Chimney Specification Draft

SPEC NO. TCE.
5607A-H-CCH400
TCE CONSULTING ENGINEERS LIMITED Chimney
SECTION: SHEET i OF iii
BHUBANESHWAR POWER PRIVATE LIMITED

(JV COMPANY OF TATA STEEL, RAWMET & JASPER)
2 X 80MW CAPTIVE POWER PLANT AT ANANTPUR, NEAR CUTTACK, ORISSA
SPECIFICATION NO.TCE.5607A-H-CCH-400
Specification For Chimney
73/1, ST. MARKS ROAD BANGALORE - 560 001 INDIA December -2009
SPEC.NO.
TCE CONSULTING ENGINEERS LIMITED

TITLE
SECTION: CONTENTS
TCE-5607A-H-CCH400
CONTENTS
SHEET ii OF iii
CONTENTS SECTION SUBSECTION A1 A2 SPECIFICATION NO. ISSUE TITLE NO. OF SHEETS
TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400
P0 P0
SCOPE OF ENQUIRY DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS TIME SCHEDULE AND WORK PROGRAMME RC CHIMNEY - SPECIFIC TECHNICAL REQUIREMENTS (DATA SHEET A)
1-3 1-6
A3
TCE.5607A-H-CCH-400
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1-9
A4
TCE.5607A-H-CCH-400
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1-4
B C C1 C2
TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400
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PROJECT INFORMATION GENERAL NOTES SCHEDULE OF QUANTITIES & PRICES FOR RC CHIMNEY LIST OF BID DRAWINGS
1-4 1-1 1-6
C3 D D1
TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 P0
1-1 1-11
EARTHWORK EXCAVATION FILLING
IN GRADING AND BACK
D2
TCE.5607A-H-CCH-400
P0
SPECIFICATION FOR TIMBER SHORING DEWATERING RAIN WATER DRAINAGE CONCRETE & ALLIED WORKS REINFORCED CONCRETE CHIMNEY-CIVIL REINFORCED CONCRETE CHIMNEY-ELECTRICAL AND INSTRUMENTATION
1-2
D3 D4 D5 D6
TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400
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1-1 1-1 1-26 1-30
D7
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1-15
ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
SPEC.NO.

TITLE
SECTION: CONTENTS
TCE-5607A-H-CCH400
CONTENTS
SHEET iii OF iii
SECTION D
SUBSECTION D8
SPECIFICATION NO.
ISSUE
TITLE
NO. OF SHEETS 1-7
TCE.5607A-H-CCH-400
P0
SUPPLY AND FABRICATION OF STRUCTURAL STEEL ERECTION OF STRUCTURAL STEEL PAINTING OF STRUCTURAL STEEL GENERAL CONDITIONS OF CONTRACT SCHEDULE OF DEVIATIONS FROM TECHNICAL SPECIFICATIONS SCHEDULE OF DEVIATIONS FROM GENERAL CONDITIONS SCHEDULE OF PRICE IMPLICATION ON ACCOUNT OF DEVIATIONS. SCHEDULE OF CEMENT REQUIREMENT SCHEDULE OF REINFORCEMENT REQUIREMENT SCHEDULE OF CONTRACTORS TECHNICAL STAFF TO BE DEPLOYED ON THIS CONTRACT SCHEDULE OF EQUIPMENT SCHEDULE OF RATES FOR LABOUR SCHEDULE OF BIDDERS EXPERIENCE
D9
TCE.5607A-H-CCH-400
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1-7
D10
TCE.5607A-H-CCH-400
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1-8
TCE.5607A-H-CCH-400
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1-36
F1
TCE.5607A-H-CCH-400
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1-1
F2
TCE.5607A-H-CCH-400
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TCE.5607A-H-CCH-400
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1-1
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SPEC NO.
SECTION: A1
TCE-5607A-H-CCH-400
SCOPE OF ENQUIRY
SHEET 1 OF 3
1.0 1.1
SCOPE Scope of Work covered under this specification comprises of a) Analysis, Design, preparation of Construction drawings and Construction of one number 150M high multiflue Reinforced Concrete Chimney with all accessories as per specification.
The scope also includes soil investigation, supply of all materials and labour along with necessary tools and tackles etc. It also includes collection of materials from the Owners stockyard either at site or from other places, transporting the same to the site, unloading, storing them in the Contractors own covered storage area. Storing shall be done in a neat & systematic manner and also providing necessary fencing and security to ensure proper utilization of such material exclusively for the project. 1.2 It is not the intent to completely specify herein all details of design, manufacture and construction. Nevertheless, the structure/equipment shall conform in all respects to high standards of engineering, design and workmanship, complying with the technical specifications and shall be capable of performing in continuous commercial operation, up to VENDORs guarantee, in a manner acceptable to OWNER, who will interpret the meaning of drawings and specifications and shall have the power to reject any work or materials which, in his judgement, are not in full accordance therewith. The scope of work includes, but is not limited to the following. The VENDOR shall furnish everything necessary and as required by OWNER although not listed herein, for the successful operation of the equipment supplied by him as specified above:
1.3
i) ii) iii)
Design of Chimney including all appurtenant civil works Supply at site of all required materials Construction of Reinforced Cement Concrete raft supporting the wind shield as well as duct supports staircases etc including excavation, dewatering, backfilling, etc complete. Construction of R.C.C wind shield using jump form slip including provision of openings of various sizes in the windshield at various levels. Construction of internal RCC corbels at various levels to support structural steel beams. Construction of RCC roof slab for wind shield including acid resistant tile protection of the roof and drainage arrangement of roof. Providing structural steel platform at various levels such as roof supporting platform, flue support platform, with openings for flues, flooring of RCC slab, hand rail etc including their bearing supports on the wind shield.
iv)
v)
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vii)
SPEC NO.
SECTION: A1
TCE-5607A-H-CCH-400
SCOPE OF ENQUIRY
SHEET 2 OF 3
viii) ix)
Providing brick flues supported on platforms. Structural steel flue gas ducting of rectangular configuration from terminal points of supply for steam generator vendor, of structural steel up to circular brick flue including structural steel stiffening arrangement for the ducting. Providing restraint and support arrangement for ducts on the windshield. Providing RCC ash hoppers connected at the lowest level of duct. Providing supporting arrangement for duct supports outside wind shield. Providing insulation on the outside of brick flues and ducts including protective aluminium sheet. Providing structural steel work for supporting ducting, both inside and outside of windshield. Provision of structural steel stair case inside wind shield from ground floor level to top platform with interconnection to various platforms and cage ladder from top platform to roof of chimney. Painting of RCC windshield and structural steel works. Aviation warning lightning, general lighting inside the chimney and obstruction lighting and all connected electrical works including embedding conduits, junction boxes, pull boxes, cabling etc. Earthing and lighting protection system including all connected works from top of chimney to terminal point outside chimney at ground level. Provision of inserts/pipe sleeves for mounting instruments for monitoring air quality, including conduiting junction, pull boxes, cabling etc. Provision of discrete strakes of galvanised structural steel, if required.
x) xi) xii) xiii)
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xviii)
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2.0 2.1
TIME OF COMPLETION Time of Completion of Works shall be as follows Chimney Work covered under this tender shall be completed within 19 (nineteen) calendar months from the date of issue of Letter of Intent or Work Order whichever is earlier.
SPEC NO.
SECTION: A1
TCE-5607A-H-CCH-400
SCOPE OF ENQUIRY
SHEET 3 OF 3
SL. NO.
DESCRIPTION
PERIOD OF COMPLETION IN MONTHS FROM THE DATE OF LOI 1 Months
1.
Completion of shell and raft design and submitting the same for approval of Consultant / Owner All foundation works below ground level including backfilling etc. Completion of remaining design and submitting the same for approval of Consultant / Owner. (a) (b) (c) Construction of Shell Construction of all internal platforms Completion of lining, insulation, hopper, duct & duct connections complete in all respects, for first Unit
2.
3 Months
4 Months
4.
8 Months 12 Months
16 Months
5.
Completion of lining, insulation hopper, duct & duct connections complete in all respects for second Unit All other accessories such as staircase, MS ladders, lighting including aviation obstruction lights and lightening system, portholes including access platform / staircase, doors, pulley brackets, wire mesh screen, louvers, caps, hand railing, duct work & its connections, painting etc and finishing works
(d)
18 Months
19 Months
2.2
Bidder shall submit a construction bar chart including all activities keeping in mind the period of completion time. SOIL CHARACTERISTICS A detailed report on geotechnical investigation and foundation recommendation for the plant site is available for reference. The BIDDER should contact TCE, Bangalore or BBPL and apprise himself of the details of the report before submitting his bid. The BIDDER, before submission of his bid, may conduct soil investigation test as required by him to ascertain the actual soil condition at site. No claim for extra payment will be entertained if the actual soil conditions are at variance with the data given in the investigation report or with the borelog data enclosed as a bid drawing and the recommended net safe bearing capacity as indicated in Data SheetA, Section-A4. However, in case the BIDDER by his investigation, arrives at a higher bearing capacity or more favourable values of soil parameters, he shall adopt the bearing capacity and parameters as specified and as given in the borelogs enclosed with this specification.
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FILE NAME: F329R4.DOC
TCE FORM NO. 329 R4
SPEC.NO.
TITLE
TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS
SECTION: A2 SHEET 1 OF 6
TCE-5607A-H-CCH-400
1.0 1.1
DEFINITION OF TERMS Owner shall mean M/s Bhubaneswar Power Private Limited. Engineer shall mean the authorised engineer of the Owner. Consultant shall mean TCE Consulting Engineers limited who are appointed by Owner for the project and shall include their duly authorised representatives. Bidder shall mean the firm / party who quotes against an enquiry. Vendor/Contractor/ Fabricator shall mean the successful Bidder whose Bid has been accepted by the Owner and on whom the contract or Purchase Order is placed by the Owner and shall include his heirs, legal representatives, successors and permitted assigns. `Sub-Vendor/ Sub-Contractor/ Sub- Purchaser shall mean the person named in the `Contract undertaking a part of the work or any person to whom a part of the `Contract has been sublet with the consent in writing of the Owner and shall include his heirs, legal representatives, successors and permitted assigns. `Manufacturer refers to a person or firm who is the producer and furnisher of material or designer and fabricator of equipment to either the Owner or the Vendor/Contractor or both under the `contract Òthers shall mean other successful bidders whose bids have been accepted by the owner and to whom the orders have been placed by the owner and shall include their heirs. legal representatives, successors and permitted assigns. Ìnspector shall mean the authorised representatives appointed by the Òwner or the Engineers/Consultant for purpose of inspection of materials/ equipment/works. `Project shall mean the project specified in the project information section -B of the `specification. `Site shall mean the actual place of the proposed ` project as detailed in the `specification or other place where work has to be executed under the contract. `Month shall mean calendar month.
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SPEC.NO.
TITLE
TCE-5607A-H-CCH-400
1.12
`Specification shall mean collectively all the terms and stipulations contained in those portions of the `contract known as General Conditions, the Specifications and such Amendments, Revisions, Deletions or Additions, as may be made in the Agreement and all written Agreements made or to be made pertaining to the method and manner of performing the work or to the quantities and qualities of the materials to be furnished under this `contract. `Bid shall mean the proposal/document that the bidder submits in the requested and specified form in the `specification. `Plant or Equipment and work or `works shall mean respectively the goods to be supplied and services to be provided by the Vendor/ Contractor/Fabricator under the purchase order or contract `Contract or `purchase order shall mean the order and associated specifications executed by the Owner and the Vendor including other documents agreed between the parties or implied to form a part of the `contract `Contract price shall mean, if there is a formal agreement, the prices referred to in the agreement or if there is no formal agreement, the price agreed to be the value of the `contract `Date of Contract shall mean the calendar date on which the Owner and Vendor/Contractor/Fabricator have signed the `contract. Effective Date of contract shall mean the calendar date on which the Owner have issued to the Vendor the `Letter of Intent or three months prior to the `Date of contract or six months prior to the date of issue of the import licence whichever is later or as otherwise mutually agreed to between the Owner and the Vendor. `Contract period shall mean the period during which the `contract shall be executed as agreed between Vendor/Contractor/ Fabricator and Owner in the Contract Guarantee period shall mean the period during which the plant or Èquipment shall give the same performance guaranteed by the Vendor in the schedule or guarantee as in the `Specification.
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1.20 Àpproved and Àpproval where used in the Specification shall mean, respectively, approved by / approval of the Owner/Purchaser or the Engineer/Consultant.
SPEC.NO.
TITLE
TCE-5607A-H-CCH-400
When the words Approved Approval subject to Approval, satisfactory Equal to proper Requested As directed Where directed `When Directed, Determined by Accepted Permitted or words and phrases of like import are used the approval, judgement, direction etc, is understood to be a function of the Owner or the Engineer/ Consultant 1.21 Engineers Instructions shall mean any drawings and /or instructions oral and/or in writing details. Direction and explanations issued by the Engineer/Consultant or the Owner from time to time during the contract period Writing shall include any manuscript. Typewritten or printed statement. Under or over signature and /or seal as the case may be. Notice in Writing or Written Notice shall mean a notice in written, typed or printed characters sent (unless delivered personally or by email or other wise proved to have been received) by registered post to the last known private or business address or registered office of the addressee and shall be deemed to have been received when in the ordinary course of post it would have been delivered. `Contractors works or Manufacturers works shall mean and include the land and other places which are used by the Vendor/Contractor/Fabricator or Sub-Vendor. Sub Contractor, Sub Fabricator for the manufacture of equipment or performing the works Virtual Completion shall mean that all work is completed as directed and the site is cleared to the satisfaction of the Owner or the Engineer/ Consultant Commercial Use shall mean that use of the Equipment or work which the contract contemplates or that for which Equipment or work is commercially capable Minor Modification shall mean the modification work which need a maximum of 8 man-hours per item of work. Major Modification shall mean the modification work needing more than 8 man-hours per item of work. Words importing persons shall include Firms, Companies Corporations and other Bodies whether incorporated or not.
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SPEC.NO.
TITLE
TCE-5607A-H-CCH-400
1.30
Words importing the singular only shall also include the plural and vice versa where the context requires Drawings shall mean all: a) Drawings furnished by the Owner or the Engineer/Consultant as a basis for proposals. b) Supplementary drawings furnished by the Owner or the Engineer/ Consultant to clarify and to define in greater detail the intent of the Contract. c) Drawings submitted by the Vendor with his proposal provided such drawings are acceptable to the Owner or the Engineer/Consultant. d) Drawings furnished by the Owner or the Engineer/ Consultant to the Vendor during the progress of the work: e) Engineering data and drawings submitted by the Vendor during the progress of the work provided such drawings are acceptable to the Engineer/Consultant.
1.31
2.0 2.1
SPECIFICATION DOCUMENT The specification document consists of six sections as listed below and all of these are to be considered together for correct understanding and interpretation of the specification. SECTION A
2.2
2.2.1 Section-A covers the scope of enquiry, definition of terms and specification documents and instructions to bidders. It also includes Data
Sheet-A, which gives specific technical requirements if any
2.3
SECTION-B Section -B furnishes relevant `Project information for the reference and use of the Bidder
2.4
SECTION-C
2.4.1 Section -C contains General notes, schedule of Quantities & rates and list of bid drawings.
SPEC.NO.
TITLE
TCE-5607A-H-CCH-400
2.5
SECTION-D
2.5.1 Section-D comprises technical specifications for works.. 2.6 SECTION-E Section-E covers General Conditions of contract and Special Conditions of Contract. 2.7 SECTION-F Section-F covers Schedule of technical and general deviations if any, Schedule of equipment and schedule of rates for labour. 2.8 The Bidder shall be deemed to have carefully examined the Specification in its complete form and to have fully informed and satisfied himself as to the details, nature, character and quantities of the work to be carried out, site conditions and other pertinent matters and details. In case of any conflict relating to the definition of the terms and conditions of contract, specifications, designs, drawings and instructions mentioned herein after and as to the quality of workmanship or materials used on the works, the decision of the Owner/Consultant shall be final, conclusive and binding on all parties to the Contract. In case of conflict between clauses of different sections of this specifications, the following section(s) shall govern in the order indicated below. 1.) 2.) 3.) 4.) 5.) 2.11 Section C Section A Section D Section C5 Other sections.
2.9
2.10
It is the intent of the Owner to incorporate these specification documents in the final Contract or Purchase order for the services. Bidders are required to review these documents and clearly state in their proposals their acceptance of the same. Exceptions, if any, shall be clearly stipulated in the appropriate bidding schedule. The final `Contract between the Owner and the Contractor shall be subjected to
ISSUE P0
TCE FORM NO. 329 R4
SPEC.NO.
TITLE
TCE-5607A-H-CCH-400
such changes, if any mutually agreed upon between the Owner and the Contractor and included in the main text of the `Contract or Purchase Order 2.12 The Bidder shall specify all the deviations with respect to this specification in the appropriate schedule.(Given in Section F) The Bidder shall furnish the data called for in the Schedules in the standard Pro forma to facilitate correct evaluation of his Bid in a most expeditious manner. The Bidder shall submit the 'Bid' in the above manner, failing which it is likely that his 'Bid' may not be considered.
2.13
SPEC.NO. TCE. 5607A-H-CCH-400

TITLE
TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS
SECTION:
A3
SHEET 1 OF 9
1.0 1.1
INFORMATION FURNISHED This specification is intended as a general description of quality envisaged for material, workmanship and of the finished work. It is not intended to cover minute details. The work shall be executed in accordance with the best modern practice and to the complete satisfaction of Owner Special techniques approved by Engineer shall be used if and where found necessary. The information given in this specification is in good faith and meant to serve as a guide to the Bidder. It is, therefore, imperative that Bidder shall obtain and examine for himself all the data, information and particulars required for the satisfactory execution of the work under this enquiry. The submission of a bid by Bidder implies that he has fully read the specifications, bid drawing, and general conditions of contract. Bidder shall make himself aware of the scope and the specifications for the work to be performed and local conditions and other features which have a bearing on the cost and execution of the work. Extra charges for any reason whatsoever will not be entertained by Owner. General Notes (given in Section-C) shall also be noted before quoting rates against various items in Section -C. In case of any conflict among clauses of different technical specifications given under Section-D, the decision of the Owner/Engineer shall be final and binding on the Contractor. INSPECTION OF SITE BY BIDDER Bidder shall inspect the site, examine and obtain all information required and satisfy himself regarding matters such as access to site, communication, transport, right of way, the type and number of equipment and facilities required for the satisfactory completion of work, the quantity of various items of the work, the availability of local labour, availability and rates of material, local working conditions, uncertainties of weather, obstructions and hindrances that may arise, etc., which may affect the work or cost thereof, before submission of his Bid. Ignorance of site conditions shall not be accepted by the Owner as basis for any claim for compensation. The submission of a bid by the Bidder will be construed as evidence that such an examination was made and any later claims/ disputes in regard to rates quoted shall not be entertained or considered by the Owner. The rates quoted by Bidder shall be based on his own knowledge and judgement of the conditions and hazards involved and shall not be based on any representations of the Engineer. VALIDITY OF BID The Bid shall remain valid for acceptance for three (3) months from the due date of receipt of the Bids and during this period no bidder shall be allowed to withdraw the bid.
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2.0 2.1
2.2
3.0

TITLE
SECTION:
A3
SHEET 2 OF 9
4.0
ACKNOWLEDGEMENT On receipt of bidding document, bidder shall acknowledge the receipt and confirm his intention to bid for the work. Any addendum issued by Owner/ Consultant shall become part of bidding document and bidder shall submit Original addendum duly signed and stamped as a token of his acceptance.
5.0 5.1
MATERIAL SUPPLY AND FACILITIES BY THE OWNER The Owner will provide the following facilities to the Contractor free of cost. (a) (b) Provision of one permanent benchmark and base line for laying out. Construction water at one point.
The owner will provide construction power at one point on chargeable basis.
6.0 6.1
PRICES AND RATES Prices and rates quoted shall include cost of all materials , labour, supervision, setting out, machinery and equipment, transport charges, wastage of material, all consumables such as, but not limited to petrol, oil, diesel, lubricants, drill bits, pipes, ropes, etc., construction facilities such as scaffolding, cribbing, tarpaulins, wind break, etc., taxes, duties, royalties, octroi and any other levies payable on all transactions, all leads and lifts, etc., overheads/profits of Contractor for due performance of the work under this contract. The rates shall also include cost for mobilization/demobilization of equipment. Prices and rates quoted shall be deemed to include everything necessary to satisfactorily complete the work as determined by the Engineer though they may not have been specifically referred to in these documents. Prices and rates quoted shall be firm for the entire duration of the contract and any agreed extensions thereafter. The rates quoted by bidder shall remain unaltered for the use of any type of. cement such as pozzolana, ordinary Portland, sulphate resisting, etc. No price escalation on any account shall be allowed during the entire period of Contract. LIST OF WORKS Bidder shall submit along with their bids complete particulars of similar jobs executed by him.
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TITLE
SECTION:
A3
SHEET 3 OF 9
8.0 8.1
BID DOCUMENTS Under Section-C3, list of the bid drawings enclosed is indicated. The drawings are intended to give the Bidder general idea of the type and extent of work involved. As such, they are indicative and for bid purpose only. Engineering design and construction drawings will be prepared by the contract. Work shall proceed only after approval of construction drawing by the Consultant/ Owner. No alteration or mutilation, other than filling in particulars wherever called for, shall be made in the bid documents. Any changes/modifications made by the Bidder on the bid documents itself shall not be taken into consideration. In case of conflict regarding interpretation of the intent or meaning of the specification or drawing, the Engineer shall interpret such intent or meaning, which will be final and binding on the Contractor. SECURITY DEPOSIT Successful Bidder shall be required to provide a security deposit of 2.5% of the total contract price and shall furnish immediately after placement of LOI, either in the form of unconditional Bank Guarantee (in the format given by owner) from a Nationalized bank or Demand Draft drawn in favour of M/s Bhubaneswar Power Private Limited payable at ________or as advised by owner. This Bank Guarantee shall be valid till completion of the defect liability period.
8.2
8.3
9.0
10.0
MOBILIZATION ADVANCE Interest free mobilization advance of 5% (Five percent) of the contract value will be paid to the successful bidder on submission of an unconditional Bank Guarantee for equivalent amount in the standard format given by the owner from a Nationalized bank. Mobilization advance will be paid only on completion of mobilization at site and after the submission of Security deposit. Mobilization advance shall be recovered from the running account bills of the Contractor on pro-rata basis till the mobilization advance is fully recovered.
11.0
RETENTION MONEY 10% of the gross value of each RA bill shall be retained as retention money. The retention money will be released only after satisfactory completion of all the works and against a bank guarantee (from a Nationalized bank) of equivalent amount. This bank guarantee towards retention money shall be valid till completion of defects liability period.

TITLE
SECTION:
A3
SHEET 4 OF 9
12.0 12.1
TIME OF COMPLETION AND WORK SCHEDULE Time is the essence of this contract. The Contractor shall, within two weeks of receipt of the Letter of Intent submit to the Owner for his approval, a detailed work schedule showing how he proposes to carry out the work. It shall specifically mention time period as well as dates of commencement and completion of each activity. Contractor must strictly adhere to the approved schedule. The Owner reserves the right to revise the schedule at his discretion in order to keep up to the completion date and to suit the project requirement and such alterations shall not entitle the Contractor to any extra payment. The whole works must be proceeded with, within such sections and at such times and in such order and manner as described in these specifications and as directed by the Engineer. No extra payment or relaxation in the rates will be permitted on account of this. Contractor shall make all necessary arrangement at site to mobilize and maintain, machinery, equipment, labour, material and operators to guarantee such minimum / peak rate of progress of the work as is required by the agreed schedule for the timely completion of the work, Bidder shall furnish along with the bid a list of machinery and other equipment he proposes to employ in the work. The Contractor shall make his own arrangements for providing accommodation for all their staff and storage space for equipment and consumables such as but not limited to petrol, diesel, lubricants, oxygen, acetylene, welding rods, etc., together with sufficient quantity of spare parts for efficient and uninterrupted execution of the work. The Contractor shall furnish the engineer monthly report describing the summary of the progress / milestones achieved on each of the major fronts during the month accompanied with Photographs. Apart from it weekly work charts shall be submitted. Extension of contract period will not be granted by the owner except only under force majeure conditions equal to the time, force majeure conditions were in existence. Monsoon or inclement weather shall not be considered as a reason for extension of time. Idle time charges for any reason whatsoever shall not be entertained by the owner If the Contractor fails to maintain the stipulated time of completion specified herein above, he shall be liable to pay penalty as set out in `General Conditions of Contract' under Section-E. It shall be clearly understood that failure to meet interim completion dates shall also attract penalty.
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TITLE
SECTION:
A3
SHEET 5 OF 9
13.0 13.1
NIGHT WORK The time of completion as defined in clause herein above, shall be deemed to exclude working during night shifts. However, Engineer may consider granting permission for working during night shifts, if he considers it essential in order to complete the work in the stipulated time, on specific request by the Contractor. Where night work is in progress, the Contractor, at his cost, to safeguard the workmen and the public shall provide sufficient lights, shall take suitable precautions to prevent accidents. Accident-prone areas shall be barricaded and provided with red lights as caution to prevent accidental falls. Contractor shall take all necessary precaution to ensure the quality of work. EQUIPMENT Contractor shall provide and maintain at the site necessary number and type of machinery and equipment including survey instruments in good working condition for proper setting out and timely completion of the various works covered under this specification. All arrangements for transporting the equipment, men and machinery, to and from the site shall be done by the Contractor at his own expense. No claim shall be entertained for mobilizing additional equipment and/or personnel to complete the work within the stipulated time. The Contractor shall ensure a continuous supply of coarse and fine aggregates and other materials conforming to the specification for the duration of the contract period. Contractor shall provide all fuels and lubricants required for the operation and maintenance of construction machinery and equipment as well as his transport vehicles. Contractor shall ensure that work shall proceed uninterrupted even in the event of power failures. As such, adequate number of diesel operated machinery (such as concrete mixers, vibrators, welding sets, etc.) shall be provided by the Contractor as an alternative arrangement in case electrically operated machinery are proposed to be brought to site. WORK EXECUTION AND SUPERVISION Contractor shall have at the site adequate number of qualified engineers and supervisors with experience in execution of similar type of works and also sufficient number of foremen and operators for machinery and equipment, for satisfactory progress and timely completion of the works. In the event of occurrence of any accident at/near the site of work or in connection with execution of the work, a report shall be made immediately to the Engineer, giving full details of the accident. He shall also report such accidents to all the competent authorities.
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TITLE
SECTION:
A3
SHEET 6 OF 9
15.3
The Engineer reserves the right to order in writing from time to time during progress of the work, removal and re-execution of any work which is not, in the opinion of the Engineer, in accordance with the specification. During inclement weather, rains, Contractor shall suspend grouting/ concreting for such time as the Engineer may direct and shall protect from damage all works already in progress or completed just then. All such temporary protective measures shall be at Contractor's cost and any damage to works shall be made good by the Contractor at his own expense. Should the works be suspended by reason of strike/riots by Contractor's own employees or any other cause whatsoever, save and except the force majeure condition, Contractor shall take all precautions necessary for the protection of work and make good, at his expense, any damage arising from any of these causes. Owner reserves the right to split up the work mentioned in the scope of enquiry among more than one Contractor at the stage of initial award of contract or during progress of work due to unsatisfactory progress of work at site by the Contractor. Bidders quoted rates shall remain unaltered even if the work is split up. Owner will not entertain any claim from the Contractor as a result of such splitting up. SURVEYING AND LAYOUT Only a base line and one permanent benchmark would be furnished to the Contractor on site. Surveying and laying out of all works shall be done by the Contractor at his cost. Contractor shall maintain without disturbance during the course of execution of the work the reference line and the benchmark. The Contractor shall also check the accuracy of positioning of the footings and anchor bolts for the structural to be erected by him. Any discrepancy shall immediately be reported to the Owner. CONTRACTOR'S RESPONSIBILITIES The Contractor will be required to provide at his own cost all facilities for his office, warehouse, tool room, change room or any other building/structure required to execute his work. Each Contractor shall establish his own office / shed at specified place inside the plant. The office/shed shall have proper ventilation lighting and sanitary facilities. The Contractor shall obtain clearance from the Owner before construction of the office/shed. All royalties shall be paid by the Contractor as also all tolls, local and other taxes, etc. at no extra cost to Owner. All materials supplied by the Contractor shall be of the best quality and shall conform to this specification. Approval in writing shall be obtained from Owner before any alternative or equivalent material is proposed to be used by the Contractor.
ISSUE P0
15.4
15.5
15.6
17.0 17.1
18.0 18.1
18.2
18.3
18.4
TCE FORM NO. 329 R4

TITLE
SECTION:
A3
SHEET 7 OF 9
18.5
Contractor shall furnish manufacturer's test certificates for the materials supplied by him. Where such certificates are not available, the specimen of the material shall be got tested at a recognized testing laboratory (approved by Owner) at Contractor's cost. Contractor shall obtain all necessary permits and licenses before commencement of work at no extra cost to Owner. Contractor shall take all necessary insurance coverage as per the statutory requirement at no extra cost to Owner. DEMOBILISATION On completion of work, the Contractor shall promptly demobilize from the site and leave the place in a manner as directed by the Owner/Engineer, including cleaning of the area. Contractor shall start demobilization only after the successful completion of the contract with the permission of Owner.
18.6
18.7
19.0
20.0
OTHER WORKS During the course of contractors works, other works either by the Owner or by other Contractors or by both simultaneously will be in progress within the project area. Contractor shall make his best effort to work in harmony with others in the best overall interest of the project and towards its speedy completion.
21.0 21.1
SECURITY & SAFETY RULES OF OWNER All persons employed or allowed at the site shall at all times conform to all regulations laid down by the Owner. Contractor shall strictly abide by the rules and regulations of security and safety enforced by the Owner. Contractor shall provide proper identity cards, badges, etc., to his employees whenever directed by the Owner. Contractor shall be solely responsible for the security of his personnel and equipment. Contractor, his employees and agents shall not disclose any information or drawing furnished to them by the Owner / Engineer. All drawings, reports or any other information prepared by the Owner / Engineer / Contractor, either individually or jointly for the execution of the contract shall not be disclosed without prior written approval of the Owner. No photographs of the work or plant within the project site shall be taken without prior written approval of the Owner. Contractor shall adopt all safety measures/provide necessary protection to already constructed foundation/structures irrespective of the sequence of construction.
21.2
21.3
21.4
21.5

TITLE
SECTION:
A3
SHEET 8 OF 9
22.0
PAYMENT The mode of submission of bills and payment shall be as indicated in the General Conditions of Contract under Section-E.
23.0 23.1
DRAWINGS AND DETAILS The Contractor shall prepare fabrication drawings for structural steel works based on his design drawings approved for construction by the Consultant / Owner. SUBMISSION OF BID Procedure for Submission The completed bids shall be submitted on or before the last date and in the manner described in the notice inviting tender
24.0 24.1
24.4
Bid shall be sealed and cover shall be superscribed BHUBANESWAR POWER PRIVATE LIMITED- Proposed 2X80MW Captive Power Plant
24.5
Each page of the bid document including the bid drawings shall be signed and dated in ink by the Bidder as a token of having examined the same. English language and metric units shall only be used. Any corrections in the rates entered in the Schedule of Quantities shall also be signed and dated by the Bidder in ink, before submitting the bid. Non-compliance with these conditions will make the bid liable for rejection.
24.6
The bid prices and rates must be filled only in the Schedule of Quantities. Bidder shall also fill in the schedule of deviations from technical specifications and general conditions of contract. If these schedules of deviations are not filled up, it shall be deemed that the bidder abides by the stipulations as in the bid documents. Bid shall be accompanied by a covering letter, in which Bidder may furnish any information, which he wishes to be considered along with the bid. All accompaniments of the bid shall be in duplicate. Bidder shall submit along with his bid an attested copy of Income Tax and Sales Tax Clearance Certificates, audited balance sheet for the last three financial years and latest solvency certificate from the competent authorities. Details of concurrent commitments of bidder along with list of similar works executed in last five years and list of Manpower and equipment to be deployed on this project and schedule of execution to be furnished along with the bid.
24.7
24.8 24.9
24.10

