Vol-2 As On 16-07-2020-Print

Volume-II, Technical Specifications
GOVERNMENT OF ANDHRA PRADESH WATER

RESOURCES DEPARTMENT
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Name of work: “Rayalaseema Lift Scheme to draw and utilize 3

TMC per day from Sangameshwaram to
SRMC @ Km. 4.00 from Pothireddypadu
Head Regulator.”
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CONTRACTOR SUPERINTENDING ENGINEER

SRBC CIRCLE NO.1, NANDYAL
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The General Technical Specification (hereinafter called GTS) broadly cover the information about
site conditions, transport requirements, excavation, execution of works like concrete, steel, etc.,
construction materials and general requirements. The GTS also covers the broad specifications
and regulations for all major civil and hydro-mechanical works, electromechanical works included
in the contract documents as well as the conditions for measurements and payments.
The items of works are based on Employer’s preliminary designs as indicated in Volume I, Part-E -
Project Profile of the Bid Document. These specifications shall be part of the requirements for
various items related to the work, which are to be provided according to the stipulations of the
contract specified in Basic Project Parameters of Volume-I, Part-D of Bid Document. The items of
works may be modified /altered to meet the requirements of Contractor’s Design and Engineering
of the permanent civil, hydro-mechanical works, electromechanical works and construction of
required substations. Accordingly, the technical specifications may require additions/alterations to
conform to Contractor’s Design and Engineering mutually agreed to with the Employer. However,
the technical specifications shall be in general as per Bureau of Indian Standards or corresponding
International Standards as mutually agreed by the Employer and the Contractor during preparation
of detail design and drawings and approval thereof.
These specifications shall be read in conjunction with the Conditions of Contract, the drawings and
the preliminary Schedule of Works. While quoting the price the Contractor shall comply with all
provisions contained within the bidding documents and instructions of the Engineer-in-Charge.
All works shall be executed according to the drawings approved by the Engineer- in-Charge for
construction, in a professional and diligent manner and all supplies and works shall comply with
the quality requirements defined in the relevant sections of these specifications and other bidding
documents. The Contractor shall endeavour to provide all such necessary efforts in order to
comply with the intent of these specifications to the satisfaction of the Engineer-in-Charge.
Addenda to these specifications may be issued, as required, during bidding that will form part of
these specifications.
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The successful Contractor, after approval of the design and drawings by the employer has to
execute the works as per the specifications given in the subsequent sections of this volume.
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1. Size of pump house
2. Bottom level of pump house
3. Shot creating details
4. Well steining thickness and specification
5. Bed concrete thickness and specification
6. Foundation concrete of pumps
a) Primary concrete - Specification, quantity, reinforcement details
b) Secondary concrete - Specification, quantity, reinforcement detail
7. Details of specifications of columns for EOT crane

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a) Specification
b) Number of columns
c) Span width
8. Pump roof details
9. Annex details
a) Number of annexes considered
b) Dimensions of annex
c) Floor concrete - thickness, specification and quantity.
10. Details of lift proposed
11. Details of stair case proposed
12. Service bay size, details of floor concrete
13. Details of flooring in pump house, annexes and other areas.
14. Other details if any "
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1. Diameter of Pressure main proposed
2. Length of Pressure mains

3. Thickness and specification of steel plates for Pressure mains
4. Total length of Pressure mains on the ground
5. Details of anchor/Thrust blocks
a) Number of blocks and Location
b) Size of blocks
c) Specification of concrete
d) Quantity of concrete
e) Reinforcement quantity
f) Pedestals details
6. Number of expansion joints
7. Number of rockers and rock pins
8. Concrete specification and quantity to be laid all around the delivery Mains
9. Details of manifold diameter, thickness, encasing
10. Other details if any
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1. Size of Cistern well
2. Details of side walls
3. Details of centre walls
4. Details of weir
5. Details of down stream apron and protection works
6. Concrete quantity specification wise
7. Other details if any
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The Contractor should make his own assessment about the accessibility to work site, quarry areas or
otherwise and also the mode and means of transportation as would be required for execution of
requisite works.
The Contractor shall be responsible to select proper routes to meet his needs and shall bear all costs
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of transportation including loading and unloading as deemed fit by the Contractor.
The costs, if any, for adjusting, modifying roads and bridges shall be borne by the Contractor. The
Contractor shall submit for approval of the Engineer the method of transportation and routes he
proposes to use.
In case any approval from the concerned authorities are required for transportation of materials
through road/railway, the Contractor shall make necessary arrangements for obtaining the same, well
in advance to avoid any interruption in works for want of materials, etc.
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The Contractor shall design, provide, erect, operate and maintain the working facilities required for
the execution of the Permanent Works, within the specified time schedule, such as but not
necessarily limited to:
Camp and Facilities

Plant and Equipment
Electric Power Supply System
Telephone and Communication Network
Water Supply System
Sewage and Waste Water System
Fire Fighting Equipment
Temporary Access and Construction Roads
Explosive Magazine
Testing Laboratory
Working facilities shall be subject to the Engineer-in-Charge’s approval. The Contractor shall
comply with all applicable laws, regulations, and ordinances relating to the construction and
operation of the working facilities.
Materials for the working facilities shall be of first-class quality and if not new, in best condition.
The capacity and number of equipment shall conform to the specific minimum requirements for the
works they are intended for and the climatic conditions prevailing at the site. The capacity and
number of equipment shall be determined taking into account of the requirement of equipment
throughout the entire work.
The Contractor shall attach to his bid documents drawings, pictures and operating descriptions for
his proposed working facilities and shall indicate weight, standards, capacity, manufacturing date
and country of origin.
The Contractor shall, prior to dispatching any items of the Working Facilities, give written notice to
the Engineer-in-Charge with clear indications about the purpose of the items, the kind, date and
place of consignment (factory or the Contractor’s premises). Said notice must be given in due time
to allow for a possible cancellation in case the items do not comply with the requirements as
stipulated. The Engineer-in-Charge will agree or disagree with the inquiry in writing within the next
15 days on arrival of the notice.
The Contractor shall provide all his equipment with sufficient spare parts, special tools for repair
work and complete standby units of vital parts to guarantee a continuous operation without
untimely delays. The Contractor is fully responsible for any delays due to disregard of said
necessity.
Should the Engineer-in-Charge determine that the equipment furnished does not meet all
requirements, the deficiencies shall be corrected by the Contractor before further use, or the
deficient equipment shall be replaced with satisfactory equipment any cost incurred in the
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correction or replacement shall be borne by the Contractor.
All Working Facilities shall be built in the areas indicated by the Engineer-in- Charge. The
Contractor shall submit prior to the start of the Works to the Engineer-in-Charge for approval, a
drawing showing the exact positions of the main Working Facilities.
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The Contractor shall submit basic plans of Working Facilities together with his bid.
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The Camp and Facilities include but are not limited to
Staff residential quarters for the Contractor’s staff

Accommodation and canteen for the Contractor’s workmen
Miscellaneous social facilities
Offices for the Contractor

Miscellaneous Working Facilities
• Warehouses and sheds for the Contractor
• Work and repair shops
• Explosive magazines
All working facilities shall be equipped with lighting arrangement, telephone, water supply with
drinking water, sewage system and if necessary with air conditioning. Contractor shall make his
own arrangement for electricity supply as would be necessary for all sorts of works.
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Offices for the Officers and staff of the Contractor shall be of sufficient size and fully furnished and
equipped with sanitary facilities, telephone, etc.
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The Contractor shall construct and maintain warehouses, storage yard, a motor tool, repair shops,
main and portable explosive magazines, workshops, vehicle sheds, garages, fuel storages and
field laboratory etc. for efficient execution of the work.
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Warehouse(s) for the storage of materials, mechanical and electrical units, spare parts etc.
shall be well secured, ventilated (if necessary) and waterproof and shall be installed with the
necessary appliances.
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All work and repair shops shall be well secured, ventilated (if necessary) and waterproof. They
shall be equipped with adequate equipment and tools necessary to carry out all works and
repairs which are usually to be done at the Site.
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The contractor shall acquaint himself with all applicable laws and regulations concerning
storage, handling and use of explosives. All such laws, regulations and rules etc., as are
amended from time to time shall be binding on the contractor.
Explosive materials required for the job shall be arranged by the contractor. For safe storage
of these materials contractor will have his own main magazine under license from explosive
authorities. Employer will give recommendation letter / necessary certificate for obtaining
license and arrangement of explosives on request by the contractor.
The contractor shall also arrange mobile / portable explosive magazine(s) of suitable capacity
and explosive van. The contractor shall arrange the security system for the contractor’s own
magazine house and mobile / portable magazine(s).
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The method of storing, handling and use of explosives and precautions to be taken in order to
prevent accidents shall conform to international safety restrictions, laws and regulations of
India and require the Engineer-in- Charge’s approval.
Blasting caps or other exploders, detonators or fuses cannot be stored, transported or kept in
the same place in which dynamite or other explosives are stored, transported or kept.
It is strictly forbidden to transport any unauthorized personnel on transport means while

carrying explosives. The contractor shall limit the handling or explosives to full-service
personnel including approved blaster and have them thoroughly instructed about dangers and
consequences. In order to distinguish full-service personnel from other individuals, full-service
personnel shall wear armbands and other identifying insignia.
The contractor shall keep an up-to-date inventory of all explosives and accessories in storage
in standard formats, and shall take all reasonable and adequate protections in order to prevent
theft and misuse thereof.
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The Contractor shall provide all construction plants and equipment necessary for the efficient
execution of the work described in Volume –II (Part –B) of the bid documents and the
Specifications and details furnished by the Contractor in the construction plant and equipment
schedule.
The Contractor shall also deploy additional equipment, if needed, at his own cost for timely completion of the
Works.
The Contractor may collect and use sand and gravel within the construction area provided by the
Employer if approved by the Engineer-in-Charge. The Contractor shall obtain aggregate at his own
expenses and responsibility
Plants and equipment for the execution of all civil works include but are not limited to:
Plant for aggregate and concrete / mortar production

Processing plant for filter and selected surfacing material
Open and underground excavations
Steel fabrications, bending and other equipment.
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The number and capacity of crushing plants for aggregate shall be sufficient enough such that
daily production shall at least meets the 2-3 days elements. The processing plant for aggregate for
concrete shall be capable of producing the separate aggregate size groups with the proper
grading stipulated in the Specifications.
Care shall be taken so that water which has been used to wash the aggregates does not cause
turbidity of the river/stream water.
The Contractor shall submit the following data for approval before ordering equipment or initiating
work on the Plant:
flow diagrams
size and capacity of each separate piece of equipment
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Transportation of bulk cement shall be accomplished in adequately designed weather-tight trucks
or other means which will protect the cement completely from exposure to moisture.
Storage of bulk cement at the Site or in the railway yard shall be done in weather- tight and
properly ventilated structures with adequate provisions for the prevention of absorption of
moisture. Said structures shall be complete with all equipment for loading, unloading and
weighing of cement.
A weather - tight equipment shall be provided for conveying cement.
The cement storage structure on the Site shall be at least for 30-day capacity.
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The mortar / concrete batching and mixing plant shall be a modern and dependable, automatically
controlled interlocked batch-type mixing plant. Manual operation shall also be possible in the event
of fault in the automatic system. The equipment shall be capable of combining the aggregate,
cement, admixtures, and water into a uniform mixture within the time limit specified and of
discharging this mixture without segregation. The equipment shall provide adequate facilities for
the accurate measurement and control of each of the materials entering plant. The complete plant
assembly, including provisions to facilitate the inspection of all operations at all times and the
adequacy and dependability of each of its parts, shall be adequate to meet the requirements of the
work.
The batching and mixing plant shall have means for readily wasting any material or concrete /
mortar that is improperly batched, mixed or held in the mixers too long.
Auto-balance scale for weighing mortar / concrete materials and digital instruments shall be
inspected, tested and calibrated in the presence of the Engineer-in-Charge after repair and
maintenance of the equipment and at least once in every two (2) months or as directed by the
Engineer-in-Charge.
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Batching shall be done by individual weight batching equipment. Aggregate weight batching may
be cumulative but by individual size. Weighing hoppers shall be arranged to permit the
convenient addition or removal of material.
Delivery of materials from the batching equipment shall be within the following limits of accuracy:
Material Percent by Weight

Cement 2
Water 1
Aggregate smaller than 5 mm 2
size
Aggregate larger than 5 mm size 3
Admixture 1
Suitable facilities shall be provided for readily obtaining representative samples of aggregate from
each of the batchers for test purposes.
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The mixing plant shall consist of batch type tilting mixers or pan type forced paddle mixer and a
discharge hopper arranged with suitable devices for obtaining representative samples and
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delivering to ground level of concrete for slump, unit weight, and uniformity tests. The operator
platform shall be conveniently located so that the operator can visually observe the mixing action
in at least one mixer and the discharge from all mixers. A platform for access from the control
room shall be provided to permit visual inspection of the mortar / concrete in the mixers while
mixing. All necessary platforms, tools, equipment shall be furnished by the Contractor.
On each mixer a consistency indicator and an acceptable device to lock the discharge mechanism
until the required mixing time has elapsed shall be provided.
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An accurate recorder of digital type shall be provided to make continuous visible combined record
on a single chart of the separate measurement of each concrete
/ mortar ingredient, including all mixing water, air-entraining admixture, water- reducing and set-
retarding admixture, and also mixing time of each batch after all materials are in the mixer, date
and time of each batch, and the type of mix proportion.
The visible portion of the chart shall cover a period of not less than 30 minutes. All digital recorder
charts shall be locked and the charts shall be submitted to the Engineer-in-Charge.
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An effective telephone or two-way communication system for the exclusive use of the batch plant
inspector, placement inspector and the laboratory shall be maintained. Telephones shall be
provided with a suitable bell, buzzer, or light to attract attention under working conditions.
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The contractor shall make his own arrangement at his own cost for power supply for construction
and other uses. The Contractor shall furnish, install and maintain the electrical distribution system
of required capacities to the required areas for his work.
For camp area, the Contractor shall arrange himself for a connection with the closer existing
power-line.
As an alternative measure, the Contractor shall install generators of required capacity and related
facilities at his own expenses in case of an excessive energy demand and/or for supply of power
at the instance of power failure at the power network.
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The temporary tale-communication system, shall be established at site and the Contractor shall
make necessary arrangement for the same.
The Contractor will be responsible for furnishing, installing and maintaining, the telephone and
communication network to individual sites/offices and other areas like quarries etc., as needed.
The contractor shall be equipped with at least one mobile connection at site office. All the charges
for telephone and communication network shall be borne by the contractor.
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The Contractor shall make all necessary arrangements for the adequate supply of raw water for
construction use and potable water for human consumption at the various work areas as well as at
the camps. Regulating, transporting, treating and distributing the water shall be included in it.
For construction and other uses, sufficient storage of water shall be secured especially during dry
seasons. The Contractor shall be fully responsible for the arrangement of necessary facilities for
water supply.
Only adequately treated water which complies with the current sanitary standards will be accepted
for human consumption. Installation of non potable water supply systems in the camp areas will
not be permitted. Storage tanks with a reserve capacity equivalent to two (2) days of normal usage
will be required for the drinking water system.
The Contractor shall take drinking water samples from time to time if so requested by the
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Engineer-in-Charge. The samples shall be sent for chemical and bacteriological analyses to
approved laboratories at his expense and the results of the analysis shall be obtained within 7
days of the sampling.
If the sampling and testing are not properly performed, the Employer may perform the same
directly and charge the Contractor for the corresponding expenses.
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The Contractor shall design, construct, equip, operate and maintain all the installation necessary
to properly collect, treat and dispose of sewage from his camps and other construction facilities.
The Contractor shall not, under any circumstances, discharge sewage or contaminated water into
natural streams or any open areas. The poundage system for treatment and disposal of sewage
shall not be used.
Treatment and disposal of sewage shall be performed in accordance with the current related
standards and laws in force in India and always subject to the Engineer-in-Charge’s approval.
The drainage systems shall be designed taking into account the rainfall rate in the area and the
disposal of rainwater shall be accomplished in such a way that no stagnation of water or any
erosion problem is caused which may alter the stability of the soil.
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The Contractor shall provide complete fire fighting equipment necessary to ensure the safety of
the Work.
The Contractor shall supply and maintain an abundant length of fire hoses, fire buckets, sand
buckets, approved fire extinguishers and alarm systems installed over the complete work and
camp sites.
The Contractor shall have on the Site at all times a trained fire fighting and first- aid crew with the
necessary mobilization means.
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The Contractor shall design, construct and maintain the construction roads and related works that
may be necessary, from the existing roads and tracks to the various work areas, and other areas
such as camps, stores, explosive magazines, plants, disposal areas and any other areas related to
the work at his own cost.
Additionally, the Contractor shall improve where necessary and maintain all the existing roads and
tracks in and adjacent to the project area to the satisfaction of the Engineer-in-Charge for
guaranteeing normal traffic for any kind of vehicle.
The Contractor shall be responsible for the safety of the traffic during the construction. The training
for safe driving together with providing number of traffic signs are the responsibility of the
Contractor. Additionally, he will be responsible for protecting against damage any part of the work
and the property of others in relation to the performance of this works.
The construction roads as well as existing roads will be utilized by the Employer, and the
Contractor will not be entitled for any payment for such use.
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The main construction roads, built or improved by the Contractor, shall be wide enough to allow
heavyweight traffic in both directions. The longitudinal roadway grades shall be as required by the
traffic conditions and in any case shall not be greater than 10%, except for short sections where
grades of up to 12% may be allowed. The cut and fill slopes shall be as required by the material
characteristics and by the safety of any part of the works and of the property of others.
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The road surface shall consist of a well-compacted layer of selected material. The roads shall be
widened sufficiently for smooth traffic control. Other related structures and facilities such as guard
rail, guide post, drainage culvert and/or trench etc. necessary to maintain traffic throughout the
construction period shall also be constructed.
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The Contractor shall maintain the construction roads together with the existing roads in
and adjacent to the project area for the use of heavyweight equipment.
Maintenance of the construction roads will include, but not be limited to, the following works:
a. Repair of irregularities produced by the traffic, water, etc. on the roadway surface;
b. Repair of related work that is damaged by traffic or by weather;
c. Periodical shaping of the roadway where necessary in order to maintain it in optimum
conditions for traffic at all times;
d. Interior cleaning of culvert, including head wall, ditches and drainage trenches;
e. Cleaning and shaping of earth ditches and cleaning of concrete ditches;
f. Maintaining the necessary traffic signs, guide posts etc.;
g. Carrying out effective dust control.
Dust control shall consists of applying either water or dust palliative, or both, for the alleviation of
prevention of dust nuisance.
For the execution of this work, the Contractor shall have appropriate personnel, materials and
equipment.
The Contractor shall submit, for the Engineer-in-Charge's approval, a work schedule and a
schedule of resources used for the execution of the work herein specified.
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The Contractor shall establish a well equipped field laboratory for testing of materials of
construction and other as required at his own cost and responsibility. This laboratory shall be of
the size with equipments and with all testing facilities as per Indian or other equivalent Standards.
Prior to setting up of the laboratory, Contractor should submit detail plan with exhaustive
equipment-list, and list of professionals and other personnel identified for laboratory work, to the
Engineer- in-Charge for approval.
The laboratory shall be established as early as possible. The Contractor shall collect the samples
as specified or as directed by the Engineer-in-Charge, carryout the relevant test under the
guidance of Engineer or Engineer-in-Charge’s representative, prepare the complete report and
submit them to the Engineer-in- Charge.
All tests shall be made according to approved standards and therefore, the equipment shall
comply with the same standard. All relevant standards shall be made available in the laboratory.
For any material/work in particular where the Contractor’s laboratory has no facility, tests shall be
got done in an outside standard laboratory with the approval of Engineer-in-Charge at Contractor’s
cost.
The laboratory shall be provided with light, ventilation, water, telephone, air- conditioner, cold and
hot water supply, tank for curing, heating, toilet, etc., and be spacious enough in order to store the
test samples. The details and location of the laboratory are subject to the Engineer-in-Charge’s
approval.
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The Contractor shall render all services for topographical survey and measurement required for
the performance of the Works.

13
These services cover in general the establishment of axis, centerlines, alignments of project
structures and features, the setting out for construction thereof, the accompanying control surveys
for correct locations, dimensions and elevations as well as the necessary surveys for
measurement to permit quantity calculations for invoicing.
Before taking up any survey work in hand, the Contractor shall be responsible for construction and
establishment of Bench marks (BM) of approved section at the salient points to form a basic
grid/triangulation points in and around project area as approved by the Engineer-in-Charge for
reference. All these BMs shall be connected to a nearby GTS Bench Mark. No separate payment
for construction and establishment at these BMs shall be made. All surveys shall be based
on and/or referred to the basic grid of datum points/triangulation points and benchmarks extended
in the project area.
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At least 14 days prior to commencing survey work the Contractor shall submit to the Engineer-in-
Charge for his approval a proposal of the sequence of the survey works to be performed, along
with the bio-data of the key personnel in-charge of survey works, the list of survey equipment and
instruments the Contractor will provide at the site, and a brief outline on methodologies of survey
works applied for the various types of survey.
At least seven (7) days prior to the commencement of any survey work the Contractor shall inform
the Engineer-in-Charge of his intention to perform the survey work. The Contractor shall indicate
the purpose of the survey, the area to be surveyed, the structure or facilities involved, the methods
to be applied and the survey period.
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The Contractor shall provide, maintain and operate suitable and appropriate
equipment/instruments, auxiliary equipment, all survey personnel and materials to commensurate
with the various tasks and precision requirements of the survey works. Type and accuracy of the
survey equipment to be used by the Contractor shall correspond to the nature of the construction,
erection works and the construction technique.
All equipment, instruments, materials and auxiliary equipment shall be in perfect operation
condition. Prior to the start of any survey, all instruments/equipments earmarked for the said works
shall be checked and adjusted, wherever necessary as a routine measure for their proper
functioning and accuracy. During the construction period also the survey instruments shall be
checked and, if necessary, adjusted at regular time intervals.
Instruments and equipment which have suffered from use, damage or accidents to a degree
making them unfit for further use at the site, shall be removed from the site and replaced
immediately.
The number of sets of instruments shall be sufficient to meet the requirements of the construction
time schedule. Delay of start of construction or construction progress caused by insufficient
quantity and quality of survey equipment including provision of professional staff shall be at the
Contractor's responsibility.
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For the execution of the survey work the Contractor shall employ and provide experienced
professionals and auxiliary staff. All survey and measurement work shall be recorded and filed
thoroughly.
The Contractor shall provide, maintain, adjust when necessary and operate the required survey
and auxiliary equipment for the performance of the Works.
All survey and measurement activities shall be recorded in maps and field books as directed.
Where required, the production of drawings and maps shall be deemed to be part of the Works.

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The Engineer-in-Charge shall have the right to check work performance, accuracy, stations, etc.,
and all survey results, measurements and calculations as well as conformity with plans and
drawings.
The Contractor shall keep and maintain professional records of all field surveys and
measurements, the related computations and calculations, manuscripts, plans, drawings and
maps, and shall make them available to the Engineer-in- Charge whenever requested.
If, in the opinion of the Engineer-in-Charge, deficiencies and/or inaccuracies in field and office work
have been found, such work shall be repeated and made good to the satisfaction of the Engineer-
in-Charge at the Contractor's expense.
The Contractor shall be solely responsible for accuracy of survey maps and drawings.
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Prior to starting survey works, the surveyors shall make adequate terrain investigations with
respect to sightings, vegetation to be removed, placement of monuments, taking into consideration
future construction work which may affect the survey points, monuments and benchmarks. Based
on these investigations a survey plan shall be developed comprising existing basic data, the
survey grid to be developed, the equipment required for the particular survey task, staff and time
requirements arranged in a way to warrant smooth progress of construction works.
All survey works shall be done with greatest care and precision. In case the survey works have
activities on lands not owned by Employer, prior consent of the land employers shall be obtained,
and proper compensation payments as decided by mutual agreement shall be made by the
Contractor at his own expenses.
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Coordinates and elevations as shown on the Drawings are based on the basic survey grid. The
same shall be verified by the Contractor.
" Cwiogpvcvkqp"qh"Dcuke"Uwtxg{"Itkf"
Existing datum points and benchmarks closely located to the permanent structures may be
endangered by construction activities. The Contractor shall therefore in due time establish
additional datum points at safe locations and elevations to augment or extend the basic grid.
The new datum points shall be of permanent nature and shall be constructed as directed by the
Engineer-in-Charge.
The Contractor shall also establish reference pillars for centerlines and line control of structures
which need frequent and extended control surveys.
New datum points, reference pillars and benchmarks shall be protected and maintained in the
same way as the original grid points.
" Uwtxg{"qh"Itqwpf"Rtqhkngu"
(1) Original Ground Profiles
The Contractor shall inform the Engineer-in-Charge in writing, at least 14 days before commencing
such work, of his intention to perform any work which will result in a change to the topography of
the existing site for the permanent works and or for temporary works. Thereupon, before
commencing any work, the Contractor shall survey the original topography to the approval of the
Engineer-in- Charge over the entire area to be occupied or disturbed. Such survey may again be
required after removal of vegetation, topsoil or other overburden.
The information so obtained shall be recorded by the Contractor on a drawing or drawings which
shall be signed by both the Contractor and the Engineer-in- Charge. The Contractor shall then
provide the Engineer-in-Charge with a reproducible copy of each drawing to serve as a permanent
record for the purpose of determining the quantities of excavation or earthworks carried out in the
construction of the permanent structures, and the extent to which temporary works shall be
removed or temporary excavations shall be refilled upon completion of the works.
(2) Excavated and Final Ground Profiles

15
The Contractor shall survey all excavated and final surfaces for the purpose of recording as-
constructed details, and for the measurement of quantities:
- On completion of excavation and prior to commencement of any work.

- On completion of the same.
" Ugvvkpi"Qwv"qh"Yqtmu"
The Contractor shall perform all setting out and check surveying of the Works. The methods and
program of checking shall be such as to ensure the construction of every part of the Works to the
correct line and level. The Engineer-in-Charge may at any time request the Contractor to submit
proof that his own setting out has been satisfactorily checked.
The number of points required for setting out as well as the spacing between these points shall be
determined by the Contractor in accordance with the type of the work. The Engineer-in-Charge
may require that some or all of the given points and datum levels be clearly marked during
construction in such a way that the marks can be retained after completion of construction.
" Ugvvkpi"qwv"Ejgemu"
The Employer may perform check surveys during the course of construction and the Contractor
shall cooperate with and provide assistance to him as required.
The Contractor is expected to liaise with the Engineer-in-Charge to program the check survey to
be carried out, if required, during non-production periods or in parallel to construction activities
such that the minimum delay or inconvenience is caused to production work, wherever and
whenever possible. The Contractor shall afford the Engineer-in-Charge every cooperation and
assistance in this regard including but not being limited to the provision of survey equipment,
drainage, lighting, ventilation and the removal of Contractor's equipment and other obstructions
such that they do not interfere with the setting out checks.
" Ceewtce{"cpf"Vqngtcpegu"
(1) Accuracy
Accuracy of survey work shall be within the following tolerances:

Triangulation
Allowable error of closure

5 seconds 10
• Average not to exceed seconds
• Maximum not to exceed
Traversing
Allowable error of closure 1/3,000

Allowable error of distance 1/5,000
Leveling
Allowable error for each 1 km 10 mm

measured forward and backward
Allowable error of closure 10 smm

16
(Where “s” is the total distance of leveling expressed in km.)
(2) Tolerances
The tolerances given below shall be the maximum permissible deviations from the specified
dimensions, levels, alignments, positions, etc. as shown on the drawings of the structures or
structural elements.
In addition, the interfaces with mechanical components, masonry / concrete surfaces shall be
finished flush and shall also meet any additional tolerances required by the mechanical designs or
works, respectively.
Where the tolerances overlap the severer tolerance shall apply.
- Determination of centerline for pipeline etc. shall meet the following criteria.
Plan position of center line  10 mm Elevations
 10 mm
- Slope protection
Benchmarks and subsidiary pillars intended to observe slope movements shall be placed with
tolerances not exceeding ±15 mm.
- Rock bolts and pre-stressed anchors (if any)
Position ±150 mm
Deviation from direction ±5 0
- Foundations and General Structures
Position plan ±20 mm

Direction ±10
Level ±20 mm
- Project Service Roads
Position ±50 mm
Level ±25 mm
Gradual Irregularity 10 mm per 3 m
Drainage
• Open Drains
The maximum permissible deviation of the level of the invert of the open drain including gutters, catch
drain, side ditch, etc. from the designated level shall be ±35 mm and/or nowhere shall the invert have an
adverse grade.
• Subsurface Drains
The maximum permissible deviation of the level of the invert of the subsurface drain including drainage
trench, drainage conduit, drain pipes, etc. from the designated level shall be ±25 mm and/or nowhere shall
the invert have an adverse grade.
" Uwdukfkct{"Rknnctu"cpf"Dgpejoctmu"
The Contractor shall erect and establish all necessary additional survey pillars, fix points,
benchmarks, etc. required for setting out of the works and construction control including
determination of coordinates and elevations.

17
" Jcpfkpi/Qxgt"qh"Dcuke"Uwtxg{"Fcvc"
(1) General Requirements
Prior to the commencement of the survey work the Engineer-in-Charge shall hand over to the
Contractor all information and data of the basic survey grid and benchmarks as available Should it
become necessary that basic datum points and benchmarks be removed because of foreseeable
construction works, the Contractor shall inform the Engineer-in-Charge of the need thereof and
obtain instruction for the establishment of new basic datum points and benchmarks
(2) Data and Documents Available
Existing topographical maps can be made available to the Contractor upon request.
Topo mapping of areas for temporary facilities like the Contractor's camp, constructional buildings,
construction plant, etc., shall be prepared by the Contractor prior to the construction of such
facilities. Equally, survey works for construction roads shall be performed, including map
production.
(3) Survey Records and Documentation
The Contractor shall keep records of all survey activities such as sketches, field- books,
calculations, etc., for the duration of the entire construction period. The Contractor shall upon
request of the Engineer-in-Charge put at his disposal all records and documentation or provide
copies thereof for his convenience.
" Cu"/"Dwknv"Ftcykpiu"
The Contractor shall prepare maps and/or plans in suitable scale of such areas where permanent
structures will be constructed. Such survey work shall be performed prior to commencing any
works. The related maps, plans, profiles, etc., shall serve as basis for quantity calculations.
During construction and/or upon completion of construction works the Contractor shall perform
surveys for the preparation of "As- Built" drawings. This may require the preparation and
production of maps, plans and drawings intended as documentation of construction works
performed, as well as documentation for quantity calculations for invoicing technical details as
to the preparation of "As- Built" drawings shall be subject to the Engineer-in-Charge’s approval.
The survey work shall include, but not be limited to, the following activities:
 all survey work, in particular field work, office work, including preparation of survey
maps/drawings/sketches, investigations, provision of skilled personnel, provision and maintenance
of survey instruments and accessories, supply of all material required for survey and associated
purposes, provision of suitable labour, protection of all survey points, etc.;
 shifting machinery and temporary plant out of the required sightlines;
 stopping all machinery, drilling, blasting, driving and other work causing vibrations, dust, gas, etc.;
 restricting or stopping traffic of persons and vehicles near instruments or in sightlines during
instrument observations;
 providing adequate lighting or cutting off sources of light which interfere with setting out or survey;
 removing all obstructive accumulation of water;
 taking all necessary safety precautions;
 clearing sightlines by removal of bushes and scrub with the prior approval of the Engineer-in-
Charge;
 Compensating land employers for use of land not owned by the Employer.

18
" Rc{ogpv"hqt"Uwtxg{u1ocru"cpf"ftcykpiu"
"
No separate payment will be made to the Contractor for the survey works, all activities and
construction related to survey works, preparation of maps and related drawings, etc. and is
deemed to be included in total price for Section – I, Design and Engineering.
"
UGEVKQP"3"
VGEJPKECN"URGEKHKECVKQPU"HQT"UWTXG["("FGUKIP"
"
"
IGPGTCN"URGEKHKECVKQPU:
a)These Technical specifications, shall apply to all works as are required to be executed under the
contract or otherwise directed by the Engineer-in Charge. In every case the work shall be carried
out to the satisfaction of the Engineer concerned and conform to the location, lines grades and
cross- sections shown on the drawings or as indicated by the Engineer, concerned. The quality of
work and materials, shall comply with the requirements set-forth in this and succeeding sections,
Where the drawings and specifications describe a portion of the work in only general terms, and
not in complete detail, it shall be understood that only the best general practice is to prevail.
Materials and workmanship of the best quality are to be employed and the instructions of the
Engineer concerned are to be fully complied with.
b) The contractor shall carryout the works in accordance with the specifications laid down in
this section together with the detailed specification stipulated under succeeding sections,
Andhra Pradesh Standard specifications, relevant codes with all amendments published
up to the date of tendering and the departmental manual for quality control.
" VGEJPKECN" URGEKHKECVKQPU" QP" UWTXG[." FGVCKNGF" KPXGUVKICVKQP."

FGUKIPU" CPF" FTCYKPIU." GUVKOCVGU." UQKN" GZRNQTCVKQP." N0R0UEJGFWNVGFU."
RKRGYKUG"C[CEWV"TGIKUVGT"GVE0."
"
The list of I.S Codes and other publications applicable to this section is given below:
1 Guidelines for preparation of project estimates for river valley projects – second revised
edition –March 1997 issued by Central Water Commission.
2. I.S 4453 – 1967 Code of practice for exploration by pits, drifts and shafts.
3 I.S 4464 ( Part – III)-1967 code of practice for presentation of drilling information and
core description in foundation investigation.
4 I.S.2132 – 1972 Codes of practice for thin walled tube sampling of soils.
5 I.S 8763-1978 Guidelines for undisturbed sampling of soils

6 I.S.5510-1969 Guide for soil survey for river valley projects.
7 I.S.5497-1983 Guide for topographical surveys for river valley projects.
8 I.S.11385-1987 Code of practice for subsurface exploration for canals and cross drainage
works.
9 I.S.6531-1992 Criteria for design of canal and head regulators.
10 I.S.5968-1987 Guide for planning and lay out of canal system for irrigation.
11 I.S.7112-1973 Criteria for design of cross section for un line canal in alluvial soils.
12 I.S. 7986-1976 Code of practice for canal outlets.
13 I.S.8835-1978 Guidelines for planning and design of surface drain.
14 I.S. 10430 – 1982 Criteria for design of lined canals and guideline for selection of type
of lining
15 I.S.12379-1980 Code of practice for lining water courses and field channels.
16 I.S.4800-1987 Code of practice for design of tunnels conveying water
17 I.S 7784- Code of practice for design of cross drainage works part – 1 General features.
(Part-1)-1975.

19
18 I.S. 7784(part-2/Sec.1) Code of practice for design of cross drainage works part-II
specific 1983 requirement section –1 Aqueducts.
19 I.S.7784(part-2Sec.2-1980 Code of practice for design of cross drainage works part-II
specific requirement section-2 Super passages .
20 I.S.7784(part-2/Sec.3-1981 Code of practice for design of cross drainages works Part-II
Specific requirement Section-3 Canal syphons.
21 I.S 7784(part-2/Sec.4/1980 Code of practice for design of cross drainage works Part-II
Specific requirement section-4 level crossings
22 I.S. 7784 (part-2/Sec.5-1980 Code of practice for design of cross drainage works part-
II Specific requirement section – 5 Syphon aqueducts canal syphons.
The contractor shall follow the following Technical Specifications while carrying out the above
work.
1) Block leveling and preparation of B.C plans with 1.00 M interval contours
(as applicable in each
block).
2) Establishing of Bench marks of 500m intervals all along the major/ as per the drawing
enclosed by conducting D.C.B.M. levels.
3) Identifying the suitable CM&CD works and other structures on pressure main.
4) Conducting site surveys for the structures identified.
5) Design of structures as per I.S.I standards, C.W.C. & C.D.O’s Manuals and as per the
design Practice in vogue with reference to Circulars issued on engineering standards by
the Irrigation Department.
6)Drilling bore holes @100M intervals on pressure main drilling bore holes at structure points
and classifying the soils met with as per the I.S. I. Code.
7) Preparation of earth work estimates for pressure Main and estimates for structures.
8) Preparation of L.P. schedules for the lands to be acquired by fixing the L.A boundary
stones ie., at 100M intervals on either side of pressure main, pump houses , delivery
cistern.
" CFFKVKQPCN"EQPFKVKQPU"CEEQORCP[KPI"VJG"VGPFGT"PQVKEG0"
"
1. The tenderer, shall assume full responsibility of Engineering adequacy, coordination and
timely completion of investigation, designs drawings and detailed estimates including all other
activities with their own modern equipment man power and other services required connected
to the work.
The tenderer shall be fully responsible for designing and estimating of all the connected and
component works of the project. The responsibility of the tenderer shall be.
a) To study in detail all the Engineering and design features.
b) To prepare technical specifications which are necessary for execution of works.
c) The tenderer shall be responsible for furnishing the most technically suitable proposals.
The Contract price quoted shall include the cost of investigation, alternative investigation,
site surveys, designs, alternative designs estimates etc., to arrive at most economically
and technically sound and suitable proposal. No separate payment shall be made for study
of alternatives.
d) The designs and specifications are to be drafted by the tenderer.

20
e) Cost of estimate:
The Tenderer shall submit a complete cost estimate adopting prevailing market rates and
with current rates of prevalent S.S.R. For adopting the market rates, the quotations from the
reputed firms are to be obtained and enclosed for the items not covered by the S.S.R.
f) Preparation of all designs, drawings, estimates ayacut registers and land acquisition
schedules as may be required for complete and correct execution of all works which are
included in the scope of the work for the block, and should conform to I.S.I. specifications.
All the above plans and documents shall be supplied in 5 copies to the Executive Engineer
in- charge of the work for onward submission to the competent authority ie., Chief Engineer,
(P) DWRO, WRD, Kurnool, Chief Engineer, Central Design Organization, Vijayawada,
Superintending Engineer, SRBC Circle No.1, Nandyal for approval. It is obligatory for the
contractor to make any modifications or alternations for designs & Drawings as required by
the Department and also in the proposals without any extra payment.
g)The Department shall not provide the village maps/ and other particulars to Contractor. The
Contractor shall have to procure the connected village maps from central survey office, land
survey and settlement department, Hyderabad at their own cost and S.No. wise particulars
from the V.R.O./ Tahsildar of the respective Revenue Mandal. Necessary authorization
letter recommending for the issue of the above maps will be issued by the Engineer-in-
Charge.
h) Investigation of pressure Main conducting site survey for structures and design of
structures, preparation of estimates of structures, pump houses, delivery cistern
Block command plans with 1.00 M interval contours as applicable to the block. Block
command plans are to be prepared by conducting the following items of work.
Reconnoiter survey of the command area verifying the village plans and topo sheets.
By fixing the bases lines and boundary lines of the area with THEODELITE including chaining or
total station and GPS Software.
Conducting block leveling by taking levels at 100M intervals and duly taking the net levels at closer
intervals viz., 30M,15M,5M etc., wherever the sudden changes of the ground occur such as vagus,
rivers, mounds, ponds, dips etc., to obtain the clear and defined configuration of the same.
Plotting C.S. net levels or block levels on the concerned village plans of 1:8000 Scales and
drawing the controus at 1.00M intervals and marking the block command plans in serial numbers
as per G.S.I toposheets pattern.
Preliminary investigation of pressureMain by study of the following items.
Study of block command plans and marking main ridges and sub-ridges, valleys and sub-
valleys on B.C. Plans.
Reconnoiter survey of field.
Identifying the boundary stones of village area and study of other salient features existing in
the field and marking the same on B.C plans and adjustments of B.C. Plans Incase of
necessity, to suit the ground conditions.
If any variations are there in the contour already plotted in the B.C Plans and to that of ground
conditions by conducting block leveling, when ever necessary as per survey Nos., which also
includes a part of this work and no extra payment will be made. The contract price quoted
should also include cost of the work of preliminary investigation also. The tenderer should
quotes his Contract price keeping in view this aspect also in block leveling.
Marking the alignment of pressure main in the B.C. Plans including alternative alignment.
Transferring the alignment marked on the B.C plan to the ground with the following operations
of work.
(i) Compass Survey.
(ii)Conducting Fly-levels.
(iii)Probing the points.
(iv) Peg marking along the alignment.
(v) Fixing the alignment on ground by transferring the alignment as per B.C.
Plans.

21
Marking the chalks, rivers, mounds anti malarial zones other salient feature of the ground on
B.C. Plans, colouring the B.C. plans in different Colours etc.,
Preparation of detailed report explaining the various alternative, discussing in detail with cost
economics about the most economical alignment.
Discussing about the existing field conditions shall be thoroughly discussed in the report.
Preliminary alignment shall be submitted for approval to the competent authority ie., Chief
Engineer, (P) DWRO, WRD, Kurnool, Chief Engineer, Central Design Organization,
Vijayawada, Superintending Engineer, SRBC Circle No.1, Nandyal with the counter
signature of the Executive Engineer concerned.
Necessary changes or alterations of the alternative alignment are to be done as per the
instructions of Chief Engineer, (P) DWRO, WRD, Kurnool, Chief Engineer, Central Design
Organization, Vijayawada, Superintending Engineer, SRBC Circle No.1, Nandyal without any
extra payment.
On approval of the preliminary alignment by the Superintending Engineer, SRBC Circle No.1,
Nandyal, only further investigation is to be taken up.
" Hkzkpi"qh"D0Ou0"
"
Supplying of B.M. stones of size 900mm x 150MM x150MM/RCC Pre-cast B.M. with M 15 mix
using 20mm metal and including fixing the stones in cement concrete M.7.5Mix.using 40mm
graded H.B. metal of approved quality from the approved quarry ,including cost of all materials and
Labour charges for fixing B.M. stones.
Labour charges for carving the letters and numbers as furnished in the drawing.
The top of the B.M. stone shall be perfectly dressed to level and making grooves of 100MM
x 75 mm size on top, and all other operations to complete the finished item of work as
directed by the Engineer-in-Charge.(The department staff will check the levels at said
points).
Conducting double check leveling to establish the value on B.M. stones fixed, duly
connecting it to a G..T.S Bench Mark.
The tolerance limit of B.M. value is +/-2/K in mm where K is 20 Km from the nearest
G.T.S.B.M
Preparation of B.M. Registers noting the bench mark values and its locations etc.,
Detailed investigation has to be taken up, only after approval of the B.M. Values by the
Executive Engineer.
" Fgvckngf"Uwtxg{<"
"
Detailed survey shall be conducted for fixing the alignment of pressure main, pump house, delivery
cistern and CM & CD Works as follows.
Chaining
Taking L.S levels at 25M intervals.
Cross sections shall be taken @ 25M intervals along the canal alignment and C.S levels on
the C.S at 3M intervals to a which of 50M or more on either side of the alignment for main
canal and 24M or more on either side for branch canal and 12M or more on either side for
Majors, Minors and Sub-minors depending upon the actual requirement.
Fixing of C.L. stones of size 750mm x 150mm as per the drawing enclosed at every 100m
intervals along the alignment and at every tangent points of the curve and @ I.P. points
etc., The C.L. Stones, I.P. Stones and stones at tangent points should be painted with
different colours to each, for clear identification.

22
Painting of the stones with good quality of paints approved by the Engineer-in-Charge with
Chainage including cost and conveyance of C.L. stones, B.M. stones end I.P. Stones paints
etc.,. The departmental staff will check the levels at salient points.
Preparation of H.Ps may be taken up only after approval of alignment by competent

authority ie., Chief Engineer, (P) DWRO, WRD, Kurnool, Chief Engineer, Central Design
Organization, Vijayawada, Superintending Engineer, SRBC Circle, No.1, Nandyal.
" EQPFWEVKPI"UKVG"UWTXG[U"QH"UVTWEVWTGU"QP"RTGUUWTG"OCKP0"
"
Conducting site surveys for all structures ident5ified in H.Ps by taking levels at 5m intervals in
area measuring 100m x 100m block for main canal and branch canals and 50m x 50m for Majors,
Minors and sub-minors where the structure is proposed to the located depending upon the actual
requirement.
Preparation of site survey plan, duly marking contours at 0.30 M intervals.
Taking cross section at the point of crossing and taking L.S at 25m and C.S. at every 100m
intervals along the vagu and road crossing up to a length of ;500m on U/S and D/S sides for
preparation; of site plan, L.S and C.S.S at the crossing and other points.
Classification; of soils as per Borehole/Trail Pits date, preparation; of Borehole/Trail pits

registers, marking classification of soils particulars on plans.
Preparation of Catchment Area Plan for vagu crossing, as per topo sheets or tracing the ridge line
in case the C.A is less than 0.5 sq. Km. Examining the feasibility of diversion of minor streams in
the adjacent major streams limiting the cross masonry works to the bearest minimum.
Suitable provision for inspection paths on the top of canal bank or adjacent to the canal bank or
adjacent to the canal on natural ground level should be made depending on site conditions and
size of canal.
" FGUKIP"QH"UVTWEVWTGU"QP"RTGUUWTG"OCKP"
All the important field features and field levels bases on site survey shall be taken into
account and the designs for structures shall be done as per the
I.S.I. standards/C.D.O. Manual/ C.W.C. Manuals/Standards / Circulars issued by the
department from time to time.
" Ugngevkqp"qh"v{rg"qh"uvtwevwtg0"
1. If drain discharge is more than the canal discharge and canal FSL is below the vagu Bed
level provide super passage. If vagu MFL below the Bed level of the canal Provide an
aqueduct. For in between cases provide under tunnels, duly training the vagu course.
2. R.C.C Barrels for canal discharge and drain discharge Box type may be provided.
10.4 Drawing for the structures
1. The drawing shall be furnished in standard plan sizes as noted below.
(i) Half plan at top and half plan at bottom.

(i) Elevations and sectional end views, with foot notes covering
Specifications and the design parameters.
2 Details of the sections and the details of joints etc with all reinforcement details
Bar-bending schedules etc.,
" Ftknnkpi"qh"Dqtg/Jqngu"1"Vtckn"rkvu"hqt"uvtwevwtgu0"
Classifying the soils and noting the classification of soils T.P./Bore Hole Register.
Bore holes shall also be drilled 10m beyond the maximum scour level, or up to hard strata
whichever is less for all the structures and core-sample of disturbed and un-disturbed soils are to
be lasted in the laboratory to find out the bearing capacity of soils, and the samples are to be
preserved for verification by the Engineer-in-Charge. Minimum 3 Numbers of bores one at center
of crossing, the other two on U/s and D/S of crossing are to be drilled for each structure. Extra
Bores are to be drilled wherever necessary, depending upon the magnitude of the structure log
book of the bores drilled shall be maintained at site during progress of drilling, besides preserving
the core samples in wooden core boxes at site.

23
"""""""""Rtgrctcvkqp"qh"guvkocvgu"
"
"""""""""Gctvj"yqtmu"Gzecxcvkqp0"
"
1. The estimates for excavation of Pressure main, pump houses and delivery cistern are to be prepared
based on classification of soils as per bore hole / Trail pits data.
2. Quantities of different soils may be worked out separately based on the areas computed by preparing
earth work area statements.
3. Necessary leads and lifts are to be calculated for different types of soils.
4. Rate analysis may be worked out as per current S.S.R 2019-20.
5. Abstract estimate may be prepared for the earth work estimates.
6. Report accompanying the estimate as per investigation standards covering all the necessary points
shall be prepared, and all salient features shall be thoroughly discussed in the report.
" Guvkocvgu"hqt"uvtwevwtgu"
"
1. Detailed estimates for the pressure main including all components and CM & CD works as per
approved design and drawing shall be prepared.
2. Quotation for materials for which the rates are not covered in S.S.R may be obtained from the requited agencies
and manufacturing firms.
3. Lead statement for the materials required shall be prepared showing the source of availability, its lead
in KM for M.R. C.T.&S.T. and cost of material at site of work is to be worked out duly considering the
cost of lead and seigniorage charges as applicable.
4. Rates analysis may be prepared as per current S.S.R of 2019-20 and standard date.
5. Quarry map and index maps to be enclosed (Scale 1:600)
6. Abstract estimates is to be prepared.
7. Report accompanying the estimate is to be prepared as per Irrigation standards covering all the
necessary points including all salient features.
" Fgngvgf0"
"
303040435" Fgngvgf0"
"
39032" EJGEMKPI"QH"UWTXG["YQTM"
"
The checking of field survey work, Longitudinal section of pressure main and
establishment of Bench Marks to an extent of about 25% of the total work will be carried out
concurrently or separately by the department during progress of survey. Necessary equipment
and Labour for carrying out such checking by the Department shall be provided by the contractor
/Tenderer.
The rates quoted shall include the cost of the above also and no separate payment will be
made or this checking.

24
"
" UGEVKQP"4"ENGCTKPI"QH"UKVG0"
" "
IGPGTCN<
The data, pertaining to the work furnished in the relevant report and drawings, are for information of
tenders the Govt. of Andhra Pradesh does not guarantee the Reliability or accuracy of any data and
shall assume no responsibilities for any deductions, conclusions or interpretations that may be
made from them. The contractor shall undertake at his expenses such studies as are necessary to
assess the reliability and accuracy of the information presented in the date.
" ENGCTKPI"CPF"ITWDDKPI"
"
a) The portion of the right of way where required for earth work under these specification, shall be
cleared of all trees, bushed, rubbish and other objectionable matter. Trees designated by the
Engineer-in-Charge shall not be cut and shall be protected from injury, such cleared material shall
be disposed, of as provided in paragraph-2.1.4 below or removed from the site of work before the
date of completion of the contract as approved by Engineer-in-Charge. The useful material should
be stacked and handed over to the Department. The clearing operation shall be in accordance
with clause 4.1,4.1.1,4.2 and 4.3 of I.S 4701- 1982 Indian Code of practice for earthwork.
Surface boulders either loose or partly embedded in the ground will have to be removed and
stacked as directed. Al holes and hollows whether originally existing or produced by digging up
roots shall be filled with suitable earth;, well rammed and leveled off the logs/stumps cleared shall
be neatly stacked and handed over to the representative of Engineer-in-Charge as directed at the
places indicated. The pits formed up roots which shall be filled with suitable earth and compacted
and leveled at the cost of contractor.
" ITWDDKPI<"
"
(a) The ground surface under all the embankments and the surface of all excavation is to be
used for embankments as shown in the drawings or as directed by the Engineer-in-Charge
shall be cleared of all stumps, roots and vegetable matter of every kind. The stumps shall be
pulled or otherwise and roots shall be grubbed.
UGEVKQP"/""E" 27"
"
IGQNQIKECN"CPF"EQPUVTWEVKQP"
OCVGTKCN"KPXGUVKICVKQP"
"
" IGPGTCN"
The Contractor shall conduct all necessary geological and construction material investigation as
specified in the various sections of the Technical Specifications of different works with the prior
intimation to the Engineer.
Deleted
" OGCUWTGOGPV"CPF"RC[OGPV"
No work related to any geological and construction material investigations will be measured for the
purpose of payment. There will be no separate payment for the investigations and related auxiliary
services, as the cost thereof is deemed to be included in quoted price
UGEVKQP"⁄"E"28"OCVGTKCNU"
HQT"EQPUVTWEVKQP"
" UEQRG"QH"YQTM"
(i) The specifications described herein under relate to the work which includes all labour, materials,
equipment, transportation and services required to arrange materials for construction of various
works under this Contract.
*kk+" Samples for testing of materials for the mortar / concrete shall be supplied by the Contractor to the
Engineer-in-Charge at the Trial Mix Stage as set out in Ugevkqp"qp"›Eqpetgvg"Yqtmufi0"
" UWDOKVVCNU"
"
"
"
"
25
(i) The Contractor shall specify in his bid and subsequently also, if asked by the Engineer-in-Charge,
the source(s) from which the cement, steel etc. will be obtained. In case the specified source(s) is
not acceptable to the Engineer-in- Charge, the Contractor shall be required to substitute the
source by an acceptable source. Additional suppliers and change of suppliers shall be subject to
the approval of the Engineer-in-Charge.
(ii) At least 52"fc{u"prior to procuring or dispatch of the materials to site, the Contractor shall submit
the following to the Engineer-in-Charge:
(a) Egtvkhkgf"swcnkv{"vguv"tgrqtvu"from manufacturers in respect of cement, steel and other

materials. This will also be necessary whenever the source is changed or when the sub-
standard materials are received on the site.
(b) If the materials are to be arranged from several sources, the estimated quantity to be
procured from each source and the proposed schedule of supply.
(ii) The layout of the stockpiles and the method of drawing aggregates from them shall be submitted
to the Engineer-in-Charge cv" ngcuv" 52" fc{u" rtkqt" vq" the commencement of stockpiling of
aggregates.
(iv) The details relating to the source, method of delivery and storage of water to be used during
construction shall be submitted by the Contractor to the Engineer-in- Charge for approval cv"ngcuv"
52"fc{u"rtkqt"to the commencement of the works.
(v) The Engineer-in-Charge reserves the right to ask for any additional information deemed necessary
to be included in the submitted documents.
" UVCPFCTFU"
(i) The specifications, production, sampling, testing and storage of constructional materials
shall conform to the following latest Indian Standards or where not covered by these
Standards, to the equivalent International Standards :
(a) Aggregates and Water
KU<678/4222"(Code of Practice for Plain & Reinforced Concrete)
KU<5:5/4222"(Specification for Coarse and Fine Aggregates for Natural Surface for
Concrete)
KU<4338/3;;4"*Ucpf"hqt"ocuqpt{"oqtvct+"
KU<45:8"*Rctv/KX+/3;85"*Tgchhktogf"3;;2+"(Method of Tests for Aggregate for Concrete)
KU<738/3;7;"*Tgchhktogf"3;;3+"(Method of Tests for Strength of Concrete)
(b) Cement
KU<48;/3;:;"(Specification for 33 Grade Ordinary Portland Cement) KU<36:;/3;;3"
(Specification for Portland Pozzolona Cement) KU<:334/3;:;"(Specification for 43
Grade Ordinary Portland Cement)
KU<3448;/3;:9" (Specification for 53 Grade Ordinary Portland Cement) KU<34552/
3;::" (Specification for Sulphate Resisting Portland Cement) KU<677/3;:;"
(Specification for Portland Slag Cement)
(c) Steel for Reinforcement
KU<654"*Rctv/K+/3;:4"*Tgchhktogf"3;;7+"(Mild Steel and Medium Tensile Steel Bar)
KU<39:8/3;:7" *Tgchhktogf" 3;;2+" (Specification for High Strength Deformed Steel Bars
and Wires for Concrete Reinforcement)
(d) Structural Steel
KU<4284/3;;4"(steel for General structural purposes)
KU<:2:/3;:;"(Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle
Sections)
KU<:722/3;;3"( Structural Steel Medium and High Strength Qualities) KU<:22/3;:6"
*Tgchhktogf"3;;3+"(Code of Practice for General Construction in Steel)
(e) Steel for fabrication of Pipes
KU<84:8/3;93" *Tgchhktogf" 3;::+" (Seamless and Welded Steel Pipes for Sub-zero
Temperature Service)
KU<57:;/3;;3"(Electrically Welded Steel Pipes for Water, Gas and Sewage) KU<3758/3;:;"
*Tgchhktogf" 3;;5+" (Centrifugally Cast (Spun) Iron Pressure Pipes for Water, Gas and
Sewage)
KU<8853/3;94"*Tgchhktogf"3;::+"(Steel Pipes for Hydraulic Purposes)
(f) Welding Electrodes

26
KU<:36/3;;3"(Covered Electrodes for Metal Arc Welding of Structural Steels)
KU<:38/3;8;"*Tgchhktogf"3;;4+"(Code of Practice for Use of Metal Arc Welding for
General Construction in Mild Steel)
(ii) In case of conflict between the above Standards and the Specifications given herein, the
Specifications shall take precedence.
" DTKEMU"
" Igpgtcn"
Bricks shall be hand moulded or machine moulded. They shall be free from nodules of free time,
visible cracks, flaws warpage and organic matter, have a frog 100mm in length 400mm in width
and 10mm to 20mm deep on one side of its flat sides. Each brick shall be marked in the frog with
the manufacturer’s identification mark. The bricks shall have smooth rectangular faces with sharp
corner and shall be uniform in colour and emit clear ringing sound when struck. Bricks shall have
nominal size of: 200mm x 100mm x 100mm ; and shall be of class designation 10 with average
compressive strength of 10N/mm2.
" Ucornkpi"cpf"Vguvu"
Sample bricks shall be subject to the following tests:
(i) Dimension tolerance
(ii) Water absorption.
(iii) Efflorescence.
(iv) Coessive strength
8060403" Ucornkpi"
For carrying out compressive strength, water absorption, efflorescence and dimensional tests, the
samples of bricks shall be taken at random. The sample thus taken shall be stored in a dry place
until tests are made. Sampling shall be done as per CPWD norms.
" TQWIJ"UVQPG"HQT"TKXGVOGPV"CPF"DGF"RKVEJKPI"
Stone shall be used from the surplus useful excavated rubble or from the approved
quarries if required, and shall be subject to thorough inspection and approval by the Engineer. The bed
pitching material shall consist of the most durable rock fragments of approved quality selected for the
purpose. The stone shall be sound, hard, dense, resistant to abrasion, durable, and free from
segregation. Seams, cracks, shale partings weathered portions, conglomerate bands and other
structural defects or imperfections tending to affect their soundness and strength are to be discorded.
Stone shall generally be freshly quarried with sharp edges and clean faces. They shall be free from
rounded, worn or weathered surfaces on skin or coating. Stone subject to marked deterioration by
water or weather shall not be used. The shape of the individual stones shall be angular. Stones when
immersed in water for 24 hours shall not absorb water by more than 5% of their weight when tested as
per IS : 1125or its latest edition.
" UK\G"QH"UVQPG"
The size of the stone to be used for various thickness of revetments shall be as follows:- The
size of stone shall be as large as possible. In no case any fragment shall weight less than 40kg. The
specific gravity of stones shall be as high as possible and it shall not be less than 2.50.
Unless otherwise specified, for revetments upto 450mm thickness, the length of the stone shall
be equal to the revetment thickness. For revetment over 450mm thick at least 50% to the stones
shall be 45Omm long. No stone shall have any dimension less than 150mm or less than 50% of the
maximum dimension of the stone.
The minimum volume to the individual stones used for various thickness of revetments shall be as
follows:
Thickness of revetment Volume of stones
225mm 0.015Cum
300m 0.015Cum
450mm 0.303Cum
600mm 0.045Cum
" "
"
27
" UVCEMKPI"
Stacking shall be done as detailed below at the locations specified or ordered by the Engineer
i) Stacks shall be formed to regular shape and uniform cross sections.
ii) Materials shall be stacked on even ground. Stacking shall not be done in flood zones or in water
logged areas.
iii) Rough stone shall be packed so closely as to give minimum quantity of voids possible without
actual dressing of stone to fill interstices. In case of improper stacking done by the contractor,
the Engineer shall have the right to either reject the stacks partly or completely.
iv) Unless otherwise specified, templates shall be provided to the size and dimension of the stack
as may be specified at the contractor’s expense.
" CIITGICVGU"
"
" Igpgtcn"
"
(i) Use of aggregates (coarse and fine) containing excessive amount of zeolites, secondary minerals
and such other components which cause alkali reactivity of the aggregates and consequent
reduction in durability of the concrete is prohibited. The Engineer-in-Charge may, however, allow
the use of such material either in part or in full keeping in view the extent of reactivity, the location,
the nature of exposure and the structure. If the Engineer-in-Charge considers necessary, he may
carry out mineralogical tests to ascertain the lack of harmful minerals in the stones.
(ii) The Contractor shall make his own arrangements for aggregate crushing plants etc. for crushing of
aggregates from stones extracted from approved quarries or other works.
(ii) The quality of all aggregates used in the works, as also processing such as washing, classifying,
screening, re-screening, crushing and blending necessary to meet the required specifications shall
be subject to the approval of the Engineer- in-Charge.
(iv) The aggregates shall be supplied only from the sources/quarries approved by the Engineer-in-
Charge. The Contractor shall supply necessary quantities of aggregates to carry out the desired
tests by the Engineer-in-Charge.
(v) The aggregates shall be sampled and tested by the Engineer-in-Charge in accordance with the
Indian Standards referred above.
(vi) The tests shall be made on samples that are representative of the grading that will be used in
concrete and the aggregates shall be processed by the equipment proposed for the works.
(vii) The Contractor shall at all times have access to and associate with sampling and testing of
aggregates and shall be entitled to discuss with the Engineer-in-Charge, the results and proposals
for grading of aggregates.
(vii) Stored Fine sand shall be stacked and maintained in such a manner as to avoid the inclusion of
any foreign materials in the concrete, and such that no equipment will be operated on the storage
piles. The storage piles shall be constructed so as to prevent contamination. The Contractor shall
remove the excess moisture in the fine sand by adequate means.
(ix) Coarse aggregate storage piles shall be built and maintained in such a manner as to avoid the
inclusion of any foreign material in the concrete and to prevent segregation and excessive
breakage. No equipment shall be operated on storage piles. Rock ladders of satisfactory design
shall be used with conveyor systems for stockpiling aggregate larger than 40 mm in size.
*z+" Sand and aggregate storage piles shall be located close to the mixing plant and shall always
contain at least a tgugtxg"hqt"qpg"oqpvj"
"
"
"
" Eqctug"Ciitgicvgu"
"
28
(i) The term coarse aggregates applies to pieces of natural or crushed rock ranging in size from 4.75
mm to 150 mm.
(ii) The aggregates shall be composed of clean, hard, strong, durable pieces of stone, angular or
rounded in shape obtained naturally or by crushing from suitable stones approved by the
Engineer-in-Charge. Coarse aggregates shall not contain more than 15% elongated or flat
particles. An elongated particle is defined as a particle having a maximum length of more than 5
times its maximum width. A flat particle is defined as a particle in which its maximum width or
length is more than 5 times its maximum thickness.
(iii) Coarse aggregates delivered to the batching plant shall have a uniform and stable moisture
content.
(iv) The coarse aggregates shall be free from objectionable materials such as wood or other
deleterious substances, the percentage of which in any size of coarse aggregate shall conform
to the relevant standards except that the coarse aggregate shall contain not more than 0.30
percent by weight of deleterious (reactive) iron sulphides. The sum of the percentage of all
deleterious substances in any size shall not exceed 3 percentage by weight. Coarse aggregates
having a specific gravity (saturated surface-dry basis) less than 2.60 shall be rejected.
(v) The aggregates shall be resistant to deleterious, chemical or physical changes such as cracking,
swelling, softening, leaching or chemical alterations after its incorporation in concrete.
(vi) For concrete exposed to the flowing water at high velocities, the coarse aggregates having high
abrasion resistance shall be used.
(vii) When subject to soundness test with a solution of Sodium Sulphate coarse aggregates shall not
suffer more than 12 percent loss of weight after five cycles.
(viii) The aggregates shall be crushed in approved type of stone crushers and different sizes of the
coarse aggregate shall be separated into nominal sizes by screening over vibrating screens as
under :
Fgukipcvkqp"qh"Uk|g"Pqokpcn"uk|g"tcpig"
"
20 mm aggregate 4.75 mm to 20 mm
40 mm aggregate 20 mm to 40 mm
(ix) The grain-size distribution of the coarse aggregate for the various maximum sizes of aggregates
shall be as set out in the relevant standards.
(x) These may be altered by the Engineer-in-Charge from time to time, if necessary, on the basis of
actual tests carried out regularly in the laboratory so as to get the best possible coarse aggregate
grading.
(xi) The percentage of weight of all the significant under-sizes shall be less than 5 percent when
tested on the designated test screens having opening 5/6 times the normal minimum size of the
material. No over size (i.e. material that would be retained on the designated test screens having
opening 6/7 times the normal sizes of the material) shall be permitted.
80705"Hkpg"Ciitgicvgu"*Ucpf+
"
*k+" Igpgtcn"
"
(a) Sand or fine aggregates shall be used for mortar in stone masonry and as fine aggregates in
concrete work. It shall be either natural river sand or manufactured sand crushed from rock/stones
or mixture of both in specified proportions. The sand shall be composed of hard, clean and gritty
pieces of stone and of a quality approved by the Engineer-in-Charge. It shall be free from injurious
amount of clay, soft and flaky particles, vegetable or organic matter, loam, mica and other
deleterious substances and shall not contain any salts.
(b) The fine aggregates shall conform to the requirements of IS:383-1970 (Reaffirmed 1990). Varying
amount of moisture in fine aggregates contributes to lack of uniformity in concrete consistency.
29
The fine aggregates shall therefore have uniform and stable moisture contents. Dry sand shall be
preferred. Hence sand stockpiles shall be protected from rainfall.
(c) The percentage of deleterious substances in the fine aggregates shall conform to relevant
standards except that the fine aggregates shall contain not more than
0.10 percent by weight of deleterious (reactive) ferrous sulphides. The total
percentage of deleterious substances must not exceed 5 percent of the weight.
(d) Fine aggregate having a specific gravity of less than 2.60 are liable to be rejected. Fine
aggregates when subjected to a soundness test with a solution of sodium sulphate, after 5 cycles
of tests, shall not suffer a loss of weight in excess of 10 percent.
(e) The sand shall be well graded and, when tested by standard sieves, shall conform to the
prescribed limits of gradation. The best gradation shall be determined after experiments and tests
and the Contractor shall follow the same on approval of the Engineer-in-charge.
(f) The sand, as delivered to the batching plant shall have a fineness modulus of 2.6 to 3. The
grading of fine aggregates shall be so controlled that the fineness moduli of at least 9 out of 10
samples of fine aggregates delivered to the batching plant shall not vary more than 0.20 from the
average of 10 samples tested. All classifying, batching or other operations on the fine aggregates
shall be done by the Contractor.
*kk+" Pcvwtcn"Ucpf"
(a) Natural sand shall be obtained from an approved source. No sand affected by salty water shall be
used. The sand shall be screened and thoroughly washed, preferably in flowing water so as to
remove all earthy impurities and very small fines unless otherwise permitted by the Engineer-in-
Charge.
(b) Natural sand shall be free from softer grains and all sources of sand showing appreciable
percentage of these impurities shall be rejected.
(c) The presence of mica in the fine aggregate has been found to reduce considerably the
compressive strength of concrete. It is advisable, therefore, to investigate the mica content of the
fine aggregates and make suitable allowances for possible reduction in strength of concrete or
mortar. The decision of the Engineer-in-Charge whether to use such sand and if so, what
allowances to be made, shall be final and binding on the Contractor.
(d) The contents of the organic matter shall conform to relevant standards.
*kkk+" Ocpwhcevwtgf"Ucpf"
"
(a) Whenever natural sand conforming to the required specifications is not available, recourse shall
be taken to manufactured sand of desired quality by crushing of stones. The Contractor shall
comply with the directions of the Engineer-in-Charge in this regard. The stone that will be used in
crushing for getting fine aggregates shall conform in all respects to the stone/coarse aggregates
specified above.
(b) In case the natural sand or the manufactured/crushed sand is not considered to be as per
specifications, the same may be rejected outright by the Engineer-in- Charge or the sand may be
allowed after processing, provided the sand conforms to the requirements after such treatment.
(c) For improving workability of pumpable concrete mixes, the Contractor may consider a combination
of natural and manufactured sands. Proposed proportion shall be submitted for approval of the
Engineer-in-Charge.
80806"Uvqtcig"qh"Ciitgicvgu"
"
30
(i) The Contractor shall, at all times, maintain storage of all grades of aggregates for atleast one
month requirement.
(ii) Adequate drainage of stockpiles shall be provided.
(iii) The stockpiling of the processed aggregate and drawl therefrom shall be such as to ensure that
the variation in the free moisture in the aggregate, during any one shift of working, does not
exceed 1 percent.
(iv) The coarse aggregate shall, as far as possible, be stored in shade or covered storage and
arrangement made for sprinkling of water to ensure wetting of the aggregates.
(v) Care shall be taken in screening and stocking of the coarse aggregates so as to avoid intermixture
of different gouge materials and inclusion of any foreign materials.
(vi) The stockpile shall be built up in horizontal or gently sloping layers.
(vii) Trucks and bulldozers shall be kept off the piles to prevent breakage and impairing the cleanliness
of aggregate.
(viii) A hard base shall be provided to prevent contamination from underlying materials in storage areas
in continuous use.
(ix) Overlap of different sizes of materials shall be prevented with suitable walls or by ample distance
between storage piles.
(x) Arrangements shall be made to store natural and manufactured sand in a way that shall protect it
from being contaminated with dust, organic matter or other deleterious substances.
"
" YCVGT"
"
(i) A reliable water supply for construction purposes shall be installed and maintained by the
Contractor.
(ii) Adequate water storage facilities shall be provided by the Contractor at the batching and mixing
plant and other work sites so that various operations of works do not suffer due to temporary
breakdown in the main supply system.
(iii) The Contractor shall supply water samples from the intended sources to the Engineer-in-Charge
for testing and approval.
(iv) The Engineer-in-Charge shall establish the suitability of water to be used for construction
purposes.
(v) Water for washing of aggregates, mixing mortar, concrete or grout and/or other construction
activities shall be clean and free from earth, vegetable or organic matter, injurious amount of oils,
acids, sugar, salt and alkaline substances in solution or in suspension and shall conform to
relevant standards. The maximum allowable contents of sulphates (SO4) shall be 250 parts per
million (ppm) and those of chlorides (Cl) shall be 2000 mg per liter for plain concrete / mortar
works and 1000 mg per liter for reinforced concrete works. Turbidity shall be within 2000 ppm (or
0.2 percent by weight) and preferably as low as possible.
(vi) Water used for curing shall be clean and free from contamination and from excess amounts of
acids or alkalis or other matter combining chemically with and thus disfiguring the concrete /
masonry surface. Water shall not contain organic matter causing stink.
(vii) Average 28 days compressive strength of at least three 15 cm concrete cubes prepared with water
proposed to be used shall not be less than 90 percent of the average of strength of three similar
concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested in
accordance with the requirements set out in Section on Concrete Works.
(viii) The Contractor shall bring to the notice of the Engineer-in-charge, of the occurrence of hot water
found in existence during excavation. He shall supply samples of such water to the Engineer-in-
Charge for testing. Suitable measures shall be taken in case such testing reveals deleterious
effect on concrete.
" "
" "
" EGOGPV"
"
31
" Igpgtcn"
"
(i) The Contractor shall procure the cement of the specified quality from the cement sources/plants
approved by Employer/Employer. For this purpose Employer/Employer will approve at least two
sources/plants out of those intimated by the Contractor so that one is a standby for taking care of
any eventualities.
(ii) Cement to be used for various works shall be of different types such as Ordinary Portland Cement
or Portland Puzzolana Cement or Portland Slag Cement as approved by the Engineer-in-Charge
and shall conform to the relevant Standards at the time of its use.
(iii) The Contractor shall deliver with each supply of 1000 tonnes of cement a certificate from the
manufactures/suppliers by which the cement is guaranteed to comply with the requirement of the
specifications. The Employer/Employer shall have the right to check or test the cement at any
stage of its manufacture or delivery and the Employer/Employer’s test reports shall supersede the
test report given in the manufacturer’s certificate.
"
(iv) Aggregate which has alkaline reactive tendency shall be avoided for use in concrete. In case, such
aggregate has to be used, prior approval of the Engineer- in-Charge shall be obtained. In that
case, the cement with alkali contents (i.e. Na2O and K2O expressed in equivalent weight of
Na2O) not exceeding 0.6 percent by weight of cement shall be used.
(v) The cement will be sampled and tested by the Engineer-in-Charge for strength and physical
properties and chemical analysis will be carried out as set out in relevant standards.
(vi) The cement samples for testing at the source/plant shall be obtained by the Contractor as the bins
are being filled. Tests for false set shall be made on samples taken at the latest time prior to
shipment.
(vii) Ordinary port land cement conforming to latest revision of IS shall be procured from the reputed
manufacturers only and will be accompanied by test certificate of manufacturers. Quality shall be
checked regularly and Employer reserve the right to reject/approve cement quality after getting the
same tested in approved Government Laboratories.
" Vtcpurqtvcvkqp"
"
(i) Cement shall be delivered on site in bulk/bags in bulk containers/trucks approved by the Engineer-
in-Charge.
(ii) All bulk containers/carriers shall be clean and dry prior to filling/loading with cement and equipped
with weather proof closures on all openings
" Uvqtcig"
"
(i) Sufficient storage facilities shall be provided at the batching plant to enable each new shipment of
cement to be stored separately from the cement stored from earlier shipments.
(ii) Cement shall be stored above ground, adequately protected against rain, sun and moisture. Bulk
storage bins and silos shall be emptied completely and cleaned of all cement accumulation chvgt"
gxgt{"5"oqpvju.
(iii) Arrangements shall be made such that stock of approved cement are adequate to meet the
programme of work at all times. The programme shall allow time for testing and approval of each
shipment before such cement is incorporated in the works.

32
(iv) Cement shall be used in the order in which it is received on site. Cement of different brands, if
received on site, shall not be combined in the same mix and structure. Such cement shall be used
in different structures as approved by the Engineer-in-Charge.
(v) Handling and storage facilities shall be such that no cement is stored before use for oqtg"vjcp"
342" fc{u0" Should any cement be unavoidably kept in storage longer than 120 days, it shall be
tested and if found defective, shall condemned for use on the project.
" UVGGN"HQT"TGKPHQTEGOGPV"
"
" Igpgtcn"
"
(i) The Contractor shall procure the steel reinforcement of the specified quality from vjg"
uqwtegu1rncpvu"crrtqxgf"d{"vjg"Gornq{gt1Gornq{gt. Sources of steel shall preferably be SAIL
and TISCO.
(ii) Steel reinforcement shall conform to relevant Indian Standards or equivalent.
(iii) Steel shall be free from loose mill scale, rust, oil, grease, dirt, paint or other deleterious matter,
when examined immediately before concrete is being placed.
(iv) Wire for tying reinforcement steel shall be black annealed iron wire or acceptable equivalent with a
suitable diameter and shall have an ultimate strength of 5.68 tonne/sq.cm. and yield strength of
not less than 8.8 tonne/sq.cm.
" Vtcpurqtvcvkqp"cpf"Uvqtcig"
"
(i) Transportation shall be undertaken in such a manner that no damage is done to the steel.
(ii) Reinforcement steel shall be stored off the ground in separate groups according to size and
length. Reinforcement steel, which has been cut and bent according to the schedules approved
by the Engineer-in-Charge, shall be marked with bar number, as shown in the schedule, by
using same form of weather proof tag or by placing marked bins, and shall be stored in such a
manner as to be readily accessible when required and to facilitate inspection.
" UVTWEVWTCN"UVGGN"
"
" Igpgtcn"
"
(i) The Contractor shall procure structural steel of the specified quality from vjg" uqwtegu1rncpvu"
crrtqxgf"d{"vjg"Gornq{gt1Gornq{gt. Sources of steel shall be limited to SAIL and TISCO.
(ii) All structural steel shall be of new/unused stock, clean and straight, free from rust or scale and
without any sharp kinks, bends or other objectionable defects.
(iii) All structural steel including steel plates, shall conform to relevant standards.
(iv) The material used in splices shall conform to the specifications of the material being spliced.
" Vtcpurqtvcvkqp"cpf"Uvqtcig"
"
Structural steel shall be transported, handled and stored in such a manner that no damage is done
to the material or the structure.

33
UGEVKQP"⁄"E"29"
GZECXCVKQP"YQTMU"
" UEQRG"QH"YQTM"
"
(i) The specifications described hereunder, relate to the work of excavation and shall include all
labour, tools, construction plant and services, necessary to carry out the excavation of different
materials, transportation and stockpiling / disposal of all excavated materials into stockpiles /
dumping areas as approved by the Engineer-in-Charge.
(ii) Excavation shall be made to the lines, grades and dimensions shown on the drawings approved
for construction or as otherwise agreed with the Engineer-in- Charge.
(ii) The Contractor shall maintain the excavated slopes, drainage and trenches and prepare
foundations as shown on the drawings or as agreed with the Engineer-in- Charge.
(iv) The area of open excavation shall, where, in the opinion of the Engineer-in- Charge clearing is
necessary, be cleared of all trees, bushes, rubbish and other objectionable matter and the
materials, so removed, shall be disposed off suitably or as directed by the Engineer-in-Charge.
(v) When additional excavation outside the lines and grades shown on the drawings is required by the
Contractor for his own convenience, such additional excavation shall be required to be backfilled
with acceptable material and compacted by the Contractor in a manner satisfactory to the
Engineer-in-Charge. The Contractor shall submit his plans for such proposed work in writing for
Engineer-in-Charge’s acceptance prior to the commencement of the work.
(vi) The removal of mud and slush resulting from heavy rains or flooding of the sites, when necessary
to ensure the safe and effective performance of the work, shall be performed by the Contractor.
(vii) At all times during construction, the Contractor shall adopt excavation procedures such that at no
time shall the stability of any slope be impaired.
(vii) The approval given by the Engineer-in-Charge to the Contractor’s methods and equipment shall
not relieve the Contractor of his full responsibility for a proper and safe execution of excavations,
or of liability for injuries to, or death of person(s), or any obligations under this Contract.
(ix) The Contractor shall comply with all safety procedures and requirements as stipulated in this
document.
" UWDOKVVCNU"
"
(i) At least 52" fc{u" rtkqt" to the commencement of excavation, the Contractor shall submit his
programme of excavation with details of his excavating methods and sequences for all open
excavation works including the equipment.
(ii) For rock excavation, the description of drilling and blasting procedures shall include the following:
(a) Diameter, spacing, depth, pattern and orientation of blast holes.

(b) Type, strength, amount and distribution of explosives to be used per hole.
(c) Description and purpose of any special method to be adopted by the Contractor.
(d) Sequence of various activities of the excavation work with an indication of corresponding time
requirements.
(iii) At least 52"fc{u"rtkqt"to dumping or stockpiling of any material, the Contractor shall submit the
layout of the spoil and stockpile areas, which shall be within the identified areas. All pertinent data
of working methods and provisions for the security, stability and temporary and permanent
drainage of the areas shall be included along with details of volumes, material types, heights and
grades provided.

SRBC CIRCLE NO.1,NANDYAL
34
(iv) To enable the Engineer-in-Charge to verify all necessary setting out and elevations carried out by
the Contractor, the later shall notify the Engineer-in- Charge in writing, giving cv" ngcuv" 9" fc{u"
pqvkeg"of his intentions to start excavation.
(v) The Engineer-in-Charge reserves the right to ask for any additional information deemed necessary
" UGVVKPI"QWV"
(i) The Contractor shall establish, at suitable points, to the satisfaction of the Engineer-in-Charge,
permanent reference marks on the centerlines, as may be necessary and directed. The permanent
marks shall be inscribed on bronze pegs, set in concrete blocks where they will be free from any
likelihood of the disturbance. Suitable number of benchmarks with corresponding co-ordinates
shall be established with reference to SOI benchmark and grid within the project area. The
reference drawing indicating all benchmarks vis-à-vis project components shall be prepared and
submitted to the Engineer-in-Charge for approval.
(ii) As the work progresses, centre line marks shall be made on pegs, inserted at the convenient
intervals to the satisfaction of the Engineer-in-Charge, for checking alignment, grades, levels etc.
The Contractor shall at all times, remain responsible for the sufficiency and accuracy of all such
benchmarks and reference points.
" CEEWTCE["QH"CNKIPOGPV."ITCFGU"CPF"NGXGNU"GVE0"
"
(i) Bench marks and fixed reference points with the value of the levels and the coordinates, will be
fixed by the Engineer-in-Charge in the work areas. The plans showing the position, co-ordinates
and the levels of the salient points as available will be supplied to the Contractor. The Contractor
shall fix his permanent points and benchmarks in relation to these.
(ii) The Contractor shall take all precautions to ensure that the points fixed by the Engineer-in-Charge
are not disturbed by his work and shall make good the damage, if any.
(iii) The Contractor shall provide all facilities like labour, instruments, etc. and all cooperation to the
Engineer-in-Charge to check the alignments, grades, levels etc. whenever and every time they are
asked for.
(iv) Any discrepancy or error detected during the course of excavations and / or at the end of work
shall be set right by the Contractor, in the manner satisfactory to the Engineer-in-Charge.
" ENCUUKHKECVKQP"QH"GZECXCVKQP"
"
All materials to be excavated shall be classified by the Engineer-in-Charge in the presence of the
Contractor into one of the following items for the purpose of measurement and progressive
payments.
" Eqooqp"Gzecxcvkqp"
"
The common excavation shall include:
" Qxgtdwtfgp"
Overburden excavation shall include all types of soil / hard moorum, which can be excavated
manually by ordinary pick and shovel or barring and wedging or by mechanical equipment such as
tractor blade, ripper, power shovel and dragline but without recourse to blasting
" Uqhv"Tqem"
"
Soft rock (dry or moist) and such other material, which can be excavated manually by ordinary pick
and shovel or barring and wedging or by mechanical equipment such as tractor blade, ripper,
power shovel and dragline but without recourse to blasting. It shall also include embedded
boulders not bigger than one metre in any one direction.
" "
35
" "
" Jctf"Tqem"
"
(i) Hard rocks shall include all rock which cannot be excavated without prior blasting to loosen the
same.
(ii) The hard rock shall also include boulders and detached rock blocks larger than one metre in any
one direction. It shall also include the removal of softer materials lying between layers of hard
rock.
" TGOQXKPI"DNWHHU"CPF"NQQUG"TQEMU"
"
All loose boulders, semi-detached rocks (alongwith the earthy stuff which might move therewith)
not directly in excavation but so close to the area to be excavated, as to be liable in the opinion of
the Engineer-in-Charge, to fall or otherwise endanger the workmen, equipment or the work, shall
be stripped and removed from the area of excavation. The methods used shall be such as not to
shatter or render unstable or unsafe any rock that was originally sound and safe. Any material not
requiring removal as contemplated in the work but which, in the opinion of the Engineer-in-Charge,
is likely to become loosened or unstable later on shall also be promptly and satisfactorily removed,
as directed by the Engineer- in-Charge.
" GZECXCVKQP"KP"QRGP"EWVU"
"
(i) The side slopes in excavation shall be maintained as per the approved drawings or as directed by
the Engineer-in-Charge.
(ii) Any changes in the slopes as shown on the construction drawings on account of site conditions
will be subject to the approval of the Engineer-in-Charge.
(iii) Every precaution shall be taken to prevent slips. In case slips occur, the slipped material shall be
removed to the designed/modified slope.
(iv) Suitable berms shall be left at appropriate places with necessary approach ramps and sump pits
for installation of dewatering pumps or other purpose, as required by the Engineer-in-Charge.
These shall be excavated and the excavation finished to lines and grades shown on the drawings
and to the satisfaction of the Engineer-in-Charge.
(v) In case of loose excavation, where the surface is left as excavated or is to be covered by pitching,
formation of rain cuts and gullies shall be avoided by proper drainages. Any gullies formed shall be
made good by properly packing excavated rock spoil in them. All holes left by removing boulders
shall also be filled in with rock spoil.
(vi) Where plain surfaces are required, such faces of excavation shall be formed in such a manner that
would least shatter the rock mass. Only light blasting or ream holes or similar methods shall be
allowed in areas adjacent to such faces.
(vii) In special locations (only in rock) where specifically indicated or ordered by the Engineer-in-
Charge, the use of explosives shall be discontinued and excavation completed by line drilling,
broaching, wedging or barring or other suitable methods approved by the Engineer-in-Charge.
(viii) All excavation done beyond the lines and dimensions shown on the drawings, which are to be
covered by concrete shall be filled back with the concrete of the same quality or as directed by the
Engineer-in-Charge.
(ix) Blasting within 30 m of masonry / concrete or grouted area will be permitted only after masonry,
concrete or grout is 7 days old and only after the submission by the Contractor and approval by
the Engineer-in-Charge of a plan showing the relative positions of structures or grouted areas and
the areas to be blasted, Contractor’s proposed drilling and blasting plan together with an outline of
precautions to be taken.
(x) The open cut excavation shall be staged as shown on the construction drawings or as directed by
the Engineer-in-Charge.The Contractor shall carry out the excavation of open cut rock slopes
utilising the controlled perimeter blasting technique wherever required by the Engineer-in- Charge.

36
(xi) Where depth of open rock excavation is more than 10 m, the excavation shall be carried out in a
descending way, from horizontal berms by benching.
(xii) Immediately after excavation and scaling to the satisfaction of Engineer-in-Charge and prior to the
excavation of next bench, the Contractor shall install rock bolts, provide wiremesh, shotcrete and
temporary relief holes, if considered necessary, as shown on the approved drawings or as directed
by the Engineer-in-Charge.
(xiii) All blasted rock shall be removed from the bench toe before undertaking further excavation/work.
(xiv) All other specifications pertaining to blasting and scaling etc. relevant to open excavation as
stipulated in the Ugevkqp"qp"›Gzrnqukxgu"cpf"Dncuvkpifi"shall be referred.
" GZECXCVKQP"HQT"HQWPFCVKQPU"QH"UVTWEVWTG"
" "
(i) While carrying out excavation for the foundations of the structure, if it is considered necessary for
a particular work the sides of the loose excavation shall be shored and strutted to the satisfaction
of the Engineer-in-Charge.
(ii) After completion of the loose excavation the rock excavation in foundations of the structures shall
be carried out to the depths as shown on the drawings. At all stages of excavation, precautions
shall be taken to preserve the rock below and beyond the lines of required excavation. The
quantity and strength of explosives used in the foundation excavation in rock in various locations
shall be such as will neither damage nor crack the rock outside the limits of excavations.
(ii) As the excavation approaches its final lines and is within 300 mm to 600 mm of the specified
foundation levels, the depth of the holes and the strength and quantity of explosives shall be
progressively and suitably reduced so as to ensure that the rock profile beyond the lines and
levels specified on the drawings shall remain undisturbed. If so directed by the Engineer-in-
Charge, this excavation shall be carried out by the line drilling.
(iv) All excavations done beyond the lines and the dimensions shown on the drawings issued shall be
back filled with concrete of the same quality as that for the foundation or as directed by the
Engineer-in-Charge.
" GZECXCVKQP"ENGCPWR"CPF"RTGRCTCVKQP"QH"HQWPFCVKQPU"
(i) After completion of excavation of foundations, trimming for the final removal of all dummy rock or
loosened mass shall be done by chiseling, barring and wedging and as directed by the Engineer-
in-Charge.
(ii) Any weathered or decomposed rock remaining shall be removed. Open fissures, joints, crevices
and other doubtful areas shall be cleaned to a suitable depth and upto firm rock on sides.
(iii) All rock surfaces of excavation shall be washed fully as per directions of the Engineer-in charge.
This washing shall be carried out initially for inspections when required by the Engineer-in-Charge.
(iv) Final washing of any section of the work prior to concreting or application of shotcrete shall be
carried out only when the blasting for the excavation and removal of projections inside the neat
lines have been completed.
(v) Final washing prior to concreting shall be done by directing a stream of water at a pressure of
about 8 to 10 bars on the rock surfaces from a distance of 1.5 metre through a nozzle of 18 mm
diameter so as to remove all loose rock, fragments, dust and debris from the surfaces.
" FKURQUCN"QH"GZECXCVGF"OCVGTKCNU"
"
(i) The excavated materials suitable for construction shall be stockpiled in areas where permanent
works are not located.

37
(ii) Excavated materials which are not suitable for construction and those in excess of the
requirement for construction shall be disposed off in the waste disposal areas as proposed by the
Contractor and subsequently approved by the Engineer-in-Charge. Surfaces of material so
disposed off shall be trimmed to regular lines and grades satisfactory to the Engineer-in-Charge.
Disposal of all materials shall be such that it will not interfere with natural drainage and is as per
the regulations for environmental protection; drains will be constructed to prevent the undesirable
accumulation of water in or around the disposal area. If additional areas are required, the
Contractor shall propose such areas for approval of the Engineer-in-Charge.
(iii) The Contractor shall ensure that no excavated materials are disposed off in the streams or at
locations, where in the opinion of the Engineer-in-Charge, these are liable to be washed away by
the floods.
(iv) All other specifications/stipulations in this regard laid in this document shall also apply.
" FTCKPCIG1FGYCVGTKPI"
"
Seepage water from springs or rain water shall be suitably collected and drained away by gravity,
wherever it is possible to do so. Where, however, drainage by gravity is not feasible, pumping
could be resorted.
The Contractor shall make all arrangements deemed necessary for keeping the excavation and
work areas dry for execution of works as per specification.
" DCEMHKNN"
"
(i) Backfill shall consist of materials as approved by the Engineer-in-Charge and shall be placed in
locations as shown on the approved drawings or as directed by the Engineer-in-Charge.
(ii) Earthfill, which on account of its nature or a location requiring no compaction, shall be classified as
backfill.
(iii) Backfill which shall be compacted by means of roller, mechanical or manual tampers is classified
as compacted backfill.
(iv) At locations, where areas to be backfilled are too small or confined, compaction may be done
manually with tampers etc.
(v) Only suitable materials obtained from excavation, if practicable, shall be used for backfill and
construction of such features as approach road, causeway etc.
(vi) Material to be used in backfill shall be free draining type.
" KNNWOKPCVKQP"
"
The Contractor shall install an adequate illumination system at the work site.
" OKUEGNNCPGQWU"YQTMU"
"
Besides the above, the Contractor shall also carry out, but not limited to, the following
activities:
(i) Excavation for drainage trenches
(ii) Clearing of all trees, bushes, rubbish and any other objectionable materials and their removal and
disposal.
(iii) Replacement of survey points fixed by the Engineer-in-Charge which are damaged by Contractor’s
negligence.
(iv) Formation of berms or ramps, sump pits for installation of dewatering pumps at places which fall
beyond the specified excavation lines.

