11V02 Acc SPC M 0001 V2 Part D

SPECIFICATION FOR CIVIL
WORKS OF AIR COOLED

CONDENSER

PROJECT
1 x 300 MW COAL BASED THERMAL POWER
PLANT, CHHATTISGARH, INDIA
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VOLUME-II

PART-D

CIVIL AND STRUCTURAL

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VOLUME-II, PART-D
CIVIL AND STRUCTURAL

I N D E X

A. GENERAL

CLAUSE NO. DESCRIPTION

1.00.00 INTRODUCTION AND SCOPE

2.00.00 CODES & STANDARDS

3.00.00 LAY OUT

4.00.00 SITE DEVELOPMENT

5.00.00 TYPE OF CONSTRUCTION

6.00.00 TECHNICAL SPECIFICATIONS

7.00.00 WORKMANSHIP

8.00.00 TEMPORARY WORK

9.00.00 DOCUMENT SUBMISSION

10.00.00 SEQUENCE OF WORK

11.00.00 MISCELLANEOUS

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B. SPECIFIC DESIGN REQUIREMENT (CIVIL)

1.00.00 LOADS AND LOAD COMBINATION

2.00.00 MACHINE FOUNDATIONS

3.00.00 STABILITY OF STRUCTURES

4.00.00 REINFORCED CONCRETE STRUCTURES AND
FOUNDATIONS

5.00.00 MATERIALS

6.00.00 FORM WORK REQUIREMENTS

7.00.00 STEEL STRUCTURES

C. RATE SCHEDULE

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CIVIL, STRUCTURAL & ARCHITECTURAL WORK

A. GENERAL

1.00.00 INTRODUCTION AND SCOPE

This specification covers design, engineering and construction of Civil,
Structural and Architectural works associated with the super structure of Air
Cooled Condenser. The scope of works covers design, Engineering and
construction of complete Civil, Structural and Architectural Works including
issue of drawings, etc complete as required for successful completion of the
works in all respects.

This section lists Codes and Standards to be adopted in design and
construction. Documents to be submitted have also been brought out in this
section along with the procedure to be followed for the same.

Scope of work includes supply of all construction materials like cement,
reinforcement steel, structural steel and all materials required for completing
the work.

The work to be performed under this specification consists of design,
engineering and providing all labour, materials, consumables, plants,
equipment, temporary works, temporary storage sheds, temporary colony for
labour and staff, temporary site offices, constructional plants, fuel supply,
transportation and all incidental items not specifically mentioned but
reasonably implied or necessary for the completion and proper functioning of
the plant, all in strict conformance with the specifications, including revisions
and amendments thereto, as may be required during the execution of the
work.

The scope of work includes design, preparation of general arrangement
drawings, construction and fabrication drawings, supply of labour, materials
and construction, fabrication and erection of civil, structural and architectural
facilities.

The scope of civil, structural and architectural work comprise complete
engineering, civil/ structural and architectural design, preparation of design and
construction drawings, submission of design documents for approval, design
basis reports, including issue of all Civil, Structural and Architectural drawings
for Air Cooled Condenser, miscellaneous related services and facilities
required for completion of the work including but not limited to the following.

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a) Complete Design, Engineering of super structure for Air cooled condenser
system.

b) Preparation of drawings showing loading data for foundations, floors and
supporting structures of all the equipments and systems.

c) Detail analysis and design of the structures, civil construction drawings
with bar bending schedule, structural steel design drawings, fabrication
drawings with bill of material, preparation of the erection
drawings/scheme, preparation of a schedule of
inserts/embedment/sleeves and a schedule of finishes required including
special protective paints if any and preparation of As built drawings after
completion of works.

d) Preparation of specifications for construction and construction material,
quality assurance plan (QAP), field quality plan (FQP), testing and
acceptance criteria, structure wise Bill Of Quantity (BOQ) including the
items of architectural works.

c) It may be noted that the foundation system of this ACC is being provided by
purchaser. All foundation loading data, equipment load data and other
information required for design and construction of foundation of ACC
system shall be provided to purchaser as required by contractor.

d) ACC super structure shall be of RCC framed system comprising of RCC
columns and tie beams. ACC fan deck shall be of structural steel system.
RCC super structure shall be designed by bidder and will be constructed by
purchaser. The structural steel platform and steel staircases will be
designed and constructed by bidder.

e) Provision of floor / grating at working platform with hand rails and access as
required.

f) Civil works related to grouting.

g) Provision of platforms / walkways as required.

The design criteria and Technical Specifications to be followed for design and
construction of civil, structural and architectural work are included hereunder.

This Section lists Codes and Standards to be adopted and the principal
structures of the plant and briefly describes the basic concept, requirements
and features pertinent to each documents to be submitted have also been
brought out in this section along with the procedure to be followed for the
same.

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2.00.00 CODES AND STANDARDS

Following is a general listing of Codes and Standards to be used in the design
of the Plant. Specific applicable codes and standards will be identified in
System Design Descriptions/Technical Specifications as appropriate. The
latest editions/revision of following codes and standards along with
addendums/ amendments, if any, shall be followed :

2.01.00 General

a) Internationally accepted design Codes and Standards which are equivalent
or more stringent than corresponding Indian Standards.

b) National Building Code of India.

c) "Accepted Standards" and "Good Practice" listed in the appendix to
National Building Code of India.

d) IS-1200 : Method of measurement of Building and Civil
Engineering Works.

e) IS-1256 : Code of Practice for Building Bylaws.

2.01.01 Earthwork

a) IS-1498 : Classification and identification of soils for General
Engineering purposes.

b) IS-3764 : Safety Code for excavation work.

c) IS-7293 : Safety Code for working with construction
machinery.

2.01.02 Concrete

a) IS-269 : Ordinary Portland Cement - 33 Grade.

b) IS-383 : Coarse and fine aggregate from natural sources for
concrete.

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c) IS-432 : Mild Steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement.

d) IS-455 : Portland Slag Cement.

e) IS-456 : Code of Practice for Plain and reinforced concrete.

f) IS-460 : Test Sieves (all parts).

g) IS-516 : Methods of test for strength of concrete.

h) IS-1199 : Methods of sampling& analysis of concrete.

i) IS-1489 : Portland Pozzolona Cement.

j) IS-1566 : Hard drawn steel wire fabric for concrete
Reinforcement.

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

l) IS-1834 : Hot applied sealing compounds for joints in
concrete.

m) IS-2386 : Methods of test for aggregates for concrete (all
parts).

n) IS-2502 : Code of practice for bending and fixing of bars for
concrete reinforcement.

o) IS-3370 : Code of practice for concrete structures for storage
of liquids (all parts).

p) IS-3414 : Code of practice for design and installation of joints
in buildings.

q) IS-4948 : Welded steel wire fabrics for general use.

r) IS-6909 : Specification for super sulphate cement.

s) IS-6452 : High Alumina Cement for Structural use.

t) IS-7320 : Concrete slump test apparatus.

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u) IS-7861 : Code of practice for extreme weather concreting (all
parts).

v) IS-8041 : Rapid Hardening Portland Cement.

w) IS-8112 : 43 grade ordinary Portland Cement.

x) IS-10262 : Recommended guidelines for concrete mix design.

2.01.03 Foundations

a) IS-1904 : Code of practice for design and construction of
foundations in Soils : General requirements

b) IS-2950 : Code of practice for design and construction of raft
foundations.

c) IS-2974 : Code of practice for design and construction of
Machine foundations (all parts).

d) IS-2911 : Code of practice for design and construction of pile
foundation.

e) Standard Specification and code of Practice for
Road Bridges Section VII : Foundation and
substructure by Indian Road Congress (IRC).
f) IS-9795 : }
(Part-I) }
} Cofferdam
g) IS-10084 : }
(Part-I) }

2.01.04 Loading

a) IS-875 : Code of practice for design loads (other than
earthquake) for building and structures.

(b) IS:1911 : Schedule of unit weights of building materials.

(c) IS:1893 : Criteria for earthquake resistant design of structure

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2.01.05 Masonry

a) IS-712 : Building limes.

b) IS-1077 : Common Burnt Clay Building Bricks.

c) IS-1127 : Recommendations for dimensions and workmanship
of natural building stones for masonry work.

d) IS-1528 : Methods of sampling and physical tests for
refractory materials.

e) IS-1597 : Code of practice for construction of stone masonry
(all parts).

f) IS-2212 : Code of practice for brickwork.

g) IS-2116 : Sand for masonry mortars

h) IS-2185 : Concrete masonry units.
(all parts - Hollow and Solid concrete blocks).

i) IS-2250 : Code of practice for preparation and use of masonry
mortars.

j) IS-2572 : Code of practice for construction of hollow concrete
block masonry.

k) IS-2691 : Burnt clay facing bricks.

l) IS-3414 : Code of practice for design and installation of joints
in buildings.

m) IS-3495 : Methods of tests of burnt clay building bricks.

n) IS-4441 : Code of practice for use of Silicate type chemical
resistant mortars.

o) IS-4860 : Acid Resistant Bricks.

2.01.06 deleted

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2.01.07 Roof and Flooring

a) IS-2204 : Code of practice for construction of reinforced
concrete shell roof.

b) IS-3201 : Criteria for the design and construction of precast
trusses and purlins.

c) IS-2210 : Criteria for Design of R.C. shell structures and folded
plates.

d) IS-809 : Rubber flooring materials for general purposes.

e) IS-1195 : Bitumen mastic for flooring.

f) IS-1196 : Code of practice for laying bitumen mastic flooring.

g) IS-1198 : Code of practice for laying, fixing and maintenance
of linoleum floors.

h) IS-1237 : Cement concrete flooring tiles.

i) IS-1443 : Code of practice for laying and finishing of cement
concrete flooring tiles.

j) IS-2114 : Code of practice for laying in situ terrazzo floor
finish.

k) IS-2571 : Code of practice for laying in situ cement concrete
flooring.

l) IS-5491 : Code of practice for laying in situ granolithic
concrete floor topping.

m) IS-5766 : Code of practice for laying burnt clay brick flooring.

n) IS-1197 : Code of practice for laying of rubber floors.

o) IS-2441 : Code of practice for fixing ceiling coverings.

