6) Technical Specs (61 Pages)

CONSTRUCTION OF BG RAILWAY SIDING AT KADAPA IRD
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TECHNICAL
SPECIFICATIONS

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TECHNICAL SPECIFICATIONS

1.0 EARTHWORK

1.1 Specifications
The work will be carried out as per Railway standard specifications
with up to date errata and as per RDSO "Guide lines for Earthwork
in Railway Projects Guideline no GE-G-1, July, 2003.

1.2 Introduction
The following IS codes (latest edition) shall be followed for
classification of soils, and for conducting various tests on soils
where required.

i) IS-2720 Part-II 1973
Method of tests for soil determination of water contents (II Edition)

ii) IS-2720 Part-III Section-I of 1980
Method of test for soil determination of specific gravity.

iii) IS-2720 Part-IV 1975
Method of test for soil grain size analysis

iv) IS-2720 Part-V 1974
Determination of liquid and plastic limit.

v) IS-2720 Part-VIII 1983
Determination of moisture contents dry density using heavy
compaction.

vi) IS-2720 Part-XIV 1985
Determination of density index (relative density) of as
cohensiveless soil.

vii) IS-2720 Part-XVIII 1964 (reprint in Jan. 1980)
Method of test for soil determination of field moisture equivalent.

viii) IS-2720 Part-XXIX
Determination of dry density of soil in place by Core cutter
methods.

ix) IS-TECHNICAL SPECIFICATIONS-Earth work)
Classification and identification of soils for General Engineering
purpose.

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x) IS-1037-1982
Method of field test for soil being taken from the borrow piles.

1.2.1 The earthwork in filling (Including murrum) will be done as per
approved profile by borrowing the earth from the nominated
borrow areas and the rate quoted will be deemed to be inclusive of
all taxes including royalty, loading, unloading, leading, handling
and re-handling of earth, lifts, ascents, descents, crossing of
nallahs, streams, tracks, leveling, dressing spreading in layers as a
complete work in all respects as per specifications indicated in
succeeding paras. The surplus earth available from bridge
openings, bridge foundations, drains, gantry foundation etc. will be
lead and spread in nearby bank

1.2.2 Before taking up earthwork in embankment;

i) All vegetation shall be uprooted and taken away from the site of
work.

ii) Earthwork shall be carried out in layers, each layer sloping out
1:30 or as per drawing and direction of Engineer In Charge and
compacting it mechanically using suitable rollers to provide the
compaction to the specified level.

iii) The width of each layer of earthwork shall be in excess by 500 mm
on either side of the designed profile to enable compaction near
the edges. The excess width, thereafter, cut and dressed, so as to
achieve the required bank profile.

iii) Earthwork shall be completed up to designed formation level
keeping due allowance for the blanket; if need be.

1.3 The earth filling (including murrum) shall be compacted
mechanically using heavy roller to 98% MDD at OMC or 70% of
Relative density, layer by layer as per specification.

1.4 The soil has to conform to specifications as mentioned in RDSO
Guidelines for Earthwork in Railway Projects. The Engineer-in-
charge (EIC) may ask the contractor/s to get the soils samples
tested as per specifications. It may please be noted that under no
circumstances, the contractors will be allowed to form the bank
with unapproved earth. Such tests may be repeated by the
Engineer, during the execution of the work. If the soil samples are
found not conforming to the required specifications the contractors
may have to bring earth from other approved sources. The cost of
all tests will have to be borne by the contractor/s.

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1.5 The contractor/s shall, set out and provide all stakes, ballies,
bamboo, strings, pegs and labour for setting out profiles, of
embankment required for the correct execution of the work and
shall also be responsible to maintain the same in proper order.
This is deemed to be included in the item rate for the earthwork.
The contractor/s shall take necessary precautions to prevent their
being removed, altered and disturbed and shall be responsible for
the consequences of such removal, alterations and disturbance and
will take action for their proper re-instatement.

1.6 Before the earthwork is started by the contractor, the ground
between the lines where filling is to be done for embankments at
site of work shall be cleared of all roots, shrubs, heavy grass and
undergrowth of every kind. None of the items of work mentioned
in this para will entitle the contractor/s to any extra payment.

1.6.1 The contractor/s should commence the work systematically at one
or more points in consultation with the EIC and should maintain
continuous and steady progress to complete the work in
continuous lengths including leveling and dressing.

1.7 Any extra earth deposited on the top and slopes of the formation
shall be removed within 48 hrs. after a written notice. If not
complied, the same shall be removed by other means at contractor
cost. The payment shall be made as per designed cross section
only.

1.7.1 It must be clearly understood that the rates are intended to cover
the full cost of the finished works. The banks and cutting are to be
correctly dressed, to profile with such slopes as specified in each
case by the EIC. The rates for earthwork shall also include the site
clearances and breaking of clods as per specifications.

1.7.2 The rates also include maintenance of the banks to correct profile
including repairs of all rain cuts, making good earth work due to
base settlement natural or otherwise due to rains etc. until the
final measurements have been recorded and banks taken over by
the HPCL. The item rates of Schedule of rates and quantities will
cover the full cost of finished work of cuttings and embankments.

1.8 For the earthwork in embankment the toes of the slopes of bank
(with 500mm extra width on either side) on both sides of the
centre line and also lines parallel to and 60 cm outside the toes of
slopes of banks should be demarcated by the contractor with a
deep burrow at least 15 cm deep. This is to be considered as a
part of setting out the work and preliminary to his being allowed to
break ground. This lock spitting is to be executed, maintained and
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renewed by him without any payment when necessary or/and
when ordered by the Engineer.

1.8.1 Centre line pillars in masonry shall be provided by the contractor in
banks more than 1 m high. The same should however, be made in
stages as the work progresses. Pillars shall be provided at every 25
m or as directed by the Engineer-in-charge. The centre line pillars
shall not be paid for separately and deemed to be included in the
item rates.

1.8.2 The item rate quoted by the contractor shall include the provision
of benching in the side long ground or side slopes in the existing
bank where the earthwork joins old embankments. This aspect
should be taken into consideration while quoting the rates.

1.8.3 The breaking of all clods shall be strictly insisted upon for all earth
work in embankment and the contractors must take special care to
ensure this.

1.9 Extra bank width of 500 mm on either side shall be rolled to
ensure proper compaction at the edges. The extra soil would be
cut and dressed to avoid any loose earth at the slopes. This should
preferably be done with help of grade cutter.

1.9.1 The top of the formation shall be finished with specified thickness
of moorum blanket to a slope of 1 in 40 as per approved profile as
per guide line for"Earthwork in Railway project, " Guide Line
no. GE:G-1 July 2003".

1.9.2 Both the Up stream & Down stream side slope of the bank shall be
protected by providing stone pitching or by Turfing. The same shall
be required to be done by the contractor/s under this contract for
which extra payment shall bemade under respective items.

1.10 SPECIFICATION FOR MECHANICAL COMPACTION OF
EARTHWORK &BLANKETING MATERIAL

1.10.1 After site clearance all pockets and depression left in the soil, if
any, shall be made good and compacted.

1.10.2 Earthwork shall be done in layers not exceeding 200 mm thick.

i.) Earthwork shall be compacted with suitable rollers to obtain the
density specified as per IS 10379-1982 and RDSO's guidelines for
"Earthwork in Railway Project GE: G-1, July 2003" with upto
date amendments.

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ii. Cohensionless soils shall be compacted to get a minimum density
index (related to density of 70 percent as obtained in accordance
with IS 2720 (Pt. XIV) 1985.

iii. All other types of soils if dry density as found out from the random
samples works out to less than 98% of the maximum dry density
at optimum moisture content further rolling shall have to be done
by the contractor till such time the required density is obtained as
confirmed from subsequent tests.

iv. Each layer shall be compacted to the specified density over its
entire width commencing from the two sides, before another layer
is started.

v. While compacting, it shall be ensured that there is a minimum
overlap of 150 mm between each run of the rollers

vi. Care should be taken during the compaction operation to slope the
surface of the bank to facilitate the shedding and to minimize the
absorption of rain water, particular attention being given to the
prevention of ponding.

vii. The density of each layer of compacted soil shall be ascertained
by the Engineer by testing of adequate number of soil samples at
the site lab provided by contractor.

viii. The contractor shall be allowed to lay a further layer of soil only
after the compaction of particular layer has been found
satisfactory.

ix. Where the moisture content of the earth in any layer is above
OMC, it shall be left for drying for a suitable period to bring down
moisture content very near to OMC before rolling is commenced. If
the soil is dry, water shall be sprinkled either in the borrow pit or
even on the spread layer, as convenient in order to obtain a
moisture content near to OMC before rolling is commenced. The
contractor shall make his own arrangement of water and nothing
extra will be paid for water used. To control moisture at which soil
is compacted and to find out the dry density of the soil the
moisture content of the soil in borrow pits and in the embankment
after compacting will be determined.

x. The optimum moisture content and the maximum dry density of
the soil shall be determined by Standard proctor compaction test
as per IS-2720 (Pt. VIII) 1983 followed by field trial as per IS-
10379-1982. This test shall be conducted for the soil taken in the
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borrow pits at least every 100 meters and whenever there is a
change in the nature of soil met with.

xi. The site tests data and results shall be maintained in a Register as
per the following Proforma:

1) Serial No.
2) Location
3) Layer No.
4) Laboratory Test results.
5) a) Maximum dry density in gms. / CC or relative Density (%)
b) Optimum moisture content expressed as percentage of the dry
weight of the soil
6) Field Test Results :
a) Dry density in Grams, CC or Relative Density (%) Field moisture
content expressed as the percentage of the dry weight of the soil.
7) Degree of compaction expressed as percentage of the density
8) Remarks.

1.11. The payment for the quantity of earthwork will be made on cross
sectional measurement. The existing ground/bank profile will be
taken and plotted by the Engineers representative in the presence
of the contractor or his authorized agent before commencement of
the work. The profile of the bank required to be provided will also
be plotted on the same sheets. The levels and cross Sections shall
be signed by both the EICs representative and the contractor/s or
his/their authorized agent. The profiles of the bank as required to
be provided are for the guidance of the contractor and not for the
purpose of measurement/payment.

1.12 The profiles of the finished and completed bank first with extra
width and subsequently after dressing will like wise be taken in the
presence of the contractor or his/their-authorized agent and
superimposed on the original ground profile. The contractor shall
be allowed to dress the bank to form finished profile only after the
bank with wider width duly compacted has been checked to the
satisfaction of the EIC. The gross value of earthwork in filling will
be calculated from the original and finally finished profile for the
purpose of payment.

1.13. Final measurements will be taken only after the bank has been
completed to the required profile irrespective of the prolongation of
period of completion and number of monsoon that may pass during
execution.

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1.14 SUITABILITY OF SOILS FOR RAILWAY FORMATIONS
Source of soil for embankments

1.14.1 No borrow pits shall be allowed with in right of way and contractor
shall bring the embankment material from his own resources
outside the right of way.

The Characteristics of soils to be used and prohibited are :
a) Soil having following characteristics should be used :

- Soils with fine particles (i.e. particles finer than 75 microns) not
more than 50%
- Soil with liquid limits less than 35% and plasticity index less than
15%
- Soils having uniformity co-efficient preferably above 7.

b) Following soils should not be used:

- Soils having 10 to 15% clay and silt greater than 50% exhibiting
dispersive nature.
- Soils having maximum dry density less than 1.5 gm/cc by light
compaction.
- Peat and organic soils.
- Soils likely to disintegrate early, like chalk with maximum dry
density less than 1.7 gm/cc.
- Poorly graded sand with co-efficient of uniformity less than 2.

1.14.2 Expansive clay like black cotton soils exhibiting marked swell and
shrinkage properties shall be avoided. Clays that have a "Free
swelling index" exceeding 50% when tested as per IS 2720-Part 40
shall not be used as a fill material.

1.15 Earth work in cutting

Earth work in widening the existing cutting to the BG standard.

The earth work in widening the existing cutting to BG standards
may have to be done to the required width on both sides of the
existing cutting or on one side of the existing cutting. The cutting
has to be done inside the terminal premises in the existing siding
area. The description of cutting is as follows.

Soil, soft murrum including all ordinary soils like black cotton soils,
ordinary earth sols like organic soils, made up ground, coal as
filling, loam or sand, hard murrum which comprises murrum, silt,
clay, gravel and material which is so hard that it cannot be
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excavated with out the use of crow bars and pick wheel also to be
included under this head.

