Vol II 32 MLD Panchak STP at Nashik

NASHIK MUNICIPAL CORPORATION
Water Supply and Sewerage Department

Rajeev Gandhi Bhavan, Sharanpur Road
Nashik - 422 002
E-Tender Notice No. 1 / 2010 - 11
TENDER DOCUMENT FOR

Design, construction, supply, erection, testing, commissioning, start
up & performance run followed by 36 months O & M
of
32 MLD Sewage Treatment Plant at Panchak on lump sum turnkey
basis in Nashik City under JNNURM
Volume II
SCOPE OF WORK, DATA SHEETS AND TECHNICAL
SPECIFICATIONS FOR CIVIL, MECHANICAL, ELECTRICAL AND
INSTRUMENTATION WORK
Contents:
Volume I:
Volume II:
Volume III:
General Conditions of Contract

Scope of Work, Data Sheets, Drawings, Technical Specifications for
Civil, Mechanical, Electrical and Instrumentation works
Financial Bid
SUPRINTENDING ENGINEER
Water Supply and Sewerage Department
Nashik Municipal Corporation, Nashik
COMMISSIONER
Nashik Municipal Corporation,
Nashik
Tender Issued to:

______________________________________
______________________________________
______________________________________
32 MLD capacity STP at Panchak, Nashik

Table of Contents for Volume II
TABLE OF CONTENTS
Volume II
Scope of Work and Drawings. 1

Data Sheets .. 48
Civil Specifications . 88
Mechanical Specifications . 239
Electrical Specifications 287
VOLUME II - A
SCOPE OF WORK
32 MLD Capacity STP at Panchak, Nashik.

Volume II A: Scope of Work
TABLE OF CONTENTS Volume II A, Scope of Work
PROJECT INFORMATION ........................................................... 1
1.1
Introduction ............................................................................................... 1
1.2
Site Information ......................................................................................... 1
1.2.1
Geo-Technical Studies......................................................................................................... 1
1.2.2
Location .............................................................................................................................. 1
1.2.3
STP Site Topography .......................................................................................................... 1
1.2.4
Climate ............................................................................................................................... 1
1.3
Proposed Sewage Treatment Plant .............................................................. 2
1.3.1
Sewage Treatment Plant Capacity (For all three schemes) .................................................... 2
1.3.2
Raw Sewage Quality (For all three schemes)........................................................................ 2
1.3.3
Treated Sewage Quality (For all three schemes) ................................................................... 2
1.3.4
Proposed Treatment Scheme ................................................................................................ 3
GENERAL TECHNICAL REQUIREMENTS .................................... 6
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
Time Limit.................................................................................................. 6
Submission During Execution of the Project ............................................... 6
Soil Investigation ....................................................................................... 8
Equivalency of Standards and Codes........................................................... 8
Sign Board .................................................................................................. 8
Quality Assurance Programme/Sample tests .............................................. 8
Protection of Utilities ................................................................................. 9
Dismantling of the Existing Units (If Applicable) ......................................... 9
Inspection ................................................................................................ 10
Ready Mix Concrete .............................................................................. 10
SCOPE OF WORK..................................................................... 12
3.1
Brief Scope of Work .................................................................................. 12
3.2
Detailed Scope of Work for Activated Sludge Process ................................ 13
3.2.1
Inlet Chamber.................................................................................................................... 13
3.2.2
Screen Channels ................................................................................................................ 14
3.2.3
Grit Removal Channel ....................................................................................................... 14
3.2.4
Flow Measuring Unit......................................................................................................... 16
3.2.5
Division Box ..................................................................................................................... 16
3.2.6
Primary Clarifier ............................................................................................................... 16
3.2.7
Aeration Tank with Diffusers & Air Blowers ..................................................................... 17
3.2.8
Secondary Clarifier............................................................................................................ 20
3.2.9
Return Sludge Pump House ............................................................................................... 20
3.2.10
Sludge Thickener .............................................................................................................. 21
3.2.11
Sludge Digester ................................................................................................................. 22
3.2.12
Gas Mixing System ........................................................................................................... 22
3.2.13
Gas Holder ........................................................................................................................ 23
3.2.14
Chlorine Contact Tank....................................................................................................... 24
3.2.15
Chlorination System .......................................................................................................... 24
3.2.16
Sludge Dewatering System ................................................................................................ 24
3.2.17
Outlet Channel .................................................................................................................. 26
3.2.18
Interconnecting Piping and Valves ..................................................................................... 26
3.2.19
Electrical Works ................................................................................................................ 26
3.2.20
Operation and Maintenance ............................................................................................... 27
CONTRACTOR
EXECUTIVE ENGINEER

Plant Utilities .................................................................................................................... 27

3.2.21
3.3
Detailed Scope of Work for Sequential Batch Reactor ............................... 28
3.3.1
Sequential Batch Reactor ................................................................................................... 28
3.4
Detailed Scope of Work for UASB followed by Aerobic Treatment ............. 30
3.4.1
Waste Water Flow Distribution.......................................................................................... 31
3.4.2
UASB Reactors ................................................................................................................. 31
3.4.3
Aeration Tank (MBBR unit) .............................................................................................. 33
3.4.4
Aeration Tank ................................................................................................................... 34
START UP AND PERFORMANCE RUN ....................................... 36
4.1
Test on Completion .................................................................................. 36
4.1.1
General ............................................................................................................................. 36
4.1.2
Dry Test Requirements ...................................................................................................... 36
4.1.3
Process Plant Item / Equipment.......................................................................................... 37
4.1.4
Hydraulic Wet Test Requirement ....................................................................................... 37
4.1.5
Process Wet Test ............................................................................................................... 38
4.2
Performance Run after Start Up ................................................................ 39
4.2.1
General ............................................................................................................................. 39
4.3
Performance Run Certificate .................................................................... 40
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
OPERATION AND MAINTENANCE ............................................. 41

Scope of Work ........................................................................................... 41
General Terms and Conditions.................................................................. 43
Financial Terms and Conditions ............................................................... 44
Description of staffing .............................................................................. 44
Deployment of Staff During Operation and Maintenance Period ............... 46
Taking over .............................................................................................. 46
BID DRAWINGS........................................................................ 47
Bid Drawings............................................................................................. 47
DATASHEETS .......................................................................... 48
CONTRACTOR
II
EXECUTIVE ENGINEER
32 MLD STP at Panchak, Nashik

Data Sheets
DATA SHEETS
7
DATA SHEETS ........................................................................................... 48
7.1
Process and Civil Units ............................................................................................................ 48
7.1.1 Civil Units for Sewage Treatment Plant................................................................................. 48
7.1.2 Process Design ...................................................................................................................... 52
7.2
Mechanical Equipment............................................................................................................ 54
7.2.1 Pumping Machinery .............................................................................................................. 54
7.2.2 Sluice Gates .......................................................................................................................... 57
7.2.3 Screening Equipment ............................................................................................................ 57
7.2.4 Grit Removing Equipment..................................................................................................... 58
7.2.5 Secondary Clarifier ............................................................................................................... 60
7.2.6 Chlorination System .............................................................................................................. 61
7.2.7 Centrifuge ............................................................................................................................. 62
7.2.8 Mixers Lime Solution ......................................................................................................... 62
7.2.9 Mixers Polyelectrolyte Solution .......................................................................................... 63
7.2.10
Mixers Sludge ................................................................................................................ 63
7.3
Electrical Power Consumption ................................................................................................ 65
7.3.1 Load List for the plant (100 % flow) ...................................................................................... 65
7.3.2 Load List for the plant (50 % flow)........................................................................................ 65
7.3.3 Transformer Sizing ............................................................................................................... 67
7.3.4 Power Transformer ................................................................................................................ 68
7.3.5 Medium Voltage Switchgear (not exceeding 1000V) ............................................................. 71
7.3.6 Shunt Capacitor Sizing.......................................................................................................... 79
7.3.7 Shunt Capacitor .................................................................................................................... 79
7.3.8 Capacitor Control Panel ........................................................................................................ 81
7.3.9 Push Button Station ............................................................................................................... 81
7.3.10
Cables ............................................................................................................................... 83
7.3.11
Lighting System ................................................................................................................ 85
7.3.12
Cable Terminations ........................................................................................................... 86
7.3.13
Cable Tray ........................................................................................................................ 86
7.3.14
Earthing System ................................................................................................................ 86
7.4
Performance Guarantee .......................................................................................................... 88
7.4.1 General ................................................................................................................................. 88
7.4.2 Functional Guarantees ........................................................................................................... 88
7.5
Miscellaneous Information ...................................................................................................... 88
Contractor
Engineer-in-charge

PREAMBLE
The Volume IIA : Scope of Work are to be read for the purpose of pricing in conjunction
with "Volume-I : Conditions of Contract" of the Tender Documents containing instructions
to Tenderer and General Conditions of Contract; Volume IIB : Civil Specifications,
Volume IIC : Mechanical Specifications, Volume IID : Electrical Specifications and
Volume-III : Financial Bid of this tender.
The prices quoted in the Volume III: Financial Bid shall be all inclusive value for the
work described including all costs and expenses which may be required in and for the
execution of the work described together with all general risks, liabilities and obligations
set forth or implied in the document on which the tender is based.
All works shall be carried out strictly as per detailed specifications whether actually
specified or not. If not specified, work shall be carried out as per directions of
Owner/Engineer-in-charge.
The total amount entered in the Volume III: Financial Bid document shall be written in ink
and shall be entered both in figures and words.
Specifications of items of work are described in Section D for each item of Volume III:
Financial Bid shall read this in conjunction with other technical specifications and specific
technical requirements and quote accordingly.
No separate payment whatsoever shall be made for dewatering if required to be done
during excavation, laying of PCC and RCC, laying and jointing of pipes, construction of
manholes, testing and back filling etc complete and Contractor should quote accordingly.
The tenderer can ask for clarifications, if any, by giving their queries in writing on or
before pre bid meeting. Verbal queries shall not be considered.
Abbreviations used in the Volume IIA : Scope of Work have the meanings shown below:
mm
cm
m
km
sq.m
cum.
M.T.
SWG
R.M.
nos.
MS
M.D
OHT
STP
CONTRACTOR
Millimetre
Centimetre
Metre
Kilometre
Square Metre
Cubic Metre
Metric Ton
Standard Wire Gauge
Running Metre
Numbers
Mild Steel
Metre Depth of Manhole
Overhead tank
Sewage Treatment Plant
CI
GI
GSW
BBCC
RCC
PCC
wt
kg
I.D.
C.M.
IS
SS
SW
MPS
III
Cast Iron
Galvanized Iron
Glazed Stone Ware
Burnt Brick Cement Concrete
Reinforced Cement Concrete
Plain Cement Concrete
Weight
Kilogram
Internal Diameter
Cement Mortar
Indian Standards
Stainless Steel
Storm water
Main Pumping Station
EXECUTIVE ENGINEER

1 PROJECT INFORMATION
1.1
INTRODUCTION
Nashik Municipal Corporation (NMC) proposes to construct 32 MLD average capacity
Sewage Treatment Plant (STP) Panchak, Nashik under JNNURM scheme. The proposed
treatment plant can be based on one of the three technologies described below followed by
chlorination of the treated sewage before discharging in to the river Godavari.
1. Activated Sludge Process (ASP)
2. Sequential Batch Reactor (SBR)
3. UASB followed by Aerobic Treatment (UASB)
1.2
1.2.1
SITE INFORMATION
Geo-Technical Studies
The water table is about 2 m below ground level. Net safe bearing capacity of the treatment
plant site at a depth of 1.5 m is about 10 T/m2. The bidder has to make his own assessment
of the ground water table and safe bearing capacity while costing their proposal. In any
case the approval of designs of the successful bidders shall be based on actual soil
investigation report to be carried out by the successful bidder after award of work.
1.2.2
Location
Nashik city is situated about 180 km from Mumbai on the Eastern slopes of the NorthSouth Sahyadri Ranges. It is located at about 565 m above MSL. The geo co-ordinates of
the area are 7350'00" E and 1958'00" N.
1.2.3
STP Site Topography

The city is situated on the eastern slopes of the North-South Sahyadri ranges at 550 meters
above mean sea level (MSL).
1.2.4
HFL at STP site is 554.50.

Minimum finished GL at anywhere in the plot shall be 555.00
Minimum invert level of disposal point at river end shall be 554.70
Minimum Top of any structure shall be 555.00
Climate
The city is known for its moderate climate all throughout the year. Being on the leeward
side of the North-South Sahyadri ranges and situated within the ring of small hillocks and
mountain ranges the summer maximum temperatures rarely exceed 40C and the winter
minimum is roughly 8 to 9. The rainfall here is also moderate to the extent of 700 mm in
about 50 days in year.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
1

1.3
PROPOSED SEWAGE TREATMENT PLANT

Bidders can quote for any one of the following alternative treatment schemes which they
think is most cost effective in terms of capital and operation cost as defined in tender.
1. Activated Sludge Process (ASP)
2. Sequential Batch Reactor (SBR)
3. UASB followed by Aerobic Treatment (UASB)
In any case bidders can quote ONLY for ONE treatment scheme. If bidder quotes for more
than one treatment scheme then tender shall be rejected.
1.3.1
Sewage Treatment Plant Capacity (For all three schemes)

Average flow
Peak factor
Peak flow
1.3.2
:
:
:
32 MLD
2.25
72 MLD
Raw Sewage Quality (For all three schemes)

An abstract of the raw water characteristics is indicated in the following table.
Sr.
Parameters
1
2
pH
Total
Suspended mg/l
Solids
BOD5 at 20 0C
mg/l
Oil & Grease
mg/l
COD
mg/l
Faecal Coliform
MPN/100 ml
3
4
5
6
1.3.3
Unit
Raw
Sewage
Design Values
Characteristics
7 to 8
200 300
7 to 8
300
100 200
10 30
350 400
200
30
400
> 1 x 107
Treated Sewage Quality (For all three schemes)
Sr.
Parameters
1
2
PH
3
4
5
5
CONTRACTOR
Unit
Total
Suspended mg/l
Solids
BOD5 at 20 0C
mg/l
Oil & Grease
mg/l
COD
mg/l
Faecal Coliform
MPN/100 ml
Discharge Standards
7.0 to 8.0
< 30.00
< 20.00
< 10.00
< 200.00
< 1000.00
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
2

1.3.4
Proposed Treatment Scheme
1.3.4.1 Activated Sludge Process

Raw sewage shall be treated by screening, degritting followed by activated sludge process
to meet the desired discharged standards.
The average capacity of the STP shall be 32 MLD. Raw sewage shall be received in the
inlet chamber and then taken to the mechanical screen channel followed by mechanical
degritter to remove floating matter and grit particles.
Sewage after removing floating matter and grit matter shall be taken to the primary
clarifier. In primary clarifier suspended solids will be allowed to settle at the bottom of the
clarifier. Floating matter in the form of scum shall be removed from the primary clarifier.
Primary settled sewage shall be treated aerobically in activated sludge process. Aerated
sewage shall be taken to the secondary clarifier for solid liquid separation. The settled
sludge from clarifier is recirculated back to the aeration tank to maintain bio mass
concentration. Excess sludge shall be taken to sludge thickener for thickening of sludge.
Overflow from secondary clarifier is further taken to chlorine contact tank for disinfection.
Chlorine will be dosed in the chlorine contact tank from a vacuum type chlorination
system. A separate building will be provided to house the chlorination system along with
all the accessories and its safety devices.
Treated sewage after disinfection shall be discharged to the nearby river Godavari through
open channel.
Primary sludge and excess sludge shall be taken to the sludge thickener for thickening of
sludge. Thickened sludge then shall be taken to the anaerobic digester for stabilisation of
sludge. Stabilised and digested sludge will then be taken to mechanical dewatering system
for dewatering of the sludge. Filtrate shall be taken back in to the system for treatment.
Gas generated from the digester shall be taken to the gas holder.
Interconnection of various units shall be made through piping or RCC channels. Piping will
be preferred over RCC channel wherever possible but the Engineer- in- Charge reserves the
right to select any option.
Chlorine house of min 150 m2 shall be provided which includes chlorine dosing unit,
tonners, booster pump etc. The chlorine house can be constructed above chlorine contact
tank.
MEP room of min 50 m2 shall be provided near transformer yard.
Blower room of min 150 m2 shall be provided to accommodate working and standby
blowers.
Schematic Flow Diagram is given in drawing no. MWH/169/Panchak/ASP
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
3

1.3.4.2 Sequential Batch Reactor Technology

Raw sewage shall be treated by screening, degritting followed by sequential batch reactor
process to meet the desired discharged standards.
Sewage after removing floating matter and grit matter shall be taken to the sequential batch
reactor (SBR) system for removal of SS and BOD.
Treated sewage after SBR shall be further taken to chlorine contact tank for disinfection.
Chlorine will be dosed in the chlorine contact tank from a vacuum type chlorination
system. A separate building will be provided to house the chlorination system along with
all the accessories and its safety devices.
Excess sludge from SBR reactor shall be taken to sludge thickener followed by mechanical
dewatering system for dewatering of the sludge. Chemical conditioning for thickening /
dewatering shall be provided. Filtrate shall be taken back in to the system for treatment.
tank.
blowers.
Schematic Flow Diagram is given in drawing no. MWH/169/Panchak/SBR
1.3.4.3 UASB followed by Aerobic treatment

Raw sewage shall be treated by screening, degritting followed by UASB reactor process
followed by aerobic treatment to meet the desired discharged standards.
Sewage after removing floating matter and grit matter shall be taken to the UASB system
for removal of SS and BOD. Outlet of UASB reactors shall be further treated with aerobic
treatment. Aerobic treatment can be aeration tank followed by secondary clarifier or
Moving Bed Bio reactor followed by secondary clarifier.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
4

Treated sewage after secondary clarifier shall be further taken to chlorine contact tank for
disinfection. Chlorine will be dosed in the chlorine contact tank from a vacuum type
chlorination system. A separate building will be provided to house the chlorination system
along with all the accessories and its safety devices.
Sludge from UASB reactor and from aerobic treatment shall be taken to the mechanical
dewatering unit for dewatering of sludge. Chemical conditioning for thickening /
dewatering shall be provided. Filtrate shall be taken back in to the system for treatment.
Gas generated from the UASB reactors shall be taken to the gas holder.
tank.
blowers.
Schematic Flow Diagram is given in drawing no. MWH/169/Panchak/UASB
All three processes considered are well-established processes for treatment of sewage. The
tenderers are to adopt the same nomenclature used for various treatment units in their
design report as used in the tender documents. The tenderer is required to fill up/complete
the Datasheets presented in this document as a part of the tender submission.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
5

2 GENERAL TECHNICAL REQUIREMENTS

The Contractor should ensure technical feasibility of their tender offer, after inspecting the
site. It must be understood that it is a turnkey project and the firm shall be required to
execute every such items of work which is considered necessary for satisfactory
completion and commissioning of the plant, even though such items are not explicitly
specified in the tender documents.
All the works mentioned under the scope are to be designed and executed as per tender
civil / electrical / mechanical technical specifications and requirements and after obtaining
approval from the engineer-in-charge.
2.1
TIME LIMIT
Time of completion construction, erection and testing of the plant as mentioned in the
scope of work shall be 18 calendar months (inclusive of monsoon period) from the date of
issue of work order. After 18 months there shall be start up and commissioning and
performance run of 3 months followed by Operation and Maintenance for 36 months.
2.2
SUBMISSION DURING EXECUTION OF THE PROJECT

The Contractor can take up the works of site clearance, dozing, grading and other
mobilization works with the permission of the Engineer after award of the Contract.
However, before taking up the construction, contractor shall be responsible for preparing
and submitting for checking and obtaining approval at his cost of the following by the
NMC / their authorised representative.
1.
A levelling / contour plan gradation plan of the site
2.
Subsoil testing and investigations to be carried out by the contractor through a

reputed and specialist firm approved by Engineer and recommendations regarding
the safe allowable bearing capacity for the foundations of various structures of the
plant and connected buildings.
3.
Process design and sizing of various units on the basis of criteria and specification
mentioned in this document.
4.
Hydraulic head loss design calculations are to be done on the basis of design
parameters mentioned in the latest CPHEEO Manual on Sewage Treatment of
Ministry of Urban Development, Govt. of India.
5.
Layout plan of entire site showing the location of 32 MLD Sewage Treatment Plant
on the basis of process design. This drawing shall shows all treatment plant units,
buildings / sheds, channels interconnecting piping, roads, pathways, storm water
drains etc. The minimum distance between the two structures shall not be less than
3.0 m.
7.
Hydraulic flow diagram shall be prepared on the basis of Hydraulic head loss
calculations, indicating top water levels of each unit, from inlet channel to chlorine
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
6

mixing chamber, side water depths, bed levels, invert levels, top of wall of each unit
including all details of each units.
8.
General arrangement drawings for each unit, buildings showing and finished ground
levels based on the levels given herein after, necessary provision for civil/structural
works and electrical/mechanical works separately.
9.
Civil structural design calculations, reinforcement drawings and drawings for bar
bending schedule etc. are to be submitted. Structural design for all liquid retaining
structures or structures in contact with sewage shall be done in accordance with the
provisions made in I.S. code 3370 (part I to part IV) as Uncracked Section and other
structures/building on the basis of IS 456-2000 (latest revision) unless otherwise
stipulated in civil specification hereafter. M 25 grade of concrete shall be used for all
liquid retaining structures and M 20 grade concrete for other structures. The plain
cement concrete shall be nominal mix 1:2:4. Minimum thickness of PCC shall be
150 mm for water retaining structures and 100 mm for other structures.
11.
Architecture drawings for all buildings, pumping station etc. An architect approved
by NMC shall approve these drawings. Necessary charges for such approval shall be
borne by contractor.
12.
Design details for electrical and mechanical equipment, machinery including

technical details of pipes, centrifuge, chlorinators, valves, gates and other drawings
including single line diagrams etc. as per specifications mentioned in Mechanical
specifications and Electrical Specifications.
13.
Schedule for designs, drawings and execution, Bar Charts-CPM-Pert network for
stage wise construction activities of sewage treatment plant.
14.
The contractor should get the approval on drawings and designs from the Dy.
Director of Industrial Health and Safety Department Govt. of Maharashtra and
submit the copy of approved plan to the engineer-in-charge at his own cost.
15.
Contractor shall be responsible for liasoning and getting clearances from all
concerned authorities at his own cost and should submit the clearances obtained to
NMC for their records.
16.
The contractor should get the layout of electrical substation and general electrical
layout from Electrical Inspector and also get the final inspection done for realising
new connection at his own cost.
17.
The contractor shall submit details of their environmental policy to carry out the
Works with due consideration for the protection of the environment as required by
the Contract. The environment policy shall be specific to the contract and address the
major environmental hazards associated with construction of the Works. It shall
include details of the organisational framework and the designation of the engineer
to take overall responsibility and to manage the environmental control facilities on a
day-to-day basis.
18.
The contractor shall submit their Health & Safety policy in sufficient details to
demonstrate the adequacy of the contractor to carry out the Works with due
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
7

consideration for health and safety of his workforce and all people in the vicinity of
the Works. It shall be shall be specific to the contract and address the major risks
associated with construction of the Works. It shall also include details of the
organisational framework and the designation of the engineer to take overall
responsibility and to manage health and safety on a day-to-day basis.
19.
During the course of construction and its completion, the contractor shall submit the
following drawings/documents for Civil, Mechanical and Electrical works.
2.3
Revised drawings and design according to requirements of the Engineer.