2.01.08 deleted

2.01.09 Soil Engineering

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a) IS-1498 : Classification and identification of soils for general
engineering purposes.

b) IS-1892 : Code of practice for sub-surface investigation for
foundations.

c) IS-2131 : Method for standard penetration test for soils.

d) IS-2720 : Methods of test for soils (all parts).

2.01.10 Water Supply, Drainage and Sewerage

a) IS-404 : Lead pipes

b) IS-458 : Precast Concrete pipes (with and without
reinforcement)

c) IS-651 : Salt glazed stoneware pipes and fittings.

d) IS-771 : Glazed fire-clay sanitary appliances (all parts).

e) IS-774 : Flushing cisterns for water closets and urinals (other
than plastic cisterns).

f) IS-783 : Code of practice for laying of concrete pipes.

g) IS-1172 : Code of basic requirements for water supply,
drainage and sanitation.

h) IS-1626 : Asbestos cement building pipes and pipe fittings,
gutters and gutter fittings and roofing.

i) IS-1742 : Code of practice for building drainage.

j) IS-2064 : Code of practice for selection, installation and
maintenance of sanitary appliances.

k) IS-2065 : Code of practice for water supply in buildings.

l) IS-2470 : Code of practice for installation of septic tanks (all
parts).

m) IS-3114 : Code of practice for laying of Cast Iron pipes.

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n) IS-4127 : Code of practice for laying of glazed stoneware
pipes.

o) IS-12251 : Code of practice for Drainage of Building Basement.

p) IS-1200 : Method of measurement : Laying of water and
[Part XVI] sewer lines including appurtenant items.

q) IS-1536 : Centrifugally cast (spun) iron pressure pipes for
water, gas and sewage.

r) IS-1537 : Vertically cast iron pressure pipe for water, gas and
sewage.

s) IS-3486 : Cast iron spigot and socket drain pipes .

t) IS-5329 : Code of practice for sanitary pipe work above
ground for buildings.

u) IS-3076 : Low density polyethylene pipes for potable water
supplies.

v) IS-1538 : Cast iron fittings for pressure pipes for water, gas
and sewage.

w) IS-1230 : Cast iron rainwater pipes and fittings.

x) IS-1729 : Sand cast iron spigot and socket soil, waste and
ventilating pipes,fittings and accessories.

y) IS-784 : Prestressed concrete pipes.

z) IS-1726 : Cast iron manhole covers and frames.

aa) IS-5961 : Cast iron grating for drainage purposes.

bb) IS-5219 : Cast copper alloys traps : `P' and `S' traps,
[Part-I]

cc) IS-772 : General requirements for enamelled cast iron
sanitary appliances.

dd) IS-775 : Cast iron brackets and supports for wash basins and
sinks.

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ee) IS-777 : Glazed earthenware wall tiles.

ff) IS-2548 : Plastic water closet seats and covers (all parts).

gg) IS-2527 : Code of practice for fixing rainwater gutters and
downpipes for roof drainage.

2.01.11 Paving and Road works

a) IS-73 : Paving bitumen

b) IS-702 : Industrial Bitumen

c) IS-1201 : Method of testing tar and bituminous materials.
thru' 1220

d) Practice followed by Indian Road Congress (all parts).

2.01.12 Earthquake Resistant Design

a) IS-1893 : Criteria for earthquake resistant design of structures.

b) IS-4326 : Code of practice for earthquake resistant design and
construction of buildings.
2.01.13 deleted

2.01.14 Structural Steelwork

a) IS-800 : Code of practice for general construction in steel.

b) IS-802 : Code of practice for use of structural steel in
Overhead Transmission Line, towers.

Part-I : Load and permissible stresses.

Part-II : Fabrication, Galvanising, Inspection
and Packing.

c) IS-806 : Code of practice for use of steel tubes in general
building construction.

d) IS-808 : Dimensions for hot rolled steel beams, channels and
angle sections.

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e) IS-813 : Scheme of symbols for welding.

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

g) IS-816 : Code of practice for use of metal arc welding for
general construction in mild steel.

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

i) IS-818 : Code of practice for safety and health requirements
in electric and gas welding and cutting operation.

j) IS-819 : Code of practice for Resistance spot welding for light
assemblies in Mild Steel.

k) IS-822 : Code of procedure for inspection of welds.

l) IS-919 : ISO system of limits and fits.

m) IS-1024 : Code of practice for use of welding in Bridges and
Structures subjected to Dynamic loading.

n) IS-1161 : Steel tubes for structural purposes.

o) IS-1182 : Recommended practice for Radiographic
Examination of Fusion Welded Butt joints in steel
plates.

p) IS-1200 : Method of measurement of steelwork and
[Part-VIII] ironwork.

q) IS-1239 : Mild steel tubes, tubular and other wrought steel
fittings (all parts).

r) IS-1363 : Hexagonal head bolts, screws and nuts of product
Grade `C' (all parts).

s) IS-1364 : Hexagon head bolts, screws and nuts of product
grades A and B.

t) IS-1365 : Slotted counter sunk head screws.

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u) IS-1367 : Technical supply conditions for threaded steel
fasteners.

v) IS-1608 : Method for tensile testing of steel products.

w) IS-1730 : Dimensions for steel plates, sheets, strips and flats
for general engineering purpose.

x) IS-1731 : Dimensions for steel flats for structural and general
engineering purposes.

y) IS-1852 : Rolling and cutting tolerances for hot rolled steel
products.

z) IS-1977 : Structural steel (Ordinary quality)

aa) IS-2016 : Plain Washers

bb) IS-2062 : Steel for General structural purposes.

cc) IS-2633 : Methods of testing uniformity of coating of zinc
coated articles.

dd) IS-3613 : Acceptance tests for wire-flux combinations for
submerged-arc welding.

ee) IS-3664 : Code of practice for Ultrasonic Pulse echo testing by
contact and immersion methods.

ff) IS-3757 : High strength structural bolts.

gg) IS-4000 : High strength bolts in steel structures.

hh) IS-4759 : Hot dip zinc coatings on structural steel and other
allied products.

ii) IS-5334 : Code of practice for Magnetic Particle Flaw
detection of welds.

jj) IS-7215 : Tolerances for fabrication of steel structures.

kk) IS-7280 : Bare-wire electrodes for sub-merged arc welding of
structural steels.

ll) IS-7318 : Approval test for welders when welding procedure

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[Part-I] approval is not required - Fusion welding of Steel.

mm) IS-8500 : Structural steel micro alloyed (medium and high
strength qualities).

nn) IS-9595 : Recommendation for metal arc welding of carbon
and carbon manganese steels.

oo) IS-11592 : Code of practice for selection and design of belt
conveyor.

pp) AWS D.1.1 Structural Welding Code.

2.01.15 Painting

a) IS-348 : Specification for French Polish.

b) IS-427 : Specification for Distemper, dry colour as required.

c) IS-428 : Specification for Distemper, oil emulsion, colour as
required.

d) IS-1477 : Code of practice for painting of ferrous metal in
[I & II] buildings.

e) IS-2338 : Code of practice for finishing of wood and wood
[I & II] based materials.

f) IS-2339 : Specification for Aluminium Paints for general
purposes in dual containers.

g) IS-2395 : Code of practice for painting concrete, masonry and
plaster surface.

h) IS-2932 : Specification for enamel, synthetic, exterior - a)
undercoating, b) finishing.

i) IS-2933 : Specification for enamel, exterior - a) undercoating,
b) finishing.

j) IS-5410 : Specification for cement paint.

2.01.06 Bridge and Culvert Work

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a) Indian Road Congress (IRC) Bridge Codes (all parts).

b) Indian Railway Standard Bridge Rules.

3.00.00 LAYOUT

Before starting the work, the Contractor shall carry out the setting out of
foundation and structures and provide levels, with reference to general existing
grid and existing Survey of India bench mark. If the Contractor uses the grid,
bench mark and reference pillar made by others, he shall satisfy himself of the
accuracy of the reference marks. The Contractor shall accurately set out the
position for holding down bolts and inserts. If he is required to set out the
foundation afresh, he shall do so independently with reference to the one
existing grid and bench mark which has been followed by other agency at the
instruction of the Engineer. In case any discrepancy be found, it shall be
immediately brought to the notice of the Engineer-in-Charge for any
rectification/ modification necessary. No complaint shall be entertained at a
later stage. The Contractor shall accurately set out the position for holding
down bolts and inserts.

If required, the contractor shall construct and maintain pillars for grid,
references and bench marks and maintain them till the completion of the
construction. He shall also help the Purchaser with instruments, materials and
labours for checking the detailed layouts and levels. The Contractor shall be
solely responsible for the correctness of the layout and levels, and Purchaser's
approval shall not be deemed to imply any warranty in carrying out the works
correctly. The Contractor shall take into account the cost of these in quoting
their price.

4.00.00 SITE DEVELOPMENT

4.01.00 Clearing & Grubbing

Clearing and grubbing within all areas where excavation, fill or other
construction is planned shall be completed prior to start of such work.

4.02.00 Miscellaneous Work

4.02.01 Lighting
Lighting requirements shall be specified by the bidder and as approved by
the purchaser. Light poles shall be of steel pipes/structural steel/pre-cast
poles as per standard developed by the bidder including foundations.

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4.02.02 Water Lines

Water lines may be designed as rigid or flexible conduits as may be
necessary. Water lines may be placed in trenches or in fill. When placed
in trench, the width of trench shall be 300 mm greater than the size of
pipe upto 300 mm nominal diameter and 400 mm greater for pipes in
excess of 300 mm diameter. The bottom of the trench or the surface of
the fill shall be accurately graded and shaped to accept the water line.

Selected backfill material shall be placed on both sides of the pipe to an
elevation 200 mm above the top of pipe for lines upto 300 mm in diameter
and to not less than 150 mm above the horizontal center line of pipe
having a diameter in excess of 300 mm. Compaction of the backfill shall
be in accordance with the recommendations of the Soil Report and as
directed by the Purchaser.

For underground road crossings, pipes shall be laid through R.C.C. Box
Culverts, NP-3 Hume pipes as required.

