9.19.

5 Fixing of Shutters
PVC door shutter shall be side hung on three bolt hinges of size 100 mm, one at the centre and the
other two at 200 mm from the top and bottom of the shutter. The flat of the hinges shall be neatly
counter sunk in to the recesses cut out to the exact dimensions of the hinge flap. The door shall be
drilled on the thickness to fit hinges. Screws for fixing the hinges shall be screwed in with screwdrivers
and not hammered. The length of the screws should be 8 mm/30 mm. The hinges used should be of
stainless steel.

9.19.6 Tolerance
The tolerance on the width and the height of the door shall be + 5 mm and the tolerance on the
nominal thickness of the door shall be + 2 mm.

9.19.7 Fittings
Fittings shall be provided as per schedule of fittings decided by Engineer-in-Charge. In moisture
prone areas M.S. fittings and screws should not be used. Hardware such as handles, tower bolt,
stopper, buffer etc. should be directly screwed (not pre-drilled) and fitted on the door.

9.19.8 Measurements
Length and width of the shutters shall be measured to the nearest cm in closed position covering the
rebates of the frames but excluding the gap between the shutter and the frame. Area is calculated to the
nearest 0.01 sqm.

9.19.9 Rate
The specified rate include the cost of the door shutter and labour involved in fixing of the shutter.
Fittings & fixtures on the door shutter except hinges & screws shall be paid extra as provided.

9.20 PVC DOOR FRAME

Solid PVC door frame and shutter shall be as per para 9.19.

9.20.1 Solid PVC Door Frames consisting of section 50 x 47 mm shall be fabricated from 5 mm PVC sheet
having density of 600 kg./cum. The sheet used may be in plain colour, printed design or prelam veneer
shade as approved by the Engineer-in-Charge. The weight per running metre of the door frame including
reinforcement should be a minimum of 1.5 kg./sq. mtr. The depth of the rebate of door frame shall be 10
mm. Frames shall have smooth surface, without any warping or bending in any member. All the parts of
the door frame are to be joined to each other using solvent adhesive conforming to IS 14182. A tolerance
of + 3 mm shall be permitted in the specified dimension of PVC section in the door frames. (Fig. 9.21)

The solid PVC door frames shall be fabricated in factory as per nomenclature of the item and
directions of the Engineer-in-charge.

9.20.2 Fixing of Frames

As per clause 9.18.2.

9.20.3 Measurements
As per clause 9.18.3.

9.20.4 Rate
As per clause 9.18.4.

9.21 PANEL PVC DOOR SHUTTER

9.21.1 Panel PVC Shutters are factory made shutter and shall be brought to site fully assembled. The
Solid Panel PVC Door shall be fabricated from 5 mm PVC sheet. The sheets used may be in plain
colour, printed design or prelam veneer shade as approved by the Engineer-in-Charge. The shutters
shall be fabricated at factory as per nomenclature of the item and directions of the Engineer-in-charge.
(a) 30 mm thick panel PVC door shutters (Figure 9.22).

349 SUB HEAD 9.0 : WOOD WORK AND P.V.C. WORK

9.21.2 Sampling and Criteria for Conformity
As per clause 9.19.3.

9.21.3 Tests
As per clause 9.19.4 except para (k), (l) & (m).

9.21.4 Fixing of Shutters

As per clause 9.19.5. In addition, it may be ensured that while fixing hinges the screws pass through
the two opposites surfaces of the M.S. reinforcement.

9.21.5 Tolerance
As per clause 9.19.6.

9.21.6 Fittings
As per clause 9.19.7.

9.21.7 Measurements
As per clause 9.19.8.

9.21.8 Rate
As per clause 9.19.9.

9.22 FIBRE GLASS REINFORCED PLASTIC (FRP) DOOR FRAMES

9.22.0 Door Frames shall be three legged of cross section 90 mm x 45 mm having single rebate of size
32 mm x 15 mm to receive shutter of 30 mm thickness. The frame shall be made of laminate of
thickness of 2 mm and shall be filled with wooden blocks of exterior grade MDF or seasoned and treated
hard wood inside the laminate in all the three legs of the frame. The frame to be moulded by either hand
lay up or resin transfer moulding process. The process shall consist of laying gelcoat at 1000 gms./m2
and laid over with layer of FRP Mat (CSM mat) gelcoat and FRP (CSM Mat) are defined in IS 14856.
The CSM mat shall be bonded with Isophatholic resin in the ratio not less than 1:2 (One part of Mat to
two parts of Isopathlic resin and fillers & additives) by weight. The edge shall be sealed with gelcoat and
FRP mat to obtain smooth finish. Sufficient roving shall be laid in the corner to have smooth curve while
laying the CSM mat. (Fig. 9.23).

