,hydraulicallyoperatedrockandconcretesplitter,rockbreaker,pneumatic/pavingbreaker, core cutter, gas cutting set,movable/crawler craneetc asrequiredfordismantling/demolitionshallbearrangedbytheContractor.

2.5 ScopeofDismantling/Demolition2.5.1 On being given the clearance for dismantling of

building/structure/equipment,theContractorshalltakeovertheareafordismantlingandshallshut‐offallutilitylinesanddisconnectpowerlinesetc.TheContractorshallthen check up all the closed valves of the utility lines like gas lines, oil lines,compressedair line,water line, steam lineetc. All these lines shall thenbeprovidedwith suitable blanking arrangements at the tapping points or at suitable pointsapprovedbytheEngineer/Consultantbeforethedismantlingworkisundertaken.

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2.5.2 Similarly, all the power cables, bus bars, control cables, instrument cables, earthingetcshallbedisconnectedfromthesupplysourcesatsuitablelocationsasapprovedbytheEngineer/Consultant.

2.5.3 Structural: All columns, supports, platforms, covers, railings, ladders, stairs, roofs,

girdersetcshallbedismantledfromtheirerectedpositionwithoutanydamage.Incase existing structures require to be cut, the Contractor shall take prior permission of theEngineer/Consultant.Allrivetsandweldingshallbeburntouttodismantlethestructures.Allboltsandnutsshallbeopenedouttotheextentpossible.

2.5.4 Refractoryandinsulationwork:Alltherefractoryandotherinsulationworkshall

be dismantled. Care shall be exercised to see that the steel shells and/or structuresarenotundulydamaged.

Muckarisingoutofdismantlingofrefractoryshallbetransportedout,dumped

andleveledinthedumpingareaallottedbytheEngineer/Consultantforthepurpose. Bricks which are not burnt out or which have not lost shape and size shall be

separatelystackedintheareasallottedbytheEngineer/Consultantwithina leadof3kminsidetheplantboundary.

2.5.5 Electrical equipment: Electrical equipment like motors, distribution board, push

button station control devices, limit switches, cabling etc shall be dismantled inidentifiablepieceswithoutanydamage.

Allthedismantledcables,wiresetcshallbemadeintosuitablerolls,packed.2.5.6 Instrumentsandcontrols: All instruments and controls including connecting cables

installedshallbedismantledwithoutdamagingthesame.2.5.7 Utility piping and equipment: All instruments and controls including

connectingcablesinstalledshallbedismantledwithoutdamagingthesame.2.5.8 Demolitionof civilworks: All concrete andothercivilconstructionworksshall

be dismantledup to a level 500mmbelow the existing ground level if andwherenonewfoundationsareinterfering.Incasethenewfoundations/structureinterferethentheconcreteandothercivilconstructionworkwillhavetobedismantledfully.

2.5.9 Disposal: All the equipment dismantled under clauses 2.5.1 to 2.5.8 above (both

inclusive)shallbetransportedthedisposalyardorscrapandsalvagestoresofVSPtothestoresasdirectedbyEngineer/Consultant.

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All dismantled muck shall be transported out, dumped and leveled in the dumping

placeallottedbytheEngineer/Consultant. Dismantled muck shall not be allowed to be heaped up in the operating area of the

plantandhencethemuckshallbedisposedoffexpeditiously. During dismantling care shall be exercised to see that the dust arising out of

dismantlingiskeptdownbythefrequentsprayingofwater.

SECTION‐3‐EARTHWORKINEXCAVATIONFORFOUNDATIONS,TRENCHES,BASEMENTS,DRAINS,CULVERTSETC

3.1 CodesandStandards IS:1200..MethodofMeasurementofBuildingand (28parts)CivilConstructionWorks. IS:1498..ClassificationandIdentificationofSoils forGeneralConstructionPurposes. IS:3764..SafetyCodeforExcavationWork 3.2 ClassificationofSoil The soil shall be classified forpayment according to IS:1200and/or asper the item

descriptions. All types of soil/rock excluding hard rock requiring blasting shallmean all soil and rock which can be excavated by axes, shovel or Spades or earthmoving equipment such as excavator, power shovels, paving/pneumatic breaker etcor quarried/split by crowbars without recourse to blasting and/or other quarryingmethodssuchaschiseling,wedging,heatingetc.

3.3 SettingOut Theworkshallbesetouttoexactdimensionsasshownontheapproveddrawingsand

excavationshallbecommencedonlyafterpriorapprovaloftheEngineer/Consultant. Sideslopes,beamsorshoring/struttingetcforexcavationworkshallbeasdirectedby

theEngineer/Consultant.PriorapprovaloftheEngineer/Consultantshallbeobtainedforasuitablemethodofprotectionbeforeexcavationworkiscommenced.

3.4 CleaningandGrubbingUp

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The Contractor shall at his own cost grub up old roots, break up and remove old

concrete or brick foundations, drains or manholes, empty and cleanse all old wells,cesspools and ponds found prior to/during progress of excavation, seal up water,sewerage and other connectionswhere required, remove all contaminated earth andfillinvoidswithapprovedmaterialsandramwell.

3.5 Stripping

TheContractorathisowncostshallstripthesurfaceofthesitepriortothe commencementofexcavationtoremovevegetablesoilandcarrysuchsoilto separatesoilheapsontheallottedsitewithin500m.

The Contractor shall not remove any tree without the

permissionoftheEngineer/Consultant. Stripping work is deemed to have been included in the rate for earthwork in

excavationandnoextrawillbepaid.3.6 Excavation TheContractorshallexcavatebymechanicalmeanstoremovematerialsofanynature

or description which may be encountered and excavate to depths, widths andinclinations as directed. The bed of the excavation shall be made level and firm bywateringandramming. While carrying out excavation for drain work, the sidesand thebottomshall be cut to theexact shape, slopeandgradient. The surface shallbe properly dressed. Excavated material shall not be placed within 1.5 m from theedgeofanyexcavation.

3.6.1 ExcavationandTransportationbyMechanicalmeans The Contractor shall excavate the earth by mechanical excavator and transport the

excavatedearthbyusingdumpers/tipper.Levelling/gradingofearthshallbedonebyusingdozer or by anyothermechanicalmeans.Before commencement ofmechanicalexcavation/gradingContractorshallobtainclearancefromEngineer/Consultanttoensure about underground facilities. Wherever excavation by normal excavator isdifficult due to shortage of space/approach, smaller/mini excavator shall be used toavoidmanual excavation. Contractor shall have sufficient numbers ofwheel barrowsto handle earth for small leadwheredisposal of earth bydumper is not suitable anddifficult due to site constraint. The excavated earth required for backfilling, the

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minimumleaddistanceconsideredas500metre. Thebalanceearthshallbedisposedoffwithinplantboundaryuptoadistanceof3km. Ifdumping isnotpossiblewithinplantboundary, thendumping tobemadeoutsideplantboundary in salt panareaofleadapprox.10km.

3.8 VariationinExcavation3.8.1 Bad ground: Should the bottom of any excavation appear

tobe soft, unsound or unstable, the Contractor shall report the matter to theEngineer/Consultant and if the Engineer/Consultant so directs, shall excavate thesame to indicated depths. In case of such extra excavations the extra depth shall befilledupwith leanconcreteorsuchothermaterialsas theEngineer/Consultantshalldirect,suchextraexcavationsandfillingsshallbevaluedandpaidforasanauthorisedextraitem.

3.8.2 Excavationtoodeep: IftheContractorexcavatestolevelslowerthanactuallevelfor

anyunauthorisedreasonheshallfill itupathisownexpensetotheproperlevelwithconcrete or such other materials as directed. No payment will be made for suchexcavationtakendowntodepthslowerthanactuallevelandforthefillingcarriedoutasdirected.

3.8.3 Slipsand falls: Everyprecautionshallbetakenagainst slipsandfallsofearth,clay,

sandorothermaterials intheexcavations,but intheeventofanysuchoccurring,theContractorshallathisownexpensemakegoodthespaceaffectedbytheslipsorfalls,eveniftheaffectedareamaybeoutsidethedimensionoftheworkordered.

TheEngineer/Consultantwilldetermineineachcasewhethersuchaffectedarea isto

be filled up inwholewith concrete, brickwork ormasonry of the quality used in theadjoiningworkorwhereonlyapartistobesofilled,thematerialstobeusedforthispart.

If intheopinionoftheEngineer/Consultantthereisapossibilityofthenewlyconstructedworkhavingbeendamagedordisturbedbysuchacollapse,theworkshallbelaidbareattheexpenseoftheContractorforinspection.AnydamageshallbemadegoodbytheContractorathisexpense.

3.9 KeepingWorksFreefromWater Theexcavationfor foundationandbuildingareashallbe kept freefromwaterbythe

Contractorathisownexpenseeitherbybailingoutwaterwithbucketsmanuallyorbypumping.Bailingoutorpumpingofwatershallbecarriedouteitherdirectlyfromthe

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excavation or from sumps made outside the excavation as directed. Adequate careshallbetakentopreventmovementofwaterthroughfreshlylaidconcreteormasonrywork.

3.9.1 Pumping: The Contractor shall provide and operate pumps of adequate capacity or

other equipment necessary to drain and keep all excavation pits, trenches etc freefromwateratalltimesduringthecontinuanceoftheContractathisownexpense.

3.9.2 De‐silting:If any excavation for foundation gets filled up with water due to rain,

seepage or for any other reason, the water shall be removed and the bottom of theexcavationshallbeclearedofallsilt/slushbytheContractorathisownexpense.

3.9.3 Disposal ofwater: All water pumped or bailed out during dewatering of pits and

trenchesshallbedisposedoftothenearestsewerornaturaldrainsorpondsthroughproperlylaidchannelsorpipesbytheContractorasdirectedathisowncost.Disposalofwatershallbecarriedoutinsuchawaythatnoinconvenienceornuisanceiscausedto thework inprogress in theareaor tootheragenciesworking in theareaor causedamagetopropertyandstructuresnearby.

3.10 ProtectionofWork3.10.1 TheContractorshallsupportandmaintainadjoiningandabutting propertyandstructurestorenderworksafetopersons,property andstructures/installationsduringthecourseofconstruction activity. TheContractorshallplankandstrutasmayberequiredon the sides of all excavation. TheContractorshallreplaceorrepairat hisowncostinan approved manner, all workdamagedthrough removalofsuchtemporaryworkorimproperprotectivework. TheContractorshallprovidenecessarydecking,guard,fences,plankingwithredflags

and red lightsatnight tomaintain safepedestrianandvehicular trafficnearall openexcavationsathisowncost.

3.10.2 Shoring and strutting: Shoring and strutting shall be

used as directedwhen excavation is to be carried out in soft, slushy or filled up soilwhich is likely to collapse during the excavation work. The shoring shall be eitheropen or close boarded type or sand bag shoring depending on the nature of the soiland depth of excavation and the type adopted shall be as directed by theEngineer/Consultant. While excavating in a very unstable ground requiring supportthroughout the period of excavation, runner rail shall be used and shall be drivenalwaysinadvanceoftheexcavation. Thesizeandspacingofdifferentmemberstobe

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usedinshoringshallbeasdirectedbytheEngineer/Consultant,dependingonthesiteconditions.

3.10.3 Openboarded shoring: Thework shall be carried out as specified in clause 3.10.2

but the poling boards shall be placed in such a way that the spacing between thepolingboardsshouldnotexceed500mmandshouldatleastcover50%ofthesurfaceareaoftheexcavationsshored.

3.10.4 Runners rails: Runners rails shall be driven slightly in

advance of the excavation to form a close vertical support to the sides of theexcavation. The runners shall be lowered one at a time by digging away the groundbelow the toe and tapping the runnerdownafter loosening thewedges. Thewedgesshallbetightenedagainafterloweringtherunnerinposition.Alltherunnersshallbelowered in a similar manner by about 150 mm to 225 mm and excavation shall becarried out to the required depth by continuously lowering the runners as statedabove always keeping the toes of the runner into the ground to prevent earth fromslippingin.

3.10.5 Protecting railway track: All running tracks in the areas

of excavations shall be protected/supported as directed in order to maintain theoperation traffic. Permission from appropriate authorities shall be taken prior tocommencinganyworkonarunningrailtrack.

SECTION‐4‐PLAINANDREINFORCEDCEMENTCONCRETEWORK

4.1 CodesandStandards General IS:1200 ‐MethodofMeasurementofBuildingandCivil (28Parts)EngineeringWorks Cement IS:269 ‐ 33gradeordinaryportlandcement IS:8112 ‐ 43gradeordinaryportlandcement IS:12269 ‐ 53gradeordinaryportlandcement IS:8041 ‐ Rapidhardeningportlandcemernt IS:455 ‐ PortlandSlagCement IS:1489 ‐ Portlandpuzzolanacement(flyashbased) (Part‐1)

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IS:1489 ‐ Portlandpuzzolanacement(Calcined (Part‐2) claybased) IS:8043 ‐ Hydrophobiccement IS:12600 ‐ Lowheatportlandcement IS:12230 ‐ Sulphateresistingportlandcement Aggregate IS:383 ‐ CoarseandFineAggregatesfromNaturalSources forConcrete IS:2386 ‐ MethodsofTestforAggregatesforconcrete(8parts) IS:2430 ‐ MethodofSamplingofAggregatesforconcrete PlainandReinforcedConcrete IS:456 ‐ CodeofPracticeforPlainandReinforced Concrete IS:1199 ‐ MethodofsamplingandAnalysisofconcrete IS:516 ‐ MethodofTestforStrengthofconcrete IS:460 ‐ TestSieves (3parts) IS:1607 ‐ MethodforTestSieving IS:1834 ‐ HotAppliedSealingCompoundsforJointin Concrete IS:2204 ‐ CodeofPracticeforConstructionofReinforced ConcreteShellRoof IS:10262 ‐ RecommendedGuideLinesforConcreteMix Design IS:4925 ‐ ConcreteBatchingandMixingPlant IS:3370 ‐ Codeofpracticeforconcretestorage (4parts) structuresforthestorageofliquids Steel IS:2062 ‐ Steelforgeneralstructuralpurposes IS:432 ‐ MildSteelandMediumTensileSteelBarsand (2parts) Hard‐drawnSteelWireforConcrete Reinforcement IS:1566 ‐ Hard‐drawnSteelWireFabricforConcrete

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Reinforcement IS:1568 ‐ WireClothforGeneralPurpose

IS:1786 ‐ HighStrengthDeformedSteelBarsandWiresfor

ConcreteReinforcement

IS:2502 ‐ CodeofpracticeforbendingandfixingofBarsfor ConcreteReinforcement

IS:2751 ‐ WeldingofMildSteelPlainandDeformedBars forReinforcedConstruction4.2 Materials4.2.1 Cement:Thecementusedshallbeanyoftheabove,mentionedinclause4.1andthetype

selected shall be appropriate for the intended use. The Contractor shall carry out therequired tests at his own cost in an approved testing laboratory, at the direction of theEngineer,forallcementssuppliedbyhimorbytheEmployerandsubmitthetestreportfortheapprovaloftheEngineer,beforeusingthecementintheworks.Cementshallbestoredon raised platforms inside stores covered on all sides and roof with provision for ampleventilation.Differenttypesofcementshallbestoredseparatelyandmorethantenbags(10)ofcementshallnotbestackedoneabovetheotherinthestack.Sufficientspaceshallbeleftaround the stacks for approach. Stacking shall be so arranged that bags from the oldestconsignmentinthestackcanbeconvenientlyremovedfirstforusefollowingtheprincipleoffirst in firstout (FIFO)basis. For thisproper label tag indicatingdateof supply shall bedisplayedoverthestackofstoredcementreceivedinaconsignment(Batch).Cementwhichhashardened,cloddedordeterioratedduetooverstackingorlongstorageshallnotbeusedin theworksandshallberemoved fromthesite immediatelywith intimation toEmployerandEngineer.

4.2.2. Aggregates: AllaggregatesshallconformtoIS:383. Coarseaggregatesshallbeapprovedcrushed stone or gravel, washed clean. Fine aggregates shall be river or pit sand. Coarse and fineaggregates shall be stored at site separately on clean and hard base or in separatecompartments/hoppers. Samples of aggregates to be used shall be submitted to the Engineer forapproval before commencement of work. No aggregate shall be used without prior approval of theEngineer.TheContractorshallensurethatovertheentireperiodofconstructionallconsignmentsofcoarseandfineaggregatesbroughttothesiteconformstothequalityandgradingasapprovedinthemixdesignbytheEngineerbeforethecommencementofwork.Ifnecessary,gradingofaggregatesshallbemaintained by blending of different sizes of aggregateswhich shall be brought to site and stacked inseparatestockpiles. WheneverdirectedbytheEngineer,theContractorshallperformtestsathisowncost to satisfy the Engineer that the grading and quality approved for coarse and fine aggregates arebeingmaintained. SamplingofaggregatesshallconformtoIS:2430andtestsshallconformtoIS:2386.Thepercentagetoflakyandelongatedpiecesshouldnotexceed15%.

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4.2.3 Reinforcement: MSandmediumtensilesteelbarsshallconformtoIS:432(Part‐I&II)orhard drawn steel wire fabric reinforcement shall conform to IS:1566, high strengthdeformedsteelbarsshallconformtoIS:1786.Allreinforcementsshallbefreefromoil,paint,looserust,mill scale,mudorothermatter likely toweakenordestroy theirbondwith theconcrete.

4.2.4 Bindingwire:Bindingwireshallbeapproved16SWGannealedironwire.4.2.5 Jointfiller:Expansionjointfillersshallbeapprovednon‐extruding,resilientfillersasshown

inthedrawings.4.2.6 Waterstops:Forallmovementjointswaterstopsusedshallbeofrubber,PVCormetallic

sheetsasindicatedinthebillofquantitiesordrawings.4.2.7 Waterproofing: Thewaterproofing compound/water‐ proofingmembranematerials and

treatmentshallbeofatypeshownonthedrawingsand/ordescribedinthebillofquantities.4.2.8 Water: Water shall be clean and reasonably free frominjurious amounts of oils, acids,

alkalis,salts,sugar,organicmaterialsorothersubstancesthatmaybedeleterioustoconcreteorsteel.

4.2.9 ChemicalAdmixtures:Thesearematerialotherthanwater,aggregatesandcement(any

selected typementioned in clause1.1 above), usedas an ingredientof concreteormortarandaddedtothebatchimmediatelybeforeorduringitsmixingtomodifyoneormoreofthepropertiesofconcreteintheplasticorhardenedstate.Dosagesofretarders,plasticisersandsuper‐plasticisers shall be restricted to 0.5, 1.0 and 2.0 percent respectively byweight ofcementitiousmaterials and unless a higher valueisapprovedby Engineer‐in‐Chargeonlyafterobtainingperformancetestfromthemanufactures.TheyshallconformtoeitherIS:9103orASTMDesignationC494‐RS.AdmixturearegenerallyofthefollowingtypesandareuseddependingontherequirementorasspecifiedintheBillofQuantities.

4.2.9.1 WaterreducingAdmixture: AsperIS:9103orASTMC‐494,whichimprovesworkability,

acceleratesthesettingandearlystrengthdevelopmentofconcrete.4.2.9.2 Retarding Admixture: As per IS:9103 or ASTM C‐494, which retards the setting of

concrete.4.2.9.3 WaterReducingAdmixture,HighRange: As per ASTMC‐ 494,which reduces the

quantity ofmixingwater required to produce concrete of a given consistency by 12% orgreater.

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4.2.9.4 WaterReducing andAcceleratingAdmixture: As per ASTM C‐494, which reduces thequantityofmixingwaterrequiredtoproduceconcreteofagivenconsistencyandacceleratesthesettingandearlystrengthdevelopmentofconcrete.

4.2.9.5 WaterReducingandRetardingAdmixture: AsperASTM C‐494,whichreducesthe

quantityofmixingwaterrequiredtoproduceconcreteofagivenconsistencyandretardsthesettingofconcrete.

4.2.9.6 Water Reducing, High Range and Retarding Admixture: As per ASTM C‐494, which

reducesthequantityofmixingwaterrequiredtoproduceconcreteofagivenconsistencyby12% or greater and retards the setting of concrete, increase in both early and ultimatestrengths.

4.3 ConcreteMix4.3.1 AlltheconcreteunlessotherwiseindicatedondrawingsorintheBillofQuantitiesshallbe

`ControlledConcrete'asdefinedbyIS:456. Thegradesofconcreteshallbeas indicatedonthe drawings and/or bill of quantities. The Contractor shall at his own cost, grade theaggregate and control the water cement ratio, to design the different mixes of requiredstrengthandworkability.ThedesignedmixshallconformtotherequirementsofIS:456andrecommended guidelines for concretemix design in IS:10262 and SP‐23. Theminimumcementcontent,maximumwatercementratioandminimumgradeofconcretefordifferentexposures with normalweight aggregates of 20mmNominalMaximum size in concretework shall conform to Table 5 of IS:456. Adjustments to minimum cement contents foraggregatesotherthan20mmnominalmaximumsizewillbeasperTable6of IS:456. Allconcrete(whethernominalorcontrolled)shallbemachinemixedandnohandmixingwillbeallowed. Chemical admixturesmay be used in themanufacture of concrete. The content,type,methodandcontrolofuseandthe locationsandtheproducts inwhichtheyareusedshallbesubjecttothewrittenapprovaloftheEngineerineachandeverycase.

Themaximumsizeofaggregatesusedshallbeasindicatedinthedrawingsand/orbillof

quantities.Wherereinforcementistoocloselyspacedforthemaximumsizeofstoneinarange,thelargestsuitablerangewillbeusedwiththeapprovalofEngineer.BeforecommencementofworktheContractorshallsubmittotheEngineerforhisapprovalcompletedetailsofthemixdesign

calculations along with test results of different ingredients, grading analysis of theaggregates, thecubetestresultsetcaccordingto IS:10262. Noconcreteshallbeplacedonsite until the Engineer has approved the mix design. The concrete shall be of suchconsistencythat itcanbereadilyworked intothecornersandanglesof the formworkand

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aroundreinforcementswithoutsegregationofthematerialsorbleedingoffreewateratthesurface.

Ifanychangeismadeinthesourceandgradingoftheaggregates,strengthofcementused,

watercontentofthemix,mannerofmaking,compactingtheconcreteoranyotherdeviationfrom the preliminary test procedure, the Engineermay instruct for fresh preliminary testwhich shall be carried out by the Contractor at his own cost. Over the full period ofconstruction theContractor shall carryoutwork/laboratory testsasperClause4.6of thisspecificationathisowncost tosatisfy theEngineer thatcorrectgradeofconcrete isbeingused.

4.3.2 Where`NominalMixConcrete'incaseofM20orlowerasdefinedbyIS:456ispermittedby

the Engineer for any specific reason, the proportion of materials shall be as indicated inTable‐9ofIS:456. Thewatercementratiosshallnotexceedthosespecifiedin Table‐9. IfthequantityofwaterisrequiredtobeincreasedforbetterworkabilitythecementcontentalsoshallbeproportionatelyincreasedsothatthelimitspecifiedinTable‐9ofIS:456isnotexceeded.

4.4 Mixing4.5 WorkabilityofConcrete4.5.1 The concrete mix proportions chosen should be such that theconcrete is of adequate

workability for theplacingconditionsof theconcreteandcanproperlybecompactedwiththemeansavailable. Suggested rangesofworkabilityof concretemeasured inaccordancewithIS:1199aregivenbelow:

PlacingConditionsDegreeofSlumpworkability

(1)(2)(3)Blindingconcrete; Verylow See1.5.2Shallowsections;PavementsusingpaversMassconcrete; Low 25‐75Lightlyreinforcedsectionsinslabs,beams,walls,columns;floors;Handplacedpavements;Canallining;Stripfootings

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PlacingConditionsDegreeofSlumpworkability

(1)(2)(3)HeavilyreinforcedsectionsMedium 50‐100Inslabs,beams,walls,Columns;Slipformwork; Medium 75‐100PumpedconcreteTrenchfill; High 100‐150In‐situpilingTremieconcrete} Veryhigh see1.5.3

Note : For most of the placing conditions, internal vibrators (needle vibrators) are suitable. Thediameteroftheneedleshallbedeterminedbasedonthedensityandspacingofreinforcementbarsandthicknessofsections.Fortremieconcrete,vibratorsarenotrequiredtobeused.4.5.2 In the `very low’ category of workability where strict control is necessary, for example

pavement quality concrete, measurement of workability by determination of compactingfactorwillbemoreappropriatethanslump(seeIS:1199)andavalueofcompactingfactorof0.75to0.80issuggested.

4.5.3 Inthe ‘veryhigh’categoryofworkability,measurementofworkabilitybydeterminationof

flowwillbeappropriate(seeIS:9103).4.6 Work/LaboratoryTest TheContractorshallcarryoutwork/laboratorytestsathisowncost.Sampling,makingup,

curingandtestingofspecimenshallconformtoIS:456,IS:516andIS:1199andothertestofthe ingredients to be carried out periodically shall conform to IS:2386. Unless otherwiseinstructed by the Engineer, frequency of work tests shall be as indicated below. Thenumberof specimen tobe testedand their criteria foracceptance shall be asper relevantclausesofIS:456.ReportofthetestresultsshallbesubmittedweeklytotheEngineer.

4.7 FrequencyofTest

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Theminimumfrequencyofsamplingofconcreteofeachgradeshallbe inaccordancewiththefollowing:

QuantityofConcretein Numberofsamples thework,cum 1–5 1 6–15 2 16–30 3 31–50 4 51&above 4plusoneadditional sampleforeachaddi‐ tional50cumorpart thereofNote : At leastonesampleshallbe taken fromeachshift. Whereconcrete isproducedatcontinuousproduction unit, such as ready‐mixed concrete plant, frequency of sampling may be agreed uponmutuallybysuppliersandpurchasers.

4.7.1 TestSpecimen Three test specimens shall be made for each sample for testing at 28 days. Additional

specimen may be required for various purposes such as to determine the strength ofconcreteat7daysoratthetimeofstrikingtheformwork,ortodeterminethedurationofcuring,ortocheckthetestingerror. Additionalspecimenmayalsoberequiredfortestingspecimens cured by acceleratedmethods as described in IS:9013. The specimen shall betestedasdescribedinIS:516.

4.7.2 TestResultsofSample

Thetestresultsofthesampleshallbetheaverageofthestrengthofthreespecimens. Theindividualvariationshouldnotbemorethan+15%oftheaverage.Ifmore,thetestresultsofthesampleareinvalid.

4.8 HeatResistantConcrete

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4.8.1 Thisspecificationlaysdownrequirementsofheat‐resisting concrete of grade

M30to withstandtemperatureupto7000C.

4.8.2 M30gradeofconcretefortemperaturesupto700oCshallbemadeupof(1)blastfurnaceslagcement,(ii)basaltcoarseaggregatesand(iii)basaltsand.ThemixshallbedesignedasperIS:10262andIS:456forsevereexposureconditions.

Blast furnaceslagcementshallconformto IS:455andslagcontentshouldnotbe less than

50%. Basaltsandshallbefreshandgoodquality.GraincompositionshallconformtoIS:383. BasaltCoarseAggregate Basaltcoarseaggregateshallbe20mmanddown‐gradedaggregateobtainedfromfreshly

quarriedbasaltsandfreefromdustandforeignmaterialsandshallsatisfytherequirementsofIS:383.

4.8.3 HeatresistingconcreteofgradeM30shallpossessthe followingphysical andmechanical

propertiestomeetdutyconditions:

a) Limittemperatureofconcrete .. 700oC servicewithone‐sidedheating

b) 28days'characteristic .. 30N/mm2 strengthon15cmcube c) Minimumpermissibleresidual .. 40% strengthwhichistheratio ofR700toR100,expressed asapercentage4.8.4 Worktestsonheatresistingconcreteshallbeconductedtofind:

a) Residual compressive strength after heating upto 700o and subsequently cooling upto100OC

b) Compressivestrengthofconcretespecimenshardenedinnormalconditionsfor7and28

days and those heated to 105OC and subsequent cooling to 27OC 2OC at normalhumidity.

10cm3specimensofconcreteshallbeprovidedfortestsasfollows:

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a) Testsforcompressionatthe .. 3Nos. naturalhumidityafter7days b) Testsforcompressionafter .. 3Nos.

dryingat105oCafter7days c) Testsforcompressionafter .. 3Nos. dryingat105OCandwith subsequentheatingupto 700OCafter7days d) Testsforcompressionunder..3Nos. normalconditionsafter28days Compactionofconcretemixtureinthemouldsshouldbemadeonthevibratingplatform.The

laying and vibration of concrete mixture in moulds shall be completed not later than 25minutesaftermixing. Durationofvibrationshallnotexceed1.5minutes. Thenthemouldswithconcreteshallbekeptcoveredwithmoistclothfor48hours.Thenthespecimensshallbetakenfromthemouldsandkeptinachamberwith90%humidityattemperature27OC2OCpriortotesting.Thespecimensshallbetakenfromthechambernotearlierthan1hourbeforetesting.

4.8.5 TestProcedures4.8.5.1 Test forcompressionatthenaturalhumidityafter7(seven)days:These testsshallbe

carriedoutinaccordancewithIS:516.

4.8.5.2 Tests for compression after drying at 105oC after 7 (seven) days (strength beforefiring):Aftercuringtheconcretecubesfor7daysat27OC2OCat90%humidity,thecubes

shallbedriedat100oCto105oCinadryingoven.Normally30‐32hoursofdryingat100oC

to105oCissufficienttodryoutthecombinedwater.Therateofraisingthetemperatureshall

begradualandshouldnotexceed50oCperhour,whichareasfollows: TimeTemperature

(hrs)(oC)0..201..602..100

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‐..100 32..100

Afterthedryingiscomplete,thecubesshallbegraduallycooledto24oCto30oCandcrushedinacompressiontestingmachine.Atleast3samplesshallbetestedfordeterminingthemarkofconcretebeforefiringandshallberecordedasR100(inN/mm2).

Studieshaveestablishedthatdryingtheconcretefor30‐32hoursat100oCto105oC,after7daysofnormalcuringwillalmostresultin28days'strength.

4.8.5.3 Test forcompressionafterdryingat105oCandwithsubsequentheatingupto700oCafter7(seven)days(strengthafter firing):Aftercuring theconcretecubes for7daysat

27oC +2oC at 90%humidity and drying for 30‐32 hours at 105oC to constantweight in a

dryingoven,thecubesshallthenbefiredinamufflefurnacetoatemperatureof700oC.The

raisingoftemperatureshallbegradualandshallnotexceed200oCperhourasfollows: Time Temperature (hrs)(0C) 0 .. 20 1 .. 200 2 .. 400 3 .. 600 4 .. 700 5 .. 700 6 .. 700 7 .. 700 8 .. 700 The cubes which have been heated through the above temperature shall be cooled down

graduallytotheroomtemperature.Aftercooling,thecubesshallbeagaincuredfor7daysat

24oCto30oCat90%humidity(orthecubesmaybesteamcuredfor7hoursundernormalatmospheric pressure and again gradually cooled down to room temperature). The cubesshallbemeasuredfordimensions,weightandcarefullyexaminedforanysurfacecracksandthenshallbecrushedtodeterminethestrengthwhichshallberecordedasR700(inN/mm2).

TheresidualstrengthwhichistheratioofR700toR100,expressedasapercentage,should

notbelessthan40%.

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4.8.5.4 Testsforcompressionundernormalconditionafter28twentyeight)days:ThesetestsshallbecarriedoutinaccordancewithIS:516.

4.8.6. Allthetestresultsof10cm3specimensshallfirstbemultipliedbyacoefficient0.90togettheequivalent values for 15 cm3 specimens. The average corrected strength of the threespecimens ineach set shall notbe less than the specified strength, subject to the conditionthat only one out of the three consecutive tests may give a corrected value less than thespecifiedstrengthbutthisshallnotbelessthan90%ofthespecifiedstrength.

The7days'compressivestrengthofM30concreteshallbeminimum20N/mm2on15cm3

specimens.Thisappliesforspecimenscuredundernormalconditionsandalsothoseheated

to105oC.Residualcompressivestrengthofthespecimensheatedto

700oCandair‐curedfor10daysshallbecalculatedasaboveandexpressedasapercentageof

theactualcompressivestrengthofspecimensheatedto105oC,subjecttotheconditionthat

the three specimens heated to 105oC themselves have passed the criteria. Residual

compressivestrengthof specimensheated to700oC,as calculatedaboveshallbeminimum40%.

4.8.7 Samples of concrete shall be collected from the actual concretingof thework to

preparecube‐specimensforallthetestsonceforevery50m3pourofconcreteorpartthereoforasdirectedbytheEngineer. Concretemaybeacceptedifallthetestresultscomplywiththe stipulations. If the specimens heated to 7000C and then cooled and cured show deepcracks outside, the concrete must be rejected even if other strength criteria are satisfied.Engineer'sopinionregardingthenatureofthecracksshallbefinal.

4.8.8 Preliminarytestsshallbeconducted,inthesamemannerasdescribedaboveforwork

tests, before commencement of concreting operation for the purpose of designing theconcretemix. However,preliminary test shall indicate28days' compressive strengthof at

least 38 N/mm2 for 15 cm3 cubes and the seven days compressive strength shall be 25

N/mm2for15cm3cubes. The final composition of concrete, gradation of aggregate, water cement ratio etc, shall be

ascertainedbymeansofaseriesofpreliminarytests.4.8.9 VacuumDewateredReinforcedCementConcrete Flooring4.8.9.1 Purpose: The purpose of providing vacuum dewatered flooring is to increase the

compressivestrengthandwearresistanceoftheconcretefloorbyreducingthewatercementratioof theconcretesubstantially. Finishingthetopsurfaceoftheconcretebyfloatingand

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trowellingwithaskim floater fittedwitha floatingdiscand/or trowellingbladesensuresawaterimpermeableconcretesurface.Theworkmanshipforlayingthefloorisgivenbelow.