Six sets of final and approved drawings and design duly bound.
Six sets of manual of operation and maintenance of the plant.
SOIL INVESTIGATION
The bidder/contractor has to carry out soil investigations and design all the structures based
on the Safe Soil Bearing Capacity as per soil investigation report. For design purpose
ground water table shall be considered at HFL.
2.4
EQUIVALENCY OF STANDARDS AND CODES

Wherever reference is made in the Contract to specific standards and codes to be met by
the goods and materials to be furnished, and work performed or tested, the provisions of the
latest current edition or revision of the relevant standards and codes in effect shall apply,
unless otherwise stated in the Contract. Where such standards and codes are national, or
related to a particular country or region, other authoritative standards which ensure an
equal or higher quality than the standards and codes specified will be acceptable subject to
the Engineer's prior review and written approval. Differences between the standards
specified and the proposed alternative standards must be fully described in writing by the
contractor and submitted to the Engineer at least 28 days prior to the date when the
Contractor desires the Engineer's approval. In the event the Engineer determines that such
proposed deviations do not ensure equal or higher quality, the Contractor shall comply with
the standards specified in the Bid Documents.
2.5
SIGN BOARD
The Contractor at his own cost, shall provide sign boards at approved locations, in English
and Marathi at the site of the Works of approved size and design which provides (i) the
name of the Project, (ii) the name and addresses of the Employer, the Contractor and the
Consultant; (iii) the name and short description of the Project, (iv) the amount of the
Contract Price; and (v) the starting and completion dates. Contractor shall take care of
signboard and redo it in case of loss, damage, theft etc., as desired by the Engineer-inCharge.
2.6
QUALITY ASSURANCE PROGRAMME/SAMPLE TESTS

The Contractor shall be responsible to develop a quality control program and to provide all
necessary materials, apparatus, instruments, equipment, facilities and qualified staff for
sampling, testing and quality control of the materials and the works under the Contractor.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
8

Without limiting the generality of the foregoing, the Contractor shall either (i) establish a
testing laboratory at the site of Works which shall be adequately equipped and staffed to
carry out all sampling and testing in accordance with the requirement set out in the tender
document specifications and provide all field equipment and apparatus as necessary to
conduct all specified in-situ tests and/or any Tests on Completion, or (ii) arrange for routine
sampling, testing and reporting, as required, through a certified independent testing
laboratory acceptable to the Engineer-in-Charge. The Contractor shall obtain the approval
of the Engineer-in-Charge for the quality control programme developed by him and
incorporate any modifications suggested by the Engineer-in-Charge at no extra cost.
All costs of such sampling, testing and reporting of test results will be borne by the
Contractor, and the Contractor shall include sufficient provisions in his tendered rates to
allow for independent sampling and laboratory testing under the direction of the Engineerin-Charge. The Contractor shall furnish certified copies of all test reports to the Engineerin-Charge within 3 days of completion of the specified tests.
The Contractor shall, within 14 days after the date of the issue of Letter of Acceptance,
submit to the Engineer-in-Charge for his consent a detailed description of the arrangements
for conducting the quality control programme during execution of the Work, including
details of his testing laboratory, equipment, staff and general procedures. If following
submission, or at any time during the progress of Works, it appears to the Engineer-inCharge that the Contractor's quality control programme is not adequate to ensure the
quality of the Works, the Contractor shall produce a revised programme, as desired by the
Engineer-in-Charge, which will be adequate to ensure satisfactory quality control. In case
of the contractor will fail to ensure quality control program the action deem fit will be
taken against the contractor. NMC shall carry out supervision and quality control and
monitoring the progress of works.
2.7
PROTECTION OF UTILITIES
The Contractor is required to carefully examine the location of the Works and their
alignments and to make special enquiries with all authorities concerning all utility lines
such as water supply, sewers, gas pipe, telephone (underground and/or overhead) lines,
electric cable (underground and/or overhead) etc., and to determine and verify to his own
satisfaction the character, sizes, position and lengths of such utilities from authentic
records. The Contractor shall be wholly responsible for the protection and/or facilitating
relocation of such utilities as may be required and shall not make any claim for extra work
or extra time that may be required to protect or facilitate relocating such utilities. If any
major shifting or realignment of water supply, sewers, gas pipes, electric and telephone
lines is necessary due to their interference with the proposed Works, the same may be done
by the contractor. The cost of such relocations will be borne by the contractor.
2.8
DISMANTLING OF THE EXISTING UNITS (IF APPLICABLE)

The existing structures at the site shall be demolished as directed by engineer-in-charge.
Cost of the demolishing shall be included in the quoted price.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
9

The scheme for demolishing shall be got approved from the Engineer-in-Charge before
starting of the work. This however will not absolve the contractor from the responsibility of
proper and safe demolition.
Necessary dropping, shoring and under pinning shall be provided for the safety of the
adjoining work or property, which is to be left intact, before dismantling and demolishing
is taken up and the work shall be carried out in such a way that no damages is caused to the
adjoining property.
Wherever required, temporary enclosures or partitions shall also be provided. Necessary
precautions shall be taken to keep the dust nuisance down as and where necessary.
Dismantling shall be commenced in a systematic manner. All materials which are likely to
be damaged by dropping from a height or demolishing roof, masonry etc. shall be carefully
dismantled first. The dismantled articles shall be properly stacked as directed.
All material obtained from demolition shall be property of NMC unless otherwise specified
and shall be kept in safe custody until handed over to Engineer-in-Charge.
Any serviceable materials obtained during dismantling or demolishing shall be separated
out and stacked properly as directed with all lead and lift. All unserviceable material, debris
etc shall be stacked as directed by Engineer-in-Charge. Disposal of the demolished material
shall be done by contractor within NMC limit as directed by engineer-in charge at no extra
cost.
On completion of work, the site shall be cleared of all debris rubbish and cleaned as
directed.
2.9
INSPECTION
Bidders to note that various items to be procured / executed under this contract are subject
to inspection by NMC or their authorised representatives at manufacturers premises. Cost
of inspection shall be borne by contractor
2.10 READY MIX CONCRETE

The contractor shall use RMC concrete for construction of treatment plant units. If
concreting quantity is less that 2 m3 then only site mix is allowed.
The bidder should submit along with the tender, a copy of letter of consent from the
approved RMC plant owner to the effect that he would be agreeable to do the RMC work
for the said contract, if the tenderer does not possess his own RMC plant, approved by
NMC.
Ready mix concrete prepared and transported will be as per IS 4926 of 1976 or the latest
I.S. Code.
No dry mix shall be brought on site and water added thereat.
Ready mix concrete will be brought to the site from R.M.C. plant only by transit mixers
(agitators).
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
10

Every transit mixer will carry delivery ticket, mentioning the minimum following details:- Name of Manufactures and Depot
- Serial No. Ticket.
- Date
- Truck No.
- Name of contractor to whom the R.M.C. is being supplied
- Location of contract
- Grade of concrete
- Specified workability
- Cement content and grade of cement
- Time of loading
- Quality of concrete
When the truck arrives on site, the drum should always be speeded to about 10 to 15
rev/min, for atleast 3 minutes, to make sure the concrete is thoroughly mixed and uniform,
before discharge.
Testing of Ready Mixed Concrete:- The sampling and testing requirements for ready mixed
concrete are the same as those for site mixed concrete. As regards testing of workability,
there is bit of problem because the standard requirement is that the sample should be made
up of at least four portions taken at intervals from the complete discharge. This obviously
involves discharging all the concrete, by which time, it is too late, for the workability,
before discharge. The following procedure is one that has been accepted by many
contractors, suppliers and clients, and recommended. After making sure that the concrete
has been uniformly mixed, take a sample from the first 0.5 cum. Of concrete discharged,
and do a slump (or compacting factor) test on the sample. If the result complies with
specified requirements, then the load should be accepted. If the results are beyond limits, a
further sample should be taken from the second 0.5 cum. of the discharged, if this is
satisfactory, the load should be accepted, if not, the concrete should be rejected, as the
same is not as per the specified range. The specified slump is 50mm. While carrying out
above tests, it may vary by 10 mm as per IS4926: 1976.
Twelve cubes shall be cast at the plant as well as at the site, where the concrete is placed.
The admixture used shall conform to IS 9103-1979 reaffirmed on 1990 or ASTM C-494 of
92.
All taxes/duties etc. will be borne by the contractors and not by NMC.
No extra payment will be made for the use of admixtures.
It will be the sole right of the Administration to allow or disallow the use of ready mixed
concrete in specified works based on the site situation, number of works, distance of plant
from the site of work, etc.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
11

3 SCOPE OF WORK
3.1
BRIEF SCOPE OF WORK

The scope of the work shall include but not be limited to the following:
1. Design, construction, supplying, erection, testing and commissioning of 32 MLD
capacity STP based on any of the three suggested technologies.
2. Required site development including levelling and grading to improve the aesthetics
and to facilitate the vehicular movement.
3. Preparation of process, hydraulic, electrical, mechanical and piping design.
Preparation all civil, mechanical, electrical and piping drawings including
architectural, construction and as built drawings.
4. Demolishing the existing structures, if any, on the site.
5. Construction of civil engineering works for all the units plus all the ancillary
structures as detailed in Volume IIB: Civil Specifications.
6. Supply, erection testing & commissioning of all the mechanical equipment as
detailed in Volume IIC: Mechanical Specifications.
7. Supply, erection testing & commissioning of all the Electrical & Instrumentation
equipment as detailed in Volume IID: Electrical Specifications.
8. Supply, erection testing & commissioning of all the interconnecting piping & valves
as detailed in Volume IIB: Civil Specifications.
9. Providing walkways, platforms and RCC staircase of minimum 1.2 m width
10. All water retaining structures shall be form finished.
11. All reinforcement steel shall be Fe 500 TMT grade of TATA Tiscon make only
12. Swelling Gasket in paste form (Masterflex or equivalent) shall be used in all
construction joints in concrete structure to avoid leakage
13. Drain with valve and pipe arrangement (min 200 mm dia) to all treatment plant units.
All drains shall be connected to the final treated sewage line.
14. Performance Run of the constructed & hydraulically tested plant along with O & M
of electrical & mechanical equipment for a period of Three (3) months and operation
& maintenance for 36 months after performance run as per tender specifications
including providing and installing all civil material, labour, tools and plants all
complete on turnkey basis
15. Defects liability period of 12 months from the date of successful completion of O &
M period
16. Supply of all documentation for the plant such as As-Built drawings, Operation &
Maintenance manuals (6 sets)
17. Supply of all spares required during performance run and during 36 months of O &
M period.
18. Zinc rich epoxy painting in two coats from inside for all shall water retaining
structures.
19. Water proof acrylic painting in two coats of approved shade to all units from outside
upto 0.5 m below ground level.
20. Oil painting with anti corrosive treatment to railing and all MS, CI and GI works.
21. Subsoil testing and investigation for water table and safe allowable bearing capacity
to be carried out by the contractor through a reputed and specialist firm approved by
Engineer-in-Charge. Based on soil investigation the contractor shall prepare
structural design and drawings.
22. Bidders are advised to visit STP site before quoting for the proposed STP.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
12

23. Any other items of work which have not been specifically mentioned in the
specifications but are necessary for construction of the plant as per good engineering
practice and safety norms and operation and guaranteed performance of the entire
plant shall be deemed to be included within the scope of work of this specifications
and shall be provided by the contractor without any extra cost to the employer.
3.2
DETAILED SCOPE OF WORK FOR ACTIVATED SLUDGE PROCESS

There shall be two independent streams. Each stream should be capable of handling 16
MLD average flow and 36 MLD peak flow.
The project shall have following major units
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Inlet Chamber
Mechanical and Manual Screen Channels
Mechanical and Manual Grit removal facility
Primary clarifiers with sludge sump and pumps
Aeration Tank with diffusers, air blowers
Secondary Clarifier with return sludge sump and pumps
Chlorine Contact Tank
Chlorine House
Sludge thickener with thickened sludge sump and pumps
Anaerobic sludge digester with digested sludge sump and pumps
Gas Holder
Gas mixing system for sludge digester.
Sludge dewatering system
Transformer yard and MEP room
Interconnecting Piping
Flow measurement units
Plant Utilities
Required site development including levelling and grading to improve the
aesthetics and to facilitate the vehicular movement.
The sizes specified in the tender document are the minimum requirement and are for
guidance purpose only. However this does not absolve the contractor from his
responsibility of giving satisfactory plant performance and meeting desired discharge
standards as specified in tender document.
3.2.1
Inlet Chamber
Inlet Chamber will receive raw sewage from the raw sewage pumping station. Inlet
chamber shall be designed for peak flow. The entire construction is in M 25 grade concrete
and as per IS 3370. RCC access platform 1200 mm wide with railing as per specifications
shall be provided on one side of the Inlet chamber. RCC staircase 1200 mm wide shall be
provided for access from the ground level to the top of the unit & to the operating
platforms.
Total Average flow
Peak factor
Design Flow
Number of Units, nos.
CONTRACTOR
:
:
:
:
32 MLD
2.25
72 MLD
1
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
13

Detention period
Min Free board
:
:
60 sec
0.5 m
Minimum volume of the Inlet chamber shall be 50 m3

3.2.2
Screen Channels
Two mechanical and one manual screens are proposed in the screen chamber. The
mechanical screens shall be working and manual screen shall be standby. The screen
channels shall be designed for peak flow.
The clear opening for mechanical screen shall be 6 mm and that of manual screen shall be
10 mm. The mechanical and manual bar screens shall be fabricated from 2 mm and 6 mm
thick Stainless Steel (SS 316) flats respectively. Conveyor belt and chute arrangement shall
be provided to take the screenings to the safe disposal. The screenings dropped from chute
will be collected in a wheeled trolley (to be supplied by contractor) of approx. 0.5 m3
capacity. This trolley will be housed in a roofed enclosure with proper access, screen
washing arrangement and drain.
Manually operated aluminium gates are provided at the upstream and downstream ends of
each screen channels to control the flow. Width of gates shall be equal to width of screen
channels. The height of gates shall be 200 mm more than the maximum water depth.
RCC platforms shall be provided at the upper level to enable operation of the gates. GI
Hand railings shall be provided around the entire periphery of the screen channel as well as
for the platform. The entire structure is to be constructed in M 25 concrete and as per IS
3370 including the platform for the gates. RCC staircase 1200 mm wide shall be provided
for access from the ground level to the top of the unit & to the operating platforms.
Total Average Flow
Peak Factor
Design Flow
Number of Units
Approach velocity at average flow
Velocity through Screen at avg flow
Velocity through Screen at peak flow
Free Board
Wheeled trolleys
:
:
:
:
:
:
:
:
:
32 MLD
2.25
72 MLD
2 W (mechanical) + 1 S (manual)
0.45 m/sec
0.6 m/sec (minimum)
1.2 m/sec (maximum)
0.5 m
2 nos.
Minimum size of the each screen channel shall be 6 m long x 0.8 m wide x 0.8 m SWD
All other accessories, whether specified or not, but required for completeness shall form
part of contractors scope.
3.2.3
Grit Removal Channel

Two mechanical and one manual grit channels are proposed after screen channels. The
mechanical units shall be working and manual shall be standby. Each mechanical grit
chamber shall be suitable to take 50% of peak flow. The manual shall be designed for 50%
peak flow. Manual grit removal channel shall have drain valve.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
14

Detritor tank chamber shall have the following:

1. One tapered inlet channel running along one side with deflectors for entry of sewage
into the grit chamber. The minimum SWD of the units shall be adopted on the basis
of design requirement of the unit,
2. One tapered outlet channel for collecting the degritted sewage, which overflow over
a weir into the outlet channel. Outlet channel of adequate size and shape to ensure
that no settling takes place.
3. One sloping grit classifying channel into which the collected grit will be classified.
4. The grit from classifier will be collected in a wheeled trolley (to be supplied by
contractor) of approx. 0.5 m3 capacity. This trolley will be housed in a roofed
enclosure with proper access, grit washing arrangement and drain.
5. A grit scraping mechanism,
6. Adjustable influent deflector,
7. Reciprocating rake mechanism to remove the grit,
8. Two-mechanism support beams with railing & chequered plates over half the
diameter of the chamber.
9. Organic matter return pump
Aluminium gates shall be provided at the entrance and at the outlet of the grit chamber. To
enable easy operation of the gates, RCC platforms with GI railing shall be provided at the
upper level. Also access is provided from this level to the mechanism support beam of the
grit chamber. The entire construction shall be in M 25 grade concrete and as per IS 3370.
RCC staircase 1200 mm wide shall be provided for access from the ground level to the top
of the unit & to the operating platforms.
Mechanical unit
Design peak Flow
No of working units
Type
Size of grit particle
Specific gravity of grit
Surface Overflow Rate
Free Board
Side Water Depth
Wheeled trolleys
:
:
:
:
:
:
:
:
:
72 MLD
2 No
Classifier
0.15 mm
2.65
960 m3/m2/day
0.50 m
0.80 m (minimum)
2 nos
Manual unit
Design peak Flow
No of units
Size of grit particle
Specific gravity of grit
Surface Overflow Rate
Free Board
:
:
:
:
:
:
36 MLD
1 No
0.15 mm
2.65
960 m3/m2/day
0.50 m
Minimum size of the mechanical grit chamber shall be 2 Nos. 7 m x 7 m x 0.8 m SWD and
that of manual grit channel shall be minimum 15 m long x 2.5 m wide x 1.6 m SWD
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
15

3.2.4
3.2.5
Flow Measuring Unit

Number of Units
1 at downstream side of Degritting Tank

and 1 at final outlet channel after chlorine
contact tank
Type
Ultrasonic mounted on concrete channel

having digital type Indicator, Integrator and Recorder
fixed in the control room.
Division Box
The Division Box will receive the flow from the grit chamber. The flow will then be split
into two equal parts with adjustable aluminium overflow weir plates and distributed to two
primary clarifiers via pipe. Aluminium gates including all specials shall be provided on all
two weirs for isolation. RCC access platform, staircase, railing and covers over division
boxes are provided as per requirement.
3.2.6
Primary Clarifier
Primary Clarifier will receive flow from grit chamber. There shall be two primary
clarifiers. It is to be provided for settlement of suspended solids present in sewage. The
inlet shall be from bottom central feed. The clarifier mechanism is provided in the primary
clarifier tank to scrap the settled solids from the bottom of the tank such that the sludge
moves to center sludge pocket.
The Primary Clarifier shall be circular radial flow type having suitable size and depth. The
tank shall be constructed in M 25 grade concrete and as per IS 3370. Each tank shall have
central stilling box, Skimmer, Trough, Scum baffle, weir plate and sludge scraping
mechanism spanning the diameter of the tank. Central stilling well shall be of FRP of 6 mm
thick plate. RCC staircase 1200 mm wide shall be provided for access from the ground
level to the top of the unit & to the operating platforms.
Scum from primary clarifier shall be taken to the sludge digester. In case of pumps,
working and standby arrangement shall be provided. The squeezes shall be of neoprene
rubber. The V-notch weir for the Primary Clarifier Tank shall be of FRP and fixed to the
RCC launder with adjustable fixtures for adjusting the level of the weir to have uniform
flow throughout the periphery. The minimum thickness of the FRP plate shall be 6 mm and
300 mm wide. The inlet pipe and outlet launder shall be designed for peak flow.
All fasteners below the water level will be of SS 316 and the steel structure will be epoxy
painted after sand/ball blasting to near white and after applying zinc rich primer.
The flow shall be received from the grit chamber by means of pipe of suitable dia. The pipe
under raft of the clarifier shall be encased with CC 1:2:4 grade concrete. The central stilling
box shall extend 100 mm above the maximum sewage level and will be designed to prevent
short-circuiting.
Total Average Flow
Number of Units
Type
CONTRACTOR
:
:
:
32 MLD
2
Central Feed, Centrally Driven,
fixed bridge
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
16

Sludge collection
Overflow Rate, m3/m2/day

Free Board, m
Side Water Depth,
MOC of sludge scrapper mechanism
:
:
:
:
Full Diameter Mechanical Sludge

Scraper
35 (maximum for average flow)
0.5
3 m (minimum)
Generally MS with epoxy paint
Minimum size of each primary clarifier shall be 24.50 m dia x 3 m SWD.