Lean concrete of the preparation of 1:4:8 may be used in lieu of back fill
to support the pipe where access is limited and might result in improper
compaction of the fill. A minimum arc of contact of 120 shall be
maintained when lean concrete support is used.

4.02.03 Electrical Conduits

Electrical cable runs and supporting structures for overhead cable runs
shall be designed by the bidder. Underground cable runs may be installed
in trenches or on fill as may be decided by the bidder. When installed in
trenches, suitable supports for the cables and the drainage arrangement
of the trenches along with the design of the trench shall be the
responsibility of the bidder. To suit site condition cable trench / cable
bridge shall be provided. For underground road crossing R.C.C. Box
Culverts shall be provided. For overhead road crossing minimum 8M
clearance between the bottom most member of the cable bridge and crest
of the road shall be maintained. Cable trenches shall be of RCC type with
minimum thickness of 150mm.

4.03.00 Requirements During Construction

4.03.01 Temporary Building

Temporary buildings shall be provided for Purchasers site office, Civil
Contractors site office, Cement godown, Open shed for storing

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machinery and materials and stores for storing TG material and other
sophisticated materials and for labour hutments including sanitary and
other facilities. The sizes and locations of the buildings shall be proposed
by the civil contractor and approved by the Purchaser. Based on design
loads and soil properties, bidder shall design foundations and foundations
shall be placed on virgin soil. Floor slabs, when used, shall be placed on
a sand bed and shall be isolated from the foundation walls.

Super-structure requirements shall be as established by the bidder and
duly approved by the Purchaser.

4.03.02 Temporary Storage Areas

Civil Contractor shall indicate area requirement and surfacing to be done
for temporary Storage areas and same will be approved by Purchaser.
Storage areas shall be level and accessible by road. Grade elevation
shall be such as to prevent inundation by flood water. Design and
Drawings for the purpose shall be provided by bidder.

4.03.03 Temporary Working area

Temporary work area shall be provided for construction personnel and
construction machinery. The parking area shall consist of a compacted
layer of 150 mm brick bats crushed stone or gravel with the surface
sealed with asphalt. However, to suit condition and layout of plot plan,
temporary parking facility may be provided at the permanent locations.
Design and Drawings for the purpose shall be provided by bidder.

5.00.00 TYPE OF CONSTRUCTION

5.01.00 Air Cooled Condenser Super structure

The A-frame assemblies in modular construction shall be mounted on the
ACC foundation supported on solid or hollow columns (circular/
rectangular) which will be selected by the contractor depending upon
height of the column calculated as per the mechanical considerations.

The super structure of Air cooled condenser is envisaged as RCC framed
structure having two structural staircases

It may be noted that the foundation system of this ACC is being provided
by purchaser.

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Fan deck shall be in structural steel system to be designed and constructed
by bidder.

5.02.00 Foundation

Foundation shall be provided by purchaser to the contractor.

6.00.00 TECHNICAL SPECIFICATIONS

The description of some of the major structures/components for the ACC is
given below :

a) Platforms and Walkways

Platforms shall be provided to all major equipment, which are not directly
accessible from the floors, for maintenance. Platforms and connecting
walkways shall have a minimum width of 750 mm. Platforms in front of the
entry shall be at least 900 mm wide. Platforms located close to each other
shall be connected with walkways.

All steel platforms above grade level shall be constructed with kick plates at
edge of the platform to prevent tools or materials from falling off. It shall
consist of 8 mm thick steel plate projecting 100 mm above the platform
surface. Kick plate shall be painted with the same type of coating as the
material to which it is attached.

Continuous walkway, at least 500 mm wide shall be provided along the
crane girder level with handrails on both sides of the building. Approach to
EOT crane shall be ensured by Cage ladder or staircase.

b) Stairs and Ladders

Steel Stairs

All steel staircases shall normally have minimum clear width (back to back
of stringer) of 1000 mm and maximum inclination with horizontal of 35.750.
However, in case of space restriction, minimum clear width upto 750 mm
and slope upto 450 may be provided. The vertical height between
successive landings shall not exceed 5 m. Channels (minimum MC200)
shall be provided as stair stringers. Treads shall be minimum 250 mm wide
of chequered plate/grating, with suitable nosing, and spaced equally so as
to restrict the rise to maximum 180 mm.

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Steel Ladders

Ladders shall be provided to platforms, walkways, instruments and
equipments which do not require frequent access. Ladders shall preferably
be vertical and its angle with vertical shall not exceed 50. Ladders shall be
of minimum 450 mm clear width with 20 mm diameter MS rungs spaced at
300 mm (maximum). Ladders shall be provided with a safety cage of
minimum 750 diameter clear when the top of ladder is more than 4.5 m
above the landing level. However safety cages shall start at 2.5 m above
the lower landing level.

RCC Stairs

All stairs shall have maximum riser of 180 mm and a minimum tread of 250
mm. However, for Administration & Control room building riser shall be
limited to 150 mm and tread width of 300 mm. Minimum width of stairs shall
be 1200 mm generally. All stairs normally shall have not more than 15
risers in one flight. Aluminium angle nosing with minimum 50X25X3 angle
or PVC nosing shall be provided for edge protection of RCC stairs.

Handrails

Handrails shall be provided at appropriate places to ensure safety
e.g. around all floors/roof openings, projections / balconies,
walkways, platforms, steel stairs etc.

All handrails shall be of 32 mm nominal bore MS pipes (medium
class) as per IS: 1161 galvanised using 750 gm/sq. m of zinc.
Handrails for platforms, walkways and projections shall be a two-rail
system with the top rail 1000 mm above the walkway surface and
the intermediate rail 450 mm below the top rail. Handrail post
spacing shall be limited to 1500 mm as far as possible but can be
proportioned to the length of the protected horizontal opening. In
such a case spacing shall not exceed 1850 mm center to center of
posts. Handrails shall be shop fabricated for specific locations and
field welded or bolted to the erected structural steel. For platforms
at elevation more than 30 m, three rail system with top rail at 1500
mm shall be adopted.
For RCC stairs, handrails with 20 mm square MS bar balustrade
with suitable MS flat & aluminium / Teakwood handrail shall be
provided, unless specifically mentioned otherwise.

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Edge Protection

Wherever possible around floor openings an RCC kerb of 100 mm wide
150 mm high shall be provided. All concrete edges, where breakage of
concrete corner is expected, shall be provided with angles at least L
50x50x6 with lugs for edge protection e.g. all round the cutouts/ openings
in floor slab, edges of drains supporting grating covers, edges of RCC
cable/pipe trenches supporting covers, edges of manholes supporting
covers and supporting edges of precast covers etc.

Anchor Bolts and Insert Plates

Anchor bolts shall be designed for working stress, in tension and shear, for
embedded length of the anchor bolts and pipe sleeves. Shear and crushing
strength of concrete shall also be checked.

Insert plates shall be designed/checked for shear and bending moment. All
lugs shall be checked for tension. Bond strength of concrete shall also be
checked. Lugs using steel bars shall preferably be fillet welded to the plate
to transfer full strength of the lug.

Vertical Headroom

All accessible areas shall be provided with a minimum clear headroom as
follows, unless otherwise specified:

Finished floors to ceiling (buildings) : 3000 mm
Doors, Walkways, Platforms, Stairs etc. : 2100 mm
False ceiling of office areas : 2400 mm
Walkway above false ceiling : 1000 mm
Safety cage for ladders : 2500 mm
Access for forklift trucks : 2800 mm
Main roads/Railway crossings & crane access : 7000 mm
Other plant roads and truck access : 6000 mm
Cable & Pipe rack : 3000 mm
(except Road/Rail crossings)

Expansion / Construction Joints

Expansion and construction joints shall be provided wherever required. All
expansion and construction joints of water retaining structures in RCC shall
be made watertight using PVC ribbed water stops with central bulb.
However, kicker type (externally placed) PVC water stops may be used for
the base slabs and in other areas where it is required to facilitate

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concreting. The minimum thickness of PVC water stops shall be 6 mm and
minimum width 225 mm. At other joints these shall be 150 mm wide.

Two part polysulphide sealant conforming to IS:12118 shall be used for
sealing of joints in contact with water. For other cases, bitumen sealing
compound conforming to IS:1834 shall be used. Preformed bitumen
impregnated fibre board conforming to IS:1838 shall be used as joint filler.

Statutory Requirements

All the applicable statutory rules pertaining to Indian Factories act, Factory
rules of state government, Fire safety rules of Tariff Advisory Committee,
Water act of Pollution Control Boards, Explosives act etc. and stipulations,
approval of other relevant statutory authorities shall be taken into
consideration at the time of design.

Provisions of safety, health and welfare according to Factories act shall be
complied with design stage. These shall include provision of continuous
walkway (minimum 500 mm wide) along crane-girder at crane girder level
on both sides of the building, comfortable approach to EOT crane cabin,
railings, fire escape, locker room for workmen, pantry, toilets, rest room etc.

Adequate number of fire escapes shall be provided in a building. Fireproof
doors, number of staircases, fire separation walls, lath plastering on
structural steel member (in fire prone areas) shall be made according to the
recommendation of TAC. For fire safety requirements of buildings IS: 1641
and IS: 1642 shall be followed in addition to TAC requirements. All
masonry firewalls shall be minimum 350 mm thick and RCC firewall shall
be minimum 200 mm thick.

7.00.00 WORKMANSHIP

Workmanship shall be of the best possible quality and all work shall be
carried out by skilled workmen except for those which normally require
unskilled persons. Welding shall be done by experienced and certified
welders in proper sequence using necessary jigs and fixtures. Fabrication
shall be done in shops having proper equipment for accurate edge
planning and milling of column shaft ends, base plate surfaces etc., and
shaping and dimensioning of anchor bolt assembly, inserts and other misc.
items. In addition to the requirement specified above, if the bye-laws of the
local Govt., Municipal or other authorities require the employment of
licensed or registered workmen for various trades, the Contractor shall
arrange to have the work done by such registered or licensed personnel.
In case of manufactured materials, the Contractor shall have, with no
additional cost to the Purchaser, the services of the supervisors of the

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manufacturers to ensure that the work is being done according to the
manufacturer's specifications.