4.8.9.2 Workmanship Preparationofsub‐base: Aleanconcrete(PCC)layershouldbelaidassub‐baseasshown

onthedrawings. Formwork: M.S. channels of approved sizeswill have to be used for formwork. Suitable

holeswill have to be provided in the channels for passing reinforcement rods and dowels.Thechannelsshouldbestraightandplacedfirmlyonsub‐basetoproperlevelandthebottomedgeof thechannelshouldbesealedproperly toavoidentryofair. Nochannelsshouldberemovedearlierthan24hoursaftertheflooriscast.

Placingofconcreteandcompaction:Concreteshouldbedistributedevenlyandshouldbe

vibratedwithan immersionvibrator inorder toremoveentrappedairandvoidsandmakethe concrete homogeneous. Surface vibrator should be used after immersion vibrator inordertomakelevelandsmoothconcretesurfaceasdirectedbytheEngineer.Thethicknessofthefloorshouldbekeptmorethantherequiredthickness,asdirectedbytheEngineer,tocompensatefortheshrinkageeffect.

Vacuumdewatering: After leveling the concrete surface by surface vibrators, the floor is

dewatered by using filtermat and suction pump of approvedmake as permanufacturer’sspecification. The dewatering time should be based on site conditions and asdirected/approvedbytheEngineer.

Floating and trowelling: Immediately after the floor is vacuum dewatered, floating and

trowellingoperationshallcommencebyusingaskimfloaterwithfloatingdiscandtrowellingbladesofapprovedmake.

4.9 Formwork4.9.1 Shuttering for concrete: The term `Shuttering' shall include all centering and formwork

requiredtosupporttheconcreteduringtheprocessoflaying,compactingandsettingandallitemssuchasplanking,lagging,walling,moulds,covers,cross‐bearers,struts,props,bracingsetcshallbecoveredbytheterm.

Shutteringshallbestrongandrigidlyconstructedsothattheremaynotbeanydeformation

underweightandpressureofwetconcrete,constructionalloads,windand/orotherforces.Itshallbeconstructedinsuchamannerthatitcanbeeasilyremovedafterwards.

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The shuttering shall have smooth and even surface and so constructed as to remainsufficientlyrigidduringtheplacingandcompactingofconcreteandshallbesufficientlytighttopreventlossofliquidfromtheconcrete.

Devices shall be provided in the shuttering for forming openings, holes, pockets, chases,

recessesetcwhererequired.Cuttingofholesetcintheconcreteaftercastingshallbeavoided.Corner fillets shall be provided in the formwork to obtain chamfered edges to beams,columns,etcwhereverrequiredandtheratequotedshallbeinclusiveofthecostofcarryingoutsuchwork.

Shutteringshallconformto IS:456and IS:14687.Formsshallbeprefabricatedstandarde.g.

Dokasystemorapprovedequivalentorshop‐builtpanelsorbuilt‐in‐placeunits,stiffenedandbraced.Asmearingofoilreleaseagentshallbegivenonthefacesoftheshutteringincontact with the concrete or mortar. Forms shall be cleaned from all dust and loosematerialsbeforeapplyingoil

releaseagentover it.Formworkwithbrick liningmaybedoneforstructuresbelowground

levelonearthfacewithpriorpermissionoftheEngineer.Bricksshallbethoroughlywettedbefore laying concrete and the brick lining may be left in position, if so desired by theContractor.

The shuttering shall be such that after its removal the exposed concrete surface shall be

smooth and even. If any unevenness is found, the bulged portion of the concrete shall bechippedoffandplasteredwith6mmthickcementplaster1:4.Noextrapaymentwillbemadeforthis.

4.9.2 StrippingTime:Formsshallnotbereleaseduntiltheconcretehasachievedastrengthofat

leasttwicethestresstowhichtheconcretemaybesubjectedatthetimeofremovalofformwork.Thestrengthreferredtoshallbethatofconcreteusingthesameconcrete,aggregatesandadmixtures,ifany,withthesameproportionsandcuredunderconditionsoftemperatureandmoisturesimilartothoseexistingonthework.

4.9.2.1 While theabovecriteriaof strengthshallbe theguiding factor forremovalof formwork, in

normal circumstances where ambient temperature does not fall below 15oC and whereordinaryportlandcementisusedandadequatecuringisdone,followingstrikingperiodmaydeemtosatisfytheguidelinegiveninclause4.9.2.

TypeofFormworkbeforeStrikingFormworkMinimumPeriod

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a) VerticalFormworktocolumns,walls, 16–24h

Beamsb) Soffitformworktoslabs(Propstobe 3days refixedimmediatelyafterremoval offormwork) c) Soffitformworktobeams(Propstobe 7days refixedimmediatelyafterremoval offormwork)d) Propstoslabs:

1) Spanningupto4.5m 7days2) Spanningover4.5m 14days

e) Propstobeamsandarches:

1) Spanningupto6m 14days2) Spanningover6m 21days

For other cements and lower temperature, the stripping time recommended above, may be

suitablymodified.4.9.3 Supports: Formwork shall be so designed that the side of beams and slabs can be

removedwithoutdisturbingsoffitformsandtheirsupports. Propsandsupportsshallallowaccurateadjustmentoftheformworktruetolineandlevelandbecapableofbeingremovedinanapprovedsequencewithoutinjurytotheconcrete.Provisionshallbemadeforremovalofformworkwithoutdisturbingpropsrequiredforsupportinghardenedconcrete.

4.9.4 Setting:Panelsandunitsshallbesettotruedimensionsandalignmentandrigidlytied,

walledandbracedtopreventdistortionanddisplacementduringconcreting.All jointsshallbe tight and close fitting to prevent leakage. At all construction joints, formwork shall betightly secured against previously cast or hardened concrete. When fixing formwork forbeamsandslabstight fittingcollarsshallbeprovidedaroundtheheadsofcolumnsandthejoints shall bemade grout tight. Slip formswhereused shall provide smootheven surfacetruetodimensionandalignmentandshallbefreeofunslightlyoff‐sets,finsandbulges.

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4.9.5 Ties:Standard formties, clamps,bolts, insertsetcshallbeofadequatestrength.Spreaders,eitherremovableorembeddedtypeshallbeusedtomaintainthewallthickness.ThematerialandpositionofanytiepassingthroughtheformworkshallbeasapprovedbytheEngineer.Alltiememberswhichwillremainembeddedintheconcreteshallbefixedinamannerthatwillprovideaminimumcoverof12mmatboththeends.AnyholesleftafterremovaloftiesshallbefilledwithconcreteormortarasapprovedbytheEngineer.Provisionshallbemadeforformingholesandchasesforservicesandforprovidingpipes,conduitsandotherfixingasshowninthedrawingand/orasdirectedbytheEngineer.

4.9.6 Cleaning and treating of forms: All rubbish shall be removed from the interior of the

formwork and inside of the formwork shall be wetted with water before commencing ofconcreting.Mouldoilorotherapprovedreleaseagentshallbeusedtoallpanels.Careshallbetakentopreventcontactofreleaseagentwithreinforcement.

4.10 Reinforcement Workmanship shall conform to IS:2502. All reinforcements shall be free from loose

mill scale, rust, oil, grease, mud and paint. Reinforcement shall not be bent orstraightened in amanner thatwill injure thematerials and all bars shall preferablybebentcold. Hotbendingshallnotbepermitted forbarswhosestrengthhavebeenincreasedbycoldworking.Cuttingandbendingof reinforcementbars shallbemadebyusingappropriatemachine.Nomanualcuttingandbendingshallbeallowed.

Reinforcementbarsshallbeplacedandmaintainedaccuratelyinpositionasshownin

the drawings. The correct cover to the reinforcement shall bemaintainedbyuse ofprecastconcreteblocks.

All intersectionsof longitudinal and transversebarsor stirrupsandall laps shall besecurely tied together with approved binding wire. The binding wire shall be soplaced that it touches all the four cornersof the intersectionand the twoends shallbeloopedwithpliersandtheendsshallbeturnedintothebodyoftheconcrete. Thecostof thebindingwireandspacer/coverblocksshallbe includedbytheContractorinhisrateforreinforcementwork.

Welded joints may be used but in all cases of important connections, tests shall bemadetoprovethatthejointsareofthefullstrengthofbarsconnected.WeldingshallbedoneinaccordancewithIS:2751andspecialprecautionsshallbeadoptedforcoldworked bars. Butt welding between the ends of a rod in line, whereby stress istransferredacrossthesectionmaybeadoptedonlyformildsteelbars.Incaseoftackwelding for fixing reinforcements in their position, no special precaution need betaken.

4.11 Embedments

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Allembedmentsshallbeaccuratelysetandrigidlyfastened.Anchorboltsshallbeset

to template and firmly secured in vertical and horizontal line at required positions.Water stops shall be secured against displacement during the placing of concrete.The joints for G.S sheet water stops shall be solderedwater‐tight and those of PVCandrubbershallbejoinedbycementingandvulcanising.Expansionjointfillersshallbe for the full depth of slabs or full width in walls and shall be cemented with abituminouscementagainstpreviouslyplacedconcrete.Theendsshallbebuttedtightandtheupperedgesetflushwithfinishedslabs.

Anchor holes and anchor bolts shall be protected by

coveringsuitablywithbrickworkinleancementmortarafterthoroughcleaning.4.12 PlacingofConcrete 4.12.1 Transportingconcrete:Concreteshallbe transported fromtheBatchingPlant

by transit mixers to the forms as rapidly as possible by means that will preventsegregationor flash set in the concreteduringhotweather. The containers shall besuch as to prevent heavy evaporation. At the time of placing concrete in very hotweather, care shall be taken to see that the temperature of wet concrete does to

exceed 38oC. Before placing the concrete, all formwork, embedments andreinforcement shall be checked for completeness, location, dimension, square andplumb.Allchipsandsawdustorotherfoulmattershallberemovedfromwithintheforms. The base surface shall be well moistened and puddles wiped up. Placingequipment and accessories shall be kept clean and free of partially set grout andconcrete,andmaintainedinproperworkingorder.

4.12.2 Placing aids: In general, placing shall be done by concrete pump. Wherever

required, concreting shall be done by direct pouring from transitmixer and also ofapproved chute. Concreting shall also bedonewith thehelpof bottomopenbucketwherever required. No head load of concrete pouring is allowed and use ofwheelbarrowismandatorywhereverdirectpumpconcreteorothermechanicalmeansarenotsuitable.

4.12.3 ConveyingEquipment : Conveyingequipmentshallbe approvedandshallbeof

size and design such that detectable setting of concrete shall not occur beforeadjacent/nextlayerconcreteisplaced.Conveyingequipmentshallbecleanedattheend of each operation or work day. Conveying equipment and operation shallconformtothefollowingadditionalrequirements.

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4.12.3.1 Truck mixers, agitators and agitating units and their manner of operation shallconformtotheapplicablerequirementsofASTMC94.

4.12.3.2 Belt conveyors shall be horizontal or at a slope which will not cause excessivesegregationorlossofingredients.Concreteshallbe protected againstunderdryingorriseintemperature.Anapprovedarrangement shall bemade at the dischargeendtopreventapparent segregation. Mortar shall not be allowed to adhere to the return lengthofthebelt.Longrunsshallbedischargedintoahopperor through abaffle.4.12.3.3 Chutesshallbemetalormetal‐linedandshallhaveaslopenot exceeding1vertical

to2horizontalandnotlessthan1verticalto3horizontal,chutesmorethan6mtrs.long and chutes not meeting the slope requirements may be used provided theydischargeintoahopperbeforedistribution.

4.12.3.4 Pumping or pneumatic conveying equipment shall be of a suitable kind with

adequate pumping capacity. Pneumatic placement shall be controlled so thatsegregation isnotapparent in thedischargedconcrete. The lossof slumppumpingorpneumaticconveyingequipmentshallnotexceed50mm.

4.12.3.5 Concreteshallnotbeconveyedthroughpipemadeofaluminiumoraluminiumalloy.4.12.4 Constructionjoints&coldjoints:Ingeneralconstructionjointsshallbelimitedto

those indicated on the drawings. Inmass concrete, construction jointsmay not beindicated in the drawings but shall bemade at breaks, offsets or other convenientlevels as controlled by volume, plant capacity, time factors etc. Such constructionjoints shall be so located that they do not impair the strength of the structure andprior approval of theEngineer are tobe taken. Inwalls and columnheight of eachlift shall not generally exceed 1.5 m unless otherwise specified in thedrawings or directed by the Engineer. Method of forming all construction jointsshallconformtotheprovisionsofIS:456. Thesurfaceofpreviouslyplacedconcreteattheconstructionjointshallbethoroughlyhackedtoexposethecoarseaggregatesof previously placed concrete and cleaned with wire brush or any other approvedmeans and high pressure water jet to remove all laitance and loose aggregates.Immediately before placing fresh concrete, such prepared surface shall be coatedwith a thin layer of cement slurry. Wherehigh shear resistance is required at theconstructionjoint,shearkeysshallbeprovided.

4.12.5 Compaction: Concrete shall be thoroughly compacted and fully worked around the

reinforcement,aroundembeddedfixturesandintocornersoftheformwork.Concreteshallbe compactedbymechanicalvibrationusinghigh frequencymechanicallydrivenvibrators

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complywithIS:2505,IS:2506,IS:2514&IS:4656.Concreteshallbeplacedinlayersatleast300 mm deep in walls and approximately 450 mm in mass pours. Vibrators shall notpenetratemorethanintothesurfaceofpreviouslyplacedlayerbutshallcompletelyvibratetheworkinglayer. Careshallbetakennot to over‐vibrateanyconcreteandespeciallythosewithhigherslumps.Undernocircumstancesvibratorsshallbeattachedtoorallowedtotouchreinforcement.Sparevibratorsingoodoperatingconditionshallbeonhandduringplacingoperation.

4.12.6 Special concreting: The placing of under water concrete

shall follow IS:456 in all respects for the method employed. Special types ofconcreteshallbeplacedbymethodsmostsuitablefortheparticularconditions.

4.12.7 Groutingbasesofmachines,columns,foundationsboltsetc.4.12.7.1 Level pads: For preparing the level pads, the top of the

foundationconcrete shall be chippedoff to remove laitance formedon the concretesurface and all loosematerials shall be thoroughly cleaned and the surface wettedbeforethegrouting.IncaselevelpadsareconstructedtheyshallbecementconcretewithgradeM25orM20inconformitywiththegroutingrequirementwith6mmsizeballast.Thetopofthelevelpadsshallbefinishedfine,truetolevelandbeofsizeasindicatedbytheEngineer.

.12.7.2 Grouting: Before placing the grout, the concrete surface

shallbethoroughlycleaned,preferablywithcompressedairandthesurfaceshallbethoroughly wetted with water for several hours. Before placing the grout all freewatershallberemovedandthe flatsurfaceshallbecoatedwiththincementslurry.The quantity of mixing water should be minimum commensurate with theworkability, compaction and filling of the grout in all corners and crevices. Thegrout shall be evenly spread and compacted by rodding or a vibrator. The groutshall be carefully observed for initial settlement. If any settlement is observedfurthergrout is tobepouredandrodded.Forbaseplateshavingribsunderside thebase plate, proper care is to be taken to ensure filling of the cavities between theribs. In case of wide base plates of bed plates having ribs under‐ side it may benecessarytodopressuregrouting.

4.12.7.3 Curing: Thegroutmustnotdryoutafter it isplaced inposition. Thesurfaceshall

bekeptmoistwithwetsacksforatleastsevendays.4.12.7.4 Admixtures: Ifanyadmixtures istobeusedwiththegrout, itshallbeasapproved

bytheEngineer.

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4.12.7.5 Non‐shrinking grout: Non‐shrinking grout where indicated or directed shall beplacedinaccordancewiththemethodspecifiedbythemanufacturer. MaterialshallbeasapprovedbytheEngineer.

4.12.8 Waterproofing:Waterproofingofconcretewithapprovedwaterproofingcompound

shallbecarriedoutstrictlyinaccordancewiththemanufacturer'sspecification.4.13 CuringandProtecting:CuringofconcretewithwatershallcomplywithIS:456.The

Contractorshallkeeptheexposedsurfacesofconcreteinaconstantlywetconditionfor at least 7days from thedate of placing the concrete. Curing compoundmaybeused subject to approval by the Engineer. Finished floors and concrete shall beprotectedcarefullyuntilconditionsshallcomplywiththecode.

4.14 RepairingandPatching: Pockets, honey combing and other defectswhichmay be

formed due to segregation, improper vibration and any other reason whatsoevershall be completely repaired to the satisfaction of the Engineer. The voids, if any,shallbeproperlykeyedandreinforced,ifnecessary.Thefaceshallbetightlyformedandarrangedforprovidingaheadintheconcrete.Thecavityshallbefilledwiththesame concrete as used for the structure and thoroughly rodded or vibrated wherepossible. Theconcretesetssufficientlytostayinplace.Whilestill`alive',theupperpart of form hopper shall be removed and excess concrete struck off and finishedwith wood flat or trowel to match existing concrete. Any fins or unsightly groutrunsorbulgesshallberemovedfrom

surfacesexposedtoview. Therodholesshallbefinishedwithcementorgroutedto

match the existing surface as closely as possible. No cement wash shall be usedunlessparticularlycalledforinthedrawings.

4.15 TolerancesforFormwork TheFormwork shall bedesignedand constructed so as to remain sufficiently rigidduring

placingandcompactionofConcreteandshallbesuchas toprevent lossofslurry fromtheConcrete.Thetolerancesontheshape,lineanddimensionsasshowninthedrawingshallbewithinlimitsasgivenintheTableofclauseno11.1ofIS:456

4.16 TolerancesforPlacingofReinforcement Unless otherwise specified, the Reinforcement shall be placedwithin the following

tolerances: a) Foreffectivedepth200mmorless +10mm

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b) Foreffectivedepthmorethan200mm +15mm

SECTION‐5‐MORTARFORMASONRYAND

PLASTERWORK5.0 WorkIncluded TheContractorshallfurnishmaterials,labour,plant,equipmentandtoolstocomplete

theworkasspecifiedherein.5.1 Materials5.1.1 Cement:AsperSection‐4.5.1.2 Sand: The sand shall be of approved river or pit sand and

it shall conform to IS:1542 for plaster and to IS:2116 formasonrymortar. Sand forthe mortar shall be evenly graded from coarse to fine, free from loam, clay, dust ororganicmatteretc.

5.1.3 Water: Water shall be clean and reasonably free from

deleteriousmaterialssuchasoils,acids,alcohol,salts,sulphateandvegetablegrowthasperclauseNo.5.4ofIS:456.

5.2 MortarProportion Theproportionofcementandsandformortarshallbeformasonryworkis1:6andfor

plasterworkis1:4.5.3 Workmanship The workmanship shall conform to IS:2250 for preparation

ofmasonrymortarsandtoIS:1661forplastermortars. The cement and sandshall be thoroughly mixed dry inspecified proportion to obtain a uniform colour. The water shall be added bysprinkler just sufficient to make a stiff and workable paste. In case of mechanicalmixing the mortar shall be mixed for at least 3 minutes and for hand mixing themortar shall bemixed back and forth for 10 to 15minuteswith additions ofwater.Mortar that has stiffened because of evaporation of water may be re‐tampered byaddingwater as frequently asnecessary to restore consistencybut this re‐tempering

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willbepermittedonlywithinone(1)hourfromtimeofadditionofcement.Innerendofthescaffoldingpolesshallrestinaholeprovidedinaheadercourseonly.Onlyoneheader for each pole shall be left out. Holes, if provided shall be filled in andmadegoodbytheContractorathisowncosttothesatisfactionoftheEngineer/Consultant.

5.4 Curing After the completion of plaster work, it shall be cured by adequate watering for a

period of seven (7) days. The plaster shall be protected during that period fromextremetemperatureandweathercondition.

SECTION‐6‐BRICKANDSTONEMASONRYWORK

6.0 WorkIncluded

TheContractorshallfurnishmaterials,labour,plant,equipmentandtoolstocompletetheworkasspecifiedherein.

6.1 CodesandStandards IS:2212..CodeofPracticeforBrickwork IS:1077..CommonBurntClayBuildingBricks IS:2691..BurntClayFacingBricks IS:3495..MethodsofTestforBurntClayBuildingBricks IS:2750..SteelScaffoldings IS:4014..CodeofPracticeforSteelTubularScaffolding (Part1) IS:3696..SafetyCodeforScaffoldsandLadders (Part1&2)

IS:1127 ...RecommendationforDimensionsandWorkmanshipofNatural BuildingStonesforMasonryWork

IS:1129..RecommendationforDressingofNatural BuildingStones IS:1124..MethodsofTestforDeterminationofWater AbsorptionApparentSpecificGravityand PorosityofNaturalBuildingStones IS:1597..CodeofPracticeforConstructionofStone (Part1&2)Masonry

IS:12894 ...CodeofpracticeforflyashlimeBricks.

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6.2 Materials6.2.1 Cement mortar: Cement mortar shall be as specified in

Section‐5ofthisspecification.6.2.2 Water: Water shall be clean and reasonably free from

deleteriousmaterialssuchasoils,acids,alcohol,saltsandvegetablegrowth.6.2.3 Burnt clay Bricks: The bricks used shall be conforming to IS:1077.Bricks shall be

whole, sound,wellburnt, free fromcracks, flawsandnodulesof free lime.Brickshallhave rectangular faces with sharp corners and shall be uniform in colour and shallemit a clear ringing soundwhen struck. The compressive strength of brick shall beminimumof50kg/sqcmor5N/sq.mm.

6.2.4 Stone:BuildingstoneshallconformtoIS:1127.Rubblestoneshall be strong,dense,compact,closegrainedanduniformintextureand colour with reasonable facilityofworking.Itshallbefreefromcracks, flaws, decay and sand holesandshallbetakenfromapprovedquarries. A freshfractureofstoneshallbebright,cleanandsharpwithout loosegrainsand freefromanydullearthyappearance.Thestoneshallbeproperlydressedinconformity withIS:1129afterquarryingbeforetheyareputtouseinthe structure.6.2.5 FlyashLimeBrick(Falg): Thebricksaremadeofquarrydust, flyash, cement, lime

and gypsum. Thewater absorption shall not bemore than 10% after immersion incoldwaterfor24hours.ThebrickshallconformtoIS:12894.

6.2.6 Wire Netting:Woven, hexagonal wire shall conform to type N3 of IS:3150 and be

galvanized.Thewidthshallsuitthethicknessofthewall.6.3 Scaffolding Generally,scaffoldingshallconformtoIS:4014andshallbedesignedtowithstandthe

required loads and to ensure complete safety of workmen and materials. Thescaffolding shall be double, i.e. it shall have two sets of stands. Where this is notpossible,theinnerendofthescaffoldingpolesshallrestinaholeprovidedinaheadercourseonly.Onlyoneheaderforeachpoleshallbeleftout.Holes,ifprovidedshallbefilled in and made good by the Contractor at his own cost to the satisfaction of theEngineer/Consultant.

6.4 LiftingandHandlingofbricksatheight

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Allbricksshallbeliftedatheightwiththehelpofbuilderhoistoranyotherapprovedmechanicalmeans.

6.5 Cleaning The Contractor shall carry out work in as clean a manner

aspossibleandshallremoveexcessmaterialandmortardroppingsandrubbishdaily.Wherebrickwallsandstonemasonryaretoreceiveplaster,thejointsshallbecleanedof excess mortar and raked to a depth of 12 mm and the surface shall be brushedclean. During cleaningoperations, adjacentwork shall be protected and anydamageresulting from improper protection shall bemade good by the Contractor at his owncost.

6.6 Brickwork6.6.1 Workmanship: The whole of the brickwork shall be

carriedoutbytheContractorinanuniformmanner.Allthebricksshallbekeptunderwater till they are completely soaked and used on their becoming skin dry. TheContractor shall set out and build all brickwork to the dimension, thickness andheights shownon theapproveddrawings.TheContractor shallbuildallbrickwork inEnglish bond and half brick walls and casing to pipe, chases etc in stretcher bond.Brickbatsshallnotbeusedexceptwhererequiredforbond.

The Contractor shall lay bricks in full mortar beds with

shoved joints. The joints shall not exceed 10 mm in thickness and shall be full ofmortar, close,well finished andneatly struck. The vertical joints in any course shallnotbenearerthanaquarterofbricklengthfromthoseinthecoursebelow.Alljointsshall be of same width except for small variations to maintain the bond. Thebrickworkshallbelaidplumbandtruetolineandlevel.Noportionofbrickworkshallbe raisedmore than1meteraboveanother inaday. If themortar inanycoursehasbegun to set, the joints shall be raked out before another course is laid. The topcourse of brickwork in reinforced concrete frame structure shall be wedged againstreinforcedconcretesurfaceandjointwellfilledwithmortar.

The Contractor shall flush up all the joints thoroughly withmortar as theworkproceeds. Where brickwork is to receiveplaster, the joints shallberakedtoadepthof12mmtoprovideproperbond.Thebrickworkasitprogressesshallbe thoroughlywateredon its facesandtop.Newworkshallbeproperlybondedwitholdwork.Newworksurfaceofunfinishedworkshallbecleanedand thoroughlywateredbeforejoiningnewworktoit.

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Any work in which the mortar deteriorates shall be dismantled and rebuilt by theContractorathisownexpense.

6.6.2 Curing: The Contractor shall keep wet all brickwork for 7

daysafterlaying.6.7 UncoursedRandomRubbleMasonry6.7.1 WorkmanshipforstonemasonryshallconformtoIS:1597.Nostoneshallbelessthan250mm

inthicknessorlessthan300mmineachhorizontaldimension.Ifthethicknessbemorethan300mmtheleasthorizontaldimensionmustnotbelessthanthethickness.

6.7.2 Dressing:Thestonesafterbeingfullycleanedandwettedaretobesetintheworkasreceived

from the quarry andwithout further dressing of any sort except that of knocking off weakcornersandedgeswiththemason’shammer.

6.7.3 Bondandlaying:Thestonesshallbecarefullylaidsoastobreakjoints byat least75mmandsolidlybeddedwithclosejoints.Nojointshall exceed20mminthickness.Chipsofstonesandspallsshallbewedgedinto thework,wherevernecessary so as to avoid thick bed or joints ofmortar. Nodryworkorhollowspacesshallbeallowedinthemasonryanywhere. Every stonewhetherlargeorsmallshallbesetflushinmortar,smaller stonesused in the filling being carefullyselectedtofitintointerstices betweenthelargeronesroughly.Theoutsideandtheinsidefacesof masonryinwallsmustbecarriedoutinthesameplaneasthefacesofthe precedinglength.6.7.4 Facestones:Thefacestonesshallbelaidasfaraspossiblewithoutpinningsinfrontandthey

shallbeselectedfromthemassorquarrystoneforgreatersize,goodbedsanduniformcolour.Theyshallbelaidsothattheyshalltailbackandbondwellintotheworkandshallnotbeofgreaterheightthateitherthebreadthonfaceorlengthoftailinthework.

6.7.5 Bondorheaderstones:Atleastone‐fifthofstonesinthefaceshallbethroughstonesevenly

distributed throughout thewall. The through stoneswill fulfil all the conditionsof the facestoneexceptasregardstheirlengthwhichmustbenotlessthan450mmandmustrunrightthroughthewallwhenthewallisnotmorethan450mmthick.Inthickerwallsalineoftwoormorethroughstonesmustbelaidfromfacetobackoverlappingeachotheratleast150mm.Throughstonesshouldnotbe in thesameverticalplan insuccessivecourses. For facilityofcheckingtheyshallbemarkedandthemarksshallbecapableofbeingeasilyrubbedout.

6.7.6 Quoins :Quoinsmustbeofthesameheightasthecourseinwhichtheyoccurandshouldbe

formedofheaderstonesfrom220mmto450mmlongaccordingtotheheightofthecourseand laid lengthwise alternatively along each face. They shouldbe laid squareon their beds

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whichshouldbedressedtoadepthofatleast100mm.Thecornerofeachquoinshouldhaveachiseldraftof25mmoneachsidetofacilitatecheckingtheverticalalignment.

6.7.7 Finishing : Where lime mortar is used, the exposed faces of work shall be cement flush

pointed,unlessotherwisespecified.Whencementmortarisusedthejointsmaybeflushedastheworkproceeds. Wherestoneworkistoreceiveplasterortobepointedotherthanflushpointing,thejointsshallberakedtoaminimumdepthof12mmtoprovideproperbond.Anywork inwhichmortarperishes shall bedimantled and rebuilt by theContractor at his ownexpense.

6.7.8 Curing:Curingshallbedoneforaperiodof7days.6.8 CoursedRandomRubbleMasonry Thespecificationshallbesameasinclause6.7aboveexceptingthattheworkshallberoughly

levelleduptocoursesatintervalsvaryingfrom300mmto900mm.

6.9 CoursedRubbleMasonry6.9.1 Heightof courses : The stones after being cleaned andwetted shall be laid in horizontal

coursesofequaldepthofnotlessthan150mmandshallbesetfullinmortar.6.9.2 Dressing : The joint between two continuous face stones in the same course shall be truly

verticalandthetwostonesshallbehammerorchiseldressedsoastobeinproximityforatleast75mmdepthfromthefaceofthewall.Thebedsoffacestonesshallalsobehammerorchiseldressedforatleast75mmdepth.

6.9.3 Bondand laying : Thestoneshallbe laidon theirbroadest face inmortarandbeaten into

positionwithmallet,carebeingtakenthatthemortariswellfilledintothejoint.Theverticaljoints in each coursemust break joint at least 75mmwith those in the courses above andbelow. No joint shall exceed12mm in thickness. The interiorof thewall is tobecarefullyconstructedwithpropersizedstonesandnot filledupwithspallsand/orchips. Spallsmayhoweverbeusedtowedgeintothemortartoavoidthickbedorjointsofmortar.

6.9.4 Facestones: Thefacestonesshallbesquaredonalljointsandbeds.Nofacestoneshallbe

narrowerorshorterthanitsdepth.Itslengthtailingintothewallshallnotbelessthantheirheightandatleastone‐thirdofthefacestonesshalltailintotheworkforalengthtwicetheirheightorinthequickwallsthreetimestheirheight.

Thewidthofthefacestonesinplanshallnotbelessthan150mmforwalls400mmthick,200

mmforwalls,450mmthickand250mmforwalls600mmthickormorerespectively.No

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stonelessthan150mminheightshallbeusedontheface.Thefacestonesshallbelaidheadersandstretchersalternatively.

6.9.5 Bondorheader stones : Through stones for headers shall fulfil all the conditions of face

stones,exceptasregardstheirlengthwhichmustnotbelessthanthewidthofthewallor450mmwhichever is less. Through stones shall be inserted approximately 1.5metre apart inevery course. Other details shall be same as for bond or header stones for random rubblemasonry.

6.9.6 Quoins:Thesamespecificationshallbefollowedasdetailedforrandomrubblemasonry.6.9.7 Finishing:Theexposedsurfaceoftheworkshallbeflushpointed.Unlesstheinteriorfaceis

tobeplastered,itshallbeofthesamefinishasthatofexteriorface.6.9.8 Curing:Curingshallbedoneforaperiodof7days.

SECTION‐7‐PLASTERWORK

7.0 WorkIncluded

TheContractorshallfurnishmaterials,labour,plant,equipmentandtoolstocompletetheworkasspecifiedherein.

7.1 CodesandStandards IS:1542..Sandforplaster IS:1661..Codeofpracticeforapplicationofcement andcement‐limeplasterfinishes IS:2250..Codeofpracticeforpreparation anduseofmasonrymortars.7.2 Materials All materials, cement mortar etc shall be as specified under Section‐4 and 5 of this

specification.7.3 PlasteringinOneandTwoOperations7.3.1 Proportion: All plaster work shall be carried out according to IS:1661 with 1:4

cementsandmortar.7.3.2 Workmanship: The surface to beplastered shall be cleanedof all extraneousmatter

and rubbish. In brickwork the joints shall be raked and concrete surface roughened

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by chipping or hacking. Any shuttering material adhering to the concrete shall beremoved. The surface shall be thoroughly watered and soaked, aerated and all logholes shall be closed before starting plastering operation. Plaster pads of requiredthicknessofplasterforcorrectnessofplumb,lineandlevelshallbeestablishedbeforestartingplasterwork.

For one coatplasterwork, theplaster shall be laid slightly thicker than the specified

thicknessandthesurfacethenleveledwithflatwoodenruletotherequiredthickness.Theplastershallbewellpressedintothejointsandthesurfacefinishedasspecified.

Where two coats of plaster work is specified, the first coat shall be applied as

described above except that the surface shall be left rough and keys formed for theapplication of second coat. The second coat shall be applied a day or two after thefirstcoathasset,but the firstcoatshallnotbeallowedtodry. Thesecondcoatshallconsist of mortar ground very fine and shall be laid on with a wooden rule to aspecified thickness, rubbed smooth and leveled and the surfaceplastered completelythe same day. The leveling shall be continued till the plaster is quite dry and allmoisturewhichexudesfromtheplastershallbewipedoffwithfinecloth.Thesurfaceshallbekeptdryuntilexudationofmoistureceases,duringtheprocessofrubbing.

7.4 Plastering(RoughCastFinish)7.4.1 Proportion: The first coat shall consist of 1 part of cement and 4 parts of sand. The

proportionofsecondcoat(roughcastfinish)shallbe3partsofcement,6partsoffinesandand4partsofshingleorcrushedstonenotexceeding10mmsize.