Sludge from primary clarifier shall be withdrawn through minimum 250 mm dia telescopic
arrangement and will be taken to RCC sump having minimum effective capacity of 32 m3.
The sump shall also have 2 (1W + 1S) submersible pumps each of 32 m3/hr capacity to
transfer the sludge to sludge thickener.
3.2.7
Aeration Tank with Diffusers & Air Blowers

There shall be two Aeration Tanks. Each aeration tank will receive flow from each primary
clarifier via pipe. Provision shall be made to receive active return sludge from return sludge
pumps. Inlet and outlet launders / pipes shall be designed for peak flow.
Aeration tanks will be constructed in M 25 grade concrete and as per IS 3370. Tank shall
have inlet launder, outlet launder. Isolating gates in inlet and outlet launders of each tank
shall be provided for maintenance purpose. RCC staircase 1200 mm wide is provided to
each aeration tank for access from the ground level to the operating platforms. All
platforms and walkways shall be provided with hand railings as per tender specifications.
The outlet pipe of suitable diameter and length shall be provided from aeration tank to the
secondary clarifier. The carrying capacity of this pipe shall be suitable for peak flow plus
return sludge flow.
Each tank shall be equipped with air diffusers. Air shall be supplied through air blowers.
Diffusers and air blowers shall be as per technical specifications. Air blower room shall be
provided to house the air blowers.
Total Average flow
No of tanks
Type of aeration
Inlet BOD5 at 20 0C
Inlet suspended solids
F/M ratio
MLSS
MLVSS / MLSS
Kg O2 / kg BOD removed
Min free board
Max depth of aeration tank
:
:
:
:
:
:
:
:
:
:
:
32 MLD
2 Nos.
Diffused aeration
140 mg/l
150 mg/l
0.3
2800 mg/l
0.8
1.2
0.5 m
6 m (liquid depth)
Minimum combined volume of both the aeration tanks shall be 6000 m3.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
17

Diffusers
The aeration system shall comprise of fine bubbled diffused aeration and shall be of
retrievable configuration for individual diffusers. The aeration system shall be capable of
delivering the required air to the aeration tank.
Diffusers shall be submerged fine bubble / fine pore, high transfer efficiency, low energy
consumption, low maintenance, non-buoyant type. Diffusers shall be either disk / dome /
tubular (membrane) type. Material of construction for diffusers and the entire under water
system including accessories shall be of non corrosive material. Complete diffuser as a unit
shall be assembled at the manufacturing factory level. Diffuser system shall be designed
considering following minimum conditions.
Each meter of diffuser membrane shall have a minimum effective aeration area of 0.16
square meters. The diffuser design gassing rate shall not exceed 0.35 m3/min per diffuser
assembly. The head loss through an individual diffuser shall not exceed 500 mm @ 0.17
m3/min. Upon the loss of air pressure the perforations shall close and the membrane shall
seat tightly over the air supply working as a check valve. The entire assembly shall be
located such that each diffuser centreline is 300 mm above the basin floor.
Each diffuser assembly shall include a manually operated isolation butterfly valve, flexible
pipe for connection to the main air distribution piping.
Elevation of the plant above MSL
factor
factor
Min. temp of water
Max. temp of water
Bubble size
Average concentration of DO in the
Aeration tank
Oxygen required under actual condition
For the entire plant (in both the aeration
tanks together)
Correction factor to calculate S.O.R.
=
=
=
=
=
=
approx. 560 m
not greater than 0.65
10 0C
32 0C
not greater than 0.8 mm
not less than 2.0 mg/lit
=
550 kg/hr
=
(Actual value will be
supported by calculations)
In case of membrane type diffusers, the diffusers shall be tubular with diffuser OD not
exceeding 90 mm. The inner support tube shall be in single piece with proper provision to
hold the membrane in place. Membrane material shall be made of silicon base rubber.
The access / maintenance facilities required for diffusers (depending on system offered)
shall be included in the bidders quoted price.
Installation of diffusers and air piping during execution shall be done based on detailed
calculations to be furnished by the contractor and approved by NMC. Diffuser layout shall
be vetted stamped and approved by the manufacturer.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
18

Air Blower:
The blowers for air diffuser system shall be positive displacement (roots) type. The head
for blowers shall be decided considering the losses between the governing point of delivery
(diffusers) and the blowers. The number of standby blower shall be minimum 50% (fifty
percent) of the number of working blowers. Blowers shall be complete with motor and
accessories like base frame, anti vibratory pad, silencer, non return valve, air filter etc as
per requirements. Vibration due to operation of blowers shall be minimum to avoid damage
to structures. Further, blowers shall have acoustic enclosures to ensure that the noise level
at 3 m from blowers is below 50 db level. The blower room shall have sufficient
ventilation, lighting and working space. The room will be equipped with sufficient capacity
EOT (Min 2 T) to facilitate removal of blower/motor etc. for repairs. The room will also
have rolling shutter.
The blower and air diffuser system shall include PLC based control for diffuser operation.
The operation and speed of blowers shall be automatically adjusted using controlled
parameter (dissolved oxygen) and manipulated parameters like Total organic carbon (ToC)
and/or flow and/or Timer such that the DO is supplied as per demand and power utilisation
for operation of blowers is optimised.
All instrumentation system required to give output signal to VFD via PLC shall be included
by bidders in their quoted price. Similarly expenses involved in carrying various analysis
and tests to stabilise and demonstrate the power saving system shall be included by bidders
in their quoted price.
Bidders shall furnish guaranteed power saving with the above system considering average
flow of 32 MLD and average raw sewage BOD of 140 mg/lit.
Bidders shall furnish detailed writeup for the energy saving system described above along
with their bids for evaluation by NMC.
There shall be min 3 Nos (2 W + 1 S) of air blower for each aeration tank. Out of three one
of the blowers shall be equipped with VFD. Capacity of each blower shall be minimum
1100 m3/hr. Operating pressure of each blower shall be min 0.85 kg/cm2.
Air Piping:
The main air header/ring main shall be in MS as per relevant IS painted both outside and
inside with corrosion resistant paint as per manufactures recommendations. The header /
ring main shall be supported on saddles at suitable intervals or will be protected against
external corrosion in case they are laid below ground. The header shall have valves at all
such locations, where regulating the airflow becomes necessary to ensure uniform supply
of air to all the diffusers. The header shall supply air to diffuser grids at various locations
through air supply pipes with isolation valve. There shall be isolation valve for each
diffuser assembly. Air supply pipe below water level shall be in PVC as per relevant I.S.
standards. Junction between air header and air supply pipe shall be suitably protected
against corrosion due to dissimilar materials.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
19

3.2.8
Secondary Clarifier
The Secondary Clarifier tank is to be provided for settlement of sludge from the Aeration
tank. There shall be two secondary clarifier tanks. Each secondary clarifier will receive
flow from each aeration tank. The inlet shall be from bottom central feed. The clarifier
mechanism is provided in the secondary clarifier tanks to scrap the settled solids from the
bottom of the tank such that the sludge moves to center sludge pocket.
These shall be circular radial flow types having suitable size and depth. The tank shall be
constructed in M 25 grade concrete and as per IS 3370. Each tank shall have weir plate and
sludge scraping mechanism.
The clarifiers shall have a sloping bottom with central hopper. The flow shall be received
from the Aeration tank by means of pipe encased with CC 1:2:4 concrete laid under the
floor of the tank upto the central pier of the clarifier to a stilling box. The central stilling
box (MOC shall be of shall extend 100 mm above the maximum sewage level and will be
designed to prevent short-circuiting. Central stilling box shall be of FRP 6 mm thick.
The squeezes shall be of neoprene rubber. The V-notch weir for the Secondary Clarifier
Tank shall be of FRP and fixed to the RCC launder with adjustable fixtures for adjusting
the level of the weir to have uniform flow through out the periphery. The minimum
thickness of the FRP plate shall be 6 mm and 300 mm wide. The inlet pipe and outlet
launder shall be designed for peak flow.
RCC staircase 1200 mm wide shall be provided for access from the ground level to the top
of the unit & to the operating platforms and peripheral walkway with railing.
Total Average Flow
Number of Units
Type
:
:
:
Sludge collection
Overflow Rate, m3/m2/day

Weir loading for each clarifier
Free Board, m
Side Water Depth,
MOC of sludge scrapper mechanism
:
:
:
:
:
32 MLD
2
Central Feed, Centrally Driven,
fixed bridge
Full Diameter Mechanical Sludge
Scraper
15 (minimum for average flow)
Max 185 m3/m/day
0.5
3.5 m (minimum)
Minimum size of each secondary clarifier shall be 26.5 m dia x 3.5 m SWD.
3.2.9
Return Sludge Pump House

Return sludge sump shall be provided to collect the sludge settled at the bottom of the
secondary clarifiers. There shall be one common sludge sump for both the secondary
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
20

clarifiers. There shall be knife gate valves valve with chamber and cover arrangement to
sludge pipe of each clarifier. Diameter of valve shall be same as that of sludge pipe.
Sludge from the sump shall be pumped to the inlet of aeration tank by means of common
rising main. There shall be division chamber before aeration tank to divide activated sludge
in two equal parts with adjustable aluminum overflow weir plates and distributed to two
aeration tanks. Aluminium gates including all specials shall be provided on two weirs for
isolation. RCC access platform, staircase, railing and covers over division boxes are
provided as per requirement.
From common rising main there shall be provision of taking excess sludge to sludge
thickener by providing T junction. Minimum dia of excess sludge pipe shall be 150 mm.
Sludge tank shall be constructed in M 25 grade concrete and as per IS 3370. Above sludge
sump there shall be pump house. This shall be RCC framed and brick masonry structure.
Minimum clear height of the pump house shall be 4.5 m from the plinth level. It shall be
provided with rolling shutter and doors and windows as per technical specifications. EOT
of minimum 5 T capacity shall be provided in the pump house to lift the pump assembly.
Flooring of the pump house shall be IPS flooring. Pump house shall be plastered from
inside and from outside as per tender specifications. Entire pump house from inside and
from outside shall be painted with approved colour and make as directed by engineer-incharge. Sludge sump shall be painted inside with bituminous paint.
Minimum size of the sludge sump in shall be 7 m dia x 3 m SWD.
Return sludge pumps
Type
No. of pumps
Capacity of each pump
:
:
:
Head
Drive
:
:
Submersible
Total 6 (4 W + 2 S)
270 m3/hr
Suitable for 80% recirculation of
average flow
Minimum 8 m
Electric motor of suitable HP
3.2.10 Sludge Thickener
Sludge thickener shall be provided for thickening of primary and secondary sludge. The
tank shall have oil skimmer, trough, scum baffle, weir plate and sludge scrapping
mechanism. There shall be provision of taking primary and secondary sludge either in one
thickener or in both thickeners by suitable piping and valve arrangement.
Scum from thickener shall be taken to the sludge digester. In case of pumps, working and
stand arrangement shall be provided. The scrapper shall have neoprene squeezes. The tank
shall be provided with telescopic sludge withdrawal arrangement. The thickener shall have
central drive with TEFC motor and reduction gear. The service factor for the gear will not
be less than 2.5
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The tank shall be constructed in M 25 grade concrete and as per IS 3370. MW ladder is
provided for access to the top of the unit and to the operating platform.
No. of unit
Solid surface loading
MOC of sludge scrapper
mechanism
:
:
:
2
30 kg/day/m2
Minimum size of each sludge thickener shall be 12 m dia x 3.5 m SWD

Sludge thickener shall have provision of addition of dilution water from secondary clarifier
outlet to meet hydraulic loading specified in CPHEEO manual. Pumps if required for this
purpose shall be minimum 1W + 1S of suitable capacity.
Pumps min 1W + 1S of required capacity (minimum capacity of these pumps shall be 50
m3/hr), if required, shall be provided to transfer thickened sludge to sludge digester.
Supernatant from both thickeners shall be taken to aeration tank either by gravity or by
pumping.
3.2.11 Sludge Digester
Anaerobic sludge digester shall be provided to digest sludge from sludge thickener. There
shall be two sludge digesters. Digester tank shall be constructed in M 25 grade concrete
and as per IS 3370. RCC staircase of 1200 mm wide is provided for access to the top of the
unit and to the operating platform. The digester shall be covered at top with RCC dome.
Digester shall be equipped with gas mixing system for effective mixing. Sampling ports at
suitable points shall be provided in the digester. Minimum solid retention time shall be 20
days.
Minimum size of each anaerobic digester shall be 2 Nos. 16.5 m dia x 8 m SWD
3.2.12 Gas Mixing System
The gas re-circulation system shall provide complete and homogenous mixing of the
digester contents including intermixing of the raw and digesting solids and breaking of
scum blanket. For maximum intensity of mixing the full discharge of compressed gas shall
have upward action minimizing the scum formation.
Gas will be taken from the gasholder and conveyed by pipes to the gas compressors, from
where it will be fed to the digester. The pipe shall enter from top of digester dome such as
to mix the entire digester contents with practically no dead zones and to prevent sand buildup on the floor. Gas flow indicator (sight glasses) to indicate flow of compressed gas
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through each pipe and facility to clean individual pipe by water pressure or flexible rods in
case of chock up, without interrupting digester operation, shall also be provided. All
connected piping with necessary fittings and support and safety/protective devices shall be
provided.
All electrical motors, local control units and associated instrumentation, etc. mounted in the
digester area shall be certified for use in a zone 1 hazardous area and have an flame proof
enclosure.
Gas mixing system shall be complete along with necessary accessories such as gas meter
for each digester, drip traps at suction and discharge pipes, electric controls, spare parts and
lowering / hoisting arrangement required in the digesters.
Dial / manometer type pressure gauge on the suction line indicating pressure to the extent
of + 300mm water column shall be provided. Dial type pressure gauge shall also be
provided on delivery line.
Protective devices such as gas pressure relief valve cum vacuum breaker assembly and
flame trap shall be provided. The gas pressure relief valve (water seal type) shall be
required to function between 200mm to 250mm water pressure.
3.2.13 Gas Holder
The gas produced in the Anaerobic Digester is to be led to the Gasholder through a
moisture trap and gas flow meter. The tap-offs are provided after the gas pipe enters the
Gasholder, one going to the generator room for supply to gas engines and the other to the
gas flaring equipment.
The biogas holder will be of the wet type with a sealing of water. The biogas holder would
be a RCC circular structure. The gas dome would be fabricated from mild steel plate
having minimum 6 mm thickness. Guide rails embedded in RCC structure facilitate the
vertical movement of the gas dome. The gas dome surface shall be coated with 350-micron
thickness three coats of Epoxy coating.
One pressure release valve will be provided at the top of the dome, which will open out
when the level reaches 100% value. One High-Level limit switch will be provided at 95%
to give an audible alarm signal in the control room.
At low-level, say 20%, the running engines will be shut off and the biogas holder will be
allowed to rise again. However, in case of heavy leakage, or otherwise, if the level goes to
a very low level of say 5%, the Vacuum Breaking Glass will break and will prevent the
biogas holder from any damages due to vacuum condition. The dome of clean gas holder
shall have provision for placing weights to ensure desired required sewage gas pressure for
100% sewage based gas engine.
Min size of Gas Holder shall be 1 No. 7.5 m dia x 5 m deep.
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3.2.14 Chlorine Contact Tank

For chlorination or disinfection of final treated sewage a provision shall be made so that no
harm is caused to the receiving water such as river. Overflow from each secondary clarifier
shall be collected in common chamber from where it shall be taken to chlorine contact tank
by RCC channel. In the proposed CCT treated sewage from existing treatment plant is also
taken. Necessary piping arrangement is to be done.
A Chlorine Contact Tank shall be provided for dosing of chlorine from the chlorination
system to the sewage from secondary clarifier. The tank shall be constructed in M 25 grade
concrete and as per IS 3370. RCC platform 1200 mm wide with railing as per
specifications shall be provided. RCC staircase 1200 mm wide shall be provided for access
from the ground level to the top of the unit and to the operating platforms.
Baffle walls shall be provided to achieve proper disinfection. The baffle walls shall be
constructed in brick masonry with CM 1:4 and 20 cm thick plaster in CM 1:3 on either
sides.
The inlet and outlet pipes shall be designed for peak flow.
Design Flow
Number of Units
Detention time (minimum)
Freeboard
:
:
:
:
32 MLD
1 no.
30 minutes for average flow
0.5 m
Minimum size of the chlorine contact tank shall be 20 m x 10 m x 3.5 m SWD

3.2.15 Chlorination System
Average flow
Peak flow
Number of Units
Type
Chlorine Dosing
Residual chlorine
Capacity of each chlorinator
:
:
:
:
:
:
:
32 MLD
72 MLD
2 (1W + 1S)
Vacuum
Max 5 mg/l
0.5 mg/l
Min 7 kg/hr
Chlorination system covering chlorine cylinder, chlorinator, water feed pumps, piping and
other ancillary shall be provided in the chlorine house. Chlorine house arrangement and
EOT of min 2 T capacity etc complete. of minimum 80-sqm plinth area shall be provided.
It shall have sufficient ventilation as per latest norms for safety purpose with necessary
lifting
3.2.16 Sludge Dewatering System
Sludge dewatering system shall comprise of centrifuge house which includes digested
sludge sump, mixer, centrifuge feed pumps, poly dosing tank with mixers and centrifuge
unit. The minimum size of the centrifuge house shall be 10 m x 15 m.
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Filtrate from the sludge shall be taken to aeration tank either by gravity or by pumping.
3.2.16.1 Digested Sludge Sump and Mixer

Digested sludge from sludge digester is collected in the digested sludge sump. The
minimum size of the sludge sump shall be 4 m x 4 m x 3 m SWD. The entire civil
construction shall be in M 25 grade concrete.
Slow speed mixer (100 RPM) shall be provided to ensure proper blending of
polyelectrolyte into the sludge and to keep the sludge in suspension. The material of
construction of the mixer shall be SS 316.
3.2.16.2 Polyelectrolyte Dosing

The polyelectrolyte will be dosed and blended with the sludge in the Filter Press sump.
Minimum does of polyelectrolyte shall be 2.5 kg/T of dry solids in sludge. There shall be
two poly-dosing tanks. Min volume of each dosing tank shall be 9 m3. Each tank shall be
equipped with slow speed mixer (100 RPM) to prepare polyelectrolyte solution. To feed
the solution into sludge sump by dosing pumps.
3.2.16.3 Centrifuge Feed Pump

The sludge pumps will be positive progressive cavity displacement types. There shall be
two pumps (One Working + One Standby) for pumping this sludge to the Centrifuge. The
minimum capacity of the pump shall be 7 m3/hr. Pumps will have solid handling capacity
of not less than 40 mm sphere.
Pump and motor will be mounted on a common GI fabricated base frame. The coupling
will be flexible coupling. The motor will be TEFC and driven through belt drive.
3.2.16.4 Centrifuge
Digested sludge shall be pumped to the centrifuge unit for dewatering. Centrifuge shall be
fully automatic. It shall be provided at suitable elevation for the dried sludge from
centrifuge to be collected in a trailer/container situated below it.
Centrifuge shall be operated for 16 hours in a day and floor mounted. It shall be suitable to
handle combined digested sludge from digester. The centrifuge unit shall be suitable to take
sludge of 6% concentration.
The material of construction of all parts coming in contact with the liquid shall be in SS
316.
Number of Units
Operation
Dry solids in dried sludge
Capacity of the each centrifuge unit
:
:
:
:
2 (1W + 1S)
16 hours running per day
20 25 percent
Minimum 7 m3/hr
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3.2.17 Outlet Channel