9.22.1 FRP door shall be manufcturred as per specifications laid down in IS 14856, nomenclature of
items & direction of Engineer-in-Charge.

9.22.2 Tolerance
Tolerance of size of frame to be + 2 mm and on size of rebate to be + 1 mm.

9.22.3 Finish
The surface of the moulded frame shall be free from any visible defects such as small pores, crazing,
blistering, wrinkling, impurities, defective impregration, colour blots and aggregate defects, as mentioned
in IS 14856. Scattered pin holes duly repaired and finished by applying resin and not noticeable shall be
acceptable. Frame laminate shall be flat and shall have smooth and level surface. Laminate shall be
finished in colour & shade as approved by Engineer-in-Charge.

9.22.4 Fixing of Frame

As per clause 9.18.2.

9.22.5 Measurement
As per clause 9.18.3.

9.22.6 Rate
As per clause 9.18.4.

CPWD SPECIFICATIONS 2009 350

9.23 FIBRE GLASS REINFORCED PLASTIC (F.R.P.) SHUTTERS

9.23.1 F.R.P. Shutters shall be manufactured conforming to the specifications as per IS 14856 and
nomenclature of item & direction of Engineer-in-Charge. (Fig. 9.24A & 9.24B).

9.23.2 Blocks of any seasoned hardwood of bulk density not less than 450 kg./m3 at 12 per cent
moisture content or any other material of sufficient thickness and length shall be provided inside the
shutter at suitable place to hold fittings and fixtures such as aldrops, tower bolt, handle, sliding door bolt,
mortice lock etc. Blocks for hinges shall be provided at three locations, unless otherwise specified by the
purchaser. One at the centre and other two at 200 mm from the top and the bottom of the shutter. Blocks
shall be provided at predetermined places in the shutter so as to fix hinges mortice locks, tower bolts,
aldrops, door closures, etc. The finished surface shall be buffed and polished with wax.

9.23.3 Location of Fittings and Accessories

The lock rail of door shutters shall be so placed that is centre line is at a height 850 + 5 mm from the
bottom of the shutter. Door shutter shall be fixed to the frame with three hinges, unless otherwise
specified by the purchaser, of the type specified. These locations shall be, one at centre and other two at
200 mm from the top and the bottom of the shutter, where blocks have already been provided and
suitable indication by depressing the profile has been made. Screws for fixing the hinges shall be
screwed in with screwdrivers & not hammered. The length of screw should be 8/30 mm. The hinges
used shall be stainless steel or aluminum.

9.23.4 Sampling & Criteria for Conformity Shall be as per clause 9.19.3.

9.23.5 Finish
As per clause 9.22.3.

9.23.6 Tests
As per para 9.19.4 except clause (j), (k), (l) & (m).

9.23.7 Fixing of Shutter

As per clause 9.19.5.

9.23.8 Tolerance
As per clause 9.19.6.

9.23.9 Measurement
As per clause 9.19.8.

9.23.10 Rate
As per clause 9.19.9.

9.24 SOLID PVC FOAM PROFILE DOORS

9.24.1 Solid PVC Foam Profile Frame

Solid PVC foam profile frame doors are made from solid PVC foam profiles 60 x 30 mm with integral
skin cut to required size. Doors are provided with naturally strong stiffener frame and sandwich panelled
to offer sound and heat insulation with pressure laminate/infill panel to provide scratch resistance
surface. (Fig. 9.25). Supporting bar at bottom side of frame shall be provided for maintaining frame in
plumb. The frame shall be fabricated in factory as per nomenclature of the item and directions of the
Engineer-in-charge. PVC door frame should have shore hardness more than 70.