8.00.00 TEMPORARY WORK

All scaffoldings, staging, temporary bracing and other necessary temporary
work required for proper execution of the Contract shall be provided by the
Contractor at his own cost and inclusive of all materials, labour, supervision
and other facilities.

The layout and details of such Temporary work shall have the prior
approval of the Purchaser, but the Contractor shall be responsible for
proper strength and safety of the same. All Temporary work shall be so
constructed as not to interfere with any permanent work or with the work by
any other agency. If it is necessary to remove any of the temporary work at
any time to facilitate execution of the work such removal and re-erection, if
required, shall be carried out by the Contractor without any delay and any
extra cost on this account shall be borne by the Contractor.

9.00.00 DOCUMENT SUBMISSION

Design and Construction documents pertaining to all Civil, Structural and
Architectural works that will be required to be submitted to Purchaser/
Purchaser's Consultant for their review/approval have been brought out
under following clauses. Approval of these documents by the
Purchaser/Consultant shall not relieve the contractor of his responsibility for
any design/construction error, mistakes and fulfillment of contract
requirements. All drawings shall be of standard sizes & in metric system
and shall be made in Auto cad (Latest). All documents shall be prepared in
MS Office/PDF, as applicable. Weekly/Daily/Monthly progress/ quality
reports shall be submitted by contractor to the Purchaser as per the
mutually agreed format or the format which shall be recommended by the
Purchaser.

9.01.00 Design Document

Design Document shall comprise Mechanical/Electrical assignment
Drawings, design data, design assumptions & references, detailed
structural analysis (including computer input and output, if any) & design
calculations and design drawings for all buildings / structures &
miscellaneous services/facilities including plumbing, drainage etc. The
drawings shall also include general plot plan, Layout plan/elevations/cross-
sections/perspective view in colour, finish schedule etc. Various plans,

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perspectives and elevations shall be submitted detailing the finish
treatment.

Selected design calculations and drawings as decided by the Purchaser
shall be submitted and reviewed only after approval of corresponding
Mechanical/Electrical/System general arrangement drawings. The bidder
shall submit approved GA drawings along with three (3) copies of design
documents (except design drawings), four (4) copies of design drawings for
comments/approval of the Purchaser/Consultants. Comments, if any, shall
be duly taken care of by the bidder and revised design calculations &
drawings shall be resubmitted, whenever so instructed by
Purchaser/Consultants, for further comments/approval. On the final
approval of the drawing and design, bidder shall submit six (6) copies of the
drawing with one reproducible transparency (RTP) and four (4) copies of
final design calculations to Consultant for distribution. Generally review of
the documents/drawings will be made by the Purchaser/Consultants by 21
days from the date of submission of the dwgs/docs by the bidder to the
Purchaser/Consultants. However the bidder should give schedule
mentioning the dates for submission of misc. dwgs/docs to
Purchaser/Consultants for prior approval.

9.02.00 Construction Document

Based on final design drawings, detailed drawings for construction will be
prepared by the Bidder. For reinforced concrete structures and foundations
detailed bar bending schedules in approved format shall accompany each
detailed drawing. For structural steel work detailed fabrication drawing
along with bill of materials will be prepared by the civil contractor.

Six (6) copies each of selected detailed drawings/ fabrication drawings as
decided by Purchaser shall be furnished to Purchaser/Consultants for their
review.

Procedures for submission and approval of Construction Documents other
than stated above shall include design of temporary works like sheet piling
for deep excavation works, and any other item stated elsewhere in this
specification.

The contractor shall submit six (6) copies of the final drawings along with
one RTP to Purchaser/Consultants.

`As built' drawings shall be prepared by the bidder after completion of
construction/erection incorporating necessary changes, if any done during
execution. The contractor shall submit two (2) copies and one RTP of the
`As- built' drawings to Purchaser/Consultants.

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All documents/drawings shall be submitted in CDs/Soft Copies to
Purchaser and Consultant.

The finishing items shall be indicated up to painting, flooring, etc. Bidder
shall provide similar details for all buildings in scope.

10.00.00 SEQUENCE OF WORK AND PROGRESS REPORT

The sequence in which the works are to be carried out shall be prepared by
bidder in accordance with the construction method accepted by the
Engineer-in-Charge and to be followed by the civil Contractor. A
programme of work is to be submitted for the Engineer-in-Charge's review
and approval and this has to be periodically updated and modified as per
actual progress to enable timely completion.

The bidder shall regularly submit to the Engineer-in-Charge progress
reports for periods of working as specified by the Engineer-in-Charge
showing upto date progress on all important items of work. L1 and L2
schedule for all works is to be submitted by the bidder.

11.00.00 MISCELLANEOUS

a) The successful bidder shall take/provide/comply with but not limited
to the following:

b) Statutory Clearances from all applicable Authorities & the certificates
to be submitted to the Purchaser.

c) Copies of all studies, reports and investigations to be submitted to
the Purchaser.

d) Construction Methodology to be submitted to the Purchaser.

e) All Statutory regulations/Factory Act/Water Act/Pollution Control
Norms/ Explosive Act/Rules of TAC/Any other state or central govt.
rules, regulations as applicable to be complied with.

f) Quality Assurance Plan (QAP) is to be submitted for the whole
project work.

g) Supervision of Quality of work at site with proper testing, inspection
etc.

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h) Design Basis Report (DBR) for the full civil, structural &
architectural work to be submitted to Purchaser/Consultant for
approval.

i) Supervision of all site construction work by civil contractor as per
specification, drawings, schedule.

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SPECIFIC DESIGN REQUIREMENT

1.00.00 LOADS AND LOAD COMBINATIONS

1.01.00 General

All structures shall be designed for the most critical combinations of dead
loads, imposed loads, equipment loads, crane loads, steam piping (static &
dynamic) and other piping loads, wind loads, seismic loads, temperature
loads, loads and forces developed due to differential settlement and any
other loading conditions which can occur during the design life of the
facility.

1.02.00 Dead Loads

Dead loads consist of the weights of the structure complete with finishes,
Dead loads consist of the weights of the structure complete with finishes,
fixtures, partitions, wall panels and all equipment of semi-permanent nature
including tanks, silos, bins, partitions, roofing, piping, cable trays, bus ducts
etc. The content of tanks, silo, bins and hoppers etc., shall be measured at
full capacity for this purpose.

The piping loads, cable tray loads and the contents of the tank, silos, bins
and hoppers shall be listed separately so that they can be excluded from
dead load when dead loads are acting as stabilizing load for uplift.

The following unit weight of material shall be considered for computation of
loads. Loads given in IS:875 (part-I) shall be made use of for material not
listed below.

Materials : Unit weight
Plan cement concrete : 2.40 t/cum
Reinforced cement concrete : 2.50 t/cum
Structural steel : 7.85 t/cum
Brick work : 2.0 t/cum
Cement plaster : 2.1 t/cum
Roof Treatment (7 course bituminous) : 0.03 t/cum
Floor Finish : 2.4 t/cum
Coal : 1.20 t/cum
Fly Ash : 1.60 t/cum
Bottom Ash : 1.60 t/cum

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1.03.00 Imposed Loads

Imposed loads in different areas shall include live loads, dust loads, minor
equipment loads, cable trays, small pipe racks / hanger, erection loads,
operation / maintenance loads, etc. The loads considered shall not be less
than that specified in IS:875 (part II). The loads listed here under are the
minimum loads for the areas involved. Special use areas shall be
investigated and loads revised upward as necessary. Floors and
supporting members which may be subjected to heavy equipment live
loads shall be designed on the basis of the weight of equipment or
specifically defined live loads, whichever is greater.

The specific minimum floor live loads are listed below:

Roofs

(a) Flat Roof : 1.5 kN/sqm for accessible roofs
: 0.75 kN/sqm for non-accessible Roofs.

: 5.0 kN/sqm for accessible roofs
with HVAC Equipment etc.

(b) Sloped Roof : As per IS: 875

Other Areas

(a) RCC floors : 5 kN/sqm for offices, laboratories,
conference rooms and general floors.
(b) Stairs and balconies : 5 kN/sqm
(c) Chequered plate/ gratings : 5 kN/sqm
(d) Walkways : 3 kN/sqm
(e) Toilet rooms : 2 kN/sqm

Piping anchor and restraint forces of major piping shall be
obtained from piping analysis results and be considered as live
load in the structure design.
In addition to the live loads, a minimum of 0.50 kN/sqm shall be
considered as Hung loads for electrical, ventilation & air
conditioning. A load of 1.0 kN/sqm shall be considered as Hung
loads for piping unless otherwise mentioned.
Live loads reduction shall be in accordance with the provisions of
IS:875 & IS:1893 in case of seismic analysis.

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1.04.00 Wind Load

Wind load on structures shall be calculated as per provisions of IS:875
(part 3). The wind shall be assumed to blow in any direction and most
unfavorable condition shall be considered for design.

The various design parameters for the project site as defined in IS 875
(Part 3).
Basic Wind Speed = 39 m/s

K1 factor = 1.06

K2 factor varies with height = corresponding to Terrain Category 2

K3 factor = 1.0

In design of structures, wind force on equipments supported on frame
including all fixtures, piping, staircase, ladders, etc., shall also be
considered.

1.05.00 Seismic Loads

Seismic analysis shall be carried out as per the latest edition of IS:1893
(Part 1 & 4). Zone II shall be considered for design.

The Structures shall be classified into four categories as per Table 5 of
IS: 1893 (Part 4)

Importance factor for each structure shall be as per Table 2 of IS: 1893
(Part 4).

Method of analysis for each structure shall be decided as per clause 10.3
IS: 1893 (Part 4), which depends on the seismic zone & category of the
structure.

Response Reduction factor shall be as per Table 3 of IS: 1893 (Part 4).

1.06.00 Temperature Load

Expansion and contraction due to changes of temperatures of materials of
a structure shall be considered and adequate provisions shall be made for
the effects produced (as per provision in relevant IS codes). Suitable
expansion joints shall be provided in the longitudinal direction wherever
necessary with provision of twin columns. The maximum distance of the

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expansion joint shall be as per the provisions of IS:800 and IS:456 for steel
and concrete structures respectively.