38
(v) All dewatering and drainage works
(vi) Methods adopted for specially controlled excavation at foundation level or near the faces where
plain surfaces are required.
(vii) Replacement or repair of concrete or other works damaged by blasting.
(viii) Draining, shaping and trimming of the dumped material in waste disposal areas to the lines and
grades as directed or approved by the Engineer-in-Charge.
(ix) All shoring, strutting and other protective as required during excavation.
9037. Gzecxcvkqp"qh"rwor"jqwug"
"
The excavations for the pump house shall conform with the specifications of excavation provided in
the document. Damage or alterations at any of the work areas caused by wrong blasting or due to
any other operation executed by the contractor shall be repaired or indemnified by him at his own
expenses in a manner acceptable to the Engineer-in-Charge. Unstable or loose material appearing
during excavation and which is in the opinion of the Engineer-in-Charge may be dangerous for the
personnel or for the work shall be immediately removed and the contractor shall have no right for
any payment for this operation.
Excavations shall comply with the lines and dimensions indicated in the approved drawings except
those areas where special protections are necessary are where due to local conditions the
Engineer-in-Charge orders modifications.
The over excavations if any, resulting from the faulty operations by the contractor / due to the
faulty rocky zone shall be filled up with concrete as directed by the Engineer-in-Charge.
The Excavation for pump house shall be done by smooth blasting technique as specified in this
document so as to ensure smooth wall excavation.
All the working faces shall be kept properly drained without allowing water being collected in the
pools and the work area
" Ogcuwtgogpvu"cpf"Rc{ogpvu"
"
(i) Immediately after the final excavation of foundation or otherwise, inspection
and approval of Engineer-in-Charge, levels at salient locations of the foundation
pit/trench, etc., shall be measured jointly by the Contractor and the Engineer-in-
Charge.
(ii) Interim/progressive payments will be made, in accordance with Encwug"36""qh"vjg"Igpgtcn"

Eqpfkvkqpu" qh" Eqpvtcev." Xqnwog"⁄" KK"*Rctv" ⁄" C+, at the appropriate unit rate entered in
the Schedule of works which shall include the entire cost of all operations required for
execution of the respective item.
" RWDNKE"UCHGV[<"
Nearest , towns, villages and all required places, trenches and foundation pits shall be securely
fenced, provided with proper caution signs and marked with red lights at right to avoid accidents.
The contract shall take adequate protective measures to see that the excavation operations do not
effect or damage adjoining structures or property.
" FKURQUCN"QH"GZECXCVGF"OCVGTKCN<"
"
(a) No rehandling of excavated material due to injudicious selection of the place for dumping will
be paid for.
(b) All surplus excavated material which is not useful for any embankment, or fillings shall be
disposed in accordance with clause 3.1.19 and as directed by the Engineer-in-Charge.

39
" Ukfg"ftckpu<"
"
The location, grades and sections of the drains shall be as shown on the drawings and or as
directed. Measurement of excavation for the above drains will be made to the lines shown on the drawings
or as directed. Payment for excavation which unit rate shall include the cost of excavation and placing the
material in embankment or other wise disposing of the excavated material and all work necessary to
maintain the work in good order.
" GODCPMOGPV"EQUVTWEVKQP<"
" UEQRG<"
Site clearance, stripping and formation of embankment of homogeneous section/zonal section viz.,
casing zone/hearting zone with the useful excavated soils and balance soils of approved quality from the
borrow area including the cost of soil, if any sampling, testing and pre- wetting of soils at source of
excavation and conveyance of soil and extra soils required for shrinkage including swell factor with all
leads, lifts, delifts, laying on bank, spreading, breaking clods, sectioning, extra watering and consolidation
including benching of old embankment slopes, joining with the new embankment formation, trimming of
side slopes, formation and removal of ramps, formation of Dowel banks etc., as per drawing and as
directed by the Engineer-in-Charge to complete the finished item of work.
" GODCPMOGGPV"EQPUVTWEVKQP"
"
Setting Out:- Specifications No.1.1.3 Shall apply
" Igpgtcn"Tgswktgogpvu"
a) The Cross sections for embankment are to be designed to suit the characteristics of the best
quality soils available in the vicinity of the proposed work. If the constructor proposes to use
any other type of soils than those mentioned in the design to save the lead and thereby the
cost pursuant to the clause of I.S Code and A.P.S.S the contractor has to from the
embankment to the revised profiles worked out by the competent authority sanctioning the
estimate. The extra quantity involved will not be measured and paid. The theoretical quantity
required based on the original cross sections will only be measured and paid. But the
Contractor has to form the bund to the revised cross section designed with the characteristics
of the proposed soils. The designs given by the estimate sanctioning authority are final.
b) Embankment shall be built to the height, top width and side slopes as shown on the drawings.
All the edges of the embankment shall be neatly aligned symmetrical to the central line. They
shall be absolutely straight in all reaches except at bends. At bends they shall be smoothly
curved.
c) The top of each embankment shall be leveled and finished so as to be suitable for road way
and given a cross slope to drain away rain water. The bank carrying road shall be given a
suitable cross slope.
" Ocvgtkcn/"Vjg"rtqxkukqpu"qh"uejgfwng"⁄"flF‚"Ujcnn"crrn{0"
"
a) The suitability of foundation of placing embankment materials thereon and all materials
proposed for use in construction of embankment shall be determined by the Executive
Engineer, well in advance on the basis of Laboratory Test results. Chemical and Physical
tests of the material proposed for construction of embankment shall be carried out to ensure
that the soil does not contain soluble lime contest, soluble lime salt content or cohesion less
fines, in quantities harmful to the embankments.
b) Material for construction of embankment should be free from the organic material. Unless
otherwise directed by the Superintending Engineer
/Executive Engineer, all materials shall be deposited in embankments so that cobbles, gravel
and boulders are well distributed through other material and not nested in any portion within or
under are embankment as per clause 6,4 of I.S 4701-1982.
c) Suitable excavated material available from the cut off trenches, canal cutting extra cutting for
seating to lining, foundation excavation for structures, approach and tail channels for
structures, vagu diversions, removal of ramps obstruction removal on the upstream and
downstream of surplus weirs and excavation in surplus course and any such excavations,
shall be used for construction of adjacent embankments and also embankments of deficit
reaches.

40
d) After completing the construction of embankments with the materials as indicated in (c) above,
material required for the construction of balance embankment shall be obtained from the
borrow areas.
e) The soils and murrum excavated and useful for construction of the embankment shall be
classified by the Superintending Engineer /Executive Engineer, as impervious and semi-
pervious based on Laboratory Test results. They shall be utilized on the embankment work.
" Rtgrctcvkqp"qh"itqwpf"uwthceg"hqt"godcpmogpv<"
a) Clearing site: Specification 2.0 shall apply.
b) Stripping : Specification 3.1.8 Shall apply.
c) All portions of excavation made for test pits or other subsurface investigations, all holes,
hollows and all other existing cavities found with in the area to be covered and to the extent
below the established lines of excavation for embankment seat shall be filled in earth of the
corresponding zone of the embankment and suitably compacted. The pits of surface boulders
shall be filled with suitable materials and compacted at no extra cost.
d) Pools of water shall not be permitted in the foundation for embankment and such water shall
be drained and cleared prior to placing the fist layer of embankment materials.
e) On sloping ground or in case of existing banks, where embankment portions are to be

modified, benching of slopes shall be done with a little slope towards the inside of beaching so
as to give a good grip to the embankment soil with the sub-grade. Unless otherwise specified
the benches shall be 0.3 X
0.6m on the front and rear slope of the embankment. Before benching, the bank slopes shall
be cleared of all roots and vegetables matter as per specification 2.0. No separate payment
will be made for either benching or refilling. The rate quoted for raising embankment is
inclusive of above operations. The bank section shall be brought to design standards by filling
the scours with suitable material and compacting to 98% proctor density by suitable measure
of compaction.
h+" Uqkn"hqwpfcvkqp<"
The ground surface under embankment and area of bed filling wherever necessary (except
rook surfaces) shall be loosened or scarified making open furrows by means of a plough, or
ripper or any other methods to a depth of not less than 200mm. deep below the stripped
surface at intervals of not more than 1m to the satisfaction of the Engineer-in-Charge. Roots or
other debris turned up during scarifying, shall be removed from the entire foundation area for
the fill. The areas under the embankments shall be prevent by sprinkler before the construction
of embankment begins. The moisture content shall be optimum.
g) Tqem"hqwpfcvkqp:
The treatment of the rock surface under the embankment shall be done so as to ensure tight
bond between embankment and the foundation this shall be done by the following procedure.
i) The area of the rock surface which is to be in contract with the embankment shall be fully
exposed by removing all the loose and disintegrated rock having the surface of rock
rugged. Hard rock projects and overhangs shall be removed. If blasting is to be resorted
to, care shall be taken to avoid objectionable shocks to foundation rock. As far as possible
the whole contract area shall be exposed at one time to enable examination of rock
surface characteristics and planning the method of treatment.
i) Exposed rock shall be benched.

" "
" "
" "
" "
" "
" "
41
" Eqorcevkqp"<"
"
a) General:
The earth compacting equipment specified in Appendix-C of I.S 4701-1982 shall be used
for compacting the soils shown against them. The compacting equipment shall confirm to the
relevant. I.S Specification. While the I.S. Specifications specify the compacting. It is contended that
the use of improved compacting. It is contended that the use of improved compaction equipment
for embankment construction shall be encouraged as may be most suited to the site conditions
and the programme of construction. The methods of compaction shall confirm to clause 7.2,7.2. 2
and 7.2.3 of I.S 4701-1982.
" Eqjgukxg"Ocvgtkcnu"<"
"
a) When each layer of material has been prepared so as to have the proper moisture content
uniformly distributed throughout the material, it shall be compacted by passing the roller. The
layer shall be compacted in strips over lapping not less than 0.30 Meter. Rolling shall
commence at edges and progress towards centre longitudinally. The roller shall travel in a
direction parallel to the axis of the bank. Turns shall be made carefully to ensure uniform
compaction. Density tests shall be made after rolling and dry density attained shall be not less
than 98% of the maximum dry density (standard proctor) as obtained in the laboratory for the
type of material used. The density achieved shall not normally be less than the designed
density. The dry density of soil in field shall be determined in accordance with I.S 2720 (Part-
XXVII)-1974 or I.S 2720 (Part.XXIX)-1975.
b) Standard proctor density test shall be carried out at regular intervals to account for variations
in the borrow area materials as well as that in situ excavated material. Not less than three
tests shall be carried out to indicate variations in the standard proctor density attained in
laboratory.
c) Engineer-might review the design if necessary on examination of density test results and the
contractor shall have no claim arising out of such a review and consequent change, If any, in
the design.
d) i) In case embankment covers the barrels of cross drainage or any other structures, first 45cm
of the embankment shall not be compacted with roller but it shall be compacted with
pneumatic/hand tampers in thin layers. The compaction above this layer of total 45cm shall be
done by using suitable light rollers to avoid damage to the structure, by adjusting the thickness
of layers until sufficient height is achieved to permit compaction by heavy rollers. Density test
shall be conducted from time to time on site to as certain whether the compaction is attained
as specified above.
ii) Separate tests shall be conducted for each zone of the embankment for every 1500 cubic
meters of compacted earth work, at least one field density test shall be taken in each layer.
Minimum two density tests shall be taken in each layer per day irrespective of the quantity of
earth work specified above. In case the test shows that the specified densities are not
attained, suitable measure shall be taken by the contractor either by moisture so as to obtain
the specified density which shall be checked again by taking fresh tests at the same locations.
Necessary unskilled labour required for carrying out such density tests shall be provided by
the contractor.
e) Compaction shall be achieved by the use of smooth rollers pneumatic type rollers, sheep foot
rollers, mechanical compactors like vibratory rollers, vibrating plates, programmers, power
rammers, slope compacting equipment, pneumatic tamping equipment and such other
equipment as shall be specified by the Engineer based on type of material and actual field
tests.
f) The dimensions and weight of the rollers should be such as to exert a ground pressure of not
less than 12kg/cm2 of tamping when it is empty and 25Kgs/ Cm2 When ballasted. The
number of passes required for each layer to obtain the specified density shall be determined
by actual field tests.

42
" Eqjguukqp"nguu"ocvgtkcnu"
a) Where compaction of cohesion less free-draining material such as sand and gravel is
required, the materials shall be deposited in horizontal layers and compacted to the relative
density specified. The excavating and placing operations shall be such that the material, when
compacted, shall be blended sufficiently to secure the highest practicable degree of
compaction and stability. Water shall be added to the materials, if required to obtain the
specified density depending on the method of compaction being used.
b) As per clause 6.6.2.1 of I.S 4701-1982, the thickness of embankment layer shall not exceed
25cm (Loose) before compaction and it should be spread over the full width of embankment
and compaction shall be done by rollers or tempers to obtain specified density. The thickness
of the horizontal layers after compaction shall not be more than 10cm. If compaction is
performed by tampers, not more than 15cm, if by 8 to 10 tones rollers and not more than
30cm. If compaction is performed by vibratory or pneumatic rollers or similar equipment. The
relative density of the compacted materials shall not be less than 70 percent as determined by
laboratory tests as per I.S 2720 Part-XIV, if compaction is performed by internal vibrators, the
thickness of layers shall not be more than the penetrating depth of the vibrator.
" Godcpmogpv"ykvjqwv"eqpvtqnngf"eqorcevkqp0"
"
a) No materials shall be placed in any section of the earth fill portion of the embankment until the
embankment seat for that section has been approved by Executive Engineer.
b) Where the natural ground surface is above the maximum water level but below the top o the
embankment, the embankment shall be built in layers not exceeding 15cm., in thickness and
to the full width of embankment. Each layer shall be commenced from the edge farthest from
excavation. It shall be compacted with two ton roller.
c) The excavating and hauling equipments shall travel over the embankment to evenly distribute
the material and compacting effort over the whole surface.
Godcpmogpv"ykvj"eqpvtqnngf"eqorcevkqp"<"
"
f+" Bushes, roots, sods or other perishable or unsuitable material shall not be placed in the
embankment0"
e) (i) Unless otherwise specified, embankment materials shall be spread in successive horizontal
layers generally not exceeding 25cm, in thickness (loose layer) in the Zones where theses are
required to be laid, extending to the full width of the embankment including slopes at the level
of the particular layer. Each layer shall be commenced from the edge farthest from excavation.
In no case shall embankments be widened by material dumped from the top.
(ii) Top of each layer shall be kept slightly depressed in the centre.
f) i) Extra width of 600 mm. in thickness as measured perpendicular to the slope shall be
provided on either side so that when compacted, lines of the finished embankment slopes shall
have not less than specified density.
ii) Later the extra width shall be neatly trimmed and the trimmed material shall be permitted
or re-use in embankment at higher elevations.
iii) No payment shall be made for providing removal of the extra section. Removal of extra
section in this embankment shall be deemed to have been included in the item of compaction.
g) Thickness of layers shall be adjusted with particular type of compactors used to give the
required density by carrying out trial compaction and requisite tests and required number of
passes should also be determined as directed by the Engineer.
h) No fresh layer shall be laid until the previous layer is properly watered and compacted as per
requirement. The work of spreading and compaction shall be so adjusted as not to interfere
with each other and in such a way that neither of the operations is held up because of non-
completion of the rolling and watering. The surface of the banking shall at all times of
construction be maintained true to required cross section. If the surface of any compacted
layer of earth fill is too dry or too smooth it shall be moistened and scarified to provide a
satisfactory bonding surface before the succeeding layer is placed. All the rollers used on any
one layer of fill shall be or the same type and same weight.

43
i) The contractor shall ensure that only approved soils are used for construction of embankment.
j) For proper bond of the embankment done in the previous seasons with the new embankment,
the work shall be carried out as detailed below.
i) In case of the old bank to extended horizontally. It shall be cut to a slope not steeper than 1 in
4 and the surface so prepared shall be scarified and made loose at least for a depth of 15cm.
Necessary watering shall be done and the earth surface shall be thus prepared to receive the
new embankments. The soils shall be laid in layers and compacted to the required degree of
compaction to have a proper bond with the old one.
i) If the old bank is to be raised vertically, vegetation shall be cleared followed by scarifying,
watering and placing of the new earth layer as specified above.
ii) The surface which are damaged due to rain shall be made good by filling with proper soil duly
compacted by tampers. A cross slope away from the centre of canal of about 1 in 80 shall be
maintained throughout the rainy season to ensure. Proper drainage in the event of occasional
rainfall. No extra or separate payment shall be made for these items of work.
m+" Ugvvngogpv"cnnqycpeg<"
"
l) The canal embankments shall be constructed to a higher elevation than that shown on drawings
at the rate of 2.5cm. per every one meter height of bank if power driven equipment is used and
meter height of bank if power driven equipment is used and 25cm/1mt height if other than power
driven equipment is used for compaction towards shrinkage/settlement.
ii) No extra or separate payment shall be made for this work as this shall be deemed to have
been included in the respective item of construction and consolidation embankment.
iii) Care shall be exercised that all large clods are broken and no clod bigger than say 8 cm. rock,
are buried in the banks.
i) Jqoqigpqwu"Ugevkqp:
The Homogenous section for canal embankments shall be provided as specified in the drawings.
The available coarser and more pervious materials shall be placed nearby outer slopes in order to
have increasing permeability from inner to outer side. The compaction shall be carried out as per
clause 6.6.2 of I.S.4701- 1982.
m) \qpcn"Godcpmogpvu:
In zonal sections the selected and approved soils shall be spread to the required widths of
respective zones. All the zones shall be tackled simultaneously and the difference in level between
zone to zone shall not be more than 150mm.
" Oqkuvwtg"eqpvgpv<"
"
a) The initial moisture content of the material shall be determined at the source of supply (all
excavations including from the borrow areas) in field laboratory test. Prior to and during compaction
operations, the embankment shall have, optimum moisture content required for the purpose of
compaction and this moisture content shall be fairly uniform throughout the layer, as per clause 6.6 of
I.S 4701-1982. In so far as practicable the moistening shall be supplemented as required by sprinkling
water at the site of compaction, if necessarily. Flooding shall not be permitted under any
circumstances. Sprinkling of water shall be done either through a proper sprinkler tanker or using
proper spray nozzles. Sprinkling straight from the water house shall not be allowed.
b) If the earth delivered to the embankment is to wet, it shall be dried by aeration, exposure to the
sun, ploughing, dick harrowing or other methods, till the moisture content is reduced to acceptable
optimum for compaction. If due to wet weather, the moisture content cannot be reduced to the required
optimum by the above procedure, work on compaction shall be suspended until such time the earth
has dried to the optimum moisture content. For such suspension of work no extra claim by the
contractor shall be allowed.
c) If the moisture content is not uniformly distributed throughout the layer or less than the optimum
rolling shall be stopped and shall be started again only when the above conditions are satisfied. After
44
adding the required amount of water, if found necessary, the soil shall be processed by means of
harrows, rotary mixers or as otherwise approved until the layer is uniformly wet to optimum moisture
content.
d) Moisture content of each layer of soil shall be checked in accordance with I.S 2720 (Part-II) 1973
and unless otherwise mentioned shall be adjusted, making due allowance for evaporation losses that
at any time of compaction, upto-1% to +2% than the optimum moisture content in casing zones and up
to +1% to -1% than the optimum moisture content in the hearing zones may be permissible. The
optimum moisture content shall be determined in accordance with I.S 2720 (Part-VII) 1972. The above
compaction tests will be conducted by the Engineer or his authorized representative and the contractor
shall ensure compaction till it is satisfied that 98% of the maximum dry density at OMC is obtained.
90420340"Urgekcn"Rtgecwvkqpu<"
"
a) During the actual construction of any earth work, maximum use should be made of construction
plant and routing of the plant should be carefully controlled to obtain uniform compaction over as
wide and areas as possible. Care should also be taken during the compaction operation to shape
the surface of the works to facilitate the shedding and to minimize the absorption of rain water,
particular attention being given to the prevention of pending of water. The contractor shall do this
at the end of each days work.
b) The earth moving machinery shall not be allowed to pass over a compacted portion of the
embankment beyond certain limits by varying the hauling routes and ramps, thus ensuring that over
compaction does not take place in any particular reach.
c) During the construction, a small transverse slope from centre towards the edges shall be given and
further in the reach when bank is being raised, the works shall be tackled in continuous horizontal
layers to avoid pools of water and concentration of allow of water during rains which will cause
damages, scours and rain gullies.
d) Special precautions shall also be taken while rolling the spread soil near structures, conduit, sluice
barrels, filters, rock toes at the junctions of bank connections with the structures, using hand or
power tampers. It is essential that the compaction of filling should be carried out in such a manner
as to avoid an unbalanced thrust on walls etc., which might displace or damage it. The equipment
shall be provided with suitably shaped heads to obtain the required density.
9042035"Godcpmogpv"Vguv"Ugevkqp<"
"
Test embankment section shall be built as directed by the Engineer-in-Charge prior to starting fill
operations or at an early stage of embankment construction. The test section shall be used to
establish.
i) Layer thickness of fill materials

ii) Optimum practicable moisture content.
iii) No of passes of sheep foot roller/vibratory roller for effective compaction.
7.20.14. OGCUWTGOGPV"HQT"RC[OGPV<"
"
i) Embankment with excavated Soils, and borrowed Soils.
The quantities between the levels taken after stripping and cross sectional levels taken after
construction of consolidated embankments with the levels taken after construction of consolidated
embankments with the available useful excavation soils and with the soils obtained from borrow
areas within the pay lines shall be worked out excluding rock toes and filter. It shall be clearly
understood that construction of embankments of extra widths and extra height formed for
shrinkage allowance as specified in proceeding paras will not include for payment.
" TGHKNNKPI"QH"MG["VTGPEJ"CPF"EQPUQNKFCVKQP<"
"
a) Key trench shall be back filled with impervious material of the same specifications and in the
same manner, as for the impervious hearting zone of the embankment of the canal. The
impervious soils shall be placed in continues and approximately horizontal layers not more than
25cm (loose) thick and compacted by 8 to 10 Tonne power roller under optimum moisture content.
b) Rolling shall be done along the key trench and the roller shall be taken close to the sides of the
trench.

45
c) In cases where the compaction by rollers is not possible, compaction to the required density
shall be achieved by such other means as specified by the Superintending Engineer/Executive
Engineer.
d) Each layer shall be compacted to achieve the required dry density of not less than 98% of the
maximum dry density (Proctor’s density) for the type of material at optimum moisture content.
e) Watering of material for its compaction shall have to be arranged by the contractor at his
cost as the quoted rate for consolidation of schedule ‘A’ is inclusive of watering.
f) During placing and compaction of impervious soils in the key trench where dewatering is
involved, the sub soil water level at every point in the key trench shall be maintained below the
bottom of the earth fill until the compacted fill in the key trench at that point has reached a height of
3m after which water level shall be maintained at least 1.5m below the top of compacted fill.
g) The quantity for payment shall be the volume of key trench measured in cubic meters. The
unit for payment shall be ten cubic meters.
" EQORCEVKPI"D["QVJGT"VJCP"RQYGT"FTKXGP"GSWKROGPV"
"
a) This shall conform to that of embankments compacted by power driven equipment except
that instead of using power driven rollers ordinary rollers driven by tillers shall be adopted for
compaction if the work is at small magnitude. No manual compaction shall be allowed except
through the use of pneumatic tampers and only very occasionally hand tampers shall be used.
b) Thickness of layer shall not exceed 150mm before compaction (loose).

c) Each layer shall be compacted to not less than 98% dry density (Proctor’s density) at optimum
moisture unless otherwise specified.
d) Any loose soil shall be removed by trimming and bringing embankment and side slopes of
canal to the section shown on the drawings. Slope compacting equipment and pneumatic
equipment should be used.
e) Measurement and rate for payment shall conform to para 3.2.14 slope compacting
equipment and pneumatic tamping equipment should be used.
" FQYGN"DCPMU<"
"
a) Dowel Banks shall be constructed to the dimensions, grades, slopes as shown on the
drawings.
b) Payment will not be made for construction of Dowel Banks.
" YGCVJGT"EQPFKVKQPU<"
"
a) Embankment soils shall be placed only when the weather conditions are satisfactory to
permit accurate control of the moisture content in the embankment material. Before closing work in
embankment, in any continuous reach prior to setting of monsoon, the top surface shall be graded
and rolled with a smooth wheeled roller to facilitate run-off away from canal. Prior to resuming
work, the top surface shall be scarified and moistened or allowed to dry as necessary.
b) The contractor shall provide suitable protection works protect the slope from erosion due to
rain water. No payment whatsoever shall be made for providing such protection work and rectifying
any monsoon damages.
" "
" "
" "
" DQTTQY"CTGC"EQPUKFGTCVKQP<"
a) The contractor shall use only the suitable soils for formation of embankments, out of the soils
46
excavated under the provisions of Schedule ’A’ if they are proved to be suitable, based on
Laboratory test results, and if they are with in the Economic lead. Other wise the contractor shall
borrow the soils from the borrow area after test checking the suitability of the soils for the
embankments for particular embankment work.
b) The contractor shall be allowed to borrow the soils from the fore shore areas of
Reservoirs/tanks, up to the MVVL contour and on the sides of the canal. Where the department is
having provision to borrow or exploit the soils. The contractor can avail this provision. If for any
reason the contractor is not interested to borrow the soils, from the above said areas the
contractor is free to borrow the soils from any other palaces of his choice.
c) The responsibility for arranging and obtaining the land for disposal of spoil and the land for
borrowing or exploitation in any other way shall rest with the contractor, who shall ensure smooth
and uninterrupted supply of materials/earth for the quantity required in construction during the
construction period.
" DQTTQY"RKVU<"
"
1) The borrow pits shall not normally be more than 25M in length, and 10M in width and 1 ½ M
depth. A clear spacing of one meter between each pit shall be left out. Each pit shall be clearly peg
marked and number tags of the pits shall be maintained.
2) In the case of earth dams unless otherwise specified the borrow pits shall not be located
within a distance of 10 times the height of the embankment on the upstream side and two times
the height of the embankment on the down-stream side.
3) The depth of the pits shall be so regulated that their bottom does not cut the hydraulic
gradient line having a slope 4:1 from the top edge of the embankment/
4) In no case the pits shall be located within 5M from the toe of the embankment. If there are
old pits in the borrow area the new pits shall be located one meter away from them.
5) If the contractor excavated the pits near to the toe against the above clauses and the same
is observed at any time during or after the execution of work, the contractor has to fill the same
pits with the soils suitable for hearting zone of embankment and compact to 98% proctors Density
at the cost of Contractor.
" Uvtkrrkpi"qh"dqttqy"ctgcu<"
"
a) Borrow areas shall be stripped of top soil and any other objectionable materials to the
required depths as ordered by the Superintending Engineer/Executive Engineer(Stripping
operations shall be limited only to designed borrow areas) materials from stripping shall be
deposited of in exhausted borrow areas are in the approved adjacent areas particular care shall be
taken to exclude all organic matter from the borrow area. The cleared areas shall be maintained
free of vegetable growth during the progress of work.
b) No payment shall be made for removal of top soil on borrow area.
" Ogcuwtgogpv"cpf"Rc{ogpv<"
"
The quantity on the embankment will be measured in terms of clause 7.20 the tenderer has
to quote his rates duly considering this aspect and it shall be included in the quoted price.
" Fgngvgf0"
"
" Dcem"hknnkpi"<"
Back filling with selected material in foundation trenches around structures and above
lining key.
3+" Igpgtcn<"
"
47
a) The type of material used for backfill, and the manner of depositing the material, shall be
subject to approval of the Engineer-in-Charge. As for as practicable, back fill material shall be
obtained from the excavation for structures or from adjacent canal excavation or from the
excavation of the other ancillary works. Back filling shall be done with approved material after
the concrete or masonry is fully set.
b) Backfill material shall not contain stone larger then 7.5cm. size.
c) The pervious materials (sand) with perfused watering used for back filling around the cut off
wall shall be placed as shown on drawings or as directed by Engineer-in-Charge.
d) Backfill shall not be placed against retaining walls until the retaining wall is cured adequately
and is strong enough to take lateral pressure of the backfill.
Trimming of the sides of excavation against which the backfill is to be laid shall be delayed
until immediately prior to back filling and any excessive drying of the surface shall be
conditioned properly and made adequately moist to avoid potential desiccation of the rock or
partly compacted/ consolidated materials.
e) The backfill material shall not be placed against retaining walls until the retaining wall is
cured adequately and is strong enough to take lateral pressure of the backfill, Trimming of
the sides of excavation against which the backfill is to be laid shall be delayed until
immediately prior to back filling and any excessive drying of the surface shall be conditioned
providing adequate earth cover over pipe to prevent damage due to loads of construction
equipment
f) If a haul road is built over a pipe, all back fill around and over the pipe shall be placed to a
uniform surface and no humps or depressions shall be permitted at the pipe crossing.
4+" Eqorcevkqp"qh"Dcemhknn<"
"
a) When compacting the soil against the steep rock, abutment walls of masonry or concrete
structures, the construction surface of embankment shall be sloped away from the rock or masonry
or concrete structure leaving a minimum distance of 0.6 meter and at an inclination of 3.1 Roller
shall not be used close to structures as structural damage is very likely more particularly when
structures have not been fully cured. The size and weight of equipment will depend on nature of
material, the height and load assumed in design of structure. The backfill close to the structure up
to the rolled layer shall be compacted in suitable uniform layers, using pneumatic tampers as
appropriate to obtain dry density of at least 98% of proctor density. The moisture content of the
earth fill placed against rock or the structure shall be on higher side of OMC by about 2% or so, to
allow it to be compacted into all irregularities of the rock. Profuse watering shall be done to
pervious materials (sand) before compaction as per instruction, shall be carried out with special
care without claiming any extra cots.
b) No payment shall be made on back filling around the structures and consolidation as the
cost of the same shall be deemed to have been included in the relevant item of concrete/masonry
payment shall not be made in full till the contractor carries out the compaction of backfill as per the
above specifications. Deployment of hand tampers be restricted to rare usage that too very shall
jobs.
5+" Uvtwevwtgu"qp"dcemhknn"<"
"
Where the original ground surface is below the base of the structure or below the bottom of
pipe, all fill required for the structure foundation and all fill up to the bottom in the pipe shall be
placed as compacted embankment. The embankment over natural ground up to pipe bottom and
over the pipe shall be laid in accordance with clause 9.2.4,9.2.5 and 9.2.6 IS 783 of 1985. The
compacted back fill shall be placed in horizontal layers not exceeding 15cm after compaction.
Heavy stones shall neither be dropped on top of pipes not shall be allowed to roll down the side of
the embankment against the pipes.
" KPURGEVKQP"CPF"VGUVU<"
"
1) General:
48
a) The contractor shall maintain and exercise through check on the quality of fill material
delivered to the embankment and shall arrange to obtain the data and in-situ properties
of the material after compaction for comparison with design assumption. To achieve
these objectives, as programme of filed testing and inspection shall be planned to effect
quality control to “ IS 9001 requirement.”
d+" Ueqrg"qh"vguvkpi"cpf"kpurgevkqp<"
"
Filed control of fill material shall be required by visual and laboratory checks. The checks on the
effectiveness of placement and compaction procedures shall be made by field density tests at
proscribed intervals.
4+" Vguvu"
The following tests shall be carried out of determining compaction.
a) Density moisture relation of the soil: In accordance with I.S.2720 (Part. VII) 1980.
b) Density of the soiling Filed: In accordance with I.S.2720 (Part XXVIII) 1974 or I.S.2720 (Part. XXIX)
1975.
c) Moisture content: In accordance with I.S.2720 Part. II) 1973. Before compaction: Materials
delivered to the fill shall be visually examined and their properties estimated by way of inspection.
5+" Godcpmogpv"
"
I. Moisture content tests shall be carried out in the field laboratory while placing the fill materials.
II. Moisture content shall be controlled by adding water or allowing the soil to dry.
III. It shall be ensured that the methods of dumping, spreading and moisture conditions are such
as will result in reducing segregation and/or variation of moisture content to a minimum.
6+" Dqttqy"Ctgc"
"
i. Excavation of borrow areas shall be limited in extent and depth as indicated in
specification.3.2.
ii. Estimation of moisture content of materials by visual examination and feel.
iii. Different samples shall be taken for laboratory analysis in case the soil is of different
characteristics.
These inspection checks shall be supplemented by sampling the materials at prescribed minimum
intervals and by testing the samples in the laboratory for gradation and moisture content.
Fwtkpi"Eqorcevkqp:
It is intended that the checks in operations during compaction shall verify.
i) That the layer thickness of the materials is as specified.

ii) That the fill is compacted at least to 98% of standard proctor’s Density of (Dry density at OMC)
or 70% relative density as the case may be.
iii) That no excessive rutting, waving or scaling of the fill occurs during compaction.
7+" Chvgt"eqorcevkqp<"
"
The condition of the fill after compaction shall be observed and recorded particularly with respect
to rutting or waving. However, the properties of materials after compaction shall be determined
primarily by field density tests. Routine tests on samples taken from constructed embankment shall
include besides density tests, grain size distribution, Attenberg limits, permeability, shear and
consolidation characteristics.
HTGSWGPE["QH"VGUVKPI:
A) It will be necessary to carry out sampling and testing of materials before and after
compaction at sufficient frequencies so that effective checks on the full operations are
maintained. Testing frequencies proposed should correspond to the frequencies as
49
mentioned in the relevant paragraphs. However, the actual materials placed and the rate
of fill placement.
B) Testing shall be performed at frequent intervals that those specified in table during initial
stages of placing in each zone in order to establish control on testing techniques and
also testing should be conducted at higher rates in case of special problem of control
caused by such factors such as material variation, equipment performance and weather.
C) Compaction:
Test location shall be chosen only through random sampling technique. Control shall not
be based on the result of any other test but on the mean value of 5 to 10 density
determinations. Generally these shall be at the locations indicated below or any other
areas so determined by the Engineer-in-Charge in addition to these tests shall be made at
the following locations.
1) In areas where the degree of compaction is doubtful.
2) In areas where embankment operations are concentrated.
3) For record tests at the locations of all embedded instruments. Areas of doubtful
density may be detected by the inspection by Engineer-in- Charge and possible
location of insufficient compaction include.
i) The junction between areas of mechanical tamping and rolled embankment along
abutment or cut-off walls.
ii) Areas where rollers turn during rolling operations.
iii) Areas where too thick layer is being compacted.
iv) Areas where improper water content exists in material.
v) Areas where less than specified number of roller passes were made.
vi) Areas where dirt clogged rollers were used to compact the materials.
vii) Ares where compacted by rollers that have possibly lost part of their ballast.
viii) Areas where oversized rock which has been over looked is contained in the fill.
ix) Areas containing materials differing substantially from the average.
" TGEQTF"CPF"TGRQTV<"
"
Record of borrow are material and embankment placing operations shall be maintained in order to
have a continuous check on the suitability and availability of fill materials and quality of fill. Thus,
shall be possible to have complete description of materials in any portion of the embankments.
The record shall be maintained on the form specified in ANNEXURE-1.
HKGNF"VGUV"FCVC:
Record of field Test Data results should be presented in the form of statistical analysis sheets
and summary sheets in order to provide control required for enforcement of statistical requirements of the
specifications.
Test data summary sheets and inspection reports be used to form the basis of construction control
report, which should be issued from the site at fortnightly intervals, during construction season. The report
would contain narrative accounts of the progress and problems of field construction, statistical analysis of
test data and photographs of the fill operations. The data sheets, and analysis reports may be kept in
computers and sent on line to the Executive Engineer/Superintending Engineer and Engineer-in-Charge of
the Project for monitoring.
"
"
"
"
"
"
"
"
CPPGZWTG/3"
"
Earth work daily Report:
Name of work:
50
Date shift weather

Inspector Following Inspector
----------Type roller equipment used ----------------------------------------- Weight of roller
*C+"GZECXCVKQP"
1. Type of Excavator.
2. Depth of Cut.
3. Type of Soil.
4. Borrow pit location.
5. Whether water added at borrow pit.
6. Percentage of moisture content.
*D+"HKNN"EQPFKVKQPU"
1. Locating of fill
2. Elevation
3. Whether water added at the fill
4. Moisture content before rolling.
5. Roller passes.
*E+"VGUV"FCVC"
1. Locating of Sampling point
(a) Chainage
(b) Off-set
2. Serial Number
3. Moisture content
4. Dry density (G/C)
5. Plasticity needle reading (Kg/Sq.cm)
6. Quality of Earth Work rolled
NCDQTCVQT["EJGEM"
1. Serial Number
2. Optimum Moisture content percent.
3. Maximum dry density (Gr/CC)
4. Plasticity needle reading (Kg/Sq.Cum)
*F+"EQORCEVKQP"GHHKEKGPE["
"
1. Field moisture deviation from optimum
2. Percentage Compaction.
UWTHCEG"FTCKPU:
a) This work shall consist of constructing surface drains, Schedule of work shall be so arranged
that the drains are completed in proper sequence with canal excavation works as necessary
subsequently or no damage is caused to these works due to lack of drainage.
b) Surface drains shall be excavated to the specified lines, grades, levels and dimensions. The
51
excavated soils shall be removed from the area adjoining the drains and is found suitable
utilized in embankment construction. All unsuitable soils shall be disposed off as directed.
c) The excavated bed and sides of drains shall be dressed to bring these in close conformity with
the specified dimensions, levels and slopes.
d) All works in drain constructions shall be planned and executed in proper sequence with other
works as approved by Executive Engineer with view to ensure adequate drainage for the area.
TQEMHKNN"KP"VQG"QH"GODCPMOGPVU"CPF"HKNVGTU:
Scope: This specification covers filters to be laid for internal drains sandy filter blankets, horizontal
and inclined filter drains, longitudinal and transverse filters around rock to etc.,
HKNVGTU:
i) Sand as filter materials; provisions of schedule ‘D’ shall apply.
ii) Scope: Formation of sand filters of specified thickness using the sand of approved quality
including cost and conveyance of sand sampling, testing and laying with all leads, lifts,
delifts and compaction to 70% relative density including hire and operational charges of
power roller seignorage charges and all other incidental and operational charges
necessary to complete the finished item of work for filter blanket, horizontal and inclined
filter drains, longitudinal and transverse filters around rock toe etc., as per drawings and as
directed by the Engineer-in-Charge.
DCUG"HKNVGT"DNCPMGVU:
a) As and where indicated in the approved drawings, Filter Blanket should be laid on the base,
under the down stream portion of the canal embankment. The number of layers in the filter
blankets and the thickness of each layer be, as specified in the drawings. Sand shall be placed
and compacted to an average relative density of 85% with a minimum relative density of 70%.
The sand shall be placed and tamped in place in such a manner that mixing of sand with
foundation or backfill materials will not occur. The filter materials should satisfy the following
criteria.
i) D.15 of Filter material > 4 < 20

D.15 base material
ii) D.15 of Filter material < 5

D.85 base material
iii) D.50 of Filter material < 5

D.50 base material
iv) Coefficient of Curvature CC = (D.30)2 >/< 3
D.10 x D.60
v) Co-efficient Uniformity : Cu = D.60 > 6 for SW
And Cu = D.60 > 4 for GW where SW = Sand Well
graded
D.10 GW = aggregate
well graded.
b) The base filter materials should be well graded so as to satisfy the above mentioned criteria.
The grain size Curve should be approximately parallel to that of base materials, especially
in the fine range. Filter materials should no contain more than 5% of fines i.e, materials finer
than 0.075 mm. (passing through sieve No-2000 I.S. sieve 75 micron) and fines should be
cohesion less to ensure that filter does not sustain a crack. The filter should not have particles
52
larger than 75mm. so as to minimize the segregation.
c) D.15 is the size at which 15% of the total soil particles are smaller, the percentage being by
weight, is being propped, to be determined by mechanical analysis. D.85 size is that at which
85% of the total soil particles are smaller. As more than one filter layer is required, similar
criteria is followed in each case, viz., the finer filter is considered as base materials for the
selection of the gradation at the coarser filter.
d) The requirement for grading of the filter shall be established by the tests conducted in the filed
laboratory on the basis of mechanical analysis of adjacent materials, Mechanical analysis shall
be performed of all samples, which have been compacted by the methods equivalent to
compaction by roller, so that the individual particles are broken to their field condition in the
embankment.
e) The filter materials shall be compacted to an average relative density of 85% with minimum
relative density of 70% as determined by the standard U.S. Bureau of Reclamation (relative
density test for cohesion less free draining soils).
Dd = emax-e
e-max-e min.
Where ‘e’ = In place void ratio
e max = Void ratio in loosened state
e min = Void ratio in most compacted state, and
Void ratio = Volume of voids

Volume of solids
The relative density may also be computed using the maximum and min, density as follows.
Dd = Yd max (Yd-Y min)/Yd (Yd max-Yd min)
Where Yd max = Maximum dry density of soil as obtained by the laboratory procedure
Yd min = Minimum dry density dry density of soil as obtained by the laboratory procedure.
Yd = The dry density at which the soil is to be placed or the in place dry density.
f) The thickness of each filter layer shall be less than 150mm.
RNCEKPI"QH"HKNVGT:
a) Filters shall be laid to the lines and grades and dimensions shown on the drawings.
b) The foundation shall be cleared and stripped in accordance with specification 2.0 before laying the
bottom layer of filter material.
c) Filter material shall be laid in layer of 150mm. adequately watered and compacted by required
number of passes of crawler type tractor or any method approved by the Superintending Engineer
to get dense and stable filter.
d) Care shall be taken to ensure that materials of different layers do not get mixed both at the time of
placing and during compaction. Extreme care shall be taken when placing materials to obtain a fill
free lenses, layers and streaks of segregated materials.
e) In case of horizontal filters after being compacted earth fill material shall be laid over it in layers of
150mm and compacted as directed by the Engineer-in-Charge sheep foot roller or DRR shall not
be used till earth has been laid and compacted to a thickness of 600mm. over the filter blanket.
However, the construction of earth fill in the initial 600mm thickness shall be subject to the same
quality control regarding moisture content and dry density as for the rest of the embankment.
f) In case of inclined filter, the filter shall be raised along the adjoining embankment layers and shall
53
be properly compacted by suitable means. In order to avoid contamination of filters with adjoining
earth fill materials, the top of filter be kept slightly higher than the adjacent embankment level and
any contaminated portion shall be scrapped and removed before adding the new layer.
" OGCUWTGOGPV"CPF"RC[OGPV<"
"
The measurement shall be in meters correct to 0.01 meter and volume shall be worked out to
nearest 0.01 cubic meter. No separate payment will be made and it shall be included in price bid
being quoted in the bill of quantities.
" OGVCN"HKNVGTU<"
"
a) Material : Provisions of Schedule ‘D’ shall apply.
b) Scope: Formation of metal filters of specified thickness using approved quality of well graded metal
of size 10mm. to 75mm at the specified place including cost and conveyance of metal, sampling,
testing sand laying with all leads, lifts, delifts, watering, compacting, seigniorage charges and all
other incidental and operational charges necessary to complete the finished item of work as per
drawings and as directed by the Engineer-in-Charge.
c) Placing:
i) The coarse aggregate filter shall be laid to the lines and grades and dimensions shown on the
drawings.
i) Filter materials shall be laid in layers of 150mm. adequately watered and compacted by any
method approved by the Executive Engineer to get a dense and stable filter, a fill free from
lens, layers and streaks of segregated materials.
ii) In case of horizontal filters, after being compacted, earth fill material shall be laid over it in
layers of 150mm. and compacted as directed by the Superintending Engineer/Executive
Engineer sheep foot roller or DRR shall not be used till earth has been laid and compacted to
a thickness of 600mm over the filter blanket. However, the construction of the earth fill in the
initial 600mm. thickness shall be subject to the same quality control regarding moisture
concrete and dry density as for the rest of the embankment.
iv) In case of inclined filters, the filter shall be raised along the adjoining embankment layers and
shall be properly compacted by suitable means. In order to avoid contaminations of filters with
adjoining earth fill material, embankment level and any contaminated portion shall be scraped
and removed before adding the new layer.
" OGCUWTGOGPV"CPF"RC[OGPV<"
All liner measurement shall be in meter correct to 0.01 meter. Volume shall be worked out to
nearest 0.01 cubic meter. No separate payment will be made, it shall be included in the price bid
being quoted in the bill of quantities.
" Tqem"hknn"kp"vqg"qh"godcpmogpv"*Tqem"vqg+"
"
a) Material : Provisions of schedule ‘D’ shall apply.
b) Scope: Formation of Rock toe using approved quality of well graded metal and stone of size 75mm
to 450mm including cost and conveyance of metal, sampling, testing laying with all leads, lifts,
delifts, and at least 225mm thick rough stone dry packing to the external face including labour
charges for packing, seignorage charges and all other operations necessary to complete the
finished item of work as per drawings and as directed by the Engineer-in-Charge.
c) Rock fill shall consist of sound, durable and well graded broken rock obtained from approved
excavation work and/or from quarries and shall be approve prior to being transported to the areas
of deposition. The materials shall range in size from 75mm to 450mm. However, no load shall
contain more than 15 percent by volume of rock fragments smaller than 75mm in size. All brush
roots, or other perishable material shall be removed from rock fill during the spreading.
f+" Rncekpi"</"
"
i) The rock fill shall be constructed, true to the lines and grades as shown in the drawings.
ii) The rock fill shall be placed and packed to obtain a suitable well graded and free draining fill.
54
iii) The smaller rock fragments shall be placed adjacent to the filter of embankment
and large rock fragments near the outer edge of the fill.
iv) The rock fill shall be placed and roughly leveled in layers not greater than one meter in
thickness.
v) The slopes shall be properly hand packed and the inter slices shall be well filled with spells
and chips and tightly wedged to ensure firm packing so as to have dense, will graded fill
with no larger voids and cavities.
vi) Contamination of rock toe with finer material room any other zone shall be avoided.
vii) Suitable out fall for draining out the seepage water collected in rock toe shall be provided
depending upon the site conditions.
OGCUWTGOGPV"CPF"RC[OGPV:
All liner measurement shall be in meters, correct to 0.01 volume shall be worked out to nearest
0.01 cum . No separate payment will be made. It shall be included in the price bid being quoted in
the Bill of quantities.
" RTQVGEVKQP<"
"
The contractor shall take all precautions necessary for the protection of the work by diversion of
stream local surface drainage, rain water etc. Of these are likely, to damage the work. Any
damage to earth work due to any reason what so ever shall be made good by the contractor at
his cost till the work is certified as completed and takeover by the Superintending Engineer
/Executive Engineer.
" TQCFU"CPF"TCORU<"
"
The contractor shall construction, operation, and maintenance roads and earth ramps adjacent to
the canal and structures at his own expanses. Suitable materials from excavation or borrow areas
shall be placed as embankment for the roads and ramps. The width of the road shall be not less
than 4.25M."
"
Ugevkqp";"
Rnckp"cpf"Tgkphqtegf"Eqpetgvg"Eqpvgpvu"
U0Pq" En0"Pq" KVGO"
1 9.1 General
2 9.2 Scope
List of applicable bureau of Indian standard

3 9.3
specifications
4 9.4 Submittals
General requirements of Materials for Cement

5 9.5
Concrete
6 9.6 Concrete mix proportioning
7 9.7 Production of concrete
8 9.8 Form work
9 9.9 Transportation of concrete

55
10 9.10 Placing of concrete
11 9.11 Compaction of concrete
12 9.12 Construction joints, green cutting and sand blasting
13 9.13 Curing
14 9.14 Sampling and strength of concrete
15 9.15 Un acceptable work
16 9.16 Concreting under special conditions
17 9.17 Inspection and testing of structures
18 9.18 Finishing
19 9.19 Measurement and payment
Load test for water tightness of joints of aqueducts

20 9.20
siphon and under tunnels (water retaining structures)
21 9.21 Steel reinforcement

"
"
" Ugevkqp";"
" Rnckp"cpf"Tgkphqtegf"Eqpetgvg"
" Igpgtcn"
"
a) M10 grade concrete shall be used for plain cement concrete for laying screed layer
(i.e. bed concrete) under the foundations of structures.
b) M15 and above grade of concrete shall be used for plain cement concrete for casting
the structural components of foundations and super structures.
c) M20 and above grade of concrete shall be used for Reinforced cement concrete for
casting the structural components of foundations and superstructures and for all
concrete components of water retaining structures.
In all the above cases, the mix shall be DESIGN MIX. For design mix, the mix
proportions shall be evolved in the laboratory and for the later, the proportions given in
the specifications shall be adopted to produce the required grade of concrete.
"

56
UEQRG"
The specifications cover the requirements of plain and reinforced concrete for various
structures and comprise of:
1) Cost of all materials of approved quality such as specified quality of cement, sand,
graded coarse aggregate specified , MSA, admixture (if necessary), water, including
the cost of Seignorage charges, sampling, testing of materials sales tax and. any other
taxes imposed by the Government, required to manufacture a structural component of
specified grade but excluding the cost of steel and its fabrication charges
2) Conveyance of all materials with all leads, and getting the mix designs conducted.
3) Mixing of all ingredients by weigh batching for the mix.
4) Hire and operations charges of all machinery (Tools, plant and equipment)
5) Preparation of surface for placing of concrete.

6) Cost of initial dewatering, and dewatering during execution, diversion of stream, and
protection works as may be necessary during or after concrete works.
7) Designing and construction of form work for the structural component including
scaffolding, shuttering and removing after curing.
8) Transporting, the concrete with all leads, lifts, delifts either by labour or by machinery
placing in position, vibrating, compacting, finishing and curing of the cement concrete,
plain or reinforced and performing all other operations necessary and ancillary thereto,
complete for finished item of works as specified for M10, M15, M20 is and above
concrete mixes in any structural portion or its components as per the drawings and as
directed by the Engineer-in-charge of the work.
9) Sampling, testing, green cutting, repairing and finishing of concrete.

" Nkuv"qh"Crrnkecdng"DKU"Urgekhkecvkqpu<"
"
All concrete, its constituents, methods and procedures of manufacture shall conform to the
specifications prescribed in the codes published by the Bureau of India Standards. In
addition to IS codes mentioned, the specifications of APDSS and manual for quality control
and inspection shall also be complied with.
UK0PQ" K0U0" Ujqtv"vkvng

Pwodgt"
1 (a) 456-2000 Code of practice for plain and reinforced
concrete
1(b) 457-1963 Code of practice for plain and reinforced
concrete for
2. 2386-1977 Method of test for aggregates for concrete
(part 1 to 8)
3. 516-1959 Method of test for strength of concrete
4. 4925-1968 Specification for concrete batching and mixing
plant.
5. 1791-1985 Specification for batch type concrete mixers
6. 650-1991 Specification for standard sand for testing
cement.

57
7. 2330-1986 Methods for sampling of aggregate for concrete
8. 2722-1964 Specification for portable swing weigh batchers
for concrete (single and double bucket type)
9. 4634-1991 Batch type concrete mixers-methods test

performance
10. 5515-1983 Specification for compacting factor apparatus
11. 5640-1970 Method of test for determining aggregates
impact value of soft & course aggregates
12. 5816-1970 Method of test for splitting tensile strength of
concrete cylinder.
13. 5889-1970 Specification for vibratory plate compactor
14. 5892-1970 Specification for concrete transit mixers and
agitators.
15. 6461-1972 Glossary of terms relating to cement concrete
& 1973 aggregates,
Part 1 to 12 Materials etc.,
16. 6925-1973 Method of test for determination of water soluble
chlorides in concrete admixtures
17. 1838 Specification for performed fillers for expansion
joints in concrete pavements and structures.
18. 7320-1974 Specifications for concrete slump test apparatus
19. 7861-1975
&1981 (Part Code of practice for extreme weather concreting
1&2)
20. 8142-1976 Method of test for determining setting time of

concrete by penetration resistance
21. 9013-1978 Method of making curing and determining
Compressive strength of accelerated cured
concrete test specimen.
22. 9284-1979 Method of test for abrasion resistance of

concrete
23. 1200-1974 Method of measurement of building &
engineering works, concrete works.
24. 5751-1984. Specifications for precast concrete coping
blocks
25. 3085-1965 Method of test for permeability of cement mortar
and concrete.
26. 3873-1978 Code of practice for laying in-situ cement
concrete lining of canals
27. 2506-1985 General requirement for concrete vibrators
screed board type
28. 3363-1965 Specification for pan vibrators
29. 1199-1959 Methods of sampling and analysis of concrete

58
30. 3370-1965 Code of practice for concrete structures for the storage of
&1967 liquids
(Part 1 to 4)
31. 2505-1980 General requirement for concrete vibrators,

immersion type.
32. 3558-1983 Code of practice for use of immersion vibrators
for consolidating concrete.
33. 4656-1968 Specifications for form vibrators for concrete
34. 8989-1978 Safety code for erection of concrete framed
structures.
35. 4990-1981 Specifications for plywood for concrete
shuttering works.
36. 6505-1985 Code of practice for installation of joints in
concrete pavements.
37. 3696-1991 Safety code of scaffolds and ladders.
" Uwdokvvcnu"
"
" Uwdokvvcnu"dghqtg"Eqpuvtwevkqp"
(1) Submittals listed herein are related to items, which require the consent of the Engineer-in-
Charge and are to be submitted by the Contractor before the appropriate work may proceed.
(2) Within 28 days from the date of issue of Notification of Award, but before procuring or
mobilising to the Site the equipment, the Contractor shall submit to the Engineer-in-Charge
updated and detailed plans and descriptions, consistent with those submitted with his
Tender and any subsequent amendments and additions agreed to by the Engineer-in-
Charge and the Contractor, including but not limited to the following:
a) Aggregates Processing Plant:
Description, flow diagrams and drawings in sufficient details to indicate layout, type and
capacity of crushing, screening, washing, conveying and other aggregate processing
and handling equipment.
b) Batching and Mixing Plants:
Description, flow diagrams, and drawings of the plants, and details of the equipment
the Contractor intends to use to determine and control the amount of each separate
concrete ingredient and mixing thereof into uniform mixture.
c) Concrete Cooling Plant:
Details of refrigeration and ice plants and methods, which the Contractor proposes to
use to comply with, concrete temperature requirements.
d) Transport and Placing of Concrete:
Full details of the equipment and methods for transporting the concrete from the
concrete plant to the final point of placing, including numbers, type and capacity of
transport vehicles, concrete pumps, vibrators, and details of standby plants to be
installed.
e) Details of concreting in various stages as per the method statement submitted along
with the tender.
f) Mode and methodology of concrete compaction, and concrete curing.

59
g) Sampling and Testing of Materials: List and details of equipment for sampling and
testing, detailed program for quality control of concrete work, and qualification and
experience of the proposed personnel.
h) Foundation and surface preparation equipment
(3) At least 56 days in advance of any concrete work being carried out at the Site, the
Contractor shall submit to the Engineer-in-Charge following notifications based on the results
of the preliminary material testing:
a) Notification whether cement is required in bulk or bags so that the, amount of cement to
be obtained from several factories can be estimated from each factory and the
proposed schedule of shipment can be finalised.
b) Notification of the source, analysis, method of delivery, and storage of water for
concrete manufacture,
c) Notification of any admixtures which the Contractor proposes to use, manufacturers
thereof, and information about the chemical names of the principal ingredients and the
effects of under or over dosage. Should the Contractor intend to use an accelerator in
any concrete work for his own convenience, he shall give full details of the type,
dosage, influence on construction, and the cost savings involved,
d) Details of the materials for formwork and surface finishes, treatment of construction
joints, and construction techniques which the Contractor proposes to use in order to
achieve the required concrete surfaces and allowable tolerances,
e) System, methods, and equipment for pre stressing steel and grouting of cables in pre
stressed concrete elements.
f) Details of special additives like silica fume & steel fibers for production of high
performance concrete,
(4) At least 28 days prior to procuring or dispatch to the Site of the particular item of work to
which the submittal relates, the Contractor shall submit to the Engineer-in-Charge the
following:
a) Details of curing compounds, if any,
b) Details of epoxy mortar for concrete repair.
(5) Drawings showing the location of construction joints proposed by the Contractor which differ
from those shown on the Construction Drawings, including formwork and reinforcement
details, shall be submitted to the Engineer-in-Charge at least 28 days prior to
commencement of work on that particular structure.
" Uwdokvvcnu"fwtkpi"Eqpuvtwevkqp"
(1) Contractor shall provide the Engineer-in-Charge with a weekly placing scheduling giving the
detailed location of the pours, the approximate extent of pours, and the date on which the
concrete will be placed. This weekly programme of concrete placement shall be submitted to
the Engineer-in- Charge for his acceptance at least 2 days prior to the commencement of
the work.
(2) Before commencement of the concrete placement the Contractor shall prepare a checklist
regarding all preparations for the specified work such as rock surfaces and foundations,
cleaning, formwork, reinforcement, embedding, instrumentation and submit this list to the
Engineer-in-Charge, who after his satisfaction about the work preparations will permit the
contractor in writing to commence concrete placement.
(3) The Contractor shall keep and make available to the Engineer-in-Charge records of the date,
amount, and storage location of each delivery of cement and of the part of the Works in
which it was used and shall provide facilities for checking the stock of cement.
(4) During the performance of the concrete work, the Contractor shall keep a diary where he
shall record the construction procedures related to concreting. This diary shall be made
available to the Engineer-in-Charge upon request. The records shall contain at least the
following:
a) Commencement and termination of concreting of various parts of the structures,
Quantities and quality of aggregates and cement provided, and the storage from which
they were drawn,

60
b) Temperature of air, water, cement, aggregates, and concrete,
c) Meteorological conditions and humidity of air,
d) Sampling and testing performed and summary of results,
e) Personnel employed during various stages of the concreting operation and name of the
responsible inspector or foreman,
f) Equipment used,
g) Directives received from the Engineer-in-Charge,
h) Any special material or procedures employed.
(5) The Engineer-in-Charge reserves the right to require any additional

information deemed necessary to be included in the submitted documents.
" Igpgtcn"Tgswktgogpvu"qh"Ocvgtkcnu"hqt"Egogpv"Eqpetgvg"
"
" Okpkowo"Egogpv"Eqpvgpv"kp"egogpv"eqpetgvg"hqt"Uvtwevwtcn"rwtrqugu<"
For Cement concrete keeping in view of durability requirements, whether it is a design or nominal
concrete mix, the minimum cement content should be as follows for 80mm/40 mm/ 20mm. M.S.A.
Grade Minimum Cement content
M 10 40 mm MSA 220 kgs / cum
20 mm MSA 220 kgs / cum
As per approved mix design, if the cement content required is less than specified above minimum cement
mentioned above shall be adopted.
As per approved mix design, if cement content is more than specified above shall be adopted.
" OCZKOWO" PQOKPCN" UK\G" QH" EQWTUG" CIITGICVG" *OUC+" HQT"

UVTWEVWTCN"RWTRQUGU<"
"
In the absence of specific mention in the drawings and contract documents, the maximum nominal size of
coarse aggregate for different structural members are shown below.
U0Pq0" UVTWEVWTCN"EQORQPGPV O0U0C"

i) Structural components of Buildings 20 mm
ii) Bridge works/ Irrigation structures
1. RCC well curb 20 mm
2. RCC/PCC well steining 40 mm
3. Well cap or pile cap, solid pier and abutments 40 mm
4. RCC work in girders, slabs wearing coat, kerb, 20 mm
approach slabs, hallow piers and abutments, pier/abutment
caps, piles
5. PCC Work 20 mm
iii) Foundations of structure and retaining walls (Mass 40 mm
concrete)
iv) Canal lining

61
1 Lining of thickness 100mm or more 40 mm
2. Lining of thickness 75 mm 25 mm
v) Cement concrete roads 25 mm
vi) Dams, spillways and mass concrete structures 75,150-
230 mm
vii) C.C Blocks in spill channel 80 mm
Pqvg</"
The maximum size of coarse aggregate shall be as large as can be used practicably and
economically under the given conditions, but shall not be larger than any one of the
following.
1/4th, the narrowest dimension between the faces of forms 1/3rd, the
depth of any slab.
3/4th, the clear space between the reinforcement bars, and
3/4th, the narrowest space through which the concrete shall have to be passed. Maximum
nominal size of aggregates shall also be restricted to the smaller of the following values.
10mm. less than the minimum lateral clear distance between the main reinforcements.
10mm. less than the minimum clear cover to the reinforcement bars.
" OCVGTKCNU<"
The provisions made in schedule ‘D’ Section-14, shall apply for cement, fine
aggregate, coarse aggregate, water, admixtures, etc.,
" EQCTUG"CIITGICVG"
GENERAL: For the purposes to these specifications the term Coarse Aggregates clean well
graded aggregate most of which is retained on 4.75mm
I.S. Seive and containing only so such finer material as permitted for various types described
under clause 2.2. of I.S. 383-1970. Coarse aggregate for concrete shall consist of uncrushed
gravel or stone, crushed gravel or stone and partially crushed gravel or stone. Course
Aggregate shall generally have uniform and stable moisture content. In case of variations,
clause 9.2.3. of I.S. 456-1978 shall govern during batching.
QUALITY: The coarse aggregate shall consist of naturally occurring (crushed or uncrushed)
stones and shall be hard, strong, durable clear and free from veins and adherent coating and free
from injurious amounts of disintegrated, pieces alkali, aggregate will be rejected if it fails to meet,
any of the following requirements.
LOS-ANGELS ABRASION TEST :- The abrasion value of aggregates when tested in accordance
with the mothod specified in I.S. 2386 (part-IV) using Los-Angels machine shall not exceed 30%
for aggregates to be used in concrete for wearing surface and 50% for aggregates to be used in
other concrete.
AGGREGATE CRUSHING .STRENGHTH TEST: Aggregate crushing value, when determined
in accordance with I.S. 2386 (Part-IV) 1963 shall not exceed 45% for aggregate used for concrete
other wearing surface and 30%for wearing surfaces. As an alternative to the crushing with the
method specified test, aggregate impact value will be determined with the method specified in
I.S. 2386 (Part-IV) 1963, the aggregate impact value shall not exceed 45% by weight for
aggregates used for concrete for other than wearing surfaces, and 30% by weight for concrete
for wearing surface such as runways, road and payments.
SOUNDNESS TEST: The coarse aggregate to be used for all concrete works shall pass Sodium or
magnesium sulfate accelerated soundness test specified in I.S. 2386 (Part-V) -1963 and the
average loss of weight after 5 cycles shall not exceed the limits specified in clause 3.6.67 of I.S.
383-1970.
SPECIFIC GRAVITY: 2.60 minimum
DELETERIOUS MATERIALS: The maximum quantity of deleterious materials in coarse aggregate
shall not exceed the limits specified in Table-I of I.S. 386- 1970 when tested in accordance with
I.S. 2386.1963.
GRADING
62
a) Coarse aggregate shall be well graded to give a dense concrete of the specified strength and
consistency that will work readily into position without segregation and without the use of on
excessive water content.
b) Coarse aggregate shall be supplied in the nominal sizes given in Table.2 of IS
: 383-1970. For anyone of the normal sizes, the proportion of other sizes as determined by the
methods described in IS ; 2386 (Part-I) -1963 shall also be in accordance with Table. 2
reproduced below.
Nominal sizes and corresponding grading for single size and graded aggregate.
Percentage passing by weight for
IS Percentage passing by weight graded for single size aggregated of nominal size
Sieve aggregated of nominal size
Design
nation
63m 40m 16m 12.5m 40m 20m 16m 12.5
m m 20mm m 10mm m m m
m mm
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
80mm 100 ---- ---- ---- ---- ---- 100 ---- ---- ----
63 mm 85- 100 ---- ---- ---- ---- ---- ---- ----

100
40 mm 0 to 85 to 100 ---- ---- ---- 95 to 100 ---- ----

30 100 100
20mm 0 to 0 to 85 to 100 ---- ---- 30 to 90 to 100 100

5 20 100 70 100
16mm ---- ---- ---- 85 to 100 ---- ---- ---- 90 to ----

100 100
12.5m ---- ---- ---- ---- 85 to 100 ---- ---- ---- 90 to

m 100 100
10mm 0 to 0 to 0 to 20 0 to 0 to 45 85 to 10 to 25 to 30 to 70 40 to 85
5 5 30 100 35 55
4.75 ---- ---- 0 to 5 0 to 0 to 10 0 to 20 0 to 0 to 0 to 0 to

mm 5 5 10 10 10
2.36 ---- ---- ---- ---- ---- 0 to 5 ---- ---- ---- ----
mm
However, the exact gradation required to produce a dense concrete of specified and desired
workability shall be decided by the Engineer.
c) The material passing through the screen shall be in grade ranging from 40mm to 4.75mm each
grade shall be stacked separately.
d) Specific gravity: 2.60 minimum.
iii) Storage

63
a) Aggregate shall be stacked in such a way as to prevent the admixture of foreign materials such
as soil, vegetable matter etc., Heaps of fine and coarse aggregates shall be kept separate.
" HKPG"CIITGICVG"*UCPF+"
GENERAL: The term sand is used to designate aggregate most of which passes 4.75mn I.S.
Sieve and contains only so much coarser material as permitted in clause 4.3 I.S. 383-1970 Sand
shall be predominantly natural sand which may be supplemented with crushed sand to make up
deficiencies in the natural sand grading.
Sand should have a uniform stable moisture content. Determination of moisture content shall be
made as frequently as possible the frequency for a given job being determined by the Engineer-in-
charge according to weather conditions. (I.S. 456-1978).
QUALITY:- The sand shall consist of clean. dense, durable, uncoated rock fragments as per
IS : 383-1970.
Sand may be rejected if it fails to meet any of the following quality requirements.
ORGANIC IMPURITIES IN SAND: Colour no darker than the specified standard In clause
6.22 of I.S 2386 (Part -II) 1963 (Indian standard method of test for aggregate for concrete part. II
estimation of deleterious materials and organic impurities).
SODIUM SULPHATE TEST FOR SOUNDNESS :- The sand to be used shall pass a sodium or
Magnesium Sulphate accelerated test as specified in I.S. 2386 (Part -V) 1963 for limiting loss of
weight.
SPECIFIC GRAVITY: 2.6 minimum
Deleterious substances
The amounts of deleterious substances in sand shall not exceed the maximum permissible limits
prescribed in table-I clause 3.2.1. of I.S. 383-1970 (Indian Standard Specification for coarse and
fine aggregates from natural source for concrete) when tested in accordance with I.S. 2386-1003
GRADING:- Sand for mortar shall conform to the grading of sand given in clause of I.S. 2116-
1960 as indicated below:
Grading of Sand for use in masonry mortars
I.S. Sieve designation Percentage by weight passing by mass
4.75mm 100
2.36mm 90 to100
1.18mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15
Sand whose grading falls out-side the specified limits due to excess or deficiency of coarse or fine
particles may be processed to comply with the standard by screening through a suitably sized
sieve and or blending with required quantities of suitable size sand particles. The sand for concrete
as batched shall be well graded and when tested by means of standard sieves shall confirm to the
limits given in table -4 of I.S. 383-1970 and shall be described as fine aggregates, grading zones -
I, II, III and IV. Sand complying with the requirements of any of the four grading zones is suitable
for concrete. But, sand conforming to the requirements of grading zone -IV shall not be used for
reinforced cement concrete work.

64
FINENESS MODULUS:
a) Sand shall have a fineness modulus between 2.4 to 3.0 subject to the gradation specified in
the preceding paragraph.
b) The modulus shall be computed by adding cumulative percentage of sand retained on the
standard screens 4.75mm, 2.36mm. 1.18mm, 600micron, 300 micron, 150 micron, IS sieves
and dividing the sum by 100. Graduation of sand shall be so controlled that the fineness
modulus of atleast 9 out of 10 consecutive test samples of finished sand shall not vary by more
then 0.10 from the average of 10 test samples. Sand having any deviation from the specified
range of gradation and fineness modulus shall not be permitted to be used in work without the
written permission of the Engineer.
STORAGE: All sand shall be stored on the site of work in such manner as to prevent intrusion
of foreign matter.
" EQPETGVG"OKZ"RTQRQTVKQPKPI<"
The mix proportions shall be selected to ensure that the workability of fresh concrete is
suitable for the conditions of handling and placing, so that it surrounds all reinforcements
(in case of R.C.C.) and completely fills the form work. When concrete is hardened, it shall
have the required strength, durability and surface finish.
The mix proposition shall be as follows.
" FGUKIP"OKZ"EQPETGVG<"
The mix shall be designed in a laboratory to produce the grade of concrete having the
required workability and a characteristic strength not less than the value given in the
following table. The procedure to design and produce the concrete, the standards given in
IS: 10262-1982- Recommended guide lines for concrete mix design and SP: 23-Hand
book on concrete mixes published by B.I.S. shall be adopted.
Specified characteristic compressive

Grade of Concrete
strength at 28 days (N/sq.mm)
M 10 10
M 15 15
M 20 20
M 25 25
M 30 30
M 40 40
M 45 45
M 50 50
" PQOKPCN"OKZ"EQPETGVG<"
The following proportion shall be adopted for the nominal mix concrete.
Grade of Total Qty. of dry aggregate per Maximum Qty. of water per 50
Concrete 50 Kg. of cement (Coarse Kgs. of cement
aggregate + Sand)
M5 800 Kgs 60 Ltrs

M 7.5 625 Kgs. 45 Ltrs.
M. 10 480 Kgs. 34 Ltrs.
M. 15 350 Kgs. 32 Ltrs.
M. 20 250 Kgs. 30 Ltrs.

65
Pqvg<Itcfgf"eqctug"ciitgicvg"ujcnn"dg"wugf0"
"
a) For an average grading of fine aggregate to coarse aggregate the proportions
shall be
1:1.5- for 10mm. M.S.A.
1:2.0- for 20mm. M.S.A. and
1:2.5- for 40mm. M.S.A.
b) In all cases, fine aggregates should conform to the grading of Zone -II or Zone-III of IS:
383-1970.
c) To overcome the difficulties of placement and compaction, if the quantity of water in a mix
is increased, the cement content of the mix specified in the above table shall be
proportionately increased, so that water cement ratio as specified is not exceeded.
d) In case of vibrated concrete, the water content shall be suitably reduced to avoid
segregation.
e) When nominal maximum size of aggregate is 20mm; a rough guide for the nominal mix
proportions by volume will be 1:3:6,1:2:4 and 1:1:5:3 for
M. 10, M.15 and M.20 concrete respectively. For other sizes of aggregates adjustments in
the ratios of the weight of coarse and fine aggregates shall be done.Production of
concrete:
"
" Dcvejkpi"Qh"ocvgtkcnu<"
" "
All materials entering in to the concrete shall be batched by weight except water which shall be
in liters. When the weight of cement is determined on the basis of weight of cement per bag, a
reasonable number of bags should be weighed periodically to check the net weight. Admixtures
if permitted by the Engineer-in-charge should be added to the concrete by weight.
All measuring equipment and weigh batching machinery shall be approved by the Engineer-in-
charge and maintained in a clean serviceable condition and their accuracy shall be periodically
checked. The batching and mixing plant for concrete is to be designed to suit the local
conditions and out put requirements as per IS : 4925-1968 specifications of batching and
mixing plant for concrete.
The aggregates of different sizes should be stocked in separate stock piles, the same shall be
blended in right proportions to ensure uniform grading of aggregate as determined by the
Engineer-in-charge.
In case uniformity in the materials used for concrete making has been established over a
period of time, the proportioning may be done by volume batching, provided periodic checks
are made on weight / volume relationships of materials.
Where weigh batching is not practicable, the quantities of fine and coarse aggregate (not
cement) may be determined by volume.
If fine aggregate (sand) is moist and volume batching is adopted, allowance shall be made for
bulking in accordance with IS: 2386 (Part.III)- 1963 methods of test for aggregate for concrete.
The amount of the added water to concrete shall be adjusted to compensate for any observed
variations in the moisture contents determined by the above tests for both design and nominal
mix of concrete making for weigh and volume batching.
" Okzkpi<"
"
Concrete shall be mixed in a mechanical mixer complying with IS: 1791- 1968 specification of
batch type concrete mixtures. The mixing shall be continued until there is a uniform distribution
of the materials and the mass is uniform in colour and consistency. If there is segregation after
unloading from the mixer, the concrete should be remixed.
The mixing time may be 1.5 to 2 minutes for all normal cements.

66
In exceptional circumstances, such as

(i) mechanical break down,
(ii) work in the remote areas,
(iii) when the quantity of concrete work is small, hand mixing is permitted subject to adding 10
percent extra cement.
The Hand mixing shall be carried out on a water tight platform and care shall be taken to
ensure that mixing is continued until the concrete is uniform in colour and consistency.
Yqtmcdknkv{<" of concrete should be controlled by direct measurement of water cement
ratio. Workability tests should be conducted at frequent intervals as per the procedure laid
down in IS: 1199-1959 methods of sampling and analysis of concrete.
Unwor"vguv"vq"ejgem"yqtmcdknkv{<"
The slump test for concrete shall be adopted only for concretes of medium to high
workabilities (i.e slump 25to 100mm). For very stiff mixes having zero slump, the slump
test does not indicate any difference in concrete of different workabilities.
Sl.No. Type Slump

1 Structure with exposed inclined surface requiring low
(a) 25 mm
slump concretes for proper compaction
(b) Plain cement concrete 25 mm
2 RCC structures with widely spaced reinforcement eg.,
40 - 50 mm
solid columns, piers, abutments putting well staining
3)
RCC Structures with fair degree of congestion of reinforcement eg.,
pier and abutment caps box culverts well curbs, and caps, walls with
50-75mm.
thickness greater than
300mm.
4)
RCC and PSC structures with highly congested 75- 125
reinforcement eg. Deck slab girders, box girder, walls with
thickness less than 300mm mm
5) Underwater concreting through tremie eg., bottom plug, 100 -200

cast-in-situ piling mm
VEE-BEE test method to check workability.
VEE- BEE test shall be done for stiff concrete mixes having ‘low’ or ‘very low’ workability.
The ranges for VEE -BEE TIME method for some placing conditions are given in clause
6of IS: 456-197, which shall be followed.
" Hqto"Yqtm<"
"
Igpgtcn:
The form work shall conform to the shape, lines and dimensions as shown on the plans
and be so constructed as to remain sufficiently rigid during the placing and compaction of
the concrete and shall be sufficiently water tight to prevent loss of cement slurry from the
concrete. The form work shall be made leak proof by providing craft paper.
Form work or centering shall be constructed of steel or timber and adequately designed to
support the full weight of wet concrete without deflection and retain its form during laying,
ramming, vibrating and setting of concrete. Timber used shall be properly seasoned to
avoid deformation when wetted.

67
All rubbish, particularly chippings, shaving and sawdust, shall be removed from the
interiors of the forms before the concrete is placed and the form work in contact with the
concrete shall be cleaned and thoroughly wetted (in case of timber) or treated by coating
with a nonstaining mineral oil or other approved material. Care shall be taken that such
approved composition is kept out of contact with the reinforcement.
The forms shall be removed after expiry of the following periods in the normal
circumstances and when O.P.C is used for making concrete.
i) Walls, columns and vertical.................. 24to 48Hrs or as directed by the faces of

all structural members Engineer-in- charge.
ii) Slabs (Props left under)................................. 3days
iii) Beam soffits (Props left under) .....................7days
iv) Removal of props under slabs:
1) Spanning up to 4.5 meter ................................ 7days
2) Spanning over 4.5 meter .............................. 14days
v) Removal of props under beams and arches:
1) Spanning up to 6.0 meter .............................. 14days
2) Spanning over 6.0meter ...............................21days
However the above periods may be increased or decreased at the discretion of the
Engineer-in charge All form work shall be removed without shock or vibration and shall be
eased off carefully in order to allow the structure to take up load gradually. Forms shall not
be disturbed until concrete has adequately hardened to take the super
imposed load coming on to it and in no circumstances shall forms be struck until the
concrete reaches a strength of at least twice the stress to which the concrete may be
subjected to at time of striking.
After removal of form work, in any case no concrete work shall be finished, plastered or
made good in any form unless and until the Engineer-in- charge, inspect and certify the
surface for such finishing, plastering or making good.
" Eqxgt"Tgswktgogpvu<"
Unless other wise specified in drawings and directed by the Engineer-in- Charge, the
cover requirements for cast-in-situ structural members shall be as follows:
At each end of reinforcing bar not less than 25mm0" nor less than twice the diameter of
such rod or bar.
For a longitudinal reinforcing bar in a vertical member or a column not less than, 40mm.
nor less than the diameter of bar. In the case of columns of minimum dimension of
200mm. or under which reinforcing bars do not exceed 12mm0"the cover of 25mm0"shall be
used.
For longitudinal reinforcing bar in a beam, not less than 20mm or not less than the
diameter of such bar.
For R.C.C. Members immersed in sea water, the cover shall be 50mm more than specified
in (a), (b) and(c) above.
For footing, resting directly on soil the minimum clear cover shall be 50mm. and in the
case of concrete in contact with earth faces contaminated with chemicals, shall be 75mm.
Lesser thickness than those specified above shall be permissible for pre cast construction
with the permission of the Engineer-in-charge.
For water retaining structures, the cover requirements are:
i) For liquid faces Minimum 25 mm or the dia of bar

whichever is greater
ii) For the faces away from The cover as prescribed above in (a) to
the liquid (f) with respect to structural members

68
All reinforcement shall be placed and maintained in position as shown in the drawings as
directed by the Engineer-in-charge adopting chairs and cover blocks with in the tolerance
limits specified in clause: 11.3of IS : 456- 2000.
The bars shall be supported/held in position by suitable means until concrete is poured.
Any one of the following devices shall be used for the purpose.(i)providing steel
reinforcement supports/spacers, (ii)providing of mortar supports/spacers and (iii) providing
plastic supports / spacers.
The steel support/spacer shall be used for slabs except in case of form finished surfaces.
The mortar units can be used for slabs, beams and columns as well as plastered or form
finished surfaces.
Use of pebbles, broken, stone, metal pipe, brick, wooden blocks etc., as devices for
positioning reinforcement will not be permitted.
(part 1 to 4).
Suitable shape and size of cement mortar cover block with proportion of (1:1) shall be
used on the work as per the drawing and as directed and approved by the Engineer-in-
charge.
" Hkpkujkpi<"
"
The following specifications shall apply for the various types of formed surfaces.
" Igpgtcn<"
"
The classes of finish for formed concrete surfaces shall be designated by the use of
symbol F1, F2,F3,F4, and shall be as described below.
Finish F1 shall apply to formed surface upon which or against which backfill of concrete is
to be placed. The surface required no treatment after removal of forms except removal and
repairs of defective concrete. Correction of surface irregularities shall be done only for
depressions which when measured exceed 25mm.
Finish F2 shall apply to all permanently expose formed surfaces for which finishes F3 and
F4 are not specified. Surfaces for which finish F2 is specified will need no filling of pits or
Sack-rub and no grinding other than that needed for repair of surface. Imperfect surface,
irregularities, measured shall not exceed 6mm. for abrupt irregularities and 12mm. for
gradual irregularities.
Finish F3: Immediately after removal of forms from surfaces designated for F3 finish, all
required patching, clean up and correction of major imperfections shall be completed and
the surfaces shall be given a sack rubbed mortar finish as described below. The surfaces
shall be thoroughly wetted and permitted to reach surface drying before starting the sack
rubbing. The surfaces shall be finished in areas sufficiently large and shall prevent
complete drying of any part before the sack- rubbing is completed for that area. The mortar
used for the sack-rubbing shall consist of one part of cement to two parts, by volume, of
sand passing on IS sieve 100 and enough water so that the consistency of the mortar is
that of thick cream.
The mortar shall be rubbed thoroughly over the area with clean brush or a sponge rubber
float, completely filling all pits and irregularities.
" Wphqtogf"Uwthcegu"
"
The classes of finish for unformed concrete surfaces are designated by the symbols U1,
U2, and U3. Interior surfaces shall be stopped for drainage where shown on the drawings.
Surfaces which will be exposed to the weather and which would normally beveled, shall be
sloped for drainage. Unless the use of other slopes or level surfaces is specified narrow
surfaces such as tops of walls and curbs, shall be sloped approximately at 3.0cm per
meter. Border surfaces such as walls, road way platforms and decks, shall be sloped
approximately at 1.5cm per meter.

69
" Vjg"Encuugu"qh"hkpkuj"vq"dg"crrnkgf"ujcnn"dg"cu"Fgvckngf"dgnqy<"
"
Finish U1: (Screened finish) shall apply to unformed surfaces that are to be covered by
back fill or by concrete, and surfaces of sub-floors which will be covered by concrete floor
topping, finish U1 is also used as the first stage for finishes U2 and U3.Finishing operation
shall consist of sufficient leveling and screening to produce even and uniform surfaces.
Surface irregularities, measured shall not exceed 10mm.
Finish U2 (floated finish) shall apply to unformed surfaces that are to be covered
by back fill or by concrete or unformed surfaces for which finishes U1 and U3 are not specified,
and shall include floors of sumps, tops of walls. Parking areas, parapet walls, surfaces of gutter,
side walls and outside entrance slabs. Finish U2 is also used as the second stage for finish U3.
Floating may be performed by use of hand or power driven equipment. Floating shall be started as
soon as the screened surface has stiffened sufficiently, and shall be the minimum necessary to
produce a surface that is free from screed marks and is uniform in texture. Finish U3 is to be
applied, floating shall be continued until a small amount of mortar with out excess water is brought
to surface so as permit effective trowelling. Surface irregularities, shall not exceed 6mm joints and
edges of gutters, side walls, entrance slabs, and other joints and edges shall be tooled where
necessary, dry ingredients of the mortar, in the same proportions shall be rubbed over the area.
After the mortar has stiffened adequately to prevent smear but before it hardened the excess
mortars shall be removed by rubbing with clean burlap. After the final scrubbing a light fog
spraying shall be applied to the coated surface, the moisture thus applied being just sufficient to
damp the surface with out allowing water to run down the face of the walls. All sack-rubbed areas
shall be kept continuously damp for at least 72 hours after the final sack rubbing or until
completion of the curing period for the concrete. When measured abrupt irregularities shall not
exceed 6mm, for irregularities parallel to the direction of flow, for irregularities exceeding these
limits shall be reduced by grinding on a level of 1 to 20ratio of height to length.
Finish F4 shall apply to form surfaces where absorptive form lining is used surfaces
provided by absorptive form lining shall not be rubbed or treated in any way except for
cleaning by finish U3 (troweled finish) shall apply to unformed surfaces such as slabs to
be covered with built up roofing or membrane water proofing, and stair trends. When the
floated surface has hardened sufficiently to prevent excess of final materials from being
drawn to the surface steel trowelling shall be started. Steel troweling shall be performed
with firm pressure so as to flatten the sandy texture of the floated surface and produce a
dense uniform surface, free from blemishes and trowel marks, light steel trowelling will be
permissible on surfaces of slabs to be covered with or membranes water proofing , in
which light trowel marks are not considered objectionable. Surface irregularities,
measured shall not exceed 6mm.
The following finishes shall be provided for the concrete used in the various. works.
1. Spillway crest F3 or U2
2 Spillway stilling basin F3 or U2
3. Spilway pipe F3or U2
4. Spillway bridge road slab F2 or U2
5. Elevator tower exterior face F4
6. -do- Interior F2 or U2
7. Around sluice F3 or U2
8. Around galleries, adits, sump well F2or U2
9. Face concrete in retaining wall
divide wall, or retaining wall (water side) F3 or U2
" Vqngtcpegu"hqt"eqpetgvg"eqpuvtwevkqp<"
"
Permissible surface irregularities for the various classes of concrete surface finishes
specified and defined as finishes are to be distinguished from tolerance described herein.

70
i) Tolerance in Dams and Appurtenant works.

ii) All structures
a) Variation of constructed line outline from established position in plan. In 6m.

12mm.
In 12m. 18mm.
b) Variation of dimension to individual structural features from

established position.
In 24 meters or more … 30mm.
In buried construction: Twice the above quantity.
Variation from the plumb from the specified batter or from the curved surface of all
structures, including the lines and surfaces of columns, walls, piers and vertical joint
grooves.
In 3 meters. 12mm.
In 6 meters. 20mm.
In 12meters or more. 30mm.
In buried construction: Twice the above quantity:
Variation from level from the grades indicated on the drawings in slabs, beams sofits and
horizontal joint grooves and visible areas.
In 3 meters. 6mm.
In 10 meters. 20 mm.
In buried construction : Twice the above quantity.
Variations in cross sectional dimensions columns, beams, piers Minus

6mm. to plus 12mm.
Variation in thickness of slabs, walls and similar members Minus

6mm. to plus 12mm.
f) For sills and side walls for gate and similar water tight joints. Variation from the plumb
and level should not be greater than 3mm. in 3meters.
Tolerance for placing reinforcement steel

Variation of protective covering
With 5 cm. cover 6mm.
With 7.5cm. cover 12mm.
Variation from indicated spacing
10 mm. for spacing .. greater than 15cm.
5mm. for spacing .. less than 15cm.
" Igpgtcn"tgswktgogpvu"
Forms shall be used wherever necessary to confine the concrete, shape it to the required
lines, or to ensure against contamination of the concrete by material caving or sloughing
from adjacent excavations or other features of the work. All exposed concrete surfaces
having slopes of 1to1 or steeper shall be formed where the side slopes of walls of an
excavation for concrete structure can be trimmed to the prescribed lines without sloughing,
the use of forms will not be required. Forms shall have sufficient strength to with stand the
pressure resulting from placement and vibration of the concrete and shall be maintained
rigidly in correct position. Forms shall be tight to prevent loss of mortar from the concrete.

71
Moulding strips shall be placed in the corners of forms so as to produce beveled edges at
formed surface and edges at formed joints will not require beveling unless so indicated on
the drawings. Forms for concrete surfaces for which finishes F3 and F4 are specified shall
be reset and tightened at construction joints, so that, they fit firmly against the hardened
concrete when concrete replacement is resumed. Additional forms ties shall be necessary
to ensure against spreading of the reset forms under pressure of the subsequently placed
concrete and consequent off-set from the previously formed face.
Vqpiwg"/"cpf"itqqxg"ujgcvjkpi<"
Tongue-and groove sheathing, where used for forming shall be 10cm to 15cm Common
T&G and shall be placed horizontally.
" Hqtou"hqt"yctrgf"uwthcegu"fgukipcvgf"hqt"H6"hkpkuj<"
Forms for warped surface shall be constructed so as to conform accurately to the required
curvatures of the sections. Intermediate sections shall be interpolated as necessary for the
type of form construction being used and the forms shall be constructed so that the
curvatures will be continuous between sections. Where necessary to meet requirements of
the curvature from sheathing built of laminated splices be cut to make tight and smooth
form surface. The forms constructed such that the joint marks on the concrete surfaces
inside of principle water conduits shall as far as possible follow the line of water flow. After
the forms have hidden and any roughness and all angles on the surfaces of the forms
caused by matching form the materials shall be dressed to the required curvatures.
" Hqtou"ujgcvjkpi"cpf"nkpkpi<"
Wood on sheathing or lining shall be of such kind and quality or shall be so treated or
coated that there will be no chemical deterioration or discoloration of the formed concrete
surfaces. The type and condition of form sheathing and lining, the ability of the forms to
withstand distortion caused by placement and vibration of the concrete, and the workmen
ship used in form construction shall be such that the formed surfaces, after being finished
will conform with the applicable requirements of these specifications pertaining to finish of
formed surface.
Required finish
of formed
surface Wooden sheathing or lining Steel sheathing or lining
Steel sheathing permitted

F1 Any Grade
Steel lining permitted
Steel sheathing permitted
F2 No. 1 Common Ship-lap Steel lining permitted if
necessary
Steel sheathing not permitted Steel

No.1 common tongue & grooved except lining not permitted
F3 where plywood lining or sheathing is
specifically required
No.1 common tongue & grooved for plane

or cylindrical surfaces Thin plywood lining Steel sheathing not permitted.
F4 for warped
surfaces Steel lining not permitted
Absorptive form lining backed with Steel sheathing not permitted

F5
No.1 common ship-lap Steel lining not permitted
Note: “Steel sheathing” denoted steel sheets not supported by backing of wooden boards.
“Steel lining” denotes thin steel sheets Supported by backing of wooden boards.