TITLE
SECTION:
A3
SHEET 9 OF 9
25.0 25.1
OWNER RESERVES RIGHT The Owner reserves the right to accept any bid irrespective of whether it is the lowest or otherwise or reject any or all bids without assigning any reasons whatsoever. Owner reserves the right to split the work and/ or delete or add some works from the scope of this contract.
SPEC.NO. TCE.5607A-H-CCH-400
TITLE
TCE CONSULTING ENGINEERS LIMITED RC CHIMNEY - SPECIFIC TECHNICAL
SECTION: A4
SHEET 1 OF 4
(A) 1.0 1.1 (a)
PRINCIPAL DESIGN PARAMETERS DIMENSIONS OF CHIMNEY Clear inside diameter of brick lining at : exit level Clear inside diameter of concrete shell at : top (Minimum) Minimum thickness of shell at the top Top elevation of concrete shell Batter of concrete surface Internal External : : : : 3000 mm
1.1 (b)
11000 mm
1.1 (c) 1.2 1.3
250 mm EL +150.000M
1.4
Maximum external diameter of shell of : chimney grade slab level Graded level of ground (EL) Chimney grade slab level (EL) Number of flue duct openings : : :
1.5 1.6 1.7 1.8
(+) 0.000 (+) 0.30 m Two 1000 mm
Minimum earth filling on top of raft (refer : 1.5 above) FLUE GAS DATA Maximum volume of flue gas through the : chimney Maximum flue gas temperature at entry : of chimney Flue gas pressure at chimney inlet Maximum flue gas quantity Gas analysis by volume % N2 CO2 O2 : : : : :
2.0 2.1
151 m3/sec. 140 0C
2.2
2.3 2.4 2.5
69.57(Prelimnary) 13.33 3.05 (-do-) (-do-)

ISSUE P0
TCE FORM NO. 329 R4
TITLE
SECTION: A4
SHEET 2 OF 4
SO2 H2O 3.0 3.1 DESIGN TEMPERATURES Outside ambient temperature : Maximum Minimum 3.2
: :
0.09 13.95
(-do-) (-do-)
: :
-0C - 0C 200C
Minimum thermal gradient in shell for : whole height ANALYSIS (a) Wind Load Analysis CD = Drag coefficient :
4.0
0.8
(For strake portion additional drag coefficient shall be considered as per Cl.A.7.1 of IS:4998 (Par-I)). Vb = Basic Wind Speed : : : : 50 m/sec. 2 C 1.00
Terrain category Class of structure Topography factor k3 (b) For Seismic Analaysis
Seismic Zone = 5.0 5.1 5.2 DESIGN DATA Modular Ratio for stress computation Increase in concrete stress permissible : due to ageing Density of ash in hopper :
III
As per IS:4998(Part-1)-1975 Nil 1.12 t/m3 0.06 kCal/m/hr/0C
5.3 5.4
Maximum coefficient of thermal : conductivity of glass / mineral wool insulation at 1500C mean temperature
TITLE
SECTION: A4
SHEET 3 OF 4
5.5
For computation of temperature stress, the modules of Elasticity of Concrete to be used shall be obtained as Es/m where modular ratio m shall be as per Clause 5.1 above, and Es taken as 210000 N/mm2. Coefficient of linear thermal expansion of : concrete and reinforcement GENERAL REQUIREMENTS Method of shell construction : Slipform above hopper ring beam and slip/jump form below this level. If required it shall be provided as per the Stipulation of IS 4998 - (Part I) Yes 11x10 6/0C
5.6
6.0 6.1
6.2
Provision of strakes
6.3
6.4
Provision for separate hoists for : materials and passenger during construction Provisions for instrumentation :
Provisions shall include embeddment plates, conduits for all I&C cables and purge air, junction boxes, etc. complete as per Specification. The number of conduits and size of conduits shall be as required during detail engineering. Suitable opening, pipe sleeve, flange, access platform for working on analyser etc. shall be provided as required for purchasers analysers.
7.0 7.1
DEFLECTION ON WIND SHIELD The permissible deflection at top of windshield shall not exceed H/500, where H is the total height of the windshield above top of foundation. The amplitude of cross wind oscillation shall also be restricted to 80% of the limits laid down as above.
7.2
TITLE
SECTION: A4
SHEET 4 OF 4
8.0
FLOODING OF CHIMNEY AREA CONTRACTOR shall be responsible for taking all safety measures necessary for protecting all materials stored by him against damage by rainwater or flooding from any other source. If any material is damaged, the CONTRACTOR shall replace the same at no cost to the OWNER. The OWNER shall not entertain any claim of the CONTRACTOR on this account.
9.0
The bidder shall assume subsoil water table at ground level for chimney foundation design. TESTS All materials and workmanship shall be of respective kinds described in the Contract and in accordance with the Engineer instructions and shall be subjected from time to time to such tests as the Engineer may direct at the place of manufacture or fabrication or on site or at all or any of such places. For other structural components like pre-cast slabs bought out materials like bitumen, water bar, tarfelt, acid resistant tiles bricks, fire clay bricks and mortar, aggregates or any other material whose conformity to requirement of specifications cannot be authenticated by CONTRACTOR by ISI certificate etc., these materials will be got tested at approved laboratories. The cost of samples and conducting all such tests as stated above shall be borne by the CONTRACTOR.
10.0
SPEC NO. TCE.5607A-H-CCH-400
TCE CONSULTING ENGINEERS LIMITED PROJECT INFORMATION
SECTION: B SHEET 1 OF 4
1.1 1.2
Owner / PURCHASER ENGINEER / CONSULTANT
: :
BHUBANESHWAR POWER PRIVATE LIMITED. TCE Consulting Engineers Limited, 73/1, St. Marks Road, Bangalore 560 001 Bhubaneshwar Power Pvt. Ltd.-2X80MW CAPTIVE POWER PLANT(coal based) near CUTTACK Ananantpur(village),Athagarh,Tehsil, Cuttack(Dist.), Orissa Undulated. (+)25 m to(+)45m above MSL 200 28 N 850 44 E Ghantikal (4KM) East Coast Railways
1.3
Project Title
1.4 1.5
Location Elevation above sea level
: :
1.6 1.7 1.8 1.9
Latitude Longitude Nearest Railway Station Name of Railway
: : : :
1.10
Nearest Airport
Bhubaneshwar (45KM)
1.11
Ambient Air Temperatures a) b) c) Maximum temperature dry bulb
: : : : : : : : : 84% 47% 77% November to February- North East/East March to October- South/ South West. 47.70 C 7.80 C 330 C
Minimum dry bulb temperature Average dry bulb temperature
1.12
Relative humidity a) b) c) Maximum Minimum Average
1.13
Wind Rose Data
1.14
Rainfall
Annual average rainfall is 1475.3 mm. Maximum rainfall occurs between June to October.
ISSUE P0
TCE FORM NO. 329 R4
1.15 1.16
Flood level Tropicalisation :
27.61M above MSL a) All equipment supplied against this specification shall be given tropical and fungicidal treatment considering the climatic conditions prevailing at site as described. Wind loads shall be considered as per IS : 875 with basic wind speed of 50 m / sec with K1 = 1.08, K2 corresponding to terrain category 2 and K3 = 1.0
1.17
Wind Load
1.18
Wind Speed Max (km/h) Min (km/h) Annual mean (km/h) 180 2 12 : : Barang to Athagarh road, 20KM from National highway no.42 at Khuntuni. Broad gauge railway line of East Coast Railways between Barang to Ghantical (Khurda Division) As per IS 1893 2002 for zone III,. Importance factor = 1.75
1.19
Transport By Road
By Rail
1.20
Seismic Data (As per IS:1893 latest issue)
1.21
Auxiliary Power Supply
Auxiliary electrical equipment to be supplied against this specification shall be suitable for operation on the following supply system. 6600V AC, 3 Phase, 4 Wire, 50 Hz, medium resistance earthed 400V AC, 3 Phase, Hz, solidly earthed 4 Wire, 50
a)
For motors rated above 200 kW
b)
For motors rated 200 kW and below
c)
DC system for emergency drives, : emergency lighting, Solenoids, DC
220V DC, 2 Wire, unearthed
alarm, control and protections d) AC controls and protective devices : 110V AC, 1 Phase, 50 Hz, 2 Wire AC supply. With one point earthed. The single phase 110V AC supply shall be derived by VENDOR by providing 400V / 110V control transformers of adequate rating with MCCB / MCB on both the primary and secondary sides. 230V, 1 Phase, 50 Hz, 2 Wire AC supply from UPS system for I&C system , SG and TG packages only. 230V, 1 Phase, 2 Wire, 50 Hz AC system. The power supply shall be derived by VENDOR by providing 400V/240V transformer of adequate rating with MCCB /MCB on primary/ secondary sides. +24 V DC, 2 Wire, unearthed, supply for I & C system, SG and TG packages only. 230V, 1 Phase, 2 Wire, 50 Hz earthed AC system 230V, 1 Phase, 2 Wire, 50 Hz earthed AC system. VENDOR shall provide suitable MCB in the panel to receive PURCHASERs supply at the panel. 415V, 3 Phase, 4 Wire, 50 Hz AC supply with neutral lead solidly earthed (provided by PURCHASER at one point only). :
e)
Uninterruptible power supply
f)
AC Solenoids, space heaters (for : motors rated 30 kW and above)
g)
Solid state controls solenoid valves)
(including :
h)
Lighting fixtures
i)
Lighting fixtures and space heaters : in panels
j)
Construction supply
k)
The above voltages will vary as follows:
All devices shall be suitable for continuous operation over the entire range of voltage
and frequency indicated below without any change in their performance.: = 10% i) AC Supply : Voltage variation Frequency variation = 5%
Combined voltage & Frequency variation = 10% Ii) DC Supply : 24V DC: Voltage variation = + 10% to - 10%. 220V DC: +10% to -15% Voltage regulation (steady state) = 20% Transient voltage Regulation = 10%
Iii)
UPS Supply (on standby AC supply with automatic voltage regulator)
Frequency variation = 5% 1.22 Design temperature equipment / devices for electrical : 500 C
SPEC.NO. TCE-5607A-H-CCH-400
TCE CONSULTING ENGINEERS LTD.

TITLE
SECTION: C1
SCHEDULE OF QUANTITIES AND PRICES GENERAL NOTES
SHEET 1 OF 1
1.0
The Schedules in SectionC2 must be read in conjunction with the enclosed specifications and drawings. The BIDDER is deemed to have examined the technical, general and special conditions of contract and to have acquainted himself with the site conditions and the details of the work to be done, and the manner in which the work is to be executed at site. The Lumpsum price should include cost of all materials (except those issued by the OWNER), labour, tools, plants, equipments all requirements of temporary work and contingencies whether referred to or not in the specification, for the satisfactory and proper completion of the job. The BIDDER shall quote his rates against items of work listed in SectionC2, which may be required to be executed or deleted by him as a variation from the Lumpsum Price quoted, and for works which may not fall under the Lumpsum Price. The rates given will not be considered for tender analysis. The rates quoted shall be reasonable. Rates and prices shall be written in ink and shall be both in figure and in words. Where there is any discrepancy between the rates quoted in figures and words, the rates quoted in words shall prevail. The unit rates quoted shall include for minor details of construction which are obviously and fairly intended and which may not have been referred to in this document but are essential for the satisfactory completion of the work. Rates against the Lumpsum Price and for item rates shall include cost of dewatering where necessary and no claim for payment on this account will be entertained by the OWNER. Rates quoted shall include for clearances of site both prior to commencement of work and after its completion. Being a Lumpsum Tender, the payment clauses mentioned in detailed specifications of SectionD are not applicable for any work / item carried out under the scope of lumpsum Contract. Abbreviations used for the unit of various items are as stated below: t kg rm mm m2 m3 No = = = = = = = tonne (1000 kg ) kilogram running meter millimeter square meter cubic meter Number
ISSUE P0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
TCE FORM NO. 329 R4
TITLE
TCE CONSULTING ENGINEERS LIMITED BIDDING SCHEDULE FOR MULTIFLUE CHIMNEY WITH BRICK FLUE
DESCRIPTION
SECTION: C2
SHEET 1 OF 6
SL. NO. 1.1
AMOUNT Rs.
Lumpsum price for designing, supplying, constructing and commissioning of one number two flues RCC Chimney 150M High including but not limited to excavation for foundation raft with de-watering, if required, back filling including compaction and disposal of surplus soil to stack or fill, concreting of raft including removal of muck, laying of PCC mudmat, casting of pedestals for supporting flue ducts and stair case, providing of dowels in raft to start shell construction, approved quality earth filling over raft, RCC flooring with integral finish inside the chimney including laying of 100mm thick PCC 1:4:8 over compacted earth filling, shell (shaft) including air inlet and outlet openings with Aluminium louvers and SST bird screens, pockets/openings to seat steel beams for intermediate internal platforms with RCC slabs, openings for aviation obstruction lights, access to roof slab, openings for flue ducts, etc., strakes (if required) with MS plates, angles etc., including cost of all materials, labour, hot dip galvanising, anticorrosive painting, designing and installation on the chimney shell with hot dip galvanised bolts in sleeves left in the shell for the purpose, intermediate internal platforms including elastomeric bearing pads below beams & filler material at top of beams, hand-rails, bottom soot / ash hoppers with cellular concrete including pipes with flanges in hoppers, fire / acid resistant brick lining with metal ties including curing, steel bands around brick lining, acid proof tile flooring on the top platform, insulation around brick lining and ducts, GI sheet cladding around insulation, access, maintenance and clean out doors, structural steel stair case, hot dip galvanised MS ladders, lightning protection system, earthing system, aviation warning beacons, flood lights, lighting conduits with cable boxes, control panel, main Distribution Board / lighting Distribution Board, photocells, CI Chimney Caps, fabrication and fixing of flue ducts including their supports, portholes with their fitting for installation of gas analysers in MS ducts with access staircase platforms arrangement, mild and /or steel reinforcement embedments / inserts, plates anchors / bolts, pipe sleeves, for instruments, fixtures, wind strakes, etc. painting both internal and external surfaces, providing and installing of hoists for construction purposes with all accessories for men & material, necessary staging, shuttering (formwork including slipform), scaffolding, bracing, centering, including supervision, supply and cost of all materials, labour, all tools and plants, equipments, winches, machinery (including diesel operated) and all leads and lifts vibrating, curing etc. dismantling etc., clearance of site to restore it to original finish and all other remaining & finishing works, complete to form a workable complete chimney arrangement as detailed in the scope of work, as per specifications, as depicted in the bid drawings and as directed by ENGINEER.
SL. NO.
DESCRIPTION
PERCENTAGE OF LUMPSUM
ISSUE P0
TCE FORM NO. 329 R4
TITLE
SECTION: C2
SHEET 2 OF 6
PRICE 2.0 Price Break up as a percentage of the total Lumpsum price quoted under item 1.1. a) b) On approval of soil investigation report, G.A. drawings and design & detailed foundation drawings On approval of design & detailed shell, shell openings drawings
2.1
0.5% 0.5%
2.2
FOUNDATION WORK a) On completion of Excavation work including disposal b) On laying raft including pedestals for duct & stair case earth filling (inside), earth filling (outside), compaction etc. On raising RCC shell to 0.00m level
1% 10%
c) 2.3
2%
RCC SHELL a) On mobilisation of slipform equipment at site b) c) On erection of slipform equipment in position On completion of RCC shell To To 45.0m level 90.0m level
3% 2% 9% 7% 5% 2%
To 135.0m level To 150.0m level 2.4 a) b) c) STEEL BEAM PLATFORMS On fabrication of steel beams On erection of steel beams On laying of RCC slabs on beams On completion of painting of steel beams
2% 1% 1%
d)
1%
2.5
RCC PLATFORMS a) On completion of RCC platforms
12%
ISSUE P0
TCE FORM NO. 329 R4
TITLE
SECTION: C2
SHEET 3 OF 6
b)
On completion of laying of concrete on top level platforms (including laying of top slab) On completion of railing work (external & internal)
1% 1%
c) 2.6
LINING & INSULATION (BOTH FLUES) a) For complete lining work b) For complete Insulation & cladding work (including provision of MS bands around brick flues)
6% 6%
2.7
HOPPERS (BOTH FLUES) a) Construction of hoppers Providing and fixing of CI caps STAIRCASE & LADDERS a) Fabrication and galvanising b) c) On completion of erection work On completion of painting work
2% 1%
2.8 2.9
2.5% 1% 1%
2.10
Provision of port holes, of completion of ducts connections including painting (both flues) Electrical works including earthing, aviation obstruction lights Lightning protection works including earthing PAINTING OF CHIMNEY a) b) c) External surface of chimney Internal surface of shell and platforms Internal provision such as railings and doors etc.
1% 3% 1%
2.11 2.12 2.13
1.5% 1.5% 0.5% 0.5%
2.14
Flooring at 0.00 metre level including laying of 100 mm thick PCC (1:4:8) over compacted sand filling Miscellaneous Fabrication, erection and painting works such as portholes including access platforms, doors, pulley brackets, wire mesh screens, louvers, etc. Finishing work, site clearance, etc
2.15
1.5%
2.16
1%
TITLE
SECTION: C2
SHEET 4 OF 6
2.17
Final commissioning and completion of all other works in all respects Total
10% 100%
NOTES: 1. In the event of the tenderer not accepting the break-up of lumpsum price his bid shall be treated as unresponsive and shall be summarily rejected. The bidder shall under no circumstances change the pattern of the break up. Intermediate payments shall be released in stages to the extent as per price break up given above. VENDOR shall quote his rates against items of work which may be required to be executed/deleted by him as a variation from the Lumpsum price quoted in Bidding Schedule and for essential works which may not fall under the Lumpsum price which the CONTRACTOR may be asked to execute/delete. This schedule will not be considered for bid analysis. The rates quoted shall be reasonable :
2. 3.
4.
5.
Sl. No.
Description
Unit
Rate (Rs.)
1.
Excavation below ground/grade level in all kinds of ordinary and hard soils for foundation/footings, trenches, etc. including desilting, dewatering, if required, shoring, strutting as necessary, backfilling around foundation with selected earth and consolidating by watering and transporting excess excavated soil to stackyards as directed by the OWNER. Providing and placing reinforced cement concrete with 40 mm down graded coarse aggregate excluding reinforcement but including dewatering if required, shuttering, scaffolding, vibrating, finishing, curing, for all,etc, complete.
m3
2.
For works below ground level as per specification and as directed by the ENGINEER:
TITLE
SECTION: C2
SHEET 5 OF 6
(a) (b) (c) (d)
M25 M30 M35 M40
m3 m3 m3 m3
3.
Providing and placing reinforced cement concrete with 20 mm down graded coarse aggregate excluding reinforcement but including dewatering if required, shuttering, scaffolding, vibrating, finishing, curing,etc complete for all works below ground level as per specification and as directed by the ENGINEER. (a) M25 (b) M30 (c) M35 Same as above but providing above ground level (a) M25 (b) M30 (c) M35 (d) M40 Providing and laying plain cement concrete in blinding layer/fill under etc. with 40 mm down graded coarse aggregate including dewatering, shuttering, curing etc. complete for the following grades : (a) 1:4:8
m3 m3 m3 m3 m3 m3 m3
5.
m3
6.
Providing, supplying, cleaning, cutting, lapping, bending as per drawings and placing in position reinforcement bars at all locations and levels including binding with 2 strands of 18 gauge soft annealed wire/welding as required etc. complete as shown on construction drawings : (a) Mild steel bars conforming to IS:432 Gr-I (b) High yield strength deformed bars conforming to IS:1786 t t
7.
Providing, supplying, placing, aligning fixing in position to correct lines and levels all steel inserts in reinforced concrete works including fabrication and painting exposed surfaces as per specification.
8.
Supply, providing and fix in position, etc. complete 5 x 6 mm GI strip down conductor anchored at every 700 mm
ISSUE P0
TCE FORM NO. 329 R4
TITLE
rm
SECTION: C2
SHEET 6 OF 6
including all necessary fixtures as per specification and as directed by OWNER, including painting with black bitumen over a coat of etching primer. 9. Supply, provide and fix in position two stranded tinned copper down conductors of area 75 sq.mm including embedding in the concrete shell, etc completed as per specification and as directed by OWNER.
rm
SPEC. NO. TCE. 5607A-H-CCH-400

TITLE
SECTION: C3 SHEET 1 OF 1
LIST OF BID DRAWINGS
LIST OF BID DRAWINGS
1.0 2.0 3.0 4.0
TCE-5607A-GA-100-1001-P5 TCE-5607A-266-RC-5004-P0 TCE 5312A-816-GL-3071-P0 TCE 5312A-815-GL-3070-P0
Plot Plan 150Mt High RCC Chimney General Arrangement RC Chimney Earthing and Lightning Protection Layout RC Chimney Lighting Layout
SPEC. NO.

TITLE
SECTION: D1 SHEET 1 OF 11
TCE-5607A-HCCH-400
EARTHWORK IN GRADING, EXCAVATON AND BACK FILLING
1.
SCOPE This specification covers the general requirements of earthwork in excavation in different materials, site grading, filling in areas as shown in drawing, filling back around foundations and in plinths, conveyance and disposal of surplus soils or stacking them properly as shown on the drawings and as directed by the Engineer and all operations covered within the intent and purpose of this specification.
2.
APPLICABLE CODES The following Indian Standard Codes, unless otherwise specified herein, shall be applicable. All Codes and Standards referred to shall be the latest version on the date of offer made by the Bidder unless otherwise indicated.
1. IS 783-1985 2. IS 1200 (Part 1) (Part 27) 3. 4. IS 3764-1992 IS 2720 (Part 1)-1973 (Part 2)-1986 (Part 4)(Part 5) (Part 7) Part (9)
- Code of practice for laying of concrete pipes. - Method of measurement of building and civil engineering works. Part 1- Earthwork Part 27- Earthwork done by mechanical appliances. - Excavation work-code of safety. - Methods of test for soils: - Part 1 Preparation of dry soil samples for various tests. - Part 2 Determination of water content. - Part 4 Grain size analysis. - Part 5 Determination of liquid and plastic limit. - Part 7 Determination of water content-dry density relation using light compaction. - Part 9 Determination of dry density - moisture content relation by constant weight of soil method. - Part 14 Determination of density index (relative density) of cohesionless soils. - Part 28 Determination of dry density of soils in place, by the sand replacement method. ISSUE P0
(Part 14) (Part 28)
TCE FORM NO. 329 R4
SPEC. NO.

TITLE
TCE-5607A-HCCH-400
(Part 33) (Part 34) (Part 38)
- Part 33 Determination of the density in place by the ring and water replacement method. - Part 34 Determination of density of soil in place by rubber balloon method. - Part 38 Compaction control test (Hilf Method).
3. 3.1
DRAWINGS The Engineer will furnish drawings wherever, in his opinion, such drawings are required to show areas to be excavated/ filled grade level, sequence of priorities etc. The Contractor shall follow strictly such drawings. GENERAL The Contractor shall furnish all tools, plants, instruments, qualified supervisory personnel, labour, materials any temporary works, consumables, any and everything necessary, whether or not such items are specifically stated herein for completion of the job in accordance with the specification requirements. The Contractor shall carry out the survey of the site before excavation and set properly all lines and establish levels for various works such as earthwork in excavation for grading, basement, foundations, plinth filling, roads, drains, cable trenches, pipelines etc. Such survey shall be carried out by taking accurate cross sections of the area perpendicular to established reference/ grid lines at 8 m. intervals or nearer as determined by the Engineer based on ground profile. These shall be checked by the Engineer and thereafter properly recorded. The excavation shall be done to correct lines and levels. This shall also include, where required, proper shoring to maintain excavations and also the furnishing, erecting and maintaining of substantial barricades around excavated areas and warning lamps at night for ensuring safety. The rates quoted shall also include for dumping of excavated materials in regular heaps, bunds, riprap with regular slopes as directed by the Engineer, within the lead specified and levelling the same so as to provide natural drainage. Rock/ soil excavated shall be stacked properly as directed by the Engineer. As a rule, all softer material shall be laid along the centre of heaps, the harder and more weather resisting materials forming the casing on the sides and the top. Rock shall be stacked separately. ISSUE P0
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5. 5.1
CLEARING The area to be excavated / filled shall be cleared of fences, trees, plants, logs, stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If any roots or stumps of trees are met during excavation, they shall also be removed. The material so removed shall be burnt or disposed off as directed by the Engineer. Where earthfill is intended, the area shall be stripped of all loose/ soft patches, top soil containing objectionable matter/ materials before fill commences. PRECIOUS OBJECTS,RELICS,OBJECTS OF ANTIQUITY,ETC. All gold, silver, oil, minerals, archaeological and other findings of importance, trees cut or other materials of any description and all precious stones, coins, treasures, relics, antiquities and other similar things which may be found in or upon the site shall be the property of the Owner and the Contractor shall duly preserve the same to the satisfaction of the Owner and from time to time deliver the same to such person or persons as the Owner may from time to time authorise or appoint to receive the same. CLASSIFICATION All materials to be excavated shall be classified by the Engineer, into one of the following classes and shall be paid for at the rate tendered for that particular class of material. No distinction shall be made whether the material is dry, moist or wet. The decision of the Engineer regarding the classification of the material shall be final and binding on the Contractor and not be a subject matter of any appeal or arbitration. Any earthwork will be classified under any of the following categories: (a) Ordinary and Hard Soils These shall include all kinds of soils containing kankar, sand, silt, murrum and/or shingle, gravel, clay, loam, peat, ash, shale, etc., which can generally be excavated by spade, pick axes and shovel, and which is not classified under "Soft and Decomposed Rock" and "Hard Rock" defined below. This shall also include embedded rock boulders not longer than 1 metre in any one direction and not more than 200 mm in any one of the other two directions. (b) Soft and Decomposed Rock This shall include rock, boulders, slag, chalk, slate, hard micaschist, laetrile and all other materials which in the opinion of Engineer is rock, but does not need blasting and could be removed with picks, hammer, crow bars, wedges, and pneumatic breaking equipment. The mere fact ISSUE P0
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that the Contractor resorts to blasting for reasons of his own, shall not qualify for classification under 'Hard Rock'. This shall also include excavation in macadam and tarred roads and pavements. This shall also include rock boulders not longer than 1 metre in any direction and not more than 500 mm in any one of the other two directions. Masonry to be dismantled will also be measured under this item. (c) Hard Rock This shall include all rock occurring in large continuous masses which cannot be removed except by blasting for loosening it. Harder varieties of rock with or without veins and secondary minerals which, in the opinion of the Engineer require blasting shall be considered as hard rock. Boulders of rock occurring in such sizes and not classified under (a) and (b) above shall also be classified as hard rock. Concrete work both reinforced and unreinforced to be dismantled will be measured under this item, unless a separate provision is made in the Schedule of Quantities. 8. 8.1 EXCAVATION All excavation work shall be carried out by mechanical equipment unless, in the opinion of the Engineer, the work involved and time schedule permit manual work. Excavation for permanent work shall be taken out to such widths, lengths, depths and profiles as are shown on the drawings or such other lines and grades as may be specified by the Engineer. Rough excavation shall be carried out to a depth 150 mm above the final level. The balance shall be excavated with special care. Soft pockets shall be removed even below the final level and extra excavation filled up as directed by the Engineer. The final excavation if so instructed by the Engineer, should be carried out just prior to laying the mud-mat. The Contractor may, for facility of work or similar other reasons excavate, and also backfill later, if so approved by the Engineer, at his own cost outside the lines shown on the drawings or directed by the Engineer. Should any excavation be taken below the specified elevations, the Contractor shall fill it up, with concrete of the same class as in the foundation resting thereon, upto the required elevation. No extra shall be claimed by the Contractor on this account. All excavation shall be done to the minimum dimensions as required for safety and working facility. Prior approval of the Engineer shall be obtained by the Contractor in each individual case, for the method he proposes to adopt for the excavation, including dimensions, side ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
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slopes, dewatering, disposal, etc. This approval, however, shall not in any way relieve the Contractor of his responsibility for any consequent loss or damage. The excavation must be carried out in the most expeditious and efficient manner. Side slopes shall be as steep as will stand safely for the actual soil conditions encountered. Every precaution shall be taken to prevent slips. Should slips occur, the slipped material shall be removed and the slope dressed to a modified stable slope. Removal of the slipped earth will not be paid for if the slips are due to the negligenc e of the Contractor. 8.5 Excavation shall be carried out with such tools, tackles and equipment as described hereinbefore. Blasting or other methods may be resorted to in the case of hard rock; however not without the specific permission of the Engineer. The Engineer may also direct that in some extreme case, the rock may be excavated by heating and sudden quenching for splitting the rock. Fire-wood shall be used for burning and payment shall be made for such work as called for in the schedule of quantities. STRIPPING LOOSE ROCK All loose boulders, semi detached rocks (along with earthy stuff which might move therewith) not directly in the excavation but so close to the area to be excavated as to be liable, in the opinion of the Engineer, to fall or otherwise endanger the workmen, equipment, or the work, etc., shall be stripped off and removed away from the area of the excavation. The method used shall be such as not to shatter, or render unstable or unsafe the portion which was originally sound and safe. Any material not requiring removal as contemplated in the work, but which, in the opinion of the Engineer, is likely to become loose or unstable later, shall also be promptly and satisfactorily removed as directed by the Engineer. The cost of such stripping will be paid for at the unit rates accepted for the class of materials in question.
8.6
9. 9.1
9.2
10. 10.1
FILL, BACK FILLING AND SITE GRADING General All fill material will be subject to the Engineer's approval. If any material is rejected by the Engineer, the Contractor shall remove the same forthwith from the site at no extra cost to the Owner. Surplus fill material shall be deposited/ disposed off as directed by the Engineer after the fill work is completed.
SPEC. NO.