Analysis shall be carried out for ambient temperature variation. The
temperature variation shall be considered as 2/3 of average maximum
annual variation in temperature. The average maximum annual variation
in temperature for this purpose shall be taken as the difference between
the mean of the daily minimum temperature during the coldest month of
the year and mean of daily maximum temperature during the hottest
month of the year. The structure shall be designed to withstand thermal
stresses due to 50% of the temperature variation.

Coefficient of thermal expansion of steel shall be taken as per IS:800.
Coefficient for thermal expansion for concrete shall be taken as per
IS:456.

1.07.00 Equipment Loads

Static and dynamic loads of major equipments shall be based on the
manufacturers data of the specified equipments and shall be considered
in design in addition to the live load. However, where the uniform floor live
load adequately accounts for the equipment moving weight, the weight of
such equipment as a dead load shall not be considered. Eg: switchgear
and control room floors are usually designed for a live load that includes
the equipment weight.

All equipment, tanks and piping design loading shall include hydraulic
testing loading. Weight of equipments, ducts, tanks, pipes, conduits, etc.,
supported by structure shall include maximum possible loading conditions
is flooded material contents and associated impacts, test loadings,
anchorages and constraint effects.

Air and gas duct loads shall include weight of insulation, duct
attachments, dust accumulation loads, seismic, wind and other loads
applicable.

1.08.00 Crane, Monorail & Elevator Loads

Crane girders and supporting columns shall be designed for vertical
(including impact forces) and horizontal forces as per crane vendors
data. All lifting beams and monorails shall have their design loads
increased for impact factor as mentioned hereinafter.

Impact Factor

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Loads for cranes, hoists and elevators shall be taken as per IS:875. The
minimum impact factor to be used in design shall be as follow

Crane loads

(a) For vertical force, an impact factor of 25% of the maximum crane
wheel load.

(b) A lateral crane surge of 10% of the weight of the trolley plus lifted
load applied at the top of each rail divided in proportion to the
relative lateral stiffness of the rail support system.

(c) A horizontal surge of 5% of the maximum static wheel loads of the
crane applied at the top of the rail.

Monorail loads

(a) Impact factor of 10% of lifted load of hoist for monorail and
support design.

(b) Impact factor of 25% of the lifted load for electrical pulley and
support design.

Elevator

(a) A 100% of the lifted load including elevator live load plus the cab
weight for the elevator support beams.

(b) Pedestals supporting gravity take ups for conveyors and
pedestals in elevator pits shall be designed assuming 100%
impact factor.

1.09.00 Basic Load Cases

The following basic load cases shall be considered for the analysis:

(a) Dead load : D
(b) Self weight of permanent equipment : EL
(c) Live load on floor / walkway : L
(d) Live load on roof : LR
(e) Crane load with lift : CR1
(f) Crane load without lift : CR2
(g) Wind load : WL
(h) Seismic load : SL

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(i) Load due to soil pressure : SP
(j) Load due to surcharge : SCL
(k) Load due to hydrostatic pressure : HP
(l) Load due to temperature : TL
(m) Special loads : SPL
(n) Live load during earthquake : LLeq

1.10.00 Load Combinations

The individual members of the frame shall be designed for worst
combination of forces such as bending moment, axial force, shear force
and torsion. Permissible stresses for different load combinations shall be
taken as per IS:875 (Part-V) and other relevant IS codes. Wind and
seismic forces shall not be considered to act simultaneously.

Criticality of erection / maintenance loads shall also be checked
separately in combination with other simultaneously occurring loads for
possible design loading.

2.00.00 MACHINE /EQUIPMENT SYSTEM

All machine / equipment foundations and structures subject to vibrations
shall be suitably proportioned so that amplitude and frequency of the
foundation / structures are within permissible limits.

All block foundations resting on soil shall be designed using the elastic
half space theory or Barkens theory. Block foundation resting on piles
shall be designed using Novaks theory or Barkens theory .The mass of
the RCC block shall not be less than three times mass of the machine
and the CG of the combined mass of foundation and equipment should
pass through the CG of the base area with tolerance not more than 5%.
Dynamic analysis shall be carried out to calculate natural frequencies in
all modes including coupled modes and to calculate vibration amplitudes.
Frequency and amplitude criteria as laid down by the relevant codes or
machine manufacturers shall be satisfied. Minimum reinforcement shall
be governed by IS: 2974 and IS:456.

For the foundations supporting minor equipment weighing less than one
ton or if the mass of the rotating parts is less than one hundredth of the
mass of the foundation, no dynamic analysis is necessary. However, if
such minor equipment is to be supported on building structures, floors,
etc. suitable vibration isolation shall be provided by means of springs,

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neoprene pads, etc. and such vibration isolation system ( VIS) shall be
designed suitably.

Major Equipment foundation shall be supported on vibration isolation
system or conventional RCC framed structure foundation. The vibration
isolation system shall consist of helical spring units and viscous dampers
supporting the RCC inertia block which support the machine. The spring
units shall conform to DIN 2089 and DIN 2096. For variable speed
machines conventional RCC framed structure foundation is
recommended.

The Vibration Isolation system supplied should be of proven make. The
Contractor / their associates for the supply of this system should have
designed spring supported machine foundations, manufactured, supplied
and installed vibration isolation systems consisting of steel helical spring
units (Conforming to DIN 2096 & DIN 2089) and viscous dampers
(Providing damping resistance in all three planes) for not less than 25
(twenty five) machine foundations of heavy rotating machine systems,
such as Turbine generators, Boiler feed pumps, ID/ PA / FD fans etc. Out
of these atleast five(5) number of vibration isolation systems should have
been installed for Turbo Generators of capacities not less than 210 MW.
All the foundation systems be in successful operation (without
replacement) for at least 3(three) years as on the date of bid opening.

For inertia block of ACC foundation the following design considerations
shall be considered. Analysis and design shall be carried out in
accordance with relevant codes IS: 2974 Part-3 and IS: 456 and/or
manufacturers requirements. Static and Dynamic analysis shall be
carried out using finite element computer program using 3D beam/shell or
3D solid elements.

Natural frequencies and amplitude of vibrations of turbine generator
foundations shall be as per relevant applicable code of practices as
indicated above and/or as per manufacturers requirements. For dynamic
analysis, masses of stator and rotor shall be lumped at their respective
CGs with rigid members. Fundamental natural frequencies in all three
directions shall be separated by at least 20% with respect to machine
speed. Forced vibration analysis shall be performed at the operating
speed and also at frequencies corresponding to certain selected modes
(natural frequencies within 0.9 to 1.1 times the operating speed) using
normal machine unbalance loads. Amplitudes calculated shall be ensured
to be within the permissible limits as specified by the manufacturer. In the
absence of specified criteria, amplitude shall be limited to alarm limit
specified in ISO 10816-2. The exercise shall be repeated by releasing the
rotor mass in the axial direction at each bearing location except at thrust

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bearing. It shall be ensured that not more than 5% of the dynamic loads
are transmitted to the substructure. Necessary provisions of DIN 4024
shall be adhered to while designing the substructure.

The loads to be considered for static analysis and design shall consist of
dead weight of the machine and foundation, machine power torque,
Turbine exhaust box and exhaust duct to ACC loads under normal
operating condition, Equivalent static load due to machine unbalance,
thermal elongation forces, forces due to partial operation of the air cooled
condenser , forces due to condensate pump failure , vacuum loads ,
forces due to piping and ducts, frictional forces at machine sole plate level
for turbine and generator, temperature distribution under operating
condition, failure loads of turbine (blade unbalance/loss of blade/bowed
rotor), failure loads of generator (short circuit loads), seismic loads due to
generator and turbine and erection loads.

The equipment foundations shall also be designed to meet the
manufacturers static deflection criteria.

For framed type foundations which support any major rotary equipment,
the criteria specified in paragraph for STG foundation shall be followed.

For design of inertia block of fan foundations, mill foundations, same
criteria as specified above shall be followed except that the analysis can
be based either on a plate model/Three dimensional solid finite element
model. The frequency and amplitudes shall be checked as per codal /
manufacturer requirements. The permissible amplitude of vibration shall
be as specified by the manufacturer and shall be in satisfactory range as
per VDI 2056, whichever is stringent. It shall be ensured that not more
than 5% of the dynamic loads are transmitted to the substructure.
Necessary provisions of DIN 4024 shall be adhered to while designing the
substructure. Substructure shall be designed for static loads.

All such foundation shall be separated from adjoining part of building
and other foundations. Joints at floor / slab shall be suitably sealed. All
appendages to such foundations shall be reinforced suitably to ensure
integral action.

2.01.00 Increase in Stresses

Where stresses due to wind (or seismic) and temperature are combined
with those due to other loads, the allowable stresses in concrete and
reinforcement steel shall be increased by 33.33% in case of working
stress design.

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Bearing capacity of the soil shall be allowed to increase by 25% under
seismic / wind load condition except for chimney where increase in
bearing capacity is not considered.

3.00.00 STABILITY OF STRUCTURES

Design shall be checked against buoyancy due to the ground water
during construction and maintenance stages for structures like under
ground tanks, pits trenches, basements, etc. Minimum factor of safety of
1.2 against buoyancy shall be ensured considering empty condition inside
and ignoring the superimposed loading. For purpose of calculating
downward load due to any overburden, only the mass located vertically
above the projected area shall be taken in to consideration.

All building sub-structures including pump houses shall be checked for
sliding and overturning stability during both construction and operating
conditions for various combination of loads. Factor of safety for these
cases shall be taken as mentioned in IS:456 and other relevant IS codes
However, following minimum factor of safety shall be followed.

a) Factor of safety against overturning due to wind, seismic or other
lateral load shall be 1.5 minimum.

b) Factor of safety against sliding shall be 1.5 minimum.

c) Factor of safety against uplift due to hydrostatic forces shall be 1.2
and due to any other loads shall be 1.5.

Stability of the structure shall also be investigated for loading conditions
during construction, repair or other temporary measures. Lower factor of
safety may be used for such loading conditions as per relevant IS codes.

In case where dead load provides the restoring force, only 0.9 times
characteristic dead load shall be considered. Imposed loads shall not be
considered as restoring force.