Rock not requiring blasting, shall comprises of soft rock which can
be excavated by means of crow bars and picks. Under this class
will also be included the detached masses of rock measuring more
than 0-03 cm, and volume 0.4 cum which can be completely and
properly removed with out-blasting.

Rock requiring blasting is not included in the specification.

The classification of earth work may got be done for the work not
included in the scope of work by the engineer. With regard to the
nature and propositions of different categories of soils, the
Engineers judgment and decision shall be accepted as final and
binding.

Cutting spoils shall be stacked on the top of cutting leaving a space
of 6 m from the toe of cutting or at designated spoil dumps by
leading

The earth work required for catch water drains on ground sloping
towards railway cutting and side drain should be done as directed
by the EIC. The cross sectional area of the catch water drain and
side drain should be so as to allow free flow of storm water with
out over flowing.

2.0 SPECIFICATION FOR BLANKETING MATERIAL
2.1 The blanket should cover the entire width of the formation from
shoulder to shoulder. The depth of blanket shall be as follows:

a) Following soils shall not need any blanket :
- Rocky beds except those consisting of shales and other soft rocks
which become muddy after coming into contact with water.
- Well graded Gravel (GW)
- Well graded Sand (SW)
- Soils conforming to specifications of blanket material.
- Soils having grain size analysis curve lying on the right side of the
enveloping curves for blanket material.

b) Following soils shall need minimum 45 cm thick Blanket :
- Poorly graded Gravel (GP) having Uniformity Co-efficient more
than 2.
- Poorly grade sand (SP) having Uniformity Co-efficient more
than 2.
- Silty Gravel (GM).
- Silty Gravel - Clayey Gravel (GM-GC).
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c) Following soils shall need minimum 60 cm thick blanket :
- Clayey Gravel (GC).
- Silty Sand (SM).
- Clayey Sand (SC).
- Clayey Silty Sand (SM-GC).

d) Following soils shall need minimum 1 m thick blanket :
- Silt with low plasticity (ML).
- Silty clay of low plasticity (ML-CL).
- Clay of low plasticity (CL).
- Silt of medium plasticity (ML).
- Clay of medium plasticity (CL).

Note: The classification and nomenclature of soils given above is as
per IS-1498-1970 Table - 2 (Annexure 'A').

2.2 The blanket can be coarse grained material like murrum which has
inherent cohesive properties, or it may be manufactured out of non
cohesive materials.

2.3 The murrum blanket shall have following properties:

(a) The liquid limit shall not exceed 35 and Plasticity Index shall be
below 10.
(b) Uniformity co-efficient d60/d10 should be above 4 and preferably
above 7.
(c) Co-efficient of curvature Sqr(Sd30)/d60 x d10 should be between
1 & 3.

Note: d60 is sieve size through which 60% of blanket material
passes and d10 is the sieve size through which 10% of the blanket
material passes and 80 so on.

2.4 In case of mechanically produced blanket material, specification
No: IRSGE 2(Provisional) Feb-2003 issued by RDSO shall be
followed.

TECHNICAL SPECIFICATION FOR CIVIL JOBS

1.0 GENERAL

1.1 Specifications

All materials and works shall conform to the latest edition of IRS
Specification, codes and manuals as applicable. If the specification
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for an item of work is not available in these Technical
Specifications and Standard Specifications, the work shall be
executed as per latest Indian Standard specifications with up-to
date correction slips and if Indian Standard specifications do not
cover the same, the work should be carried out as per standard
engineering practice and as directed, to the entire satisfaction of
the Engineer-In-Charge.

1.2 Sampling and Testing
All materials used in the works shall be subjected to inspection and
test. Samples of all materials proposed to be used in the
permanent works shall be submitted to the Engineer-In-Charge for
approval, before they are brought to the site. These samples shall
be submitted 15 days in advance than required for works. After the
sample is approved the material shall be arranged and brought to
site within a fortnight. Samples provided to the Engineer-In-
Charge or his representative for their retention are to be provided
in labeled boxes suitable for storage.

1.3 Storage of Materials
All materials used in the works shall be stored on racks, stored in
bins, under cover etc. as appropriate, to prevent deterioration or
damages from any cause whatsoever, to the entire satisfaction of
the Engineer-In-Charge. Cement shall be stored in such quantities
as can be consumed within a short time after receipt from the
manufacturers. It shall be stored in such a manner as to permit
easy access for proper inspection and in a suitable weather tight
building to protect it from dampness and to minimize deterioration.
Standard method established by BIS shall be followed for
designing the cement store.

1.4 Setting out
The Contractor shall be responsible for the true and proper setting
out of the works in relation to the original points, lines and levels
of reference given by the Engineer-In-Charge in writing and for the
correctness, subject as above mentioned of all the parts of the
works and for the provision of all necessary instruments,
appliances and labour etc. at his own cost in connection therewith.
If at any time, during the progress of the Works any error shall
appear or arise in the position, levels, dimensions and alignments
of any part of the Works, the Contractor, on being required to do
so by the Engineer-In-Charge shall at his own cost rectify such
error to the satisfaction of the Engineer-In-Charge. The checking of
any setting out of any line or level by the EIC shall not in any way
relieve the Contractor of his responsibility for the correctness
thereof and the Contractor shall carefully protect and preserve all
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benchmarks, sightrails, pegs and other things used in setting out
the work.

2.0 EARTH WORK

2.1 Site Preparation

2.1.1 The Contractor shall remove all vegetation and foreign materials
from the area as instructed by the Engineer-In-Charge. The
removed materials shall taken to the approved disposal areas on
or near the job site at his own cost as directed by the EIC.
Employer shall give one reference benchmark in the near vicinity.
The Contractor shall maintain and project all benchmarks from
reference point.

2.2 Excavation
2.2.1 This section of the specification covers excavation for foundations,
of bridges, drains, culverts and underground facilities as shown on
the drawings and as directed. The Contractor shall furnish all
labour, plant and equipment to complete the work indicated or
specified herein.

2.2.2 Site Clearance
The Contractor shall remove roots, break and remove old concrete
or brick foundations, drains and clear all old wells, cess pools,
ponds and burn or remove organic materials found during progress
of excavation, remove all contaminated earth and fill in voids with
hard materials and well rammed. The cleared and grubbed areas
shall be maintained free from vegetation and any vegetation
growth during the progress of Work. All materials obtained from
clearing and grubbing shall be suitably disposed off as directed by
the EIC. Any jungle clearance if required will be deemed to be
included in the rate for excavation.

2.2.3 The Contractor shall excavate to remove material of any nature
and excavate to the width, depth and inclinations as per the
drawings. The Contractor shall arrange necessary tools and plants
required by the nature of materials to be excavated and also
arrange to maintain the bottom and sides of the excavation true to
shape and levels as per drawings. Undercutting shall not be
permitted.

2.2.4 When machines are used for excavations, this layer shall be
excavated by such implements that will leave the strata at the
required final level in its natural condition.

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2.2.5 If the bottom of any foundation is found to be soft, unsound or
unstable, the Contractor shall inform the EIC and shall excavate
the same as directed by the Architect/Engineer. No foundation
shall rest on loose/filled up earth
.
2.2.6 Every precaution shall be taken against slips and falls of earth,
clay, sand or other materials in the excavations, but in the event of
any such occurring, the Contractor shall make it good at his own
expense. The Contractor shall be held responsible for any damage
to any part of the work by the collapse of sides of excavation and
this shall be made good by the Contractor at his own cost.

2.2.7 The Contractor shall plank and strut at the sides of excavation as
required and wherever excavation requires bracing, strutting or
shoring etc. the Contractor shall submit to the EIC, the drawings
showing the arrangement and will do at his own expense. This
however will not relieve the Contractor from his responsibility for
the safety and adequacy of bracing, strutting etc.

2.2.8 The Contractor shall control the grading in the vicinity of the
excavation so that the surface of the ground is properly sloped or
diked to prevent surface water from running in to the excavated
areas during construction. Wherever water table is met with during
excavation the Contractor shall immediately inform the EIC. As per
the directions of the EIC, the Contractor shall dewater and
maintain the water table below the bottom of the excavation level
during excavation, concreting and back filling. All water which gets
accumulated in the excavated trenches during the progress of the
works, from whatsoever cause or source shall be pumped out as
directed by the EIC at no extra cost to the Employer. The rates
quoted are for all types of hard /dense ordinary soil met at site,
inclusive of cost of planking, shoring and de-watering.

2.2.9 Blasting
Blasting is prohibited in the Works area.

2.2.10 Returning, Filling and Ramming
After completion of foundations, footings and walls and other
construction below the elevation of the final grades, and prior to
back filling all forms of temporary shoring, timber, cement bags
etc. shall be removed and the excavation cleaned off all trash,
debris and perishable materials. Back fill shall begin only after the
approval of the EIC. Back filling shall be placed in horizontal layers
not exceeding 200 mm in thickness and rammed, watered as
required to consolidate properly. Before a new layer is laid,
existing ruts or other unevenness in the surface of the layer shall
be removed and the surface shall be roughened by harrowing or
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ploughing to obtain good bond with the material to uniform
thickness. Each layer shall be compacted to proper moisture
content and with such equipment as may be required to obtain a
density equal to or greater than 94% of the dry density of the soil
as determined by the laboratory tests. The filling under the floor
shall be in layers not exceeding 200 mm in thickness. Each layer
shall be thoroughly consolidated by watering and ramming. When
the filling has reached an appropriate level, the filled area shall be
flooded with water and the fill shall be allowed to settle. When the
water has been absorbed by the soil, the whole area shall be finally
rammed and dressed to the required level. Back fill adjacent to the
pipes shall be hand placed, free of stones, concrete etc. compacted
uniformly on both sides of the pipes. If sufficient quantity of
suitable material is not available at the site, the same shall be
brought to site from outside and the same shall be used after
approval by the EIC. Stone/boulders, if obtained from excavation,
will not be used in backfill.

On completion of the work, the surrounding earth shall be
accurately finished to the line and grade as shown on the
drawings. The Contractor shall arrange to transport surplus
excavated materials and stack at a place as directed by the EIC or
shall be disposed off.

3.0 CONCRETE: PLAIN AND REINFORCED
( The contractor to use Ready mix concrete for all RCC work
wherever specifically mentioned in the schedule of
quantities)

3.1.0 Cement
The cement used shall be of the following types with the prior
approval of the EIC.

a) Ordinary Portland Cement grade 43/53 as per relevant IS Code
(IS-8112).
b) Portland Pozzolona Cement as per relevant IS code. Portland
Pozzolona cement shall not be used for PSC works. When Portland
Pozzolona cement is used in plain and reinforced concrete, it is to be
ensured that proper damp curing of concrete at least for 14 days
and supporting form work shall not be removed till concrete attains at
least 75% of the designed strength. Cement shall be used in the
order in which it is received. Cement bags in storage for more than 3
months shall be retested before use.

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3.1.1 Testing
A sample shall be taken once for every 1000 bags received at site.
Tests shall be carried out for fineness, initial and final setting time
and compressive strength as per IS 4031. The results shall be
submitted to the EIC for approval. The methods and the procedure
of sampling shall be in accordance with IS 3535. The EIC may
specify any other form of sampling and testing including chemical
analysis as per IS 4032, if the quality of the cement is found to be
unacceptable. The cost of these tests including the chemical
analysis of the cement etc shall be borne by the Contractor.

3.1.2 The successful bidder shall along with the bill of purchase of
cement shall also obtain test certificate for the cement purchased
/issued by the manufacturer for each batch of cement and shall
submit the copy of the same to HPCL for verification. Any other
tests required by HPCL will be carried out by the party at no extra
cost to HPCL.

The contractor shall make his own arrangements for storage of
cement and see that no damage will takes place during storage
period of procurement and usage shall be taken. Cement damage
due to any reason shall not be used in the work and no
compensation can be made for the loss, if any, sustained in this
account.

HPCL reserves the right to inspect the storage accommodation of
the contractor and to reject in the event of any cloded/ damaged
cement is noticed or any other cement which is not suitable for
used in work and not in conformity with the specification of the
work. Contractor shall maintain a register showing the quantity of
cement procured, date with cement consumption and balance
available at site. The register is to be signed by the contractor.
HPCL will inspect the register and stocks of cement frequently.