Treated sewage after chlorine contact tank shall be taken to the river through RCC channel.
Parshal flume along with ultrasonic flow meter shall be provided after chlorine contact tank
in the RCC channel to measure the flow. The length of the channel shall be as per approved
layout. Capacity of the channel should be such that it can carry peak flow.
The channel shall be constructed in M 25 grade concrete and as per IS 3370. RCC platform
1000mm wide with railing as per specifications shall be provided.
The hydraulic design of the entire treatment plant shall be such that the invert level of the
outlet channel/pipe at final discharge point (at river) shall be 0.2 m above the HFL i.e.
554.70 m
3.2.18 Interconnecting Piping and Valves
All interconnecting piping including valves, specials and other appurtenances, auxiliaries
and accessories required as per process design and scope of work. All the piping, valves,
specials shall be designed for peak flow. All valves shall be Knife gate valves.
In case of pumping mains thrust blocks shall be provided whenever required. In case of
buried pipes warning tapes shall be provided of the appropriate colours.
All interconnecting piping unless otherwise stated shall be DI K-9. Minimum diameter of
the any pipe shall be 150 mm.
3.2.19 Electrical Works
The Employer will make available power supply from their local transformer to the
proposed STPs main electrical panel room. The entire plant will be operated on 415 V, 3Phase, 50 c/s, 4-wire system. The electrical system proposed for the STP shall include the
following components;
1.
2.
3.
4.
5.
6.
415V Switchgear,
Motor Starters,
Safety Earthing,
Cables and Cabling System,
Internal Lighting, and
Plot and area Lighting.
The scope starts from Employers supply point at STP premise (MEP room) upto motor
terminals. The scope also includes lighting and earthing. The Sub Contractor shall work out
the details based on his equipments power consumption. The execution should take care of
I.E. rules, Electricity Boards requirement and other local authorities and site condition.
The sub-panels are to be provided and located near the respective load centres. All motors
and panels for operation of various are to be supplied as part of the equipment, the same
have not been considered as part of scope of work for electrical work. However, these
should meet the requirements as specified under electrical works. The major items of work
for the electrical works will be as under:
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1.
2.
3.
4.
5.
6.
7.
8.
L. T. Panels generally will be as following:

Main Electrical Panel (MEP)
Power distribution panel (PDB)
L.T. Power and control cabling with cable accessories
Local Push Button Stations
Lighting for all buildings, panel room and workshop
Earthing
Instrumentation including Instrument-cum-Annunciation panel
3.2.20 Operation and Maintenance

The proposed treatment plant shall be operated and maintained by the contractor for a
period of 36 months as per the scope of work mentioned in the tender document.
3.2.21 Plant Utilities
3.2.21.1 Fire Extinguishers

The portable fire extinguishers with ISI mark of approved make shall be provided at the
MEP room, chlorine house and centrifuge house.
Each building shall be provided with following portable fire extinguishers
Dry chemical powder type fire extinguishers of 3.2 kg capacity - 6 cylinders

Buckets filled with dry clean sand 6 Nos
All buildings shall be provided with manual fire alarm system connected with main control
panel. The alarm system shall be with pillboxes and hooters. The layout of the fire alarm
system shall be in accordance with the relevant ISI.
3.2.21.2 Site Office

The contractor shall provide temporary site office during entire contract period. The
minimum area of this office shall be 40 m2. It shall have atleast two rooms each of 20 m2
area. One of the rooms shall be equipped with air condition.
The contractor shall provide following for NMC use in the office of NMC for this project
for entire contract period.
Sr
1
Item of work
DELL Laptop
Work
Dell Inspiron 15
Printer
01 No: HP or equivalent- All in one- A4 size Xerox, Scanner,

Fax, Printer, Laser Mode.
The above computer and printer shall be property of NMC.
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3.3
DETAILED SCOPE OF WORK FOR SEQUENTIAL BATCH REACTOR

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Inlet Chamber
Sequential Batch Reactors with air diffusers and air blowers
Chlorine House
Sludge thickener with sludge sump and pumps
Plant Utilities
Required site development including levelling and grading to improve the
For scope of work for Inlet chamber, manual and mechanical screens, mechanical and
manual grit removal system refer the clause Nos. 3.2.1, 3.2.2, 3.2.3 and 3.2.4.
3.3.1
Sequential Batch Reactor

From grit chambers sewage shall be taken to the SBR unit by gravity. Outlet of SBR unit
shall be taken to the chlorine contract tank by gravity.
Biological treatment for removal of carbonaceous BOD shall be provided by Sequential
Batch Reactor System (SBR). The SBR system shall be designed in such a way that it shall
have continuous raw sewage inflow and outflow. The system shall be designed to take care
of peak flow and shall have following features.
Complete Mix Kinetics

DO Control in proportion to organic loading within the current operating cycle.
Quiescent settling for optimizing the clarification process.
The system shall provide for:1. Equipment for mixing and aeration, wherever required, to enable separate time
phases
2. Withdrawal of treated sewage at suitable velocity to prevent short circuiting.
3. Efficient scum withdrawal system.
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4. Dynamic control of Air Blower operation to achieve a minimum preset DO of 2

mg/l within the SBR system.
Design criteria for SBR
Maximum F/M ratio 0.1
Minimum HRT 17 Hrs.
Minimum SRT 20 days.
SBR process basins will be constructed in M25 concrete and as per IS 3370. RCC staircase
is provided to the basin for access from the ground level to the operating platforms.
Walkways / platforms with chequered tiles shall be provided as per requirement during
detail engineering. All platforms and walkways shall be provided hand railings. 1.2m plinth
protection along periphery shall be provided. Entire structure from inside and from outside
shall be painted with approved colour and make as directed by engineer-in-charge.
Decanter
The Decanter shall be Mechanical, Moving, Trough type. The wetted Decanter components
shall be in SS 304. All piping shall be in SS 304 / FRP. Any other components shall be in
SS 304
Bidders shall provide evidence of having supplied, installed, commissioned and operated
similar type of Decanter in a plant of the size required for qualification Bidders shall
provide cross sectional drawing to clearly establish the above requirement.
The SBR System shall have the following Controls:
The control system shall be designed to optimize the SBR process while minimizing
operator attention and to accommodate the continuous maximum daily flow without
adjusting cycle structures. The control software program shall be factory tested prior to
installation at the jobsite.
The control system shall be a timer based system with level overrides and shall provide
control, sequence, monitoring, and alarm annunciation capabilities. The operator shall be
able to access the timer values and set points through the operator interface panel to allow
for adjustment of cycle times and system flexibility. The control system shall be designed
to automatically accommodate the plant's full range of loads and flows.
A complete control system (consisting of two identical panels) shall be provided as
described in the following and as shown on the contract drawings. The control system
shall include 220 volt control circuit breaker, microprocessor control, operator interface
display, indicator lights, and HAND-OFF-AUTOMATIC selector switches.
PLC based control system

REMOTE ACCESS MODEM
Shall provide with facility of remote monitoring, control and diagnosis of plant
OPERATOR INTERFACE DISPLAY
Shall provide with facility of Local monitoring, control and process parameter adjustments
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SOFTWARE
The PLC function shall be to control, sequence, and monitor the continuous flow and
constant level SBR system.
PHASE CONTROL, the regulation of the process cycles of the continuous flow and
constant level SBR system up to the maximum daily flow of the plant.
AERATION CONTROL, the regulation of the aeration and mixing systems to achieve
optimum process control.
COMPONENT MONITORING the monitoring of components for fault conditions and the
orderly alarming and logging of the fault.
Diffusers, air blowers and air piping shall be provided as per clause No. 3.2.7.
Outlet of SBR unit shall be taken to the chlorine contact tanks by gravity. Chlorination
contact tank and chlorination unit shall be provided as per clause No. 3.2.14 and 3.2.15.
Excess sludge from SBR unit shall be taken to the sludge thickener and mechanical sludge
dewatering unit. The sludge thickener and sludge dewatering unit shall be provided as per
clause No. 3.2.10 and 3.2.16 respectively.
Scope of work for outlet channel, electrical works, O & M and plant utilities shall be as per
clause No. 3.2.17, 3.2.18, 3.2.19, 3.2.20 and 3.2.21.
3.4
DETAILED SCOPE OF WORK FOR UASB FOLLOWED BY AEROBIC

TREATMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Inlet Chamber
Flow distribution system
UASB Reactors
Moving Bed Bio Reactor or Aeration tank
Secondary settling tank
Gas Holder
Chlorine House
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14. Plant Utilities

15. Required site development including levelling and grading to improve the
For scope of work for Inlet chamber, manual and mechanical screens, mechanical and
manual grit removal system refer the clause Nos. 3.2.1, 3.2.2, 3.2.3 and 3.2.4.
3.4.1
Waste Water Flow Distribution

In order to achieve uniform distribution of sewage throughout the UASB reactor, the
following scheme is developed. The sewage from grit chamber is diverted to Division box.
From here the sewage is fed to the distribution boxes by CI / DI pipeline separately with
knife gate valve for further distribution. Two such distribution boxes are provided per
UASB reactor.
3.4.1.1 Division Box

The Division Box will receive the flow from the grit chamber. The flow will then be split
proportionately to eight equal parts with adjustable aluminum overflow weir plates and
distributed to Distribution Box via 350 mm diameter CI pipe. Sluice valves including all
specials shall be provided on all the outlet pipes of Division Box. RCC access platform,
staircase, railing and covers over division boxes are provided as per requirement.
3.4.1.2 Distribution Boxes

Two distribution boxes are provided for each reactor, each of this box shall consist one
central compartment and 8 individual compartment. The Distribution Box will receive the
flow from the Division Box and distribute to the UASB reactor. 180 OD HDPE pipes will
be provided to convey this flow to feed inlet boxes placed on top of UASB reactor. HDPE
pipe should have a minimum of three numbers of double flanged joints in between for ease
in maintenance. RCC access platform, staircase, railing and covers over distribution boxes
are provided as per requirement.
3.4.2
UASB Reactors
The UASB system shall be provided to treat the average flow of 32 MLD. There shall be 4
nos. of UASB reactors. Each reactor shall be painted with bitumen paint from inside up to
bottom of gas dome beam and with polymer paint from gas dome beam bottom to top of
the reactor. The UASB system shall consist of the following sub-systems:
Feed inlet system

Gas collection system
Treated Effluent collection system
Sludge discharge system
3.4.2.1 Feed Inlet System

Sixteen (16) nos. FRP feed inlet boxes shall be provided on the top of the each UASB
reactor. Each FRP feed Inlet Box is connected with Distribution box through 200 OD
HDPE feeding pipe (pressure class 10 kg/sq.cm) to convey the raw sewage into the UASB
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reactor. Feeding boxes shall be one piece moulded FRP boxes having a central
compartment and 14 individual outlet compartments. The flow from central compartment
of feed inlet box shall be distributed over 14 individual outlet compartments through Vnotches. There should be V notches with 900 angles and crest of the V notch should be at
the same level to ensure the equal distribution of the flow. These V-notches shall be made
of FRP and will be adjustable in nature. The thickness of the FRP sheet to be used shall be
8 mm. From individual compartment of Feed Inlet Box, raw sewage will be distributed
uniformly at the UASB reactor bottom by 150 OD HDPE pipe (pressure class 10
kg/sq.cm).
Down take pipe shall be rested on RCC pre cast blocks of size 200 x 200 x 200 mm with
SS clamping. All clamping and nut bolts shall be in SS 304. Clamp shall be made of 3 mm
thick x 25 mm wide strip of SS 304.
3.4.2.2 Gas Collection System

In one UASB reactor, there shall be 8 bays of gas collectors of FRP. Each gas hood is an
inverted U shaped box. The gas hoods are covered with a pre-cast concrete slabs to counter
balance the upward pressure of the gas. The size of pre cast slab shall be designed in such a
manner to handle it easily. Pre cast concrete slab shall be casted on vibrating platform.
These gas hoods are supported over PVC truss arrangement and shall be of one piece
moulded of minimum 8 mm thick FRP. Each reactor is to be provided with deflector beams
running along the width of the reactor. Two lateral deflector beams are also to be provided
on the two walls of the reactor. The rising gas is deflected by these beams into the hoods at
an angle of 500. The cover plates are of rigid PVC 6.0 mm thick running along the whole
width of the reactor. The cover plates are supported on extruded rigid PVC double angle
frames spanning between the gas hood and the deflector beam. FRP gas hood will collect
gas from GLSS and convey it to the main gas pipe through 50mm flexible nylon reinforced
pipe. FRP gas dome should not be interconnected.
PVC angle trusses shall be supported on deflector beam by rigid PVC pipe of 10 mm thick.
PVC pipe shall be fixed in deflector by RCC. All clamping and nut bolts shall be in SS
304. Clamp shall be made of 3 mm thick x 25 mm wide strip of SS 304.
3.4.2.3 Treated Effluent Collection System

The effluent is collected in FRP channels running along the width of the reactor. Each FRP
channel discharges through openings into the main RCC channel running along both side of
the reactor. 8 nos. of effluent gutters of FRP, one on either side of each gas collector shall
be provided. To prevent any scum from entering the FRP effluent channels a FRP baffle is
provided. 90 degree V notches shall be provided to FRP channels for uniform distribution.
The FRP baffle plates and gutters shall be a single piece moulded of appropriate length but
not less than 3.0m in length. The FRP baffle is to be provided of 8.0 mm FRP sheet. The
common effluent channel shall be connected to a RCC pipe, which shall carry the treated
effluent to aeration tanks. The pipe shall be lined internally by polymer paint to prevent any
damage to concrete surface due to gases.
3.4.2.4 Sludge Collection

Each reactor shall have four RCC sludge withdrawal chamber two on each longer side. The
excess sludge is withdrawn from each reactor from two levels. Sludge is withdrawn
through cast iron double flanged class B pipes (DN200) and each outlet from reactor is
provided with a ball valve (200 mm dia aluminium body) of pressure 6 Kg/cm2 with
flushing arrangement. A sludge chamber is provided at each vertical row of pipes for
operation of the valves. The sludge is then taken to the sludge pump house sump via
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sludge pipe (DN 200 CI, S&S Class LA). From Sludge sump, it shall be pumped to the
centrifuge unit for dewatering. One additional outlet at settling zone level shall also be
provided for flushing of sludge pipes.
200 mm dia FRP guide pipe shall be provided in the deflector beam. This pipe shall be
placed in vertical position from top of the reactor up to 150 mm below bottom of deflector
beam at 4 different locations in each reactor.
3.4.2.5 Design criteria for UASB Reactor

Solids Retention Time
Design temperature
Sludge Bed Concentration
Maximum Sludge Bed Height
Average Up flow velocity
Maximum Up flow velocity
Maximum aperture velocity
Angle of gas collector
Hood width
Settling zone surface %
Feed inlet point distance
Overlap of gas collector over
deflector beam
C/C distance between gas domes
Aperture percentage
Angle of deflection beam
Average retention time in settling zone
Volumetric loading
Freeboard
:
:
:
:
:
:
:
:
:
:
:
38 days
20 deg C
65 Kg TSS/cum
90 % of height to Gas Collector
0.55 m/h
1.13 m/h
5 m/h
50 degrees to horizontal
0.44 m
75 %
2.0 m (maximum)
:
:
:
:
:
:
:
0.15 m
4.0 m
22.5 %
45o
1.0 hrs. (Minimum)
1.12 kg COD / cum / day
0.5 m
There shall be 4 Nos. of UASB reactors. Minimum size of each reactor shall be 28.0 m x
24.0 m x 5.5 m SWD.
3.4.3
Aeration Tank (MBBR unit)

For MBBR there shall be minimum two independent streams of equal capacity to take care
of designed peak flow.
MBBR basins will be constructed in M25 concrete and as per IS 3370. RCC staircase is
provided to the basin for access from the ground level to the operating platforms.
Walkways / platforms with chequered tiles shall be provided as per requirement during
detail engineering. All platforms and walkways shall be provided hand railings. 1.2m plinth
protection along periphery shall be provided. Entire structure from inside and outside shall
be painted with approved colour and make as directed by engineer-in-charge.
The bio film carrier elements are formed as 3 concentric tubes with internal spacing walls
and external surface corrugated. The division honeycomb formed with innermost room
being circular shaped. In the middle there are 6 chambers formed by the 6 spacing walls
between the inner pipe and the middle ring. The outer part consists of 12 compartments
formed by the middle tube and the outer corrugated ring, also containing 12 equidistant
short ribs.
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Nominal diameter
Nominal length
Material
Density
Effective Surface Area
Loading rate
:
:
:
:
:
:
25 mm
10 mm
Polyethylene, high density (HDPE)
95 kg/m3
600m2/m3
4.8 kg BOD/m3
Makes of BIO FILM Carrier

1. ANOX KALDNES- NORWAY
2. GLOBAL ENGINEERING - UAE
3. MASS TRANSFER UK
For MBBR unit diffuser and air blower requirement shall be as per clause No. 3.2.7
3.4.4
Aeration Tank
The bidder can provide aeration tank without media. In this case specifications shall be as
follows
Overflow from all four UASB reactors shall be conveyed through a single RCC pipe to a
common chamber before aeration tanks. The Aeration Tank shall be constructed into two
compartments. Provision shall be made to receive active return sludge from return sludge
pumps. The inlet and outlet launders / pipes shall be designed for peak flow.
The aeration tanks will be constructed in M 25 grade concrete and as per IS 3370. The tank
shall have inlet launder, outlet launder and Aerator platforms with handrails. Isolating gates
in the inlet and outlet launders of each tank shall be provided for maintenance purpose.
RCC staircase 1200 mm wide is provided to each aeration tank for access from the ground
level to the operating platforms. All platforms and walkways shall be provided with hand
railings as per tender specifications. 1.2 m Plinth protection along the periphery shall be
provided as per technical specifications.
The outlet pipe suitable diameter and length shall be provided from aeration tank to the
secondary clarifier. The carrying capacity of this pipe shall be suitable for peak flow plus
return sludge flow.
Total Average flow
No of tanks
Type of aeration
Inlet BOD5 at 20 0C
Inlet suspended solids
F/M ratio
MLSS
MLVSS / MLSS
Min free board
Max depth of aeration tank
:
:
:
:
:
:
:
:
:
:
:
32 MLD
2 Nos.
Diffused aeration
90 mg/l
100 mg/l
0.15
3500 mg/l
0.8
1.2
0.6 m
6 m (liquid depth)
Minimum volume of the aeration tank shall be 7400 m3.
CONTRACTOR
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Overflow from aeration tank or from MBBR unit shall be taken to the secondary clarifier.
The bidder shall provide secondary clarifier and return sludge pump house as per clause
No. 3.2.8 and 3.2.9.
Overflow from secondary clarifier shall be taken to the chlorine contact tank by gravity.
Chlorination contact tank and chlorination unit shall be provided as per clause No. 3.2.14
and 3.2.15.
Sludge from UASB and secondary settling tank shall be taken to sludge mechanical sludge
dewatering unit. The sludge dewatering unit shall be provided as per clause No. 3.2.16.
Gas holder shall be provided as per clause No. 3.2.13
Scope of work for outlet channel, electrical works, O & M and plant utilities shall be as per
clause No. 3.2.17, 3.2.18, 3.2.19, 3.2.20 and 3.2.21
CONTRACTOR
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4 START UP AND PERFORMANCE RUN

This section is valid for three treatment process
4.1
4.1.1
TEST ON COMPLETION
General
Prior to the commencement of Tests on Completion the Contractor shall submit for
approval the following:
Site Acceptance Test Documents
As-Built Drawings
Operation & Maintenance Manuals
Tests on Completion shall not be commenced until the aforementioned documents are
approved.
The initial charges necessary for Tests on Completion shall be provided by the Contractor.
Electricity required for Tests on Completion will be provided by NMC free of charge for a
period not exceeding 30 days. In case the test on completion period exceeds 30 days, the
cost of power till start of performance run shall be borne by contractor.
The cost of any consumables and chemicals required for the Tests on Completion shall be
borne by the Contractor.
4.1.2
Dry Test Requirements
4.1.2.1 General
As a minimum requirement, the following dry tests shall be carried out as a general
requirement:
a general inspection to check for correct assembly and quality of workmanship,
a check on adequacy and security of Plant fixing arrangements
a general check to ensure that all covers, access ladders, water-proofing, guard railings
etc. are in place,
a check on damp proofing, rust proofing and vermin proofing and particularly the sealing
of aperture between building structure , chambers, etc. and the outside.
4.1.2.2 Civil and Building Works

As a minimum requirement the following dry tests shall be carried out on the civil
engineering and building works:
Check for the presence of foreign bodies in pipe work and structures.
4.1.2.3 Mechanical Works

As a minimum requirement the following dry tests shall be carried out on the mechanical
systems:
Carry out preliminary running checks as far is permitted by circumstances in order to
ensure smooth operation of Plant.
CONTRACTOR
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4.1.2.4 Electrical Works

As a minimum requirement the following dry tests shall be carried out on the electrical
systems:
Check phasing and polarity
Carry out point to point check on all cables;
Check on security of cable terminations
Check on completeness and adequacy of earthing systems;
Check setting on protection relays, sizes of fuses and motor overload settings;
Carry out checks on cabling systems in accordance with the requirements of the
relevant standards;
Check operation of main circuit breakers by secondary injection methods;
Check rotational direction of plant;
Check instrument loop integrity, functionality and calibration;
Check operation of standby generator installation and mains/generator changeover
procedures; a 4 hrs load test (using the normal load of the Works) shall be carried
out on the generator when the load is available;
Check plant functionality
Check functionality of the central MMI and its power supply;
4.1.3
Process Plant Item / Equipment

All process plant items/equipment shall be tested to ensure they meet the Employers
Requirements for quality of workmanship, construction and performance.
4.1.4
Hydraulic Wet Test Requirement