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4.00.00 REINFORCED CONCRETE STRUCTURES AND FOUNDATIONS

All structures, building foundations, machines / equipments foundation,
water retaining structure, trenches, pits, etc., shall be designed as per
relevant IS codes in general. Construction in general shall follow
provisions of IS:456 and IS:3370 for normal and water retaining structures
respectively.

4.01.00 Design Methodology

General

All designs of RCC structures shall be carried out by limit state method
as per IS:456 unless use of working stress method is specifically
mentioned. Design strength of materials and design loads shall be
calculated using appropriate partial safety factors over characteristic
strength and characteristic loads as per IS:456.

For reinforcement detailing IS:5525 and SP:34 shall be followed.

4.02.00 Minimum Thickness Of Structural Elements

The following minimum thickness shall be followed :

(a) Suspended floor / slab / walkways / canopy slabs, etc 125 mm

(b) Ground floor slab (non-suspended) 150 mm

(c) Water Retaining slabs / walls 200 mm

(d) Cable / pipe trenches / underground pits / Launder
walls and base slab 125 mm

(e) All footings (including raft foundations) 300 mm

(f) Parapets 125 mm

(g) Sunshades 75mm at stage

(h) Precast louvers / fins 50 mm

(i) Precast trench cover slabs / floor slabs / louvers 75 mm

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(j) Paving 100 mm

(k) Pile cap 600 mm

(l) Basement walls and base slab 200 mm

(m) Silo / bin walls 150 mm

(n) Underground reservoir
Below ground water table 200 mm
Above ground water table 150 mm

From fire resistance point of view minimum thickness of reinforced
concrete members shall be as per fig 1 of IS 456. Minimum fire rating of 2
hours shall be considered where fire hazard is expected.

4.02.00 Minimum Heights For Pedestals Of Steel Columns

Pedestals to Steel Columns for building structures :

Top or RCC foundations (pedestals) shall normally by kept at a lower
level so that the column base plates together with gussets and stiffeners,
remain below finished floor level (FFL) unless specified otherwise.
Foundation levels for some columns shall be changed suitably to
accommodate underground services, pits, trenches, etc.

Stair and ladder pedestal shall be kept 200 mm above the finished floor
level.

Pedestals to Steel Columns for Equipment structure :

(a) Equipment in open area : as required (300mm min)

(b) Equipment in covered area : as required (150 mm min)

(c) Structures and equipment : as per vendors data subject
supplied by vendor to minimum as specified
above.

Minimum Heights for Encasement for Steel Columns

In case the top of pedestal is kept at a lower level so that the column
base plate together with gussets and stiffeners remain below finished
floor level (FFL) the column bases as well as the column sections shall be
encased in concrete above FFL as per following.

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(a) Open area : 300 mm above paved level
(b) Covered area : 150 mm above FFL

5.00.00 Materials

Concrete Mix

The following minimum grades of concrete as per IS:456 shall generally
be used for the type of structures noted against each grade. Cement used
shall be ordinary Portland cement (OPC) of 43 Grade conforming to IS
8113, unless the chemical nature of the soil warrants special cement for
structures below ground level.

Mix (1:5:10) : Fill concrete.

Mix (1:4:8) : Foundation below brick wall, blinding layer below
foundations, trenches and underground
structures, minimum thickness of the layer shall
be 75 mm.

Grade M20 : Base plate encasement, pavement around
building including plinth protection work,
encasement of structural steel work, etc.

Grade M25 : Ground floor slabs , SG area paving etc.,

Grade M25 : All RCC members except where other grades are
specified e.g. Foundation and super structure,
grade beams, pedestals, roof slabs, Cable and
pipe trenches, etc.

Grade M25 : Water retaining structures below and above
ground, Cooling water channel , fore-bay & sump,
cooling tower basin etc.

Intermixing of different grades of concrete in the same structure shall not
be allowed in a particular structural element.

Minimum cement content shall be governed by the requirement of
IS:456 for normal concrete structures and IS:2911 for piles.

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However higher grade of concrete shall also be used than the minimum
specified to satisfy the design requirement for TG foundations, BFP
foundations , under ground structures etc.,

The clear cover to reinforcement shall be for 2 hours fire rating as per
table 16 A of IS456 and also meet the requirement of durability
requirements based on exposure conditions as per table 16 , whichever is
stringent.

Reinforcements

Reinforcement bars shall be as per the following codes :

High Yield Strength Deformed bars : IS:1786
Mild steel bars : Grade I of IS:432
Welded wire fabric : IS:1566

Intermixing of different grades of re-bars or re-bars of different material
composition in same structure shall not be allowed.

Contractor shall supply to the Purchaser copies of all manufacturers
test certificates for reinforcement bar delivered to site. The certificate shall
show the results of tests necessary to prove that the reinforcement
complies in respects with the relevant Indian Standards.

Bars shall not be bent or straightened in a manner that will damage the
bar Reinforcement shall be bent cold.

All reinforcement shall be accurately fixed by approved means and
maintained in correct position as shown in the drawings by use of blocks,
spacers and chairs as per IS 2502 to prevent displacement during placing
and compaction of concrete.

No metal part of any device shall be used for connecting bars or for
maintaining reinforcement in the correct position with in the specified
minimum concrete cover to the reinforcement.

Welding of reinforcement shall not be carried out without the permission
of the Purchaser.

Projecting reinforcement or dowel bars for future connection of the
structural works shall be protected by lean cement concrete, if they are to
be left exposed for a long time.

Reinforcement detailing shall be as per IS 456,SP 34.

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Two layers of reinforcement (on both inner and outer faces) shall be
provided for RCC wall sections having thickness 150 mm or more.

Grouting

Non-shrink flowable grout shall be used for under pinning work below
base plate of columns. Non-shrink cum plasticizer admixture shall be
added in the grout. For grouting of base of machine foundation high
strength flowable ready mixed non-shrink grout shall be used.
Type and grade of grouting for structural columns and equipment bases
shall be indicated. Crushing strength of the grout shall generally be one
grade higher than the base concrete. Minimum grade of grout shall be
M30.

Nominal thickness of grouting shall be atleast 50 mm for building
columns and pedestals of major equipment. For secondary posts, stair
and ladder base, etc. grouting shall not be less than 25 mm thick.

Minimum Cover To Foundation Bolts

Minimum distance from the center line of foundation / anchor bolt to
edge of pedestal shall be the maximum of the following :

(a) Clear distance from the edge of base plate / base frames to the
outer edge of the pedestal shall be minimum 50 mm .

(b) Clear distance from the face of pocket to the outer edge of
pedestal shall be 75 mm.

(c) Clear distance from the edge of sleeve to the outer edge of
pedestal shall be 75 mm.

6.00.00 Formwork requirements

Plywood formwork shall be used for all water retaining / conveying
structures and for all over ground concrete works. For other areas steel /
plywood formwork may be used.

No metal part of any device for maintaining formwork in the correct
location shall remain permanently within the specified concrete cover to
the reinforcement.

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In watertight construction, methods of fixing formwork, which result in
holes through the concrete section when the formwork is removed, shall
not be used. All wall ties shall have water baffles and wall kickers shall be
cast monolithically with the base slab.

Approval for the size, type and position of any holes, insert or fixing
required by CONTRACTOR shall be obtained before work proceeds.
Unless otherwise specified or approved all holes shall be formed and all
inserts cast in at the time of pouring and no part of the concrete works
shall be drilled or cut away without approval.

Formwork panels shall be stiff enough to prevent damage to the
concrete surface caused by excessive movements of the panel during
vibration of the concrete.

Damaged and used formwork shall not be re used without repairing.

All joints in form work and joints between the form works shall be
sufficiently tight to prevent loss of liquid from the concrete through these
joints.

The part of the ties shall be capable of being removed, so that no part
remaining embedded in the concrete shall be nearer the surface of the
concrete than the specified thickness of cover to the reinforcement. Holes
left after the removal of ties shall be filled with concrete or mortar of
approved composition.

Formwork props shall be positioned between permanent supports so
that all members are supported at not more than 3 meters centre in both
directions.

The props shall be in the form of space frames, composite or single
members with sufficient stiffness or bracing so that props will neither
sway nor buckle under loads which they are designed to carry.

The formwork or the false work shall not be removed from a structural
component until CONTRACTOR ensure that the concrete has attained
sufficient strength.

The concrete is to be regarded as sufficiently hardened when the
component has attained such strength that it can resist all loads acting at
the time of removal of the formwork.

Particular care shall be taken with components which have to carry
virtually the full design load directly upon removal of the false work (e.g. in

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the case of roofs, or floor slabs which have to support loading from floors
above them which have not yet hardened).

Props shall remain in position for as long a period a possible, particularly
for structural components, which are subjected to a major proportion of
their design loading as soon as the formwork has been removed.

No superimposed load shall be allowed on any part of the concrete work
prior to the removal of the forms and props.

Unless specified 20mm and down graded aggregates shall be used for
all structural concrete works. However 40mm and down graded
aggregates may also be used under special conditions for foundation.

Tolerance for formed and concrete dimension shall be as per IS:456.

Placing of concrete

Before each concreting, CONTRACTOR shall give sufficient notice to
the Purchaser as directed such that an inspection will be made before the
concreting.

The concrete shall be mixed in the mixer of adequate capacity having a
power elevated loading hopper. The mixer shall be equipped with an
automatic water-measuring tank filled with a device for locking the
discharge setting. The Mixing shall continue until there is a uniform
distribution of the materials and the mass is uniform in colour and
consistency.

Any concrete surplus to immediate requirements shall be thrown away.
In no case or circumstances may the surplus be used later.
The volume of mixed materials in each batch shall comply with the mixer
manufacturers written recommendations.

Concrete shall be transported as quickly as possible from the mixer to
its final position without segregation or loss of any of the ingredients.

All equipment to be used for transporting material shall be kept clean; all
containers used for transporting concrete shall be thoroughly washed out
whenever mixing ceases.

Concrete shall be placed continuously up to construction joints while it is
still sufficiently plastic for adequate compaction.