TITLE
TCE-5607A-HCCH-400
No earthfill shall commence until surface water discharges and streams have been properly intercepted or otherwise dealt with as directed by the Engineer. 10.2 Material To the extent available, selected surplus soils from excavated materials shall be used as backfill. Fill material shall be free from clods, salts, sulphates, organic or other foreign material. All clods of earth shall be broken or removed. Where excavated material is mostly rock, the boulders shall be broken into pieces not larger than 150 mm size, mixed with properly graded fine material consisting of murrum or earth to fill up the voids and the mixture used for filling. 10.3 If any selected fill material is required to be borrowed, the Contractor shall make arrangements for bringing such material from outside borrow pits. The material and source shall be subject to prior approval of the Engineer. The approved borrow pit area shall be cleared of all bushed, roots of trees, plants, rubbish etc. top soil containing salts/ sulphate and other foreign material shall be removed. The materials so removed shall be burnt or disposed off as directed by the Engineer. The Contractor shall make necessary access roads to borrow areas and maintain the same, if such access road does not exist, at his cost. Filling in pits and trenches around foundations of structures,walls etc. As soon as the work in foundations has been accepted and measured, the spaces around the foundations, structures, pits, trenches etc. shall be cleared of all debris, and filled with earth in layers not exceeding 15 cm., each layer being watered, rammed and properly consolidated, before the succeeding one is laid. Each layer shall be consolidated to the satisfaction of the Engineer. Earth shall be rammed with approved mechanical compaction machines. Usually no manual compaction shall be allowed unless the Engineer is satisfied that in some cases manual compaction by tampers cannot be avoided. The final backfill surface shall be trimmed and levelled to proper profile as directed by the Engineer or indicated on the drawings. 10.5 Plinth filling Plinth filling shall be carried out with approved material as described hereinbefore in layers not exceeding 15 cm, watered and compacted with mechanical compaction machines. The Engineer may however permit manual compaction by hand tampers in case he is satisfied that mechanical compaction is not possible. When filling reaches the finished level, the surface shall be flooded with water, unless otherwise directed, for at least 24 hours allowed to dry and then the surface again ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
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compacted as specified above to avoid settlements at a later stage. The finished level of the filling shall be trimmed to the level/ slope specified. Where specified in the schedule of works, compaction of the plinth fill shall be carried out by means of 12 tonne rollers smooth wheeled, sheep-foot or wobbly wheeled rollers. In case of compaction of granular material such as sands and gravel, vibratory rollers shall be used. A smaller weight roller may be used only if permitted by the Engineer. As rolling proceeds water sprinkling shall be done to assist consolidation. Water shall not be sprinkled in case of sandy fill. The thickness of each unconsolidated fill layer can in this case be upto a maximum of 300 mm. The Engineer will determine the thickness of the layers in which fill has to be consolidated depending on the fill material and equipment used. Rolling shall commence from the outer edge and progress towards the centre and continue until compaction is to the satisfaction of the Engineer, but in no case less than 10 passes of the roller will be accepted for each layer. The compacted surface shall be properly shaped, trimmed and consolidated to an even and uniform gradient. All soft spots shall be excavated and filled and consolidated. At some locations/ areas it may not be possible to use rollers because of space restrictions etc. The Contractor shall then be permitted to use pneumatic tampers, rammers etc. and he shall ensure proper compaction. 10.6 Sand filling in plinth and other places At places backfilling shall be carried out with local sand if directed by the Engineer. The sand used shall be clean, medium grained and free from impurities. The filled-in-sand shall be kept flooded with water for 24 hours to ensure maximum consolidation. Any temporary work required to contain sand under flooded condition shall be to the Contractor's account. The surface of the consolidated sand shall be dressed to required level or slope. Construction of floors or other structures on sand fill shall not be started until the Engineer has inspected and approved the fill. 10.7 Filling in trenches Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipes and drains have been tested and passed. The backfilling material shall be properly consolidated by watering and ramming, taking due care that no damage is caused to the pipes. ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
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Where the trenches are excavated in soil, the filling from the bottom of the trench to the level of the centreline of the pipe shall be done by hand compaction with selected approved earth in layers not exceeding 8 cm; backfilling above the level of the centreline of the pipe shall be done with selected earth by hand compaction or other approved means in layers not exceeding 15 cm. In case of excavation of trenches in rock, the filling upto a level 30 cm. above the top of the pipe shall be done with fine materials, such as earth, murrum etc. The filling up of the level of the centreline of the pipe shall be done by hand compaction in layers not exceeding 8 cm. where as the filling above the centreline of the pipe shall be done by hand compaction or approved means in layers not exceeding 15 cm. The filling from a level 30 cm. above the top of the pipe to the top of the trench shall be done by hand or other approved mechanical methods with broken rock filling of size not exceeding 15 cm mixed with fine material as available to fill up the voids. Filling of the trenches shall be carried simultaneously on both sides of the pipe to avoid unequal pressure on the pipe. 11. 11.1 GENERAL SITE GRADING Site grading shall be carried out as indicated in the drawings and as directed by the Engineer. Excavation shall be carried out as specified in the specification. Filling and compaction shall be carried out as specified under Clause 10.0 and elsewhere unless otherwise indicated below. If no compaction is called for, the fill may be deposited to the full height in one operation and levelled. If the fill has to be compacted, it shall be placed in layers not exceeding 225 mm and levelled uniformly and compacted as indicated in Clause 10.0 before the next layer is deposited. To ensure that the fill has been compacted as specified, field and laboratory tests shall be carried out by the Contractor at his cost. Field compaction test shall be carried out at different stages of filling and also after the fill to the entire height has been completed. This shall hold good for embankments as well. The Contractor shall protect the earthfill from being washed away by rain damaged in any other way. Should any slip occur, the Contractor shall remove the affected material and make good the slip at his cost. The fill shall be carried out to such dimensions and levels as indicated on the drawings after the stipulated compaction. The fill will be
11.2
11.3 11.4
11.5
11.6
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considered as incomplete if the desired compaction has not been obtained. 11.7 If specifically permitted by the Engineer, compaction can be obtained by allowing loaded trucks conveying fill or other material to ply over the fill area. Even if such a method is permitted, it will be for the Contractor to demonstrate that the desired/ specified compaction has been obtained. In order that the fill may be reasonably uniform throughout, the material should be dumped in place in approximately uniform layers. Traffic over the fill shall then be so routed to compact the area uniformly throughout. If so specified, the rock as obtained from excavation may be used for filling and levelling to indicated grades without further breaking. In such an event, filling shall be done in layers not exceeding 50 cms approximately. After rock filling to the approximate level, indicated above has been carried out, the void in the rocks shall be filled with finer materials such as earth, broken stone, etc. and the area flooded so that the finer materials fill up the voids. Care shall be taken to ensure that the finer fill material does not get washed out. Over the layer so filled, a 100 mm thick mixed layer of broken material and earth shall be laid and consolidation carried out by a 12 tonne roller. No less than twelve passes of the roller shall be accepted before subsequent similar operations are taken up. FILL DENSITY The compaction, only where so called for, in the schedule of quantities/ items shall comply with the specified (Standard Proctor/ Modified Proctor) density at moisture content differing not more than 4 percent from the optimum moisture content. The Contractor shall demonstrate adequately at his cost, by field and laboratory tests that the specified density has been obtained. LEAD Lead for deposition/ disposal of excavated material, shall be as specified in the respective item of work. For the purpose of measurement of lead, the area to be excavated or filled or area on which excavated material is to be deposited/ disposed off shall be divided into suitable blocks and for each of the blocks, the distance between centrelines shall be taken as the lead which shall be measured by the shortest straight line route on the plan and not the actual route taken by the Contractor. No extra compensation is admissible on the grounds that the lead including that for borrowed material had to be transported over marshy or 'katcha' land/ route. ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
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12. 12.1
13. 13.1
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14. 14.1
MEASUREMENT AND PAYMENT All excavation shall be measured nett. Dimensions for purpose of payment shall be reckoned on the horizontal area of the excavation at the base for foundations of the walls, columns, footings, tanks, rafts or other foundations/ structures to be built, multiplied by the mean depth from the surface of the ground in accordance with the drawings. Excavation in side slopes will not be paid for. The Contractor may make such allowance in his rates to provide for excavation in side slopes keeping in mind the nature of the soil and safety or excavation. Reasonable working space, beyond concrete dimensions and shuttering where considered necessary in the opinion of the Engineer will be allowed in excavation and considered for payment. However, if concreting is proposed against the excavated sides, no such overexcavation will be permitted. In such cases over-excavation shall be made good by the Contractor with concrete of the same class as in the foundations at his cost. Unless otherwise specified, the unit rates quoted for excavation in different types of material shall also account for a basic lead of 100 metres for disposal as specified or directed. Only leads beyond the basic lead of 100 metres will be considered as extra lead and paid for at the rates quoted in the schedules. Backfilling as per specification the sides of foundations of columns, footings, structures, walls, tanks, rafts, trenches etc. with excavated material will not be paid for separately. It shall be clearly understood that the rate quoted for excavation including backfilling shall include stacking of excavated material as directed, excavation/ packing of selected stacked material, conveying it to the place of final backfill, compaction etc. as specified. As a rule material to be backfield shall be stacked temporarily within the basic lead of 100 metres unless otherwise directed by the Engineer. If the Engineer directs/ permits a lead of over 100 metres for such material, the conveyance of the material for the extra distance over the basic lead of 100 metres for backfilling will be paid for. Payment for fill inside trenches, plinth or similar filling with selected excavated material will be made for only compaction as specified/ directed. Cost of all other operations shall be deemed to have been covered in the rate quoted for excavation. Payment for this work will be made based on measurement of plinth/ trench dimensions filled. The plinth ground levels shall be surveyed before hand for this purpose. If no compaction is specified/ desired such filling will not be separately paid for. In such a event the fill shall be levelled/ finished to the profile as directed at no extra cost. ISSUE P0
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14.5
Backfilling, plinth filling etc. with borrowed earth will be paid for at rates quoted. The quoted rate shall include all operations such as clearing, excavation, lead and transport, fill, compaction etc. as specified. Actual quantity of consolidated filling or actual quantity or excavation in the borrow pits (less such top soil which has been excavated and not used for filling) whichever is less shall be measured and paid for in cubic metres. The lead, lift etc. shall be as indicated in the schedule of quantities. Actual quantity of consolidated sand filling shall be measured and paid in cubic metres.
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SPEC. NO. TCE. 5607A-H-CCH400 TITLE
TCE CONSULTING ENGINEERS LIMITED SPECIFICATION FOR TIMBER SHORING
SECTION : D2
SHEET 1 OF 2
1.0
SCOPE This specification covers the general requirements of timber shoring for excavation of trenches, pits, open excavations etc.
2.0
Close timbering shall be done by completely covering the sides of the trenches and pits generally with short, upright members called 'polling boards'. These shall be of minimum 25 cm x 4 cm sections or as directed by Engineer. The boards shall generally be placed in position vertically side by side without any gap on each side of the excavation and shall be secured by horizontal walings of strong wood at maximum 1.2 metres spacings, strutted with ballies or as directed by Engineer. The length of the ballie struts shall depend on the width of the trench or pit. If the soil is very soft and loose, the boards shall be placed horizontally against each side of the excavation and supported by vertical walings, which in turn shall be suitably strutted. The lowest boards supporting the sides shall be taken into the ground and no portion of the vertical side of the trench or pit shall remain exposed, so as to render the earth liable to slip out. Timber shoring shall be 'close' or 'open' type, depending on the nature of soil and the depth of pit or trench. The type of timbering shall be as approved by Engineer. It shall be the responsibility of Contractor to take all necessary steps to prevent the sides of excavations, trenches, pits, etc., from collapsing. Timber shoring may be required to keep the sides of excavations vertical to ensure safety of adjoining structures or to limit the slope of excavations, or due to space restrictions or for other reasons. Such shoring shall be carried out, except in an emergency, only under instructions from Engineer. The withdrawal of the timber shall be done very carefully to prevent the collapse of the pit or trench. It shall be started at one end and proceeded with systematically to the other end. Concrete or masonry shall not be damaged during the removal of the timber. No claim shall be entertained for any timber which cannot be withdrawn and is lost or buried. In the case of open timbering, the entire surface of the side of trench or pit in not required to be covered. The vertical boards of minimum 25 cm x 4 cm sections shall be spaced sufficiently apart to leave unsupported strips of maximum 50 cm average width. The detailed arrangement, sizes of the timber and the spacings shall be subject to the approval of Engineer. In all other respects, specification for close timbering shall apply to open timbering. In case of large pits and open excavations, where shoring is required for securing safety of adjoining structures or for any other reasons and where the planking for sides of excavations/pits cannot be strutted against, suitable inclined struts supported on the excavated bed shall be provided. Load from such struts shall be suitably distributed on the bed to ensure no yielding of the strut. If, however, Engineer directs any timbering to be left-in, keeping in mind the type of construction or any other factor, Contractor shall be paid for at the scheduled item-rate for such left-in timbering.
2.1
2.2
2.3
2.4
2.5
SPEC. NO. TCE. 5607A-H-CCH400 TITLE
TCE CONSULTING ENGINEERS LIMITED SPECIFICATION FOR TIMBER SHORING
SECTION : D2
SHEET 2 OF 2
3.0
MEASUREMENT The actual effective area of shored faces as approved by Engineer shall be measured in sq.m. The area of planking embedded in the bed/sides of excavation will not be considered, nor the area supporting inclined struts in case of large pits/open excavation. All planks, boards, walings, verticals, struts, props and all other materials required for shoring and subsequent safe dismantling and removal shall be included in the quoted unit rates. Unless separately provided for in the Schedule of Prices, the cost of shoring/struting shall be included in the item rate for excavation.
TCE CONSULTING ENGINEERS LIMITED DEWATERING
1.0
SCOPE This specification covers excavations in general. the general requirements of dewatering
2.1.
All excavations shall be kept free of water. Grading in the vicinity of excavation shall be properly closed to prevent surface water running into excavated areas. Contractor shall remove by pumping or other means approved by Engineer any water inclusive of rain water and subsoil water accumulated in excavation and keep all excavations dewatered until the foundation work is completed and backfilled. Sumps made for dewatering must be kept clear of the excavations / trenches required for further work. Method of pumping shall be approved by Engineer; but in any case, the pumping arrangement shall be such that there shall be no movement of subsoil or blowing in due to differential head of water during pumping. Pumping arrangements shall be adequate to ensure no delays in construction. When there is a continuous inflow of water and quantum of water to be handled is considered in the opinion of Engineer, as large, well point system - Single stage or multi stage, shall be adopted. Contractor shall submit to Engineer his scheme of well point system including the stages, the spacing, number and diameter of well points, headers etc., and the numbers, capacity and location of pumps of approvals. Unless separately provided for in the Schedule of prices, the cost of dewatering shall be included in the item rate for excavation.
2.2.

TITLE
RAIN WATER DRAINAGE
1.
SCOPE This section covers the drainage of rain water in excavated areas.
2.
Grading in the vicinity of excavation shall be such as to exclude rain / surface water draining into excavated areas. Excavation shall be kept clean of rain and such water as the Contractor may be using for his work by suitably pumping out the same at no extra cost to the owner. The scheme for pumping and discharge of such water shall be approved by the Engineer.
SPEC. NO TCE.- 5607A-H-CCH-400 TITLE
TCE CONSULTING ENGINEERS LIMITED CONCRETE AND ALLIED WORKS
SECTION : D5 SHEET 1 OF 26
1.0 1.1
SCOPE This Specification covers the general requirements for concrete using on-site production facilities including requirements in regard to the quality, handling, storage of ingredients, proportioning, batching, mixing, transporting, placing, curing, protecting, repairing, finishing and testing of concrete; formwork; requirements in regard to the quality, storage, bending and fixing of reinforcement; grouting as well as mode of measurement and payment for completed works. Section D6,D7 covers the specific requirements for Chimney Section D6, D7 and this specification are complementary and are to be read together. It shall be very clearly understood that the specifications given herein are brief and do not cover minute details. However, all works shall have to be carried out in accordance with the relevant standards and codes of practices or in their absence in accordance with the best accepted current engineering practices or as directed by ENGINEER from time to time. The decision of ENGINEER as regards the specification to be adopted and their interpretation and the mode of execution of work shall be final and binding on CONTRACTOR and no claim whatsoever will be entertained on this account. APPLICABLE CODES AND SPECIFICATIONS The following specifications, standards and codes, including all official amendments/revisions and other specifications & codes referred to therein, should be considered a part of this specification. In all cases the latest issue/edition/revision shall apply. In case of discrepancy between this specification and those referred to herein below or other specifications forming a part of this bid document, this specification shall govern. MATERIALS 1) IS:269 Specification for 33 grade ordinary portland cement. Specification for portland slag cement. Specification for portland-pozzolana cement
1.2
1.3
2.0 2.1
2.2
2) 3)
IS:455
IS:1489 (Parts 1 & 2) IS:8112 -
4)
Specification for 43 grade ordinary portland cement. Specification for sulphate resisting Portland Cement. Specification for coarse and fine aggregates from natural sources for concrete.
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IS:12330
6)
IS:383
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7) IS:432 (Parts 1 & 2) IS:1786 -
Specification for mild steel and medium tensile steel bars and hard-drawn steel wires for concrete reinforcement. Specification for high strength deformed steel bars and wires for concrete reinforcement. Specification for hard-drawn steel wire fabric for concrete reinforcement. Specification for admixtures for concrete. Specification for integral cement waterproofing compounds. Specification for plywood for concrete shuttering work. Specification for 53 grade ordinary portland cement.
8)
9)
IS:1566 (Parts II) IS:9103 IS:2645
10) 11)
12)
IS:4900
13)
IS:12269
2.3
MATERIAL TESTING 1) IS:4031 (Parts 1 to 15) IS:4032 Methods of physical tests for hydraulic cement. Method of chemical analysis of hydraulic cement. Specification for standard sand for testing of cement. Methods for sampling of aggregates for concrete. Methods of test for aggregates for concrete.
2)
3)
IS:650
4)
IS:2430
5)
IS:2386 (Parts 1 to 8) IS:3025
6)
Methods of sampling and test (physical and chemical) water used in industry. Methods of test for determination of water soluble chlorides in concrete admixtures.
7)
IS:6925
2.4
MATERIAL STORAGE 1) IS:4082 Recommendations on stacking and storing of construction materials at site.
2.5
CONCRETE MIX DESIGN

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1) IS:10262 -
Recommended guidelines for concrete mix design. Handbook on Concrete Mixes.
2)
SP:23 (S&T)
2.6
CONCRETE TESTING 1) 2) 3) IS:1199 IS:516 IS:9013 Method of sampling and analysis of concrete. Method of test for strength of concrete. Method of making, curing and determining compressive strength of accelerated cured concrete test specimens. Method of test for determining setting time of concrete by penetration resistance. Method of test for abrasion resistance of concrete. Methods of testing bond in reinforced concrete.
4)
IS:8142
5)
IS:9284
6) 2.7
IS:2770
EQUIPMENT 1) 2) 3) IS:1791 IS:2438 IS:4925 Specification for batch type concrete mixers. Specification for roller pan mixer. Specification for concrete batching and mixing plant. Specification for concrete transit mixer and agitator. Specification for concrete spreaders. General Requirements for concrete vibrators : Immersion type. General Requirements for screed board concrete vibrators. Specification for concrete vibrating tables. Specification for pan vibrators. Specification for form vibrators for concrete. Code of practice for use of screed board concrete vibrators.
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IS:5892
5) 6)
IS:7242 IS:2505
7)
IS:2506
8) 9) 10) 11)
IS:2514 IS:3366 IS:4656 IS:11993
TCE FORM NO. 329 R4
12) 13) 14) 2.8
IS:7251 IS:2722 IS:2750
Specification for concrete finishers. Specification for portable swing weigh batchers for concrete (single and double bucket type). Specifications for steel scaffoldings.
CODES OF PRACTICE 1) IS:456 Code of practice for plain and reinforced concrete. Code of practice for general construction of plain and reinforced concrete for dams and other massive structures. Code of practice for concrete structures for storage of liquids.
2)
IS:457
3)
IS:3370 (Parts 1 to 4) IS:3935 IS:2204
4) 5)
Code of practice for composite construction. Code of practice for construction of reinforced concrete shell roof. Criteria for the design of reinforced concrete shell structures and folded plates. Code of practice for bending and fixing of bars for concrete reinforcement. Recommendation for detailing of reinforcement in reinforced concrete works. Code of practice for welding of mild steel plain and deformed bars used for reinforced concrete construction. Specification for welding cold worked bars for reinforced concrete construction. Code of practice for use of immersion vibrators for consolidating concrete. Code of practice for design and installation of joints in buildings. Code of practice for earthquake resistant design and construction of buildings. Code of practice for steel tubular scaffolding.
6)
IS:2210
7)
IS:2502
8)
IS:5525
9)
IS:2751
10)
IS:9417
11)
IS:3558
12)
IS:3414
13) 14)
IS:4326 IS:4014 (Parts 1 & 2)
15)
IS:2571
Code of practice for laying in-situ cement concrete flooring. Code of practice for extreme weather concerning. Recommended practice for hot weather concreting Recommended practice for cold weather concreting
16)
IS:7861
Part -1
Part-2
2.9
CONSTRUCTION SAFETY 1) IS:3696 (Parts 1 & 2) IS:7969 Safety code for scaffolds and ladders.
2)
Safety code for handling and storage of building materials. Safety code for erection of concrete framed structures.
3)
IS:8989
2.10
MEASUREMENT 1) IS:1200 (Part 1 to 12) Method of measurement of building and engineering works.
3.0 3.1
GENERAL ENGINEER shall have the right at all times to inspect all operations including the sources of materials, procurement, layout and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and ENGINEERs approval obtained, prior to starting of concrete work. This shall, however, not relieve CONTRACTOR of any of his responsibilities. All materials which do not conform to this specification shall be rejected. Materials should be selected so that they can satisfy the design requirements of strength, serviceability, safety, durability and finish with due regards to the functional requirements and the environmental conditions to which the structure will be subjected. Materials complying with codes/standards shall generally be used. Other materials may be used after approval of the ENGINEER and after establishing their performance suitability based on previous data, experience or tests. MATERIALS CEMENT
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3.2
4.0 4.1
TCE FORM NO. 329 R4

4.1.1
Unless otherwise specified or called for by ENGINEER/OWNER, cement shall be ordinary portland cement conforming to IS:269, IS:8112 or IS:12269. Where portland pozzolana or slag cements are used, it shall be ensured that consistency of quality is maintained, there will be no adverse interactions between the materials and the finish specified is not marred. Only one type of cement shall be used in any one mix. The source of supply, type or brand of cement within the same structure or portion thereof shall not be changed without approval from ENGINEER. Cement which is not used within 90 days from its date of manufacture shall be tested at a laboratory approved by ENGINEER and until the results of such tests are found satisfactory, it shall not be used in any work.
4.1.2
4.1.3
4.1.4
4.2 4.2.1
AGGREGATES (GENERAL) Aggregates shall consist of naturally occurring stones (crushed or uncrushed), gravel and sand. They shall be chemically inert, strong, hard, clean, durable against weathering, of limited porosity, free from dust/silt/organic impurities/deleterious materials and conform to IS:383. Aggregates such as slag, crushed over burnt bricks, bloated clay ash, sintered fly ash and tiles shall not be used. Aggregates for special purposes shall be as specified elsewhere. Aggregates shall be washed and screened before use where necessary or if directed by the ENGINEER. Aggregates containing reactive materials shall be used only after tests conclusively prove that there will be no adverse affect on strength, durability and finish, including long term effects, on the concrete. The fineness modulus of sand shall neither be less than 2.2 nor more than 3.2. The maximum size of coarse aggregate shall be as stated on the drawings, but in no case greater than 1/4 of the minimum thickness of the member. Plums 160 mm and above of a reasonable size may be used where directed. Plums shall not constitute more than 20% by volume of the concrete.
4.2.2 4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.3 4.3.1
WATER Water used for both mixing and curing shall conform to IS:456. Potable waters are generally satisfactory. Water containing any excess of acid, alkali, sugar or salt shall not be used. REINFORCEMENT
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TCE FORM NO. 329 R4
4.4.1
Reinforcement bars shall conform to IS:432 or IS:1786 and welded wire fabric to IS:1566 as shown or specified on the drawing. All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill scales, rust, dirt, dust, or any other substance that will destroy or reduce bond. If permitted by ENGINEER, welding of reinforcement shall be done in accordance with IS:2751 or IS:9417 as applicable. ADMIXTURES Accelerating, retarding, water-reducing and air entraining admixtures shall conform to IS:9103 and integral water proofing admixture to IS:2645. Admixtures may be used in concrete as per manufacturers instructions only with the approval of ENGINEER based upon evidence that with the passage of time neither the compressive strength nor its durability is reduced. An admixtures suitability and effectiveness shall be verified by trial mixes with the other materials used in the works. If two or more admixtures are to be used simultaneously in the same concrete mix, their interaction shall be checked and trial mixes done to ensure their compatibility. There should also be no increase in risk of corrosion of the reinforcement or other embedments. Calcium chloride shall not be used for accelerating set of the cement for any concrete containing reinforcement or embedded steel parts. When calcium chloride is permitted such as in mass concrete works, it shall be dissolved in water and added to the mixing water by an amount not exceeding 1.5 percent of the weight of the cement in each batch of concrete. The designed concrete mix shall be corrected accordingly. WASTAGE Wastage allowance for cement and steel shall be as specified under Instruction to Bidders.
4.4.2
4.4.3
4.5 4.5.1
4.5.2
4.5.3
4.6 4.6.1
5.0 5.1 5.2
SAMPLES AND TESTS All materials used for the works shall be tested before use. Manufacturers test certificate shall be furnished for each batch of cement/steel and when directed by ENGINEER samples shall also be got tested by the CONTRACTOR in a laboratory approved by ENGINEER at no extra cost to OWNER. However, where material is supplied by OWNER, all testing
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charges shall be borne by OWNER, but transportation of material samples to the laboratory shall have to be done by CONTRACTOR at no extra cost. 5.3 Sampling and testing shall be as per IS:2386 under the supervision of ENGINEER. The cost of all tests, sampling, etc. shall be borne by CONTRACTOR. Water to be used shall be tested to comply with requirements of IS:456. CONTRACTOR shall furnish manufacturers test certificates and technical literature for the admixture proposed to used. If directed, the admixture shall be got tested at an approved laboratory at no extra cost. STORING OF MATERIALS All material shall be stored in a manner so as to prevent its deterioration and contamination which would preclude its use in the works. Requirements of IS:4082 shall be complied with. CONTRACTOR will have to make his own arrangements for the storage of adequate quantity of cement even if cement is supplied by OWNER. If such cement is not stored properly and has deteriorated, the material shall be rejected. Cost of such rejected cement, where cement is supplied by OWNER, shall be recovered at issue rate or open market rate which ever is higher. Cement bags shall be stored in dry weatherproof shed with a raised floor, well away from the outer walls and insulated from the floor to avoid moisture from ground. Not more than 15 bags shall be stacked in any tier. Storage arrangement shall be approved by ENGINEER. Storage under tarpaulins shall not be permitted. Each consignment of cement shall be stored separately and consumed in its order of receipt. Each size of coarse and fine aggregates shall be stacked separately and shall be protected from leaves and contamination with foreign material. The stacks shall be on hard, clean, free draining bases, draining away from the concrete mixing area. CONTRACTOR shall make his own arrangements for storing water at site in tanks to prevent contamination. The reinforcement shall be stacked on top of timber sleepers to avoid contact with ground/ water. Each type and size shall be stacked separately. CONCRETE GENERAL Concrete grade shall be as designated on drawings. In concrete grade M15, M20, etc. the number represents the specified characteristic compressive strength of 150 mm cube at 28 days, expressed in N/sq.mm as per IS:456 . Concrete in the works shall be DESIGN MIX CONCRETE OR NOMINAL MIX CONCRETE. All concrete works of grade M5, M7.5 and M10 shall be
5.4 5.5
6.0 6.1
6.2
6.3
6.4
6.5
7.0 7.1 7.1.1
NOMINAL MIX CONCRETE whereas all other grades, M15 and above, shall be DESIGN MIX CONCRETE. 7.2 7.2.1 DESIGN MIX CONCRETE Mix Design & Testing
7.2.1.1 For Design Mix Concrete, the mix shall be designed according to IS:10262 and SP:23 to provide the grade of concrete having the required workability and characteristic strength not less than appropriate values given in IS:456. The design mix shall in addition be such that it is cohesive and does not segregate and should result in a dense and durable concrete and also capable of giving the finish as specified. For liquid retaining structures, the mix shall also result in water tight concrete. The CONTRACTOR shall exercise great care while designing the concrete mix and executing the works to achieve the desired result. 7.2.1.2 Unless otherwise specifically mentioned in Data Sheet-A or respective Section-D, the minimum cement content for Design Mix Concrete shall be as per Table-5 of IS:456 or as given below, whichever is higher. Grade of Concrete Minimum Cement Content in Kg/cu.m of Concrete ----------------------------------------M20 300 M25 300 M30 320 M35 340 The minimum cement content stipulated above shall be adopted irrespective of whether the CONTRACTOR achieves the desired strength with less quantity of cement. The CONTRACTORs quoted rates for concrete shall provide for the above eventuality and nothing extra shall become payable to the CONTRACTOR in this account. Even in the case where the quantity of cement required is higher than that specified above to achieve desired strength based on an approved mix design, nothing extra shall become payable to the CONTRACTOR. 7.2.1.3 It shall be CONTRACTORs sole responsibility to carry out the mix designs at his own cost. He shall furnish to ENGINEER at least 30 days before concreting operations, a statement of proportions proposed to be used for the various concrete mixes and the strength results obtained. The strength requirements of the concrete mixes ascertained on 150 mm cubes as per IS:516 shall comply with the requirements of IS:456.
Grade of Concrete
-------
Minimum Compressive Strength N/Sq.mm at 7 days -----------
Specified Characteristic compressive strength N/sq.mm at 28 days ------------------ISSUE P0
TCE FORM NO. 329 R4

M15 M20 M25 M30 M35 M40 10.0 13.5 17.0 20.0 23.5 27.0 15.0 20.0 25.0 30.0 35.0 40.0
7.2.1.4 A range of slumps which shall generally be used for various types of construction unless otherwise instructed by the ENGINEER is given below : Structure/Member -----------------------------------Slump in millimeters --------------------------------Maximum Minimum ------------------------75 25
Reinforced foundation walls and footings Plain footings, caissons and substructure walls T.G. and massive compressor foundations Slabs, Beams and reinforced walls Pumps & miscellaneous Equipment Foundations Building columns Pavements Heavy mass construction 7.2.2 Batching & Mixing of Concrete
75
25
50
25
100
25
75
25
100 50 50
25 25 25
7.2.2.1 Proportions of aggregates and cements, as decided by the concrete mix design, shall be by weight. These proportions shall be maintained during subsequent concrete batching by means of weigh batchers capable of controlling the weights within one percent of the desired value. 7.2.2.2 Amount of water added shall be such as to produce dense concrete of required consistency, specified strength and satisfactory workability and shall be so adjusted to account for moisture content in the aggregates. Watercement ratio specified for use by ENGINEER shall be maintained. Each time the work stops, the mixer shall be cleaned out, and while recommencing, the first batch shall have 10% additional cement to allow for sticking in the drum. 7.2.2.3 Arrangement should be made by CONTRACTOR to have the cubes tested in an approved laboratory or in field at his own expense, with prior consent of ENGINEER. Sampling and testing of strength and workability of concrete shall be as per IS:1199, IS:516 and IS:456.