Hydraulic wet tests shall be carried out on completion of dry tests.
Potable water shall be used for hydraulic wet tests. The purposes of the tests is to prove as
far as is practical the hydraulic performance of the Works. In order to demonstrate this the
Contractor shall ensure that each part of the Works is hydraulically loaded to its maximum
rated load throughout for a period of at least seven days at twenty-four hours intervals.
In order to ensure a sufficient supply of potable water to carry out these tests the Contractor
shall provide facilities for the disposal off site in an approved manner.
In order to remove doubt the following tests inter alia shall be carried out.
Pressure testing of all piped systems laid direct in ground in accordance with the
relevant standards;
Fill all structures and check for leaks as per IS:3370;
Running of all pumped systems in order to check for
Correct functionality
Absence of leaks
Correct running temperatures
Smoothness of running and the absence of undue vibration or stress;
Check drive running currents
Carry out calibration of instruments where appropriate
Carry out valving, diversion etc. to fully hydraulically load each process element
(or where there is a requirement to withstand an over load), overload each process
element;
Demonstrate correct functionality of electrical, control and instrumentation
systems.
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The Contractor shall simulate where practical the conditions that will prevail when
operating as a process in order to demonstrate the correct functionality of process control
loop etc.
During these tests a check on the performance of Plant shall be made, as far as site facilities
will allow, to compare its site performance with the factory test data and to identify and
constraints on performance due to site conditions.
4.1.5
Process Wet Test

On approval by the NMC the Contractor shall carry out process wet tests.
Raw water shall be used as the primary feed stock for process wet tests. These tests shall be
carried out to demonstrate the process performance of the Works. In order to demonstrate
this, the Contractor shall ensure that each part of the Works is located to its rated
throughput (including a period of overload if required in order to demonstrate compliance
with the Employers Requirements) for continuous stable operating period of not less than
48 hours.
The Contractor shall provide facilities for the disposal off site in an approved manner.
The following tests inter alia shall be carried out;
Check and rectify leakage on civil structures, pumps and pipework;
Running of all pumped systems in order to check for;
Correct functionality,
Absence of leaks,
Correct running temperatures,
Smoothness of running and the absence of undue vibration or stress,
Check drive running currents where the solution pumped is different from that
pumped during hydraulic wet tests;
Carry out calibration of instruments;
Carry out valving, diversion etc to fully hydraulically load each process element
(or where there is a requirement to withstand an over load), overload each process
element;
Demonstrate correct functionality of electrical, control and instrumentation systems
not checked during dry or hydraulic wet tests or which may have changed as a
result of the different operating conditions now prevailing.
On completion of process wet test on the various parts of the works the Contractor shall run
the plant as a whole in order to demonstrate the full functionality and performance of the
Works at various throughput rates for a continuous period of not less than 7 days. In this
period power utilised by the contractor shall be compared with the guaranteed power
consumption given by the contractor. This shall be considered as completion of Test on
Completion and shall be certified by NMC.
CONTRACTOR
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4.2
4.2.1
PERFORMANCE RUN AFTER START UP

General
On successful completion of Test on Completion i.e. Start up and commissioning,
certified by NMC, Contractor should start the performance run of the plant for 3 months.
The Contractor is to carryout Operation & Maintenance (O&M) of the whole plant
including civil works for 3 (three) months under performance run. NMC shall monitor the
operation and maintenance by the Contractor.
During performance run period, the Contractor shall provide following as minimum for
round the clock operation.
Staff
Plant in charge
Chemist
Operators
Maintenance unit
Helpers
Watchmen
:
:
:
:
:
:
One
One
One for each shift
One fitter, One electrician
One for each shift
One for each shift
Chemicals and consumables: As required

Spares: As required for replacement during performance run period. The spares used from
the spare supplied under the contract shall be replaced by the Contractor.
NMC shall supply power and water during Performance Run period free of cost. All other
material such as chemicals, consumables, lubricants, tools & plants, spares etc shall be
provided by the contractor. The contractor, if required, shall provide activated sludge or
any other material for the stabilisation of the plant.
The Contractor shall provide operators for various units/plants for three shifts and other
staff/supporting personnel in general shift.
The Contractor shall submit a weekly report to the Employer, about the operation and
maintenance indicating the manpower, electric power, chemicals and other consumables
consumed and also problems faced and rectified.
During this period, the Contractor shall ensure that the design treated sewage quality
standards are met in accordance with the specification within the rate of power and
chemical consumption as committed by the Contractor. The raw and treated sewage
analysis pH, SS, BOD and oil & grease shall be carried out on daily basis from the day of
commissioning at a reputed laboratory as approved by Engineer-in-Charge. 90% of the
treated sewage samples should fall within prescribed limits of the treated sewage. The
sampling location for raw sewage shall be at raw sewage sump and that of treated sewage
shall be at outlet of chlorine contact tank.
The analysis of sewage for the above parameters at different locations such as outlet of
secondary clarifier shall also be carried out on weekly basis. The Contractor shall take
CONTRACTOR
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immediate steps to correct the operation of the plant to meet the guaranteed performance.
The charges for analysis at the laboratory are to be borne by the Contractor.
The Contractors responsibility includes the safety and security of the works/plants during
the course of performance run of three month.
The Contractor shall provide the key personnel for performance run with the minimum
qualification and experience as given below.
Sr.
Category
1.
Plant
charge
2.
3.
4.
4.3
Qualification and Experience
in Graduate in Engineering/Technology (Civil/ Environmental

Engineering) having 5 years of experience in O & M/
Maintenance of water /wastewater treatment plant.
Plant Operator Diploma in Engineering/Technology (Civil/ Environmental/
Chemical Engineering) having 3 years of experience in
Operation/ Commissioning of water/wastewater treatment
plants.
Chemist
Graduate in Environmental Science/ Chemistry having 5
years of experience in sampling/ analysis in water
/wastewater treatment plants.
Electrician / Diploma in respective field with 5 years of experience in
Fitter
erection, commissioning and O&M of M&E equipment in
water/ wastewater treatment plants.
PERFORMANCE RUN CERTIFICATE

The conditions for issuance of a Performance Run Certificate as detailed in the Conditions
of Contract shall comprise:
1.
The completion of the three months operation and maintenance under performance
rum of the treatment plant to the satisfaction of NMC.
2.
90% of the treated sewage samples fall within the prescribed limits of the treated
sewage as mentioned in the tender document.
3.
The O & M Manuals have been updated following three months operational
experience and approved by NMC.
4.
All defects identified during the three months operation of the works have been
rectified
NMC shall issue a Completion Certificate for Performance Run of Plant after successful
completion of Performance Run of plant for 90 consecutive days by Contractor to the
satisfaction of NMC.
CONTRACTOR
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EXECUTIVE ENGINEER
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5 OPERATION AND MAINTENANCE

This section is valid for three treatment scheme
5.1
SCOPE OF WORK
The contractor is to operate, maintain and monitor the proposed 32 MLD STP for 36
months after successfully completing performance run. The scope of work is given below
but not limited to the following. This may include other incidental items of work connected
with the regular operation & maintenance of the treatment plant as decided by Engineer-inCharge from time to time.
The contractor shall execute separate agreement for O & M with Executive Engineer (E &
M)
1.
The contractor shall ensure proper running of the plant to give the desired effluent
standards i.e. BOD less than 20 mg/l, TSS less than 30 mg/l, O & G less than 10
mg/l. The contractor shall also be responsible for overall maintenance of the plant
i.e. civil, electrical, and mechanical system. The contractor shall also be responsible
for all repairs of equipment/machinery.
2.
The contractor shall monitor the quality of raw and treated sewage. The contractor
shall intimate and take adequate action to ensure smooth and satisfactory running of
the plant. The raw and treated sewage analysis for DO, pH, SS, BOD and oil &
grease shall be carried out on daily basis during O & M period at any MPCB
approved laboratory. The above analysis shall also be carried out once in a week for
water samples collected from up stream and down stream side of the site of treated
sewage disposal.
Further, additionally, the above analysis shall also be got carried out by the
contractor at his cost once in a week at the MPCB / its approved laboratory as
directed by engineer in charge.
3.
The contractor shall prepare and implement an effective plant maintenance

programme in consultation with Engineer-in-Charge. It shall be absolutely
contractors responsibility to look after all sorts of maintenance whether preventive
or break down. The contractor shall maintain the operational activity record as
prescribed in this volume.
4.
The contractor shall be responsible for keeping updated record of documents

including History-Card for equipment and maintaining every day logbook relating to
running of machinery, consumption of energy, and other consumables etc. and
various analysis performed. In addition to above the contractor shall maintain the
operation and maintenance data for the following.
CONTRACTOR
Daily status record of STP

Daily flow record
Daily analysis record
Operation records of mechanical screens in STP
Operation record of grit channel
NO. OF CORRECTIONS
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41

Operation record of Primary clarifier

Operation record of air blowers and diffusers
Operation record of Secondary clarifier
Operation record of sludge pumps
Operation record of chlorination system
Record of quantity of sludge generation and sludge dewatering system
Performance data of Aeration tank.
Performance data of Chlorination system
Any other allied works required by EIC during O&M.
5.
The Contractor shall submit a monthly report to NMC, about the operation and
maintenance indicating the manpower, electric power, chemicals and other
consumables consumed, problems faced and rectified along with various analysis
performed for raw and treated sewage.
6.
The contractor shall be responsible to carry out day to day as well as periodic
maintenance necessary to ensure smooth and efficient performance/running of all
equipment/instruments installed at the Sewage Treatment Plant. The contractor shall
hand over the machinery & site to the department after expiry of the contract period
in good running condition.
7.
The contractor shall maintain all treatment plant and other civil structures in the STP
premises including boundary wall in sturdy manner to complete its natural / designed
life. He should paint all MS / CI / GI structures at least once in a year to prevent
rusting as and where required and as directed by EIC.
8.
The contractor shall also be responsible for proper upkeep of administrative block of
the Sewage Treatment Plant.
9.
He shall be responsible for proper maintenance of all the pumps and allied items
including mechanical screens, gates, diffusers, primary and secondary clarifiers, air
blowers, sludge pumps, centrifuge, chlorinator etc.
10.
He shall be responsible for timely removal and safe disposal of the dried sludge
including transportation, loading and unloading etc. He should get approval for the
location of the disposal of the dried sludge from NMC.
11.
He shall be responsible for maintenance of streetlight, poles & fixtures also.
12.
The sewerage system in the STP premises, roads and pathways provided at the
sewage treatment plant shall be maintained properly.
13.
Round the Clock watch and ward of the entire premises including plants/machinery
etc. will also be the responsibility of the contractor.
14.
The entire STP premises including will be kept neat and clean.
15.
The records maintained by the contractors shall be produced periodically to the

Engineer-in-charge for proper monitoring as desired by him.
CONTRACTOR
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16.
5.2
Operation & maintenance of boundary wall of STP, Landscaping and Forestation

done in the Sewage Treatment Plant premises etc. shall be carried out.
GENERAL TERMS AND CONDITIONS

1. NMC shall supply power, chlorine and water to the contractor free of cost during O &
M period of 36 months.
2. During O & M period the contractor is to keep their staff engaged continuously
without any break for Operation, Maintenance and Monitoring of STP.
3. The contractor will supply all consumable, reagents and spares. The contractor will
employ its own staff for testing purpose. However the department will be at liberty to
get random sampling & testing done on its own or from any other agency, to the entire
satisfaction of Engineer-in-charge. In case of testing from other agency, charges will
be borne by NMC
4. Contractors labourers and supervisors shall have to normally observe office timings
of general shift.
5. Plant and equipment covered under this contract shall be totally attended to by the
contractor including any Trouble Shooting to ensure smooth and trouble free
operation.
6. For effective maintenance of STP, the contractor shall employ sufficient staff with
proper qualification. For his guidance the pattern and no. of minimum staff to be
engaged is described in this chapter.
7. The maintenance period shall be thirty months from the date of completion of
successful performance run of sewage treatment plant. In this period the contractor
shall supply all spares required for maintenance of the plant free of cost.
8. The contractor shall take operational measures that there shall be no flooding of STP
area.
9. The contractor shall abide by all central/state govt./Semi govt./Local Bodies rules
regulations, pertaining to this contract, without any extra cost.
10. In the event of any damage/loss of life/theft of property, due to negligence on the part
of contractor, the contractor shall be solely responsible and liable for compensation
and damages, regarding negligence and the decision of Engineer-in-charge shall be
final.
11. The contractor should maintain all kinds of securities in the premises round the clock
for that he should arrange manpower to prevent theft, robberies and malpractice. No
unknown person shall be allowed to enter the STP premises except municipal staff,
officials and elected representatives of the NMC body without permission.
Educational study visits of the students are permissible only on written permission
from EIC.
CONTRACTOR
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12. The site will be open for inspection by the designated officers/official of NMC at all
times during the contract period.
13. The contractor should observe all safety rules and regulations corresponding to
electricity, factory act, bio-chem process fire and as per building codes. Any accident
causing by over sighting the rules, the contractor at his own cost and risk shall handle
the related cases. Insurance of the entire staff at site is compulsory under insurance
policy drawn from Govt. of Maharashtra. The copy of the cover note should be
submitted to NMC.
5.3
FINANCIAL TERMS AND CONDITIONS

During the operation and maintenance period Electricity charges will be borne by the
department. The electricity charges will be paid directly to MSEB by NMC on actual basis
as per electricity bill raised by the MSEB. Chlorine charges will be reimbursed by the
NMC to the contractor on submission of detailed documents showing the actual
consumption. The reimbursement rate will be as per market rate during the day of delivery.
However the department will be at liberty to arrange supply of chlorine to the contractor for
consumption at STP. All other consumable material and required staff for Operation &
Maintenance will be provided by contractor.
The operation & Maintenance cost approved by the Department shall be payable on
monthly basis on completion of every month on submission of bill by the contractor. The
contractor shall maintain the attendance record of the staff employed by him, which can be
checked by the department any time. The contractor will also submit copy of all the data
sheets every month for evaluation.
The spares required shall not be payable to the contractor as the machinery is within his
guarantee period.
The Sludge and treated wastewater available from Sewage Treatment Plant shall be
property of NMC. The sludge and wastewater will not be sold by the Contractor. However,
NMC is at liberty to do so, and retain the proceedings, if any.
All sorts of Tool & Plant, required for proper operation & Maintenance of the plant, shall
be arranged by the contractor at his own cost.
5.4
DESCRIPTION OF STAFFING
Details of minimum staff required to be employed for the operation and maintenance of the
sewage treatment plant for 36 months is given below. However, additional staff, if
required for proper operation and maintenance of STP, will be provided by the contractor
without any additional charges.
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
44

Sr.
Personnel
No.
Total
experience
Main Task of the Personnel
Plant in charge
5 years
Co-ordination of activities for

satisfactory performance of the
STP and reporting to the Engineerin-charge and responsible for the
proper
functioning
&
maintenance, data collection of
STP.
5 years
Co-ordination of activities for

satisfactory performance of the
STP and reporting to the Engineerin-charge and responsible for the
proper
functioning
&
maintenance, data collection of
STP.
3 years
Responsible for overall operation

for STP
3 years
Responsible for maintenance of

electrical equipment.
3 years
Responsible for maintenance of

mechanical equipment.
1 years
Responsible for keeping the STP

premises clean and neat. Also they
will assist operators in day to day
activities
1 years
To
maintain
the
garden/landscaping of the plant
1 years
Assisting day to day activities in

office, keeping office clean and
neat
1 years
To
maintain
the
garden/landscaping of the plant
(BE,
Civil
Environmental)
Deputy Plant in charge
(Diploma Civil
Operators
(Diploma, ITI Qualified)
Electrician
Fitter
Helpers
(12th pass)
Gardener
(12th pass)
Office boy
(12th pass)
Security Guards
(12th pass)
CONTRACTOR
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
45

5.5
DEPLOYMENT OF STAFF DURING OPERATION AND MAINTENANCE

PERIOD
The Contractor shall arrange at his cost the staff required during the Operation and
Maintenance period of 36 months. The Lump sum tender cost shall also include all
expenditure likely to incurred for repairs/replacement of any items executed in the tender
during this period.
The department shall provide electric power free of cost. The Contractor should submit
detailed information regarding the staff likely to be deployed by him during O&M period
of 36 months.
5.6
TAKING OVER
The plant will be taken over on satisfactory completion of the operation and maintenance
of the contract for 36 months provided that,
1.
The plant/equipment are in running condition
2.
The result of the treated sewage quality during O & M of the plant is within the
limits specified in the tender document.
3.
All treatment plant units including interconnecting piping, hand railings, ladders,
staircases, buildings, various tanks, machines, panels etc are neatly painted.
4.
All records of operation and maintenance during the 36 months period are handed
over to NMC in proper condition.
5.
The O & M manuals have been updated following 36 months operational experience
and approved by NMC.
In case taking over is delayed on account of Contractors failure, the O & M period will be
extended further till it meets the above requirement without any extra cost to NMC.
CONTRACTOR
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6 BID DRAWINGS
6.1
BID DRAWINGS
The bid drawings provided for bidding purposes are listed below and are enclosed in this
Volume.
Sr.
Drawing Number
MWH/169/Panchak/ASP
Schematic Flow Diagram for ASP
MWH/169/Panchak/SBR
Schematic Flow Diagram for SBR
MWH/169/Panchak/UASB
Schematic Flow Diagram for UASB
CONTRACTOR
Drawing Title
NO. OF CORRECTIONS
EXECUTIVE ENGINEER
47

Data Sheets
7
7.1
PROCESS AND CIVIL UNITS
7.1.1
Civil Units for Sewage Treatment Plant
Sr.
I
i)
Units
Details
General & Process

Process details
Average flow
Peak factor
Peak flow
Raw sewage BOD5 at 20 0C
Raw sewage SS
32 MLD
2.2500
72 MLD
100 200 mg/l
200 300 mg/l
Treated sewage BOD

Treated sewage SS
< 20 mg/l
< 30 mg/l
(ii)
Total head loss (m) in STP (Water level in Inlet Chamber

to water level in outlet channel near river).
(iii)
Total land area (hectare) proposed for STP and all units
as mentioned above and specified elsewhere in the tender
document.
II
Sewage Treatment Plant
(a)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Inlet Chamber
Design peak flow
No of units
Detention period
Liquid depth (m)
Length (m)
Width (m)
Water level (m)
(b)
(i)
(ii)
Screen Channel
Design peak flow
No of units
2 W (mechanical) & 1 S (manual)
Clear spacing through bars
Width of channel (m)
Length of channel (m)
Liquid depth (m)
Upstream water level (m)
Downstream water level (m)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
DATA SHEETS
Contractor
48
Engineer-in-charge

Data Sheets
Sr.
Units
(ix)
(c)
(i)
(ii)
(i)
(ii)
(iii)
(iv)
(vii)
(viii)
(ix)
(ix)
Head loss (mm)

Degritting System
Design flow
No of units
Particle size to be removed (mm)
Specific gravity
Efficiency of removal (%)
Length of channel between screen chamber and grit
chamber (m)
Width of channel between screen chamber and grit
chamber (m)
Degritting units
- Capacity (MLD)
- Size (m)
Surface overflow rate (cum/sq.m/day)
Water level (m)
Number of gates (nos.)
Size of gate openings (m)
(d)
(i)
(ii)
(iii)
(iv)
Flow Measuring Channel

Width of Flow Measuring Channel
Length of Flow Measuring Channel
Depth of Flow Measuring Channel
Size of Parshal Flume
(v)
(vi)
(e)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
(xvii)
(e)
(i)
Details
UASB Reactor
Size of the reactor
Solid retention time
Sludge bed concentration
Sludge bed height
Average Upflow velocity
Maximum Upflow velocity
Aperture velocity
Angle of gas deflector
Hood width
Feed inlet pipe distance
Overlap of gas deflector
C/C distance of gas domes
Aperture percentage
Angle of deflection beam
Retention time in settling zone
Volumetric loading
Free board
SBR Reactor
Size of the reactor
Contractor
49
Engineer-in-charge

Data Sheets
Sr.
Units
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
No of reactors
Inlet BOD, mg/l
Inlet SS, mg/l
BOD removal efficiency
SS removal efficiency
F/M ratio
(f)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
Aeration Tank
Inlet BOD, mg/l
Inlet SS, mg/l
BOD removal efficiency
SS removal efficiency
F/M ratio
MLSS, mg/l
MLVSS / MLSS
Yield coefficient, day -1
Decay coefficient, day -1
MCRT, days
Water depth in tank
No of tanks
Min power requirement for mixing
Details of each tanks
- Volume (cum)
- Hydraulic Retention Time (hours)
- Side Water Depth (m)
- Length (m)
- Width (m)
- Freeboard (m)
- F/M ratio (kg BOD removal / kg of MLVSS/day)
Length of Inlet Weir (m)
Length of Outlet Weir (m)
Size of pipeline/channel to Secondary Clarifier Tank (m)
Length of pipeline/channel to Secondary Clarifier Tank
(m)
Material of Construction of pipeline to Secondary
Clarifier Tank (m)
(xvi)
(xvii)
(xviii
(xix)
(xx)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Details
Diffusers for any technology

Type of diffusers
Make
Material of diffusers
Dia and length of each diffuser
Total no of diffusers
Air flow through each diffuser
Contractor
50
Engineer-in-charge