Contractor should ensure the consumption of cement, specified for
each item of work correctly. No sub-standard work in this account
will be permitted. If for any item of work, at any stage, HPCL finds
less consumption, such item of work will be rejected and cost of
removal of such item and redoing the same shall be on contractors
account. The decision of EIC in this regard is final and binding and
no claim in this account will be entertained.

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3.2.0 Fine Aggregate

3.2.1 It shall pass through IS sieve no. 4.75 mm test sieve, leaving a
residue of not more than 5%. The sand shall consist of natural
sand, crushed stone sand or combination. The sand shall be hard,
durable, chemically inert, clean and free from harmful impurities.
It shall be washed, if required.

The sand is graded into four zones as under:

IS Sieve
Desi
gnati
on
Percentage Passing for
Grading
Zone - I
Grading
Zone - II
Grading
Zone - III
Grading
Zone - IV
10 mm
4.75 mm 90-100 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 micron 15-34 35-59 60-79 80-100
300 micron 5-20 8-30 8-30 20-65
150 micron 0-10 0-10 0-10 0-15

Note: Fine Aggregate conforming to grading zone IV shall
not be used in RCC works.

3.2.2 Fine Sand

Fine sand shall be in Grading Zone IV and its fineness modulus
shall not be less than 1.0.

3.2.3 Coarse Sand
It shall fall in Grading Zone I to III and its fineness modulus shall
not be less 2.5.

3.2.4 Testing

Fine aggregate shall be tested as per IS - 2386 (1963)
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3.3 Coarse Aggregate
3.3.1 It shall consist of natural gravels, broken stone or other suitable
materials. It shall be hard, strong and durable and shall be clean
and free from clay and other deleterious materials. The aggregate
shall be washed, if necessary. Graded coarse aggregate of nominal
size shall be used conforming to requirements given below.

3.4 Water
Water from approved source shall be used for the Works. It shall
be clean and free from any deleterious matter in solution or in
suspension and be obtained from an approved source. The quality
of water shall conform to I:S 456. The water shall be stored in
drums and tanks or cisterns to the approval of the EIC. Care shall
be exercised to see that water is not contaminated in any way.

3.5 Batching Plant and Vibrators

3.5.1 The Contractor shall provide Batching Plant and Transit Mixers as
may be required for the work.

3.5.2 He shall also provide vibrators of the following types as required fo
concreting:
Immersion type (IS 2505), Screed board type vibrators (IS 2506)
and form vibrators (IS 4656).

I.S. SIEVE
DESIGNATION
%
PASSING
40 mm
%
Passing
20mm
%
passing
12.5 mm
40 mm 95-100 100 NIL
20 mm 30-70 95-100 100
12.5 mm -- -- 100
10 mm 10-35 25-55 40-85
4.75 mm 0-5 0-10 0-10
2.36 mm -- -- --
18

3.6.0 Concrete Mixes

3.6.1 The concrete shall be of grade M-20/ M-25/M-30/M-35 with
characteristic strength of 20/25/30/35 N/sqmm respectively,
unless otherwise specified.

3.7.0 Design of mixes

3.7.1 Entire cement concrete job needs to be carried out necessarily
thru ready mix concrete only unless otherwise specified in job
schedule. Party may set up batching plant on their own at site and
produce design mix as per requirement of job schedule and
technical specifications and relevant standards. The samples of all
components of Design mix like cement, aggregates, admixtures etc
shall be given to reputed engineering college or an approved
laboratory in sealed containers to enable vetting of the submitted
design mix. The Contractor shall make trial mixes using samples of
coarse aggregates, sand, water and cement, typical of those to be used
in the Works and which have been tested in an approved laboratory.
Design mix of concrete of all the grades as required shall be carried
out by the Contractor & the contractor will have to get the same vetted
by reputed engineering institute like IIT, Chennai or any other
reputed Engineering Institutes/ Consultant duly approved by
HPCL.at his own cost. Party has to submit the vetted design
calculations to EIC and obtain approval of the same before
commencement of the job.

The Contractor is entirely responsible for the design of the Concrete
mixes. The design is however to be approved by the EIC at least 4
weeks before commencing any concreting works.
A clean dry mixer shall be used and the first batch shall be discarded.
The required average strengths at 28 days for which various mixes
shall be designed are specified below:

19

Grades
of
Concrete
Characteristic
Strength
(fck) At
28 days

(N/Sqmm)
Target
or mean
crushing
strength
at 7 days
(N/Sqmm)
f'cm
at
28 days
(N/Sqmm)
M 15 15 18 24
M 20 20 22 29
M-30 30 32 40

3.7.2 The mixes are designed to yield mean strengths (fcm) greater
than the corresponding specified characteristic strengths (fck) as
indicated in the table above. The difference between fck and fcm
is called the current margin.
The value of the current margin has been set at 9 or 10 N/sq mm
for all grades of concrete. The concrete mixes shall be designed on
the basis of required strength, desired workability, the
maximum size of the aggregate and also upon the various grades
of cement. Accordingly the required quantity of cement shall be
ascertained. The Contractor may be allowed to use either
approved plasticizers or increased cement content to achieve the
required strengths at his own cost. Minimum quantity of cement to
be usedin a specific grade of mix shall not be less than as
specified in IS:456.Wherever in the BOQ, control concrete mix as
well as nominal mix is defined, control mix is to be adopted unless
otherwise permitted by EIC. However consumption of cement in
control mix shall not be more than nominal mix. If so, theoretical
consumption shall be accounted for by adopting factor of cement
consumption as per nominal mix.
3.7.3 For each grade, a total no. of 18 cubes shall be made. Of these 18
cubes made, not more than 6 may be made on any day, further of,
the 6 cubes made in one day not more than 2 cubes may be made
from any single batch. Of these 9 cubes, each representing a batch
of concrete shall be tested at the age of 7 days and the remaining
20

9 cubes shall be tested at the age of 28 days. The making of the
cubes, their curing, storing, transporting and testing shall be in
accordance with IS-516. The test shall be carried out at site
laboratory or any designated laboratory approved by the EIC.
3.7.4 If the average strength of the concrete cube falls below the
required strength, fresh preliminary mixes for that grade shall be
made as before, until the trial mix yields cubes of compressive
strength at 28 days greater than the required average strength at
that age.
3.7.5 Whenever there is a significant change in the quality of any of the
ingredients for concrete, the EICmay at his discretion order the
carrying out of the fresh trial mixes. All costs for trial mixes and
tests shall be to the Contractors account and held to be included
in the Contract rates.
3.7.6 Before commencing the works, the Contractor shall submit to the
EIC for approval, full details of all preliminary trial mixes and tests.
3.7.7 When the proportions of a concrete mix have been approved by
the EIC, the Contractor shall not vary the quality or source of the
materials or the mix without the written approval of the EIC.
3.7.8 Whenever there is a significant change in the quality of any of the
ingredients for concrete, the EIC may at his discretion order the
carrying out of the fresh trial mixes. All costs for trial mixes and
tests shall be to the Contractors account and held to be included
in the Contract rates.
3.7.9 Before commencing the works, the Contractor shall submit to the
EIC for approval, full details of all preliminary trial mixes and tests.

3.8.0 Concrete Cube Tests

3.8.1 The quality of the hardened concrete will be verified by the
following procedure:

a) The EIC shall select random batches of concrete for examination
without any warning to the Contractor and sampling will generally
be done at the point of discharge from the mixer.

b) From the batches thus selected 6 concrete cubes shall be made in
accordance with IS codes. However not more than 2 cubes be
made from any single batch. Of these 6 cubes thus made, 3 cubes
(each cube representing concrete of different batches) shall be
21

tested at 7 days and the remaining 3 cubes shall be tested at 28
days.

c) All cubes shall be made, cured, stored, transported and tested in
accordance with IS codes. The tests shall be carried out in a
laboratory approved by the EIC.

d) At least 6 cubes shall be made on each days concreting until 60
cubes have been made for each grade of concrete. This is in the
initial period.

e) After the initial period, subject to the acceptance of the EIC, the
frequency at which the cubes shall be made be reduced as follows:
(1 set = 6 cubes, each pair representing concrete from a different
batch) At least one set for each days concreting consisting of: One
set for 10 cum or part thereof of concrete for critical structural
elements like main beams, columns, masts, large cantilevers, plus
one set for every 40 cum or parts thereof for all other elements.

f) If concrete is batched at more than one point simultaneously, the
above frequency of making cubes shall be allowed at each point of
batching. 3 cubes of each set shall be tested at 7 days and the
remaining 3 cubes shall be tested at 28 days from the day of
casting the cubes.

3.9.0 Acceptability Criteria

3.9.1 The strength requirement of any particular grade of concrete will
be considered satisfactory if the 28 days compressive strength of
individual sets (each set consisting of 3 cubes) and of individual
cubes satisfy the requirements of IS 456 : 2000 (Clause 16)

3.9.2 If the concrete produced at site does not satisfy the above
strength requirements, the EIC will reserve the right to require the
Contractor to improve the method of batching, the quality of the
ingredients and redesign the mix with increased cement content if
necessary. The Contractor shall not be entitled to claim any extra
cost for the extra cement used for the modifications stipulated by
the EIC for fulfilling the strength requirements specified.

3.9.3 It is the responsibility of the Contractor to design the concrete
mixes by approved standard methods and to produce the required
concrete conforming to the specifications and the strength
requirements approved by the EIC. It is expected that the
Contractor will have competent staff to carryout this work.

22

3.10 Failure to meet specified requirements

3.10.1 If from the cube test results it appears that some portion of the
Works has not attained the required strength, the EIC may order
that portion of the structure be subjected to further testing of any
kind whatsoever as desired by the EIC, including, if so desired by
him, full load testing of the suspected as well as the adjacent
portions of the structures as specified in the Conditions of
Contract. Such testing shall be at the Contractor's cost., The EIC
may also reject the work and order its demolition and
reconstruction at the Contractors cost.

3.10.2 If the strength of the concrete in any portion of the structure is
lower than the required strength, but is considered nevertheless
adequate by the EIC so that demolition is not necessary, the work
shall be devalued by the EIC to that extent and amount of
devaluation recovered from Contractor's RA bills. The decision of
EIC shall be final and binding on the Contractor.

3.11 Admixtures

Approved admixtures and air entraining agents may be permitted
at no extra cost by the EIC at his discretion provided that the
strength requirements are not affected by their use.

3.12.0 Concrete Placing Temperature in varied temperature

3.12.1 During extreme temperatures, high or low, the concreting shall be
done, as per procedures set out in IS 7861 (Part I & II). The
aggregate shall be kept under shades and it shall be sprinkled with
water for sufficient time before concreting in order to ensure that
the temperature of these ingredients is as low as possible prior to
batching. The mixer and batching shall also be kept under shades
and if necessary painted white in order to keep their temperatures
as low as possible. The placing temperature of concrete shall be as
low as possible in warm weather and care shall be taken to protect
freshly placed concrete from overheating by sunlight in the first
few hours of its laying. The time of the day selected for concreting
shall also be chosen so as to minimize placing temperature. In
case of concreting in exceptionally hot weather the EIC may in his
discretion specify the use of either ice flakes or chilled water for
mixing the concrete.

3.13.0 Transporting, placing, compacting and curing

3.13.1 Transporting, placing, compacting and curing of concreting of any
portion or
23

section of the works shall be carried out in one continuous
operation and no interruption of concreting work will be allowed
without prior approval of the EIC.

3.13.2 The concrete shall be compacted with mechanical vibrators and
over vibration shall be discouraged until the air bubbles cease to
come to the surface.

3.16.0 Construction Joints

3.16.1 Construction joints in concrete

3.16.1 Construction joints in concrete work shall be made as directed by
the EIC. Where vertical joints are required, these shall be
shuttered as directed and not allowed to take the natural slope
of the concrete.

3.16.2 Before fresh concrete is placed against a vertical joint, the old
concrete shall be chipped, cleaned and moistened. Where required,
suitable expansion joints shall also be provided as directed by the
EIC.

3.16.3 When a horizontal construction joint is formed, provision shall be
made for interlocking with the succeeding layer by the embedment
of saturated wooden blocks or strips bevelled on four sides to
facilitate their removal. Prior to the next pour the wooden pieces
shall be loosened and removed in such a manner as to avoid injury
to the concrete.