7.3 7.3.1 NOMINAL MIX CONCRETE Mix Design & Testing
7.3.1.1 Mix Design and preliminary tests are not necessary for Nominal Mix Concrete. However works tests shall be carried out as per IS:456. Proportions for Nominal Mix Concrete and w/c ratio may be adopted as per Table 3 of IS:456. However, it will be CONTRACTORs sole responsibility to adopt appropriate nominal mix proportions to yield the specified strength. 7.3.2 Batching & Mixing of Concrete
7.3.2.1 Based on the adopted nominal mixes, aggregates shall be measured by volume. However cement shall be by weight only. 8.0 8.1 FORMWORK Formwork shall be all inclusive and shall consist of but not limited to shores, bracings, sides of footings, walls, beams and columns, bottom of slabs, etc. including ties, anchors, hangers, inserts, falsework, wedges, etc. The design and engineering of the formwork as well as its construction shall be the responsibility of CONTRACTOR. However, if so desired by ENGINEER the drawings and calculations for the design of the formwork shall be submitted to ENGINEER approval. Formwork shall be designed to fulfill the following requirements : a) Sufficiently rigid and tight to prevent loss of grout or mortar from the concrete at all stages and appropriate to the methods of placing and compacting. Made of suitable materials. Capable of providing concrete of the correct shape and surface finish within the specified tolerance limits. Capable of withstanding without deflection the worst combination of self weight, reinforcement and concrete weight, all loads and dynamic effects arising from construction and compacting activities, wind and weather forces. Capable of easily striking without shock, disturbance or damage to the concrete. Soffit forms capable of imparting a camber if required. Soffit forms and supports capable of being left in position if required. Capable of being cleaned and/or coated if necessary immediately prior to casting the concrete; design temporary openings where necessary for these purposes and to facilitate the preparation of construction joints.
8.2
8.3
b) c)
d)
e)
f) g) h)
8.4
The formwork may be of timber, plywood, steel, plastic or concrete depending upon the type of finish specified. Sliding forms and slip form may be used with the approval of ENGINEER. Timber for formwork shall be well seasoned, free from sap, shakes, loose knots, worm holes, warps and other surface defects. Joints between formwork and formwork and between formwork and structures shall be sufficiently tight to prevent loss of slurry from concrete, using seals if necessary. The faces of formwork coming in contact with concrete shall be cleaned and two coats of approved mould oil applied before fixing reinforcement. All rubbish, particularly chippings, shavings, sawdust, wire pieces, dust etc. shall be removed from the interior of the forms before the concrete is placed. Where directed, cleaning of forms shall be done by blasting with a jet of compressed air at no extra cost. Forms intended for reuse shall be treated with care. Forms that have deteriorated shall not be used. Before reuse, all forms shall be thoroughly scraped, cleaned, nails removed, holes suitably plugged, joints repaired and warped lumber replaced to the satisfaction of ENGINEER. CONTRACTOR shall equip himself with enough shuttering to allow for wastage so as to complete the job in time. Permanent formwork shall be checked for its durability and compatibility with adjoining concrete before it is used in the structure. It shall be properly anchored to the concrete. Wire ties passing through beams, columns and walls shall not be allowed. In their place bolts passing through sleeves shall be used. Formwork spacers left in situ shall not impair the desired appearance or durability of the structure by causing spalling, rust staining or allowing the passage of moisture. For liquid retaining structures sleeves shall not be provided for through bolts nor shall through bolts be removed if provided. The bolts, in the latter case, shall be cut at 25 mm depth from the surface and the hole made good by cement mortar of the same proportion as the concrete just after striking the formwork. Where specified or shown on drawings all corners and angles exposed in the finished structure shall have chamfers or fillets of 20 mm x 20 mm size. Forms for substructure may be omitted when, in the opinion of ENGINEER, the open excavation is firm enough (in hard non-porous soils) to act as a form. Such excavations shall be slightly larger, as directed by ENGINEER, than that required as per drawing to compensate for irregularities in excavation. CONTRACTOR shall provide adequate props of adjustable steel pipes carried down to a firm bearing without overloading any of the structures. The shuttering for beams and slabs shall be so erected that the side shuttering of beams can be removed without disturbing the bottom shuttering.
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8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
TCE FORM NO. 329 R4
If the shuttering for a column is erected for the full height of the column, one side shall be built up in sections as placing of concrete proceeds or windows left for placing concrete from the side to limit the drop of concrete to 1.0 m or as directed by ENGINEER. CONTRACTOR shall temporarily and securely fix items to be cast (embedments/inserts) in a manner that will not hinder the striking of forms or permit loss of grout. 8.14 Formwork showing excessive distortion, during any stage of construction, shall be removed. Placed concrete affected by faulty formwork, shall be entirely removed and formwork corrected prior to placement of new concrete at CONTRACTORs cost. The striking time for formwork shall be determined based on the following requirements : a) b) c) d) e) f) g) Development of adequate concrete strength; Permissible deflection at time of striking form work; Curing procedure employed - its efficiency and effectiveness; Subsequent surface treatment to be done; Prevention of thermal cracking at re-entrant angles; Ambient temperatures; and Aggressiveness of the environment (unless immediate adequate steps are taken to prevent damage to the concrete).
8.15
8.16
Under normal circumstances (generally where temperatures are above 20 Deg. C) forms may be struck after expiry of the time period given in IS:456 unless directed otherwise by ENGINEER. For Portland Pozzolona/slag cement the stripping time shall be suitably modified as directed by the ENGINEER. It is the CONTRACTORs responsibility to ensure that forms are not struck until the concrete has developed sufficient strength to support itself, does not undergo excessive deformation and resist surface damage and any stresses arising during the construction period. REINFORCEMENT WORKMANSHIP Reinforcing bars supplied bent or in coils shall be straightened cold without damage at no extra cost. No bending shall be done when ambient temperature is below 5 Deg.C. Local warming may be permitted if steel is kept below 100 Deg.C. All bars shall be accurately bent gradually and according to the sizes and shapes shown on the drawings/ schedules or as directed by ENGINEER. Re-bending or straightening incorrectly bent bars shall not be done without approval of ENGINEER.
ISSUE P0
9.0 9.1
9.2
9.3
TCE FORM NO. 329 R4

9.4
Reinforcement shall be accurately fixed and maintained firmly in the correct position by the use of blocks, spacers, chairs, binding wire, etc. to prevent displacement during placing and compaction of concrete. The tied inplace reinforcement shall be approved by ENGINEER prior to concrete placement.Spacers shall be of such materials and designs as will be durable, not lead to corrosion of the reinforcement and not cause spalling of the concrete cover. Binding wire shall be 16 gauge soft annealed wire. Ends of the binding wire shall be bent away from the concrete surface and in no case encroach into the concrete cover. Substitution of reinforcement, laps/splices not shown on drawing shall be subject to ENGINEERs approval. TOLERANCES Tolerance for formed and concrete dimensions shall be as per IS:456 unless specified otherwise. Tolerance specified for horizontal or vertical building lines or footings shall not be construed to permit encroachment beyond the legal boundaries. PREPARATION PRIOR TO CONCRETE PLACEMENT Before concrete is actually placed in position, the inside of the formwork shall be cleaned and mould oil applied, inserts and reinforcement shall be correctly positioned and securely held, necessary openings, pockets, etc. provided. All arrangements-formwork, equipment and proposed procedure, shall be approved by ENGINEER. CONTRACTOR shall maintain separate Pour Card for each pour as per the format enclosed. TRANSPORTING, PLACING AND COMPACTING CONCRETE Concrete shall be transported from the mixing plant to the formwork with minimum time lapse by methods that shall maintain the required workability and will prevent segregation, loss of any ingredients or ingress of foreign matter or water. In all cases concrete shall be deposited as nearly as practicable directly in its final position. To avoid seggregation, concrete shall not be rehandled or caused to flow. For locations where direct placement is not possible and in narrow forms, CONTRACTOR shall provide suitable drops and Elephant Trunks. Concrete shall not be dropped form a height of more than 1.0 m as stipulated in clause 8.13. Concrete shall not be placed in flowing water. Under water, concrete shall be placed in position by tremies or by pipeline from the mixer and shall never be allowed to fall freely through the water.
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9.5
9.6
10.0 10.1
10.2
11.0 11.1
11.2
12.0 12.1
12.2
12.3
TCE FORM NO. 329 R4

12.4
While placing concrete the CONTRACTOR shall proceed as specified below and also ensure the following : a) Continuously abutments. between construction joints and predetermined
b) c)
Without disturbance to forms or reinforcement. Without disturbance to pipes, ducts, fixings and the like to be cast in; ensure that such items are securely fixed. Ensure that concrete cannot enter open ends of pipes and conduits, etc. Without dropping in a manner that could cause segregation or shock. In deep pours only when the concrete and formwork is designed for this purpose and by using suitable chutes or pipes. Do not place if the workability is such that full compaction cannot be achieved. Without disturbing the unsupported sides of excavations; prevent contamination of concrete with earth. Provide sheeting if necessary. In supported excavations, withdraw the linings progressively as concrete is placed. If placed directly onto hardcore or any other porous material, dampen the surface to reduce loss of water from the concrete. Ensure that there is no damage or displacement to sheet membranes. Record the time and location of placing structural concrete.
d) e)
f)
g)
h)
i) j) 12.5
Concrete shall normally be compacted in its final position within thirty minutes of leaving the mixer. Concrete shall be compacted during placing with approved vibrating equipment without causing segregation until it forms a solid mass free from voids thoroughly worked around reinforcement and embedded fixtures and into all corners of the formwork. Immersion vibrators shall be inserted vertically at points not more than 450 mm apart and withdrawn slowly till air bubbles cease to come to the surface, leaving no voids. When placing concrete in layers advancing horizontally, care shall be taken to ensure adequate vibration, blending and melding of the concrete between successive layers. Vibrators shall not be allowed to come in contact with reinforcement, formwork and finished surfaces after start of initial set. Over-vibration shall be avoided. Concrete may be conveyed and placed by mechanically operated equipment after getting the complete procedure approved by ENGINEER. The slump shall be held to the minimum necessary for conveying concrete by this method. When concrete is to be pumped, the concrete mix shall be specially designed to suit pumping. Care shall be taken to avoid stoppages in work once pumping has started . Except when placing with slip forms, each placement of concrete in multiple lift work, shall be allowed to set for at least 24 hours after the final set of
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12.7
TCE FORM NO. 329 R4
concrete before the start of subsequent placement. Placing shall stop when concrete reaches the top of the opening in walls or bottom surface of slab, in slab and beam construction, and it shall be resumed before concrete takes initial set but not until it has had time to settle as determined by ENGINEER. Concrete shall be protected against damage until final acceptance. 13.0 13.1 MASS CONCRETE WORKS Sequence of pouring for mass concrete works shall be as approved by ENGINEER. CONTRACTOR shall exercise great care to prevent shrinkage cracks and shall monitor the temperature of the placed concrete if directed. CURING Curing and protection shall start immediately after the compaction of the concrete to protect it from : a) b) c) d) e) f) Premature drying out, particularly by solar radiation and wind; leaching out by rain and flowing water; rapid cooling during the first few days after placing; high internal thermal gradients; low temperature or frost; vibration and impact which may disrupt the concrete and interfere with its bond to the reinforcement.
14.0 14.1
14.2
All concrete, unless directed otherwise by ENGINEER, shall be cured by use of continuous sprays or ponded water or continuously saturated coverings of sacking, canvas, hessian or other absorbent material for the period of complete hydration with a minimum of 7 days. The quality of curing water shall be the same as that used for mixing. Where a curing membrane is directed to be used by the ENGINEER, the same shall be of a non-wax base and shall not impair the concrete finish in any manner. The curing compound to be used shall be got approved from the ENGINEER before use and shall be applied with spraying equipment capable of a smooth, even textured coat. Curing may also be done by covering the surface with an impermeable material such as polyethylene, which shall be well sealed and fastened. Extra precautions shall be exercised in curing concrete during cold and hot weather. CONSTRUCTION JOINTS AND KEYS
14.3
14.4
14.5 15.0

15.1
Construction joints will be as shown on the drawing or as approved by ENGINEER. Concrete shall be placed without interruption until completion of work between construction joints. If stopping of concreting becomes unavoidable anywhere, a properly formed construction joint shall be made with the approval of ENGINEER. Dowels for concrete work, not likely to be taken up in the near future, shall be coated with cement slurry and encased in lean concrete as indicated on the drawings or as directed by ENGINEER. Before resuming concreting on a surface which has hardened all laitance and loose stone shall be thoroughly removed by wire brushing/hacking and surface washed with high pressure water jet and treated with thin layer of cement slurry for vertical joints and a 15 mm thick layer of cement sand mortar for horizontal layers, the ratio of cement and sand being the same as in the concrete mix. When concreting is to be resumed on a surface which has not fully hardened, all laitence shall be removed by wire brushing, the surface wetted, free water removed and a coat of cement slurry applied. On this a layer of concrete not exceeding 150 mm thickness shall be placed and well rammed against the old work. Thereafter work shall proceed in the normal way. FOUNDATION BEDDING All earth surfaces upon which or against which concrete is to be placed, shall be well compacted and free from standing water, mud or debris. Soft or spongy area shall be cleaned out and back filled with either soil-cement mixture, lean concrete or clean sand compacted as directed by ENGINEER. The surfaces of absorptive soils shall be moistened. Concrete shall not be deposited on large sloping rock surfaces. The rock shall be cut to form rough steps or benches by picking, barring or wedging. The rock surface shall be kept wet for 2 to 4 hours before concreting. FINISHES GENERAL
15.2
15.3
15.4
16.0 16.1
16.2
17.0 17.1
17.1.1 The formwork for concrete works shall be such as to give the finish as specified. The CONTRACTOR shall make good as directed any unavoidable defects consistent with the type of concrete and finish specified; defects due to bad workmanship (e.g. damaged or misaligned forms, defective or poorly compacted concrete) will not be accepted. CONTRACTOR shall construct the formwork using the correct materials and to meet the requirements of the design and to produce finished concrete to required dimensions, plumbs, planes and finishes. 17.2 Surface Finish Type F1
17.2.1 This type of finish shall be for non-exposed concrete surfaces against which back fill or concrete is to be placed. The main requirement is that of dense, well compacted concrete. No treatment is required except repair of defective areas, filling all form tie holes and cleaning up of loose or adhering debris. For surfaces below grade which will receive waterproofing treatment the concrete shall be free of surface irregularities which would interfere with proper and effective application of waterproofing material specified for use. 17.3 Surface Finish Type F2
17.3.1 This type of finish shall be for all concrete work which will be exposed to view upon completion of the job. The appearance shall be that of a smooth dense, well-compacted concrete showing the slight marks of well fitted shuttering joints. The CONTRACTOR shall make good any blemishes. 17.4 Surface Finish Type F3
17.4.1 This type of finish shall be for concrete work which will be exposed to view but to give an appearance of smooth, dense, well-compacted concrete with no shutter marks, stain free and with no discolourisation, blemishes, arises, air holes, etc. Only lined or coated plywood with very tight joints shall be used to achieve this finish. The panel size shall be uniform and as large as practicable. Any minor blemishes that might occur shall be made good by CONTRACTOR. 17.5 INTEGRAL CEMENT FINISH ON CONCRETE FLOOR
17.5.1 In all cases where integral cement finish on a concrete floor has been specified, the top layer of concrete shall be screeded off to proper level and tamped with tamper having conical projections so that the aggregate shall be forced below the surface. The surface shall be finished with a wooden float and a trowel with pressure. The finish shall be continued till the concrete reaches its initial set. No cement or cement mortar finish shall be provided on the surface. Where specified, a floor hardener as approved by the ENGINEER shall be supplied and used as recommended by the manufacturer. 18.0 18.1 REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE Immediately after the shuttering is removed, all the defective areas such as honey-combed surfaces, rough patches, holes left by form bolts, etc. shall be brought to the notice of ENGINEER who may permit patching of the defective areas or reject the concrete work. All through holes for shuttering shall be filled for full depth and neatly plugged flush with surface. Rejected concrete shall be removed and replaced by CONTRACTOR at no additional cost to OWNER.
18.2
18.3

18.4
For patching of defective areas all loose materials shall be removed and the surface shall be prepared as directed by the ENGINEER. Bonding between hardened and fresh concrete shall be done either by placing cement mortar or by applying epoxy. The decision of the ENGINEER as to be the method of repairs to be adopted shall be final and binding on the CONTRACTOR and no extra claim shall be entertained on this account. The surface shall be saturated with water for 24 hours before patching is done with 1:5 cement sand mortar. The use of epoxy for bonding fresh concrete shall be carried out as directed by ENGINEER. VACUUM DEWATERING OF SLABS Where specified floor slabs, either on grade or suspended, shall be finished by vacuum dewatering including all operations such as poker vibration, surface vibration, vacuum processing, floating and trowelling as per equipment manufacturers recommendation. The equipment to be used shall be subject to ENGINEERS approval. HOT WEATHER REQUIREMENT Concreting during hot weather shall be carried out as per IS:7861 (Part I). Adequate provisions shall be made to lower concrete temperatures which shall not exceed 40 C at the time of placement of fresh concrete. Where directed by ENGINEER, CONTRACTOR shall spray non-wax based curing compound on unformed concrete surface at no extra costs. COLD WEATHER REQUIRMENTS Concreting during cold weather shall be carried out as per IS:7861 (PART 2). The ambient temperature during placement and upto final set shall not fall below 5 deg.c. Approved anti-freeze/accelerating additive shall be used where directed. For major and large scale concreting works the temperature of concrete at times of mixing and placing, the thermal conductivity of the formwork and its insulation and stripping period shall be closely monitored. LIQUID RETAINING STRUCTURES The CONTRACTOR shall take special care for concrete of liquid retaining structures, under ground structures and those other specifically called for to guarantee the finish and water tightness. The minimum level of surface finish for liquid retaining structures shall be type F2. All such structures shall be hydro-tested.
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19.0 19.1
20.0 20.1 20.2
20.3
21.0 21.1 21.2
21.3
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TCE FORM NO. 329 R4

22.3
The CONTRACTOR shall include in his price hydro-testing of structure, all arrangements for testing such as temporary bulk heads, pressure gauges, pumps, pipe lines, etc. Any temporary arrangements that may have to be made to ensure stability of the structures shall also be considered to have been taken into account while quoting the rates. Any leakage that may occur during the hydro-test or subsequently during the defects liability period or the period for which the structure is guaranteed shall be effectively stopped either by cement/epoxy pressure grouting, guniting or such other method as may be approved by the ENGINEER. All such rectification shall be done by the CONTRACTOR to the entire satisfaction of the OWNER/ENGINEER at no extra cost to the OWNER. TESTING CONCRETE STRUCTURES FOR LEAKAGE Hydro-static test for water tightness shall be done at full storage level or soffit of cover slab, as may be directed by ENGINEER, as described below : a) In case of structures whose external faces are exposed, such as elevated tanks, the requirements of the test shall be deemed to be satisfied if the external faces show no sign of leakage or sweating and remain completely dry during the period of observation of seven days after allowing a seven day period for absorption after filling with water. In the case of structures whose external faces are submerged and are not accessible for inspection, such as underground tanks, the structures shall be filled with water and after the expiry of seven days after the filling, the level of the surface of the water shall be recorded. The level of water shall be recorded again at subsequent intervals of 24 hrs. over period of seven days. Backfilling shall be withheld till the tanks are tested. The total drop in surface level over a period for seven days shall be taken as an indication of the water tightness of the structure. The ENGINEER shall decide on the actual permissible nature of this drop in the surface level, taking into account whether the structures are open or closed and the corresponding effect it has on evaporation losses. Unless specified otherwise, a structure whose top is covered shall be deemed to be water tight if the total drop in the surface level over a period of seven days does not exceed 40 mm. Each compartment/segment of individually and then all together. the structure shall be tested
22.4
22.5
23.0 23.1
b)
c)
23.2
For structures such as pipes, tunnels, etc. the hydrostatic test shall be carried out by filling with water, after curing as specified, and subjecting to the specified test pressure for specified period. If during this period the loss of water does not exceed the equivalent of the specified rate, the structure shall be considered to have successfully passed the test.

24.0 24.1 OPTIONAL TEST
If the ENGINEER feels that the materials i.e. cement, sand, coarse aggregates, reinforcement and water are not in accordance with the specifications or if specified concrete strengths are not obtained, he may order tests to be carried out on these materials in laboratory, to be approved by the ENGINEER, as per relevant IS Codes. OWNER shall pay only for the testing of material supplied by the OWNER, otherwise CONTRACTOR shall have to pay for the tests. Transporting of all material to the laboratory shall however be done by the CONTRACTOR at no extra cost to OWNER. In the event of any work being suspected of faulty material or workmanship requiring its removal or if the works cubes do not give the stipulated strengths, ENGINEER reserves the right to order the CONTRACTOR to take out cores and conduct tests on them or do ultrasonic testing or load testing of structure, etc. All these tests shall be carried out by CONTRACTOR at no extra cost to the OWNER. Alternately ENGINEER also reserves the right to ask the CONTRACTOR to dismantle and re-do such unacceptable work at the cost of CONTRACTOR. If the structure is certified by Engineer as having failed, the cost of the test and subsequent dismantling/reconstruction shall be borned by CONTRACTOR. The quoted unit rates/prices of concrete shall deemed to provide for all tests mentioned above. GROUTING Grout shall be provided as specified on the drawings. The proportion of Standard Grout shall be such as to produce a flowable mixture consistent with minimum water content and shrinkage. Surfaces to be grouted shall be thoroughly roughened and cleaned. All structural steel elements to be grouted shall be cleaned of oil, grease, dirt, etc. The use of hot, strong caustic solution for this purpose will be permitted. Prior to grouting, the hardened concrete shall be saturated with water and just before grouting water in all pockets shall be removed. Grouting once started shall be done quickly and continuously. Variation in grout mixes and procedures shall be permitted if approved by ENGINEER. The grout proportions shall be limited as follows : Use -----Fluid mix General mix Grout Thickness ---------------Under 25 mm Mix proportion -----------------------One part Portland Cement to one part sand. One part Portland Cement to 2 parts of sand W/C Ratio (max) -------------0.44
24.2
24.3
24.4
25.0 25.1
a)
b)
25 mm and over but less than 50 mm
0.53

c) Stiff mix 50 mm and over One part Portland cement to 3 parts of sand 0.53
25.2 25.2
NON-SHRINK GROUT Non-shrink grout where called for in the Schedule of Quantities or specified on the drawings shall be provided in strict accordance with the manufacturers instructions/ specifications on the drawings. INSPECTION All materials, workmanship and finished construction shall be subject to continuous inspection and approval of ENGINEER. Materials rejected by ENGINEER shall be expressly removed from site and shall be replaced by CONTRACTOR immediately at no extra cost to OWNER. CLEAN-UP Upon the completion of concrete work, all forms, equipment, construction tools, protective coverings and any debris, scraps of wood, etc. resulting from the work shall be removed and the premises left clean. ACCEPTANCE CRITERIA Any concrete work shall satisfy the requirements given below individually and collectively for it to be acceptable. a) b) c) d) e) f) g) h) i) j) k) l) properties of constituent materials; characteristic compressive strength; specified mix proportions; minimum cement content; maximum free-water/cement ratio; workability; temperature of fresh concrete; density of fully compacted concrete; cover to embedded steel; curing; tolerances in dimensions; tolerances in levels;
ISSUE P0
26.0 26.1
27.0 27.1
28.0 28.1
TCE FORM NO. 329 R4

m) n) o) durability; surface finishes; special requirements such as : i) ii) iii) iv) v) vi) vii) 28.2 water tightness resistance to aggressive chemicals resistance to freezing and thawing very high strength improved fire resistance wear resistance resistance to early thermal cracking
The ENGINEERs decision as to the acceptability or otherwise of any concrete work shall be final and binding on the CONTRACTOR. For work not accepted, the ENGINEER may review and decide whether remedial measures are feasible and so as to render the work acceptable. The ENGINEER shall in that case direct the CONTRACTOR to undertake and execute the remedial measures. These shall be expeditiously and effectively implemented by the CONTRACTOR. Nothing extra shall become payable to the CONTRACTOR by the OWNER for executing remedial measures. MODE OF MEASUREMENT AND PAYMENT The unit rate for concrete work under various categories shall be all inclusive and no claims for extra payment on account of such items an leaving holes, embedding inserts, etc. shall be entertained unless separately provided for in the Schedule of Quantities. No extra claim shall also be entertained due to change in the number, position and/or dimensions of holes, slots or openings, sleeves, inserts or on account of any increased lift, lead of scaffolding etc. All these factors should be taken into consideration while quoting the unit rates. Unless provided for in the schedule of Quantities the rates shall also include fixing inserts in all concrete work, whenever required. Payments for concrete will be made on the basis of unit rates quoted for the respective items in the Schedule of Quantities. No deduction in the concrete quantity will be made for reinforcements, inserts etc. and opening less than 0.100 of a Sq.m, in areas where concrete is measured in sq.m. and 0.010 cu.m where concrete is measured in cu.metres. Where no such deduction for concrete is made, payment for shuttering work provided for such holes, pockets, etc. will not be made. Similarly the unit rates for concrete work shall be inclusive or exclusive of shuttering as provided for in the Schedule of Quantities. Payment for beams will be made for the quantity based on the depth being reckoned from the underside of the slabs and length measured as the clear distance between supports. Payment for columns shall be made for the quantity based on height reckoned upto the underside of slabs/beams.
28.3
29. 29.1
29.2
29.3
29.4
The unit rate for precast concrete members shall include formwork, mouldings, finishing, hoisting and setting in position including setting mortar, provision of lifting arrangement etc. complete. Reinforcement and inserts shall be measured and paid for separately under respective item rates. Only the actual quantity of steel embedded in concrete including laps as shown on drawings or as approved by ENGINEER shall be measured and paid for, irrespective of the level or height at which the work is done. The unit rate for reinforcement shall include all wastages, binding wires, chairs, spacer bare etc. for which no separate payment shall be made. Where the formwork is paid for separately, it shall be very clearly understood that payment for formwork in inclusive of formwork, shuttering, shoring, propping, scaffolding, etc. complete. only the net area of concrete formed (shuttered) shall be measured for payment.
29.5
29.6
CONCRETE POUR CARD CLIENT : POUR NO. : PROJECT : CONTRACTOR : SLUMP : MM/ DRG. NO. : CONCETE GRADE/QUANTITY : M SR. NO. 1. BEFORE CONCRETING 2. 3. 4. ITEM CENTERLINES CHECKED FORMWORK AND STAGING CHECKED REINFORCEMENT CHECKED COVER0000000 TO REINFORCEMENT CHECKED VERFIED TEST CERTIFICATE FOR CEMENT /STELL YES/NO YES/NO / MM START/COMPLETION TIME : M3 MIXING TIME : ENGINEERS SIGNATURE REMARKS DATE : STRUCTURE : MAX AGGREGATE SIZE
CONTRACTORS REP. SIGNATURE
5.
6.
ADEQUENCY OF MATERIALS/EQUIPMENT FOR POUR EMBEDED PARTS CHECKED (LOCATION & PLUMB) CIVIL MECHANIC AL ELECTRICA L
YES/NO
YES/NO
7.
POUR AUTHORISED SITE ENGINEER 8. SOFFIT(S) AND POUR TOP(T) LEVELS CHECKED BEFORE(B) AND AFTER(A) FROM REMOVAL (ONLY OF BEAMS OF OVER 10 M SPAN & IMPORTANT STRUCTURES LIKE T.G. ETC.) CONSTRUCTION JOINT LOCATION & TIME (IF NOT AS PER DRAWING) CEMENT CONSUMPTION IN KGS. NUMBER OF CUBES AND IDENTIFICATION MARK TEST CUBE RESULTS (7 DAYS/ 28 DAYS) CONCRETE CONDITION ON FORM REMOVAL / / / S(B) S(A) T(B) T(A)
9.
10. 11. 12. 13.
V.GOOD/GOOD/FAIR/POOR SITE-IN-CHARGE
NOTES: 1. EACH ITEM TO BE CHECKED & SIGNED BY THE RESPECTIVE ENGINEERS. 2. ITEMS 8 TO 13 (BOTH INCLUSIVE) TO BE FILLED BY ONLY TCE ENGINEER. 3. EACH POUR TO HAVE SEPARATE CARDS, IN TRIPILCATE ONE EACH FOR CLIENT, TCE & SITE OFFICE. FORM 279 4. UNDER REMARKS INDICATE DEVIATIONS FROM DWGS & SPECIFICATIONS, CONGESTION IN REINFORCEMENT IF ANY, UNUSUAL OCCURENCES, SUCH AS FAILURE OF EQUIPMENTS, SINKING OF SUPPORTS/PROPS, HEAVY RAINS AFFECTING CONCRETEING, POOR COMPACTION, IMPROPER CURING, OTHER DEFICIENCIES, OBSERVATION ETC.
SPEC NO. TCE- 5607A-H-CCH-400

TITLE
SECTION : D6
SHEET 1 OF 40
REINFORCED CONCRETE CHIMNEY

1.0 1.1 SCOPE This specification covers the general requirements for design and construction of a reinforced concrete chimney of circular cross section including foundations, RCC shell, brick lining, appurtenances, fixtures, fittings, conduit and other embedments, lift where specified, etc., complete. The scope of work shall not be deemed to have changed in case BIDDERS drawings submitted with his bid do not show some part of the work as called for in this specification and the attached bid drawings unless categorically agreed to in writing before contract award. The CONTRACTOR shall not be entitled to any extra claim on account of his having (in OWNERS opinion) mis-interpreted, misjudged or overlooked any aspect called for in this specification. It is not the intent to specify completely herein all the details of design and construction of the works involved under this specification. However, the works shall conform, in all respects, to high standards of engineering, design and workmanship. APPLICABLE CODES, SPECIFICATIONS & REFERENCES The following specifications, standards and codes are made a part of this specification. These shall be the latest edition including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, the former shall govern: IS:6 IS:158 Moderate heat duty fire clay refractories,Group-A.
1.2
1.3
2.0 2.1
Ready mixed paint, brushing, bituminous, black, lead free; acid, alkali and heat resisting. IS: 195 Fireclay Mortar for laying fireclay refractory bricks-specification. IS:456 IS:732 IS:800 IS:875 Code of Practice for plain and reinforced concrete. Code of Practice for electrical wiring installations. Code of Practice for general construction in steel. Code of practice for design loads (other than earthquake) for buildings and structures: Part 1 to 3.
IS:1526 Sizes and shapes for fire bricks. IS:1528 Methods of sampling and physical tests for refractory material. IS:1893 Criteria for earthquake resistant design of structures. IS:1904 Code of Practice for design and construction of foundations in soils: General requirements.

TITLE
SECTION : D6
SHEET 2 OF 40

IS:2042 Insulating bricks. IS:2062 Steel for general structural purposes. IS:2750 Steel scaffoldings. IS:2932 Enamel, synthetic, exterior (a) under coating, (b) finishing. IS:2933 Enamel, exterior (a) under coating, (b) finishing. IS:3346 Method for the determination of thermal conductivity of thermal insulation materials (two slab guarded hot-plate method) IS:3696 Safety code for scaffolds and ladders. (Parts 1 & 2) IS:4014 Code of practice for steel tubular scaffolding. (Parts 1 & 2) IS:4289 Flexible cables for lifts and other flexible connections : Part 1 Elastomer insulated cables. IS:4456 Methods of test for chemical resistant mortars: Part 1 Silicate type and Resin type. IS:4687 Gaskets and packings - Gland packing asbestos. IS:4832 Specification for chemical resistant mortars: Part- 1 silicate type. IS:4860 Acid resistant bricks. IS:4998 Criteria for design of reinforced concrete chimneys: Part 1 - Design criteria - 1975 IS:4998 Criteria for design of reinforced concrete: Part 1 Assessment of loads1992 IS:8112 OPC Cement Garde 43 IS:8183 Bonded Mineral wool. IS:8500 Structural steel - microalloyed (Medium and high strength qualities). IS:13947 Low voltage switchgear and controlgear : Part 1 General rules Annexure-14 International Standards and Recommended Practices Aerodromes International Civil Aviation Organisation.