9.24.2 Fixing of Frames

As per para 9.18.2.

351 SUB HEAD 9.0 : WOOD WORK AND P.V.C. WORK

9.24.3 Test in PVC Foam Profiles
Tests on PVC Foam Profiles shall be as per Table 9.24 below:

TABLE 9.24

Sl. No. Property Test Method Unit Acceptable Value

1 Density (at 27°C) ASTM D 792 gm/cc 0.5-0.7

2 Tensile strength at yield ASTM D 638 PSI % 2000

(B) Elongation at Break ASTM D 638 20
3 Tensile Modulus ASTM D 638 N/Sq.mm 200
(Modulus of Elasticity)
4 Impact strength ASTM D 256 ftIb/sq.In 7
(charpy Unnotched)
5 Durometer Hardness DIN 53505 Shore D 70
6 Vicat Softening Point ASTM D 1525 C 75
(at 10N Load)
7 Flammability UL 94 Self Extinguishing

9.24.4 Measurements
As per clause 9.18.3.

9.24.5 Rate
As per clause 9.18.4.

9.25 SOLID PVC FOAM SHUTTERS

Solid PVC foam shutters are made from solid PVC foam profiles with integral skin. Doors are
provided with naturally strong stiffener frame and sandwich panelled to offer sound and heat insulation
with pressure laminate/infill panel provides scratch resistance surface. Door shutters can be nailed,
screwed, drilled, glued, sawn lapped or welded just like wood and characterized by excellent screw
holding strength (200 kgf.).

9.25.1 28 mm Thick Door Shutters

Profile is cut in required length to make vertical & horizontal stile. Mitered cut joint are made using
solvent based PVC adhesive & epoxy solvent. GI ‘C’ stiffner 39 x 19 x 19 or 40 x 20 x 19g. M.S. Pipe is
fixed in the grooves made in frame. Telescopic polymeric corners are provided at corners for better
rigidity. Infill panel 3 mm thick HPL sheet is fixed with csk screws of required size to the profile frame as
specified. Mirror image of shutter frame is joined using solvent based PVC adhesive as well as csk type
sheet metal screws of required size at four corners at top & bottom. Additional bonding strength is
provided by using silicone sealant epoxy sealant at joints. Lock rail is provided by using PVC profile & ‘C’
type GI stiffener 40 x 10 in the groove & fixed with adhesive to frame & infill. Decorative corner moulding
is fixed to impart elegant look. (Fig. 9.26)

The fabrication shall be done in factory as per nomenclature of the item and directions of Engineer-
in-Charge.

9.25.2 Sampling and Criteria for conformity

As per clause 9.19.3.

9.25.3 Tests
As per clause 9.19.4.

9.25.4 Fixing of Shutters

As per clause 9.19.5.

CPWD SPECIFICATIONS 2009 352

9.25.5 Tolerance
As per clause 9.19.6.

9.25.6 Fittings
As per clause 9.19.7.

9.24.7 Measurements
As per clause 9.19.8.

9.24.8 Rate
As per clause 9.19.9.

9.26 FACTORY MADE FIBRE GLASS REINFORCED PLASTIC CHAJJA

9.26.1 F.R.P. chajja shall be 4 mm thick of required colour/size, design and drawing as approved. The
chaja shall have smooth gradual slope curvature for easy drainage of water & shall be factory
manufactured as per nomenclature of item & directions of Engineer-in-Charge. (Fig. 9.27).

9.26.2 Material
(1) Glass Fibre (chopped strand mat) shall be as per IS 11551
(2) Unsaturated Polyester Resin shall be as per IS 6746
(3) Surface Burning Characteristics of Building Material – ASTM E 84-77a
(4) Unsaturated Polyester Resin Gel coat shall be as per IS 6746
(5) Curing Agents – Cobalt Napthanate and MEKP
(6) Test of products – IS 14425
(7) Glass Fiber Roving – IS 11320

The F.R.P. chajja laminate shall be water and chemical resistant and shall have very high transit
strength to weight ratio and high modulus of elasticity, good textile processing and excellent fiber
reinforcement properties. The laminate shall have low coefficient of thermal expansion and a high
thermal conductivity and high dielectric constants. The F.R.P. laminate shall be diversionally stable, shall
have moisture and corrosion resistance.