72
" Cduqtrvkxg"hqto"nkpkpi<"
"
Absorptive form lining, where directed to be used, shall be of the type and quality
approved by the Engineer-in-Charge. The form lining shall be highly absorptive to air and
water and through its absorptive capacity able to eliminate voids, pits and other common
effects from the concrete surface. The lining shall be readily removable from the concrete
without damage to the surface. It shall produce dense concrete surface of uniform and
satisfactory texture and colour. The lining itself and treatment employed in its manufacture
shall not discolour the concrete nor interfere with normal chemical reaction of the cement.
The backing to which absorptive lining is attached shall be sufficiently smooth, even and
free from cracks, knot holes, and other imperfection to avoid uneven in the finished
surface. The lining shall be in sheets of uniform length and width. Location and direction of
the joints shall be approved by the Engineer-in-Charge. The joints between sheets shall be
fitted smoothly and accurate and patching shall be avoided. Cutting and trimming shall be
true and shall be done with tools well adapted to this work so that sharp, smooth, square
edges are produced. The lining shall be attached to the forms in such a manner that it is
held securely and smoothly in place. Nails or tacks, if used, shall be spaced in uniform
pattern and shall be driven flush. Dents and hammer marks in the surface of the lining
shall be avoided. After the lining has been attached to the form, the joints shall be ribbed
with a smooth tool to press down any projecting fibers. Where absorptive form lining is in
contact with the face of previous pour, care shall be used in setting and sufficient pressure
shall be applied in tightening form anchors to produce continuity and evenness at the face,
free from offset, and streaks, and other irregularities. The lining shall be kept dry and shall
not be reused.
" Vtcpurqtvcvkqp"qh"eqpetgvg<"
Concrete shall be transported from the mixer to the form work as rapidly as possible by
methods approved by the Engineer-in-charge, which will prevent the segregation or loss of
any of the ingredients and maintaining the required workability.
The concrete shall be transported, laid and compacted in its final position with in
30minutes of its discharge from the mixer unless carried by properly designed agitators,
where the time of haul exceeds 20minutes, Mixed concrete shall be transported in suitable
agitators or transit mixer as directed and approved by the Engineer-in-charge.
" Rncekpi"qh"Eqpetgvg<"
"
All surfaces upon or against which concrete is to be laid shall be prepared in accordance
with the drawings.
No concrete shall be placed until all form works, installation of parts to be embedded and
preparation of surface involved in the placing have been approved by the Engineer-in-
charge .No concrete shall be placed
in water except when specifically so permitted. All surfaces of forms and embedded
materials have become incrusted with dried mortar from previously placed shall be
cleaned before surrounding or adjacent concrete is placed.
If concreting is not started within 24 hours of the approval being given, it shall have to be
obtained again. The contractor shall notify the Engineer-in- charge at least 24 hours before
batching begins for placement of concrete.
All absorptive surfaces against which concrete is to be laid shall be moistened thoroughly
so that moisture will not be withdrawn from the freshly placed concrete. The concrete shall
be deposited as nearly as possible in its final position and compacted before setting
commences and should not be subsequently disturbed.
Methods of placing should be such as to preclude segregation.
Care should be taken to avoid displacement of reinforcement or movement of form work.

Placing is allowed with a limitation of free fall of 1.5 meter.

73
All concrete shall be placed in continuous and approximate horizontal layers, the thickness
of which shall not more than 450mm. for mass concrete and 150mm. for R.C..C. and plain
cement concrete works.
Concrete shall not be placed faster than the placing crew can compact it, properly. On
sloping surface, concrete should be placed at the lower end of the slope first, progressing
upwards, and thereby increasing natural compaction of the concrete.
High velocity discharges which may cause segregation of the concrete should be avoided.
Recommended methods of placing concrete in segregation prone locations area:
c+" Kp"pcttqy"hqtou<"
If very wet concrete is to be placed in narrow, deep form work, water content in the
upper layers should be gradually reduced to compensate for water gain.
d+" Rncekpi"vjtqwij"ukfg"rqtvu"kp"eqnwop"hqto"yqtm<"
Concrete shall be dropped vertically in to the outside pockets under each form work
opening (part) so that concrete stops and then flows easily into the column form work.
e+" Rncekpi"qp"unqrkpi"uwthcegu<"
Concrete shall not be discharged from pre end of a chute on to a sloping surface, as
the heavier coarse aggregates are separated and carried down the slope. The chute
should be fitted with a baffle and a drop at its end, so that concrete remains on slope.
f+" Vgorgtcvwtg"<"
Concrete when deposited shall have a temperature of not less than 5 degrees Celsius,
and not more than 40 degrees Celsius.
Ygcvjgt"eqpfkvkqpu="
Concreting operations shall temporarily be suspended during excessively hot or rainy
weather when conditions are such that the concrete cannot be placed and cured.
During the hot weather, no concrete shall be deposited when the temperature with in
the forms is more than 40 degree Celsius. When ever necessary expressed surface of
fresh or green concrete shall be shaded from the direct rays of sun and immediately
protected against premature setting or drying by being cured under conditions fine
spray of water.
During contained rainy weather or heavy downpour all freshly placed concrete shall be
covered and protected against surface wash. Then all badly washed or stressed
surfaces shall be removed and washed before depositing the next course.
g+" Rtgrctcvkqp"qh"hqwpfcvkqp"uwthceg"<"
Immediately before placing concrete all surfaces of foundations upon or against which
concrete is to be placed shall be free from standing water mud, debris, free from oil,
objectionable casting, loose, semi detached or unsound fragments of rock. Surface of
rock shall be cleaned with the use of high velocity air jet, webs and blasting staff
brooms, picks or by effective means.
h+" Rtgrctcvkqp"qh"eqpetgvg"uwthceg"<"
Concrete surface upon which fresh concrete is to be placed shall be chipped and
roughened to a depth of not greater than 25mm. The roughening shall be performed
by chipping or other satisfactory methods and in such a manner as not to loosen,
crack or shatter any part of the concrete beyond the roughened surface.
After being roughened, the surface of the concrete shall be cleaned thoroughly of all
loose, dirt and other objectionable substances and shall be sound and hard and in
such conditions as to assure good, mechanical bond between old and new concrete.
All concrete which is not hard, dense and durable shall be removed to the depth
required to secure a satisfactory surface.
i+" Egogpv"unwtt{"cpf"Oqtvct"nc{gt"<"
After surfaces have been prepared satisfactorily, all surfaces, rock, old concrete and
old masonry shall be coated with a thin layer of cement slurry ( comprising 1 cement to
2/3 water by volume ) and covered with a layer of mortar not less than 12mm not more
than 20mm thick. The mortar shall be similar.to the mortar in the regular concrete
mixture having the same cement, sand ratio of the mortar used in concrete unless
otherwise directed. The cement slurry and mortar shall be spread uniformly and shall
be worked thoroughly into all irregularities of the surface. Concrete shall be placed
immediately up on the fresh mortar.

74
" Eqorcevkqp"qh"eqpetgvg<"
"
" Igpgtcn<"
"
Compaction should preferably be achieved by mechanical vibration. But in isolated
locations, it can also be achieved if approved by the Engineer-in- charge by manual
methods, namely, ridding, spading and tamping. The mechanical compaction is achieved
by vibration. The methods like spinning mechanical tamping and use of shock are
restricted to special situations as approved by the Engineer-in-charge.
Under - vibration is harmful & should be avoided Over-vibration may cause.

(i) Settlement of the coarse aggregate
(ii) Heavy bleeding of the concrete,
(iii) Excessive form work deflection and from work damage.
The following vibrators shall be used for compaction as per the directions of the
Engineer-in-charge.
" Koogtukqp"Xkdtcvqtu<"
"
Immersion vibrators as per IS: 2505-1980 shall be used for consolidation of plain as well
as reinforced concrete. They shall be of either.
a) Flexible shaft type, powered by different types of motors or
b) Motor-in-head type, hectically or pneumatically driven.
While compacting with internal vibrators, concrete should be deposited in layers of 300 to
450 mm. thick and the vibrator inserted vertically at uniform spacing over the entire area of
placement. The vibrator should penetrate rapidly to the bottom of the layer and at least
150mm. into the preceding layer, if there is any. It should be held (generally 5 to 15
seconds) until the compaction is considered adequate and then withdrawn slowly at the
rate of about 80 mm./second.Operational frequency 8,000 to 12,000 per minute.
;0330"5" Uetggf"Dqctf"v{rg"xkdtcvqtu<"
Concrete vibrators of screed board type as per IS: 2506-1964 shall be used for
compaction of concrete roads, floors, pavements and thin slabs, where the area to be
compacted is large or the thickness is too small (less than 200 mm.) to allow the use of
immersion vibrators.
Operational frequency: 3500 per minute (under no load state).
" Hqto"Yqtm"Xkdtcvqtu<"
Form work vibrators as per IS: 4656-1968 shall be used for compaction of concrete,
precast concrete moulds, gullies and deep post-tensioned beams. They shall be used for
compaction of in-situ concrete in small and narrow sections of very heavily reinforced
section where immersion vibrators cannot be used. These are two types.
a) The fixed or clamped type, and
b) The manual type
Operational frequency: 2800 per minute (under no load state)
" Xkdtcvkpi"Vcdng<"
"
Vibrating table as per IS: 2514-1963 shall be used for compaction of concrete in moulds
for the manufacture of precast products and structural elements. They compact concrete
through rapidly alternating horizontal, vertical or circular vibrations which are transmitted to
moulds filled with concrete and placed or clamped on the table top.
Operational frequency : 3000 to 6000 cycles per minute.
Immediately after compaction, concrete shall be protected against harmful effects of

weather, including rain, running water, shocks, vibration, traffic, rapid temperature changes
and drying out.
" Eqpuvtwevkqp"lqkpvu"itggp"Ewvvkpi"cpf"Ucpf"Dncuvkpi<"
75
"
" Eqpuvtwevkqp"lqkpvu<"
"
Construction joints are the stopping places in the process of placing of concrete as it is
impracticable to place concrete in a continuous operation. The position and arrangement
of joints are predetermined as shown in the drawings and as directed by the Engineer-in-
charge as per site conditions of placing.
The spacing of construction joints shall be determined by the design parameters,

construction limitations, and type of work and site conditions and shall be as few as
possible. These shall be provided at proper places where they may be carefully
constructed with attention to workmanship. From the strength of structural consideration, it
is desirable to position construction joint at points of MINIMUM. (Clause 12.4.1 and 12.4.2
of IS: 456-200)
If directed by the Engineer-in-Charge, joint should be supplemented by dowels to provide

adequate bond between the old and new concrete.
When the work has to be resumed on a surface which has hardened, such surface shall
be roughened. It shall then be swept clean and thoroughly wetted. For vertical joints neat
cement slurry shall be applied on the surface before it is dry. For horizontal joints the
surface shall be covered with a layer of mortar about 10 to 15 mm. thick composed of
cement and sand in the same ratio as the cement and sand in concrete mix. This cement
slurry or mortar shall be freshly mixed and applied immediately before placing of the
concrete.
Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the
wet surface with wire or bristle brushes, care being taken to avoid dislodgment of particles
of aggregate. The surface shall be thoroughly wetted and all free water removed. The
surface shall then be coated with neat cement slurry. On this surface, layer of concrete not
exceeding 150 mm . in thickness shall first be placed and shall be well rammed against old
work, particular attention shall be paid to corners and close spots. Work thereafter shall
proceed in the normal way.
" Itggp"Ewvvkpi<"
"
The surface of the respective lift shall be thoroughly green cut with an air water jet. Green
cutting is usually done 8 to 12 hours after the top surface of a concrete lift had been
completed and sufficiently hardened. The actual time for taking up the green cutting
operation shall depend upon the following factors.
a) Concrete placement temperature

b) Atmospheric temperature.
c) Concrete mix, and
d) Slump.
The air water jet will remove the thin surface film of latency and grout to expose clean
surface.
Green cutting, if done at the proper time, shall yield very good results. When started too
early, it shall result in over cutting and removing too much mortar. It is also liable to loosen
the aggregate particles and leaving too poor a surface to bind the fresh concrete. On the
other hand, if green- cutting is delayed too long, the cutting action of the air and water jet
would be ineffective for proper removal of latency. It therefore, requires much greater care
and judgment for proper use at proper time.
Skill of jet Operator: Besides determining the proper time for initiating green cutting, the
process will require constant attention on the part of the air water jet operator. By correct
manipulation of the high velocity air-water jet, a trained operator can ensure the removal
of the thin surface film of laitance and grout effectively and at the same time, leaving, the
aggregate, already embedded in the mortar, undisturbed.

76
Proper Air-water Gun: In addition to the skill of the jet operator, a proper air water gun is
also a vital requirement for effective green-cutting. The issuing nozzle must be about 460
mm. (18inches) long to ensure the requisite cutting force close to the concrete surface.
Quantum of Compressed Air and Water: - For effective green cutting, it is essential that
the air pressure should be around 6.33 to 7.03 kg/cm2. It should not be allowed to fall
below 6.33Kg/cm2. The water pressure, of course, should be sufficient to bring the water
into effective influence of the air pressure. As an approximate estimate, the quantity of
compressed air required by the green-cutting gun is 2 cubic meters per minute and the
quantity of water is 60 gallons (273 Liters) per minute.
An important aspect to be taken note of is that green-cutting as an exclusive operation

shall be fully useful only if the next lift of concrete is placed within 3 to 4 days (or a
maximum of 5 days of the placement of the previous lift. If there be a delay in concrete
placement beyond this period, the laitance will come up to the concrete surface again at
some places. Removal of such laitance shall then be not possible by the ordinary green-
cutting operation alone light sand blasting of even the green-cut lifts shall have to be
resorted to. However, if there is excessive delay in concrete placement, it will require
either “Wet sand” blasting of the application of high pressure “water blaster” to remove the
laitance for effective binding with the fresh concrete. The effect to achieve this will be
considerably less if green cutting has already been done.
;034050" Ucpf"dncuvkpi<"
"
Sand blasting is the process of roughening and cleaning the surface of old and set
concrete by means of coarse sand and air applied under pressure of 6.33 to 7.03 Kg/Cm2
through a nozzle, so as to erode the laitance and grout from the old concrete. Sand
blasting of rock is also done so that concrete may be placed on or against a clean surface
of rock as required according to specifications.
There are two types of sand blasting, namely “wet sand blasting” and “dry sand blasting” In
wet sand blasting water is also used along with sand and air under pressure, while in the
later, only sand and air under pressure are used. Normally the concrete and rock surface
etc., are wet sand blasted to keep down the dust.
The percentage of different sizes of sand particles for efficient sand blasting shall be as
follows.
Size Percentage
8 mesh per inch (25.40 Millimeters) 26

For effective sand blasting, it is essential that pressure of air should be between 6.33 to
7.03 Kg/cm2. Sand blasting becomes ineffective, if sand having large percentage of fines
is used. It will not provide the requisite cutting power and the whole effort goes waste.
Good quality well graded sand (sand-blast-sand) is needed for achieving the objective of
sand blasting.
High pressure Water Blasters: Green cutting is far cheaper than sand blasting. Proper
quality sand (Known as sandblast sand) is most expensive item and special efforts are
needed to arrange such sand. A high pressure water blaster offers a workable alternative
to sand blasting.
Uwooct{<" Green cutting offers the most economical methodology in the preparation of
77
good construction joints. It has, however, to be initiated at the proper time and with a
proper air- water gun to yield the best results. It is far cheaper than sand blasting. If a
delay of more than 3 to 5 days is anticipated in placing the concrete over the previous lift
the concrete surface of the lift should be properly “green cut” and thereafter (say one day
prior to placement of concrete) it should be light sand blasted or water blasted in order to
remove the “re-appeared” laitance.
Qvjgt"Tgswktgogpvu"qh"eqpetgvg"eqpuvtwevkqpu:
All concrete construction shall conform to the permissible tolerances and technical provisions as
described in the section. All structures shall be built in a workman like manner, to the lines grades
and dimensions shown in the drawings or as prescribed by the Engineer-in-charge. The location
of all the construction joints shall be subject to the approval of the Engineer-in-charge. The
dimensions of each structure shown on the drawings shall be subject to such changes as may be
found necessary by the Engineer-in-charge, to adopt the structure to the conditions disclosed by
the excavation.
" Eqpetgvg"kp"xctkqwu"eqorqpgpvu"qh"Dtkfigu."wpfgt"vwppgnu."Cswgfwevu"gve0."
Expansion joints shall be constructed as shown on the drawings or as directed. Pre

moulded bituminous fibre type expansion joint material shall be placed in the expansion
joints. Lighting recesses shall be constructed in the parapets as directed by the Engineer-
in-charge. Open joints or false joints shall be constructed as shown on the drawings or as
directed by the Engineer-in-charge. Preformed expansion joint filler shall be placed in the
road way and side walls where shown on the drawings or as directed by the Engineer-in-
charge.
" EQPETGVG"KP"DNQEMQWVU<"
"
a) Care shall be taken in placing the concrete in blockouts in order to ensure satisfactory
bond with the concrete previously placed and to secure complete contact with all metal
work in the blockouts.
b) The roughening of the concrete surface of the blockouts shall be performed by
chipping or sand blasting as approved by the Engineer-in- charge. and in such a
manner as not to loosen, crack or shatter any part of the concrete beyond the
roughened surface. The surface of the concrete shall then be cleaned thoroughly of
loose fragments, dirt and other objectionable substances in order to ensure good
mechanical bond between the existing and new concrete. All concrete which is not
hard, dense and durable shall be removed to the depth required to the satisfaction of
the Engineer-in-charge.
" Godgfogpv"Kp"Eqpetgvg<"
"
In some of the locations of structures, a few conduit openings shall have to be provided
through RCC/PCC as shown in the drawings. Placement of concrete shall be suitably
carried out around such conduits or openings. No extra claim shall be entertained.
" Ewtkpi<"
"
" Igpgtcn<"
"
All equipment, material etc., needed for curing and protection of concrete shall be at hand
and ready for installing before actual concreting begins. Detailed plans, methods and
procedures and protection shall be settled and got approved in writing from the Engineer-
in-Charge sufficiently in advance of the concreting. The equipment and method proposed
to be utilized shall avoid interruption or damage to the work.
The vertical and sloping concrete surfaces shall be kept saturated with a system of
perforated pipes mechanical sprinklers/porous hoses /any other suitable method which will
keep all surfaces continuously wet.
" Oqkuv"Ewtkpi<"
"
78
Exposed surfaces of concrete shall be kept continuously in a damp or wet condition (to
avoid formation of surface cracking due to alternate wetting and drying) by impounding
water or by covering with layer of sacking, canvas, hessian or similar materials and kept
constantly wet for at least SEVEN DAYS from the date of placing of concrete, if O.P
cement is used in the concrete.
It may be reduced to 3 to 4 days when rapid hardening Portland cement is used, but
greater care shall be exercised, particularly at early stages when rate of hydration is high.
" OGODTCPG"EWTKPI<"
"
Approved curing compounds shall be used in lieu of moist curing with the permission of
the Engineer-in-charge. These compounds shall be applied to all exposed surface of the
concrete as soon as possible after the concrete has set and the free water on the surface
has disappeared and no water sheet is seen. But not so late that, the compound will be
absorbed into the surface pores of the concrete.
" Ucornkpi"cpf"Uvtgpivj"QH"eqpetgvg<"
"
" Igpgtcn<"
"
The sampling shall be done as per the specifications laid down in IS 1199- 1959-
specification for sampling and analysis of concrete and testing of concrete shall be carried
in accordance with IS : 516-1959 specification for testing strength of concrete.
For relatively small and unimportant buildings and structure in which quantity of concrete is
less than 15 cum; the strength tests may be waived by the Engineer-in-charge.
The sampling scheme given in clause: 14 and the acceptance criteria given in clause 15 of
IS 456-2000 are applicable to both design mix and nominal mix concrete. In the case of
the later, the preliminary tests for establishing the mix proportions are not necessary.
Concrete of each grade shall be assessed, separately.
The concrete under acceptance shall be notionally divided into lots for the purpose of
sampling, before commencement of work. The delimitation of lots shall be determined by
the following:
i) No individual lot shall be more than 30 cum. in volume.

ii) At least one cube forming an item of the sample representing the lot shall be taken
from concrete of the same grade and mix proportions cast any day.
iii) Different grades of mixes of concrete shall be divided into separate lots.
iv) concrete of a lot shall be used in the same identifiable component of the structures.
" Ucornkpi"cpf"vguvkpi<"
"
a) Concrete for making 3 test cubes shall be taken from a batch of concrete at point of
delivery into construction according to procedure laid down in IS: 1199.
b) A random sampling procedure to ensure that each of the concrete batches forming
the lot under acceptance inspection has equal chance of being chosen for taking
cubes shall be adopted.
c) 150 mm. cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with IS: 516. The 28day test strength result for
each cube shall form an item of the sample.
d) Three test specimens shall be made from each sample for testing at 28days.
Additional cubes may be required for various purposes such as to determine the
strength of concrete at 7 days or for any other purpose.
e) The test strength of the sample shall be the average of the strength of 3 cubes. The
individual variation should not be more than +15% or- 15% of average.Frequency:
The minimum frequency of sampling of concrete of each grade shall be At least one
sample shall be taken from each shift of work.

79
Quantity of concrete in work, cum No. of samples
1–5 1
6 – 15 2
16 – 30 3
31 – 50 4
51 – and above 4 + 1 additional sample for each
additional 50 cum or part thereof
" Vguv"rtqegfwtg<"
In order to get a relatively quicker idea of quality of concrete, optional tests one beams for
modulus of rupture at 72+2 hours or at 7days, or compressive strength tests at 7days may
be carried out in addition to 28 days compressive strength tests. For this purpose, the
values given in Table may be taken for general guidance in the case of concrete made
with Ordinary Portland cement. In all cases, the 28 days compressive strength specified in
Table shall alone be the criterion for acceptance or rejection of the concrete. If however,
from tests carried out in a particular job over a reasonably long period, it has been
established to the satisfaction of the Engineer-in-Charge that a suitable ratio between 28
days compressive strength and the modules of rupture at 72+2 hours or 7 days or
compressive strength at 7 days may be accepted, the Engineer-in-Charge may suitably
relax the frequency of 28 days compressive strength provided the expected strength
values at the specified early age are consistently met.
QRVKQPCN"VGUVU"TGSWKTGOGPVU"QH"EQPETGVG"
"
Grade of Compressive Strength on Modules of Rupture by
concrete 1.5m Cubes, Min. at 7 Beam test, Min.
days
" " At 72 +2h at 7 days
1 2 3 4
N/mm2 N/mm2 N/mm2
M – 10 7.0 1.2 1.7
M – 15 10.0 1.5 2.1
M – 20 13.5 1.7 2.4
M-25 17.0 1.9 2.7
M-30 20.0 2.1 3.2
M-40 27.0 2.5 3.4
"
" Uvcpfctf"fgxkcvkqp<"
"
*k+" Uvcpfctf" Fgxkcvkqp"dcugf"qp"Vguv"tguwnvu<"
"
Number of test results: The total number of test results required to constitute as
acceptable record for calculation of standard deviation shall be not less than
30.Attempts should be made to obtain in the 30 test results, as early as possible,
when a mix is used for the first time check additional condition of about 5 samples.
Standard deviation to be brought up to date. The calculations of the standard deviation
shall be brought up to date after every change of mix design and at least once a
month.
*kk+" Fgvgtokpcvkqp"qh"Uvcpfctf"Fgxkcvkqp"
"
*c+"The standard deviation of concrete of a given grade shall be calculated using the
following formula from the results of individuals tests of concrete of that grade.

80
*d+"Estimated standard deviations
S= ( )2
Where
n 1
Delta = deviation of the individual test strength from the average strength of n
samples
n = number of sample test results
When significant changes are made in the production of concrete batches (for
example changes in the materials used, mix design, equipment or technical
control), the standard deviation value shall be separately calculated for such
batches of concrete.
Cuuwogf"uvcpfctf"Fgxkcvkqp<"
Where sufficient test results for a particular grade of concrete are not available, the value
of standard deviation given in the following table may be assumed.
Assumed Standard Deviation
Standard Deviation for Different

Grade of Degree of control in N/mm2
Concrete
Very Good Good Fair
M10 2.0 2.3 3.3
M15 2.5 3.5 4.5
M20 3.6 4.6 5.6
However when adequate past records for a similar grade exist and justify to the designed
value of standard deviation different from that shown in the above Table, it shall be
permissible to use that value.
Ceegrvcpeg"Etkvgtkc:
The concrete shall be deemed to comply with the strength requirements if.
Eqortguukxg"uvtgpivj"
The concrete shall be deemed to comply with the strength requirements when both the
following condition are met:
a) The mean strength determined from any group of four consecutive test results complies
with the appropriate limits in col. 2 of Table below.
b) Any individual test result complies with the appropriate limits in col.3 table below.
" Hngzwtcn"uvtgpivj"
When both the following conditions are met, the concrete complies with the specified flexural
strength,
a) The mean strength determined from any group of four consecutive test results
exceeds the specified characteristic strength by at least 0.3 N/mm2.
b) The strength determined from any test result is not less than the specified characteristic
strength less 0.3 N/mm2.

81
"
"
" Eqtg"cpf"nqcf"vguvu<"
Kpurgevkqp" <" Immediately after stripping the form work, all concrete shall be carefully
inspected and any defective work or small defects either removed or made good before
concrete has thoroughly hardened.
Incase of doubt regarding the grade of concrete used, either due to poor workmanship or
based on results of cube strength tests, compressive strength tests of concrete core
samples and or load test may be carried out.
a) Eqtg" Vguv" The points from which cores are to be taken and the number of cores
required shall be at the discretion of the Engineer-in-charge shall be representative of
the whole of concrete concerned. In no case, however fewer than three cores shall be
tested.Cores shall be prepared and tested as described in IS: 516-1959.
Concrete in the member represented by a core test shall be considered acceptable if

the average equivalent cube strength of the cores is equal at least 85 percent of the
cubes strength of the grade of concrete specified for the corresponding age and no
individual core have strength less than 75 percent.
In case the core test results do not satisfy the requirements of or where such tests
have not been done, load test may be resorted to.
b) Nqcf" vguvu"qp"rctvu"qh"uvtwevwtgu<"Loading tests should be carried out as soon as

possible after expiry of 28 days from the time of placing of concrete.
The structure should be subjected to a load equal to full dead load of the structure plus
1.25 times the imposed load for a period of 24 hours and then the imposed load shall
be removed.
PQVG<" Dead load includes self weight of the structure members plus weight of
finishes and walls or partitions, if any, as considered in the design.

82
The deflection due to imposed load only shall be recorded. If within 24 hours of removal of
the imposed load, the structure does not recover at least 75 percent of the deflection under
superimposed load, the test may be repeated after a lapse of 72 hours. If the recovery is less
than 80 percent, the structures shall be deemed to be unacceptable.
" Ceegrvcpeg"Etkvgtkc<"
"
Two sets of criteria for demonstrating that the concrete as produced and cast either
complies or does not comply with the IS : 456-2000 requirements for concrete quality.
a) requirements of strength, and
b) requirement of workmanship
Eqortguukxg" uvtgpivj<" When both the following conditions are met, the concrete
complies with the specified compressive strength:
a) The mean strength determined from any group of four consecutive samples should
exceed the specified characteristic compressive strength.
b) Strength of any sample is not less than the specified characteristic compressive
strength minus 3MPs.
" Tglgevkqp"Etkvgtkc<"
"
Concrete is liable to be rejected if it is.
a) Porous or honeycombed,(due to incorrect mix proportions or improper compaction
techniques)
b) Its placing has been interrupted without providing a proper construction joint.
c) The reinforcement has been displaced beyond the tolerance limit.
d) If the core tests/load test does not yield the results.
e) If the strength of the concrete produced and cast does not yield the strength
requirements of the code.
f) If the test results of the test cubes obtained as per IS : 1199 and tested as per IS : 516
does not yield the strength requirements of the code acceptance criteria, the Engineer-
in-charge with the consultation of the Designer will consider the technical
consequences such as durability, strength, serviceability, economic consequences,
cost replacement, cost of strengthening the weak point etc.,
However, the hardened concrete shall be accepted only after carrying out suitable
remedial measures to the satisfaction of the Engineer-in-charge.
" Wpceegrvcdng"Yqtm<"
All defective concreting work including but not limited to defects arising out of honey
combing, under sizing, under strength etc., are liable to be demolished and rebuilt by the
contractor at his cost. In the event of such work being accepted by carrying out repairs
etc., as specified by the Engineer-in-charge the cost of repairs shall be borne by the
contractor. Acceptance of such works will be in accordance with the provisions of IS: 456-
2000.
Visible defects noticed in the workmanship and quality which could be rectified through
remedial measures shall be rectified to the satisfaction of the Engineer-in-charge.
Deficiency in workmanship which is considered to be attributable to some inadequacy in
concrete production or concrete haulage, or concrete placement method, or compaction,
should be got remedied from the contractor by the Engineer-in-charge through additional
inputs and upgradation of methodology and work taken up subsequently only when the
needed augmentation has been done. If the subsequent work is within acceptable level,
steps should be taken to remedy the defects noted in the earlier work through appropriate
measure. After the defects have been remedied to the satisfaction of Engineer-in-charge
and provided that the inputs (Cement, aggregates, water etc.,) are within the specified
quality standards, the concerned work shall be accepted.

83
In case the Engineer-in-charge observes basic and serious deficiencies in the quality of
inputs and outputs as well as in the workmanship, revealed through perusal of test records
and visual inspection as well including say, examination of cores (taken from insitu concrete
lining) as also serious in adequacies in construction equipment and job facilities in enforcing
the technical specifications, such portions of works shall be rejected and not accepted for any
payment. In the absence of any positive measures to strengthen these structures/works, the
Engineer-in-charge may arrange for their demolition and reconstruction.
There could be portions of works/works, where some sort of slight transgression of
specifications/ quality levels has taken place and which is not feasible of rectification in full. In
case it is determined that the integrity of such portions of work is not significantly impaired
and that the functional capability can be assured, consideration may be given by the
Engineer-in- charge (subject to full satisfaction of the Engineer-in-charge) to accept these at
reduced payment to the contractor instead of demolishing the concerned portion of work and
reconstructing it.
" Eqpetgvkpi"wpfgt"Urgekcn"Eqpfkvkqpu<"
"
" Eqpetgvg"wpfgt"ycvgt<"
"
When it is necessary to deposit concrete underwater, the methods, equipment, materials

and proportions of mix to be used shall be got approved from the Engineer-in-charge
before any work is started. Concrete shall contain 10 percent more cement than, that
required for the same mix placed in the dry.
Concrete shall not be placed in water having a temperature below 5 degrees Celsius. The
temperature of the concrete, when deposited, shall not be less than 16 degrees Celsius,
not more than 40 degrees Celsius.
Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if
practicable, and in any case to reduce the flow of water to less than 3 meters per minute
through the space into which concrete is to be deposited. Coffer dams or forms in still
water shall be sufficiently tight to prevent loss of mortar through the joints in the walls.
Pumping shall not be done while concrete is being placed or until 24 hours thereafter. To
minimize the formation of laitance, great care shall be exercised not to disturb the concrete
as far as possible while it is being deposited.
All under water concreting shall be carried out by tremie method only, using tremie of
appropriate diameter. The number and spacing of the tremie should be worked out to
ensure proper concreting. The tremie concreting when started should continue without
interruption for the full height of member being concreted. The concrete production and
placement equipment should be sufficient to enable the underwater concrete to be
completed uninterrupted within the stipulated time. Necessary stand-by equipment should
be available for emergency situation.
The top section of the tremie shall have a hopper large enough to hold one full batch of the
mix or the entire contents of the transporting bucket as the case may be. The tremie pipe
shall not be less than 200 mm. in diameter and shall be large enough to allow a free flow
of concrete and strong enough to withstand the external pressure of the water in which it is
suspended, even if a partial vacuum develops inside the pipe. Preferably flanged steel
pipe of adequate strength for the job shall be used. A separate lifting device shall be
provided for each tremie pipe with its hopper at the upper end. Unless the lower end of the
pipe is equipped with an approved automatic check valve, the upper end of the pipe shall
be plugged with a wadding of gunny sacking or other approved material before delivering
the concrete to the tremie pipe through the hopper, so that when the concrete is forced
down from the hopper to the pipe, it will force the plug (and along with it any water in the
pipe) down the pipe and out of the bottom end, thus establishing a continuous stream of
concrete. It will be necessary to raise slowly the tremie in order to allow a uniform flow of
concrete, but it shall not be emptied so that water is not allowed to enter above the
concrete in the pipe. At all times after placing of concrete is started and until all the
required quantity has been placed, the lower end of the tremie pipe shall be kept below the
surface of the plastic concrete. This will cause the concrete to build up from below instead
of flowing out over surface and thus avoid formation of layers of laitance. If the charge in
the tremie is lost while depositing the tremie shall be raised above the concrete surface
and unless sealed by a check valve, it shall be replugged at the top end., as at the
beginning, before refilling for depositing further concrete.
84
" Eqnf"Ygcvjgt"Eqpetgvkpi<"
"
Where concrete is to be deposited at or near freezing temperature, precautions shall be
taken to ensure that at the time of placing, it has temperature of not less than 5 degrees
Celsius and that the temperature of the concreting shall be maintained above 4 degrees
Celsius until it has thoroughly hardened. When necessary, concrete ingredients shall be
heated before mixing but cement shall not be heated artificially other than by the heat
transmitted to it from other ingredients of the concrete. Stockpiled aggregate may be
heated by the use of dry heat or steam. Aggregates shall not be heated directly by gas or
on sheet metal over fire. In general the temperature of aggregates or water shall not
exceed 65 degrees Celsius. Salt or other chemicals shall not be used for the prevention of
freezing. No frozen material or materials containing ice shall be used. All concrete
damaged by frost shall be removed. It is recommended that concrete exposed to freezing
weather shall have entrained air and the water content of the mix shall not exceed 30 liters
per 50 kg , of cement.
" Jqv"Ygcvjgt"Eqpfkvkqpu<"
"
When depositing concrete in very hot weather, precautions shall be taken so that the
temperature of wet concrete does not exceed 40 degrees Celsius while placing. This shall
be achieved by stacking aggregate under the shade and keeping them moist, using cold
water, reducing the time between mixing and placing to the minimum, cooling form work by
sprinkling water, starting curing before concrete dries out and restricting concreting as for
as possible to early morning and late evenings. When ice is used to cool mixing water, it
will be considered a part of the water in design mix. Under no circumstances shall be
mixing operation be considered complete until all ice in the mixing drum has melted.
The contractor will be required to state his methodology for the approval of Engineer -in-
charge when temperatures of concrete are likely to exceed 40 degrees Celsius during the
work.
" Kpurgevkqp"cpf"vguvkpi"qh"Uvtwevwtgu<"
"
Immediately after stripping the form work, all concrete shall be carefully inspected and any
defective work or small defects either removed or made good before concrete has
thoroughly hardened. In
case of doubt regarding grades of concrete used, either due to poor workmanship or based
on results of Cube strength tests, Compressive strength tests on concrete structural
elements shall be done for core test and for load tests on the part of the structures as
specified in relevant clauses of IS codes.
" Hkpkujkpi<"
"
" Igpgtcn<"
Immediately after removal of forms exposed bars or bolts, if any, shall be cut inside the
concrete member to a depth at least 50 mm. below the surface of the concrete and the
resulting holes filled with cement mortar. All fins caused by form joints, all cavities
produced by the removal of form ties and all other holes and depression honey comb
spots, broken edges or corners and other defects, shall be thoroughly cleaned, saturated
with water, and carefully pointed and rendered true with mortar of cement and fine
aggregate mixed in the proportion used in the grade of concrete that is being finished and
of as dry a consistency as is possible to use. Considerable pressure shall be applied in
filling and pointing to ensure thorough filling in all voids. Surfaces which have been pointed
shall be kept moist for a period of 24 hours. Special pre-packed proprietary mortars shall
be used where appropriate or where specified in the drawing.
All construction and expansion of joints in the complete work shall be left carefully tooled
and free from any mortar and concrete. Expansion joint filler shall be left exposed for its
full length with clean and true edges.
Immediately on removal of forms, the concrete work will be examined by the Engineer-in-
charge before any defects are made good.
a) The work that has sagged or contains honeycombing to an extent detrimental to
structural safety or architectural appearance will be rejected.
b) Surface defect of a minor nature shall be made good as directed by the Engineer-in-
85
charge.
" Eqpetgvg"uwthceg"Kttgiwnctkvkgu<"
"
a) Igpgtcn" <" Bulges, depressions and offsets are defined as concrete surface
irregularities Concrete surface irregularities are classified as ‘abrupt’ or ‘gradual’ and
are measured relative to the actual concrete surface.
b) Cdtwrv" uwthceg" kttgiwnctkvkgu<" Abrupt surface irregularities are defined herein as
offsets such as those caused by misplaced or loose forms, loose knots in form timber,
or other similar forming faults. Abrupt surface irregularities are measured using a short
straight edge, at least 150 cm. long, held firmly against by direct measurement.
c) Gradual surface irregularities are defined herein as, bulges and depressions resulting
in gradual changes on the concrete surface. Gradual surface irregularities are
measured using a template conforming to the design profile of the concrete surface
being examined. Templates for measuring gradual surface irregularities shall be
provided by the contractor. Templates shall be at least 2.5 m. in length. The
magnitude of gradual surface irregularities is defined herein as a measure of the rate
of change in slope of the concrete surface.
d) The magnitude of gradual surface irregularities on concrete surface shall be checked
by the contractor to ensure that the surfaces are within specified tolerances. The
Engineer-in-Charge will also make checks of hardened concrete surface as deemed
necessary to ensure compliance with these specifications. Templates for these
surfaces shall be furnished by the contractor free of charge and shall be available for
use by the Engineer-in-Charge at all times.
" Tgrckt"qh"eqpetgvg<"
"
" Igpgtcn"
"
c+" Repair of concrete shall be performed by skilled workers and in the presence of
Engineer-in-charge. Repairs and correction of all imperfections on formed concrete
shall be completed as soon as practicable after removal of forms and within 24 hours
after removal of forms. Concrete that is damaged from any cause and concrete that is
honey combed, fractured or otherwise defective and concrete, which because of
excessive surface depressions, must be excavated and built up to bring the surface to
the prescribed lines, shall be removed and replaced by dry pack mortar or concrete as
hereinafter specified. Where bulges and abrupt irregularities protrude outside the limits
specified the protrusions shall be reduced by bush hammering and grinding so that the
surfaces are within the specified limits.
d+" Before repair is to commence, the methods proposed for the repair shall be approved
by the Engineer-in-charge Routine curing should be interrupted only in the area of
repair operations.
" Ogvjqfu"qh"Tgrcktu<"
For new works four methods are used as under.
c+" Ft{" Rcem" ogvjqf<" These methods should be used for holes having a depth nearly
equal to, or greater than the least surface dimensions; For cone bolt, the bolt and
grout insert holes, and narrow bolts cut for the repair of crakes, dry pack should not be
used.
For relatively shallow depressions where lateral restraint cannot be obtained; for filling
in back of considerable lengths of exposed reinforcement; nor for filling holes which
extend entirely through the wall, beam etc.,
d+" Eqpetgvg" Tgrncegogpv" ogvjqf" <" Concrete repairs made by bonding concrete to
repair area (without use of an epoxy bonding agent or mortar grout applied on the
prepared surface) should be made when the depth of the area exceeds 15 cm. and
the repair will be of appreciable continuous area, as determined by the Engineer-in-
charge.
Concrete repairs should also be used for holes extending entirely through concrete
sections, for holes in which no reinforcement is encountered and which are greater in
area than 900Sq.cms. and deeper than 10cms., and in reinforced concrete for holes
greater than 1400Sq.cms. The Engineer-in-charge may also permit Epoxy bonded
concrete repair as an alternative to concrete repair.
86
kk0" Oqtvct" Tgrncegogpv" ogvjqf" =" Portland cement mortar may be used for repairing
defects on surface not prominently exposed where the defects are too wide for a dry
pack filling, the defects are too shallow for concrete filling and where they are not
deeper than the far side of the reinforcement, that is nearest the surface.
kkk0" Grqz{"Ogvjqf<"A thermo setting plastic known as epoxy can be used as a bonding
medium whenever long time curing of conventional concrete cannot be assured.
Epoxies can be used to bond new concrete or mortar to old concrete when ever the
depth of repair is between about 3.75cm. and 15cm. Also epoxy mortars of fine sand
as well as plain epoxy are suitable for concrete repair work and should be used
whenever every thin patch is to be placed or immediate reuse of the area is required
or where moist curing cannot be effectively accomplished. Preparation for epoxy
bonded repairs should in general be identical to that for other concrete repairs except
that every effort should be made to provide surfaces thoroughly dry. Drying of the
immediate surface for at least 24hours and warming to temperature between 18º to
27º C are essential for proper application of epoxy bonded repairs. Preparation for the
use of epoxy mortars should include thorough cleaning and drying of the areas to be
repaired. A wash of dilute (1:4) muriatic acid rinsing with clean water and subsequent
drying is desirable, where feasible. If acid wash is not feasible, preparation may be
accomplished as for other concrete repairs with final cleanup being by means of
sand blast method, followed by air water jet washing and thorough drying. Epoxy
repairs shall be carried out only by trained personnel.
e+" Tgoqxcn" qh" Eqpetgvg<" All concrete of questionable quality should be removed. It is
better to remove too much concrete than too little because affected concrete generally
continues to disintegrate and while the work is being done, it costs but little more to
excavate to sample depth. Moistening, cleaning, surface drying and complete curing
are of at most importance when making repairs which must be thoroughly bonded,
watertight and permanent. Surfaces within trimmed holes should be kept continuously
wet for several hours, preferably overnight prior to placing new concrete. Immediately,
before placement of the filling, the holes should be cleaned so as to leave a surface
completely free from chipping dust, dried grout and all other foreign materials. Final
cleaning of the surfaces to which the new concrete is to be bonded should be done by
wet sand blasting followed by washing with air water jet for thorough cleaning and
drying with an air jet.
Care should be taken to remove any loose materials embedded in the surface by
chisels during the trimming and to eliminate all shiny spots indicating free surface
moisture. Cleaning of the steel if necessary should be accomplished by sand blasting.
The prepared surface shall be approved by the Engineer-in-charge.
(d) Ft{" rcem" qh" eqpetgvg: For this method of repair, the holes should be sharp and
square at the surface edges, but the corners within the holes should be rounded.
Especially when water tightness is required, the interior surfaces of holes left by cone
bolts, the bolts etc. should be roughened to develop an effective bond. Other holes
should be under cut slightly in several places. Holes for dry pack should have a
minimum depth of 25 mm.
(e) Concrete Replacement :i) Holes should have minimum depth of 100 mm. in new
concrete and the minimum area of repair should be 500 Sq.cms for reinforced and
1000 Sq.cms. for unreinforced concrete.
i) Reinforcement bars should not be left partially embedded. There should be a
clearance of at least 25 mm. around each exposed bar.
ii) The top edge of the face of the structure should be cut to a fairly horizontal line. If
the shape of the defect makes it advisable, the top of the cut may be stepped
down and continued on a horizontal line.
The top of the hole should be cut 1 to 3 up ward slope from the back towards the
face of the wall or beam. It may be necessary to fill the hole from both sides, in
which case the slope of the top of the cut should be modified accordingly.

87
iii) The bottom and sides of the holes should be cut sharp and approximately square
with the face of the wall when the hole goes entirely through concrete section.
Spalls or feather edges shall be avoided by having chippers worked from both
faces. All interior corners should be rounded to maximum radius of 25 mm.
h+" Oqtvct" Tgrncegogpv<" When mortar gun is used with this method, comparatively
shallow holes should be flared outwardly at about 1 to 1 slope to avoid inclusion of
rebound. Corners within the holes should be rounded. Shallow imperfections in new
concrete may be repaired by mortar replacement if the work is done promptly after
removal of the forms and while the concrete is still green. For instance, when it is
considered necessary to repair the peeled areas resulting from surface material
sticking to steel forms the surfaces may be filled using mortar gun without further
trimming or cutting. Whenever hand placed mortar replacement is used, edges of
chipped out areas should be squared with the surface leaving no feather edges.
Best results with replacement mortar are obtained when the mortar is pneumatically
applied using a small mortar gun. After the areas to be repaired have been cleaned
and surface dried, the mortar shall be applied immediately. No initial application of
cement, cement grout etc. is to be made. The mix proportion shall be 1 part cement to
4 parts natural sand by dry volume or weight .Well graded sand passing No. 16 screen
shall give best results. Cement and sand shall be mixed with water to approximately
the same consistency as for dry pack repair.
For repairs of more than (2.5cm.) depth, the mortar shall be applied in layers not
more than about 20 mm. thick to avoid nagging and loss of bond. After completion
of each layer a time of about 30minutes shall be allowed before the next layer is
placed. This time shall be so adjusted that the mortar of the previous layer does not
get dry.
i+" Wug"qh"Ft{"rcem"Oqtvct<"/"The Surface after preparing should be thoroughly brushed

with a stiff mortar or grout barely wet enough to thoroughly wet the surface after which
the dry pack material should be immediately packed into place before the bonding
grout has dried. The mix of bonding grout shall be 1to 1 cement and fine sand
mixed to a consistency like thick cream. Under no circumstances should bonding coat
be wet enough or applied heavily enough to make the dry pack materials more than
very slightly rubbery. Dry pack is usually a mix (by dry volume or weight) of one part of
cement to 1½ part of sand.
" Ogcuwtgogpv"cpf"Rc{ogpv<"
"
" Ogcuwtgogpv<"
"
a) Except or otherwise especially provided for in the specifications measurement of
concrete for payment shall be made on the basis of the volume of concrete calculated
as contained within the concrete out lines shown on the relevant drawings.
b) Measurement for payment for the concrete laid in pockets in the foundation shall be
made on the basis of the volume of the pockets filled.
c) No measurements shall be made for the concrete backfill beyond the minimum lines of
excavation shown on the drawings except where such payment is specifically
authorized. Measurement of concrete shall be made after deducting the volume of all
recesses, passageways, chambers, openings, cavities and depressions, but without
deductions for round or beveled edges or space occupied by electrical conduits and
reinforcement.
d) Concrete in bridges, side walls, kerbs and parapets in full length of the structure and
block-outs etc., shall be measured on the relevant drawings.
Tcvg<"No separate payment will be made. It shall be included in the price Bid quoted in the
Bill of Quantities.

88
" "
" Nqcf"vguv"hqt"Ycvgt"Vkijvpguu"qh"Lqkpvu"qh"Cswgfwev"U{rjqpu"cpf"wpfgt"Vwppgnu"
*Ycvgt"Tgvckpkpi"Uvtwevwtgu+"
"
i) Loading test is to be conducted after the completion of the construction duly filled with
water to 0.45m. above F.S.L. All the joints should also be tested for its effective water
tightness. The test is to be conducted simultaneously with the load test of
superstructure specified.
ii) These tests are to be carried at the contractor’s expenses and the rate quoted by the
contractor is expected to be including all these operations. However the withheld
amounts by way of deposits will be released only after observance of the leakages for
one year after release of water through the cross drainage works or after one year
of the completion of the work in all respects and handing over it to the department.
iii) Testing of water tightness:
a) Contractor has to erect cross masonry bunds across canals at both the ends of
structure upto the full height of side walls to required sections at his own cost for
testing the water tightness of the trough slab and side walls of the structure.
b) The contractor has to arrange for pumping of the water. Once the structure is filled
with water upto full supply level, it shall be observed for the period as desired by the
Engineer-in-Charge, during which time at any leakages are observed, it has to be
rectified by the contractor at his cost to the full satisfaction of the Engineer-in-Charge.
c) Once the observation period is satisfactorily over, he has to clear the debris, without
damaging the concrete work of canal as directed by the Departmental officers.
d) Till the satisfactory testing is over, he will be paid 80% of quoted rates for the
components of structure in contact with water at the intermediate stage of payment.
After the satisfactory water tightness testing is over as certified by the Engineer-in-
Charge to this effect, remaining 20% payment for the above concrete item will be
released. He should quote his rates for the above items considering the water
tightness test which he has to undertake at his cost.
e) In case of default,20% payment withheld in part bills will be permanently recovered
and the contractor has to dismantle the bottom slab and side vertical slabs of the
trough of structure and rebuilt at his own cost. If the contractor fails to do so, the
Engineer-in-Charge will recover the cost required for construction of the same through
other agencies from the monies due to the contractor.
" Uvggn"Tgkphqtegogpv<"
"
" Igpgtcn<"
c+" This section covers specifications for providing steel reinforcement to Bridges. Under
Tunnels, Aqueducts, Super passages, Retaining walls, Canal Side walls, Inlets,
Outlets, Head Walls, Cut off walls / diaphragm walls, Cross Regulators, Off-take
Sluices and other similar structures.
d+" A list of IS codes applicable is furnished below.
Nkuv"qh"K0U0"Eqfgu:
I.S.456-2000 Code of practice for plain and Reinforced Concrete

I.S. 1786-1985 Specifications for high strength deformed steel bars
and wires for concrete reinforcement.
I.S. 432-1982 Specifications for mild steel and medium tensile steel (Part –
I) bars for concrete reinforcement and hard drawn steel wire.
I.S. 818-1968 Code of practice for safety and healthy requirement and
gas welding and cutting operations
I.S. 3016-1986 Code of practice for fire precautions in welding and cutting operation.
I.S. 280-1978 Mild Steel wire for general Engineering purposes
I.S. 2502-1963 Code of practice for bending and fixing of bars for concrete
reinforcement.

89
I.S. 9417-1989 Recommendations for welding cold worked bars for reinforced concrete
Construction
I.S. 2751-1979 Welding of mild steel plain and deformed bars for
reinforced Construction.
I.S. 814-1991 Covered electrodes for manual metal arc welding of carbon
and carbon maganese steel.
I.S .1278-1972 Filler rods and wires for gas welding
In addition to the above Indian Standard specifications, wherever necessary, the

specifications prescribed in APSS shall also be followed.
" Ueqrg<"
Supplying, fabrication and placing grills of M.S. /HYSD Reinforcement of different diameter
including cost and conveyance of reinforcement bars, sampling, testing, binding wire,
cleaning, cutting, bending, welding, tying the grills and placing them in position with
necessary chairs and cover blocks including all leads, lifts, delifts and all other operations
necessary to complete the finished item of work as per drawings, specifications and as
directed by the Engineer-in-charge.
" Ocvgtkcnu<"
i) The provisions of schedule ‘D’ Section-14 shall apply
ii) Cutting, bending and Binding of Reinforcement.
a) Reinforcing Steel shall conform accurately to the dimensions given in the bar bending
schedules shown on relevant drawings.
b) Bars shall be bent cold to the specified shape and dimensions by a bar bender by
hand or power to attain proper radii of bends as shown in drawings or as directed by
the Engineer-in-charge.
c) Bars shall not be bent or straightened in a manner that will injure the material.
d) Bars bent during the transport or handling shall be straightened before being used on
work, they shall not be heated to facilitate bending.
e) “U” hooks shall invariably be provided at the end of each bar,. if specified in drawing or
ordered by the Engineer. The radius of the bend shall not be less than twice the
diameter of round bar and the length of the straight part of the bar beyond the end of
the curve shall be at least four times the diameter of the round bar. In the case of bars
which are not round and in the case of deformed bars, the diameter shall be taken as
the diameter of a circle having an equivalent effective area.
f) The hook shall be suitably encased to prevent any splitting of the concrete.
" Rncekpi"qh"Tgkphqtegogpv<"
c+" Before the reinforcement is placed, the surfaces of the bars and the surface of any
metal bar supports shall be cleaned of the rust, loose mill scale, dirt grease and other
objectionable foreign substances.
d+" All reinforcing bars shall be securely held in position during placing of concrete by
annealed binding wire, and by using stays, blocks or metal chairs, spacers, metal
hangers, supporting wires or other approved devices at sufficiently close intervals.
e+" Wire for binding reinforcement shall be soft and annealed mild steel of 16 SWG and
shall conform to IS: 280-1978. Binding wire shall have tensile strength of not less than
5600 Kg/Sqcm2, and an yield point of not less than 3850 Kg/CM2.
f+" Bars shall not be allowed to sag between supports. They shall not be displaced during
concreting or any other operation over the work.
g+" The contractor shall also ensure that there is no disturbance caused to the reinforcing
bars already placed in concrete.
f ) All devices used for positioning shall be of non-corrodible material. Metal supports shall
not extend to the surface of the concrete, except where shown on the drawing. Pieces
of broken stone or brick and wooden blocks shall not be used. Where portions of such
supports will be exposed on concrete surfaces designated to receive F2 or F3 finish,
the exposed portion of support shall be galvanized or coated with other corrosion
resistant material without which the concreting will not be permitted. Such supports
shall not be exposed on surfaces designated to receive F4 finish unless otherwise
90
shown on the drawings.

91
g) Placing of layers of freshly laid concrete as work progresses for adjusting bar spacing
shall not be allowed.
h) Layers of bars shall be separated by spacer bars, pre cast blocks or other approved
devices.
i) Reinforcement after being placed in position shall be maintained in a clean condition
until completely embedded in concrete. Special care shall be taken to prevent any
displacement of reinforcement in concrete already placed.
j) To protect reinforcement from corrosion, concrete cover shall be provided as indicated
on the drawings. All bars protruding from concrete and to which other bars are to be
spliced and which are likely to be exposed for an indefinite period shall be protected
by thick coat of neat cement grout.
k) Bars crossing each other, where required, shall be secured by binding wire (annealed
of size not less than 1mm dia and conforming to IS :280- 1978) in such a manner that
they do not slip over each other at the time of fixing and concreting.
l) As far as possible, bars of full length shall be used. In case this is not possible,
overlapping of bars shall be done as directed by Engineer-in- charge. When
practicable, overlapping bars shall not touch each other, but be kept apart by 25 mm
or 1 ¼ times the maximum size of the coarse aggregate whichever is greater, by
concrete between them. Where not feasible, over lapping bars shall be bound with
annealed steel wire, not less than 1mm. thickness twisted tight. The overlaps shall be
staggered for different bars and located at points, along the span where neither shear
nor bending moment is maximum.
m) The minimum allowable clearance between parallel round bars shall not be less than
1½ times the diameter of the larger bars and for square bar shall not be less than
twice the side dimensions of the larger bars or 1½ times, the maximum size
aggregate whichever is greater.
n) Dissimilar diameter rods should not be jointed together.
" Urnkekpi<"
"
c+" Where it is necessary to splice reinforcement the splices shall be made by lapping, by
welding or by mechanical means.
i) When permitted or specified on the drawings, joints of reinforcement bars shall be
but welded so as to transmit their full strength. Welding of bars shall be done as
directed by the Engineer-in-charge and conforming with requirements of Clause
11.4 of IS.456-2000.
ii) If it is proposed to use welded splices in reinforcing bars, the equipment, the
material and all welding and testing procedures shall be subject to the approval of
the Engineer-in-charge. The Contractor shall also carryout test welds as required
by the Engineer-in- charge. No extra rate will be paid for welding reinforcement
test- welds as tender rate in schedule-‘A’ is inclusive of this item.
iii) For welded splices for reinforcing bars conforming to IS 1786-1985, welding shall
be done in accordance with IS: 9417-1979. For reinforcing bars conforming to IS:
432 (part-I)-1982,
Welding shall be done in accordance with IS: 2715-1979. Electrodes for manual
metal arc welding shall conform to IS: 814(part,I) 1974 and IS: 814(part,II) 1974.
Mild steel filler rods of Oxy- acetylene welding shall conform to IS: 1278-1972
provided they are capable of giving a minimum but weld tensile strength of
41kg/mm2.
iv) Only electric arc welding using process which excludes air from the moten metal
and conforms to any or all other special provisions for the work shall be accepted.
Suitable means shall be provided for holding the bars securely in position during
welding. It must be ensured that no voids are left in welding and when welding is
done in two or three steps. Previous surfaces shall be cleaned well. Ends of bars
shall be cleaned of all Iron, scale, rust, grease, paint and other foreign matter
before welding.

SRBC Circle No.1, Nandyal.
92
d+" Reinforcing bars of 28 mm is diameter and larger may be connected by but welding
provided that lapped splices will be permitted if found to be more practical than but welding
and if lapping does not encroach on cover limitation or hinder concrete or reinforcement
placing.
e+" Reinforcing bars 25 mm in diameter and less may be either, lapped or But welded,
whichever is the most practicable.
i) Butt welding of reinforcing bars shall be performed either by the gas pressure or flash
pressure welding process or by the electric arc methods under cover from weather.
ii) Welded pieces of reinforcement shall be tested at the rate of 0.5% of total number of joints
welded. Specimen shall be taken from the actual site of work. Strength of the weld
provided shall be at least 25% higher than the strength of bar.
f+" Welded joints of splices shall preferably be located at points where steel will not be subject
to more than 75% of the maximum permissible stresses and welds so staggered that at
any section not more than 20% of rods are welded. Approval of such additional splices will
generally be restricted to splices not closer than 8 meters in horizontal bars or 4 meters in
vertical bars measured between midpoint of laps.
" Eqwrnkpi"qh"Dctu<"
Where ever indicated on the drawings or desired by the Engineer to use mechanical
couplings for reinforcing bars, bars shall be joined by couplings which shall have a cross -
section sufficient to transmit the full strength of bars. The ends of bars that are joined by
couplings shall be for sufficient length, so that the effective cross-section of the base of
threads is not less than normal cross section of the bar. The threads shall be standard whit
- worth threads. Steel for couplings shall conform to IS. 226. The contractor shall submit
samples of the proposed coupling to the Engineer -in-charge for approval not less than 60
days prior to their proposed use.
" Ectg"qh"rncegf"Tgkphqtegogpv"cpf"Eqpetgvg<"
"
Where reinforcement bars are bent aside at construction joints and afterwards bent back
into their original position, care shall be taken to ensure that at no time the radius of the
bend is less than 6 x diameters for deformed bars and 4 x diameters for plain mild steel
bars. Care shall also be taken, when bending such bars, to ensure that the concrete
around the bars is not damaged.
" Vqngtcpegu<"
"
c+" As specified in clause 11.3 of IS: 456-2000 unless otherwise specified by the
Engineer, reinforcement shall be placed within the following tolerances.
i) For effective depth 200 mm. or less = + 10 mm.
ii) For effective depth more than 200 mm. + 15mm.
d+" The cover shall in no case be reduced by more than one third of specified cover or 5
mm whichever is less.
" Fqygnu<"
"
c+" The dowels shall be of the same H.Y.S.D. bars of grade Fe 415 conforming to I.S.
1786-1985 as used for reinforcement.
d+" Details for dowels shall be as shown on the drawings or as directed by the Engineer-
in-charge.
e+" Dowels shall be placed in the concrete where shown on the drawings or where
directed and will be inspected for compliance with requirements as to size, shape,
length, position, and amount after they have been placed, but before being covered by
concrete.
f+" Before the dowels are embedded in concrete, the surfaces of dowels shall be cleaned
of all dirt, grease or other foreign substances which in the opinion of the Engineer-in-
charge are objectionable.
g+" The dowels shall be accurately placed and secured in position so that they will not be
displaced during the placing of the concrete.

93
" Ogcuwtgogpv"cpf"rc{ogpv<"
"
c+" Ogcuwtgogpv: Measurement for payment, for furnishing and placing reinforcing bars
will be made only on the calculated weight of the bars placed in concrete, in
accordance with the drawings or as directed by the Engineer-in-charge.
D+" VJG"ECNEWNCVGF"YGKIJV"HQT"TGKPHQTEKPI"DCTU"UJCNN"DG"FGVGTOKPGF"
CU"HQNNQYU<"
(i) Reinforcement shall be measured in length separately for different diameters as
actually used in the work excluding overlaps. Length shall include hooks at ends.
(ii) From the length measured, weight of reinforcing bars shall be calculated on the
basis of weights specified in the table in schedule ‘D’ Section-14.
(ii) Wastage, overlaps, couplings, welded joints, spacer bars, dowels and annealed
steel wire for binding shall not be measured and the cost of these items shall be
deemed to have been included in the rates for reinforcement.
(iv) No separate payment will be made for items mentioned at (iii) above. It shall be
included in the price Bid quoted in the Bill of Quantities.
UGEVKQP"⁄"E"32"
"
UVGGN"HQT"TGKPHQTEGOGPV"
"
" UEQRG"QH"YQTM"
"
The specifications described hereunder relate to the work which includes all labour, materials,
equipment and services required for the supply, handling, storing, cutting, bending, cleaning,
placing and fastening into position all reinforcing steel as shown on the drawings, to be carried out
by the Contractor under this contract.
" UWDOKVVCNU"
()i Ykvjkp" 52" fc{u" from the date of issue of the Letter of Acceptance, but before procuring the
equipment or mobilisation to the site, the Contractor shall submit to the Engineer-in-Charge, the
description and drawings showing the sufficient details of the layout and capacity of the equipment
proposed for the fabrication of reinforcing steel.
()i Cv"ngcuv"52"fc{u"in advance of the reinforced concrete works being carried out on the site, the
Contractor shall submit to the Engineer-in-Charge for approval, detailed bar list and bending
diagrams showing the number, size, length and bending of all bars required for various parts of the
work on the basis of the reinforcement drawings approved by the Engineer-in-Charge from time to
time during the progress of works.
()i The Engineer-in-Charge reserves the right to ask for any additional information deemed necessary
" UVCPFCTFU"
"
(i) The cutting, welding, placement and binding of reinforcing steel shall conform to following Indian
Standards or, where not covered by these standards, to their equivalent International Standards.
IS : 456-2000
IS : 1786-1985 (Reaffirmed 1990)
IS : 2502-1963 (Reaffirmed 1990)
IS : 2751-1979 (Reaffirmed 1992)

IS : 9417-1989
(ii) In case of conflict between the above standards and the specifications given herein, the
specifications shall take precedence.
" "
94
" IGPGTCN"
"
*k+" Steel for reinforcement shall conform to the standards and requirements outlined in the Ugevkqp"
qp"›Ocvgtkcnu"hqt"Eqpuvtwevkqpfi0"
"
(ii) Cutting, bending, cleaning, placing and fastening in position of the reinforcement steel shall
conform to the requirements of relevant Indian Standards and as shown on the drawings.
(iii) Transportation and storage of reinforcing steel shall conform to the requirements outlined.
" HCDTKECVKQP"
"
(i) All bars shall be cut and bent in accordance with the bar bending schedules approved by the
Engineer-in-Charge.
(ii) Reinforcing steel bars shall be cut and bent on the site of the works.
(iii) Reinforcing steel shall not be straightened or rebent in a manner that will damage the materials.
Bars with kinks or bends other than those indicated on the drawings and schedules shall not be
used.
(iv) Shorter lengths of steel shall not be used in places where continuous lengths are required as per
the drawings without the approval of the Engineer-in-Charge. Shorter bars, if approved for use,
shall be lapped or spliced to achieve continuity in accordance with the requirements of relevant
Indian Standards or as approved by the Engineer-in-Charge.
(v) Bars shall be bent cold to the shape and dimensions shown on the drawings using a bar bender
operated by hand or power to attain the proper radii of bends.
(vi) A hook at the end of the M.S. bar, if used, shall have an inner diameter not less than four times the
diameter of the bar and shall have length of straight part beyond the curve of at least four times
the diameter of the bar. Hooks shall be used only where shown on drawings or as required by
The radii of bends for stirrups and ties shall not be less than twice the diameter of the bar.
(vii) Heating of reinforcement bars to facilitate bending shall not be permitted.
(viii) The reinforcement available from rejected concrete shall not be used without prior approval of the
Engineer-in-Charge.
" RNCEKPI"
"
(i) Before being placed in position, the reinforcing steel shall be thoroughly cleaned of loose mill scale
and rust, grease, paint, or other coatings that would reduce bond. All splashed concrete which has
dried on reinforcing steel shall be removed.
(ii) Reinforcing steel to be incorporated in the works shall be placed accurately in position as shown
on the drawings and shall be held firmly in place during the placing and setting of the concrete.
(ii) Reinforcing steel shall be placed such that there will be a clear distance of at least 50 mm
between the reinforcing steel and anchor bolts or embedded metal work.
(iv) Reinforcing steel shall be maintained in position by the use of small concrete blocks, steel chairs,
steel spacers, steel hangers and other steel supports and ties, acceptable to the Engineer-in-
Charge at sufficiently close intervals so that they do not either sag between supports or be
displaced during placing of concrete or by any operation on the work. Wood supports or spreaders
shall not be used. All intersections shall be securely tied except that where the bar spacing is less
than 300 mm in each direction, when only alternate intersection need to be tied.
(v) Binding wire and steel chairs shall not be carried to permanently exposed surfaces and shall be
subject to the same requirements with regard to concrete cover as for the reinforcing steel.
(vi) Special care shall be exercised to prevent any disturbances of the reinforcement in concrete that
has already been placed. The reinforcement after being placed in position shall be maintained in a
clean condition until it is completely embedded in concrete.
(vii) The longitudinal bars shall be straight and fixed parallel to each other and to the sides of the form.
The ties, links and stirrups connected to the bars shall be tightly fixed so that the bars are properly
braced. The inside of their curved part shall be in actual contact with the bars around which they
are fixed and their position shall be exact as shown on the drawings.
Wire for tying reinforcement shall be black annealed iron wire. The diameter of wire shall be
adequate and shall have ultimate strength of 5.63 tonnes per sq.cm and yield point of not less than
95
3.87 tonnes per sqm.
(vii) Reinforcement for lining in special locations, as required, may be fixed in position by means of
anchor rods or supporting and hanger rods as approved by the Engineer-in-Charge. In difficult
locations, tack welding of bars at isolated spots may be permitted to keep these bars in position
provided that diameter of the bars is not reduced adjacent to the weld.
(ix) The steel bars shall be joined by providing lap joints in accordance with the requirements of the
relevant Indian Standards or as approved by the Engineer-in- Charge. “Bar-Grip” type joints may
also be adopted by the Contractor for deformed bars of 25mm diameter and above, subject to the
approval of the Engineer-in-Charge. Splices at points of maximum stress shall however, be
avoided. Splices in adjacent bars shall be staggered as directed by the Engineer- in-Charge. Lap
length of bars shall be as shown on the drawings. This length may be changed by the Engineer-in-
Charge in special locations.
(x) Sufficient concrete coverage as indicated on the drawing shall be provided to protect
reinforcement from corrosion. All protruding bars from which other bars are to be attached and
which shall be exposed to action of the weather for long period shall be protected from rusting by
thin coat of neat cement grout. Accurate record shall be kept at all the times of the number, sizes,
lengths and weights of bars placed in position for different parts of the work.
(xi) Where reinforcement bars are bent aside at construction joints and afterwards bent back into their
original positions, care shall be taken to ensure that at no time is the radius of the bend less than 4
times of bar diameter for plain mild steel or 6 times of bar diameter for deformed bars. Care shall
also be taken when bending back bars to ensure that the concrete around the bar is not damaged.
" YGNFKPI"HQT"TGKPHQTEGOGPV"DCTU"
(i) Lap splices shall not be used for bars larger than 36 mm diameter, which may be welded with the
approval of the Engineer-in-Charge. In case where welding is not practicable, lapping of bars
larger than 36 mm may be permitted, in which case, additional spirals shall be provided around the
lapped bars. Where welding is approved, the Contractor shall prepare at least three samples of
butt welds as directed by the Engineer-in-Charge in recognised laboratory. If the results are
satisfactory, the Engineer-in-Charge may allow welding in place of lap joints. The decision of the
Engineer-in-Charge in this regard shall be final. The joint shall be butt welded by the electric-arc-
method. The ends of the bars shall be cleaned of all loose scale, rust, grease, or other foreign
materials and all welding shall conform to the relevant standard specifications for welding or
reinforcement bars used in reinforced concrete construction or as directed by the Engineer-in-
Charge.
(ii) A weld shall be considered unsatisfactory if it fails to sustain a tensile stress of at least 90% of the
tensile strength of the bar in which the weld has been made.
" VQNGTCPEG"HQT"RNCEKPI"TGKPHQTEKPI"UVGGN"
"
Unless otherwise required by the Engineer-in-Charge, reinforcement shall be placed within the
following tolerances.
(a) For effective depth of 200mm or less + 10mm

(b) For effective depth more than 200mm +15mm
The cover shall, in no case, be reduced by more than one-third of specified cover or 5 mm
whichever is less.
" Vguvu"
"
The Contractor shall carry out tests
(a) for checking butt welds to replace lapping/ splicing of reinforcing bars.
(b) for to quality of steel reinforcement to be used as per Indian Standards or as directed by the
Engineer-in-Charge.
" Ogcuwtgogpvu"
"
Measurement of steel reinforcement placed will be made for making progressive payments against

96
total contract price as per the rate entered in the Contract document.
UGEVKQP"/"E"33"
HQTOYQTM"
" UEQRG"QH"YQTM"
"
(i) The specifications described hereunder relate to the Formwork. This work shall include all labour,
plant and materials and services related to the design, fabrication, supply, erection, maintenance
and removal of formwork and false work to be carried out by the contractor under this contract.
(ii) The formwork shall be fabricated and erected to the dimensions of finished surfaces of concrete /
masonry as shown on the approved construction drawings or as otherwise directed by the
Engineer-in-Charge.
" UWDOKVVCNU"
"
(i) Cv" ngcuv" 52" fc{u" rtkqt" to the construction of formwork for concrete and other works, the
contractor shall submit, to the Engineer-in-Charge, the following:
a) Shop drawings, details and structural computations of the formwork construction.

b) Details of materials, which the contractor intends to use for the fabrication of formwork.
(ii) The Engineer-in-Charge reserves the right to ask for any additional information deemed necessary
" IGPGTCN"
"
(i) Forms or formwork shall mean the mould into which concrete / masonry is placed.
(ii) False work or shoring shall mean the structural supports and bracing for forms used in any part of
the works.
(iii) All exposed concrete surfaces having slopes of 1.5 : 1 or steeper shall be formed unless otherwise
directed.
(iv) Where the character of the natural material cut in, to receive concrete is such that it can be
trimmed to the prescribed lines, the use of forms shall not be required.
(v) In this specifications form work / false work has been indicated for concrete work, the same shall
apply for other works also like masonry etc.
" OCVGTKCNU"
"
(i) Forms shall be of timber, steel or other approved material except that the sheeting for all exposed
surfaces, where form lining is not specified, shall be of tongue and groove timber of uniform width
unless otherwise directed by the Engineer-in-Charge.
(ii) All materials used in formwork construction shall be of adequate strength and quality for their
intended purpose and shall be satisfactory to the Engineer-in- Charge.
(iii) Timber shall be sound, straight, free from warp, decay and loose knots and shall be dressed
smooth.
(iv) Where plywood is used, it shall be non-warping, non-wrinkling and manufactured with special
water-proof glues. Plywood sheets shall be of uniform width and length.
(v) The surface of steel or steel lined forms shall be smooth. Forms with dents, buckled areas or other
surface irregularities shall not be used.

97
(vi) Reuse of forms and form lumber shall be allowed only if they are cleaned and repaired and
capable of producing the finish required for the concrete. Timber or plywood forms repaired with
metal patches shall not be used unless permitted by the Engineer-in-Charge.
(vii) Damaged forms or forms which have been deteriorated through usage shall not be used.
(viii) Form oil used on surfaces of timber or plywood forms shall be a straight, paraffin base refined,
pale, mineral oil. The oil used on the surface of steel forms shall be specially compounded
petroleum oil and other oils of animal or vegetable origin and gums or resins which are heavier in
body and frequently darker than straight petroleum oils shall be used in case of steel lining forms.
The contractor may use any other material also for coating of the formwork with the approval of
(ix) Forms of like character shall be used for similar exposed surface in order to produce a uniform
appearance.
(x) The type, size, shape, quality and strength of all materials from which forms are made shall be the
sole responsibility of the contractor but subject to the approval of the Engineer-in-Charge.
(xi) In general, forms for permanently exposed surfaces shall consists of or shall be lined with
matched or dressed edge grain timber of appropriate thickness, free from loose or cracked knots.
(xii) Metal forms or metal-lined forms shall be permitted for permanently exposed surfaces only when
an entire surface is to be built completely with such forms.
" FGUKIP."HCDTKECVKQP."GTGEVKQP"CPF"OCKPVGPCPEG"QH"HQTOYQTM"
"
(i) Forms and false work shall be designed, fabricated, erected and removed in accordance with the
applicable provisions of the Recommended Practice for Concrete formwork of IS:456-1978 and as
specified herein.
(ii) All false work shall be designed to withstand safely all live and dead loads, necessary pressures,
ramming and vibrations without significant deflection from the prescribed lines, which might be
applied to the false work during all stages of construction, service and removal.
(iii) The Contractor shall be solely responsible for the design, construction and maintenance of all
formwork and false work required in the work.
(iv) Detailed drawings of shoring and false work shall be prepared by the Contractor. The calculations
and drawings shall show the size and specification of the false work, including the type and grade
of all materials used in the construction, design loads on false work supports, horizontal forces
imposed on the false work and used for design purpose and details of splices and connections
including nails, spikes and other fasteners. If mechanical equipment such as concrete buggies,
screening machines etc. are to be used, this information shall be shown on the drawings.
(v) False work shall be constructed only after the false work drawings have been approved by the
Engineer-in-Charge.
(vi) The approval of Contractor’s drawings by the Engineer-in-Charge shall not relieve the Contractor
of his responsibility for the adequacy of form and false work or for the successful completion of the
work.
(vii) The Contractor shall construct the false work strictly in accordance with the approved false work
drawings, one set of which shall be kept on the site at all times and no changes shall be allowed
without prior written acceptance of such changes by the Engineer-in-Charge.
(viii) Forms shall be designed to permit the concrete to be deposited, as nearly as is practicable,
directly in its final position and to allow inspection, checking and clean up of the formwork and
reinforcement to be completed without delay.

98
(ix) Formwork and false work shall be designed, constructed, erected and maintained such as to
confine the concrete without loss of mortar and produce finished surface which are within the
tolerances specified.
(x) Forms for concrete against which backfill is to be placed or which shall not be exposed to view
may be constructed of smooth tight boards not less than 25 mm nominal thickness.
(xi) Forms for concrete exposed to flow of water or exposed to view shall be constructed of steel or
plywood which is smooth and free from defects with matched and sanded joints to give a
symmetrical pattern over the entire area. Chamfer strips (40 mm x 40 mm) shall be used on all
exposed concerns, unless otherwise specified or required by the Engineer-in-Charge.
(xii) Forms ties, supports, anchors, braces, spreaders and other similar devices which shall be
embedded in the concrete for holding the forms shall incorporate threaded metal bars to facilitate
removal of forms. Wood spreaders shall not be left in the forms. Any metal remaining embedded in
the concrete shall be at least 50 mm from the surface of concrete. Holes left in the concrete by
removal of parts of form ties or similar devices shall be well filled with cement mortar and neatly
finished to match the adjacent concrete.
(xiii) Form inserts or similar permanently embedded items shall be accurately located and securely
fastened in place. The number and location of form ties and bolts shall be such as to ensure that
forms fit tightly against the concrete previously placed and remain in tight contact during
operations.
(xiv) Forms shall be set and maintained within the specified tolerance limits such that the complete
concrete surfaces are within these limits.
(xv) All form surfaces shall be thoroughly cleaned before erection and shall be lubricated with a non-
staining mineral oil. All excess oil shall be wiped off the forms prior to placement of concrete. Oil
shall not be allowed to come into contract with reinforcing steel or other embedded items. For use
of timber forms, the oil shall be capable of penetrating the timber and keeping it sufficiently oily to
eliminate sticking and preventing absorption of water and consequent warping.
(xvi) The oils shall be applied by brush, spray or swab and the forms shall be covered fully and evenly
without excess or drip. Care shall be taken to prevent oil from getting in the surface of construction
joints. Special care shall be taken to oil thoroughly the form strips for narrow groove seats,
windows, doors and elsewhere so as to prevent swelling of the forms and consequent damage to
concrete prior to the removal of forms.
(xvii) Immediately before concrete is placed, all forms shall be inspected to ensure that they are
properly placed, sufficiently rigid, clean, tight and properly surface treated and free from
encrustations of mortar, grout or other foreign materials. No concrete shall be placed until
formwork has been inspected and accepted by the Engineer-in-Charge. Where forms of
continuous surfaces are placed in successive units, the forms shall fit tightly over the surface so as
to prevent leakage of mortar from the concrete and to maintain accurate alignment of the surface.
(xviii) The formwork for the gate groove areas shall be accurately drilled to be held with first stage
anchor couplings/plates to be embedded in primary concrete. Both shall be fixed through formwork
into the first anchor couplings/plates to ensure that the coupling/plates remain flush with primary
concrete face and the coupling do not get plugged.
(xix) Where timber forms are used, the laying shall be in the direction which will blend architecturally
into the lines of the structures as decided by Engineer-in-Charge.
(xx) Curved and special forms shall be such that these will result in smooth concrete surfaces. They
shall be designed and constructed so that they will not warp or spring up during erection or placing
concrete.
(xxi) When metal sheets are used for lining forms, the sheets shall be placed and maintained on the
form with the minimum amount of wrinkles, humps or other imperfections. The use of sheet metal
to cover imperfections in the lining of timber faced forms for surfaces that shall be permanently
exposed to view shall not be permitted.

99
(xxii) Where plywood or hardboard is used for form lining, the joints between the sheets shall be smooth
and as perfect as practicable and no patching of the plywood or hardboard shall be permitted for
permanently exposed surfaces. Minor imperfections in the plywood may be corrected by the use of
plastic wood secured firmly in place and sand papered smooth.
(xxiii) Wire ties shall be permitted for the forms when specially approved by the Engineer-in-Charge and
shall be cut off flush with the surface of concrete, after the forms are removed. Wire ties shall not
be used when permanently exposed finished surfaces are required.
(xxiv) Forms shall be so constructed that the finished concrete surfaces shall be of uniform texture in
accordance with the type of finish specified for concrete surfaces in these specifications.
(xxv) The erection of formwork in position shall be rapid enough, rigid and strong to withstand concreting
operations and maintain the alignment. Panels of similar shape shall be identical and inter-
changeable.
(xxvi) For special section/shapes, timber/steel form shall be used as approved by the Engineer-in-
Charge.
(xxvii) The contractor shall strengthen or modify the formwork whenever required by the Engineer-in-
Charge.
(xxviii) Unless authorised, suitable mouldings shall be placed to level all exposed edges at construction
joints and any other edges shown on the drawings or as required by the Engineer-in-Charge. The
final detailed drawings shall show any formed recesses, slots, block outs and similar construction
details which have to be taken into account in fixing the formwork.
(xxix) Forms shall be maintained, at all times, in good condition particularly as to size, shape, strength,
rigidity, tightness and smoothness of surface.
(xxx) The Engineer-in-Charge will, at any time, have the right to reject formwork which he considers to
be no longer fit for use.
" TGOQXCN"QH"HQTOYQTM"
"
(i) Forms shall not be removed until the concrete has hardened and has attained a crushing strength
of at least twice the stress which the concrete may be subjected to at the time of removal of forms.
(ii) Duration for which the forms shall remain in place shall be decided by the Engineer-in-Charge,
with reference to weather condition, shape, position of the structure or structural members and the
nature and magnitude of dead and live loads. The forms shall not be removed without the
permission of the Engineer-in- Charge.
(iii) The following minimum intervals of time shall generally be allowed between completion of placing
of concrete and removal of forms but the period shall be increased in case of wet or cold weather
and also at the option of the Engineer-in- Charge.
Uvtwevwtg" Rgtkqf"kp"fc{u"ykvj"pqtocn"
Rqtvncpf"Egogpv"
"
(a) Beam sides, walls, columns (unloaded) 3
(b) Slabs and arches (Props left under) 4
(c) Props to slabs and arches 10
(d) Beam soffits (Props left under) 8
(e) Props to beams 21
(f ) Mass concrete 2
The above minimum periods are only recommendatory. The Contractor may where he so desires,
extend the above to longer intervals. This shall not, however, constitute any reason for any claim
for extension of time or damage to concrete etc.
CONTRACTOR SUPERINTENDING ENGINEER,

100
(iv) If the Contractor desires to remove the forms earlier than the period stated above by addition of
cement and/or suitable admixtures in the concrete, so as to gain early strength without affecting
long term strengths, the matter shall be examined by the Engineer-in-Charge in each case and his
decision in the matter shall be final and binding.
(v) Heavy live loads shall not be permitted until after the concrete has reached its design strength.
(vi) The forms shall be removed with great caution and without jarring the structure or throwing heavy
forms upon the floor. In order to achieve this end, wedges and clamps shall be used whenever
practicable instead of nails.
(vii) In order to avoid excessive stresses in concrete that might result from swelling of the forms, wood
forms for wall opening shall be loosened as soon as this can be accomplished without damage to
the concrete. Forms for the opening shall be constructed so as to facilitate such loosening.
(viii) The Contractor shall be solely responsible for any damage that may be caused by negligence, lack
of proper precautions of hastiness etc. in the matter of removal of forms and shall make the same
good to the satisfaction of the Engineer-in- Charge.
" Ogcuwtgogpv"
"
No separate measurement or payment will be made for any formwork used, as required, at any
location of any works and the costs for this is deemed to be included in the contract price.
UGEVKQP"/"E"34"OCUQPCT[
" FGNGVGF"
"
340503"
UGEVKQP"/""E" 35"
"
FGYCVGTKPI"CPF"FTCKPCIG"
"
" UEQRG"QH"YQTMU"
"
i. The specifications described hereunder relate to the works of dewatering and drainage to be carried
out by the Contractor, which shall include supply of all labour, construction plant and material and
performance of all services required to remove sludge/ muddy water, service water and natural surface
flow or ground water seepage from the Work areas for the construction of various structures covered
under the contract.
i. The works shall be executed in accordance with the Contractor’s designs, specifications and
sequences as approved by the Engineer-in-Charge.
" UWDOKVVCNU"
"
()i Ykvjkp"52"fc{u"after the date of issue of the Letter of Acceptance, the Contractor shall submit, to
the Engineer-in-Charge, the detailed design of dewatering system.
()i This design shall be consistent with the outline description submitted by the Contractor with his bid
and shall include the following :
a) Design assumptions and calculations

b) Layouts of drainage / dewatering facilities
()i The Engineer-in-Charge reserves the right to require any additional information deemed
necessary to be included in the submitted documents.
" IGPGTCN"
The pumped water carried in pipes or channels shall be discharged at point sufficiently away from
the edge of foundation excavation as directed by the Engineer-in-Charge. Care shall be taken to
ensure that there is no seepage and flow of water back to the pit of the working areas.

101
" "
" "
" FGYCVGTKPI"QH"UWTHCEG"YCVGT"CV"EQPUVTWEVKQP"UKVGU"
"
" Igpgtcn"
"
(i) The Contractor shall perform all works necessary to drain out the surface water which happen to
be accumulated at work site due to rain, ground water and / or service water. The works shall
include, but not be limited to the following :
a) Design and construction of drainage, ditches, pits and pump sumps

b) Design, furnishing, operation and maintenance of dewatering
equipment
c) Relocation of dewatering facilities required for the performance of other works, if
any.
d) All auxiliary works required for safe and continuous dewatering of the construction
sites.
(ii) river/stream Dewatering of construction sites located near a river/stream shall be done upto the
existing water level in the river/stream by gravity or otherwise as directed by the Engineer-in-
Charge. Suitable drainage shall be made joining the course downstream of the construction site to
provide required gradient to facilitate proper and efficient dewatering. Below the water level of the
stream, dewatering shall be done by pumping water collected in the sumps and discharging the
same into course of the downstream of the construction site.
" Tgswktgogpvu"cpf"Fgukip"
"
(i) The Contractor shall design and install complete facilities at the surface construction sites.
(ii) The surface water dewatering systems shall be designed to accommodate, without undue
disruption to the works, any rainfall event and taking into account the extent of the sites to be
dewatered and the dewatering arrangements proposed.
(iii) Claims for extension of time due to delays caused by unfavourable weather conditions will not be
considered.
(iv) The Contractor shall provide adequate pumps of suitable capacity, including standby units, to
handle all water entering into any of surface construction sites. In addition, he shall provide sumps
and pumps and or well points in the immediate vicinity of the structure foundations using such
water conductors as are necessary to conduct the water away from the work site as per the
requirement of works to be executed in an manner so that such operation shall be kept free from
standing or running water.
(v) Power for operating the dewatering system shall be arranged by the Contractor. The Contractor
shall make his own arrangements for sufficient standby power at his cost to carry on the works
during any interruption of power. The standby power supply shall undergo weekly trial runs lasting
at least 30 minutes.
(vi) The Contractor shall ensure that all dewatered / drainage water is disposed off without causing
interference on the site and that no drainage water runs into adjacent works.
(vii) The dewatering systems shall be designed and installed in such a way that modifications and
extensions to the systems are possible while they are in full operation.
(viii) All the components of the dewatering systems shall be installed and operated in accordance with
the approved method and the construction time schedule or approved modification thereof.
(ix) The approval by the Engineer-in-Charge of the dewatering system shall not relieve the Contractor
from being fully responsible for the design, construction, operation, maintenance, safety and
removal of the facilities provided for the dewatering system and he shall be liable for any damage
or delays caused by its failure.

102
" Ocvgtkcnu"cpf"Gzgewvkqp"
"
(i) Drainage ditches shall be excavated along the top of excavated slopes. Such ditches shall be kept
well back from excavation edges in order to prevent saturating the upper part of the slopes. The
ditches shall be regularly cleaned out of all accumulated silt and other matter so that water may
flow freely at all times.
(ii) Where excavation is to be made below the ground water table, the Contractor shall lower the
water table sufficiently below any working surface by means of properly screened wells and/or
ditches to ensure that the foundation surface remain free of standing water and undamaged by
the passage of construction traffic. All ditches shall be outside the foundation areas. The
water shall be collected and removed by pumping, if no outflow by gravity is possible.
(ii) Where concrete / masonry is to be placed, the water table shall be maintained below the lowest
part of the finished excavation for minimum of one day following the raising of structure above the
natural ground water table and for such additional time as may be necessary to preclude damages
to structure foundation.
(iv) In trenches and foundations, the dewatering shall at all times enable to carry out the excavation
works in dry.
(v) Upon completion of dewatering, temporary pipes and pump sumps beneath permanent structures
shall be closed off and completely filled with grout, mortar or concrete as directed by the Engineer-
in-Charge.
" OGCUWTGOGPV"CPF"RC[OGPV"
"
No measurement for payment against dewatering and drainage would be recorded as the cost for
the same are deemed to be included in the contract price.
UGEVKQP"/"E"36"
OGVCN"YQTM"
" IGPGTCN"
"
" Ueqrg"
"
The work to be performed under this section consists of furnishing and installing the various metal
works as necessary in the execution of structures including all the auxiliary works in all structures
of the Work as shown on the approved drawings or as directed by the Engineer-in-Charge.
" Uwdokuukqpu"
"
Cv" ngcuv" vjktv{" *52+" fc{u" prior to commencing the work, the Contractor shall submit to the
Engineer-in-Charge the following documents for his approval.
- Detailed shop and construction drawings which shall include complete details, sections and
plans of all parts, assemblies, components, connections and supports, and connections to the
work of other items.
- Detailed structural analysis of the proposed metal structures, if required.
- Test certificates proving the physical properties stipulated in the Specifications.

Before purchase, samples of all materials proposed for incorporation in the works shall be
submitted for approval to the Engineer-in-Charge, as and when required.
" Uvcpfctfu"cpf"Eqfgu"
"
Unless otherwise specified the materials to be used for the works shall conform to the Indian
standards or equivalent International standards with regard to quality, properties and workmanship.