TITLE
SECTION : D6
SHEET 3 OF 40

2.2 The following is the list of publications referred to in this specification. Manohar,S.N Tall Chimneys-Design and Construction", Tata McGraw Hill Publishing Co.Ltd., New Delhi, 1985. Pinfold,G.M "Reinforced Concrete Chimneys and Towers", Publication, Cement and Concrete Association, U.K., 1975. View Point
ACI 307 - 88 Standard Practice for the Design and Construction of Cast-in-place reinforced concrete chimneys 2.3 3.0 3.1 3.2 3.3 SI units shall be adopted for all design and drawing work. DESIGN REQUIREMENTS The principal design parameters for this chimney are indicated in DATASHEET-A. The design shall be based on working stress method. The design and construction of the chimney and its foundation shall conform to the requirements of all statutory rules and regulations of local and national authorities. Where such requirements are less conservative than the corresponding requirements of this specification, the latter shall govern. The chimney and its foundation shall be designed to resist stresses due to the most critical combination of any of the following: (a) Weight of the chimney with or without lining, platforms, accessories and all other dead loads. Wind loads (both along-wind and across wind) or earthquake forces whichever is governing. Temperature gradient across the chimney shell. Eccentric loads from corbels/platforms supporting the lining, soot hopper, etc. Live loads on platforms. Also weight of equipment and materials and other live loads during construction. For the foundation and portion of the shell below grade level, appropriate earth pressures, hydrostatic forces, surcharge etc., as applicable. Local moments due to ovalling. Forces from the lift and operating equipment. Loads from flue duct supports, staircase, etc.
3.4
(b)
(c) (d) (e)
(f)
(g) (h) (i)

TITLE
SECTION : D6
SHEET 4 OF 40

(j) Construction loads such as those due to plant and equipment, stacked materials, live loads due to movement of plant, materials and personnel, etc.
3.5
The total design stresses at a section shall include all secondary effects, viz., corbel effect, eccentric loading due to platforms, secondary moments due to p- effect, etc. The total design stress in no case shall exceed the permissible stresses specified in clause 7.0 of IS:4998 (Part-1) 1975, except for (DL+WL) case, for which the permissible stress 0.275fcu shall be if the circumferential tensile stress in concrete due to wind induced ring moment exceeds the value specified in clause 7.1.1 (g) of IS : 4998 Part I, additional reinforcement shall be provided in 2 layers limiting the stress in reinforcement steel to value specified in clause 7.1.2 (g). The safety factor against over-turning under worst combination of loads, shall not be less than 1.5 in any direction during construction and 2.0 after construction is complete. For the purpose of calculating safety factor against overturning, only 90% of the dead loads as calculated from dimensions and densities of materials, shall be taken into account. Also, at critical sections in the foundation, diagonal tensile stresses and bending stresses about two orthogonal axis shall be checked. For estimating the deflections of the chimney in lined and unlined conditions, the modulus of elasticity of concrete shall be as per the mean value specified in clause A-3.1 of IS:4998 (Part-1). Stresses in the shell shall be shown to be within permissible limits at 10 metre intervals along the height of the shell or at every corbel level whichever distance is less and in addition at the critical locations across openings. Air inlets shall be provided near the base as indicated in tender drawings. The openings shall be provided with a GI wire mesh on the outside mounted on a GI frame, so as to prevent dirt or tiny creatures entering the access void through the opening. These openings shall be provided with aluminium louvred fins within sloped up towards inside. Calculation of air inlet opening area shall be as per IS:4998(Part-1)-1975. Air outlets shall be provided near the top as indicated in the tender drawings with proper SST (stainless steel) wire mesh mounted on SST frame at the outside, and with aluminium louvres sloped up towards the inside. Area of air outlet opening shall be same as area for air inlet opening. Temporary openings, if any, required by the CONTRACTOR at the base or any where along the height of the shell, for the purpose of placement of concrete, access of material and personnel, to provide support platforms for material, etc., shall be indicated during bid stage and finalised before the award of the contract. Only these openings finalised and shown in the released for construction drawings approved by the OWNER shall be provided. These openings shall be closed up after use at no extra cost by providing extra reinforcement and with the grade of concrete same as that of the shell around the opening.
3.6
3.7
3.8
3.9
3.10
3.11

TITLE
SECTION : D6
SHEET 5 OF 40

3.12 Corbels, if required, shall be designed to take the load of platforms, lining, insulation, hopper, etc., supported on them. The maximum width of the openings shall normally be limited to an angle of not more than 60 subtended at the centre of the concrete shell. Where the extent of shell left between two openings is limited such that the subtended angle is less than 45, procedures as normally adopted for column design, shall be adopted to check the adequacy of the shell in this region. The analysis of the windshield for wind and earthquake forces shall be done as per the requirements of clause 13 and 14 of this specification. The foundation shall be designed as a rigid member. The thickness of the foundation below the shell shall not be less than 0.40 times the overhang of the foundation beyond the shell, or 0.09 times the foundation diameter whichever is more. For the purposes of analysis/design, the following shall be assumed: a) b) 3.17 Stiffness of shell shall not be considered for design of the foundation. Shell fixed to foundation for shell design.
3.13
3.14
3.15
3.16
Foundation design shall be based on the foundation criteria as indicated in Data sheet-A. Permissible increase in safe bearing capacity of soil shall be 25% under seismic load condition. Such increase shall be only on the net bearing pressure of soil. No such increase in safe bearing capacity of soil will be permitted for wind load combination. For foundation design, no increase in permissible material stresses will be permitted for wind load combination. Permissible increase in material stresses shall be 33-1/3 % under seismic load condition. REQUIREMENTS IN RESPECT OF CONCRETE All concrete work shall be carried out strictly in accordance with the specification, except as otherwise specified hereunder. The source and type of the basic ingredients of concrete, viz., cement, aggregates, water and approved admixtures, if any, shall be unchanged throughout the construction of the chimney shell, particularly in case, slipforming technique is adopted for shell construction. The maximum size of coarse aggregates, unless specified otherwise, shall not be larger than 1/8th the narrowest dimension between forms nor larger than one-half the minimum clear distance between reinforcing bars nor more than 20 mm. Natural gravel and rounded aggregates of acceptable quality shall be preferred to broken stone with sharp angular corners for slipformwork, in particular.
3.18
4.0 4.1
4.2
4.3
4.4

TITLE
SECTION : D6
SHEET 6 OF 40

4.5 When slipforming is adopted, the slump shall be between 100 mm and 150 mm at the point of placement. However, precise requirements in this regard shall be established from field tests and shall be subject to ENGINEERS approval. If necessary, approved admixtures such as retarders/ plasticizers to maintain the workability shall be used with the prior consent of the ENGINEER. Such admixtures shall be identified after preliminary tests to prove their satisfactory performance and compatibility with the particular type of cement envisaged to be used in the shell construction. After identification and determination of dosage for varying weather conditions, the total quantity of admixture required for the complete work shall be estimated and shall be procured in batches to ensure that the same is utilised before expiry of its shelf life. In no case shall the admixture be used if its shelf life has expired due to delay in construction activities. No additional payment shall be made to CONTRACTOR for providing and using retarders/plasticizers. The minimum cement content and maximum water cement ratio shall be as given in Table 5 of IS:456-2000. Maximum cement content shall be limited to 450 kg/cum. Degree of exposure for foundation shall be moderate for foundation and sevre for wind shield. The minimum thickness of the concrete shell shall be 250 mm. The clear concrete cover over the vertical reinforcement in the shell shall not be less than 50 mm. In foundations, the clear concrete cover shall be 75 mm. Minimum grade of concrete for chimney shell and minishell shall be M30. For foundation, platform, slab, beams, corbels, hopper and other structural work, minimum grade shall be M25. Maximum grade of concrete shall be M40. While concreting shell at corbels and platform levels, care shall be taken to ensure that the dowels for corbels and platforms are initially bent within the wall thickness and concrete of specified grade for shell at that level is placed and well compacted. The dowels may be later exposed by chipping the shell surface only after the concrete is well set. On no account will the method by packing the area with sand or any other material be allowed for the purpose of exposing dowels at a later date. REQUIREMENTS IN RESPECT OF REINFORCEMENT The minimum vertical reinforcement on each face with deformed bars shall be 0.125% of the concrete area of the section under consideration. For mild steel bars, the minimum reinforcement to be provided on each face shall be 0.15% of the concrete area of the section under consideration. The minimum diameter of vertical reinforcing bars shall be 12 mm and they shall not be spaced at more than 300 mm centres. Laps for the vertical reinforcement shall be staggered. Not more than one-third of the bars shall be lapped at any one level. The laps at a level should be distributed around the perimeter and not concentrated in only one part of the perimeter of the
4.6
4.7
4.8 4.9
4.10
4.11
5.0 5.1
5.2

TITLE
SECTION : D6
SHEET 7 OF 40

shell. Where vertical reinforcement is required to be lapped above openings, lap shall be allowed only after a height of B/2 above the opening for the whole section, where B = width of opening. While curtailing reinforcement above openings, care shall be taken to ensure proper transfer of tensile forces if present in the section to the subsequent section by provision of adequate reinforcement. The bars shall not be curtailed abruptly and an adequate development length shall be provided. 5.3 The circumferential reinforcement on each face of shell, for deformed bars, shall not be less than 0.1% of the concrete area of the section. When mild steel bars are used, the percentage on each face shall be 0.125. The minimum diameter of these reinforcing bars shall be 10 mm and they shall be spaced at a centre to centre distance not exceeding 300 mm or the shell thickness whichever is less. Circumferential reinforcement shall be evaluated so as to satisfy the minimum requirements as mentioned above and to safely withstand the circumferential forces and moments. However, for a height from the top equal to half the shell outer diameter or 3 metres whichever is more, the quantity of circumferential reinforcement shall be twice that arrived at as stated above. Circumferential reinforcement shall be placed around the exterior of and securely wired or welded to the vertical bars at an interval of not more than 600 mm. Particular attention shall be paid to placing and securing the circumferential reinforcement so that it cannot bulge or get displaced during the placing and working of the concrete. Dowels, wherever provided, shall extend on either side of the construction joint by a length equal to the full development length of the bars in tension. The reinforcement for corbels and dowels for platform reinforcement shall be of mild steel and of size not larger than 12 mm diameter. In addition to the reinforcement determined from structural considerations as well as to meet temperature and other stresses, extra reinforcement shall be provided around and at corners of openings. The extra reinforcement shall be placed near the outside surface of the chimney shell as close to the opening as proper detailing of reinforcement will permit. Unless otherwise specified, all such extra reinforcement shall extend past the opening to a length equal to its development length in tension. At each side of the openings, the extra vertical reinforcement shall have a total area equal to the design reinforcement for one-half of the width of the opening. This steel shall be placed on each side of the opening within a distance not exceeding 1.5 times the shell thickness wherever column design procedure specified in clause 3.13 above is not applicable. The extra reinforcement shall extend past the opening by a length equal to 1/2 the width of opening plus its development length in tension.
5.4
5.5
5.6
5.7
5.8
5.9

TITLE
SECTION : D6
SHEET 8 OF 40

5.10 At both top and bottom of each opening, extra horizontal reinforcement shall be placed having an area atleast equal to one-half of the design circumferential reinforcement interrupted by the openings but the area 'As' of this extra reinforcement shall not be less than that given by the following : As (mm2) = fck.t.s/c Where, fck t s c steel 5.11 characteristic strength of concrete in N/mm2, = shell thickness at opening in mm, = width of opening in mm, = 16000 and 13000 for high yield strength deformed bars and mild bars, respectively. =
One half of this extra reinforcement as stipulated in clause 5.10 above, shall extend completely around the circumference of the chimney and the other half shall extend beyond the opening to a length equal to the development length of the bars in tension. This steel shall be placed within a height not exceeding the thickness of the shell. 5.12.1 For shell thickness greater than 250mm, diagonal reinforcement with a total cross sectional area in sq.mm of not less than 5 times the shell thickness (in mm) shall be placed at each corner of an opening. These bars shall also extend on either side of the corner a distance equal to the development length of the bars in tension. 5.12.2 For the shell of thickness less than 250 mm additional steel of a total cross sectional area in sq. mm of not less than 3.5 times the shell thickness (in mm) shall be placed horizontally/vertically. These bars which shall extend to a distance equal to the development length in tension on either side shall be in addition to the entire steel already provided as per clauses 5.8 to 5.11. 5.13 Foundation of chimney shall be provided with a minimum layer of reinforcement at top and same shall not be less than 12 mm deformed bars at 250 mm centres placed orthogonally. Temporary openings, if any, required by the CONTRACTOR along the height of shell, for the purposes of access to material and personnel, placement of concrete, for supporting temporary platforms while laying of bricks, etc. shall be allowed only on the approval of the ENGINEER. They shall be designed as permanent openings with provision of extra reinforcement as per the requirements of clauses 5.8 to 5.12. The edges of openings shall be provided with suitable MS rods as dowels which shall be bent and exposed as per the requirement of clause 4.12. Additional bars if required, shall be tied to the dowels to form a reinforcement mesh work within the opening and the opening later filled with concrete of same grade as of the surrounding shell. The maximum width of temporary opening shall be as per the requirement of clause 3.13.
5.14

TITLE
SECTION : D6
SHEET 9 OF 40

6.0 6.1 BRICK LINING The chimney shall be lined with fire/acid resistant bricks for the full height of the chimney above the hopper. The lining shall be supported on concrete platforms at intervals of not more than 10 metres unless otherwise shown in the tender drawing. Lining bricks shall be hard, uniformly well burnt, uniform in colour, of correct shape and size, homogenous in texture and free from cracks, voids and other flaws and shall be of material suitable to withstand the service conditions. No broken bricks shall be allowed to be used except for closing the course. Each brick shall be clearly marked with the MANUFACTURERS name and trade mark. (a) The sizes and shapes of fire clay bricks shall conform to IS :1526 and shall be of Group-A Type 1 conforming to IS:6. These bricks shall be laid in air setting mortar and cured as per MANUFACTURERS specification. The mortar for laying fireclay refractory bricks shall be of grade-2 conforming to IS:195.
6.2
6.3
(b) Prior to despatch of mortar material from MANUFACTURER, at least five (5) samples of the lot to be despatched shall be tested for bond strength as specified above, and the test reports submitted to OWNER/CONSULTANT for approval and permission for despatch of material. Similarly, five (5) samples of the lot to be despatched shall also be tested for chemical resistance as per IS:4456 (Part-1) and loss in weight and loss in compressive strength of the test specimen shall not exceed 5 %. The test reports on chemical resistance shall be reported as per clauses 10.11.2 and 10.11.3 of IS:4456 (Part-1). 6.4 The acid resistant bricks shall conform to Class I of IS:4860 and the mortar for this brickwork shall conform to IS:4832 (Part 1) - Silica type with potassium silicate liquid binder. In the case of Acid resistant Brick lining, the mortar joints shall be cured with 25% dilute HCl for a minimum period of 3 days and as per MANUFACTURERS specification after which exposed face shall be thoroughly cleaned with water. The value of the coefficient of thermal conductivity for fire clay and acid resistant lining bricks shall not exceed K = 1.25 Kcal/m/hr/C and shall be considered as K = 1.25 Kcal/m/hr/C for the purpose of design of shell for temperature effects. Prior to despatch of bricks from MANUFACTURER at least five (5) samples of the lot to be despatched shall be tested for K-value at an approved laboratory and test reports submitted to ENGINEER for approval and permission for despatch of material. While testing, the hot-face temperature of the bricks shall be 300C. Similarly, test certificates for acid resisting properties shall also be furnished for acid resisting bricks. Provision shall be made for differential vertical expansion at the lining support.
6.5
6.6.1
6.6.2
6.7

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SECTION : D6
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6.8 The thickness of lining shall be as shown on the bid drawings. The radial joints shall be broken in each course. Lining shall be strapped with circumferential and vertical galvanised mild steel bands having a minimum dimension of 75x6 mm and 50x6 mm respectively, both spaced at one metre centres, on the exterior of the brickwork throughout the full height of the lining. The vertical and horizontal bands shall be joined together by either (a) suitable spot welding and all weld joints painted with 2 coats of zinc rich aluminium paint over a coat of compatible primer as per the requirement of the MANUFACTURER, or (b) fixed by bolting arrangement, with counter sunk bolts and slotted holes as indicated in relevant bid drawings. Special care shall be taken to ensure proper laying of bricks to cover the RCC platforms so as to protect them from the action of gases. Glass/mineral wool insulation of 25 mm thick shall be provided between the face of the platform and brick lining with a sealing by 2 Nos. 25 mm dia asbestos chords conforming to Grade 3 of IS: 4687. Bricks shall be laid on corbels on 12 mm thick asbestos sheet. Mortar for lining shall be used within the initial setting time and no retempering shall be permitted. Joints shall be properly filled and at a given cross section, the thickness of the joint shall not be more than 2 mm along the inner periphery of the lining and not more than 12mm along the outer periphery. In case where the inner diameter of the lining is less than 4500, shaped bricks shall be used to maintain the thickness of joints mentioned above. The lining shall be as specified in the bid drawing. INSULATION AND PACKING All insulation and packing shall be of dimensions specified on the drawing. The materials for insulation and packing shall be mineral/glass wool, asbestos rope, asbestos mill boards, insulation bricks, etc., of approved quality. The mineral/glass wool shall be of resin bonded type conforming to IS:8183 or equivalent with a maximum coefficient of thermal conductivity of 0.060 Kcal/m/hr/C at a mean temperature of 150C. The material shall have a minimum density of 0.80 kN/m3. The diameter of the asbestos rope conforming to Grade 3 of IS:4687 shall be 25 mm unless otherwise specified on the drawing. The strands shall be long, well twisted and stranded and no torn fibre shall stick out. The rope of approved quality shall be firmly packed so as to prevent gas leakage at all locations where the lining overlaps. Asbestos mill board shall be 12 mm thick, unless otherwise specified on the drawing. It shall be plain, dense and have a homogenous texture, without cracks, flaws or any other manufacturing defect. It shall be laid directly over the concrete after removing all loose materials but without any mortar/plaster bedding.
6.8.1
6.9
6.10
6.11 7.0 7.1
7.2
7.3
7.4

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7.5
The base for acid resistant brick lining in hopper portion shall be either cellular concrete or insulating bricks of Grade 'C' conforming to IS:2042 or equivalent unless otherwise specified on the drawing. 22 gauge GI sheet covers shall be provided all around the insulation wrapping around the lining of flues and ducts. The sheeting shall be in three segments with all necessary fixing arrangements with rivets including overlapping and work shall be executed as per drawings and as directed by the ENGINEER. ACCESSORIES CAP To prevent gas-entrained matter from falling into the space between the liner and the mini shell and also to prevent the chimney top from chemical attack of flue gases, a sectional grey cast-iron cap of minimum 12 mm thickness over 25 mm thick asbestos shall be provided, unless otherwise specified on the drawing. The cap shall cover the concrete shell, brick lining and air space between them. The cap shall slope towards the inside of the chimney at approximately 30 to the horizontal. All sections of the cap shall be anchored in place with bronze bolts and bronze rag bolts respectively.
7.6
8.0 8.1
8.3
LADDER
8.3.1 The chimney shall be provided with a hot dip galvanised steel ladder as shown in bid drawing. 8.3.2 The ladder shall consist of 75 x 12 mm stringers and 75 x 8 mm cage rings and cage verticals. The stringers shall be spaced 400 mm clear inside width with 25 mm dia rungs. The rungs shall be spaced 300 mm on centres and shall be atleast 230 mm away from the chimney surface. Each ladder section shall be bolted together with the next section. The ladder shall be provided with stays of same section as the stringers spaced 1000 mm on centres. These shall be bolted/welded to the stringers and fixed to the chimney shell with 22 mm dia GI rag bolts/dash bolts 150 mm long. The ladder shall have straight sides and its construction shall conform to all state and local laws and regulations governing such installations. The ladder shall be provided with a safety cage made up of hot dip galvanised steel flats as shown on the bid drawings. All inserts shall also be hot dip galvanised. The ladder and its connection shall be designed to support a concentrated load of 175 kg at any location. DOORS The number and size of doors to be provided shall be as specified herein. These doors shall be fabricated from mild steel sections with steel plates. The minimum
8.3.3
8.3.4
8.4

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SECTION : D6
SHEET 12 OF 40

thickness of mild steel shall be 3 mm for sheets and 6 mm for rolled sections. In all cases, the surface preparation and painting thereafter shall be as per paint MANUFACTURERS requirement and shall be subject to ENGINEERS approval. 8.4.1 Access Door One access door of size 1000 x 2100 mm size shall be provided at ground level, 300 mm above grade elevation. The door shall be hinged and provided with an aldrop. It shall be painted with acid and heat resistant paint conforming to IS: 158 Type-1 to give a dry film thickness of 75 microns in three coats. 8.4.2 Clean Out Doors
8.4.2.1 Two pairs of doors comprising of 750 x 900 mm door in the concrete shell and 650 x 825 mm door in the lining shall be provided for cleaning soot hoppers and for access to inside of the flue. Doors shall properly seal the escape of flue gases by suitable construction and same shall be acceptable to the ENGINEER. The door in the concrete shell shall be provided with three coats to give a dry film thickness of 75 microns of acid and heat resistant paint conforming to IS:158 Type-1 and that in lining shall be painted with high heat resistant bitumen paint to give a dry film thickness of 75 microns in three coats. 8.4.2.2 The doors shall be hinged and provided with a locking device in addition to swivel studs with wing nuts on the remaining three edges at spacings not more than 500 mm. 8.4.2.3 Suitable castable refractory lining 230 mm thick, covering the shell, air gap and lining shall be provided all round the doors. 8.4.4 Four (4) no. maintenance doors (2 in each flue) of 750mm x 600mm size shall be provided in the flue at every external platform level. Details of the door shall be similar to the clean out door provided in the flue One no. mechanically operated rolling shutter of 4000mm x 5000mm size shall be provide at ground level. Complete details of rolling shutter shall be as per IS:6248.
8.4.5
8.5 8.5.1
SOOT HOPPER This shall be of reinforced concrete and lined with acid resistant brickwork laid in acid resistant mortar. Only shaped acid resistant bricks shall be used in the hopper portion. The bricks, mortar and details of laying and joining shall conform to the requirements laid down for acid resistant brick lining. Between the reinforced concrete hopper and acid resistant brick lining, 75 mm thick (unless otherwise specified on the drawing) insulation bricks of Grade C conforming to IS:2042 or equivalent cellular concrete shall be provided. At the
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bottom of the hopper, CI flanged pipe with puddle flange of specified dia and length shall be embedded as shown on the drawing. Inside of this pipe sleeve shall be coated with sodium silicate. 8.6 8.6.1 CASTABLE REFRACTORY LINING Castable refractory lining material at duct opening, around door etc., shall have the following properties : Grain size Porosity : : 5mm down graded 20% when hand applied 16% when gunited 0.8 Kcal/m/h/C At ambient temperature
Thermal conductivity Setting 8.6.2
: :
MANUFACTURERS certificates shall be submitted to OWNER/ CONSULTANT for approval prior to use in the works. INTERIOR PLATFORMS The platforms for the brick flue chimney shall be of RCC with slab and steel beam arrangement. The minimum grade of concrete shall be M25. The platforms shall be seated / supported on the wind shield by means for pockets. The platform shall be designed for its self weight, liner loads and live load of 5.0kN/m2. The fabrication work of all steel beams shall be completed by the CONTRACTOR well before the completion of the wind shield at that level so that beams could be erected. No extra cost shall be payable to the CONTRACTOR for design, supply, fabrication and erection of structural steel beams for internal platforms immediatly. The structural steel beams shall be designed to carry self weight of platform slab, live load of 500 kg/m2, self weight and liner loads. It shall also be designed for movement due to temperature. The complete workmanship for these structural steel beams shall be as per specification. Structural steel work shall be painted with 2 coats of zinc rich red oxide paint and 3 coats of synthetic enamel paint. Elastomer bearing pads shall be provided below the steel beams, to transfer the loads to shell. These bearings shall be designed for all the loads it is subjected to and the design shall conform to IRC:83(Part-II). HAND RAILING The hand railing shall be of medium quality 32 mm NB GI pipe conforming to IS:1161 in 3 rows with railing post of 90 x 90 x 6 mm MS angles spaced at approximately 1300 centre to centre. Hand railings shall be provided at locations as shown on drawings and for all platforms.
8.7 8.7.1
8.7.2
8.8
8.9
FLUE OPENINGS
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8.9.1
The number, size and location of flue openings in shell shall be as shown on the drawing. The size of duct, number and type of bolts/inserts for connecting the duct outside the chimney including the mating flange shall be as per the requirement of boiler vendor. All inserts in concrete shall be hot dip galvanised.
8.9.2 The concrete shell at the flue entries and at openings shall be adequately protected against high temperature by brick lining/castable refractory lining. Adequate arrangement shall be made to seal the air gap between the shell and lining against ingress of flue gases 8.10 DUCT WORK
8.10.1 The connection between MS flue duct and chimney flue shall be as indicated in the bid drawing. Gap between the MS duct and chimney sheel shall be properly sealed to prevent ingress of water. 8.10.2 The CONTRACTOR shall be responsible for furnishing, design, fabricating, shop painting and delivery of ducting which shall run from the chimney liner to the flange of the boiler vendors duct including all necessary auxiliary ducting. 8.10.3 The ducting material inclusive of stiffeners, flanges, bolts, suspension elements shall be of mild steel confirming IS:2062 (Grade A). 8.10.4 The duct shall include all necessary stiffeners, flanges, sealing materials, bolts, suspension elements, temperature and pressure measuring points, test ports for flue gas analysers, supports and access doors. Baffle or bellow type expansion joints may be provided to cater for expansion and slip type joints made by lapping will not be permitted. 8.10.5 The ducts shall be constructed in such a manner that they are true to the tolerance levels indicated. 8.10.6 The duct work shall be insulated as per the requirement of clause 7.0 but with 100 thick insulation ( 2 layers of 50 thick sheets) and provided with aluminium foil of minimum 1 mm thickness as indicated in relevant bid drawing and access doors shall be provided for the ducting as per the requirement of clause 8.4 where required for inspection and cleaning. 8.11 CHIMNEY ROOF
8.11.1 The chimney roof shall be of a RCC slab suitably supported on a grillage of structural steel beams for brick flue chimney. The roof shall be sloped towards rain water down take pipes to provide positive draining. CONTRACTOR shall ensure that the roof is built conforming strictly to the tolerance limits as required in this specification. 8.11.2 The roof shall be provided with a hatch for access from the flue support platform. The hatch shall have a single leaf door with a minimum thickness of 6 mm to cover

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a clear opening of 750 mm x 1000 mm. The hatch shall include the door, metal curb, draft seal, spring latch, hold open device and all hardware. All joints shall be welded and ground smooth. The curb shall be 300 mm in height with a suitable lip which shall include a continuous neoprene seal strip to make the hatch air tight when the cover is closed. The hatch shall be operable from both inside and outside and shall be provided with automatic hold open arm, easy one hand release and spring latch. 8.11.3 The roof slab shall be lined with acid proof / chemical resistant tiles bedded on acid proof / chemical resistant mortar. The mortar which shall be laid to the full height of the tiles shall have the same properties of the tiles with regard to acid proof / chemical properties; fixing shall be done in accordance with the MANFACTURERS requirements and / or as approved by the ENGINEER. 8.11.4 The tiles shall be unglazed and conform to IS:4457 and be of vitreous ware and free from deletrious substances. They shall be of I class quality and free from manufacturing defects and be true to size. The tiles shall be of size 198.5 sq x 40 mm with grooves not exceeding 3 mm deep provided at the underside. 8.11.5 The tiles shall be tested for squareness, warpage, water absorption, compressive strength, flexural strength, resistance to acid and abration as per requirements and methods specified in IS : 4457 8.11.6 The cement should be acid-proof, chemical resistant and water-proof. It shall be in particular resistant to sulphuric acid and hydrochloric acid and shall have the properties listed out hereinafter. 8.11.7 The bedding mortar shall conform to the requirements of IS:4832 (part-I) and be of potassium silicate base having a minimum flexural strength of 4 N/mm2 and compressive strength of 15 N/mm2 both at 7 days. The mortar shall have a minimum bond strength of 0.5 N/mm2. The mortar shall be tested for the above requirements, working time and absorption of toulence in accordance with IS:4456, Part-I. 8.11.8 The tiles shall be pointed using a phenolic based resin cement conforming to IS : 4832 (Part 2) having a minimum flexural strength of 7.5 N/sq.mm and compressive strength of 35 N/sq.mm both at 7 days . The mortar shall have a minimum load strength of 1 N/mm2. Apart from the above, the mortar shall be tested for working time and absorption in accordance with the requirements of IS : 4832 (Part 2) and IS : 4456 ( Part I ). 8.11.9 The bedding mortar and phenolic based resin mortar should be acid proof, chemical resistant and water proof. They shall, in particular, be resistant to sulphuric acid and hydrochloric acid. 8.11.10 CI/HDPE rain water pipes shall be provided within the interior of the shell to remove rain water collected on the roof cap. Rain water inlet into the pipes at roof slab level shall be provided with CI grating and connected to the CI/HDPE

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downtake pipe along with wall/any other permanent structure by providing suitable bend at roof level as indicated in relevant bid drawings. 8.12 LOUVRES
8.12.1 Air inlet and outlet louvres shall be provided as per the requirement of this specification and as indicated in relevant drawings. The louvre fins shall be of Zshape in cross section and made from anodised aluminium plates of a minimum thickness of 5 mm. The frame work supporting the louvre fins shall be made from extruded aluminium sections of minimum thickness 6 mm. The louvres shall be mounted in the form of panels. The fins shall be closely spaced to cut off any driving rain entering the chimney wing shield. All panels must be approved by the ENGINEER before installation. 8.13 FITTINGS FOR AVIATION LIGHTS, AND LIGHTING
8.13.1 Hatches of size and location as indicated in bid drawings shall be provided in the shell at each platform level for the purpose of mounting aviation warning lights. The light fittings shall be mounted on MS brackets welded to MS doors of minimum thickness 3 mm. The inner face of door frame shall be provided with adequate stiffners comprising of structural members of minimum thickness 6 mm. The door frame shall be side hinged and have a locking system easily accessible and operable. The door and fittings shall withstand the prevailing wind and access void pressure. The MS doors and frame work shall be painted with 2 coats of zinc rich red oxide primer and 3 coats of synthetic enamel paint. 8.13.2 Light fittings for the staircase shall be suitably clamped to the staircase column as indicated in bid drawings and platform light fittings shall be suitably fixed to the handrailing at each level. 8.13.3 All brackets, embedded parts, bolts, nuts, washers etc. used for the purpose of fixing of lighting units shall be hot dipped galvanised. 8.16 STAIRCASE A steel staircase shall be provide internally within the shell from the bottom to the top to provide access to all platforms. It shall be fabricated from MS rolled I or channel section stringers. Treads shall be of steel grating designed for self weight and a live load of 500 kg/m2. Treads shall be provided with an approved antislip nosing set flush with the stairs tread. Handrailing shall be provided for the stairs for the whole height. The staircase shall be of a steel frame work supported from each platform independently with all members connected with suitable bolted / welded connections. The supporting structure shall be painted as per the requirements of IS : 1477 with 2 coats of zinc rich redoxide paint and 3 coats of synthetic enamel paint of approved shade. The steel treads shall be hot dip galvanised. The fabrication work of staircase shall be completed by the CONTRACTOR well before the completion of the intermediate plat forms. Minimum clear width of each flight shall be 750mm.