7.4.2 Workmanship:Theworkmanshipshallconformtotwo coatsplasterasindicated

in IS:1661andsurfacepreparationshallbeas specifiedunderClause7.3.2. The firstcoatshallbedashedontothepreparedsurfacewithatroweltofillupallunevennessinthesurface. Thesurfaceshallnotbesmoothenedbut leftrough. Awetplasticmixofsecondcoatasspecifiedaboveshallbethrownonthefirstcoatbymeansofascooporplasterer'strowelwhilethefirstcoat isstillsoft. Thethicknessofthesecondcoatshallnotexceed12mm.

7.5 Plastering(Pebble‐dashFinish)7.5.1 Proportion:Thefirstcoatofplastershallconsistof1partof cementand4parts

ofsand.

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The secondcoat (i.e.pebble‐dash finish) shall consistof1partof cement, 4partsofsand upon which shingle is thrown. The second coat shall not exceed 10 mm inthickness.

7.5.2 Workmanship: The workmanship shall conform to two coat plaster as indicated in

IS:1661andthesurfacepreparationshallbeasspecifiedunderClause7.3.2. The first coat of plaster shall be dashed on to the prepared surface to the specified

thicknesswith a trowel to fill up all unevenness in the surface, but the surface shallnotbesmoothened. The firstcoatshallbeallowedtodryandshrinkproperlybeforethesecondcoatisapplied.Awetplasticmixofsecondcoatasspecifiedaboveshallbeapplied upon which selected shingle which has been well washed shall be thrownwhileitisstillsoft.

7.5.3 Curing

Afterthecompletionofplasterwork,itshallbecuredbyadequatewateringforaperiodofseven(7)days.TheplastershallbeprotectedduringthatperiodfromextremesoftemperatureandweatheratnoadditionalcosttotheEmployer.

SECTION‐8‐WATERPROOFINGANDDAMP‐PROOFING

8.1 WATERPROOFINGOFUNDERGROUNDSTRUCTURES BYPRESSUREGROUTINGWITHNON‐SHRINKING POLYMERICWATERPROOFINGGROUTINGCOMPOUND

The Contractor shall furnish materials, labour, plant, equipment and tools tocompletetheworkasspecifiedherein.

8.1.1 CodesandStandards IS:2645.. Integralcementwaterproofingcompounds IS:9103.. Admixturesforconcrete8.1.2 Materials8.1.2.1 Cement:AsmentionedinSection‐4.

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8.1.2.2 Aggregates: All aggregates shall conform to IS:383. Fine aggregates shall beapproved river or pit sand. Coarse aggregates shall be approved crushed stone.Aggregatesshallbecleanandfreefromanyforeignmaterial.

8.1.2.3 Cement waterproofing compound: All cement waterproofing compound shall

conformtoIS:2645andshallbeofapprovedbrandandquality.8.1.2.4 AcrylicPolymerModified CementitiousCoating: Acrylic PolymerModified

Cementitious Coating to form a thick resilient and flexible membrane onconcrete/plastered surfaces with high resistance to oil and water shall be ofapprovedbrandandquality.

8.1.2.5 Nozzle:Nozzlesshallbe15mmdiathreadedG.S.pipesofsuitablelengthplugged

atbothendsandofapprovedquality.8.1.2.6 Superplasticiser:Highrangewaterreducingadmixtureand integral cement

waterproofer forconcreteshallbeofapprovedbrandandquality. SuperplasticisershallconformtoASTMC‐494TypeForIS:9103andIS:2645.

8.1.2.7 Non‐shrink polymeric waterproofing grouting compound: The non‐shrink

polymericwaterproofinggroutingcompoundshallbeofapprovedbrandandquality.8.1.3 Workmanship Waterproofing of underground structures shall be carried out as per approved

manufacturer’sspecificationsandasstatedbelow:8.1.3.1 Raft:Thesub‐base(PCC)oftheundergroundstructureshall be cleaned of all

dirtsandkeptdrybycontinuouspumpingofwater. The surface shall then be painted with two (2) coats of approved acrylic polymer

modified cementitious compound to form a thick resilient and flexible membraneoverthesubbase.

Threadednozzlesof15mmdiaandof suitable lengthshallbeplacedand fixed ina

gridpatternofmaximum1.5mcentertocenteroverthewholeraft,priortocastingofRCCraft.Similarnozzleswillalsobeplacedalongtheconstructionjoints,ifany,atregular intervals not exceeding 1.5 m c/c. Adequate precautions shall be taken tokeep the nozzles plugged at both ends to prevent them from getting clogged byconcrete. Similar nozzles shall also be post fixed at critical points, if required.Approvedsuperplasticiser‐cum‐cementwaterproofershallbeaddedtotheconcrete

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for the raft as permanufacturer's specification. The concrete shall be at leastM25grade as defined by IS:456 and the water cement ratio of the concrete shall notexceed0.50. Adequateprecaution shall be taken to keep thenozzles verticalwhileconcreting.

Approved non‐shrink polymericwaterproof grouting compoundmixedwith cement

slurry shall be injected through the nozzle (after removal of plugs) under pressurebypumpasper the instructionsof themanufacturer. When the injectionoperationis over the nozzles shall be sealedwith a sealing compound as permanufacturer'sspecificationandinstruction.

8.1.3.2 VerticalWall 15mm dia threaded nozzles of suitable lengths (about half of the thickness of the

wall) shallbeplacedand fixed inagridpatternofmaximum1.5mcenter tocenterovertheentiresurfacepriortoconcretingoftheverticalwall.Similarnozzlesaretobe also fixed at construction joints, if any, at regular intervals not exceeding 1.5mc/c. Adequate precaution shall be taken to keep the nozzle plugged at both theendstoavoidcloggingofthenozzlesbyconcrete.

Similarnozzlesshallalsobepostfixedatcriticalpoints,ifrequired. The concrete for the vertical wall shall be at leastM25 grade as defined by IS:456

having a maximum water cement ratio of 0.50. Approved super plasticiser‐cum‐cement waterproofer shall be mixed with the concrete as per the manufacturer'sspecification. Adequate precaution shall be taken to keep the nozzles horizontalduringconcreting.

The exterior surface of the concrete shall be finished smooth andpaintedwith two

(2)coatsofapprovedacrylicpolymermodifiedcementitiouscoatingto formathickresilientandflexiblemembraneoverthesurface.

Approved non‐shrink polymericwaterproof grouting compoundmixedwith cement

slurryshallbe injected throughthenozzles (afterremovalofplugs)underpressurebypumpasperthemanufacturer'sinstruction.Whentheinjectionoperationisoverthe nozzles shall be sealed with a sealing compound as per manufacturer'sspecificationandinstruction.

8.1.3.3 GuaranteeforWaterproofs

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The Contractor shall furnish a guarantee of at least ten (10) years for thewaterproofsoftheundergroundstructures(inabonedrycondition)treatedbyhimbypressuregroutingasspecifiedabove.

8.2.0 WaterproofingwithLiquidWaterproofingMembrane8.2.1 Materials8.2.1.1 Liquidwaterproofingmembrane:Itshallbeofapprovedmakeandquality.8.2.1.2 Thinner: Approvedquality thinner aspermanufacturer’s recommendation shall be

used.8.2.1.3 Water:Watershallbecleanandofpotablequality.8.2.2 Workmanship8.2.2.1 Surfacepreparation: The surface shall be dry and free from dust, grease, oil and

looseparticles.Theroofsurfaceshallberegardedtorequiredlevelsandslopepriortowaterproofingwithscreedconcreteorcementmortar. If laitanceisfounditshallbe removed by acid etching using a mixture of 1 part muriatic acid to 3 parts ofwaterbyvolume.Theacidsolutionshallbescrubbedintothesurface

with a shift broom while it effervescence for approximately two minutes. Thesurface shall then be thoroughly washedwith freshwater and broomed to removeacid solution and slurry residue and allowed to dry completely. When dry thesurfaceshallbefinallybroomedtoremovealldustanddirt.

8.2.2.2 Application: The surface shall be completely dry. A coat of primer as

recommended by themanufacturer shall be evenly sprayed/ poured or brushed onthesurface.Itshallthenbeallowedtoairdryundisturbedforabout24hours.

The liquid waterproofing compound shall be stirred well before use and

thinner/liquidizer shall be added if necessary as per the recommendations of themanufacturer only. The first coat of the liquidwaterproofmembrane shall then beappliedontheprimedsurfacebysprayer/widethinhairbrush. Thecoatshall thenbe allowed to air dry for 24 hours before the final coat is applied. The final coatshall then be applied in amanner same as that of the first coat and allowed for airdryundisturbedfor24hours.

Atperimetercaveorinotherareaswhereverticalwallandhorizontalslabmeetsthe

primerandtheliquidmembranecoatingshallbeturnedupandfinishedinagroove.

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The membrane shall then be finally protected by providing a suitable cover to

preventitgettingphysicallydamaged.8.2.3 Guarantee:TheContractorshallprovideguaranteeagainstleakageoftreatmentfor

aminimumperiodoften(10)yearsfromthedateofhandingoverofthestructure.8.3 ROOFWATERPROOFING

8.3.1 The waterproofing work shall be done in four (2) layers. The details of two (2)layersincludingsurfacepreparationsareasfollows:

8.3.1.1 Surfacepreparation: Surfaceshallbedryandfreefromdust,anylaitance,grease,oilandotherlooseand

deleteriousmaterials.

The roof surface shall begraded to required slopesand levelswith screedconcrete

or cement mortar and rendered smooth prior to waterproofing work. For waterproofingofexistingroofsurfaces,theconcretesurfaces

Any laitance foundshallberemovedbyacidetchingusingamixtureofone(1)part

muriatic acid to three (3) parts of water by volume. The acid solution shall bescrubbed into the surfacewith a hard brushwhile it effervesces for approximatelytwo minutes. The surface shall then be thoroughly washed with clean water andbroomed to remove the acid solution and slurry residue from the surface andallowedtodrycompletely.Whendrythesurfaceshallbefinallybroomedtoremovealldustanddirt.

8.3.1.2 BottomLayer Exactly over the prepared roof surface, a coat of XIPEX shall be applied over new

concretesurfaces.8.3.1.5 TopLayer Thetoplayershallbeof50mmthickplasterwith1:4cementmortar. Thetoplayer

shallbecoveredforatleastseven(7)dayspriorheadingoverthesame.8.4 HYDROANDTHERMALINSULATIONTOROOF

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8.4.1 Thehydroandthermalinsulation(CFCfree)toroofshallbedoneinmultiplelayers.

Thedetailsofalltheselayersincludingsurfacepreparationsaregivenbelow: 8.4.1.0 SurfacePreparation Similartoroofwater‐proofingwithfibreglasscloth.8.4.1.1 FirstLayer/BottomLayer Exactlyover [email protected]/sqmsuitable for

polypropylenewaterproofingmembranetobeapplied.8.4.1.2 SecondLayer Approvedmakewhitegranularpolymermodifiedpolypropylenemembrane"MOPLY

FP‐3 MM" with 160 gsm polyester non oven mat reinforcement over the primesurfaceofM/sTexaIndiaPvtLtdorotherapprovedequivalent,shallbelaidoverthefirstlayer.

8.4.1.3 ThirdLayer Providing and laying PVC/polyester sheet of 150 gsm as separating layer (vapor

barrier).8.4.1.4 FourthLayer Providing and laying 50 mm thick extruded polystyrene slab, having density 30

kg/cum,thermalconductivity0.023Kcal/mhdegreeC"ROOFMATETG"ofM/sTexaIndiaPvtLtdorotherapprovedequivalent.

8.4.1.5 FifthLayer Providing and layingPVC/polyester sheet of 150 gsmas vaporbarrier (all joints to

besealedwithselfadhesivetape).8.4.1.6 SixthLayer

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ProvidingandlayingPCC(1:2:4),average40mmthicklaidtoslope1:20withchickenwiremeshof20mmx26swgasreinforcement.ThePCCtobedoneinpanelsofsize1mx1.5m(max)withjointssealedwithmasticsealant.

8.4.1.7 SeventhLayer On top of PCC panels having control joints, 40mm thick top cover with “ broken

China mosaic” to be laid. The broken China mosaic tiles shall be broken pieces ofceramic tiles 8mm thk, solar reflectance 0.7 ( min ) of approvedmake and colourfixedontopofPCCpanelswith1:3beddingcementsandmortar.

8.5DAMP‐PROOFCOURSE8.5.1 WorkIncluded The Contractor shall furnish materials, labour, plant, equipment and tools to

completetheworkasspecifiedherein.8.5.2 Materials Cement:AsmentionedinSection‐4. Aggregates: All aggregates shall conform to IS:383. Fine aggregates shall be

approved river sandor pit sand. Coarse aggregate shall be approved stone chips ofsize not exceeding 6 mm. Aggregate shall be clean and free from any foreignmaterial.

Water:WatershallbecleanandofpotablequalityofPHvaluerangesfrom8to6. Bitumen:BitumenshallconformtoIS:3384.8.5.3 Proportion: The proportion of cement and aggregates (fine and coarse) and thickness of the

damp‐proofcourseshallbe1:1.5:3&40mmasperrequirement.8.5.4 Workmanship

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Themasonry surface shall be leveled and joints shall be raked to receive the dampproof course.Dampproof courseshallbeprovidedat requiredpositions. It shallbelaid for the fullwidthof thewall.The top surface shall bekept roughor ribbed forproper adhesionwith themortar formasonry coming over it. All other surfaces ofthe damp proof course shall be finished fair and smooth. After the surface haspartiallysethotbitumenshallbeapplied intwocoatsat therateof1.7kgpersqmpercoatanddrysandspreadoverit.

SECTION‐9‐FLOORINGANDFLOORFINISHES

9.0 WorkIncluded

The Contractor shall furnish labour, plant, equipment and tools to complete the

workasspecifiedherein.9.1 CodesandStandards IS:653 .. SpecificationforLinoleumsheetsandtiles IS:809 ..RubberFlooringMaterialsforGeneral Purposes IS:1197.. CodeofPracticeforLayingofRubberFloors IS:1195 .. SpecificationforBitumenMasticforFlooring IS:1196 .. CodeofPracticeforLayingBitumenMastic

Flooring IS:1198 .. CodeofPracticeforLaying,fixingand MaintenanceofLinoleumFloors IS:1237 .. SpecificationforCementConcreteFlooring Tiles IS:1443 .. CodeofPracticeforLayingandFinishing ofCementConcreteFlooringTiles IS:1580 .. Bituminouscompoundsforwater‐proofing andcaulkingpurposes IS:2114 .. CodeofPracticeforLayingin‐situTerrazzo FloorFinish IS:2571 .. CodeofPracticeforLayingin‐situCement concreteflooring IS:3462 .. SpecificationforunbakedflexiblePVCflooring IS:3464 .. MethodofTestforPlasticFlooringandWall

Tiles IS:4443 .. CodeofpracticeforuseofResintype

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Resistantmortars. IS:4457.. CeramicUnglazedVitreousAcidResistingTiles IS:4832 .. SpecificationforChemicalresistantmortar (Part‐II) (Resintype) IS:5318.. CodeofPracticeforLayingofPVCsheetand

TileFlooring IS:5491 .. CodeofPracticeforLayingin‐sitGranolithic

ConcreteFloorforTopping9.2 Cast‐in‐SituConcreteFlooring9.2.1 Materials Cement:CementshallbeasperSection‐4. Sand:Thesandshallbeof riversandor fromapprovedpitsandshall confirmto

IS:383. Aggregates: The aggregates shall conform to IS:383. The coarse aggregate shall

generallybeofthefollowingsizes: Baseconcrete..Gradedfrom40mmandbelow Cementconcretetoppingofthickness25mm.. Gradedfrom10mmandbelow Cementconcretetoppingofthickness40mm.. Gradedfrom10mmandbelow. Cementconcretetoppingintwolayers: i)Underlayer..Gradedfrom10mmandbelow ii)Toplayer..Gradedfrom6mmandbelow Grading of coarse aggregates shall conform to Table‐1 of IS:2571. The fine

aggregatesshallbeeitherofgradingzone1or2ofTable‐2,IS:2571. Water:Watershallbecleanandreasonably free fromdeleteriousmaterialssuch

asoils,acids,alcohols,saltsandvegetablegrowth.

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Aluminium and glass divider: Strips used shall be 2 mm thick and the depthshallbeequaltotheoverallthicknessoftheflooring.

Colouring pigment: Pigments, synthetic or otherwise, used for colouring shall

have permanent non‐fading colour and shall not contain matters detrimental toconcrete.Thepigmentshallbeofapprovedbrandandtintsshallbeuniform. AllpigmentsusedshallconformtotherelevantIndianStandards.

9.2.2 Workmanship9.2.2.1 Plain cement concrete flooring: Generally workmanship shall conform to

IS:2571. If the floor finish is to be laid over consolidated ground or a layer ofhardcore,cementconcreteofapprovedmixshallbepouredasabaselayertotherequired thickness. In the case of structural slabs, the slab itself will form therequiredbase.

Thearearequiring floor finishshallbedivided intosuitablepanels toreducethe

riskof cracking. Nodimensionofapanel shallexceed4m incaseof floor finishlaid monolithically with base concrete and 2 m in case of floor finish laidseparatelyonahardenedbase.Lengthofthepanelshallnotexceedoneandhalftimesitsbreadth.

Paneling shall be done by fixing glass or aluminium strips of depth equal to the

combinedthicknessofbaseconcreteandtopping. Beforebeingfixedinpositionthesestripsshallbecoatedwithathickcoatof limewash. Flooringshallbelaidinalternatepanels,theintermediatepanelsbeingfilledinafteroneortwodays.

9.2.2.2 Floorfinishlaidmonolithicallywithbaseconcrete:The sub‐base shall be

properlywettedanddividedintopanels.Forstructuralslabs, theformworkshallbeerectedtothefinishedthicknessoffloorfinishandstructuralconcreteshallbedeposited in the forms and finished below the top edge of the form toaccommodate the required thickness of the topping. The base concrete shall bepouredand tampedand screeded to levels suitable to accommodate toppingandtogivethedesiredslope.Thesurfaceshallbeleftroughtoprovidebondwiththetopping.

On the green surface of the base concrete, topping shall be placed in position as

soon as the base has stiffened enough to allow workmen to tread over it byplacingplanksonthesurface.Themixforthetoppingshallbeasstiffaspossibleconsistent with workability so as to prevent accumulation of excess water orlaitance. Should any water rise to surface during compaction and screeding, it

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shall be mopped up. The topping shall be then floated with a wooden float torenderthesurfaceeven.

9.2.2.3 FloorFinishlaidseparatelyonhardenedconcrete base: The sub‐

grade shall be properly wetted and the base concrete laid, if possible over thewholeareaatastretch. Thesurfaceshallbeleftroughtoprovideadequatebondforthetoppingbywirebrushingtwotothreehoursafteritslaying.

Before the topping is laid, the surface of the base shall be thoroughly cleanedof

loose materials, dirt and laitance by wire brushing. Where this is not possible,chippingorhacking shallbedone.Thesurfaceshallbe soakedwithwater for12hoursbefore laying the topping.Thesurpluswater shallbemoppedup,1:1sandcement slurry spread and the concrete for the topping deposited in suitablydividedpanels.Themixforthetoppingshallbeasstiffaspossibleconsistentwithworkability so as to prevent accumulation of excess water or laitance. Afterthorough consolidation the topping shall be struck off level and surface floatedwith a wooden float. It shall be tested with a straight edge and mason's spiritlevel to detect any inequalities and any undulations found shall be made goodimmediately.

9.2.2.4 Layingtoppingintwolayers:Whereithasbeen specified that the

toppingistobelaidintwolayerstoobtainverysmoothanddensefinish,thebaseconcreteandunderlayerof toppingshallbe laidasabovewiththeexceptionthatthe surface of the concrete in the underlayer of topping shall not be finishedsmoothbutleftroughaftertampingandleveling.

Beforeplacing the top layer,anywateror laitancewhichmayhaveworkedupto

thesurfaceoftheunderlayershallberemoved. Thetop15mmthicktoplayerof1:1.5:3cementconcreteofconsistencystiffer thanthatofunderlayerofconcreteshallthenbeimmediatelylaidovertheroughbutgreensurfaceofunderlayerandthoroughly tamped, struck off level and the surface floatedwith awooden float.The surface shall then be testedwith a straight edge andmason's spirit level todetectanyundulationsand ifany, theseshallbemadegoodandthenthesurfacefinishedsmoothasspecifiedbelow.

9.2.2.5 Finishingthesurfacebytrowelingoffloating:Afterthe concrete has

slightly hardened it shall be finished by troweling or floating. Finishingoperationsshallstartshortlyafterthecompactionofconcreteandshallbespreadover a period of one to six hours depending upon the temperature andatmosphericconditions.Thesurfaceshallbetrowelledthreetimesatintervalssoastoproduceauniformandhardsurface.Immediatelyafterlaying,justsufficient

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troweling, the duration being guided by temperature and rate of set of cement,thesurface shallberetroweledtocloseanyporesinthesurfaceandtodrawoutand mop up any excess water in the concrete and laitance. The final trowelingshallbedonewellbeforetheconcretehasbecometoohardbutatsuchatimethatconsiderable pressure is required to make any impression on the surface.Trowellingwithdrycementmixonthesurfaceshallnotbepermitted.

9.2.2.5.1 Curing: Assoonasthesurfacehashardenedbeyonddamage,itshallbekept

continuously moist for at least 15 days by impounding water on the finishedsurfaces.

9.2.2.6 Finishingthesurfacebygrindingandpolishing:Wheregrindingandpolishing

is indicated, the topping shallbe laid in two layersas specified inClause1.2.2.4.Aftertheconcretehasslightlyhardened, itshallbefinishedwithsteeltrowelbutthetrowellingshallbelighttoavoidexcessivelaitancecominguponthesurface.

9.2.2.6.1 Curing: Immediately after final trowelling, the surface shall be laid for drying,

and as soon as it has hardened sufficiently,water shall be sprinkled over it andkeptwetcontinuouslyforatleastfifteen(15)days.

9.2.2.6.2 Grinding: When the floor has sufficiently hardened and cured for 3‐4 days

after laying, initial grinding with a coarse grade of carborundum stone shall becarriedoutandallpitsorairholesobservedshall be filledupwith cementgroutofcreamyconsistency.Thesurfaceshallbesaturatedwithwaterduringgrinding.After a further curing of 3‐4 days, the second grinding shall be carried outwithmedium grade carborundum stone. The final grinding shall be carried out withfinegradecarborundumstoneaftercuringofthefloorfinishincomplete.

9.2.2.6.3 Polishing: The finishedfloorshallbethoroughlycleanedandthenpolishedwith

approvedwaxpolish.9.2.2.7 Coloured cement concrete flooring: Wherecolouredfinishisindicated,the

topshallbefinishedwithcolouredcementasspecified.Ifcolouredcementisnotavailable pigment shall be mixed in the proportion, one part of pigment withthreepartsofcement.

Thecolouringmaterialandcementshallfirstbemixeddry.Specialattentionshall

bepaidtothemixingofcolour,whichshouldbescreenedtwicewithafinescreenand again through fine muslin before use. All the colour required for one roomshall bemixed in one lot. For red colour,mixture shall consist of 1 part of ironoxide to 3 parts of cement. For green colour mixture shall consist of 1 part of

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chromiumoxideto3partsofcement.Afterdrymixing,theminimumquantityofwater required for workability shall be added gradually until a paste of therequiredconsistencyisobtained.Drycolourshallnotbeusedtofinishthesurfaceofcolouredconcrete floor. Colouredpasteshallbeappliedwithwooden floatingboardsandEnglishtrowels.Thequantityofcolourmixtureshallbe0.06cumforevery10sqmofsurface.

Any cracks, ruts, disfiguration or discolouring of surface shall bemade good by

theContractorathisowncost.Thefinishedportionofthefloorshallbekeptwetforatleast15days.

9.3 GranolithicFinishandFloorHardenerFinish9.3.1 Materials9.3.1.1 Cement:CementshallconformtoIS:455orIS:8112orIS:12269.9.3.1.2 Aggregate: It shall be approved granite, basalt, trap or quartzite chippings

andthegradingshallconformtoTable‐1ofIS:5491.9.3.1.3 Sand:ThesandshallbeapprovedriversandandshallconformtoIS:383.The

gradingshallconformtoTable‐2ofIS:5491.9.3.1.4 Water:Watershallbecleanandreasonably free fromdeleteriousmaterialssuch

asoils,acids,alcohols,saltsandvegetablegrowth.9.3.1.5 FloorHardener:Itshallbeapprovedqualitymetallic/non‐metallic hardenerofapprovedmake.9.3.2 Proportionof Mix:The proportion of mix forgranolithic flooring shall be1

partofcement,1.5partofsandand3partsofstonechips. Theproportionofmixforfloorhardenershallbeaccordingtothemanufacturer's

instructions.9.1.3.3 Workmanship9.3.3.1 General:Thefloortoppingshallbelaidinsuitablepanels. While laying the

toppingonstructuralslabmonolithically,nodimensionofpanelshallexceed4mandwhenthetoppingislaidonhardenedbase,nodimensionshallexceed2m.In

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caseofgroundfloorthedimensionsofthetoppingpanelsshallmatchthoseofthebaseconcrete,lengthofpanelshallnotexceedoneandhalftimeitsbreadth.

9.3.3.2 Layinggranolithictoppingmonolithicallywithbaseconcrete:Thetopping

shallbelaidwithintwotothreehoursof layingthebaseconcrete. Atthetimeoflaying the topping thebaseshallbe still greenbut sufficiently firm toenable theworkmen to treadover itbyplacingplankson the surface. The topping shallbelaidon suitablepanels and thoroughly compacted to the finished thickness. Thesurface shall be checked for undulation and made even using wooden floats.Whenthesurfacehasslightlyhardeneditshallbefinishedsmooth.

9.3.3.3 Layingtoppingonhardenedbaseandhardenedstructuralslab:Thebase

concreteshallbethoroughlycleanedofalldirt, looseparticlesetcandroughenedby chipping or hacking at close interval. The surface shall then be soaked inwater for several hours and the excesswater removed bymopping immediatelybefore laying the topping. Cement sand (1:1) slurry shall be spread on theprepared surface of the base concrete and the topping laid in suitable panels asdescribedinclause9.3.3.1.

9.3.3.4 Laying floorhardener finish:The thicknessof the floorhardener toppingshall

be 15mmor as indicated on the drawings and shall be laid over the granolithicfinish when it has partially dried as per instructions of the manufacturer. Thesurfaceshallbeleveledandfinishedsmooth.

The finishedsurfacesafterhardeningbeyonddamageshallbecured foraperiod

ofseven(7)daysbyimpoundingwateronthefinishedsurfaces.9.4 In‐situTerrazzoFlooring9.4.1 Materials9.4.1.1 Cement: The cement shall conform to IS:455 or IS:8119 or IS:12269.White

cementofapprovedqualitymaybeusedforthetopping.9.4.1.2 Sand:Thesandshall beofriversandorfromapprovedpitsandshallconformto

IS:383.9.4.1.3 Aggregates: The aggregatesused in the topping shall be ofmarble chips. The

size shall be as approved in accordance with clause 5.2 of IS:2114. Marblepowder used in the topping shall pass through IS sieve 30. Aggregates for theunderlayerandbaseconcreteshallconformtoIS:383.

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9.4.1.4 Pigments: Pigmentsto be incorporated shall be ofpermanentcolourand

shallconformtoAppendixAofIS:2114.9.4.1.5 Dividing strips: Dividing strips shall be of aluminium, glass or plastic of

thicknessnotlessthan1.5mmandwidthnotlessthan25mm.9.4.1.6 Water:WatershallbeasspecifiedinSection‐4. Mixproportionand thickness: Thebase concrete when terrazzo finish is laid over

groundshallbeleancementconcretemix1:2:4.Thethicknessofbaseconcreteshallnotbe less than100mm. Thecushioning layer,whenterrazzo finish is laidoverstructuralslabshallpreferablybeoflimeconcrete.Thethicknessofcushioninglayersshallnotbelessthan75mm.

Theunderlayershallbecementconcreteofmix1:1.5:3and themaximumsizeof

aggregate shall not exceed 10mm. Themix for the topping shall have cement,marble,powderandmarbleaggregateandwaterintheproportionasspecifiedinclause5.3.2ofIS:2114.

If coloured terrazzo finish is indicated, the proportions in which pigments are

mixedwithordinaryportlandcementorwhitecementtoobtaindifferentcoloursshallbeasspecifiedinTable1ofIS:2114.Thecompletequantitiesofcementandpigment required for one operation shall bemixed at the beginning ofwork andstoredproperlytoavoidvariationincolour.

9.4.3 PreparatoryWork: All inside walls and ceiling shall be plastered, doors

framesandwindowsshall be fixed inplaceandallheavywork in the room/areashall be completed before commencing terrazzo flooring work. Clean and drystorages shall be provided at the site for all the materials conforming to theprovisionsofrelevantIndianStandards.

9.4.4 Workmanship: The base concrete shall be finished to a reasonably true plane

surface and to a level which is lower than the level of the finished floor by thedepthspecifiedforthethicknessoftheterrazzoflooring. Anyslopeindicatedforthefinishedfloorshallbeincorporatedinthisbasecourse.

Topreventchancesofcracking,thefloorshallbedividedintosuitablepanels,not

exceeding2sqminarea.Ifdividingstripsareindicated,theseshallbefixedoverthebaseconcretetothefulldepthoftheterrazzofinish.

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The coloured cement shall be mixed thoroughly in the dry state with marblepower.Thebindersoobtainedandchipsmixedintherequiredproportionsshallthenbemixeddry together. Water shall thenbeadded ina fine spraywhile thematerialsareworkedtoaconsistencywhichisplasticbutdoesnotflow.Themixshallbeusedintheworkwithinhalfanhouroftheadditionofwater.

Thebaseoverwhichflooringistobelaidshallbecleanedofalldirt, laitanceand

loose material and then well wetted without forming any water pools on thesurface. It shall thenbesmearedwithcementslurryand immediately thereaftertheunderlayershallbespreadandleveledwithascreedingboard.

Terrazzotoppingshallbelaidwhiletheunderlayerisstillplastic,about20hours

aftertheunderlayeris laid. Acementslurrypreferablyofthesamecolourasthetoppingshallbebrushedonthesurfaceimmediatelybeforelayingiscommenced.The terrazzo mix shall then be placed on the screed bed and compactedthoroughlybytampingandtrowelledjustsufficienttogivealevelsurface.

Thesurfaceshallthenberammedinordertoconsolidatetheterrazzo,preferably

withapieceofsmoothmarblestoneofsize15cmx15cmx2.5cm. Thismaybefollowedbytrowelling. Introwelling,pressureratherthanrotaryactionshallbeusedtoachieveasmoothsurface.

9.4.5 Curing: The surface shall beleft dry for air‐curingforadurationof12to18

hours depending upon temperature conditions. It shall then be cured byimpoundingwaterforatleastfour(4)days.

9.4.6 Grinding:Four (4)days shall be allowed to elapse aftercompletionof

laying for grinding to commencemanually. Ifmachine grinding is specified thisperiodshallbeseven(7)days.

The first grinding shall be done with carborundum stone of 60 grit size. The

surfaceshall thenbewashedcleanandgroutedwithneatcementgroutofcreamlikeconsistency. Itshallthenbeallowedtodry for 24hours andwetcuredforfour days again. The second grinding shall be done with 80 grit stone. Afteranothersurfacegrouting,athirdgrindingwith120to150gritsizestoneshallbedone. The surface shall then be washed clean, allowed to dry for 12 hours andwetcuredagainforfourdays.Afterafinalgrindingwithcarborundumstone320to400gritsize,thesurfaceshallbewashedcleanafterrubbinghardwithfeltandslightly moistened with oxalic acid powder. When all construction work andfinishingworkarecompletedandjustbeforehandingovertheareathefloorshallbe washed clean with dilute oxalic acid solution and dried. Floor shall then be

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finallypolishedwithmachinefittedwithfeltandwithapprovedfloorpolishuntilthe floor shines cleananddry. Sawdust shall thenbe spreadover the floor andthepolishingmachineagainappliedtoremoveexcessfloorpolish.

9.5 TerrazzoSkirtingandDados For terrazzo finish on vertical surfaces the underlayer shall consist of a layer of

stiffcementsandmortar1:3finishedroughtoprovidekeying. Thecombinedthicknessofunderlayerandterrazzoshallnotbe less than25mm

andtheterrazzotoppingshallnotbelessthan6mm. Otherdetailsshallbethesameasforin‐situterrazzoflooringinclause1.4except

thatgrindingshallbemanual.9.6 TerrazzoFlooringwithTiles9.6.1 Materials Plain or coloured terrazzo cement tiles: The tiles shall conform to IS:1237.

Theyshallbeof thetype,quality,colourandsize indicatedonthedrawingsor inthebillofquantitiesandshallbeapprovedbytheEngineer/Consultant.Thetype,quality, distribution and size of marble chips shall be as approved by theEngineer/Consultant.

Cement: Thecementshallconformto IS:455or IS:8112or IS:12269. Whiteand

coloured cement shall also conform to the requirements specified for ordinaryportlandcementintheabovespecification.

Sand:ThesandshallbeapprovedriverorpitsandandshallconformtoIS:383. Aggregate: Aggregateused in themortar for fixing the tiles and in thebacking

layerof tilesshall conformto IS:383. For the top layerof tiles,unlessotherwisespecified,marblechips,marblepowderoramixtureofthetwo,shallbeused.

Pigment: Pigment, synthetic orotherwise, shall conform to the relevant Indian

Standards.9.6.2 PreparatoryWork: Before commencement of tilingwork, all insidewalls and

ceilingshallbeplastered,doorframesandwindowsshallbefixedinplaceandall

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heavy work in the rooms shall be completed. All the materials at site shall bestoredincleananddrystoragespace.