Data Sheets
Sr.
Units
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Air blowers for any technology

Type of air blower
Make
No of working blowers
No of stand by blowers
Capacity of blower
Head of blower
Motor rating
(g)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
Secondary Clarifier Tank (SCT)

Number of Secondary Clarifier (SCT) (nos.)
Diameter (m)
Side Water Depth (m)
Freeboard (m)
Volume (cum)
Hydraulic Retention Time (hours)
Surface Overflow Rate (cum/sq.m/day)
Weir Loading Rate (cum/sq.m/day)
Bottom floor slope
Diameter of Influent pipe(s) to SCT (mm)
Material of Construction of Influent pipe(s) to SST
(xii)
Diameter of pipe(s) from SCT to Return Sludge Sump for

sludge withdrawal (m)
Length of pipe(s) from SCT to Return Sludge Sump for
sludge withdrawal (m)
Material of Construction of pipe(s) from SCT to Recycle
Sludge Sump for sludge withdrawal (m)
(xiii)
(xiv)
Details
(h)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
Chlorine Contact Tank (CCT)

Number of Tanks(nos.)
Size of tank (m x m)
Side Water Depth (m)
Freeboard (m)
Volume (cum)
Hydraulic Retention Time (hours)
Diameter of pipe from SCT to CCT
Material of construction of pipe from SCT to CCT
(i)
(ii)
(iii)
Plant Utilities
Storm water drain provision (size, length in m)
Water Supply and Sewerage Provision (Yes / No)
- Capacity and size of water storage tank(cum)
- Capacity and size of overhead tank (cum)
Numbers and size of Culverts, road crossing, etc.
Area allocated for green belt (sq.m)
Width of approach road to site (m)
(iv)
(v)
(vi)
Contractor
51
Engineer-in-charge

Data Sheets
Sr.
Units
Details
(vii)
(viii)
(ix)
(x)
(xi)
(xiv)
(xv)
(xvi)
Length of approach road to site (m)

Width of roads inside the plant (m)
Length of roads inside the plant (m)
Length of compound wall (m)
Height of compound wall (m)
Size of security shed (m)
Number of MCC rooms (nos.)
Size of MCC rooms (m x m)
(j)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Reclamation/Site Development
Proposed area of Reclamation (sq.m)
Top levels after Reclamation (m)
Average depth of filling (m)
Total quantity of earth required (cum)
Side slope of the filling
Slope Protection Measures
- Provision of retaining wall (Yes / No)
- Height of retaining wall
- Width of retaining wall
Proposed compaction equipment to be deployed (Type and
Numbers)
Test apparatus to be provided in field soil laboratory
Proposed open channel dimension
- Top width (m)
- Bottom width (m)
- Side slope
- Longitudinal slope
- Length (m)
Bottom slope protection for open channel
Proposed equipment (type and number) for excavation
handling, transporting
Miscellaneous
The Tenderer shall list here details of any other/ additional
items required for a complete installation and successful
commissioning of the plant.
(vii)
(viii)
(ix)
(x)
(xi)
(k)
7.1.2
Process Design
The Tenderer shall provide following documents / drawings in details along with the tender
documents:
1. Process design of all units
2. Hydraulic design and head loss calculations for all the units, pipes, etc.
3. Schematic, mass balance and hydraulic flow diagram
4. Layout Plan and Process & Instrumentation Diagram
5. Single Line Diagram
Contractor
52
Engineer-in-charge

Data Sheets
6. Mechanical equipment data sheets as mechanical specifications of this document

7. Electrical system design, rating, etc. for all the power cables earthing system and
instrumentation systems as per electrical specifications of this document
8. Instrumentation & Automation System design, rating, etc. as per Instrumentation
Specifications of this document
Contractor
53
Engineer-in-charge

Data Sheets
7.2
MECHANICAL EQUIPMENT
7.2.1
Pumping Machinery
7.2.1.1
Return Sludge Pumps
Sr.
Description
(a)
(i)
(ii)
(iii)
(iv)
(v)
General
Make
Model
Type
Numbers of Working pumpsets
Numbers of Standby pumpsets
(b)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Performance
Capacity
Total head
Speed
Overall efficiency (Pump + Motor)
Motor Rating
Motor Enclosure
(c)
(i)
(ii)
(iii)
(iv)
Materials of Construction
Impeller
Casing
Shaft
Delivery pipe
(d)
(i)
(ii)
(iii)
(iv)
Induction Motor
Make
Rating
Speed
Efficiency
- Full Load
- Load
Power Factor
- Full Load
- Load
Class of Insulation
Temperature rise by resistance method
Type of enclosure
Degree of protection
Weight
(v)
(vi)
(vii)
(viii)
(ix)
(x)
Contractor
Unit
Particulars
cum/hr
mlc
rpm
%
kW
kW
rpm
%
%
kg
54
Engineer-in-charge

Data Sheets
7.2.1.2
Centrifuge feed Sludge Pumps
Sr.
Description
(a)
(i)
(ii)
(iii)
(iv)
(v)
General
Make
Model
Type
(b)
(i)
(ii)
(iii)
(iv)
Performance
Capacity
cum/hr
Total Head
mlc
Efficiency
%
Maximum pump input at 50 Hz for
single pump operation
Shut off Head
mlc
Speed
rpm
Size of solids that can be handled
mm
(v)
(vi)
(vii)
(c)
(i)
Unit
(ii)
(iii)
(iv)
(v)
(vi)
Construction
Type of Impeller (Enclosed / Semi
open)
Number of Impeller vanes
Stuffing box sealing liquid
Surface hardness of shaft sleeve
BHN
Suction/discharge
mm/mm
Weight
kg
(d)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Impeller
Casing
Shaft
Casing ring
Shaft Sleeve
Stuffing box packing
Base Plate
(e)
(i)
Testing and Inspection

Pump Performance testing Standard
(f)
(i)
(ii)
Performance
Maximum velocity of vibration
Maximum noise level
mm/sec
dBA
(g)
(i)
(ii)
Induction Motor
Make
Rating
kW
Contractor
55
Details
Engineer-in-charge

Data Sheets
Sr.
Description
Unit
(iii)
(iv)
Speed
Efficiency
- Full Load
- Load
Power Factor
- Full Load
- Load
Class of Insulation
Type of enclosure
Weight
rpm
(v)
(vi)
(vii)
(viii)
(ix)
(x)
7.2.1.3
Details
%
%
kg
Centrifuge Feed Pumps
Sr.
Description
(a)
(i)
(ii)
(iii)
(iv)
(v)
General
Make
Model
Type
(b)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Performance
Capacity
Total head
Speed
Overall efficiency (Pump + Motor)
Motor Rating
Motor Enclosure
(c)
(i)
(ii)
(iii)
(iv)
Impeller
Casing
Shaft
Delivery pipe
(d)
(i)
(ii)
(iii)
(iv)
Induction Motor
Make
Rating
Speed
Efficiency
- Full Load
Contractor
Unit
Particulars
Positive Displacement
cum/hr
mlc
rpm
%
kW
kW
rpm
%
56
Engineer-in-charge

Data Sheets
Sr.
(v)
(vi)
(vii)
(viii)
(ix)
(x)
Description
Unit
- Load
Power Factor
- Full Load
- Load
Class of Insulation
Type of enclosure
Weight
kg
7.2.2
Sluice Gates
Sr.
Description
(i)
(ii)
(iii)
Make
Size
mm x mm
Opening required on the wall to mount mm x mm
the wall thimble
No of gates
(iv)
7.2.3
Particulars
Unit
Particular
Screening Equipment
7.2.3.1
Mechanical Screen
Sr.
Description
(a)
(i)
(ii)
(iii)
(iv)
General
Make
Model
Type
Numbers
(b)
(i)
(ii)
(iii)
(iv)
Screen
Width
Height
Raking speed
Motor rating
(c)
(i)
(ii)
(iii)
(iv)
(v)
Frame
Rake carriage
Screen bars
Fasteners
Canopy
Contractor
Unit
Particulars
mm
mm
m/mm
kW
57
Engineer-in-charge

Data Sheets
Sr.
Description
(d)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Conveyor System
Material of belt
Width of conveyor
Speed of conveyor
Thickness of belt and ply rating
Make of the belt
Motor rating
(e)
(i)
(ii)
Unit Control Panel

Make
Over all dimensions
(iii)
(iv)
(v)
(vi)
Timer
Make
Type
7.2.3.2
Unit
Particulars
mm
m/sec
kW
mm x mm
x mm
Manually Raked Bar Screen
Sr.
Description
(a)
(i)
(ii)
(iii)
General
Make
Size
Numbers
(b)
(i)
(ii)
(iii)
(iv)
Screen
Width
Height
Bar size
Clear space between bars
(c)
(i)
(ii)
Material of Construction
Screen bars
Guide channel
7.2.4
Grit Removing Equipment
Sr.
Description
(a)
(i)
(ii)
Reduction Gear
Make
Type
(b)
Drive Motor
Contractor
Unit
Particulars
mm x mm
mm
mm
mm x mm
mm
Unit
58
Particulars
Engineer-in-charge

Data Sheets
Sr.
Description
(i)
(ii)
(iii)
Make
Speed
Rating
(c)
(i)
(ii)
Scraper
Frame
(d)
(i)
(ii)
(iii)
Classifier Mechanism
Make
Type
Drive System
- Make of reduction gear
- Make of motor
Material of rake
(iv)
(e)
(i)
(ii)
(iii)
Unit
rpm
kW
Organic Return Pumpset

Make
- Pump
- Motor
Motor rating
- Impeller
- Shaft
Contractor
Particulars
kW
59
Engineer-in-charge

Data Sheets
7.2.5
Sr.
Secondary Clarifier
Description
(a)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
General
Tank size
Type
Make
Feed Inlet
Overflow
Sludge Scraper
Type of Bridge
Scum removal
Overload protection
Direction
Torque
(b)
(i)
Drive Mechanism
Drive System
- Prime Mover
- Make
- HP/RPM
Gear Box
- Gearbox
- Make
Center Mechanism
Transmission
Gear reducer
- Make
- Type
Motor
- Make
- Rating
(ii)
(iii)
(iv)
(v)
(vi)
(c)
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(d)
(i)
Unit
Particulars
kW
Material of Construction of Rake

Arms
Feed Well
Rake Arms
Blades
Overflow Weir
Squeezes
Bridge
Walkway
Railings
Fasteners
Painting
Submerged Parts
Contractor
60
Engineer-in-charge

Data Sheets
Sr.
Description
(ii)
Other Parts
7.2.6
Unit
Particulars
Unit
Particulars
Chlorination System
Sr.
Description
(a)
(i)
(ii)
(iii)
(iv)
(v)
General
Make
Type of injector
Injector capacity
Injector Pressure
Accuracy as a percent of actual rate
in the operating range
(b)
(i)
(ii)
Automatic drum changeover device

Make
Type
(c)
(i)
(ii)
(iii)
(iv)
Booster Pumps
Make
Capacity
Total head
Motor rating
cum/hr
m
kW
(d)
(i)
(ii)
(iii)
Chlorine Leak Detector

Make
Type
Range
Ml/cum
(e)
Chlorine
equipment
Make
Type
(i)
(ii)
(f)
(i)
(ii)
(iii)
(g)
Residual
kg/h
Bar
%
monitoring
Ventilation System for Container

Store Area and Chlorinator Room
Make
Capacity
cum/h
Power rating
kW
(i)
(ii)
EOT Crane for Chlorine Drum

Storage Area
Make
Capacity
Tonne
(h)
(i)
Weighing Equipment
Make
Contractor
61
Engineer-in-charge

Data Sheets
Sr.
Description
(ii)
(iii)
Type
Number
7.2.7
Description
(a)
(i)
(ii)
(iii)
(iv)
(vi)
(vii)
(viii)
General
Make
Model
Type
Numbers
Capacity of each Centrifuge
Duration of Operation of
Centrifuge per day
Dry solids in dried sludge
(b)
(i)
(ii)
(iii)
Plates
Cloth
Skeleton
(c)
(i)
(ii)
(iii)
(iv)
Motor
Make
Motor Rating
Speed
Efficiency
- Full load
- 3/4th load
Power Factor
- Full load
- 3/4th load
Class of Insulation
Type of Cooling
Degree of Protection
Type of Enclosure
Class of temperature rise
(vi)
(vii)
(viii)
(ix)
(x)
(d)
7.2.8
Sr.
(i)
Particulars
Unit
Particulars
Centrifuge
Sr.
(v)
Unit
nos.
cum/hr
each hours
%
cum/hr
rpm
Weight
kg
Mixers Lime Solution

Unit
Details
Number of working units (nos.)
Contractor
62
Engineer-in-charge

Data Sheets
Sr.
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
7.2.9
Sr.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
Unit
Details
Number of standby units (nos.)

Type
Tank Size (mm x mm)
SWD in Tank (mm)
Tank Type
Drive
Motor
- Make
- Power Supply
- Motor Rating
- Efficiency
- Speed
- Type of cooling
- Type of enclosure
- Degree of Protection
- Class of insulation
Mixers Polyelectrolyte Solution

Unit
Details

Type
Tank Size (mm x mm)
SWD in Tank (mm)
Tank Type
Drive
Motor
- Make
- Power Supply
- Motor Rating
- Efficiency (%)
- Speed (rpm)
- Type of cooling
- Type of enclosure
7.2.10 Mixers Sludge

Sr.
Unit
Contractor
Details
63
Engineer-in-charge

Data Sheets
Sr.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
Unit
Details

Type
Tank Size (mm x mm)
SWD in Tank (mm)
Tank Type
Drive
Motor
- Make
- Power Supply
- Motor Rating
- Efficiency (%)
- Speed (rpm)
- Type of cooling
- Type of enclosure
Contractor
64
Engineer-in-charge

Data Sheets
7.3
ELECTRICAL POWER CONSUMPTION
Bidders to give the power consumption of the proposed STP as per following format on their letter
head.
7.3.1
Sr.
Load List for the plant (100 % flow)

Equipments,
Rating
Buildings, area (kW)
lighting,
yard
lighting
Description
Quantity
No of hrs kW
Power
of
consumed / consumed per
operation absorbed at day in kWH
rated
duty
conditions by
a single unit
Guaranteed
power Consumed
(kWH)
7.3.2
Sr.
Load List for the plant (50 % flow)

Equipments,
Rating
lighting,
yard
lighting
Description
Quantity
Contractor
No of hrs kW
Power
of
rated
duty
conditions by
a single unit
65
Engineer-in-charge

Data Sheets
Sr.
Equipments,
Rating
lighting,
yard
lighting
Description
Quantity
No of hrs kW
Power
of
rated
duty
conditions by
a single unit
Guaranteed
power Consumed
(kWH)
We confirm that that we have included all process equipment required to operate the plant and
this shall be sum total of maximum power consumed by the STP for its operation for treating raw
sewage to get the desired treated sewage parameters as given in the addendum. NMC reserves the
right to use higher figure for power consumptions for bid evaluation in case of any discrepancy.
The list of equipment and the power consumption is final and guaranteed.
The above table along with the guarantee mentioned above shall be submitted on the letter of the
bidder.
Contractor
66
Engineer-in-charge

Data Sheets
7.3.3
Transformer Sizing
Particulars
Value
Unit
Formula
Total working load as per list furnished

load list
Loading of all motors
kW
Total running load
kW
C= A x B /100
Efficiency
Operating corrected power factor (0.98)
Total kVA drawn from the system
kVA
F= Cx100/
(DxE)
Add lighting load of the plant
kVA
Total load on the transformer
kVA
H= F+G
Add allowance as contingency
(I)
Total max. load on transformer

Considering the operating loading of
transformer
=
=
kVA
%
J= H x (1+I/100)
K
Minimum transformer capacity required
kVA
L= (J x 100) /K
Selected Transformer Size
kVA
Contractor
67
Engineer-in-charge

Data Sheets
7.3.4
Power Transformer
Sr.
Item
A
(i)
(ii)
(iii)
(iv)
General
Application/Designation
Manufacturer
Quantity
Installation Indoor / Outdoor
B
(i)
(ii)
Ratings
Rating
No. Load voltage :
- LV Winding
- LV Winding
Quantity supplied
Rated Frequency
Rated Percentage Impedance
at 75C
(iii)
(iv)
(v)
C
(i)
(ii)
(iii)
Transformer Protection
provided Buchholz relay,
winding & oil temp.
indicators, OLTC, surge
relay, PRD, MOG
E
(i)
System Data
System Voltages
- HV Nominal/Highest
- LV Nominal/Highest
Fault Levels
- HV System
- LV System
System neutral earthing
- HV system
- LV system
(iii)
(iv)
Description
Remarks/ make
kVA
kV
kV
Nos.
Hz
Winding Connections
HV
LV
Vector Group
Application/Direction of
Power Flow
Cooling Method
(ii)
Unit
Efficiency at 75C at unity PF

at full load
Contractor
kV
kV
MVA
MVA
68
Engineer-in-charge

Data Sheets
Sr.
(v)
Item
Full load regulation at 75C
F
(i)
Losses
No load loss on principal tap
at 100% rated voltage &
frequency subject to +10%
tolerance as per IS
Load loss on principal tap &
rated current at 75C winding
temp. (guaranteed subject to
+10% tolerance as per IS &
excluding copper losses)
(ii)
Winding Insulation
Whether fully
insulated/material of
insulation
Guaranteed maximum
temperature rise over 40C
Ref. Ambient Temp.
Temp. rise of oil by
Thermometer
Temp. rise of winding by
resistance
(i)
(ii)
(iii)
I
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Tappings
Tapping on winding
Whether on load/off Load
Total Tapping Range
Step
Capacity full/reduced
On HV/LV Winding
If on load taps specify details
of OLTC gear
- Manual/Automatic
- Remote/Local Control
- Voltage class of OLTC
- Current rating of OLTC
J
(i)
(ii)
Terminal Bushings
Rated Voltage Class
Minimum clearance in air
- Phase to phase
- Phase to ground
Minimum creepage distances
(Total)
(iii)
Contractor
Unit
Description
Remarks/ make
kW
kW
C
C
C
kV
mm
mm
Mm
69
Engineer-in-charge

Data Sheets
Sr.
(iv)
(v)
Item
One minute power frequency
withstand dry & wet
1.2/50 impulse withstand
K
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Terminal Connections
HV winding
LV winding
Mounting
Class of Insulation
Busbar size in secondary
LV wdg neutral end
Disconnecting chamber
/cable box
Magnetizing current at rated

voltage & frequency
When excited from LV side
When excited from LV side at
110% rated voltage
(i)
(ii)
Unit
M
(i)
(ii)
Maximum Flux Density

At rated voltage
At 110% rated voltage
N
(i)
(ii)
Current Density
HV
LV
O
(i)
Miscellaneous
Final painting Color shade as
per IS:5
P
(i)
(ii)
(iii)
(iv)
(v)
Weight
Core & windings
Oil
Tank, coolers & fittings
Total
Untanking weight
kg
kg
kg
kg
kg
Q
(i)
(ii)
(iii)
Dimensions
Width
Height
Depth
mm
mm
mm
Details of Fittings &

Accessories
Inspection Cover
a)
Contractor
Description
70
Remarks/ make
Engineer-in-charge

Data Sheets
Sr.
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
u)
v)
w)
7.3.5
Item
Unit
Rating Plate
Terminal marking plate
Two earthing terminals
Lifting lugs
Drain valve
Dehydrating breather
Oil level prismatic
Thermometer pocket
Oil filling hole with cover
Conservator
Air release plug
Jacking pads
Filter valves
Weatherproof marshalling
box with internal connecting
cabling
Cable box air insulated on HV
Side with disconnecting
chambers with suitable lugs &
glands
Winding temp. indicator with
Mercury switches for alarm
and trip
Oil temperature indicator with
mercury switches for alarm
and trip
Magnetic oil level gauge with
mercury switch for Alarm
Dial Size of magnetic oil level
gauge
Pressure relief valve with
alarm contacts
Buchholz Relay with Alarm
and Trip contacts
Neutral CT 2 Nos. Mounted
on Tank /L.V Bus Box
Wheels
Flat/flanged
Unidirectional/Bidirectional
Quantity
Gauge
Description
Remarks/ make
Medium Voltage Switchgear (not exceeding 1000V)
Sr.
Item
General Construction of
Switchgear
Contractor
Unit
Description
71
Remarks/ make
Engineer-in-charge

Data Sheets
Sr.
Item
a)
b)
c)
d)
e)
Manufacturer/Assembler
Quantity offered
Switchgear designation
Applicable Standards
Installation
Indoor/Outdoor
Single front or double front
Module Construction
Degree of Protection (As per
IS:2147)
Cable Entry
- for incoming cables
- for outgoing cables
Sheet Steel Construction
- Cold rolled/Hot rolled
- Thickness
Frames
Door
Rear cover
Side and top covers
Panel partitions
Has the sheet metal been
treated in accordance with the
specifications
One minute power frequency
with stand voltage
Main circuit
Control circuit
Aux. Circuits connected to
CTs/PTs
Painting/Powder Coating
Paint Shade
Acceptable temp rise inside
the panel above amb. Temp.
Socket / Space heater /
internal cubicle lighting
Control Supply
Total Dimensions of each
switchgear
Length x Width x Depth
Fully drawout/semi drawout/
Fixed
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
B
(i)
Unit
Description
Remarks/ make
No.
mm
Busbars
Material
- Phase
- Earth
Contractor
72
Engineer-in-charge