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9.0 9.1
PAINTING Inside surface of concrete shell including corbels, platforms, hopper, ring beams CI cap shall be provided with four coats of acid and heat resisting paint. The paint shall conform to the requirement of IS:158 an the work shall be done as per MANUFACTURERS recommendations : Top 15mts or two-thirds of diameterof shell at top most level whichever is higher of the external portion of the chimney, external platform, handrails, embedments etc shall be painted in alternate bands (with a band width of 2.5mts) of colours signal red and pure/bright white. Painting system shall be acid and heat resistant and shall comprise of two primer coats of clear epoxy paint and minimum two finish coats of acrylic polyurethane paint.
9.2
Remaining portion of external surface of chiney shell shall be painted with single pack polyurethane enamel paint in a colour / shade / pattern as per the prevailing norms specified by Aviation authorities. This painting system will comprise of two coats of single pack acrylic polyurethane enamel paint over two coats of primer as per manufacturers requirements. External painting shall commence immediately after the shell construction/platform is completed and the concrete is well cured. The painting shall preferably be started from the top. This is to ensure visibility of stack to low flying aircraft at day time even during the period of construction of the internals of the chimney. STRAKES Strakes shall be provided based on design requirement. The strakes shall be designed for a pressure three times the maximum wind pressure expected at top of chimney. Strakes, if required, shall be made up of hot double dipped galvanized (qith 700 gms/sqm) mild steel plates and rolled sections of thickness not less than 6 mm. A corrosion allowance of 1.5 mm in the structural members shall be provided for, beyond the design values. A minimum gap of 500 mm between the top of strake and the bottom of external platform/landing, shall be ensured. Fixing arrangement of strakes to the chimney shell shall ensure full fixity for the design load. All strakes, embedded parts, bolts, nuts, washers, etc., shall be hot dip galvanised. DESIGN AND DRAWINGS The CONTRACTOR shall submit his method of analysis, design parameters, allowable stresses, method and sequence of construction including staging, details
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9.3
10.0 10.1 10.2
10.3
10.4
10.5
11.0 11.1
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of proposed site testing facilities, etc., strictly as per specifications for the CONSULTANTS review and approval within 15 days from the date of issue of Letter of Intent or Purchaser Order, whichever is earlier. 11.2 The CONTRACTOR shall submit his design/drawing submission schedule and a construction schedule giving the monthwise requirement of materials to be supplied by the OWNER; within 15 days from the date of award of work. The CONTRACTOR shall submit, detailed working drawings/design for the foundation (with dowels for the shell), complete and detailed general arrangement drawing for the CONSULTANTS approval within 15 days from the date of issue of Letter of Intent or award of contract whichever is earlier. The remaining drawings shall be submitted in a progressive manner within six months from the date of award of contract. These design/drawings will be returned after the CONSULTANTS review within about one month from the date of receipt by CONSULTANT. No claims shall be entertained due to delay in review of the CONTRACTORS drawings.
11.3
11.3.1 All drawings shall accompany with bar bending schedule & Bill of materials. 11.4 In case the CONTRACTOR adopts computerised designs, only validated computer programs shall be used for the analysis and design. The computer output listing should include all input data covering the loads and load combinations. The CONTRACTOR shall submit typical manual calculations in order to validate the computer program / Spread sheets used for analysis / design. Timely submission of design/drawings to the CONSULTANT for review is the sole responsibility of the CONTRACTOR and postal or other delays will not be entertained as reasons for late/non-submission of design/drawings. All modifications suggested by the CONSULTANT to meet specification requirements and sound engineering practice, shall be incorporated by the CONTRACTOR at no extra cost to the OWNER. In this respect, the decision of the OWNER shall be binding on the CONTRACTOR. The CONSULTANT will accord his approval only after the CONTRACTOR has incorporated in his design/drawings all modifications required by the CONSULTANT. Any modifications/change in subsequent revisions of design/drawings shall be clearly marked and identified with a revision for the ENGINEERS review/approval. Construction of work shall commence only after the written approval of drawings by the CONSULTANT. However, the CONSULTANTS approval of the design/drawings shall not absolve the CONTRACTOR of his responsibility for correctness of design, accuracy of dimensions, loadings, details, etc., or safety and stability of the structure including foundations, accessories, appurtenances, etc. The CONTRACTOR may have to support flue duct supporting columns from the chimney foundation. The design loads for these columns shall be provided by the CONSULTANT.
11.5
11.6
11.7
11.8
11.9

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11.10 The CONTRACTOR shall distribute copies of drawings/schedules, etc., prepared by him in accordance with the schedule given below :
PRELIMINARY
COMMENTED
FINAL
SCHEDULES DESIGN
DWG
DESIGN
DWG
SCHEDULE S
DESIGN
DWG
OWNER (HEAD OFFICE)
2P
1P
1P
2P
1P
10 P+ 1C
OWNER (SITE OFFICE)
2P
---
1P
---
2P
---
1P
TCE
2P
6P
6P
1P
3P
3P +1 C S
VENDOR
LEGEND P Prints S Source C Soft copy in CD The CONTRACTOR shall send one copy of all correspondence to OWNERS head office and site office. The cost of these and that due to design/drawings submission as per distribution schedule specified above is deemed to have been included in his quoted rates.
12.0 12.1
CONSTRUCTION GENERAL
12.1.1 CONTRACTOR shall ensure that the excavation and sub- structures are free from water during construction and shall take all necessary precautions and measures to prevent ground water, storm water, etc., from entering the excavation so as to carry out the work in reasonably dry conditions in accordance with the construction schedule.

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12.1.2 The CONTRACTOR shall dewater and maintain reasonably dry, the excavation for structures and all other areas of the site, where build up of water (in the opinion of ENGINEER) is likely to obstruct the progress of work, or lead to insanitary conditions by stagnation, or retard the speed of construction, or is detrimental to the safety of men, materials and equipment or is undesirable due to any other reasons. 12.2 STAGING
12.2.1 Design and erection of staging shall conform to the requirements of all relevant IS Codes and National safety standards/regulations. 12.2.2 CONTRACTOR, at his own cost, shall prepare a detailed erection scheme. If called upon, he shall submit to the CONSULTANT detailed drawings with supporting calculations showing all details of formwork, staging, scaffolding, member sizes, connection details and other arrangements for slipforming and for the concreting work and submit the same for review. Any suggestions/ comments on the scheme/details conveyed to the CONTRACTOR shall be carried out by the CONTRACTOR at no extra cost. Scheme submitted for approval shall incorporate separate provision of material hoists and a passenger hoist. 12.2.3 As the staging serves a dual purpose, viz., as an access tower and as a bearing structure to support construction loads, it shall be designed for all possible loads that could be imposed on it such as self-weight, weight of ladder and timber platforms at all levels, weight of men, weight of construction materials and equipment, wind loads, seismic loads, etc. 12.2.4 Minimum live load on staging due to labour and personnel movement shall be considered at 300 kg/m2. It may be taken as 150 kg/m2 when earthquake loads are also taken into account. No increase in stresses shall be considered for wind and seismic conditions. 12.2.5 Special inspection hoist of approved make shall be provided by the CONTRACTOR for regular inspection, checking of scaffolding members, joints, etc. Fortnightly detailed inspection record shall be maintained by the CONTRACTOR and shall be produced to the ENGINEER whenever required for his verification. 12.2.6 Notwithstanding the approval from the ENGINEER, the CONTRACTOR will be solely responsible for the safety, security and proper functioning of the staging and formwork. 12.2.7 Where conventional/jumpform shuttering is provided, minimum stripping time of formwork shall not be less than 12 hours for sides of RCC shell. However, the stripping time to be adopted on the works shall be subject to the ENGINEERS approval. The CONTRACTOR shall not be permitted any increase in construction period if the stripping time for shell exceeds 12 hours. 12.3 SHELL CONSTRUCTION

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12.3.1 The CONTRACTOR shall prepare and submit a detailed quality assurance plan within one month of award of work. This plan shall include the following : a) Design criteria The CONTRACTOR shall give the criteria to be adopted for design of various temporary works and the slipforms. The following requirements shall be met. i) Staging materials shall conform to IS:2062.
ii) Minimum design live load from personnel shall be 500 kg/sq.m. To this shall be added the self- weight and weight of construction materials and equipment, etc. iii) The staging shall be designed as per the requirements of IS:800 (for conventional type) and IS:4014 (for tubular scaffolding type). The CONTRACTORS design calculations shall be based on normally accepted calculation techniques for the structural forms which the CONTRACTOR adopts for staging. b) Statement of detailed 'Construction Method' This shall include atleast the following : i) Structural analysis providing adequacy of jacks, slipforms, and their supports and staging.
ii) Planned interruptions. Also the operations during planned interruptions such as retrieval of jack rods, resetting of form panels, etc., shall be stipulated. iii) Method of preparing, transporting, pouring, vibrating and finishing concrete. iv) Quantity of various materials required during each stage of construction including inserts, cutouts, reinforcement, dowels, etc., for procurement and timely supply. v) Properties of concrete such as w/c ratio, strength, workability, etc. vi) Rate of slipping which shall be adopted. vii) Treatment at construction joints during unplanned interruptions. c) Construction Equipment

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The CONTRACTOR shall furnish a detailed description of the following : i) The type and number of equipment and facilities to be used for slipforming such as jacks, working platforms at various levels, yokes, walers, etc. There shall be atleast a 50% standby capacity of jacks, jack rods, hydraulic pump, hose pipes, etc. ii) Provision, including standby, of concrete mixing units and pumps to cater to the planned rate of progress of slipping. iii) Material hoists and buckets for transport of concrete, reinforcement, scaffolding components, etc. iv) Curing arrangements consisting of pumps, pipelines, etc. There shall be atleast 50% standby pumps v) Provision of precision survey instruments including lasers for verticality check. The laser instrument shall emit a long range visible laser which has a self-levelling platform which electronically levels the instrument and has a fail-safe system that shuts off the beam when out of level. There shall be a standby. vi) Stipulation of power requirement for operation and the CONTRACTOR shall provide adequate standby diesel generating sets. Details of night lighting shall also be specified. vii) Communication arrangements between ground and working deck.

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12.3.2 Concreting a) Particular attention must be given to concrete placement because of the thin wall section and the presence of reinforcing steel. Compaction of concrete shall be by vibration. Under no circumstances shall the point of discharge of the concrete into the forms be more than 1.5 m above the concrete surface on which it is to be deposited. Also, not more than 2 metres height of chimney shall be concreted on any one day if permission is given to proceed with jump forms. Concrete in the shell shall be poured in about 200 mm layers uniformly. The concrete in each lift (where jump form is used) shall be laid in one continuous operation for the full circumference of the shell so that there will be no vertical or inclined construction joints. Horizontal construction joints shall be maintained at uniform spacing throughout the height of the chimney. If the ENGINEER so requires, the CONTRACTOR shall make immediate arrangements, through an approved agency, to undertake ultrasonic tests to prove the quality of concrete. The quality of concrete shall be considered as satisfactory if it meets specification requirements and the sonic velocity is atleast 4000 m/s. If the tests prove that the quality of concrete is not satisfactory, then all costs associated with the tests and any rectification shall be borne by the CONTRACTOR. The interior and exterior surfaces of the shell shall be kept moist for 14 days after exposure from the forms as the chimney construction progresses upwards. For this purpose, circumferential perforated pipes shall be hung from immediately below the forms and raised along with them. The vibrator needle size should normally be 62 mm dia, however the size shall be restricted to 37 mm dia for sections wherein the use of 62 mm dia needle size vibrators are not amenable to use. Standby vibrator units shall be maintained on top of the working deck at all times during the slipforming operation. The vibrator poker shall only be lowered into the concrete to a depth corresponding to the height of the last placed layer of concrete. During the first pouring, when the forms are empty, vibration should be avoided or carried out with utmost care in order to prevent bending of the yokes. To achieve good bond between the foundation and the first lift of the shell, or at horizontal joints caused by interruptions to sliding, an initial layer of rich mix cement/sand slurry of 1:1 proportion shall be placed. h) The slipping rate of the forms shall be such that the concrete, when exposed has already achieved enough strength to support the vertical pressure from the concrete still in the forms as well as to withstand lateral pressure caused
b)
c)
d)
e)
f)
g)

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by wind, inclination of walls, etc. The slipping rate shall be limited to 200mm/hour. i) Small openings and pockets less than 600 x 300 mm can be formed by inserting blocks. Larger openings shall be formed using frames which shall be formed well in advance of the sliding. All frames, blocks, bolts, tubes, etc., must be 12-15 mm narrower than the nominal wall thickness to allow for form taper. When jacking rods unavoidably have to pass through openings more than 600 mm high, the jacking rods must be braced laterally against buckling.
12.3.3 Physical Checks Some of the mandatory physical checks to ensure that construction tolerances are met with shall be carried out by the CONTRACTOR, as under : a) b) c) d) The twist or rotation of the slipform every 60 minutes. Level of top of jacks every thirty minutes. Verticality with the help of lasers atlease once in four hours. Inside and outside diameters/dimensions and wall thickness, once in each shift of 8 hours. Level of top of form panels once initially and subsequently after each interruption. Level of working platforms once initially and subsequently after each interruption. Batter of the form panels and yoke legs once on erection and subsequently after each interruption. Condition of jack rods for ovality, indentation, buckling, moving out of alignment, etc., before fixing each rod. Bracing of jack rods passing through openings. Live load on working deck to avoid accidental overloads. Workability of concrete at mixer and at point of placement, once an hour. Temperature of concrete, once in 4 hours.
e)
f)
g)
h)
i) j) k) l)
12.3.4 Construction Tolerance The following shall be the limiting construction tolerances to be strictly adhered to by the CONTRACTOR.

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a) Verticality : 1 in 1000 subject to a maximum of 75 mm. In addition, no two points 10 m apart vertically shall be more than 20 mm out of plumb wrt each other + 10 mm, - 0. + 10 mm for every 3m diameter without any abrupt changes but in no case more than 40 mm. Rate of spiralling of forms not greater than 10 mm circumferential rotation at the outer face of the concrete per metre of vertical travel.
b) Wall thickness c) Shell diameter
: :
d) Spiralling
e) Openings, inserts, pocket : f) Cover :
12 mm + 5 mm, - 0.
g) Level of any part of structure : 12.4
20 mm
CONSTRUCTION TOOLS AND MATERIALS
12.4.1 CONTRACTOR shall provide and maintain at the site necessary number and type of machinery and equipment including survey instruments in good working condition for proper setting out and timely completion of the works covered under this specification. All arrangements for transporting the equipment to and from the site shall be done by the CONTRACTOR at his own expense. 12.4.2 It shall be ensured by the CONTRACOR that work shall proceed uninterrupted even in the event of power failures. As such, adequate number of diesel generator sets and diesel operated equipment (such as concrete mixers, vibrators, etc.) shall be provided by the CONTRACTOR, as an alternative arrangement. 12.4.3 All materials supplied by the CONTRACTOR shall be of the best quality and shall conform to this specification. Approval in writing shall be obtained from ENGINEER, before any alternative or equivalent material is proposed to be used by the CONTRACTOR. 12.4.4 CONTRACTOR shall furnish MANUFACTURERS test certificate for the materials supplied by him. Where such certificates are not available, the specimen of the material shall be got tested at a recognised testing laboratory at CONTRACTORS cost. 12.4.5 Climbing or slip-forms shall be controlled by linked hydraulically operated jacks that are reversible, driven by an electrically operated pump and with provision for manual operation in the event of a break down.

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12.4.6 CONTRACTOR shall provide all fuels and lubricants required for the operation and maintenance of construction machinery and equipment as well as for his transport vehicles. 12.4.7 CONTRACTOR shall, at his cost, arrange for all his requirements of materials such as, but not limited to, oxygen, acetylene, welding electrodes, ropes, form ties, turnbuckles, clamps, wiping rags, sand paper, etc., which are required to satisfactorily perform his work. 12.5 WORK EXECUTION AND SUPERVISION
12.5.1 CONTRACTOR shall have at the site accredited and qualified engineers and foremen/supervisors with adequate number of years of experience in execution of similar works and operators of machinery and equipment, for satisfactory progress and timely completion of the works. The number, qualification and experience of such staff shall be subject to OWNERS approval. 12.5.2 All temporary electrical installation shall be supervised by a qualified electrical supervisor of the CONTRACTOR. 12.5.3 CONTRACTOR shall be fully responsible for the correctness and accuracy of the works, which shall be executed in a professional manner. 12.5.4 The OWNER reserves the right to order from time to time, during progress of the work, removal and re-execution of any work which is not, in the opinion of the ENGINEER, in accordance with the specification. 12.5.5 During inclement weather, rains, etc., CONTRACTOR shall suspend concreting for such time as the ENGINEER may direct and shall protect from damage all work already in progress or completed just then. All such temporary protective measures shall be at CONTRACTORS cost and any damage to works shall be made good by the CONTRACTOR at his own expense. 12.5.6 Should the work be suspended by reason of strikes/riots by CONTRACTORS own employees or any other cause whatsoever, save and except the force majeure condition, CONTRACTOR shall take all precautions necessary for the protection of works and make good, at his own expense, any damage arising from any of these causes. 12.5.7 In the event of occurence of any accidents at/or near the site of the work or in connection with execution of the work, a report shall be made within 24 hours to the ENGINEER, giving full details of the accident. He shall also report promptly such accidents to all the competent authorities wherever such reports are required by them. 12.5.8 One hoist for passengers/supervisory staff and one for transport of goods shall be provided by the CONTRACTOR. These hoists shall be operational not later than the time when construction first reaches 10 m and should be available throughout the construction period. Access between various working levels shall be provided

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by an approved system of ladders. Under no circumstances shall staging or scaffolding be relied upon to provide such access. The CONTRACTOR shall give enough notice to ENGINEER of his intention to remove access to the various areas of work as construction proceeds which would therefore be rendered inaccessible, to allow final inspection by ENGINEER. 12.6 FOUNDATION REQUIREMENTS
12.6.1 In case any ID duct supports are fouling with the chimney foundation, the CONTRACTOR shall design his foundation according to these loads. The CONTRACTOR shall include in his lumpsum price, the design and construction of these supporting pedestals complete in all respects. Also the CONTRACTOR if required shall supply and use templates to hold any anchor bolts for ID duct supports on foundation. 12.6.2 All brackets, projections, insert plates required to be provided from the outside of the shell to support ID duct of boiler supplier, shall be provided by the CONTRACTOR as per loads indicated by the boiler supplier. Also, the supply, fabrication and erection of the ID duct piece connecting the flue to the main ducts is in the scope of the CONTRACTOR upto the match point. 12.6.3 The foundation shall be constructed in a maximum of four pours or as per the directions of the ENGINEER. The CONTRACTOR shall not be paid any extra amounts in case the foundation has to be constructed in less than four pours as per project requirement. 12.6.4 The foundation sections shall be sized / designed and reinforced adequately for circumferential and radial moments and shear stresses. 12.6.5 There should be no uplift under any portion of the foundation for any loading condition. 12.6.6 A 100 mm thick levelling course of plain cement concrete (1:4:8) shall be provided before casting the foundation. 12.7 SAFETY PRECAUTIONS 12.7.1 The Bidder shall provide all safety requirements for the personnel as per the standard for the high altitude work. 12.7.2 If the sequence of work recommended by the ENGINEER so requires that the Bidder shall have to carry out work simultaneously at different levels, the Bidder shall provide all safety measures required to ensure the safety of the personnel working at lower levels. 12.7.3 The CONTRACTOR shall take a comprehensive insurance policy including third party riskes at his own cost before start of the work. The OWNER shall not make any such payments.

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13.0 13.1 WIND LOAD ANALYSIS WIND SPEED The basic wind speed (Vb) for the location of the project shall be as indicated in DATA SHEET- A. The estimation of wind speed/pressures shall conform to the requirements of IS:875 (Part-3). 13.1.1 3-sec Gust Wind Vz = Vb K1 K2 K3 .......... (1)
here, K1 = a probability factor as obtained from Table-1 of the Code.The mean probable design life of the structure may be taken as: a) 25 years for shell alone condition; b) 100 years for completed chimney condition K2 = Terrain category factor obtained from Table-2 of the Code. The terrain category for the project and class of the structure shall be as indicated in DATA SHEET- A K3 = Topography factor shall be as indicated in DATA SHEET- A.
13.1.2 Mean Hourly Wind Vz = Vb K1 K2 K3 ........ (2) here, K1 and K3 shall be as in clause 14.1.1. K2 as per Table-33 of the Code depending on the terrain category as indicated in DATA SHEET- A. 13.2 WIND PRESSURE Pz = 0.60 V 2 ........... (3) z 13.3 ALONG WIND RESPONSE This response will be evaluated by the following two methods: Method-1 For 3-sec gust wind, Fz = 0.60 Cd Dz V 2 ............ (4) z Here, Cd = Coefficient of drag

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DZ = Diameter of chimney at height Z Deflections, moments and shears shall be evaluated for lateral loads Fz acting on the chimney as a cantilever. Vz to be as per clause 14.1.1 Method-2 For mean hourly wind analysis the Gust factor Approach as outlined in clause A.5 IS:4998 (Part 1)-1992 shall be followed. Deflection, moments and shears shall be evaluated for the lateral loads Fz (Load per unit height at an height 'Z' on the chimney) acting on the chimney as cantilever. Vz to be as per clause 14.1.2. 13.4 ACROSS WIND RESPONSE The across wind response shall be evaluated for the first two modes as per requirement of clause A.5.3 a) of IS:4998 (Part 1)-1992 for chimney having taper less than or equal to 1 in 50. If chimney taper is more than 1 in 50 then procedure outlined in paper by Vickery B J and Basu R I as indicated in clause 2.2. 13.5 COMBINATION OF RESPONSE This shall be checked as under : (a) The critical wind velocity for across wind response shall be evaluated from: ni Dc Vcc = -------S Here, Vcc = Critcal wind speed ni vibration Dc = Effective diameter of chimney S = Strohal number = Natural frequency of chimney in the ith mode of
...... (5)
(b) Knowing the height (Zc) at which Vcc acts, corresponding value of K2 is read from table 33 of the Code for the particular terrain category. Vcc ' V b = ----------
(6)
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TCE FORM NO. 329 R4

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K1 K2 K3
' V 'Z = V b .K2 K3
(7) for
Then, response will be evaluated by equation (4). substituting V 'Z Vz
(c) Response evaluated as per 14.5 (b) above will be vectorially combined with that obtained for the particular condition outlined in clause 14.4 above. NOTES The response under wind load at any level to be used for design shall be the highest of the following values: a) As obtained for 3-sec gust wind, as per Eqn. (4) b) As obtained for mean hourly wind, as per clause 14.3 Method 2 c) As obtained vide description in Cl.14.5(c), above. 14.0 SEISMIC ANALYSIS Seismic analysis shall be done as per the procedure outlined in IS: 1893(Part 4). Model analysis shall be used and seismic accelaeration spectra as give in IS: 1893- Part 4 shall be iutilised. The analysis shall be furnished for a minimum of five models. An importaince factor of 1.75 and damping coefficient of 5% shall be considered for analysis. Seismic design data shall be as per DATA SHEET- A.
SPEC. NO. TCE. 5607A-H-CCH400
TCE Consulting Engineers Limited

ELECTRICAL AND I&C REQUIREMENTS
SECTION:
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1.0
GENERAL This specification lays down broad nature of work to be executed. The Bidder shall however include all such items of work whether specifically mentioned here or not but are essential to make the individual equipment / system complete in all respects for satisfactory completion of the proposed scheme. This specification shall be read in conjunction with the bid drawings and other particulars covered in general conditions of contract. The make of all items shall be as per the list of "preferred makes of equipment" and duly approved by the purchaser / consultant and fixture of one type shall be identical and of one make. All equipment / fittings shall be easily approachable for maintenance / replacement. All equipment and accessories covered under this specification shall conform to Technical specification given in this document. The purchaser however, reserves the right to accept or reject the proposal without assigning any reason. All safety measures as required to be adopted as per the statutory regulations and the safety rules of the plant shall be strictly followed by the Bidder during execution of the contract. The Bidder will be provided 415V construction power supply at only one point. Bidders scope shall start from outgoing terminals of construction power distribution board under Purchasers scope. Supply laying & termination of incoming cable to Normal Lighting Distribution Board and Emergency lighting Distribution Board shall be under Bidders scope. Size of cable and MCCB/ switch fuse unit shall be decided by the Bidder based on his requirement.
2.0
SCOPE AND BRIEF DESCRIPTION OF WORK The scope of work includes design, detail engineering, procurement of items, shop testing, packing, transportation, loading and unloading, delivery at site, storage, handling, erection and commissioning. The Bidders scope of work shall include : Earthing & Lightning protection of RCC Chimney Aviation warning system of RCC chimney 3 General illumination of RCC Chimney The lighting system for chimney shall comprise the following categories. a) Normal lighting system

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Emergency lighting system Aviation warning lighting system.
b) c)
NORMAL LIGHTING SYSTEM: In this system, the lighting circuits shalll be fed by the 3 phase, 4 wire normal AC supply from the normal lighting Panel. All the lighting fixtures connected to this system shall be available as long as supply is available from normal source through lighting transformer. The 63A receptacles located at each platform shall also be fed from the LDB. The normal lighting distribution board shall be fed from Purchasers LT Switchgear located in ESP Control Room. Supply, laying and termination of incoming cable is included in Bidders scope. EMERGENCY LIGHTING SYSTEM: In this system, the lighting circuits shalll be fed by the 3 phase, 4 wire AC supply from the emergency lighting distribution boards. The lighting fixtures indicated in the drawing shall be connected to this system. The emergency lighting distribution board shall be fed from Purcghasers Emergency lighting distribution board located in Main Plant building. Supply, laying and termination of incoming cable is included in Bidders scope. AVIATION WARNING LIGHTING SYSTEM: The aviation warning lights shalll be fed by the 3 phase, 4 wire AC supply from the Emergency lighting distribution board. Supply, laying and termination of incoming cable is included in Bidders scope. Required number of lighting panels/JBs for staircase and platform lighting shall be provided. The incoming cable from Ash handling switchgear and station building shall be laid in cable rack/ trench. Whereever existinmg Purchasers cable trench/rack shall be employed. Size of the cable trench shall be depending on the number of cables. Bidder shall consider suitable protection arrangement such as laying in GI pipe etc. for road, drain and pipe crossings on a cable route. However crossing arrangement shall be provided as per the actual site condition. For installation of fixtures etc, the Bidder shall have to arrange tools, tackles, welding sets, pipe bending machine, cable crimping tools etc. The Bidder shall be responsible for supply and fixing of all accessories required for installation of earthing & lightning protection equipment, aviation lighting system equipment, normal & emergency lighting system, distribution panel etc. on required places even though every individual item necessarily may not have been detailed out explicitly in the specification. The main items shall be as follows.

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AC distribution board with lighting transformer Emergency lighting distribution board Lighting panels/JBs for staircase and platform lighting Cables Air termination rods
- GI strips - 65x 10 mm, 50X8 mm, 25X6 mm, 25X3 mm, 8 SWG GI wire, 12 SWG GI wire Earthing electrodes 36 mm dia Aviation warning lights with control system Photo electric light detector 1 x 70 W HPSV light fittings. 63 A power receptacles, 15/5A single phase power receptacles for I&C requirements
Bidder shall supply approved type danger boards in English, Hindi and Oriya Bidder shall supply fixing accessories such as nut bolts, check nuts, bushes, clips, nails, hoopers, clamps, screws, conduits, etc. Bidder shall have to take approval on following data / drawing - GA drawing of LDB/Emergency LDB - Lighting calculations and lighting layout - Earthing and lightning protection layout - Single line diagram of the power distribution network - Incoming cable route layout with sections - Make of the items Bidder shall be responsible to maintain all fittings/ equipment till handing over the chimney and shall change free of cost any fitting /equipment / accessories if found not in working condition. Bidder shall be responsible for taking approval of the installation and permission to energise the system from statutory authority.

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Bidder shall be responsible for storage and safety of equipment at site. Bidder shall supply and install GI pipe conduit risers of 38 NB diameter or larger as required, cleated on inner face of the concrete shell. Following minimum number of conduit risers shall be provided. One conduit riser to carry the cables to the aviation warning lights to be provided at the platforms, the tentative levels of which are specified in the drawing. Another conduit riser to carry the power supply cable to lighting fixtures to be provided on platforms. The third set of two conduit risers shall be provided for power supply to receptacles. The fourth set of conduit riser shall be for lift cables. Three more conduit risers shall be provided, two for I&C and one spare. GI pull boxes, provided on inner face of the concrete wall by suitable anchor fastners shall be installed at 2.5 metre intervals vertically, unless specified elsewhere. The lowest pull box shall be located 450 mm above grade. Each conduit riser shall run from the lowest pull box to the highest junction box. The conduit risers shall run adjacent to the stair case such that pull boxes are easily accessible. Suitable surface cleated pipe / conduits shall also be provided from the lowest pull box to a suitable outlet point at the base of the chimney to receive cables. Each conduit riser other than those provided for instrumentation and lift shall be connected to a circumferential conduit at each platform level. The circumferential conduit at each level for the platforms shall be provided with necessary GI junction boxes, equally spaced, at the location of the aviation warning lights or lighting fixtures as the case may be. Suitable surface cleated conduits shall also be provided from the junction box to the respective light point. The GI pull boxes and junction boxes shall be fabricated from 16 SWG sheet steel and shall be of size 200X200X100. The pull boxes shall be provided on the concrete shell over the inner face. The supply and installation of cable from pull boxes to junction boxes near the fixture shall be included in Bidders scope. Bidder shall provide two numbers of embeded conduit for instrument air to respective analyzer. Purchasers terminal point for instrument air shall be at the ground level at one point. Further distribution till the analyzer shall be included in Bidders scope. The make of equipment shall be limited to preferred makes as given in preferred makes of equipment. If the equipment/components are outside from preferred makes separate approval from the purchaser shall be obtained for the list. For lightning protection, Bidder's scope of work shall include supply and installation of the complete system up to and including the earth electrodes / mat and air termination rods.