103
The Contractor shall inform the Engineer-in-Charge of the standards he follows if no particular
ones are specified hereinafter. In case the Contractor wishes to follow any other standards and
codes, he shall submit sufficient copies of the same to be applied in English to the Engineer-in-
Charge for his approval.
" OCVGTKCNU"
All materials and structural components to be supplied, erected or installed and, therefore,
ultimately incorporated in the structure shall be new and unused. They shall be suitable for their
intended purpose and appropriately match each other.
Unless otherwise specified, all materials of metal work shall conform to applicable BIS Codes or
the following requirements or equivalent:
- Structural steel : ASTM A6/A6M, A36

- Steel tube and pipe : ASTM A53, A500, A501
- Welding : AWS A5.1, A5.17
In the drawings and the specifications, the size of steel pipes and shaped steel are indicated in the
metric system as a rule. The Contractor will be permitted to use those of inch size which are
approximately same or more in size as those indicated on the drawings or the specifications
" Gzgewvkqp"
"
" Igpgtcn"
"
*3+" Hcdtkecvkqp"cpf"Kpuvcnncvkqp"
"
All works shall be executed by skilled workers in a workmanlike manner.
All members shall be cut in such a manner as not to cause deformation or distortion. Irregularity
of cut surface shall be properly finished by planer.
The work shall be shop fitted and shop assembled where possible, and shall conform to the
details on approved shop drawings to be provided by the Contractor.
Welding shall be made by arc welding unless otherwise directed by the Engineer-in-Charge.
Where necessary, metals shall be insulated to prevent electrolysis due to contact between
dissimilar metals and to prevent corrosion due to contact between metals and masonry or
concrete. Insulation shall be by means of bituminous paint or other approved means.
All fastenings, anchors and accessories required for fabrication and erection of the work under
this section shall be provided by the Contractor. Exposed fastenings shall be kept to an absolute
minimum, evenly spaced and neatly set out. Wood plugs shall not be permitted.
Metal work to be embedded in concrete shall be set and fixed in position as shown on the
drawings or as directed by the Engineer-in-Charge before placing concrete. If blockouts will be
arranged at the locations where embedded parts are set in concrete as shown on the drawings or
directed by the Engineer-in- Charge, the metal work shall be fixed in place by the second stage
concrete.
The bond surfaces between the first and the second stage concrete shall be roughened. The
cross-section dimensions of the second stage concrete and the locations of embedded anchor
bolts shall be as shown on the drawings or as directed by the Engineer-in-Charge.
Where it is impracticable to place anchors or anchor bolts when the concrete is placed, holes will
be drilled in the hardened concrete 28 days after placing concrete. And expansion bolts, adhesive
anchor bolts or other approved anchors will be installed and fixed in place, and then grouted or
backfilled with mortar.

104
*4+" Rckpvkpi"cpf"Icnxcpk|kpi"
"
All components of the metal works shall either be painted or galvanized against corrosion prior to
assembly and/or erection. Any preliminary treatment against corrosion shall ensure a basic
protection remain effective for at least six months.
All steel surface except galvanized surface and embedded parts in concrete shall be painted.
Rust-resistant paint shall be applied in two coats and finishing paint shall be applied in two coats.
The quality of paint and the painting works shall be performed in accordance with the provisions
in the Specification. The color of paint shall be approved by the Engineer-in-Charge.
Components to be installed to the exterior shall in any case be hot dip galvanized. Galvanizing of
steel shall be in accordance with ASTM A123 A153 and A386 or equivalent and the zinc coating
shall be not less than 610 g/m.
*5+" Cwzknkct{"Yqtmu"
"
The following auxiliary works and services shall be deemed to be included in the metal works.
- transport, storing and protection of all structural components on site;

- protection of the executed works from detrimental influences, theft and damages until the time
of handover;
- supply of consumable stores;
- removal and making good of all contaminations (building rubbish, refuse and the like) arising
from and in connection with the Contractor's works;
" Uvggn"Eqxgt"
"
Steel covers shall be installed at openings designated on the approved Drawings or as directed by
Steel covers shall be of steel plate or chequered steel plate, with lifting devices as shown on the
drawings or as approved by the Engineer-in-Charge.
Frames shall be composed of shaped steel sections, angles, etc. and shall be anchored to
concrete as approved by the Engineer-in-Charge. The frame shall be adjusted during installation to
provide an accurate fit with the cover.
In order to ease removal and setting, all covers shall be tapered along the perimeter towards the
bottom. The maximum clearance between hatch cover and outer frame shall be 5 mm around at
finished floor level.
The corrosion protection shall be generally achieved by painting.
" Uvggn"Itcvkpi"
"
The steel gratings will serve as covers for gutters, sump and trench, and as tread for step ladder
etc.
The steel gratings are normally of a rectangular shape. Some are to be provided with openings for
the passage of pipes or ducts as directed by the Engineer-in- Charge or shown on the drawings.
Sizes of steel gratings shall be such as to afford easy handling.
Minimum support width shall be the height of the grating and not less than 30 mm.

105
The bearing frames of steel angles or channels shall be anchored to the concrete with steel bolts
or straps as shown on the drawings or as directed by the Engineer-in-Charge.
Before installation the frame shall be adjusted to allow the steel grating to have a continuous
support by the frame.
Before ordering the gratings, the Contractor shall check all relevant locations, dimensions and
shapes of the openings.
Steel gratings and frames shall be galvanized. Damaged finishing shall be repaired on site as
specified by the manufacturer and to the approval of the Engineer-in-Charge.
" Ncffgt"
"
The Contractor shall supply and install step ladders and steel ladders to the numbers and
dimensions as required. Ladders shall be installed where shown in the drawings or where directed
by the Engineer-in-Charge. The details of the ladders are referred to the approved drawings or as
directed by the Engineer-in- Charge.
Step ladders shall be securely fastened at top and bottom to the wall and shall have intermediate
clips and plates be riveted or welded to the side.
All steel members shall be galvanized. All bolts for fastening the ladder to the concrete wall shall
be of stainless steel. Where splices are required, bolted connections have to be used.
" Uvggn"Uvckt"cpf"Ecv"Ycnm"
"
The Contractor shall prepare his own design of steel stairs and cat walks in accordance with the
layout and details shown in the approved drawings or as directed by the Engineer-in-Charge.
All landings, stairs and cat walks shall be made of standard steel sections of angle, channel and I-
beam shape.
Components or portions thereof shall be pre-assembled with field points designed such as to allow
fast and easy erection on site.
Treads of stairs and landings shall be of galvanized steel grating, which have slipless nosing.
The catwalk shall be covered by steel checkered plate.
All outdoor metal parts shall be hot-dip galvanized after manufacture but prior to assembly and no
tooling on these parts will be permitted after galvanization.
Of indoor sections only the steel gratings and the chains of railings shall be galvanized; the entire
supporting steel structure and railings shall be painted.
" Gpvtcpeg"Icvg"
"
The Contractor shall design, manufacture, supply and install the entrance gates at the structures to
prevent unauthorized persons from entering to the relevant structures as shown in the approved
construction drawings or as directed by the Engineer-in-Charge. The gate shall be of a rigid
construction. The materials shall be of hot dip galvanized steel sections unless otherwise
specified.
" Uvggn"Jcpftckn"
"
The Contractor shall position the steel handrails in places as shown on the approved construction
drawings or as directed by the Engineer-in-Charge. The Contractor shall be responsible for
furnishing of materials, fabrication and installation of the handrails.
Steel handrails shall be fabricated and installed in the places as shown on the drawings. Steel
handrails shall be properly anchored to the structures. In general blockouts shall be provided
whenever possible and the blockout shall be filled with the concrete after installation.
All parts shall be rust proof painted after manufacturing but prior to installation.

106
" Htcog"hqt"Qrgpkpi"cpf"Eqxgt"
"
c0" Htcog"hqt"qrgpkpi"
"
Steel angle, z-and/or channel profiles shall be provided for all openings in the size and shape
indicated in the approved drawings. These frames shall be embedded in the concrete and attached
to the concrete by anchors securely welded to each side of the frame. Anchors may be replaced by
anchor plates and stud bolts whenever possible and where shown in the drawings and/or
instructed by the Engineer-in-Charge.
All corners of the frames shall be mitered. The surfaces of the frames shall be flush with the
concrete surface and the supporting parts, if any, shall be aligned in a way to prevent riding of the
covers.
d0" Htcog"hqt"Eqxgt"
"
Concrete covers such as concrete hatch cover and concrete trench cover shall be provided with
steel frames as shown in the approved Drawings and/or directed by the Engineer-in-Charge. In
general these frames shall be formed by channel profiles, however, the lateral vertical surface
shall be slightly inclined to ease lifting of the covers.
All corners of the frame shall be mitered and continuously flush- welded. All welding seams shall
be ground smooth. For the connection between the frame and the cover concrete anchors or steel
bars shall be welded to the frames.
The frames shall be provided with lifting rings or other arrangements to allow lifting of the covers.
" Qvjgt"Ogvcn"Yqtmu"
"
Any other metal shall be furnished and installed as shown on the approved drawings or as directed
or approved by the Engineer-in-Charge.
" Ogcuwtgogpv"cpf"Rc{ogpv"
"
Measurement and payment for metal works shall be made on the basis of the respective items in
accordance with the approved Drawings and Specification for the purpose of making progressive
payments on the basis of unit rates entered in the contract against total price of the relevant items.
"
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"
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This chapter shall include all work in connection with anchor bolts, structural steel works for
approach bridge and other miscellaneous works the steel frame of Pumphouse etc., as shown in
the approved drawings and as specified hereafter.
The work shall consist of preparation of shop drawings, supply of all materials, fabrication,
transportation, storage, erection, painting, inspection, quality control including survey, loading and
unloading, protection from damages and other auxiliary works as required.
" Uwdokuukqp"
"
The following documents shall be submitted to the Engineer-in-Charge for approval.
(1) Schedule
The Contractor shall uwdokv" c" yqtm" uejgfwng" kpfkecvkpi" vkog" uejgfwng" of all works including
shop fabrication, transportation, field fabrication, erection at the site and other necessary items
related to the work.
(2) Detail Design, Calculation and Shop Drawing

107
The Contractor shall submit complete shop drawings supported by structural computations, of all
structural steel work showing sizes, type and grade of metal, method of assembly, hardware and
anchorage or connection with the main structures at least one month before beginning the
manufacture of the various items.
Full account shall be made in the design for all temporary loads and stresses which may occur
during fabrication, assembly, transportation or erection.
(3) Erection Procedure
The Contractor ujcnn" uwdokv" ftcykpiu" qt" fqewogpvu" gzrnckpkpi" erection procedure including
the temporary bracing method and installation equipment or machinery, at least one month before
beginning the erection.
(4) List of Materials
Prior to the procurement of materials, the Contractor shall submit list of materials to be used. The
name, official address and brochures showing manufacturing facilities of the manufacturer of
materials shall be attached with the list.
(5) Mill Sheet and Certificates of Materials
Mill sheets or certificates of materials which are based on the tests performed in the steel maker or
an approved independent laboratory shall be submitted to the Engineer-in-Charge.
" Uvcpfctfu"cpf"Eqfgu"
"
All design, material, execution of work shall comply with the applicable Indian standards and codes
or where not covered by these standards to the equivalent International Standards.
" OCVGTKCN"
"
Except as otherwise specified, all material furnished by the Contractor under this section shall be
new, free from defects and imperfections and conform to the BIS or equivalent International
Standards.
" GZGEWVKQP"
"
" Ujqr"Hcdtkecvkqp"
"
(1) Measuring Tape
Measuring tapes for shop fabrication and for erection at site shall be of steel, and deviation of each
other shall be measured and informed to the Engineer-in- Charge for approval.
(2) Marking-Off on Material
The positions of bolt hole and shape, dimensions of plate shall be accurately marked on base
metal using full size templets.
(3) Cutting and Forming
In cutting base metal, automatic flame-cut method shall be employed. Base metal shall be
accurately cut at right angle to the axis and true to marked line and well- formed to size and shape
as marked on. Roughness, burrs or any other irregularity of all edges shall be removed using a
grinder or a planer.

108
(4) Bending
Except where inevitable, bending of structural steel shall be done cold. In case that it is necessary
to employ a heating process, bending of steel shall be done while the steel is red hot with the
approval of the Engineer-in-Charge.
(5) Bolt Hole
Holes shall be drilled with a bit at right angles to the surfaces, and shall not be made or enlarged
by burning holes. All bolt holes shall be clean-cut without any burrs or ragged-edges resulting from
drilling.
Diameters of holes provided for insertion of bolts shall be as follows:
D Diameter of bolt hole

More than 20 mm D + 1.5 mm
Not more than 20 mm D + 1.0 mm
D: Nominal diameter of bolt
When loose bolt holes are employed, the shape of loose bolt holes shall be shown on the
approved drawings.
(6) Welding
a. Welder
Welding shall be executed only by profesional welders who are skillful with welding with all position
and experienced in welding of structural steel more than 6 months and approved by the Engineer-
in-Charge.
b. Edge preparation and assembling
Edge to be welded shall be made into shape in accordance with the approved edge preparation
plan, and shall be free from loose scale, slag, grease, paint or other objectionable materials.
Materials to be welded shall be held firmly by an adequate method so as not to move during the
welding works. Tack welding shall be performed in such a manner as to minimize residual internal
stress. The Contractor shall take other proper means to prevent strain or residual internal stress
from welding.
c. Handling of welding rod
The welding rod shall be stored in their original packing in a dry place, with appropriate protection
against the weather. If the welding rod which seem to have suffered the effects of moisture but do
not have any other damage can only be used when they have been dried in satisfactory manner.
Welding rod which have areas where the flux covering is broken or damaged shall be rejected.
(7) Permissible Variation
Permissible variation in dimensions of the steel members fabricated at the manufacturer shall be in
accordance with the relevant standards stipulated before.
(8) Shop Painting
a. Base preparation and treatment
After the completion of fabrication at shop all of the surface to be painted shall be cleaned of all
rust, dirt, oil, slag, scale and any other foreign substance. Cleaning of the surface shall be
executed with sandblasting or shotblasting and immediately thereafter wash-primer shall be
applied to the surface.
CONTRACTOR SUPERINTENDING ENGINEER ,

SRBC CIRLCE NO.1, NANDYAL.
109
b. Rust-resistant painting
Rust-resistant paint shall be applied in two coats prior to the shipment.
c. Contacting faces for friction grip joint
Contacting faces for friction grip joint of high strength bolt shall be cleaned with sand blasting or
shot blasting. Wash-primer, or rust-resistant paint shall not be applied on those faces.
" Vtcpurqtvcvkqp"
"
The Contractor shall be responsible for all necessary notifications to the concerned office or
Authority concerning to the transportation of the member and parts of structural steel. They shall
be transported carefully to the site in such a manner as to prevent deformation, corrosion, or other
damages.
If necessary, adequate reinforcements, bracing, stiffeners or other means shall be provided.
" Uvqtcig"
"
The member and parts of structural steel shall be stored under proper covers and placed on
supports, so that they are not in contact with the ground or with substances which may cause
oxidation and deterioration.
" Gtgevkqp"
"
(1) General
The erection work shall be executed in such a manner that the steel structure do not suffer
permanent deformation, and are not subject to stress greater than those considered in the design.
During the erection work the Contractor shall adopt all measures which are necessary to prevent
injuries to persons and damage to the neighboring works.
(2) Installation of Anchor Bolts
Anchor bolts shall be installed accurately to meet the positions shown on the approved drawings
and the positions of anchor bolts shall be inspected before placing of concrete. When placing
concrete, care shall be taken so as not to move the position of anchor bolts.
(3) Friction Grip Joint
a. Length of high strength bolt
Standard length of stem shall be obtained by adding respective length tabulated below to the grip
thickness.
D (mm) L (mm)
16 30
20 35
22 40
24 45
Where,
D : Nominal diameter of bolt
L : Length to be added to grip thickness
The bolt set shall be stored in their original packing, and care shall be taken so that materials
would be free from dirt, damage and corrosion.

110
b. Treatment of contacting surfaces
The surfaces to become in contact with surface of another steel plate in friction grip joint shall be
free from paint, oil and other defects that would decrease friction force.
c. Tightening
Temporary tightening shall be performed using bolts not less than one third (1/3) of the total
number of bolts in each completed joint but never less than two. Bolts for temporary tightening
shall be distributed uniformly about the joint.
Tightening shall be done using either the impact wrench method or the "turn-off- nut" method in
accordance with the instruction of the bolt manufacturer. The work shall be done by competent and
experienced bolting crews.
70 percent of design bolt tension shall be given to the bolts at preliminary tightening and then 100
percent of design bolt tension shall be given to the bolt finally. Excessive tightening of the bolts
shall not be permitted.
d. Calibration of impact wrench
If the bolts are tightened by impact wrench method, each impact wrench shall be calibrated prior to
the commencement of the work each in the morning and the afternoon.
The impact wrenches shall be equipped with torque indicating scale or calibrating means so that
the torque can be measured clearly.
(4) Erection
All steel members shall be installed accurately to meet the positions and level shown on the
approved drawings and the positions and level shall be inspected before permanent fixing.
During the erection works, the steel structure shall be ensured sufficiently to withstand all loads
such as its own weight, live loads, wind loads and erection loads. All temporary bracing, guys and
bolts necessary to ensure safety of the structure shall be provided.
(5) Permissible Variation
Permissible variation shall be in accordance with the relevant Indian standards.
" Hkgnf"Tgvqwej"Rckpvkpi"
"
After installation, all damaged shop coated areas and all bolting, welded and other surfaces left un-
painted with rust-resistant paint shall be cleaned of all rust, dirt and any other foreign substances
and shall be painted with rust-resistant paint.
" Kpurgevkqp"
"
(1) General
All materials supplied and all work performed shall be subject to inspection by the Engineer-in-
Charge at the place of manufacture, fabrication and/or erection. Unless inspection is waived by the
Engineer-in-Charge, no material shall be shipped until after such inspection and acceptance of the
material has been performed.
Where directed by the Engineer-in-Charge, certified mill or shop-test reports shall be furnished in
lieu of inspection at the mill. Acceptance of material or waiving of inspection thereof shall in no way
relieve the Contractor of the responsibility of furnishing the materials and workmanship conforming
with the Specifications in all respects.
The Contractor shall submit the records of tests stating the name of test, time and place, results
and name of inspector.

111
The judgement of results of test and inspections shall be made according to the applicable
provisions of the standards stipulated before.
Tests or inspections may be waived with the approval of the Engineer-in-Charge in case mill
sheets or certificates or other appropriate evidences are submitted by the Contractor.
(2) Material Test
Quality of the principal materials to be used, such as rolled steels, bolt and nuts, electrodes shall
be tested.
(3) Qualification Test for Welding Operators, Welders and Welding

Procedures:
Shall be performed in accordance with the applicable standards.
(4) Inspection of Edge Preparation
Shall be performed in accordance with the approved plan of edge preparation.
(5) Appearance and Measurement Inspection
The appearance inspection shall be made on welded joints, bolts holes to be bolted in the field,
coated surfaces and on other items for defects.
(6) Inspection of Welded Joint
Welded joint shall be inspected by means of radiographic (X-ray) method and/or ultrasonic
method.
The rate of spot inspection shall be not less than 10% of the total welded length.
" Swcnkv{"Eqpvtqn"
"
The Engineer-in-Charge reserves the right to ask for independent analysis and tests on the
materials by an analyst or testing laboratory selected by him, in order to check the works, analysis
and tests. For this purpose the Engineer-in-Charge may take samples for analysis and have
pieces cut out side by side with pieces subjected to test in the workshops. Should the comparison
of the result of any independent analysis or test be unsatisfactory, the materials represented will
be rejected. All incidental cost for the above shall be borne by the Contractor.
" Cwzknkct{"Yqtm"
"
Mortar grouting at the base plate, installation of embedded steel parts in concrete structure shall
be included in the work. Shuttering needed for these works shall also be included in the work.
MEASUREMENT
Measurement of structural steel shall be based on weight by metric ton. All materials including
bolts, deck plates and other steel parts shall be measured. Measurements will be made for making
the progressive payments against the total contract price for the work, on the basis of rates
entered in the schedule of works
UGEVKQP"/"E"38"
GZRNQUKXGU"CPF"DNCUVKPI"
" UEQRG"QH"YQTM"
"
(i) The Specification described hereunder relate to supply, transportation, handling, storage and use
of explosives. All operations shall be carried out by the Contractor as per Indian Explosive Act and
regulations.

112
(ii) The Contractor shall, in due time, apply for a permit which allows him to buy, store and use the
explosives required for the works. He shall acquaint himself with all applicable latest laws and
regulations concerning storing, handling, safety and use of explosives. The Engineer-in-Charge
may issue modifications, if required and the Contractor shall comply with the same without these
being made a cause for claim, whatsoever, against the Employer.
" UWDOKVVCNU"
"
()i At least 52"fc{u"rtkqt"vq"the commencement of the excavation works, the Contractor shall submit
to the Engineer-in-Charge for approval, the details relating to transportation, storage and use of
materials such as explosives, detonators, fuse coils, tamping materials etc.
()i The Engineer-in-Charge reserves the right to require any additional information deemed
necessary to be included in the submitted documents.
" UVCPFCTFU"
"
(i) Transportation, handling, storage and use of explosives shall conform to the following Indian
Standards or where not covered by these standards, to equivalent International Standards:
Indian Explosives Act

IS : 4081 – 1986 (Reaffirmed 2002)
IS : 7526 – 1984 (Reaffirmed 2002)
IS : 7632 – 1984 (Reaffirmed 1999)
IS : 5878 (Part-II/Sec.-I) – 1970 (Reaffirmed 2000)
(ii) In case of conflict between the above standard and the specifications given herein, the
specification shall take precedence.
" UWRGTXKUKQP"
"
Excavation by blasting shall be permitted only under the supervision of competent and trained
workmen who are fully experienced in the work and who have received adequate instructions. The
Contractor shall make sure that his blasting crew is fully conversant with the rules and regulations
concerning storing, handling and use of explosives.
" VTCPURQTVCVKQP"CPF"JCPFNKPI"
"
(i) Explosives shall not be transported to the site of operation except in suitable cases or containers
which are so made as to prevent any spillage of explosives during conveyance. No explosive shall
be removed from such cases or containers except when it is to be used forthwith for the purpose
of the work.
(ii) Suitable Explosive Vans, duly approved by the Engineer-in-Charge, shall be used for
transportation of explosives and detonators. The following rules shall be observed for use of
Explosive Van:
(a) Vehicles shall have proper springs under the body and tyre pressures shall be as per Indian
Explosives Regulations.
(b) Detonators and ignitors shall not be carried in the same vehicle with explosives.
(c) Beside the driver, only one helper shall be accommodated in the Explosive Van. The vehicle
carrying the explosives shall not be used to transport workmen or other materials to workspots
although there may be enough space for men or materials.
(d) Drivers shall not leave the vehicle unattended while transporting explosives.
(e) All vehicles transporting explosives shall be marked or placarded on both sides and ends with the
word ‘GZRNQUKXGU’ in bold letters. All explosive boxes shall bear explosive’s Lot No.,
manufacturing date, Expiry date etc. clearly on them.

113
(f) A motor vehicle carrying explosives shall not be refueled except in emergencies and that too only
when motor is stopped, and other precautions taken to prevent accidents. Such vehicles shall
invariably have at least two fire extinguishers placed at convenient points.
(g) Vehicles transporting explosives shall never be taken into a garage, repair shop, parked in
congested areas, or in a public garage or similar buildings.
(h) Explosives shall not be transported on a public highway during hours of darkness except in
extreme emergency and that too only with the written approval of the Engineer-in-Charge.
(i) Explosives shall not be transported in any form of trailer, nor shall any trailer be attached to a
motor truck or vehicle hauling explosives.
(j) No transfer of explosives from one vehicle to another shall be made on any highway except in
case of emergency.
(k) Persons employed in the transport or handling of explosives shall not carry with them or in the
vehicles, matches, loaded fire arms, petrol or any flame-producing devices.
(l) All explosives shall be adequately protected against theft.
(m) Smoking shall be prohibited during handling and transport of explosives.
(n) The speed of the vehicle shall not exceed 25 km per hour on rough roads and 40 km per hour
elsewhere.
(o) The interior of the body of the vehicle shall not have any exposed metal parts except those of
copper, brass and other non-sparking metals and shall be preferably lined with wood.
(iii) Motor vehicle used for transporting explosives shall be carefully inspected daily to ensure that:
(a) Filled and serviceable fire extinguishers are in position

(b) The electric wiring is well insulated and firmly secured
(c) Chassis, engine and body are clean and free from surplus oil and grease
(d) Fuel tank and feed lines are not leaking
(e) Lights, brakes and steering mechanism are in good working order
(f) Vehicle is in proper condition in all respects for the safe transportation of explosives
(iv) Boxes of explosives shall not be handled roughly or allowed to fall.
(v) Containers of explosives shall be opened only by means of non-sparking tools or instruments.
(vi) After the loading of blast holes is completed, all excess explosives and detonators shall be
removed to a safe location or returned at once to the storage magazine, observing the same rules
as when being conveyed to the blasting areas.
(vii) Containers for detonators shall always be used only for storing detonators.
(viii) Explosives and detonators shall be carried in separate containers.
(ix) The drivers of the vehicle carrying explosives shall be trained in use of fire extinguishers on his
vehicle.
(x) If any fire occurs on a vehicle carrying explosives, the driver shall take all practicable steps to
ensure that all other traffic is stopped at least 300 m from the vehicle and that all persons in the
vicinity are warned of the danger.
(xi) Loading, unloading and handling of explosives shall be supervised by qualified personnel. At the
time of loading or unloading of explosives no electrical gadget shall be operated.
(xii) Explosives shall not be placed where these may be exposed to flame, excessive heat, sparks or
impact.

114
(xiii) The covers of the explosives cases or packages shall be replaced every time after taking out part
of the contents as long as any explosives are left in them.
(xiv) Explosives shall not be carried in the pockets or folds of clothing by any person.
(xv) Primers shall not be made up in a magazine or near excessive quantity of explosives or in excess
of immediate needs.
(xvi) Nothing shall be inserted in the open end of a blasting cap except fuses.
(xvii) No person shall strike, tamper with, or attempt to remove or investigate the contents of a blasting
cap or an electric blasting cap or attempt to pull out the crimped safety fuse out of a blasting cap.
(xviii) No attempt shall be made to soften hard set explosives by heating over a fire or by rolling the
explosive on the ground.
(xix) The blasting powder, explosives, detonators, fuses, etc. shall be in good condition and not
damaged due to dampness / moisture or any other cause. They shall be inspected before use and
damaged articles shall be discarded totally and removed immediately.
(xx) No attempt shall be made to reclaim or use fuses, blasting caps, electric blasting caps or any other
explosives which have been water soaked, even if these have been dried out. The manufacturers
shall be consulted for this.
(xxi) The Contractor shall make all necessary arrangements for the security of the explosives during
transportation. However, the Engineer-in-Charge, upon a request by the contractor, may arrange
protection by the Govt. security forces for large quantities of explosives, and the corresponding
cost shall be borne by the Contractor.
" UVQTCIG"
"
(i) The Contractor shall obtain license for construction and use of explosive magazine of adequate
capacity for storing the explosives at work sites in accordance with Indian Explosives Act.
(ii) The magazine shall, at all times, be kept scrupulously clean. High explosives like dynamite shall
be stored in a dry, clean, well-ventilated, and fire-proof building constructed in accordance with
Indian Explosives Act, on an isolated site. The area around the magazine for a distance of 8 m
shall be kept clear of all vegetation and combustible matter. There shall be a barded wire fencing
and security lights around the magazine and security guards shall be posted for 24 hours to
prevent loss or theft of explosives.
(iii) Explosives, detonators and fuse coils shall be stored separately.
(iv) A record of storage and withdrawal of all explosives shall be maintained . The record shall be
made available to the Engineer-in-Charge on request. The Engineer-in-Charge shall be promptly
notified of any loss or theft of explosives.
(v) Explosives shall be stored and used chronologically to ensure that the once received earlier are
used first. There shall be sufficient space between the stacks.
(vi) A “make up house” shall be provided at each working place in which cartridges shall be made up
by experienced men as required for the work. All safety measures shall be ensured in the “make
up house”.
(vii) Unauthorised persons shall not be allowed at any time to enter the magazine.
(viii) The Person-in-Charge of the magazine shall, at all times, ensure that the magazine is well and
securely locked.
(ix) The magazine, on no account, is to be opened during or on the approach of the thunder storm and
no person shall remain in the vicinity of the magazine during such storm. Sufficient number of
lightning conductors shall be provided on top of the magazine.

115
(x) Magazine shoes, without nails, shall be kept at all times in the magazine, and a wooden tub or
cement trough, about 30 cms high and 45 cms in diameter, filled with water shall be fixed near the
doors of the magazine.
(xi) Persons entering the magazine shall put on the magazine shoes provided for the purpose, and be
careful not to allow the magazine shoes to touch the ground outside the clean floor.
(xii) Persons with bare feet shall, before entering the magazine, dip their feet in water, and then step
direct from the tub over the barrier (if there is one) on to the clean floor.
(xiii) A brush or broom shall be kept in the lobby of the magazine for cleaning the magazine on each
occasion it is opened for the receipt, delivery or inspection of explosives.
(xiv) No matches shall be allowed in a magazine.
(xv) No person having articles of steel or iron on him shall be allowed to enter a magazine.
(xvi) Oily cotton rags, cotton waste and articles liable to spontaneous ignition, shall not be taken into a
magazine.
(xvii) No tools or implements other than those of copper, brass, gun metal or wood shall be allowed
inside the magazine. Tools shall only be used with great gentleness and care.
(xviii) Boxes of explosives shall not be thrown down or dragged along the floor and shall be stacked on
wooden trestles. Where there are white ants, the legs of the trestles shall rest in shallow copper,
lead or brass bowls containing water.
(xix) Package containing explosives shall not be allowed to remain in the sun.
(xx) Empty boxes shall not be stored in the magazine nor let any packing material lie loose.
(xxi) Blasting caps and electric blasting caps shall never be stored in the same box, magazine or
building with other explosives.
(xxii) The following shall be hung in the lobby of the magazine:
a) A copy of these rules

b) A statement showing the stock in the magazine
c) Certificate showing the last date of testing of the lightning conductor
(xxiii)Adequate fire fighting equipment shall be provided in the magazine.
(xxiv) Signboards reading “DANGER, HIGH EXPLOSIVES” “PROTECTED AREA” “NO SMOKING” etc.
shall be conspicuously displayed in front of the magazine.
(xxv) If nitroglycerine from deteriorated explosives has leaked down onto the floor of explosives
magazine, the floor shall be desensitized by washing thoroughly with an agent obtained
beforehand from the supplier of explosives. For this purpose, desensitizing agents and the
instructions for using them shall always be obtained alongwith the supply of nitroglycerine.
" FKURQUCN"QH"FGVGTKQTCVGF"GZRNQUKXGU"
"
All deteriorated explosives shall be disposed off in an approved manner. The quantity of
deteriorated explosives, to be disposed off, shall be intimated to the Engineer-in-Charge prior to its
disposal.
" FTKNNKPI"QH"JQNGU"HQT"DNCUVKPI"
"
(i) The position of all holes to be drilled shall be marked out with paint.
(ii) All holes shall be of greater diameter than the diameter of the cartridges of explosives
used.
(iii) Loading and drilling shall not be carried out simultaneously in the same area.
(iv) A drill or pole shall not be inserted in butts of old holes even if examination fails to disclose
explosives.
(v) Drilling shall not be resumed after blasts had been fired until a through examination has
been made to make sure that there are no unexploded charges which the drills may strike.
(vi) Drilling shall not be started until all remaining butts of old holes are examined for
unexploded charges.
(vii) Rock drillers shall be provided with approved respirators in siliceous dusty atmosphere
arising out of drilling operations.
" "

116
" NQCFKPI"1"EJCTIKPI"QH"JQNGU"
"
(i) The holes shall be cleared of all debris before a cartridge is inserted.
(ii) In loading the holes, tamping shall be done with a wooden mallet having no exposed metal parts.
(iii) Primed cartridges shall be seated by even steady pressure only.
(iv) All loaded holes or charges shall be checked and definitely located before firing.
(v) When holes are sprung, ample time shall be left between spring shots for the holes to cool, and
also between the last springing shot and the loading of the main charge.
(vi) When practicable, no more cartridges shall be primed than are required for a round of blasting.
(vii) Detonators shall be inserted only in a hole in the end of a cartridge prepared specially for the
purpose.
(viii) Holes in cartridge shall be made with a sharpened wooden stick.
(ix) All charges, before being fired, shall be covered with blasting mats where blasting is done in the
vicinity of structures likely to be injured by flying debris.
(x) Detonating card shall be cut from supply reel before attaching to explosive or tamping in hole. Use
of the short pieces of fuse shall be prohibited for detonation purpose.
(xi) Naked flames and lamps shall be kept away at the time of the loading of holes.
(xii) Such of the electrical lines as could constitute danger for work of loading / charging shall be
removed from the site.
(xiii) Highly insensitive caps shall be used in case parasite electric current are anticipated within the
ground and if lighting is frequent.
" YKTKPI"
"
(i) All electric caps in a blast shall be of the same manufacture.
(ii) Each electric blasting cap tested with an approved galvanometer before and after tamping in a
hole to determine whether it will carry the current. All testing shall be done away from the heading
face.
(iii) After testing the leg wires of electric blasting caps, they shall be short circuited by twisting the bare
ends together and shall remain so twisted until ready to be connected into the circuit prior to
connection to the firing line.
(iv) Unless, the power supply is heavy, it is recommended that all electric blasting caps shall be wired
in series and the firing line shall not be smaller than No. 14B and S-gauge copper wire.
(v) The number of electric blasting caps used in a circuit shall not exceed the tested capacity of the
blasting machine.
(vi) The circuit, including all caps, shall be tested with circuit tester or galvanometer, operating
accurately, before being connected to the firing line.
(vii) Cartridges shall not be primed nor holes loaded during the approach of a thunderstorm or while it
is in progress. If a charge has been primed or holes loaded, every person shall be ordered to a
safe distance until the storm is over.
(viii) Blasting circuit wires shall never touch other wires carrying electric current.
(ix) Blasting operation control shall be consist of two switches, a safety switch and a firing switch
located at least 2 meters apart, the connection between the switches to be made by a ‘Plug-in’
jumper which may be permanently attached to the safety switch. The ‘Plug-in’ jumper is so made
that it cannot be plugged into or connected to the firing switch until the firing switch is unlocked,
and the jumper must be disconnected from the firing switch before the firing switch can be locked.
(x) Both the safety switch and the firing switch shall be of the locking, double pole, double throw type
which, when opened and locked in downward position short circuit and ground the leading wires.
(xi) Both the switches shall be locked immediately after firing the shot and before any person is
allowed to return to the area. Keys to the switches shall remain in the possession of the starter at
all times.
" HWUG"DNCUVKPI"
"
(i) The length of fuse to be used in blasting shall in no case, be less than 75 cms or that as directed
by the Engineer-in-Charge.
(ii) Blasters or shot fires shall be cautioned always to use sufficient lengths of fuse to permit them to
reach a safe place before the first hole is fired.

117
(iii) Not more than 12 holes shall be loaded and shot at one time if cap and fuse are used to detonate
the Charge.
(iv) Mudcap blasting being insufficient and dangerous shall be avoided. Two or more mudcaps shall
not be placed on one rock except when electrically detonated.
" HKTKPI"
"
(i) Shots shall, so far as practicable, be fired electrically and only apparatus especially designed for
the purpose shall be used. Power lines shall not be tapped for the purpose. No shot shall be
fired except by a licentiate blaster authorised by the Engineer-in-Charge.
(ii) The charge shall be fired successively and not simultaneously.
(iii) Prior to firing of a shot, all persons in the blasting area shall be warned of the blast and ordered
to be at a safe distance from the notified area.
(iv) Competent flagmen, equiped with red flags and whistles shall be posted to stop traffic at access
points on each possible route of travel, to the vicinity of the blasting area.
(v) Blasting shall be done at fixed hours performable during lunch hours or as directed by the
Engineer-in-charge and the blasting times shall be displayed on a Notice Board at some
convenient location .
(vi) Order to fire shall be given only by the Supervisor-in-Charge of the work after giving three
warning signals to enable all the workmen to reach safe shelters.
(vii) Blast shall not be fired until it is absolutely certain that every person has retreated to a safe
distance.
(viii) The person-in-charge of blasting shall be the last one to leave the area to be blasted.
(ix) A bugle with a distinctive note shall be used to give warning signals. This bugle shall not be
used for any other purpose. All the labour shall be made acquainted with the sound of the bugle
and shall be strictly warned to leave their Site of Work immediately for safe shelters at the first
warning signal and not to leave the shelters till all clear signal has been given.
(x) An all clear signal shall be given when the blasting is over.
(xi) Definite places of shelter, natural or artificially constructed, shall be assigned to the crew.
Workers shall be made to go to these shelters rather than trust each other’s judgement about a
safe place.
(xii) Only Supervisor-in-Charge shall be responsible for the safe custody of the firing apparatus.
(xiii) For blasts in series, only detonators of the same brand and same electrical resistance shall be
used. All detonators shall be checked before use.
(xiv) The firing cables shall be with a proper insulating cover to avoid short circuiting due to coming in
contact with water, metallic parts or rock.
(xv) Use of earth as a return line shall not be permitted.
(xvi) The firing cable shall be connected to source of current only when no body is in the area of
blasting.
(xvii) Mats or rubber tyres tied together with rope shall be used as protection from flying debris to
cover the charges where blasting may expose persons or property to injury of damage.
(xviii) Blasting shall be permitted only after adequate provisions have been made for the protection of
persons, the works, and public and private property. The Engineer-in-Charge’s approval of any
of the Contractor’s blasting operations shall not relieve the Contractor of his sole responsibility
for the safety of persons and property. Any damage done to the works or property by blasting
shall be repaired by the Contractor.
" KPURGEVKQP"CHVGT"DNCUVKPI"*OKUHKTG"FTKNN+"
"
(i) Immediately after a blast has been fired, the firing line shall be disconnected from the blasting or
other source of power.
(ii) After a blast has been fired, a careful inspection shall be made by the blaster to determine if all
charges have exploded. The blaster shall count the number of the exploding shots in blasting.
Misfires in fuse blasting shall not be examined before sufficient time after its failure to explode.
Electric blasting misfires shall not be examined for at least 15 minutes after failure to explode.
Other persons shall not be allowed to return to the area of blast until an “All Clear”, signal is
given.
(iii) All wires shall be carefully traced and search made for any unexploded cartridges by the
Person-in-Charge of the blasting operation.

118
*KX+" Loose pieces of rock and other debris shall be scaled down from the sides of the face of
excavation and the area made safe before proceeding with the work.
" OKUHKTGU"
"
(i) Misfired holes shall be placed in the charge of competent person.
(ii) If broken wires, faulty connections, or short circuits are determined as the cause of a misfire,
proper repairs shall be made, the firing line reconnected, and the charge fired. This shall be done,
however, only after a careful inspection has been made of burdens remaining in such holes and
no hole shall be fired when the burden has been dangerously weekend by other shots.
(iii) The charge of explosives from a misfired hole shall not be drilled, bored or picked out.
(iv) Misfired charges tamped with sold material shall be detonated by the following method:
(a) Float out the stemming by use of a water or air jet from hole until hole has been opened to within
60 cm of charge;
(b) Water shall be siphoned off or pumped out;
(c) New charge shall be placed and detonated. Whenever this method is not practicable, then a new
parallel hole, not nearer than 60 cms, shall be drilled, loaded and detonated. A careful search shall
be made of unexploded material in the debris of the second stage.
(v) If misfire has been found to be due to defective detonators or dynamite, whole quantity or box from
which the defective article was taken must be withdrawn from the works site for return to the
manufacturer or destruction as decided by the Engineer-in-Charge.
(vi) The Contractor shall report, in writing, to the Engineer-in-Charge, all cases of misfire, causes of
the same and steps taken in connection therewith.
" Eqpvtqn"Dncuvkpi"
In case blasting is requested to be carried out nearby the existing structure / structure under
construction, special precautions are to be taken to prevent the travel of shock wave generated by
blasting activities. Besides other necessary precautions to be taken as per site condition, the
maximum permissible charges that can be safely blasted per short delay (not less than 12.5
milliside) be as follows :
Fkuvcpeg" kp" Ejctig"kp"Mi0 Fkuvcpeg"kp"Ovtu0 Ejctig"kp"Mi0"

Ovtu0"
0.5 0.02 4.0 0.5
0.75 0.04 6.0 0.9
1.0 0.06 8.0 1.3
1.25 0.09 10.0 2.0
1.50 0.12 15.0 3.8
2.0 0.16 20.0 6.5
2.5 0.25 25.0 8.0
3.5 0.40 30.0 11.0
UGEVKQP"⁄"E"39"
"
HKPKUJKPI"CPF"OKUENNGPGQWU"KVGOU"
"
3902" UEQRG"QH"YQTM"
"
This section covers specifications for miscellaneous item like providing and fixing aluminum
windows/doors with glazing, rolling shutters, terrazzo tiles, vinyl asbestos tiles, improved flooring,
CC flooring, M.S. grating, steel work in single section in cable duct, RCC jali, W.C. Pan, wash
basin, urinal unit and aluminum pipe railings, joints and water proofing treatment in intake and
pump house building, pipes, installation of embedded parts, shotcreting, brickwork, coursed rubble
masonry, sausage wall, approach road, and drainage arrangement etc. The work shall include all
labours, materials, equipment tools and tackles etc. required for completion of the works.

119
390303"Crrnkecvkqp"Rwdnkecvkqpu"
"
All methods and procedures shall conform to Indian Standard Specification some of which are
listed below :
KU<:38" Ygnfkpi"
IS:1038 Specification for steel doors and windows
IS:1081 Glazing
IS :1239 Mild steel tubes
IS:1761 Glazing
IS:3548 Glazing
IS:4351 Door Frames
IS:269 Portland Cement
IS:800 Structural Steel
IS:814 Welding Electrodes
IS:2556 (Part. II) Water Closet
IS:2556 (Part. IV) Wash Basin
IS:2556 (Part. VI) Urinals
IS:774 Flushing System for W.C.
IS:781 Copper alloy bib taps
IS:775 Cast iron brackets

IS:1948 Specification for aluminum doors
windows and ventilation
IS:1949 Aluminum Windows for industries
building
" CNWOKPKWO"FQQTU."YKPFQYU"CPF"XGPVKNCVQTU"
"
" Igpgtcn"
"
The contractor shall submit shop drawings details of various parts, methods of anchoring and any
other pertinent details for the approval of the Engineer-in- charge. Before placing orders the
contractor shall submit sample of hardware to the Engineer-in-charge for approval.
" Ocvgtkcnu"
"
a) Aluminum alloy used in the manufacture of extruded window sections shall correspond to IS
designations HEO 9-WP of latest edition of IS : 733. Hollow aluminum alloy sections used shall
conform to IS Designation HV9-WP of latest edition of IS : 1285. Dimensions and weight per metre
run of the extruded sections shall conform to latest edition of IS : 1948 and IS : 1949.
b) Coupling sections – Aluminum alloy coupling sections used shall conform to IS Designation HV9-
WP of latest edition of IS : 1285.
c) Glass panes – Glass panes shall weigh atleast 7.5 kg/cm2 and shall be free from flaws, specks or
buggles. All panes shall have properly squared corners and straight edges. The sizes of glass
shall conform latest edition of IS : 1948.
d) Screw threads of machine screws used in the manufacture of aluminium doors and windows and
ventilators shall conform to the requirements of latest edition of IS : 1362.
e) The metal thickness shall not be less than 1.6 mm for frame and 2.3mm for threshold.

120
" Hcdtkecvkqp"
Frames shall be square and flat, the corner of the frame being fabricated to a true right angle. Both
the fixed and opening frames shall be constructed of sections which have been cut to length,
metred and welded at the corners. Where hollow sections are used with welded joints, argon arc
welding or flash butt welding shall be employed (gas welding or brazing not to be done).
Subdividing bars of units shall be tenoned are riveted into the frame.All fabrication shall conform to
latest edition of IS 1948, 1949 and other relevant IS wherever available. Generally side hung
shutters shall be used for door and windows.
Top-hung shutters shall be used for ventilators. And Central hung shutters shall be used for doors
also. For fixing aluminum alloy hinges, slot shall be cut in the fixed frame and the hinges inserted
inside and may be riveted to the frame. Cast or extruded aluminum alloy hinges for doors shall
conform to latest edition of IS
:1949, IS :617 and IS :733. The hinge shall be of projecting type. Non projecting type of hinges
may also be used. The handle for doors and windows shall conform to latest edition of IS 617 and
other relevant Indian Standards wherever applicable. Suitable lock for door operable either from
inside or outside shall be provided. Any steel lugs coming in contact with aluminum should be
either galvanized or given one coat of bituminous paint.
" Hkpkuj"
Aluminum doors, windows and ventilators shall be supplied & be anodized. Colour anodizing to
be done using approved light fast shades.
A thick layer of clear transparent lacquer based on methacrylates shall be applied to protect the
surface from wet cement during installation and after installation the lacquer coating shall be
removed.
" Inc|kpi"
"
Glazing shall be provided on the outside of the frames.
" Jctfyctg"
Hardware for the Aluminum doors, windows and ventilators shall comply with the requirements
specified on the drawings. The contractor shall submit catalogues and samples to the Engineer-in-
charge for approval prior to supplying hardware. The hardware shall comply with the following
requirement :
Hinges Conforming to latest edition of IS :1948, IS :617, IS

:753, IS :1949.
Knobs Aluminum approved quality.
Lock sets Aluminum cylinder lock of approved make.
Flush bolts Wall or floor mounted type with rubber bumper and holder.
Door stops Wall or floor mounted type with rubber bumper and holder
Door closers As per relevant IS code
Hand plates Aluminum approved make as per IS code Hand
Balls Aluminum approved make as per IS code The
contractor shall supply three keys for each lock fitted.
" Inc|kpi"
"
Materials
Glass for glazing of windows and doors shall be sound free from specks, waves and flows
and shall be conforming to latest edition of IS : 1761, IS : 1081 and IS : 3548.
Execution
Glass shall be accurately cut to size to suit the dimension of openings. Glazing to
Aluminum doors, windows and ventilators shall be carried out by means as described in IS
code wherever available. Glass shall be cleaned and polished on completion of building
works.

121
" UVGGN"TQNNKPI"UJWVVGT"FQQT"
"
Steel Rolling Shutter doors capable of both electric and manual operation shall be installed at the
location shown in the approved drawings and in accordance to the relevant IS Specifications. All
steel plate and angles, welding and bolting shall conform to the specifications provided in section-
7. The doors shall be composed of a shutter, guide rails, rolling drum and cover case, with a motor
control gear, safety switch, wiring and all other accessories.
The various components shall be as follows :
Iwkfg"tcknu: 2.3 mm thick roll-formed steel plates, depth 75 mm, with safety stop at a height 2.2
mm above the floor.
Eqxgt"Ecug: 1.6 mm thick steel plate with adequate reinforcement and inspection hole.
Oqvqt": Electric Source A.C. 230 Volt, 3 Phase 50 Hz. Operation speed 3 to 5 m/min. Motor to be
installed in the cover case, operation box to be installed in the side wall at adequate height and
provided with both electric and manual operation devices with all necessary accessories including
hand plate and hand bar of stainless steel. The manual operation device shall be suitably geared
to allow operation by one man.
17.3.1 Measurement
Measurement for providing, fabricating and fixing for Aluminum windows, doors with glazing and
steel rolling shutters shall be measured on the basic of square metre.
" HKPKUJGU"HQT"YCNNU."EGKNKPI"CPF"HNQQTU"
" Egogpv"Rncuvgt"
The walls and the ceilings of the intake structure and the pumphouse shall be finished
smooth with cement plaster as specified below:
Rctvkewnctu" Vjkempguu"qh" Rtqrqtvkqp"
rncuvgt"
1. Wall 15 mm 1 cement: 4
sand
2. Ceiling 6 mm 1 cement : 3 sand
" Ocvgtkcnu"
Cement mortar shall consist of cement and sand and shall conform to the following.
1. Cement shall be ordinary Portland cement type in accordance with latest editions of IS : 269. The
supply, use, storage and testing of cement shall be in accordance with IS specification.
2. Sand shall be clean, hard and durable, of proper grading and free from dirt, organic or deleterious
materials.
The grading of the sand shall be within the following limits:
Encuukhkecvkqp" Uetggp"Fgukipcvkqp" Rgtegpvcig"d{"ygkijv"

"""""""""""""""Rcuukpi"uetggp"
Rendering Coat 5 mm 100%

0.15 mm 10% or under
Finishing Coat 2.5 mm 100%
0.15 mm 10% or under

122
3. The quality of the mortar. If required by the Engineer-in-charge water shall be tested Water used in
the mixing of mortar shall be fresh, clean water suitable for drinking. Water shall not contain salt,
oil, alkali, organic matter or other deleterious substances which would impair.
4. Waterproofing and colored admixture shall be used in the cement mortar in strict accordance with
the manufacturers printed instructions.
The mix proportions of the cement mortar shall be as specified in the bill of quantity of this work.
Water proofing compound @ 5% by weight of cement (maximum) shall be used in strict direction
of the Engineer-in-charge.
Rate of respective items of work shall include cost of admixture etc.
The pigment of the coloured cement mortar shall be of good quality and approved by the
Engineer-in-charge. It shall be used in accordance with the manufacturer’s instructions.
" Rtgrctcvkqp"qh"Uwthceg"
The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence if
any shall be removed by brushing and scrapping. The surface shall then be thoroughly washed
with water, cleaned and kept wet before plastering is commenced.
In case of concrete surface if a chemical retarder has been applied to the form work, the surface
shall be roughened by wire brushing and all the resulting dust and loose particles cleaned of and
care shall be taken that none of the retarders is left on the surface.
" Oqtvct"
"
The mortar of the specified mix using the type of sand described in the item shall be used. For
external work and under coat work, the fine aggregate shall conform to grading IV. For finishing
coat work the fine aggregate conforming to grading zone V shall be used.
" Crrnkecvkqp"qh"Rncuvgt"
Ceiling plaster shall be completed before commencement of wall plaster.Plastering shall be

started from the top and worked down towards the floor. All putlog holes shall be properly filled in
advance of the plastering as the scaffolding is being taken down. To ensure even thickness and a
true surface, plaster about 15 x 15 cm shall be first applied horizontally and vertically at not more
than 2 metre intervals over the entire surface to serve as gauges. The surfaces of these gauged
areas shall be truly in the plane of the finished plaster surface. The mortar shall be applied in a
uniform surface slightly more than the specified thickness. This shall be beaten with thin strips of
bamboo about one metre long to ensure thorough filling of the joints, and then brought to a true
surface, by working a wooden straight edge reaching across the gauges, with small upward and
side ways movements at a time. Finally the surface shall be finished off with trowel or wooden float
accordingly, as a smooth or a sandy granular texture, as required. Excessive trowelling or of
working the float shall be avoided. During this process, a solution of lime putty shall be applied on
the surface to make the later workable.
All corners, arises, angles and junctions shall be truly vertical or horizontal as the case may be
and shall be carefully finished. Rounding or chamfering corners, rises, junctions etc. where
required shall be done without any extra payment. Such rounding or chamfering shall be carried
out with proper templates to the sizes required.
In suspending work at the end of the day, the plaster shall be left, cut clean to line both
horizontally and vertically, when recommencing the plastering the edge of the old work shall be
scraped and wetted with lime putty before plaster is applied to the adjacent areas, to enable the
two to properly join together. Plastering work shall be closed at the end of the day on the body of
wall and not nearer than 15 cm to any corners or arises. It shall not be closed on the body of the
feature such as plasters, bands cornices, nor at the corners or rises. Horizontal joints in plaster
work shall not also occur on parapet tops and copings, as these invariably lead to leakage. No
portion of the surface shall be left out initially to be patched up later on.

123
a) Beating with thin bamboo strips shall not be done on the cement plaster and
b) No lime putty solution shall be applied on the face when finishing. Further the plastering and
finishing shall be completed within half an hour of adding water to the dry mortar.
" Ewtkpi"
"
Curing shall be started as soon as the plaster has hardened sufficiently not to be damaged when
watered.
The plaster shall be kept wet for a period of not less than 7 days. During this period, it shall be
suitably protected from all damages at the contractor’s expense by such means as the Engineer-
in-charge may approve. The dates on which the plastering is done shall be legibly marked on the
various section plastered so that curing for the specified period there after can be watched.
" Hkpkuj"
"
The plaster shall be finished to a true and plumb surface and to the proper degree of smoothness
as required. The work shall be tested frequently as the work proceeds with a true straight edge not
less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a
level and all jambs and corners with a plumb bob as the work proceeds.
" Ogcuwtgogpvu"hqt"Rc{ogpv"
Length and breadth shall be measured for payment correct to a cm and its area shall be calculated
in square metres correct to two places of decimals.
Thickness of the plaster shall be exclusive of the thickness of the key i.e. grooves, or open joints
in brick works.
The measurements of wall plaster shall be taken between the walls or partitions (the dimensions
before plastering shall be taken) for the length, and from the top of the floor or skirting to the
ceiling for the height. Depth of coves or cornices if any be deducted.
Deductions in measurement, for openings, etc. will be regulated as follows :-
a) No deduction will be made for openings or ends of joints, beams, posts, girders, steps etc. upto
0.5 sq m in area, no additions shall be made either, for the jambs, soffits and sills of such
openings. The above procedure will apply to both faces of wall.
b) Deduction for openings exceeding 0.50 sq. m but not exceeding 3 sq. m each shall be made for
reveals, jambs, soffits, sills etc. of these openings.
i) When both face of walls are plastered with different types of plaster or if one face is plastered and
other is pointed, or one face is plastered and other is unplastered, deductions shall be made from
the plaster or pointing on the side of the frame for the doors, windows, etc. on which width of
reveal is less than on the other side but no deductions shall be made on the other side.
i) Where width of reveals on both faces faces of are equal, deduction of 50% of area of opening on
each face shall be made from area of plaster and/or pointing as the case may be
ii) For opening having door frame equal to or projecti.ng beyond thickness of wall, full deduction for
opening shall be made form each plastered face of wall.
" PGCV"EGOGPV"RWPPKPI"
"
Specifications for this item of work shall be same as described in clause 17.4 except for the
additional floating coat of neat cement to be carried out as below :
When the plaster has been brought to a true surface with the wooden straight edge it shall be
uniformly treated over its entire area with a paste of neat cement and rubbed smooth, so that the
whole surface is covered with neat cement coating. The quantity of cement applied for a floating
coat shall be 1 kg sq. m smooth finishing and shall be completed with trowel immediately and in no
case later than half an hour of adding water to the plaster mix. The rest of the specifications
described in 17.4.4 shall apply.

124
" HKPKUJGU"QH"HNQQT"
"
" Tguknkgpv"Vkngu"
Resilient tile and skirting shall be approximately 250 mm x 250 mm x 3 mm and 100 mm x 100
mm x 3 mm, respectively. Colour and patterns shall be selected by the Engineer-in-charge from
the standard range.
The tiles shall be set on a thoroughly dried rendered base.
The layout shall be subject to the approval of the Engineer-in-charge.
Tile and skirting shall be adequately protected during the time of setting for a subsequent period.
No traffic shall be allowed on the tiles for 48 hours after setting
" Rtg/ecuv"Vgttc||q"Vkngu"
"
Pre-cast terrazzo floor tiles shall be made from portland cement and coloured stone chipping and
shall be pressure moulded and ground to size. The tiles shall be hard, durable and sharp, true
edges. Colours and patterns and patterns shall be selected by the Engineer-in-charge from a
standard range.
The size of tile shall be as follows :

Floor tiles : 300 mm x 300 mm x 20 mm thick Floor
skirting 100 mm and 200 mm high.
Tiles and skirting shall be bedded and pointed in 1:3 cement mortar. Bedding for tiles shall be of
required thickness to suit finished floor levels.
" Egtcoke"Inc|gf"Ycnn"Vkngu"*Kpvgtpcn+"
The ceramic will tiles for interior use shall be made of porcelain or earthenware. Tiles shall be
100mm square x 6 mm thick. Tiles shall be hard, durable and non- absorbent of exact shape and
even thickness and shall have cushioned edges. Coloured and patterns shall be selected by the
Engineer-in-charge from a standard range. Tiles shall be bedded in adhesive supplied by the tile
manufacturers and pointed with white cement.
" HCNUG"EGKNKPI"
"
The entire area to be air conditioned shall be provided with false ceiling of hard board three layer
flat pressed teak timber tile each of size 60 cm x 60 cm x 12 mm thick or other approved suitable
material for the false ceiling and the supporting frame material which shall be supplied & installed
by the contractor. The complete material for the false ceiling and the supporting frame work shall
be supplied by the contractor & shall conform to the relevant Indian Standards. After installation,
the false ceiling (face towards the floor of the air condition rooms), shall be given suitable coating
for protection as well as better finish. The colour of the coating shall be as approved by the
Engineer-in-charge. Detailed embedment drawing showing details of necessary embedments
(Aluminum) to be provided in the ceiling for supporting the false ceiling frame work and ducts etc.
shall be furnished by the Contractor alongwith their offer. A suitable arrangement properly utilising
these plates shall be furnished for approval of the Employer. All supporting material shall be
supplied by the contractor.
" Urgekhkecvkqp"
Suitable provision such as semi-transparent panels or louvered openings etc., for illumination of
the room shall be made in the design of the false ceiling. Full information regarding the proposed
fittings for illumination purposes shall be furnished by the Contractor to the Employer. Supply and
installation of lighting equipment shall be the responsibility of Contractor.
False ceiling supporting frame work including the Aluminum plates shall be given suitable rust
resistant coating after proper cleaning of the surfaces.
The supporting arrangement shall be so designed as to permit easy dismantling etc. for
maintenance of air conditioning equipment’s or light fittings, etc.
" RCKPVKPI"

125
"
" Ocvgtkcnu"
"
Paints, oils, varnishes, etc., of approved brand and manufacture shall be used. Paints shall be
synthetic enamel ready mixed paints and shall be used as received from the manufacturer. If for
any reason, thinning is necessary in case of ready mixed paint, the brand of thinner recommended
by the manufacturer or as instructed by the Engineer-in-charge shall be used.
Approved paints, oils, or varnishes shall be brought to the site of work by the contractor in their
original containers in sealed condition.
" Gzgewvkqp"
"
Painting shall not be started until the Engineer-in-charge has inspected the items of work to be
painted, satisfied himself about their proper quality and given his approval to commence the
painting work. Painting of external surface should not be done in adverse weather condition like
hail storm and dust storm.
Painting, except the priming coat, shall generally be taken in hand after practically finishing all
other builder’s work.
The rooms should be thoroughly swept out and the entire building cleaned up, at least on day in
advance of the paint work being started.
" Rtgrctcvkqp"qh"Uwthceg"
"
The surface shall be thoroughly cleaned and free from dust. All rust, dirt, scales, smoke and
grease shall be thoroughly removed before painting is started. The prepared surface shall have
received the approval of the Engineer-in-charge after inspection, before painting is commenced.
" Crrnkecvkqp"
"
Painting/Varnishes of approved colour and quality shall be done two coats over a priming coat
over steel/wood works
Before pouring into smaller containers for use, paint shall be stirred thoroughly in its containers,
when applying also, the paint shall be continuously stirred in the smaller containers so that its
consistency is kept uniform.
The painting shall be laid on evenly and smoothly by means of crossing and laying off, the latter in
the direction of the grain of wood. The crossing and laying off consists of covering the area over
with paint, brushing the surface hard for the first time over and then brushing alternately in
opposite direction two or three times and then finally brushing lightly in a direction at right angles
to the same. In this process, no brush marks shall be left after the laying-off is finished. The full
process of crossing and laying off will constitute one coat.
Where so stipulated, the painting shall be done by spraying. Spray machine used may be (a) high
pressure (small air aperture) type, or (b) a low pressure (large air gap) type, depending on the
nature and location of work to be carried out. Skilled and experienced workmen shall be employed
for this class of work. Paints used shall be brought to the requisite consistency by adding a
suitable thinner.
Spraying should be done only when dry condition prevails. Each coat shall be allowed to dry out
thoroughly and rubbed smooth before the next coat is applied. This should be facilitated by
thorough ventilation. Each coat except the last coat, shall be lightly rubbed down with sand paper
or fine pumice stone and cleaned off dust before the next coat is laid.
No hair marks from the brush or clogging of paint puddles in the corners of panels, angles of
mouldings, etc shall be left on the work.
In painting doors and windows, the putty round the glass panes must also be painted; but care
must be taken to see that no paint stains etc., left on the glass. Tops of shutters and surfaces in
similar hidden locations shall not be left out in painting.
In painting steel work, special care shall be taken while painting over bolts, nuts, rivets, overlaps
etc.
" "

126
" "
" Dtwujgu"cpf"eqpvckpgtu"
"
After work, the brushes shall be completely cleaned of paint and linseed oil by rinsing with
turpentine. A brush in which paint has dried up is ruined and shall on no account be used for
painting work. The containers when not in use, shall be kept closed and free from air so that paint
does not thicken and also shall be kept safe from dust. When the paint has been used, the
containers shall be washed with turpentine and wiped dry with soft clean cloth, so that they are
clean, and can be used again.
" Ogcuwtgogpvu"
"
The length and breadth shall be measured for payment to a cm. The area shall be calculated in
sq. metres (correct to two places of decimal), except otherwise stated.
Small articles not exceeding 10 sq. decimetre (0.1 sq. m) of painted surfaces where not in
conjunction with similar painted work shall be enumerated.
Painting up to 15 cm in width or in girth and not in conjunction with similar painted work shall be
given in running metres.
Components of trusses, compound girders, stanchions, lattices and similar work shall, however,
be given in sq. metres irrespective of the size or girth of members.
In measuring painting, varnishing, oiling etc., of joinery and steel work etc. the coefficients as in
following tables shall be used to obtain the area payable.
The following coefficients shall be applied to the areas measured flat and not girthed.
Vcdng"3"Gswkxcngpv"Rnckp"Ctgcu"qh"Wpgxgp"Uwthcegu"
"
Un0" Fguetkrvkqp"qh"yqtm" Jqy"ogcuwtgf" Ownvk"rn{kpi"
Pq0" eq/ghhkekgpv"
3" 4" 5" 6"
" "
a) Panelled or framed and Measured flat (not girthed) including1.30 (for each braced
doors, windows etc. Chowkhat or frame Edges, chocks,side)
. Cleats,etc. shall be deemed to be
included in the item.
b) Ledged and battened or
ledged, battened and
braced, doors, windows
etc.
c) Flush doors etc. DO 1.20 (for each

side)
d) Rolling shutters of Measured flat 1.10 (for each
interlocked laths (size of opening) side)
all over jamp guides,
bottom rails and
locking arrangement
etc. shall be
included in the item
(top
cover shall be measured
separately)
e) Fully glazed or Measured flat 0.50 for each

gauged steel doors (not girthed) side) windows
including frame
edges etc.

127
f) Expanded metal, hard Measured flat 1 (for paint all

drawn steel wire overall ; no over)
fabric of approved deduction shall
quality, grill works be made for open
and gratings in guard spaces; supporting
Bars, balustrades, members shall not
Railings, partitions be measured
And M. S. Bars in separately
Windows frames
g) Open palisade fencing ------Do--------- 1 (for paint all
and gates including over)
standards, braces;
rails stays etc,. in
timber or steel
Gzrncpcvqt{"pqvgu"hqt"vcdng"3"
"
1. Measurement for doors windows etc. shall be taken flat (and not girthed) over all including chowkhats
or frames, where provided. Where Chowkhats or frames are not provided, the shutter measurements
shall be taken.
2. Where doors, windows, etc., are of composite types other than those included in Table 1 the different
portion shall be measured separately with their appropriate coefficients, the center line of the common
rail being taken as the dividing line between the two portions.
3. The coefficients for doors and windows shall apply irrespective of the size of frames and shutter
members.
4. In case steel frames are used the area of doors, windows shutters shall be measured flat excluding
frames.
5. When the two faces of a door, windows etc., are to be treated with different specified finished,
measurable under separate items, the edges of frames and shutters shall be treated with the one or
the other type of finish as ordered by the Engineer-in-charge and measurement of this will be deemed
to be included in the measurement of the face treated with that finish.
6. In the case where shutters are fixed on both faces of the frames. The measurement for the door frame
and shutter on one face shall be taken in the manner already described, while the additional shutter on
the other face will be measured for the shutter area only excluding the frame.
7. Where shutters are provided with clearance at top or/ and bottom each exceeding 15 cm height, such
openings shall be deducted from the overall measurements and relevant coefficients shall be applied
to obtain the area payable.
8. Measurements of painting as above shall be deemed to include painting all iron fittings in the same or
different shade for which no extra will be paid.
9. The measurements of guard bars expanded metal, hard drawn steel wire fabric of approved quality grill
work and gratings, when fixed in frame work, painting of which is once measured else where shall be
taken exclusive of the frames. In other cases the measurements shall be taken inclusive of the frames.
10. 10. For painting open palisade fencing and gates etc., the height shall be measured from the bottom of
the lowest rail,. if the palisades do not go below it, (or from the lower end of the palisades, if they
project below the lowest rail), upto the top of rails or palisades whichever are higher, but not up to the
top of standards when the latter are higher than the top rails or the palisades. Measurements of wall
surfaces and wood and other work not referred to already shall be recorded as per actual.

128
"
390:0507"Rtgecwvkqpu"
"
All furniture’s, fixtures, glazing, floors, etc., shall be protected by covering and stains, smears,
splashings, if any shall be removed and any damage done shall be made good by the contractor
at his cost.
" Rckpvkpi"rtkokpi"eqcv"qp"yqqf."ktqp"qt"rncuvgtgf"uwthcegu0"
"
" Rtkogt"
The primer for wood work, iron work or plastered surface shall be as specified in the description of
the item.
Primers for plaster/ wood work/iron & steel/ aluminum surfaces shall be as specified below :
TABLE - 2
Uwthcegu" Rtkogt"vq"dg"wugf"
"
1. Wood work (hard & soft wood) Pink conforming to latest edition of
IS 3536)
2. Resinous wood and plywood Aluminum Primer
Aluminum steel and galvanised Zinc chromate primer
Steel work conforming to latest edition of IS : 104
4. Cement brick work, plaster Cement Primer
surface, asbestos surface for
oil bound distemper and paint
The primer shall be ready mixed of approved brand and manufacture.

Preparation of Surface
390:060403Yqqfgp"Uwthceg"
"
The wood work to be painted shall be dry and free from moisture.
The surface shall be thoroughly cleaned. All unevenness shall be rubbed down smooth with
sand paper and shall be well dusted. Knots, if any shall be covered with preparation of red lead
made by grinding red lead in water and mixing with strong glue sized and used for. Appropriate
filler material with same shade as paint shall be used where specified.
Iron & Steel Surface
All rust and scales shall be removed by scraping or by brushing with steel wire brushes. Hard
skin of oxide formed on the surface of wrought iron during rolling which becomes loose by
rusting, shall be removed.
All dust and dirt shall be thoroughly wiped away from the surface.
If the surface is wet, it shall be dried before priming coat is undertaken.
" Rncuvgt"Uwthceg"
The surface shall ordinarily not be painted until it has dried completely. Trial patches of primer
shall be laid at intervals and where drying is satisfactory, painting shall then be taken in hand.
Before primer is applied, holes and undulations, shall be filled up with plaster of Paris and
rubbed smooth.

129
" FT["FKUVGORGT"
"
" Ocvgtkcnu"
"
Dry distemper of required colour and (IS-427) of approved brand and manufacture shall be used.
The shade shall be got approved from the Engineer- in-charge before application of distemper.
The dry distemper colour as required shall be stirred slowly in clean water using 6 decilitres (0.6
litre) of water per kg of distemper or as specified by the manufacturer. Warm water shall
preferably be used. It shall be allowed to stand for at least 30 minutes (or if practicable over night)
before use.
" Crrnkecvkqp"
"
i) Before application of distemper is taken up, the surface shall be thoroughly brushed free from
mortar dropping, other foreign matter and sand and prepared smooth. New plaster surface shall
be allowed to dry for at least two months before applying distemper.
ii) After preparation of the surface A priming coat of whiting shall be applied over the prepared
surface. No white washing coat shall be used as a priming coat for distemper. The treated surface
shall be allowed to dry before distemper coat is given.
iii) Whiting (ground white chalk) shall be dissolved in sufficient quantity of warm water and stirred
to form a thin slurry and two kg of gum and 0.4 kg of copper sulphate dissolved separately in hot
water shall be added for every cum of slurry. The mixed slurry shall then be diluted with water to
the consistency of milk so as to make a wash ready for use.
iv) Distemper shall be applied two or more coats over the dried surface of the primary coat till
the surface shows an even colour. The entire surface shall be coated with mixture uniformly, with
proper distemper brushes in horizontal strokes followed immediately by vertical ones which
together shall constitute one coat. The subsequent coat shall be applied only after the previous
coat has dried. The finished surface shall be even and uniform and shall show no brush mark.
" RTQXKFKPI"CPF"HKZKPI"CPQFK\GF"CNWOKPKWO"RKRG"TCKNKPI"
62"OO"FKCOGVGT"
" Igpgtcn"
Anodized aluminum pipe railing shall be provided as shown on the drawing or as directed by the
Engineer-in-charge. The railing shall be made of 3 rows of 40 mm diameter anodized aluminum
pipes conforming to IS fixed in position one above the other as shown on the drawings in 1.2
metre height with vertical supports of 100 x 50 x 5 mm J section, 1.5 meter center to center. In the
construction drawing suitable adjustment in the pattern as indicated above and as required as per
actual site condition and as directed by the Engineer-in-charge shall have to be carried out by the
contractor. All railing shall be so constructed as to enable removal of the parts for repair and
replacement.
" RKRGU"
" Igpgtcn"
The work to be done under these specifications include providing and installing mild steel black
perforated pipes, G.I. pipes required for water supply system connecting drainage holes to the
gallery, and internal drainage of intake and pump house building, vertical drainage pipe, rigid un-
plasticized PVC pipes for potable water supplies.
" Crrnkecvkqp"Rwdnkecvkqpu"
"
All methods and procedures for installing and testing of pipes shall conform to latest edition of
Indian Standard Specification listed below, unless otherwise specified.

130
Kpfkcp"Uvcpfctfu":
30" KU<4248" Urgekhkecvkqp"hqt"Uvtwevwtcn"Uvggn"*Uvcpfctf"Swcnkv{+"
40" IS:554 Dimension for Pipe Thread where Pressure Tight Joints are Required in
Threads.
50" i) IS:1239 (Part – I) Specification for Mild Steel Tubes, Tubulars and other Wrought Steel
Fittings.
ii) IS :1239 (Part – II) Mild steel Tubulars and other wrought steel pipe fittings.
60" IS:3589 Specification for Electrically Welded Steel Pipes of Water and Sewage.
70" IS:4711 Methods of Sampling of Steel Pipes, Tubes and Fittings.
80" IS:4984 Specification for high Density polythylene pipes for potable water supply.
" Tkikf"*Wprncuvkek|gf+"RXE"Rkrgu"
"
17.11.3.1 The pipes shall be reasonably round and shall be supplied in straight lengths with socketed end.
The internal and external surface of pipes shall be smooth and clean, free from grooving and
other defects. The pipe shall be designated by external diameter and shall conform to latest
edition of IS 4985.
17.11.3.2
Fittings :- Fittings used shall be of the same make as that of PVC pipes,
injection moulded or made in cast iron and shall conform to relevant Indian Standard.
" LQKPVKPI"
"
" I0"K0"Rkrgu"
"
The pipes shall be cleaned and cleared of all foreign matter before being laid. In jointing the pipes,
the inside of the socket and the screwed end of the pipes shall be oiled and rubbed over with white
lead and a few turns of spun yarn wrapped round the screwed end of the pipe. The end shall then
be screwed in the socket, tee etc., with the pipe wrench also as not to damage the pipe care shall
also be taken that all pipes and fittings are properly jointed so as to made the joints completely
water tight and pipes are kept at all times free from dust and dirt during fixing.
" RXE"Rkrgu"
"
Solvent cement joints/ flanged joint/rubber ring joints shall be provided and shall conform to
relevant Indian Standards.
" Ecuv"Ktqp"Fgvcejcdng"Lqkpvu"
"
The joints shall consist of a central collar, two rubber rings two flanges of cast iron and the
required number of bolts and nuts. One flange and rubber ring shall be placed one end of the pipe
already laid and the other flange, rings and central collar shall be slipped on the pipe to be
assembled. The rubber ring shall be kept positioned at half the collar width less 2.5 mm from the
end of the pipe already laid. A site gauge may be used for convenience. The other pipe shall be
brought nearer leaving a gap of 5 mm between the two pipe ends. This gap will facilitate
maneuvering of deflection at joints after assembly and will take care of an expansion in the pipe
line. The collar shall be slided to sit square around the rubber ring on pipe to sit around collar. The
flange shall be moved on both ends to enclose rubber rings. The fastenings bolts shall be inserted
through the holes of the flanges and the bolts shall be tightened alternately and evenly for proper
sitting of the joint.
390330605" Ecuv"ktqp"hkvvkpiu"cpf"ceeguuqtkgu"
"
Cast iron fittings are jointed by cast iron detachable joints only. Cast iron specials having flanges
jointed in the pipe with the cast iron flange adapters having one end flanged and the other plain
ended. When there will be tendency for the pipe ends or specials ends to slipout of the joints
anchorage shall be provided against the direction of thrust.

131
" YCVGT"UWRRN[."UCPKVCT["CPF"FTCKPCIG"HKVVKPIU"
" RTQXKFKPI"CPF"HKZKPI"YCVGT"ENQUGV"
White vitreous china water closet squatting pan (Indian type) shall be provided and shall conform
to latest edition of IS : 2556 Pt.II. The pan shall have following accessories :
a) ‘P’ or ‘S’ trap
b) Foot rest pair in white vitreous china (size 25 x 13 x 3 cm.)
c) Low level flushing cistern of 12.5 litre capacity of white vitreous china including 15 mm dia inlet,
float valve, C.P. brass heavy stop cock and handle etc.
The squatting pan shall be fitted flush with floor level. Brick lime coba shall be filled under the
pan after fixing it to the correct position.
In fixing the pan if holes are made in the floors or wall the same should be repaired with
1:3 cement mortar, complete.
Flushing cistern to the wall shall be with CI bracket and repair of wall with 1:3 cement mortar.
" Rtqxkfkpi"cpf"Hkzkpi"kp"Rqukvkqp"Yjkvg"Xkvtgqwu"Hncv"Dcem"Nkrrgf"Wtkpcn"
"
White vitreous flat back lipped urinals shall conform to IS : 2556 (Pt. IV). The urinal unit shall
have following fittings and accessories.
a) Flushing cistern of 5 litre capacity – conforming to IS : 774 with flush pipe for back and front flush
with spreader pipes with fittings.
b) Standard urinal C.I. trap 65 mm dia with vent arm and outer gratings and coupling in C.P. brass
trap and unions.
c) White vitreous china tiling upto 1200 mm height on front and side walls.
The urinal shall be fitted on C.I. bracket embedded in wall. In fixing the urinal if wall is damaged
the same shall be made good by repair. All fittings and C.I. bracket shall be painted with ready
mixed paint of approved quality.
Payment for the item shall be made on the basis of numbers of urinal units fixed in position.
" Rtqxkfkpi"cpf"Hkzkpi"Ycuj"Dcukp"
White vitreous china wash basin shall conform to IS : 256 (Pt. IV). The wash basin of size 55 x 40
cm size shall have following accessories.
a) Rolled Steel or Cast Iron conforming to IS :775 duly painted

b) 15 mm dia C.P. brass pillar taps and C.P. brass chain rubber plug.
c) 32 mm dia brass waste coupling
d) 15 mm dia lead inlet connection of minimum 40 cm in length
e) 15 mm dia brass heavy duty stop cock
f) 32 mm C.I. trap and brass cleaning thimble upto and outside wall till gully trap
g) C.I. clips, 40 mm dia G.I. pipe sleeve.
The wash basin shall be fixed on C.I. bracket embedded in wall. In fixing the wash basin if holes
are made in floor or walls the same should be repaired with 1:3 cement mortar to the original
condition. All fittings and C.I. bracket shall be painted with ready mixed paint of approved quality.
" OU"ITCVKPI"CPF"UVGGN"YQTM"KP"UKPING"UGEVKQP"*ECDNG"
FWEV+"
" Fguetkrvkqp"
400 mm wide M. S. grating over drain is consisting of 25 x 3 mm MS flats 50 mm c/c both ways
welded to IS Angles of size 30 x 30 x 5 mm. All structural steel used for grating shall conform to
latest edition of IS : 226. The welding shall conform to latest edition of IS : 816.

132
17.13.1.1 Steel work in single section for cable duct consists of 9 rows of angles 50 x 50 x 5 mm on both
sides fixed in R.C.C. wall.
" T0E0E0"RTGECUV"EQXGT"
The specification for providing and fixing RCC pre-cast cover of size 750 x 750 x 300 mm over
drain shall conform to Section-5 concrete and reinforcement of this specifications.
" LQKPVU"CPF"UGCNU"
"
" Ueqrg"qh"Yqtm"
"
17.15.1.1 The section covers specifications for providing Polyvinyl Chloride (PVC) waterstops, asphalt
seals with or without stainless steel strip. 12 gauge steel plate formed holes, joints filler and
water proofing treatment over slab and corner joints at the location of joints as shown on the
drawings or as directed by the Engineer-in-charge.
3903703" Encuukhkecvkqp"
The items covered under the specifications are as under :
Providing and fixing in position PVC water stop 305 mm/ 225 mm wide embedded in concrete
with heat sealed joint, etc. complete as per drawings and specifications.
Providing and fixing in position PVC joints strip with 12 gauge stainless steel strip and
stainless steel bolts and washer expansion anchors, etc. complete as per drawings and
specifications.
Providing and laying asphalt seal in formed hole, at joints, including 12 mm diameter standard
steam pipe duly fitted in 20 gauge sheet metal all along pipes including clamps, nuts, bolts,
couplings, plugs and steam supply filled with an approved ‘H’ grade asphalt etc. Complete as
per drawings and specifications.
Providing and laying joint filler of approved quality in joints as per drawings and
specifications.
Providing and fixing 20 gauge stainless steel strip (175 mm x 27 mm) with 12 mm dia, 80 long
hexagonal head, stainless steel bolts embedded in concrete and nuts and washer, etc
complete as per drawings and specifications.
Providing formed holes of different sizes and shape varying form 50 mm to

175 mm for joints including centering, shuttering, etc. complete as per drawings and
specifications.
Providing and laying 6 layer water proofing treatment including 12 gauge 200 mm wide
galvanised steel plate embedded in bituminous plastic cement, including fixing the plate at
both corner joints to the standard galvanised shape anchor 20 mm wide 200 mm, providing
flushing reglet and fixing the plate at corner joints with the help of 35 mm long 28 gauge
galvanised barbed roofing nails in nailing concrete a the corner joints including providing 100
mm thick, 600 mm wide A. 20 S-200 RCC with 8 mm dia bars both ways over the steel plate
including water proofing treatment etc. complete as per drawings and specification.
" Crrnkecvkqp"Rwdnkecvkqpu"
"
All methods of tests and welding procedure shall conform to latest Indian Standard
Specification and other publication listed below unless otherwise specified.

133
Indian Standards
IS:702 Asphalt
KU<3544" Dkvwogp"hgnv"
IS:1346 Water proofing treatment 6 course.
IS:3384 Asphalt primer
IS:8004 Recommended procedure for welding of

Flexible PVC (Flexible Polyvinyl Chloride)
Other Publications
American Society for Testing and Materials Designation D-638. American

Society for Testing and Materials Designation D-2240.
" Rqn{xkp{n"Ejnqtkfg"*RXE+"Ycvgt"Uvqru"
General
The dimension of Polyvinyl Chloride (PVC) waterstops, shall normally be as shown in approved
drawings. The Contractor, however, will be permitted to use waterstops of any alternative
manufacturer, such as waterstops with diamond shape and bulb, provided they conform with the
specifications and the functional and construction requirement. For this purpose, the Contractor
shall submit to the Engineer-in-charge for approval four sets of drawings, showing details of the
waterstops, including shapes and details of intersections and splices between water stops of the
same sizes and of different sizes. Fabrication and procurement of materials shall be made only
after approval of the drawings by the Engineer-in- charge. Any fabrication or procurement of
materials done prior to approval of the drawings shall be at the Contractor’s expense. The
Engineer-in-charge shall have the right to require the Contractor to make any changes in the
drawings which may be necessary to make the finished installations conform to the requirements
and intent of these specifications, without additional cost to the Employer. Approval by the
Engineer-in-charge to the Contractor’s drawings shall not be held to relieve the Contractor of any
part of this obligations to meet all of the requirement of these specifications or of the responsibility
for the correctness of his drawings.
One set of the above drawings will be returned to the Contractor, either approved, disapproved, or
conditionally approved. All drawings that are disapproved shall be revised and resubmitted for
approval, as directed.
The waterstops shall be dense, homogeneous and free from holes and other imperfections. The
waterstops shall meet the material and test requirements given in concrete specifications. The
cross-section of the waterstops shall be uniform along its length and thickness shall be
symmetrical transversely. Tolerance from the dimensions given above shall be plus 5 mm in width,
plus 2 mm in thickness and plus 1 mm for the rest.
Certified copies of laboratory test reports on the physical properties of the PVC waterstops and a
certificate stating the PVC waterstops as furnished meet all other requirements of these
specifications, shall be obtained by the Contractor from the manufacturer of the PVC waterstops
and submitted to the Engineer-in- charge for approval. Three 1.5 m long samples of the PVC
water stops shall be obtained by the contractors from the suppliers and submitted to the Engineer-
in- charge. These samples shall be furnished atleast 60 days prior to embedding of any
waterstops in the structures.
The contractor shall arrange to obtain the water stops from the suppliers in rolls securely packed,
containing a single length of not less than 12 linear metres and having inside diameter of not less
0.3 meter.
" "

134
" Kpuvcnncvkqp"
The location and embedding of the PVC waterstops shall be as shown on the drawings, with
approximately one half of the width of the waterstops embedded in the concrete on each side of
the joint. In order to eliminate faulty installation that may result in leakage, particular care shall be
taken that the waterstops are correctly positioned and secured during installation. Where the
bottom end of PVC waterstops contact rock at the base shall be embedded at a minimum depth of
30 cm into sound rock, All waterstops shall be so installed as to form a continuous water tight
diaphragm in the joint unless otherwise shown. Adequate provision shall be made to completely
protect the waterstops during the progress of the work.
Additional vibration, over and above that used of adjacent concrete placement, shall be employed
near the waterstops to assure complete embedding of the waterstops in the concrete. Larger
pieces of aggregates near the waterstops shall be removed by hand during embedding to assure
complete contact between the waterstops and the surrounding concrete.
Splices of waterstops shall be fabricated only by workmen who have demonstrated to the
satisfaction of the Engineer-in-charge that they are sufficiently skilled to fabricate the required
splices. Splices in the continuity of or at the intersection of runs of PVC waterstops shall be
performed by heat sealing the adjacent surfaces in accordance with the manufacturer’s
recommendations. A thermostatically controlled electric heat source shall be used to make all
splices. The correct temperature at which splices should be sufficient to melt but not char the PVC
material. All splices shall be neat with the ends of the joined waterstops in the true alignment. A
meter box guide and portable saw shall be provide and used to cut the ends to be
joined to ensure good alignment and contact between the surface joint. After splicing, a
remoulding iron with ribs and corrugations to match the pattern of the waterstop, shall be used to
reform the ribs at the splice. The continuity of the characteristic members of the waterstop design
(ribs, tubular central axis, protrusions and the like) shall be maintained across the splice.
Where splices are required between waterstops of different sizes the splices shall be made as
recommended by the manufacturer of the waterstops and drawings showing the details of the
splices shall be submitted to the Engineer-in-charge.
Prior to embedding, the edges of the waterstop shall be secured to looped wire in the end bulbs to
improve the concrete bond as shown on the drawings. The bars shall conform to the provision of
Section-9 “Concrete works”. The manner in which the waterstop is secured to the reinforcing bars
shall be subject to approval of the Engineer-in-charge.
" Curjcnv"Ugcn"
General
The contractor shall construct asphalt seals in contraction joints of dam intake and pump house
and intake structure as shown on the drawings or as directed by the Engineer-in-charge.
Material
Asphalt fill hole shall be filled with ‘H’ grade asphalt or blow bitumen asphalt R 85/25. 11mm
diameter heating pipes and fittings shall be provided in the formed hole for asphalt fill as shown in
the drawing.
PVC Joints Strip
PVC joint strips : PVC joint strips with or without stainless steel metal strips shall be
installed in the places shown on the drawings and elsewhere as directed. The Contractor shall
furnish the PVC joint strips, metal strip, expansion anchors, bolts and washers. The joint strips
shall be furnished in not less than 3.5 m length. All PVC joint strips shall be stored in as cool
place as practicable, preferable at 700 F or less, and in no case shall the rubber be stored in the
open or exposed to the direct rays of the sun. PVC material for the joint shall have the physical
characteristics as per para 17.15.4.1 of this section.
All PVC joint strips shall be extruded and cured in such a manner that any cross section will be
dense, homogeneous, and free from porosity and other imperfection. Surface defects such as
surface peel, flow lines, blisters, nonfills and air traps shall be minimum. Any defects which is
not acceptable shall be repaired to the satisfaction of Engineer-in-charge or shall be removed
from the finished product by cutting out a length of joint strip containing such defect.
The Contractor shall also furnish to the Engineer-in-charge with three 300mm samples of the
PVC joints strips for testing for tensile strength and elongation by the Employer. The samples
shall be cut from the finished product in the presence of the Engineer-in-charge. The contractor
shall furnish samples at no extra cost to the Employer.

135
PVC joint strips shall not be installed until at curing of the adjacent concrete has been complete.
The joint strips shall be installed as shown by close fitting butt joints and the location of all such
joints shall be submitted to the approval of the Engineer-in-charge. The metal strips for the PVC
joint strips shall be fastened to the concrete with, bolts as shown on the drawings. Where
required, the metal strips shall be bent to conform to the angles formed by abutting surface.
Joint filler
The joint filler shall normally be as shown on drawing. The Contractor however, will be permitted to
use, joint filler of the approved quality as per relevant Indian Standard, or any alternative
manufacturer of joint filler, provided they conform to the specification and the functional and
construction requirement The Contractor shall submit to the Engineer-in-charge for approval the
proposal 30 days before for using such joint filler along with relevant certificate from manufacturer
of joint filler.
The joints in the joint filler shall be scarfed, made tight and filled with suitable material so that
mortar from the concrete will not seep through the opposite surface. The joint filler shall be racked
out after the concrete has set.
Ycvgt"Rtqqhkpi"cttcpigogpv"cv"vjg"eqtpgtu"cpf"lqkpvu"kp"uncd.
The water proofing arrangements shall be provided on the roof at the junction of roof and the wall.
The arrangement including providing fixing and laying 12 gauge G.I. plate embedded in 100 mm
thick 600 mm wide RCC, including 28 gauge roofing nails of 30 mm long fixed in nailing concrete
in the corner and providing and fixing flashing reglet and standard galvanized anchor strap of 200
mm long
20 mm wide, 6 layer of water proofing membrane, caulking compound etc. complete as per
drawing and specification.
" OKUEGNNCPGQWU"YQTMU"HQT"EKXKN"UVTWEVWTGU"
3903803TQCFYC["
The approaches to pump houses of Gouravelly reservoir shall be black-topped metallic road and
shall consist of stone metal mechanically interlocked by rolling and bonded together screening and
binding material, where necessary and water laid on a prepared subgrade. The road will be
finished in accordance with the requirements of these specifications, description of item of work
and in conformity with the lines, grades and cross-sections shown on the drawings or otherwise
directed by the Engineer-in-charge.
" OCVGTKCNU"
"
c+" Eqctug" ciitgicvgu"
"
Coarse aggregates shall be stone aggregate with impact value conforming to IS : 2386 and IS :
5640. The grading of aggregates shall be as under :
-------------------------------------------------------------------------------
Size range Sieve Percent by
designation weight passing
the sieve
-------------------------------------------------------------------------------
63 mm to 40 mm 80 mm 100
( For Stone metal) 63 mm 90-100
50 mm 35-70
40 mm 0-15
20 mm 0-5
-------------------------------------------------------------------------------
"
"
"

136
"
d+" Etwujgf"qt"Dtqmgp"Uvqpg"
Crushed or broken stone shall be free of flat, elongated, soft and disintegrated particles and should
not contain any excess of dirt or other objectionable materials.
i) Screening
Screening to f ill voids in the coarse aggregate shall generally consist of the same
material as the coarse aggregate. However, where permitted, predominantly non-
plastic material such as morrum or gravel (other than rounded river-borne material)
may be used for this purpose provided liquid limit and plasticity index of such
material is below 20 and 6 respectively and fraction passing 75 micron sieve does
not exceed 10 percent.
As far as possible, screening shall conform to the following gradings

:
------------------------------------------------------------------------------
Size of Screening Sieve Percent by
designation weight passing
the sieve
------------------------------------------------------------------------------
10 mm 10 mm 100
4.75 mm 85-100
150 micron 10-30
------------------------------------------------------------------------------
ii) Binding Material
Binding material to be used for water-bound macadam construction shall comprise a suitable
material approved by the Engineer-in-charge having plasticity index value of less than 6 as
determined in accordance with IS : 2720 (Part V).
Application of binding material may not be necessary, when the screenings used are of crushable
type such as moorum or gravel.
" EQPUVTWEVKQP" QRGTCVKQPU"

"
a) Preparation of Subgrade
The subgrade to receive the water-bound macadam course shall be prepared to the specified
grade and camber and made free of dust and other extraneous material. Any ruts or soft yielding
places shall be corrected in an approved manner and rolled until firm.
d+" Urtgcfkpi"Eqctug" Ciitgicvg"

"
The coarse aggregates (stone metal) shall be spread uniformly upon the prepared subgrade in two
layers in such quantities so that the compacted thickness of each layer is 100 mm. Each layer is to
be rolled separately but no binding material will be used in the first layer.
The spreading shall be done from stockpiles along the side of the roadway or directly from
vehicles. In no case shall the aggregate be dumped in heaps directly on the surface prepared to
receive the aggregate nor shall hauling over uncompacted or partially compacted base be
permitted.
The surface of the aggregates spread shall be carefully checked with templates and all high or low
spots remedied by removing or adding aggregate as required. No segregation of large or fine
particles shall be allowed and the coarse aggregate as spread shall be of uniform gradation with
no pockets of fine material.
The coarse aggregate shall not normally be spread more than 3 days in advance of the
subsequent construction operations.