9.26.3 Tolerance
Tolerance of + 10 mm in overall size of FRP chajja is permissible.

9.26.4 Finish
The F.R.P. laminate to be finished with polyurathene based or equivalent paint as final coat or gloss
or mat followed by clear lacquer coat to get the shine of required shade.

9.26.5 Tests
Frequency of tests as per direction of Engineer-in-Charge & tests to be conducted as per para
9.19.4.

9.26.6 Measurement and Rate

The width and length to be measured in centimetres and area to be calculated as square metre
correct upto two places of decimal. The rate includes cost of all the materials, labour scaffolding, fittings
& fixing upto all heights etc. involved in operations described above, but excludes the cost of paint.

9.27 WALL PANELLING (Fig. 9.28)

All specification same as per clauses 9.17.1 to 9.17.7.

353 SUB HEAD 9.0 : WOOD WORK AND P.V.C. WORK

 APPENDIX A

TABLE FOR PERMISSIBLE DEFECTS FOR VARIOUS GRADES OF TIMBERS

(Clause 9.1)

Sl. No. Defects First Grade Second Grade

(1) (2) (3) (4)
(i) Cross-grain Not steeper than 1 in 15 Not steeper than 1 in 10
(ii) Sound knots (i) Stiles and Rails (i) Stiles and rails
and live knots
(a) Short Exposed Face: Not (a) Short exposed Face – Not more
more than 15 mm size and than 15 mm size and not more than
not more than 1 knot/metre 3 knots per stile and 1 knot per rail
(b) Long Exposed Face- Not (b) Long Exposed Face- Not more
more than 15 mm size and than 20 mm size and not more
not more than 1 knot/m. No than 3 knots per stile and 1 knot
knot shall occur within 20 mm per rail
of the edges

(ii) Panels – Not more than 20 mm (ii) Panels – Not more than 20 mm size
size and not more than 2 and not more the 4 knot/m2. No knots
knots/m2. No knot shall occur on shall occur on edge of any component
edge of any component of a of a panel.
panel.
(iii) Dead and loose (i) Stils and Rails – Not more than 10 (i) Stiles and Rails – Not more than 10
knots (plugged) mm size – centrally located and mm size, centrally located and not
not more than 1 knot / m more than 3 knots per stile and 1 knot
per rail.
(ii) Panels – Not more than 15 mm (ii) Panels – Not more than 15 mm size
size and not more than 2 and not more than 4 knots/m2. No
knots/m2. No knot shall occur on knot shall occur on edge of any
edges of any component of a component of a panel.
panel.
(iv) Pitch pockets or None Permissible except on exposed edges
streaks provided that they are clean and filled up
with suitable putty or filler when pitch
pockets or streaks are located on the
exposed edges of the core, they shall be
cut out and filled with piece of wood of
similar species with grain running in the
same direction. The piece shall be well
glued.
(v) Sapwood Total not exceeding 5 mm wide and Total not exceeding 10 mm wide and 300
150 mm long per metre. (This mm long per metre. (This restriction
restriction applies only to super group applies only to super group species).
species).
(vi) Pin holes Permitted provided they are not in Permitted.
cluster
(vii) Worm holes None Permitted provided they are not more than
10 mm in diameter and not more than one
per metre and provided such worm holes
are plugged with similar timber in such a
manner that the pluging merges with the
surrounding area both as to colour and
grain.
Note :
(i) Dead and loose knots are permitted only if they are suitably plugged.
(ii) Knot shall not occur where hinges or locks are to be fixed.