3.17.0 Cracks

If any structural crack develops in the concrete construction, the
Contractor shall dismantle the construction, carry away the debris,
replace the construction and carry out all consequential work
thereto at his own cost.

3.18.0 Defective Concrete

Should any concrete be found honeycombed or with hair-line
shrinkage cracks, or in any way defective, such concrete shall on
the instruction of the EIC, be cut out by the Contractor and made
good at his own cost.

24

3.19.0 Exposed faces, Holes and Fixtures

On no account shall concrete surfaces be patched or covered up or
damaged concrete rectified or replaced until the EIC has inspected
the Works and issued written instructions for the rectification.
Failure to observe this procedure will render that portions of the
works liable to rejection which has failed to meet specified strength
requirements. Holes for foundation or other bolts or for any other
purposes shall be moulded and steel angles, holds fasts or other
fixtures shall be embedded, according to the drawing or as
instructed by the EIC.

3.20.0 Finishes
Unless otherwise instructed the face of the exposed concrete
placed against formwork shall be rubbed down immediately on
removal of the formwork to remove irregularities. The face of the
concrete for which the form work in not provided other than slabs
shall be smoothed with a float to give a finish equal to that of the
rubbed down face, where form work is provided. Faces of concrete
requiring surface treatment shall be plastered in mix of 1:4 of
5mm thickness.

3.21.0 Measurement

All concrete and reinforced cement concrete items are including
cost of formwork and excluding reinforcement which shall be paid
for separately unless specified otherwise. The volume of concrete
measured shall include that occupied by:

a) Reinforcement and other metal sections.
b) Cast-in components each less than 0.01 cum in volume.
c) Rebates fillets or internal splays each less than 0.005 Sqm in cross
sectional area.
d) Pockets and holes not exceeding 0.01 cum in volume.
e) For M10 and below concrete, no payment shall be made for any
shuttering
used, if any.

3.22 READY MIX CONCRETE :

The provision in this section shall apply to all concrete grades and
is to be considered as a supplementary to general provisions for
Plain Cement Concrete & Reinforced Cement Concrete works.

ll Ready mix concrete (RMC) may be manufactured in a central
weigh batching plant and transported to the job by agitating
Transit mixers. The RMC is to be sourced from reputed & approved
25

batching plants as mentioned in the approved list of manufacturers
or suppliers only. The design mix from either RMC plant or weigh
batching plant at site shall be vetted by reputed Consultant or
engineering institute duly approved by HPCL. The samples of all
components of Design mix like cement, aggregates, admixtures etc
shall be given to reputed engg college in sealed containers to
enable vetting of the submitted design mix. Party has to submit
the vetted design calculations to EIC and obtain approval of the
same before commencement of the job.

ll The design mix is to be carried out as per IS-10262 or any other
HPCL approved standards sound engineering methods.

ll Note : No puzzolonic material such as Metakaoline & rice husk ash
etc shall be used for the work unless otherwise specified.

ll The standard deviation for concrete mix design will be considered
as per Table 8 of IS-456-2000.

ll The proportion of fine aggregates to coarse aggregates should be
adjusted so as to keep them within the specified limits as
mentioned in IS-383.

ll The Bidders have to submit the Quality Assurance Plan of theirs as
well as the RMC plant for approval and shall strictly adhere to the
same
.
ll The admixtures used shall confirm to IS-9103.

4.0 FORMWORK

4.1 Form work shall include all forms, moulds, sheeting, shuttering
planks, walers, poles, post, shores, struts and strutting, ties,
uprights, wallings, steel, bolts wedges and all other temporary
supports to the concrete during the process of setting.

4.2. Design
Formwork shall be designed and constructed so that the concrete
can be properly placed and thoroughly compacted to obtain the
required shade, position and level subject to specified tolerances.
It is the responsibility of the Contractor to obtain the results
required by the EIC, whether or not some of the works is sub
contracted. Approval of the proposed formwork by the EIC, will not
diminish the Contractors responsibility for the satisfactory
performance of the formwork, nor the safety and the coordination
of all operations.
26

4.3 Erection of Form work

4.3.1 The following shall apply to all formwork:

a) To avoid delay and unnecessary rejection of the shuttering, the
Contractor shall obtain the approval of the EIC for the design of
forms and the type of material used before fabricating the forms.

b) All shutter planks and plates shall be adequately backed to the
satisfaction of the EIC by a sufficient number and size of walers or
form work to ensure rigidity during concreting. All shutters shall be
adequately strutted, braced and propped to the satisfaction of the
EIC to prevent deflection under deadweight of concrete and
superimposed live load of workmen, materials and plant and to
withstand vibrations. In case props are supported on a floor slab
underneath, all the floors below the member / slab being laid be
supported by designed propping unless otherwise Contractor may
establish adequacy of these floors and propping be dispensed with.
For any damage on this account, sole responsibility will be of the
Contractor. No joints in the props shall be allowed.

4.3.2 Vertical props shall be supported on wedges or other measures
shall be taken where the props can be gently lowered vertically
during removal of formwork. Props for an upper lowest prop shall
bear on a sufficiently strong area.

a) Care shall be taken that all formwork is set plumb and true to line
and level or camber or batter where required and as specified by
the EIC.

b) Formwork shall be so arranged as to permit removal of forms
without jarring the concrete. Wedges, clamps and bolts shall be
used wherever practicable instead of nails. The formwork for
beams and slabs shall be so erected so that forms on the side of
the beams and the soffit of slabs can be removed without
disturbing the beam bottoms or props under beams.
c) Surfaces of formwork in contact with concrete shall be oiled with a
mould oil of approved quality or clean diesel oil. If required by the
EIC, the Contractor shall execute different parts of the work with
different mould oil to enable the EIC to select the most suitable.
The use of oil that results in the blemishes to the surface of the
concrete shall not be allowed. Oil be applied before reinforcement
has been placed and care shall be taken that no oil comes in
contact with the reinforcement while it is being placed in position.
27

The formwork shall be kept thoroughly wet during concreting and
the whole time that it is left in place.

d) Formwork shall be continuously watched during the process of
concreting. If during concreting, weakness develops and form work
shows any distress the work shall be stopped and remedial action
taken.

4.3.3 The tolerances and the age of concrete and removal of formwork
shall be as per IS :456.

4.3.4 Stripping of Form work

Formwork shall be removed carefully without jarring the concrete.
Concrete surfaces to be exposed shall be rubbed down with
carborundum stone to obtain a smooth and even finish. Where the
concrete requires surface treatment, it shall be hacked
immediately all over.

4.3.5 The Contractor shall not be permitted reuse of timber facing form
work brought new on the works more than 5 times for exposed
concrete form work and 8 times for ordinary form work. 5 or 8
uses shall be permitted only if forms are properly cared for, stored
and the ones which go bad are repaired after each use. The EIC
may, in his absolute discretion, ask for removal from the site of
any forms he considers unfit for use for particular item and other
brought on the site will be proportionately allowed fewer uses as
decided by the EIC. Use of different quality boards or the use of
old and new boards in the same form work shall not be allowed.

4.3.6 Mode of Measurement (Form work Not to be paid
separately, but included in cement concrete scope of work)

4.3.6.1 Only where form work is specified to be paid for separately,
measurement shall be of the area of shuttering actually in contact
with RCC/PCC requiring shuttering including curves, angles, splays,
mitres, bevels etc., for which nothing extra shall be allowed. The
rates shall be inclusive of all work connected with provision of form
work, its erection and removal and treatment of the concrete
surface immediately after the removal of the form work.

4.3.6.2 No extra payment shall be made for holes to be made in form work
for inserting electrical conduits, hooks for fans and plumbing work
or leaving chases for any work
.
4.3.6.3 Where boxes or pockets are required to be formed in the concrete,
they will be paid for separately as specified in the Bill of Quantities,
28

but in measuring the area of concrete surface shuttered, no
deduction will be made for opening upto 0.4 sqm. For voids larger
than 0.4 sqm the surface of form work forming the voids shall be
paid at the rates of form work set out in the schedule and the area
of voids deducted from the face area of shuttering.

4.3.6.4 No deduction shall be made from form work of main beams where
the secondary beam intersects it. Form work to secondary beams
shall be measured upto the sides of the main beams. No deduction
shall be made from the form work to stanchion or column castings
at intersections of beams.

4.3.6.5 No payment shall be made for temporary form work used in
concreting, or for joints or bulkheads, in floors, or elsewhere,
whether such joints are to be covered later with concrete or
bitumen mastic or other material as approved by the EIC.

5.0 REINFORCEMENT:

5.1 Reinforcement

Supply, straightening, cutting, bending, fabrication, tying and
laying in position TMT (Thermo Mechanically Treated) steel
reinforcement conforming to IS 1786, Fe-500 (latest edition)
manufactured by SAIL/TISCO/RINL. They shall be of tested quality
and the manufacturers test certificate shall be produced by the
Contractor.

Reinforcement steel shall be procured from primary producers like,
SAIL, TISCO, RINL, IIISCO. The bars may be procured from
authorized rerollers of primary producers, if those diameters are
not produced directly by them. Reinforcement shall be fabricated,
placed in position as shown on drawings and specified. All
reinforcement shall be bent cold. The laps and splices shall be as
specified in the drawings. All reinforcement shall be free from rust
and scales, tied with 18 SWG soft drawn annealed binding wire
with suitable chairs, if required. Proper chairs and spacers shall be
provided to maintain the cover requirements. All reinforcement
shall be provided a protective coat of truncated inhibited cement
slurry.

HPCL reserves the right to inspect the storage yard of the bidder
where the steel materials are stored and take samples wherever
considered necessary, direct the bidder get them tested by
approved agency to find out if such steel is suitable for use. The
bidder shall along with the bills of purchase of steel should also
29

obtain the test certificate issued by the manufacturer and shall
submit the copy of the same to HPCL for verification and record.

5.2 Mode of Measurement

Reinforcement Steel

It shall be measured in running meter.Authorised Laps, Chairs,
splices, hook, spacer bars, etc shall be considered for
measurement and payment purposes . The running length shall be
converted to corresponding weight by applying weight per running
meter.

6.0 STONE PITCHING
Pitching shall be as provided in drawing, unless specified otherwise.
Profiles shall first, be put up by means of pegs and strings or by
placing stones, at interval of not more than 15 mtr. Stone shall
then be laid closely in position in between the profile and firmly
embedded with joint staggered and with exposed faces true to line,
gradient and in uniform slope throughout. The cross bands of
approx. 22.5 cm width through bond stones equal to the full depth
of pitching, shall be provided at an interval of approx. 3 m centre
to centre both longitudinally and transversely. The interstices
between adjacent stones shall be filled in with stones of proper
size, well driven in with crowbars to ensure tight packing and
complete filling of all interstices. Such filling shall be carried on
simultaneously with the placing in position of the large stones and
shall in no case be permitted to fall behind. Final wedging shall be
done with the largest sized chip particles, each chip being well
driven home with a hammer so that no chip is possible of being
picked up or removed by hand. The stones shall be of min. 150
mm on any side and not less than 30 kg in weight.

6.1 MEASUREMENTS:
The exposed finished surface shall be measured after the pitching
has been done. The length, width and depth and side slope shall
be measured correct to a cm. The volume of pitching for drains
shall be calculated in cum. By multiplying the perimeter (bed width
plus side slope) by the length & depth of the pitching.
30

7. Technical Specification for Permanent Way

7.1 General

All works relating to permanent way shall generally conform to
provisions contained in Indian Railway Permanent Way Manual
1986 reprinted in 2004 with up to date correction slips, Indian
Railway Standard Specifications, RDSO Drawings, RDSO
Specifications & Guidelines and Indian Railway Track Manual (all as
amended up to date), as applicable. The word IRPWM where ever
used in these specifications shall mean `Indian Railway Permanent
Way Manual 1986 reprinted in 2004 with up to date correction
slips.

7.2 Materials
The track shall consist of following elements: -

7.2.1 Rails 60 Kg/90 UTS flat bottom (1st quality/ IU as specified in
schedule of quantity) as per I.R. Specification with up to date
amendments.

7.2.2 Rail fastenings

60kg Fish Plates to RDSO Drg. No. T-1898 (M), in length of
610mm to IRS specifications No. T 1-66.

Fish Bolts 25mm Dia with nuts to RDSO Drg. No, 1899 - IRS
Specification T-23/67.