9.6.3 Workmanshipforlayingconcretetiles9.6.3.1 GenerallyworkmanshipforlayingtilesshallconformtoIS:1443.9.6.3.2 Bedding: Thesurfaceof thesub‐floor shallbe thoroughlycleanedofdirt, loose

particles and laitance (in case of cement slabs) by scrubbingwith awire brush.Thesurfaceshallthenbethoroughlycleanedandwellwettedbutwithoutforminganywaterpoolson the surface. Screedpads shall be setup to indicate requiredlevels on the clean damp surface of the sub‐floor and cement sandmortar shallthenbeevenlyspread.Themortar for thesettingbed for tilesshallbeconsistofcement and coarse sand in the proportion of 1:3. The thickness of the beddingmortarshallnormallybenotlessthan10mmandnotmorethan20mm.

9.6.3.3 Fixing:When the bedding mortar acquires sufficienthardness toprovidea

fairlyrigidcushionforthetiles,neatcementslurryofhoneylikeconsistencyshallbespreadoveranareaata time,aswouldaccommodateabout20tiles.Thetilesshall then be fixed in this grout one at a time and gently tampedwith awoodenmallet to setproperlyon thebeddingat the levelof theadjoining tiles. Inareasadjoiningwalls, the tilesshall extendabout10mminside theplaster, skirtingordado as the casemay be. The joints between tiles shall be straight and shall notexceed1.5mminwidth.

9.6.3.4 After fixingthetiles, the jointsshallberefilledonthe followingdaywithcement

pasteorgroutofthesameshadeasthatofthematrixofthetile.Beforethejointsarefilled,theyshallbecleanedwithwirebrushorwiththepointofatrowelandanyloosecement,dirtordustinthejointsshallberemoved.

9.6.3.5 Polishing:Afterfixingoftilestheflooringshallbeallowedtomatureundisturbed

for seven (7) days. Then the floor shall be polished by machine usingcarborundumstonesofthefollowinggrit:

a) Forleveling(wherethetiles aresuppliedungrounded) .. 24to60 b) Forsecondgrinding(forremoval offillingofplasteronthe surfaceofthetile) .. 120to150

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c) Forfinalgrinding .. 220to350 Floorsurfaceshallbekeptwateredcontinuouslywhilepolishingsoastoprevent

scratching. Afterpolishing the floorshallbe thoroughlywashedcleananddried.Prior to handing over the buildings to the Employer, the floor shall be washed,cleanwithdiluteoxalicacidsolutionand

dried. Floor shall thenbe finallypolishedwithmachine filledwithhessianbobsor felts andapproved floorpolishuntil the floor shines. Cleananddry sawdustshall then be spread over the floor and the polishing machine again applied toremoveallexcessfloorpolish,leavingglossynon‐slipperysurface.

9.6.3.6 SkirtingandDadoWork : Skirtinganddadoshallbe fixedonlyafter laying the

tilesonthefloor. Theportionofthewallwheretilesaretobefixed,shallbeleftunplastered.

Before fixing tiles onbrickor concretewall, the surfaceof thewall shall be first

wettedwithcleanwater.Thereafter,itshallbeevenlyanduniformlycoveredwitha coating of cement sand mortar about 10 mm thick. Before the cushioningmortarhashardened,thebackofeachtiletobefixedshallbecoveredwithathinlayer of neat cement paste and the tile shall then be gently tamped against thecushion with a wooden mallet. Fixing of tiles shall be done from the bottomupwards.Eachtileshallbefixedascloseaspossibletotheoneadjoining,andanydifference in the thickness of the tiles shall be evened out in the cushioningmortar or cement paste so that all the tile faces are set in conformity with oneanother.

Skirting and dado shall be ground and polished as for floor bymachine suitable

forthepurpose.Skirtinganddadomayalsobepolishedbyhandbyrubbingdownwithsuitablepolishingstonesevenlyandwithoutscratchingthesurface.

Upon completion of polishing, it shall be thoroughly washed clean and dried.

Before handing over the building the skirting and dado shall be cleaned withdiluteoxalicacidandpolishedasspecifiedinclause9.6.3.5.

9.7 VitreoustileFlooring9.7.1 Materials9.7.1.1 Vitreous tiles: Thevitreous tiles shallbe flatandglazedon the topsurfaceand

completelyfreefromglazeontheunderside.Sizeofthetilesshallbeasshowninthe drawings or as approved by the Engineer/Consultant. Unless otherwise

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specified the thickness of the tiles shall be minimum 8 mm thick. They shallconform to IS:777 in all other respects. The Contractor shall submit to theEngineer/Consultant forhisapprovalsamplesof tiles tobeused in theworkandalltilesshallbesimilartotheapprovedsample.

9.7.1.2 Cement:ThecementshallconformtoIS:455orIS:8112orIS:12269.9.7.1.3 Sand: Sand shall be river sand, or sand from approved pit and shall conform to

IS:383.9.7.14 Water:WaterusedshallbeasspecifiedinSection‐4.9.7.2 Workmanship TheworkmanshipshallconformtoclauseNo.9.6.3.2and9.6.3.4ofthissection.9.7.3 Skirting and dado work: Beddingandfixingofvitreoustilesinskirtingand

dadoshallconformtoclause1.6.3.6ofthissection. Upon completionof tilingwork in floorand skirting/dado, it shall be thoroughly

cleaned with a scrubbing brush, coarse cloth or broom and allowed to matureundisturbedforseven(7)daysandthencleanedwithsoapandwater.

9.8 Acid/AlkaliResistantCeramicUnglazedTileFlooring9.8.1 Materials9.8.1.1 Ceramic tiles: The tiles shall be glazed/unglazed vitreous ceramic tiles of

approvedmake and shall conform to IS:4454& IS:4457. Size of tiles shall be asshownondrawingsorasapprovedbytheEngineer/Consultant. Thethicknessofthe tile shall be 25 mm for flooring and 6/8/12 mm for dado as per therequirement.

9.8.1.2 JointFiller:EpoxypolyesterresintypemortarconformingtoIS:4832(Part‐II).9.8.1.3 Beddingmortar:Beddingmortarshallbe1:3cement:sandmortar.9.8.2 Workmanship Thebedding&fixingshallbeasperclauseNo.9.6.3.2&9.6.3.3ofthissection.

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The epoxy/polyester resin shall be prepared according to manufacturersspecifications.

When the surface is dry, the joints in tiles shall be cleaned andwell raked. The

joints shallbe sealedwith resin typemortar conforming to IS:4832 (Part‐II) andfinishedflushwiththesurfaceoftiles.

9.8.3 SkirtingandDadoWork:TheworkshallbecarriedoutasperclauseNo.9.6.3.6.9.9 PVCFlooring9.9.1 Materials9.9.1.1 SemiFlexible tiles: The tiles shall generallybe rigid,plainormottled,200

mm, 250mm or 300 mm square, 2.0 or 3.0 mm thick, smooth surfacedhomogeneousPVCfloortiles.Thesizeandthicknessofthetilesshallgenerallybeas specified above. These shall be of a fast, uniform colour as approved by theEngineer/Consultant and shall complywith all relevant requirements associatedwithtestsspecifiedinIS:3464.

9.9.1.2 Fully Flexible Rolls: The sheets or rolls and tiles shall be homogeneous,

flexiblematerialofthickness2mm,conformtotherequirementsofIS:3462whentestedinaccordancewithIS:3464.

9.9.1.3 AntistaticPVCtiles:Thesheetsorrollsandtilesshallbeasspecifiedinclause9.9.1.2

above.InadditiontocomplyingtherequirementsofIS:3462andtestsasperIS:3464thesurfaceresistance(electricalresistance)shouldbelimitedasperrelevantclauseofIndianStandard.

9.9.1.4 Underlay:Theunderlayshallbein‐situtrowelledscreedingtothesub‐floor.9.9.1.5 Adhesives: For fixing rigid and flexible tiles/rolls the adhesives used shall

generally be rubber based of approved make like Fevicol S 505 or approvedequivalent and shall conform to the recommendation of the flooringmanufacturer. Incaseof fixingofantistaticflooring, 100gmsof99.99%puritycopper powder is to bemixed with 1 kg. of rubber based adhesive to make theadhesiveconductive.

9.9.2 Workmanship

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9.9.2.1 WorkmanshipshallgenerallycomplywithIS:5318.9.9.2.2 Preparationofsub‐floors:Concrete sub‐floors shall be laid in two layerswith

an effective damp‐proof course located in between. The top of the lower layershall be finished smooth and when set and sufficiently hard, painted with two

coatsofbitumenconformingtoIS:1580appliedattherateof1.5kg/m2.Thesub‐floorconcreteshallbefinishedusingapowerfloat.

Six (6) weeks time shall be allowed for the water to dry completely from the

concrete floor. Then if power floating has not already been adopted, the finishrequired for laying PVC flooring shall be produced with a trowel on a screedappliedtothesub‐floorconcrete.

Foroldconcretesurfacescleaninganddegreasingshallsufficeiftheexisting

flooriseven. Ifunevennessexists,thesurfaceshallbescrapedfreeofall foreignmaterials,sweptcleanandwettedfor24hoursbysprinklingwater. Thenscreedtoppingof3mmthicknessshallbeprovidedovertheconcrete.

9.9.2.3 Settingout: The surface tobe floored shall becleaned withadryclothand

checked for sufficient dryness in accordance with Appendix A of IS:5318. Theflooring shall not be laid under high humidity conditions (>70%) as this effectstheadhesivestrength.

Thetilesshallbespreadonthefloor,withoutanyadhesive,fromthecenterofthe

roomtowardsthewalls. Whileplacingthetiles,thesidesofeachtileshallbecutand finished as necessary to make a uniform setting. The alignment shall bechecked after setting out each row. Cut pieces of tiles, if necessary, shall be setalong the walls, subject to Engineer/Consultant's approval. To minimise theshadevariationsoftilesofdifferentbatchesshallnotbeused.

9.9.2.4 Fixing: The adhesive shall be applied according to the recommendation of the

manufacturer. It shallbeapplieduniformlyon thebackof tilesaswellason thefloor. After application, sufficient time (abouthalf anhour) shall be allowed fortheadhesivetobecometacky.

The tiles shall then be placed in position on the floor along one edge and rolled

outtoremoveanyentrappedairbubbles. Afterlayingallthetiles,a5kgwoodenroller shall be used to ensure full contact between tiles and theunderlay. Workshallbeconstantlycheckedagainstguidelinestoensurethatallthefouredgesofadjacenttilesmeetaccurately.

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In case of antistatic flooring normally a copper foil approximate size 50 mm X0.15mm thick shall be laid first in a grid pattern of 1.0m X 1.5mwith properearthingconnection,overwhich the tilesshallbe fixedbyusingadhesivesmixedwithcopperpowder. Thecoppergridshallbeproperlyearthed,generallyatonepointper30sqmoffloorsurface.

Any adhesive that may squeeze up between tiles shall be removed with a wet

cloth before it hardens. Adhesives and scuff marks shall be removed first byscrubbingwith ‘00’gradesteelwool.Hardenedadhesiveshallberemovedwithasolvent consisting of one part of commercial butyl‐acetate and three parts ofturpentineoil.

Thefloorshallnotbeputtoservicewithin72hoursof laying. Afterthetilesare

fully bonded, they shall be cleanedwithwet cloth soaked inwarm soap solution(twospoonsofsoapin5litersofwarmwater).

9.10 KotaStone,MarbleandGraniteflooring9.10.1 Materials9.10.1.1 Kotastone:Thekotastoneslabsshallbeofapproved shade in tile or

slabformsofvarioussizes. The stone slabs shall be machine‐cut, polished on top surface and machine cut

edgesandbottomshallberough.Stonetilesshouldbefreefromcracksandotherdefects.Beddingmortarshallbesameasforterrazzotileflooring.

9.10.1.2 Cement:CementusedshallconformtoIS:455orIS:8112orIS:12269.9.10.1.3 Sand: The sand shall be of approved river or pit sand and shall conform to

IS:383.9.10.1.4 Pigment:PigmentsusedforcolouringcementshallconformtoIS:2214.9.10.1.5 Water:WaterusedshallbeasspecifiedinSection‐4.9.10.2 PreparatoryWork: Before commencement of stone flooring work, all inside

walls and ceiling shall be plastered, door frames and windows shall be fixed inplaceandallheavyworkintheroomsshallbecompleted.

9.10.3 WorkmanshipforLayingKotaandMarbleStoneSlabs

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9.10.3.1 Bedding:Thesurfaceofthebaseconcreteshallbethoroughlyscrapedto

remove dirt, loose particles and laitance by scrubbing with a wire brush. Thesurface shall then be thoroughly cleaned and well wetted but without forminganywater pools on the surface and any excess water shall be removed. Screedpads shall be set up to indicate finished floor level on the cleandamp surface ofthe base concrete and setting mortar bed shall then be evenly spread. Theproportion of setting bed shall be one (1) part of cement and three (3) part ofcoarsesand.Thethicknessofthisbeddingshallnormallybenotlessthan10mmandnotmorethan15mm.

9.10.3.2 Fixing:Whenthebeddingmortaracquiressufficient hardness to

provideafairlyrigidcushionforthetiles/slabs,neatcementslurryforhoneylikeconsistencyshallbe spreadoveranareaata time,aswouldaccommodateabout10stoneslabs. Thestoneslabsshallthenbefixedinthisgroutoneatatimeandgently tampedwith awoodenmallet to set properly on the bedding and in levelwith the adjoining stone slabs. The joints between slabs shall be straight andshallnotexceed1.5mmwidth. The top surfaceof the slabs shall be laid true toplane with levels and/or slopes. After the slabs have been laid, the surpluscementgrout thatmayhavecomeoutof the joints, shallbecleanedoff. Inareasadjoiningwalls,theslabsshallextendabout10mminsidetheplaster,skirtingordadoasthecasemaybe.

The day after the stone slabs have been fixed, the joints shall be re‐filled with

cementpasteorgroutmixedwithpigmenttomatchtheshadeoftheslabs.Beforethe joints are filled, they shall be cleanedwithwirebrushorwith thepoint of atrowelandanyloosecement,dirtordustinthejointsshallberemoved.

9.10.3.3 Polishing:Afterfixingthestoneslabs,theflooringshallbe allowed to

mature undisturbed for a period of seven (7) days. Polishing should start onlyafter the floor as well as joints have dried out. The floor shall be polished bymachine using carborundum stones of 200 to 350 grit. Sufficient quantity ofwatershallalwaysbecontinuouslyusedduringpolishingoperation. Durationofpolishingor numberofoperation willdependon joint condition. Normallyoneoperationshouldbeenoughforproperlylaidmachinepolishedstoneslabs.Afterpolishing, the floor shall bewashed clean and dried. Prior to handing over, thesawdustshallberemovedandfloorshallbewashedcleanwithdiluteoxalicacidsolution and dried out. Floor shall then be finally polished withmachine fittedwithhessianbobsorfeltsuntilthefloorshines.

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9.10.3.4 Fixing of kota stones /marble/granite in skirting and dado: Skirting anddado shall be fixed only after laying the tiles of the floor. Where the portion ofthewallistobesotileditshallbeleftunplastered.

Thekota/marble stone slab/tile shall be fixedonmasonry/concretewall surface

in the samemanner as followed for stone flooring. The polishing work shall bedonebyhandpolishingwithcarborundumstoneof200to350girtetc.

9.11 ParquetFlooring/Skirting Parquet floor/skirting tobeprovidedovera leveled floor/wallsurfacewhich is

sufficiently free from dampness and moisture. The floor / wall surface has to bepaintedwithantitermitepaint.

9.12 Ordinary Parquet Floor: 0.6mm thick HDPE sheet to be laid over anti termite

paintedsurfacetoactasamoisturebarrierand4mmhighdensity foamisspreadover it uniformly. 15mm thick rubberwood /agrowood/certifiedwood strips ofapproved size and quality tongue and groove jointed and laid over foamwith thehelp of approved adhesives. All work to be carried out as per approvedmanufacturer’sspecificationandworkmanship.

9.13 SportsTypeParquetFloor:75mmthick&50mmwide hardwood battenstobefixedrigidlyover10mmthickrubber pads at 460mm c/c with floor. 21 mm thickwoodenstriptobe fixed over the battens tongue and groove jointed with approved quality adhesive. All work to be carried out as per manufacturer’s specification.9.14 ParquetSkirting:15mmthickRubberwood/Agrowood/Certifiedwoodstripsof

approvedsizeandqualitytongueandgroovejointedlaidoveranti‐termitepaintedsurface with the help of approved adhesives. All work to be carried out as perapprovedmanufacturers'specifications.

9.15 Glassmosaicfaciatilestoexternalfinishes

Colouredglassmosaictile20mmX20mmX4mmthickin305mmX305mmpapersheetand to be fixed to the plastered wall surface by adhesive as per manufacturer’sspecification.

9.16 Externalqualityceramictiles

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‘Eurocon’ or approved equivalent externalwall cladding ceramic tiles to be fixed as permanufacturer’sspecification.SECTION‐10–METALDOORSANDWINDOWSANDMISCELLANEOUSSTEELWORK

10.0 METALDOORSANDWINDOWS10.1 CodesandStandards IS:1038 .. SteelDoors,WindowsandVentilators IS:1081 .. CodeofPracticeforFixingandGlazingof Metal(SteelandAluminium)Doors, WindowsandVentilators. IS:1361 .. SteelWindowsforIndustrialBuildings IS:1948 .. AluminiumDoors,windowsandVentilators IS:1949 .. AluminiumWindowsforIndustrialBuildings IS:6248 .. MetalRollingShuttersandRollingGrills10.2 Materials10.2.1 Structuralsteel:AllstructuralsteelmaterialsshallconformtoIS:1977orIS:2062.10.2.2 Steeldoors,windowsandventilators: Steeldoors,windows,ventilatorsand their fittings

forresidentialandofficebuildingsshallconformtoIS:1038. SteelwindowsforindustrialbuildingsshallconformtoIS:1361. ExternaldoorsshallbeprovidedwiththresholdasshowninIS:1081andthedoorsrequired

forinternaluseshallbeprovidedwithanapprovedsizebasetie‐barinlieuofthreshold. Unlessotherwisespecified,couplingsectionsshallbeofmildsteelandhandles,pegstaysand

pivotsofcentrehungventilatorsshallbeoflead‐tin‐bronzealloy(gunmetal).Hingesforsidehung shutter shall be projecting non‐friction type. Weather bars shall be provided as perrequirement.Thetype,size,numberandpositionoffixinglugsshallconformtoIS:1038.Thesteel doors shall be painted with one coat of zinc chromate primer conforming to IS:2074beforetheyaresupplied.Finalpaintingshallbedonewithtwocoatsofreadymixedapproved

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synthetic enamelpaintof approvedcolour.Glazing clips shallbeprovidedwherepane sizesexceed600x300mmandshallbeofshapeasshowninIS:1038.

10.2.3 Glazingfordoor,window,structuralglazing10.2.3.1 SingleGlazing :Where single glazing is specified for the work, it shall be of float glass of

specified thickness, with permissible tolerance. Float glass shall be clear or tinted as perrequirement. For some specific purpose thismay even be toughened. Float glass shall havesolar low e, UV resistant, light transmittance (min) 55%, U‐value 0.32 BTU/sqft0F, solarefficiency0.44.

10.2.3.2 InsulatedDoubleGlazing: Insulated double glazing shall comprise of two (2) numbers of

float glasses (clear/tinted/ toughened as per requirement) as specified for single glazingabove, hermitically factory sealed together with a specified argon gas gap in between. Theglazing shall be kept in position using aluminium spacers, primary& secondary sealant forwater, air tightness and structural integrity respectively. The argon gas gap in between theglasspanesshallbekeptdryusingproperdesiccant.

10.2.4 Glazingputty:TheGlazingputtyshallconformtoIS:419.10.3 Workmanship Allsteeldoors,windowsandventilatorsshallbefixedtruetolineandlevel.Fixingandglazing

ofmetaldoors,windowsandventilatorsshallbeinaccordancewithIS:1081.10.4 Rollingshutters

Rollingshuttersshallbefabricatedfrom18gaugesteelsheetandmachinerolledwith75mmrollingcenterswitheffectivebridgedepthof12mmlathesections,interlockedwitheachotherandendslockedwithmalleablecastironclips.

Theguidesshallbeeitherrolledorpresseddeepchannelsectionsfittedwithnecessaryfittings

andfixtures.ThesizeoftheguidechannelshallconformtoIS:6248. The suspension shaft of the roller shall bemade of steel pipe of heavy duty conforming to

IS:1161, andof sufficientdiameter so as to resistdeflectiondue to theweightof the rollingshutter. Thedeflectionshallnotexceed5mmpermeterwidth. TheshaftshallbeprovidedwithC.I.pulleysandhelicalspringforcounterbalancingtheweightoftheshutteradequately.Thespringshallbemadeofhigh tensile springsteelwireconforming tograde2of IS:4454.For largesizerollingshutters, therollershallbeprovidedwithdoublerowself‐aligningballbearings. Forwire opening the roller shall be of fabricated cage type. The roller assembly

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shallbedesignedsoastobecapableofproducingsufficienttorquetoensureeasyoperationoftherollingshutterinanyposition.Thespringtensionshallbeadjustablebymeansofsuitablyadjustmentholesdrilledontherimsofthepulleys.

Thehoodcovershallbemadeof20gaugegalvanizedsteelsheetswithnecessarystiffenersand

framework toprevent sag. Thebottom lockplate shallbemadeofmild steel sheetnot lessthan3.15mmthickand95mmwidereinforcedwithangle/Tironofsuitablesectionwith6mm dia M.S. rivets interlocked with last stride of curtain. The locking arrangement shallconsistofhaspandstapleonthebottomplatelockablefrombothsides.

Unlessotherwisespecified,foroverallareaofrollingshuttersupto8sqm,pullandpushtype

hand operated shutters shall be used, for area between 8 and 12 sqm, pull and push typeshutters shallbeprovidedwithballbearings, forarea larger than12 sqm,mechanical geartypeorelectricallyoperatedshuttersshallbesupplied.

AllrollingshuttersshallbeofreputedmakeasapprovedbytheEngineer/Consultant.Rolling

ShuttersshallbepaintedwithonecoatofzincchromateprimerconformingtoIS:2074beforetheyaresuppliedandtwocoatsofreadymixedsyntheticenamelpaintaftererection.

10.5 SteelGrills Thegrillsforwindows,verandahs,balconiesetcshallbeofmildsteel. Theedges,anglesand

corner shall be cleanedand true to shape. The joints shall bemechanically interlockedandoverlappingandneatlyspotweldedinsuchawaythatthegrillisrigid.Wheremouldedgrillsare specified, the moulded work shall be carried out shall have clear, straight and sharplydefinedprofile.

All necessary cutting, fitting, drilling, tapping, scrubbing etc shall bedone to fix grills to the

openingadjacentsurfaces.Thegrillsshallbefixedplumbinlineandlevel. ThegrillsshallbepaintedwithonecoatofzincchromateprimerconformingtoIS:2074before

theyarefixedandtwocoatsofreadymixedsyntheticenamelpaintaftererection.10.6 TubularRailings SteeltubesforrailingshallconformtoIS:1161.Electrodesusedforweldingshallconformto

IS:814. Fabrication and erection of railing shall be in accordance with IS:806 and IS:800.Railings shallbepaintedwithonecoatof zincchromateprimerconforming to IS:2074afterfabricationandtwocoatsofreadymixedsyntheticenamelpaintaftererection.

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10.7 CollapsibleGates ThegatesshallbemanufacturedoutofM.S.channelpicketsofsize20x10mmandflats20x6

mm. The top runner flat shall be at least 50 x 12 mm in section.

Thebottomguideshallconsistofachannelortwoanglesofspecifiedsizelaidintheflooringtoguidethe freemovementof thegate. Thegateshallmove intheguidechannelonrollersofadequate size fixed at the top and bottom of thegate. ThegateshallbepaintedwithonecoatofzincchromateprimerconformingtoIS:2074beforefixinginpositionandtwocoatsofreadymixedsyntheticenamelpaintaftererection.

10.8 SubsidiaryGates The subsidiary gates, unless otherwise specified, shall bemade of ‘A’ grade pipe of 38mm

nominalboreand3mmweldmeshfabricat50mcentersbothwaysandshallbefullywelded.Thecornersshallbesquare.Thegateshallbeadditionallyreinforcedwithflats.

10.9 SteelWireFencing Chainlinkfencingshallbe75mmsquaremeshsizeof4mmnominaldiagalvanisedsteelwire

conforming to IS:2721. The barbed fencingwire shall consist of 2 ply, 12 gauge galvanisedwireswith4pointthicksetbarbsat75mmcenters.

FencingpostsshallbeeitherofM.S.orreinforcedconcreteorpre‐stressedconcreteortimber

asperrequirement.Thepostshallbefixedinpositioninaconcreteblock.Cornerpostsshallbesuitablystrengthenedbystrutsortiestoresisttheforcesactingonthem.

Wire shall be fully stretched and securely tied to the posts. The fixing shall be done in a

workmanlikemannerwithoutleavinganykinksetc.Thewireshallbeheldtightinapositionbyeyeboltsetc.

All steelwork shall receive one coat of zinc chromatepaint conforming to IS:2074. wooden

postsshallbetreatedwithfungusresistingapprovedpaintbeforefixing.Concretepostsshallbepaintedwithtwocoatsofcementwash.

10.10 WeldedmeshandExpandedMetalPartitions Weldedmeshshallbeofmakeapprovedby theEngineer/Consultant. Expandedmetal shall

conformtoIS:412.TheframingshallbeofM.S.angleortees,withadditionalstiffeningbyM.S.

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flats. The frame shall beof fullywelded construction. The connectionof theweldmeshorexpandedmetaltotheframeshallbewithstandardbolts&nuts.

10.11 Firecheckdoors Firecheckdoorsshallbefabricatedfrom6mmthickM.S.plate,conformingtoGradeSt32.0of

IS:1977, stiffenedall roundatone faceat theedgeswithT‐barsnot less than ISNT80. Thedoorshallbefurtherdividedintopanelsnotexceeding0.8M2eachwithISNT80.Theyshallberivetedtogetherwithrivetsnotlessthan8mmindiameterandspacednotmorethan150mmcentres.

Thedoubleleafdoorsshallbesoconstructedthatarivetedjointnotlessthan12mmwideis

formedatthemeetingstileswhenthedoorisclosed.Thedoororleafshallnotbesub‐dividedintopartshingedtogether.

ConstructionfeaturesoffirecheckdoorsshallconformtoClause6.1ofIS:3614(Part‐1)except

asstatedabove. All leaf‐type fire check doors shall be hinged type, openable from either side and shall be

providedwithhydraulicdoorclosers. Thedoorsshallbeprovidedwithboltsat topandbottomof the leafandacentral latchand

lockarrangement.10.12 Aluminiumdoubleswingdoorwithfloorspring ThedoorframesectionshallbeUVresistantpowdercoated/anodizedaluminiummadefrom

101.6mmx44.45mmx3.18mmthickanodizedaluminiumsectionofapprovedmakeINDALoranyotherapprovedequivalent.

Doorstiles,topandbottomrailsetcshallbemadeasperapproveddrawingwithanodised

aluminiumboxsectionhavingwallthicknessofnotlessthan2.5mm.Glazingshallbefixedtotheshutterframewithsnaponbeadofapprovedqualityandmakeandneoprenegaskets.Thedoorshallbefixedwithdoubleactionfloorspring(IS:6315)securedlyanchoredtofloorandpivottedforswingaction.

Allnecessaryfittingsandfixtureslikeanodisedaluminiumdoorhandle,weatherstrips,bolting

andlockingarrangementswithkeysinduplicateofapprovedqualityandmakeshallbeprovided.

10.13 Aluminiumwindow

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Thetop,bottom,intermediateandsideframeofthewindowshallbe101.6mmx44.45mmx

3.2mmthickanodizedaluminiumsectionof approvedmake (INDALoranyotherapprovedequivalent)respectivelyandsidehung18mmx18mmx0.75mmthickanodizedaluminiumbeadshallbefixedtoglassonbothfaces.ThewindowshallbefixedasperIS:1948.

10.14 AluminiumDoubleGlazedDoors,Windows&Ventilators Theframesectionshallbeanodizedaluminiumextrudedbuilt‐upstandardandothersections

of approved make conforming to IS:733 and IS:1285. Extruded anodised aluminium boxsectionshavingwallthicknessnotlessthan2.5mmtoaccommodatetwonumbers6mmthicktoughened float glasses of approved qualitywith an air gap of 12mm hermetically factorysealed shall beused. Glazing shall be fixed to the shutter framingswith snaponbeadsandapprovedqualityneoprenegaskets.

Theframesshallbesecuredlyfixedtomasonryworkwithrawlplugsandscrewsorwithfixing

clipsorwithexpansionholdfastenersincludingnecessaryfillingupofgapsatjunctionsattop,bottom and sides with required sealant. Aluminium sections shall be smooth, rust free,straight, mitered and jointed wherever required including cleat angles, Chromium Platedbrass/Stainless Steel screws all complete for shutters of doors, windows and ventilatorsincluding provision double/single action floor spring (IS:6315)/hinges, handles, weatherstrips, bolting and locking arrangements, all materials and method of fixing as permanufacturer'sspecifications.

10.15 AluminiumJoinery Anodized Aluminium joinery shall conform to the requirements specified in IS:1948 and

IS:1949andshallbeofINDALorequivalentreputedmake.Theaveragethicknessofnodiccoatshallnotbelessthan20microns(IS:7088)andshallbemattfinished.

Aluminiumdoors,windows, ventilators shall bemade of Aluminium alloy conforming to IS:

733andsections shall generally conform to IS:1948.Couplingmembers formingcompositesectionsshallbeofextrudedtruerightangle.Forsidehungshutters.hingesshallnormallybeofprojectingtypemadeofAluminiumalloyandriveted/machinejointedtoframeandshallhavestainlesssteel/Aluminiumalloypins. Irrespectiveofthehingesbeinganodizedornot.theAluminiumalloypins shall be anodised to aminimum film thickness of 25microns andshallbesealedwithoilorwax.

Handles,pegstaysshallbeofapprovedheavy‐dutyqualityAluminiumoritsalloyconforming

toISspecifications.

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Thedoorframeandshuttersshallbesingleactionordoubleactionasperrequirementwithhydraulicdoorcloserinthefloor.ThedoorsshallbeprovidedwithanodizedAluminiumdoorhandles for full width of door inside and outside. The door frame shall be provide withapprovedanchorsspacednotmorethan900mmcentres.

Before erecting. frames coming into contact with concrete masonry, plaster or dissimilar

metals.shallbecoatedwithathicklayerofcleartransparentlacquerbasedonmethacrylatesorcellulosebutyrate,whichiscompatiblewithzincchromatetoprotectthesurfacefromwelcement during installation. This lacquer coating shall be removed after installation iscompleted.Beforehandlingover, theAluminiumworkshallbewashedwithmildsolutionofnon‐alkalisoapandwater.

Gasketstobeusedshallbemadeofneoprene/EDPMofapprovedmakeandshallbeapproved

by theEngineer/Consultantbefore fixing inposition.The sealant shallbeof approvedmakeand shall be duly approved before application. Aluminium doors, windows and ventilatorsafterfixinginpositionshallbewatertightandairtight.

Aluminium material used shall be specially anodized for protection against corrosion in

marineenvironmentinapprovedshade.TheanodiccoatingshallconformtoIS:1868andshallbeofAC25gradewithminimumthicknessof20micronswhenmeasuredasperIS660/2anddensityshallbeatleast32MG/sqm.Theanodiccoatingshallbedoublesealedoralternativelysealedwithsteamandshallbeofminimumthicknessof50microns.TheanodiccoatingshallbetestedinalaboratorybyEddycurrentmethodasperIS:6012forthickness.Sulphuricacidshallbeusedastheelectrolytefortheanodicprocess.

10.15.1 HydraulicDoorCloser TheseshallconformtoIS:3564andbeofbrandapprovedbytheEngineer/Consultantforboth

leftandrighthandopenings. Allhardwareandfixturesshallbemadeabletowithstandrepeateduse.Doorclosershallbe

suitable fordoorsweighing61‐80kg.Eachclosershallbeguaranteedagainstmanufacturingdefect for one year and any defect foundwithin this period shall be rectified or the closerreplaced free of charge. Concealed door closures shall be either floormounted or transomssounded suitable for installation with metal doors. It shall conform to the performancerequirementsandenduranceteststatedinIS:3564.

10.16 PressedSteelDoorFrame Theframeshallbe105x60x1.67mmthickpressedsteelhavingbestmaterialasperIS:513.

All joints shall be welded and necessary fittings and fixtures shall be as per IS:4351 and

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IS:1341forholdingthedoorframeinposition.TheframeshallbeprovidedwithUVresistantpowdercoatedpaintfinishofapprovedmakeandshadeovergalvanization(asperIS:1477).

10.16.1 PressedSteelDoorShutter Thetopandintermediaterailofthepaneldoorshallbe100mmx35mmx1.25mmthick

CRCAsteelsectionandstiles.Thebottomrailismadeupof200mmx35mmx1.25mmthickCRCAsheetsection.Incaseofflushdoortheshuttershallbemadeof1.25thickCRCAsheetonbothsidesweldedover35mmx18mmx1.25mmthickpressedsteel channels@300c/cbothways.

PressedsteeldoorsshallbemadefrommaterialsasperIS:513andshallbeprovidedwithUV

resistantpowder coatedpaint finishof approvedmakeand shadeover galvanization asperIS:277.

Thehandles,locks,hinges,boltsandlugsshallbeofapprovedmakeasperIS:4351.10.17 PressedSteelWindow Providingandfixingpressedsteelglazedwindowsfabricatedfromrollformedsectionsmade

of galvanised steel colour coated/powder coated (Base steel as per IS:513 `D' quality,galvanisedasperIS:277withzincof120GM/sqmtr)withtotalcoatedthicknessof0.6mm.Allthepressedsteelwindowshallbefabricatedandpaintedatshop.