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At all times when reinforced concrete is being placed a competent steel
fitter shall be in continuous attendance. CONTRACTOR shall adjust and
correct the position of any reinforcement, which may be displaced.

CONTRACTOR shall keep on site a complete record of the works
showing the time and date when concrete is placed in each part of the
work.

Concrete shall be thoroughly compacted by suitable mechanical
vibrators during placing and shall be carefully worked around all
reinforcement and embedded fixtures and in to the side and corners of
the formwork.

For top surfaces of slab and other surfaces for which formwork is not
provided a smooth finish shall be provided with a wooden float after
compaction.

Whenever, concrete is being vibrated at least one spare vibrator of each
type in use shall be available in case of breakdown.

Compaction shall start as soon as there is sufficient concrete within the
formwork to immerse the vibrator and vibration shall continue during the
placing operation so that at no time shall there be a large volume of un
compacted concrete in the form work.

The concrete shall not be placed directly against a vertical form face but
shall be placed to flow to this surface during the compaction process.
Care shall be taken to avoid the form face being splashed with mortar
during the placing operation.

Exposed surfaces, immediately after final set, shall be protected from
the sun. All concrete shall be well watered after it has been set and shall
be kept continuously damp until thoroughly cured. Provision shall be
made for adequate water distribution to all parts of the work so that if
required this treatment can be continued sufficiently throughout the whole
period of construction. In order to keep the concrete continuously damp,
all exposed surface shall be covered with continuously damped gunny
bags or shall have water compounded on them, for full period of curing.

On exposed concrete surfaces in high sun temperatures and /or strong
drying wind conditions CONTRACTOR shall use curing method, which
also shields the concrete, and this shall be placed in position not later
than half an hour after final tamping.

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7.00.00 STEEL STRUCTURES

Framing

All steel framed structures shall be either rigid frame or simple space
frames or a combination of two.

Lateral forces shall be resisted by stiff jointed moment connections in rigid
frame design. The column bases shall generally be fixed to concrete
foundation pedestal by providing moment resistant base detail.

Simple space frame design utilises single-span beam systems, vertical
diagonal bracing at main column lines and horizontal bracing at the roof
and major floor levels. Most of the plant steel buildings shall be designed
as simple space frame structures.

The turbine building design shall be a combination of rigid frame in
transverse direction and simple frame in longitudinal direction.

Pipe rack shall consist of rigid main frame in transverse direction spaced
longitudinally as required. In longitudinal direction, pipe rack shall be
divided into sections of suitable length with an anchor bay. The main
transverse frames shall be connected with longitudinal beams which will
transmit horizontal forces to braced anchor bays. The pipe and cable rack
bridge structure shall be adequately rigid to carry the forces from
pipelines at anchor points without undue deflection so that pipelines are
really anchored at the anchor points.

Concrete floors shall be considered to provide continuous lateral support
to the top (compression ) flange of the support beams. However wherever
large cut outs are provided in the floor slabs horizontal floor bracing shall
be provided. Grating/chequered plate floor shall neither be considered to
provide lateral support to the top flange of supporting beams nor to
provide a shear diaphragm. Adequate lateral support and horizontal
bracing shall be provided as required.

Floors for vibrating machines of all kinds together with supporting
framework shall be adequately braced in both horizontal and vertical
planes. Floors or structure supporting mechanical equipment shall be
designed to minimise vibration, avoid resonance and maintain alignment
and level.

Columns shall be designed to support the load combination which
produces the maximum interaction ratio. Exterior columns shall be
designed to resist wind moments between braced elevations as

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appropriate. Columns shall also be designed to resist moments caused
by discontinuous vertical bracing or non-concentric bracing work points.

7.01.00 Materials

Structural steel shall conform to Grade A of IS:2062 for rolled steel
members or plates up to 20 mm thickness. For plates above 20 mm
thickness or welded construction, steel conforming to Grade B (Killed) of
IS:2062 shall be used except for crane girders where Grade C (IS:2062)
steel shall be used.

Checkered plates shall conform to IS:3502. All gratings shall be
pressure locked type (preferably electro-forged) manufactured in
accordance with applicable Indian standard. Pipes for handrail shall be as
per medium grade of IS:1161.Crane rails shall conform to IS:3443.

7.02.00 Connections

Welding shall be used for fabrication and joints. For site connections,
welding or high strength MS bolts of property class 4.6 or 6.6 shall be
used, except in few cases for shear connections of lighter members or
removable beam connections where bolted joints may be adopted e.g.
purlins, side girts etc with ordinary MS black hexagonal bolts. A minimum
of two bolts per connection shall be used. High strength friction
grip(HSFG) bolts shall be used as necessary if required.

IS:816 and IS:9595 shall be followed for welding of structures.

For high strength friction grip bolt connections IS:4000 shall be followed.
High strength friction grip bolts shall be of property class 6.6 or 8.8 and
shall conform to IS:3757 and shall not be less than 20 mm in diameter
unless designated otherwise. High strength bolts shall be installed as
bearing type joint except where loads are reversible.

All bolted connections shall have bolts of minimum 16 mm dia. The
connections of stairs and hand railing shall be made with 20 mm diameter
threaded fasteners conforming to IS:1363. Erection bolts shall be black
bolts of minimum 12 mm dia.

All bolts and nuts shall have property class compatible to each other.
For bolts carrying dynamic or fluctuating loads and those in direct tension
shall be provided with an additional double coil helical spring washer
conforming to IS:6755. The threaded portion of the bolt shall project
through the nut at least by one thread.

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Where a steel beam or member is to be connected on RCC structure, it
shall be connected using an insert plate and preferably through shear
connection.

For crane girders, welding between web and flange plates shall be
carried out by submerged arc welding process. Full penetration of weld
between web plate and top flange shall be ensured. Intermediate
stiffeners shall be connected with top flange plate by full penetration butt
weld. Welding across tension flange will not be permitted. Bearing edges
of crane girders shall be machined.

The working point of the bracing connection shall be the center of
column and girder to which it connects, where practical. The connections
of gusset plates to column and girders shall be made to include
provisions for eccentricity in connection. The double angle back-to-back
with gusset plate in between shall not be used in dust laden areas. Where
double angles are not adequate, beam sections with web in the plane of
bracing are used.

Horizontal bracings shall be angle / tee section located at the bottom of
framing beams. Field welding of bracing at the underside of beam as
required to meet slenderness requirement of bracing member shall be
indicated on the drawings. Horizontal bracing shall be arranged to avoid
framing into the beams at column locations.

For Major columns of main building, column splices shall be designed to
resist the greater of the design axial tension load and moments or an
axial tension load of 45 t plus 50% of the member capacity in bending in
either the major or minor axis, whichever produces the greatest number
of bolts.

Minimum size of fillet weld shall be 5 mm. Main structural elements shall
be welded continuously. Intermittent weld shall be used only on
secondary members, which are not exposed to weather or other corrosive
influence.

Efficiency of site welds to be considered shall be as follows:

a) Butt weld above 25 m from ground : 50%

b) Others : 80%

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7.03.00 Design Methodology

The Design of steel structures shall be done by working stress method
in accordance with the provisions of IS:800 and other relevant IS Codes
as applicable to specific structures.

All buildings/structures shall be framed structure. Basic consideration for
structural framing shall be stability, rigidity, building uses, ease of
fabrication / erection and overall economy. Additional bracings/moment
connections shall be used to assure stability of structures. Structure shall
be designed such that the surfaces of all parts shall be accessible for
inspection, cleaning, painting and maintenance.

Crane gantry girders shall be single web plate girder of welded
construction with bearing and intermediate stiffeners. Crane girder shall
be designed as simply supported and of single span length. Chequered
plate shall be used for gantry girder walkway flooring. For lifting
/monorails beams ISMB sections shall be preferred and the bottom flange
of all beams shall be checked separately for distortion and reinforced
suitably if required.

Permissible stresses for different members shall be allowed to exceed
up to 33.33% only under normal loads along with wind and seismic
conditions. The members which are designed primarily to resist wind load
such as bracing members , no increase in permissible stress will be
permitted. However, permissible stresses in bolts and welds shall be
allowed to exceed up to 25 % only under wind and seismic conditions.

For design which requires the use of the minimum column load ( such
as, uplift on anchor bolts, column axial tension, etc.) the following criteria
shall be used in determining minimum load: Use 90% of the column dead
load, No live load is used, Uplift forces from vertical bracing are included
where applicable and Wind uplift on the roof is included where applicable.

Base plates shall be placed on foundation pedestal with grouting. For
large base plates necessary grout holes shall be provided. All anchor
bolts for fastening steel columns on foundation shall be embedded in
foundation during concreting itself. No anchor pockets in foundation shall
be allowed. Design of base plates shall be based on design pressure on
foundation which shall not exceed the following:

(a) Pedestal in concrete grade M20 5.0 N / sq. mm
(b) Pedestal in concrete grade M25 6.25 N / sq. mm
(c) Pedestal in concrete grade M30 7.5 N / sq. mm

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The total horizontal shear force at the base of column is transferred to
the column pedestals through friction between the base plate and the
grout. A coefficient of friction of 0.30 shall be used in conjunction with the
minimum column load as defined above. If the horizontal shear force
exceeds the frictional resistance force or if the column is subjected to a
net uplift load, the total force shall then be transmitted through shear bars
/ shear keys welded to the base plate. Anchor bolts are not assumed to
resist any horizontal shear force. Necessary recesses shall be kept in the
foundation concrete for shear lugs.

The following criteria shall be followed for posting loads on the design
drawings. For vertical beam reactions, the load shall be posted whenever
the value exceeds the maximum allowable uniform distributed load. For
axial loads in floor beams, the actual horizontal load which the beam end
connection must resist shall be posted for each end of the beam. Note
that this value may be different for opposite end of the same beam. For
truss members, only one member force shall be noted for each member.

7.04.00 Permissible Deflections

The permissible deflections of various steel members under normal
loading conditions shall be as specified below. For calculation of
deflections in structures and individual members dynamic effects shall not
be considered, unless specified otherwise. Also, no increase in deflection
limits shall be allowed when wind or seismic load are acting concurrent
with normal loading conditions.