137
c) Rolling
Immediately following the spreading of the coarse aggregate, rolling shall be started with three-
wheeled power rollers of 8 to 10 tonne capacity or tandem or vibratory rollers of approved type.
The weight of the roller shall depend upon the type of the aggregate and be indicated by the
Engineer-in-charge. Except on super-elevated portions where the rolling shall proceed from inner
edge to the outer, rolling shall begin from the edges gradually progressing towards the centre.
First the edge/edges shall be compacted with roller running forward and backward. The roller shall
then move inwards parallel to the centre line of road, in successive passes uniformly lapping
preceding tracks by at least one half width.
Rolling shall be discontinued when the aggregates are partially compacted with sufficient void
space in them to permit application of screenings. However, in the case of first layer, where
screenings are not to be applied, compaction shall be continued until the aggregates are
thoroughly keyed. During rolling slight sprinkling of water may be done, if necessary. Rolling shall
not be done when the upgrade is soft or yielding or when it causes a wave-like motion in the sub-
grade or sub-base course.
The rolled surface shall be checked transversely and longitudinally with templates and
irregularities corrected by loosening the surface, adding or removing necessary amounts of
aggregate and re-rolling until the entire surface conforms to desired camber and grade. In no
case shall the use of screening be permitted to make up depressions.
f+" Crrnkecvkqp"qh" Uetggpkpiu"

"
After the coarse aggregate has been rolled, screenings to completely fill the interstices shall be
applied gradually over the surface. These shall not be damp or wet at the time of application. Dry
rolling shall be done while the screening are being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregate. The screenings shall not be dumped in piles
but be spread uniformly in successive thin layers either by the spreading motion of hand shovels
or by mechanical spreaders, or directly from trucks. Trucks operating for spreading the screenings
shall be so driven as not to disturb the coarse aggregate.
The screening shall be applied at a slow and uniform rate (in three or more applications) so as to
ensure filling of all voids. This shall be accompanied by dry rolling and brooming with mechanical
brooms, hand-brooms or both. In no case shall the screenings be applied so fast and thick as to
form cakes or ridges on the surface in such a manner as would prevent filling of voids or prevent
the direct bearing of the roller on the coarse aggregate. These operations shall continue until no
more screenings can be forced into the voids of the coarse aggregate.
The spreading, rolling and brooming of screenings shall be carried out in only such lengths of the
road which could be completed within one day’s operation.
g+" Urtkpmnkpi"cpf" Itqwvkpi"

"
After the screenings have been applied, the surface shall be copiously sprinkled with water, swept
and rolled. Hand brooms shall be used to sweep the wet screenings into voids and to distribute
them evenly. The sprinkling, sweeping and rolling operations shall be continued, with additional
screenings applied as necessary, well-bonded and firmly set in its full depth and a grout has been
formed of screenings. Care shall be taken to see that the base or subgrade does not get damaged
due to the addition of excessive quantities of water during construction.
h+" Crrnkecvkqp"qh"Dkpfkpi"Ocvgtkcn"
"
After the application of screenings, binding material where it is required to be used shall be applied
successively in two or more thin layers at a slow and uniform rate. After each application, the
surface shall be copiously sprinkled with water, the resulting slurry swept in with hand brooms, or
mechanical brooms to fill the voids properly, and rolled, during which water shall be applied to the
wheels of the rollers if necessary to wash down the binding material sticking to them. These
operations shall continue until the resulting slurry after filling voids, forms a wave ahead of the
wheels of moving roller.

138
i+" Ugvvkpi"cpf" Ft{kpi"

"
After the final compaction of water-bound macadam course, the road shall be allowed to dry
overnight. Next morning deficient spots shall be filled with screenings of binding material as
directed, lightly sprinkled with water if necessary and rolled. No traffic shall be allowed on the road
until the macadam has set. The Engineer-in-charge shall have the discretion to stop hauling traffic
from using the completed water-bound macadam course if in his opinion it would cause excessive
damage to the surface.
17.16.2 Specifications for the work of preparation of road base, laying and compaction of road base,
providing water-bound macadam base course and asphalt wearing course/carpet shall be done as
per IRC/IS specifications applicable from time to time.
" TCKNKPI"
"
" T0E0"E0"Tcknkpi"
"
Railing shall not be cast until the centering or form-work for the span has been removed, and the
span is self-supporting. The type of railing to be constructed shall be as shown on the drawings.
The railing shall be carefully erected, true to line and grade. Posts shall be vertical within a
tolerance not to exceed 6 mm in 3 metres.
Forms shall either be of single width boards or shall be lined with suitable material duly approved
by the Engineer-in-charge. Form joints in plane surface will not be permitted.
All mouldings, panel work and level strips shall be constructed according to the details shown on
the drawings. All corners in the finished work shall be sheared and clean-cut and shall be free
from cracks, spalls or other defects. Payment for railing will be made at the rate per running
metres. The rate shall include cost of labour, material, tools, and plant required for doing the work
complete in all respects as per specifications.
" I0K0" Tcknkpiu"
"
All pipes and all steel elements used for railing, terminal sections, posts, bolts, nuts, hardware and
other steel fittings shall be galvanized.
All elements of the railing shall be free from abrasions, rough or sharp edges, and shall not be
kinked, twisted or bent. If straightening is necessary, it shall be done by methods approved by the
Engineer-in-charge.
The railing shall be carefully adjusted prior to fixing in place to ensure proper matching at abutting
joints and correct alignment and camber throughout their length. Holes for field connections shall
be drilled with the railing in place in the structure at proper grade and alignment. Welding may be
substituted for riveting in field connections only with the approval of the Engineer-in-charge. The
payment for G.I. Railing will be made at the rate per running metre. The rate shall include cost of
all labour, material, tools and plant required for doing the work complete in all respect as per
specifications.
" UJQVETGVKPI"
"
" Igpgtcn"
"
The item covers specifications for Items for Shotcreting, and for wire mesh reinforcement.
" Encuukhkecvkqp"
"
The items covered under these specification are as under :
- Providing and laying 100 mm thick shotcrete lining as per mix design to rock
face in two layers of 50 mm each with 12 mm downgraded metal including cleaning by
air and water under pressure, additives, scaffolding batching, mixing, transporting curing and
finishing with all lifts and leads.
- Providing and installing welded wire mesh 50 mm x 50 mm of 10 gauge steel to the
surface including rolling, f ixing with all accessories etc. complete and as
directed by the Engineer-in- charge.
" "

139
" "
" Crrnkecvkqp" Rwdnkecvkqpu"
"
All methods and procedures for providing shotcreting, and providing and installing reinforcement
fabric shall conform to latest edition of Indian standard listed below unless otherwise specified.
Indian Standards :
1. IS : 269 Specification for Ordinary
Portland Cement
2. IS : 1566 Specification for Hard- Drawn Steel
Wire Fabric for Concrete
Reinforcement
3. IS : 456 Code of Practice for Plain and
Reinforced Concrete
4. IS : 9012 Recommended Practice for
Shotcreting
5. IS : 383 Specification for Coarse & Fine
Aggregates
6. IS : 9103 Specification for Admixture for
Concrete.
The Contractor shall apply shotcrete to excavated surface where shown on the drawings and as
directed by the Engineer-in-charge. For purpose of these specifications, shotcrete in concrete or
mortar, with or without admixtures, pneumatically applied at high velocity on to a prepared
surface, Except as otherwise specified, shotcrete shall be applied in accordance with the
requirements of Indian Standard 9012 - 1978 “Recommended Practice of Shotcreting”.
" Ocvgtkcnu"
"
Cement conforming to the specifications laid down in IS : 269 - 1976 shall be used by the
Contractor.
Water to be used for shotcreting shall conform to the requirement of IS : 456 - 1978.
Sand must be well graded and with a gradation according to the requirements of concrete
specified in Section - 7 and in conformity with IS : 9012 - 1978 or its subsequent revision
“Recommended Practice for shotcreting”.
Coarse aggregates when used shall comply with the requirements of concrete specified in
Section - 9 and in conformity with IS : 9012 - 1978 or its subsequent revision “Recommended
Practice for Shotcreting”.
Where the use of a set accelerating admixture is required to successfully apply shotcrete or to
maintain safe conditions, the type and amount of admixture used shall be as approved by the
Engineer-in-charge. Admixture when used, shall meet the requirements of IS : 456 - 1978 and IS :
913 - 1979. The quantity of admixtures used in any shotcrete shall not exceed the quantity
approved by the Engineer-in-charge.
" Rtqrqtvkqpkpi"
"
The mix proportions and the quantity of water to be used shall be determined and adjusted
at the work site in order to obtain shotcrete of optimum consistency. The water cement ratio
shall be between 0.35 and 0.50 by weight.
The compressive strength of shotcrete shall conform to the following requirements.
After - 2 Hours 14.8 kg/cm2
After - 28 days 280 kg/cm2
The flexural strength of test beams for shotcrete at 28 days shall not be less than 42.25
kg/cm2.

140
The shotcrete shall have cement, sand and coarse aggregates in proportion of mix design by
weight. The weight of each component shall be decided by trial mixes in the laboratory in
order to obtain a dense mix with minimum compressive strength as mentioned above. The
fine and coarse aggregates shall be thoroughly mixed in an approved mixer and fed with the
cement and admixture, if used, at the correct rate to achieve proper mixing. Shotcrete shall
have a minimum cement content of 400 kg/m3 as discharged from the nozzle and maximum
water cement ratio of 0.5 by weight.
The Contractor shall provide for sufficient over-design strength to allow for variation in his
workmanship and meet the strength and other requirement during shotcrete application.
The relative proportions of fine aggregates, coarse aggregates, cement, set accelerating
admixtures and moisture content of the ingredients when mixed shall be as approved by the
Engineer-in-charge.
The dry mix shall be first prepared with required moisture so as not to allow cement particles
to fly in the atmosphere. The additional water as required according to water cement ratio
should be added at the nozzle.
Mixed dry aggregates and cement, which do not contain a set accelerating admixture and
which are not placed within 30 minutes after mixing, shall be discarded. Mixed dry
ingredients which contain a set accelerating admixture shall be discarded, if they are not
placed within the time as determined by the Engineer-in-charge, depending on the moisture
content of the mix and the amount of admixture. Payment will not be made for such
discarded materials.
" Crrnkecvkqp"
"
Shotcrete shall only be applied in the presence of the Engineer-in-charge and shall be built
up in successive layers, each layer shall be 50 mm in thickness, so that sagging and
bleeding do not occur. Care shall be taken to ensure that cavities resulting from cutting back
to clay seams are completely backfilled with shotcrete. Where wire mesh is used, mortar
shall cover the reinforcement to a depth of at least 25 mm.
The gun nozzle shall be placed normally to the surface and close enough to operate
efficiently without exceeding a distance of 1.5 metres. For a 38 mm diameter nozzle, the
discharge velocity shall be 125 metres per second and for a 25 mm diameter nozzle, the
discharge velocity shall be 200 metres per second. The velocity shall be uniform as
recommended by the equipment manufacturer and it will be measured by the instrument
connected to the gun which shall be supplied by the Contractor. It is necessary that the
water pressure be greater than the air pressure to get complete dampening of the mix at the
nozzle and to enable the operator for an easier control of the gun. In order to prevent runoff
a minimum period of 30 minutes to one hour shall elapse between application of two
consecutive layers but the second layer will be placed before the first one has hardened. It is
absolutely necessary that all laitance, loose material and rebound shall be removed by
brooming from the surface to be lined with shotcrete or to receive a new shotcrete layer.
When finishing and placing of layer, its free end shall be finished by gradually diminishing its
thickness. Construction joints with square ends shall not be permitted. Before starting
placing of the adjacent layer at a construction joint, the area having variable thickness shall
be carefully cleaned and dampened and the adjacent new layer will be overlapped on it.
The application of shotcrete will be executed by qualified and experienced persons only and
the qualification of these personnel shall be submitted to the Engineer-in-charge for
approval.
The thickness specified for the shotcreting shall be minimum thickness and no minus
tolerance will be acceptable.
During application of shotcrete, any water flowing over or seeping through the surface to
which the shotcrete is to be applied shall be diverted by the use of panning, pipes, felt strips
or other approved means. Where directed by the Engineer-in-charge, formed holes or pipe
outlets shall be provided in the coating to relieve water pressure on the coating.
Shotcrete shall not be applied to an area until all blasting within 30 metres of the area has
been completed, unless otherwise approved or directed by the Engineer-in-charge.
" "
" Hkpkujkpi"

141
Shotcrete application shall be made to protect the rock surface against deterioration due to
atmospheric agents or due to physical and chemical reactions. Shotcrete surface shall be
screeded to obtain a slightly smooth surface but the Contractor must take care to prevent
excess of exudation of fine material and water to the surface.
All damage caused to shotcrete shall be repaired by the Contractor at his own expense.
However, where lining has been damaged due to blasting operations and in the opinion of
the Engineer-in-charge such damage could not have been avoided by suitable reductions in
charge, levels and/or excavations patterns and sequence or by deferring the placing of
lining, the repair to such damage as may be approved by the Engineer-in-charge shall be
paid for.
The finished surface of lining to be permanently exposed shall generally follow the profile of
the excavation surface or a previously applied surface, provided that all abrupt changes in
the profile are filled in so as to present at worst a uniform waviness.
The normal surface finish shall be a natural nozzle finish as left by the nozzle when applied
by an experienced operator and having a texture and appearance not less than as agreed
between the Engineer-in-charge and the Contractor on the basis of trial specimens regarding
abruptness of irregularities in the plane of the surface and intensity of pitting and protrusions.
3903:0:"Ewtkpi"
Shotcrete, shall be cured with water, and shall be kept continuously wet for atleast 7 days
immediately following placement.
" Uchgv{"qh" Yqtmu"

Application of shotcrete, as temporary or permanent support, shall not be considered as
relieving the Contractor of his responsibility to maintain all portions of the works in a safe
condition.
" Tgrcktu"
Areas of shotcrete, which are drummy, below strength or otherwise defective, as
determined by the Engineer-in-charge shall be removed and repaired within 7 days of the
Engineer-in-charge, informing the Contractor that such are required.
" Ogcuwtgogpv"cpf" Rc{ogpv"

Shot Crete lining shall be measured based on the theoretical area of the finished lining
measured along the pay lines.
Payment for shotcrete will be made at the tendered rate per square metre of shotcrete lining
of the thickness specified. The rate shall include the cost of all labour, materials, equipment
and tools necessary to execute the shotcreting. The rate shall also include the cost of
removing loose materials from rock surface, washing of rock surface with air and water jet,
curing, providing works in safe condition, repairing the areas of shotcrete which are below
strength and defective and wastage of mortar/concrete due to rebound including its removal.
The rate shall also include the cost of protection of all drains in the way shown in the
drawings, including supply, placing and later removal of the wooden plugs before starting the
curing and all other incidental operations required to complete the work in accordance with
the specifications.
" Tgkphqtegogpv" Hcdtke"

"
Shotcrete shall be reinforced with welded wire mesh, designed 50 mm x 50 mm x 10 gauge
mesh or its substitution, with another type of mesh of best quality and characteristics
approved by the Engineer-in-charge. The supply of mesh shall be done by the Contractor
and its placing shall meet the requirements of these specifications. The mesh shall be
placed as close to the rock as possible to prevent the shotcrete jet producing undesirable
vibration to the mesh.
Steel mesh support may be ordered to be fixed after the application of an initial shotcrete
layer. Prior to fixing the steel mesh support, the excavated surfaces shall first be trimmed to
the required lines and all loose rock, rock fragments and debris removed where these would
not normally be able to be removed from beyond the mesh without disturbing the same.
The steel mesh shall be secured to the excavation face with holding points generally set at a
maximum spacing of 0.5 m so as to draw the mesh tightly against the excavation face. The

142
holding points shall be positioned so as to grip at least two strands of mesh at each
anchorage point.
The Contractor shall ensure that the ends of the anchors do not project to closer than 50 mm
from the final lining face or beyond the excavation clearance line by more than 70 mm in the
case of excavation receiving only a nominal shotcrete.
Laps in steel mesh support shall be lapping the mesh for a length of at least 3 bar spaces for
welded mesh and 6 bar spaces for chain link or expanded metal mesh and by inserting rock
anchors at a spacing not exceeding 750 mm along the length of the lap. When used in
conjunction with rock bolts, the laps shall be arranged to coincide with the lines of rock
bolts.
Where steel mesh is required to contain rock spalls and fragments, the rock anchors shall be
installed in a staggered pattern in order to provide maximum support to the mesh. Anchors
shall be inserted in area relatively of sound and massive rock.
" Ogcuwtgogpv"cpf" Rc{ogpv"

"
Measurement for payment of providing and installing wire mesh reinforcement shall be the
area in square metres measured along the paylines.
Payment for providing and installing wire mesh reinforcement will be made at the rate
tendered as per Schedule. The rate shall include the cost of furnishing and installing the wire
mesh/steel mesh supports complete with all accessories. This rate shall also include the cost
of all incidental operations required to complete the work as per specifications.
" Cpejqt"Dct"
The Contractor shall place anchor bar as shown on the Drawings.
Anchor bars shall be of reinforcing steel bars of Fe-415 and 25 mm or 32 mm in diameter, and the
Contractor shall cut and bend the steel bars in accordance with Chapter - 10 "Reinforcing Steel" of
the Specifications.
The Contractor shall drill holes for anchor bars in rock by the approved drilling machine and the
diameter of drillholes shall be more or less 42 mm for 25 mm steel bar and more or less 49 mm for
32 mm steel bar.
Drillholes shall be kept plugged until commencement of grouting. Before inserting the steel bars
the drillholes shall be thoroughly flushed with water and cleaned with compressed air.
The steel bars shall be inserted into holes partly filled with mortar grout before it has set. After
inserting the steel bars, the holes shall be completely filled with the mortar grout and compacted
with a suitable vibrating method.
Grouting of anchor bars shall be completed not less than 7 days in advance of placing base
concrete. The steel bars, after inserting, shall be protected in such a manner as to prevent any
movement until the grout has hardened. Grout mix shall be subject to the Engineer's approval.
The upper end of the anchor bars shall be fixed to the reinforcing steel bars of the base concrete
by the approved methods.
Measurement for payment of anchor bars shall be made in number of anchor bars as actually
installed and accepted by the Engineer.
The unit price for anchor bars shall include all the cost for drilling in the rock, grouting, inserting
steel bars and any other incidental works.
" Iwctf"Tckn"
"
the Contractor shall furnish and install guard rails at the location as shown on the drawings or as
directed by the Engineer.
Prior to the work the Contractor shall submit to the Engineer for his approval shop drawings and
installation method of guard rails.

143
The rails and posts shall be structured conforming to international standard and formed to the
dimensions as shown on the Drawings or as directed by the Engineer.
Required bolts, nuts and washers shall be galvanized. The post shall be set to the required depth
and be held firmly in place by concrete foundation.
After the guard rails are installed in place, painting shall be executed in accordance with the
relevant provisions of the Specifications.
Reflector strip shall be attached to the guard rail wherever instructed by the Engineer and at
maximum distance of 30 m along straight stretch.
Measurement for payment of guard rail shall be made at actual length in meter installed in service
roads and accepted by the Engineer.
The unit prices for guard rail in service roads shall include all the cost for furnishing, installing and
painting of guard rails and any other incidental works.
Guard rials installed in other construction roads including existing roads shall not be paid for
separately, and the cost for which shall be included in the lump sum price of construction road in
the Bill of Quantities.
" Nc{kpi"qh"Eqpetgvg"Dnqem"
"
*3+" Igpgtcn"
"
The concrete block work shall be provided as indicated on the Drawings
Concrete block may be pre-cast / cast-in-situ and the volume of which should not be less than 0.3
m3. Concrete mix should be of 1:2:4 with 20 mm nominal size of aggregate. In case pre-cast
blocks proper arrangement for placement of the same without damage and according to the line
and levels shall be made.
In case of cast-in-situ blocks casting is to be done over the bed itself. Alternate blocks are to be
taken up for casting at one time. Placement of pre-cast block/cast-in-situ block should be done in
such a manner as there should not be any continuous joints.
Measurement for concrete block shall be made as per gross volume of each block in cubic metres.
Rate for concrete block shall include:
i) Cost of find and coarse aggregate / cement etc.

ii) Mixing, placing, compaction
iii) Shuttering and curing
iv) Placement of block over prepared bed.
UGEVKQP"⁄"E"3:"
O"U"RKRGU"
"
" FKUEJCTIG" RKRGU1TCKUKPI" OCKPU/" IGPGTCN" IWKFGNKPGU"
EQPUVTWEVKQP"
"
Manufacturing of MS pipes shall be done in conformity with IS: 3589 subject to following :
The pipe shall be fabricated out of steel plates or strips of mild steel conforming to IS: 2062 and
having minimum specified tensile strength of 410 Mpa. MS pipelines shall be of grade 410, helical
seams/spiral longitudinally welded with Straight seams, without circumferential joints with beveled
ends as per IS 3589. The pipes shall be manufactured in an approved factory/fabrication yard having
quality control system, well equipped testing laboratory.
The end of the pipes, short pipes shall be beveled end for welding.

144
C0" Manufacturing process shall ensure that
1) Base material i.e., HR coils/ steel plates shall be of required Quality.
2) Production equipment is well designed automatic machine.
3) Quality control is comprehensive.
4) Hydro test of each pipe before lining.
D0" The thickness of the pipe line shall be as per design to meet the requirements. Also the thickness
calculations shall be furnished for approval of the Engineer-In- Charge before procurement.
E"Flanges should be machined on both faces. Fabrication of flanges from segment plates
should be avoided. However, if under special circumstances flanges from segment plates are to be
provided, on specific instructions of the Engineer-In-Charge, such flanges should be completely
stress relieved after welding and all welds shall be subject to dye penetration test. These flanges
should also be machined.
F0" All welds are to be continuous single V butt welds with finished head of size equal to
thickness of plate. All welding shall be as per provisions laid in IS-816/equivalent standard (latest
revision). Welding shall be done by experienced and good operators who have been qualified by tests
as specified in IS-817/equivalent standard (latest revision). Welding shall be by automatic machine
and shall be carried out by using approved electrode with compatible flux.
G0" Bolts and nuts shall be of hexagonal head conforming to -1367/equivalent standard (latest
revision).
H0" The pipe sections shall be carefully placed on the sand bed of approved thickness prepared as per
specification. All joints before welding shall be thoroughly cleaned and requisite welding gap
maintained.
I0" Welding sequence shall be done in such a way so as to minimize the distortion due to
welding shrinkage. Any distortion will be duly rectified by the Contractor without additional
cost.
J0" Welding shall not be carried out when the surface of the parts to be welded are wet for any
cause and during periods of rain and strong winds unless the welder and work are properly
shielded.
K0" Precaution shall be taken to prevent any crack or damage in the external coating during
installation. Pipes shall be laid in trenches excavated along the route and the over- ground portion
shall be installed as per final layout drawings.
L0" The damaged portion of External coating or internal lining of the pipe
Length at the joints due to welding shall be made good by manual application of external
coating/internal lining to the required thickness and shall form a smooth continuous surface
particularly with internal lining of the two adjacent pipes welded so that the flow through the
pipeline is not affected due to manually applied coating.
M0" On completion of all welding in the pipe lines, the same shall be tested hydrostatically and
after successful testing, shall be covered by sand wrapping and backfilling with earth where the pipes
are laid in trenches
N0" Installed pipe shall be closed up at both ends at the end of each day by water tight plug or
other means approved by the Engineer-In-Charge to prevent debris/animals/human beings from
entering the pipe.
O0" Specific Guidelines for Spirally/Longitudinally Welded MS Piping: All spirally/Longitudinally

welded MS pipes proposed to be procured under this section shall be fabricated out of steel plates or
strips of mild steel coils (HR coils) conforming to IS 2062 and to the requirements of IS-3589 or

145
equivalent standard and shall have minimum thickness as per recommendations of standards which
shall be got approved by the contractor.
i) Tolerance on outside dia of pipes (12.3.1 – IS 3589-2001: Table 6) Outside dia

Tolerance (For all sizes)
For seamless pipes ±1% For

Electric resistance Welded
Pipes (ERW) & Submerged Arc
Welded (SAW) (including spirally
Welded pipes) ±0.75%
Tolerance for straightness of pipeline (12.5.1 – IS 3589 –2001)

Each of the finished pipe shall not deviate from straightness by more than 0.2% of the total length.
Checking shall be carried out using a taught string or wire from end to end along the side of the pipe
to measure the greatest deviation. Ovality (Clause 12.3.3 – IS 3589 –2001)
Ovality shall not exceed 0.75% of the specified outside diameter of the pipes.
P0" VGUVKPI"QH"RKRGU"
The pipes shall be tested to the following requirements.
a) Continuous monitoring of dia. Thickness fabrication.
b) Visual inspection of all pipes from inside and outside for permissible tolerances as per IS: 3589
c) Online ultrasonic testing of weld and body as per IS: 4260 during welding
d) Radiographic testing as per IS: 4853
e) Each pipe shall be hydraulically tested at 1.5 times the design pressure s per IS 3589 at the
manufacturer’s works to a test pressure of 15 Kg/sqcm for 16 mm thick pipe f) Mechanical test of
finished pipes as per IS: 3589.
Q0" OCTMKPI"
Each pipe shall be legibly marked as per clause 18 of IS: 3589 with following details
:
a) Manufacturer’s name or trademark.b) Outside diameter & specified wall thicknessc) Pipe
designation
R0" SWCNKV["CUUWTCPEG"
During the whole process of manufacturing, Engineer-In-Charge’s representative shall have authority
to supervise the Quality assurance process and witness the tests performed and also to get any pipe
selected at random for repetition of tests and the Contractor shall carry out the tests at no extra cost
to the Engineer-In- Charge.
S0" HCDTKECVKQP"QH"OU"URGEKCNU"CPF"HKVVKPIU"
Unless and otherwise mentioned in the para below all MS specials and fittings (bends, tees,
reducers, enlargers etc.) shall be fabricated using MS plate/sheet conforming to IS: 2062. the
thickness shall be adequate to sustain field test pressure but shall not be less than the thickness of
the pipe at that point. The Contractor shall submit the detailed drawing for each special to be used in
the pipeline. On approval of the same by the Engineer-In-Charge, the Contractor will take-up the
manufacturing. All specials shall be manufactured and coated at the manufacturer’s premises. In
exceptional circumstances when welding in trench is unavoidable a flanged opening shall be provided
for access inside the special for welding. The Contractor has to ensure the timely manufacturing of
the MS specials so that they can be laid in synchronization with the pipe laying. The joints of adjacent
pipe stretches have to be made with gap pieces approved by the Engineer-In-Charge. On completion
of the manufacturing, the coating and lining for the special will be done by the Contractor as per the
specifications for coating mentioned in specification. The Engineer-In-Charge or his representative
may at his discretion check the same and if the lining and coating are found defective in quality or
thickness, the Contractor shall carryout the tests on all the remaining pipes not laid, again in the
presence of the Engineer-In-Charge or his representative.
"
"
k+"HNCPIGF"DTCPEJGU"

146
Flanged branches shall be fabricated in accordance with the general specification and to the
Engineer-In-Charge’s requirement. Flanged branches for air valves shall be welded into pipe in the
required position. The branch for an air valve shall be vertical and at right angle to the longitudinal
axis of pipe. All the flanges shall be machined to standard thickness, square to the axis of the pipe.
kk+" DGPFU"
Bends to provide change of alignment in pipe laying shall be manufactured to suit the site
conditions from manufactured and tested pipes by angle cutting of the barrel or by such other
standard procedure and re-welding. Bends shall be lined internally and coated externally as
specified that for the pipes.
a) Bends shall be fabricated taking into account the vertical and horizontal angles for each case.
C. The bends shall have welded joints and the upstream and downstream ends of each bend
shall have a straight piece of variable lengths as required. CI. When the point of intersection of a
horizontal angle coincides with that of a vertical angle, or when these points can be made to coincide,
a single combined or compound bend shall be used.
kkk+" VCRGTU"
Tapers shall be manufactured out of steel plates and lined internally and coated externally.
Stiffener rings shall be provided to afford rigidity to pipe. They shall be manufactured generally in
accordance with IS: 7322.
kx+" OU"HNCPIGU"
Welding neck flanges confirming to IS 6392 be used in accordance to the design pressure at the
place appurtenance with which they are to Be used. The flange drilling shall conform to IS: 1538. The
Contractor shall assemble the flanges in the exact position by marginal cutting, if necessary so as to
get the desired position of the sluice valves etc., either vertical or horizontal and shall then fully weld
the flanges from both sides in such a way that no part of the welding protrudes beyond the face of the
flanges. In case the welding protrudes beyond the flanges and if the Engineer-In-Charge orders that
such protrusions shall be removed, the Contractor shall file or chip them off. If required and when
desired by the Engineer-In-Charge, the Contractor shall provide and weld gusset stiffeners, as
directed on site.
x+" DNKPF"HNCPIGU"
Blank flanges shall be provided at all ends left unattended for the temporary closure of work and also
for commissioning a section of the pipeline or for testing the pipeline laid. For temporary closure, non-
pressure blank flanges consisting of mild steel plates, tack welded at the pipe ends may be used. For
pipes subjected to pressures, the blank flanges or domes suitably designed as per Engineer-In-
Charge’s requirement shall be provided. The thickness of the blank flanges shall be as defined in IS:
6392 for the nominal size and design pressure at the place of installation, the flange drilling for all
flanges upto 1500 mm shall conform to the provision of IS: 1538 and those above 1500 mm shall
conform to IS: 6392.
xk+" UVKHHGPGT"TKPIU"
The Contractor shall provide stiffener rings wherever required as per designs. The Contractor shall
weld the same to the pipes with one circumferential run on each side.
xkk+" OCPJQNGU"
For manhole installation, a fabricated tee with one side flanged must be used. The size of manhole
shall not be less than 600 mm and it shall project at least 27.5 cm above the pipe crown. The 600 mm
end must be provided with blind flanges.
xkkk+" ENQUKPI"QT"OCMGWR"UGEVKQPU"
Closing or make up sections shall be furnished at appropriate locations on the line to permit field
adjustments in pipeline length to compensate for shrinkage in field welded joints, differences between
actual and theoretical lengths and discrepancies in measurements.
kz+" VGUV"JGCFU"
Test heads may be ellipsoidal, standard dished as per relevant ASME code or hemisphericalheads.
They shall be welded and removed after the test. Allowance shall be made in the length of the pipe

147
section receiving the test head for the welding and removal of the head and preparation of the plate
edges for the final weld after testing.
z+" YCNMYC[U."UVCKTU."NCFFGTU."JCPF"TCKNU"GVE0"
Walkways, stairs, rungs ladders, hand rails etc wherever necessary shall be provided or as per the
directions of Engineer-In-Charge or his representatives. These shall conform to well establish good
Engineering practices.
zk+" FKUOCPVNKPI"LQKPV"
All butterfly, or any other online valves etc. shall be installed between flanges with a flexible MS
dismantling joint at one side. The joint must allow dismantling of the valve meters, etc. without
causing stress to the joints of the attached pipes. The minimum clearance of the dismantling joint
shall be five (5) cm. The pressure class of the dismantling joint shall be the same as that of the pipe.
Drawings of the dismantling joint shall be submitted to the Engineer-In-Charge for approval. The nuts
and bolts of the joint shall be galvanized. The joints shall be painted/ coated as per specification given
for exposed pipes.
T0"KPURGEVKQP"CPF"VGUVU"QP"RKRG"CPF"HKVVKPIU"1"URGEKCNU"
The hydraulic test pressure shall be as per clause 13 of IS: 3589 for specials. Dye penetration test as
prescribed in IS: 7322 and VT is acceptable in lieu of hydraulic test for bends only. All works and
material under specification will be rigidly inspected during all phases of manufacture and testing and
such inspection shall not relieve the Contractor of his responsibility to furnish material and perform
work in accordance with these specifications. The Engineer-In-Charge or the authorized inspection
agency shall have free access to those parts of the plants that are concerned with the furnishing of
materials of the performance of work under this specification. The Contractor shall furnish the
Engineer-In-Charge reasonable facilities and space without charge for
inspection, testing and obtaining of any information he desires in respect of the quality of material
used and the progress and manner of work. Contractor shall provide and operate suitable equipment
capable of conducting the specified hydraulic test pressure to the inside surfaces of the pipe and of
sustaining the required period.
" UWTIG"UJCHVU"1RTGUUWTG"UWUVCKPKPI"XCNXGU"
"
The Contractor shall carry out surge analysis duly taking in to account the length of delivery pipe up
to the delivery pond including valves, expansion joints, etc. and propose a system suitable to take
care ofthe surges during shut down of pump sets. The Contractor shall install a surge tank or suitable
system based on the surge analysis studies and same shall be provided duly obtaining necessary
approval from the competent authority.
" NKPKPI"("EQCVKPI"
"
*3+" Nkpkpi<"
"
Painting in the pipe on the sand blasted surface with one coat of zinc silicate primer 106microns thick
and two coats of solventless coal tar epoxy paint of 150 micron thick each. Total thickness
406microns (as per IS 3589-2001).
1. Unless otherwise specified by the employer, the minimum dry film thickness DFT provided shall be
atleast 406 microns. After curing, but prior to burial the incoating system shall be a continuous
film free of thin spots and other imperfections and shall pass electrical inspection.
2. The pipe coating shall be applied in accordance with the manufacturers recommendations.
Application by airless spray or centrifugal wheel equipment is preferred.
3. Prior to sand blast cleaning the surfaces shall be cleaned to remove oil, grease or other foreign
matter. Only approved solvents that do not leave a residue shall be used. Preheating to remove
oil, grease, mill scale, water and ice may be used provided all pipe is preheated in a uniform
manner to avoid distortion.
4. The inner pipe surface shall be sand blasted to achieve a white metal surface. Sand blasting and
coating shall be performed when the metal temperature is more than 3 degrees centigrade above
due point.

148
5. The interior of the pipe surface shall be inspected for surface imperfections such as slivers, scabs,
burrs, weldspatter, and gouges shall be removed by grinding.
6. Abrasive and other loose foreign matter entered in the interior of pipe shall be cleaned by
compressed air. The temperature of mixed coating material and off the pipe at the time of
application shall not be lower than 10 degrees centigrade. Preheating of the coating material, use
of inline heaters to heat the coating material or heating of the pipe, fittings or specials may be
used to facilitate the application.
7. If more than one coat is applied, the second coat shall be applied within the time limits, surface
conditions and the temperature recommended by the manufacturer. If the period between the
coats is exceeded, then a repair procedure shall be obtained from the coating manufacturer and
its recommendations followed.
8. After application of coating, it shall be test for cure.
9. After curing, but prior to installation the coating system applied to the pipe shall be tested for the
holidays according to the procedure and using voltage settings.
10. Any holidays indicated by the detector shall be marked with chalk or felt tip marker to identify the
area to be repaired.
11. Accessible areas of pipe requiring coating repairs shall be cleaned to remove debris and
damaged coating using surface grinders. The adjacent coatings shall be feathered by sanding,
grinding. Accumulated debris shall be removed by vacuume, blowing or whiping with clean rags.
Repairs shall be electrically inspected using a holiday detector. The coated pipe shipped from
plant shall be holiday free.
12. The weld joint shall be cleaned so as to be free from mud, oil, grease, welding flux, weld spatter
and other foreign contaminants. The cleaned metal surfaces of the weld joint shall then be
abrasive blasted, vacuum blasted, or abraded using rotary abrading pads. The adjacent liquid
epoxy coating shall be feathered by abrading the coating surface for a distance of 25mm.
13. After curing, the coating system applied to the welded joints shall be holiday tested. Any holidays
indicated by the detector shall be marked with chalk or felt tip marker to identify the area for
repair.
*4+" Eqcvkpi<"
The external protection of steel pipe shall be a reinforced cement mortar coating applied over the
outer surface of the pipe section. Cement mortar applied by mechanical placement shall consist of
not more than 3 parts sand to 1 part cement by weight. Cement mortar coating shall be uniform in
thickness except at joints or other discontinuities and shall be of minimum thickness 30mm for all
sizes of pipe as per IS 3589:2001. The reinforcement of the coating of pipe section may be spiral
wire, wire fabric or wire mesh of size 50x50x3mm.
*5+" Engcpkpi<"
Pipe surfaces shall be thoroughly cleaned and dried before the application of lining / coating, and
shall be free of dirt, grease, oil rust, scale or other foreign matter. The pipe shall be cleaned by any
one of the following methods:
A. Grit/shot blasting
B. Sand blasting, and
C. Mechanical cleaning
Before sand or shot/ grit blasting, all oil and grease if present on the metal surface should be
removed by using suitable solvent and clean rags. Other foreign matters which cannot be removed by
blast cleaning should be removed by suitable means. Surfaces then should be thoroughly cleaned by
blast cleaning and the operation should remove scale, rust or any other superficial impurities from the
surfaces exposing base metal presenting a grayish matter appearance except that slight shadows,
streaks or discoloration caused by rust stings or mill scale oxides need not be removed. Adequate
moisture separators should be used so as to remove effectively oil and moisture from the air supply of
the blasting unit. After cleaning, the pipes shall be protected from and maintained free from all oil,
grease and dust that may fall on the pipes from outside sources till the pipe has received lining /
coating. Any pipe, that show deep pitting after blasting has been done, should be set aside pending
examination by the Engineer-In-Charge or his representative for approval for reconditioning or
rejection.
kkk+"QWVGT"EQCVKPI"
Outside surface of buried / over ground steel pipes and fittings shall be protected by the application of
Reinforced cement-mortar coating with guniting applied over the outer surfaces of the piping sections

149
and specials as per the requirement of AWWA C 205/ IS 3589
C+"EGOGPV"OQTVCT"EQCVKPI"
If the pipe has been mortar lined, the curing time specified for cement-mortar lining must elapse
before the coating is applied.
Thickness: - Cement mortar coating shall be uniform in thickness except at joints or other
discontinuities in the pipes. Coating thickness shall be 30 mm for all pipe sizes. Ends of coatings shall
be uniform and square to the longitudinal axis of the pipe, and the coating holdback shall be as
specified by the purchaser for the type of joint required.
D+"TGKPHQTEGOGPV"
Unless otherwise specified by the Engineer-In-Charge, the reinforcement for the coating of pipe
sections shall be spiral wire fabric/mesh of approved gauge size (ribbon mesh). Reinforcements shall
be free of oil, grease, and other contaminants that might reduce the adherence between the coating
and reinforcement. All reinforcement shall be placed in the middle third of the coating. When cement
mortar coating is applied over a dielectric undercoat, the reinforcement shall not be attached to or
otherwise be in contact with the steel pipe.
E+"URKTCN"YKTG"CPF"YKTG"OGUJ"
Attachments of ends and splices in the wire shall be by welding or other suitable means acceptable to
the Engineer-In-Charge. Maximum spacing of the wire shall be 35 mm. The wires on 50 mm spacing
on the 50mm x 100mm fabric shall extend circumferentially around the pipe. Attachment of ends and
splices in the wire shall be approved by the Engineer-In-Charge. In 25mm x 25mm fabric, the spiral
lap shall be 35mm and the sliced lap shall be 110 mm minimum.
F+"CRRNKECVKQP"QH"OQTVCT"EQCVKPI"
Mortar coating shall be applied by mechanical or steam pneumatic placement to the specified
thickness in one or more continuous application and shall consist of not more than 3 parts sand to 1
part cement by weight. The water in the mixture shall be carefully controlled so that mortar will not
run, sag or segregate. The soluble chloride-ion (Cl) content of the cement mortar mix shall not exceed
0.15 percent expressed as a percentage of cement weight. Allowance shall be made for splices of
reinforcing wire. When reinforcement of special wire type is used, the end of the wire at the edges of
the portion to be left uncoated shall be attached to the pipe shell by welding or other suitable means.
If applied in more than one course, the interval between the first and last course shall be not more
than 2 hrs. The mortar shall be projected at high velocity against the exterior surfaces of the pipe or
shall be applied by an equivalent method to produce a hard, tight adhering coating of the specified
thickness in one or more continuous applications.
G+"FGHGEVKXG"EQCVKPI"
If any sand pockets and porous spots occur they shall be completely cut out and replaced by
pneumatic placement or hand application of mortar in the proportion of 2 parts sand to 1 part cement,
by weight.
H+"EQCVKPI"ETCEMU"
Care shall be exercised to minimize the occurrence of cracks in the mortar coating. Repair
procedures shall include the brushing or wiping of near cement into cracks, autogenously healing of
the cracks by additional moist curing the painting of the cracks with an epoxy coating, or combination
of these methods.
I+"FCOCIGU"VQ"NKPKPI1EQCVKPI"
During the process of welding the pipe joints or any other location, the inner lining and outer coating
may get damaged. At all such locations, the damaged or peeled off portion of the lining/coating shall
be restored by Hand application of lining/coating material. Such application shall also ensure smooth
continuous surface at all the joints to ensure smooth flow of water.
J+"EWTKPI"QH"EQCVKPI"
After the initial set has taken place, the mortar coating shall be cured by the moist or accelerated
curing methods or unless otherwise specified by the purchaser, a membrane material may be applied

150
immediately following the coating application. Moist and accelerated curing may be used
interchangeably on a time ratio basis of 5 hrs or moist curing to 1 hr of accelerated curing, except
curing temperatures shall not exceed the maximum allowable for dielectric undercoat material. The
coating shall be kept continually moist by intermittent or continuous spraying for a period of at
least four days. Moist curing may be used only if the minimum ambient temperature exceeds 5 deg-c
continuously during the minimum required curing period, and no credit shall be allowed for any time
during which the temperature drops below 10 deg-c.
K+"CEEGNGTCVGF"EWTKPI"
Accelerated curing of the pipe or special may begin immediately after completion of the coating
operation or within 6 hrs thereafter. The temperature of the pipe or special shall not exceed 30 deg
C until the cement mortar coating has taken its initial set or until a period of 3 hrs has elapsed,
whichever occurs first. The relative humidity shall be not less than 85% at a temperature between 45
deg C to 65 deg C for at least 18 hrs. Coating of Specials- Mortar coating for pipe bends & other
special section shall be reinforced with wire fabric or ribbon mesh. Fabric shall be applied over
surface of pipe to be coated and shall be
held away from pipe shell with self-furring mesh, furring clips etc. The application of coating shall
conform to clause 5.6 of AWWA C-205 with the exception that hand application shall be substituted
for mechanical/ pneumatic placement. Thickness shall be as required for straight section.
L+"OGODTCPG"EWTKPI"
Membrane curing shall consist of the complete encapsulation of the coating by application of a
material that will retain the moisture of the applied cement mortar coating.
M+"RTGECWVKQPU"
During the entire period of the application of the lining and coating and the curing thereof, the section
shall be carefully supported and handled to avoid damage to the mortar. If a pipe section must be
moved such an operation shall be done with every reasonable precaution to protect against damage.
Any damaged portion of the lining or coating shall be cut out and replaced.
" FTCYKPIU."EWTXGU"CPF"KPHQTOCVKQP"TGSWKTGF"
The various drawings/data and documents to be furnished by the successful CONTRACTOR after
award of contract shall include the following
A. A complete list of all piping and fittings of various sizes including but not limited to transition,
bends, taper pieces, bulkheads, manhole arrangement with their quantities and details eg. nominal
size, O.D, I.D (as applicable), thickness, design pressure, material of construction/code/standards
etc.
B. GA of piping system based on tender drawings on verification of site condition.

C. A complete list of all valves and specials with their Data Sheets
D. Manufacturer's catalogue indicating complete range of available size and rating of pipes and
fittings and other procured items.
E. Descriptive literature on the manufacturing process and quality control procedures highlighting the
manufacturing, fabricating and testing facilities available in the shop.
a. Detailed fabrication drawing showing the sizes, materials and weld edge preparation etc. The
fabrication drawings shall give all necessary information for fabrication, erection and painting of steel
work in accordance with provisions of this specification. Welding symbols used shall be in accordance
with the requirements of IS:813 latest revision and shall be consistent throughout. Weld lengths called
on the drawings shall be net effective lengths.
G. Welder’s Qualification record.
a) Contractor shall submit working drawing for excavation, sand-Filling and backfilling
purpose as mentioned earlier.
b) Any other drawings or calculations that may be required for the clarification of work.
c) Instruction Manuals covering maintenance, repair and replacement of equipment fabricated and
supplied by the CONTRACTOR.
" VGUVKPI"

151
All the tests mentioned in the following shall be arranged by he CONTRACTOR.
i) RADIOGRAPHY: The Longitudinal & circumferential joints will be random radio graphed limited to
2% of the total number of pipes for longitudinal joints and 5% of number of joints in case of
circumferential joints at the discretion of the ENGINEER- IN-CHARGE. The testing shall be arranged
by the CONTRACTOR. Necessary labour & materials for welding of support etc. required for carrying
out X-raying shall be provided by the CONTRACTOR for carrying out the test.
ii) ULTRASONIC TESTING:

Longitudinal and circumferential joints will be subjected to ultrasonic sound test randomly to the
extent of 2% of number of pipes for longitudinal joints and 5% of the number of circumferential joints.
Necessary labour, equipment ad material required shall be provided by the CONTRACTOR for
carrying out the test.
iii) Dye penetration test on the root runs shall be carried on 100% joints after grinding before
proceeding with filler runs.
vi) RECTIFICATION & RETESTING:
Any defect noticed by radiographic / U.T shall be provided by the CONTRACTOR free of cost. The re-
testing charges will be to the account of the CONTRACTOR.
J[FTCWNKE"VGUVKPI"QH"RKRGNKPG"Each pipe shall be hydraulically tested after the pipe is

internally cement mortar lined / externally coated in accordance with AWWA M11. Water required
for testing shall be arranged by the CONTRACTOR at his own cost.
All the longitudinal and circumferential welded seams shall be subjected to chalk and kerosene test
prior to hydraulic testing of the complete pipe line. This shall be done in the presence of the Engineer-
In-Charge. In addition to this, test coupons shall have to be provided for each longitudinal seam
forNmechanical tests (tensile and bend), if considered necessary by the Engineer-In-Charge. The test
coupons are to be broken in presence of the Engineer-In-Charge. Contractor shall satisfy the
Engineer-In-Charge that work is being carried out in accordance with the specification drawings and
other conditions. Engineer-In-Charge shall have full access to the Contractor's working area.
Testing shall be done before backfilling & under dewatered condition. However, the Contractor shall
backfill & compact the soil in the region of bends to avoid undue thrust on the anchor blocks. Any
temporary arrangements that may be required to ensure stability of pipeline are also deemed to have
included in the quoted rate.
Cement Mortar Lined pipes to be tested should be filled with water of appropriate quality & allowed to
stand for at least 24 hours to permit maximum absorption of water by the lining. Additional water
should be added to replace water absorbed by the Cement Mortar Lining. The hydraulic test pressure
is usually applied for a period of 24 hours before the test is assumed to begin, primarily to allow for
the lining material to absorb as much water as is possible. After that the pipeline should be inspected
for evidence of leakage.
" DCEMHKNNKPI"QH"RKRG"NKPG"VTGPEJU<"
c+" UEQRG"QH"YQTM"
This section covers specification for the work consists of backfilling the pipeline trenches with
selected soil from excavated/selected soil from borrow area in layers of 150mm thickness including
watering and compacting the backfill to the desired compaction etc., complete with all leads and lifts.
All fill material will be subject to ENGINEER-IN-CHARGE’s approval. If any material is rejected by
ENGINEER-IN- CHARGE, Contractor shall remove the same forth with from the site at no extra cost.
Surplus fill material shall be deposited / disposed off as directed by ENGINEER-IN- CHARGE after
the fill work is completed. No earthfill shall commence until surface water discharges and streams
have been properly intercepted or otherwise dealt with as directed by ENGINEER-IN-CHARGE.
Material to the extent available, selected surplus soils from excavated materials shall be used as
backfill. Fill material shall be free from clods, salts, sulphates, organic or other foreign material. All
clods of earth shall be broken or removed. Where excavated material is mostly rock, the boulders
shall be broken into pieces not larger than 150mm size, mixed with properly graded fine material
consisting of murum or earth to fill up the voids and the mixture used for filling. If any selected fill
material is required to be borrowed, Contractor shall make arrangements for bringing such material
from outside borrow areas. The material and source shall be subject to prior approval of ENGINEER-
IN-CHARGE.
The approved borrow area shall be cleared of all bushes, roots of trees, plants, rubbish etc., top soil
containing salts / sulphate and other foreign materials. The materials so removed shall be burnt or
disposed off suitably as directed by ENGINEER-IN- CHARGE. Contractor shall make necessary
access roads to borrow areas and maintain the same, at his cost, till completion of the work.

152
d+" HKNNKPI"KP"VTGPEJGU"
After laying and testing of the pipeline and construction of valve cistern, anchor blocks, thrust blocks
etc., the filling in trenches shall be commenced immediately with soft selected excavated materials.
This shall be done without any delay. The materials shall be laid, adequately watered and tamped in
layers of 23 cms with a small tamper under, around and over the pipes and specials upto the original
ground level taking due care that no damage is caused to the pipes, specials, structures etc. The
compaction shall comply with the specified density at moisture content, differing not more than 4%
from the optimum moisture content. The Contractor shall arrange for sampling and testing of the filling
as directed by the Engineer-In-Charge to ascertain whether specified density has been achieved. The
cost of all such sampling and tests shall be borne by the Contractor and is deemed to be included in
the rates quoted. Filling of the trenches shall be carried simultaneously on both sides of the pipe to
avoid unequal
pressure on the pipe. Backfill shall not be dropped directly upon or against any structure / facility
where there is a danger of displacement or damage. Trucks or heavy equipment for depositing or
compacting backfill shall not be used within 1.5m of head walls, piers or other facilities which may be
damaged by their weights or operation method of compaction. The method of depositing and
compacting backfill
UGEVKQP"⁄"E"3;"YGNN"
HQWPFCVKQPU"
3;0" FGUETKRVKQP:
This work consists of construction of well foundation, taking it down to the hard strata i.e,
foundation level designed through all kinds of sub-strata, plugging the bottom, filling the inside
of the well, plugging the top and providing a well cap in accordance with the details shown in
the approved drawing and as per the specifications, or as directed by the Engineer.
In case of well foundations of size larger than 12m diameter, supplemental
construction specification will be necessary.
IGPGTCN:
(a)" Ygnnu"oc{"jcxg"c"ektewnct."tgevcpiwnct."qt"F/ujcrg"kp"rncp"cpf"oc{"eqpukuv"qh"qpg."
vyq"qt"oqtg"eqorctvogpvu"kp"rncp0"Vjg"qwvgt"ygnn"qh"vjg"ygnn"ku"mpqyp"cu"ygnn"uvgkpkpi."
yjkej"oc{"dg"ektewnct1tgevcpiwnct
"
The process of taking down the well to the design founding level is known as well
sinking. After reaching the design founding level, the hollow inside the well (Dredge hole) is
plugged at the bottom by concrete (bottom plug). The dredge hole is then filled with approved
filling up to the level indicated on the drawings and provide with a concrete plug (top plug).
To facilitate sinking of well, steel cutting edge is fabricated and connected to a

concrete well curb of required shapes. On top of the well curb, adequate height of well
steining is cast and the process of sinking is carried out. After a portion of the well has been
sunk, another height of well steining is cast on top of the previous section and further sinking
carried out. This process is continued till the bottom level of the well reaches the hard strata
i.e, foundation level designed.
At the top of the well steining, an adequately designed “well cap” is laid which
transmits the loads and forces from the Sub-structure (Piers abutments) to the foundations.
(b) At least one bore-hole must be available / carried out in accordance with these
specifications at each well foundation location, prior to commencement of work. The depth of
bore-holes should extend upto a depth equal to one and a half time the outer diameter/least
dimension of the well below the anticipated foundation level designed. The results of soil
exploration should be presented in accordance with SS 3.11 in case the well foundation is to
rest on a rocky strata, it may be necessary to undertake additional borings/probing prior to
commencement of work to ascertain the actual profile and the quality of the rocky state, at the
level of which the well has to be seated etc.
(C) Blasting may have to be resorted to in order to facilitate sinking through difficult strata,
such as boulders and rocks etc. In case blasting in anticipated, protective/strengthening
measuring specified in SS 3.3 shall be taken. The grade of concrete in bottom 3 meters of
steining shall not be leaner than M 20 or as shown on the drawings.

153
(d) In case the bore hole data shows the presence of steeply dipping rock, chiseling may have
to be resorted to so as to obtain proper seating of the foundation. For this purpose, the well may
require to be dewatered completely under high air pressure inside the well. This process is
known as pneumatic sinking. Pneumatic sinking may also have to be resorted to in cases
where obstacles such as tree trunks, large size boulders or hard strata etc., not be removed by
open dredging. The necessity of adopting pneumatic sinking shall be decided by the Engineer.
The curb and steining have to be specifically designed for special loading when
pneumatic sinking is adopted.
UGVVKPI"QWV"CPF"RTGRCTCVKQPU"HQT"UKPMKPI:
(a) Necessary reference points shall be fixed, away from the Zone of blow-ups or possible
settlements resulting from well sinking operations. Such reference points shall be connected to
the permanent theodolite stations with the base line on the banks. The center of the individual
wells shall be marked with reference these stations. The distance, wherever practicable, shall
be checked with the help of accurate tapes and precision distance meter. Reference points
shall also be fixed to mark X-X axis (usually canal flow direction) and Y-Y axis (normal to X-X
axis) accurately.
A temporary benchmark shall also be established near the well foundation, away from the
zones of blow-ups or possible settlement. The bench mark shall be checked regularly with
respect to the permanent benchmark established at the site.
(b) For wells which are to be pitched in water, an earthen or sand island shall be constructed.
Sand islands are practicable for water depths of about 5 M under stable bed soil conditions. For
greater depths or in fast flowing rivers or for locations where soil is too weak to sustain Sand
Island, floating caissons may have to be adopted.
The plan dimensions of sand islands shall be such as to have a working space of at least 2
meters all around the steining. The dimension of the sand island shall extend at least 3m
beyond outer periphery of the wells to be sunk. The dimension in plan of the well or caisson.
Sand islands shall be maintained to perform their functions, until the well is sunk to a depth
below the bed level at least equal to the depth of water. .
Sand Island shall be protected against scour and the top level shall be sufficiently
above the prevailing water level to be decided by the Engineer so that it is safe against wave
action.
While Sand Island are constructed at well location, floating caissons are generally
fabricated at or near the banks on dry land or dry docks, bloating caissons are towed into
position in floating caissons are towed into position in floating condition.
Floating caissons may be of steel, reinforced concrete or combination of the two. They
should have at least 1.5m free board above water level and increased, if considered necessary,
in case there is a possibility of caissons sinking suddenly owing to reasons such as scour likely
to result from the lowering of caissons, effect of waves, sinking in very soft strata etc.,
Stability of floating caissons shall be ensured against overturning and capsizing while
being towed and during a sinking for the caution of water current, wave pressure, wind etc.,
For floating caissons, a detailed method statement for fabrication, floating and sinking
of caissons shall be prepared and furnished to the Engineer. Such statement shall include the
total tonnage of steel involved, fabrication and welding specifications, list of materials and plant
and a description of operations and manpower required for the work. The caisson shall be
tested for leakages before being towed to site.
(C) GSWKROGPV:
Equipment shall be deployed for construction of well foundation as required and as

154
directed by the Engineer. Generally, the following equipment may be required for the work.
i) Crane with grab buckets-capacity 0.5 to 2.0 cum.

ii) Submersible pumps.
iii) Air compressors, air locks and other accessories where pneumatic sinking of well is
anticipated.
iv) Chisels of appropriate sizes.
v) Aqua-header for cutting rocky strata.
vi) Diving helmets and accessories.
vii)Equipment for concrete production, transportation planning and
compaction.
EWVVKPI"GFIG:
(a) The mild steel culling edge shall be made from structural steel sections. The cutting
edge shell weigh not less than 40 Kgs. per meter length and be properly anchored into the well
curb, as shown in the drawing.
When there are two or more compartments in a well, the bottom end of the cutting edge
of the inner walls of such wells shall be kept at about 300mm above that of outer walls.
(b) The parts of cutting edge shall be erected on level firm ground. Temporary supports
shall be provided to facilitate erection and maintaining the assembly in true shape. The
fabrication may be carried out in the shop or at site. Steel sections shall not be heated and
forced into shape. However, ‘V’ cuts may be made in the horizontal portion, uniformly throughout
the length, to facilitate old bonding. After bending, such “V” cuts should be closed by welding.
Joints in the length of structural sections, unless otherwise specified shall be fillet welded using
single cover plate to ensure the requisite strength of the original section.
(C) The cutting edge shall be laid about 300mm above prevalent water level.
YGNN"EWTD:
a) The well curb may be precast or cast-in-situ. Steel form work for well curb shall be fabricated
strictly in conformity with the drawing. The outer face of the curb shall be vertical. Steel
reinforcements shall be assembled as shown on the drawings. The bottom ends of vertical
bend rods of steining shall be fixed securely to the, cutting edge with check nuts or by welds.
The form work on outer face of curb may be removed within 24 hours after concreting. The form
work of inner face shall be removed after 72 hours.
(c) All concreting in the well curb shall be done in one continuous operatio
3;07"YGNN"UVGKPKPI<"
(a) The dimensions, shape, concrete strength and reinforcements of the well shall strictly
conform to those shown on the drawings. The form work shall preferably be of M.S. Sheets
shaped and stiffened suitably. In case timber forms are used, they shall be lined with plywood
or M.S. Sheets.
(b) Steining built in the first lift above the well curb shall not be more than 2 meters and in
subsequent lifts it shall not exceed the diameter of the well or the depth of well sunk below
the adjoining bed level at any time. For stability, the first lift of steining shall be cast only
after sinking the curb at least partially for stability. Concreting of steining may be carried out
in subsequent lifts of about 2 to 2.5 meters. Attempts should be made to minimize the
number of construction joints. The concreting layers shall be limited to about 450mm
restricting the free fall of concrete to not more than 1.5m .Laitance formed at the top
surface of a lift shall be removed to expose coarse aggregates before setting of concrete at
the proposed construction joint. As per as possible, construction joints shall not be kept at
the location of laps in the vertical steining bars.
(c) The steining of the well shall be built in the straight 1 m from bottom to top such that if the
wall is tilted, the next of steining will be aligned in the direction of the tilt. They will be
checked carefully with the said of straight edges of lengths approved by the Engineer.
Plumb bob or spirit level shall not be used for alignment. After sinking of a stage is

155
complete, damaged portions if any, of steining at top of the previous stage shall be properly
repaired before constructing the next stage.
(d) The height of steining shall be calibrated by making at least 4 gauges ( preferably in canal
flow direction and in a direction normal to canal flow direction) distributed equally on the
outer periphery of the well each in the form of a 100mm wide strip painted on the well, with
every meter mark shown in black paint. V The gauges shall start with zero at the bottom of
the cutting edge. Marking of the gauges shall be done carefully with a steel tape.
(e) After reaching the founding level, the well steining shall be inspected to check for. any
damage or cracks. The Engineer will direct and the contractor shall execute the remedial
measures before acceptance of the well steining. In case the well cannot be accepted even
with any remedial measures, then the well shall stand rejected.
(B) Use of Kent ledge as sinking load.
Kent ledge shall be placed in an orderly and safe manner on the loading platform
and in such a way that it does not interfere with the excavation of the material from inside
the dredge hole and also does not in any way damage the steining of the well.
Where tilts are present or there is a danger of well developing a till, the position of the
load shall be regulated in such a manner as to provide greater sinking effort on the higher
side of the well.
(f) Wug"qh"Ycvgt"lgvvkpi.
Water jetting may be employed for well sinking wherever necessary.
(g) Wug"qh"Gzrnqukxgu.
Mild explosive charges may be used as aid for sinking of the well only with prior permission of
the Engineer. Blasting of any sort shall only be done in the presence of the Engineer and not
before the concrete in the steining has hardened sufficiently and is more than 7days old.
When likelihood of blasting is predicted in advance, protection of the bottom portion of the
well shall be done as per these specifications. After blasting operations are completed, the
well curb and steining should be examined for any cracks and remedial measures taken.
HI
If blasting has been used after the well has reached the design foundation level, normally
24 hours shall be allowed to lapse before the bottom plug is laid.
The charges shall be exploded well below the cutting edge by making a sump so as to
avoid chances of any damages to the or to the steining of the well. A minimum sump of 1
meter depth should be made before resorting to blasting. Use of large charges, 0.7 Kg. Or
above, may not be allowed except under export direction and with the permission from the
Engineer. Suitable pattern of charges may be arranged with delay detonators to reduce the
number of charges fired at a time. The burden of the charges may be limited to 1 meter and
the spacing of holes may normally be kept as 0.5 to 0.6 metres.
All prevalent laws concerning handling, steining and using of explosives shall be strictly
followed.
All safety precautions shall be taken as per IS 4081 “Safety code for Blasting and related
Drilling operations”. To the extent applicable, whenever blasting is resorted to. • .
There should be no equipment inside the well nor there any labour in the close vicinity of
the well at the time of exploding the charges.
If rock blasting is to be done for seating of the well, the damage caused by flying debris should be
minimized by covering blasting holes by rubber mats before blasting.
*E+" Wug"qh"fkxgtu<"
"
Use of divers may be made both for sinking purpose like removal or obstructions, rock

156
blasting and for inspection. All safely precautions shall be taken as per any acceptable
safe code for sinking with divers or any statutory regulations in force.
Only persons trained for the diving operation shall be employed and shall be. Certified to
befit for diving by an approved doctor.
They shall work under expert supervision. The diving and other equipment shall be
of acceptable standard and certified to this effect by an approved independent agency.
It shall be well maintained for safe use.
Arrangement for sample supply of low pressure clean cool air shall be ensured
through an armored flexible hose pipe stand by compressor plant shall be provided in
case of breakdown.
Separate high pressure connection for use of pneumatic shall be made. Electric
lights w\here provided shall be at 50 (maximum). The raising of the diver from the
bottom of wells be controlled so that decompression rate conforms to the rate laid down
in appropriate regulations.
f) Use of Pneumatic sinking.
i) General.
The Engineer shall familiarize himself with particular reference to caisson diseases and
working of the medical air-lock. A Doctor competent to deal with cases of “Caisson
Diseases” or other complications rising as a result of working under high pressure, shall
be stationed at the construction site when pneumatic sinking is under progress.
The Contractor shall provide complete facilities including the issuing of orders to
ensure strict enforcement of the equipment outlined in these specifications.
Safely provisions as contained in IS 1138 and these specifications shall be strictly

followed.
Pneumatic sinking shall be restricted to a depth of 30.0m.
ii) Man-locks and shafts
Locks, reducers, and shaft used in connection with cassion shall be of relevant to
Construction throughout. The material used in their manufacture shall be steel plate with
thickness not less than 6 mm.
Shafts shall be subjected to hydrostatic or air pressure test of at least
0.5 Mpa, at which pressure they shall be tight. The pressure at which testing has been
done shall be clearly and visibly displayed.
Shafts shall be provided, with a safe, proper and suitable staircase for its entire
length including landing platforms which are not more than 6 metres apart. Where this
is impracticable due to space constraint, suitable ladders along with landing platforms
shall be installed. These shall be kept clear and in good condition at all time and shall
be constructed, inspected and maintained to the entire satisfaction of the Engineer.
A one metre wide platform with 1.0 m.high railing shall be provided, all round the caisson
air locks.
Where 15 or more man are employed, caissons shall have to locks, one of which
shall be use dasa man lock.
Locks shall be located so that the lowest part of the bottom door shall not be less than
1metre above high water level
The supply of fresh air to the working chamber shall at all times be sufficient to
permit work to be done without any danger or excessive discomfort. All air supply lines
shall be supplied with check valves and carried as near to the face as practicable.

157
A man-lock shall be used solely for the compression or de compression of persons,
and not for the passage of plant and shall be maintained in a reasonably clear and
sufficiently term state. However, any hand tool or hand instruments used for the
purpose of the work may be carried in to the man- lock.
Where it is not reasonably practicable to provide a separate man-lock for use by
persons only, the lock when it is in actual use for compression or decompression of a
person shall not be put simultaneously, to any other use and shall be in a reasonably
clean and sufficiently war state..
iii) Valves:
Exhaust valves shall be provided, having risers extending to the upper part of the
chamber. These shall be operated, whenever necessary especially after a blast.
Precautions shall be taken that men and not allowed to resume work after a blast until
the gas and smoke are cleared.
iv) Medical supervision and certification.
Every employee absent from work for 10 or more consecutive days due to illness or any
other disability shall be required to pass the regular physical examination by the doctor
before being permitted to return to work.
After a person has been employed continuously in compressed air for a period of 2
months. He shall be re-examined by the doctor and shall not be permitted to work until
such re-examination has been made and the report in satisfactory.
No person known to be addicted to the excessive intoxicants shall be permitted towork in
compressed air.
The doctor shall, at all times keep a complete and full record of examination made by
him, which shall contain dates of examination, a clear and full description of the person
examined, his age and physical condition at the time of examination and a statement as to
the period such a person has been engaged in such employment. Records shall be kept at
the place where the work is in progress and shall be subject to inspection by authorized
officers.
Every man lock shall always have a doctor or a responsible person in attendance. In
case the person in charge is note doctor he must have positive means of promptly
communicating with and securing the services of a competent doctor in case of
emergency. Such arrangements shall invariably be subject to the approved of the
Engineer.
If the air pressure exceeds 0.2 Ta gauge of if 50 or more men are employed, it is
obligatory for the person in charge of medical lock to be doctor experienced in this type of
work.
All cases of compressed air illness shall be reported and copies of all such reports
shall be kept on file at the place of work.
(ii) Lighting:
All lighting in compressed air chambers shall be operated only by electricity. Two
independent electric lighting system with independent sources of supply shall be used.
These shall so arranged that the emergency source shall become automatically operative
in case of failure of the regularly used source.
The minimum intensity of light on any walkway ladder, stairway, or lower working level
shall be one quarter (1/4) candlepower. In all work places, the lighting shall always be
such as to enable workmen to sec their way about clearly. All external parts of lighting
fixtures and electrical equipment lying with the 2.5 metres above the floor shall be
constructed of non-combustible non-absorbing insulating materials.- If metal is used it
must be effectively earthed. Portable lamp shall have non-combustible non- absorbing
insulating sockets, approved handles, bucket guards and approved cables. The use of
worn of defective portable and pendant conductors, shall be prohibited.
(vi) Safety against fire hazard.
No oil, gasoline, or other combustible material shall be stored within 30 metres of any shaft,
caisson, or funnel opening. However, oil may be stored in suitable tanks in isolated fire

158
buildings, provided such buildings are not less than 15 meters any shaft, caisson, or tunnel
opening or any building directly connected there to.
Positive means shall be taken to prevent leaking flamable liquids from flowing into
areas specifically mentioned in the proceedings paragraph.
Where feasible, a fire hose connected to a suitable sources of water shall be

provided at the top o every caisson. Where fire means are not accessible, a supply of water
shall be stored in tanks near the top of every caisson, provided fire pails or suitable pumps
are kept available. Approved fire extinguishers shall also be provided.
(vii) Sanitation:
Properly boated, lighted and ventilated dressing rooms shall be provided for all employees
engaged in compressed air work, such rooms shall contain lockers and benches and be
open and accessible to men during intermission between shifts. Adequate toilet gas
accommodation of one for every twenty five employees shall be provided.
Care shall be taken to keep all parts of the caissons and other working
compartments, including locker rooms, dry rooms, rest house; and other equipment in a
good sanitary condition an free from fuse, decaying or other objectionable matter.
No nuisance shall be tolerated in the air chamber. Sinking shall be strictly prohibited
and all matches and smoking materials shall be left out of the locker rooms.
A separate dry-room shall be provided where working clothes may be dried within
reasonable time.
(viii) Protection against gases:

In all cases where gas is expected including alluvium impregnated with decayed
vegetable matter the use of davy safely lamp shall be compulsory.
(ix) Additional safely provisions.
a) The weight of the pneumatic platform and that of steining and Kent ledge, if any, shall be
sufficient to resist the uplift from air in side, skin friction being neglected in this case. If at
any section the total weight acting down word pressure more than the uplift pressure of air
inside, additional Kent ledge shall be placed on the wall.
If it is not possible to make the wall heavy enough during excavation, blowing down“may
be used. The men should be within and air pressure reduced. The well should then begin to
move small deduction in air pressure. "Blowing down" should only be used when the ground
is such that it will not heavy up inside chamber when the pressure is reduced. When the well
does not with the reduction in air pressure, Kent ledge should be added. "Blowing down”
should be in short stages and the drop should not exceed metre at any stage. To control
sinking during blowing down, use of packings are recommended.
(b) The pneumatic sinking plant and other allied machinery shall not only be of proper
design and make, but also shall be worked by complete at and well trained personnel.
Every part of the machinery and its fixtures shall be minutely examined before installation
and use. Availability of appropriate spares, standbys, safety of personnel as recommended
in IS 14138 for working in compressed air must be ensured at site. Codes for safely and for
working in compressed air & other labour laws and practices prevalent in the country, as
specified to provide safe, efficient and expeditious sinking shall be followed.
c) Inflammable materials shall not be taken in to air locks and smoking shall be prohibited.
Wherever gasses are suspected to be gushing out of dredge hole, the same shall be
analyzed by trained personnel and necessary precautions adopted to avoid hazard to life
and equipment.
d) Where blasting is resorted to, is shall be carefully controlled and all precautions regarding
blasting shall be observed. Workers shall be allowed inside after blasting only when a
competent and qualified person has examined the chamber and steining thoroughly and
found the same to be safe.

159
g) Precautions during sinking.
a) When the wells have to be sunk close to each other and clear distance between them is not
greater than the diameter of wells, sinking shall be taken up on all wells and they shall he
sunk alternately so that sinking of wells proceeds uniformly. Simultaneous and even
dredging shall be carried out in the wells in such a manner that the difference in the levels
of the sump and cutting edge in the adjacent wells does not exceed half the clear gap
between them. Plugging of all the wells shall be done together.
b) During sinking of dumb-bell or double D-Shaped wells, the excavation in both the dredge
holes should be carried out simultaneously and equally.
c) Bore chart shall be referred to constantly during sinking for taking adequate care while
piercing different types of strata. The type of soils as obtained during the well sinking should
be compared with bore chart so as to take prompt decisions.
d) Before seasonal floods all wells on which sinking in progress shall be sunk to sufficient
depths bellow the designed occur level. Further, they shall be temporarily filled and plugged
so that they do no suffer any tilt or shift during the floods.
e) All necessary precautions shall be taken against any possible damage to the
foundations of existing structures in the vicinity of the wells, prior to commencement of
dredging from inside the well.
f) The dredged material shall not be allowed to accumulate over the well, It shall be dumped
and spread, as far away as possible, and then continuously and simultaneously recovered as
directed by the Engineer. In case the river steam flows along one edge of the well being sunk,
the dredged material shall not be dumped on the dry side of the bank but on the side on
which the river current flows.
g) Very deep sump shall not be made below the well curb, as it entails risk of jumping (sudden
sinking) of the well. The depth of sump shall be generally limited to one-sixth of the outer
diameter/least lateral dimension of the well in plan. Normally, the depth of sump shall not
exceed 3.0 metres flow the level of the cutting edge unless otherwise specifically permitted by
the Engineer.
h) In case a well sinks suddenly with a jerk, the steining of the well shall be examined to the
satisfaction of the Engineer to see that no damage has occurred to it.
i) In pneumatic sinking, the well shall not, at any time, be dropped to a depth greater than 500
mm by the method of “blowing down”.
j) Dewatering shall be avoided if sand blows are expected. Any equipment and men working in
side the well shall be brought out of the well as soon as there are any indications of a sand-
blow.
k) Sand blowing in wells can often be minimized by keeping the level of water inside the well
higher than the water table and also by adding heavy kept ledge.
l) In soft strata prone to settlement/creep, the construction of the abutment wells shall be taken
up only after the approach embankment for a sufficient distance near the abutment has been
completed.
H) Tills and Shifts:-
The inclination of the well from the vertical is known tilt and the horizontal
displacement of the center of the work at the founding level from it’s theoretical position
is known as shift.
Unless otherwise specified, the tilt of any well shall not exceed 1
(HORIZONTAL ) in 80 ( VERTICAL ), and the shift at the well base shall not be more
than 150mm in any resultant direction.
Tilts and shifts shall be carefully checked and recorded in the format vide Appendix-
II regularly during sinking operations. For the purpose of measuring the tilts along the
work axes of the aqueduct reduced level of the marks painted on the surface of the
steaming of the well shall be taken. For determination of shifts locations of the ends of

160
the two diameters shall be precisely measured along the two axes, with reference to
fixed reference points.
Whenever any tilt is noticed, adequate preventive measures like placing eccentric
Kent ledge, pulling, strutting, anchoring or dredging unevenly and depositing dredge
material unequally, putting obstacles below cutting edge. Water jetting etc., shall be
adopted before any further sinking. After correction, the dredged material shall be spared
out uniformly.
A pair of wells close to each other have a tendency to come closer while sinking,
timber struts may be introduced in between the steining of these wells to prevent tilling.
Tilts occurring in a well during sinking in dipping rocky strata can be safeguarded by
suitably supporting the curb.
In the event of a well developing tilt or shift beyond the specified permissible
values, the Contractor shall have to carry out, at his own cost, suitable remedial
measures to satisfaction of the Engineer, to bring the tilt and shift within permissible
values, as far as practicable.
If the resultant tilt and / or shift of any well exceeds the specified permissible values,
generally it should not exceed 1 in 50 and 300 mm respectively. The well so sunk shall
be regarded as not conforming to specifications and a substandard work. The Engineer
in his sole discretion, may considered accepting such a well provided.
(i) Calculations for foundation pressures and steining stresses, accounting for the actual till
and shift furnished by the contractor show that the well is safe. Any remedial measures
required to bring the stresses within permissible values (such as increase in the dimension of
the well cap, provision of dummy weights on the well cap etc.,) shall be carried out by the
Contractor without claiming for any extra cost.
In case the Engineer, in his discretion, rejects the wells, the Contractor shall
dismantle the rejected well to the extent directed by the Engineer and remove the debris.
Further, the contractor shall; at his own risk and expense complete the work with modified
span arrangement acceptable to the Engineer.
I) Seating of Wells
The well shall be uniformly seated at the founding strata. It shall be ensured by test
borings that the properties of the soil encountered at the foundation strata and up to a depth
of one and a half times the well diameter is identical to the adopted in the design. The
procedure for test borings shall satisfy the provisions of these specifications. In case, the soil
encountered is inferior to that adopted in design, the well shall be redesigned by the Engineer
adopting the soil properties actually encountered and the design foundation level intimated
the contractor, who shall carry out the work.
In case of seating of wells in hard rocky strata, where the rock profile is steeply
sloping, pneumatic methods of sinking may be adopted to seat the well evenly as directed by
the Engineer. The decision of adopting pneumatic sinking shall be taken by the Engineer. The
cutting edge may also be embedded for a suitable depth in the rocky strata ,and decided by
the Engineer keeping in view the quality of rock. As an additional measure of safety, the well
shall be anchored to the rocky strata by anchor bars provided in the steining of the well, as
shown on the drawing irrespective of the fact of the well, as shown on the drawing
irrespective of the fact that tension develops or riot at the base of the well under design loads.
After the wall has been evenly seated on good hard rock, arrangements shall be made to
facilitate proper in dry and visible conditions before the bottom plug is laid.
3;08"DQVVQO"RNWI0"
For bottom plug, the concrete mix shall be designed (in dry condition) to attain the
concrete strength as mentioned on the drawing and shall contain 10 per cent more cement that
required for the same mix placed dry, to cater for under wafer concreting. However, the total
cement content shall not be less than 363 Kg/Cum. of concrete with as lump in the range of 150
mm to 200mm. Admixtures maybe added to the concrete to impart the required characteristics
indicated herein.
Concrete for the bottom plug shall be laid by trimee pipe method, trimie concrete when
started shall be continued without interruption for full operating in the bottom plug. The
Concrete reduction equipment and placement ' equipment should be sufficient to enable under
water concreting within stipulated time. Necessary standby equipment should be available for
emergency situation.

161
Before commencing plugging, all loose material from the bottom of the well shall be
removed.
Concreting shall be done in one continuous operation till the dredge hole is filled up to
the required height and there after sounding shall be taken up to ensure that the concrete has
been laid to the required height.
Least disturbance shall be caused to the water inside the well while laying concrete in
the bottom plug. Concrete shall not be disturbed in any way for at least. 14 Days.
In order to check any rise in the level of the bottom plug soundings should be taken at
the close of concreting and once every day for the subsequent 3 days.
The soundness of the bottom plug may be tested by dewatering the well by 5 metres
below the surrounding water level and checking the rise of water. The rate of rise shall
preferably be less than 10 cum. per hour. In case the rate is higher, suitable remedial measures
as directed by the Engineer, shall be taken by the Contractor at his own cost.
UCPF"HKNNKPI:
Sand filling shall commence after a period of 3 days of laying of bottom plug. Also, the
height of the bottom plug shall be verified before starting sand filling.
Sand shall be clean and free from earth, clay clods, roots, boulders, shingles, etc., and
shall be compacted as directed, sand filling shall be carried out up to the level shown on the
drawing, or as directed by the Engineer.
VQR"RNWI:
After filling sand up lo the required level a plug of concrete shall be provided over it as
shown on the drawing, or as directed by the Engineer.
YGNN"ECR:
A reinforced cement concrete well cap will be provided over the top of steining in
accordance with the drawing. Form work will be prepared conforms the shapes of well cap.
Concreting shall be carried out in dry condition. Properly designed false steining may be
provided where possible well cap is laid in dry conditions.
The bottom of the well cap shall be laid preferably and lows possible, account the
water level prevalent at the time of casting. Bond rods of steining shall be anchored in to the
well cap.
VQNGTCPEGU:
The permissible tilt and shift shall not exceed I (horizontal) in 80 (Vertical) and the
shift at the well base shall not be more than 150 mm in any resultant directions.
For the well steining and well cap the permissible tolerances shall be as follows:
(a) Variation in dimension 1 + 50mm— 10 mm

(b) Misplacement from specified position in plan. 15 mm
(c) Surface irregularities measured with 3 m straight edge, 5mm
(d) Variation of levels at the top +25 mm
" OGCUWTGOGPV"HQT"RC[OGPV"
"
All quantities shall be measured from the drawing, or as ordered by the Engineer, excepting
those required to be provided by the contractor at his cost.
(a) The cutting edge shall be measured in tones based on the net weight of material used in
it, as per A.P.S.S. 110.
(b) The concrete in curb, well steining and well cap shall be measured in cubic meters in
each of the items as per 5.5.4.18. The reinforcements shall be measured in tones separately
in each of the items as per 5.5.4.20.10.

162
(c) The measurement for well sinking shall be made in running metres only irrespective of
clarification of soils met with. The depth of sinking shall be measured from the level specified
in the contract. If no level has been specified in the Contract, sinking shall be measured
from the low water level or from the level at which the cutting edge was laid, whichever is
higher. Pneumatic sinking shall not be paid separately. The quoted rate for well sinking shall
include this cost also.
(d) The quantity of concrete in bottom and top plug shall measured in cubic metres.
(e) The quantity of sand filling shall be measured in cubic metres.
" TCVG<"
a) The Contract unit rates of cutting edge shall cover all costs of labour material, tools, plant
and equipment, including placing in position, sampling and testing, and supervision, all as per
respective section of Structural steel work and as described in this section.
b) The Contract unit rates for concrete in curb, steining, bottom plug, top plug and well cap
shall cover all costs of labour, material, tools, plant and equipment, form work and staging
including placing, in position, sampling and testing, and supervision, all as per respective
section of structural concrete and as described in this section.
c) The Contract unit rates for reinforcement in curb, steining, and well cap, shall cover all
costs of labour material, tools, plant and equipment, including bending to shape, placing in
position, sampling, testing and supervision, all as per respective section of steel reinforcement
and as described in this section.
d) The Contract unit rates for sand filling shall cover all costs of labour, materials, tools, plant
and equipment, including placing in position, sampling testing and supervision, all as described
in this section.
e) The concrete unit rates for sinking shall cover the costs of labour, tools, and
equipment and plant and for all operations and other incidentals for sinking of well including
seating excepting provisions, of pneumatic sinking described in this Section. The unit rates
shall be for, all soils, H.D.R. I & rock and Hard rock. The rate shall cover all testing and
supervision, required for the work.The contract unit rate of material to be excavated
pneumatic sinking shall cover all costs of labour, materials, tools, plant and other equipment
and other incidental and safety provision and supervision required for pneumatic sinking as
per this section.
If any well with tilt and / or shift exceeding beyond permissible values is accepted by the
Engineer, the Contractor shall give a reduction is the rates as follows:
Coqwpv"qh"Vknv"cpf"1qt"Ujkhv" Rgtegpv""fgfwevkqp"qp"
vjg""tcvg*u+""Qt"ukpmkpi"
Tilt exceeding the specified permissible Value but equal to or

5%
within 1 m 60.
Tilt exceeding 1 in 60 but equal to or within 1 in 50 10%
Tilt exceeding 1 in 50 20%
Shift exceeding the specified permissible Value but equal to
or within 200mm. 2%
Shift exceeding 200mm but equal to or within 300

mm. 5%
Shift exceeding 300 mm. 10%.
Penalties for excessive tilt and shift shall be deducted separately.

☼ ☼ ☼

163
"""""""""""""""RCTV"⁄"D"
"J[FTQ⁄OGEJCPKECN"YQTMU"

164
"
"
"
"
SECTION - HM 01
J[FTQ"⁄"OGEJCPKECN"YQTMU"
"
" Ueqrg"qh"Yqtm"
"
The scope of work includes, but not limited to the following:
1. Designing, supply and manufacture, inspection, shop assembly, testing, painting, transportation
etc.
2. Site storage, including insurance transportation and handling, site erection, painting, testing and
commissioning including provision of labour, plant material etc. for the above.
.
3. Handing over to employer/supply of necessary spares of 5 years trouble free operation/supply of
installation of all incidentals not specified but is necessary for proper completion and satisfactory
functioning of the system.
It is not the intention of these specifications to specify complete details of equipment. However, the
Contractor shall supply the equipment which will meet in all respects, the requirements of
employer in regard to performance durability and satisfactory operation. All the equipment
supplied shall conform to the relevant Indian Standards. Wherever, Indian Standards are non-
existent or silent, relevant International Standards (as agreed between the Employer and the
Contractor) shall be followed. The sizes and numbers of units in each case are based upon
employer’s preliminary design and may vary to suit modified site conditions and design
requirements.
Gates for intake structure:
Suitable number of gates for intake structure at the entrance of sump of pump house are to be
arranged.
3040"VTCUJ"TCEM"TCMKPI"U[UVGO"
"
" Fguetkrvkqp"
This specification describes the design, manufacturing, testing requirements for Trash
Rack Raking System to be supplied for cleaning the screens in the fore bay of the main Pumps.
Technical Particulars
One no. movable type raking mechanism shall be provided in each pumping station. The trash-
raking machine shall be automatic. The raked trash shall be stored in a trolley that runs on rubber
wheels.
The raking machine shall be movable type capable of servicing any of the screens in the pumping
station. The raking machine will comprise of the following components:
Skip rake assembly

Hoisting gear & motor
Control Panel
Trash trolley
Moving rails
Drive mechanism for moving raking to any of the pump bays. Necessary
Controls & Instrumentation
Power supply cables, control cables etc.
Hoisting gear incorporated in the head frame will operate a rake assembly, designed to run in
guides located in recesses in the civil work walls at each side of the bar screen and arranged to
clean the screen bars as it is hoisted to deck level.