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The Bidder shall furnish a detailed drawing of the lightning protection system and earthing system and execution of work shall be commenced only after obtaining approval to this from the owner. Additional corrosion protection for grounding material, underground piping and other equipment shall be provided. For aviation warning system Bidder's scope of work shall include supply and installation, testing & commissioning of the complete aviation warning system including power receptacles and cabling between main board / switch and aviation warning beacons. Aviation lighting system shall be test operated by the Bidder for not less than 60 days. Equipment and work which fails during the test period shall be repaired or replaced at the option of the owner. Upon any failure in this system during the test period, a new test period shall be required after repair or replacement of the equipment which failed. The scope shall also include the civil works associated with aviation lighting. The Bidder shall furnish a detailed drawing of aviation warning system and associated control system scheme, power distribution scheme and execution of work shall be commenced only after obtaining approval to this from the owner/consultant. For general illumination of RCC Chimney, scope of work includes supply and installation of complete illumination system including power receptacles and cabling. The Bidder shall also furnish a detailed drawing of illumination system and associated power distribution net work. 3.0 TECHNICAL SPECIFICATION INSTALLATION EARTHING SYSTEM DETAILS OF EQUIPMENT AND
Separate earthing conductors of 65 x 10 G.I shall be run in the outer side of RC shell, supported at 2500mm interval. Only risers shall be brought out at all platforms for equipment earthing. A circular earth mat of 36mm dia MS round bar shall be provided at 600mm below the ground. The earth mat shall be connected to the earth electrodes and shall be connected to plants earth grid through Test pits. The Earth electrode shall be of 36mm dia, 3M long GI round bar. The earthing resistance of earthing system shall be less than 1 Ohm. If the earth resistance is found as more than one ohm, Bidder shall provide additional earth electrodes or mat to bring down the earth resistance to a

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value of less than one ohm. All welded joints shall be protected against corrosion. The joint portions shall be thoroughly cleaned before welding. All metallic parts, lighting fixtures, JBs , Lift motor, Handrail etc., shall be earthed to the nearest earthing grid by using suitable earth conductor at two points. JBs, lighting fixtures, handrail ---- 8 SWG & 12 SWG GI wire DB, LP & metallic structure ---------25x6 GI flat 2.2 AVIATION WARNING SYSTEM Bidder shall supply and install, including wiring, Medium and low intensity aviation warning lights with all associated accessories such as sockets, special cables, electrical controllers / Flashers and necessary mounting brackets/supports. The aviation warning lights shall be provided at the locations shown in the drawing. Aviation lighting fixtures securely mounted at the top of the chimney shall be within the zone of protection of vertical air terminations. The aviation warning lights shall meet the recommendations of ICAO, FAA and Director General of Civil Aviation, India. The arrangement of lights shall be marked such that the object is indicated from every angle in azimuth. The aviation warning lighting system shall also confirm to the latest Indian standard, IS 4998. All the aviation light fixtures shall be weatherproof and outdoor type suitable for highly humid and flue ladden atmosphere. The Medium Intensity aviation warning beacons shall generally meet the following requirements: a) Type of Lamp b) Type of fitting (Type B) c) Control of flash intensity operation d) Intensity of flash e) Frequency of flashes f) Type of flashes : : Red coloured LED Medium intensity flashing type
Automatic for day and night
: : :
1600 cd (minimum) of red light 20 to 60 flashes per minute Synchronised flashing of all the lights
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g) Rated power supply voltage & frequency h) Type of enclosure
: :
240V, 1 phase and 50 Hz Weather proof conforming to IP 55 classification as per IS:13947
The Low Intensity aviation warning beacons shall generally meet the following requirements: a) Type of Lamp b) Type of fitting c) Control of flash intensity operation : : : Red coloured LED Low intensity fixed type (Type B) Automatic for day and night
g) Rated power supply voltage & frequency h) Type of enclosure
: :
240V, 1 phase and 50 Hz Weather proof conforming to IP 55 classification as per IS:13947
Wiring of aviation warning lights and other light fixtures shall be carried out using 1100V grade, copper/Aluminum conductor, XLPE insulated and overall HR PVC-FRLS sheathed cables. The cable shall be clamped by the side of the ladder at 750 mm centres by means of GI clamps. Weather proof terminal boxes with cable glands made of brass, tin plate shall be provided at the location of each of the aviation warning lights for termination of cables Normal lighting distribution board with lighting transformer shall consist of an incoming MCCB/ switch-Fuse unit of 415V, 100A, TPN and required number of outlets of 63A, 32A & 16 A TPN MCBs shall be supplied, installed and commissioned at a height of 1.5 meter from grade level on a supporting structure with proper grouting. In addition to the feeders required for lighting circuits and receptacles, minimum 3 nos. 10 A SPN MCB for instrument supply shall be provided in LDB. Atleast 20% of outgoing feeders for each type and rating with minimum of one number shall be provided as spare.The distribution board shall be supplied with tinned brass glands and tinned crimping type cable lugs for termination of cables. The panel shall have two distinct earthing terminals and shall be earthed at both points. The distribution boards shall confirm to IP: 55 class of enclosure and provided with suitable rain canopy over the top. Sheet steel thickness of distribution board shall not be less than 2mm for load bearing structures and 1.6 mm for others. The board shall be painted with one coat of zinc chromats primer (yellow) and two coats of synthetic enamel paint of approved shade. The switches shall be of heavy duty type conforming to the requirements of

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IS:13947. The fuses shall be HRC link type. Aviation lights supports etc. shall be fitted to the chimney by GI nuts on to GI inserts projecting from concrete surface. All bolts clamps etc used shall be hot dip galvanised. For the top platform for fixing aviation warning lights suitable mounting arrangement shall be provided as shown in the drawing. Aviation lighting system shall be fed from separate distribution board which shall be fed from emergency LDB. The aviation light circuits shall be distributed among R.Y and B phase of 3 phase, 4 wire supply. The Bidder shall install weatherproof terminal boxes with MCBs and cable glands on each platform of the chimney at location close to the aviation warning beacons. The maximum conduit fill shall not exceed 60%. Suitable pull boxes shall be provided at convenient locations. All aviation light fixtures, conduits and junction boxes etc, shall be properly earthed. Earth wire shall run inside along the entire length of conduit between the fixtures and distribution board where it shall be connected to earth. For aviation warning during daytime the external surface of the top of the chimney shall be painted with special paints as approved by the owner. The depth of the painting and type to be used (chequered or stripe) shall meet the aviation requirements of civil aviation department and owners approval. Temporary warning lights shall be installed during construction to meet the requirement of civil aviation department. The temprory warning lights installed during construction shall be shifted up as the construction progresses. These lights need be installed only after the level of obstruction is greater than 40 m above the grade level. Lightning protection and earthing required during the construction stage of the chimney shall also be provided by the Bidder. Temporary warning lights shall be four fixtures (Low intensity type A) each with not less than 10 candelas of red light. Power for operation of the temporary lights shall be obtained from the construction power system. Supply circuits for these lights shall be furnished, installed and maintained by the Bidder. These lights shall be operated right from sunset to sunrise. The Bidder shall provide sufficient hand railing ladders platforms to attend any maintenance work. 2.3 GENERAL ILLUMINATION Each landing of the staircase shall be provided with one 1x70 watt HPSV bulk head dust proof light fixture. The Bidder shall provide suitable mounting arrangement for the above fixtures capable of withstanding high wind pressure. General lighting system of chimney shall be fed from a separate feeder of distribution board mentioned above. The cables for wiring all lighting fixtures and power receptacles shall be sized

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considering the voltage drop. The cables shall be clamped by the side of the ladder at 750 mm centres by means of GI clamps. Lighting fixtures, conduits junction boxes etc. shall be properly earthed using galvanised steel wire of 12 SWG. Earth wire shall run inside along the entire length of conduit between the fixtures and distribution panel where it shall be connected to the earth. One number of 63A, 3 Phase, 4 pin industrial type power receptacle with controlling switch and loose matching plug mounted in weather proof and dust tight box shall be supplied and installed at each of the platform near access doors. The box shall be fabricated of galvanised sheet steel having suitable hinged door properly gasketed to make it dust proof. The 400V, 3ph, power cables will be 1100V grade, single / multi-core, stranded aluminium conductor grade H4 Class 2, XLPE insulated, with extruded PVC inner sheath Type ST2, armoured and outer sheath made of specially formulated FRLS extruded PVC Type ST2 compound. Minimum cabling requirement shall be as follows. For cabling of aviation lights, LPSV lamps and receptacles, armoured cables shall be laid on vertical trays. One run of 4C x 10 sqmm Al cable for receptacles for each platform. One run of 4C x 10Sqmm Al cable for each of the two Aviation lights circuits and further distribution to each platform by 2C x 2.5 sqmm cables. One run each of 2C x 2.5 sqmm cable for HPSV lights on each platform. Photoelectric light detectors shall be furnished and installed at bottom of the chimney and above the distribution board to monitor the light intensity. The detector shall cause the control unit to energize the lighting system when the illuminance on a vertical surface decreases to less than 35 candela. Lights shall be deenergised when the illuminance on a vertical surface increases to more than 58 candelas. The lighting system may be energized during short periods of decreasing illumination due to abrupt periods of shadow during day light hours, but shall not be deenergised as the result of short periods of increasing illumination levels due to lightning flashes or stray light sources when overall illumination level is such that the system has to operate. In case of malfunction of photoelectric circuit, manual bypass arrangement through bypass switch shall be provided. The lighting fixtures and receptacles shall be fed such that loading of all the three phases is balanced. The lamp on the same vertical line shall be fed from different phases, so that failure any one phase shall not cause total block out on one side. 2.4 INSTRUMENTATION & CONTROL REQUIREMENT 1. For each flue six (6) number sampling ports for measurement of NOx, SOx and opacity (SPM) of flue gas through openings (SS pipes with flanges with necessary fittings) will be installed in liners at height as required during detailed engineering/design. The pipe & flange details also shall be provided to bidder during detailed engineering. Suitable operating platform shall be provided. Perforated cable trays as

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suitable shall be provided for routing the sample probe/tube, cables from chimney sampling height to stack analyzer room. 2. Twelve gas sampling ports, six on each vertical face of MS flue duct, for mounting particulate emission monitor and one port for laboratory gas sampling fabricated from SST or MS pipes as the case may be with flanged ends shall be provided for each flue as indicated in the bid drawings, including proper insulation, blank plates, nuts, bolts, etc. The location, orientation and level of ports inclusive of size and thickness of material to be used shall be as per the details indicated in the tender drawing. The sampling equipment is not in the scope of this contract. The CONTRACTOR shall, however, provide all the necessary fittings required for the port holes. The number & locations of these ports indicated in the bid drawings are tentative and actual number and locations will be indicated during detail engineering. The cost of these provisions shall be included in Bidders lumpsum price. It shall also include providing a power connection with 15/5 Amps, 230V AC plug sockets near every port hole. The load shall be 1000 Watts. Access platforms for installation/maintainance of sampling ports shall be provided by the contractor as indicated in the tender drawing. 3. Bidder shall provide for the purposes of instrumentation other than the sampling ports mentioned in clause 2 above, required number of 38 NB conduits including pull wires, junction boxes and pull boxes, all securely tacked / anchored to internal of shell and SS 316 L plates below each pipe insert for fixing of measuring instruments.
2.5
LIGHTNING PROTECTION Air terminals of 20 mm dia, 2000mm long, lead coated copper rod with dom and spike, projecting not less than 750 mm above the highest part of th chimney and securely anchored and braced with at least two lead covere copper alloy anchors spaced not more than 750mm shall be provided. A terminal shall be equally spaced at a maximum of 2500 mm centres around th outside circumference. Air terminals shall be mechanically and electricall connected by the use of pressure type fittings to the Chimney shell peripher and to a continuous circumferential conductor. The installation work sha conform to IS:2309. The ohmic resistance of the lightning conductor system complete with air termination, but without the earth connection, shall be fraction of an ohm. The circumferential conductor shall be 65 x 10 mm GI flat lead covered formin closed loop at 600mm below the top of the shell. Each segment of cap of the chimney shall be connected to the circumferentia
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band by means of tightly bolted connections. The joints in the lightning / ground conductors shall be kept to a minimum an there shall be no joint in the underground portions of conductors. Overlapping o conductors at straight joints shall not be less than 150mm. Brass rods shall be used for brazing. The down comers of 65 x 10 mm GI flat shall be run on outer side of th concrete shell. Down conductors shall be connected to the circumferentia conductor at the top of the chimney and to the testing point at the chimney base Lapping of down conductor by bolting is not acceptable. The circumferential band shall be supported at intervals of 600mm and dow comers shall be supported at interval of 2500mm. The down comers shall come out from the shell to facilitate connection with th test link. The down conductors shall be spaced atleast 2000 mm away from the vertica conduit risers as well as the ladder. Lightning system grounding shall be distinct from the plant grounding system Lightning down conductors shall be separately ground through earth electrod rods. The connection between Earth electrode and Earth mat shall be of 40mm dia G pipe test pit The conductor from earth electrode to a height of about 250mm above groun level shall be of 36 mm dia MS round bar and thereafter 65x 10 GI flat. All vertical reinforcing bars at the top and at the bottom of the chimney shell sha be electrically connected to the nearest horizontal reinforcing rods and thes rods shall in turn be connected to the down conductors. Where vertica reinforcing bars are spliced, each spliced bar shall be electrically connected to a least one horizontal reinforcing bar which in turn shall be electrically connecte to each of the down conductors. All the metallic parts such as platform, railings, pull boxes, junction boxes etc shall be grounded using 8 SWG GI wire to the nearest 65X10 mm GI fla provided by Bidder. During construction, temporary lightning protection should be maintained b connecting the concrete reinforcement to two permanent electrical groundin conductors. After the top lift of the chimney shell has been completed, temporar air terminals which may consist of reinforcing bars, should be installed at the to to serve as a temporary protection until the lining and cap are completed an permanent air terminals are installed.

SECTION:
SHEET 12 OF 15
Chimney staircase / Ladder shall be electrically connected to the dow conductors both at top and bottom. For this, the two lower pairs of insert supporting the Staircase / ladder shall be adequately connected to the groundin system and the top pair of inserts shall be connected to the circumferentia conductor connecting the down conductor. All intermediate breaks in the ladde should be electrically bonded to form a continuous support from top to bottom. Each down conductor shall be provided with a testing point around 1500 mm above ground level but inaccessible in order to avoid interference. Test link sha be enclosed in 200X200X100 GI box fabricated out of 16 SWG sheet steel. A bolt-nuts and washers in the test link shall be electroplated. Incoming and outgoing portion of the lightning down conductor from the test lin shall be galvanised to length of atleast 500mm. All connections, clamps, anchors, etc., of the lightning protection system shall b made of GI and shall conform IS-2309. All electrical connections or joints, unles otherwise specified, shall be clamped or bolted by high-pressure contact to form a connection of adequate current carrying capacity and mechanical strength Soldered connections shall not be permitted. Air terminals, connections, conductors, clamps, fixtures, anchors, etc., expose within 25000 mm of the top of the chimney shall have a continuous lead coverin of a sheath of commercially pure lead not less than 2mm in thickness extruded the ends being covered by soldering or puddling. Where lead covering i specified, after the joints have been made, they shall be again covered wit solder or lead either by wiping or casting. 3.0 3.1 INSPECTION TESTING AND COMMISSIONING After completion of erection / installation, such piece of equipment shall b thoroughly inspected in presence of the owner for correctness and completenes of erection and acceptability A checklist shall be furnished for owner/consultants approval wherein all detail to be checked and necessary instruction shall be listed. The inspection an checking shall strictly follow the checklist. On completion of the inspection two copies of the checklist dully filled in shall b handed over to the owner. The checklist shall be jointly signed by the Bidder and the owner. Suc endorsement, however shall not relive the Bidder of his obligation under th contract. The Bidder shall provide all tools, materials, labour and supervisory personne for carrying out field tests on equipment and materials under his scope of work. The tests shall be conducted in presence of the owner and according to hi directions. All temporary arrangements, rigging and connections required for the tests sha be provided by the Bidder.

SECTION:
SHEET 13 OF 15
The Bidder shall record the test results on approved proforma and furnish six (6 copies of the results to the owner for approval within a week of the date of test completed. On successful inspection and testing the equipment shall be commissioned an put on service in a manner mutually agreed upon. 3.2 RECTIFICATION The Bidder shall carry out all rectifications, repairs or adjustment work foun necessary during testing, commissioning at his own cost TAKING OVER On commissioning and on carrying out necessary rectification work, the owne shall take over the installation either wholly or in parts, as the case may be. DEFECTS FOUND AFTER TAKING OVER If any defects of design, workmanship and materials are observed within on year from the date of completion of work as certified by the Engineer, it shall b corrected by the Bidder, entirely at his risk and cost. If the work of repairs o replacement is carried out by the owner, actual cost shall be recovered from th Bidder. 4.0 LIST OF SPECIFICATION DRAWINGS Sl No 1 2 Description RC Chimney Earthing Lightning Protection Layout RC Chimney Lighting Layout Drg. No and TCE 5312A-816-GL-3071 TCE 5312A-815-GL-3070
3.3
3.4
ANNEXURE -1 LIST OF SPARES FOR 3 YEARS OF OPERATION & MAINTENANCE 1 2 3 4 Photo electric device Junction boxes Termination boxes Aviation lamps(LED type Medium intensity & Low intensity) MCB/SFU 1 set 4 nos of each type 4 nos of each type 3 nos
3 nos of each type

SECTION:
SHEET 14 OF 15

1 set of each type
Flasher unit complete with electronic cards etc 70W HPSV light fittings
10 nos
ANNEXURE II The installation of electrical system shall be in strict accordance with the latest editions of relevant Indian Standards, Codes of Practice and Regulations existing in the locality where the system is installed. In particular, the following standards shall be applicable: LIST OF APPLICABLE CODES FOR ELECTRICAL EQUIPMENT 1 2 3 4 5 6 Protection against lightning Earthing Aviation warning lighting Dust proof electric light fittings Switches Indian Electricity Rules IS-2309 IS-3043 IS-4998 IS-4012 IS-13947
ANNEXURE III PREFERRED MAKES OF EQUIPMENT Distribution panel Switch socket outlet/power receptacle Cables S&S/MDS/HAVELLS/INDO-ASIAN ANCHOR/ELLORA/ESSEN/CGL/ ALSTOM/ BEST & CROMPTON/ CCI/ASIAN CABLES /UNIVERSAL/ FORT GLOSTER/ NICCO/ FINOLEX / POLYCAB/ KEI / PARAMOUNT/ INDUSTRIAL CABLES/ CRYSTAL CABLES

SECTION:
SHEET 15 OF 15

PHILIPS/AVAIDS TECHNOVATORS PVT LTD/ WIPRO/BINAY/ALTUS / KANMUR ADVANCE/ELECTRONICS/ VIJAY FIRE PROTECTION SYSTEM/ PHILIPS/ TATA HONEYWELL PHILIPS / CGL/ BAJAJ / GE/ WIPRO MDS/STANDARD/ INDO KOPP/S&S/ INDO ASIAN/HAVELLS SIEMENS/ L & T/TM
Aviation obstruction luminaire Photo electric light detector
Light fittings MCBs Contactor O/L relay
SIEMENS/ L & T/TM Motor BHEL/ CGL /KEC/ SIEMENS/ ABB/ALSTOM/BBE Note : Similar items shall be of one make only. For items not indicated above, the Bidder shall obtain approval from the purchaser.

TITLE
SUPPLY AND FABRICATION OF STRUCTURAL STEEL

1.0 1.1 SCOPE This specification covers the general requirements for supply where specified, fabrication and delivery at site of structural steel. This specification also covers fabrication and painting of structures. APPLICABLE CODES & SPECIFICATIONS The following specifications, standards and codes are made as a guide line and a part of this specification. All standards, specifications and codes of practices referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy between this specification and other documents referred to herein, this specification shall govern. a) MATERIALS i) ii) IS : 2062 IS : 2074 Steel for General Structural Purposes Ready Mixed Paint, Air drying, Red Oxide Zinc Chrome and Priming General Requirements for Plain Washers and Lock Washers Taper Washers for Channels Taper Washer for I Beams Hexagonal bolts for steel structures
1.2 2.0.
iii)
IS : 5369
iv) v) vi) b) i)
IS : 5372 IS: 5374 IS : 6639
CODES OF PRACTICE IS : 800 Code of Practice for General Construction in Steel Code of Practice for use of Metal Arc Welding for General construction in Mild Steel
ii)
IS : 816
iii)
IS : 818
Code of Practice for safety and health requirement in electric and gas welding and cutting operations Code of Procedure for Inspection of Welds Code of Practice for Painting of Ferrous Metals in Buildings (Parts 1 & 2)
iv) v)
IS : 822 IS : 1477
vi)
IS : 3016
Code of Practice for fire precaution in welding

ISSUE P0
TCE FORM NO. 329 R4

TITLE

and cutting operations vii) IS : 3600 Methods for testing fusion welded joints and weld metal in steel Tolerances for Fabrication of Steel Structures Approval test for welders when welding procedure Approval is not required Part IFusion welding of steel
viii) ix)
IS : 7215 IS : 7318
3.0 3.1
SUPPLIED MATERIALS Materials supplied by Owner free of cost basis should be collected from Stock Yard / Works Material Yard / authorised Dealer as instructed While executing the Work the Contractor shall indicate the quantity of steel required, sufficiently in advance. All other materials required to complete the work shall be supplied by the contractor. All the charges for taking delivery, loading, unloading, stacking, transporting and storage shall be borne by the contractor. The Contractor shall be responsible for timely collection of materials from any location as specified, in full / part in quantity requires to complete the job within agreed schedule. The materials to be supplied Free of Cost by the Employer as mentioned above to the contractor, for execution of this would always remain the property of the Employer throughout the duration of the order and therefore should not be used by the contractor for any purpose other than the scope specified under the order. It will be responsibility of the contractor to keep these materials in safe custody, during the execution of the order against any loss, pilferage etc. On completion of work contractor shall submit reconcillation statement and surplus materials shall be returned by the contractor to the Employer, at the places as may be directed by the Employer/Engineer. Sortage return of surplus excess materials issued by the Employer will be charged to the contractor @ 1.25 times of the prevailing market rate on the date of enquiry. The market rate as decided by owner will be final & binding on the contract. DRAWINGS PREPARED BY THE OWNER Design drawings will be furnished to the VENDOR/CONTRACTOR and all drawings so furnished shall form a part of this specification. These design drawings prepared by the ENGINEER will show all the, levels,forces on members where shall necessary, size and orientation of each member, location/size of openings, to enable the VENDOR/CONTRACTOR carry out fabrication and erection.
ISSUE P0
3.1.1 3.1.2 3.1.3
3.1.4
3.1.5
3.1.6
4.0 4.1
TCE FORM NO. 329 R4

TITLE

4.2 The ENGINEER reserves the right to make changes. Revisions to drawings, even after release for preparation of shop drawings, are very likely to be made to reflect additional data/details received and updated requirements. Revisions to drawings and any new drawings made to include additional work by the VENDOR/CONTRACTOR shall be considered a part of this specification and contract. Should the VENDOR/CONTRACTOR during the execution of his work find discrepancies in the information furnished by the ENGINEER, he shall refer such discrepancies to the ENGINEER before proceeding with such work. FABRICATION General All workmanship and finish shall be of the best quality and shall conform to the best approved method of fabrication. All materials shall be finished straight and shall be machined/ground smooth true and square where so specified. All holes and edges shall be free of burrs. Shearing and chipping shall be neatly and accurately done and all portions of work exposed to view shall be neatly finished . Unless otherwise directed/ approved, reference may be made to relevant IS codes for providing standard fabrication tolerance. Material at the shops shall be kept clean and protected from weather. 5.2 5.2.1 5.2.2 Connections Shop/field connections shall be as per approved design drawings. In case of bolted connections, taper washers or flat washers or spring washers shall be used with bolts as necessary. The length of the bolt shall be such that atleast one thread of the bolt projects beyond the nut, except in case of high strength friction grip bolts where this projection shall be atleast three times the pitch of the thread. In all cases where bearing is critical, the unthreaded portion of bolt shall bear on the members assembled. A washer of adequate thickness may be provided to exclude the threads from the bearing thickness, if a longer grip bolt has to be used for this purpose. Fastners of all grades, consumables etc. shall be supplied/brought to site 10% in excess of the requirement in each category and size. Straightening All materials, shall be straight and, if necessary, before being worked shall be straightened and/or flattened by pressure and shall be free from twists. Heating or forging shall not be resorted to without the prior approval of the ENGINEER in writing.
4.3
5.0 5.1
5.2.3
5.2.4
5.3

TITLE

5.4 Cutting, punching, drilling, welding and fabrication tolerances shall be generally as per relevant IS codes. Welding Welding shall be entrusted to only qualified and experienced welders who shall be periodically tested and graded as per IS 817, IS:7310 (Part 1) and IS:7318 (Part 1). While fabricating plated beams and built up members, all shop splices in each component part shall be made before such component part is welded to other parts of the members. Wherever weld reinforcement interferes with proper fit-up between components to be assembled for welding, these welds shall be ground flush prior to assembly. Approval of the welding procedure by the ENGINEER shall not relieve the CONTRACTOR of his responsibility for correct and sound welding without undue distortion in the finished structure. No welding shall be done when the surface of the members is wet nor during periods of high wind. Each layer of a multiple layer weld except root and surfaces runs may be moderately peened with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of weld and base metal from overpeening. No welding shall be done on base metal at a temperature below -5 Deg.C. Base metal shall be preheated to the temperature as per relevant IS codes. Electrodes other than low-hydrogen electrodes shall not be permitted to use for higher thicknesses as per standard practice. Inspection of Welds All welds shall be inspected for flaws by any of the methods described under clause 8 "Inspection". The choice of the method adopted shall be determined by the PURCHASER/ENGINEER. 5.5.9 The correction of defective welds shall be carried out as directed by the ENGINEER without damaging the parent metal. When a crack in the weld is removed, magnetic particle inspection or any other equally positive means as prescribed by the ENGINEER shall be used to ensure that the whole of the crack and material upto 25 mm beyond each end of the crack has been removed. Cost of all such tests and operations incidental to correction shall be to the VENDOR/CONTRACTOR's account. Tolerances The dimensional and weight tolerances for rolled shapes shall be in accordance with IS:1852 for indigenous steel. The tolerances for fabrication
5.5 5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.6

TITLE

of structural steel shall be as per IS:7215. 6.0 6.1.1 INSPECTION The VENDOR/CONTRACTOR shall give due notice to the PURCHASER/ENGINEER in advance of the works getting ready for inspection. All rejected material shall be promptly removed from the shop and replaced with new material for the PURCHASER's/ENGINEER's approval/inspection. The fact that certain material has been accepted at the VENDOR/CONTRACTOR's shop shall not invalidate final rejection at site by the PURCHASER/ENGINEER if it fails to conform to the requirements of these specifications, to be in proper condition or has fabrication inaccuracies which prevents proper assembly nor shall it invalidate any claim which the PURCHASER may make because of defective or unsatisfactory materials and/or workmanship. Vendor shall have to extend all facilities to Engineer to inspect the material at any stage during execution. No materials shall be painted or despatched to site without inspection and approval by the PURCHASER/ ENGINEER unless such inspection is waived in writing by the ENGINEER. The VENDOR/CONTRACTOR shall provide all the testing and inspection services and facilities for shop work except where otherwise specified. For fabrication work carried out in the field the same standard of supervision and quality control shall be maintained as in shop fabricated work. Inspection and testing shall be conducted in a manner satisfactory to the ENGINEER. Tests on Welds Dimensions, Workmanship & Cleanliness Members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment, surface finish and painting are in accordance with the requirements shown in the VENDOR/CONTRACTOR's approved fabrication drawings and the ENGINEER's drawings. 6.4 Test Failure In the event of failure of any member to satisfy inspection or test requirement, the CONTRACTOR shall notify the ENGINEER or his authorised representative. The VENDOR/CONTRACTOR must obtain permission from the ENGINEER before repair is undertaken. The quality control procedures to be followed to ensure satisfactory repair shall be subject to approval by the ENGINEER. 6.5 The ENGINEER has the right to specify additional testing as he deems necessary, and the additional cost of such testing shall be borne by the PURCHASER, only in case of successful testing.
6.1.2
6.1.3
6.1.4
6.2 6.3

TITLE

6.6 The VENDOR/CONTRACTOR shall maintain records of all inspection and testing which shall be made available to the ENGINEER or his authorised representative. MARKING OF MEMBERS After checking and inspection, all members shall be marked for identification during erection. This mark shall correspond to distinguishing marks on approved erection drawings and shall be legibly painted and stamped on it. The erection mark shall be stamped with a metal dye with figures at least 20 mm high and to such optimum depth as to be clearly visible. All erection marks shall be on the outer surface of all sections and near one end, but clear of bolt holes. The marking shall be so stamped that they are easily discernible when sorting out members. The stamped marking shall be encircled boldly by a distinguishable paint to facilitate easy location. Erection marks on like pieces shall be in identical locations. Members having lengths of 7.0 m or more shall have the erection mark at both ends. ERRORS Any error in shop fabrication which prevents proper assembling and fitting up of parts in the field by moderate use of drift pins or moderate amount of reaming will be classified by the ENGINEER as defective workmanship. In case ENGINEER rejects such material or defective workmanship, the same shall be replaced by the materials and workmanship conforming to the ENGINEER's requirements by VENDOR/CONTRACTOR free of cost at site. 9.0 9.1 PAINTING All fabricated steel material, except those galvanised shall receive protective paint coating as specified. METHOD OF MEASUREMENT For the purpose of payment, the weight of the actual completed structures shall be calculated from the approved drawings for different items of work. The VENDOR/CONTRACTOR shall submit to the PURCHASER relevant material list containing weight of each item. No allowances will be permitted for bolts, nuts, washers, studs, screws etc, galvanizing, welding or for rolling margins. One tonne for the purpose of payment shall mean ONE METRIC TONNE i.e. 1000 Kg. The weight of a member made out of standard rolled section such as beams, channels, angles, etc. shall be based on the standard IS:808 without deductions for holes, notches, bevel cuts, etc. Where a component consists of a cut joist or channels, the full weight of the rolled section shall be
7.0 7.1
7.2
7.3
8.0
10.0 10.1
10.2
10.3