Mono block Pre-stressed concrete sleepers as per IRS
Specification T-39/1996.

For plain track on straight & curves of radius > 350m to Drg. No.
T- 2496 with modifications, if any.

For curves sharper than 50 (Radius <350m) as per Drg. No.
RDSO/T-5738 to T-5740 for track gauge of 1675, 1677 & 1679
with uses of normal liners.

For level crossing to RDSO Drg. No. T-4148A with modifications, if
any.

For ballasted deck bridges as per RDSO drawing no. T-4088-4097.

Sleepers at Joints will be provided as per RDSO Drg. No. T-4322
for 52 kg rails with ERC clips as per RDSO Drg. No. T-4158.
31

For bridge approaches for provision of Guard rails as per RDSO
Drg. No. T-4088 to 4097.

PSC Sleeper Fittings: The sleepers shall be for 60 kg rails as per
RDSO drg. No. T-2496 and sleeper fittings shall be for 60kg rail
section on 60kg sleepers as per specifications and drawings.

Grooved Rubber Sole Plate 6mm thick to RDSO Drg. No. T-3711.

Elastic Rail Clips to RDSO Drg. No. T-3701. IRS Specification T-
31/1992.

Glass Filled Nylon (GFN) Liners (GFN-66 insulating liners for 60 kg
Rails on 60kg sleepers as per RDSO Drg. No. T 2496.) as per
RDSO drawing no. T-3707 (GS) & T-3708 (NGS). IR Specification
T-44/95

Metal Liners as per RDSO drawing no. T-3741 (GS) & T-3742
(NGS).

Steel channel sleepers for girder bridges as per RDSO Drg. No.
BA1636/R2, BA1636/1/R2, BA1636/2 and rail fastening assembly
& guard rail as per RDSO Drg. No. T-5155 to T-5164, T-5464, T-
5465 to T-5468.

All other fittings, unless otherwise secified above shall be as per
RDSO Drg, latest edition.

7.2.3 Ballast

Track ballast machine crushed, conforming to RDSO specifications
of Track ballast, June 2004 with up to date modifications thereto,
shall be procured and used on the work.
8.0 Technical Specifications for laying of Permanent Way

8.1 Track Structure

8.1.1 Components

The track shall consist of the following elements.
i) Rails 60 kg/, 90 UTS flat bottom (1st quality/ IU)

ii) Rail fastenings - Fish plates 60 kg, with bolts and nuts.
32

iii) Monoblock pre-stressed concrete sleepers for plain tracks, level
crossings, bridges, fish plated joints, bridge approaches, fan type
turnouts.

iv) Guard rails on bridges, check rail on level crossings.

v) Fittings for sleepers - grooved rubber sole plates, elastic rail clips
Mark - III (RDSO drawing no. T-3701) for normal track and Elastic
rail - J-clips for fish plated rail joints to RDSO Drg No. T-4158,
GFN liners, metal liners.

vi) Track Ballast as per RDSO Specifications of June 2004

vii) Gradient posts, KM posts, curve monuments, curve boards, whistle
boards, W/L boards creep posts and other boards and indicators
etc., as per IRPWM.

viii) Points and crossings

ix) .Steel Channel sleepers for girder bridges with fastenings and track
fittings.

8.1.2 The track will be laid on monoblock PSC Sleepers conforming to
specifications IRS T-39 (Except on open deck girder bridges where
steel channel sleepers shall be provided) and as specified in
Schedule of Quantities. The ballast cushion will consist of Track
ballast as per RDSO specifications to a depth of 250mm below the
bottom of sleepers as measured under the rail seat. Turn out PSC
sleepers shall conform to specifications IRST-45.

8.1.3 The mono block PSC sleepers shall be laid @ 1540 nos/km (M+7
sleeper density) for main line and @ 1340 nos./km (M+4 sleeper
density) for loops and sidings in yards unless otherwise specified.

8.1.4 Guard Rails to be provided at bridges as per para 275 of IRPWM.

8.1.5 Check Rails at level crossings to be provided as per IRPWM.

8.2 Procurement of Materials:

8.2.1 All the materials and equipment required for track construction
materials and equipment required for track construction shall be
procured from the suppliers /Manufacturers approved by
Rly./RDSO duly inspected by approved inspecting Authority.

33

8.2.2 Other track materials, for which approved manufacturers/suppliers
are not available, shall be procured from sources after getting
them approved/ inspected from HPCL.

8.2.3 All the materials shall be got inspected and passed from the
Railways authorized inspecting agencies such as
RDSO/Railway/HPCL etc. at Contractors own cost and certificates
obtained to this effect which will be submitted to site Engineer-in-
charge.

8.2.4 Ballast

The Contractor shall procure, at his own cost, track ballast
conforming to RDSOs `specifications for Track Ballast, June 2004
with up to date correction slips, of approved quality for use on all
lines with 250mm cushion. The test reports for the ballast for
quality as required, should be submitted to HPCL before ballast is
brought to site. Ballast should be supplied in stacks on levelled
ground along the proposed alignment.

9.0 Linking

The formation shall be constructed and mechanical compaction
shall be done as per RDSO `Guidelines for Earthwork in Railway
Projects Guideline no. GE : G-1, July 2003. Track ballast be then
compacted by at least 2 passes of 5 to 10 t roller before laying the
PSC sleepers and rails.

9.1 Dismantling & Re-linking

If required and so directed by the Engineer - in - Charge, the
contractor shall carry out dismantling of existing track structure at
Bhakrapeta Station premises/Take-off point with 60 kg single rail /
3 rail panel (SWP) & stacking the same, duly segregated as per
direction of site Engineer, within 50m of track and relaying the
same, if required duly recouping the missing/damaged fittings i.e.
sleepers, fish plate with bolts & nuts, liners, ERC, GR Pad etc;
nothing extra shall be paid for recouped materials/fittings.
Contractors to please note that existing track structure is in good
working condition & it is assumed that all fittings are also in good
condition so contractors are advised to dismantle the track
carefully and keep the same in safe custody. Before re-linking all
the materials/fittings to be checked by the authorized Engineer,
rejected fittings/materials shall be replaced by new of same
standard & specification. This aspect may be kept in view while
quoting the rates.

34

9.2 Curves

i) The alignment of track on certain locations is on curved alignment
as per index plan. While laying track on such locations, the layout
of the curve shall be done accurately with deflection angle, degree
of curvature, transition length and curve length and laid to
required super elevation for each curve as directed by Engineer-In-
charge.

ii) The design of curves specifying all parameters (transition length,
total length of curve, super elevation etc.) shall be done by
Engineer- In-charge and advised to the contractor who shall then
lay the curves accordingly as indicated in the above para so that it
conforms to the designed parameters.

iii) The station numbers shall be marked, starting from zero at TP (i.e
from the start of curve) at 10 meter interval on the inside web of
outer rail of the curve and shall be continued over the entire length
of the curve with figures in white paint over black back ground and
the super elevation at each station shall be indicated just opposite
to the station number on inside web of inner rail with black back
ground and figures with white paint.

iv) Curve posts as per Railways design shall be fixed at both ends of
curves, at TP (Transition Point) and TTP (Transition Tangent Point),
and the details of the curve shall be written on TP post of both
ends mentioning curve no: degree of curvature, transition length,
curve length and super elevation with appropriate painting scheme
as followed by Railways.

9.3 Longitudinal level of Track

The longitudinal level of the track shall be in accordance with the
gradients as indicated in L-Section supplied by Engineer -In-
charge Gradient posts at each change of gradient shall be provided
as per approved design and shall be engraved with the values and
arrow indicating rise, fall or level as the case may be, on both
faces with figures in black on white back ground.

- The gradient post shall be provided as per L-Section.

- Sketch of gradient post and km post is placed as Annexure PW-VI
in IRPWM.

9.4 Kilometer & Gradient Posts

35

RCC Kilometer and gradient posts as per drawing, (IRPWM
Annexure PWVI) shall be cast and fixed at each Kilometer / Point
of change of gradient on cess and number engraved on both faces
and surface painted with white and engraved figure written with
black.

9.5 Ballasting
i) Once the central line and level pegs have been provided, the
ballast should, on clearance by the Engineer in charge/his
authorized representative, be lead out from the stacks and spread
on the track formation. The ballast layer shall be consolidated by
running of heavy rollers (5-10 tonne). The ballast cushion which is
to be finally achieved shall be 250mm. Hence about 8% more
cushion shall be provided initially, which on consolidation, shall
come down to the required dimensions. The profile of ballast,
finally to be provided shall be as per IRPWM para 263.

ii) The payment for supply of ballast will be made on the basis of
stack measurement of ballast without deduction for any shrinkage,
as laid down in RDSO specifications, June 2004. The measurement
and passing of ballast in stacks shall be done by Engineer -In-
charge as per RDSO specifications.

iii) Ballast under dismantled (existing) track - Total ballast under
dismantled (existing) track shall be removed, screened & stacked
as per direction of site Engineer. Ballast so stacked shall be
measured by the Engineer-in charge and there after re-spread in
track. The contractor shall be paid only for spreading against
relevant item of the schedule.

iv) Ballast shall conform to the detailed specification issued by RDSO.
The salient features as thereof are the ballast shall be obtained
only from quarries containing good quality parent rock. The ballast
shall not contain any inorganic or inorganic matter and shall be
free from inferior or harmful substance. The decision of the EIC in
this will be final and conclusive. Where the supplies are made from
a central quarry the stone used for crushing in to ballast shall
exclude top layer, if weathered and shall be extracted only from
those locations specifically approved by EIC.

v) The ballast shall not contain any inorganic or inorganic matter and
shall be free from inferior or harmful substance. The decision of
the EIC in this will be final and conclusive.

vi) Ballast should satisfy the following size and gradation
36

Retained on 65 mm sqmesh sieve- Nil

Retained on 40 mm sq mesh sieve-40 % to 60%

Retained on 20 mm sq mesh sieve- Not less than 98% for machine
crushed.

vii) Over size Ballast
In case ballast retained on 65 mm sq mesh sieve is at variance
from the above, stack shall be rejected. In case ballast retained on
40 mm sq mesh sieve exceeds 60 % limit prescribed above,
payment will be made at reduced rate as follws.

95% of quoted rate if retention on 40 mm sq mesh sieve is
between 60 % (excluding) and 65% (including)

90% of the quoted rate if retention on 40 mm mesh sieve is
between 65% (excluding) and 70% (including)

In case retention on 40 mm sq sieve exceeds 70%, the stock shall
be rejected.

viii) Under size ballast
The ballast shall be teated as undesized and shall be rejected if :

Retention on 40 mm sq mesh sieve is less than 40%

Retention on 20 mm sq mesh sieve is less than 98% (for machine
crushed) or 95% (for hand broken)

ix) Method of sieve analysis

The screens for sieving of ballast shall be of square mesh and shall
not be less than 100 cm in length and 10 cm in height on sides.

While carrying out sieve analysis, the screen shall be kept in
inclined but horizontal position and Shaken vigorously. The piece of
ballast retained on the screen shall not be pushed through screen
openings. The percentage passing through or retained on the sieve
shall be determined by weight only.

The successful vendor shall submit three samples of ballast in
sealed transparent jars containing 3 kgs each. The above samples
received shall be tested in approved laboratory and test reports on
impact value, abrasion vale, flakiness index and water absorption.
37

The successful bidder shall furnish an undertaking that ballast
supply at all times will confirm to specification for track ballast as
specified by railways.

ix) Method of measurement

Stacking shall be done on a neat plane, firm ground with good
drainage. The height of he stack shall not be less than 1 m except
in hilly area, where it will be .5 m. Top width of the stack shall not
be less than 1.0 m. Top of the stack shall be kept parallel to
ground. The side slope of the stacks should not be greater than
2.5:1. Cubical content shall not be less than 30 cum for each stack

9.6 Concrete Sleepers

i) Mono block pre-stressed concrete sleepers will be used for the
siding. The same will be used in loop line, level crossings,
approaches, deck bridges, bridge approaches, switch expansion
joints at the end of long welded panels, at trap switches and on
curves. Concrete sleepers are very heavy and prone to develop
cracks/ chipping, if handled roughly. Manual handling of these
sleepers is, therefore, not desirable. The sleepers directly received
at site through road trucks shall be unloaded using mechanical
gantries/cranes, whereas those received on railway BFRS shall be
unloaded through cranes/mechanical unloading equipment. One
such device is Jib crane attachable to BFR/BRH for handling
concrete sleepers. The shifting of sleepers shall be done using
slings which should lift the sleepers through hooks fixed to inserts.

ii) Unloaded sleepers shall be kept at site of placement, properly
supported underneath.

iii) On the ballast already laid and consolidated, PSC sleepers 60/52
kg to RDSO drg no. T-2496 shall be laid at specified spacing. All
care be taken in handling the sleepers so as to avoid breakage.
The sleepers shall be laid to a density of 1540 nos/km (M+7
Sleeper density) / or 1340 nos./km (M+4 Sleeper density) as
specified. For fish plated joints, the spacing shall be 40 cms
(centre to centre). The sleeper spacing at welded joints shall be
the same as intermediate sleeper spacing as per para 244 (h) of
IRPWM. No damaged sleepers will be accepted.

iv) To get proper track alignment, it is necessary that the centre line
of the sleepers coincides with the centre line of the alignment
marked.