165
The rake assembly will comprise a rake carriage, fitted with wheels that run in the guides, and
pivotin skip, fitted with replaceable tines, which allows the teeth to swing into engagement with the
screen bars during the hoisting cycle.
As the hoisting continues, debris will be raked from the screen bars and carried up over to the
discharge point where the debris will be cleaned from the skip by a scraper mechanism. Mounted
in the leading edge of the scraper will be a nylon wiper blade.
Nylon rollers mounted on the skip will form the only positive contact points between the skip and
the scraper.
Screenings will be discharged down a fabricated plate into a Trolley in the raking machine.
Control of the upper and lower stop positions will be by means of a rotary cam limit switch driven
from the hoist shaft. Safety switches will be provided to detect slack rope and over hoist.
The hoist shaft will be driven via a shaft mounted reduction gear unit fitted with a flange mounted
electric brake motor. Torque overload protection will be by means of a current sensing device
incorporated in the control panel. The motor will be fitted with anti-condensation heaters and
thermistors.
Removable mesh type guards will be provided fixed to the screen head structure along with
upstream end and each side enclosing the hoist assembly.
Shop Test All items shall be tested & inspected before dispatch as per approved QAP.
Test at site The mechanism shall be tested at site to check its smooth running, noise, vibration and
the parameters as per approved data sheet.
" Icvg"Ugcnu"
"
All gate stoplog units, zero shaft gate, draft tube gate shall be provided with natural rubber /
Neoprene sealing elements in a sections appropriate to the functional requirements and gate type.
In cases where low frictional resistance is necessary, the seals will be provided with a PTFE insert
bonded during the moulding process. Thickness of bottom seal shall not be less than 20mm and
this shall be of wedge type. All corner seals between lintel seals and side seals shall be of
continuous moulded piece. All seals will be clamped to gate units by stainless steel fasteners.
Suitable chamfer shall be provided in the base plate and clamps of seal assembly. The properties
of natural rubber / Neoprene seals shall be as under:
a) Shore Adurometer hardness 65+5

b) Minimum elongation 450%
c) Ultimate tensile Strength (Minimum) 14.5 N/mm2
d) The rubber compound shall not absorb more than 10% by weight, of water in 7 day test
e) The tensile strength of the test specimen, after being subjected to an accelerated ageing
test of 48 hours in oxygen at 70o C and 2.1 N / mm2 pressure, shall be not less than 80%
of the strength of the test specimen before ageing.
" Htkevkqpcn"Tgukuvcpeg"
"
The following frictional resistance co-efficient shall be adopted in the Design of gates and
associated equipment.
Sl. No. Kvgo" Static Dynamic

1. Rubber seal on Stainless steel 1.5 1.2
2. Seals with PTFE inserts 0.2 0.15
3. Roller bearing Factor 0.015 0.01
4. Self –lubricating bearing 0.2 0.15
5. Plain bearings 0.4 0.3
6. Steel on steel 0.6 0.4
7. Brass or bronze on steel 0.5 0.3
" "
" "

166
" Qrgtcvkpi"Gswkrogpv"
"
The capacity of the hoist and crane for various gates and stoplog units be calculated on the basis
of self weight of the gate, weight of lifting beam (where applicable) frictional forces (including static
seal friction, wheel / trunnion friction, hoist friction, silt load etc.) and down pull forces. The hoist
capacity thus arrived shall be increased by 20 percent to cater for reserve hoist capacity.
Similarly in the case of gates designed for closing under self weight, the downward forces closing
the gate while lowering shall be at least 20% higher than the forces opposing down ward motion.
However the sealing pressure shall not be less than the values mentioned in the IS code.
" Icvg"Ugcn"Ngcmcig"
"
The leakage allowance for gate as well as stoplogs and bulkheads shall not exceed the
permissible limits.
" Icpvt{"Etcpgu"cpf"Jqkuvu"
"
Mono/double rail cranes and hoists for handling the various Stoplogs / Trash rack gates shall be
designed and shall conform to requirements of applicable to Indian codes. Cranes will be classified
according to its specific duty, service life and load status gear mechanism. The winding drums
shall have single layer of rope, as far as practical.
Mono/double rail cranes shall be supplied complete with rails equipped with necessary
anchorage to withstand wind and seismic loads transmitted from the gantry structure. Electro-
mechanical hoist shall consist of wire ropes, drums, reduction gear, couplings, brakes, electric
motors, limit switches. Both electromagnetic and thruster brakes shall be provided on hoist drives
where LT and CT drives shall be equipped with electro magnetic brakes. Necessary provisions for
connections to remote control system shall be provided on local control panels.
" Nkhvkpi"Dgcou"
"
The lifting beams for handling the stoplog sections will be of the automatic type, being preset to
release or engage the hooks prior to lowering. Presetting is by manual positioning of a central
counterweight system, and an interlock arrangement prevents premature release of the hooks
during lowering. A probe rod incorporated in each stoplog unit releases the locking arrangement
when the section is fully lowered, enabling the hooks to disengage.
" Tqrg"Ftwou"cpf"Yktg"Tqrgu"
"
The rope drums and wire ropes shall conform to the Indian Standards in general. The ropes shall
conform to IS 2266 improved plow steel and fiber core extra flexible high grade improved wire
rope. The ropes shall have a factor of safety of six (6).
The drums shall be made of cost steel of fabricated from steel plates and shall be reinforced to
sustain concentrated loads due to rope tensions. The drums shall have a diameter not less than 20
times the rope diameter and shall have sufficient length to adopt full length of rope of specified lift
and number of falls, in one layer plus two idle turns at each fastening end and minimum one extra
groove. The drums shall be checked for crushing and combined stress as per IS – 6938.
" Gngevtkecn"Gswkrogpv"
"
All electrical equipment, including motors, starters, control panels, Solenoids and associated
instrumentation shall be of international standard and shall be suitable for the climatic conditions
prevailing at the project site and shall be provided with all necessary anti-condensation heaters
and other protection against the ingress of dirt and insects.
All motors shall be induction type with water tight terminals, anti-friction bearings and built in totally
enclosed fan ventilated enclosures. All motors have speed not exceeding 1500 rpm. Creep speed
motors shall also be continuously rated. All hoists including crane hoists shall be provided with at
least two sets brakes working on different principles viz. Electromagnetic, thruster, eddy current
braking system etc.
All motions shall be provided with limit switches at both extreme ends of travel. For hoist motion

167
the system shall be provided with overload limit switches and slack rope limit switches. Indications
and protections shall be provided on the control panel.
" Kpurgevkqp"("Vguvu"
"
All materials shall be of tested quality and all work performed shall be subject to rigid inspection
and no articles or materials shall be dispatched until all tests, analysis and shop inspection have
been completed or certified copies of reports or results of tests and analysis have been accepted.
Duplicate copies of manufacturer’s test certificates including chemicals analysis and mechanical
properties shall be made available for all materials. In case test certificates are not available for
any of the material the same shall be got tested and only these materials which fulfill the
requirements of these specifications shall be used. From any part / item, it should be possible to
locate its manufacturer’s batch / lot mark, which shall be achieved by transferring the batch marks
before parting the materials.
All castings shall be annealed and forging shall be normalized.
" Ujqr"Cuugodn{"cpf"Vguvkpi"
"
During the course of manufacture, the equipment included in the scope of supply shall be subject
to rigorous inspection and testing.
All components, sub-assemblies and assemblies will be dimensionally and functionally checked
against the relevant drawing.
All gate units shall also be fully shop assembled (with temporary bolting where necessary), and
checked for dimensional and flatness checks with all fitments such as wheels, guides, seals,
bypass valves etc., attached. The correct Center of Gravity shall be established during shop
assembly before final welding of lifting lugs.
Reception frames and guides shall be assembled on the shop floor for dimensional and
straightness checks, also alignment of connecting members with the required tolerances.
In all cases the various connecting parts shall be match marked to facilitate site erection.
Hoisting units shall be fully assembled on the hoist platform and test run to at least 20 minutes and
load tested to 1.25 times the rated capacity. All lifting beam shall be shop assembled and hooks
will be similarly load tested. Automatic engaging and disengaging of lifting beam hooks shall also
be tested in the shop. During test run all the components of the hoist shall be tested for their
performance.
The gantry crane / monorail crane and hoist shall be fully shop assembled and tested to 1.25 times
the rated capacity. The hoist shall be operated for 15 to 30 minutes in slowest speed to
demonstrate that equipment has been designed for continuous duty. The gantry crane shall be
made to travel for a distance of 30 m if so permitted or otherwise the driving wheels shall be
rotated under power, by jacking of wheel carriage / crane.
Trashrack cleaning machine, shall be completely assembled and shall be tested for operation with
load. The hydraulic thruster winches are to be tested for proper operation with load. Simulation
load test at 125% on hoists and gear drive shall be carried out. Raking operation shall be
performed above the deck level.
" Ukvg"Vguvkpi"cpf"Eqookuukqpkpi"
"
All embedded reception frames and support frames etc., shall be erected and checked for
dimensional accuracy and alignment in accordance with the assembly drawing with the required
tolerances and level limits before and after concreting After site assembly of the gate units within
their respective reception frames, all gates will be checked for roller alignment, seal compression
and guide clearances.
The operating equipment will be checked for correct positioning and alignment, and undergo full
functional tests over the operation range of the particular gate, checking operating speeds and
performance of the hydraulic and electrical control systems.
Hydraulic systems will be pressure tested to 1.5 times the maximum rate operating pressure.
Gantry cranes and hoisting winches shall be load tested, all in accordance with standard.

168
" Pqp"Fguvtwevkxg"Vguv"
"
The fabricated gate / stoplog units, embedded parts, penstocks, hoist components and other load
carrying members, shall be subjected to the following Non destructive tests.
" Uvggn"
"
i) Butt welds Radiography 100%
ii) All fillet welds in the gate " "
beam, end plate and lifting Magnetic particle 100%
point
iii) Other fillet welds Magnetic particle 10%

iv) Root runs of important
Dye-penetrant 100%
load bearing joints
"
"
" Ecuvkpi"cpf"Hqtikpi"
"
Castings Ultrasonic Level I SA 603 ASME Sec. V Forgings Ultrasonic SA388 ASME Sec. V 2.3.20
" Uvtguu"Tgnkgxkpi"
"
Trunnion bearing hub casting prior to machining shall be stress relieved, if welded. Yoke girder
and the anchor girders shall also be stress relieved. Elsewhere welded plates thicker than 28 mm
will also be stress relieved. The procedure for stress relieving shall be per ASME section VIII
Division –1.
" Uwthceg"Rtgrctcvkqp"cpf"Rckpvkpi"
"
All exposed and under water steel works shall be sand blasted to at least Sa 2 ½ quality of
Swedish Standards. SIS 055900. The Contractor shall clearly indicate the painting system
proposed by them for under water as well as exposed surfaces of steel works including liners
indicating the type of primers, protective coatings, No. of coats proposed and their dry film
thickness. However, the dry film thickness should be around 70-80 microns for primer protections
and 400 microns (in two coats) for final paintings.
" Igpgtcn"
The Contractor shall include necessary ladders, platforms, handrails in and around gate
installations in order to provide approach for inspection and maintenance. Removable steel covers
shall also be provided on gate openings at deck level wherever required.
Necessary cabling (within this scope of work) for various hoist installations including remote control
system shall be provided by the Contractor without additional cost to the Employer.
Contractor shall indicate the approximate weight of the various components of each gates
and its hoists.
a. Weight of gates / stoplogs / bulkhead

b. Weight of embedded parts
c. Weight of hoists / cranes and its capacity
d. Weight of hoist supporting structure
e. Weight of lifting beams

169
""""""""""""""""" 42" NKUV"QH"K0U0"EQFGU"TGSWKTGF"KP"IGPGTCN"
"
Sl. "
No Description IS
. Number
1 Recommendation of structural design of fixed wheel gates IS 4622

Recommendations for structural design criteria for low head
2 IS 5620
slide gates
Recommendations for structural design of medium & high head
3 IS 9349
slide gates
Code of practice for design of rope drum and chain hoists for
4 IS 6938
hydraulic gates
Code of practice for electric overhead Traveling cranes other
5 IS 3177
than steel works cranes
Code of practice for design manufacture erection & testing of
6 IS 807
cranes & hoists.
Code of practice for use of structural steel in general building
7 IS 800
construction
IS
8 Design criteria for hydraulic hoists for gates
10210
Recommendation for inspection testing & maintenance of fixed IS 7718
9
wheel & slide gates (Part –
Recommendation for inspection testing & maintenance of fixed (Part –
10
wheel & slide gates II)
Recommendation for inspection testing & maintenance of fixed (Part –
11
wheel & slide gates III)
" " IS
Recommendation for Inspection, testing & maintenance of Radial gates & 10096
12 their hoists (Part –
I)
Recommendation for Inspection, testing & maintenance of (Part –

13
Radial gates & their hoists II)
Recommendation for Inspection, testing & maintenance of (Part –
14
Radial gates & their hoists III)
" " IS 7307
15 Approval test for welding procedures (Part – I) (Part –
I)
" " IS 7310

16 Approval testing of welders working to welding procedures (Part –
I)
Approval tests for welders when welding procedures approval is

17 IS 7318
Not required
18 Code of practice for liquid penetrant flow detector IS 3658

170
Code of practice for Ultrasonic tube echo testing by contact and

19 IS 3664
immersion methods
20 Code of practice for magnetic flow detector IS 3703
21 Code for unfired pressure vessels IS 2825
22 Code of practice for radiographic testing IS 2595
23 Code of practice for structural safety of buildings : Loading Std. IS 875
24 Code of practice for plain & reinforced concrete IS 456
25 Criteria for Earthquake resistant design of structures IS 1893
26 Steel wire ropes for General Engg. Purposes IS 2266
"
" VTCUJTCEMU"
"
The structural steel for trashrack bearing plates including anchor plates and bolts shall be
assembled as shown in the approved drawings. All structural steel for trashrack will be shop
fabricated in convenient sizes for transport, accurate positioning and alignment of the bearing,
guides will be required to ensure that the rack sections will properly site / slide. The trashrack
section will be furnished completely fabricated and will require only setting in position as directed
or shown in the drawings. Rack shall be cleaned, painted and installed as shown in the drawing or
as directed.
Each trashrack panel shall be so nearly rectangular that the diagonal dimensions will not vary
more than 12 mm. Each trashrack shall be properly supported on the supported structures
consisting of R.S.J’s, channel, angle as specified in the approved drawings. Line level and centers
of the supported structure shall be properly checked before final placement of trashrack.
Measurements for hydro-mechanical works will be made for making the progressive payments
against the total contract price for the work.
CPPGZWTG"/"CJO"23"
URGEKHKECVKQP"QH"OCVGTKCN"
"
Materials for various components of Hydro-mechanical equipment shall conform to the requirements given
below. The successful Contractor should submit the exact specification of material proposed by them in
this Annexure before execution of work.
Sl. No. Component Material Conform to

Gate, Embedded parts, groove-
1
liner, bonnets etc.
a) Steel Plate Mild steel weldable
quality
b) Rolled section Mild Steel Weldable
quality
2 Main rollers, Guide roller,
Cast steel
Forged Steel
Self-lubricating bearings and “Lubrite” or approved
3
washers equal
4 Main and guide roller axles Corrosion-resistant Steel

171
5 Side Guides
a) Steel plate Mild steel weldable
quality
b) Rolled Sections Mild steel-weldable
quality
Sl. No. Component Material Conform to

Main Roller track Corrosion – resistant
6
steel
7 Side and back roller track Carbon steel
8 Sealing surfaces Corrosion-resistant steel
9 Seal fasteners Corrosion-resistant steel
Structural members of hoist
10
platforms, columns etc.
a) Steel plate Mild steel- weldable
quality
b) Rolled sections Mild steel- weldable
quality
Hoist drums and achieve Steel platge - weldable
11
quality, cast steel
12 Gears Cast steel
13 Pinions Forged steel
Pins, shafts, sheave, axles, less than Cold rolled steel corrosion
75 mm dia above 75 mm dia resistant steel, carbon steel,
14 Forged steel, Corrosion
resistant
steel
15 Wire rope 6 x 37 construction

16 Bearing Pedestal Cast steel
Bronze bush other than Plain bronze
17
specified above
Lifting pins Carbon steel Corrosion
18
resistant steel
Bolts for connecting flange Corrosion – resistant
19
plates of Hydraulic Hoist Steel
Spherical / roller bearings SKF, FAG or approved
20
equal
21 Machine bolts and nuts Carbon steel
Steel plate for penstocks Pressure vessel quality
22
plate
☼ ☼ ☼

172
KK0" RCTV"⁄"E""
GNGNEVTQ⁄OGEJCPKECN"YQTMU"

173
"
"
INDEX
Section No. Description
A)" Equipment Details
1. Pumps
2. Pump Discharge Valves.
3. Dismantling Joints
4. Synchronous Motors & Static Excitation System.
5. Motor Starting Equipment.
6. 11 KV Switchgear Cubicles (Panels).
7. Control & Relay Equipment, Data Acquisition system.
8. LT Switch Gear
9. Station Transformers
10. 220V Battery, Battery Charger and DC Distribution Boards.

11. Station UPS & ACDB.
12. Fire Fighting Equipment.
13. Pump House Lighting (Illumination)
14. EOT Crane
15. Pump House Earthing & Grounding
16. DG Set
17. Pump House HVAC
18. H.T Cables
19. L.T, Control and Instrumentation Cable.
20. HT, LT, Control and instrumentation cable trays lying& termination.
21. Equipment grounding & earthing

174
VGEJPKECN"URGEKHKECVKQPU"QH"
GNGEVTQ/OGEJCPKECN"("J[FTQ/OGEJCPKECN"YQTMU"
"
"
URGEKHKECVKQPU"QH"RWOR/OQVQTU"("GNGEVTKECN"("OGEJCPKECN"GSWKROGPVU"
"
"
EQFGU"URGEKHKGF"
The design, material, construction, manufacture, inspection, testing and performance of the equipment
shall comply with all currently applicable standards, regulations and safely codes in locality where the
equipment will be installed. Minors shall conform lo latest revision of following Indian Standards.
1. IS 325 : Three Phase Induction Motors

2. IS 1271 : Thermal Evaluation and classification of electrical insulation
3. IS 4691 : Degree of protection Provided by enclosures fur rotating electrical machinery.
4. IS 4728 : Terminal marking and direction of rotation for rotating electrical machinery
5. IS 6362 : Designation of methods of cooling for rotating electrical machines.
6. IS 4029 : Guide for testing three phase induction motors.
7. IS 2253 : Designations for types of construction and mounting arrangements rotating
electrical machines.
8. IS 900 : Code of practice for installation and maintenance of induction motors
9. IS 4729 : Measurement and evaluation of vibration or rotating electrical machines.
10. IS 4889 :Methods of determination of efficiency of rotating electrical machines
11. IS 2060 : Dynamic balancing
12. IS 4054 : Air Break Switches
13. IS 2516 : Circuit Breakers
14. IS 10118 : Switch gear and control gear selection
installation and maintenance-code of practice
15. IS 2419 :Panel mounted indicating and recording instruments
16. IS 3042 :Earthing
17. IS 1554 : PVC insulated electric cable for working voltage up to and including 1100V
GO"23"XQNWVG"RWORU"
"
UEQRG<"
"
i) The scope of this section covers design, manufacture, testing at manufacturer’s works
before dispatch, supply, delivery at site, erection, testing and commissioning of adequate number of
Pump –Motor sets of suitable capacity each along with main discharge valve in delivery line (MDV) and
with all associated auxiliary and ancillary equipment, OPU system for MDV, and all other auxiliary
equipment like compressed air, dewatering and drainage, lubrication systems, water and air piping with
necessary instrumentation, control and safety devices etc. complete with all accessories, mandatory
spares, as well as special tools and plant detailed in the specification and in schedule of requirement for
Pumping Station to be constructed for lifting ;:5043"Ewogeu"of water.
ii) The scope of supply shall also include all parts, accessories, and spares etc., which are
required for construction, operation and maintenance of Pump –Motors, even though these are not
specifically stated or enumerated. The corresponding parts of all the Pump -Motors, associated
equipment and spares shall be of same material dimensions, workmanship and finish and shall be
interchangeable.
" "
" "
" "
" "
" "

175
" J[FTCWNKEU"("QVJGT"FCVC"
"
Fkuejctig" <" ;:5043"Ewogeu"
"""""""""""""""""""""""""""""""""""""""""""""Rworu"("Oqvqtu<"Tgswktgf""pq"qh""Rworu"qh"uwkvcdng"v{rg"cpf"ecrcekv{"
"
RWOR"/"MOTOR:
V{rg"cpf"tcvkpi0"
"
i) The pump shall be of vertical shaft, single stage uwkvcdng" hqt" fktgev" coupling to motor of
uwkvcdng" capacity with 42'" over load rating. The direction of rotation shall be anti-clockwise when
viewed from top. Each pump shall be so designed and constructed that all removable parts including
impeller, shaft, guide bearing, shaft seal, guide apparatus etc., can be easily removed. It shall be
possible to repair/replace pump shaft seal without de-watering the Draft tube, for which purpose
additional repair seal shall be provided.
ii) The pumps shall be capable of giving rated discharge of ;:5043"Ewogeu"as directed and decided
by the Department with maximum of rated suitable power input to the motor, at rated voltage and
frequency. The bidder shall evaluate the losses in the water conductor system to arrive the dynamic
head and shall design pump-motors accordingly. The net head and Gate opening at which the machine
gives the best efficiency shall be indicated, while delivering the rated discharge. The pump shall be
designed and constructed to operate satisfactorily with complete safety and without objectionable
vibrations, noise and cavitations at all heads within the range of head variation indicated above.
ii) The maximum discharge and the corresponding Valve opening at minimum and maximum net
head, best efficiency head shall be stated in the offer. Capability of pump for giving higher output shall
also be stated in the offer. Graphical data regarding the gate opening, discharge, efficiency, shall be
furnished along with the bid. The pump shall operate satisfactorily for a variation in capacity up to 125%
of the rated capacity at a total head and at higher frequencies ( 51.5 Hz ). The bidder shall indicate
clearly the suitability of the pump for operation at heads higher than the designed net head for half an
hour to one hour
CHECKING GUARANTEES FROM MODEL TEST RESULTS:
Field test as per IEC form the final basis to establish the fulfillment of guarantees.
The purchaser shall have option of carrying out the field test by the manufacturer. Such tests shall
be to the bidders account.
Model tests as provided in encwug"3032"of this section shall however be carried out by the manufacturer
prior to taking up manufacture so as to satisfy the Employer(purchaser) of the capability of the design to
meet all the guaranteed values. Modification of design, if necessary shall be made so that the
guaranteed performance can be obtained as determined by model tests and manufacturer shall
proceed with only after satisfactory results have been obtained. In case of inability to obtain such
satisfactory results, the purchaser reserves the right to cancel the contract or to accept the same to
subject, to levy of penalty as specified in clause 1.4.2.
" Rgpcnv{"qp"ceeqwpv"qh"hcnn"kp"ygkijvgf"Cxgtcig"Ghhkekgpe{"cpf"Qwvrwv<"
"
For any shortfall in the tested values of rated output and weighted Average Efficiencies (as determined
by the following basis) from the guaranteed values, a penalty shall be applicable at the rate of
Rs.2,50,000(Rupees two lakhs fifty thousand only) per pump for each 0.01'" *" " qpg" " jwpftgfvj"
rgtegpv"+"by which the test figure is less than the corresponding guaranteed figures. The penalties on
account of the output and efficiencies shall be computed separately and the total amount of penalty
shall be the sum of these two. No tolerance limit shall be permissible over the test figures of rated
output. Tolerance on measurement of efficiencies shall be allowed in accordance with the IEC test
code or any other equivalent standard for Field tests of pumps
" Tglgevkqp"Nkokv<"
"
The purchaser has right to reject the equipment if the test values of either weighted average efficiency
(as determined on following basis) or the rated output falls below 3 % of the corresponding guaranteed
figures as per IEC standards.
" Eqorwvcvkqp"Qh"Ygkijvgf"Cxgtcig"Ghhkekgpe{<"

176
"
The weighted average efficiency of the prototype machine shall be determined from the guaranteed and
field test values of the efficiencies at the rated Static head in accordance with, for the purpose of
penalty and rejection limits of efficiencies guaranteed.
" TGEVKHKECVKQP"VQ"OGGV"IWCTCPVGGU<"
"
The bidder shall make good and meet the guarantees again within a period of 4 (Four) months
from the date of witnessing the original tests, should the original test be unsuccessful in meeting
the guarantees. However, no delay in the original delivery schedule shall be allowed due to this
reason.
The penalty or rejection shall be applied if the second attempt is also unsuccessful in meeting the
guarantees.
" ECXKVCVKQP"IWCTCPVGG<"
"
The Bidder shall guarantee the impeller, discharge ring and other hydraulic passage against
excessive pitting caused by cavitation for 60 months from date of commissioning or 12,000 hrs. of
actual operation, whichever is earlier.
Excessive pitting shall be defined as the removal of metal from impeller and other
passages exceeding a weight of W = 0.1D² per 1,000 hrs of operation during the guarantee
periods defined above, where W is weight in kg. and D is the throat diameter of impeller in meters.
The bidder shall indicate the method which he proposes to use for measuring the amount if the
metal removed on account of cavitations, which shall be subject to the approval of purchaser.
If the 60 months guarantee period expires prior to the completion of 12000 hrs. of actual operation,
the bidder shall guarantee, that the weighted loss shall not exceed the value proportional to the
number of hours actually operated.
In case of excessive cavitations being present, the Bidder at his cost shall correct the condition
and rectify and/or replace the part thus affected. The pump after such modifications and repairs
and/or replacements of part or parts shall be subject to the same cavitations guarantee as for the
original equipment.
In determining whether or not excessive pitting has occurred, metal removed by erosion, corrosion
by the presence of injurious foreign element in water or by chipping and grinding preparatory to
repairing the pitted area, shall be excluded. The manufacturer shall adopt necessary
improvements modifications in the designs, manufacturing to minimize the cavitations pitting within
the permissible limit.
" ETKVKECN"UKIOC<"
"
Values of critical sigma as calculated by IEC code or any other equivalent standard on the basis of
model test for pump shall be given in the form of curves efficiency versus sigma for different heads
of operation. Plant sigma curves shall also be plotted on it to clearly show the safety margin
available. Cavitations model tests shall also be given.
" URGGF"TGIWNCVKQP<"
"
The limits on speed rise shall not exceed the values given in the schedule of guaranteed technical
particulars of this section.
" TWPCYC["URGGF"CPF"PQKUG"IWCTCPVGGU<"
"
The maximum runaway speed of the pump under any combination of cistern water and
Forebay water conditions shall be stated. The pump shall be capable of running safely at the
maximum runaway speed, without damage to its parts for not less than 15 minutes, on every such
occurrence. The duration for which the pump can run at runaway speed safely shall be stated in
the offer.
Maximum noise level of operation shall be 120 decibels, and the guaranteed value shall not
exceed 120 decibels in the machine hall. The bidder shall supply necessary instruments for
recording & analyzing vibration levels & shall include these in the bid.

177
" OQFGN"VGUVU"
Model test shall be performed by the bidder (before commencement of manufacture of the
prototype) in the presence of the Purchaser’s representative to demonstrate the efficiency and
other guarantees as well as requirement of specification for the performance of pump shall be met.
Model tests shall be carried out as per IEC test codes or any other equivalent standards which is
more stringent.
The hydraulic parts of the model shall be completely homologous with the corresponding
parts of the prototype units as per relevant IEC recommendations or any other equivalent standard.
Hydraulic performance Tests shall be made to determine machine characteristics. Values

of unit torque and unit discharge shall be plotted against unit speed. These tests shall include
determinations of capacity, efficiency, cavitations limits, hydraulic thrust, runaway speed etc., and
shall be in accordance with relevant IEC or other equivalent test codes.
In deriving prototype step-up efficiencies from model tests data formula given in relevant
IEC test or any other equivalent standards shall be used. Similarly, head-discharge relationship
shall be stepped up from the model by the affinity law with an additional correction to the
discharge as per relevant IEC code or any other equivalent standards recommendations.
Cavitations limits of critical sigma shall be determined from the model test.
Other model tests as considered desirable to check guarantees or determine operating

characteristics under unusual conditions shall be carried out as agreed jointly between the
purchaser and the bidder.
Copies of model test reports giving performance of pump operation shall be furnished after
completion of model tests to Engineer-in-charge.
The manufacture of prototype pump shall be commenced on approval of model test

results by the purchaser.
Detailed graphs regarding plant sigma and machine sigma shall be finalised at the time of
model test.
Photographs and sketches of cavitations phenomena shall be furnished.
" IGPGTCN"CTTCPIGOGPV"QH"RWOR<"
"
The pump shall be so constructed that all removable parts including impeller, shaft, guide
and thrust bearings and supports, gate-operating mechanism etc., can easily be removed. The
design of pump shall permit a vertical movement of the impeller shaft by an amount sufficient for
adjustment of the thrust bearing and for clearing the joints at the coupling of the pump and motor
shaft.
The bearing arrangement of the pump/motor shall be so designed as to ensure trouble

free operation of the unit and permit repair/replacement of parts without disturbing the adjacent
components.
All equipments shall be readily accessible for operation and maintenance. All necessary
walkways ladders, hand rails, chequered plates required for the equipment covered under the
specification shall be provided.
" EQPUVTWEVKQPCN"HGCVWTGU0"
"
" Rwor"korgnngt"
"
The impeller shall be designed and constructed to safely withstand, without damage, the
stresses resulting from running at the maximum runaway speed under conditions of maximum operating
head with no input power to motor. All surfaces of the impeller which are in contact with moving parts
shall be finished smooth, and shall be free from hollows, depressions, cracks, or Scheme ions that
might cause disturbances in the flow.
" UJCHV"
"

178
1..13.1 The shaft shall be of forged carbon or heat-treated alloy steel machined all over and with
integral flanges for bolting to the impeller and to the motor rotor shaft. An integrally forged collar
accurately machined and polished shall be provided forming the guide-bearing journal. The shaft shall
be able to withstand short circuit and other incidental extraordinary stresses. The upper flange of the
shaft shall be machined for coupling to the motor.
1.13.2 A removable and renewable abrasive and corrosion resistant steel sleeve shall be
provided where the shaft passes through pump main packing box.
" ECUKPI"CPF"UVC["EQNWOP<"
"
The casing (Spiral casing & Draft tube) to be formed in the concrete of the pump house
substructure shall be furnished by the bidder. Piping and fittings to be embedded in the concrete
work of the pump shall be supplied by the bidder. These shall include piping and valves, grating,
covers, etc., for (i) emptying pump casing and draft tube. (ii) man hole with bolted cover for access
.
The stay cone shall be shipped in one complete assembly if within transport limitation; inner stay
cover shall be assembled with the stay vane by welding at site. The stay ring shall be sectionalized for
convenience of transport and handling, the various sections shall be provided with suitable flanged and
bolted joints. Each of these sections shall also be provided with eyebolts and lugs for attaching slings
for handling. Sufficient number of supporting brackets and machined pads for the application of jacks
and corresponding number of suitable jacks and lugs with hold down rods and turn-buckles shall be
provided for supporting, leveling and holding the stay vane in position during erection. Any other
accessories required for convenience of erection of the stay ring shall be supplied by the bidder.
" IWKFG"DGCTKPI<"
"
The main guide bearing shall be of self lubricated journal type lined with Babbitt metal divided into
two sections for ease of maintenance, located at the impeller adjacent to its stuffing box The design of
the guide bearing shall be such that under any conditions of operation within the range of the head
water and tailrace water levels, no water shall enter the bearing. The temperature for alarm and trip out
for high bearing temperature shall not be higher than 65 degrees centigrade & 70 degrees centigrade
respectively at rated operating conditions.
The bearing shall be capable of safe operation for a period of at least 15 minutes without any
damage under the following conditions.
i) After the failure of the lube oil coolers water supply, with the pump operating at rated capacity and
rated speed.
Under maximum runaway conditions with cooling water supply available.
Bearing and oil temperature detectors, level indicator & level switch and signalisers shall be provided.
The contacts for safety and other control devices shall be suitable for 220 Volts DC/DC voltage
available in pump house. Suitable top and bottom labyrinth seals shall be provided to prevent escape
of oil vapors into the bulb.
The first fill of oil plus 10% in excess shall be supplied by the bidder in non-returnable drums. The
bidder shall indicate quantity and pressure of cooling water required, quantity of oil, specification of oil
etc. in the bid. The oil shall be normally available in India for replenishment or replacement in future.
High-pressure oil injection device for start/stop of the machine shall be provided so as to secure
lubrication of the bearing at low speed.
" UJCHV"UGCN<"
"
The main shaft seal shall be of the carbon ring type/ ring type segmental carbon seal with adhesive
resin sea only l provided around the shaft where it passes through pump inner cover and shall be so
designed that it can be adjusted without disturbing the guide bearing. It shall prevent the leakage of
water at stand still and under all conditions of operation. An emergency isolating seal of inflatable
rubber type or equivalent for maintenance of the shaft seal without dewatering the machine shall be
provided, as the water is likely to contain considerable silt necessitating frequent replacement of shaft
seal. Necessary instruments, cooling arrangement and safety devices for the shaft seal such as flow
relay, pressure gauge, wear-indicator etc., shall be provided.
Leakage water from the carbon seal shall be led and drained out by gravity. In order to improve the life
of the shaft seal, duplex filter and hydro cyclone (Sand separator) shall be provided by bidder which

179
should be capable of working continuously as a normal source of supply of water to shaft seal. The
shaft seal shall be easily accessible for inspection adjustments/ replacements of the sealing rings. The
bidder shall indicate quantity, pressure, and purity of seal water required.
" URKTCN"ECUKPI<"
Spiral casing shall be fabricated from steel plates in suitable number of transportation sections
It shall be fully assembled in manufacturers works and fitted to full scale dummy stay ring. Each section
shall be match marked for dismantling for transport.
The spiral casing thickess shall be such that it will withstand 1.5times the maximum pressure.
Number of spiral segments shall be as minimum as possible subject to transportation limitations.
" QWVNGV"RKRG<"
Outlet pipe shall be of fabricated from steel plate with necessary manhole, drain connection
etc. it shall be edge prepared for welding to delivery line at site.
RKV"NKPGT<"
"
Pit liner shall be fabricated from steel plates in suitable number of sections. The pit liner shall extend to
bottom of motor barrel and shall cover the complete pit. Necessary arrangement for pit lighting shall be
made. All fittings necessary for pit Illumination shall be provided.
" FTCHV"VWDG"NKPGT<"
The draft tube liner shall be fabricated of welded steel plate consisting of a heavily ribbed cone.
The draft tube liner shall be divided into suitable sections for transport and for handling during
erection and shall be in ready condition for welding at site. Its length shall extend up to a point where
the average velocity of water is 1.5Mtrs/sec.
Specifications and quantity of the welding electrodes required and the welding sequence of draft
tube liner shall be indicated by the bidder.
The draft tube liner shall be assembled and match-marked in the manufacturing shop for
convenience of proper assembly and alignment at site. Suitable spiders as the reinforcement during
pouring and curing of concrete and transportation shall be supplied.
Off-take piping connections with in line valves for dewatering of the draft tube shall be provided.
The bidder shall provide one aeration valve of suitable size mounted on the upstream side of each draft
tube gate for facilitating dewatering operation. Adequate stiffening ribs, anchor rods, turn buckles;
support feet and foundation bolts shall be supplied for anchoring the liner securely into the concrete and
for leveling it in place. Adequate number of suitable openings shall be provided around the liner for free
passage of air and grouting material during concrete placing. Piezometric taps shall be provided at
suitable locations for measurement of pressure/vacuum in the draft tube. Pipe nipples of suitable design
shall be welded to the liner for connections to the float switches.
" RWOR"RNCVHQTO."YCNMYC[U."TCKNKPIU<"
Pump platform, walkways, comprising of chequered plating, railings, ladders, etc. complete with
supporting steel work shall be provided in the pump pit.
" FTCKPCIG"("FGYCVGTKPI<"
"
The pump manufacturer shall design and supply complete equipment for draft tube dewatering and
drainage system.
Ftckpcig"
"
The system shall be suitable for removing any leakage that may occur within pump and pump house
area requirement of capacity work redundancy shall be design duly taking in to consideration leakages
from pump and seepage in wells of depth flow of on fluming required Necessary piping to carry the
drainage water to station sump shall also be provided.
Fgycvgtkpi"Rkrkpi"
"

180
Unit dewatering piping with valves required for emptying of draft tube into the dewatering gallery
shall be provided by the bidder. Suitable size of the dewatering pipes and valves shall be provided.
The system for pumping out the water from the sumps shall also be arranged. The dewatering and
drainage system shall be separate and shall be common for all the units. The equipment for each of
the dewatering and drainage system shall comprise100% redundant motor driven Submersible/Verticle
pumps associated piping, valves, float switches, suitable controls, accessories etc. required for
completeness of the system. The motors shall be suitable for 415 V, 3 Phase 50 Hz, AC supply and
rated for continuous duty. They shall be suitable for continuous starting and stopping duty. The motors
shall be in complete form with their star/Delta starters depending upon the capacity, over load
protection and single phase preventing devices, control gear for starting and stopping both
automatically through the contacts of adjustable level sensing devices to be installed in the sumps.
" Eqqnkpi"Ycvgt"Rkrkpi"("Gswkrogpv<"
Cooling water required for the pump-motor, and other equipment have to be pumped from Forebay
through pumps and strainers and shall be arranged by the bidder. The pressure required at the inlet
and outlet of the oil/air coolers shall be indicated by the Bidder. All connections necessary piping,
fittings, valves, flow relays, pressure gauges etc. and other devices required within and out side casing
and for connecting to the discharge pipe shall be arranged by the manufacturer. Piping arrangement for
discharge of cooling water outside the pump access shaft shall also be arranged. The quantity, purity
and inlet pressure of cooling water required for the pump bearing shaft seals, impeller labyrinths and
any other components etc. that may require water for cooling, or lubrication shall be indicated by the
bidder. Fine strainers required for shaft seal cooling water shall be provided by the bidder which shall
be capable of working continuously as a normal source of supply.
The cooling system shall be so designed that back flushing shall be possible by reversing the
direction of flow of cooling water to avoid clogging of cooler pipes.
" Okuegnncpgqwu"Rkrkpi"cpf"Gswkrogpv<"
"
The bidder shall supply all other miscellaneous equipment like air, water, and oil piping along with
their accessories directly associated with the units. Such piping shall be the various pump drain piping;
air inlet piping, controller and lubrication oil supply and return piping, etc. Suitable steel pipes shall be
provided for all embedded piping. For connection to the exposed piping and for erection/replacement,
flanged connections shall be provided.
30470"JKIJ"RTGUUWTG"EQORTGUUGF"CKT"U[UVGO<"
i) A Common high-pressure compressor air system with a common bus to meet the requirement of
allpumps with one additional compressor as stand by shall be provided.
ii) Equipment common for all pumps shall be brought under one head as station auxiliary.
iii) The system shall be provided with suitable pressure switches for automatic start/stop controls of
compressors and indication of low and high pressure in the common air receiver.
iv) The air receiver shall conform to the requirements of ASME code for unfired pressure vessels
(Section-VIII) or any other equivalent code.
v) The air receiver shall be provided with pressure gauges, pressure switches, safety valves, air inlet
and outlet connections, manhole and drain and moisture trap connections etc.
vi) The high-pressure compressed air system shall be capable to supply pressure air requirement
for motor brakes, and auxiliary inflatable seal for the pump shaft seal
vii) All the piping, valves, pressure switches, pressure reducers etc. required for the motor brakes and
inflatable seals also are covered in the scope of supply.
KPUVTWOGPVCVKQP"CPF"EQPVTQNU"HQT"RWOR"CPF"RWOR"EQPVTQNNGT.
Instrumentation, alarms, safety devices and controls necessary for automatic control,
monitoring and efficient operation of the pump with its associated equipment shall be supplied by
the manufacturer so as to constitute a complementary part of the complete and coordinated set of
such instruments, gauges, controls and safety devices required for supervision and controls of the
unit during normal running and in emergencies.
Tentative requirements of the instrumentation etc. are given in the schedule of

requirement . The Bidder shall however, offer any additional instruments and safety devices which
the bidder considers, necessary for the unit and the bidder shall guarantee the sufficiency and

181
adequacy of the provisions in this regard. The Pump-motor is normally started from the SCADA
system in the control room and brought to synchronous speed and then synchronized with the grid
and pumping of water is done. In general the instrumentation and control scheme shall be such as
to provide for manual mechanical control, manual local electrical control and automatic remote
control and emergency shut down. The local electrical control and emergency shut down from unit
control panel( Local control panel) and the remote electrical control from unit control board / MMI
panel to be mounted in the control room shall be provided.
All necessary indicating instruments, gauges and controls etc. for the pump shall be
mounted on the unit control board and wherever necessary on unit control panel. All temperature
indicating/recording instruments, associated relays, certain electrical instruments on the unit
control board shall be provided by the manufacturer.
For remote control of the units from the main control room, all necessary items of the
controller and also alarm/safety devices shall be provided on the main control panels in control
room. The controller controls and indicating instruments shall be provided. The control which are
provided both on the unit control board/Machine control panel and the controller cabinet (Main
control Board) shall be so interlocked electrically as to eliminate the possibility of simultaneous
operation of any control from both the boards.
One set of apparatus for measurement and recording of the pump discharge pressure
shall be supplied with each pump. The apparatus shall be complete with all necessary instruments,
piezometers, tapings, interconnecting tubing etc. and shall be calibrated at the time of efficiency
and out-put tests on the pump.
One set of Ultrasonic transducer type water level transmitter and indicator/recording instrument
shall be provided in Forebay. Set of vibrating monitoring system with required equipments for the each
pump shall be provided.
" Rwor"eqpvtqnngt"
Pump- Vibration Monetary system with necessary equipment Speed System devise:
Toothed wheel with 2 sets of providing switch for serving of speed shall be provided deriving the
speed and serving of speed relay.
" URGEKCN"VQQNU."UNKPIU."EQPUWOCDNGU"GVE0"
"
All special tools, slings, lifting devices, jacks, turn-buckles, foundation plates, bolting
materials etc. required for assembly, erection, dismantling of the pump, and other equipment of
bidder’s supply shall be included by the bidder. A list of the special tools and equipment required
for assembly/erection and maintenance of pump components as listed in “Schedule of
Requirement”, item- 4 shall be supplied. First filling of the controller and lubrication oil with 10%
spare capacity, for pump shall be supplied by the manufacturer and the brand and grade of the oil
shall be specified.
" URCTGU"
"
Spare parts for the pump as required and desired by the employer for successful commissioning
and maintenance along with the main equipment. All spare parts supplied shall be interchangeable with
and shall be of the same material and workmanship as the corresponding parts of the equipment. The
spares shall be supplied along with the first unit. The bidder shall also indicate additional spares
considered essential for five (15) years normal operation and maintenance.
TESTING DEVICES AND INSTRUMENTS FOR TESTING DURING ASSEMBLY, ERECTION AT
SITE AND FOR FIELD ACCEPTANCE TESTS
Testing tools and equipment required for testing during assembly/erection at site and all instruments
and devices required for field acceptance tests for fulfillment of efficiency and output guarantees, shall
be supplied.
" UJQR"CUUGODNKGU"CPF"VGUVU"
The first pump shall be completely assembled in shop and properly match-marked and
dowelled to ensure correct assembly and alignment in the field except that where necessary
suitable dowels shall be furnished for insertion after field assembly and drilling.
In the case of subsequent pumps, part assemblies to the required extent shall be done and
match marked to avoid any problem of matching during erection at site.

182
The bidder shall give a list with details of the shop assembly tests to be performed on the
components of the pump such as impeller, guide bearing, mechanical seal etc. controller and other
accessories etc. These shall be subject to the approval of the purchaser.
The purchaser or his authorized representative shall have access to the manufacturer’s
works for all purpose of witnessing the manufacture, Inspection of various assemblies and for
testing of all components. The equipment shall be assembled and shop tested in the presence of
the purchaser or his authorized representative, prior to dispatch. Any work found defective or
unsatisfactory shall be rejected.
The bidder shall conduct non-destructive tests on components of pump.
" HKGNF"CEEGRVCPEG"CPF"QVJGT"UKVG"VGUVU"
"
Hydro pressure tests, leakage tests and operation tests where applicable shall also be
performed on components such as the pump components, pressure tanks, , sump tank, pumps,
motors etc.
The manufacturer shall furnish a list of all the field tests to be performed during site
assembly and erection of the pump prior to commissioning.
Field Acceptance tests shall be performed on the fully erected pump-motor units to
determine the actual performance of the unit vis-à-vis the guaranteed performance. The field
acceptance test shall be performed as per IEC test code for Hydraulic pumps or any other
equivalent standard.
The pump shall be given a over speed test for a period of 15 (fifteen) minutes to
demonstrate their ability to withstand successfully the mechanical stresses and hydraulic
performance incident to maximum runaway speed at an effective maximum head with Discharge
Valve fully open. The cost for any component replacement/rectification that may be required shall
be to the account of manufacturer.
" FTCYKPIU."FCVC."OCPWCNU"GVE0."CPF"FQEWOGPVCVKQP"VQ"DG"HWTPKUJGF"D["VJG"
DKFFGT"
"
The bidder shall furnish all drawings, data, manuals and other necessary literature in six copies.
The Bidder shall, in addition, supply the documentation for the design and manufacture of the pumps as
given below:
i) Supply of complete information on Scheme design including basic data on Scheme

information, model test report, characteristic curves etc. for operation.
ii) Supply of detailed design drawings and calculations, strain gauging results, computer
programmes, plate development data for draft tube assembly, dimensional tolerances particulars
iii) Complete specifications of materials. Copies of specifications relating to inspection and testing
of material and finished components
iv) Detailed manufacturing drawings for various pump components and information.
v) Tooling information.
vi) Recommended list of suppliers for supply of components.
vii) All information necessary for co-ordination of station and control equipments.
viii) Drawings clearly showing the various components/ assemblies of the pump,
equipment draft tube,Spiral Casings, Bearings etc. in plan and elevation.
ix) Layout drawings of the pump house both in section and plan showing the overall dimensions and
layout of the pumps, auxiliaries, general run off pipes etc. clearly indicating unit spacing dimensions of
draft tube etc. and all important elevations.
x) Comprehensive operation, maintenance and installation instructions along with O&M manuals of
all bought out items.

183
xi) Supply of dimensional drawing of all the vital hydraulic passages. No load to full load pump
performance curves, efficiency and cavitation characteristic curves. Plant and machine sigma curves for
pump operation.
xii) A complete list of equipments, Auxiliaries etc. covered in the offer.
xiii) Schematic drawings for electrical controls, instrumentation and Hydraulic controls.
xiv) Physical and schematic drawings and descriptive literature on the Pump controller and control
mechanism.
The bidders shall furnish all the data, especially guaranteed and other technical particulars called
for in the schedules and also include their experience in the manufacture, erection, testing and
commissioning of pump giving details of their technical particulars. Any offer lacking complete
information in this respect is likely to be rejected
Vtckpkpi"qh"gornq{gt‚u"gpikpggtu"
"
The bidder shall arrange training for 6 engineers of the purchaser for a period as mutually agreed upon
during the design and manufacture of the pump at the manufacturer’s design and drawing office and
manufacturing shops to familiarise with all aspects of design and manufacture of , associated
auxiliaries, control systems etc. All expenses including to fro, lodging and boarding charges for training
the engineers of the purchaser shall be borne by the bidder.
" Eqorngvgpguu"qh"gswkrogpv"
"
All the fittings and accessories of the pump and associated auxiliary and ancillary equipment
though may not have been specifically mentioned in the specification but are usually necessary for
completeness of the above equipment shall be deemed to be covered by the specification and shall be
indicated and furnished by the bidder with out any extra cost to the purchaser.
Fgxkcvkqpu"htqo"urgekhkecvkqpu"
The deviations from the specification shall be listed in the Annexure, absence of which it shall be
presumed that the provisions of specifications are completed with by the bidder.
30570"UEJGFWNG"QH"TGSWKTGOGPVU"
Kvgo"Pq030" Rwor"
Suitable type of pumps with required capacity discharging 983.21 cumecs.
Qpg"impeller of stainless steel and cast steel boss complete.

Qpg"shaft of forged electric furnace steel properly heat-treated and forged with connecting flanges
at both ends, keys coupling bolts, nuts, covers etc. for connecting to the impeller and to the auxiliary
shaft and motor rotor.
Qpg"Set of guide bearing of oil-lubricated type with bearing housing and with temperature detector,
temperature detection relay, oil piping, pressure gauges, cooling water piping, water flow indicators
differential pressure relay and other accessories.
Qpg"Stuffing box/Mechanical seal with sealing water piping, differential pressure relay, and water
flow indicators, for alarm annunciation in U.C.B. and local indication.
Qpg"Draft tube of steel plate suitably sectionalized and equipment for assembly of sections access
door with hinged cover and provision for connecting to discharge ring.
Qpg" Set of embedded piping including leakage water drain piping, pump sets and other
miscellaneous piping.
Qpg"Discharge ring with a provision for connecting to the draft tube on one side and to the guide
vane supporting cover on the other side with necessary connecting bolts etc. A manhole with bolted
cover for access shall be provided in the discharge ring.
Qpg"Stay ring of cast steel or welded plate steel, which shall be embedded in the concrete.
Qpg" Inner stay vane welded with stay column and one outer stay vane with drain piping,

184
peizometer tapings.
Qpg"Speed indicator motor.
Qpg" complete system of equipment, piping, connecting pipes, valves, bends, drains etc. for
cooling water, oil and High-pressure compressed air systems for pump and controller equipment.
Qpg"complete system of draft tube, drainage and dewatering system.
Qpg"Set of water level indicator for indication of cistern water levels which are common to all the
three units with instruments/transmitters, sensing element, piping, valves, complete system for
monitoring the reservoir level. The wells for water level sensors and wiring materials between each
equipment shall be supplied.
Vyq"Sets of erection tools common to all the three units.
Qpg"Set of special tools, slings and consumables etc.
Qpg" Set of tools and plant for maintenance of the plant to be provided immediately after
commissioning of pump-I for operation & maintenance.
GO"24<Rwor"Fkuejctig"Xcnxgu"
Igpgtcn<" Each Metallic Volute pump shall be provided with One Hydraulic Actuated & One Electric
Actuator Operated Butterfly Valve.
Valve diameter shall be matched nearest to Spiral casing out let diameter.
" <"J{ftcwnke"Cevwcvqt"Qrgtcvgf"Dwvvgthn{"Xcnxg<"
V{rg"cpf"fguetkrvkqp"
"
Each pump shall be provided with oil pressure operated butter fly valve or through flow type
valve, and oil pressure operated needle valve or sluice valve as by pass use. The valve shall have
maximum capacity to allow maximum flow of pump discharge. The inside diameter of the valve shall be
recommended by the bidder. The valve shall be so designed as to be capable of closing from fully
opened Position under the condition of maximum flow at every head with minimum oil Pressure
supplied to servomotor.
The opening and closing time of the valve shall not be more than 80seconds
including the operating time of bypass valve with normal operating pressure.
Amount of leakage passing through the gaps shall not exceed 5 litres/min. under the Static
head. including leakage through the bypass valve.
" XCNXG"DQF["
"
Valve body shall be fabricated of rolled steel plate welded structure or made of steel casting, and shall
be sectionalized to suit transportation limitations if any. Each section shall be jointed at site by flange
and bolts with sufficient Strength to with stand the maximum hydraulic pressure .as well as to withstand
the maximum transient head without any distortion or deformation. Both ends of the valve body shall be
provided with grooves for grease lubrication.
The bearings shall be provided with necessary packing glands to prevent inflow of sand or other
foreign material contained in the water.
The valve shaft shall be horizontal type and the bearings shall support the full weight of
the valve disc and shaft, and assure smooth opening and closing operations. The bearings shall be
suitable for lubricating with grease from the grease supply device. All bearings shall be so constructed
that the replacement of the liner and packing can easily be carried out.
The joint between the valve and the spiral case shall be made by flanges packing and shall
be free from any leakage. The Contractor shall furnish all the bolts, nuts, packing and other necessary
and bolts for making perfect tightness of the joint. Necessary connecting pipes, flanges, bolts, nuts,

185
packing and other required parts shall be furnished by contractor. The valve body shall be provided
with a set to mount the bypass valve.
Slip joint/Dismantling joint shall be provided as required for dismantling of valve without
dismantling other arrangement.
" XCNXG" FKUM"

"
The valve disc shall be made of carbon steel casting or fabricated of rolled steel plates.
The disc shall be designed with sufficient strength not to cause any distortion or deformation nor to
cause any abnormal vibration when the valve is in open position or during operation. The disc shall be
supported by forged steel trunnions through the disc. On the peripheral surface of the disc a rubber ring
shall be provided to seal off leakage together with a stainless steel seat provided on the valve body
inner surface. The rubber ring shall be firmly fixed to the valve disc by metal fitting. The fitting bolts shall
be made of stainless steel. The design shall fabricate easy renewal of the rubber ring on the spiral case
side with the valve in its position
" D["RCUU"XCNXG"
"
Bypass valve shall be designed to assure the least amount of corrosion due to cavitation and
cause the least noise or vibration during operation.
Metal sealing shall be provided to obtain a leak-proof seal when the valve is closed.
The operation shall be provided to obtain a leak-proof seal when the valve is closed. The operation of
the bypass valve shall be carried out by oil pressure commonly used for discharge valve. One end of
the bypass valve shall be connected to the seat provided on the discharge valve body and a manual
gate valve shall be provided on upstream of the hydraulic operated bypass valve. The valve shall be
of such construction to permit easy manipulation by one man. The other end shall be connected to the
seat provided. The valve shall be made of stainless steel.
40306EQPPGEVKQP"VQ"RKRG"VQ"FGNKXGT["NKPG"
"
In order to facilitate erection of the discharge valve, connecting pipe between the discharge
valve and the delivery line shall be furnished. The connection pipe shall be fabricated with rolled steel
connection between delivery line and connecting pipe at a suitable distance away from the pump
center line shall be done by welding at site . Specifications of material for connecting pipe shall be
determined after award of contract. Particulars of the connection shall be decided after award of
contract. The connecting pipe shall be provided with pipe.seats and taps for delivery line drain ,
pressure gauge pipe etc. The location and inside diameter of those pipe seats and taps shall be
decided after award of contract.
" Fkuejctig"xcnxg"qrgtcvkpi"ogejcpkuo"
"
Discharge valve operating mechanism shall consists of servomotor ,rod , link , and lever. The
cylinder and head of servomotor shall be made of carbon steel casting or rolled steel for welded
structure. The servomotor piston shall be made of carbon steel casting or cast iron. The operating
mechanism , including that for the bypass valve shall be provided with manual locking devices which
can lock both the inlet and bypass valve when they are closed. When the valve is locked, both opening
and closing operation by oil pressure shall be blocked
Operation of the valve shall be such that ,in opening, the bypass valve is opened first and the
discharge valve shall be opened after the delivery line is filled with water and , in closing ,the discharge
valve is closed first and the bypass valve is closed after the discharge valve is closed.
The bypass valve shall be provided with a hydraulic oil distribution valve to establish a condition to
open or close the discharge valve in conjunction with the operating .
Two limit switches shall be provided for the discharge valve . Each limit switch shall be provided
with two normally open auxiliary contacts and two normally closed auxiliary contacts.
A scale plate and a needle shall be provided to indicate the discharge valve position in
percentage of 100 , when the valve is fully open.

186
" Rkrkpi"cpf"xcnxgu"
"
The pipes, valves flanges, bolts, nuts, packing’s, pipe supports and other necessary
accessories for inter connecting the equipment specified in the specifications shall be furnished by the
contractor so that the equipment specified herein can function as a complete set. The automatic valve
and throttle valve for water drain for delivery line shall also be supplied by the contractor. The automatic
valve shall be driven by 50 Hz, A.C 415 volts. and shall be provided with necessary control gear.
" FKUEJCTIG"XCNXG"QKN"RKRKPI"CPF"XCNXGU"
"
All valve oil piping and valves complete with flanges, bolting materials, gaskets; packing etc.
required for inter-connections between the various equipment shall be included in the offer. All piping
shall be steel, suitable for maximum oil working pressure. All valves shall be cast or forged steel valves
having flanged ends.
" Hqwpfcvkqp"ocvgtkcnu"
"
The contractor shall furnish all foundation materials required for installation of the
discharge valve including foundation bolts and nuts , base plates or sole plates.
" Rckpvkpi"vq"vjg"kpvgtkqt"uwthceg"qh"vjg"Fkuejctig"xcnxg"
"
All surfaces of water passages of the discharge valve shall be shop coated with two
coats of tar epoxy resin paint
" Gngevtke"Cevwcvqt"Qrgtcvgf"Dwvvgthn{"Xcnxgu<"
Butterfly valves shall be of flanged construction and shall be complete with actuating mechanism,
matching counter flanging, bolts, nuts, gaskets, lifting lugs, sole plate for supporting feet in the valve
body etc. The butterfly valves shall be supplied from such manufacturers who have supplied at least
two (2) nos of butterfly valves of size 2000mm NB and above which are in successful operation for at
least two (2) years as on date of bid opening.
Contractors shall furnish this information along with the bid.
" FGUKIP"1"EQPUVTWEVKQP"1"OCVGTKCNU"RCTVKEWNCTU"
The valves shall be designed for the design pressure / temperature as specified and in accordance
with IS7326/BS EN 593. The vales shall be suitable for installation in any position (horizontal / vertical
etc.).All valve components and accessories of the same type shall be perfectly identical in size and
material so as to guarantee interchangeability of the parts. This specification is valid also for the spare
parts. The actuator-operated valves shall be designed on the basis of the following prescriptions.
The internal parts shall be suitable to support the stresses due to the actuator, the valve-actuator
unit shall be suitably stiff so as not to cause vibrations, misalignments, etc. All flanged ends shall
comply with the standard specified. The valve flanges shall be flat faced. The Contractor shall furnish
the coefficient of capacity of each valve (CV in metric units) and the characteristic curves. Necessary
shaft seal shall be provided and adequately designed to ensure no leakage across the seal. This seal
shall be designed so that they will allow replacement without removal of the valve shaft.
The operating mechanism shall be mounted directly on or supported from the valve body. The
Sealing ring on the disk shall be continuous type and easily replaceable. Rubber seal shall be fitted on
the periphery of the disc by clamping between the disc and clamping ring. The seal design shall be T
type and shall be held in machined grooves on the disc and clamping ring. Seal design with clamping
bolts passing through seal shall not be acceptable. The shaft shall be solid type and shall pivot on
bushings. Bushings/sleeve type bearings shall be contained in the hub of valve body.The material of
bearing shall be self-lubricated type with low coefficient of friction that does not have any harmful effect
on water and on valve components. Bearing shall be provided beyond the shaft seal. The housing for
this bearing shall be rigidly attached to the valve body.
The minimum length of the disk hubs shall be at least 1.5 the diameter of the shaft or of the stems.
The shaft shall be connected to the disk through keys or taper pins or screws of stainless steel. The
connections shall be designed so as to avoid looseness during the operation; moreover, they shall be
provided with suitable disassembling systems. The design of the shaft shall be such that it will safely
sustain maximum differential pressure across the closed valve. The shaft and any key (taper pin or
other) for transmitting the torque between shaft and disk shall be capable of with standing the maximum
torque required to operate the vale.

187
The disc shall rotate from the full open to the tight shut position. The disc shall be contoured to
ensure the least possible resistance to flow and shall be suitable for throttling operation. While the disc
is in the throttled position, valve shall not create any noise or vibration.
All butterfly valves shall have permanent arrow inscription on the valve body indicating direction of
flow. All valves shall be complete with:-graduated position indicator (located in a visible place for the
operation).Adjustable mechanical stop limiting devices to prevent over travel of valve disk in open and
closed position.Valves shall have integrally cast supporting feet.
Cevwcvqtu"qrgtcvgf"xcnxgu"
Actuators will be with Limit and Torque switches for either end of travel for control and interlocking
purpose.The characteristics of the actuators to be located on the valves are indicated in the actuators
specification.
Should the actuator be located on the control column, all connecting accessories shall be supplied
(extensions, joints, articulations, etc.). The valves 350Nb and above shall also be provided with hand
wheel drive arrangement suitable for manual operation. Manual operation of valve shall be through
worm and gear arrangement having totally enclosed gearing with hand wheel diameter and gear ratio
designed to meet the required operating torque. It shall be designed to hold the valve disk in
intermediate position between full open and full closed position without creeping or fluttering. Adjustable
stops shall be provided to prevent over travel in either direction.
Limit and torque switches shall be enclosed in water tight enclosures along with suitable space heaters.
" OCVGTKCNU"1"FGUKIP"FGVCKN"
Materials, design and other specific requirements of various categories of BF valves shall be as
indicated below.
Sl. Description Requirement.

No
.
a) Design As per IS 13095/ BS 5155/BS EN 593
b) Type Double flanged Short Body
c) Material
i) Body and Disc Carbon Steel (IS 2062 Gr. 250BR)
Fabricated
iii) Shaft Stainless steel AISI:
431/SS410T/Equivalent
iv) Disc Seat EPDM
v) Bearing PTFE LINED ST.ST.
vi) Testing AWWA-C-504/Equivalent
" URGEKHKE"RGTHQTOCPEG"IWCTCPVGG"
"
For the rubber seated valves, the Contractor shall guarantee that in the closed position and with a disc
differential pressure as specified the valves shall be water tight.
The Contractor shall guarantee that the operating mechanism shall open and close the valve under the
specified maximum differential pressure within the time specified.
The valve shall be suitable for frequent operation during initial commissioning operation after a long
period of inactivity.
" OCTMKPI"
The mark stated by the Employer in the Material Request shall be printed on the body of all valves and
relevant accessories (control columns and relevant connecting elements to the valve, counter flanges,
valves for the auxiliary control if separately supplied, etc.).
The face of each hand wheel shall be clearly marked "Open" and "Shut" with arrows indicating the
direction of rotation to which they refer. Each hand wheel shall also be fitted with a circular name plate
indicating the service for which the valve is intended and valve tag number. The name plates shall be
engraved in black lettering.
Each spare part shall be individually marked with metal plates suitably punched for an easy
identification.
" VGUVKPI"CPF"KPURGEVKQP"

188
All valves shall be checked for correctness in respect of flange details as specified. The valves shall be
tested as per the requirement of AWWA C-504 (latest version).Proof of design-tested valve shall not be
supplied for the project.
Hqt"ecuv"eqpuvtwevkqp"<"Body and Disc shall be subjected to MPI/LPI and shaft shall be subjected to
UT and LPI.
Hqt"Hcdtkecvgf"Eqpuvtwevkqp<"All Butt welds having thickness 20mm and above shall be subjected to
Radiography and stress relieving. Only qualified welders shall be used for the purpose of carrying out
welding. Shaft shall be subjected to UT and LPI.
Site Test
The valves shall be tested at site for opening and closing time, valve operation etc. The valve should
operate without any flutter, noise, and vibration.
" GNGEVTKE"CEVWCVQTU"HQT"DWVVGTHN["XCNXGU"
FGUKIP"TGSWKTGOGPVU:
Electric actuators shall essentially consist of electric motors, limit switches, hand wheel and gear trains,
mechanical position indicators, internal wiring and terminal block. The electrical actuator assembly
inclusive of drive motor and unit switches compartment shall conform to IP 55 degree of protection.
Actuators shall be sized so as to open / close the valve at the rated speed against the design differential
pressure at 90% of the nominal voltage. Operators shall be designed to be self locking (i.e. maintains
the stem position) upon loss of electric power supply. Motors shall be installed on the operator prior to
shipment to the valve manufacturer. Actuators shall be provided with lifting lugs for handling it along
with the bonnet. Actuator assembly shall have all metal gear trains.
Operators shall be flange mounted on the valve bonnet. Welding of operators onto bonnets is not
permitted.
All actuators shall be either Auma or Rotork or employer approved equal.
" QRGTCVKPI"URGGF"
All actuators shall have operating speeds as per the manufacturer's standard. However, this shall meet
operating requirement of the system. Actuator operating times (opening and closing) shall be furnished
with actuator details.
UGTXKEG"EQPFKVKQPU"
i. The actuator shall be suitable for operation in a hot, humid and tropical atmosphere.
ii. Unless otherwise stated in the equipment specification, the ambient air temperature shall be taken as
50 dg. C, relative humidity 100% and mean sea level less than 1000 meters.
" TCVKPI"
The actuator shall be designed for operation on a 415 V + 10%, 3-Phase 50 Hz + 5% solidly grounded
system. The combined voltage & frequency variation shall be +/- 10%. The control circuit voltage shall
be 240/110 V A.C. or 220V D.C.
The actuator shall be rated for three successive open-close operation of the valve or 15 minutes,
whichever is longer.
The normal torque rating of each drive unit shall have adequate margin and at least equal to theoretical
brake torque required to drive the equipment under full load, including all losses in speed reducers and
power transmission.
The drive shall take into account valve operating speeds and differential and static pressures required
for the service. The Contractor shall select operating speeds and design pressure to satisfy
requirements of the equipment furnished and acceptable to the Employer. Motor actuator assemblies
shall have all metal gear trains. Fibre gears are not acceptable.
" RGTHQTOCPEG"
The actuator shall open and close the valve completely and make lead-tight valve close, without
jamming.
The actuator shall attain full speed operation before valve load is encountered and impart an unseating
blow to start the valve in motion (hammer blow effect).
The actuator shall operate the valve stem at standard stem speed and shall function against design
differential pressure across the valve seat.
The motor reduction gearing shall be sufficient to lock the shaft when the motor is de energized and
prevent drift from torque switch spring pressure.
The entire mechanism shall withstand any shock resulting from closing with improper setting of limit
switches or from lodging of foreign matter under the valve seat.

189
" "
" URGEKHKE"TGSWKTGOGPV"
" Eqpuvtwevkqp"
" "
The actuator shall essentially comprise of the drive motor, torque/limit switches, gear train, clutch, hand
wheel, position indicator / transmitter, space heater and internal wiring. The actuator enclosure shall be
totally enclosed, dust tight, whether proof suitable for outdoor use without necessity of any canopy. All
electrical equipment, accessories and wiring shall be provided with tropical finish to prevent fungus
growth.The actuator shall be designed for mounting in any position without any lubricant leakage or
operating difficult.
" Oqvqt"Ftkxg"
" "
The drive motor shall conform to sub-section E2 of this specification.
The drive motor shall be three phase, 415V, squirrel cage, induction machine with class B insulation
and IPW-55 enclosure, totally enclosed and self ventilated and designed for high torque low inertia and
reversing service suitable for operation at 50 deg. C ambient temperature.The motor shall be designed
for full voltage direct on-line start, with starting current limited to 6 times full-load current.
All motors shall have TEFC enclosures with space heaters to maintain the internal temperature above
dew point when the motor is idle. Space heaters shall be rated for 240V AC. The motors shall be
capable of operating the valve against the maximum load on the valve disc. with drive bearings in dry
and dirty condition. Each motor shall be provided with two direct temperature-sensing thermostats to
prevent thermal overload. All motors shall have O-ring seals to provide complete environmental
protection when the motor is idle. Earthing terminals shall be provided on either side of the motor.
Double shielded grease pre-lubricated, regreasble, antifriction bearings having a minimum life rating of
1,00,000 hours shall be furnished.
Limit switch
" Rqukvkqp"Nkokv"Uykvejgu<"
" "
Each actuator shall have rotary drum position limit switches, two (2) for open and two (2) for close
position, each with adjustable setting between fully open and fully close positions. Each rotary drum
position limit switch shall have two normally closed (NC) and two normally open (NO) independent
contacts. The adjusting mechanism for the limit switches shall be easily accessible.
" Vqtswg"nkokv"uykvejgu<"
" "
Each actuator shall have two torque limit switches with suitable arrangement to limit the opening /
closing thrust. The torque switch, actuated by the torque clutch when the valve is restricted during
opening / closing shall stop the motor thereby protecting the motor from overloading torque. The torque
switches shall be set as near as possible to the pull out torque of the motor without damaging the valve
of the operation.Each torque switch shall have two normally open (NO) and two normally close (NC)
independent contacts. The torque limit switch adjusting mechanism shall be easily accessible.Limit
switches along with all necessary electrical wiring shall be housed in a weather proof NEMA-3
enclosure and shall have gasketted cover and space heater to maintain the temprature above dew
point. Each torque / position limit switch shall have 2 No + 2 NC potential free contacts. Contacts shall
be rated to make and carry continuously 10 A at 110 V AC and 0.5A (inductive) 220 V DC.
Manual operation: All actuators shall have mechanically independent manual drive arrangement with
hand wheel and motor declutching mechanism. The manual drive shall be provided with clutch and
gearing as required to limit hand wheel effort to 25 kgt maximum along with suitable latch and locking
arrangement to keep the hand wheel in engaged position using manual operation.The hand wheel shall
disengage automatically during motor operation.
Position indicator/Transmitter: All actuators shall have one (1) built-in local position indicator for 0-100
% travel. All actuators shall be provided with mechanical 3-point dial position indicators. Rising steam
valve shall additionally have visual position indication through plastic stem covers. Where required,
valves shall be provided with continuous remote position indicators of the potentiometric type. The
available voltage sources for the potentiometric position transducers are 220V DC and 240 V AC. The
tranducer shall be suitable for stablished 4-20 mA current signal. The associated wiring for the
transducers shall be housed in the limit switch compartment.
Urceg" Jgcvgt<" A space heater shall be included in the limit switch compartment suitable for

190
240 V AC, 50 Hz supply 220 V DC.
Yktkpi<"All electrical devices shall be wired up to and terminated in a terminal box. The internal
wiring shall be of sufficient size for the power rating involved but no case less than 1.5mm copper. All
wiring shall be identified at both ends with ferrules. Internal wiring diagram shall be neatly pasted on the
rear side of the terminal box cover. Motor power, heater and all control wiring shall be wired at shop to
suitably rated master terminal blocks located within the limit switch compartment. All internal wiring shall
be of 650/1100 V grade flexible standard copper conductor cables with tropical fungicidal treatment and
the insulation shall be flame resistant. The limit switch terminals should be capable of terminating two
nos. 2.5 mm copper cable.Terminal boxes shall be provided with removable undrilled gland plates to
terminate following sizes of cable.
. I) 1 no. - 14 core 2.52 (Cu)
ii) 1 no. -10 cores - do -
iii) 1 no. - 2 pair
iv) 1 no. - 10 pair
v) 1 no. - Power cable
" Vgtokpcn"Dqz"
Actuator terminal box shall be suitable to receive and terminate the following cables:
a) 1 No. power cable details of this shall be intimated later.
b) 3 Nos. 19 C x 2.5 copper conductor PVC insulated unarmoured control cable.
Actuator terminal box shall be provided with a removable front cover plate, and an undrilled
detachable gland plate.
Data to be furnished: Motor data sheet for each type of actuator shall be furnished along with internal
wiring diagram, suggested control schematic and torque / limit switch contact development.
GO25<"GZRCPUKQP"LQKPV"1"FKUOCPVNKPI"LQKPV"
"
" IGPGTCN"
Expansion Joint will be provided for Each Volute pump in the discharge piping
Eqfgu"cpf"uvcpfctfu"
The design, manufacture and performance of metallic expansion joints shall be as FSA, USA or
equivalent standard and comply with or all currently applicable statues, regulations and safety codes in
locality where the equipment will be installed. The equipment shall also conform to the latest editions of
fluid sealing association.
Qrgtcvkpi"Eqpfkvkqpu"cpf"Fgukip"Tgswktgogpvu: For operating conditions and design

requirements refer to design data sheet enclosed.
" Eqpuvtwevkqpcn"Hgcvwtgu"
All parts of expansion joints shall be amply proportioned for all stresses that may occur
during continuous operation and for any additional stresses that may occur during installation and also
during transient conditions.
" The expansion joints shall be single bellow metalic expansion joints. The arches of the
expansion joints shall be filled with soft metalic0"
"
The design shall be suitable for the pressures and type of fluid i.e. raw river water.
The tube (i.e. inner cover) and the cover (outer) shall be made of natural or synthetic
metallic of adequate hardness. The shore hardness shall be less than 50 deg. A for outer and 50
deg. A for inner cover.
The carcass between the tube and the cover shall be made of high quality cotton duck,
preferably, square woven to provide equal strength in both directions of the wave. The fabric plies
shall be impregnated with age resistant metallic or synthetic compound and laminated into a unit.
Reinforcement, consisting of solid metal rings embedded in carcass, shall be provided.
Gzrcpukqp" lqkpvu" ujcnn" dg" eqorngvg" ykvj" uvtgvejgt" dqnv" cuugodn{" vq" cduqtd" rkrkpi"

191
oqxgogpvu"cpf"ceeqooqfcvg"okuocvej"dgvyggp"rkrgnkpes.
Main Body
The expansion joints shall be of heavy-duty construction made of high-grade abrasion resistant natural
or synthetic metalic compound. The basic fabric for the “duck” shall be either a superior quality braided
cotton or synthetic fiber having maximum flexibility and non-set characteristic
Note: Slip type metallic joint should be provided with relevant specifications instead of metalic
expansion joint.
" Tgkphqtegogpv"
The expansion joints shall be adequately reinforced, with solid steel rings, to meet the service
conditions under which they are to operate.
" Tgvckpkpi"Tkpiu"
All expansion joints shall be provided with stainless steel retaining rings for use on the inner face of the
metalic flanges, to prevent any possibility of damage to the metalic when the bolts are tightened. These
rings shall be of split and beveled type for easy installation and replacement and shall be drilled to
match the drilling on the end metalic flanges and shall be in two or more pieces. The split retaining rings
shall be of 10 mm thick stainless steel of tested quality. Steel washers shall be provided at the boltholes
where retaining rings are split.
" Gpf"Hncpigu"
The expansion joints shall be integral fabric reinforced full-face metalic flanges. The bolt hole on one
flange shall have on eccentricity in relation to the corresponding bolt hole on the flange on the other
face. The end metalic flanges shall be drilled to suit the companion pipe flanges.
Qwvgt"Eqxgt"
All exposed surfaces of the expansion joints shall be given a 3 mm thick coating of neoprene. This
surface shall be reasonably uniform and free from any blisters porosity and other surface defects.
" Eqpvtqn"Wpkvu"
"
Each control unit shall consist of two (2) numbers of triangular stretcher bolt plates, a stretches bolt
washers, nuts and lock nuts. Each plate shall be drilled with three holes, two for fixing the plate on to
the companion steel flange and the third for fixing the stretcher bolt.
" Gzrcpukqp"lqkpv"vci"pq0"("pcog"rncvg"
Each joint shall have a permanently attached brass or stainless steel metal tag indicating the tag
numbers and other salient design features which will be indicated by the engineer in the expansion joint
drawing submitted for his approval by the Contractor.
" VGUVKPI"HQT"OGVCNKE"GZRCPUKQP"LQKPVU"
"
Manufacturer’s standard test shall be performed during manufacture and after the completing the
manufacturing. Tests shop shall include but not limited to the following.
All bear bellows shall be subjected to deflection test under pressure, pressure being raised from
zero to design pressure in regular steps and deflection measured at each step.
Material test shall be conducted as given below:
a) Metalic compound test slab after vulcanizing shall be tested for tensile strength, elongation and
hardness.
b) Fabric strength of synthetic fibre for reinforcement shall be checked and test for metalic to fabric,
metalic to metal adhesion shall be carried out. Test on metalic shall include hydraulic stability check as
per ASTM D- 471.
" Xcewwo"Vguv"
" "

192
All expansion joints shall be subjected to an absolute internal pressure of 25 mm Hg.The
test shall be conducted in three different positions for a minimum period of thirty (30) minutes
duration in each position.
" Koogfkcvgn{"chvgt" vjg" xcewwo"vguv."c"j{ftcwnke"vguv." cu"rgt"vjg"tgngxcpv."uvcpfctfu"ujcnn"

dg" eqpfwevgf" qp" vjg" gzrcpukqp" lqkpvu0" Vjg" tcvg" qh" rtguuwtg" fwtcvkqp" vjg" vguv" ujcnn" pqv" dg"
nguu" vjcp" 3" dct1" ugeqpf0" Vjg" j{ftcwnke" vguvu" ujcnn" dg" eqpfwevgf" qp" vjg" gzrcpukqp" lqkpv" kp"
vjtgg"fkhhgtgpv"rqukvkqpu"hqt"fwtcvkqp"qh"52"okpwvgu"*okpkowo+"kp"gcej"rqukvkqp0"
"
" Gkvjgt"fwtkpi"vjg"j{ftcwnke"vguv"qt"fwtkpi"vjg"xcewwo"vguv."vjg"gzrcpukqp"eqpvtcevkqp"qt"
fghqtocvkqp" ujcnn" pqv" dg" oqxg" 307'0" Jqygxgt." c" ewowncvkxg" gttqt" ku" pqv" cnnqygf0" Vjg"
rwtrqug"qh"eqpfwevkpi"j{ftcwnke"vguv"qt"xcewwo"vguv"ku"vq"gpuwtg"vjg"uvcdknkv{"vq"ykvjuvcpf"
fghngevkqp"kp"czkcn"cpf"vtcpuxgtug"fktgevkqp0"
"
Twenty four (24) hours. After the above test, the permanent set (variation in dimensions with respect to
its original dimensions) shall be measured and recorded. The permanent set shall not be more than
0.5%.
Test Results
Vjg"tgeqtf"qh"vjg"vguv"tguwnvu"vq"guvcdnkuj"vjg"vgpukng"uvtgpivj."rgtocpgpv"ugv"jctfpguu"cpf"
cfjgukqp"ejctcevgtkuvkeu"qh"vjg"ogvcnke"wugf"kp"vjg"eqpuvtwevkqp"qh"vjg"gzrcpukqp"lqkpv"ujcnn"dg"
ocfg"cxckncdng"vq"vjg"gpikpggt"hqt"jku"crrtqxcn0"
"
" Ujqr"Kpurgevkqp"
The surface of the expansion joints shall be examined by the engineer and/or his representative
and abnormalities, if any, noted0" The Contractor shall arrange training on the equipment supplied for
engineers of the purchaser , as mutually agreed upon during the design and manufacture of the
equipment to familiarise with all aspects of design and manufacture of Pumps, associated auxiliaries
etc. All expenses like living, traveling and other expenses of the trainee engineers of the purchaser
shall be borne by the Contractor. The supplier shall also arrange and meet the expenses of stay of
Engineers of the purchaser for witnessing the Model Tests.
GO<"26"U[PEJTQPQWU"OQVQT"
"
" UEQRG<"
The scope covers design, manufacture, testing at manufacturer’s works before dispatch, supply,
erection at site, testing and commissioning of A.C synchronous motors, each complete with associated
auxiliary equipment like static excitation, automatic voltage regulating equipment, pumps starting
equipment (2 sets) etc. and other ancillary equipment, like cooling water, lubrication, compressed air
system for brake system, firefighting equipment with associated piping and valves, necessary
instrumentation, controls, safety devices etc. and spares as well as special tools and plants for
pumping station as described in this specification. The scope of supply shall also include all parts,
accessories, and spares etc., which are necessary for erection, operation and maintenance of
complete motors for fifteen years, even though they are not individually or specifically stated in the
specification. Corresponding parts of the motors, associated equipment and spares shall be of same
material, dimensions, workmanship and finish and shall be interchangeable.
The scope of supply shall also include all parts, accessories, and spares etc., which are necessary for
erection, operation and maintenance of Motors. The Motor shall match in respect of speed,
runaway speed, moment of Inertia, overload capacities and any other requirement with that of the
Pump.
" V[RG"CPF"TCVKPI<"
" "
Each Motor shall be of vertical shaft, alternating current synchronous type, conforming to the latest
edition of IS 4722 or IEC 34 or any other equivalent international standards unless other wise specified
here in and shall be directly coupled to the shaft of MetalicVolute Pump.
The rating of each Motor shall be as follows:

193
1. Type: Vertical mounting, alternating current synchronous
Machine
.2. Rated continuous output 120% of rating of the pump, 0.95 pf lead
3. Power factor 0.95 lead.
4. Speed Matching with the rotational Speed of the Pump.
5. Frequency 50 Hz(+ / -3%)
6. No. of phases Three (3)
7. Rated terminal voltage between phases 11 KV
8. Range of voltage variation +/- 10%

Output must be obtained.

194
9. Range of Frequency variation 48.5 Hz to 51.5 Hz.
10. Direction of rotation As per pump
11. Short circuit ratio Shall be greater than 0.75.
12. Inertia constant. Shall be less than 1.5
The Motor shall be suitable for operation in all respects and shall deliver the rated output over the
range of voltage variation and of frequency variation as specified above.
Each Motor shall be star connected and the main and neutral leads shall be brought out of the
stator frame for insertion of current transformers for protection and metering and surge protection
apparatus. The motor shall be grounded though a grounding transformer/ resistance grounding device,
to limit the ground fault current to less than 10 (ten) Amps.
The moment of inertia of the motor shall be coordinated with pump parameters, to meet the requirement
of pressure and speed rise as specified in Section-1. The inertia constant shall preferably be less than
1.5. The flywheel effect shall be built into pump-motor and not added in the shape of weights.
" IGPGTCN"<"
"
The Motor shall be designed and constructed so as to facilitate easy repair/replacement of Motor
stator bars and rotor poles. Starting of the Motor is envisaged through SFC Method of starting shall be
with starter at Phase/Neutral side.
The equipment offered shall be suitable for local manual/ auto control from the machine control panels
located near the machine/ units control room and remote auto-control from the common control room of
the pump house.
" TWPCYC["URGGF<"
Each Motor shall be designed and constructed so as to capable of running at the maximum
possible runaway speed of the unit for 2 minutes and all parts of motor, and other rotating equipment
shall be fully and safely withstand the stresses resulting from operation at this runaway speed. The
runaway speed test shall be considered successful only if after undergoing the test for two minutes, no
injury is apparent and the Motor is able to successfully withstand the high voltage test at 85% of the
dielectric test voltage.
" KPUWNCVKQP"CPF"IWCTCPVGGF"VGORGTCVWTG"TKUGU<"
"
Insulation of the motor shall be provided as follows:
i) Stator winding : Thermo setting Epoxy resin of class F

insulation.
ii) Rotor winding : Thermo setting Epoxy impregnated suitable insulation

material corresponding to Class-F insulation.
With a maximum cooling water temperature of 35º C. the motor shall be capable of
delivering rated output continuously at any voltage, and frequency in operating range, and rated
power factor without exceeding the following temperature rise over a maximum cooling water temp
of 35 º C .
a) Stator winding : 95º C. above ambient
b) Field winding : 95º C. above ambient
c) Bearings by embedded : 70 –80º C above ambient

temperature detector
(Indicated Temperature)
The temperature of stator winding shall be determined by means of embedded resistance

type temperature detectors located in the stator winding between coils at the centre of the core.
The temperature of the field winding shall be determined by the resistance method.

195
" GHHKEKGPE["CPF"QWVRWV"IWCTCPVGGU<"
" GHHKEKGPE["IWCTCPVGGU<"
The efficiencies of the Motor at full load, shall be greater than 94% (ninety four percent ). The
above efficiencies shall be subject to penalty and rejection as defined.
" FGVGTOKPCVKQP"QH"GHHKEKGPEKGU<"
" "
The efficiencies shall be determined by summation of losses method in accordance with the latest issue
of IEC: 34-2 or IS: 4889. The static excitation equipment losses shall also be included in the Motor
losses. No tolerance in the efficiency for guarantee purposes shall be permitted.
" QWVRWV"CPF"VGORGTCVWTG"TKUGU<"
The Motor shall be guaranteed to be capable of giving its rated output and maximum output without
exceeding the temperature rise.
RGPCNV["HQT"UJQTV/HCNN"KP"GHHKEKGPE["CPF"QWVRWV:
While testing Motor, for any short-fall in the tested values of rated output, maximum output and
weighted average efficiency from the guaranteed values, penalty shall be applied Tu0" 4.72.222"
*Twrggu"Vyq"ncmju"hkhv{"vjqwucpf"qpn{+"hqt"gcej"2023'*qpg"jwpftgfvj"rgtegpv+"by which the test
figure is less than the corresponding guaranteed figure.
The penalties on account of shortfall in output and the efficiency shall be computed separately and
the total amount of the penalty shall be algebraic sum of these two.
No tolerance shall be permitted over the test figures of output. Tolerance in computation of losses for
determining efficiency shall be allowed in accordance with IEC codes.
" TGLGEVKQP"NKOKV<"
The purchaser has a right to reject the motor equipment if the test values of either of the
maximum output or the average efficiency is less than the corresponding guaranteed value by 3
(three) percent or more.
The motor is also liable for rejection if either of the stator or rotor winding temperature
exceeds the specified limits while operating corresponding to maximum output. This guarantee
shall be without bonus in case of temperature raises being less than those specified.
" OQVQT"VGTOKPCN"EWDKENGU"*NKPG"("PGWVTCN+<"
All the six terminals of Motor (three phase and three neutral) shall be brought out of the Motor with
suitable cable sealing ends. Connections between these terminals and the line terminal cubicles as
well as neutral terminal cubicles shall be made at site. The line and neutral terminal cubicles shall be
complete with all equipments/devices such as Surge arrestors, capacitors, Current and voltage
transformers for Protection and metering, and shall include all necessary insulating supports,
enclosures, supporting frames, flexible connections, insulating boards, rigid conductors etc., The bus-
bar connections shall be adequately supported on insulators and designed to take care of terminal
thermal expansion, short circuit stresses etc. and also the line and neutral terminals will be connected
to the required Switchgear through XLPE cables. All joints shall be of bolted type. The entire assembly
shall be suitably guarded by strong metallic screen and the housing shall be provided with arrangement
for proper ventilation and shall be vermin proof.
The motor is also liable for rejection if either of the stator or rotor winding temperature exceeds the
specified limits while operating corresponding to maximum output. This guarantee shall be without
bonus in case of temperature raises being less than those specified.
All current transformers, voltage transformers, isolating switches and lightning arrestors provided shall
comply with the latest issues of relevant Indian or equivalent International Standards. Neutral point of
Motor will be made star connected through soft starters being envisaged.
" EQQNKPI"U[UVGO<"
Each Motor shall be provided with a suitable cooling system based on the closed circuit air circulation
principle, complete with sufficient number of air circulating fans, air coolers, cooling water pipes, valves,
alarm and indicating devices, flow relays and all other accessories. Each air-cooler shall be provided
with an inlet and outlet valves and a pressure gauge.

196
The cooling capacity of the surface air coolers shall be such that one cooler can be taken out of service
and 10% of the remaining tubes choked without the Motor exceeding the permissible temperature rise,
while Motor delivering its maximum output. The air cooler tubes and plates shall be made of material
suitable for the water and range of temperature expected without over stressing any part of tubes and
or tube plate. The water supply to each of the air coolers shall be controlled by separate valves so that
any one of the coolers can be isolated, if necessary.
All water piping including ring header, connecting pipe from the cooling header, control valves near
each cooler etc., shall be supplied. The extent of supply of cooling water pipes shall be in complete as
required.
Resistance temperature detectors shall be provided in air coolers for indication and recording of inlet
and outlet air temperatures.
Dial type thermometers shall be provided in air coolers for indication of inlet and outlet air temperature,
and to provide alarm and trip initiations in case of high temperature of inlet/outlet air.
water flow indicators, relays shall be provided with flow indicator and suitable contacts to provide
normal flow indicators and alarm in case of failure of cooling water flow in bearings as well as stator
coolers.
" J0U"NWDTKECVKQP"U[UVGO"
"
HP oil lifting pumps shall be used during starting and stopping of the units, and a DC stand by
pump shall also be provided.
" EQ4"HKTG"GZVKPIWKUJKPI"U[UVGO"*Pqv"crrnkecdng"hqt"ugnh/gzvkpiwkujkpi"oqvqt+"jqygxgt"
kv"ku"c"uvcvwct{"tgswktgogpv0"
The fire extinguishing equipment shall be of the carbon dioxide (CO2) type, protection system with
automatic operation shall be installed for the protection of Motor. Protection being effected by filling the
motor air circuit with CO2 at the concentration sufficient to dilute the air content to a point where
combustion cannot continue.
Necessary high-pressure pipe-work, distribution nozzles and electrical release trips etc. shall be
provided. The battery of CO2 cylinders should be of sufficient capacity to provide the rapid total
flooding of the Motor air circuit at a high concentration.
A pressure-operated switch should be fitted in the pipe work to each machine to initiate the alarm on the
release of CO2 gas. In the event of a fire occurring inside the Motor discharge of CO2 gas should be
manually initiated on observation of Fire/ smoke detection alarm. The system should be arranged such
that the testing of electrical circuit could be carried out without the release of CO2 gas. In addition, a
beam scale-weighing unit shall be provided to enable the cylinders to be weighed in-situ to ascertain
whether any gas has been lost.
The smoke detectors shall be so designed that the operation of any detector shall actuate an alarm-
giving device to give indication and alarm in the control room.
The equipment shall be simple in design, easily operated, inspected and maintained. The equipment
shall comply in all respects with the appropriate regulations of Insurance Association of India or similar
approved organization.
" EQPUVTWEVKQP<"
Each motor shall be provided with main thrust, and guide bearings located at the top and
bottom of rotor. Another option like common thrust bearing located on pump shaft between motor &
pump and guide bearing located at top of rotor. Static excitation system together with automatic voltage
regulator/ constant current regulator shall also be included in the scope of supply of the motor. The
motor shall be designed to have adequate ventilation The design of ventilation channels must be simple
so that the motor can easily be maintained.
The rotor shall be salient pole, overhung, bolted on or shrink fitted to the flange of main
shaft. The auxiliary shaft (if required) of less diameter provided for mounting the slip ring (top of rotor)
shall also be bolted to the flanges of the common shaft .
All parts of motor shall be designed and constructed to safely withstand maximum
stresses during operation, run away speed, short circuit conditions out of phase synchronizing and
brake application. The stator of motor shall be supported on concrete foundation. All necessary sole
plates, dowels, etc. required for the erection of the stator shall be furnished by the bidder. The stator
shall be suitable for lifting from service bay after being completely assembled and wound. Suitable lugs
with stator frame for lifting purposes shall also be provided.
All internal wiring and conduits for control and other systems shall be brought out to
terminal boxes outside the access shaft.
The arrangement of speed switch etc. should be suitably arranged to present stream line appearance.
Suitable platforms, walkways and handrails in motor housing shall be provided for

197
inspection and maintenance of the bearings, slip rings, coolers etc. (Not applicable for compact size
motor).
" UVCVQT<"Htcog<"
The stator frame shall be built up of welded steel plates and shall have adequate depth to
prevent distortion during transport or under any operating conditions. The stator frame shall be
designed to carry the weight of the top bracket ,brush gear assembly, stationary parts and flooring in
addition to weight of the rotating parts of pump and hydraulic thrust.
The sub-assemblies of the motor shall be assembled to maximum extent taking the
transport limitations into consideration so as to reduce the site work to minimum. The stator frame core
and coils shall be assembled in the factory and transported in one piece or two pieces depending on the
permissible package sizes for transport.
Ocipgvke"Eqtg<"
"
The magnetic cores shall be of high grade, non ageing, high permeability and low specific
loss, cold rolled, silicon steel, coated on both sides with a thin uniform film of the special insulating
varnish by totally vacuum impregnated method. The magnetic cores shall be laminated in a half overlap
pattern and mounted on keys fixed directly to the inner face of the stator frame. All ducts in the stator
core shall be designed to facilitate the flow of cooling air into and through the ducts with minimum
friction and noise. The stator windings shall be star connected, having suitable number of parallel paths
and insulated with insulation of Class ‘F’,
For the coils inside the slot as well as leading out coils from the slot, a special low
resistance corona preventive treatment shall be applied to suppress formation of corona.
The design of the winding shall be such that the circulating current losses and eddy
current losses are kept to minimum. Adequate arrangement of insulating bars along the slot portion
shall be made to ensure complete elimination of voids and a high factor of safety against breakdown.
The end connections of the coils shall be rigidly supported and braced to prevent vibration or
displacement and the armature winding shall be capable of withstanding, without injury, a three phase
short circuit at full voltage and load at the motor terminals provided, the duration of such short circuits is
not sufficient to cause injurious heating. A suitable automatic dehumidifying system or heaters shall be
provided in the barrel to prevent excessive moisture condensation along the interior surface of the
winding and on the internal machinery under all operating and shut down conditions. The provision of
heaters shall also be made.
Embedded type temperature detectors of resistance type shall be incorporated in the

motor stator. The leads from the detectors shall be brought out to the Marshalling box, provided,
suitably on the motor barrel from which suitable cable could be run to the indicating and recording
instruments in control panels in the control room
" TQVQT<"
"
The design and construction of the rotor shall be in accordance with the best modern
practice. The factor of safety at runaway speed, based on the yield point of the materials shall not be
less than 1.2 and shall be stated in the offer.
Motor rotor design should enable starting of the motor by SFC.
The insulation between turns of field winding and insulation to the ground shall be epoxy
(class ‘F’). Suitable tools and devices for removing the poles shall also be included in the scope of
supply. Adequate means shall be provided to prevent the end turns from deforming and slipping due to
centrifugal stresses on the inter-connection.
The rotor or pump shaft shall be provided with a suitable brake ring with which the brake
shoe shall make contact. The wearing surface of the brake ring shall be made in segments, which shall
be easily removable and renewable.
" UJCHV<"

198
"
The motor shaft shall be made of special quality forged carbon or alloy steel, properly
heat-treated. The shaft shall be of ample size to operate at all speeds including maximum runaway
speed without vibration or distortion and shall be able to withstand short circuit and other stresses
without. damage. The shaft shall be machined accurately all over and polished where it passes through
the guide bearing for alignment checks.
The motor shaft shall have a suitably shaped flange for connection to the pump shaft. The
coupling flange shall be forged integral with the shaft coupling shall comply with the requirement of
International standards for shaft coupling.
All coupling bolts, nuts, nut guards for couplings shall be furnished by the bidder. The
coupling bolts shall be provided with the locking devices.
The responsibility for proper alignment of the motor shaft to pump shaft shall rest with the
motor manufacturer and the alignment limit shall be as per the latest IEC standards. Necessary data
shall be supplied by the pump manufacturer to the motor manufacturer for determination of shaft
diameter and critical speed calculations. The lowest critical speed of the combined parts of the
complete unit shall be at least 30% higher than the maximum runaway speed.
" CWZKNKCT["UJCHV"*qrvkqpcn+<"
"
The auxiliary shaft shall be on the top of the rotor and shall be bolted to the flange of the
main shaft rotor centre. The slip rings along with the shield/enclosed shall be mounted at the top side of
the auxiliary shaft.
The slip rings shall be made of stainless steel or some other suitable material well
insulated with epoxy glass laminates for use with carbon brushes.
The slip rings shall be spaced sufficiently apart or separated from each other by a barrier
to prevent any accidental short circuit. The slip rings shall be located so as to be easily accessible for
inspection and maintenance. The brushes shall consist of a number of carbon graphite blocks placed in
heavy box type of holders and mounted on a ring. Suitable shield/ filter shall be provided to prevent
escape of carbon dust on the motor windings. The design of the brushes shall be such that the current
density under the operating conditions shall be in accordance with relevant/ applicable standards.
Provision shall be made to measure the field winding temperature and suitable temperature indicator to
be provided shall be mounted on the control board.
DGCTKPIU<"
Each motor shall preferably be equipped with suitable guide bearings located on top and bottom side of
the rotor and thrust bearing shall be provided along with lower guide bearing. Another option like
common thrust bearing located on pump shaft between motor & pump and guide bearing located at top
of rotor. The bidder however, is free to recommend any other type of bearing arrangement, which is
considered by the bidder to be appropriate or more economical.
The thrust bearing shall be provided with lubrication system which shall be provided with
oil sump arrangement. The thrust bearing shall consists of normal direction thrust pads and reverse
direction thrust pads, as required one thrust impeller and their supporting covers. The thrust pads shall
be made of steel plate lined with high quality Babbitt metal on their sliding surface.
The removing/ replacing of the thrust-bearing pad shall be done without disturbing/
dismantling the thrust collar. An effective sealing cover shall be provided to prevent leakage of oil vapor
through close running clearance between the bearing housing and the shaft.
The design of the bearing shall be such that temperature for alarm and trip out for high bearing
temperature shall not be higher than 65º C and 70º C respectively at rated operating conditions.
The bearing shall be capable of operating without any damage for a period of at least 2 minutes after
the failure of cooling water supply to bearing oil coolers with motor loaded up to the rated capacity and
rated speed at the end of which it is expected that the unit shall be shut down. The bearings shall be
suitable for operation under maximum runaway conditions for 2 minutes with cooling water supply
available to the oil coolers.
The guide bearing shall be made of steel plate lined with high quality Babbitt metal on its inner surface.