Data Sheets
Sr.
Item
(ii)
Size
Phase
Earth
Voltage Rating
System Frequency
HV Power Frequency
withstand test voltage
Rated Current
- Continuous
- Short time
Maximum limit of
temperature
Whether busbars have been
insulated
Type of insulation
Temperature rise over the
reference ambient when
carrying rated current
Material of busbar supports
Clearances in air in mm
- Between phases
- Between phases & earth
Short time rating in kA (One
sec)
Momentary rating (peak
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
C
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(x)
(xi)
Air Circuit Breakers

Make
Applicable standard
Type designation
Rated Voltage
Rated Current
Number of Poles
Short circuit withstand
capacity (RMS)
Type of Operating mechanism
Insulation level
(1 minute power frequency
withstand )
voltage)
Details of Releases provided
Type of Releases
(i)
(ii)
Moulded Case Circuit

Breaker (MCCB)
Make
Applicable standard
(viii)
(ix)
Contractor
Unit
Description
Remarks/ make
mm
mm
V
Hz
A
A
C
V
A
73
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
(iii)
(iv)
(v)
(vi)
Type designation
Rated Voltage
Rated Current
Protections
V
A
Fuse Switch Units

Make
Applicable standard
Type designation
Rated Voltage
Rated Current
Maximum prospective fault
current withstand of
composite unit of switch &
fuse
V
A
(i)
(ii)
(iii)
(iv)
(v)
(vi)
D
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Fuses
Make
Type
Applicable standard
Rated voltage
Rated current for individual
circuits to be provided as per
requirements of protection &
coordination
Reputuring capacity at rated
voltage (prospective current)
Remarks/ make
V
A
E
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Control/Selector switch
Make
Type designation
Number of positions
Number of poles
Contact rating
Rated Voltage
A
V
F
(i)
(ii)
(iii)
(iv)
(v)
Starters
Applicable Standard
Starter Type
Class of duty
Rated Voltage
Quantity of each type
V
nos.
G
(i)
(ii)
Contactor
Make
Type
Contractor
Description
74
Engineer-in-charge

Data Sheets
Sr.
Item
(iii)
(iv)
(v)
(vi)
Applicable standards
Rated duty
Rated Utilization Category
No. of auxiliary contacts
required
Rated voltage of main
contacts
Rated (thermal) current
Rated voltage of auxiliary
contacts
Rated voltage of coil
Rated breaking capacity
Factor of rated Current
Rated making capacity
Factor of rated current
Insulation class for winding of
electromagnet
Limits of operation
Supply voltage variation
Supply frequency variation
for closing
Drop out voltage
Number of auxiliary contacts
- Normally open
- Normally closed
Current rating of auxiliary
contacts at Control Voltage
Make and carry
Break
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
H
(i)
(ii)
(iii)
(iv)
(vii)
Single Phasing Reventers

Make
Type designation
Rated voltage
Setting (voltage unbalance as
percentage of rated voltage)
Operating time
Number of contacts
- Normally open
- Normally closed
Contact rating
I
(i)
(ii)
(iii)
(iv)
Current Transformers
Make
Type
CT Ratio
(v)
(vi)
Contractor
Unit
Description
Remarks/ make
V
A
V
V
A
A
Sec
75
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
(v)
(vi)
(vii)
(viii)
(ix)
(x)
VA Burdon
Accuracy class
Instrument security factor
Short time current for 1 Sec
Momentary current
Class of insulation
VA
J
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Voltage Transformers
Make
Ratio
VA Burdon per phase
Accuracy class
Over voltage factor
Class of insulation
K
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Control Transformer
Make
Type
Ratio
Class of insulation
VA Rating
Instantaneous Over current

Relay (External)
Application (phase fault or
earth fault)
Make
Type designation
Setting range
(i)
(ii)
(iii)
(iv)
M
(i)
(ii)
(iii)
(iv)
(v)
N
(i)
(ii)
(iii)
(iv)
Description
Remarks/ make
Inverse Time & Thermal

Over current relay
Application
Make
Type
Current setting range
Time setting range at 10 times
the current setting
Under voltage Relay
Make
Type
Voltage rating
Setting range
Contractor
76
Engineer-in-charge

Data Sheets
Sr.
Item
O
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Auxiliary Relays and Timers

Make
Type
Coil voltage
Time delay range (for timers)
Resetting features
No. of contacts
Normally open/Normally
closed
Contact rating
Whether operation indicator
is provided
(vii)
(viii)
P
(i)
(ii)
(iii)
(iv)
Voltmeter
Make
Type
Applicable standard
Accuracy class
Q
(i)
(ii)
(iii)
(iv)
Ammeter
Make
Type
Applicable standard
Accuracy class
R
(i)
(ii)
(iii)
(iv)
Wattmeter
Make
Type
Applicable standard
Accuracy class
S
(i)
(ii)
(iii)
(iv)
(v)
Space Heater
Make
Type
Rated voltage
Heater output for each
vertical panel
Thermostat setting range
T
(i)
(ii)
(iii)
(iv)
(v)
Control Wiring
Size
Type
Insulation
Voltage grade
Colour Code
Contractor
Unit
Description
Remarks/ make
V
Sec
V
W
C
77
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
(vi)
Minimum size of conductor

for
- Power wiring
- Control wiring
mm
mm
U
(i)
(ii)
(iii)
(iv)
(v)
(vi)
V
(i)
(ii)
(iii)
(iv)
Control Terminal Blocks

Make
Type of terminal blocks
- For withdrawable type
- For Fixed Type
Voltage grade
Current rating
10%spare terminal to be
furnished
Whether terminals for CT's
have been provided with short
circuiting facilities
(v)
Push Button
Make
Type designation
Rating
Number of contacts
- Normally open
- Normally closed
Emergency Push Button
W
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Indicating Lamps
Make
Type
Voltage
Lamp Watts
Colour
Series resistor
X
(i)
(ii)
(iii)
Indicating Meters
Type
Dial Size
Accuracy Class
Y
(i)
Relays
Type of State
- Solid state
- Electromagnetic
- Microprocessor based
Type of Relay
(ii)
Contractor
Description
Remarks/ make
V
A
V
W
78
Engineer-in-charge

Data Sheets
Sr.
Item
(ii)
Over current
Short Circuit
Under Voltage
CT Ratio
Class of Accuracy
Type of Relay
- Over current
- Short Circuit
- Under Voltage
- CT Ratio
- Class of Accuracy
Z
(i)
(ii)
(iii)
(iv)
Annunciation
Make
Make
Number of windows
Voltage
7.3.6
Unit
Description
Remarks/ make
Shunt Capacitor Sizing
Total Working load
Present
P.F (1)
New
P.F.
(2)
TAN
(1)
TAN (2)
KVAR
Required
D = Ax (B-C)
Configuration of the Capacitor Bank selected

Rating of the Capacitor Bank selected
7.3.7
Shunt Capacitor
Sr.
Item
(i)
(ii)
Name of manufacturer
Manufacturer's type and
designation
Reference Standards
Rated VAR capacity of
the capacitor bank
Rated voltage
Rated frequency
Output of the capacitor
bank at rated voltage
(iii)
(iv)
(v)
(vi)
(vii)
Contractor
Unit
Description
Remarks/ make
KVAr
79
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
(viii)
Temperature rise over the

specified ambient temperature
as mentioned
Hot spot temperature
at rated current
Maximum operating
Temperature
Capacity of Bank
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
(xv)
2.0
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
Rated line current

Maximum permissible
overload current
Capacitor Losses
- For complete Bank
- For individual units
Electrical clearance in the
capacitor bank
- Phase to phase min
- Phase to earth min
Permissible Harmonics
Unit Capacitors
Rated Voltage
Rated Output
Number of phases
Whether single bushing or
multibushing type
Maximum overvoltage the
unit capacitor is capable of
with standing continuously
Insulation strength to earth
Number of capacitor elements
per capacitor
Mode of internal connection
of the capacitor element
Type of active element
- Watt loss of paper at various
dielectric temperature
enclosed
- Thickness
- Alternating nominal r.m.s.
voltage stress on the dielectric
paper
Type of impregnant used
Pressure at which the
impregnant is kept within the
Contractor
Description
Remarks/ make
C
C
Micro
farads
A
A
Watts
Watts
mm
mm
%
V
kVAr
Yes / No
Mm
Volts /
mm
kg/mm2
80
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
Description
Remarks/ make
Description
Remarks/ make
Description
Remarks/ make
unit
3.0
3.1
3.3
Capacitor Fuses
Rating of the fuse element
Current
Voltage
Strength of the fuse elements
in Amp Sec at which it melts
Type of the fuse
3.5
Discharge device used
3.6
No. of stages
4.0
4.1
General
Overall dimensions of bank
and units
Layout and dimension
drawings attached
Type test certificates enclosed
3.2
4.2
4.3
7.3.8
Item
(i)
(ii)
(iii)
Manufacturer/Assemble
Quantity
Dimensions of capacitor
control panel
- Width
- Depth
- Height
Enclosure Protection
Auto Power factor relay
- Manufacturer
- Type
- Number of stages
7.3.9
mm
Yes / No
Yes / No
Capacitor Control Panel
Sr.
(iv)
(v)
A
V
Amp
Sec.
Unit
mm
mm
mm
Push Button Station
Sr.
Item
(i)
(ii)
Manufacturer
Enclosure thickness
Contractor
Unit
81
Engineer-in-charge

Data Sheets
Sr.
Item
(iii)
(iv)
Number of contacts
Contact rating at 240V AC
Contractor
Unit
Description
82
Remarks/ make
Engineer-in-charge

Data Sheets
7.3.10 Cables
Sr.
Item
1.1
11 kV XLPE UNEARTHED
POWER CABLE
Manufacturer
Permissible voltage, frequency
& combined Variation
Continuous current rating
De-rating factors for
Variation in ambient
temp. in steps of 5deg.
Cent.
Grouping of cables in
covered trenches
Short circuit capacity
Current & duration
Maximum conductor
temp
Loss tangent at normal
frequency
Conductor
Composition
- Cross section
Type of conductor screening
a
b
c
d
f
g
h.
i
j
k
n
o
p
Insulation
Composition
- Thickness
Type of insulation screening
Inner sheath
Material
Calculated dia. Over stranded
cores
Outer sheath
Material
Thickness
Armour
Type
Nominal diameter of cable
over inner sheath
Armour thickness/wire
diameter
Overall diameter of cable
Recommended minimum
bending radius
Safe pulling force when pulled
by pulling eye
Contractor
Unit
Description
Remarks/ make
kA/sec
C
sq.mm.
Mm
Mm
mm
Mm
mm
mm
mm
83
Engineer-in-charge

Data Sheets
Sr.
Item
Unit
Standard length of cable in

drum
1.2
650/1100V grade PVC

INSULATED POWER
CABLES
Manufacturer & cable type
Rated Voltage
Permissible voltage, frequency
Variation
Continuous current rating
De-rating factors for
Variation in ambient
temp. in steps of 5deg.
Cent
Grouping of cables in
covered trenches
Short circuit capacity
Current & duration
Maximum conductor temp
Conductor
Composition
Cross section
Insulation
Composition
Thickness
Inner sheath
Material
Calculated dia. Over stranded
cores
Outer sheath
Material
- Thickness
a
b
c
d
e
l
m
n
1.3
Armour
Type
over inner sheath
diameter
Recommended minimum
bending radius
drum
650/1100V grade PVC
INSULATED CONTROL
Contractor
Description
Remarks/ make
kA/sec
C
sq.mm.
Mm
Mm
mm
mm
mm
mm
mm
m
84
Engineer-in-charge

Data Sheets
Sr.
a
b
c
e
f
h
i
Item
CABLES
Manufacturer & cable type
Rated Voltage
Conductor
Composition
Cross section
Insulation
Composition
Thickness
Inner sheath
Material
Outer sheath
Material
- Thickness
Armour
Type
over inner sheath
daimeter
drum
Unit
Description
Remarks/ make
Description
Remarks/ make
sq.mm.
Mm
mm
mm
mm
mm
mm
Mtr.
7.3.11 Lighting System

Sr.
Item
A
(i)
(ii)
(iii)
Lighting Fittings
Manufacturer
Nominal working voltage
Maximum permissible supply
voltage variation
Power factor at normal
working voltage & frequency
(iv)
(v)
Power loss per ballast at

normal working voltage &
frequency
B
(i)
(ii)
(iii)
(iv)
(v)
Emergency Lighting Fittings

Manufacturer
Rated voltage
Light output duration
Lamp rating (AC/DC)
Catalogue containing
technical literature enclosed
Contractor
Unit
V
%
V
W
85
Engineer-in-charge

Data Sheets
Sr.
C
(i)
(ii)
(iii)
Item
Unit
Description
Remarks/ make
Unit
Description
Remarks/ make
Unit
Description
Remarks/ make
Unit
Description
Remarks/ make
Yes/No
Lighting Installation
Earthing conductor
- Size
- Material
Conduit
- Size
- Material
Wire/cables
- Conductor
- Material
- Size
7.3.12 Cable Terminations

Sr.
Item
(i)
(ii)
(iii)
Gland type
Lugs
Application
Indoor/Outdoor
7.3.13 Cable Tray

Sr.
Item
a
b
c
d
e
f
Manufacturer
Type
Material
Finish
Tray width
Cable tray supports and fixing
- Type
- Material
- Finish
7.3.14 Earthing System

Sr.
Item
(i)
Earthing conductor buried in

Ground
- Material
- Size
Earthing conductor above
(ii)
Contractor
86
Engineer-in-charge

Data Sheets
Sr.
(iii)
Item
ground upto equipment
terminal
- Material
- Size
Earth Electrode test pits
- Material
- Size
- Type of Electrode
Contractor
Unit
Description
87
Remarks/ make
Engineer-in-charge

Data Sheets
7.4
7.4.1
PERFORMANCE GUARANTEE
General
The Tenderer shall provide requirement of electrical energy and chemical usage for the qualities of
raw sewage and effluent standards to be met as detailed in Volume IIIA: Scope of Work.
Note: The values provided in this schedule will be used to determine a typical annual running cost
for the Works. These costs shall be used in calculations of NPV for the bid.
7.4.2
Functional Guarantees
The Tenderer Guarantee the performance of the Plant namely 100 MLD capacity STP at Kalwa in
the performance and in O & M period as per following format:
7.4.2.1
Plant Effluent
The characteristics of treated sewage achieved is guaranteed to be

1.
BOD5 20oC, mg/l
:
2.
Suspended Solids, mg/l
:
3.
pH
:
4.
Oil & Grease, mg/l
:
7.4.2.2
Electrical Energy Usage per Unit Volume of Treated Sewage
The energy usage for the Plants during the Performance and O & M period is guaranteed to be not
more than ____________ kWh per m3 of treated sewage
The energy costs detailed above shall be for the whole plant.
7.4.2.3
Chlorine usage per Unit of Treated Sewage
The consumption of chlorine during Performance and O & M period is guaranteed to be not more
than ________ kg per m3 of treated sewage.
7.5
MISCELLANEOUS INFORMATION
The Tenderer shall provide other supporting data, which he considers necessary to complete his
proposal.
Contractor
88
Engineer-in-charge
VOLUME II-B
CIVIL SPECIFICATIONS
32 MLD Capacity STP at Panchak, Nashik

Volume II B: Civil Specifications
TABLE OF CONTENTS Volume II B, Civil Specifications

List of Tables............................................................................................................................ x
GENERAL ................................................................................................... 88
1.1
1.2
1.3
Specification Drawings ............................................................................................... 88

Geo-Technical Studies ................................................................................................ 88
Materials ..................................................................................................................... 88
1.3.1
1.4
1.5
Samples and Tests Of Materials ............................................................................................. 88
Standards .................................................................................................................... 89
List of Important Indian Standards........................................................................... 90
SPECIFIC CIVIL REQUIREMENTS ............................................................ 92
2.1
2.2
2.3
Design Submissions .................................................................................................... 92

Design Standards........................................................................................................ 92
Design Loadings ......................................................................................................... 92
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
Dead Load ............................................................................................................................. 92

Live Load .............................................................................................................................. 93
Wind Load ............................................................................................................................ 93
Earthquake Load ................................................................................................................... 93
Dynamic Load ....................................................................................................................... 94
Other Loads ........................................................................................................................... 94
2.4
Joints ........................................................................................................................... 94
2.5
Design Conditions for Underground or Partly Underground Liquid Retaining
Structures ............................................................................................................................... 94
2.6
Foundation .................................................................................................................. 94
2.7
Design Requirements.................................................................................................. 95
2.8
Minimum Cover to Main Reinforcement .................................................................. 96
2.9
Minimum Bar Diameter ............................................................................................. 97
2.10 Bar Spacing ................................................................................................................ 97
2.11 Materials ..................................................................................................................... 97
2.11.1
2.11.2
2.11.3
2.11.4
2.12
2.13
2.14
2.15
Samples and Tests of Materials.................................................................................. 98

Orientation ................................................................................................................. 99
Roadways, Pathways & Hardstandings ..................................................................... 99
Site Drainage .............................................................................................................. 99
2.15.1
2.15.2
2.16
2.17
2.18
2.19
General ............................................................................................................................. 97
Cement ............................................................................................................................. 98
Reinforcement Steel .......................................................................................................... 98
Minimum Cement Content ................................................................................................ 98
Storm Water Drainage ....................................................................................................... 99

Foul Drainage.................................................................................................................. 100
Cables and Pipework Trenches ................................................................................ 100

Pipes and Ducts ........................................................................................................ 100
Soil Data & Ground Water Table ............................................................................ 100
Buildings and Structures .......................................................................................... 100
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
I

2.20
Pressure Grouting .................................................................................................... 102
2.20.1
2.20.2
2.20.3
2.20.4
2.20.5
Products .......................................................................................................................... 102

Surface Inspection and Preparation .................................................................................. 102
Identification of Methods of Grouting .............................................................................. 103
Grouting for Honey Combed Surfaces ............................................................................. 104
Size and Spacing of Nipples ............................................................................................ 104
EARTHWORK AND EXCAVATION ......................................................... 105
3.1
3.2
Relavent IS Code ...................................................................................................... 105

Excavation ................................................................................................................ 105
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
3.2.12
3.2.13
3.2.14
3.3
3.4
3.5
Dewatering ................................................................................................................ 112

Timber Shoring ........................................................................................................ 113
Rain Water Discharge .............................................................................................. 114
3.5.1
Definitions .......................................................................................................................... 105

Site Clearance ..................................................................................................................... 105
General Excavation ............................................................................................................. 106
Lift and Lead ....................................................................................................................... 106
Excavation in Hard Rock ..................................................................................................... 107
Excess excavation to be made good...................................................................................... 109
Stripping Top Soil ............................................................................................................... 109
Supporting Excavations ....................................................................................................... 109
Trimming Excavations ......................................................................................................... 110
Inspection by the Engineer-in-Charge .............................................................................. 110
Disposing Excavated Material ......................................................................................... 110
Back-Filling General Site Grading And Sand Filling ........................................................ 110
Fill Density ..................................................................................................................... 112
Local Rules And Regulations........................................................................................... 112
Scope .................................................................................................................................. 114
ANTI TERMITE TREATMENT .................................................................. 115
4.1
4.2
4.3
4.4
Delivery, Storage and Handling ............................................................................... 115

Safety Requirements ................................................................................................ 115
Warranty .................................................................................................................. 115
Quality Assurance .................................................................................................... 115
4.4.1
4.5
Products .................................................................................................................... 116
4.5.1
4.5.2
4.5.3
4.5.4
5
5.1
5.2
5.3
5.4
5.5
5.6
Application Report .............................................................................................................. 115

Pesticides ............................................................................................................................ 116
Execution ............................................................................................................................ 116
Application.......................................................................................................................... 116
Rates and Methods of Application ....................................................................................... 116
CONCRETE AND ALLIED WORKS ......................................................... 117

General ..................................................................................................................... 117
Applicable Codes ...................................................................................................... 117
Materials for Standard Concrete ............................................................................. 119
Fine Aggregate.......................................................................................................... 121
Coarse Aggregate ..................................................................................................... 122
Water ........................................................................................................................ 123
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
II

5.7
Steel and Aluminium Members Encased in Concrete ............................................. 124
5.7.1
5.8
5.9
Anchor Bolts, Anchors, Sleeves, Inserts, .............................................................................. 124
Controlled Concrete ................................................................................................. 125

Mix Design ................................................................................................................ 125
5.9.1
5.9.2
5.10
General ............................................................................................................................... 125

Preliminary Tests ................................................................................................................. 126
Proportioning, Consistency, Batching and Mixing of Concrete .............................. 127
5.10.1
5.10.2
5.10.3
5.11
5.12
Sampling and Testing of Concrete in the Field........................................................ 131

Concrete Tests .......................................................................................................... 132
5.12.1
5.12.2
5.13
General ........................................................................................................................... 139

Formulation..................................................................................................................... 140
Application ..................................................................................................................... 140
Handling Precautions ............................................................................................... 141