10.17.1 PaintSpecifications Primercoatwithepoxyprimerof 5‐7micronsthick, finishpaintedwithapolyesterpaintof

12‐16micronsthickandbackcoatedwithalkydlackerof5‐7micronsorpowdercoatedwithpurepolyesterpowderupto50‐60micronsthick.

10.17.2 Dimensions Sectionsforshuttershouldbe46mmx46mmandexternalframeshouldbe46mmx52mm.

Sectionforglassbeadingshouldbeof18mmx25mmandcentremullionshouldbeof46mmx70mm.

10.17.3 Accessories Handlemadeofhighgradealuminiumpowdercoatedandwithnylonreceiver.Gasketsmade

of Ethyl Propylene Diamine Monomer (EPDM). Corner brackets made of CRCA with zincphosphating.Mullioncapsmadeofglassfillednylon.

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10.17.4 FixingDetails Thesectionaretobecuttolength,mitrejoinedwithcornerbracket.Centremullionsaretobe

fixedusingmullioncap. Theaboveframesshouldbefixedtotheconcrete/masonrywallsbymeansofselfexpanding

screws.10.18 uPVCdoor10.18.1 Door frame: Door frame shall bemade up of factorymade extruded PVC section having

overalldimensionof 48mmx40mm,withwallthickness2.0mm. Thecornersofthedoorframe shall bemitredand joinedbymeansofplastic/M.S. galvanisedbrackets and stainlesssteel self tapping screws. The hinge side, vertical of the frames shall be reinforced bygalvanisedM.S.tubeofsize19mmx19mmwithwallthicknessof1mm. Atleastthree(3)Nos.hingesshallbefixedtoonesideofthedoorframewithstainlesssteelselftappingscrew.

10.18.2 Shutter:Shuttershallbe30mmthickfactorymadeextrudedPVCdoorshuttermadeofstyles

andrailsofauPVChollowsectionofsize60mmx30mmwithwallthicknessof2mmhavingdecorativemouldingedgingononeside.ThestylesandrailsshallbemitredandjoinedatthecornersbymeansofMSgalvanised/plasticbrackets of size75mmx 220mmhavingwallthickness1.0mmandself tapping stainless steel screws. The stylesof the shutter shallbereinforcedbyinsertinggalvanisedM.S.tubeofsize25mmx20mmand1mmwallthickness.The lock rail shall bemade up of PVC hollow section of size 100mm x 30mmwith wallthicknessof2mm,fixedtotheshutterbystylesbymeansofplastic/galvanisedMS`U'cleat.The shutter frameshallbe filledwitha uPVCmulti chamberedsinglepanelof sizenot lessthan620mmhavingoverallthicknessof20mmandwallthicknessof1mm.Thepanelsfilledvertically and tie bar at two places by inserting horizontally 6 mm galvanisedMS rod andfastenedwithnutsandwashers.AllthejobshallbecarriedoutasperrelevantIScodeandasdirectedbyEngineer/Consultant.

10.19 FRPdoor: Thedoorsaremadeupof1.5mmthickFRPskinandmouldedusinghighquality

polyester/isothalic gel coat and resin. Sufficient number of layers of fibre glass are to beappliedfordevelopmentofhighstrengthofthedoor. Theinteriorsofthedooris filledwithlightweightclosecelledfoamandcompactedunderpressureforsolidityandstrengthofthedoor. Woodenstiffenersareprovided forhingesand locks tobe fitted. FittingcanalsobescrewedasdirectedbyEngineer/Consultant.Thestandarddoorthicknessshallbe35mm.

10.20 Galvanisedlinkchainforhandrailing

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Galvanisedlinkchainsusedforhandrailingshallbeofmildsteelmadefrom6mmdia.Roundselectricallywelded.Outsidelengthandwidthoflinksshouldnotexceed6timesand3½timesthediameterofthematerialrespectively.

10.21 AluminiumStructuralGlazing

ThealuminiumstructuralglazingshallbedesignedasperIS:875(Part‐3)withtheglassfacadeoutsidethebuildingelevation.

FrameWork

The frame work shall be of aluminium extruded sections made of alloy confirming to I.S.:63400,withUVresistantpowdercoating/anodisationofapprovedmakeandshadeasdirectedbytheEngineer/Consultant.. The frame work shall consist of Mullion, Transome and sub frame, and shallwithstandawindloadof200kg/sqm.

Thealuminiumsectionswillhavethefollowingproperties:a) PHYSICAL E‐Valueofaluminium = 68950N/Sq.mm. Poissonratio = 0.33 Density =26.603KN/Cum.b)MECHANICAL UltimateTensileStrength= 21Kg/Sq.mm. CorrespondingPercentage= 10 Elongation Alloy = T6 Temper = 6063

Glazing

Glazingmaybesingleorinsulateddoubleglazingdependingontheuse.Fordetailsofglazing,referspecifications"Glazingfordoors,window,structuralglazing".Sealent

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ThestructuralgradesupporttotheglasspanelsshouldbeDOWCORNINGorequivalent.

Thesealantshouldhavethefollowingproperties:

Excellentadhesiontoglass,aluminiumglazinggaskets,stone,R.C.C.andtothepaintedandexposedsurfaces.

Dynamicmovementcapacityshallbe±50% Shore(A)hardnesswillbe35. Tensilestrengthshouldbe300psiasperASTM412. Anchoring AllanchoringoftheframetothesuperstructurewillbedoneusingHILTIorequivalentmake

HVUtypeadhesiveanchoringsystem. Theanchoringshouldhavethefollowingproperties: Itshouldconsistof flexible foilcapsuleofvinylurethane,matheuexylateresinandstain free

hardness in pre‐weighted pack condition and HAS‐E (HIL TI version), high tensile fullythreadedanchorrodof5.8gradesteel.

Theanch orshallbehighlyresistanttomoisture,chemicalandatmosphericgasandshouldbe

suitableforhorizontal,verticalandoverheadapplication. Hardwares AllgasketstobeusedshallbeEthylenePropyleneDianeMonomerbasedandresistanttoall

kindsofweathering.Itshallhavetheabilitytorecoverfromcompressionordeformationandshallhavethepropertytoallowjointmovement.

Allbracketsshallbeof6mmthickM.S.Galvanisedbentat90degreewithroundorovalslotsformanueovrity,

Fullorhalfthreadedstainlesssteelscrews(selftappingtype)withcountersunkorPan‐head

shallbeused. Hightensile8.8gradeM.S.Galvanisedbolt(TVSorequivalentmake)shallbeused.

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AirAndWaterTightness ThestructuralglazingsystemshallbedesignedtopreventAirandWaterpenetrationasper

relevantIndianstandards. Load Thestructuralglazingsystemshallbecapableofaccommodatingdeadload,windload,seismic

force, thermalmovementandanyotherforceswithoutreducing itsperformancesorcausingpermanentdamages.

However maximum permissible deflection should not exceed 1/200 and no permanent

deformationshallbepermitted. Static/StructuralPerformance Thesystemshallbestrongenoughtowithstandapositiveandnegativepressurefromany

particulardesignatedsection. StructuralGlazingsystemwithglazedpanelswouldbefactorymadetotheunitsizeasshown

inthedrawingandasdirectedbytheEngineer/Consultant. Poly‐carbonateRoofCover Polycarbonatesheetsforroofcovershallbeofminimum6mmthick,UVresistant,hardcoated,

heatstrengthened,clearortinted,fixedtosuitablealuminiumalloyorsteelframework.TheframeworkshallbeofUVresistantpowdercoated/anodisedorotherapprovedfinishedrigidframecapableofwithstandingextremeclimaticconditions.

Theshapeoftheroofcovermaybepyramidal,dome,vaultoranyotherapprovedshape.The

polycarbonatecoveringsheet shallbesolar lowe, low thermal conductiveandofhigh lighttransmittant.Propersealant,washersandgasketsshallbeprovidedtoassurecompletewatertightness.

StainlessSteelModularBalustrade/Handrail StainlessSteelModularBalustrade/HandrailofTechnorailoranyotherapprovedequivalent

madeof 38mmdia, topmounted tubular handrail over balustrade at 1000‐1500mmc/c ofanticorrosivehighgradeAISI304‐18/8stainlesssteelwith6mmthickcleartoughenedglassbetweenthebalustersfixedbyglassholdersatsuitablepointsand3nos.19mmdia.stainless

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steel tubular intermediate horizontal/angular members fixed between the balustersapproximately200c/c.

ThemountingofbalustersshallbewithGrubBoltandAnchorFastenersandSystemshouldbeassembledwithAllenKeyfixing(noweldingallowedfor assemblingthehandrail).Allmaterialsandfixingshallbedoneasper manufacturer’sspecifications.

SECTION‐11‐PIPEWORK,SANITARYANDPLUMBINGWORK11.1 General Allwater supply,drainageandsanitarywork shallbe executedbya licensedorauthorised

plumbingsupervisororalicensedorauthorisedplumberandshallbeinaccordancewiththerequirementsofrelevantbye‐lawsofMunicipalorotherAuthoritiesinwhosejurisdictiontheworkisbeingcarriedout.

For items such as earthwork, excavation, concrete, brickwork, stonework, pointing etc

relevantspecificationsfortheseshallapply,unlessspecifiedotherwise. Unlessotherwise specified, all exposedwork suchas cisterns, bracketsetc shall bepainted

withonecoatofredoxidepaintandtwocoatsofoilpaintofapprovedcolourandmake. The diameter of pipes and fittings wherever mentioned shall mean the internal diameter,

unlessotherwisespecified. Thejobshallincludethecostofmakingthenecessarychases,holesetcinwalls,floorsandin

otherplacesandalsomakinggoodoncompletionoftheworks.Anydamagecausedtofloors,wallsetcduringthesanitaryandplumbingworksshallbemadegoodbytheContractorathisowncosttothesatisfactionoftheEngineer/Consultant.

11.2 CodesandStandards Roofdrainagesystem IS:1230 ‐ Castironrainwaterpipesandfittings IS:2527 ‐ Codeofpracticeforfixingrainwaterguttersand downpipesforroofdrainage IS:1742 ‐ Codeofpracticeforbuildingdrainage Pipesandfittingsforsanitary,plumbinganddrainage

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IS:404 ‐ Leadpipesforotherthanchemicalpurpose IS:405 ‐ Leadsheetandstrips (2Parts) IS:458 ‐ PrecastConcretepipes(withorwithout Reinforcements) IS:651 ‐ Salt‐glazed‐stonewarepipesandfittings IS:771 ‐ Glazedfireclaysanitaryappliances IS:3597 ‐ Methodsoftestforconcretepipes IS:774 ‐ Flushingcisternsforwaterclosetsand urinals(otherthanplasticcistern) IS:775 ‐ Castironbracketsandsupportsforwashbasins andsinks IS:781 ‐ Castcopperalloyscrewdownbiptapsandstop valvesforwaterservices IS:782 ‐ Caulkinglead IS:783 ‐ Codeofpracticeforlayingofconcretepipes IS:804 ‐ Rectangularpressedsteeltanks IS:1239 ‐ Mildsteeltubes,tubularandotherwroughtsteel (2Parts) fittings IS:1703 ‐ Copperalloyfloatvalves(Horizontalplungertype) forwatersupplyfittings IS:1711 ‐ Selfclosingtapsforwatersupplypurposes IS:1726 ‐ Castironmanholecoversandframes IS:1729 ‐ Sandcastironspigotandsocket,soil,wasteand ventilatingpipes,fittingsandaccessories IS:1795 ‐ Pillartapsforwatersupplypurposes IS:2065 ‐ Codeofpracticeforwatersupplyinbuildings IS:2104 ‐ Watermeterboxes(domestictype) IS:2326 ‐ Automaticflushingcisternsforurinals IS:779 ‐ Watermeters(domestictype) IS:1536 ‐ Centrifugallycast(spun)ironpressurepipes forwater,gasandsewage IS:1537 ‐ Verticallycastironpressurepipesforwater,gas andsewage IS:2470 ‐ Codeofpracticefordesignandconstruction (2Parts) ofseptictanks IS:2548 ‐ Plasticseatsandcoversforwaterclosets (2Parts) IS:2556 ‐ Vitreoussanitaryappliances(vitreousChina) (Parts1to5)

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IS:2963 ‐ Copperalloywastefittingsforwashbasinsand sinks IS:3004 ‐ Plugcocksforwatersupplypurposes IS:3006 ‐ Chemicallyresistantglazedstonewarepipesand andfittings IS:3114 ‐ Codeofpracticeforlayingofcastironpipes IS:3311 ‐ Wastepluganditsaccessoriesforsinksandwash basins IS:4127 ‐ Codeofpracticeforlayingofglazedstonewarepipes IS:4346 ‐ Washersforusewithfittingsforwaterservices IS:778 ‐ Copperalloygate,globeandcheckvalves forwaterworkspurposes IS:4984 ‐ Specificationforhighdensitypolyethylene pipesforportablewatersupply IS:7634 ‐ Codeofpracticeforplasticpipesworkforportable (3Parts) watersupplies IS:8008 ‐ SpecificationforinjectionmouldedHDPE (7Parts) fittingsforportablewatersupplies11.3 Materials11.3.1 Materials,fittingsandappliancesforsanitaryandplumbingwork:Thematerials,

fittingsandappliancesused in thework shallbeas specifiedhereunder. The type,quality,class, size, finish and make shall be specified. The Contractor shall submit to theEngineer/Consultant samples of all materials, fittings and appliances for approval well inadvance of starting thework. Allmaterials, fittings and appliances used in thework shallconformtotheapprovedsamples.

11.3.2 UPVCpipes&fittingsaretobeprovided.11.3.5 Bottletrap:Brasstrapsshallbeofapprovedqualityheavybrasschromiumplatedtrapand

made particularly smooth on the inside and shall have minimum 50 mm water seal andcleaningscrewatbottom.

11.3.7 High density polyethylene pipes and fittings: High densitypolyethylenepipesand

fittingsshallbeoftestedqualityandshallconformtoIS:4984andIS:8008.11.3.8 Castironpipesandaccessories:Castironpipeswithsocketandspigotendsshallconform

toIS:1230andIS:1729.

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11.3.9 Manholecovers:ManholecoversshallconformtoIS:1726.11.3.10 HeavyDutyCastIronGratings: ThegradeofrawmaterialsshallconformtoFG‐150of

IS:210.Thesizewillbeasindicatedintheapproveddrawings.Theguaranteewillbegivenbythesuppliertowithstandaminimumappliedloadof20tons.

11.3.11 Concretepipes:Concretepipesshallbenon‐pressure type and shall conform to IS:458

andthetypeofjointsshallbeasindicatedintheapproveddrawings.Theclassofpipeshallbe NP‐2/NP‐3/NP‐4 as per the design requirement of sewer pipe & shall be tested as perIS:3597.

11.3.12 Salt glazed stoneware appliances and pipes: Saltglazedstonewareappliancesand

pipesshallconformtoIS:651andIS:3006. 11.3.13 Sanitary appliances and non‐ferrous fittings: All sanitary appliances andnon‐

ferrousfittingsshallbeoftestedqualityandshallconformtotherelevantIndianStandards.11.3.14 uPVCPipesandFittings: Pipes: All uPVC soil, waste, ventilating and overflow pipes, accessories and fittings shall

comply with the requirements of IS: 4985. All uPVC rainwater pipes and fittings shall becircularandgreyincolourandshallcomplywiththerequirementsofIS:7834.

JointingMaterials:Joiningmaterialsforpiperunsshallbeasrecommendedbythepipe

manufacturer. Holderbats:HolderbatsshallbeofPVCcoatedsteelandshalbesizedtosuitthevarious

diametersofpipes. BracketsandClips: Hangerbracketsandclipsshallbefabricatedfrom50x6mmthickflat

barofsufficientlengthtosuitparticularrequirementsandshallbeholedforfixingtosteelorconcretesurfacesandendsshallbecrankedwherenecessary.Pipeclipsshallbesemi‐circularwithcrankedendsholedforboltingtogetherandtohangerbrackets.Allhangerbracketsandclipsshallreceivea0.5mmthickPVCcoatingafterfabrication.

11.4 Joints11.4.1 Cast ironpipes: The type of jointing for CI pipes shall be either socket and spigotwith

moltenleadorleadwoolorflangedtypewithnuts,boltsandgasket.

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If the joints used are spigot and socket type, the spigot shall be carefully centered in thesocket by one or more laps of clean white hemp spun yarn with about 25 mm overlap.Sufficientyarnonlyshallbeforcedintothesockettoleaveacorrectdepthofleadforcaulking.Thepipeshall thenbeexaminedagain for lineand levelandtheproperdepthofeach jointshallbetestedbeforerunningthemoltenlead.Forpouringofmoltenleadaringofhempropeshallberappedaroundthepipeattheendofthesocketandthejointshallbecoveredwithstiffdampclay.TheropeshallthenberemovedcarefullyleavingaV‐shapedlargeholeatthetopofthejointtopourthemoltenlead.Leadshallbepouredinoneoperationonly.Afterasection of convenient length of pipe has been laid, lead shall be caulked sufficientlywith ahandhammerandthejointshallbemadeneatandclean.

ThetypeofjointingC.I.pipesconformingtoIS:1230shallbesocketandspigotwithcement

andsandmortar(1:1)andgasketyarn. Thespigotshallbecarefullyinsertedandcenteredinthesocketbyoneormorelapsofthin

cleanhempspunyarnandshallbeforcedintothesockettoleaveacorrectdepthof30mmallroundforcementmortar. Thepipeshallthenbeexaminedagainforlineandlevelandtheproperdepthofeachjointshallbetestedbeforeinsertingthecementmortar.Thejointsshallthenbecarefullyfilledwithstiffcementandsandmortar(1:1)andthejointsshallbeleveledtotheedgeofthesocket.Eachjointshallbeadequatelycuredbycoveringwithwetclothandpouringwateratfrequentintervals.

Thepackingringorwasherfortheflangedjointsshallberubberforthefulldiameterofthe

flangewithproperpipeholeandboltholescutoutsuitably. Thepackingshallbesmearedwith graphite paste or a mixture of red lead and white lead and shall beintroducedbetweentheflangesofboththepipesandnutstightenedinoppositepairskeepingthelongitudinalaxesandadjoiningpipelinesinexactlythesamestraightline.Leadwashersshallbeprovidedalongwithboltstopreventanyleakagethroughboltholes.

11.4.2 Stonewarepipes: Thetypeof jointingforstonewarepipesshallbesocketandspigot. The

insideofthesocketshallbefirstpaintedwithathinlayerofcementmortar1:2andagasketof yarn dipped in cement slurry shall be inserted in the socket of the pipewith awoodencaulkingtoolandwoodenmalletinsuchawaythatthegasketshallfullyencirclethespigotwithaslightoverlap. Where thespigotendreceived thegasket, it shallbewrappedroundwithtwoorthreeturnsoftreatedspunyarnatitsendbeforebeinginsertedintothesocket.Therestofthejointshallthenbecompletelyfilledwithcementsandmortar(1:1)havingvery

littlewaterandthejointshallbeleveledtoformasplayedfilletatanangleof45o.Allexcesscementmortar left inside the pipe joint shall be neatly cleaned off and the joint shall beadequately cured by covering with wet gunny bags and pouring water at frequentintervals. Injointingstonewarepipes,careshallbetakenthatthepipesarekeptconcentricand the socket, specially on the underside, shall be completely filled with cement mortar.

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Wheresettlementofearthisenvisaged,thejointsshallbemadewithbitumasticfilleroranyothermaterialsasapprovedbytheEngineer/Consultant.

11.4.3 Concretepipes:Thetypeofjointingforconcretepipes shallbewithlooseconcrete

collarsandthejointsshallbepackedfromeithersidewithspunyarndippedincementslurryas specified for jointing stoneware pipes. For higher diameter of pipe, joints shall be ofsocketing type & jointing shall be as per clause No.11.4.2 mentioned above. Stiff cement

mortar(1:1)shallbefilledfrombothsidesandsplayedatanangleof45oonbothsides.Thejointsshallbeadequatelycuredasspecifiedforjointsinstonewarepipes.

11.5 LayingofPipes11.5.1 Castironpipes:Thelayingofcastironpipelinesshallcommenceonlyafterthebottomof

thetrenchatvariouspointshavebeenleveledandaligned.Thesidesofthetrenchesshallbeasverticalaspossible,andthewidthatthebottomshallbe450mmwiderthanthediameterofthepipe.Wherejointsaremade,thetrenchshallbewidenedsuitablytoprovideroomforcaulking joints. Shoring and timbering shall not be used without prior approval of theEngineer/Consultant. For pipes buried in the ground, the Contractor shall take care tomaintainalwaystheminimumcushionofearthoverthepipes.Allpipes,watermains,cablesetcmetwithinthecourseofexcavationshallbecarefullyprotectedandsupported.Allpipesand fittings shall be soundedwith a light hammer to detect any cracks before laying. Theexcavatedmaterials shall beplacedonone sideof the trenchand thepipes stackedon theotherside. Theinsideofsocketandtheoutsideof spigotshallbethoroughlycleanedofallforeign matter before laying. The pipes shall be laid with their socket ends facing thedirectionoftheflow.ThepipesshallbeloweredinthetrenchesbyamethodasapprovedbytheEngineer/Consultant. Thepipes shall thenbe jointedby caulkingas specified in clause11.4.1. Aftereachsectionofthepipelinehasbeenlaiditshallbetestedforwater‐tightnessbefore backfilling the trench. On successful completion of testing, the trench shall bebackfilledwith theexcavatedearth in layersof200mmandshallbewateredandrammed.Any subsidence occurring in the line of trenches after backfilling shall be repaired by theContractorathisowncost.Wherethepipelinescrossroads,thesidesofthetrenchesshallbesuitablyshored.

11.5.2 Concretepipes:ThelayingofconcretepipesshallconformtoClause9ofIS:783.Pipes

shallbelaidtruetolineandgrade.Layingofpipesshallalwaysproceedupgradeinaslope.11.5.3 Stonewarepipes:Thelayingofstonewarepipelinesshallcommenceonlyafterthebottomof

the trench at various points have been leveled. The center line of the trench shall first bemarkedoutonthegroundandexcavationdonecorrecttodepthandwidthatallpoints.Thepipes shall be carefully laid to the alignment, levels and gradients. The trench shall beexcavatedwideenoughunderthesocketstoallowhandstopassformakingjoints.Thepipes

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betweenmanholesshallbelaidtrulyinstraightlinesandwithoutanyverticalorhorizontaldeviationsonabedof concrete. While layingpipes,portionof concreteundereach socketshallbedugand takenoff so thatbarrelof thepipegets full support on theconcretebed.Pipesshallbehaunchedwithconcreteuptoadepthofhalfthediameterofthepipe.Whenitcrossesunderaroad,thepipesshallbefullyencasedinconcrete.TheContractorshalltakeprecautionstomaintainalwaysaminimumcushionofearthoverthepipes.Allpipesshallbecarefullyexaminedwithalighthammerforsoundnessbeforelaying.Aftereachsectionofthepipelinehasbeenlaid,thejointsshallbeallowedtosetproperlyandshallbeinspectedandtestedasdirectedbytheEngineer/Consultant. Backfillingofthetrenchshallbecarriedoutonlyafterapprovalof theEngineer/Consultant. After testing, the trenchshallbebackfilledwithselectedearth in layersof200mmandshallbewateredandthoroughly rammed. Allpipes,watermains,cablesetcmetwithinthecourseofexcavationshallbecarefullyprotectedandsupported.

Whenthepipelinescrossroads, thetrenchesshallhaveverticalsideswithsuitableshoring.

AnysubsidenceinthelineoftrenchesafterbackfillingshallberepairedbytheContractorathisowncost.

11.5.4 Castironrainwaterpipes:CastironrainwaterpipesshallconformtoIS:1230. Cast iron rainwater pipes fixed to the externalwalls shall conform to IS:1230 and shall be

blockedoutat least25mmfromtheplasteredsurfacebymeansof cast ironbobbins. Therainwaterpipesattherooflevelshallbefittedwithcastironbellmouthroofoutletbendoracastironbendwithamasonrybellmouthofsuitablesizefittedwithacastirongrating.Thebottomofthedownpipeshallbefittedwithashoefixed150mmaboveground/apronlevelofthebuilding.Thesocketsandspigotsofpipesandfittingsshallbejointedusinghempspunyarnandcementmortar(1:2).

CastironrainwaterpipesembeddedinconcreteormasonryshallconformtoIS:1230and

shallbesecurelyfixedtowallwithwoodenplugsandnails.Jointsofthesocketsandspigotsofpipesandfittingsshallbewithhempspunyarnandleadcaulking.

11.5.5 HDPErainwaterpipes:HDPErainwaterpipesshall conformtoIS:4984andIS:8008.

HDPE rainwaterpipes shall be fixed to the externalwalls andblockedout at least25mm

from the plastered surface. The rainwater pipes at the roof level shall be fittedwith bellmouth roofoutletbendorabendwithamasonrybellmouthof suitable size fittedwithagrating. The bottom of the down pipe shall be fitted with a shoe fixed 150 mm aboveground/apron level of the building. The sockets and spigots of pipes and fittings shall bejointedusinghempspunyarnandcementmortar(1:2).

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HDPErainwaterpipesembeddedinconcreteormasonryshallbesecurelyfixedtowallwithwoodenplugsandnails.

11.5.6 PVCPipework All pipes and supports shall be sufficiently strong to carry the various systemswhen fully

charged. Vertical pipes stacks shall be erected perfectly straight and shall be jointed andsealed at each connection and shall include expansion joints as shall be positioned on allverticalstacks.

Verticalstacksshallbesupportedbyholderbatsundereachcollarandwherepipelengthsare

inexcessof2000mm.Thestacksshallbesupportedatcentresnotexceeding2000mm. Horizontalpiperunsshallbeerectedwithout`kinks'pr`sags'toevengradientsof1in120for

100mmdiapipesand1in200for150mmdiapipes.Pipesshallbejoinedandsealedateachconnection and shall include expansion joints as and when recommended by the pipemanufacturer.Cleaningeyesshallbepositionedateachchangeindirectionandpipesshallbesupportedbyclipsandbracketsateachconnectionandatcentresnotinexcessof1250mm.

The thickness of fittings used in uPVC System shall not be less than that of the pipeswith

whichtheyareused.Careshallbeexercisedinthefixingofallpipestoensurethatpipesandfittingsarenotdamagedbyfixingwhichhavebeenboltedtotightlybutwhenerectedthepipeand fixing shall be provide a secure component. The screws used in concrete block work,concretewalls and the soffitsof concrete slabsorbeamcasings shallbenon‐ferrous screwsnotlessthan50mmlongwithappropriatelysizedrawlplugs.

11.6 InspectionPitandTrapPits Constructionofpitsshallcommenceonlyafterthepipeshavebeenlaidinpositiontruetoline

andlevelstothesatisfactionoftheEngineer/Consultant.11.6.1 Inspectionpit:Allinspectionpitsshallbeconstructedwithbrickmasonryincementmortar

(1:4). Half round channels of size suitable for the inlet and outlet pipe diameters shall beformed onthefloorofthepitwithPCCM10.Thefloorofthepitshallbehaunchedtowardsthechannel.Insideofpitshallbefinishedwithcement‐sandplaster(1:4)andfinishedsmoothwithcementpunning.InvertlevelafterfinishingshallbeasdirectedbytheEngineer/Consultant.

11.6.2 Intercepting/mastertrappit:Theconstructionandfinishingofthepitshallbeasdescribed

for inspection pit. The floor of the pit shall be haunched towards the intercepting/mastertrap.

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11.6.3 Gullytrappit:TheConstructionandfinishingofthepitshallbeasdescribedforinspection

pit.Thecastirongratingshallbesetflushwiththefinishedground/apronlevel.11.7 TestingofCastIron,SoilandWastePipelines Oncompletionoflaying,thecastiron,soil,wasteandventilationpipelinesshallbetestedby

theContractorathisowncosttodetectleakagesandanyotherdefectsinthepipelines. Testshallbeconductedusingproperapparatuswithattachmentsforsmokemakingmachine

for applying smoke to the pipe lines under pressure. Only cotton waste or brown papersoaked in creosote shall be used and fired to obtain dense and pungent smoke. Whileconductingsmoketest, topofsoil,wasteandventilationpipesshallbekeptopentillsmokestarts comingoutof theopenings. Theopeningsshall then be securely plugged withexpanding rubber or any other approved plug. The entire pipeline shall be tested insuitable sections asdirectedby theEngineer/Consultant. The entire lengthof thepipelineincludingall jointsunder test shallbecloselyobserved foranysignof smoke leakage. Anyleakage and defects detected shall be rectified by the Contractor at his own cost to thesatisfactionoftheEngineer/Consultant.

11.8 TestingofUndergroundSewerlines ThedrainagesystemshallbetestedinaccordancewiththeprovisionofIS:1742.Alldefects

anddeficienciesdetectedduringthetestshallbepromptlyrectifiedbytheContractorathisowncosttothesatisfactionoftheEngineer/Consultant.

11.9 WaterSupply11.9.1 Jointingandlayingofgalvanisedsteelwatersupplypipes:Threadedgalvanisedsteel

pipesshallbejointedwiththreadedsocketjointsandthreadedfittingsofthesamematerialsasthatofthepipes.Anyburrsremainingonthepipeendsafterthethreadsarecutshallberemoved. Anapprovedjointingcompoundtogetherwithafewstrandsoffineyarnshallbeusedforjointingpipesandfittings. Anypipethreadsexposedafterjointingshallbepaintedorinthecaseofundergroundpipingthicklycoatedwithapprovedbituminouscompoundtopreventcorrosion.

Theservicepipepassingintoorbeneaththebuildingshallbelaidatleast200mmbelowthe

groundfloorlevelandaccommodatedinthepreviouslylaidsleeveinthestructurewhereitentersthebuilding.Thespacebetweenthesleeveandthepipeatitsentryintoandexitfromthebuilding shall be filledwithabituminousmaterial for aminimum lengthof150mmatbothends.

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Pipingshallnotbeburiedinwallsorfloorsasfaraspossible. However,whenunavoidable,

piping shall beburied for the shortestdistancenecessaryandadequateprotection shall beprovidedagainstdamage.

Galvanised steel piping shall be secured by iron or steel clamps and hookswhen fixed on

walls. All pipework shall be completelywatertight and the joints shall be such that there are no

projections of jointingmaterials or the like in the interior of pipes. Before the pipeline iscommissioned,allpipingandfittingsshallbeflushedclean.

11.9.2 Jointing and layingofhighdensitypolyethylenewatersupplypipes: Allhighdensity

polyethylenepipesshallhavescrewedendsandshallbejointedwithscrewedfittingsofthesame materials as that of the pipes. Any burrs remaining on the pipe ends after cuttingthreadsshallberemoved.Ifnecessary,anapprovedjointingcompoundwithafewstrandsoffineyarnmaybeusedfor jointingpipesandfittings. Allexposedhighdensitypolyethylenepipes shall be installedwithPVC saddles screwedon25mm thickwoodenblocks securelyfixed on walls at suitable intervals, not exceeding 1 m. Pipes wherever installed in wellchasingshallbeoffixedasinthecaseofgalvanisedsteelpipes.

11.9.3 Testing:Afterthelayingandfixingofallgalvanisedsteel and high density

polyethylene water supply pipes and fittings are completed, the line shall be slowly andcarefully chargedwithwater to a test pressureof 5 kgper sq cmor the specifiedworkingpressureplus50%asmaybeprescribedbytheEngineer/Consultant.Careshallbetakenthatairinpipelinesiscompletelyexhaustedwhilefillingthepipelineswithwater.Thispressureshallbemaintainedforat leastonehour,unlessotherwisespecified. Thepipesandfittingsshallthenbeinspectedforanyleakageofwater.Defectsinpipesandfittings,ifdetected,shallberemediedbytheContractorathisowncost.

11.9.4 Jointingofleadpipes:Jointsinleadpipesshallbewipedsolderjoints.Jointsshallbewiped

in a continuous circular motion in one direction so as to leave a neatly formed ellipticalshapedjointfreefromtears,burrs,droppingsetc.Allexposedleadpipes,exceeding25mmindiametershallbesecuredtowallsbyironclipsorleadears.Thespacingoftheclipsshallnotexceed900mm.

11.9.5 Storageofwater:Alltanksforstorageofwatershallbecompletelywatertightandproperly

coveredwithdust,lightandmosquitoproofcoverofapprovedtype.Theyshallbefittedwith

aheavyduty(10kg/cm2)ballvalveofapprovedtype,securelyfixedtothetankindependentof the inlet pipe. Amosquito proof overflow pipe shall be fixed to the tankwith the pipeinvert about 25 mm above the top of water line. Approved type of stop valve shall be

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providedforeveryoutletpipe.InsidesurfaceoftheHDPEtanksshallbepaintedwithanti‐corrosivedrinkingwaterpaints.

11.9.6 Cleaning anddisinfection: All storage tanks, watersupplyfittingsandpipesbefore

beingputintocommission,shallbedisinfectedbytheContractorathisowncost.11.10 InstallationofSanitaryAppliances Allsanitaryappliancesshallbefixedinpositionrigidlyonfloorandwallsasdirectedbythe

Engineer/Consultant.11.10.1 Watercloset‐squattingtype:Squattingtypewaterclosetshallbefittedonthetrap

and shall be jointedwith gasket yarn and cementmortar. Rim of the pan shall be leveledproperlyandsetflushwiththefinishedfloor. Thepanshallbeconnectedtocastironhighlevelpullandletgoorcastironlowlevelpushdowntypeflushingcisternofcapacity.TheflushingcisternshallbesupportedonapairofCIcantileverbracketsfirmlyembeddedinthewall incementmortar(1:4)orscrewedtowallwithsuitableplugs.Theflushpipefromthecisternshallbe32mmdiatestedqualitygalvanisedsteelpipe(light)orHDPEpipeandconnectedtothepaninletbymeansofhempandputtyjoint.