CPWD SPECIFICATIONS 2009 354

 APPENDIX B

DIFFERENT CLIMATIC ZONES FOR MOISTURE CONTENT OF TIMBER

(Clause 9.1.6)

68° 7 2°AFGHANISTAN 76° 80° 84° 88° 92° 96°

36°
36°
Gilgit INDIA
SHOWING
JAMMU AN D KASHM IR
DIFFERENT CLIMATIC ZONES
Srinagar Leh FOR MOISTURE CONTENTS
AN FOR SEASONED WOOD
32° ST
KI C 3 2°
PA HIMACHAL H
I N
PRADESH A
PUNJAB Shimla
Ch andigarh
Dehrad un
T
HARYANA I B
E IM ok
28° Delhi UT T KK angt
TA NE SI G ARUNACHAL 28°
R PA
Bikane r PR L PRADESH
RAJASTHAN Jaipu r AD
BHUTAN
Agra Itanagar
Jodhp ur Lu ES M
ck H SA
no A S NAGALAND
w Ko hima
Barmer Gwalior Ka npur MEGHALAYA
Patna Shilong MANIPUR
Bhagalpur Imphal
24° Gaya BIHAR BANGLADESH 24 °
GUJARAT la
I N A ga rta Aizwal
D I A WE ST
Ahmedab ad Indore Bhopal Jabalpu r Durgapur BENGAL
MIZORAM
MADHYA PRADESH Calicutta
R aipur
Diu Daman Silvasa gpur
20° MA HARASHTRA Na 20°
ORISSA Bhubaneshwa r
Dadra & Nagar Haveli
Bombay
Pune BAY OF BENGAL

Hyderabad Vishakhap atnam

ARABIAN SEA SH
16° Bijapur ADE
R 16°
P
A
Pananji R
DH
(Goa, Daman & Diu ) Goa AN NOTE OF SHADING Na rcondam
KA Zone I Ireland
RN
AN

AT (Ind ia)
AK
DA

A Madras Barren Irelan d

Bangalore Zone II
MA

12° (Ind ia)

N

Zon e III Port B lair

& N iSLA

LA PONDICHERRY
K TAMIL NADU
Zone IV
IC ND

SH
KE

OB S

D Kavaratti
W
RA

E
AR

EP
Madurai
LA

IS
.
Trivandrum 8°
8°

O C E A N
I N D I A N
88° 92°
72° 76° 80° 84 °

Note 1 : Based upon Survey of India map with the permission of the Surveyor General of India.
Note 2 : The territorial waters of India extend into the sea to a distance of twelve nautical miles measured from the appropriate base line.
Note 3 : The boundary of Meghalaya shown on this map is as interpreted from the North-Eastern Area (Reorganisation) Act, 1971, but has
yet to be verified.
Note 4 : The administrative headquarters of Chandigarh, Haryana and Punjab are at Chandigarh.

355 SUB HEAD 9.0 : WOOD WORK AND P.V.C. WORK

 APPENDIX C

MOISTURE CONTENT OF TIMBER

(Clause 9.1.6)

C-1 Moisture content of timber shall be checked for every 1 cum or part thereof by electrical moisture
meters as per IS 287.

C-2 Electrical moisture meters are of resistance type and shall be used when the moisture content is
within a range of 8 to 25 per cent. When checking moisture content with electrical moisture
meter, it shall be ensured that :
(a) Timber is not hot or surface wet and the moisture gradient is not large due to wet cores.
(b) Electrode probes are of adequate depth (not less than one-fifth the thickness of the timber).

C-3 Sufficient number of reading at different positions are taken on each piece of timber to eliminate
localised variations in surface moisture and species corrections are applied for the make of
electrical resistance type moisture meter.

C-4 If for any reason, whatsoever, the result of electrical moisture are not to be relied upon the
moisture content shall be checked by the oven drying method.

C-5 For checking moisture content by oven drying method, a complete test cross section, 12 to 19
mm long in the direction of timber grain, free from all defects shall be cut from each piece of
timber selected for test as follows :
(a) If weighing can be done immediately, the test section shall be cut from a point at least 45
cm from one end of the piece or from its centre.
(b) In case cutting of test section from the piece is not permissible the moisture content in the
whole section can also be determined by collecting a boring to a depth of half of the
thickness of the piece by means of an auger, in a preweighed weighing bottle which should
then be sealed properly.

C-6 The test sections obtained above shall be weighed, immediately after cutting, on a balance the
sensitivity of which is not less than 10 mg. They shall be dried in a ventilated, and preferably
thermostatically controlled, oven at a temperature of 100°C to 105°C untill the weight is constant.
The weight of the test section shall be deemed to have become constant if successive weighing
at intervals of 2 to 5 hours do not differ from one another by more than 50 mg. The test weight
shall be taken to be the oven dry weight of the test section.