199
However manufacturer can also provide better material.
The bearing shall be adequately insulated at the support of distributing oil head where considered
necessary, to prevent any harmful circulating currents from passing through the bearing surface. This
insulation shall be arranged to break the possible path of such currents. Continuous monitoring
arrangement of shaft current/shaft voltage shall be provided along with provisions for alarm in case of
excess abnormal conditions.
The bearings shall be sump oil-lubricated type. The cooling water for the oil coolers shall be
available at a temperature not exceeding 35º C.
Baffles & guides shall be fitted in the oil bath, to assist correct oil distribution and to minimize
splashing and formation of froth. An efficient oil vapor seal shall be provided for the bearing.
High-pressure lubrication shall be provided to ensure oil film between bearing surfaces during
starting and stopping operations of the unit. A set of main and standby high-pressure pumps shall be
provided for the purpose.
All oil and water piping, valves, drain cocks, sumps, flow indicators etc. to complete the
lubricating system shall be provided. For recording, indication, alarm and shutdown, the provision shall
be made as under as minimum.
1. Thrust bearing normal a) 2 Nos. Resistance

direction pads. temp. detectors (RTDs)
(Lower& Thrust bearing pad) (one for recording
and one for indication)
b) 2 Nos. Dial type thermometer

(DTT) (for indication
and alarm)
2. Thrust bearing reverse a) 2 Nos. Resistance

direction pads. (Lower & thrust temp. detectors for each pad
bearing pads ) (for recording and indication)
b) 2 Nos. Dial type thermometer for

each pad (for indication and
alarm)
c) 1 No. thermostat (for shut down)
3. Guide bearing a) 2 Nos. RTDs in bearing

(Lower or upper) (for recording and indication).
b) 1 No. Thermostat (if applicable)
c) 2 Nos. DTT (for

alarm & indication)
4. Bearing oil reservoirs a) 2 Nos. RTD (for indication and

recording)
b)
1 No. DTT (for alarm &
indication)
Flow switches and pressure gauges shall be supplied for cooling water to the lubricating
oil coolers.

200
" QKNU"
Oil for the first filling plus 10% as spare required for the Motor bearings lubrication system etc. shall be
supplied by the Contractor. The oil to be used for Motor bearing lubrication etc. shall be identical with
that used for the pump bearing lubrication and shall be confirming to relevant Indian/International
standards.
" DTCMGU"*pqv"tgswktgf"kh"Dtcmg"ku"rtqxkfgf"qp"rwor"ujchv+<"
Under normal running conditions the unit shall be brought to rest by applying mechanical brakes from
20% speed to 0 % speed.
Each motor shall be provided with pneumatic operated type brakes of sufficient capacity mounted on
the bearing bracket to bring the rotating parts of motor and pump to stop, from 20% of the rated speed
in normal operating condition. The brakes shall be normally applied in auto. Under emergency
condition, it shall be possible to apply the brakes at 50% of the rated speed without any damage to the
brakes/ brake ring in case of emergencies.
The brakes shall normally be applied automatically with suitable inter locks. It shall be possible to apply
the brakes manually from unit control board by means of push button or manually from the brake control
panel.
Each brake cylinder shall be provided with a limit switch with auxiliary contacts to provide
lamp indication on the unit control board when brakes are “On and Off” and to provide starting
interlocks. Dust collecting cover shall be provided for the Brake dust collection.
The mechanical brakes shall consist of brake shoes mounted on a piston moving in a cylinder and
operated by compressed air. The brake shoes shall be provided with suitable wearing surfaces which
shall be easily renewable. Adequate provision shall be made for dissipating the heat resulting from the
application of the brakes. The bidder shall furnish all necessary piping connections, valves, control
switches, interlocks, so as to make braking system complete in all respects.
One vacuum cleaner along with required bottles etc. shall be provided to remove the dust
generated during mechanical braking so as to avoid the dust settling on the stator winding. The
compressed air for operation of the brakes shall be taken from the High compressed air system shall be
supplied by the pump manufacturers. The motor supplier shall provide all the necessary valves, non-
return valves and piping including the pressure reducer etc. required to complete the system.
" URCEG"JGCVGTU"("NKIJVKPI<"
"
Suitable space heaters shall be provided to prevent condensation of moisture on the motor
windings during the period of shutdown. The heaters shall be of tubular type consisting of a coiled
resistance wire embedded in an electrically insulating the heat conducting compound and protected by
a metal sheath and shall be evenly distributed. The heaters shall be so arranged to form a balanced
three-phase load. A suitable terminal box shall be provided at convenient location for connection of
these heaters to 415 V 3 Ph, 50 Hz AC supply. A suitable ON/OFF control device for the heaters shall
be supplied mounting near the motor housing.
Sufficient lighting fixtures to provide general lighting and socket out lets for small power
tools and extension light shall be installed within the pump - motor housing wired to a suitable terminal
box.
" OQVQT"PGWVTCN"GCTVJKPI<"
"
Neutral point of the star connected stator of each motor shall be grounded through a
grounding transformer/ resistance device consisting of isolating switch, resistor to limit the ground fault
current to less than 10A. The isolating switch shall be connected between the neutral lead of motor and
the grounding Resistance. The resistance shall be housed in a metal clad cubicle (IP45).

201
" ETGGR"FGVGEVKQP"FGXKEG<"
Creep detection equipment shall be provided to detect speeds in the whole range up to
zero and provide suitable arrangement and give alarm in case of creeping speeds.
" EWDKENGU<"
"
All the equipment of control and instrumentation and static excitation and AVR shall be
suitably housed in sheet metal, dust proof cubicles. All these cubicles shall be located at one place in a
row without any gap in between. The dimensions (depth, height, etc.) and outside appearance of the
cubicles shall be identical to present a neat and functional line up. The overall appearance shall also
match with the other group of panels like unit control panels, machine control panels, etc. These
cubicles shall be of self-cooled type without provision for any external cooling fans.
" OQVQT"KPUVTWOGPVCVKQP"CPF"EQPVTQNU"CPF"UCHGV["FGXKEGU<"
"
The supplier shall furnish all ancillary equipment relating to the motor as outlined under
schedule of requirements. This equipment together with the other motor equipment supplied, shall
constitute a complete and co-coordinated set of instruments, gauges, controls and safety devices for
the supervision and control for the units during normal running and in emergencies. The instrumentation
and controls of the units shall be provided on machine control panels/ unit control panels and the main
control board. The bidder shall provide equipment in accordance with schedule of requirements for
mounting on these boards and locally on the equipment of his supply. The instruments and controls
shall have to be suitable and adequate for manual control, automatic sequential control. The bidder
may, however, provide any additional instruments, alarm control or safety devices that are considered
necessary.
The unit control panels shall be supplied by the bidder. Indicating instruments, gauges,
and controls for the motor as detailed in the schedule of requirements shall be provided by the motor
manufacturer and shall be mounted on the unit control panel.
" URCTGU<"
"
Spare parts for the motors as listed in the schedule of requirements shall be supplied along with the first
motor. All spare parts supplied shall be interchangeable, and shall be of the same materials and
workmanship as the corresponding parts of the equipment. The bidder shall also recommend any
additional spares consider essential for 5 years of normal operation.
6032"UJQR"CUUGODN["CPF"VGUVU<"
"
In case motors and other major equipment, they shall be part assembled to the maximum extent
and match-marked to avoid any problem of matching during erection at site. The bidder shall provide all
the instruments/ equipments and apparatus required in the contract for conducting the tests. The bidder
shall conduct non-destructive test on components of motor as detailed in Appendix.
The tests shall be in accordance with the applicable requirements of the ASA, BSS, IEEE 115
“Test procedure for Synchronous machines”. The supplier shall intimate the testing programme
sufficiently in advance so that the tests may be witnessed by the purchaser or his authorized
representative. The witnessing of the tests by the Purchaser or his representative (s) shall not relieve
the bidder of his responsibility to fully meet the requirements of these specification and the Guarantees.
Advance copies of the test certificates shall be sent to the purchaser for his approval. The
equipment shall not be dispatched until the Purchaser’s approval in writing for the test certificates is
obtained.
" VGUVU"CV"YQTMU<"
"
The first motor along with the excitation system and other auxiliaries shall be completely
assembled at the manufacturer’s works. The following tests shall be carried out on the motor at works in
accordance with IS 4722/1968 and IEEE 115 or relevant IEC:
c+" Vgorgtcvwtg"tkug"

202
"
The test shall be carried out in accordance with Indian Standards, IEC or any other
equivalent standard.
d+" Kpuwncvkqp"Tgukuvcpeg"Vguv<"
"
The above test shall be carried out on all machines, both before and after high voltage
test. The insulation resistance shall be measured between open windings and between windings and
frame. The test for insulation resistance shall be carried out
e+" Fkgngevtke"vguvu<"
"
The high voltage test shall be applied between the winding and the frame with the core
connected to the frame and to the windings not under test. Connections between the windings (e.g.
neutral point) shall be separated before making the tests. It shall be applied to the complete machine
with all its parts in place under conditions equivalent to normal working conditions and shall be carried
out at the manufacturer’s works after the temperature rise test of the machine. The test voltage shall be
alternating and shall be as nearly a sine wave as possible. Tan-delta tests shall also be conducted on
specified number of coils in accordance with relevant standard.
f+" Ghhkekgpe{<"
"
The efficiency of the motor shall be determined by the summation of losses method. All the
losses shall be measured in accordance with the approved standards.
g+" Dgctkpi"Ewttgpvu<"
"
These shall be determined in accordance with IS7132 – 1973, IEC or AIEE code or equivalent
for synchronous machines, alternatively shaft voltage may be measured in terms of IS or equivalent
AIEE or IEC code.
h+" Ujqtv"Ektewkv"Vguvu"*kp"Yqtmu+"
"
To verify the capabilities of the motor to withstand short circuit stresses without injury, short
circuit tests shall be carried out. Oscillograph records shall be made of the currents and voltages in
motor and excitation windings.
i+" Ejctcevgtkuvkeu"vguvu"*Kp"Yqtmu+"
"
1) Direct axis transient time constants
i) Open Circuit.
ii) Short Circuit.
2) Direct axis transient reactance.
i) Rated current
ii) Rated voltage.
3) Synchronous reactance direct axis saturated & unsaturated and quadrature axis
unsaturated.
4) Sub transient reactance.
5) Negative phase sequences reactance.
6) No load and short circuit saturation curves.
7) Wave form: Oscillographs shall be taken of the armature winding when the motor is
operating at rated voltage
8) Resistance of armature and field windings (on all machines).
9) Moment of Inertia of rotating parts (WR)
10) Short Circuit ratio.
11) Phase sequence tests.
12) Runaway speed test shall be done on unexcited machine, if excited
voltage shall not exceed 105% of rated Voltage (for one machine only).
13) Hydrostatic test pressure on each surface cooler.
14) Test for accuracy of each resistance temperature detector.
15) Tests on static excitation and regulation equipment.

203
i. Insulation resistance test.
ii. Dielectric test on cubicles and transformers. In addition to above, test

shall be carried out on motors, relays, circuit breaker, AVR etc. and
all other auxiliaries.
Additional tests if any required shall be carried out on the motor and its auxiliaries.
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The following tests shall be carried out on the motors at site in accordance with IS
a) Dielectric Test: In case of motor already tested at the manufacturer’s works, the dielectric test
shall be carried out with 85% of the test voltage where as all other motors shall be tested at the
full test voltage.
b) Determination of the resistance of armature and all field windings.
c) Hydro-static pressure test of 1 ½ (one and half) times the normal working pressure applied for a
period of not less than one hour without showing any leaks or any drop in pressure for bearing
oil coolers, surface air coolers and cooling water piping.
d) Determination of time for stopping the machine with zero field current on application of brakes at
20% of normal operating speed. (Time-rpm deceleration curve).
e) Synchronous reactance direct axis, saturated and unsaturated and quadrature axis unsaturated.
i) Rated current, zero power factor lagging and saturated current test.
ii) Phase sequence test.
iii) Test on excitation system
iv) Temperature rise test
v) Visual inspection and wiring check.
vi) Insulation test voltage withstand test.
vii) Checking of control and relay logic.
viii) Excitation system frequency response (phase and gain) curves to be made on each motor.
ix) Overall response of machine and excitation system voltage changes.
x) Test of maximum over excitation system limiter.
xi) Test of ‘volts per cycle’ - regulator.
xii) Minimum under excitation limiter test.
xiii) Effectiveness of voltage regulator forcing action in demagnetising of the main regulator field.
xiv) Tests to determine the field current under the following conditions.
a) Rated KVA. rated power factor and 110% voltage.
b) 115% rated KVA. rated power factor and 110% voltage.
xv) Dielectric test for excitation transformer.
xvi) Adjustment of AVR.
xvii) Relay test.
xviii) Shaft voltage.
xix) Phase sequence.
xx) Automatic start and stop test.
xxi) Synchronising test.
xxii) Quick and emergency stop test.
xxiii) Exciting current test: The exciting current test shall be performed at rated or near the rated
voltage provided that the unit transformer is able to withstand 50% exciting
current for 15 seconds at rated voltage.
xxiv) Alignment check of motor rotor and impeller and shaft system.

204
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Field-testing equipment required for testing of the equipment shall be supplied by the
bidder.
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All necessary special tools and devices such as lifting devices for stator, rotor, pole. Tools
like lifting clamps and slings for use with equalising beam etc., for erection and maintenance of the
motor shall be supplied in accordance with the “schedule of requirements”.
The following drawings and data shall be submitted by the bidder within one month from
the date of signing of contract.
i) The general drawings and overall dimensions of the motor showing position of
main and neutral leads, important elevation etc.
ii) Drawings showing thrust bearing and guide bearing assemblies.
iii) Drawings showing arrangement of air cooler, air ducts etc.
iv) Diagram of lubricating system.
v) Physical and schematic drawings of excitation system, automatic voltage

regulator equipment, field discharge equipment and descriptive literature.
vi) Graphs showing predicted characteristics of the motor (capability curve).
vii) General layout drawings showing overall dimensions and layout and relative
position of all auxiliaries, ducts spaces for cables and piping etc.
viii) Details of fire fighting protection -schematic diagram, literature, etc.
ix) Start/ stop sequence logic diagrams.
x) Protection and Metering systems.
PROGRAMME OF SUPPLY OF ENGINEERING INFORMATION:
i) Within four weeks of the effective date of the contract the bidder shall furnish. The schedule of issue
of documents and drawings.
ii) A detailed scheduled listing out all major assemblies and critical parts and dates by which the
related information shall be supplied should be appended to the bid.
iii) The supply of above information should be in the form of CDs of all drawings along with one full
size print of each drawing.
iv) Twelve copies of the comprehensive, erection, operation and maintenance instruction books for the
motor and its auxiliaries, static excitation equipment, and control equipment should also be supplied,
free of cost.
v) The bidder shall indicate requisite capacity, span, lift etc. in respect of E.O.T. crane required for
installation and maintenance of the pump -motor units. These items are also in the scope of supply.
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The motor supplier shall be completely responsible for overall scheme co-ordination
comprising of the station layout, control schematics, and machine protection.

205
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The bidder shall arrange training for 6 engineers of the purchaser for a period as mutually agreed upon
during the design and manufacture of the motor at the manufacturer’s design and drawing office and
manufacturing shops to familiarise with all aspects of design and manufacture of , associated
auxiliaries, excitation, control systems etc. All expenses including boarding and lodging, to and fro
charges for training of engineers of the purchaser shall be borne by the bidder.
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Three (3) Nos. vertical shaft 3 Ph., 11 KV, 50 c/s, 0.95 pf Lagging/ leading synchronous
motors of suitable capacity each, directly coupled to pump. Each motor shall consist of the following:
1. One Stator consisting of stator core, frame (part of shell of steel plates) stator windings,
space heaters with control switch, cooling ducts and other necessary accessories.
2. One set of main connections for segregated phase bus duct and 3 neutral leads for
segregated phase bus duct and grounding resistance connection.
3. One rotor, consisting of poles, field winding with amortisure, rotor rim and other necessary
accessories.
4. One shaft current insulation.
5. One set of slip rings with carbon brushes, brush holders, leads etc.
6. One bearing bracket bolted. The bearing bracket shall be complete with housing and the
guide bearing with all the necessary piping.
7. One set of air coolers complete with connecting piping valves and all other accessories.
8. One set of lube oil pumps, oil coolers with necessary piping and other accessories and
controls for all bearings (inclusive of pump guide bearings).
9. One set of brakes (not required if brake is provided on pump shaft) mounted on a bracket
with dust collectors and all necessary internal pipe work. The system shall be complete with electrically
and manually operated valves.
10 One vacuum cleaner along with required babbles etc. to remove the braking dust from the
stator winding.
11. One set of limit switches for the braking system with sufficient contacts for brake ON and OFF
indication and starting confirmative circuit. (not required if brake is provided on pump shaft).
12. One set of ladder and platform in the motor (if applicable).
13. One set of terminal box and internal wiring and conduits for auxiliary circuit inside the
motor shell.
14. One device for creep detection and over speed contacts for shut down.
15. One set of vibration detectors.
16. One set of static excitation equipment, complete in all respects along with control and protective
devices.
17. One set of automatic voltage regulator equipment complete with contactors, over voltage
protection, grounding protection, necessary accessories, potential and current transformers and
complete set of controls and indicators for manual and automatic operation. The equipment shall be
complete with suitable cubicles for housing external wiring, cables, etc.
18. One set of anti-condensation heaters.

206
19. The equipment shall be complete with suitable cubicles for housing external wiring, cables
etc.
20. One set H.S lubrication system (if applicable)
21. Fire extinguishing equipment (Not applicable for self-extinguishing motor)
Two sets CO2 type fire extinguishing system complete with nozzles, piping, scheme or
nozzles, smoke detectors, fire alarm etc.
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4.18.1. General:
Each motor shall be equipped with static excitation equipment conforming to the latest applicable
standards. The equipment shall provide fast response and accurate excitation system shall permit
continuous stable operation of the motors under manual excitation control or automatic voltage
regulator control for all operating conditions. The excitation system shall be capable of fully controlling
its output voltage in response to control signal during pump running.
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Motor excitation cubicles comprising a regulator cubicle containing the automatic voltage
regulator, (Digital voltage regulator) manual control unit, and associated equipment and two converter
cubicles each containing a thyrister converter, a firing circuit and associated equipment. The thyrister
bridge should have one redundancy bridge (N+1) one field breaker cubicle. One starting excitation
cubicle with the required thyristers and control system to provide required excitation current to motor .
Transformer cubicle containing a three phase double wound, dry type excitation transformer
whose supply shall be fed from 11KV motor terminals. The secondary of the transformer shall be
connected to all excitation cubicles. During starting of motor excitation system supply shall be taken
through a separate transformer of suitable capacity One transformer will be fed station auxiliary supply
board. Necessary inter locks for change over of supply from auxiliary excitation system to main
excitation system shall be provided .
The suppression of the field winding shall be achieved by the field breaker and discharge
resistor. The rapid de-excitation shall be achieved by tripping the field breaker after bringing the
discharge resister into the circuit through magnetic contactor.
Direct current measuring equipment consisting of shunts and leads, etc. and all other
equipment required to provide indication at the AVR panel for motor field shall be furnished.
The rectifier shall be designed for duty cycle consisting of series of close-in faults and
reclosures during which period the motors are expected to continue in service.
The fault duty cycle is as follows:
a) Continuous operation at its maximum rating.
b) Three phase fault adjacent to HV terminals of step down transformer

(assume10%reactance) cleared in 5 cycles.
c) First and second auto re-closure on the fault after 20 cycles interval cleared in 5 cycles
after each re-closure.
d) Field forcing at ceiling current between re-closures and following final lock out for 5
seconds.
e) The rectifiers shall be suitable to work at a maximum ambient temperature of 50º C for
the above duty cycle.

207
f) The ceiling voltage of the rectifier shall be 1.8 times the motor field voltage when delivering rated
load at rated voltage.
g) The excitation system shall be complete with all necessary devices for indication, protection, alarm
and control of the equipment. The excitation system shall not relay on any other source of power except
for the 415, volt 3 phase alternating current. The use of oil as an insulating medium in any of the
components is prohibited.
Rectifiers of the exciter shall be of the silicon controlled type. The initial capacity of the
rectifiers shall have an allowance to cover any loss in capacity, which may be caused by ageing.
The rectifier shall have a PIV rating of not less than four times the maximum RMS voltage of the
input. Sufficient number of rectifiers shall be used in parallel in each arm so that failure of anyone
of them shall not cause failure of excitation. Unbalance current between each rectifier shall not be
more than 20% of average current on three rectifiers. Necessary protection along with the
following shall be provided.
a) Fuse set with trip contact (for over-current protection of each thyristor unit).
b) Selenium arrestor (for protection against surge voltage transferred from motor field
windings).
c) Gap arrestor (for protection against surge voltage from motor main circuit through
excitation transformer).
d) In addition, air flow detecting relay combined with under voltage relay shall be
provided in the forced air cooling type cubicle incorporating these thyristors.
The static exciter shall be of modular design in such a way that it can be readily removed
for inspection or replacement of parts. Light emitting diodes (LEDs) shall be provided on such
module to indicate and locate rectifier failure.
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Three-phase excitation power shall be obtained through a three-phase transformer connected to
11KV bus duct.
The excitation transformer shall be designed and manufactured in accordance with the
latest standards for transformers.
The transformer shall be self-cooled, indoor, dry type epoxy moulded and shall be housed
in a cubicle. Surge transmission from H.V. side to L.V. side shall be prevented by suitable means.
The transformer shall be equipped with winding temperature detector with necessary provision for
remote indication.
The excitation transformer shall be provided with
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The high voltage windings shall be included in the protection zone of surge absorber installed in
the motor main circuit. For the protection of low voltage windings, following measures shall be taken:
i) Electro - static shield, which restricts to approximately zero the surge voltage transferred electro-
statically from high voltage windings to low voltage windings.
ii) Gap arrestor, which restricts the surge transferred electro-magnetically to the low voltage
windings.
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The short circuit fault occurred in the excitation transformer shall be detected by over current

208
relays. Necessary CTs shall be provided on the HV and LV side of the excitation transformer.
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Dial type thermometer with alarm contact shall be provided for the excitation transformer itself.
Also, an air flow detecting relay for cooling fan shall be provided in the excitation transformer cubicle
(forced air cooling) as combination of under - voltage relay for fan source.
The power supply for the static exciter shall be provided by a double wound three phase
transformer fed from the motor input.
The 11 KV terminals of the transformer shall be suitable for connection with 11 KV bus duct/
cables. The low voltage terminals of the transformer shall be suitable for connection with LV cables.
The transformer shall be completely assembled at the factory and shall be subjected to
standard dielectric tests and other type/ routine tests as per relevant standards. Dielectric tests
and other tests shall also be carried out at site.
4.20.D.C. CIRCUIT BREAKER & A.C. CIRCUIT BREAKER
D.C. Circuit breaker shall be provided in the field circuit. The circuit breaker shall be draw
out type, electrically operated for its closing and tripping by means of control.
The interrupting capacity of the breaker shall be adequate to ensure clearing of maximum
short circuit current possible assuming ultimate fault current supply on direct current side of the
rectifiers. Necessary relays and suitable current transformers on the LV side of excitation
transformer for operation of this breaker shall be provided. The air circuit breaker shall be given
routine tests in accordance with the latest standards.
EXCITATION CONTROL :
The voltage regulating excitation control equipment(Digital voltage regulator) shall be

suitable for local manual and automatic remote control from control room panel. Suitable
circuits
containing position switches and internal wiring within the equipment required to give correct operation
and indication and all necessary equipment for this operation shall be provided.
The voltage regulator control switch shall be provided on AVR panel and also in control room
panel for manual control. All equipment required to provide smooth change from ‘Auto’ position of
voltage regulator to ‘Manual’ position and vice-versa shall be provided. Voltage regulator balance
indicator shall be provided for the purpose.
VOLTAGE REGULATOR:
The Automatic voltage regulator of digital type with microprocessors of 16/32 bit shall be
provided.
The digital voltage regulator shall be designed to have 100% redundancy and shall be reliable,
so that failure of any equipment shall not cause mal-operation of the system and provide required
excitation current and voltage. The voltage regulating system shall be of modular design.
The voltage regulators shall automatically actuate on the controlled rectifiers and shall be
capable of giving required excitation for the motor and shall maintain the power factor within these
limits throughout the period of motor.
a) Under steady speed condition for any over speed up to 150% of normal, maintain motor voltage
within plus or minus 5 percent of the value of the voltage regulators were holding before over speed.

209
Also under steady state speed conditions for any over speed between 150 percent the maximum
possible over speed maintain motor voltage within plus or minus 10% of the value the voltage
regulators were holding before over speed.
b) Permit continuous stable operation of the motor under control of the voltage regulators while
meeting line-charging requirements.
c) Under steady state conditions with the motor open circuited, the regulator shall not permit the
terminal voltage of the motor to vary by more than 2.5 percent.
d) The circuitry shall trip the field circuit breaker automatically upon the detection of a fault in the
motor, main power transformer, or cables.
The voltage regulator shall be provided with the following features:
a) Cross current compensating devices to permit stable operation with other motors, or with grid
system.
b) An adjustable minimum excitation limit device. This device shall be excited from potential and
current transformers and shall automatically limit the decrease of motor excitation below that which may
result in pull out of the motor when operating under all specified operating conditions. The
characteristics of the minimum excitation limiter shall closely match the motor capability curves.
c) An adjustable maximum excitation limit device. This device shall automatically limit the
excitation of the motor to a safe value with the excitation under control of the regulator. The device
shall have an adjustable time delay feature to permit short time operation (subject to thermal limitations
with ceiling excitations).
d) Prevent over fluxing of motor transformer.
e) Follow up circuit and Null balance.
i) Provision shall be made to follow-up changes in auto mode so that in case of a sudden
change to ‘Manual’ there shall be no dip in motor voltage. An alarm and visual facia /LED indication
shall be provided to indicate change from ‘Auto’ to Manual’ Mode. Automatic change over shall also be
possible from ‘Auto’ to ‘Manual’ in case of loss of main feed back by any of P.T. fuse failure.
ii) Null balance: Shall compare the outputs on the AVR and manual control
amplifiers. This shall be capable to change over from manual to auto control and vice versa with
minimum disturbance to the motor output.
f) The voltage regulating system shall include devices for improving the damping of active
electromechanical oscillations. These devices shall operate to supplement the voltage regulating action
by adding an additional control signal into the excitation system input. This supplemental input signal
shall influence the excitation system so as to cause a change in field current of the machine for
stabilized operation.
g) Suitable equipment shall be provided for exciter over voltage protection under all conditions of
regulator in or out of operation of mal-operation. The protective circuitry shall be responsive only to the
exciter terminal voltage.
The equipment shall have an adjustable time delay feature and means for adjusting the operating
voltage level so as to permit operation that does not interfere with the normal regulator functions. The
protection circuitry shall operate at a voltage level slightly higher than that reached when the maximum
excitation limiter functions normally and with sufficient time delay to avoid interference with all normal
voltage regulations. If an exciter output over voltage condition persists for a sufficient time, such
conditions shall initiate the following actions
h) The motor lockout relay shall be tripped to shut down and lockout the pump-motor along with the
excitation system.
i) Provide annunciation.

210
Also the following additional features shall be provided. If the regulator control switch is in
“MANUAL’ or “AUTO” position and the machine speeds to 115 percent over speed or if the regulator
transfer switch is in “AUTO” position and the regulator drops out of service resulting in exciter over
voltage, then the exciter over voltage protection shall operate as described above except that the motor
lockout relay shall not operate. However the motor breaker shall be opened and the exciter voltage
shall be immediately reduced to the value necessary to return motor voltage to normal.
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Motors should be capable of starting only by Static Frequency Convertor (SFC) to limit the
starting current to less than twice the full load current of the motor and limiting the voltage dip in the
system within the permissible limits based on the prevailing fault levels of the power system at the
location.
Two (2) sets of static frequency convertors (SFC) to be considered to have redundancy and is
common for all pump – motor sets in the pump house. The SFC offered shall be suitable to start the
pump- motor smoothly and without excessive inrush current with impeller fully immersed in water as
per submergence of pump. The motor shall be soft started and reach 90% of rated speed less than 10
minutes. The bidder shall include the necessary control equipment, inter locks and pump starting
isolators etc.in a separate cubicles. in their scope of supply. The cubicles shall be suitable to connect
300 Sq.mm copper/ aluminium conductor with XLPE insulation. The cables shall be single core.
The starting equipment offered shall be of proven design and shall be robust and can with
stand no. of starts in a day and it shall be suitable for watered start of the pump-motor set.
All the protection and control circuits of starting equipment shall be incorporated in the system.
The system shall be suitable to start one pump at a time either from local panel or from remote control
panel/ MMI panel in the control room.
The power circuit panels (11KV system) shall be designed so that it can with stand fault
system fault currents during starting of pump.
The starting equipment shall be housed in a sheet steel cubicles of thickness not less than 14
gauge and painted with anti corrosion resistive paint. The colour of the final paint shall be finalized
during detailed engineering.
The manufacturer shall conduct all the routine tests as per IEC standards on the equipment
offered.
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11 KV Breaker cubicles of Indoor type shall be supplied for extending of 11KV supplies
from 220/11KV & 132/11 KV transformers of SS. The breaker cubicles shall receive 11 KV supply
from outdoor 220/11KV sub station with incoming sources through 11KV XLPE cables.
The following are in the scope of supply erection & commissioning.

11KV VCB cubicles, For incomer -- - 3000 amps
For Bus coupler - 3000 Amps
For Outgoing feeders - 800 amps
Bus PT panel .
Breaker trolley
Earthing trolley
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211
Each incomer shall consists of
11KV /110 V Potential transformers at incoming terminals 1 set
3000 / 1 A current transformer for metering & protection 1 set
Draw out type Vaccum Circuit breaker
Neutral displacement relay and master protection relays
Under voltage relay
Control relays, switches, MCB’s , Bus bar & accessories etc
Circuit Breakers: All the Switchgear cubicles compartments shall be draw out type Vaccum circuit
breakers of 40KA interrupting capacity generally confirming to IS 2516 and shall
comply with the following requirements.
The following shall be provided on the door of Vaccum circuit breaker compartment.
1. 1 No.3 position. (Trip-Neutral-close) spring return to neutral control switch for operating the
breakers electrically. The contacts of the switches shall be suitable for 220V DC
operation.(KAYCEE/GEC ALSTHOM Make)
2. 1 No. Local/Remote selector switch for selecting the control of the breaker. (KAYCEE/GEC
ALSTHOM Make)
3. 6Nos. Indication lamps (Technic/BCH make)
Red – ON indication
Green – OFF indication
Amber – Trip circuit healthy indication (2nos one each for TC-1 and TC-2)
Blue – Spring charge indication
Amber – Breaker Trip indication. This indication should be latched till reset
Yellow- DC supply fail indication (shall be provided in AC circuit)
4. 1 No. P.B for lamp test along with required circuitry (Technic/BCH make)
5. 1 No. P.B for reset (Technic/BCH make)
6. Indication Lamps for Bus PT supply indication.
7. 1 No. Ammeter with ammeter selector switch (R-Y-B-Off) (ENERCON/MECO make and
class of accuracy:1.0)
8. 1 No. Volt meter. 110V rating with 4 position selector switch (RY-YB-BR-OFF)
(ENERCON/MECO make and class of accuracy:1.0)
9. Redundant motor protection relays / Over Current and Earth fault relay- with IDMT and
with instantaneous trip arrangement. The relays shall have a setting range from 50% to 200% of 5 /1 A.
Only numerical relays shall be quoted. (GE/ABB/SIEMENS/AREVA)
10. DC supply supervision relay.
11.Trip circuit supervision relay.
12. High speed Master Trip relay with manual reset. Detailed tripping scheme will be furnished to
the tender.
13. Auxiliary relay with flag indication
14.Under Voltage relay
15.2 pole MCB with NC contact for DC supply control.
16.2 pole MCB for AC supply control.
17.3 pole MCB for Bus PT.
18.3 pin 5A socket
19.space heater with thermostat
20.Illumination lamp with door limit switch
All the Vaccum Circuit breakers shall comply with the following requirements.
a). Nominal system Voltage : 11 kV
b). Highest equipment voltage : 12 kV
c). Rated normal current : 2500A/800A
d). Symmetrical three phase breaking current : 40KA
e). i). Rated short time withstand current : 40KA for 3 sec.
ii). Rated short circuit making current : Not less than 2.5 times the rated short
circuit breaking capacity.
f) 1Minute Power frequency withstand voltage : 28KV
g) Impulse with stand voltage : 75KV.
h) Frequency : 50Hz
i) Control circuit voltage : 110/220 V DC

212
j) Leaching requirement : Trip free.
k) Opening time : 3cycles –(60ms)
l)Operating control : To be suitable for local as well as remote
operation
m) operating mechanisms : Mechanical spring charging type. The spring
charging motor shall be suitable for 110/220V,
DC operation.
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a) The Vaccum circuit breaker shall be equipped with anti pumping protection. Only one closing
operation of the circuit breaker mechanism shall result from each closing operation of a manually
operated initiating control device, even though the breaker trips while the initiating control devices being
held in the closed position.
b) The design of the breaker shall be as to minimize switching over voltages and C.B s shall be
suitable for full out of phase switching. The C.B s shall be with Vaccum interrupter and shall not have
more than one breaking chamber per phase. All the three poles of the C.B shall close/open
simultaneously.
c) In addition to the auxiliary contracts required for normal operation and control, 10 normally open
and 10 normally closed Auxiliary contacts shall be provided and wired to terminal blocks for use in
remote panels.
d) Necessary interlocks shall be provided to prevent closing or opening of the breaker under low gas
pressure and devices for initiating alarm shall be provided. Potential free contacts are to be wired for
terminals blocks for remote panel.
e) The breaker shall have two trip coils each operating on two independent sources of supply. Trip
circuit supervision relays shall be provided for each coil independently.
Operating mechanism: The spring operated mechanism shall be compete with motor, opening
spring, closing spring and all other necessary mechanism to complete the operating unit. Each
mechanism shall be so designed as to enable a continuous sequence of circuit breaker opening,
closing and opening in the event of failure of supply to motor. Spring charging by the motor shall be
automatic and charging time shall not exceed 15 seconds.
f) Charging of closing spring after each operation of the breaker shall occur automatically. It shall
also be possible to charge the spring manually by means of an emergency handle. A local indication
shall be provided to show the status of the spring. Potential free contacts of spring charged ON/OFF
indication shall be wired to terminal blocks for remote indication.
The breaker mechanism shall be such that failure of any spring shall not prevent any tripping.
g) The closing coils and other auxiliary devices shall operate satisfactorily at all voltages between
85% -110% of the control voltage. The trip coil shall operate satisfactorily at all voltage between 70-
100% of the rated control voltage i.e110/220V DC.
h) When the breaker is in closed or open position, same operation of an initiating control devices
shall not result in the further operation of the breaker closing or opening mechanism or discharging of
the closing spring.
i) Mechanically operated targets to show the open and closed positions of the breaker shall be
provided.
j) The draw out mechanism shall have four positions: service, test, isolate and maintenance position.
a) Service : Both power and auxiliary contacts in Service.
b) Test : Power contacts isolated but the auxiliary contacts are in service.
c) Isolated : Both power and auxiliary contacts are isolated.
d) Maintenance : Both power and auxiliary contacts isolated and the CB is partially
withdrawn on to the special rails temporarily inserted inside the cubicle, suitable for maintenance.
There should be a provision to lock in the isolated position. In the maintenance position,
the breaker shall remain in the cubicle providing access to all the parts enabling to attend simple
maintenance. When the C.B. is drawn out, provision shall be made to close the shutters provided for
the purpose to avoid accidental contacts with live parts.
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All the CTs and PTs shall comply to the following requirements.

213
• Nominal System Voltage : 11KV

• Rated frequency : 50Hz
• Highest System Voltage : 12 KV
• One minute power frequency with stand voltage
(Primary) : 28 KV
• One minute power frequency with stand voltage
(Secondary) : 2 KV
Impulse with stand voltage : 75 KV
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a) Type : 1 Phase, Epoxy Cast resin draw out type
b) Primary Voltage : 11 KV
c) Secondary Voltage : 110 V (Metering) - 0.5 Class
110 V (Protection ) – 3 P class.
d) Burden. : 100 VA. each.
e) HV Fuses
i) Type : HRC
ii) Full load current : 6 A (RMS) rating at 11 KV
iii) Symmetrical fault : 100 KA rating.
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b) Continuous full load current rating of fuses : 10 A
c)Symmetrical fault rating of fuses : 50 KA
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a) Type : Gapless Metal Oxide
b) Voltage Class : 13 KV
Capacitors
a) Type : Single pole, Non - Inflammable oil impregnated
b) Voltage Rating : 15 KV
c) Capacitance : 0.25 Micro Farad
All the materials shall be of the quality as per the Indian or International Standards.
CURRENT TRANSFORMERS
a) Type : Single phase Epoxy cast resin
b) Voltage class : 14 KV
c) Transformation ratio : 2000 /1 A, 800/1A
d) Rated output : 60 V A
e) Class of Accuracy : PS, 5P20, 0.5
f) Minimum Knee point -- >400 Volts for class PS
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214
A Latest type of data acquisition, control and monitoring 1 Lot system having provision for
Local/Remote control panels as per requirement with built in Sequence of event recorder, Automatic
Start/stop sequences for Pump –Motors, HT & LT Switchgear sand other station auxiliaries .Each
pump house shall be operated by independent control center.
Protective Relaying panels for
- Motors
- 11 KV Incoming and Out going feeders
- Bus coupler
- Station supply Transformers

Communication
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The proposed layout of the control room shall be finalized during detailed design and engineering
as per requirement. Panels shall be of simplex type fabricated front MS sheet of not less than 3 mm
thickness for weight bearing members and 2 mm thick for other portions conforming to IEEE or other
standard as applicable. All equipments on and inside panels shall be mounted and completely wired to
the terminal blocks ready for external connections. All control wiring shall be carried out with 650 V
grade, single core, stranded copper conductor of size 1.5/2.5 mm2 FRLS cables
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The computerized control and monitoring system shall be of high end PLC / distributed type built
up on the following components:
- Workstation/plant computer for programming and central control and supervision of the plant.
- Pump level control and common Auxiliaries control.
- Each controller shall have the redundant CPU, I/O cards ,out put and other relays , Temperature
recorders, Indicating instruments etc as required.
- Dual Communication network allowing the data interchange between the unit controller and the
central control system.
- Dual operator stations for man-machine interface
- Provision for Remote control of the station i.e pumps control from other station / control center
through standard communication networks and protocol
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Centralized data acquisition and control system (DACS) having following facilities shall be provided:
i) Control for starting / stopping of the pump/feeder from the unit control board(UCB) locally and from
DACS in control room.
ii) Each auxiliary shall have a local control board near the device with necessary controls, indication and
protection i.e. overload relays, voltage and current meters, control switch for start/stop, MCCB/HRC
fuses for incoming supply, indication & single phase preventer.
iii) For unit auxiliaries, necessary controls, interlocks, instruments and relay panel shall be provided
along with unit. All unit auxiliaries can be also be controlled form unit control board in remote mode.
iv) Automatic voltage regulator shall have local control from respective panels and from unit control
board for start / stop and raise / lower operations and also from Data Acquisition and Control System
(DACS)
v) Status indication of unit and its auxiliaries shall be provided as under:
a) For unit auxiliaries at local control panel and unit control boards.
b) For excitation system locally at their respective panel and on remote control desk.
c) Status indication of switchgear equipment on local control panel as well as DACS through
indicators.
vi) Annunciation system having adequate number of ways with facility to accept, reset and test, for
various fault conditions or abnormal running conditions shall be provided.
i) Analog/digital meters for measurement of MW, MVAR, voltage, current, speed etc. shall be provided
ii) All temperature measuring devices, oil level indicators, pressure gauges, flow measurement
devices shall be mounted on the gauge panel with their contacts wired further to UCB for necessary

215
fault annunciation alarms and tripping.
iii) Status indication of switchgear equipment i.e. isolators, breakers.
Provision for logging of temperature of Motors, bearing shall be made as required. Logging of important
levels shall also be done.
Necessary control and metering functions for AC auxiliaries shall be provided.
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i) The architecture of the proposed system shall comprise the following:
a) Automation cells for the local data acquisition and control comprising:
- Unit level dual controllers
- Station auxiliaries dual controller
b)Programming console (Portable)
c) Three No.s Operator/work stations for man-machine interface
d) High speed Dual data way system connecting the controllers and Operating / work stations
ii) Each controller shall comprise Redundant Power supplies, Redundant CPUs and redundant
communication ports connected to the dual communication network.
iii) The dual computer shall be distributed around a local network and each shall have three dedicated
operator stations, a data server station and a system maintenance station. This shall provide following
facilities: -
- Individual or overall control of the units
- Printing reports
- Graphic displays
- Fault annunciation and alarm management
- Logging facilities
- load, discharges and levels
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Input/Output capacity of various controllers shall be as per system requirement with 3 to 5% spares
input/output provision.
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Each controller shall consist sequence of event recorder with display and printer.
The SOE shall be with 1 milli second resolution
- Critical alarm
- Non critical alarm
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In addition to the equipment already described, each panel shall be equipped with the following as per
requirement:
- Anti condensation heaters with thermostat
- Illumination with door operated switches
- Three pin 15A power socket with switch
- Fuses, terminal blocks, MCBs
- Cable glands
- Annunciation relays
- Flasher relay
- Contact multiplication relays
- Bell/hooter for fault annunciation
- Misc. auxiliary relays as per requirement
It shall comprise the following components:
- A system maintenance workstation with printer
- A colour hard copy printer for the copy of any one of the operator CRT’s.
- Three Dot matrix printers for event logging and report printing
" HGCVWTGU"QH"RNCPV"EQORWVGT"

216
The centralized computer system shall have following facilities:
a) Display Functions
- Alarm display
- Group display
- Bar chart display
- Trend curve display
- Profile display
- Plant schematic display
- Mimic display
b) Recording Functions
- Alarm log
- Post Trip log
- Trend log in 1 Hour/ 10 Hour/ 24 Hour/ 10 days formats
- Plant status logs
c) Supervisory Functions
- Maintenance log
- Hourly /Daily log
- Shift log
- Calculation function
d) System Customization Start up and maintenance
e) Storage of Data
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The following protective relays of Numerical type shall be provided in the 11 KV Switchgear panels
in the feeders as detailed below.
Motor Feeders
Each Motor feeder shall comprise: Redundant Integrated Numerical Motor protection relays with
featuring
Stator earth fault protection (64 N)

Negative Phase Sequence Protection (46)
Over Current Protection (50/51)
Loss of field protection (40)
PT fuse failure protection (60)
Excess Power Protection (32)
Over Voltage Protection (IDMT & Instantaneous type) (59)
Under Voltage Protection (27)
Impedance Back up Protection (21G)
Motor Differential Protection (87 G)
Bearing temp. rise protection
Breaker failure protection (50 BF)
Auxiliary high speed trip relays
Contact Multiplier relays , Auxiliary relays , Aux. CT’s, Test blocks ,
Stabilising resistors, Metrosils and other required items for completeness of scheme.
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Station Auxiliary Transformers 750 KVA indoor type (Dry type with epoxy cast resin winding /
750 KVA oil filled out door type
Each Transformer feeder shall consist of following protections
Over-current protection (50/51)
E/F protection By nuetral displacement detection on 11KV delta Bus(64 UTR)

217
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E/F protection By nuetral displacement detection on 11KV delta Bus(64 UTR)
Breaker failure protection (50 BF)
In addition to the above Auxiliary high speed trip relays, Contact Multiplier relays , Auxiliary relays
, Aux. CT’s, Test blocks , Stabilising resistors, Metrosils and other required items for completeness
of scheme shall be included.
GENERAL INFORMATION
The relays shall be mounted in the 11 KV Switchgear panels.
The relay panels shall be wired with latest Numerical relays containing all the following features.
a) Relays shall, unless otherwise specified, be suitable for operation from instrument transformers
having 5 amps CT or 1 amp CT secondary and 110 V (phase to phase) PT secondary.
b) The relays shall provide comprehensive protection against phase and earth faults and abnormal
voltage, frequency, power, field failure and over fluxing conditions.
c) Two stages of phase over current and earth fault protection shall be provided, with a selection of
nine IDMT characteristics for one of the stages. An additional CT shall be provided for sensitive and
restricted earth fault protection. It shall be possible to set the power element for under power or reverse
power as well as for over power.
d) Plant supervision features like Trip circuit supervision, Circuit Breaker state and condition
monitoring etc. Trip circuit supervision relays shall be provided to both the trip coils of all the circuit
Breakers
e) Required number of LEDs shall be provided and assigned for the different protections operated.
Potential free contact outputs shall be provided / assigned for connecting to external alarms.
g) Programming of the device shall be possible using a front panel user interface, local and remote
communications ports.
h) A configuration feature shall be provided to enable selection of required functions. This shall allow
menu customization, removing unwanted functions and settings groups from the settings displays. The
front panel user interface shall provide independent keys for the viewing and acknowledgement of
alarms.
i) Fixed and programmable scheme logic shall be provided upload able from relay to PC and PC to
relay.
j) The relay shall store factory default protection and scheme logic settings for restoration or upload
to a PC.
k) Different setting groups shall be provided for the protection settings to allow for different operating
conditions and adaptive relaying.
l) Time tagged Event Recorder with 1milli sec resolution, Internal Disturbance recorder with
adjustable Pre-Fault & Post-fault time settings and Fault Recorder to memorize the last few trippings
data such as relay indications, CB timings etc shall be provided.
m) The relays shall be able to provide software support for local and remote programming and
extraction of records from the device.
n) A comprehensive range of instantaneous and integrated measurement values shall be available
for viewing on the user interface and the communications ports.
o) Auxiliary voltage of the relay shall be of 220 V DC provided from the station Battery with redundant
source.
p) Terminal Blocks for CT and PT circuits shall be of Disconnecting type (like Elmex make CATDM4)
only. All other terminal blocks shall be of non - disconnected, stud type similar to Elmex make CATM4.
q) MCBs / Fuses for DC, AC and PT supplies shall be provided.
Apart from different main relays, Auxiliary/ Flag relays must also be provided in relay panels for all
the protections covered in main relays along with the auxiliary protections coming from Motors and
transformers.
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218
MICROPROCESSOR BASED AUTOMATIC RELAY TEST KIT for testing the NUMERICAL / STATIC /
ANALOG relays supplied with all necessary softwares and accessories shall be supplied for
commissioning and periodical maintenance and testing of the relays. The test kit shall be capable of
testing the Transducers and Energy meters. Self calibrating facility shall be available for the kit. The test
kit shall be operable from a PC connected to it. Reputed make such as MEGGER / DOBBLE /
OMICRON
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i) One (1) EPABX equipped with 32 extension and 8 P&T lines including one operator
console and Main Distribution Frame (MDF) and Power supply unit rated 240 V, 50Hz
communication system at Pump House.
ii) Thirty two (32) Push button type telephone sets
iii) One (1) complete set of cables, fixing and erection material for telephone exchange at site.
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A public address system for remote calling of operating personnel, fire/emergency warning in the
Power House comprising.
i) One (1) Power amplified Station for Public Address System with radio, cassette tape and record
player and Power Supply Unit, rated 240V, 50 Hz.
ii) One (1) Master control Unit with microphone, mixer and selection panel for Public Address System
described at (a)
iii) Fifty (10) loud speakers indoor type for Public Address System
iv) Five (5) Loudspeakers outdoor type for Public Address System
v) Complete set of cables, fixing and erection material for Public Address System
vi) One (1) set of tools, handling devices, testing instruments for erection, testing and maintenance of
the complete system
vii) One (1) set of spare parts sufficient for 5 years of operation as detailed below:
Description Qty.
External loudspeaker 1 no
Internal loudspeaker 1 no
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The EPABX interface and the telephone etc. shall be as per the relevant CCIIT recommendation of
ITU. The exchange shall be compatible for interconnection to other similar exchanges through fiber
optics link as well as overhead line alignment for trunk working.
The exchange shall incorporate a built in diagnostic unit, which shall assist in identification and
localization of various system faults. Visual and audible alarm shall be provided in the system for fault
conditions.
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415 Volts A.C. 3 Phase 4 wire LT Switchgear panels shall consists of the following equipment.
Station auxiliary boards (SABs) : 3Nos.
Each LT Board shall consist of the following
a) Potential Transformers
b) Under voltage relays
c) Current Transformers
d) Voltmeters with selector switch
e) Energy meters
f) Current Transformers
g) Air circuit breaker (ACB)
h) Ammeter with selector switch.(Ammeter for 3 phase current)

219
The feeders shall be provided with electrically operated draw out type air circuit breaker of
3 phase, 415 volts, 2000 Amps capacity, 40 KA/1sec. short circuit capacity and shall have shunt trip
facility with built in static type adjustable thermal over load and short circuit protection with suitable high
interrupting capacity etc. These Air circuit breakers can be able to be operated from local /remote with
necessary interlocks in full auto operation through station auxiliary controller.
Each SAB shall able to feed the each pump house auxiliaries and Each load shall be fed
through MCCBs of suitable capacity All the pumps shall have the similar type of equipment and system.
The SAB shall have two incoming feeders from Reserve boards
Reserve Boards shall able to feed all the powerhouse loads (Common auxiliaries) and
SAB’s
a) Complete power house lighting
b) EOT Cranes
c) Air compressors
d) Other loads if any
The above loads shall be fed from any Station Transformers or DG Sets.
STATION AUXILIARY BOARD:
The Station Auxiliary Board shall consist of the following equipment.
1. Incoming feeders, (from Reserve boards ) : 2 Nos.
2000A drawout type ACBs
2. Outgoing feeders with 200 A Non drawout type MCCBs : 4Nos.
3. Outgoing feeders with 100A Non drawout type MCCBs : 20 No.
4. Outgoing feeders with 63A Non drawout type MCCBs : 10 Nos
5. Outgoing feeders with 32A SFU : 30 Nos
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The incoming & outgoing feeders 2000A- shall consist of the following.
a) Voltmeter with selector switch : 1 No.
b) KWH meter with suitable CTs : 1 No.
c) Ammeter with selector switches : 1 No.
d) (2 O/L + 1 E/L) relay with suitable CTs : 1No.
e) Controls, indications and necessary interlocking facilities between the two incomers
Qwv" iqkpi" hggfgtu: The out going feeders shall consists of Non draw out type MCCBs of
respective current rating i.e.100A for 100Amp feeders,200A for 200Amp feeders and likewise. Each out
going feeder other than 63A and 32A feeders shall consist of 1 No. Ammeter with selector switch and
suitable current transformers (CTs) - 3 nos.
The distribution of the feeders should be done in accordance with the single line diagrams.(Drawing
No. ).
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The 2000A feeders shall be provided with electrically operated draw out type 4 pole air circuit
breakers of 40KA interrupting capacity (i.e. service breaking capacity shall not be less than 40 KA) and
shall have shunt trip facility with built in static type adjustable thermal overload and short circuit
protection generally conforming to IS:2516 and shall comply with the following requirements.
(i) The air circuit breakers shall comply with the following requirements.
(i) Nominal system voltage : 415V

(ii) Number of poles : 4 pole R,Y,B and N.
b) Highest equipment voltage : 650V
c) Rated Normal Current : 2000A
d) Symmetrical three phase breaking current : 40KA
e) Rated short time withstands current : 40KA for 3 secs.
f) Rated short circuit making current : 40 KA
Not less than 2.5 times the rated short circuit breaking capacity.
g) 1 Minute power frequency withstands voltage:

220
For Main circuits : 2500V(RMS)
For control and other ckts : 2000V (RMS)
h) Rated frequency : 50Hz
i) Number of poles : 4 (For breaking R-Y-B and N)
j) Rated operating duty : Continuous
k) Closing/shunt trip coil voltage : 230V AC
l) Latching requirements : Trip free
m) Contacts:
All current carrying contacts in the breaker shall be silver-plated and suitable
arcing contacts shall be provided. Arc chutes shall be provided for each pole and these shall be fitted in
such a way that they are suitable for being lifted out for inspection.
n)Operating temperature: The final steady temp. of all silver faced contacts in air when carrying
their rated current shall not exceed 105 degrees C.
o) Opening time : 3 cycles (60msec)
p)Operating Control : To be suitable for local as well as remote
control.
q) Operating mechanism : Mechanical spring charging type. The spring
charging motor shall be suitable for 230 V AC.
r) MCB with a suitable Breaking capacity shall be provided for 2300 V AC Control Circuits
separately along with supply supervision relays viz.,
i) Breaker closing and trip circuit.
ii) Spring charging motor control circuit.
s) Indicating lamps
(i) Breaker ON : Red
(ii) Breaker OFF : Green
(iii) Breaker Trip : Amber
(iv) Breaker spring charged : Violet
(v) Control supply ON : White
Lamp test push button with necessary arrangement shall be provided for lamp test.
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a) The circuit breaker shall be provided with the anti pumping protection.
b) Auxiliary Contacts:
In addition to the auxiliary contacts required for normal breaker operation and
control, 4 normally open and 4 normally closed auxiliary contacts shall be provided. Terminals of each
contact shall be brought out to terminal blocks for customer’s use.
c) Operating mechanism:
Each breaker shall be power operated by stored energy charged spring
mechanism for both closing and opening operations. The mechanism complete with opening spring,
closing spring and other accessories shall operate breaker through local/remote control switches. Once
charged, the springs shall be capable of B-M-B operation of the breaker. Accidental failure of any spring
shall not trip or close a breaker. Charging shall be automatic by DC motor complete with accessories
and the motor shall keep the spring charged at all times. The maximum charging time of fully exhausted
springs shall not exceed fifteen (15) seconds. Charging motor and closing coil shall operate between
85% and 110% of 230V AC and trip coil between 70% and 110% of 230V AC. The making capacity of
the breaker shall be certified for manual as well as electrical closing.
d) Breaker shall close upon closing a contact in its closing circuit momentarily. A sustained
closing impulse shall have no effect on the closing mechanism.
e) Manually operated lever or push buttons shall be provided to close and trip the breaker
mechanically without opening the door. Means shall be provided for emergency manual operation of
electrically operated breaker without opening the door. Arrangement shall also be provided to slowly
open and close the breaker for maintenance.
f) Breaker shall be provided with No Volt trip and static type adjustable thermal overload and
short circuit protection.

221
g) Arrangement for obtaining auto trip annunciation of the breaker shall be provided.
h) Mechanically operated targets should be provided to show the open and closed positions
of the breaker
i) The drawout mechanism shall have 4 positions - Service, test, isolated and maintenance
positions.
1) Service : Both power and aux. contacts are in service.
2) Test : Power contacts isolated but the aux contacts are in service.
3) Isolated : Both power and aux contacts are isolated.
4) Maintenance: Both power and aux contacts are isolated and ACB is partially withdrawn on to
the special rails temporarily inserted inside the cubicle. Suitable for maintenance. In the maintenance
position, the breaker shall remain in the cubicle providing access to all the parts enabling to attend
simple maintenance. When the ACBs are drawn out, provision shall be made to close the shutters
automatically to avoid accidental contact with the live parts.
KPUVTWOGPV"VTCPUHQTOGTU:
All Potential Transformers and current transformers shall comply with the following requirements :
a) Nominal System voltage: 415 V
b) Highest system voltage : 660 V
c) One minute power freq withstand voltage. : 2KV
d) Rated frequency : 50Hz
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A) Details of CTs to be provided in the Incoming feeder breaker compartments.
1) CT Ratio: Shall be 1000/5A: 6Nos.(3 for Protection & 3 Nos

(As per requirements) for Metering)
2) For over current (2 Nos.) and Earth Fault (1 No.)
Accuracy class : 5P
Accuracy Limit Factor : 10
Secondary burden : 15VA
3) For metering in the panel
Accuracy class : 0.5
Secondary burden : 15VA
The Ammeter shall be provided with Ammeter selector switch for measurements of currents R – Y
– B – OFF.
The Voltmeter shall be provided with voltmeter selector switch (7 Positions SS)for
measurement of voltages R – Y, Y – B, B – R, R– N, Y – N, B – N and OFF.
c) Details of CTs to be provided in the 250A/100A breaker Compartments for
metering.
1) CT Ratio 250/5A, and 100/5A : 3 Nos each.
Accuracy Class : 1
Rated secondary Burden : 15VA
d)CT’s for the outgoing MCCB feeders: CT’s are to be mounted only on the three phases
of the respective MCCB compartment for metering purpose. The CT’s shall be of Class 1 and
burden 15VA.

222
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a) The instrument transformers shall confirm to the requirements of the latest addition of the
relevant Indian Standards. It shall be the responsibility of the tenderer to ensure that the VA burdens
are adequate for the relays and meters furnished by him.
b) The CT’s shall be able to withstand the thermal and momentary stresses resulting from the
short circuit and momentary current ratings of the switchgear. The core laminations shall be of high
grade silicon steel or other similar alloy. The exciting current shall be as low as possible.
c) CT’s shall have polarity markings clearly marked on each transformer and at the load
terminations at the associated terminal block. Facility shall be provided for short circuiting and
grounding the CT secondary at the terminal blocks.
MOULDED CASE CIRCUIT BREAKERS:
The following shall be provided on the door of the Moulded case circuit breaker
compartment.
a) The MCCB shall be mounted such that the compartment door cannot be opened when the
MCCB is in OFF position and it should be possible to operate the MCCB only with the door in the
closed position. Facility shall be provided for locking the MCCB in OFF position.
b) Ammeter - 1 No. The make and class of accuracy of Ammeter shall be stated. The scale
of the ammeter shall be 0 – 300A for 250A MCCB , 0 - 150A for 100A MCCB and the ammeter shall be
suitable for connecting to 5A CT. The ammeter shall be connected to 3 nos suitable CTs provided in R,
Y. B phases through ammeter selector switch.
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a) Only MCCBs of reputed make like L&T/ABB/Siemens/C.G are accepted.
b) The MCCBs shall be provided with the interrupting capacity of 40 KA current at 415V ,0.25
PF (i.e. Service Breaking Capacity shall not be less than 40 KA).
c) The MCCBs shall be of quick make / quick break type and shall be provided with the
adjustable thermal overload and magnetic short circuit releases.
d) The operating mechanism of MCCBs shall be trip free type.
e) The MCCBs shall be provided with 2Nos additional auxiliary contacts for external use and
the contacts shall be brought to the control terminal blocks for customers use.
INDICATING INSTRUMENTS:
a) The indicating instruments shall confirm to relevant ISS. The instruments shall be square
dial, flush mounting type and its size shall not exceed (110 mm x 110 mm for ammeters and
voltmeters. Energy meters (rectangle) of suitable dimensions shall be provided and the over all
dimensions shall not exceed 200x150 mm.
b)The calibration of scale on ammeters and voltmeters shall be uniform to the extent possible.
Crowded scale at higher and lower range shall be avoided.
c) Current transformers of appropriate accuracy confirming to relevant ISS shall be used in
conjunction with indicating ammeters wherever required.
d)Type of finish of indicating instrument cases shall be indicated in the bid and shall be subject to
Purchaser's approval.
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a) Control and selector switches shall be rotary type and provided with properly designated
plates clearly marked to show operating positions.
b) The contacts of the switches shall be rated for 415V AC operation. Current rating shall be
stated in the tender.
c) Circuit breaker control switches shall have required number of electrical ways and 3
positions in scribed OPEN/NEUTRAL/CLOSE. They shall have spring return to neutral feature and
pistol grip handle.
d)Local/Remote selector switch handles shall be either spade or pointer or oval shaped. These
shall have required number of positions and contacts. One set of contacts in each position of the
Local/Remote selector switch shall be wired to the terminal blocks for customers use.

223
ENERGY METERS:
a) KWH meters shall be suitable for operation with 415 V and 5A CT supply as required. The
Energy meters shall be of flush mounting type and shall be static type.
b) Energy meters shall be of class of accuracy 0.5 and display shall be of 6 digits.
c) The energy meters shall operate for forward power only.
d) Suitable test terminal blocks of reputed make shall be provided for testing of energy meters.
PROTECTIVE RELAYS:
a) The relays shall be suitable for operation from instrument transformers having 5A CT
secondary.
b) The over current relays shall be of inverse characteristic type with instantaneous trip
arrangement. The relays shall have a setting range from 50% to 200% of 5A.
c) The Earth fault relay shall have a setting range from 20% to 80% of 5A.
d) Only relays of reputed make like GEC/ABB/L&T shall be quoted by the tenderer. The
relays shall be modular in construction and draw out type. Operation indication shall be provided for
each phase.
e) The aux. relays shall be designed to operate on 230 / 415V AC and shall operate
satisfactorily between 85% to 110% Value of the rated voltage.
f) Voltage Supervision relays (A.C) shall have sufficient thermal capacity for continuous
energisation.
g) Relays shall be equipped with manual positive action operating indications.
h) Supply supervision relays shall be inverse flag type. The setting of the relays shall be from 30%
to 80%.
i) Relays shall be flush mounting type and shall have dust tight covers. The relays shall be
draw out /Plug in type and shall have the facility to short the CT circuits when the relays are drawn out/
removed.
j) The under voltage relays should be of reputed make like GEC/ABB/L&T and the make of
the relays should be stated in the tender. The relays shall be provided with adjustable setting and
adjustable time delay to prevent inadvertent operation during surges.
k) In addition to the normal aux contacts used in the control and interlocking scheme, four
normally open and normally closed contacts should be brought to the terminal blocks for purchaser's
external use(for remote alarm and control system).
" DWUDCTU<"
a) The Board shall be provided with 1000A three Phase and Neutral bus bars.
b) The bus bars shall be of high conductivity Aluminium confirming to IS: 5082, liberally sized
for the specified current ratings (both short circuit and continuous current ratings). Maximum
temperature rise of the bus-bar and bus bar connections when carrying rated normal current shall not
exceed 40 degrees C above ambient temperature. The neutral bus shall run along side and full length
of the phase busbar and it shall be rated for half the normal current rating of the main bus for the same
short circuit current.
c) Calculations for arriving at the cross section of the bus bars taking into consideration the
temperature rise and fault level shall be furnished along with the prequalification bid.
d) Busbar shall be of uniform section/rating throughout the length of the panel and shall be
capable of being easily extended at site on either side.
e) The horizontal and vertical busbars shall be insulated throughout their length by heat
shrunk, colored PVC sleeves to provide protection. The sleeves shall be able to withstand the
temperatures attained by busbars during normal service and short circuit conditions. Painting of
Busbars will not be considered as Insulation .Main busbar joints shall be provided with removable
thermosetting plastic shrouds/heat shrinkable PVC tape.
f) Appropriate colour bands shall be used in each compartment to identify the phase
sequence of the horizontal and vertical busbars.
g) Busbars shall be adequately supported and braced to withstand the stresses due to short
circuit currents. All the busbar supports shall be made of glass reinforced thermosetting plastic having
anti tracking design.
h) Separate support shall be provided for each phase of the bus bars. If a common support is
provided for all the three phases, anti tracking barrier shall be incorporated.
i) The busbars shall be housed in totally enclosed bus bar chambers completely shrouded
from the feeder units and cable chambers. The incoming connections from the bus bars to various
feeders shall be so designed as not to disturb the cabling connection, to ensure safety of operating and
maintenance personnel and facilitate work on the outgoing side of a particular feeder without the
necessity to switch off the adjacent feeders .
j) Horizontal and vertical bus bars shall be enclosed in separate chambers.

224
k) The bus bars and supports shall be designed to withstand a short circuit fault level of
(40KA) for 3 seconds. (Necessary type test certificates shall be enclosed.)
l) All joints of bus bars shall be made by suitable bolts and nuts only and shall be tightened
using Belleville washers only.
m) Disconnect able neutral link shall be provided for each out going feeder.
n) A separate aluminum/copper earth bus of adequate cross section as per the relevant IS
shall be provided through out the length of the Board.
MIMIC DIAGRAM:
The panels shall be provided with PVC/Painted or Aluminum overlaid mimic showing the
bus connection and tap off feeders.
" RCPGN"EQPUVTWEVKQP<"
a) The panels shall be metal enclosed sheet steel cubicle, indoor, floor mounting free
standing type. Panels shall be totally enclosed, dust and vermin proof with IP-52 degree of protection as
per IS:2147. These shall be made out of at least 3.0mm thick cold rolled sheet steels suitably reinforced
to provide rigid flat level surfaces, resistant to vibration during transportation and installation. Non load
bearing members such as doors or removable covers shall be at least 2mm thick. No welds rivets,
hinges or bolt threads shall be apparent from outside. The colour of the panels ( interior with Milk white
and exterior with RAL 7032) . The panels shall be modular in construction.
b) Barriers shall be provided between panels and modules.
c) The panels shall be provided with a base channel of 100 X 50 X 6mm size.
d) Soft compressible gaskets are to be used between all mating surfaces including frame to
base and adjoin shipping sections.
e) Hinged doors shall be provided on both front and rear side of the panels. Separate
chamber shall be provided in each panel for providing bus bars.
f) Construction of the panels is such that all identical parts of the panel are interchangeable.
g) Entry for cables shall be from bottom and terminal blocks shall be at rear side of the panels.
h) For convenience of operation at least a gap of 300mm should be left between the base of
the panel and bottom most equipment.
i) Necessary door interlocks shall be provided for all Switch Fuse Units/MCCBs /ACBs in
such a way that it should be possible to open the door only in 'OFF' position.
j) All apparatus shall be operated without excessive vibrations and with the least practicable
amounts of noise.
k) When a unit is drawn out, provision shall be made for automatic closing of shutters to
prevent accidental contact with live parts. When the unit is inserted back in the compartment, it shall
open the shutters automatically allowing the unit to continue its travel until fully engaged.
l) The framework shall house SFUs and breakers in multi - tier form.
m) Colour of the panel : The exterior and interior colors of the panels will be RAL 7032 / white
Space Heater and Panel illumination lamp shall be incorporated as per statutory requirement.
" VGTOKPCVKQPU<"
All the incomers and outgoing feeders will be terminated using 1100V grade PVC insulated
Aluminum/ Copper cables. The entry for these cables and terminations shall be from bottom rear side of
the panels only. The termination shall be located at least a gap of 300mm above ground level.
WIRING:
a) Internal wiring shall be properly dressed and supported over cable ways. All equipment
shall be completely shop wired and be ready for external connections at site.
b) All wires connecting the equipment on the front door to the internal position of the cubicle
shall have suitable flexible arrangement to facilitate frequent opening and closing of the door.
c) For control circuits minimum 1.5 sq.mm, copper,pvc insulated flexible, wire shall be used.
For CT, and metering circuits minimum 2.5 sq.mm , copper, PVC insulated flexible wire shall be used
with colour coding.
d) All the wires shall have PVC insulation for 1100 Volts grade and shall be suitable for
switchboard wiring and comply with requirements of latest issue of IS 1554(Part I). Each wire shall bear
an identifying ferrule at both ends. All the operating coils and small wires shall withstand as erected, a
power frequency test voltage of 2 KV for 1(one) minute.
e) All outgoing control wiring, including that for connecting between shipping sections shall terminate
on terminal blocks preferably vertically mounted on the side of each cubicle. Suitable cable glands and
supports shall be provided for the incoming cables. All spare contacts of the relays, contactors, circuit
breaker auxiliary contacts etc shall be supplied wired up to the terminal blocks for customer use.
" VGTOKPCN"DNQEMU<"
a) The terminal blocks for control circuits shall be of CATM4 type of ELMEX make or

225
equivalent and shall be stud type and suitable for connecting ring type lugs
b) For CT circuits CAT DM4 type of ELMEX make or equivalent make, disconnecting type and
shall be suitable for connection of ring type lugs.
c) The power and control TB’s shall be separated by a barrier in order to avoid accidental touching
of Power terminal while working on control circuits.
d) All TB’s shall be suitably labeled for identification.
e) Terminal blocks for power circuits shall be sturdy and made of good quality molded
phenolic resin or other suitable synthetic insulating materials. Terminals shall be designed to avoid
bimetallic corrosion. Any changes in site connections should be such that it should not disturb internal
wiring.
f) Required number of terminals with at least 20% spare shall be provided for all control, CT
circuits.
" PCOG"RNCVGU<"
Engraved acrylic resin labels for identification of the switch gear, switch gear boards and on all
incoming and outgoing feeder compartments and various equipment thereof shall be provided. The
exact legend to be engraved will dg"hwtpkujgf"vq"vjg"uweeguuhwn"vgpfgtgt0"
" VGUVU<"
a) All the type tests on the panels shall be done as per relevant IS. List of type tests and test
certificates of similar panels shall be furnished along with the quotation.
b)All the routine tests shall be carried out as per the relevant IS on the panels in the factory before
dispatch in the presence of purchaser’s representatives.
c) All the major components used in the panels shall have undergone type tests as per their
relevant standards. Test certificates shall be submitted with the quotation.
PUMP AUXILIARY CONTROL PANELS
Pump Auxiliary Control Panels supply shall be fed from SABs and shall be fed to pumps/valve
controls The panel shall contain Star/Delta starters with minimum protection ‘3’ phase over current
relays, Earth fault relays, temperature relays, oil pressure relays etc. The electrical system shall
consists of the following:
For Incoming Supply
1. MCCBs: For Each Pumps
a) Suitable Starters - One No.
b) O/L Relays (Phase Wise) - Three Nos.
c) Selector switch - One No.
(Stand-by, Neutral, Local)
d) Proper indications for - One Set
Motor ON, OFF
e) Alarms - One Set
f) volt meter with selector switch for the motor 40kW above -One
g) Ammeter with selector switch for the motor 40kW above -One
h) Ammeter for motor of 10kW above and under 40kW -One
i) Control Panel for control of motor of 22.5kW and above shall be Provided with
star/delta starting.
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The capacitors shall be directly connected to the Reserve board switchgear system for automatic power
factor correction. The capacitor shall be rated so that motor power factor is corrected to 0.95 lagging
when on full load with due consideration for the limit imposed by motor magnetizing current. Calculation
for selection of capacitor bank rating shall be forwarded to Engineer for approval. Capacitor units shall
conform to relevant Indian Standards,
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a) Each capacitor bank shall comprise 3 Nos. single phase units and shall be complete with all
pans That are necessary or essential for efficient operation. Such parts shall be deemed to be
within the scope of supply whether specifically mentioned or not.
b) The capacitor banks shall be complete with the required capacitors along with the supporting post
insulators steel rack assembly copper bus bars,copper connecting strips, foundations channels, I IRC
fuses fuse clips, internally connected discharge devices, lifting facilities terminal chamber and a gland to
suit bottom entry of suitable XLFE unearthed grade cable. The steel rack assembly should be not dip
galvanized.
c) The complete bank with its accessories shall be placed in steel structural frame and covered by
wire mesh all around and at bottom and 16 gauge sheet on top. Wire mesh opening shall not be more

226
man 6 mm x 6 mm.The bank shall be floor mounting with sufficient bottom clearance and shall be free
standing type.
d) The assembly of the banks shall be such that it provides sufficient ventilation for each unit.
e) Each capacitor case and the cubicle shall be earthed to a separate earth busin the cubicle
f) Each capacitor / bank / unit shall be fitted with directly connected continuously rated, low
loss discharge device to discharge the capacitors to reduce The volume lo 50 volts within one minute in
accordance within the provisions of relevant Indian Standards IS 2834.
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"
Ueqrg: 2No’s of 750KVA,3 Phase, 11 KV/415 Volts, Delta/Star, %impedance 5.% at normal tap
Inndoor/Outdoor type, oil filled, ONAN type cooling, type transformer , copper winding capable to
feed the loads of pump house with minimum protection, features such as PRV and Bucholtz
protections. The standards shall be of IS 2026. The details of transformer being supplied shall be
enclosed
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The offer for supply of transformer shall include all parts and accessories which are useful and
necessary for the efficient and safe operation, such parts and accessories shall be deemed to be within
the scope of this specifications whether specifically mentioned or not.
Drawings showing the general arrangements foundation details, fittings shall be
furnished along with the offer. The schedule of guarantees and technical particulars shall be furnished
along with the offer for each type of transformer. List of past supplies made to Govt. / Quasi Govt.
Corporation/Undertakings shall be enclosed. The rates quoted for the transformers shall be for designs,
manufacturer, supply and deliver at respective destinations.
Packing shall be sturdy and adequate to protect all assemblies, components and
accessories from injury by corrosion, dampness heave rains, breakage, vibration
encountered during transportation, handling and storage at site.
" VGEJPKECN"URGEKHKECVKQPU"<"
;0403(a) The Transformer shall be copper wound distribution Transformer.
(b) The Transformer is of 3 phase, 50Hz. AC double wound, oil immersed Naturally
cooled, core type and suitable for outdoor installations. The Rating of the Transformer shall be not less than
750 KVA.
(c) The make of the Transfer should have been approved by AP DISCOM’s A certificate to that extent
shall have to be enclosed along with the tender.
Transformers with ISI marking shall be specifically mentioned in the tender.
The Distribution Transformer should confirm to IS 2026 of 1962 or the latest revision thereof.
The transformer shall be Delta-star connected with neutral brought out on LT Side,
with Vector group Dyn11.
The Transformers shall be supplied with first filling or transformer oil. The drain valve shall be provided
with locking arrangements.
The transformer shall be provided with LV cable box on LT side with a base plate and glands shall be
provided for cable entry.
(d) Temperature rise shall not increase 40 degrees centigrade for oil and 55 degrees
centigrade for winding over a maximum ambient temperature of 45 degrees centigrade.
Off load tap switch shall be provided to vary HT Volts by +5% to –10% in steps of 2.5% the tap switch
should be gang operated operating simultaneously on all three phases with multiple indicator and
mechanical locking devices.
(e) The LT cable boxes (of adequate size with sufficient space for free movement of
cables for connecting Aluminum armoured cables) with cable entries, with suitable cable glands
suitable to receive purchasers incoming cable of the following sizes shall be provided.
(e) The bottom plate of the cable box shall be detachable type where the cable glands
are provided.
The Transformer shall be painted with one coat of red oxide initially and two coats
of epoxy gray enamel paint.
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"

227
a) Air release devices : 1 No
b) Drain valve with locking arrangement : 1 No
c) Oil Filter Valve : 1 No.
d) Earthing terminals (Body ) : 1 No.
e) Explosion vent with diagram : 1No.
f) Lifting tongs : 4Nos.
g) Bottom channels : 1set
h) Conservator with oil level gauge : 1set
i) Dehydrating breather with silica gel : 1No.
j) Thermometer pocket : 1No.
k) Paracillers on HT on LT : 1Set
l) Rating and Diagram plate : 1No.
m) Insulated earth point outside the LT cable box :1 No.
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Routine tests shall be conducted on the transformer as per applicable Indian standards
and copies of Test Certificates shall be furnished to the Consignee and also one set to
Regd. Office. Impulse with stand test/certificate shall be submitted before, the
guaranteed period on a similar indenting call type of transformers manufactured by
the supplier.
All tests shall be carried out in accordance with clause 16 of IS 2026/Part-l/1977 or any other
authoritative standard for power transformers.
" TQWVKPG"VGUVU<"
All transformers shall be subject to routine test at the manufacturer's works. The following tests are to
be carries out.
I. Measurement of winding resistance.
II. Ratio, polarity and phase relationship.
III. Impedance Voltage.
IV. Load losses.
V. No-load losses and no-load current.
VI. Insulation resistance.
VII. Induced over voltage withstand test.
VIII. Separate source voltage withstand test.
IX. Unbalance test.
X. Dielectric test of Oil.
" V[RG"VGUVU<"
The following type tests shall be made on the transformers:
I. Temperature Rise Test
II. Lightning Impulse Voltage Test.
GO"32"UVCVKQP"DCVVGT[."DCVVGT["EJCTIGT"("FE"FKUVTKDWVKQP"DQCTFU.
220 V DC Batteries of minimum of 200-Ampere Hour or suitable higher capacity shall be provided.
The battery shall be able to support the complete station load for a period of 24 hrs, without AC supply.
Maintenance free Ni -Cd, or maintenance free lead acid battery and charger with static control
circuits and Thyristor bridge rectifiers with complete automatic voltage, current regulation.
Type of battery : Maintenance free lead acid high discharging Performance indoor PLANTE
type station battery.
Nominal Voltage : 220 Volts

228
AH efficiency : 90% minimum
Watt Hour efficiency : 82% minimum
Time required for Boost : 8-10 Hrs charging from completely discharged condition
Nominal life of battery : 20 Years
Terminals : Integral lead terminal with solid copper core
Connectors : Heavy duty lead plated copper connectors.
The battery charger shall consists of twin type boost and float chargers with latest control
technology to suit the requirement of charging of batteries and for feeding the loads. The rectified DC
shall be fed into Main DCDB. From there the DC supply shall be extended to individual Unit DCDBs
located at Unit areas. Necessary indications and alarms for status and faults shall be provided. DCDB
shall consists two incomers sourcing from two battery sets and one Bus coupler with necessary
interlocking.
GO"33"UVCVKQP"WRU"U[UVGO"CPF"CEFDu"
"
The contractor shall design and supply redundant UPS of suitable capacity for each pump house
suitable to meet,
1. Constant Voltage Constant Frequency (CVCF), 50 Hz, 100% redundancy UPS system
and which shall be able to meet main control(SCADA). The UPS battery shall meet the UPS load for
Two hour back-up in case of AC supply failure.
2. Power House emergency lighting load shall be considered on the second UPS system.
The contractor shall be taken care the extra lighting load on the UPS system while designing.
3. Necessary ACDB with required no of feeders for SCADA , controllers, Emergency lighting
with suitable MCB, s , fuses and indicating lamps shall be provided.
GO34"HKTG"HKIJVKPI"U[UVGO"
"
The Contractor shall design, supply, testing & commissioning of fire protection equipment along
with necessary control and annunciation arrangements comprising of
a) Fire Hydrant System
b) Portable fire extinguishers
- Fire Hydrant system with fire hydrants to be located at the specified locations all over the
pump House. The system shall be complete with piping, fire hose cabinets, fire hose and all other
accessories required.
- Portable Fire Extinguishers both wall mounting type and tyre mounted type like
a) CO2 type – 35 Nos.
b) Foam type – 25 no.s
- Smoke / Heat detectors to be placed in the specified area to generate automatic alarm in
case of fire to indicate the zone under fire.
- Linear Heat Sensing Cable shall be laid in the control cable-duct to sense the zone under
fire.
GO"35"RWOR"JQWUG"NKIJVKPI"
a) Complete lighting system shall be provided for the following places in the Pump House.
The illumination levels as requires in various locations of Pump House are as given below.
Sl No Place/Location Type of lighting Fixture
Lighting level
1 Main control room Decorative lighting fixtures 300 lux
2 Other areas inside The pump house LED type fixtures 70 –100 lux
3 Machine hall (high bay) High bay fixtures MH & HPSV 260 lux
4 Transformer area MH fixtures 100 lux
5 outside yard and other approach Roads
a) Street light fixtures HPSV / LED fixtures 150 lux
b) Auxiliary supply: 415+/- 10%, 3 phase, 4 wire, 50HZ AC supply grounded neutral shall be provided
for lighting system:
c) Layout of wiring:
i) LT Power Cables from main lighting board shall be run in surface conduits or in trays to
the branch lighting boards or S.D.B. The wiring from SDB to the individual lighting point shall be in

229
surface PVC conduits of size 25mm dia. The conduits shall be supported by suitable places. In all
types of wiring, neatness and good appearance shall be maintained. No joint shall be made at
intermediate point in the run of cables unless the length of route is more than the standard length of coil
as given by the manufactures.
ii) To eliminate the stroboscopic effect from continuous row of luminaries, the alternate
lamps shall be connected to different phases of the 3 phase system.
iii) The main lighting boards shall be energized from the Reserve board / station auxiliary board/
unit auxiliary board where normal AC supply is available.
iv) Main lighting boards shall have MCCB (40KA) on incoming and outgoing circuits deputing
upon load requirement.
v) Lighting boards (LDB) shall have MCCB with 40KA short circuit capacity incoming and
outgoing SP MCB (9KA) as four ways or 6 ways as required or depending upon the lighting
fixture.
d) Emergency lighting:
Emergency lighting shall be provided with 230V, AC, CFL type fixtures on UPS system. These
fixtures shall be fed from the sub/circuits of UPS distribution boards. The UPS lighting wiring shall be
laid in independent conduit system.
e) Portable lighting units:
Portable type (6 hours discharge capacity) self-charging light units shall be provided. These
lighting units shall be complete with battery charges etc.
f) 1 phase and 3 phase sockets:
i) 1 phase, 240V, 5A and 15A 3 pin/ industrial type socket outlets for light and power circuits
along with MCB shall be provided. The socket outlets shall be suitable for wall/column mounting while
those in office room and control room shall be recessed in wall.
ii)415V, 30A power outlets each controlled by MCB (industrial type) shall be provided.
Connections to the sockets shall be given by means of independent sub circuits from AC LDB or MLB.
g) Inspection lighting socket outlets: 24volts, 5A, 1 phase socket outlets meant for inspection lighting
purpose in the Motor barrel shall be provided. These sockets fed from 500VA, 240/24V AC 1 phase air-
cooled transformer, and these shall be fed from LDB. The wiring for these sockets shall be run in
separate conduits.
h) Main lighting board (MLB):
i) The metal clad MLB shall be of freestanding, totally enclosed, dust vermin and drip proof and
shall be compartmentalized. The panel (MLB) shall be made of 2.0mm CR sheet or 2.5mm Hot rolled
sheet and having smooth finish and elegant appearance. All door panels and removable covers shall
be provided with gaskets to render effective protection against dust.
Each vertical panel of all boards shall be equipped with space heaters and shall
be provided with voltmeter and ammeter and shall be illuminated suitably by lamps.
ii) All in coming and outgoing power cables shall enter bottom.
i) Lighting distribution boards (LDB)/Sub distribution board (SDB):
LDB shall be suitable for mounting on wall or column. The enclosure shall be constructed of sheet
steel of thickness 2.0mm.
j) Conduits & other Accessories:
a) Conduits: Conduits shall be of rigid PVC with dia of 25mm. All conduits in Air-conditioned areas
where false ceiling is provided shall be concealed in the false ceiling. However in these areas conduits
leading to switches and sockets shall be concealed in walls. Screwing of conduits shall be carried out to
give clean threads standard bends, inspection type fittings shall be used. All conduits shall be
terminated by screwing and securing by a lock nut to the respective accessory, outlet or luminaire and
fully protected from the weather. Opening through walls and floors for conduits shall be sealed and
made weather proof.
b)Junction boxes: FRP junction boxes shall be used. The size of such J.B. shall be adequate to
house the bends and extra length of PVC wires and double check nuts for conduits termination.
c) Cables/Wires: The LT power cables shall be 1.0 KV grade Aluminum stranded conductor, PVC
sheathed (un -armoured) confirming to standards. The lighting wires shall be 650V grade copper PVC
insulated single core (sheathed) confirming to standards Color code for respective phase and black for
neutral shall be maintained within enclosure such as for switches, J.B. and sockets etc, shall be used
with green color PVC wire.
k) Brackets and supports: Wherever necessary, brackets and supports shall be provided for luminaries.
All brackets and supports shall be of hot-dip galvanized.
l) Earthing: All the equipments of lighting system such as MLB’s LDB’s lighting fixtures sockets etc. shall
be provided with earthing terminals ,all accessories and shall be connected to purchaser’s ground mat.
To achieve perfect electrical, earthing continuity, the grounding wire shall run through the PVC conduits

230
throughout the installation of lighting fixtures.
m) Illumination level verification: After completion of lighting installation in the Power House, the
illumination level at different locations shall be measured by lux meter as per requirement. If measured
illumination levels are lower than the specified extra lighting fixtures shall be added so as to achieve the
specified lux level.
GO"36"GQV"ETCPGU"
The capacity of main hoist shall depend on the heaviest package or assembly to be lifted. The
capacity of crane shall suit to the heaviest package or assembly to be lifted. The type of cranes shall
be of Indoor type Double Girder Goliath (A Frame) type electrically operated Crane or Electric operated
double girder overhead traveling crane. It shall comprise main & auxiliary hoists for each crane. The
main hook of crane shall be of Rams-horn type swiveling hook with standard depressed type safety
latch.
The scope and supply covers the design, manufacture, testing at works, supply erection, testing
and commissioning of indoor, bridge type electrically operated over head cranes of intermittent duty,
controlled from cabin through master controllers / down control. The cranes shall be supplied along with
the hoist with Main and auxiliary hooks, Girders, wheels and rails, end carriages, trolleys, walkways,
ladders, hooks, hoist ropes, rope drums, slings, sheaves, drives, Shrouded down shop leads etc.
complete with all other accessories and necessary mounting fittings , maintenance and erection tools
and spares etc.
The crane shall be conformed to high standards of engineering, design, workmanship and shall
also conform to IS 807 and 3177 with latest amendments.
The cranes will be normally used for erection and maintenance works of equipment connected with
the Pump House.
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tco/ujqtp"v{rg"uykxgnkpi"jqqm"ykvj"uvcpfctf"fgrtguugf"v{rg"uchgv{"ncvej0"
SALIENT FEATURES OF THE CRANES:
a) Type: Electrically operated overhead traveling crane.
b) Minimum Capacity: Main Hook : Based on Heaviest equipment
: Aux. Hook : 15 tonnes
c) Hoist Speed : Main Hook : 1.5M / min
: Aux. Hook : 3M / min
d) Highest point of hook above Motor floor :as required
e) Maximum Lift : as required
f) Cross Travel speed : 8 M/min.
g) Long Travel speed : 20 M/min.
Wire Ropes:
a) Construction : Suitable size as per IS: 2266 of 1963 with latest Amendments.
b) Factor of safety: As per IS with latest amendments.
14.3.a) Crane Span-center to center distance between runway rails: as required with a minimum margin
of 400 mm on either side.
b) Side clearance from wall to center of rail :As per requirement.
14.4.Length of runway
14.5. Duty or class of crane as per ISS latest:
i) Crane structure : Class 2
ii) Main Hoist : Class 2
iii) Auxiliary Hoist : Class 2
iv. Cross travel : Class 2
v. Long travel : Class 2
14.6.a) Bridge Girder and walkways: The individual bridge girders shall be of box girder construction
without rigger girders. Diaphragms and rigs shall reinforce the box section.
b) Design requirements for structure: A seismic co-efficient of 0.1 shall be used for all structural
design.
36090FGUKIP"TGSWKTGOGPVU"QH"ETCPG"CPF"ETCPG"UVTWEVWTG<"
The design of the crane and its structure shall be such that:

231
i. Low Head room.
ii. Possible to X-ray all the main butt-weld joints of the web and flange plates of the crane girders.
iii. Pleasing appearance.
iv. Easy maintenance.
v.Anti-vibration design: The crane shall be designed for strength and deflection and also to avoid
excessive vibrations in order that the crane as a whole shall have a greater service life. The box girder
of the crane offered shall be designed to limit the natural vibration damping time less than 15 seconds.
The crane shall be designed so as to avoid the vibration in the crane rail also due to vibration in the
crane bridge.
vi.End carriage & Girder joints: The contractor shall incorporate taper thickness plate design for joining the
end carriage to the main girders, thereby ensuing smooth flow of stresses and avoiding sharp bends
which result in concentration of stresses.
vii. VVVF controllers shall be adopted for fine control.
viii. Shrouded DSL with copper conductor shall be envisaged.
" CWZKNKCT["RQYGT"UWRRN[<"
Auxiliary power supply 415V, 3 phase, three wire 50 cycles/ second with voltage variation of 10%
and frequency variation of + 5%.
" OCKPVGPCPEG1"URGEKCN"VQQNU"CPF"VCEMGU<"
The contractor shall furnish a complete list of maintenance tools required for proper maintenance of the
crane in the offer.
" TCKNU"HQT"GQV"ETCPG<"
Suitable size rails section of required length with all accessories shall be supplied and erected by
contractor
" FTCYKPIU"VQ"DG"HWTPKUJGF<"
The contractor shall submit the following drawings.
a) General arrangement of the equipment offered (scope of supply and total weight of crane to be
indicated).
b) Detailed dimensioned drawings and descriptive literature of all the components supplied.
c) Electrical wiring diagram.
" KPUVTWEVKQP"CPF"OCKPVGPCPEG"OCPWCNU<"
The supplier shall furnish ten bound copies of instruction and maintenance manuals for installation,
operation and maintenance of all the equipment furnished by him. The manuals shall be specific to the
equipment furnished and not of general nature.
" RTQVGEVKXG"VTGCVOGPV<"
The crane will be required to operate in a hot and humid climate. All parts of the crane shall be
designed to withstand such atmospheric conditions, without any deterioration. Necessary protective
treatment to withstand against fungi, rust, condensation and corrosive atmosphere, shall be given to all
electrical and mechanical components, parts etc., of the crane, crane girders, structures etc., Final
coating with anti bee paint shall be done after erection at site
" EQFGU"CPF"TGIWNCVKQPU<"
The crane in its entity shall comply with all currently applicable statutes, regulations and safety
codes relative to the design, construction and operation of crane in the locality where the crane will be
installed. Nothing in these specifications shall be construed to relieve the seller of his responsibility.
In particular, the crane shall conform to the latest addition of the following standards with latest
amendments:
a) BS:466 “Electric overhead traveling Crane”.
b) BS:3037 “Tyres for crane rail wheels”
c) BS:302, 621 “ Steel wire ropes for cranes, excavators & general engineering
purposes”
d) BS:482, 2903 “ General requirements for lifting hooks “ M.S. shackles” and 3017:
e) BS:825 or BS 3032 “ High tensile steel shackles”
f) BS:436 or “ Spur and helical gears”
BS:544 or “ Bevel gears ( machine cut)”
BS:721. “ Worm gearing”.
g) BS:46 “ Keys and keyways and taper pine:.
h) BS:2059 “Straight sided.
i) BS:2613 “ The electrical performances of rotating electrical machinery”
j) BS 587 “ Motor starters and controllers”.