11.10.2 Watercloset‐pedestaltype:Pedestaltypewatercloset shallberigidly fixedonthe

finishedfloorbymeansof75mmlongbrassscrewswithsuitableplugs.Theflushingcisternshallbeofporcelainorcastironlowlevelpushdowncistern.Thecisternshallbesupportedonapairofcastironorrolledsteelcantileverbracketsfirmlyfixedonwallwithbrassscrewsandsuitableplugs.Theflushpipefromthecisternshallbe40mmdiachromiumplatedbrassbendandfittedtotheclosetbymeansofrubberadopter. Theclosetshallbeprovidedwithdoubleblackplasticseatcoverandchromiumplatedhinges.

11.10.3 Urinals:Standingtypeurinalsshallbefirmlyfittedonfinishedwallbymeansof50mm

longbrassscrewsandsuitableplugs.Urinalsshallbefittedwithcastironautomaticflushingcistern. Flushingpipesshallbeofgalvanisedsteelpipesofrequiredsizesandconnectedtotheurinalwith15mmdia leadconnector fittedwithbrass capand liningatoneend. Thejointtotheinletofurinalshallbeneatlyfinishedwithputtyjoints.

Thearrangementofwastepipesanddischarge to the floor trap shall beasdirectedby the

Engineer/Consultant.Forsingleurinalthedischargemaybedirecttothefloortrapthrougha40mmdia leadpipe. Forarangeofurinals, thedischargemaybecollectedinacommongalvanised steel orHDPEpipeof50mmdia leading to the floor trap. Eachurinal shall beconnectedtothecommondischargepipeby40mmdialeadorHDPEpipes.Alternatively,thedischargefromeachurinalthrough40mmdialeadpipeshallbeledtohalfroundchannellaidonthefloorleadingtothefloortrap.

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11.10.4 Washhandbasin:Washhandbasinshallbefittedinpositionontruelevelonapairofcast

iron brackets rigidly fixed onwallwith 50mm long brass screws and suitable plugs. Thebasinshallbefittedwith15mmdiaapprovedqualitychromiumplatedpillartapand32mmdiawastefittings. ThetypeofwastepipesandtheirconnectionsshallbeasdirectedbytheEngineer/Consultant.

11.10.5 Sink:Whiteglazedpercolinsinkofstandardmakehallbefittedinpositiononapairofcast

ironcantileverbracketsfirmlyembeddedinthewallincementmortar(1:4). Thesinkshallbefittedwithchromiumplatedbrasswastefittingsofstandardsize.ThetypeofwastepipesandtheirconnectionsshallbeasdirectedbytheEngineer/Consultant.

11.10.6 Othermiscellaneousfittings(e.g.mirror,towelrails, soap case etc): All such

fittingsshallbeoftypeandsizesofapprovedmanufacturerandshallbefittedinpositiontruetoline,levelandplanetothesatisfactionofEngineer/Consultant..

SECTION‐12‐ROADWORK

12.1 ROADWORK12.1.1 General All road works ie. Quality of material, construction of roads and quality of

executionshallconformtospecification forroadandbridgeworksunderMinistryof Road Transport and Highways (MORTH) (4th Revision). Road work shall beexecuted in a most professional way by deploying all mechanical equipment likevibratory rollers, smooth wheeled roller, hydraulic excavators, batch mixer, rockbreaker, mobile crusher (if applicable), self propelled paver finisher or motorgrader, hotmixplant, tippervehicles, plate compactor, bitumenpressure sprayer,compressoraircleaner etc.Noadditionalamount shallbepayableonaccountofusinganymechanicalequipmentnotlistedaboveormaybedirectedfurtherbytheEngineer/Consultant for deployment during the construction work. Providedwhereanyprovisionofthespecificationstatedhereinafteriscontrarytoprovisionof specification for road and bridgeworks underMinistry of Road Transport andHighways(MORTH)(4thRevision),provisionofthelatershallprevailtotheextentofsuchcontradictionunlessotherwisedirectedbytheEngineer/Consultant.

12.1.2 PREPARATIONOFSUB‐GRADE

Bottomofexcavationbefore layingofsub‐baseshallbeprepared,wateredandre‐

rolled for compactionwithminimum six (6) passes of 80‐100 kN power roller to

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thespecifiedlinesandcrossfall(camber),togettherequiredCBRvalueof4%/6%as per requirement. Any ruts or soft yielding places shall be corrected in anapprovedmanner and rolledwithminimum two passes of 80 – 100 kN smoothedwheeled roller with sprinkling of water to achieve the required dry density.Haulageofmaterialsovertheformedsurfaceshallnotbepermitted.

The sub‐grade shall comply with the following requirements to receive the

granularsub‐basecourse:

a)Nosoftspotsshallbepresent. b)Itshallbeproperlydrainedduringconstruction. c) The minimum compaction shall not be less than 97 per cent of maximum

laboratorydrydensity as per IS:2720 (PartVIII). This should be ensuredbytakingsamplefromfinishedtopandtestedinlaboratory.

d) CBR value at sub‐grade level shall not be less than specified value as

mentionedabove.This shouldbeensuredby takingundisturbedsample fromfinishedtopandtestedin laboratoryasperIS:2720(PartXVI).FieldCBRtestshall also be done as per IS:2720 (Part XXXI) at a depth of about 500mm toascertaintheCBRvalue.

12.2 SUB‐BASES(NON‐BITUMINOUS)ANDSHOULDERS12.2.1 Scope Thisworkshallconsistoflayingandcompactingwell‐gradedmaterialonprepared

subgrade in accordance with the requirements of these specifications. Thematerial shallbe laid inoneormore layersas lowersub‐baseanduppersub‐base(termed as sub‐base hereinafter) as necessary according to lines, grades, camberandcross‐sectionsasdirectedbytheEngineer/Consultant.

12.2.2 Granularlowersub‐base(withgranulatedBFslagandgravel) The material recommended for lower subbase layers is gravel (60%)mixed with

GranulatedBlastFurnaceslag(GBFS)(40%)byweight.Therequisitequantitiesofmaterials shall be spread over the prepared sub‐grade and thoroughly mixedpreferablybyusingmechanicalmixers like `rotillor' andcompacted in layerswithcompactedthicknessof150mmeach layerwithoptimummoisturecontentto100percentofthemaximumlaboratorydensityasperIS:2720(Part‐VIII).

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The gravel fromapprovedquarry is to be collected and the gravel‐GBFS are tobemixed as per the Grading‐1 as shown in TABLE‐1 on the next page and thematerialswillbeusedinthelowerlayersofroads.

Themixedmaterialshallbefreefromorganicorotherdeleteriousconstituents.

TABLE‐1‐GRADINGFORGRANULARLOWERSUB‐BASEMATERIALS

ISSieveDesignation

PercentbyweightpassingtheISsieveGradingI GradingII GradingIII

80mm 100 100 10063mm 90‐100 90‐100 90‐1004.75mm 35‐70 40–90 50–10075micron 0‐20 0‐25 0‐30CBRValue(Minimum)

30%

25%

20%

Note: The material passing 425 micron sieve for all the three gradings when tested

according to IS:2720 (PartV) shall have liquid limit andplasticity indexnotmorethan25and6percentrespectively.

12.2.2.1 Physicalrequirements Thefractionofmaterialpassing22.4mmsieveshallgiveaCBRvaluenotlessthan

30%, when tested in accordance with IS:2720 (Part‐XVI) after preparing thesamplesatmaximumdrydensityandoptimummoisturecontentcorresponding toIS:2720 (PartVIII) and soaking the same inwater for a period of 4 days prior oftesting.

12.2.2.2 ConstructionOperations:12.2.2.2.1 Preparationofsubgrade Immediatelyprior to the layingof sub‐base, the sub‐gradealready finishedasper

clause 1.2, shall be prepared by removing all vegetation and other extraneousmatter, lightlysprinkledwithwater ifnecessaryandrolledwithtwopassesof80‐

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100 kN smooth wheeled roller to attain CBR value of 4%/6% as per therequirement.

12.2.2.2.2 Spreadingandcompacting Thesub‐basematerialofgradingspecified inTable‐1shallbemixedmechanically

bymix in placemethod and spread on the prepared sub‐gradewith the help of amotorgraderofadequatecapacity, itsbladehavinghydrauliccontrolssuitable forinitialadjustmentandmaintaintherequiredslopeandgradeduringtheoperationorothermeansasapprovedbytheEngineer/Consultant.

Manualmixing shall be permitted onlywhere thewidth of laying is not adequate

formechanicaloperations,asinsmall‐sizedjobs. Theequipmentusedformix‐in‐placeconstructionshallbearotavatororsimilarapproved

equipment capable ofmixing thematerial to the desired degree. If so desired by

the Engineer/Consultant, trial runs with the equipment shall be carried out toestablishitssuitabilityforthework.

MoisturecontentoftheloosematerialshallbecheckedinaccordancewithIS:2720

(Part‐II) and suitably adjusted by sprinkling additional water from a truckmountedor trailermountedwater tankandsuitable forapplyingwateruniformlyandatcontrolledquantitiestovariablewidthsofsurfaceorothermeansapprovedby theEngineer/Consultant so that at the timeof compaction it is from1percentaboveto2percentbelowtheoptimummoisturecontentcorrespondingtoIS:2720(Part VIII). While adding water, due allowance shall be made for evaporationlosses. Afterwaterhasbeenadded,thematerialshallbeprocessedbymechanicalorotherapprovedmeans if sodirectedby theEngineer/Consultantuntil the layerisuniformlywet.

Immediately thereafter, rolling shall start, if the thickness of the compacted layer

doesnotexceed100mm,a smoothwheeledrollerof80 to100kNweightmaybeused. For a compacted single layer upto 225 mm the compaction shall be donewith the help of a vibratory roller of minimum 80 to 100 kN static weight withplain drumor pad foot‐drumor heavy pneumatic tyred roller ofminimum200 to300 kN weight having a minimum tyre pressure of 0.7 kN/sq m or equivalentcapacity roller capable of achieving the required compaction. Rolling shallcommence at the lower edge and proceed towards the upper edge longitudinallyfor portions having unidirectional crossfall and super elevation and shallcommence at the edges and progress towards the centre for portions havingcrossfallonbothsides.

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Eachpassof therollershalluniformlyoverlapnot less thanone‐thirdof the track

made intheprecedingpass. Duringrolling, thegradeandcrossfall (camber)shallbe checked and any high spots or depressions,which become apparent, correctedby removing or adding freshmaterial. The speed of the roller shall not exceed 5kmperhour.

Rolling shall be continued till the density achieved is at least 97 per cent of the

maximumdrydensity for thematerialdeterminedasper IS:2720 (PartVIII). Thesurfaceof any layerofmaterial on completionof compaction shall bewell closed,free from movement under compaction equipment and from compaction planes,ridges, cracks or loose material. All loose, segregated or other defective areasshallbemadegoodtothefullthicknessoflayerandre‐compacted.

12.2.3 Granularuppersub‐base(GravelorCrushedStone) Thematerialtobeusedfortheworkshallbegravel,crushedstoneorcombination

thereof depending upon the grading required. The material shall be free fromorganic or other deleterious constituents and conform to Grading‐1 as shown inTable‐2/3.

Grading‐1 in Table‐2 are in respect of close‐graded granular sub‐base materials,

one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, thecorresponding Grading‐1 for the coarse‐graded materials for each of threemaximumparticlesizesaregiveninTable‐3.

12.2.3.1 Physicalrequirements Thematerial shall have a10per cent fines valueof 50kNormore (for sample in

soaked condition) when tested in compliance with BS:812 (Part III). The waterabsorptionvalueof the coarse aggregate shall bedeterminedasper IS:2386 (PartIII); if thisvalue isgreater than2percent, thesoundnesstestshallbecarriedoutonthematerialdeliveredtositeasperIS:383.

TABLE‐2‐GRADINGFORCLOSE‐GRADEDGRANULARSUB‐BASEMATERIALS

ISSieve

DesignationPercentbyweightpassingtheISsieveGradingI GradingII GradingIII

75.0mm 100 ‐ ‐53.0mm 80‐100 100 ‐

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26.5mm 55‐90 70‐100 1009.50mm 35‐65 50‐80 65‐954.75mm 25‐55 40‐65 50‐802.36mm 20‐40 30‐50 40‐650.425mm 10‐25 15‐25 20‐350.075mm 3‐10 3‐10 3‐10CBRValue(Minimum)

30%

25%

20%

TABLE‐3‐GRADINGFORCOARSE‐GRADED

GRANULARSUB‐BASEMATERIALS

ISSieveDesignation

PercentbyweightpassingtheISsieveGradingI GradingII GradingIII

75.0mm 100 ‐ ‐53.0mm ‐ 100 ‐26.5mm 55‐75 50‐80 1009.50mm 4.75mm 10‐30 15‐35 25‐452.36mm 0.425mm 0.075mm <10 <10 <10CBRValue(Minimum)

30%

25%

20%

Note: Thematerialpassing425micron(0.425mm)sieveforallthethreegradingswhen

tested according to IS:2720 (Part V) shall have liquid limit and plasticity indexnotmorethan25and6percentrespectively.

12.2.3.2 ConstructionOperations12.2.3.2.1 Preparationoflowersub‐base The upper sub‐base shall be laid over the prepared lower sub‐base in moist

conditionasenumeratedinClause2.2andpreparedasperClauseNo.2.2.2.1.

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2.3.2.2 Spreadingandcompacting The upper sub‐base material of grading as per Table 2/3 shall be spread and

compactedasperClauseNo.2.2.2.2.12.2.4 Strengthofsub‐base Itshallbeensuredpriortoactualexecutionthatthematerialtobeusedinthesub‐

base satisfies the requirements of CBR not less than 30% and other physicalrequirementswhencompactedandfinished.

When directed by the Engineer/Consultant, this shall be verified by performing

CBR tests in the laboratory as required on specimens remoulded at field drydensityandmoisturecontentandanyother tests for the "quality"ofmaterials, asmaybenecessaryasperIS:2720(Part‐XVI).

12.3.0 WETMIXMACADAMBASE12.3.1 Thisworkshallconsistoflayingandcompactingclean,crushed,gradedaggregate

andgranularmaterial,premixedwithwater,toadensemassonapreparedgranularsub‐base.Thematerialshallbelaidinoneormorelayersasnecessarytolines,gradesandcross‐sectionsasdirectedbytheEngineer/Consultant.

ThethicknessofasinglecompactedWetMixMacadamlayershallnotlessthan75mm.Whenvibratingorotherapprovedtypesofcompactingequipmentareused,thecompacteddepthofasinglelayerofthewetmixmacadamcoursemaybeincreasedto200mmuponaapprovaloftheEngineer/Consultant.Thetested CBRvalueofwetmixmacadamshallbe60%(minimum).

12.3.2 Materials12.3.2.1 Aggregates Physical requirements: Coarse aggregates shall be crushed stone. If crushed

gravel/shingle is used, not less than 90 per cent by weight of the gravel/shinglepieces retained on 4.75 mm sieve shall have at least two fractured faces. TheaggregatesshallconformtothephysicalrequirementssetforthinTable4below:

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TABLE4‐PHYSICALREQUIREMENTSOF

COARSEAGGREGATESFORWETMIXMACADAM

FORSUB‐BASE/BASECOURSES

___________________________________________________________________Test Test

Method Requirements___________________________________________________________________ 1. *LosAngeles IS:2386 40percent(Max) Abrasionvalue (Part‐4)or 2. *Aggregate IS:2386 30percent(Max) Impactvalue (Part‐4)or IS:5640** 3. Combined Flakinessand IS:2386 30percent(Max)** Elongation (Part‐1) Indices(Total) __________________________________________________________________

* Aggregatemaysatisfyrequirementsofeitherofthetwotests.

** Todeterminethiscombinedproportion,theflakystonefromarepresentativesampleshouldfirstbeseparatedout.Flakinessindexisweightof``flakystonemetaldividedbyweightofstonesample.Onlytheelongatedparticlesbeseparatedoutfromtheremaining(non‐flaky)stonemetal.Elongationindexisweightofelongatedparticledividedbytotalnon‐flakyparticles.Thevalueofflakinessindexandelongationindexsofoundareaddedup.

Ifthewaterabsorptionvalueofthecourseaggregatesisgreaterthan2percent,thesoundnesstestshallbecarriedoutonthematerialdeliveredtositeasperIS:2386(Part‐5).

12.3.2.2 Grading requirements: The aggregates shall conform to the grading given in

Table5below:TABLE5‐GRADINGREQUIREMENTSOFAGGREGATESFORWET

MIXMACADAM

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___________________________________________________________________________

ISSieveDesignationPercentbyweightpassingtheISsieve

53.00 mm 100 45.00 mm 95‐100 26.50 mm ‐ 22.40 mm 60‐80 11.20 mm 40‐60 4.75 mm 25‐40 2.36 mm 15‐30 600‐00 micron 8‐22 75.00 micron 0‐8 _____________________________________________________________________ Materialsfinerthan425micronshallhavePlasticityIndex(PI)notexceeding6.

The final gradationapprovedwithin these limits shall bewell graded fromcoarseto fine and shall not vary from the low limit on one sieve to the high limit on theadjacentsieveorvice‐versa.

12.3.3 Kerb stones: Theworkshallconsistofconstructingcementconcrete(M25)kerb

stone along the central median (if roadwidth is more than 11m) and shoulder.The kerb stone shall be cast in continuous length with kerb casting machine incentralmedianportionandshoulderportion.At theplaceofbend/curve,pre‐castkerbstonemaybeplacedasperthedirectionofEngineer/Consultant. Thebaseofthe kerb stone of suitable size shall be laid over 150 mm thick M10 cementconcrete or extended width of pavement with proper anchorage. Saw cut grooveshall be provided at an interval of 5 m or as directed by Engineer/Consultant.Verticalandhorizontaltoleranceswithrespecttotruelineshallbe±6mm.

12.3.4 ConstructionOperations12.3.4.1 Formation of shoulders: While constructing Wet Mix Macadam (WMM)

arrangementshallbemade for lateralconfinementofwetmix. Thisshallbedonebylayingmaterialsinadjoiningshouldersalongwiththatofmatchingthicknessofwet mix macadam layer. The pavement layer shall be compacted first. Thecorresponding layer in shoulder portion shall be compacted thereafter withwatering and rolling using 80 kN vibratory roller. During all stages of shoulderconstruction,therequiredcrossfallshallbemaintainedtodrainoffwater.

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12..4.2 Preparationofmix: WetMixMacadam shall beprepared in an approvedmixingplant of suitable capacity having provision for controlled addition of water andforced/positive mixing arrangement like pug mill or pan type mixer of concretebatchingplant.

OptimummoistureformixingshallbedeterminedinaccordancewithIS:2720(Part‐VIII)afterreplacingtheaggregatefractionretainedon22.4mmsievewithmaterialof4.75mmto22.4mmsize.Whileaddingwater,dueallowanceshallbemadeforevaporationlosses.However,atthetimeofcompaction,waterinthewetmixshallnotvaryfromtheoptimumvaluebymorethanagreedlimits.Themixedmaterialshallbeuniformlywetandnosegregationispermitted.

12..4.3 Spreading of mix: Immediately after mixing, the aggregates shall be spread

uniformlyandevenlyupon thepreparedgranular sub‐base in requiredquantities.Innocaseshouldthesebedumpedinheapsdirectlyontheareawherethesearetobelaidnorshalltheirhaulingoverapartlycompletedstretchbepermitted.

ThemixmaybespreadeitherbyaPaverfinisherormotorgrader.Forportionswheremechanicalmeanscannotbeused,manualmeansasapprovedbytheEngineer/Consultantshallbeused.Themotorgradershallbecapableofspreadingthematerialuniformlyalloverthesurface.Itsbladeshallhavehydrauliccontrolsuitableforinitialadjustmentsandmaintainingthesamesoastoachievethespecificslopeandgrade.

Thepaverfinishershallbeself‐propelled,havingthefollowingfeatures:

i) Loadinghoppersandsuitabledistributionmechanism.

ii) Thescreedshallhavetampingandvibratingarrangementforinitialcompactiontothelayerasitisspreadwithoutruttingorotherwisemarringthesurfaceprofile.

iii) The Paver shall be equipped with necessary control mechanism so as toensurethatthefinishedsurfaceisfreefromsurfaceblemishes.

Thesurfaceoftheaggregateshallbecarefullycheckedwithtemplatesandallhighorlowspotsremediedbyremovingoraddingaggregateasmayberequired.The

layermaybetestedbydepthblocksduringconstruction.Nosegregationoflargerandthefineparticlesshallbeallowed.Theaggregatesasspreadshallbeofuniformgradationwithnopocketsoffinematerials.

12.3.4.4 Compaction: After the mix has been laid to the required thickness, grade and

cross fall/camber the same shall be uniformly compacted to the full depth withsuitableroller.Ifthethicknessofsinglecompactedlayerdoesnotexceed100mm,asmoothwheelrollerof80to100kNweightmaybeused.Foracompactedsingle

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layerupto250mm, thecompactionshallbedonewith thehelpofvibratoryrollerofminimumstaticweightof80to100kNorequivalentcapacityroller. Thespeedoftherollershallnotexceed5km/hr.

Inportionshavingunidirectionalcrossfall/superelevation,rollingshallcommencefromtheloweredgeandprogressgraduallytowardstheupperedge.Thereafter,rollershouldprogressparalleltothecenterlineoftheroad,uniformlyover‐lappingeachprecedingtrackbyatleastonethirdwidthuntiltheentiresurfacehasbeenrolled.Alternatetripsoftherollershallbeterminatedinstopsatleast1mawayfromanyprecedingstop.

Inportionsofcamber,rollingshallbeginattheedgewiththerollerrunningforwardandbackwarduntiltheedgeshavebeenfirmlycompacted.Therollershallthenprogressgraduallytowardsthecentreparalleltothecentrelineoftheroaduniformlyoverlappingeachoftheprecedingtrackbyatleastone‐thirdwidthuntiltheentiresurfacehasbeenrolled.

Anydisplacementoccurringasaresultofreversingofthedirectionofarollerorfromanyothercauseshallbecorrectedatonceasspecifiedand/orremovedandmadegood.

Alongforms,kerbs,wallsorotherplacesnotaccessibletotheroller,themixtureshallbethoroughlycompactedwithmechanicaltampersoraplatecompactor.Skinpatchingofanareawithoutscarifyingthesurfacetopermitproperbondingoftheaddedmaterialshallnotbepermitted.

Rollingshallnotbedonewhenthesubgradeissoftoryieldingorwhenitcausesawave‐likemotioninthebasecourseorsubgrade.Ifirregularitiesdevelopduringrollingwhichexceed12mmwhentestedwitha3metrestraightedge,thesurfaceshallbeloosenedandpremixedmaterialaddedorremovedasrequiredbeforerollingagainsoastoachieveauniformsurfaceconformingtothedesiredgradeandcross‐fall.Innocasetheuseofunmixedmaterialbepermittedtomakeupthedepressions.

Rollingshallbecontinuedtillthedensityachievedisatleast98percentofthemaximumdrydensityforthematerialasdeterminedbythemethodoutlinedinIS:2720(Part‐8).Theexactnumberofpassesrequiredforachievingthedesiredresultshouldbeestablishedbeforehandbytestrollingoveratestbedoversimilarsubgrade.

Aftercompletion,thesurfaceoftheanyfinishedlayershallbewell‐closed,freefrommovementundercompactionequipmentoranycompactionplanes,ridges,cracksandloosematerial.Allloose,segregatedorotherwisedefectiveareasshallbemadegoodtothefullthicknessofthelayerandrecompacted.

12.3.4.5 Settinganddrying: After final compactionofwetmixmacadamcourse, the road

shall be allowed to dry for 24 hours. No vehicular traffic of any kind shall be

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allowed on the finishedwetmix macadam surface till it is dried and next courselaid.

12.4 PRIMECOATOVERGRANULARSUB‐BASE/BASECOURSE 12.4.1 Scope of work: The work shall consist of the application of a single coat low

viscosityliquidbituminousprimeroverweightmixmacadamcausepreparatorytothesuperimpositionofbituminoustreatmentormix.

12.4.2 Material:Thelowviscositybituminousprimershallcomplywith therequirementofIS:8887withkinematicviscosityat600Cis30– 60 centistokes whentested.Thequantityofprimerforroad surfaceis6to9kgper10sqm.12.4.3 Construction12.4.3.1 Preparation of road surface: Prior to application of primer the road surface

shallbefreeofdust,looseparticlesandkeptmoist(lightlysprayedwithwaterandthesurfaceallowedtodry)untiltheprimerisapplied.

12.4.3.2 Equipment and application: The primer distributor shall be self propelled or

towed bitumen sprayer equipped for spraying the primer uniformly at specifiedratesand temperatures. Themethodofapplicationof theprimershalldependontype of equipment used, size of nozzles, pressure of the spray bar and speed offorwardmovement.

12.4.3.3 Curing:Theprimedsurfaceshallbeallowedtoaircureforatleastfor24hoursas

directedbyEngineer/Consultant.12.5.0 TACKCOAT12.5.1 Scopeofwork:Sameasthatofprimecoatandoverexisting/newbituminousroad

surface.12.5.2 Material: Material shallbesameas thatofprimecoatand thequantitiesshallbe

asperTable6onthenextpage.

TABLE–6–RATEOFAPPLICATIONOFTACKCOAT

Sl.No.

Typeofsurface

QuantityofliquidbituminousMaterialsin

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Kgpersqmarea1. Normalbituminoussurfaces 0.20to0.252. Dry and hungry bituminous

surface0.25to0.30

3. Granular surfaces treated withprimer

0.25to0.30

4. Non‐bituminoussurfaces:a) Granularbase(nonprimed)b) Cementconcretepavement

0.35to0.400.30to0.35

12.5.3 Construction12.5.3.1 Preparation of road surface: The road surface shall be free from dust, road

particles, any extraneous materials etc and immediately before application ofprimer, theroadsurfaceshallbesweptcleanwiththemechanicalbroomandhighpressureairjetasdirectedbyEngineer/Consultant.

12.5.3.2 Equipmentandapplication:Sameasthatofprimecoat.12.5.3.3 Curing:Sameasthatofprimecoat.12.6.0 BITUMINOUSMACADAM12.6.1 Work Included: The work shall consist of construction, in a single course, of

compactedcrushedaggregatespremixedwithabituminousbinder, laid immediatelyaftermixing,onabasepreparedpreviouslyinaccordancewiththerequirementofthisspecificationandinconformitywiththelines,gradesandcross‐sectionsasdirectedbytheEngineer/Consultant.

12.6.2 Materials Bitumen: The bitumen shall be paving bitumen of suitable penetration grade

(30/40)asperIS:73. Aggregates: The coarse aggregates shall consist of crushed stone,

crushedgravel/shingle or other stones retained on 2.36 mm sieve. They shall beclean, strong, durable, of fairly cubical shape and free from disintegrated pieces,organicorotherdeleteriousmatterandadherentcoating.Ifcrushedshingle/gravelisused,notlessthan90percentbyweightofthegravel/shinglepiecesretainedon4.75mmsieve shall haveat least two fractured faces. The fine aggregates shall pass2.36

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mm sieve and retained on 75 micron sieve. The aggregates shall preferably behydrophobic and of low porosity. If hydrophilic aggregates are to be used, thebitumen shall preferablybe treatedwith anti‐strippingagents of approvedquality insuitabledoseasdirectedbytheEngineer/Consultant.TheaggregatesshallsatisfythephysicalrequirementssetforthinTable7.

TABLE‐7‐PHYSICALREQUIREMENTSFORCOARSE

AGGREGATESFORBITUMINOUSMACADAM

Property Test SpecificationCleanliness Grainsizeanalysis1 Max5%passing

0.075mmsieveParticleshape FlakinessandElongation

Index(Combined)2Max30%

Strength* LosAngelesAbrasionValue3

Max40%

AggregateImpactValue3 Max30%Durability Soundness4

SodiumSulphateMagnesiumSulphate

Max12%Max18%

WaterAbsorption

Waterabsorption5 Max2%

Stripping Coatingandstrippingofbitumenaggregatemixtures6

Minimumretainedcoating95%

WaterSensitivity7

Retainedtensilestrength Min.80%

Notes: 1. IS:2386Part1 4. IS:2386Part5 2. IS:2386Part1 5. IS:2386Part3 (theelongationtesttobedoneonlyonnon‐flakyaggregatesin thesample) 3. IS:2386Part4* 6. IS:6241 7. Thewatersensitivitytestisonlytobecarriedoutiftheminimumretainedcoating

inthestrippingtestislessthan95%. *Aggregatemaysatisfyrequirementsofeitherofthesetwotests.

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12.6.3 Proportioning of materials: Thebitumen content for pre‐mixingshallbe3.1to

3.5 per cent by weight of the total mix except when otherwise directed by theEngineer/Consultant.The compositionofbituminousmacadam shall conform tooneofthetwogradinginTable‐8onthenextpage.

TABLE‐8–COMPOSITIONOFBITUMINOUSMACADAM

MixdesignationNominalaggregatesizeLayerthicknessISSieve(mm)

GradingI40mm

80–100mm

Grading219mm

50–75mm

Cumulative%byweightoftotalaggregatepassing45 10037.5 90‐10026.5 75‐10010019 ‐90‐10013.2 35‐6156‐884.75 13‐2216‐362.36 4‐194‐190.3 2‐102‐100.075 0.80.8

Bitumencontent,%Byweightoftotal

Mixture

3.1‐3.43.3‐3.5

Bitumengrade 35to9035to90 Themaximumcompactedthicknessofalayershallbe100mm. The quantities of aggregates to be used shall be sufficient to yield the specified

thicknessaftercompaction. Variation in proportioning of material: The Contractor shall have

theresponsibility for ensuring proper proportioning of materials and producing auniformmix.Avariationinbindercontent±0.3percentbyweightoftotalmixshall,however,bepermissibleforindividualspecimenstakenforqualitycontroltests.

TackCoat:TackcoatshallbeasperClauseNo.5.0ofthisSection.

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12.6.4 Workmanship12.6.4.1 Weatherandseasonallimitations: Theworkoflayingshallnotbetakenupduring

rainyor foggyweatherorwhenthebasecourse isdamporwet,orduringduststormorwhentheatmospherictemperatureinshadeis10oCorless.

12.6.4.2 Preparationof thebase: The base onwhich bituminous macadam is to be laid

shall be prepared, shaped and conditioned to the specified lines, grades and cross‐sections and a priming coat where needed shall be applied as directed by theEngineer/Consultant.

12.6.4.3 Preparationand transportation ofmix: Bituminous macadammixshallbeprepared in a hot mix plant of adequate capacity and capable of yielding a mix ofproperanduniformqualitywiththoroughlycoatedaggregates.

Hot mix plant shall be of suitable capacity preferably of batch mix type. The total

systemforcrushingofstoneaggregatesandfeedingofaggregatefractionsinrequiredproportionstoachievethedesiredmix,deployedbytheContractormustbecapableofmeetingtheoverallspecificationrequirementsunderstringentqualitycontrol.

Thetemperatureofbinderatthetimeofmixingshallbeintherangeof 150oCto163

oC and that of the aggregate in the range of 155 oC to 163 oC provided that thedifferenceintemperaturebetweenthebinderandaggregateatnotimeexceeds14oC.

Mixing shall be thorough toensure thatahomogeneousmixture isobtained inwhich

allparticlesof theaggregatesarecoateduniformly,andthedischargetemperatureofmixshallbebetween130oCto160oC.

Themixtureshallbetransportedfromthemixingplanttothepointofuse insuitable

tippervehicles. Thevehiclesemployedfortransportshallbecleanandbecoveredintransit if so directed by the Engineer/Consultant. Any tipper causing excessivesegregationofmaterialsbyitsspringsuspensionorothercontributingfactorsorthatwhich shows undue delay shall be removed from thework until such conditions arecorrected.

12.6.4.4 Spreading:Themixtransferredfromthetipperatsitetothepavershallbe

spreadimmediatelybymeansofself‐propelledmechanicalpaverwithsuitablescreedscapableofspreading,tamping,andfinishingthemixtruetothespecifiedlines,gradesandcross‐sections.ThemanufacturingandrollingtemperatureshallbeasperTable‐9.

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TABLE‐9–MANUFACTURINGANDROLLINGTEMPERATURES

BitumenPenetrati

on

BitumenMixing(0C)

Aggregate

Mixing(0C)

MixedMaterial(0C)

Rolling

(0C)

Laying(0C)

35 160‐170 160‐175 170Max. 100Min

130Min.

65 150‐165 150‐170 165Max. 90Min.

125Min.

90 140‐160 140‐165 155Max. 80Min.

115Min.

However, in restricted locations and in narrow widths where the available plant

cannotbeoperated in theopinionof theEngineer/Consultant,hemaypermitmanuallayingofthemix.

Thetemperatureofthemixatthetimeoflayingshallbeintherangeof120oCto160

oC. Inmulti‐layer construction, the longitudinal joint in one layer shall offset that inthelayerbelowbyabout150mm.However,thejointinthetop‐mostlayershallbeatthelanelineofthepavement.

Longitudinal jointsandedgesshallbeconstructedtruetothedelineatinglineparallel

tothecenterlineoftheroad.Alljointsshallbecutverticaltothefullthicknessofthepreviously laid mix and the surface painted with hot bitumen before placing freshmaterial. Longitudinal and transverse joints shall be offset by at least 250mm fromthose in the lowercoursesandthe jointonthetopmost layershallnotbeallowedtofall within the wheel path. All transverse joints shall be cut vertically to the fullthicknessofthepreviouslylaidmixwithasphaltcutter/pavementbreakerandsurfacepaintedwith hot bitumen before placing freshmaterial. Longitudinal joints shall bepreferably hot joints. Cold longitudinal joints shall be properly heated with jointheater to attain a suitable temperature of about 80 oC before laying of adjacentmaterial.