C-7 The percentage moisture content in the test section shall be calculated as follows :

W1 – WO
Moisture content (Per cent) = ——————— × 100
WO
Where :
W1 =initial weight of test section and
WO = oven dry weight of test section

C-8 When moisture content of timber is checked by oven drying method, results of electrical moisture
meter shall be ignored.

CPWD SPECIFICATIONS 2009 356

 APPENDIX D

PHYSICAL AND MECHANICAL PROPERTIES OF PLYWOOD

(Clause 9.2.2.6)

D-1 Moisture content

5 to 15 per cent.

D-2 Shear Strength

Dry State Resistance to Moisture
Average 135 100
Individual 110 80

APPENDIX E

PHYSICAL AND MECHANICAL PROPERTIES OF FPT OR GRADED

PARTICLE BOARD
(Clauses 9.2.3.4 )
Sl. No. Properties Flat pressed Three layer multi layer and graded
Grade- I Grade-II
(i) Density variation, percent ± 10 ± 10
(ii) Water absorption, percent
(a) 2 h soaking 10 40
(b) 24 h soaking 20 80
(iii) Linear expansion (swelling in water).
2 h soaking-percent
(a) Length 0.5 0.5
(b) Width 0.5 0.5
(iv) Thickness, swelling, percent 2 h soaking 8 12
(v) Swelling in thickness due to surface absorption, 6 9
percent
(vi) Modulus of rupture, N/mm2
(a) Average 15 11
(b) Minimum 13 10
(vii) Modulus of elasticity, N/mm2
(a) Average 2500 2000
(b) Minimum 2250 1800
(viii) Tensile strength perpendicular to surface, N/mm2
(a) Upto 20 mm thickness 0.45 0.3
(b) Above 20 mm thickness 0.40 0.3
2
(ix) Tensile strength perpendicular to surface, N/mm
(a) After cyclic test 0.2 -
(b) Accelerated water resistance test2) 0.15 -
(x) Screw withdrawal strength, N
(a) Face 1250 1 250
(b) Edge (for thickness >12mm) 850 700
1) Cyclic Test— Specimen are immersed in water at 27 ± 2°C for a period of 72 h, followed by drying in air at 27 ± 2°C for 24
H and then heating in dry air at 70°C for 72 h. Three such cycles are to be followed and then the specimens are tested for
tensile strength perpendicular to surface.

2) Accelerated Water Resistance Test— Specimen are immersed in water at 27 ± 2°C and water is brought to boiling and
kept at boiling temperature for 2 h. Specimen are then cooled in water to 27 ± 2°C and then tested for tensile strength
perpendicular to surface.

357 SUB HEAD 9.0 : WOOD WORK AND P.V.C. WORK

 APPENDIX F

TESTS FOR FLUSH DOOR SHUTTERS

(Clause 9.7.1 to 9.7.10)

F-1. END IMMERSION TEST

Door shutters shall be tested for resistance of their base to immersion in water as follows :

The door shutter shall be immersed vertically to a height of 30 cm in water at room temperature for 24
hours and then allowed to dry for 24 hours at 27 ± 2°C and relative humidity of 65 ± 5 per cent. The
cycle shall be repeated eight times. There shall be no delamination at the end of the test.

F-2. KNIFE TEST

(i) Apparatus : The type of knife required to be used in the test is given in Fig. below. It may be made
from a 250 x 25 mm file. The cutting edge should be kept chiselsharp. The test shall be carried out on a
stout table to which a wooden batten is screwed against which the edge of test piece is placed.
( Appro
x .)
m
250 m

25 cm

Drawing not to scale

KNIFE FOR TESTING PLYWOOD FOR ADHESION OF PLIES

(ii) Procedure : The knife is inserted with its cutting edge parallel to the grain of the outer veneer and
worked into, or if possible along a glue line and the veneer is prised upwards. A hard and dense specie
of plywood requires considerable force to effect entry and to prise and veneer. In a soft timber the knife

CPWD SPECIFICATIONS 2009 358