38

v) Greasing of Elastic rail clips and MCI/SGCI Inserts: All the
Elastic rail clips and inserts fixed in the concrete sleepers shall be
thoroughly cleaned and grease to IS specification IS: 408 - 1981
(Specification for Grease No. "O Graphited) should then be applied
on the central leg of ERC and eye of the insert and then the clip be
driven at the time of assembly of the rail with the sleeper as per
provisions of para 1411 (5) (a) of IRPWM. ERCs shall be provided
with anticorrosive treatment before putting in track. Nothing extra
shall be payable for any of the elements stated above.

9.7 Rails
9.7.1 Rails 60 kg/m to IR specification T-12 shall be used for main line.
The same has to manufactured by M/s SAIL/ equivalent approved
by railways . The supply of rails are in the scope of the contractor.
It is the contractor responsibility to laison and obtain permission
from railways for the supply of Rails to HPCL for siding.
a). The contractor at its own cost shall lead the same to site for use on
the work.
b) The rails and other fittings shall be lead to site of actual laying in
track by any means convenient to the contractor depending upon
the site conditions and be placed at places where these are to be
laid. The rails shall be adjusted in pairs along the alignment on the
cess. The contractor will remove kinks from each rail, if any, with
the help of jim Crow, etc. Handling of rails shall be done as per
Manual of Instructions on Handling of Rails- July 2000 issued by
RDSO.
c) Single rails so brought to site shall as required be converted into 3
rail welded panels by Short Pre Heat process of Thermit Welding by
the contractor on the cess or at site.
d) The cutting of rails, where required shall be done using Abrasive
rail cutting Machines and the holes drilled with rail drilling
machines approved by Railways/HPCL. All the holes drilled in rails
shall be chamfered using approved chamfering kit in terms of para
251 (5) of IRPWM (CS No. 51 dated 21.4.00)
e) The rails shall be ultrasonically tested to IRS specification.

39

9.7.2 Welding of Rail Joins:
a) The rail joints shall be welded with Alumino Thermit welding of rail
joints by short pre-heating (SKV) process to IR Specification no. T-
19-1994 as detailed in RDSO `Manual for Fusion welding of Rails
by the Alumino- Thermic Process `September 1998.
b) The welding shall be got done only from approved portion
manufacturing firms with portions, consumables, equipment and
RDSO certified welders/welding supervisors.
c) The portion shall conform to IRS specification no. T-19-1994. (para
4.2.1 of AT welding Manual).
d) For field welding of rail ends provisions of para 4.4 to 4.10 of the "
Manual for Fusion welding of rails by Alumino Thermic process,
September 1998 referred above shall be followed. Post welding
operations shall be carried out as per para 5 and tests as per para
6 of the aforesaid manual. Sample tests of welds done shall be
carried out as per para 7 of AT welding manual.
e) The finishing tolerances of the weld must conform to provision of
para 5.4.2 indicated below:-
- Vertical alignment : Variation not more than +/-0.5mm, -0mm
measured at the end of 1.0metre straight edge.
- Lateral alignment : Variation not more than +/- 0.5mm measured
at the centre of 1.0metre straight edge.
- Head Finishing: top table surface: +0.3mm, -0mm, measured at
the end of 10cm straight edge.
f) While welding, adequate precautions as laid down in para 9 of the
Manual shall be followed.
g) Welds found defective shall be replaced by the contractor as per
para 6.4 of the Manual.
h) Flame cutting / gas cutting of 52 kg 90 UTS (1st quality) rail ends
for welding them is not permitted. Rail ends for welding shall be
cut by sawing or by abrasive disc cutter as laid down in para 3.3
(vi) of A.T. Welding Manual.
i) All thermit welds shall be ultra sonically tested by the contractor at
his cost and all welds, found defective in such testing, shall be
40

replaced by the contractor at his cost. The contractor shall remove
all welds found defective either in ultrasonic testing or any other
tests or failure of welds or welds found defective on any other
account, by cutting the rail on both sides of the defective weld
including the heat effected zone, and then welding the rail joints so
created. In certain locations, two welds may have to be done to
replace one defective weld. All these works of replacement of
defective welds including all materials, equipment, machinery and
labour etc. shall be done by the contractor at his cost.
j) All Thermit welds shall be painted as per para 5.7 of Manual for
fusion welding of rails by Alumino Thermic Process, September
1998 issued by RDSO.
k) The acceptance tests required for accepting the Thermit welds
shall be as per para 6 and 7 of Thermit welding manual.
m) Sample test Joints
i) One out of every 100 joints welded, shall be selected at random by
the purchaser or by the inspecting officer with in one month of
welding and subjected to hardness, transverse load/deflection
tests and porosity as per clause 4.3 of IRS:T-19-1994.

ii) If the sample test joint fails to satisfy any of the requirements of
specification IRS:T-19-1994. Engineer In charge will be at liberty
to suspend further welding. However, two more randomly selected
joints from the same lot of 100 joints shall be subjected to re-tests
as per clause 4.2 of IRS: T-19-1994. Both the joints should clear
all the tests. If this report is also not satisfactory, further welding
of joints shall be suspended until the firms welding technique has
been examined and the same satisfies the requirement of clause 4
of IRS: T-19-1994. The clearance for re-commencement of welding
shall be given by the Engineer-in-charge.
n) The following checks shall be performed be performed on the
welds executed on the track.
Visual check , using perfectly straight scales one metre and 10 ten
centimetre long accurate to with in one tenth of a mm for lining
and levelling of the welded joints. The checks shall extend over a
length of 2 m centre on the weld and deformation defects shall not
exceed those present in the body of the rail.
41

Visual checks for the integrity of the weld
Check by means of the special ultrasonic apparatus operating at
about 1 to 4 MHZ frequency. Welding is permitted to be done in
situ or in cess. The guidelines for technical control for welding rails
will be as follows.
Only approved samples should be used for the work. Only a welder
holding a valid competency certificate should weld the rail joints.
Care should be taken to see that the rail are correctly aligned,
vertically, longtitudaly and transversely. The ends of the rails to be
welded should be kept apart at specified distance. Those two sets
of rail (in nos to be specified for each panel) will form one
complete panel. There shall be three rails per panel in this case
unless otherwise decided.
No work out should be carried out between sunset and sun rise in
the field. The welding work should not he done in rainy weather in
the field. The test weld rails should be of the same section as of
rails to be welded for the work. Rail joints welded by the contractor
shall be guaranteed by him against failure for a period of at least
two years from the date of welding or one year from the date such
welded joints are inserted in the track. Any welded joints, which
fails by cracking with in this period of guarantee should be
rewelded free of cost by the supplier. In the event of any welded
joints failing in any one or more requirement of this specification,
the Engineer will be at liberty to suspend forthwith further welding
of joints. The work shall remain suspended until the supplier has
improved his welding technique and can satisfy the EIC that the
joint welding can stand up to the above tests. Further, the period
of guarantee of the joints already welded shall be extended for a
further period of one year guarantee and if any weld shows signs
of failure by cracking during the extended guarantee periods, the
same shall be rewelded free of cost by the supplier. The welded
joints with the extended period of guarantee should be marked `A
on the outer side of he head of the rails near the joints in addition
to the markings (month, year, firms initial) stamped by the
supplier. Such marked joints shall be kept under careful
observation by the Engineer. The code of practice for welding the
rail joints by Alumnio Thermit process issued by RDSO should be
referred for complete detail.

42

9.7.3 Short Welded Rails (SWR)
i) The laying and maintenance of short welded rails shall conform to
provisions of para 505 to 510 of Part `B of chapter V of IRPWM.
Special care shall be taken to provide expansion gaps at fish plated
joints as per IRPWM para 508 table 1 for initial laying and para
510(3), table II for maintenance.
ii) The fishing planes of fish plates and rails shall be lubricated with a
paste of workable consistency (Plumbago and kerosene oil) in the
following proportions and fish bolts be oiled. The material for
lubrication of joints shall be arranged by the contractor. No extra
payment will be made for the same. Plumbago (Dry Graphite) - 5
kg Kerosene oil (2nd quality) - 3.5 ltrs for 100 joints Black or
reclaimed oil - 2.75 ltrs
9.7.4 Bridges
a) The rail joints on girder bridges with opening less than 6.1m shall
be avoided. For other spans, the preferred position of rail joints is
at 1/3rd of span from either end as per para 272(3) of IRPWM.
b) Guard rails shall be provided on bridges as per para 275 of IRPWM.
c) The design of guard rails on the bridge and its approaches shall be
as per para 275(2) of IRPWM.
d) PSC sleepers to RDSO drg. No. T-4088 to Drg. No. T-4097 with
complete fittings as shown in the drawings, shall be used on
ballasted deck bridges with guard rails and their approaches. The
fixing of guard rails shall be done as per RDSO drg. No. T-4088 to
Drg. No, T-4097 as per para 275(3) of IRPWM, CS no. 63 dated
27.1.2003 M.S. flat/tie bars for tying PSC sleepers together at
ends is not required. (CS 63 dated 27.1.2003 to IRPWM).
e) Gang path as per para 276 of IRPWM, shall be provided on the
sleepers on the bridge only in case of un-ballasted girder bridges.
9.7.5 Level Crossings
i) Asphalting of road surface between gate posts to full width of road
on level crossings shall be provided by the contractor. The road
shall be provided complying with instructions contained in items 12
to 15, of Annexure 9/1 para 904, Chapter IX of IRPWM.
43

ii) Gate posts made out of 52 kg rails shall be provided at the level
crossing to hold the chain as per IRPWM. Chain shall also
beprovided by the contractor.
iii) Whistle boards (W/L) and Stop boards shall be provided as per
IRPWM. Similarly, Level Crossing indicator boards and Speed
breaker indicator boards shall be fixed on the road approaches as
per IRPWM.
9.7.6 Points and Crossings
(i) Points and crossings shall conform to RDSO Drawings and
specifications and shall be procured from manufactures / vendors
approved by RDSO duly inspected by RDSO/HPCL as per direction
of the Engineer-in- charge.
(ii) 60 kg 1 in 8.5 turn out shall conform to RDSO Drawing No T-
4865, Switch sub-assembly drawing No. T-4866. and crossing sub-
assembly drawing No. T-4867. Switches shall be 6400 mm over-
riding curved switches for 1 in 8.5 lBG (1673 mm) for 52 kg on
PSC sleepers with all parts and fittings as per drawing No. T- 4866
with latest alteration. CMS Crossings for PSC lay out to RDSO
drawing No.RT-4867 with latest alterations complete with all
fittings shall be used.
(iii) 60 kg 1 in 12 turn out shall conform to RDSO Drawing No T- 4732,
Switch sub-assembly drawing No. T-4733. and crossing sub-
assembly drawing No. T-4734. Switches shall be 10125 mm over-
riding curved switches for 1 in 12 BG (1673 mm) for 52 kg on PSC
sleepers with all parts and fittings as per drawing No. T-4733 with
latest alteration. CMS Crossings for PSC lay out to RDSO drawing
No.RT-4734 with latest alterations complete with all fittings shall
be used
9.7.6.1 Fan type turnouts
PSC sleepers for Fan type Turnouts to the extent required shall be
supplied by the contractor. The contractor at its own cost shall lead
the same to site for use on the work.
Turnout sleepers shall conform to Indian Railway Standard
specification for pre tensioned concrete sleepers serial No.T-45-96
(latest revision) as per RDSO Drawings.