12.6.4.5 Compaction: After the spreading of mix, rolling shall be done by 80 ‐ 100 KN

rollersorotherapprovedequipment. Rollingshall startassoonaspossibleafter thematerialhasbeenspreaddeployingasetofrollersastherollingistobecompletedinlimited time frame. Therollershallmoveataspeednotmore than5km/hr. Rollingshallbedonewithcaretoavoidundulyrougheningofthepavementsurface.

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Rolling of the longitudinal joints shall be done immediately behind the pavingoperation. After this, the rolling shall commence at the edges and progress towardsthecenterlongitudinally.

Theinitialorbreak‐downrollingshallbedonewith80‐100kn.staticweightsmooth

wheel roller (3 wheels or tandem), as soon as it is possible to roll the mix withoutcracking the surface or having themix pick up on the roller wheels. The second orintermediaterollingshall followthebreak‐downrollingwithvibratoryrollerof80to100 kn. static weight or pneumatic tyred roller of 150 to 250 kn. weight, withminimum 7wheels and minimum tyre pressure of 0.7MPa as closely as possible tothepaverandbedonewhilethepavingmixisstillatatemperaturethatwillresultinmaximum density. The final rolling shall be done while material is still workableenoughforremovalofrollermarks,with60‐80kn.tandemroller.Duringthefinalrolling, vibratory system shall be switched off. The joints and edgers shall be rolledwitha80to100kn.staticroller.

When the roller has passed over thewhole area once, any high spots or depressions

which become apparent shall be corrected by removing or addingmixmaterial. Therollingshallthenbecontinuedtill theentiresurfacehasbeenrolledto95percentofthe average laboratory density (obtained from Marshall specimens compacted asdefinedinTable‐10),thereisnocrushingofaggregatesandallrollermarkshavebeeneliminated.Eachpassoftherollershalluniformlyoverlapnotlessthanone‐thirdofthetrackmadeinthe

precedingpass. Therollerwheelshallbekeptdampifnecessarytoavoidbituminousmaterial from sticking to the wheels and being picked up. In no case shall fuel,lubricatingoilbeusedforthispurpose,norexcessivewaterpouredonthewheels.

Rollingoperations shall be completed in every respect before the temperatureof the

mixfallsbelow100oC. Roller(s) shallnot standonnewly laidmaterialwhile there is a risk that surfacewill

bedeformedthereby.Theedgesalongandtransverseofthebituminousmacadamlaidand compacted earlier shall be cut to their full depth so as to expose fresh surfacewhich shall bepaintedwith a thin surface coatof appropriatebinderbefore thenewmixisplacedagainstit.

The bituminous macadam shall be covered with either the next pavement course or

wearingcourse,asthecase,asthecasemaybe,withoutanydelay.

TABLE‐10‐REQUIREMENTOFBITUMINOUSMACADAM

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Sl. No. Description Requirement 1. Marshallstability(ASTMDesignationD‐1559) 820kgdeterminedonMarshall

specimenscompac‐ minimum tedby75compactionblowsoneachend 2. Marshallflow(mm) 2mmto4mm 3. PercentAirvoidsinmix 3%to5% 4. Minimumvoidsinmineralaggregates(VMA) 10%to12% 5. Percentvoidsinmineralaggregates 65%to75% filledbybitumen(VFB) 6. Bindercontentpercentbyweightoftotalmix Minimum4.0%12.7.0 DENSEGRADEDBITUMINOUSMACADAM(DBM) 12.7.1 Scope This clause specifies the construction of Dense Graded Bituminous Macadam (DBM)

foruseasroadsurfacematerial. Thisworkshallconsistofconstructioninasingleormultiple layers of DBMon a base. The thickness of a single layer shall be 50mm to100mm.

12.7.2 Materials12.7.2.1 Bitumen: The bitumen shall be paving bitumen of penetration Grade (60/70)

complyingwithIndianStandardSpecificationsfor“PavingBitumen”IS:73.12.7.2.2 Coarse Aggregates: The coarse aggregate shall consist of crushed rock, crushed

gravel or other hard material retained on the 2.36 mm sieve. They shall be clean,hard, durable or cubical shape, free from dust and soft or friable matter, organic orother deleterious substances. Where the Contractor’s selected source of aggregateshave poor affinity for bitumen, as a condition for the approval of that source thebitumen shall be treated with an approved anti‐stripping agent, as per themanufacturer’s recommendations, without additional payment. Before approval ofthe source, the aggregates shall be tested for stripping. The aggregates shall satisfythephysicalrequirementsspecifiedinTable‐11fordensebituminousmacadam.

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Wherecrushedgravelisproposedforuseasaggregate,notlessthan90%byweightof

the crushedmaterial retainedon the4.75mmsieve shall haveat least two fracturedfaces.

12.7.2.3 Fine aggregates: Fine aggregates shall consist of crushed stone or naturally

occurringmineralmaterialoracombinationofthetwo,passingthe2.36mmsieveandretainedonthe75micronsieve.Theyshallbeclean,hard,durable,dryandfreefromdustandsoftorfriablematter,organicorotherdeleteriousmatter.

The fineaggregateshallhaveasandequivalentvalueofnot less than50whentested

inaccordancewiththerequirementofIS:2720(Part‐XXXVII). The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4

whentestedinaccordancewithIS:2720(PartV).

TABLE11‐PHYSICALREQUIREMENTSOFCOARSEAGGREGATEFORDENSEGRADEDBITUMINOUSMACADAM

Property Test Specification

Cleanliness(dust)

Grainsizeanalysis(1)

Max 5% passing0.075mmsieve.

Particleshape Flakiness and elongationindex(combined)(2)

Max30%

Strength* Los Angles AbrasionValue(3)AggregateImpactValue(4)

Max.35%Max.27%

Durability Soundness(5):SodiumsulphateMagnesiumsulphate

Max.12%Max.18%

Waterabsorption

Waterabsorption(6)

Max.2%

Stripping Coating and stripping ofbitumen aggregatemixtures(7)

Minimum retainedcoating95%

Watersensitivity**

Retained tensilestrength(8)

Min.80%

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Notes:1.IS:2386PartI 2. IS:2386PartI (theelongationtesttobedoneonlyon non‐flakyaggregatesinthesample) 3. IS:2386Part4* 4. IS:2386Part4* 5. IS:2386Part5 6. IS:2386Part3 7. IS:6241 8. IS:AASHTOT283**

* Aggregatemaysatisfyrequirementsofeitherofthesetwotests.

** Thewatersensitivitytestisonlyrequirediftheminimumretainedcoatinginthestrippingtestislessthan95%.

12.7.2.4 Filler: fillershallconsistoffinelydividedmineralmattersuchasrockdust,hydrated

limeorcementapprovedbytheEngineer/Consultant. Thefillershallbegradedwithinthelimitsindicatedin Table–12.

TABLE12‐GRADINGREQUIREMENTSFORMINERALFILLER

Cumulativepercentpassing ISSieve(mm) byweightoftotalaggregate 0.6 .. 100 0.3 .. 95–100 0.075 .. 85‐100 ThefillershallbefreefromorganicimpuritiesandhaveaPlasticityIndexnotgreater

than 4. The Plasticity Index requirement shall not apply if filler is cement or lime.When the coarseaggregate isgravel,2percentbyweightof totalaggregate, shallbePortland cement or hydrated lime and the percentage of fine aggregate reducedaccordingly.Cementorhydratedlimeisnotrequiredwhenthelimestoneaggregateisused.Wheretheaggregatesfailtomeettherequirementsofthewatersensitivitytestin Table –11, then 2 per cent by totalweight of aggregate, of hydrated lime shall beaddedwithoutadditionalcost.

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12.7.3 Aggregategradingandbindercontent: WhentestedinaccordancewithIS:2386PartI(wetsievingmethod),thecombinedgradingofthecoarse and fineaggregatesandaddedfillerfortheparticularmixtureshallfallwithinthelimitsshowninTable–13 fordensebituminousmacadamgrading1or2. The typeandquantityofbitumen,andappropriatethicknessarealsoindicatedforeachmixturetype.

TABLE13‐COMPOSITIONOFDENSEGRADEDBITUMINOUSMACADAMPAVEMENTLAYERS

Grading 1 2Nominal aggregatesize

40mm 25mm

LayerThickness 80–100mm 50–75mmISSieve(mm)Cumulative%byweightoftotalaggregatepassing45 100 ‐37.5 95‐100 10026.5 63‐93 90‐10019 ‐ 71‐9513.2 55‐75 56‐809.5 ‐ ‐4.75 38‐54 38‐542.36 28‐42 28‐421.18 ‐ ‐0.6 ‐ ‐0.3 7‐21 7.210.15 ‐ ‐0.075 2‐8 2‐8Bitumen content% bymassoftotalmix2

Min4.0 Min4.5

Bitumengrade(pen) 65or90 65or90Notes:1. Thecombinedaggregategradingshallnotvaryfromthe lowlimitononesieveto

thehighlimitontheadjacentsieve. 2. DeterminedbytheMarshallmethod.12.7.4 MixtureDesign

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12.7.4.1 Requirement for the mixture: Apart from conformity with the grading andquality requirements for individual ingredients, the mixture shall meet therequirementssetoutinTable–14.

TABLE14‐REQUIREMENTSFORDENSEGRADE

BITUMINOUSMACADAM

Minimumstability(kNat60oC)Minimumflow(mm)Maximumflow(mm)Compaction level (Number ofblows)PercentairvoidsPercentvoidsinmineralaggregate(VMA)Per cent voids filled with bitumen(VFB)

9.024

75blowsoneachofthetwo

facesofthespecimen

3.6

SeeTable15below.

65‐75

TABLE15‐MINIMUMPERCENTVOIDSINMINERALAGGREGATE(VMA)

NominalMaximum

ParticleSize1(mm)

MinimumVMA,PercentRelatedto

DesignAirVoids,Percent2

3.0 4.0 5.09.5 14.0 16.012.5 13.0 14.0 15.019.0 12.0 13.0 14.025.0 11.0 12.0 13.037.5 10.0 11.0 12.0

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Notes:1. Thenominalmaximumparticlesize isonesize largerthatthe firstsievetoretainmorethan10percent.

2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voidsvaluesbetweenthoselisted.

12.7.4.2 Binder content: The binder content shall be optimised to achieve the

requirementsofthemixturesetout inTable–14andthetrafficvolume. TheMarshallmethodfordeterminingtheoptimumbindercontentshallbeadoptedasdescribed intheAsphalt InstituteManualMS‐2, replacing theaggregates retainedon the26.5mmsievebytheaggregatespassingthe26.5mmsieveandretainedonthe22.4mmsieve,where approved by the Engineer/Consultant. Where 40 mm dense bituminousmacadammixture is specified, themodifiedMarshallmethoddescribed inMS‐2 shallbe used. This method requires modified equipment and procedures, particularly theminimum stability values in Table –14 shall bemultiplied by 2.25, and theminimumflowshallbe3mm.

12.7.4.3 Job mix formula: The Contractor shall inform the Engineer/Consultant in

sufficient advance before the start of the work, of the jobmix formula proposed foruseintheworks,andshallgivethefollowingdetails:

i) Sourceandlocationofallmaterials. ii) Proportionsofallmaterialsexpressedasfollowswhereeachisapplicable: a) Bindertypeandpercentagebyweightoftotalmixture.

b) Coarseaggregate/fineaggregate/mineralfilleraspercentagebyweightoftotalaggregateincludingmineralfiller.

iii) Asingledefinitepercentagepassingeachsieveforthemixedaggregate; iv) The individual gradings of the individual aggregate fractions, and the

proportionofeachinthecombinedgrading. v) TheresultsoftestsenumeratedinTable–14asobtainedbytheContractor. vi) Where the mixer is a batch mixer, the individual weights of each type of

aggregatesandbinderperbatch. vii) Testresultsofphysicalcharacteristicsofaggregatestobeused;

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viii) Mixingtemperatureandcompactingtemperature. Whileestablishingthejobmixformula,theContractorshallensurethat it isbasedon

acorrectandtrulyrepresentativesampleofthematerialsthatwillactuallybeusedinthe work and that the mixture and its different ingredients satisfy the physical andstrengthrequirementsoftheseSpecifications.

Approval of the job mix formula shall be based on independent testing by the

Engineer/ConsultantforwhichsamplesofallingredientsofthemixshallbefurnishedbytheContractorasrequiredbytheEngineer/Consultant.

TheapprovedjobmixformulashallremaineffectiveunlessanduntilarevisedJobMix

Formula is approved. Should a change in the source ofmaterials be proposed, a newjob mix formula shall be forwarded to the Engineer/Consultant for approval beforetheplacingofthematerialwithoutanyadditionalpaymenttocontractor.

12.7.5 Planttrials–permissiblevariationinjobmixformula: Oncethelaboratory

jobmixformulaisapproved,theContractorshallcarryoutplanttrialsatthemixertoestablish that the plant can be set up to produce a uniform mix conforming to theapprovedjobmixformula. Thepermissiblevariationsofthe individualpercentageofthevariousingredientsintheactualmixfromthejobmixformulatobeusedshallbewithin the limits as specified in Table‐16. These variations are intended to apply toindividual specimens taken for quality control tests in accordancewith Clause 11 ofthisSection.

TABLE16‐PERMISSIBLEVARIATIONSFROMTHE

JOBMIXFORMULA

___________________________________________________________________________ PermissiblevariationsDescriptionBase/bindercourseWearingcourseAggregatepassing19mmsieve 8% 8%orlargerAggregatepassing13.2mm,9.5mm 7% 6% Aggregatepassing4.75mm 6% 5%Aggregatepassing2.36mm,1.18mm, 5% 4%0.6mm

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Aggregatepassing0.3mm,0.15mm 4% 3%Aggregatepassing0.075mm 2% 1.5%Bindercontent 0.3% 0.3%Mixingtemperature 100C 100C Once theplant trialshavedemonstrated thecapabilityof theplant, and the trials are

approved, the layingoperationmaycommence. Over theperiodof the firstmonthofproduction for laying on theworks, the Engineer/Consultant shall require additionaltestingoftheproducttoestablishthereliabilityandconsistencyoftheplant.

12.7.5.1 LayingTrials: Once theplant trialshavebeensuccessfullycompletedandapproved,theContractorshallcarryout layingtrials, todemonstratethat theproposedmixcanbe successfully laid and compacted all in accordance with Clause 6.4.5. The layingtrial shall be carried out on a suitable area which is not to form part of the works,unlessspecificallyapprovedinwritingbytheEngineer/Consultant.

Theareaofthelayingtrialsshallbeaminimumof100sqmofconstructionsimilarto

that of the project road and it shall be in all respects, particularly compaction, thesameastheprojectconstruction,onwhichthebituminousmaterialistobelaid.

The Contractor shall previously inform the Engineer/Consultant of the proposed

methodforlayingandcompactingthematerial. Theplanttrialsshallthenestablishiftheproposedlayingplant,compactionplantandmethodologyiscapableofproducingsatisfactory results. The density of the finished paving layer shall be determined bytakingcores,nosoonerthan24hoursafterlaying,orbyotherapprovedmethod.

Once the laying trials have been approved, the same plant andmethodology shall be

applied to the layingof thematerialof theproject,andnovariationofeithershallbeacceptable, unless approved in writing by the Engineer/Consultant, who may at thediscretionrequirefurtherlayingtrials.

12.7.6 Workmanship12.7.6.1 Weather and seasonal limitations:Thework of laying shall not be taken up

during rainy or foggy weather or the base course is damp or free standing water ispresentonthesurfaceoratmospherictemperatureislessthan10oC.

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12.7.6.2 Preparationofbase:ThebaseonwhichDenseGradedBituminousMaterial istobelaidshallbeprepared,shapedandconditionedtothespecifiedlines,gradesandcrosssections.Thesurfaceshallbethoroughlyswept,cleanedbyamechanicalbroom,and the dust removed by compressed air. In locations, where mechanical broomcannot access, other approved methods shall be used as directed by theEngineer/Consultant. A prime coat shall be applied as directed by theEngineer/Consultant. The type and viscosity of the primer shall comply withrequirementsofIS:8887.

12.7.6.3 Preparationand transportation ofmix: Dense bituminousmacadammix shall be

prepared in a hot mix plant of adequate capacity and capable of yielding a mix ofproper and uniform quality with thoroughly coated aggregates. Hotmixplant shallbe of suitable capacity preferably of batch mix type. The total system forcrushing of stone aggregates and feeding of aggregate fractions in requiredproportions to achieve the desired mix, deployed by the Contractor must becapable of meeting the overall specification requirements under stringentqualitycontrol.

Thetemperatureofbinderatthetimeofmixingshallbeintherangeof 150oCto163

oC and that of the aggregate in the range of 155 oC to 163 oC provided that thedifferenceintemperaturebetweenthebinderandaggregateatnotimeexceeds14oC.

Mixing shall be thorough toensure thatahomogeneousmixture isobtained inwhich

allparticlesof theaggregatesarecoateduniformly,andthedischargetemperatureofmix shall be between130 oC to 160 oC.Themixtureshallbe transported from themixing plant to the point of use in suitable tipper vehicles. The vehiclesemployedfortransportshallbecleanandbecovered intransit ifsodirectedbythe Engineer/Consultant. Thin coating of diesel or lubricating oil may beapplied to the interior of vehicles to prevent sticking and to facilitate easydischarge of the materials. Any tipper causing excessive segregation ofmaterials by its spring suspension or other contributing factors or thatwhichshows undue delay shall be removed from thework until such conditions arecorrected.

12.7.6.4 Spreading: The mix transferred from the tipper at site to the paver

shall be spread immediatelybymeans of self‐propelledmechanicalpaverwithsuitablescreedscapableofspreading,tamping,andfinishingthemixtruetothespecified lines, grades and cross‐sections.However, in restricted locations andinnarrowwidthswheretheavailableplantcannotbeoperatedintheopinionoftheEngineer/Consultant,hemaypermitmanuallayingofthemix.

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Thetemperatureofthemixatthetimeoflayingshallbeintherangeof120oCto160oC. Inmulti‐layer construction, the longitudinal joint in one layer shall offset that inthelayerbelowbyabout150mm.However,thejointinthetop‐mostlayershallbeatthelanelineofthepavement.

Longitudinal jointsandedgesshallbeconstructedtruetothedelineatinglineparallel

tothecentrelineoftheroad.Alljointsshallbecutverticaltothefullthicknessofthepreviously laid mix and the surface painted with hot bitumen before placing freshmaterial. Longitudinal and transverse joints shall be offset by at least 250mm fromthose in the lowercoursesandthe jointonthetopmost layershallnotbeallowedtofall within the wheel path. All transverse joints shall be cut vertically to the fullthicknessofthepreviouslylaidmixwithasphaltcutter/pavementbreakerandsurfacepaintedwith hot bitumen before placing freshmaterial. Longitudinal joints shall bepreferably hot joints. Cold longitudinal joints shall be properly heated with jointheater to attain a suitable temperature of about 80 oC before laying of adjacentmaterial.

12.7.6.5 Compaction: After thespreadingofmix,rollingshallbedoneby80 ‐100KNrollers

orotherapprovedequipment.Rollingshallstartassoonaspossibleafterthematerialhasbeenspreaddeployinga setof rollersas the rolling is tobecompleted in limitedtimeframe. Therollershallmoveataspeednotmorethan5km/hr. Rollingshallbedone with care to avoid unduly roughening of the pavement surface.Rolling of thelongitudinaljointsshallbedoneimmediatelybehindthepavingoperation.Afterthis, the rolling shall commence at the edges and progress towards the centrelongitudinally.

The initial or break‐down rolling shall be done with 80‐100 kN static weight

smoothwheel roller (3wheels or tandem), as soon as it is possible to roll themixwithoutcrackingthesurfaceorhavingthemixpickupontherollerwheels.The second or intermediate rolling shall follow the break‐down rolling withvibratoryrollerof80to100kNstaticweightorpneumatictyredrollerof150to250kNweight,withminimum7wheelsandminimum tyrepressureof0.7MPaascloselyaspossible to thepaverandbedonewhile thepavingmix isstillatatemperaturethatwillresultinmaximumdensity. Thefinalrollingshallbedonewhilematerialisstillworkableenoughforremovalofrollermarks,with60 ‐80kN tandem roller. During the final rolling, vibratory system shall be switchedoff.Thejointsandedgersshallberolledwitha80to100kNstaticroller.

When the roller has passed over the whole area once, any high spots or

depressionswhich become apparent shall be corrected by removing or addingmixmaterial.Therollingshallthenbecontinuedtilltheentiresurfacehasbeen

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rolled to95percentof theaverage laboratorydensity(obtained fromMarshallspecimenscompactedasdefinedinTable‐10),thereisnocrushingofaggregatesand all roller marks have been eliminated. Each pass of the roller shalluniformly overlap not less than one‐third of the trackmade in the precedingpass. The roller wheel shall be kept damp if necessary to avoid bituminousmaterial fromsticking to thewheelsandbeingpickedup. Innocaseshall fuel,lubricating oil be used for this purpose, nor excessive water poured on thewheels.

Rollingoperations shall be completed in every respect before the temperatureof the

mixfallsbelow100oC. Roller(s)shallnotstandonnewlylaidmaterialwhilethereisariskthatsurface

will be deformed thereby. The edges along and transverse of the bituminousmacadam laid and compacted earlier shall be cut to their full depth so as toexpose fresh surface which shall be painted with a thin surface coat ofappropriatebinderbeforethenewmixisplacedagainstit.

Thedensebituminousmacadamshallbecoveredwitheitherthenextpavement

courseorwearingcourse,asthecasemaybe,withoutanydelay. 12.8.0 BITUMINOUSCONCRETE12.8.1 Work included: The work shall consist of constructing in a single layer,

bituminous concrete of thickness 40 mm on previously prepared BituminousMacadam(open/dense)coursetotherequirementsofthespecification.

12.8.2 Materials12.8.2.1 Bitumen: The bitumen shall be paving bitumen of Penetration Grade

(60/70)asperIS:73suppliedfromapprovedmanufacturer inproperlysealeddrumstothesatisfactionoftheEngineer/Consultant.

12.8.2.2 Coarse aggregates: The coarse aggregates shall consist of crushed

rock/stone,crushedgravel/shingle orotherstonesretainedon2.36mmsieve. Theyshall be clean, strong, durable, of fairly cubical shape and free from disintegratedpieces,organicorotherdeleteriousmatterandadherentcoating.Theaggregatesshallpreferably be hydrophobic and of low porosity. The aggregates shall satisfy thephysicalrequirementssetforthinTable17.

TABLE17‐PHYSICALREQUIREMENTSFORCOARSE

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OFAGGREGATESFORBITUMINOUSPAVEMENTLAYERS

Property Test Specification

Cleanliness Grainsizeanalysis1 Max5%passing0.075mmsieve

Particleshape FlakinessandElongationIndex

Max30%(Combined)2

Strength* LosAngelesAbrasionValue3

Max30%

AggregateImpactValue4 Max24%Polishing PolishedStoneValue5 Durability Soundness4

SodiumSulphateMagnesiumSulphate

Max12%Max18%

WaterAbsorption

Waterabsorption7 Max2%

Stripping Coatingandstrippingofbitumenaggregatemixtures9

Minimumretainedcoating95%

WaterSensitivity**

Retainedtensilestrength8

Min.80%

Notes: 1. IS:2386Part1 6. IS:2386Part5 2. IS:2386Part1 7. IS:2386Part3 (theelongationtesttobedoneonlyonnon‐flakyaggregatesin thesample) 3. IS:2386Part4* 8. AASHTOT283**

4. IS:2386Part4* 9. IS:62415. BS:812Part114

* Aggregatemaysatisfyrequirementsofeitherofthesetwotests. ** Thewatersensitivitytestisonlyrequirediftheminimumretainedcoatinginthe

strippingtestislessthan95%.

TABLE18–COMPOSITIONOFBITUMINOUSCONCRETEPAVEMENTLAYERS

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Grading 1 2 Nominalaggregatesize 19mm 13mm LayerThickness 50‐65mm 30‐45mm ISSieve(mm)Cumulative%byweightoftotalaggregatepassing 45 37.5

26.5 100 19 79‐100 100 13.2 59‐79 79‐100 9.5 52‐72 70‐88 4.75 35‐55 53‐71 2.36 28‐44 42‐58 1.18 20‐34 34‐48 0.6 15‐27 26‐38 0.3 10‐20 18‐28 0.15 5‐13 12‐20 0.075 2‐8 4‐10 Bitumencontent%by Massoftotalmix2 5.0–6.0 5.0–7.0 Bitumengrade(pen) 65 65 Notes:1. Thecombinedaggregategradingshallnotvaryfromthelowlimitononesieve

tothehighlimitontheadjacentsieve. 2. DeterminedbytheMarshallmethod.12.8.2.3 Fineaggregates: Fine aggregates shall be the fraction passing 2.36mmsieve

andretainedon75micronsieve,consistingof crusher‐runscreening,gravel,sandoramixture of both. These shall be clean, hard, durable, uncoated, dry and free fromanyinjurious,softorflakypiecesandorganicorotherdeleterioussubstances.

TABLE19–REQUIREMENTFORBITUMINOUS

PAVEMENTLAYERS

Minimumstability(kNat600C) 9.0 Minimumflow(mm) 2 Maximumflow(mm) 4

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Compactionlevel 75blowsoneachofthetwo (Numberofblows) facesofthespecimen Percentairvoids 3‐6 Percentvoidsinmineral SeeTable15 Aggregate(VMA) Percentvoidsfilledwith 65‐75 Bitumen(VFB) LossofstabilityonimmersionMin.75percent Inwaterat600C(ASTMD retainedstrength 1075)12.8.2.4 Filler:Fillershallconsistoffinelydividedmineralmattersuchasrockdust,hydrated

limeorcementasapprovedbytheEngineer/Consultant. ThefillershallbegradedwithinthefollowinglimitsasperTable20.

TABLE20‐GRADINGLIMITOFFILLERS ISSievePercentpassingbyweight 600micron ..100 300micron ..95‐100 75micron ..85‐100 ThefillershallbefreefromorganicimpuritiesandhaveaPlasticityIndexnotgreater

than 4. The Plasticity Index requirement shall not apply if filler is cement or lime.Whenthecoarseaggregateisgravel,2percentbymassoftotalaggregateofportlandcementorhydrated limeshallbeaddedandthepercentageof fineaggregatereducedaccordingly.Cementorhydratedlimeisnotrequiredwhenthegravelislimestone.

12.8.2.5 Aggregatesgradation:Themineralaggregates,includingmineralfillershallbeso

gradedorcombinedastoconformtothegradingsetforthinTable‐18.12.8.3 MixDesign

12.8.3.1 Requirementof mix: Apart from conformity with the gadingand quality

requirements of individual ingredients, the mix shall meet the requirements as perTable‐19.

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12.8.3.2 Binder content: The binder content shall be so fixed as to achieve the

requirements of the mix set forth in Table 18. Marshall method for arriving at thebindercontentshallbeadopted.

12.8.3.3 Job mix formula: TheContractorshallintimatetothe Engineer/Consultantin

writing,atleast20daysbeforethestartofthework,thejobmixformulaproposedtotheusedbyhimfortheworkandshallgivethefollowingdetails:

(i) Sourceandlocationofallmaterials. (ii) Proportionsofallmaterialsexpressedasfollowswhereeachisapplicable.

(a) Binder,aspercentagebyweightoftotalmix;(b) Coarseaggregate/Fineaggregate/Mineralfilleras percentagebyweightoftotalaggregateincludingmineralfiller;

(iii) Asingledefinitepercentagepassingeachsieveforthemixedaggregate;

(iv) TheresultsoftestsasenumeratedinTable19asobtainedbythe Contractor;

(v) Testresultsofphysicalcharacteristicsofaggregatestobeused.

(vi) Mixingtemperatureandcompactingtemperature.

While workingoutthejobmixformula,theContractorshallensurethatit isbased

on a correct and truly representative sample of thematerials thatwill actually beused in theworkand that themixand itsdifferent ingredients satisfy thephysicalandstrengthrequirementsofthesespecifications.

For obtaining approval of the job mix formula, if required, samples of all

ingredients of the mix shall be furnished by the Contractor to theEngineer/Consultant.

The approved jobmix formula shall remain effective unless and until modified by

theEngineer/Consultant.Shouldachangeinthesourceofmaterialsbeproposed,a

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new job mix formula shall be established and approved from theEngineer/Consultantbeforeactuallyusingthematerials.

12.8.4 Workmanship12.8.4.1 Weatherandseasonallimitations:Theworkoflayingshallnotbetakenup

during rainy or foggyweather orwhen the base course is damp orwet, or duringduststormorwhentheatmospherictemperatureinshadeis10oCorless.

12.8.4.2 Preparationofbase:Thebaseonwhichbituminousconcreteistobelaid

shall be prepared, shaped and conditioned to the specified levels, grade and crossfall(camber)asdirectedbytheEngineer/Consultant.

Prior to the application of tack coat, alldust, dirt, loose and foreignmaterials etc

shall be removed and the interstices of the stone aggregates inwetmixmacadamshallbeexposeduptoadepthof12mmbywirebrushing. Finallythesurfaceshallbe brushed with soft brushes and the dust which gets accumulated shall bethoroughlyremovedbydustingwithgunnybags. Incasethebituminouswork laidonanoldbituminousroad theoldsurfaceshallbe scarifiedbycloseapplicationofpicks,uptoadepthof12mmfortheentireareaoftheroad.

12.8.4.3 Tackcoat: Thework shall consist of application of a single coat of low

viscosity liquid bituminous material to an existing road surface preparatory toanother bituminous construction over it. The binder used for tack coat shall be abituminousmaterialandasapprovedbytheEngineer/Consultantandspreadonthebase.Thebindershallbeapplieduniformlywithnozzleshavingconstantvolumeorpressuresystem,capableofsprayingbitumenatspecifiedratesandtemperaturesoastoprovideauniformlyunbrokenspreadofbitumen. Workshouldbeplannedsothat nomore than the necessary tack coat for the day’s operation is placed on thesurface. After application and prior to succeeding construction the tack coat shallbe allowed to cure,withoutbeingdisturbed,until thewater/cutterhas completelyevaporated,asdeterminedbytheEngineer/Consultant.

12.8.4.4 Preparationofmix:The bituminous concretemix shall be prepared in a hotmix

plant of adequate capacity and capable of yielding a mix of proper and uniformqualitywiththoroughlycoatedaggregates.

Hotmix plant shall be of suitable capacity preferably of batchmix type. The total

systemdeployedby theContractor for crushingof stoneaggregates and feedingofthe aggregate fractions in required proportions to achieve the desired mix,

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deployed by the Contractor must be capable of meeting the overall specificationsrequirementsunderstringentqualitycontrol.

The temperature of binder at the time ofmixing shall be in the range of 150oC to

163oCandthatof theaggregate intherangeof 155oCto163oC providedthatthedifference in temperature between the binder and aggregate at no time exceeds14oC.

Mixingshallbethoroughtoensurethatahomogenousmixtureisobtainedinwhich

allparticlesof theaggregatesarecoateduniformly,and thedischarge temperatureofmixshallbebetween130oCto160oC.

The mixture shall be transported from the mixing plant to the point of use in

suitable tippervehicles. Thevehiclesemployedfor transportshallbecleanandbecovered in transit if so directed by the Engineer/Consultant. Any tipper causingexcessive segregation of materials by its spring suspension or other contributingfactorsorthatwhichshowsunduedelayshallberemovedfromtheworkuntilsuchconditionsarecorrected.

12.8.4.5 Spreading: The mix transported from the hot mix plant to the site shall be

spread by means of a self‐propelled paver with suitable screeds capable ofspreading,tampingandfinishingthemixtospecifiedgrade,linesandcross‐section.However, in restricted locations and in narrow widths where the availableequipment cannot be operated in the opinion of the Engineer/Consultant, manuallaying of the mix may be permitted. Similarly for smaller jobs, mechanical pavermaybeusedwiththeapprovaloftheEngineer/Consultant.

Thetemperatureofthemixatthetimeoflayingshallbeintherangeof120oC‐160

oC. Mixeswith a temperatureof less than120oC shall notbeput intopaver spreader.

Longitudinal joints and edges shall be constructed true to the delineating linesparallel to the center line of the road. Longitudinal and transverse joints shall beoffsetbyat least250mm from those in the lower coursesand the jointon the topmost layer shall not be allowed to fall within the wheel path. Longitudinal jointsshallbepreferablyhotjoints.

12.8.4.6 Rolling: After spreadingthe mix by paver, it shall be thoroughly compacted

by rolling with a set of rollers moving at a speed not more than 5 km/h,immediatelyfollowingclosetothepaver.Generallyrollingshallbedonewith80to100KN staticweight smooth‐wheeled roller. The exact pattern of rolling shall be

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established after trial compaction as approved by the Engineer/Consultant. Anydisplacement occurring as a result of reversing of the direction of a roller or fromany other cause shall be corrected at once as specified and/or removed andmadegood.Therollersshallnot be permittedtostandonpavementwhichhasnotbeenfully compacted and where temperature is still more than 70oC. Necessaryprecautionsshallbetakentopreventdroppingofoil,grease,petrolorotherforeignmatter on the pavement either when the rollers are operating or standing. Thewheelsofrollershallbekeptmoist toprevent themix fromadheringtothem. Butin no case shall fuel/lubricating oil be used for this purpose nor excessive waterpouredonthewheels.

Rolling shall commence longitudinally fromedges andproceed towards the center,

except that on superelevated and unidirectional cambered portions, it shallprogress from the lower to upper edgeparallel to the center lineof the pavement.Therollershallproceedonthefreshmaterialwithrearorfixedwheelleadingsoasto minimise the pushing of the mix and each pass of the roller shall overlap theprecedingonebyhalfthewidthoftherearwheel.