232
k) IS:807 “ Code of practice for design, manufacture, erection and testing of cranes and
hoists”.
l) IS:226 “ Structural steel ( Standard quality)”.
m) IS:1364 “ Precision and turned hexagonal bolts”.
n) BS:1856 “ General requirements for the metal are welding or mild steel”.
o) BS:2573 “ Permissible stresses in cranes”.
P) BS: 229 “ Flame proof enclosures of electrical apparatus”.
" RGTHQTOCPEG"TGSWKTGOGPVU"CPF"IWCTCPVGG<"
The crane shall be capable of raising, lowering, holding in any position and transporting an occasional
load of 120 percent of rated load without any damage or distortion to any crane part. The crane and
each hoist shall operate within the following tolerances.
With hook carrying 100 percent of rated load and with all hoist brakes properly adjusted and operating
normally, it shall be possible to control the vertical movement to within 2mm.
Motion of bridge and trolley shall be controllable to within 6 mm under all normal and overload
conditions of loading as specified herein.
The crane shall be guaranteed by the manufacturer to be of accepted modern design, free from
inherent defects in either workmanship or material and to safely handle its rated capacity load without
undue deflections in its structure or mechanism.
All materials shall be best of the respective kinds. Any parts found defective within 12 months from the
date of commissioning shall be replaced to the complete satisfaction of the purchaser free of charge.
" FGUKIP"CPF"FTCYKPIU<"
Supplier shall furnish for the purchaser’s review three copies of complete design calculations for the
structural design, general arrangements drawings of the crane, trolley and bridge, structural detail
drawings showing equipment with identifying name plates, warning signs, framed instructions etc., and
all electrical drawings complete with dimensions necessary to understand and install all electrical
equipment circuit diagrams elementary panel wiring, inter connections diagrams, resistor connections
and electrical bill of material showing all material required electrical rating of motors, switches, starters
and heaters.
Examination and approval of drawings by the purchaser shall not relieve the supplier from the entire
responsibility for engineering design, workmanship and material under the contract.
" ETCPG"CEEGRVCPEG"CPF"VGUV"EGTVKHKECVGU<"
The supplier shall provide at his expense, a competent, experienced representative, who shall on
completion of the crane installation check and certify that the crane has been properly erected,
demonstrated to the purchaser the crane operation, lubrication and periodic maintenance adjustments,
and also direct the purchaser in the initial crane operation to demonstrate its satisfactory performance
for acceptance by the purchaser.
" RCKPVKPI0"
All fabricated steel material shall receive one shop coat of anti-corrosive paint after having
been thoroughly cleaned of all loose mill scales, rust and foreign matter. Machine finished surfaces
shall be coated with white lead and yellow before dispatch. Paint shall be applied at temperature of 4-
5o C or lower. Paint shall be stirred frequently to keep the pigment in suspension. One additional coat
of read lead paint shall be applied for all steel work after erection.
The interior surfaces of box sections and surfaces in accessible after assembly or erection, shall be
thoroughly cleaned and painted with two coats of red lead paint or any other anti-corrosive paint, before
assembly.
Any steel scratches during erection shall be touched up after erection with lead paint.
All bright parts shall be applied with suitable rust preventive paint which can be easily removed during
erection.
The slings, D - shackles of various capacities for general purpose, spares for five years of operation &
maintenance and special tools, tackle etc., shall also be supplied.
GO"37"RWOR"JQWUG"GCTVJKPI"("ITQWPFKPI"
"
Pump House Earthing shall be provided with suitable size of Mild steel (MS) flat as per the standards
from the bottom most point of pump house. The earthing system shall be suitable to meet the earthing
of all the electrical equipment in the powerhouse.
All the electrical equipment shall be grounded at two points. Earthing shall be provided by
means of an earth mat laid right into the tail race to keep the earth resistance to minimum. The earth
mat shall be designed duly taking into consideration of the local soil particulars.
GO38"CKT"EQPFKVKQPKPI"("XGPVKNCVKQP"
Air conditioner system with split Air conditioner for all the required rooms like control rooms, office

233
rooms etc. with false ceiling and necessary glass partition shall be made with aluminum frames.
Ventilation system of Civil masonry spray type Air Washer unit with Double inlet Double width (DIDW)
centrifugal supply air blower suitable for adequate air handling capacity against 50 mm WG static
pressure. The Air washer shall comprise of air intake louvers, pre-filters, double bank spray set, mist
eliminator, split casing pump, etc. And also the Air washer system shall consist of required GI ducts, air
grills, dampers etc.
Czkcn"Hnqy"Hcpu<"These fans shall have cast aluminum impeller with blades of aero foil design. The fan
casing shall be of heavy gauge sheet steel construction. Necessary rain protection cowl, inlet and outlet
cones; bird protection screen, dampers etc. shall be provided.
Egpvtkhwicn"Hcpu<"These fans shall have scroll fabricated out of heavy gauge steel sheet. The impeller
shall have die formed backward curved blades and shall have non-overloading characteristics. The fan
bearings shall be ball or roller of the self-aligning type. The fans shall be belt driven. Necessary
accessories like fan belt protection screen, vibration isolation damper, base plate etc., shall be
provided.
Tqqh"Xgpvkncvqtu<"
Roof Ventilators shall be located in the Pump House. The impeller shall be of axial flow type, cast in
one piece and casing shall be heavy gauge construction. The head shall be provided to protect from
rain and other contingencies. All accessories, steel supports as required will be provided.
GO"39"FI"UGV"qh"tgswktgf"ecrcekv{"pqv"nguu"vjcp"472"MXC""
"Ueqrg<Contractor shall design and supply 2 no.(five) No. 250 KVA (Ecoustic Enclosure type), 3
phase, 415 Volts 50Hz or suitable higher capacity Diesel Motor with control & protection panels,
Battery, Battery charger, AVR and Remote starting facility meeting to the latest pollution control
standards.
The starting of DG set engine shall be by electrical self-starting unit with source of energy
from batteries. Its cranking device should be so designed that it would operate automatically whenever
starting impulse is received. The priming of the fuel oil system and the pressure lubrication of the
bearings and cylinder valves should also start simultaneously to obviate any chance of seizure of
pistons and bearings as well as air locking in the fuel supply system.
The engine should be suitable for running on high-speed diesel oil as available in India. The
engine shall be capable of running on load within 15 to 20 seconds of its starting.
The cooling of the engine shall be by water filled radiator.
" Oqvqt"Urgekhkecvkqp"
1. Rating : 250 KVA or suitable higher capacity
2. Power Factor : 0.85 lagging
3. Rated Voltage : 415 V
4. Rated frequency : 50 Hz
5. No. of Phases : 3
6. Type of insulation : Class F
7. Noise level : <75 dB
" Fkgugn"Gpikpg"
The engine shall be stationary type, four-stroke, preferably in-line cylinders, normally aspirated or
super charged with inter-cooler and pre-combustion chambers capable of developing adequate Horse
Power to deliver 250 KVA at Motor terminals at the site conditions of average 50 degrees Centigrade
ambient air temperature and maximum ambient temperature of 55 degrees centigrade.
" VGUVU"
a) All the type tests on the following equipment shall be done as per relevant Indian or International
standards, list of type tests and test certificates of similar equipment shall be furnished along with the
bid.
b) All the routine tests shall be carried out as per the relevant Indian or International standards on
the equipment, in the factory before dispatch in the presence of purchaser’s representatives.
c) All the major components used in the equipment shall have under gone type tests as per their
relevant standards. Test certificates shall be submitted with the bid.
1. Motor Protection Relays
2. sequence control and data acquisition, Programmable logic control.
3. 11 KV switch gear panels
4. Station Auxiliary Transformers(Indoor / outdoor type)
5. 415 V LT Distribution Boards (SABs & RBs)

234
6. Power House & Switchyard lighting
7. EOT Cranes
8. Power & Control Cables, Cable Trays
9. Power House earthing & Grounding
10. A/C & Ventilation
11. Internal telephone system
12. DG Set 250 KVA
13. UPS System
14. Fire Fighting System
15. Testing Equipment
GO"3:"JV"ECDNGU"
"
" UEQRG<"
Design, manufacturing, testing at manufacturer’s works before despatch, packing and
transportation to site of fire retardant low smoke (FRLS) type power and control cables.
" IGPGTCN"KPHQTOCVKQP<"
The cables furnished under this specification shall conform to the standards specified in Section-
Cables.
The design and workmanship shall be in accordance with the best Engineering practices to ensure
satisfactory performance throughout the service life.
" IGPGTCN"TGSWKTGOGPVU<"
Before dispatch, the cables offered shall be made available for inspection to a duly authorized
representative of the Purchaser. Inspection may also be made at any stage of manufacture at the
option of the Purchaser and the cables found unsatisfactory due to the material used or poor
workmanship shall be rejected. The Contractor shall guarantee free access to the places of
manufacture to the Purchaser’s representative at all times when the work is in progress. The
Contractor shall inform the Purchaser in advance the time of starting of manufacture and the
progress of manufacture of the cables offered by him, so that arrangement can be made for
inspection.
Inspection and acceptance of cables by the Purchaser or his authorized representative
shall not relieve the Contractor of his obligation of furnishing cables in accordance with the
specification and shall not prevent subsequent rejection, if such cables are later found to be
defective.
Test reports for all type tests shall be submitted.
All type and size of cables shall be subjected to routine and acceptance tests in
accordance with the requirements stipulated in Section-Cables relevant standards without any
extra cost to the Purchaser. Cables should not be dispatched until the test reports are duly
approved by the Purchaser or his authorized representative.
The Purchaser reserves the right of having at his own expense any other tests of
reasonable nature carried out at site or at manufacturer’s works or at any other place in addition to
the aforesaid type and routine tests to satisfy himself that the cables comply with the specification.
" IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU<"
The contractor shall furnish all the guaranteed and other technical particulars for the cables.
Any other particulars considered necessary may also be given in addition to those listed in the
Schedule.
" UVCPFCTFU<"
The cables covered under this specification shall comply with the requirements of latest edition of the
following standards including amendments*:
i) IS:1444(Part-I) PVC insulated (Heavy Duty) Electric Cables for working
voltage unto and including 1000 V.
ii) IS:7098(Part-I) Cross linked Polyethylene Insulated PVC sheathed cables.
iii) IS:3961 Recommended current ratings for cables.
iv) IS:8130 Conductors for insulated electrical cables and flexible cords.
v) IS:4831 PVC insulation and sheath of electric cables.
vi) IS:1743 Aluminum conductors for insulated cables.
vii) IS:2982 Copper conductors in insulated cables and cords.
viii) IS:3974 Mild steel wires, strips and tapes for armouring of cables.
ix) IEC:402 Extruded solid dielectric insulated power cables for rated

235
voltage from 1KV up to 30KV.
x) IEC:440 Test methods for insulation and sheaths of electric cables and
cords.
xi) ASTM D-2863 Method for measuring minimum oxygen concentration to support
candle like combustion of plastics.
Note: IEC standards or equivalent Chinese standards are acceptable
Cables meeting the requirement of any internationally recognized standards which ensures quality
equal to or better standards shall also be acceptable.
" VGEJPKECN"TGSWKTGOGPVU<"
Igpgtcn<" The cables shall be suitable for laying in racks, ducts ,covered trenches, conduits
and underground buried installation with chances of flooding by water.
The aluminum/copper wires used for manufacturing the cables shall be true circular in shape
before stranding and shall be of uniformly good quality, free from defects. All aluminum used in the
cables shall be of H2 grade. The fillers and inner sheath shall be of non-hygroscopic, fire retardant
material, shall be softer than insulation and outer sheath shall be suitable for the operating
temperature of the cable.
Suitable chemicals shall be added to the outer sheaths of all cables to protect them from rodent
and termite attack. These chemicals shall not have any harmful effect on the human being.
The cables shall have an Oxygen index of not less than 29 as per ASTM D 2963 and
temperature index of not less than 240 deg. C.
The normal current rating of all PVC insulated cables shall be as per IS-3961.
The XLPE insulated cables shall be capable of withstanding a conductor temperature of 240 deg.
C during a short circuit and PVC insulated cables shall be able to withstand a temperature of 160 deg.
C during short circuit.
Allowable tolerance on the overall diameter of cables shall be ± 2mm.
Repaired cables shall not be accepted.
The XLPE insulated LT power cables shall withstand with out damage a 3 phase fault current of at
least 40 KA for at least .12 sec. with an initial peak of 104 KA in one of the phases. The armour of
XLPE insulated power cable shall be acceptable of carrying 40 KA for at least .12 sec. without
exceeding the maximum allowable temperature of PVC outer sheath.
GO"3;"NV"RQYGT"("EQPVTQN"ECDNGU"
"
" NV"Rqygt"Ecdngu<"
The XLPE insulated 1000 V grade power cables shall be FRLS type of category C1
conforming to IS:7098 Part-I (as amended up to date). The conductor shall be stranded
aluminum, circular/shaped and compacted. In multi core cables, the core shall be identified by red,
yellow, blue and black colored strips or coloring of insulation. For multi core cables the inner
sheath shall be of extruded PVC of Type ST-2 of IS:4831 or equivalent of any International
standard. Armoring for single core cables shall be aluminum strips/wires and for multi core
cables galvanized steel strips/ wires. Outer sheath for all cables shall be extruded PVC of Type
ST-2 of IS:4831 or equivalent of any International standard.
The PVC insulated 1000V grade power cables shall be FRLS type of category C1
conforming to IS:1444(Part-I) (as amended up to date) and shall be suitable for a steady conductor
temperature of 70 deg. C. The conductor shall be stranded aluminum. The insulation shall be
extruded PVC of Type-A of IS:4831 or equivalent of any International standard. The inner and
outer sheath shall be of extruded PVC of Type ST-1 of IS:4831 or equivalent of any International
standard. The armour shall be galvanized steel wire or strip for multi core cables and aluminum
wire or strip for single core cables conforming to IS:3974 or equivalent of any International
standard.
Control Cables:
The 1000V grade PVC insulated control cables shall be FRLS type category conforming to
IS:1444(Part-I) (as amended up to date). The conductor shall be stranded copper. The insulation
shall be extruded PVC of Type-A of IS:4831 or equivalent of any International standard. The inner
and outer sheath shall be extruded PVC of type ST-1 of IS:4831 or equivalent of any International
standard, and shall be gray in color except where specifically advised by the Purchaser to be
black. The armour shall be of galvanized steel wire/strip for control cables.
Cores shall be identified as per IS:1444 (Part-I) or equivalent of any International standard, for
cables up to five (4) cores. For cables with more than five (4) cores, the identification shall be
done by printing legible alphabets on all cores. The alphabets shall be white, and shall be
printed at about 100 mm interval all along the cable length. Cables without such core

236
identifications shall not be accepted.
" ECDNG"FTWOU<"
Cables shall be supplied in non-returnable wooden/steel drums of heavy construction. For
wooden drums, the wood used for construction for the drum shall be properly seasoned, sound and
free from defects. Wood preservative shall be applied to the entire drum.
The standard lengths for each size of power cables shall be 500/1000 meters. and control cables
shall be 1000 meters. The cable length per drum shall be subject to tolerance of ± 4% of the
standard drum length agreed between Purchaser and Contractor. However the total quantity of
cables after taking into consideration of all cable drums shall be within the tolerance of ± 2%.
A layer of water-proof paper shall be applied to the surfaces of the drums and over the outer most
cables layer.
A clear space of at least 40 mm shall be left between the cables and the logging.
Each drum shall carry the manufacture’s name, the Purchaser’s name, address and contract
number, item number and type, size and length of cable, net and gross weight printed on both sides of
drum. A tag containing the same information shall be attached to the leading end of the cable. An
arrow and suitable accompanying wordings shall be marked on one end of the reel indicating the
direction in which it should be rolled.
Packing shall be sturdy and adequate to protect the cables from any injury due to
mishandling or other conditions encountered during transportation, handling and storage. Both cable
ends shall be sealed with PVC/Rubber caps so as to eliminate ingress of water during
transportation, storage and erection.
Armouring: No armouring is required for cables laid inside the power house.
GI round wire Armouring shall be provided for cables laid outside the power-house. All LT cables
shall be of FRLS .
GO42" JV"("NV"RQYGT"("EQPVTQN"ECDNG"VTC[U."N[KPI"CPF"VGTOKPCVKQP"
2. Ueqrg<" The quantity and types of power & control cable trays and their accessories shall be
estimated by the Contractor and shall be indicated in the tender. All the 11 KV cables shall be of XLPE
insulated copper conductor and screened with overall PVC sheath. The cables shall be laid in
galvanized Iron (GI) perforated trays. The trays shall be run under the panels/in trenches as the case
may be and shall be supported on mild steel painted supports inside the power house and GI supports
out side the power house.
" Nc{kpi"
Cables shall be laid in ducts and in Cable trays. Segregation shall be made in laying the control
and power cables. Cables shall have identification tags.
Termination
The cables shall be terminated to the panels / equipment with suitable cable glands. The 11 kV
XLPE Cables shall be terminated with suitable HV termination kits. All materials such as cable Glands,
Copper Lugs for termination, Bolts and nuts and 11KV termination kits are included in the scope.
The cores of the cable shall be terminated with suitable copper lugs and identification ferrules. The
ferrules provided for identification shall have the termination identification to which it is being terminated
and also the identification of the termination at other end for clear understanding. The terminations shall
be carried out based on the customer approved cable schedules and termination drawings.
" VGUVU<"
XLPE insulated power cables shall comply with all type tests and subjected to all routine and
acceptance tests as per IS:7098 Part-I (as amended up to date) or equivalent of any IEC or
International standards.
PVC insulated power and control cables shall comply with all type tests and be subjected to all
routine and acceptance tests as per IS:1444 Part-I. (as amended up to date) or equivalent of any IEC
or International standards.
Cffkvkqpcn"V{rg"Vguvu<"
The cables of all types and sizes shall also meet the following additional type tests.
i) Oxygen index and temperature rise test as per ASTMD-2863. The minimum value of
oxygen index shall be 29.0
ii) Flame retardence test on single cable.
iii) Flame retardence test on bunch cable.
iv) Rodent and termite proof test.
Additional Acceptance Tests:
The following additional acceptance test on cables of each type and size shall be carried out
and cover at least 10% of the cable drums:-
i) Flame retardance test on single cable.

237
ii) Oxygen index and temperature index test as per ASTMD- 2863.
iii) Cold bend test for outer sheath.
iv) Cold impact test for outer sheath.
v) Resistance test for armour.
vi) Rodent and termite proof test.
vii) Tests for low smoke
" FTCYKPIU"
The manufacturing of the equipments shall be strictly in accordance with the approved drawings
and documents and no deviation shall be permitted without the written approval of the purchaser.
GO43" GCTVJKPI" " QH" " " EQORQPGPVU" " " YKVJKP" " " UY3VEJIGCT1EQPVTQN" RCPGNU"
GVE0"
3. Ueqrg<"Each switchgear/switchboard, control panel etc., shall be provided with an earth bus bar
running along its entire length. The earth bus bar shall be located at the bottom of the board/panel.
Each switchgear panel and electrical equipment shall be provided with terminals for double earthing
connections system voltage of 415
V and above, for lower voltage one earthing terminal shall be provided. Earthing terminals shall be
identified as per IS codes, except as noted, earth bus bars shall be of copper. Earth bus bars shall be
rated to carry the rated symmetrical short circuit current of the associated board/panel for one second.
Each bus bars shall be supported to withstand stresses induced by the momentary current of value
equal to the momentary rating of the associated switchgear / switchboard. Size of earth bus bar and
sizes of lead connections shall be subject to approval by the Engineer.
Name Plates, Rating Plates and Labels:
a) Where appropriate, each item of plant shall have permanently attached to it in a conspicuous
positions label or labels upon which shall be engraved or stamped the manufacturer's name, type and
serial number of plant and details of the loading and duty at which the item of plant has been designed
to operate. A label denoting the plant or function identification number shall also be attached. Such
labels shall be of non-hydroscopic materials to be approved by the Engineer.
b) Labels shall be provided for every panel to describe its function identify every instrument, relay of
item of control equipment mounted instrument, relay or item of control equipment mounted externally
and internally.
c) Danger labels e.g., "DANGER - 415 V" shall be coloured red with while lettering.
d) Caution labels e.g., 'CAUTION - ISOLATE BEFORE REMOVAL" shall be white with red
lettering. Details of proposed inscription shall be submitted to the Engineer for approval before any
labels are manufactured.
e) Details of proposed inscriptions shall be submitted to the Engineer's Representative for
approval before any labels are manufactured. Such name plates, rating plates and designations shall be
of non hydroscopic material to be approved by the Engineer's representative with engraved or
stamped lettering of a contrasting colour or of transparent plastic materials with suitable coloured
lettering engraved on the back. Items such as valves shall have direction of rotation for closing and
opening indicated.
Only non-flame propagating materials may be used for such plates and labels.
TGSWKTGOGPV"HQT"KPUVCNNCVKQP"QH"GCTVJKPI"CPF"NKIJVKPI"RTQVGEVKQP"U[UVGOU"
The contractor shall install bare steel conductors, wire/strips required for system and individual
equipment earthing. All work such as cutting, bending, supporting, coating, drilling, brazing, clamping,
bolting and connections into structures, pipes, equipment frames, terminals, rails or other devices
shall, be in the contractor's scope of work. The excavation and trenching and backfilling shall be
carried out by the contractor as required together with the supply of the material. AM incidental
hardware and consumables such as fixing cleats / clamps, anchor fasteners. lugs, bolts, nuts,
washers, welding electrodes, flux, bituminous compound, anti-corrosive paint etc.. for the
complete installation work shall be deemed to the included in contractor's scope.
Earthing shall confirm to the Indian standard Code of practice IS : 3043 and Indian electricity Rules.
1956 and Indian Electricity Act, 1910. all materials and fittings used in the earthing installation shall
confirms to the relevant Indian Standards or shall be as approved by the Engineer's
Representative. Installation work shall be in accordance with approved earthing drawings (to be

238
prepared by contractor) and any change in routing, size of conductors etc., shall be subject to prior
approval of . the Engineer's Representative. Earthing conductors below ground level shall be laid
at a depth of 600 mm and 2000 mm away from buildings.Backfill material to be placed over
buried conductor shall be free from stones and other harmful mixtures, backfill shall be placed in
layers or 150 mm uniformly spread along the trench and consolidated. Earth pits shall be
constructed according to the stipulations of IS : 3043.Earth electrodes shall be fabricated in
accordance with IS : 3043 from 38 mm diameter, 3 meters long, galvanized iron heavy pipes. The
minimum spacing between two adjacent earth electrodes shall not be less than 6 meters. Earth
electrodes shall be housed in concrete inspection chambers with suitable lids and provided
with facilities for the periodic testing of the earth receptivity.
Electrodes shall, as far as practicable, be embedded below the permanent moisture level. The
metallic frame of all electrical equipment shall be earthed by two separate and distinct connections
with the earthing system Cable armour shall be bounded to the earthing system. Metal pipes, trays
and conduits through which cables run shall be efficiently bounded and earthed.For conduits,
armoured cables and metal raceways, the connection to the earthing system shall be as near
as possible to the point where conductors in the raceways receive supply. All underground
connections for the earthing system shall be welded. Connection to equipment and devices shall
be of the bolted type. Neutral connection shall never be used for earthing. On completion of the
installation, continuity of all conductors and efficiency of all bounds and joints shall be tested. The
earth resistance shall be tested in presence of Engineer's Representative.
All equipment necessary for the test shall befurnished by the contractor. The work of
embedment of earthing conductor in RCC floors / walls along with provision of earth plate inserts /
pads / earth resists shall be done by the contractor when the floors / walls are cast. The tap
connections (earthing leads) from the floor embedded main earthing grid to the equipment of more
than 500 mm long shall be embedded in the floor where required. The concrete cover over the
conductor shall not be less than 50 mm.
The scope of installation of earth connection leads to equipment and risers on steel structures / walls
shall include laying the conductor welding / cleating at intervals of 750 mm. Welding brazing to the
main earth grids, risers, bolting at equipment terminals and coating welded/Brazed joints by
bituminous joints by paint.Galvanized conductors shall be touched up with zinc rich paint where
holes are drilled at site for holding to equipment / structures. Earthing conductors run-on walls and
columns shall be supported by cleating /welding at intervals of 750 mm. Wherever earthing
conductors cross underground service ducts and pipes. It shallbe laid 300 mm below them. If the
distance is less than 300 mm the earthing conductor shall be bounded to such service ducts
pipes. Suitable earth risers subject to approval by the Engineer shall be provided above finished
floor/ground level, if the equipment is not available at the time of laying of the main earth
conductors, the minimum length of such riser inside the building shall be 200 mm and outdoors
shall be 500 mm above ground level.
The risers to be provided shall be marked in the project drawings. Welding and brazing operations
and fluxes / alloys shall be of approved standards All connections shall be of low resistance.
Contact resistances shall also be minimum. Bimetallic connections, if any, shall be treated
with a suitable
compound to prevent moisture ingress. Earth pits shall be treated with salt and charcoal. The
lighting protection air termination rods and / or horizontal air termination conductors shall be fixed
in such as way that they remain in their installed position even during severe weather conditions.
The lighting protection system shall comply with IS: 2309.All joints in the down conductors shall be
of welded / brazed type.
All metallicstructures with 2 mm vicinity of down conductors shall be bonded to the
lightingprotection system. Every down conductor shall be provided with a test joint at about 1000
mm above ground level. The test joint shall be directly connected to the earthing system electrode.
The lighting protection system shall not be in direct contract with underground metallic service
ducts, cables, cable conduits and metal enclosures of electrical equipment.
The Contractor shall design the earthing system in such a way that the over all earth resistance of
pump house, without connecting to any other earth grid shall not exceed 3 Ohms. The design
calculations are subject to the approval of Engineer. Supply and installation of earthing conductors
for interconnection of pumping station earthing grid with adjacent earthing grid shall be covered
under contractors scope.

239
Urctgu"Nkuv"
The given spares list is tentative & if any component is not applicable same shall be replaced with
suitable equivalent
30" Nkuv"qh"Ocpfcvqt{"urctgu"hqt"Ogvcnnke"Xqnwvg"Rworu"hqt"gxgt{"rwor"jqwug"
"
I. Complete impeller with imp. Nut 1 No.s
II. Impeller wear rings 1 Set
III. Guide Bearing 1 Set
IV. Coupling Fasteners 1 Set
V. Mechanical. Seal Wear out parts(contact with shaft) 1 Sets
VI. Set of packings and gaskets 1 Sets
VII. Set of fasteners 1 Sets
40" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"GQRF."JQRF"Xcnxg"
GQRF"hqt"gxgt{"rwor"jqwug"
I. Seats ring and seal ring 1 Nos.
II. Actuator gear box ` 1 No.
III. Actuator complete unit 1 No.
IV. Actuator control cards 1 Nos
V. Actuator Power cards 1 Nos.
VI. Limit & Torque for actuators(if applicable) 1 set.
JQRF<"
i. Seats ring and seal ring 1 Nos.
ii. Hydraulic oil Pumpset ` 1 No.
iii. Seals for power pack 1 Set.
iv. Pressure Switch 1 Nos
v. Limit switches 1 Set.
50" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"Oqvqt"hqt"gxgt{"rwor"jqwug"
"
I. Field poles, each suitable either for North or South polarity 4 pcs.
II. Motor Bearing set 1 set
III. Thrust bearing pads 1 set
IV. Brushes 1 sets
V. Guide bearing pads 1 set
VI. Brake shoes 1 sets
VII. Brush-holder 1 set
VIII. Air cooler unit with water chamber 1 set
IX. Oil cooler of the plug-in type 1 set.
X. RTDs used for air circuits & bearings 20% of total quantity
XI. Dial type thermometer each for circuit,
bearing and bearing oil system 1 Nos.
XII. Thermostat for bearings As required
(for each bearing)
XIII. One piece each of contacts, springs
and coils, for each relay, contactor,
breaker and auxiliary switch 1 set
XIV. Water flow relay each for air cooler
and bearing oil reservoir 2 Nos.
XV. Fire/smoke detectors 1 set
XVI. Water spray nozzles 1 set.
XVII. Stator heaters 1 set.
XVIII. Cooling Fans 1 Nos.
XIX. Control cards for AVR Panels 1 set
XX. Power cards for AVR Panels 1 set

240
60" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"Uykvej"igct"Rcpgnu"hqt"gxgt{"rwor"jqwug"
I. Circuit Breaker 1 No. for Each Rating
II. Current transformers 2 Nos. for Each Rating
III. Potential Transformers 2 Nos. for Each Rating
IV. Spring Charge Motors 5% of total quantity
V. Protection relays 5% of total quantity
VI. Indicating and recording Meters 5% of total quantity
VII. Selector switches 5% of total quantity
VIII. Indicating Lamps 20 Nos for each type and color
70" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"RNE"UECFC"U{uvgo"hqt"gxgt{"rwor"jqwug"
I. Digital Input Modules 1 Nos. for each type
II. Digital Output Modules 1 Nos. for each type
III. Processor Internal Battery 1 Nos. for each type
IV. Indicating Meters/Display Units 1 Nos. for each type
V. Temperature scanners 1 Nos. for each type
VI. Level Switches 1 No.
VII. Indicating Lamps 5 Nos for each type and color
80" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"NV"Fkuvtkdwvkqp"Rcpgnu*UCD+"hqt"gxgt{"rwor"jqwug"
I. LT Contactors 1 No. for Each Rating
II. MCB/MCCB 1 No. for Each Rating
III. Switch fuse Unit 1 No. for Each Rating
IV. Indicating and recording Meters 5% of total quantity
V. Selector switches 5% of total quantity
VI. Indicating Lamps 5 Nos for each type and color
90" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"Dcvvgt{"cpf"Dcvvgt{"ejctigt"hqt"gxgt{"rwor"jqwug"
I. Thyristors/SCR 5% of total quantity
II. Diodes 5% of total quantity
III. Multipliers Contactors 5% of total quantity
IV. Multipliers Contactors 5% of total quantity
V. Control cards 1 No. for Each type
VI. Control transformers 1 No. for Each type
VII. Indicating Lamps 5 Nos for each type and color
:0" Nkuv"qh"Ocpfcvqt{"Urctgu"hqt"GQV"Etcpgu"hqt"gxgt{"rwor"jqwug"
I. Thrust Breaks 1No each Type
II. Coils for Break solenoids 1 Set
III. Control contactors 5% of total quantity
IV. Brake pads/Linings 5% of total quantity
V. Fuses 5% of total quantity
VI. Limit switches 1 Nos each.
VII. Bearings 1 No. for Each type
VIII. Oil seals 1 No. for Each type
IX. Carbon Brushes 1 set
X. Fuses all ratings 1 set

241
List of Special Tools, Instruments and T&P.
K0" Nkuv"qh"Urgekcn"Vqqnu"hqt"gxgt{"rwor"jqwug"
"
One complete set of following special tools and equipment shall be supplied for erection & maintenance
of pump components separately.
1) Lifting and sliding devices for main shaft 1 set
2) Shaft moving device 1 set
3) Supporting fixture for main shaft 1 set
4) Attachment device for impeller blade 1 set
5) Chain block (special) 1 set
6) Separating bolts (Special) 1 set
7) Special Spanners for Pumps 1 set
KK0" Nkuv"qh"vguvkpi"kpuvtwogpvu"hqt"gngevtq"ogejcpkecn"gswkrogpv"
"
The following testing instruments and equipment shall be supplied for testing of Pump Motor sets
(units).
1) A.C. Analog Voltmeter,

a. 0-150 / 300V 1No.s each
b. 0-75 / 150V 1No.s each
2) A.C. Analog Ammeter, 0-1/5A, 0-5/25A 1 No.s each
3) Analog Watt meter 3 Phase, 1/5A, 600 V 0.5 class 1 No. each
4) Frequency meter (Digital), 45-55 Hz & 1 No.
5) D.C. Analog Voltmeter, 0-100m V. 0-100V/300 V 2No.s
6) D.C. Analog Ammeter 0-1/5A. 0-5/25 A 2 No.s
7) Phase angle meter Analog, 120/240 V.
50/60 Hz 0.5/1A. & 2.5/5A. 1 No
8) Phase rotation meter, AC, 60 V-500V 1 No.
9) Wheatstone Bridge, 0.0001-10 ohms 1 No.
10) VAR Meter Analog 2.5/5A, 120V, 0.5 Class 1 No.
11) Earth megger 500V 1 No
12) Variac, 0-250 V, 15 A 2 Nos.
13) 3 Phase Variac 0 -500V, 15A 1 No.
14) Testing Transformers:
a. 1 Ph. 30 KVA, 220/30 V, 1000A 1 No
b. 3 Ph 440 V, 0 to 50 A. 1 No.
15) DC High voltage testing kit, 0 to 60 KV/10 mA 1 No.
16) Megger Digital, 500 V, 1000 M ohm 2 Nos.
17) Megger Digital, 1000V, 2000 M ohm 2 No.
18) Motor operated Megger 2.5 KV/5 KV (Digital) 2 No.
19) Oscilloscope dual champed storage 1 No.
20) Stop watch, 1/5 sec. (60 sec.) 4 Nos.
21) Electric Hand tachometer (Digital) (0-3000 rpm ) 2 Nos.
22) Mercury thermometer, 0-150 Deg. C 10 Nos.
23) Manometer Gauge Tester 0.05 kg/cm2 1 set
24) Manometer Gauge Tester 2.50 kg/cm2 1 set

242
25) Manometer for oil use, 0-50 kg/cm2 2 sets.

26) Manometer for water use 2 sets.
27) Resistance box, 6 element 1 No.
28) Open Angle measuring tool 1 set
29) Shunt, 5A or 7.5 A/50 mV 1.No.
30) Bell, 110 V DC. 4 Nos.
31) Elec. Soldering iron, 230 V AC 100W (with temp. control). 2 Nos.
32) Noise Meter A/B/C range 1 No.
33) Hand Operated crimping tool 2 Nos
34) Hydraulic operated criping tool 2 Nos
35) Vernier calipers 150mm, 300mm 6 Nos.
36) Pitch gauge 2 Nos.
37) Out side micro meters 0 to 150mm, 0 to 300mm 2Nos.
38) Slip gauge up to 100mm 1 No.
39) Straight edge 150mm, 300mm and 1 meter 1 No.
40) Telescope gauge up to 150mm 1 set
41) Dail gauges 8 Nos
42) Automatic Tan Delta Testing Kit 230 V, 50 Hz. (Portable) 1 No.
43) Transformer Turns ratio test Kit 230 V, 50 Hz. (Portable) 1 No.
44) Tong Tester (Jaw capacity 100 mm)
a) Digital (3 ½ LCD) 4 Nos.
b) Analog 4 Nos.
45) Temp. Measurement Kit. 2 Nos
46) Digital Multi meter 5 Nos.
47) Step down Transformers 240/24 V, 500 VA 10 Nos.
48) Sub-standard Pressure gauge meter for (Range 0 to 100 Kgs/Cm2., Resolution 0.5 Kg/Cm2)
a) Liquid measurements. 2 Nos.
49) Fully automatic Relays testing kit 1 No.
50) Primary injection kit with all accessories full 1 No.
51) Opening and closing time testing kit 1 No.
KKK0" Nkuv"qh"Vqqnu"cpf"rncpv<"
The following tools and equipment shall be supplied for regular operation & maintenance of pump
units.
1) Double end ring spanners 6mm to 36mm 3 sets
2) Open end type spanners 6mm to 36mm 3 sets
3) Box spanners with ratchet handle and extension rod.
6mm to 36mm 2 sets
4) Feeler gauge 0.01mm to 2.5mm 2 sets
5) Screw drivers with insulation 150mm to 600mm 3 sets
6) Cutting player with insulation 3 sets
7) Bearing Pullers varies sizes 2sets
8) Aluminum ladders 30 feet 1 No.
9) Drilling machines 6mm, 13mm and 25mm 2 Nos.
10) Welding Transformer 230 V, 300 A to 600 A 1 No.
11) Portable welding machine 0 to 150 A 2 Nos.
12) Bench grinder 150mm 2 Nos.
13) Horizontal grinder 100mm 2 Nos.

243
14) Angel grinder 180mm 2 Nos.

15) Flexible shaft grinder 2 Nos.
16) Vacuum cleaners heavy duty, 230 V. 2 Nos.
17) ‘D’ shackles 3T, 5T and 10T 4 Nos.
18) Slings (Steel) 8 mtrs. Length 3T, 5T and 10T 4 Nos.
19) Portable Hot air blower 2 Nos.
20) Oxygen regulators 2 sets
21) Blow pipe set 2 sets
22) Tap sets 6, 8, 12, 16, 20, 24mm 2 sets
23) Hammers (Steel) 2, 6, 8 LBS 2 Nos.
24) Hacksaw frame 300 mm 2 Nos.
25) Sheet metal cutters 300 mm 4 Nos.
26) BSP taps ¼ , ½, ¾ and 1inch 2 sets
27) Chain block pulleys. 1 T, 3 T and 5 T 2 Nos.
28) Bench vise 8 inches 1 No.
29) Surface plate 400 mm 1 No.
30) Pipe bending Kit. 1 No
31) Align keys 3 sets
Q(O"Uvchh"Tgswktgf"hqt"Q"("O"qh"Rwor"Jqwug"cpf"Rtguuwtg"Ockp"
"
Un0"
Fguetkrvkqp"qh"yqtm" Sv{"
Pq"
3" Rwor"Jqwug"
K" Qrgtcvkqpcn"("Ockpvgpcpeg"etgy"
a Qrgtcvqt"Rwor/Gngevtkecn"*Fkrnqoc1KVK+" 4 ShiftsX4 = 16
b Qrgtcvqt"Rwor/Ogejcpkecn *Fkrnqoc1KVK+ 4 ShiftsX4= 16
c Hkvvgt"*KVK+" 1 shift X 4 = 4
d Jgnrgt"*32vj+" 4 ShiftsX9= 36
e Ictfgpgt" 1 ShiftsX2 = 2
f Uyggrgt" 1 ShiftsX4= 4
g Ugewtkv{1ycvejocp" 4 ShiftsX3 = 12
KK" Uwrgtxkuqt{"uvchh"
a Itcfwcvg"Gngevtkecn"Gpikpggt" 1 ShiftsX1 = 1
b Itcfwcvg"ekxkn"Gpikpggt 1 ShiftsX1 = 1
c Itcfwcvg"Ogej"Gpikpggt 1 ShiftsX1 = 1
d Uwrgtxkuqt"*Fkrnqoc"/Gngevtkecn+ 1 ShiftsX3 = 3
e Uwrgtxkuqt"*Fkrnqoc/"Ogejcpkecn+ 1 ShiftsX3 = 3
2 Rtguuwtg"Ockp"
K" Qrgtcvkqpcn"("Ockpvgpcpeg"etgy"
a Uwrgtxkuqt"*Fkrnqoc/"Ogejcpkecn+ 1 ShiftsX1= 1
b Hkvvgt"*KVK+" 1 ShiftsX3 = 3
c Ygnfgt"*KVK+" 1 ShiftsX1= 1
d Jgnrgt"*32vj+" 1 ShiftsX4 = 4
e Ugewtkv{1ycvejocp" 3 ShiftsX4 = 12

244
"
"
CPPGZWTGU"
CPPGZWTG"/"CGO"23"
30" IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"RWOR"
"
Type of pump :
1. Rated Horse Power :
2. Maximum Horse Power at
i) …………............m head : (at main discharge valve opening 100%)

ii) ………… ..........m head : (at main discharge valve opening 96.7%)
iii) …….. ........……… m head : (at main discharge valve opening 79.9%)
3. Discharge of each pump for above conditions
i) ………… ..........m head :
ii) ………............m head :
iii).......................... m head
4. Output
i) Main discharge valve opening & corresponding efficiency at

maximum output and at rated head.
a) Maximum output :
b) Rated head :
c) Main discharge valve:
opening
d) Efficiency :
ii) Output and efficiency at rated head and full gate

opening.
a) Output :
b) Efficiency :
5. Efficiency in percentage at 100%, 80%, 60%, 30% and 110% load at.
i) m head
Output (%) : 100% 80% 60% 30% 110%
Input (kw) :
Efficiency (%) :
Discharge (m3/sec) :
ii) m head (rated)

Output (%) : 100 80 60 30 110
Intput (kw) :
Efficiency :
Discharge (m3/sec) :
iii) m head
Output (%) : 100 80 60 30 110
Input (kw)
Efficiency (%)
Discharge (m3/sec)

245
6. i) Guaranteed best efficiency :
a) At head of :
b) At an output of :
c) At main discharge valve opening of:
ii) Efficiency curve for full range of output and head :
90" Urggf"<"
"
a) Rated :
b) Maximum Run away speed :

under transient conditions
c) Specific :
d) Steady state runaway :

speed at design head
8. Rotation of the pump when viewed from Motor side :

Anti Clockwise when looking from Top of the Motor.
9. a) Guaranteed minimum factor of safety under worst conditions based on the yield
point of material :
Please refer to the table of next item (b)
b) Name and location of the part having the factor of safety in (a) above.
10. Momentary rise in speed on (in Reverse direction) when breaker trips
Full load : %
11. Time of main discharge valve closing for regulation in Item `10' above
a) Full load : sec.
12 Time of full main discharge valve opening for above regulation (excluding dead time)
Full load : sec.
13. Flywheel effect of rotating parts for regulation as stated above.
For entire unit :
Motor rotor :
Pump impeller
360" Uvc{"eqpg"("uvc{"xcpg"
"
c+" Type (constant velocity, accelerating etc.)
d+" Material :
e+" Construction :
f+" Thickness : :
i) Maximum :
ii) Minimum :
g+" Maximum velocity of :

water with full discharge
and rated head
h+" Method of ensuring

water tightness of shaft :
entry.
i+" Velocity in the concrete :

casing at inlet

246
j+" Material and construction :

of stay cone
k+" Number of stay vanes :

l+" Weight of stay cone :
m+" Weight of stay vanes :
370" Korgnngt"
"
c+" Impeller material and
composition.
i) Blade material and :
composition
ii) Boss material and :
composition
d+" Number of blades :

e+" Method of attachment :
to shaft
f+" Weight of impeller :
g+"out let dia of impeller
h+" Inlet dia.of impeller :
i+" Throat dia.of impeller :
j+" Elevation of centre line of impeller R.L.M. :
k+" Velocity of water at impeller exit :
l+" No. of labyrinth ring and material :
380" Iwkfg"dgctkpi"V{rg"
"
c+" Bearing area location :
d+" Composition of bushing metal :
e+" Method of lubrication :

(if forced lubrication is adopted).
i) Number & Type of pump :

ii) Rating of motors :
f+" Amount of lubricant for one filling

(one machine) ltrs /gall. :
(Including generator bearing)
g+" Lubricant used :
390" Ftchv"vwdg"
"
c+" Type of draft tube :
d+" Elevation of lowest point in draft tube :

liner concrete :
e+" Distance from centre

line of unit to draft :
tube exit (concrete exit)
f+" Weight of draft tube liner :
g+" Thickness of draft tube liner :

247
h+" Velocity of water (At full load and rated discharge)
i) At draft tube exit :

ii) At draft tube liner :
i+" Material of the draft tube :
3:0" Vjtwuv"Dgctkpi"
c+" Bearing area location :
d+" Composition of bushing metal :
e+" Method of lubrication :

(if forced lubrication is adopted).
i) Number & Type of pump :

ii) Rating of motors :
f+" Amount of lubricant for one filling

(one machine) ltrs /gall. :
(Including generator bearing)
f) Lubricant used
3;0" Ujchv"
a) Shaft diameter:
b) Length:
420" Uchgv{"fgxkegu"rtqxkfgf"kp"vjg"rwor0"
a) Weights of pump rotating parts : ton
b) Total net weight of pump : ton.
430" Oczkowo"J{ftcwnke"vjtwuv"cv"
a) Normal speed
b) Runaway speed
440"
Nctiguv"rcemcig"hqt"vtcpurqtv"
a) Name :
b) Weight :
c) Dimensions :
450" Jgcxkguv"cuugodn{"vq"dg"nkhvgf"d{"etcpgu."fwtkpi"gtgevkqp0"
a) Name :
b) Weight :

248
CPPGZWTG"/"CGO"24"
"
IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"DWVVGTHN[" XCNXGU"
"
1) General requirements:
1. Size of the valve: mm
2. Quantity
3. Fluid handled . . . . . . . . . .
4. Maximum working............ MPapressure
5. Design pressure ....................... MPa
6. Maximum differential pressure ( when valve shut ) ........................ MPa
7. Maximum flow . . . . . . . . ..m3/h and corresponding pressure ............ MPa
8. Normal flow ....................... m3/h
9. Temperature of fluid ................... K
10. Maximum allow able pressure drop ( meters of water column ) ....................... MWC
11. Operating time( for power operated valves ) ........................ S
2) Service:
1. Tight shut off
2. Regulation
3. Low leakage rate
4. Suitability for flow in both directions
3) Mode of operation:
1. Manual with lever or handwheel or chainwheel or power actuator
2. Power/voltage/frequency/No. of phases/air supply pressure/type of operator.
3. Direction of rotation of hand wheel.
4. Orientation of hand wheel/lever with reference to pipeline
4) Type of construction:
1. Flanged or wafer [ lug wafer single/ wafer flange/flangeless wafer/U-section wafer ]
2. Face to face dimension ( short or long series )
3. Flange specification
4. Whether lifting lugs and mounting feet
6) Any other information not covered under in the section
"
"
"
"
"
"
"
"
"
"

249
CPPGZWTG"/"CGO"25"
"
GUARANTEED TECHNICAL PARTICULARS OF MOTOR
(The items with mark (*) are guaranteed particulars)
1. Type : motor
*2. Rating
a)KW
b) KVA
c) KVAR
*3. Max. continuous rating
(10% over load)
*4. Output with one cooler out of

service and 10% of tubes of
remaining coolers plugged in
5. Power factor
6. Voltage (Normal) between phases.
a) Maximum
b) Minimum
7. Frequency : 50 Hz.
8. No. of phases : 3
9. Speed :
a) Normal
b) Runaway
c) Specific speed at
rated head
*10. Efficiency (%) at 100%, 80%, 60% and 30% of output (The windage friction loss by the integral parts of
motor is included).
a) 0.9 P.F. 100% Discharge
b) unity P.F. 100% Discharge
11. Moment of inertia :
12. Inertia constant :
13. Short circuit ratio :
14. Line charging capacity :
15. Stator winding connection :
16. Direction of rotation :
17. Insulation class (Both :

field and armature windings)

250
18. Armature windings :
Field windings
19. Temp. rise (over cooling air temp. of 45

Deg.C. at rated output)
a) Stator winding :
b) Rotor winding :
c) Other parts :
20. Stator
a) Number of sections :
b) Material of stator core :
c) Outer diameter of stator core :
d) Height of stator core :
e) Type of slots in stator core :
f) Number of slots in stator core:
g) Number of conductor per coil:
h) Number of parallel paths in stator winding. :
i) Type of stator winding :
j) Total thickness of stator insulation (copper :

to iron in slots, excluding liners)
i) Normal coil :
ii) Terminal coil :
k) Total thickness of stator insulation :

(between turns in slots)
i) Normal coil :
ii) Terminal coil :
l) Stator frame construction. :
m) Width Air Gap :
22. Rotor
a) Rotor diameter :
b) Type of pole fixing :
c) Number of poles :
d) Lowest factor of :
safety of any part of
rotor, calculated on
yield stress when
running at runaway speed
e) Part of rotor with lowest :

251
factor of safety
f) Type of pole face damping windings :
g) Air gap width :
23. Motor air coolers
a) Type :
b) No. of coolers :
including one spare cooler
c) Maximum safe pressure :
d) Water pressure required :
e) Cooling water requirements :
i) Quantity :
ii) Water pressure :
iii) Temperature of cooled air :
f) Continuous output of motor with one

coolers out of service
24. Cooling
a) Type
i) Rotor :
ii) Stator :
25. Excitation system

Type
a) Rating
b) Excitation power transformer

rating and voltage ratio
c) Direct current requirements of

excitation control system
d) Range of voltage level setting
e) i)Sensitivity at which Motor voltage is held

ii)Ceiling voltage of excitation system
f) Excitation system response time :
g) Regulator gain :
h) Regulator time constant :
i) Feedback gain :
j) Feedback time constant :
k) Max. - Min. limits of exciter :

voltage in per unit.
l) Damping signal stabiliser gain :

252
m) Damping signal time constant :
n) Percentage transformer drop :

compensation.
o) Max. change in Motor terminal :

voltage when AVR is transferred
from AUTO to Manual under all
conditions of excitation.
p) Manual control range of excitation :
q) Thyrister type, rating and its :

temp. limitations
r) Cooling method of thyristers :
s) Redundancy available in bridges :
t) Monitoring arrangement for the :

conductivity of thyristers
u) Loss in static excitation system :
26. Voltage regulators
a) Name of manufacturer :
b) Type :
*c) Guaranteed sensitivity :
d) Min. time taken to respond :

at given sensitivity
e) Range of voltage level setting :
f) Range of adjustment of line :

drop compensation at full load
27. Nature of Insulation
a) Stator conductors (in core)

i) To earth
ii) Between turns
b) Stator end windings
c) Stator laminations
d) Rotor windings
i) To earth
ii) Between turns
28. i) Reactance
a) Synchronous (Direct axis) : (Saturated)

(Unsaturated)

253
b) Synchronous (Quadrature axis) :
(Unsaturated)
*c) Transient (Saturated) :
d) Transient (Unsaturated) :
e) Sub-Transient (Direct axis) :

(Saturated)
f) Sub-transient (Quadrature) :
(Unsaturated)
g) Negative phase sequence :
h) Zero phase sequence :
ii) Resistances :
a) Armature winding per phase (at 20 Deg.C)
b) Field winding (at 20 Deg.C)
29. Characteristic curves to be furnished.
a) Open circuit saturation.

b) Saturation at rated KVA and zero power factor under excited and over excited.
c) Saturation at rated KVA and unity power factor.
d) Saturation at rated KVA and 0.90 power factor lagging.
e) Saturated when loaded to requisite temp. rise at 0.90 power factor.
Synchronous impedance
30. Motor time constant
a) Direct axis transient, open circuit :

b) Direct axis transient, short circuit:
c) Direct axis sub-transient, short circuit:
d) Direct current component
31. Name and location of part having the least factor of safety under runaway or short circuit conditions :
32. a) Approximate rating of transformer for neutral earthing .

i) Capacity KVA :
ii) Ratio :
b) Approximate resistance (ohms) at the

secondary of transformer
33. Thrust bearing
a) Type of thrust bearing :
*b) whether Guarantee to operate success- :

fully for 15 minutes at the runaway speed
of the turbine with the total load. (yes/no)
c) Diameter of bearing :
d) Bearing cooling water :

254
i) Quantity :
ii) Pressure :
e) Location :
34. Guide bearings
a) Location
b) Type
c) Bearing area
d) Cooling water
i) Quantity
ii) Pressure
35. Lubricating system (one machine)
i) Quantity & type of oil in one filling
a) Thrust bearing system
b) Guide bearing system
ii) If forced oil lubrication is adopted
a) For guide bearing
i) Type of oil pumps

ii) H.P. and speed for each motor
b) For thrust bearing
i) Type of oil pumps.

ii) H.P. and speed for each motor.
36. Weights
a) Total weight of complete motor:
b) Weight of rotor and shaft :
c) Weight of stator
d) Heaviest assembly to be lifted by main crane.

Name, weight and dimensions.
Name
Weight
Dimensions Approx.
e) Largest assembly to be lifted by main crane.
Name
Dimensions
f) Heaviest package for transport

255
Name
Weight
Dimensions
g) Largest package for transport
Name Weight
Dimensions
37. Main shaft
i) Material
Dia.
iii) Length
iv) Dia. of coupling flange
v) Dia. of axial holes
vi) Weight
38. Bearing bracket material and construction
i) Material
ii) Construction
39. Air pressure for brakes
CPPGZWTG"/"CGO" 26"

256
"
IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"33"MX"UYKVEJ"IGCT"RCPGNU"
"
Separate schedule shall be furnished for each type of bus duct if used.
K0" KUQNCVGF"RJCUG"DWUFWEV<"
"
1. Continuous full load current
rating at rated Voltage,
50 C/s (Amps).
2. Momentary asymmetrical current

rating (Amps) RMS.
3. Sustained symmetrical over

current rating (Amps)
4. Rated working Voltage at

50 c/s (KV)
5. Basic impulse insulation level

(1.2 x 50 micro second wave) (KV)
6. Max. temp. rise of conductor at

continuous full load current
over an ambient temp. of outside
the enclosure. (50 deg. C)
7. Max. temp. rise of enclosure at

full load rating over an ambient
temp. of 50 deg.C (Deg.C)
8. Conductor Material
9. Bus enclosure material
10. DC Resistance per phase per meter

of conductor at 20 deg.C ambient (Ohms)
11. Inductive reactance per phase

per metre at 20 deg.C ambient 50 c/s (Ohms)
12. Capacitance per phase per metre to

ground at 20 deg.C and 50 c/s (Micro farad)
13. Heat loss in the isolated phase bus duct

at full load:
14. Type of duct
15. Shape of duct
16. Phase to Phase spacing (mm)
17. Standard section length (mm)
18. Dimension of bus enclosure (mm)
19. Dimensions of bus (conductor)
20. Weight (Kgs/Metre)

21. Type of cooling

257
22. Minimum recommended clearance

between periphery of the bus duct
enclosure and structural steel
& reinforced concrete. (mm)
i) Structural steel work parallel

with duct. (mm)
ii) Structural steel work perpendicular

to duct (mm)
iii) Reinforced concrete (mm)

23. Bus insulator characteristics :
Voltage Class (KV)
Dry withstand Voltage 1 - Min (KV)
Wet-withstand voltage 1 - Min (KV)
Impulse withstand Voltage (KV)
Minimum creepage distance (mm)
Cantilever strength
a. Upright (KG)
b. Under hung (KG)
c. Weight of each insulator (KG)
24. Skin effect factor (for motor protection)
II) Potential Transformer

i) Type and make
ii) Rated primary Voltage
iii) Rated Secondary Voltage
iv) Rating
v) Accuracy classification
vi) HV withstand primary
vii) HV withstand secondary
viii) Rated voltage factor &
corresponding rated time
ix) Class of insulation
x) Impulse level
KKK+" HWUGU"J0X0"<"
"
1. Type and make
2. Full load current rating

at amps 11 KV, 50 c/s (rms)
3. Symmetrical fault rating of

amps fuses 11 KV, 50 c/s.
KX+" HWUGU"N0X0"<"
"
1. Type and make
2. Continuous full load current

rating of fuses (Amps)
3. Symmetrical fault rating of

fuses (Amps)

258
X+" NKIJVPKPI"CTTGUVQTU"<"
"
1. Type and make
2. Voltage class (KV)
3. Dry & Wet Power frequency

Voltage (KV (RMS))
4. Minimum Power frequency

spark - over Voltage (KV (rms))
5. Maximum 1.2 x 50 Micro Sec.

impulse sparkover voltage
(KV (peak))
6. Front wave spark-voltage (KV (Peak))

7. Residual voltage at 0.5,
1 & 2 times the nominal discharge current (KV (Peak))
8. Nominal discharge current

(9/20 micro Sec.) (Amps)
9. High current impulse (4 x 10 micro

second) (Amps)
10. Long duration rating :
a) 1000 micro seconds (Amps)

b) 2000 micro seconds (Amps)
XK+" EWTTGPV"VTCPUHQTOGT"<"
"
1. Type and make
2. Voltage Class
3. Transformation ratio
4. Rated output
5. Class of accuracy
6. Short time thermal current and
its duration
7. Accuracy limit factor
8. Characeterstics :
i) Ratio & Phase angle curves
ii) Magnetisation curve
iii) Ratio correction factor curves
9. One minute power frequency voltage (KV)

10 Impulse level (KV)
XKK+"ECRCEKVQT"<"
1. Make and Type
2. Voltage rating (rms) (KV)
3. Capacitance, (Micro farads)
.DC hold test (10 Secs.)
4. Test voltage between terminal
and tank (KV)
5. Impulse Voltage (KV)
6. Compliance with standards
7. Discharge time of discharge resistor (Secs)

259
8. Maximum 1.2 x 50 Micro Sec.

impulse sparkover voltage
(KV (peak))
9. Front of wave spark-voltage (KV (Peak))

10. Residual voltage at 0.5,
1 & 2 times the nominal
discharge current (KV (Peak))
11. Nominal discharge current

(9/20 micro Sec.) (Amps)
12. High current impulse (4 x 10 micro

second) (Amps)
13. Long duration rating :
a) 1000 micro seconds (Amps)

b) 2000 micro seconds (Amps)
XKKK+" EWTTGPV"VTCPUHQTOGT"<"
1. Type and make
2. Voltage Class
3. Tranformation ratio (KV)
4. Rated output
5. Class of accuracy
6. Short time thermal current and
its duration
7. Accuracy limit factor
8. Characeterstics :
i) Ratio & Phase angle curves
ii) Magnetisation curve
iii) Ratio correction factor curves
9. One minute power frequency voltage (KV)

10 Impulse level (KV)
KZ+" ECRCEKVQT"<"
1. Make and Type
2. Voltage rating (rms) (KV)
3. Capacitance, (Micro farads)
a.DC hold test (10 Secs.)
4. Test voltage between terminal
and tank (KV)
5. Impulse Voltage (KV)
6. Compliance with standards
7. Discharge time of discharge resistor (Secs)

260
CPPGZWTG"/"CGO"27"
"
IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"EQPVTQN"CPF"TGNC[KPI"GSWKROGPV"
"
1. Motor Protection & Relay Panels.
2. Sequence control and data aquisition
3. Unit Auxiliaries Control Panels
4. LAVT Cubicles
5. Auto Synchronising Equipment
6. Synchronising Panel
7. Motor Transformers Control & Protection Panels
8. Feeder Control & Protection Panels
(Separate Schedule shall be furnsihed for each of the above equipment).
K0" Uykvejigct"Rcpgnu"1"Ewdkengu<"
"
1. Type.
2. Thickness of sheet metal.
3. a) Front.
b) Back.
c) Side.
4. Dimensions of complete cubicle
5. Total weight of complete cubicle.
6. Features provided to make the cubicle

dust and vermin proof.
KK0" Igpgtcn"Fcvc"
"
1) Temperature range
a) Operation range :
b) Storage range.
2) Humidity :
3) Seismic test :
4) Insulation test
a) High voltage test
b) Impulse voltage test.
5) Surge voltage test :
6) transient test :
7) Electrostatic discharge test :
8) Radio frequency interference test (RF)

261
9) Electromagnetic interference test.
KKK0" Ogejcpkecn"fgukip"
"
1) Weight
2) Mounting arrangement :
3) Enclosure protection class :
(shall be IP54 or Better)
KX0" Hqt"Pwogtkecn"tgnc{u"
"
1. Type
2. Make
3. No. of Protections Available with

Technical data for each protection.
4. Software configuration
5. Setting range may be furnished

for each protection separately.
6. Type of programming Tool.
7. Type of Hardware
8. Sampling frequency
i) Analog
ii)Digital
9) Processor details
a) Type.
b) Make
c) whether 32 bit or 64 bit.
d) Medium of storing application software.
e) Medium of storing data.
f) Medium of storing settings.
10) Interfacing with primary system (CTs, PTs, Aux. Relays)Á
a) No. of CT inputs.
b) No. of PT Inputs Á
c) No. of Analog outputs.
d) Whether CT, PT Inputs can be connected

directly.
e) Facility for display of analog &

Digital Inputs/outputs.
f) No. of Digital Inputs

No. of Digital Outputs.
g) No of Tripping Output relays.

h) Types of Input/ Output relays.

262
11) Communications:
a) Internal:
b) Remote :
12) Auxiliary supplies
13) Method of MMC (Man Machine Communication):
14) Disturbance recorder
15) Event recorder
16) Facility for online measurement of data
17) No. of interfacing ports for connecting

18) Applicable standards.
19) Method of long time storage of software.
20) Whether built in testing facility available.
21) Self diagnostic facilities and frequency of Self diagnosis for trouble shooting in case of faults.
22) Minimum response time. (may be furnished separately for each protection if applicable)
23) Degree of redundancy
Processor.
Power supply.
24) Whether provision for synchronising with external clock is available
X+" Hqt"Uvcvke"Tgnc{u"
"
Type.
Make.
Technical Particulars.
Auxiliary supplies.
Any other particulars not mentioned above and in the scope of supply shall be given.
XK+" MISCELLANEOUS EQUIPMENT
1. Control Wiring.
(Type.....Make ........ )
Voltage Grade.
Insulation.
Conductor material.
Colour code of wires used.
2. Terminal Blocks (Control wiring)

(Type.............Make.......... )
Voltage Grade.
Type of terminals.
Conductor Material.
Colour code of wires used.
3. Terminal blocks (control wiring):

(Type.......Make ..... )
Voltage grade
Type of terminals.

263
CPPGZWTG"/"CGO" 28"
"
IWCTCPVGGF"""VGEJPKECN"""RCTVKEWNCTU"""QH""" 637"""X" NV"DQCTFU"QH"STATION
AUXILIARY BOARDS.
K0" Uykvejigct"Ewdkengu<"
"
1. Type.
2. Thickness of sheet metal.

a) Front.
b) Back.
c) Side.
3. Dimensions of complete cubicle
4. Total weight of complete cubicle.
5. Features provided to make the cubicle

dust and vermin proof.
KK0" Ckt"Ektewkv"Dtgcmgt<"
"
1. Maker's Name and country of manufacture.
2. Maker's type, designation.
3. Standard applicable.
4. Rated Voltage.
5. Maximum continuous voltage at which

breaker can operate.
6. Current Rating.
a) As per manufacturer's standard.
b) Derating factor (if any) for site conditions.
7. Rated frequency.
8. Rated voltage.
9. Ultimate breaking capacity (KA Rms), Icu.

10. service breaking capacity (% of utimate breaking capacity), Ics (Service breaking capacity shall not
be less than 65 KA).
11. Overload and short circuit protection.
12. Symmetrical interrupting capacity, MVA
13. Symmetrical interruption current, KA
14. Making current, KA (peak).
15. Rated 1 second current, KA (rms) or

264
16. Main contacts:
i) Material
ii) Whether silver faced.
17. Auxiliary contacts: i) Rated voltage

ii) Material
iii) Whether silver faced.
18. Whether arcing contacts are provided.
19. Material of arcing contacts
20. Steady state operating temp. of main contacts when carrying rated current under ambient
conditions specified.
21. Standard duty cycle of breaker on which interrupting rating is based.
22. Voltage withstand levels (One minute
a) For main circuits, KV (rms)
b) For control & Auxiliary circuits KV (rms)
23. Clearance in Air.

a) Between phases.
b) Between Live parts and ground.
24. No. of breaks in circuit per pole
25. Means provided for charging closing spring.
a) Manual
b) Electric Motor.
26. Whether circuit breaker is fixed trip or trip free.
27. Whether circuit breaker is designed to close and latch on making ..
28. Rating of motor used to charge closing spring.
a) H.P.
b) Voltage.
c) Speed.
d) Insulation Class.
e) Temperature rise
f) Reference ambient temperature
g) Time required by motor to charge the spring completely.
29. Closing mechanism:

a) ated voltage of closing coil.
b) Voltage range over which closing mechanism would operated satisfactorily.
c) Power required at normal voltage for closing.
30. Shunt trip coil:

a) Rated voltage of shunt trip coil.
b) Voltage range over which shunt trip mechanism would operate satisfactory.
c) Power required at normal voltage for tripping
31. Opening time.
32. Make time.
33. Arc duration.
34. Mechanical and Electrical endurance (i.e., on load operation.
35. Weight and dimensions of complete circuit breaker.
36. List of type tests carried out (Certificate to be attached with the tender) List of routine tests
proposed to be carried out.

265
KKK0" MOULDED CASE CIRCUIT BREAKERS

4. Rated Voltage..
5. Maximum continuous voltage at which
breaker can operate.
6. Current Rating.
a) As per manufacturer's standard.
b) rating factor (if any) for site conditions.
c) Under site conditions.
7. Rated frequency.
8. Rated voltage.
10. Service breaking capacity (% of ultimate breaking capacity), Ics (Service breaking capacity shall
not be less than 65 KA).
13 Symmetrical interruption current, KA
14. Main contacts:
i) Material
ii) Material
17. Material of arcing contacts.
20. Voltage withstand levels (One minute)
a. For main circuits, KV (rms)

b. For control & Auxiliary circuits KV (rms)
a. Between phases.
b. Between Live parts and ground.
24. Whether circuit breaker is designed to close and latch on making or is fitted with making current
release.
25. Opening time.
26. Make time.
27. Arc duration.
30. List of type tests carried out (Certificate to be attached with the tender)
31. List of routine tests proposed to be carried out.

266
IV Motor Protection CBs

4. Rated Voltage.
5. Maximum continuous voltage at which breaker can operate.
6. Current Rating.
a. As per manufacturer's standard.
b. Derating factor (if any) for site conditions.
7. Rated frequency.
8. Rated voltage.
10. Service breaking capacity (% of ultimate breaking capacity), Ics (Service breaking capacity shall
not be less than 65 KA).
13 Symmetrical interruption current, KA
16. Main contacts:
i) Material

ii) Material

19. Material of arcing contacts.
22. Voltage withstand levels (One minute)
a. For main circuits, KV (rms)
b. For control & Auxiliary circuits KV (rms)

a. Between phases.
b. Between Live parts and ground.
26. Whether circuit breaker is designed to close and latch on making or is fitted with making current
release.
27. Opening time.
28. Make time.
29. Arc duration.
33. List of routine tests proposed to carried out.
V BUS BARS
1. Material.
2. Size
3. Type of insulation.

267
4. Minimum clearance : Between Phases.
Phase to nearest earthed part.
5. Continuous current rating.
6. 3 second short time current Amps (rms)

7. Momentary current rating Amps (Peak)
8. Temp.rise over the specified ambient temp. Deg.C.
9. One minute Power frequency withstand test voltage.
VI) CURRENT TRANSFORMERS

1. Make
2. Type.
3. Applicable Standards.
4. Ratio
5. Accuracy Class.
6. Rated burden.
7. Rated accuracy limit factor.
8. 3 second short time thermal rating KA (rms)
9. Rated dynamic current KA (peak)
10. Type of insulation
11. Maximum temp. rise of wining above ambient temp. specified.
12. One minute Power frequency test voltage.
13. List of type tests carried out (test certificate to be attached with the tender).
VII. RELAYS AND AUXILIARY RELAYS AND TIMERS
1. Make
2. Type.
4. Setting range for Over current element.
5. Setting range for instantaneous element.
6. Burden characteristics.
7. Characteristic curves (to be attached with the tender)
XKKK0" OGVGTU"*XQNVOGVGTU"CPF"COOGVGTU+"
"
1. Make
2. Type.
4. Accuracy.
5. Case size.
6. No. digits of display.
7. Burden characteristics.
KZ0"RQVGPVKCN"VTCPUHQTOGTU"
"
1. Make
2. Type.
4. Ratio
5. Accuracy.
6. Burden.
7. Type of insulation

268
X. CURRENT TRANSDUCERS
1. Make
2. Type.
4. Input range
5. Output range.
6. Accuracy.
7. Overload capacity.
8. Details of Auxiliary supply.
ZK0" XQNVCIG"VTCPUFWEGTU<"
"
1. Make
2. Type.
4. Input range
5. Output range.
6. Accuracy.
7. Overload capacity.
8. Details of Auxiliary supply.
XII. SINGLE PHASE PREVENTOR
1. Make
2. Type.
4. Range of U/V and O/V settings.
5. Time delay provided.
6. No. of contacts Provided for external use.
7. Type of indication for
a) Under voltage
b) Over voltage
c)Reverse sequence.
8. Auxiliary supply
9. Input Voltage (110/415V)
XIII. MISCELLANEOUS EQUIPMENT
1. Control Switches and Push Buttons.

Make
Type.
Voltage grade Volts
Current rating Amps.
2. Indicating Lamps:
Make
Type.
Voltage
Power consumption.
ZKX0" YKTKPI<"
"
1. Control Wiring:
(Type.......Make ......)
Voltage gradeInsulation.

269
CPPGZWTG"/"CGO"29"
"
IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"UVCVKQP"VTCPUHQTOGT"
"
1. Name of the Manufacturer
2. Manufacturer’s type
3. Country of origin
4. Type of construction - core or shell type
5. Standard according to which

transformer is manufactured
and guaranteed figures are given.
6. Type of cooling.
7. Rating
a) Rated KVA
b) Rated voltage of HV
c) Rated Voltage of LV
d) Temp. rise by resistance winding
e) Rated frequency
8. No. of Phases
9. Connections
HV
LV
10. Vector group
11. Tappings
High voltage Percentage
Low voltage Percentage
12. No-load losses (core loss plus

dielectric loss plus stray losses due
to excitation current) at rated
frequency at
13. Load losses (copper losses
plus stray losses) at rated
current at 75 Deg C winding
temperature.
14. Tolerance.
15. Percentage impedance at rated

current and frequency at 75
Deg C on _MVA basis
a) Positive sequence at principal tap.

b) Zero sequence at
principal tap.
c) Positive sequence at
maximum voltage tap.
d) Positive sequence at
minimum voltage tap.

270
16. Percentage reactance at rated
current and frequency.
17 Efficiency (at 75 Deg C wind- 0.9 lag P.F

ing temperature
a) 100% load
b) 50% load
18. Percentage regulation at full

load at 75 Deg C.
19. No-load current at rated
frequency at
100% rated voltage
50% rated voltage
20. Power factor of no-load

current at 100% rated voltages
and rated frequency
21. Flux density in core at rated

frequency at
a) 100% voltage CGS lines/cm2
b) 110% voltage CGS lines/cm2
22. Over load capacity
23. Net core area
24. Current density and conductor area

HT winding
LT winding
25. Insulation between laminations:
26. Type of joints between core :

limb and yoke
27. Bolt insulation flash voltage

(one minute)
28. Type of winding

a) HT winding
b) LT winding
29. Winding insulation

a) Type
b) Graded or ungraded
c) Temp rise allowed over
ambient
30. Insulation material

a) Turn insulation HV
b) Turn insulation LV
c) Core to low voltage
d) HV to LV
31. Type of joints in winding
32. Type of tap changer

271
33. Noise level of transformer

34. Test voltages for impulse
withstand
HV
LV
Line
Neutral
35. Test voltages for power

frequency withstand
HV
LV
Line
Neutral
36. Clearance (in air) to ground

between phases.(min mm)
HV
LV
37. Approx. weight in Kgs

a) Core and coils.
b) Total weight.
c) Untanking weight
38. Overall dimensions

a) Length
b) Breadth
c) Height
CPPGZWTG"/"CGO" 2:"
"
IWCTCPVGGF""VGEJPKECN""RCTVKEWNCTU""QH" DCVVGT[." EJCTIGT.(" F0E"FKUVTKDWVKQP"
DQCTFU"
"
A. GENERAL
1. Manufacturer's name and

country of Manufacture.
2. Applicable standards
B STATION BATTERY PARTICULARS
1. Type
2. Manufacturer's type designation
3. Ampere-hour capacity at
10Hr. rate of discharge.
4. Terminal voltage
5. Capacity in Amperes of the

battery for : Amps End cell Voltage per
i) 1 Minute load
ii) 2 Hour load.
iii) 10 Hour load.

272
6. Short circuit current (Amps)
7. Material of containers.
8. a) Specific gravity of electrolyte

at 27 deg C with all cells fully
charged.
b) Specific gravity of the

electrolyte at the end of:
discharge at 10 Hour rate:
9. Weight of Electrolyte per cell:
10. Dimensions of each cell

Length mm
Width mm
Height mm
Thickness of container mm
11. Net weight of the cell,
complete with acid Kg.
12. Expected life of battery
13. Ventilation required in

battery room.
E0" Dcvvgt{"Ejctikpi"Gswkrogpv0"
"
Type :
1. a) Boost charger.
b) Float charger.
2. Manufacturer's type and designation.
3. A.C. supply required

Voltage.
Current
No.of phases
Frequency
Power factor.
4. D.C. Output voltage regulation

from no load to full load
5. Maximum ripple content
6. Maximum permissible temparature

rise over an ambient temperature of 55 deg.C.
7. Overall efficiency
8. Unit shipping weight (Kg.)
9. Load limiting feature (please :

attach characteristic showing :
variation of voltage with increase in load).
10. List of Major accessories provided.
11. Recommended spares.

273
F0" F0E"Fkutkdwvkqp"OEEDu"<"
"
1. Make
2. System voltage.
3. Maximum interrupting current.
4. Current rating.
G0" JTE"ECTVTKFIG"HWUGU"
1. Make
2. Type
F. INSTRUMENTS AND METERS
1. Make
2. Type
CPPGZWTG"/""CGO"2;"
"
UEJGFWNG"QH"IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"GQV"ETCPG"
"
1) Type and class of crane
a) Crane structure.
b) Main hoist
c) Cross traverse
d) Long travel
2) Crane capacity
3) Safe working Load in Tonnes :
4) Centre to Centre of Gantry/ Track Rails (S)
5) Operating speeds (Loaded) in M/Min.
i) Hoist
ii) Cross travels
iii) Long travel
iv) Acceleration values
for
a) Cross Travel
b) Long Travel
6) Material and type of Hook Supplied :
7) Height of Hook above Floor Level in Metres.
8) Minimum movement in inching operation in mm :
i) 100% load hoisting with electric brake operating normally.
Maximum hoist i) Expected :

ii) Guaranteed :
ii) 100% load lowering at full speed with the brake blocked open.

274
Main hoist I) Expected :

ii) Guaranteed :
iii) With 50% load as in : I) Expected :

ii) Guaranteed :
iv) With 50% load as in : I) Expected :

ii) Guaranteed :
9) Hoisting Rope :
Diameter Con Quality No. of Minimum

in mm stru of Falls Breaking
tion steel Load
i) Main hoist
10) Factor of safety :
i) Main hoist
11) Description of Brakes :
Type Type Make Drum Torque

Diameter rating
i) Hoisting-motion
brakes.
ii) Traversing brakes
iii) Travelling brakes
12) Driver's cabin size (LxBxH)

Provided with Tools Box, extra
plug, Horn Electrical
Ventilation fan and fire
extinguisher.
13) Necessary provisions for guarding.
14) Bearings :
15) Details of power supply
AC :
DC :
16) Particulars of Safety Devices.
17) Net Mass in Tonnes.
i) Complete unladen crane :
ii) Complete unladen crab :
18) Other Information not Scheduled above
19) General Arrangement Drawing Furnished : YES/NO
20) Supplier should indicate willingness to submit following

test certificates : YES/NO.

275
a) Wire rope break load test as per IS or BS.

b) Hook-load test.
c) Steel-Chemical and physical tests.
d) Motor insulation high voltage flash test.
21) Supplier agrees or not to conduct

following tests at site : YES/NO
a) Overload tests.
b) Moor insulation tests.
c) All necessary speed tests.
d) Inching tests.
22) Dead weight of the complete crane (kg)

Dead weight of the crab (kg)
Dead weight of the trolley (kg)
CPPGZWTG"/""CGO"32"
"
IWCTCPVGGF"VGEJPKECN"RCTVKEWNCTU"QH"CKT"EQPFKVKQPKPI"(XGPVKNCVKQP"
"
"
30" GNGEVTKE"HCPU<"
"
i) Name of manufacturer.
ii) Type of fan.
iii) Number of stages.
iv) Capacity (CFM)
v) Class of construction
vi) Volumetric efficiency (%)
vii) Design Pressure (Kg/Cm)
viii) Seal system
ix) Cooling water requirement
x) Hydrostatic test pressure (Kg/Cm)
xi) Any other details:
40" KPFWEVKQP"OQVQTU<"
"
i) Name of Manufacturer.
ii) Rated:
a) Output KW:
b) Speed (RPM):
iii) Suitable for Indoor Operation (Yes/No)

276
50" HKNVGTU<"
"
i) Name of Manufacturer.
ii) Type offered (washable/throwaway)
60" OGVCN"CKT"FWEVU<"
"
i) Material construction
ii) Thickness of sheet
iii) Type of construction
70" ITKNNGU1FKHHWUGTU<"
"
i) Name of manufacturer:
ii) Capacity of CFM
iii) Material
iv) Volume control damper provided Yes/No.
CPPGZWTG"/"CGO"33"
IWCTCPVGGF"RCTVKEWNCTU"QH"FI"UGV"
"
I. DIESEL ENGINE
1. Type of engine : ............
2. Manufacturer (Name and place) : .............
3. Design standard : .............
4. a) Rating at site condition : ……….
5. (a) Continuous rating of engine : .............................. BHP(kW)

at rated R.P.M. and at 50 deg.
design temperature.
(b) I.S. Rating "A" of Engine : ................... BHP(KW)
(c) Continuous hours of operation : ................... Hours

in full load of the engine, at
the site elevation & design
temperature of 52 deg. C.
6. Self starting system
(a) Time required by the : ...............

engine to accept full
load after receipt of the
signal to start from cold
condition.
7. Cooling system Engine mounted air : .........

cooled radiator for cooling system.
I) Fan cooled Radiator
(i) Type :

277
(ii) Make : ...............
II) Cooling Fan
(i) Type : ..........
(ii) Capacity of fan in mm3/hr: ..........
8. Exhaust system
(a) General information
(i) Type : ........
(ii) Height of main exhaust : ………
(b) (i) Type :
(ii) Make :
(iii) Maximum noise level (db):
9. Engine protection
(a) Type of engine protection provided : . .........
10. Whether emergency stop push button at : YES/NO

the engine provided
11. Whether flywheel with guard provided : YES/NO.
12. Weight of the engine (dry) : …….Kg
13. Whether engine is provided with all : ..........

accessories e.g. walkways & stairs,
base plate inlet & exhaust duct with
filters, silencers etc ?
II) MOTOR/ALTERNATOR
:
1. Manufacturing standard ..........
:
2. Manufacturer's name and place : ..........
3. Type & designation : ..........
4. Rated output at rated Voltage for frequency : .......KVA
5. Rated voltage .......kV

278
6. Max. reactive power : ................. KVAR
7. Max. permissible over load capacity : .................. KVA
8. Rated power factor : ..........
9. Rated frequency : ................... Hz
10. Insulation class
(i) Rotor winding : ...........
(ii) Stator winding : ...........
11. Temperature rises at rated output condition : ..........

above ambient temperature of 50 deg. C
12. Type of excitation system : .........
13. Type of auxiliary exciter : .........
14. Percentage efficiencies
a) 100% load at rated pf of 0.75 lag.: ................. %

Tolerance (if any) : (-) ..... %
b) 75% load at rated pf of 0.75 lag. : .................... %

tolerance (if any) : (-) ..... %
c) 50% load at rated pf of 0.75 lag. : .................... %

Tolerance (if any) : (-) ...... %
15. Weight of Motor : .................. kg
KKK+" EQOOQP"GSWKROGPV"
"
C0" CUUGODNGF"F0I0"UGVU"
"
1. Noise level at full load : .................. db(A)
2. Vibration at no load : ................. micro mm
3. Vibration at full load : ................. micro mm
4. Overall dimensions of assembled Diesel : ................... mm

Generating Set complete with
accessories (L X B X H).
5. Assembled weight of complete Diesel : ...................... Kgs

Generating set along with accessories.
6. Transportation weight of the D.G. Sets : ................. Kgs
7. Weight of heaviest part to be : ................. Kgs

transported.
8. Weight of heaviest part to be installed : ................. Kgs

at a time.

279
D0" ELECTRICAL EQUIPMENT

a) Details of each Protection relays provided, shall be mentioned
i) Type : ...........
ii) Make : ...........
iii) Rating : ...........
b) Details of electrical panels/boards of each type shall be given
c) Degree of protection class : ..........
d) Technical specification of CTs, PTs : ..........
e) Accuracy class of instruments : ..........
☼"""☼"" ☼"


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Volume-II, Technical Specifications

GOVERNMENT OF ANDHRA PRADESH WATER

PKV"Pq0" 314242/43" Fv03702904242"

Name of work: “Rayalaseema Lift Scheme to draw and utilize 3

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

7. Details of specifications of columns for EOT crane

2. Length of Pressure mains

Camp and Facilities

Staff residential quarters for the Contractor’s staff

Offices for the Contractor

It is strictly forbidden to transport any unauthorized personnel on transport means while

Plant for aggregate and concrete / mortar production

A weather - tight equipment shall be provided for conveying cement.

Material Percent by Weight

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

(1) Original Ground Profiles

(2) Excavated and Final Ground Profiles

- On completion of excavation and prior to commencement of any work.

Accuracy of survey work shall be within the following tolerances:

Allowable error of closure

Allowable error of closure 1/3,000

Allowable error for each 1 km 10 mm

CONTRACTOR SUPERINTENDING ENGINEER

(Where “s” is the total distance of leveling expressed in km.)

Where the tolerances overlap the severer tolerance shall apply.

- Rock bolts and pre-stressed anchors (if any)

- Foundations and General Structures

Position plan ±20 mm

- Project Service Roads

CONTRACTOR SUPERINTENDING ENGINEER

(1) General Requirements

(2) Data and Documents Available

(3) Survey Records and Documentation

 shifting machinery and temporary plant out of the required sightlines;

 removing all obstructive accumulation of water;

 taking all necessary safety precautions;

CONTRACTOR SUPERINTENDING ENGINEER

" VGEJPKECN" URGEKHKECVKQPU" QP" UWTXG[." FGVCKNGF" KPXGUVKICVKQP."

5 I.S 8763-1978 Guidelines for undisturbed sampling of soils

CONTRACTOR SUPERINTENDING ENGINEER

4) Conducting site surveys for the structures identified.

a) To study in detail all the Engineering and design features.

b) To prepare technical specifications which are necessary for execution of works.

CONTRACTOR SUPERINTENDING ENGINEER

Preliminary investigation of pressureMain by study of the following items.

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

Preparation of H.Ps may be taken up only after approval of alignment by competent

Classification; of soils as per Borehole/Trail Pits date, preparation; of Borehole/Trail pits

(i) Half plan at top and half plan at bottom.

CONTRACTOR SUPERINTENDING ENGINEER

4. Rate analysis may be worked out as per current S.S.R 2019-20.

5. Abstract estimate may be prepared for the earth work estimates.

5. Quarry map and index maps to be enclosed (Scale 1:600)

6. Abstract estimates is to be prepared.

CONTRACTOR SUPERINTENDING ENGINEER

(a) Egtvkhkgf"swcnkv{"vguv"tgrqtvu"from manufacturers in respect of cement, steel and other

(f) Welding Electrodes

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

(ii) Steel reinforcement shall conform to relevant Indian Standards or equivalent.