44

Salient aspects of fan shape layout are:
(i) The sleepers under switch portion are having dowels in which slide
chairs are fixed with the help of screws. These sleepers are laid
perpendicular to the main line and therefore, can be used for left
hand and right hand turnouts.

(ii) The sleepers between the switch and the crossing (lead portion)
are designed and laid at an angle of Q/2 with respect to main line
where Q is the angle between the main line and the lead rail at
that particular location. The same sleeper can be used for left hand
and right hand by laterally shifting the sleepers by an angle of Q.

(iii) The sleepers under crossing are laid perpendicular to the center
line of the crossing and as such the same sleeper can be used for
left hand and right hand by lateral shifting.

(iv) For laying sleepers in the lead portion correctly, spacing of
sleepers on left rail seat and right rail seat on main straight track
are given which define the center line of the sleepers. PRC fan
shape layouts have curved switches. Before laying the turnouts,
the correctness of the switch as well as its curvature should be
checked in advance by pre-assembling and then once again after
laying it in track. This layout needs efficient drainage and adequate
ballast cushion. It may be noted that the sleepers are the same for
52Kg as well as 60Kg rails. A mark `RE is provided on fan shape
PRC turnout sleepers at one end. The sleepers should be laid in a
manner that the end having the mark `RE is always laid on the
right hand side.The dowel fixed in the PRC sleepers should be
cleared with the help of a suitable diameter soft brush so that all
dirt/muck is removed. All the screws required to be fixed in the
dowels should be greased before being put in.

45

FAN SHAPE LAYOUT ASSEMBLY
A) 1 in 81/2 Turnout
Main drgs
of T/Out
Switch
sub-
Assembly
Crossing
sub-
Assembly

60 KG RDSO/T-4865 RDSO/T-4866 RDSO/T-4867

(B) 1in 12 Turnout

60Kg RDSO/T-4732 RDSO/T-4733 RDSO/T-4734

DISPOSITION OF SLEEPERS
Type of
layout

Sleeper under switch
which are to be
perpendicular to main
line

Sleeper Nos
which are to be
laid at angle
Q/2 where Q is
inclination of
outer
lead rail with
respect to main
line at that
location

Sleeper Nos to
laid
perpendicular to
centre line of
crossing

1 in 12

1 to 20 21 to 64 65 to 83

1 in 81/2

1 to 13 14 to 41 42 to 54

APPROACH SLEEPERS
Type of
layout
ENTRY EXIT

1 in 8 1/2 5Nos: 60-S,60-4A,60- 3A, 60-
2AS & 60-1AS

8 Nos: (4 Sleepers on
main line & 4 on
turnout side)

1 in 12 5Nos: 60-S,60-4A,60- 3A, 60-
2AS & 60-1AS
8 Nos: (4 Sleepers on
main
line & 4 on turnout
side)

46

Long sleepers shall be provided for point machines to meet the
requirement of S&T.

It shall be ensured that the turnout is perfectly in line and duly packed
both for the main lines as well as the siding served/connected by the
turnout Any adjustments as required shall be carried out by the
contractor so that the layout and the connections meet the standard
requirements Nothing extra shall be payable for the same.

9.7.6.2 Fouling Marks made out of Cement concrete shall be provided as
per approved drawing at locations as required as per directions of
the Engineer-in-charge.

9.7.7 Glued Joints
Supply and Fixing of 52Kg. Glued Insulated Rail Joint G3(L) as per
RDSO Drg. No. T-1276 along with welding is to be provided in
running/ non running lines as per direction of the Engineer-in-
charge. The welds are to be ultrasonically tested as per RDSO
manual of Sept 1998. These Joints consist of web fitting fish plates
glued to the rails with a high polymer adhesive and bolted with
high tensile steel bolts. The insulation is provided by special type
of insulating side channels, bushes and end posts made of
fiberglass cloth roving. The instructions for fabrication and
installation of glued insulated rail joints should be strictly followed
as given in the manual for glued insulated rail joints 1998 issued
by RDSO. In this type of joint 1 m. long fish plates with 6 HTS
bolts are used. The pull out strength should be more than 160
tons.
The insulation resistance test should satisfy the following criteria:
(i) In Dry Condition: After glued insulated joint is prepared,
meggering voltage of 100 VDC shall be applied across the joint.
The value of the insulation resistance shall not be less than 25
Mega-ohms.

47

(ii) In wet Condition: The value of resistance shall not be less than 3
Kilo-ohms.

9.7.8 Follow up Packings
i) The track shall be lifted to the correct profile as directed by the
Engineers representative.

ii) The sleepers shall be well packed with the ballast under them
taking care that the ballast shall be worked under throughout the
length of the sleepers without damaging the bottom edges of the
sleepers and sleepers repacked till no more ballast can be packed
in and or as directed by Engineer/his representatives.

iii) Stone ballast from the stacks along the alignment shall be lead and
dumped over the track to correct profile as indicated in para 263 of
Indian railway permanent way manual 1986 reprinted 2004 and as
directed by the Engineer or his representative.

iv) Correct track parameters i.e. Gauge, alignment of rails,
squareness of the sleepers, longitudinal and cross levels,
expansion gaps at rail joints etc. shall be achieved as directed by
the Engineers representative.
10.0 Final Adjustment and Packing
i) Any sleeper which has been shifted from correct spacing or gone
out of square shall be moved back and squared after loosening the
fastenings, care being taken not to cause damage to PRC Sleepers
while slewing the sleeper. The fastenings shall be tightened again
after squaring.

ii) The track shall be slewed to correct alignment by sighting along
the rail head of the base rail. It should be ensured that track does
not get lifted in the process of slewing. Any defects developed in
gauge shall be rectified by adjusting the liners.

iii) The track shall then be given a final packing. For this, sighting
shall be done along the base rail and any dip or low joint lifted
correctly and packed, attending the adjacent sleepers also. After
the base rail is thus packed for 2 or 3 rail lengths, the cross levels
should be checked and the opposite rail lifted wherever necessary
and sleepers under the rail seat packed.

48

iv) The joint and shoulder sleepers shall be repacked and cross levels
adjusted. The ballast section shall be dressed neatly as directed by
Engineers representative to uniform height and width with correct
side slopes.
v) Testing - The track completed as above will be rolled with a light,
diesel engine (which is presently stationed at site) .If aviliable
HPCL will supply the same and the vendor to do rolling complete
with fuel and crew. After 4 such movements of the engine, the
contractor will attend to the defects developed, by packing,
aligning, levelling and gauging the track. No extra payment will be
made for this.
11.0 Specifications for Finished Work
a) Ballast Profile
i) The ballast profile should be in conformity with para 263 of IRPWM
and brought to specified section, as directed by the Engineers
representative.

ii) The ballast cushion shall be checked at three places in each km at
random locations (these locations shall be recorded) and the
average value shall be considered for acceptance.

iii) The expression "Ballast Cushion wherever used in these
specifications, shall mean depth of clean layer of ballast below the
bottom of sleepers and above the finished top of formation,
measured under the rail seat of the sleeper.

49

b) New Track Tolerances
The new track shall conform to the following track standards. The track
measurements should be taken in floating conditions.

S.N Track
Parameter
Items for measurement Value

1 Gauge - Gauge
-Sleeper to sleeper variation

1673mm +
3mm
2mm

2 Expansion Gap Maximum deviation from
the prescribed gap (Average
gap worked out by recording
20 successive gaps)

+/- 2mm

3 Joints - Low joints not permitted.
- High joints not more than
- Maximum out of Square
ness of joints on straight
- Maximum out of square
ness of joints on curves

-----
2 mm
-/+ 10mm

pitch of fish
bolts holes

4 Spacing of
Sleeper

With respect to theoretical
spacing

+/- 20mm

5 Cross level To be recorded on every 4
th

sleeper

+/- 3mm

6 Alignment - On straight on 10m chord

- On curves of radius more
than 600m on 20m chord -
variation over theoretical
versines.

- On curves of radius less
than 600m on 20m chord

- variation over theoretical
versines.

2mm

5mm

10mm

50

** Values upto
7mm can be
accepted at few
isolated
locations.

7 Longitudinal level Variation in longitudinal level
with reference to approved
longitudinal sections.
Unevenness (variation in
longitudinal profile of track as
measured on 3.5m chord at the
centre.

50mm

Not more than
6mm values of
10mm can be
tolerated at few
locations

LIST OF APPROVED MAKE

S. NO.

DETAILS OF MATERIALS MANUFACTURERs NAME
1 RAILS SAIL/JINDAL
2 P-WAY & OHE MATERIALS APPROVED AGENCEY BY
RAILWAYS
3 CEMENT

LAFARGE/ACC/BIRLA/AMBUJA
4 RMC APPROVED RMC PLANT
USING LAFARGE/ ACC/ BIRLA/
AMBUJA
5 REINFORCEMENT SAIL/ RINL/TISCO


51

SPECIFICATIONS FOR P. WAY WORKS

1. All works - linking of Railway tracks, assembly, laying and linking at points and
crossings, ballasting, through packing and connected works shall confirm to the
various instructions and specifications stipulated in "Indian Railways Permanent
Way Manual with upto date correction slips, IRS drawings, track manual and
other relevant Railway Codes / Manuals.

2. The Turn - outs / Diamond double slip (1 in 8) assembly i.e. switch assembly,
lead portion and crossing assembly will be laid by 60 Kg/90 R rails as the case
may be to the Indian Railway Standard on PSC sleepers with a ballast cushion as
directed by Engineer in-charge or his authorized representative at site.

3. The operation of dumping ballast, lifting and packing should continue till such
time the track attains final level and shape of ballast section.

4. Pack the sleeper with ballast as directed by Engineer in-charge or his authorized
representative at site.

5. Lift the track to the required level as directed by Engineer in-charge or his
authorized representative at site.

6. Rails shall be connected by means of pair of fish plate in the first instance only
with two bolts and nuts, one in each rail. The fishing planes of the fish plates and
rail are to be greased. Proper size of expansion liners are to be provided at the
joints to ensure correct expansion gaps. Cutting of rails where necessary, will be
done to suit squaring of joints.

7. On curves sharper than 6 (radius less than 290m) the rail joints will be mid-
staggered and check rails to be provided. All the sleepers of the sharper curves
(radius less than 290m) to be provided with PSC sleepers having provision with
check rail.

8. All the drilled bolt holes are to be chamfered by chamfering tools.

9. Paint mark shall be made on the rails showing the spacing of sleepers as directed
by Engineer - in - Charge at site.

52

10. Sleeper spacing :

a. Sleeper spacing for fish-plated joints having 13m/12m single rails:

Sleeper spacing M+7 density M+4 density M+4
density
13m 12m 13m 12m 11m
i) Rail ends to centre of
sleeper
15cm 15cm 15cm 15cm 15cm
ii) Centre of joint sleeper to
centre of 1
st
shoulder sleeper
61 cm 60cm 61cm 60cm 60cm
iii) Centre of 1
st
shoulder
sleeper to centre of 2
nd

shoulder sleeper
iv) Centre of 2
nd
shoulder
sleeper to centre of
intermediate shoulder sleeper

b. Sleeper spacing for SWP of 3 X 13m / 3 X 12m / 3 X 11 m rails:

Sleeper spacing M+7 density M+4 density
39m 36m 39m 36m 33m
i) Rail ends to centre of sleeper 15cm 15cm 15cm 15cm 15cm
ii) Centre of joint sleeper to
centre of 1
st
shoulder sleeper
iii) Centre of 1
st
shoulder
sleeper to centre of 2
nd

shoulder sleeper
61 cm 62cm 75cm 67.5cm 68cm
iv) Centre of 2" shoulder
sleeper to centre of
66cm 64cm 78cm 77cm 77.5cm

53

c. Sleeper spacing for curve with Mid - staggered Joint : Sleepers = 18 nos. per
single rail length.

Sleeper spacing 18 sleeper per rail
13m 12m
i) Rail ends to centre of sleeper 15cm 15cm
ii) Centre of joint sleeper to centre of 1
st
shoulder
sleeper
65cm 65cm
iii) Centre of 1
st
shoulder sleeper to centre of 2
nd

shoulder sleeper
75cm 70cm
iv) Centre of 2
nd
shoulder sleeper to centre of
intermediate shoulder
85cm 75cm

11. Full quantities of small fittings are to be fitted completely after slewing the track
to correct alignment as directed by Engineer - in - Charge at Site.