Rollingshallbecontinued till thedensityachieved isat least98percentof thatof

laboratory Marshall specimen (compacted as defined in Table 10) and all rollermarks are eliminated. Skin patching of an area that has been rolled will not bepermitted. Rolling operations shall be completed in all respects before thetemperatureofthemixfallsbelow100oC.

12.9.0 OPEN‐GRADEDPREMIXCARPETUSINGBITUMEN12.9.1 Work Included: This work shall consist of laying and compacting an open‐

graded carpet of 20 mm thickness in a single course composed of suitable smallsizedaggregatespremixedwithabituminousbinderonapreviouslypreparedbase,in accordance with the requirements of this specification, to serve as a wearingcourse.

12.9.2 Materials12.9.2.1 Binder : The binder shall be bitumen of a suitable grade of 60/70 grade as per

IS:73.12.9.2.2 Aggregates:Thecoarseaggregatesshallconsistofcrushedrock,crushedstone,

crushed gravel or other hard material. The aggregates shall satisfy the qualityrequirement mentioned in Table‐21. The Stone Polishing Value as measured byBS:812‐(Part114)shallnotbelessthan55.

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TABLE‐21‐PHYSICALREQUIREMENTSOFAGGREGATESFOROPENGRADEDPRE‐MIXCARPET

_____________________________________________________________________________Sl.No.TestTestMethodRequirement___________________________________________________________________________________1. LosAngelesAbrasionValue* IS:2386(Part‐4)40percentMaximum2. AggregateImpactValue* IS:2386(Part‐4)30percentMaximum3. FlakinessandElongation** IS:2386(Part‐1)30percentMaximum Indices(Total) 4. Waterabsorption IS:2386(Part‐3) 1%(Maximum) _____________________________________________________________________

* Aggregatesmay satisfy requirementsof eitherof the two tests as given in Sl.Nos1

and2.** To determine this combined proportion, the flaky stone from a representative

sampleshouldfirstbeseparatedout. Flakinessindexisweightofflakystonemetaldivided byweight of stone sample. Only the elongated particles be separated outfrom the remaining (non‐flaky) stone metal. Elongation index is weight ofelongatedparticlesdividedbytotalnon‐flakyparticles.Thevalueofflakinessindexandelongationindexsofoundareaddedup.

12.9.2.3 Proportioning of materials: The materials shall be proportioned as per

quantitiesgiveninTable22.

TABLE22‐ QUANTITIESOFMATERIALSREQUIREDFOR

10M²OFROADSURFACEFOR20MMTHICKOPEN‐GRADEDPREMIXCARPETUSINGBITUMEN

AggregatesforCarpet

___________________________________________________________________________________

Aggregates

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(a) Nominalstonesize‐13.2mmsize(passing22.4mm.. 0.18m³ sieveandretainedon11.2mmsieve)(b) Nominalstonesize‐11.2mmsize(passing13.2mm ..0.09m³ sieveandretainedon5.6mmsieve) Total .. 0.27m³ Binder(quantitiesintermsofstraightrunbitumen)(a) For0.18m³of13.2mmnominalstonesize .. 9.5kg at52kgperm³(b) For0.09m³of11.2mmnominalstonesize .. 5.1kg at56kgperm³ Total ..1 4.6kg12.9.3 Workmanship12.9.3.1 Weather and seasonal limitations:Thework of laying shall not be taken up

during rainyor foggyweather or thebase course is dampor free standingwater ispresentonthesurfaceoratmospherictemperatureislessthan10oC.

12.9.3.2 Preparationofbase:Theunderlyingbaseonwhichthebituminouscarpetisto

be laid shall be prepared, shaped and conditioned to the specified lines, grade andcross‐section. A prime coat where needed shall be applied as directed by theEngineer/Consultant.

12.9.3.3 Preparationofpremix:Hotmixplantofappropriatecapacityandtypeshallbe

used for the preparation of mix material. The hot mix plant shall have separatedryer arrangement for heating aggregates and pugmill for mixing aggregates andbinder.

The temperature of binder at the time of mixing shall be in the range of 150ºC to

163ºC and that of the aggregates in the range of 155ºC to 163ºC provided that thedifference in temperature between the binder and aggregates at no time exceeds14ºC.Mixingshallbethoroughtoensurethatahomogeneousmixture is

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obtained in which all particles of the aggregates are coated uniformly and thedischargetemperatureofmixshallbebetween130ºCand160ºC.

The mix shall be immediately transported from the mixer to the point of use in

suitable vehicles or wheel barrows. The vehicles employed for transport shall beclean and the mix being transported covered in transit if so directed by theEngineer/Consultant.

12.9.3.4 Spreadingandrolling:Themixedmaterialshallbespreadbysuitablemeans.

As soon as sufficient length of bituminous material has been laid, rolling shallcommencewith80‐100KNrollers,preferablyofsmoothwheeltandemtype,orotherapprovedequipment.Rollingshallbeginattheedgeandprogresstowardthecentrelongitudinally, except that on the super elevated and uni‐directional camberedportions,itshallprogressfromthelowertoupperedgeparalleltothecentrelineofthepavement.

Whentherollerhaspassedoverthewholeareaonce,anyhighspotsordepressions

which become apparent shall be corrected by removing or adding premixedmaterials. Rollingshallthenbecontinueduntiltheentiresurfacehasbeenrolledtocompactionandalltherollermarkseliminated.Ineachpassoftheroller,precedingtrackshallbeoverlappeduniformlybyatleast1/3width.Therollerwheelsshallbekeptdamp toprevent thepremix fromadhering to thewheels andbeingpickedup.Innocaseshallfuel/lubricatingoilbeusedforthispurpose.Excessuseofwaterforthispurposeshallbeavoided.

Rollers shall not stand on newly laid material while there is a risk that it will be

deformedthereby.Rollingoperationsshallbecompletedineveryrespectbeforethetemperatureofthemixfallsbelow100ºC.

Theedgesalongandtransverseofthecarpetlaidandcompactedearliershallbecut

to their full depth so as to expose fresh surfacewhich shall be paintedwith a thinsurfacecoatofappropriatebinderbeforethenewmixisplacedagainstit.

12.10.0 SEALCOAT12.10.1 Work included: Thework shall consist of applicationof a seal coat for sealing

the voids in a bituminous surface laid to the specified levels, grade and cross fall(camber). Sealcoatshallbepre‐mixedseal coat comprisingofa thinapplicationoffineaggregatepremixedwithbituminousbinder.

12.10.2 Material

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12.10.2.1 Bitumen: The bitumen shall be paving bitumen of PenetrationGrade

60/70asperIS:73.Thequantityofbitumenshallbe6.8kgper10sqmarea.12.10.2.2 Aggregates forsealcoat: Theaggregates shallbe sandorgrit and shall consistof

clean, hard, durable uncoated dry particles and shall be free from dust, soft orflaky/elongated material, organic matter or other deleterious substances. Theaggregates pass 2.36mm sieve and be retained on 180micron sieve. The quantityusedforpremixingshallbe0.06cumper10sqmarea.

12.10.3 Constructionoperations12.10.3.1 Weather&seasonallimitations:Therequirementsofclause9.3.1shallapply.12.10.3.2 Preparation of surface: The seal coat shall be applied immediately

afterthe laying of bituminous course which is required to be sealed. Beforeapplication of seal coatmaterials, the surface shall be cleaned free of any dust orotherextraneousmatter.

12.10.3.3 Preparation and application of seal coat: A mixer of appropriate capacity and

type approved by the Engineer/Consultant shall be used for preparation of themixedmaterial.Theplantshallhaveseparatearrangementforheatingaggregate.

Thebinder shall beheated inaboiler toa temperature conforming to thegradeof

bitumenusedandasdirectedby theEngineer/Consultant. Theaggregate shallbeequally heated to a temperature 1500C to 1600C, before these components areplaced in themixer. Mixingof binderwith aggregates to the specifiedproportionshallbecontinuedtillbotharethoroughlymixed.

Themixshallbe immediately transported to thepointofuseandspreaduniformly

onbituminoussurfacetobesealed. Assoonassufficientlengthiscoveredwithpre‐mixedmaterial,thesurfaceisrolled

with 80‐100 KN smooth wheeled roller. Rolling shall be continued until pre‐mixmaterial completely seals the void in the bituminous course and smooth uniformsurfaceisobtained.

12.10.3.4 Openingtotraffic: Trafficmaybeallowedsoonafterfinalrollingwhenpre‐mixed

materialhasbeencooleddowntothesurroundingtemperature.12.11.0 TRAFFICSIGNS:

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The colour, configuration, size of location of all traffic signs for highways is in

accordance with IRC 67‐1977, or as shown in drawings. The signs shall be eitherrefloctorisedornon‐refloctorisedasshownonthedrawingsorasdirected.

12.11.1 Materials: Thevariousmaterialsandfabricationof theTrafficSignsshallconformtoMinistry

ofSurfaceTransport,Specificationsforroadsandbridgeworks–(fourthrevision).12.11.2 Installation: Sign posts, their foundations and sign mountings shall be as indicated in the

drawings.12.12.0 ROADMARKINGS: Thecolourwidthand layoutofroadmarkingsshallbe inaccordancewith thecode

ofpracticeforroadmarkingswithpaintsIRC–35–1970.12.12.1 LaneMarkings: Traffic lane linesshallbesinglebroken lines, theirwidthshallbe10cm(4 inches)

andthelengthofsegmentsandgapsshallbeasunder: Onstraightreaches 1.5metressegmentsand 4.5metresgaps OncurvesandApproaches 1.5metressegmentsand tointersection 1.5metresgaps12.12.2 ArrowMarkings: Thesizeandlocationshallbeasindicatedinthedrawings.12.13.0 QUALITYCONTROLFORROADWORK12.13.1 General: All materials to be used, all methods adopted and all works performed

shall be strictly in accordance with the requirement of these specification. TheContractor shall set up a field laboratory at locations approved by theEngineer/Consultant and equipment at the same with adequate and personnel in

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ordertocarryoutallrequiredtestsandqualitycontrolworkasperspecification/asdirectedbyEngineer/Consultant.

12.13.2 Themethodofsamplingandtestingofmaterialsshallbeasrequiredbythe“HandbookofQualityControlforConstructionofRoadsandRunways”(IRC:SP:11)andasperthisspecification.

12.13.3 AllmaterialswhichtheEngineer/Consultanthasdeterminedasnotconformingtotherequirementsofthespecificationshallberejectedandremovedfromthesitewithimmediateeffectasdirected.Materialswhichhavebeensubsequentlycorrected,shallnotbeusedintheworkunlessotherwiseapprovalisaccordedfromEngineer/Consultant.

12.13.4 ControlofAlignment,LevelandSurfaceRegulations12.13.4.1 Horizontal Alignment: The edges of the carriage way shall be correct within a

toleranceof±10mmand±25mmfromthecentral lineof theroadand lower layeroftheroadrespectively.

12.13.4.2 SurfaceLevel:ThetolerancelimitofthesurfacelevelismentionedintheTable‐23

onthenextpage.

TABLE23–TOLERANCESINSURFACELEVELS___________________________________________________________1. Subgrade +20 mm ‐25 mm2. Sub‐base+10mm

(a) Flexiblepavement ‐20 mm

3. Base‐courseforflexiblepavement(a) Bituminouscourse +6 mm ‐6 mm(b) Otherthanbituminous +10 mm (i) Machinelaid ‐10 mm +15 mm (ii) Manuallylaid ‐15 mm

4. Wearingcourseforflexiblepavement(a) Machinelaid +6 mm

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‐6 mm(b) Manuallylaid +10 mm ‐10 mm

For checking compliance with the above requirement for subgrade, sub‐base andbase courses,measurements of the surface levels shall be taken on a grid of pointsplaced at 6.25m longitudinally and 3.5m transversely. For any 10 consecutivemeasurementstakenlongitudinallyortransversely,notmorethanonemeasurementshallbepermittedtoexceedthetoleranceasabove,thisonemeasurementbeingnotinexcessof5mmabovethepermittedtolerance.For checking the compliance with the above requirement for bituminous wearingcoursesmeasurementsofthesurfacelevelsshallbetakenonagridofpointsspacedat 6.25 m along the length and at 0.5 m from the edges and at the centre of thepavement. Inanylengthofpavement,complianceshallbedeemedtobemetforthefinal road surface,only if the tolerancegivenabove is satisfied foranypointon thesurface.

12.13.4.3 Surface Regularity of Pavement Courses: The maximum number of surfaceirregularitiesshallbeasperTable‐24onthenextpage.

TABLE24–MAXIMUMPERMITTEDNUMBEROF

SURFACEIRREGULARITIES_______________________________________________________________Irregularity 4mm 7mm 4mm 7mmLength(m) 300 75 300 753007530075RoadsoflowerCategory* 40 18 4 26027 63________________________________________________________________________Themaximumallowabledifferencebetween the road surface andundersideof a 3mstraight‐edge when placed parallel with, or at right angles to the centre line of theroadatpointsdecidedbytheEngineer/Consultantshallbe: (a) Forpavementsurface .. 3 mm

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(bituminous) (b) Forbituminousbasecourses .. 6 mm (c) Forgranularsub‐base/basecourses.. 8 mm

12.13.5 QualityControlTestsduringConstruction12.13.5.1 TestsonEarthwork forEmbankment: Grid the area at 25m c/c (or closer, if the

variabilityishigh)tofulldepthofproposedworking.Thesepitsshouldbeloggedandplottedforproperidentificationofsuitablesourcesofmaterial.Thefollowingtestsonrepresentativesamplesshallbecarriedout:

(a) SandContent(IS:2720(Part‐4):2testsper3000cubicmetresofsoil.

(b) PlasticityTest(IS:2720(Part‐5):Eachtypetobetested,2testsper3000cub,

metresofsoil.

(c) DensityTest (IS:2720 (Part8): Each soil type tobe tested,2 testsper3000cubemetresofsoil.

(d) Deleterious Content Test (IS:2720 (Part‐27): As and when required by the

Engineer/Consultant.

(e) MoistureContestTest(IS:2720(Part‐2):Onetestforevery250cubicmetresofsoil.

(f) CBR Test on materials to be incorporated in the sub‐grade on

soaked/unsoaked samples (IS:2720 (Part‐16): One CBR test for every 3000cumaltestorclosetasandwhenrequiredbytheEngineer/Consultant.

12.13.5.2 CompactionControl: Control shallbeexercisedoneach layerby takingat leastone

measurementofdensity foreach1000squaremetresof compactedarea,or closerasrequired to yield theminimumnumber of test results for evaluating a day’swork onstatistical basis. The determination of density shall be in accordance with IS:2720(Part‐28). Test locations shall be chosen only through random sampling techniques.Controlshallnotbebasedontheresultofanyonetestbutonthemeanvalueofasetof5‐10densitydeterminations.Thenumberoftestsinonesetofmeasurementsshallbe 6(ifnon‐destructivetestsarecarriedout,thenumberoftestsshallbedoubled)as long as it is felt that sufficient control over borrow material and the method ofcompaction is being exercised. If considerable variations are observed between

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individual density results, theminimum number of tests in one set ofmeasurementshallbeincreasedto10. Theacceptancecriteriashallbesubjecttotheconditionthatthemeandensityisnotlessthanthespecifieddensityplus.

1.65‐____1.65______timesthestandarddeviation (No.ofsamples)0.5 However, for earthwork in shoulders (earthen) in the subgrade, at least one density

measurement shall be taken for every 500 square metres for the compacted areaprovidedfurtherthatthenumberoftestsineachsetofmeasurementsshallbeatleast10.Inotherrespects,thecontrolshallbesimilartothatdescribedearlier.

12.13.5.3 FormationControl:SameasthatofClauseNo.11.5.2.12.13.6 TestsonGranularSubBase:ThisshallbedoneasperTable‐25. TABLE25–CONTROLTESTSANDTHEIRMINIMUM

FREQUENCYFORSUB‐BASESANDBASES(EXCLUDINGBITUMENBOUNDBASES)________________________________________________________________

Sl. Typeof No. Construction Test Frequency (min.) ________________________________________________________________________

1. Granular i) Gradation Onetestper200m3 ii) Atterberglimits Onetestper200m3 iii) Moisturecontent Onetestper250m2 priortocompaction iv) Densityofcompacted layer Onetestper500m2 v) DeleteriousconstituentsAsrequired vi) C.B.R Asrequired2. WetMix i) AggregateImpactValue Onetestper200m3 Macadam ofaggregate ii) Grading Onetestper100m3 ofaggregate iii) FlakinessandElongationOnetestper200m3 Index ofaggregate iv) Atterberglimitsofportion Onetestper100m3 ofaggregatepassing ofaggregate 425micronsieve

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v) Densityofcompactedlayer Onetestper500m2________________________________________________________________________Theacceptancecriteriaforthetestisthatthemainvalueisnotlessthanthespecifiedvalue+1.65‐1.65(No.ofsamples)0.5Xstandarddeviation.

12.13.7 TestsonBituminousWork TABLE26–CONTROLTESTSFORBIOTUMINOUSWORKS,

ANDTHEIRMINIMUMFREQUENCY_________________________________________________________________

Sl. Typeof No. Construction Test Frequency (min.) ________________________________________________________________________

1. PrimeCoat/Tacki)Qualityofbinder Numberofsamplesper Coat lotandtestsasper IS:73,IS:217&IS:8887 asapplicable. ii) BindertemperatureAtregularcloseintervals forapplication iii) Rateofspreadof Onetestper500m2and

binder notlessthantwotests perday.2. SealCoat i)QualityofBinder Sameasmentionedunder

SerialNo.1. ii)AggregateImpactOnetestper50m3of Value/LosAngeles aggregate AbrasionValue iii) FlakinessIndexand ‐do– ElongationIndex iv) Strippingvalueof Initiallyonesetof3

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aggregates representativespecimens (ImmersionTrayTest) foreachsourceof supply. Subsequentlywhen Warrantedbychangesin thequalityofaggregates. v) Waterabsorptionof ‐do– aggregates vi) Watersensitivityof Initiallyonesetof3 mix representativespecimens foreachsourceofsupply. Subsequentlywhen warrantedbychangesin thequalityofaggregates (ifrequired). vii) Gradingofaggregates Onetestper25m3 ofaggregate. viii) Soundness Initially,onedetermination (Magnesiumand byeachmethodforeach SodiumSulphate) sourceofsupply,thenas warrantedbychangeinthe qualityoftheaggregates._________________________________________________________________

Sl. TypeofNo. ConstructionTestFrequency(min.) ________________________________________________________________________ ix) Polishedstonevalue Asrequired. x) Temperatureof Atregularcloseintervals binderatapplication xi) Rateofspreadof Onetestper500m2of materials work,andnotlessthan

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twotestsperday. xiii) Percentageof Whengravelisused,one fracturedfacestestper50m3ofaggregate3. Open‐graded/ i) Qualityofbinder Sameasmentionedunder Dense‐graded SerialNo.1. Premixcarpeting ii) AggregateImpact Sameasmentionedunder Value/LosAngeles SerialNo.2. AbrasionValue iii) FlakinessIndexand ‐do– ElongationIndex. iv) Strippingvalue Sameasmentionedunder SerialNo.2. v) Waterabsorptionof Sameasmentioned

aggregates under SerialNo.2. vi) Watersensitivityof Sameasmentioned mix underSerialNo.2. vii) Gradingofaggregates Sameasmentioned

underSerialNo.2

viii) Soundness Sameasmentionedunder (Magnesium SerialNo.2. andSodiumSulphate)

ix) Polishedstonevalue Asrequired. x) Temperatureofbinder Atregularclose at

application intervals xi) Bindercontent One test per 500m3 and not less than two

tests perday.

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xii) Rateofspreadof Regularcontrolthrough mixedmaterial checksoflayerthickness

xiii) Percentageof Sameasmentionedunder

fracturedfaces SerialNo.24. Bituminous i) Qualityofbinder Sameasmentionedunder Macadam SerialNo.1 ii) AggregateImpact Sameasmentionedunder Value/Los

AnglesAbrasionValue SerialNo.2 iii) FlakinessIndexandSameasmentionedunder ElongationIndex SerialNo.2________________________________________________________________

Sl. TypeofNo. ConstructionTestFrequency(min.) ________________________________________________________________________ iv) StrippingValue Sameasmentionedunder SerialNo.2 v) Watersensitivity ‐do– ofmix vi) Gradingofaggregates Two tests perdayperplant bothon

the individual constituents and mixedaggregatesfromthedryer.

vii) WaterabsorptionofSameasinSerialNo.2 aggregates viii) Soundness Sameasmentionedunder (Magnesiumand SerialNo.2 SodiumSulphate) ix) Percentageof Sameasmentionedunder fracturedfaces SerialNo.2. x) Bindercontentand Periodic,subjectto

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aggregategrading oftwotestsperday perplant xi) Controloftemperature Atregularclose

intervals ofbinderandaggregate formixingandofthe mixatthetimeof layingandrolling xii) Rateofspreadof Regularcontrolthrough mixedmaterial checksoflayerthickness xiii) Densityofcompacted Onetestper2.50m2of layer area 5. Dense i) Qualityofbinder Sameasmentionedunder Bituminous SerialNo.1 Macadam/Bituminous Concrete ii) AggregateImpact Sameasmentionedunder Value/LosAngelesSerialNo.2 AbrasionValue iii) FlakinessIndexand ‐do– ElongationIndex iv) StrippingValue Sameasmentionedunder SerialNo.2 v) Soundness Sameasmentionedunder (MagnesiumandSerialNo.2 SodiumSulphate)________________________________________________________________________

Sl. Typeof No. ConstructionTestFrequency(min.)

______________________________________________________________________

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vi) Waterabsorptionof AsinSerialNo.2. aggregates vii) Sandequivalenttest Asrequired. ix) Polishedstonevalue Asrequired,forSemi DenseBituminous Concrete/Bituminous Concrete x) Percentageof Sameasmentioned fracturedfaces underSerialNo.2. xi) Mixgrading Onesetoftestson individualconstituents andmixedaggregate fromthedryerforeach 400tonnesofmixsubject

toaminimumoftwotests perplantperday.

xii) StabilityofMix Foreach400tonnesof mixproduced,asetof 3Marshallspecimensto bepreparedandtested forstability,flowvalue, densityandvoidcontent subjecttoaminimumof twosetsbeingtestedper plantperday. xiii) WatersensitivityofSameasmentionedunder mix(Retained SerialNo.2 TensileStrength) xiv) Swelltestonthemix Asrequiredforthe BituminousConcrete. xv) Controloftempera‐Atregularcloseintervals tureofbinderin boiler,aggregatein

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thedryerandmixat thetimeoflayingand rolling. xvi) Controlofbinder Onetestforeach400 contentandgradingtonnesofmixsubjectto ofthemix aminimumoftwotests perdayperplant xvii) Rateofspreadof Regularcontrolthrough mixedmaterial checksontheweightof mixedmaterialandlayer thickness xviii) Densityofcompacted Onetestper250m2area layer

_________________________________________________________________________________________Theacceptancecriteriashallbeasper13.6.

12.13.8 Rectification: The rectificationwork (if required) shall be done as per the direction ofEngineer/Consultant and/or as per the specification for road and bridge works underMinistryofRoadTransportandHighways(MORTH)(4thRevision).

LISTOFAPPROVEDMAKESOFMATERIALS

SL. ITEMOFWORK APPROVEDMAKES

A CIVIL1 CEMENT ACC ULTRATECH KONARK2 STEEL SAIL TATATISCON JINDAL3 VITRIFIEDTILES SOMANY KAJARIA NITCO4 CERAMICTILES SOMANY KAJARIA NITCO5 GLAZEDTILES SOMANY KAJARIA NITCO

6

CLADDINGCONCRETETILES/CONCRETETILEFORPAVING/INTERLOCKING

BLOCKS

AMAN EUROCON PAVIT

7 WALLPUTTY LATICRETE BIRLA JKWALLPUTTY

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8PLASTICEMULSIONPAINTS‐LOWVOC

ASIAN BERGER DULUX

9WEATHERCOATPAINT‐LOWVOC

ASIAN BERGER DULUX

10 ENAMELPAINT ASIAN BERGER DULUX11 TEXTUREDPAINT ASIAN BERGER DULUX12 EPOXYPAINT ASIAN BERGER DULUX13

WATERPROOFING SIKA FOSROC PIDILITE

14 MS/SSSECTIONS SAIL TATATISCON JINDAL15 UPVCWINDOWS TORFENSTER REHAU FENESTA

17 FLUSHDOOR GREEN SONEAR MERINO18 LAMINATES SONEAR GREEN MERINO19

LOCKS/HANDLES/HARDWARE

DORMA DORSET HAFELLE

20 GLASS SAINTGOVIN MODIGUARD EQUIVALENT21 EPOXYGROUT LATICRETE DOW EQUIVALENT

22POLYCARBONATE

SHEETSDUNPALON GE EQUIVALENT

WATERSUPPLY&SANITARYINSTALLATION

SLno Material Make

1

Sanitaryware

Jaquar/Parryware/Kohler

2

ToiletAccessories


3

CPfittings


4

Waterclosetseats&

Cisterns


5

Mirrors

SaintGobain/Modi/Atul

6

Kitchensink

Franke/Diamond/Nirali

7

uPVCpipes&fittings

Astral/supreme/Ashirbad

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8

Manholeframe&coverinFiberreinforcedconcrete

SouthernConcreteIndustries/ApprovedEquivalent

9

ManholePVCsteps

SouthernConcreteIndustries/Approved

Equivalent10

CPVCPipes&Fittings

Astral/Supreme/Ashirvad

11 polyethylene TANKS

SINTEX/RHINO/SUDHAKAR

Note:OPGCdecisionregardingtheMAKEshallbefinal.Howeverifduetonon‐availabilityoranyothertechnical reasons, the alternative make is allowed, it shall be subject to prior approval of the ProjectManager.

1. Thecontractorshallproduceallsamplesincludingnaturalstones,beforeprocurementofthematerials,forapprovaloftheOPGC/Architects/ProjectManagers.

PARTB:TECHNICALSPECIFICATIONforSTRUCTURALSTEELWORK&CLADDING

1.0DESIGNPARAMETERSANDCONSIDERATIONSFORSTRUCTURALSTEELWORK&CLADDING

1.1General

1.1.1 This section covers the design criteria for structural steelwork and provides guidelines for thedesign of steel structures for various units. The design of the steel structures shall provide for theappropriateconditionsofloading,stresses,deflectionandstabilityrequirements,effectofbothstaticanddynamicloads,effectofweather,provisionsforthermalexpansion,naturallightingandventilation,roofdrainage system etc. The design shall also cater to repair and service facilities with access formaintenanceofcranes,claddingandotherservices.Moreover,thedesignshalltakeintoaccountfacilitiesfor fabrication, transportation, storage, erection,maintenance and construction. The objective of thedesignshallbefunction,service,economyandsafety.

1.1.2Thedesignof steel structures in general shall be according to IS:800.Theprovisionsof “FactoryRules”and/orasstipulatedbythelocalauthoritiesshallbefollowed.ThedesignshallalsoconformtothestatuteslaiddownbyCentralPollutionControlBoard,NewDelhiand/oranyotherregulatorybodies.

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1.1.3AlistofrelevantISCodesoflatesteditionisindicatedinAnnex‐1enclosed.AllworkshallbebasedonthelatestCodes.

1.2ArchitecturalPlanning

1.2.1 Any addition of unplanned annexes such as lean‐to to themain buildings at a later stage is notrecommendedandshallbeavoidedasfaraspossible.

1.2.2Roofwith1:5slopeshallgenerallybeadoptedforpitchedroofbuildings.Adequatemeasurestobetakentopreventingressofrainwaterthroughthesideandendlapsofroofandsidecladding.

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1.3HeightofPremises

1.3.1Sufficientheadroomshallbekeptabovethecranerailforthepassageofthecraneandheightabovethe crane top to the bottompart of roof structure shall not be less than 200mm.However,minimumheadroomof2000mmtobekeptaboveanyplatformonthecranetoundersideofstructuralmemberoranyotherpermanentobject.

1.3.2Ingeneral, forallbuildingsminimumclearheightbetweenfloorstobekeptas3.5munlessmoreheightisrequiredfromsomeotherconsiderations.

1.4Material

1.4.1Structuralsteel:Rolledsteelsectionsandplatesupto20mmthicknessshallbesemi‐killedandconformtoIS:2062GradeE250(Fe410W),QualityA.Platesabove20mmthicknessshallbekilledandconformtoIS:2062GradeE250(Fe410W)QualityB.SectionsandplatesmadeofmediumorhightensilesteelshallconformtoIS:8500orequivalent.AbrasionresistantsteellinerplatesshallbeTISCRALupto12mmthickandSAILHARDformorethan12mmthick.ChequeredplatesshallconformtoIS:3502/IS:2062GradeE250(Fe410W),QualityA.Allplates40mmthickandaboveusedincranegirdersandsimilardynamicallyloadedstructuresshallbeofUTgrade.Platesbelow40mmthickforsuchapplicationshallbeultrasonicallytestedatsite.WeatheringSteel(SAILCOR)maybeusedforareassuchasroofoverslagyardpits.CranerailsshallconformtoIS:3443orequivalent.SteelTubesshallconformtogradeYst240ofIS:1161.ColdformedStructuralHollowsteelsectionsshallconformtoGradeYst310ofIS:4923.Allstructuralsteelshallbefreefromrust,scales,laminations,cracks,fissuresandothersurfacedefects.

Materialofgutters,collectorpipesanddownpipesshallbe

Gutters‐Mildsteelofminimum6mmthickness

Collectorpipe‐Mildsteelofminimum5mmthickness

ERWpipesmaybeusedsubjecttominimumthicknessrequirements.

1.4.2BoltsandNuts:AllboltsandnutsshallconformtoIS:1363orIS:1364asapplicable.NutsshallhavepropertyclassconformingtoIS:1367compatibletothepropertyclassofthematingbolts.HighstrengthstructuralboltsandnutsshallconformtoIS:3757andIS:6623respectively.

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1.4.3Washers:Plainwashers shall conform to IS:2016 unless otherwise specified. Each bolt shall beprovidedwithonewasherandincaseofspecial typeofboltsmorethanonewasherasneededforthepurposeshallbeprovided.AnadditionaldoublecoilhelicalspringwasherconformingtoIS:6755shallbeprovided for bolts carrying dynamic or fluctuating loads and those in direct tension. Taper washersconforming to IS:5372 and IS:5374 shall be used for channels (MC) and I‐beams (MB) respectively.WashersforhighstrengthstructuralboltsandnutsshallconformtoIS:6649.

1.5RoofandSideCoverings

General:Roof andwalls of structural buildings and galleries shall be coveredwith Pre‐coated sheets andmatchingFRPsheets/Polycarbonate sheetsonwalls.AdditionalFRP sheetson roof,matchingwith Pre‐coated sheets, shall be used for buildings. Suitably designed safety guard,made ofstructuralsteel,shallbeusedbelowFRPsheetonroofinordertoavoidaccidentduetobreakageofFRPsheetsduringroofmaintenance.

Pre‐CoatedSheets:Pre‐colourcoatedsheetsusedinroofandwallsshallbeoftrapezoidalprofilewithgalvanizedprocessedsteelsubstrate.Stainlesssteelselftappingscrews,havingwashersbuiltmonolithically with the screw head and with bonded EPDM washers shall be used for fastening thesheets.

1.6MinimumThicknessofMetal

1ForminimumthicknessofmetalprovisionsunderIS:800shallgenerallybefollowed.

1.6.2Sealedtubesandsealedhollowboxsectionsusedforexternalconstructionexposedtoweathershallnotbethinnerthan4mmandforconstructionnotexposedtoweathershallnotbethinnerthan3.2mm.Where structures are not readily accessible for maintenance the minimum thickness shall be 5mm.However,forsecondarymemberslikehandrails2.5mmthicknessmaybeadopted.

1.7TypeofStructures

1.7.1Shopconstruction:Allsteelstructuresshallbedesignedandconstructedaswelded,conformingtoguidelinesofIS:816andIS:9595.

1.7.2Siteconnection:Siteconnectionshallbemadeweldedorboltedwithhighstrengthstructuralboltsfor connectionsof all important structural elements carryingheavy loads,moments ordynamic loads.For secondary members carrying static loads of small magnitude e.g. purlins, side runners, hangers,handrails, stairs, ladders, small platforms, gangways etc., ordinary unfinished bolts may be used. Allunfinishedboltsunderdirecttensionandvibrationshallbeprovidedwithlocknuts/spring.

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washers. Where site connections are developed by welding, necessary erection bolts, minimum twonumbersateachend,shallbeprovided.However,numberofboltsprovidedshallbesufficienttocarrythedeadloadpriortowelding.

1.7.3Splicesinstructures

1.7.3.1Shop splice:Where shop splices in plates are necessary due to non‐availability ofmembers inrequiredlengths,fullpenetrationdefectfreesoundbuttweldsshallbemade.Shopsplicesinrolledsteelangles,joistsandchannelsshallpreferablybedevelopedbyfilletweldingandcoverplates,anglesetc.Incase buttwelds in rolled sections are called for, complete detail of face preparation andprocedure ofweldingtoachievedefectfreeweldshallbefurnishedinthedrawings.

1.7.3.2 Site splice: Site splices for members required due to transportation, assembly and erectionfacilitiesshallbedevelopedbyfilletweldsorhighstrengthstructuralboltswithnecessarycoverplatesandanglesetc.Incasebuttweldinginplatesisemployedforsitesplice,thesameshallbesound,defectfree and of full penetration and shall be carried outwith run‐on and run‐off plates having same edgepreparation.Afterweldingrun‐onandrun‐offplatesshallberemoved.

technical specification civil, structural, part-a,b

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