TITLE

considered only if more than half the depth of the original section is used. Otherwise, only half the section unit weight shall be considered for calculation of the weight of the components. Deductions shall be made in the weight of gussets/plates for cuts and notches of 900 sq. cm. or larger. 10.4 For gussets/plates used in trusses, bracings, columns, beams, etc, the area shall be that of the minimum circumscribing rectangle except as stated in 10.3 above. The weight of any built-up members shall be based on the weight of each component.
10.5
Spec No. TCE-5607A-H-CCH-400
TCE CONSULTING ENGINEERS LIMITED ERECTION/DISMANTLING OF STRUCTURAL STEEL
Section : D9 SHEET 1 OF 7
1.0
SCOPE This specification covers the general requirements for erection/dismantling of structural steel. It covers the supply and delivery of all necessary materials, labour, scaffolding, tools, tackles, cranes, equipment and everything that is necessary for the satisfactory completion of the job on schedule. Special Technical Requirements covers the specific requirements for the project. The two parts are complementary and are to be read together for a correct interpretation of the provisions of this specification. Where requirements of the two sections conflict, those of Special Technical Requirements shall govern.
2.0 2.1 2.2
SITE OPERATIONS An experienced and qualified engineer shall be in full time charge of the job. CONTRACTOR shall complete all preliminary works at site well before the arrival of structural steel, such as establishment of electrical and water connections, derricks, cranes, all tools and tackles, welding sets, staging, etc. as well as experienced erection and supervisory personnel as part of this contract and any other work that may be necessary so as to start erection immediately after the arrival of the first batch of steel at site. CONTRACTOR shall furnish at his own expense, the necessary noninflammable staging and hoisting materials or equipment required for the erection work and shall remove and take them away after completion of the job. CONTRACTOR shall also provide necessary passageways, fences, safety belts, helmets, lights and other fittings to the satisfaction of OWNER/ENGINEER and to meet the rules of local authorities and for protection to his men and materials. A licensed electrician shall be kept on the job for the entire duration of the work to maintain CONTRACTOR's electrical equipment and connections. CONTRACTOR shall protect all existing plant, structures, piping, conduits, equipment and facilities against damage during erection. Any damage caused by CONTRACTOR shall be rectified entirely at CONTRACTOR's cost,to the satisfaction of OWNER/ENGINEER. If work has to be carried out adjacent to existing switch yards or electrical installations which are live, CONTRACTOR must ensure suitable safety precautions in consultation with ENGINEER. If a portion of the work of the project area cannot be made available to CONTRACTOR for his activities due to operations being carried out by other agencies, he shall suitably modify his sequence of operations so as to continue work without interruption. CONTRACTOR shall work in coordination with other agencies working on the project site and plan his work suitably so as not to hinder the progress of construction at site.
2.3
2.4
2.5
3.0
ACCEPTANCE OF STEEL, ITS HANDLING & STORAGE
3.1
No dragging of steel shall be permitted. All shall be stored 300mm above ground on suitable packing to avoid damage. It shall be stored in the order required for erection, with erection marks visible. All storage areas shall be prepared and maintained by CONTRACTOR. Steel shall not be stored in the vicinity of areas where excavation or grading will be done and, if so stored temporarily, this shall be removed by CONTRACTOR well before such excavation and/or grading commences to a safe distance to avoid burial under debris. Scratched or abraded steel shall be given a coat of red oxide zinc chromate primer confirming to IS:2074, for protection after unloading and handling prior to erection. All milled and machined surfaces shall be properly protected from rust/corrosion by suitable coating and also from getting damaged. ANCHOR BOLTS & FOUNDATIONS CONTRACTOR shall carefully check the location and layout of anchor bolts embedded in foundations constructed , to ensure that the structures can be properly erected as shown on the drawings, Any discrepancy in the anchor bolts/foundation shall be reported to ENGINEER well in advance for any correcting measures. Levelling of column bases to the required elevation may be done either by providing shims or three nuts on the upper threaded portion of the anchor bolt. All shim stock required for keeping the specified thickness of grout and in connection with erection of structures on foundations shall be of good M.S. plates and shall be supplied by CONTRACTOR at his cost. A certain amount of cleaning of foundations and preparing the area is considered normal and shall be carried out by CONTRACTOR at not extra cost. All grouting under column base plates or beam bearing plates will be carried out by CONTRACTOR, unless the grouting is specifically excluded from the CONTRACTORS scope. Even though foundation bolts are placed in position by other agency, minor modifications and adjustments, if necessary, shall be carried out by the CONTRACTOR for erection purposes without any additional cost to OWNER The final adjustment of the foundation bolts and their grouting are included in the scope of this contract ASSEMBLY & CONNECTIONS Field connection shall be by means of black MS bolts conforming to IS or by means of welding as would be indicated in design drawings. All assembling shall be carried on a level platform.
3.2
4.0 4.1
4.2
4.3
4.3
4.4
4.5
5.0 5.1
5.2
5.3
Drifts shall be used only for drawing the work to proper position and must not be used to such an extent as to damage the holes. Size of drifts larger than the nominal diameter of hole shall not be used. Any damaged holes or burrs must be rectified to the satisfaction of ENGINEER. Corrections of minor misfits and reasonable amount of reaming and cutting of excess stock from rivets shall be considered as a part of erection. Any error in the shop, which prevents proper fit on a moderate amount of reaming and slight chipping or cutting, shall be immediately reported to ENGINEER. ERECTION All structural steel shall be erected as shown on the drawings. Proper size steel cable slings, etc., shall be used for hoisting. Guys shall not be anchored to existing structures, foundations, etc. unless so permitted by ENGINEER in writing. Care shall be taken to see that ropes in use are always in good condition. Any item requiring/if felt necessary to strenghten to prevent buckling/damage should be welded before dismantling /erection and the same has to be cut off and repainted locally at no extra cost. Structural steel frames shall be erected plumb and true. Frames shall be lifted at such points that they are not liable to buckle and deform. Frames/Trusses shall be lifted only at node points. In the case of trusses, roof girders, all of the purlins and wind bracing shall be placed simultaneously and the columns shall be erected truly plumb on screed bars over the pedestals. All steel columns and beams shall be checked for plumb and level individually before and after connections are made. Temporary bracings shall be introduced wherever necessary to take care of all loads to which the structure may be subjected, including erection equipment and the operation thereof. Such bracings shall be left in place as long as may be required for safety and stability. As erection/dismantling of structure progresses, the work shall be securely bolted to take care of all dead load, wind, seismic and erection stresses. No riveting or welding or final bolting shall be done until the structure has been properly aligned and approved by ENGINEER. No cutting, heating or enlarging of the holes shall be carried out without the prior written approval of ENGINEER. Final alignment by the CONTRACTOR with help of surveying instrument shall be submitted at no extra cost. INSPECTION ENGINEER/OWNER or their authorised representatives shall have free access to all parts of the job during erection/dismantling and all work shall be subjected to their approval. In case of faulty erection/dismantling , all rework required will be at CONTRACTOR's cost. No paint shall be applied to field welds or bolts until these have been approved by ENGINEER.
5.4
6.0 6.1
6.2
6.3
6.4
6.5
6.6
7.0 7.1
8.0
TOLERANCES Tolerances mentioned below shall be achieved after the entire structure or part thereof is in line, level and plumb. The tolerances specified below do not apply to steel structures where the deviations from true position are intimately linked with and directly influence technological process. In such cases, the tolerances on erected steel structures shall be as per recommendations of process technologists/suppliers which will be indicated in the drawings.
8.1 8.1.1
Columns Deviation of column axes at foundation top level with respect to true axes : (a) (b) In longitudinal direction In lateral direction : : 5 mm 5 mm
8.1.2
Deviation in the level of bearing surface of columns at foundation top with respect to true level
5 mm
8.1.3
Out of plumbness (verticality) of column axis from true vertical axis, as measured at column top : (a) For columns upto and including metres in height : 1/1000 of column height in mm or 15mm whichever is less : 15
(b)
For columns exceeding 15 metres in height
1/1000 of column height in mm or 20 mm whichever is less : 1/1000 of column height in mm or 10 mm whichever is less 10 mm
8.1.4
Deviation in straightness in longitudinal and transverse planes of column at any point along the height
8.1.5
Difference in erected position of adjacent : pairs of columns along length or across width of building prior to connecting trusses/beams with respect to true distance Deviation in any bearing or seating level with respect to true level Deviation in differences in bearing levels of a member on adjacent pair of columns both across and along the building Trusses And Beams :
8.1.6
5 mm
8.1.7
10 mm
8.2
8.2.1 Shift at the centre of span of top chord
: 1/250 of height of truss in

ISSUE P0
TCE FORM NO. 329 R4
member with respect to the vertical plane passing through the centre of bottom chord 8.2.2 Lateral shift of top chord of truss at the centre of span from the vertical plane passing through the centre of supports of the truss Lateral shift in location of truss from its true vertical position Lateral shift in location of purlin true position
mm or 15 mm whichever is less : 1/1500 of span of truss in mm or 15 mm whichever is less
8.2.3
: 10 mm
8.2.4
: 5 mm
8.2.5
Deviation in difference of bearing levels of trusses or beams from the true difference
: i) 20 mm for trusses ii) For beams : Depth < 1800mm : 6mm Depth > 1800mm : 10 mm : 1/1500 of length in mm or 10mm whichever is smaller : 1/1000 of span in mm subject to a maximum of 10 mm : 1/500 of diagonal length in mm
8.2.6
Deviation in sag in chords and diagonals of truss between node points Deviation in sweep of trusses, beams etc. in the horizontal plane Deviation in diagonal length in any horizontal cross section from the true diagonal length SHEETING
8.2.7
8.2.8
9.0
Sheetingwork including cutting, welding, placing & fixing in position at all heights above ground level, 10/75 G.C. Sheets 20/22G, ridging ,flashing with 20G G.P. Sheet bent to shape as shown in drawing including supply and fixing of galvanised steel bolt and other accessories. For all items, only net area, lengths as laid excluding laps will be considered for measurement and payment. 10.0 10.1 PAINTING After steel has been erected, all bare and abraded spots, field welds, bolt heads and nuts shall be spot painted with red oxide zinc chromate primer as per IS:2074. Before paint is applied, the surface shall be dry and free from dust, dirt, scale and grease. All surfaces inaccessible after erection shall receive two coats of the approved paint before erection. Paint damaged portions shall also be painted with one coat (25 micron) of primer and two coats (2 x 25 microns) of finished paint. METHOD OF MEASUREMENT
11.0
11.1
For the purpose of payment, the weight of the actual, completed structures shall be calculated from the approved drawings for different items of work. CONTRACTOR shall submit to OWNER relevant material list containing weight of each item. No allowance will be permitted for weights of welds, bolts,washers,screws etc. in calculating the weight of the completed structure. No allowances will be permitted for galvanizing, welding or for rolling margins. One tonne for the purpose of payment shall mean ONE METRIC TONNE i.e. 1000 Kg. The weight of a member made out of standard rolled sections such as beams, channels, angles, etc. shall be based on the weight of the member given in IS 808, without deducting for holes, notches, bevel cuts, etc. Where a component consists of a cut joist or channel, the full weight of the rolled section shall be considered only if more than half the depth of the section is used. Otherwise only half the section unit weight shall be taken. Deductions shall be made in the weight of gussets/plates including chequered plates for skew cuts, notches and openings of 900 sq.cm. or larger. For gussets/plates used in trusses, bracings, columns, beams etc. the area shall be that of the minimum circumscribing rectangle, except as stated in clause 14.3 above. The weight of any built-up member shall be separated into the weight of each component. No additional payment shall be made for supply or use of Erection bolts. If erection bolts are removed after erection is complete, holes shall be plug welded and ground smooth. No extra payment shall be made for such plug welding. For modification to existing structures, only new tonnage of steel required for modification shall be considered for payment. CLEAN UP OF WORK SITE During erection/ dismantling, the CONTRACTOR shall without any additional payment, at all times keep the working and storage areas used by him, free from accumulation of waste materials or rubbish. Before completion of erection/dismantling work, he shall remove or dispose of in a satisfactory manner all temporary structures, waste and debris and leave the premises in a condition satisfactory to OWNER/ENGINEER.
11.2
11.3
11.4
11.5
11.6
11.7
12.0 12.1
SPEC NO. TCE. 5607A-H-CCH-400
TCE CONSULTING ENGINEERS LIMITED PAINTING OF STRUCTURAL STEEL
SECTION : D10
SHEET 1 of 8
1.0 1.1
SCOPE This specification covers the general requirements for painting structural steel work involving the supply and delivery of all necessary materials, labour, scaffolding, tools and equipment. This document covers the aspects of surface treatment, application of primer paint and finish painting.
2.0
APPLICABLE CODES AND SPECIFICATIONS The following Standard Specifications and Codes of Practice are made a part of this Specification. All standards and codes referred to herein shall be the latest editions including all applicable official amendments and revisions. In case of discrepancy between this specification and those referred to herein, this specification shall govern. i) IS:102 Priming. ii) IS:110 Ready Mixed paint, Brushing, Red Lead, Non-setting,
Ready Mixed paint, brushing, grey filler for enamels for use over primers. Ready Mixed paint, Brushing, Finishing, Exterior Semigloss general purposes, to Indian Standard colours. Ready Mixed paint, Brushing, Bituminous, Black, Lead free, Acid,alkali and heat resisting. Ready Mixed paint, Brushing, Acid resisting. Black Japan, Types A, B and C Codes of Practice for painting of ferrous metals in buildings. Part I - Pretreatment Part II - Painting Ready Mixed paints, Red Oxide Zinc chrome priming. Aluminium paint for general purposes, in Dual container Specification for enamel, synthetic, exterior, type 1, (a) undercoating (b) finishing Specification for enamel, exterior, type 2, (a) undercoating, (b) finishing
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iii) IS:117 for iv) IS:158
v) IS:159 vi) IS:341 vii) IS:1477
viii)IS:2074 ix) IS:2339 x) IS:2932
xi) IS:2933
TCE FORM NO. 329 R4
SECTION : D10
SHEET 2 of 8
xii) IS:5905 xiii)IS:6005 xiv)IS:9862
Sprayed aluminium and zinc coatings on Iron and Steel. Code of practice for phosphating of Iron and Steel. Specification for ready mixed paint, brushing, bituminous, black, lead free, acid, alkali, water & chlorine resisting. Aluminium paint, Heat resistant.
xv) IS:13183
xvi)SIS-05-5900 Swedish Standard 3.0 3.1 SURFACE TREATMENT All the surfaces of steel work to be painted shall be thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter. The type of surface treatment shall be as specified in the respective item of work. The workmanship shall generally conform to the requirements of IS 1477-Part I. Oil and grease removal shall be carried out either by solvent cleaning or by using alkali type degreasing agents. To remove grease material the surface shall be cleaned with solvents containing emulsifier. After cleaning, the surface shall be washed with water. When the surface has cement pelts or salts, the cleaning shall be done with strong alkalies. After cleaning, water rinsing and subsequent passivation by dilute chromic acid rinsing shall be carried out to ensure that no traces of alkali is left on the surface. The procedure for cleaning by above mentioned methods shall be as per manufacturers instructions. Derusting and descaling of steel shall be carried out either manually, mechanically or chemically. Manual Or Hand Tool Cleaning Loose mill scale, loose rust and loose paint shall be removed by wire brushing, scrapping, chipping and rubbing with abrasive paper or steel wool. This method shall not be employed when the surface has firmly adhering mill scale. After hand tool cleaning, the surface shall be rubbed with sand paper so as to ensure that no loose material exists and the surfaces shall be dusted off. 3.3.2 Mechanical Cleaning
3.2
3.3
3.3.1
3.3.2.1 Power Tool Cleaning
SECTION : D10
SHEET 3 of 8
This shall be carried out by employing power operated wire brushes. Power tool cleaning shall be resorted to only if sand/shot blasting is not possible/permissible and high quality of surface preparation is required. The surface prior to such cleaning shall be cleaned of dust, grease etc. and heavier layers of rust shall be removed by chipping. The powertool cleaning shall remove loose mill scale and rust by adopting very thorough scrapping, grinding and machine brushing. After the surfaces are cleaned by compressed air, it shall have a pronounced metallic sheen. 3.3.2.2 Flame Cleaning Hard mill scale and rust shall be removed through Oxy- acetylene flame. The work shall be carried out by trained workmen to ensure that only mill scale is removed without affecting the parent steel. The work shall be carried out carefully on welded surfaces so that the strength of weld is not affected due to heating. 3.3.3 Sand Blasting And Shot Blasting
3.3.3.1 Sand/shot blasting shall be resorted to only after removal of grease, oil and other contaminants. The work shall be carried out by impinging under pressure of air, a jet of sharp sand or granulated steel (steel grits) on to the metal surface. The process shall ensure complete removal of rust and firmly adhering mill scale. Special care shall be taken on weld areas to remove flux and spatter. Blasting shall ensure an even colour of the surface and the surface shall have silver grey colour. Precautions shall be taken when sand or shot blasting of light gauge steel surfaces to ensure that buckling does not occur to continuous impingement of sand or steel shots under high velocity. 3.3.3.2 Sand/shot blasting shall be adopted for structures which are exposed to corrosive conditions for which superior paint protection is to be adopted. The finished surfaces shall conform to the requirements of Sa 2 or Sa 3 as per Swedish Standard SIS-05-5900 as specified in the item of work. 3.3.3.3 As Sandblasting causes dust nuisance necessary clearance shall be obtained by the CONTRACTOR from Competent authorities prior to commencing Sand blasting. 3.4 3.4.1 Chemical Cleaning (Pickling) The cleaning shall be done by pickling in sulphuric, hydrochloric or phosphoric acids. Pickling shall be carried out in accordance with detailed procedure as given in IS 6005.
SECTION : D10
SHEET 4 of 8
3.4.2
Washing after pickling shall remove all traces of the acids. All work pieces shall be thoroughly inspected and in particular the inaccessible corners. MATERIALS Primer Paint Anti-corrosive primers shall be either lead based or lead free types. Red lead primer shall conform to IS 102 and red oxide zinc chrome primer shall conform to IS 2074. Finish Paint Synthetic enamel painting for undercoat and finish coat shall conform to IS 2932/IS 2933. Acid, alkali and heat resistant bituminous paint shall conform to IS 158. Acid, alkali, water and chlorine resisting bituminous paint shall conform to IS 9862. Heat resistant aluminium paint shall conform to IS 13183. Epoxy primer and epoxy paint shall be of the type as specified in the item of work from an approved manufacturer. Chlorinated rubber based paint shall be of the manufacture as specified or any equivalent approved manufacture. All the materials shall be of the best quality from an approved manufacturer. CONTRACTOR shall obtain prior approval of the ENGINEER for the brand of manufacture and the colour/shade prior to procurement for usage in the works. Primer and finish paints shall be compatible with each other to avoid cracking and wrinkling. As such it is recommended that the primer and finish paint shall be from the same manufacturer. The colour and shade shall conform to IS Standards referred to in Appendix 'D' of IS 1477-Part II. To facilitate choosing the correct shade/number from the alternatives available, CONTRACTOR shall adopt trial painting in small patches in consultation with and as directed by the ENGINEER. All paint delivered to the fabrication shop/site shall be ready mixed, in original sealed containers, as packed by the manufacturer. Thinner shall not be permitted for usage unless specifically directed by the ENGINEER.
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4.0 4.1 4.1.1
4.2 4.2.1
4.2.2 4.2.3
4.2.4 4.2.5
4.2.6
4.3
4.4
4.5
4.6
TCE FORM NO. 329 R4
SECTION : D10
SHEET 5 of 8
4.7 4.8
Paints shall be stirred thoroughly to keep the pigment in suspension. CONTRACTOR shall at his own cost arrange for testing of paints as per relevant Indian Standards in standard laboratory whenever OWNER wants the tests to be carried out for each batch of paints. Test results shall be submitted to the OWNER for obtaining approval. Surfaces inaccessible after assembly and after erection shall receive 2 coats of the above paint prior to assembly. Colour code shall be as desired by the OWNER and will be indicated during execution. Welds and adjacent parent metals shall not be applied with primer and/or painting prior to deslagging, inspection and approval WORKMANSHIP The type and the number of coats of the primer paint and finish paint shall be as specified in the respective items of work. Painting shall be carried out only on thoroughly dry surfaces. No painting shall be done in frosty/foggy weather or when the humidity is high enough to cause condensation on the surface to be painted. Paint shall not be applied when the temperature of the surface to be painted is at 5C or lower. Primers shall adhere to the surface firmly and offer a key to the subsequent coats. The application of paint film shall serve the twin purpose of protecting the steel from corrosion and giving the decorative appearance. A paint which gives the steel adequate protection over a long period together with good appearance shall therefore be adopted. Workmanship shall generally conform to requirements specified in IS:1477Part II. It is essential to ensure that immediately after preparation of the surfaces, the first coat of primer paint shall be applied by brushing and working it well to ensure a continuous film without "holidays". After the first coat becomes hard dry a second coat of primer shall be applied by brushing to obtain a film free from holidays. Structural steel surfaces shall be given the first coat of primer at shop and the second coat after it is erected in position. Further, any abraded surfaces
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4.9
4.10
4.11
5.0 5.1
5.2 5.3
5.4
5.5
5.6
5.7
5.8
TCE FORM NO. 329 R4
SECTION : D10
SHEET 6 of 8
of the first coat during transport from shop to site and during erection shall be provided with a touch-up coat of the primer. Shop coat of primer, touch up coat before erection, touch up coat after erection and second coat of primer after erection shall be of red oxide zinc chromate primer as per IS.2074. Paint shall be applied by brush. 5.9 The dry film thickness of each coat of primer shall be not less than 25 microns. Application of finishing paints shall be carried out within the shortest possible time interval after primer since the primer coats are too thin to give adequate corrosion protection to the steel surface over a long duration. Filler coats shall be applied to fill dents and to obtain a smooth finish wherever necessary. Only factory prepared filler suitable for steel work shall be used. Fillers prepared by whiting and linseed oil by craftsmen at site shall never be used as such fillers may be unbalanced and incompatible with primer and finishing coats. Application of filler shall be done with good `putty knife' and necessary skill. Filler applied shall be just sufficient to fill the depression or unevenness and it shall be restricted to the minimum. It shall be applied in thin layers. In filling depression or unevenness, due as many coats as are necessary may be applied allowing each layer to dry hard. The hardened coat shall be cut down by wet rubbing before the subsequent coat is applied. Where necessary, filler coats shall be applied over the undercoats also. Painting shall be carried out either by brushing or by spraying. CONTRACTOR shall procure the appropriate quality of paint for this purpose as recommended by the manufacturer. After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting down to a smooth uniform surface. When the surface becomes dry, the undercoat of paint of optimum thickness shall be applied by brushing/spraying with minimum of brush marks. The coat shall be allowed to hard-dry. The under coat shall then be wet rubbed cutting down to a smooth finish, taking adequate care to ensure that at no place the undercoat is completely removed. The surface shall then be allowed to dry. The first finishing coat of paint shall be applied by brushing or by spraying and allowed to hard-dry. The gloss from the entire surface shall then be gently removed and the surface dusted off. The second finishing coat shall then be applied by brushing or by spraying. At least 24 hours shall elapse between the application of successive coats. Each coat shall vary slightly in shade and this shall be got approved by the ENGINEER.
5.10
5.11
5.12
5.13
5.14
5.15
SECTION : D10
SHEET 7 of 8
5.16
Minimum dry film thickness of each coat of finish paint of synthetic enamel shall be 25 microns. Minimum dry film thickness of other finish paints shall be as specified in the respective item of work. The thickness of film shall be measured by an Elcometer to be supplied by the CONTRACTOR. The CONTRACTOR shall calibrate the Elcometer frequently for differentsettings. Necessary calibrating accessories should be kept ready for calibration/testing of Elcometer at any time. Epoxy primer and epoxy paint shall be applied within the specified pot life all as per recommendations of the manufacturer. Surfaces inaccessible after assembly shall receive two coats of primer prior to assembly. Surfaces inaccessible after erection, including top surfaces of floor beams supporting grating or chequered plate shall receive one additional coat of finish paint over and above the number of coats specified prior to erection. Portion of steel members embedded/to be encased in concrete shall not be painted. Joints to be site welded shall have no shop paint for atleast 50mm from the welding zone. Similarly, the steel surfaces shall not be painted in areas where connection is by use of friction grip bolts. On completion of the joint, the surfaces shall receive the painting as specified. Maintenance painting of steel structures will become necessary if the painting already carried out shows signs of chalking, hairline cracking, deep checking, fine checking, peeling, blistering and rusting. The breakdown of a paint film is progressive from the top finish paint to the primer coat and the object of maintenance painting is to renovate periodically to effectively check the breakdown and protect the steel surfaces from corrosion. It is essential that same quality of paint as specified earlier need be adopted to ensure compatibility. The general workmanship for maintenance painting shall conform as per Clause. 7 of IS 1477-Part II. CONTRACTOR shall provide suitable protection as necessary to prevent paint finishes from splashing on equipment, floors, walls etc. MEASUREMENT Method of measurement for payment for painting shall be in sq.metres, correct to two places of decimals, if so specified, in the respective item of work. Painting work shall not be measured separately, if primer painting and/or primer and finish painting is already included in the scope of the item of
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5.17
5.18
5.19
5.20
5.21
5.22
5.23
6.0 6.1
6.2
TCE FORM NO. 329 R4
SECTION : D10
SHEET 8 of 8
work of fabrication and erection of structural steel since the rate per tonne of steel is deemed to include for painting as specified. 6.3 In cases where primer and/or finish painting work as specified is carried out on erected structural steel executed by a different agency, the method of measurement for painting shall be on the basis of tonnage of the steel erected. For this purpose, the tonnage of erected steel as certified for payment to the different agency shall be considered as the basis and no measurement will be carried out separately.
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF DEVIATIONS FROM TECHNICAL SPECIFICATIONS
SECTION: F1 SHEET 1 OF 1
All deviations from the Technical Specifications shall be filled in by the BIDDER clause by clause in this schedule. SECTION SPECIFICATION NO. CLAUSE NO. DEVIATION
The BIDDER hereby certifies that the above mentioned are the only deviations from the PURCHASERs Technical Specifications for this enquiry. The BIDDER further confirms that in the event any other data and information presented in the BIDDERs proposal and accompanying documents including drawings, catalogues, etc., are at variance with the specific requirements laid out in the PURCHASERs Technical Specifications, then the latter shall govern and shall be binding on the BIDDER for the quoted price.
COMPANY SEAL
SIGNATURE NAME DESIGNATION COMPANY DATE
ISSUE P0
FILE NAME: F329R4.DOC TCE FORM NO. 329 R4
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF DEVIATIONS FROM GENERAL CONDITIONS
All deviations from the General Conditions shall be filled in by the BIDDER clause by clause in this schedule. SECTION SPECIFICATION NO. CLAUSE NO. DEVIATION
The BIDDER hereby certifies that the above mentioned are the only deviations from the PURCHASERs General Conditions of Contract. The BIDDER further confirms that in the event any other data and information presented in the BIDDERs proposal and accompanying documents are at variance with the specific requirements laid out in the PURCHASERs General Conditions of Contract, then the latter shall govern and shall be binding on the BIDDER for the quoted price.
COMPANY SEAL
SPEC NO.
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF PRICE IMPLICATIONS ON ACCOUNT OF DEVIATIONS
TCE. 5607A-H-CCH-400 TITLE
The price implication on account of all deviations as listed out in the Schedule of Deviations shall be indicated here below : Sl. No. Section No. of Tender Documen t (2) Clause No. of Tender Documen t (3) Page No.of Tender Document Clause as given in Tender Document Deviation as proposed by the Tenderer in Forms (6) Variation in Quoted Price, if deviation not acceptable to the Owner ( mention Plus or minus) (7)
(1)
(4)
(5)
Note : 1. The Bidder hereby certifies that the above mentioned are the only price implications on account of deviations to the tender conditions. All price implications on account of deviations shall be given only in this Schedule. Price implications on account of deviations furnished elsewhere shall be summarily rejected and shall also be ignored. The Bidder also certifies that the price implications mentioned herein are for deviations furnished in the Schedules of Deviations.
2.
3.
4.
(SIGNATURE OF BIDDER) COMPANY SEAL
SPEC.NO.
TITLE
SECTION: F4
TCE-5607A-H-CCH-400
SCHEDULE OF CEMENT REQUIREMENT
SHEET 1 OF 1
FOR QUARTER YEAR PERIOD TAKING THE DATE OF AWARD OF CONTRACT AS BASE I II III IV V VI VII VIII IX X
REQUIREMENT OF ORDINARY PORTLAND CEMENT IN TONNES Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
(Bidders signature)
SPEC.NO.
TITLE
SECTION: F5
TCE-5607A-H-CCH-400
SCHEDULE OF REINFORCEMENT
SHEET 1 OF 2
(A)
Requirement of Deformed Bars, in Tonnes
For quarter year period taking the date of award of contract as base I II III IV V VI VII VIII IX X
36 Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
32
28
Diameters 25 20 16 12 10
(Bidders signature)
SPEC.NO.
TITLE
SECTION: F5
TCE-5607A-H-CCH-400
SCHEDULE OF REINFORCEMENT
SHEET 2 OF 2
(B)
Requirement of Mild Steel Bars in Tonnes
For quarter year period taking the date of award of contract as base I II III IV V VI VII VIII IX X
32
28
25
Diameters 20 16 12 10
(Bidders signature)

TITLE
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF CONTRACTORS TECHNICAL STAFF TO BE DEPLOYED ON THIS CONTRACT
No.
DESIGNATION
QUALIFICATION
PREVIOUS EXPERIENCE
SIGNATURE
DESIGNATION SEAL OF COMPANY DATE
SPEC NO.
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF EQUIPMENT
SECTION: F7
SHEET 1 OF 1
TCE. 5607A-H-CCH-400
The BIDDER shall indicate hereunder the equipment he has in possession and the equipment he proposes to bring to the site, in case the work is awarded to him. Sl. No. 1 Type and description of the Equipment 2 Numbers the BIDDER has in possession 3 Numbers he proposes to bring on to site 4
BIDDER hereby confirms that the quantity and type of tools he will employ for construction will not be less than those listed above, and agrees to bring more equipment, if so warranted, in the opinion of the Engineer.
COMPANY SEAL
SPEC NO.
TCE CONSULTING ENGINEERS LIMITED SCHEDULE OF RATES FOR LABOUR
SECTION: F8
TCE. 5607A-H-CCH-400
SHEET 1 OF 1
\BIDDER shall quote hereunder the all-inclusive price of labour assumed for the purposes of this Contract. Supplying Labour --------------------i. Unskilled Labour male ii. Unskilled Labour female iii. Skilled Labour male iv. Mason v. Carpenter vi. Painter vii. Fitter (reinforcement) viii. Fitter (Structural steel) ix. Welder x. Rigger xi. Welders with welding equipment xii. Gas cutter with all equipment ENGINEER/PURCHASER shall have the right to ask Contractor to supply labour for any work at the rates quoted above. COMPANY SEAL SIGNATURE NAME DESIGNATION COMPANY DATE Per hour Per day of Over time rate 8 hrs. Each per hour ------------------------------
SPEC NO.
TCE CONSULTING ENGINEERS LTD. SCHEDULE OF BIDDERS EXPERIENCE
SECTION: F9
TCE-5607A-H-CCH-400
SHEET 1 OF 1
The BIDDER shall furnish hereunder a list of similar jobs executed by him to whom a reference may be made by the PURCHASER in case the PURCHASER considers such a reference necessary.
Sl. No. (1) Name and description of work (2) Scheduled completion period (3) Actual completio n period (4) Valu e of work (5) Year of start and completion (6) Persons to whom ref. may be made (8)
Client (7)
COMPANY SEAL

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SPEC NO. TCE.

TCE CONSULTING ENGINEERS LIMITED Chimney

SECTION: SHEET i OF iii

BHUBANESHWAR POWER PRIVATE LIMITED

2 X 80MW CAPTIVE POWER PLANT AT ANANTPUR, NEAR CUTTACK, ORISSA

Specification For Chimney

TCE CONSULTING ENGINEERS LIMITED

CONTENTS SECTION SUBSECTION A1 A2 SPECIFICATION NO. ISSUE TITLE NO. OF SHEETS

TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400

1-4 1-1 1-6

EARTHWORK EXCAVATION FILLING

IN GRADING AND BACK

TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400 TCE.5607A-H-CCH-400

1-1 1-1 1-26 1-30

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

SHEET iii OF iii

NO. OF SHEETS 1-7

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TCE CONSULTING ENGINEERS LIMITED

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

x) xi) xii) xiii)

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED

PERIOD OF COMPLETION IN MONTHS FROM THE DATE OF LOI 1 Months

FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

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TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

TCE CONSULTING ENGINEERS LIMITED DEFINITION OF TERMS AND SPECIFICATION DOCUMENTS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

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SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

FILE NAME: F329R4.DOC

TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400

TCE CONSULTING ENGINEERS LIMITED INSTRUCTIONS TO BIDDERS

ISSUE P0 FILE NAME: F329R4.DOC TCE FORM NO. 329 R4

SPEC.NO. TCE. 5607A-H-CCH-400