12. The track so linked shall be aligned correctly to the alignment pegs given or as
directed by Engineer till it takes correct position and the remaining two bolts to
be fixed in fish plated joints.

13. During the above process, alignment, adjustment and squaring of sleepers,
gauging, Cross level and longitudinal levels should be checked and rectified by
doing packing as directed.

14. The operation of spreading of stone ballast, lifting and packing should continue
till such time the track attains final level and shape.

15. Greasing of fish plates, fish bolts and nuts with lubricating oil and graphite
grease to be done by cleaning fishing planes of rail ends with wire brush.

16. Screening of Track should be done as per Indian Railways Permanent Way
Manual Para - 238 and as per direction of Engineer - in - Charge. For screening
work, required wooden blocks & wedges are to be arranged by the
contractors. No extra payment will be made for arranging wooden
blocks.

54

17. The works should be executed in a workman like manner to the satisfaction of
the Engineer - in - Charge at site. The contractor will be primarily responsible for
Safety of traffic that moves on opened up track, notwithstanding the presence of
Owners representative at site.

18. Good quality track ballast as per specification and of approved quality will have
to be supplied and stacked on `Cess of formation or at the toe of bank or at
suitable places as directed by HPCL representative. Stacks will be measured
jointly by the contractor and HPCLs representative and entered in a register to
be signed jointly by them.

19. Lifting and spreading of stone ballast includes all lead, lift, ascent, descent,
crossing road / railway, handling as required for packing tracks from the stacks
measured and passed already including all labour, tools and plants for the
operation and the same will be arranged by the contractor at his own cost. The
payment for spreading will be made based on measurement of ballast supplied in
stacks, less shrinkage.

20. Pulling out of ballast on to the formation by ballast rakes and boxing is to be
done as per specified profiles. Proper templates and loglines should be used. The
width at the shoulder should be as directed by Engineer-in-Charge which will
normally be not less than 3.55 metre (11'-0") and not more than 3.66 metre
(12'-O").

21. No ballast should be wasted on the slopes of banks or in cuttings or any places.

22. After the ballast is measured, the Contractor shall spread it on top of the
blanketing surface/formation/in the track with standard profile. After
spreading, the ballast profile should be consolidated.

23. The thickness of the finished ballast spread should be as specified by the Field
Engineer, and the layer should be dressed and boxed to proper profile and
dimensions.

24. While spreading the ballast on the finished formation, care shall be taken that
the formation / blanketing surfaces is not damaged. In no circumstances,
vehicular carts / trucks shall be permitted to ply on the finished blanketing /
formation. In case some damage to the surface is done, the Contractor shall
repair the damages at his own cost before spreading the ballast.

55

25. Through packing of railway track on any type and any density of sleepers which
will consist of -

(i) Opening of the road,
(ii) Examination of rails, sleepers and fastenings,
(iii) Squaring of sleepers,
(iv) Slewing of track to correct alignment,
(v) Gauging,
(vi) Packing of sleepers including lifting & leveling,
(vii) Repacking of joint sleepers,
(viii) Boxing of ballast section & tidying.

26. The length of track to be opened out on any day must not be more than that can
be efficiently tackled by the end of the day. Broken or missing fittings are to be
replaced and loose ones tightened. Cross drains are to be provided at mid section
each rail except sharper curve track. On sharper curve track the cross drains are
to be provided as per direction of Engineer - in - charge.

27. Through packing of points and crossings 1 in 8.1/2 or diamond x-over will
comprise opening out of ballast, squaring of sleepers, replacing or readjusting
fittings to keep correct gauge clearances of check rail, wing rails, etc. including
lifting or lowering as necessary and packing all the sleepers in the points and
crossings efficiently and finishing all works with boxing and dressing of the
shoulder ash ballast neatly. All bolts and nuts including crossing bolts, check rail
bolts, slide chairs, tongue rails, heel block bolts etc. are to be properly oiled and
greased also.

28. Picking up slacks will include lifting and packing of sleepers where necessary,
attention to all fittings and fastenings, adjusting gauge, cross level and
longitudinal level, cleaning of drain etc. as directed by the RITES' representative
at site at specified scattered locations. The work should be neatly finished with
proper boxing.

29. Any sleeper which have shifted from correct spacing or gone out of square shall
be moved back and square after loosening the fastenings. The fastenings shall be
tightened again after squaring.

30. The track shall be clewed to correct alignment by sighting along the rail head of
the base rail. It should be ensured that track does not get lifted in the process of
slewing.

56

31. The track shall then be given a final packing. For this, sighting shall be done
along the base rail and any dip or low joint are found, the same are to be
attended for its correction by packing of sleepers. After the base rail is thus
packed for two or three rails length, the cross level should be checked and the
opposite rail lifted wherever necessary and sleepers under the rail seat packed.

32. The joint and shoulder sleepers shall be re-packed and cross level adjusted at
the time of each through packing of sleepers.

33. Oiling and greasing hand operated points will include adjusting the point Roding
and fixing hand lever frame, where found necessary by means of spikes with the
sleepers for smooth operation of the point and adjusting the opening between
tongue rail and stock rail. For any bent tongue rail, if required, Jim-crowing may
have to be done and the gap adjusted as required. Blacksmith and other staff for
this work, as required, will be deputed by the Contractor at his cost. Oil & Grease
to be supplied by the Contractor at his own cost.

34. Gauge :

Will be with standard broad gauge on straight and curves upto 350 m radius and
5 mm slack on sharper curves with a Permissible variation with (+) or (-) 3mm.
But not exceeding 1 mm between consecutive sleepers.

35. Alignment :

Should be perfectly straight verified by sighting. On curves, the alignment should
be correct of versine or as directed by the Engineer-in-Charge, who will pass the
work.

i) Straight on 10M chord = (+) or (-) 2mm;
ii) Curves of radius 600M on 10M chord = (+) or (-) 5mm;
iii) Curves of radius 600M on 20M chord = (+) or (-) 10mm.

57

36. Level :

To be checked by level board and spirit level. Track should be free from sag and
low joints. Permissible variation of Cross levels being (+) or (-) 3 mm. but not
exceeding 1 mm between consecutive sleepers.

37. Joint out of square :

i) On straight = (+) or (-) 10mm;
ii) On curves = 112 pitch of fish bolt holes.

38. High Joint : Permissible upto 2mm.

39. Low Joint : Not permissible.

40. All the elastic rail clips should be thoroughly cleaned. Grease to IS : 400 - 1981
(Specifications for Grease No. '0' Graphite) should then be applied on Central leg
of the E.R.C. and eye of Inserts and then the clip should be driven at the time of
assembly. The rate accepted includes the cost of the grease as per specifications
and labour.

41. During execution of the work, contractor should arrange for protection of track
and displaying the signals as per extent rule of Indian Railways.

42. All the P. Way tools such as (a) Rail tongs, (b) Crow bars, (c) Fishing spanners,
(d) Hammers, (e) Keying hammers, (f) Cotter splitters, (g) Shovels, (h) Mortar
Pans, (i) Beaters, (j) Track Lifting Jacks, (k) Gauges, (l) Level Board, (m) Spirit
levels, (n) Cant Board, (o) Expansion Liners, (p) Wooden Squares, (q) Steel Tape
(r) Wire brushes, (s) Cotton waster, (t) Rake Ballast, (u) Chamfering tools, (v)
Soap as required for the work as assessed by the Engineer- in-Charge depending
on the labour strength will be arranged by the contractor at his own cost.

58

SPECIFICATIONS FOR SUPPLY OF BALLAST.

1.0. Ballast Supply :

1.1. This specification will be applicable for stone ballast to be used for all types of
sleepers on normal track, turn-outs etc.

1.2. The rates, as per the Schedule, are inclusive of all taxes viz. commercial sales
tax, octroi etc. and other charges levied by the State / Central government. The
rate also includes all lead, lift, ascent, descent, loading, unloading, royalty etc.
and all other incidental charges.

1.3. The contractor shall stack the ballast, normally over the entire length of the
section at specified locations duly certified by the Engineer-in-Charge except at
those certain locations which are found to be inaccessible for certain reasons.
The decision of Engineer-in-Charge at site will be final and binding on the
contract for the locations, inaccessible for supply of ballast.

1.4. The ballast shall be supplied as per the requirement given by the Engineer - in -
Charge at site.

1.5. The ballast shall be in conformity with "Specifications for Track Ballast issued by
RDSO in January 1999 with latest correction slips.

1.6. The Contractor must submit the test report of impact value, Abrasion value and
water Absorption value from any of the following approved laboratories along
with name of quarry / quarries from where supply is intended prior to
commencement of supply of ballast.

i) S. C Rly Laboratory or any Railway approved Laboratory / Institution.

ii) JNTU,Anantapur
59

iii) National Test House

iv) RITES Laboratory

v) NIT

vi) Any Govt. approved recognized lab.

* The test report should not be more than 90 (ninety) days old
from the date of opening of the tender.

1.7. The contractor shall ensure that the ballast supply at all times shall conform to
Specifications for track ballast as specified by Railway.

1.8. The contractor shall make his own arrangement at his own cost for the
construction of service roads within the Siding corridor land as well as outside
Siding corridor land, for transportation of ballast, if required. No separate
payment shall be admissible to the contractor for the construction of such roads
and its repairs & maintenance.

1.9. The contractor shall have to make necessary arrangement for leveling the
nominated grounds for stacking of ballast at cess, as per the direction and to the
satisfaction of Engineer-in-Charge, without any additional claim of payment.

1.10. The cost of routine testing of ballast, as per RDSO guidelines shall be payable by
the contractor. However HPCL is at liberty to collect the ballast sample as and
when, required and send the same for testing at the cost of Contractor.

60

1.11 The contractor shall make necessary arrangement for the security of the ballast
supplied during the progress of the work till final bill is paid. No separate
payment shall be admissible to the contractor for guarding the ballast,

1.12. The ballast shall be supplied as per the requirement given by the Site Engineer.
Quantity supplied extra over the required quantity may not be paid.

1.13. Safety of ballast against any theft or loss remains solely with the contractor
during the entire period of the contract agreement and the same has to be made
good by contractor. This responsibility of the contractor remains even if the
ballast stacks are measured and paid for.
2.0. Quality of stone ballast in General :

2.1. The Stone ballast should be machine crushed and shall consist of hard and
durable stone and conform to the approved sample of stone ballast and test
certificate for physical properties in accordance with IS : 2386 (Part - IV) - 1963
that shall be supplied by him.

2.2. The stone ballast should be got inspected by the Engineer at regular intervals to
ensure quality and samples tested for physical properties (abrasion test, impact
test and water absorption test values).

2.3. Attempts should be made to have ballast of the best available quality. For
approving the ballast quarry, the following norms will be adopted :-

Basic quality : Ballast should be hard durable and as far as possible angular
along edges/corners, free from weathered portions of parent rock, organic
impurities and inorganic residues.

Particle shape : Ballast should be cubical in shape as far as possible. Individual
pieces should not be flaky and should have generally flat faces with not more
than two rounded/ sub- rounded faces.

61

Mode of manufacture : The ballast shall be machine crushed and conforming to
the Railway specifications for machine crushed ballast.

Physical Properties : The ballast samples when tested for physical properties
(abrasion and impact) in accordance with IS: 2386 (Part - IV) - 1963 should
have the under mentioned values:

i) Aggregate Abrasion Test (Using 105 Angles Abrasion Testing Machine).
Aggregate Abrasion value (Percent) - Maximum 30%.

ii) Aggregate Impact Test.
Impact values (Percent) - Maximum 20%

2.5 The water absorption tested as per IS: 2386, Part-III-1963, which should not be
more than 1%.

NOTE :- THE SPECIFICATION OF TRACK BALLAST HOWEVER SHOULD BE
AS PER RAILWAY BOARD'S LETTER NO. 94 / CE - II / HB / 2 DATED
22.04.1997.

2.6 Track ballast should be obtained from good quality stones / boulder; and top
layer, if weathered, must not be used.

6) Technical Specs (61 Pages)

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CONSTRUCTION OF BG RAILWAY SIDING AT KADAPA IRD

CONSTRUCTION OF BG RAILWAY SIDING AT KADAPA IRD

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