Vertical Deflection

a) For beams supporting dynamic equipment : Span / 500
b) For beams supporting floors / masonry : Span / 325
c) For beams supporting pipes ( pipe racks ) : Span / 400
d) For roofing and cladding components : Span / 250
e) For gratings and chequered plates : Span / 200 subject to a
maximum of 6 mm
f) Coal conveyor gallery bridges : Span / 450

For crane gantries or any member subjected to working loads, the
maximum deflection under dead load and live load excluding impact shall
not exceed the following values:

a) For manually operated cranes &
monorails
: Span / 500
b) For electric overhead cranes

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i) up to 50 t capacity : Span / 750
ii) over 50 t capacity : Span / 1000

Horizontal Deflections

The permissible horizontal deflections shall be as per following unless
specified otherwise:

a) Single storey building(without crane load ) : Height / 325
b) Multistoried building (without crane load) : Height / 500
c) Pipe rack columns : Height / 200
d) Open Structures : Height / 200
e) Crane gantry girder due to surge : Span / 2000 limited to
maximum of 15 mm.
f) Building main columns at crane rail : Height / 2500 limited to
maximum of 10 mm
level due to action of
crane surge load only
g) Open gantry columns at crane rail level
due to action of crane surge load only
: Height / 4000 limited to
maximum of 10mm.
h) Coal handling trestles : Height / 1000

Provisions of IS: 800 and relevant IS Code shall be followed for limiting
deflections of structural elements not listed above.

7.05.00 Minimum Thickness and Sizes Of Steel Elements

Minimum Thickness

The minimum thickness of various components of a structure and hot
rolled sections shall be as follows. The minimum thickness of rolled
shapes shall mean flange thickness regardless of web thickness.
Structural steel members exposed to significantly corrosive environment
shall be increased suitably in thickness or suitably protected otherwise as
per good practice and sound engineering judgement in each instance.

a) Trusses, purlins, girths and bracing : 6 mm
b) Columns and beams : 8 mm
c) Gussets : 8 mm
d) Stiffeners : 8 mm
e) Base plates : 10 mm & above
f) Chequered plates : 6 mm o/p & above
g) Grating flats : 5 mm

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h) Minimum thickness of structural members other than gratings and
chequered plate, directly exposed to weather and inaccessible for
painting and maintenance shall be 8 mm.

Minimum Sizes

The flange width of purlin, supporting light weight concrete slab shall not
be less than 65 mm and for those supporting roof sheeting and wall
cladding it shall not be less than 50 mm. Width of steel rolled section
connected to other member shall be at least 50 mm. The depth of beams
for platform of all structures shall not be less than 125 mm.

7.06.00 Slenderness and Depth Ratio

The slenderness ratio of main members in tension, compression or
bending shall be in accordance with IS:800.

The following limiting ratios of depth to span shall be considered as a
general guide.

(a) Truss 1 / 10
(b) Rolled beams and girders for 1 / 24
Ordinary floors and rafters
(c) Supporting floor beams for vibrating 1 / 15
Machinery / equipment
(d) Roof purlins and girths 1 / 45
(e) Gable columns 1 / 30

7.07.00 Fabrication and Erection

CONTRACTOR shall prepare detailed fabrication drawings and erection
scheme based on the design drawings approved by PURCHASER.
Fabrication drawings are to be submitted to PURCHASER for approval.
Fabrication shall commence only on the basis of the fabrication drawings
approved by the PURCHASER.

Fabrication shall in general follow the provisions of IS:800, and good
engineering practice where provisions of IS:800 are not clear.

Tolerance in fabricated steel work shall be as per IS:7215.

Erection of fabricated steel components shall be as per erection
drawings prepared by CONTRACTOR and approved by his
CONSULTANT.

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Tolerance for erected steel structures shall be as per IS:12843.

Inspection of Welding

The extent of quality control in respect of welds for structural elements
shall be as follows.

Visual Examination

All welds shall be 100% visually inspected to check the following:
i) Presence of undercuts
ii) Surface cracks in both welds and base metals.
iii) Unfilled craters
iv) Improper weld profile and size
v) Excessive reinforcement in weld
vi) Surface porosity

Before inspection, the surface of weld metal shall be cleaned of all slag,
spatter matter; scales etc. by using wire brush or chisel.

Dye Penetration Test (DPT)

This shall be carried out for all important fillet welds and groove welds to
check the following:

(i) Surface cracks
ii) Surface porosities

Dye Penetration Test shall be carried out in accordance with American
National Standard ASME165.

Ultrasonic testing

Ultrasonic test shall be conducted for all groove welds and heat affected
zone in dynamically loaded structures and for other important load
bearing butt welds in statically loaded structures as desired by
PURCHASER to detect the following:

i) Cracks
ii) Lack of fusion
iii) Slag inclusions
iv) Gas porosity

Ultrasonic testing shall be carried out in accordance with American
National Standard ANSI / AWS D1-92 Chapter 6 : Part C.

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Before Ultrasonic test is carried out, any surface irregularity like
undercuts, sharp ridges etc. shall be rectified. Material surface to be used
for scanning by probes must allow free movement of probes. For this
purpose, surface shall be prepared to make it suitable for carrying out
ultrasonic examination.

Radiographic Testing (X ray and Gamma ray Examination)

This test shall be limited to 2% of length of welds for welds made by
manual or semiautomatic welding and 1% of length of weld if made by
automatic welding machines. The location and extent of weld to be tested
by this method shall be decided by PURCHASER to detect the following
defects:

i) gas porosity
ii) slag inclusions
iii) lack of penetration
iv) lack of fusion
v) cracks

Radiographic testing shall be conducted in accordance with American
National Standard ANSI / AWSD1.1-92.

Any surface irregularity like undercuts, craters, pits etc shall be removed
before conducting radiographic test. The length of weld to be tested shall
not be more than 0.75 x focal distance. The width of the radiographic film
shall be width of the welded joint plus 20 mm on either side of the weld

CONTRACTOR shall provide testing equipment for conducting
nondestructive
tests for confirming the integrity of welding wherever necessary as
directed by the PURCHASER.

Acceptable Limits of defects of weld

Limits of Acceptability of welding defects shall be as follows.

i) Visual inspection & Dye Penetration Test
The limits of acceptability of defects detected during visual inspection and
Dye Penetration Test shall be in accordance with clauses 8.15.1 &
clauses 9.25.3 of American National Standard ANSI / AWS D1.1-92
respectively, for statically and dynamically loaded structures.

ii) Ultrasonic Testing

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The limits of acceptability of defects detected during ultrasonic testing
shall be in accordance with clause 8.15.4 & clause9.25.3 of American
National Standard ANSI / AWS D1.1-92 respectively, for statically and
dynamically loaded structures.

iii) Radiographic Testing
The limits of acceptability of defects detected during Radiographic testing
shall be in accordance with clause 8.15.3 & 9.25.2 of American National
Standard ANSI / AWS D1.1-92 respectively for statically and dynamically
loaded structures.

Rectification of Defects in Welds

In case of detection of defects in welds, the rectification of the same
shall be done as follows:
i) All craters in the weld and breaks in the weld run shall be thoroughly
filled with weld.

ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so
as to provide smooth transition of weld to parent metal.

iii) Welds with cracks and also welds with incomplete penetration,
porosity, slag Inclusion etc. exceeding permissible limits shall be rectified
by removing the length of weld at the location of such defects plus 10 mm
from both ends of defective weld and shall be rewelded. Defective weld
shall be removed by chipping hammer, gouging torch
or grinding wheel. Care shall be taken not to damage the adjacent
material.

7.08.00 Painting

All steel structures shall receive two primer coats and two finish coats of
painting. First coat of primer shall be given in shop after fabrication before
dispatch to erection site after surface preparation as described below.
The second coat of primer shall be applied after erection and final
alignment of the erected structures. Two finish coats shall also be applied
after erection.

Steel surface which is to painted shall be cleaned of dust and grease
and the heavier layers of rust shall be removed by chipping prior to actual
surface preparation. The surface shall be abrasive blasted to Sa-2. Finish
as per SIS05-5900. Primer paint shall be zinc silicate of approved brand.
Dry film thickness of each primer coat shall be minimum 25 microns.

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Finish paint shall be 2 coats of synthetic enamel of approved brand. Dry
film thickness of each finish coat shall be 40 microns. The undercoat and
finish coat shall be of different tint to distinguish the same from finish
paint. The total dry film thickness shall be 130 microns. All paints shall be
of approved brand and shade as per the PURCHASERs requirement.

Joints to be site welded shall have no paint applied within 100 mm of
welding zone. Similarly where Friction grip fasteners are to be used no
painting shall be provided. On completion of the joint the surfaces shall
receive the paint as specified.

Surfaces inaccessible after assembly shall receive two coats of primer
prior to assembly. Surfaces inaccessible after erection including top
surfaces of floor beams supporting gratings or chequered plate shall
receive one additional coat of finish paint over and above number of coats
specified before erection. Portion of steel member embedded / to be
encased in concrete shall not be painted.

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RATES SCHEDULE

SCHEDULE FOR RATES OF MATERIAL

DESCRIPTION UNIT RATE
Rs

1 Cement OPC 43 grade Ton

2 Reinforcement steel Fe-415/ 500 grade Ton

3 Structural steel conforming to IS: 2062 Ton

4 Fine aggregate for concrete Cu.m

5 Coarse aggregate for concrete Cu.m

6 Sand

7 Fabrication, erection of structural steel including painting Ton

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SCHEDULE DAY WORK RATES FOR LABOUR

DESCRIPTION UNIT RATE
Rs

1 Bar Bender Day

2 Reinforcement bar fixer Day

3 Mason / Plaster Day

4 Fitter/ Mechanic Day

5 Painter Day

6 Welder Day

7 Operator of Machine / Crane Day

8 Survey helder Day

9 Rock Cutter Day

10 Semi skilled labour Day

11 Un-skilled labour Day

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SCHEDULE DAY WORK RATES FOR PLANT

DESCRIPTION RATE PER
HOUR (Rs)

1 Bull dozer

2 Rear Dump Truck

3 30 Ton Capacity crane

4 Concrete Mixer

5 Concrete Batching plant with transit mixer

6 Welding machines

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