Construction Joints .................................................................................................. 141
Movement Joints ...................................................................................................... 142
Water Stops and Joint Fillers................................................................................... 142
5.20.1
5.20.2
5.21
5.22
General ........................................................................................................................... 135

Retempered or Contaminated Concrete ............................................................................ 136
Avoiding Segregation ...................................................................................................... 136
Placing by Manual Labour ............................................................................................... 136
Placing by Mechanical Equipment ................................................................................... 136
Placement of Restricted Forms ........................................................................................ 136
Chuting ........................................................................................................................... 137
Placing by Pumping/Pneumatic Placers............................................................................ 137
Concrete in Layers .......................................................................................................... 137
Cover Blocks................................................................................................................... 137
Bedding of Layers ........................................................................................................... 138
Compaction ..................................................................................................................... 138
Placement Interval ........................................................................................................... 139
Special Provision in Placing ............................................................................................ 139
Placing Concrete Through Reinforcing Steel .................................................................... 139
Bleeding.......................................................................................................................... 139
Application of Araldite for Bonding of New and Old Concrete .............................. 139
5.16.1
5.16.2
5.16.3
5.17
5.18
5.19
5.20
General ........................................................................................................................... 134

Air Entraining Agents...................................................................................................... 134
Water Reducing Admixtures ............................................................................................ 134
Retarding Admixtures...................................................................................................... 134
Water Proofing Agent ...................................................................................................... 134
Other Admixtures ............................................................................................................ 134
Preparation Prior to Concrete Placement, Final Inspection and Approval ........... 134
Transportation.......................................................................................................... 135
5.15.1
5.15.2
5.15.3
5.15.4
5.15.5
5.15.6
5.15.7
5.15.8
5.15.9
5.15.10
5.15.11
5.15.12
5.15.13
5.15.14
5.15.15
5.15.16
5.16
Load Test on Members or Any Other Tests ...................................................................... 133

Unsatisfactory tests.......................................................................................................... 134
Admixtures ............................................................................................................... 134
5.13.1
5.13.2
5.13.3
5.13.4
5.13.5
5.13.6
5.14
5.15
Mixing of Concrete ......................................................................................................... 128

Grade of Concrete ........................................................................................................... 128
Workmanship .................................................................................................................. 131
Water stops ..................................................................................................................... 142

Jointing fillers ................................................................................................................. 143
Sealing Compounds .................................................................................................. 143

Tolerances in Concrete Surfaces .............................................................................. 143
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
III

5.23
Curing, Protecting, Repairing and Finishing .......................................................... 144
5.23.1
5.23.2
5.23.3
5.23.4
5.23.5
5.23.6
5.23.7
5.23.8
5.23.9
5.24
5.25
5.26
Hot Weather Requirement ....................................................................................... 148

Placing Concrete Underwater .................................................................................. 148
Precast Concrete....................................................................................................... 148
5.26.1
5.26.2
5.26.3
5.26.4
5.27
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
General ........................................................................................................................... 148

Striking Forms ................................................................................................................ 149
Precast Units ................................................................................................................... 149
Curing ............................................................................................................................. 149
Slots, Openings, Etc. ................................................................................................. 149
5.27.1
5.27.2
5.28
5.29
5.30
5.31
5.32
5.33
Curing ............................................................................................................................. 144

Curing with Water ........................................................................................................... 144
Continuous Spraying ....................................................................................................... 144
Alternate Curing Methods................................................................................................ 144
Curing Compound ........................................................................................................... 145
Curing Equipment ........................................................................................................... 145
Protecting Fresh Concrete ................................................................................................ 145
Repair and Replacement of Unsatisfactory Concrete ........................................................ 145
Finishing ......................................................................................................................... 146
General ........................................................................................................................... 149

Grouting.......................................................................................................................... 149
Inspection.................................................................................................................. 151
Clean-Up ................................................................................................................... 151
Records of Concreting .............................................................................................. 151
Supply of Cement ..................................................................................................... 151
Foundation Bedding, Bonding and Jointing ............................................................ 151
Preparation of Rock Strata of Foundations............................................................. 152
FORMWORK ............................................................................................ 153

Formwork, Fixing and General ............................................................................... 153
Removal of Formwork ............................................................................................. 154
Formed Surfaces - Classes of Finish ........................................................................ 155
Defects in Formed Surfaces ...................................................................................... 155
Holes to be Filled ...................................................................................................... 155
Tolerances ................................................................................................................. 156
Bracing, Struts and Props ........................................................................................ 158
REINFORCEMENT ................................................................................... 159

Relevant IS Codes..................................................................................................... 159
General ..................................................................................................................... 159
Storage ...................................................................................................................... 159
Quality ...................................................................................................................... 159
Laps .......................................................................................................................... 159
Bending ..................................................................................................................... 160
Fixing ........................................................................................................................ 160
Cover......................................................................................................................... 160
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
IV

7.9
7.10
7.11
Inspection.................................................................................................................. 161
Welding OF Reinforcement ..................................................................................... 161
Supply of Reinforcing Bars ...................................................................................... 161
STRUCTURAL STEEL WORK ................................................................. 162
8.1
8.2
8.3
8.4
8.5

General ..................................................................................................................... 162
Materials ................................................................................................................... 162
Fabrication and Erection ......................................................................................... 163
Painting..................................................................................................................... 164
8.5.1
8.5.2
General ............................................................................................................................... 165

Ironwork and Ungalvanised Steelwork ................................................................................. 165
BRICK WORK AND STONE MASONRY ................................................. 167
9.1
9.2

Materials ................................................................................................................... 167
9.2.1
9.2.2
9.3
9.4
9.5
9.6
9.7
Bricks.................................................................................................................................. 167
Mortar ................................................................................................................................. 167
Construction ............................................................................................................. 168

Curing ....................................................................................................................... 169
Scaffolding ................................................................................................................ 169
Stone Masonry for Retaining Walls ......................................................................... 169
Uncoursed Stone Masonry ....................................................................................... 169
9.7.1
9.8
9.9
9.10
Pointing of Uncoursed Masonry ........................................................................................... 170
Stone Pitching ........................................................................................................... 171

Rubble Packing......................................................................................................... 171
Concrete Block Masonry .......................................................................................... 171
9.10.1
9.10.2
9.11
Materials ......................................................................................................................... 171

Workmanship .................................................................................................................. 172
Damp-Proof Course.................................................................................................. 173
9.11.1
Materials and Workmanship ............................................................................................ 173
10
PLASTERING ........................................................................................ 175
10.1
10.2
10.3

Plastering .................................................................................................................. 175
Neeru......................................................................................................................... 176
10.3.1
10.3.2
Material .......................................................................................................................... 176

Workmanship .................................................................................................................. 176
11
FLOORING ............................................................................................ 177
11.1
11.2
11.3

General ..................................................................................................................... 177
Cement Concrete Flooring ....................................................................................... 177
11.3.1
CONTRACTOR
General ........................................................................................................................... 177
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
V

11.3.2
11.3.3
11.3.4
11.3.5
11.4
Granolithic (IPS) Flooring ....................................................................................... 179
11.4.1
11.4.2
11.5
Material .......................................................................................................................... 182

Preparation of Surface and Laying Over Base Course Concrete ........................................ 182
Curing, Polishing and Finishing ....................................................................................... 182
Glazed Tile Flooring ................................................................................................. 182
11.7.1
11.7.2
11.7.3
11.7.4
11.7.5
11.7.6
11.8
Tolerances ....................................................................................................................... 180

Manufacture .................................................................................................................... 180
Laying............................................................................................................................. 180
Curing, Polishing and Finishing ....................................................................................... 181
Terrazzo (Mosaic) In-Situ Flooring ......................................................................... 182
11.6.1
11.6.2
11.6.3
11.7
Finished Layers ............................................................................................................... 179

Curing ............................................................................................................................. 179
Terrazzo (Mosaic) Tile ............................................................................................. 180
11.5.1
11.5.2
11.5.3
11.5.4
11.6
Filling ............................................................................................................................. 177

Base Coarse .................................................................................................................... 178
Floor Finish Plain Cement Finish ..................................................................................... 179
Curing ............................................................................................................................. 179
White Glazed Tiles .......................................................................................................... 182

Size and Tolerance .......................................................................................................... 183
Coloured Tiles ................................................................................................................. 183
Decorative Tiles .............................................................................................................. 183
Preparation of Surface and Laying ................................................................................... 183
Pointing and Finishing ..................................................................................................... 184
Kota Stone Flooring ................................................................................................. 184
11.8.1
11.8.2
11.8.3
11.8.4
Tolerances ....................................................................................................................... 184

Dressing .......................................................................................................................... 184
Surface Preparation and Laying ....................................................................................... 184
Polishing and Finishing ................................................................................................... 185
11.9 Mosaic Finished Dado or Skirting ........................................................................... 185

11.10 Hardonite Flooring ................................................................................................... 185
11.10.1
11.10.2
Workmanship .................................................................................................................. 185

Preparation of Surface ..................................................................................................... 185
12
DISTEMPERING AND PAINTING ......................................................... 187
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
General ..................................................................................................................... 187

Concrete, brickwork and plaster ............................................................................. 187
Ironwork and Ungalvanised Steelwork ................................................................... 187
Galvanised Steelwork ............................................................................................... 188
Bituminous Surfaces ................................................................................................. 189
Aluminium Surfaces ................................................................................................. 189
Woodwork ................................................................................................................ 189
Waterproof Cement Paint ........................................................................................ 189
12.8.1
12.8.2
12.8.3
12.8.4
12.9
Surface Preparation ......................................................................................................... 189

Mixing the paint .............................................................................................................. 190
Method of Application..................................................................................................... 190
Curing ............................................................................................................................. 190
Silicon Paint .............................................................................................................. 190
12.9.1
12.9.2
12.9.3
CONTRACTOR
Preparation ...................................................................................................................... 190

Application ..................................................................................................................... 190
Spraying Equipment ........................................................................................................ 191
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
VI

12.9.4
Safety.............................................................................................................................. 191
12.10 Relevant IS Codes..................................................................................................... 191

12.11 Distempering ............................................................................................................ 191
12.11.1
12.11.2
12.11.3
12.11.4
Type ............................................................................................................................... 191

Material .......................................................................................................................... 191
Preparation of Surface and Priming Coat.......................................................................... 191
Application ..................................................................................................................... 192
12.12 Decorative Finish Cement Paint .............................................................................. 192

12.12.1
12.12.2
Surface Preparation ......................................................................................................... 192

Preparation of Mix and Application ................................................................................. 192
12.13 Painting..................................................................................................................... 192

12.13.1
12.13.2
12.13.3
12.13.4
12.13.5
Painting General .............................................................................................................. 192

Commencing the Work .................................................................................................... 192
Workmanship .................................................................................................................. 193
Application ..................................................................................................................... 193
12.14 Painting with Synthetic Enamel/Enamel Paint........................................................ 193

12.14.1
12.14.2
12.14.3
Material .......................................................................................................................... 193

Application ..................................................................................................................... 194
13
EXPANSION JOINTS AND CONSTRUCTION JOINTS ....................... 195
13.1
13.2
13.3
13.4
General ..................................................................................................................... 195

Material .................................................................................................................... 195
Joints In Floor .......................................................................................................... 195
Joints In Walls .......................................................................................................... 195
13.4.1
13.4.2
13.4.3
Expansion Joint ............................................................................................................... 195

Construction Joint ........................................................................................................... 196
Complete Construction Joints .......................................................................................... 196
14
EPOXY COATING, BITUMINOUS, POLYMER PAINTING ................... 198
14.1
Epoxy Coating .......................................................................................................... 198
14.1.1
14.1.2
14.1.3
14.1.4
14.2
General ........................................................................................................................... 198

Materials ......................................................................................................................... 198
Subsurface Preparation .................................................................................................... 198
Curing ............................................................................................................................. 198
Bituminous Painting ................................................................................................. 198
14.2.1
14.2.2
Material .......................................................................................................................... 198

Application ..................................................................................................................... 199
14.3
Polymer Painting ...................................................................................................... 199
15
DOOR, WINDOWS, GRILLS, SHUTTERS, ETC................................... 200
15.1
15.2
15.3
15.4
15.5

General ..................................................................................................................... 200
Woodwork in Doors, Windows, Partitions, Louvers, Railings etc. ......................... 200
Steel Doors, Windows and Fittings .......................................................................... 202
Rolling Shutters ........................................................................................................ 202
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
VII

16
HAND RAILING ..................................................................................... 204
17
RUNGS .................................................................................................. 205
18
PIPING WORK ...................................................................................... 206
18.1
Reinforced Cement Concrete Pipes (Class NP 3) .................................................... 206
18.1.1
18.1.2
18.1.3
18.1.4
18.1.5
18.1.6
18.1.7
18.1.8
18.1.9
18.1.10
18.2
Centrifugally Cast (Spun) Ductile Iron Pipe ........................................................... 211
18.2.1
18.2.2
18.2.3
18.2.4
18.2.5
18.2.6
18.2.7
18.2.8
18.2.9
18.3
Scope of Work ................................................................................................................ 211

Applicable Codes ............................................................................................................ 211
Pipe & Pipe Joint............................................................................................................. 211
Rubber Gasket ................................................................................................................. 212
Hydrostatic Test .............................................................................................................. 212
Pipe Lining ..................................................................................................................... 213
Use and Laying of Ductile Iron Pipe ................................................................................ 213
Hydraulic Testing of Pipeline .......................................................................................... 214
Restoration and cleaning up ............................................................................................. 215
General Specifications for CI Piping Work ............................................................. 215
18.3.1
18.3.2
18.4
Applicable Codes ............................................................................................................ 206

Laying of Pipes ............................................................................................................... 206
Pipe Bedding ................................................................................................................... 208
Jointing ........................................................................................................................... 208
Testing ............................................................................................................................ 209
Inspection of the Joints .................................................................................................... 209
Cleaning of the Pipes ....................................................................................................... 209
Fracture of Pipes ............................................................................................................. 210
All works to be clear clean and perfect ............................................................................. 210
Measurement of Pipes ..................................................................................................... 210
Cast Iron Pipe and Specials .............................................................................................. 215

Cast Iron fittings.............................................................................................................. 216
Specification for Laying, Jointing & Testing of CI pipe.......................................... 216
18.4.1
18.4.2
18.4.3
18.4.4
18.4.5
18.4.6
Stacking .......................................................................................................................... 216

Trench For CI Pipes and Specials .................................................................................... 216
Laying of Pipes and Specials ........................................................................................... 217
Jointing ........................................................................................................................... 217
Testing of Joints .............................................................................................................. 218
Backfilling ...................................................................................................................... 218
19
VALVES................................................................................................. 219
19.1
19.2
19.3
Solid Wedge Gate-Type Sluice Valves ..................................................................... 219

Knife Gate Valves ..................................................................................................... 222
Check Valves ............................................................................................................ 224
20
WATER SUPPLY AND SANITARY WORKS ........................................ 225
20.1
20.2
20.3
20.4
20.5
Applicable Codes ...................................................................................................... 225

Sanitary Installation ................................................................................................. 226
Indian Type Water Closet ........................................................................................ 226
Urinals ...................................................................................................................... 227
Wash Basin ............................................................................................................... 227
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
VIII

20.6
20.7
20.8
20.9
20.10
Sinks.......................................................................................................................... 227
Cast Iron Soil Waste and Vent Pipes and Fittings................................................... 227
Asbestos Cement Pipes and Fittings ........................................................................ 228
Galvanised Mild Steel (GI) Pipes ............................................................................. 228
Stoneware pipe and fittings ...................................................................................... 230
20.10.1
20.10.2
20.10.3
20.10.4
Spigot and Socket Joint (Cement Joint) ............................................................................ 231

Spigot and Socket Joint (Rubber Ring Joint) .................................................................... 231
Cleaning of Pipes ............................................................................................................ 231
Testing at Work Site ........................................................................................................ 232
20.11 Stop Cock and Bib Cock .......................................................................................... 232

20.12 Soak Pit ..................................................................................................................... 233
20.13 Manholes/Inspection Chambers............................................................................... 233
20.13.1
20.13.2
20.13.3
20.13.4
20.13.5
20.13.6
20.13.7
20.13.8
20.13.9
20.13.10
20.13.11
20.13.12
20.13.13
Location .......................................................................................................................... 233

Excavation ...................................................................................................................... 233
Bed Concrete................................................................................................................... 233
Bricks ............................................................................................................................. 233
Cement Mortar ................................................................................................................ 234
Brick Masonry ................................................................................................................ 234
Cement Plaster ................................................................................................................ 234
Cement Concrete Channel ............................................................................................... 235
Pipe Entering or Leaving Manhole / Inspection Chamber ................................................. 235
Cast Iron Steps ............................................................................................................ 235
Frame and Covers ....................................................................................................... 236
Drop Manhole ............................................................................................................. 237
RCC Manhole ............................................................................................................. 237
20.14 Vent Shafts................................................................................................................ 237

20.14.1
20.14.2
20.14.3
General ........................................................................................................................... 237

GI Pipe Vent Shaft .......................................................................................................... 237
RCC Vent Shaft .............................................................................................................. 237
20.15 Septic Tank ............................................................................................................... 238

20.16 Miscellaneous............................................................................................................ 238
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
IX

LIST OF TABLES
Table 1: List of IS
Table 2: Foreign Material Limitations in Fine Aggregate
Table 3: Grading of Sand for Fine Aggregate
Table 4 : Foreign Material Limitations in Coarse Aggregate
Table 5: Grade of Concrete
Table 6: Compressive Strengths at 28 days
Table 7: Minimum Cement Content in Concrete
Table 8: Limits of Consistency
Table 9 : Types of Water Stops
Table 10 : Proportions for Standard Grout
Table 11 : Proportions for Non-Shrinking Grout
Table 12 : Period for Formwork
Table 13 : Sizes of Terrazzo Tiles
CONTRACTOR
NO.
OF
CORRECTIONS
90
121
122
123
128
129
129
131
143
149
150
154
180
EXECUTIVE ENGINEER
X

PREAMBLE
1.0
The Volume IIB: Civil Specifications are to be read for the purpose of pricing in
conjunction with "Volume-I: Conditions of Contract" of the Tender Documents
containing instructions to Tenderer and General Conditions of Contract; Volume IIA:
Scope of Work under this tender; Volume IIC: Mechanical Specifications, Volume
IID: Electrical Specifications and Volume-III: Financial Bid of this tender.
2.0
3.0
specified or not. If not specified work shall be carried out as per directions of
Owner/Engineer.
4.0
The total amount entered in the Volume III: Financial Bid shall be written in ink and
shall be entered both in figures and words.
5.0
Specifications of items of work described in Section D for each item shall read this in
conjunction with other technical specifications and specific technical requirements and
quote accordingly.
6.0

during excavation, laying of PCC and RCC laying and jointing of pipes, construction of
manholes, testing and backfilling etc. and Contractor should quote accordingly.
7.0
If the Tenderer needs any clarification, they shall obtain the same in writing from
Owner/Engineer. No notice will be taken of any verbal discussions in such matters.
8.0
Abbreviations used in this Volume IIB : Civil Specifications document have the
meanings shown below:
mm
cm
m
km
sq.m
cum.
M.T.
SWG
R.M.
nos.
MS
M.D
CONTRACTOR
Millimetre
Centimetre
Metre
Kilometre
Square Metre
Cubic Metre
Metric Ton
Standard Wire Gauge
Running Metre
Numbers
Mild Steel
NO.
OF
CI
GI
GSW
BBCC
RCC
PCC
wt
kg
I.D.
C.M.
IS
SS
CORRECTIONS
Cast Iron
Galvanized Iron
Glazed Stone Ware
Weight
Kilogram
Internal Diameter
Cement Mortar
Indian Standards
Stainless Steel
EXECUTIVE ENGINEER
XI

1
1.1
GENERAL
SPECIFICATION DRAWINGS
The site plan, schematic flow diagram and layout plan drawings of the proposed
work(s)/plant(s) are incorporated in tender documents. These drawings are made for
Tenderers guidance only.
The Contractor will have to submit detailed design as well as General Arrangement
drawings as well as structural drawings to the Engineerin-Charge and obtain prior
approval to start the construction, erection and commissioning of civil, electrical and
mechanical components of the treatment plant.
Work shall be carried out by Contractor exactly in accordance with the Drawings marked
as RELEASED FOR CONSTRUCTION and approved by Engineer-in-Charge and as per
the instructions of the Engineer-in-Charge in writing.
1.2
GEO-TECHNICAL STUDIES
The bidders are free to visit and inspect the sites till the submission date for the purpose
of quoting and estimation. The Contractor shall carry out geo-technical studies at their
cost at the site and with prior permission of Engineer-in-Charge, from NMC approved
soil consultant and the report should be furnished to the NMC/Consultant and should
approved by NMC/Consultant prior to start of structural design & drawings. NMC
accepts no responsibility, whatsoever for inferences drawn from this data and the
Contractor is to satisfy NMC on his own responsibility as to the extent to which this
information represents the conditions to be encountered.
1.3
MATERIALS
The term Materials shall mean all materials, goods and articles of every kind whether
raw, processed or manufactured and equipment and plant of every kind to be supplied by
the Contractor for incorporation in the works.
Except as may be otherwise specified for particular parts of the Works the provision of
clauses in materials and workmanship shall apply to materials and workmanship for
any part of the works.
All materials shall be new and of the kinds and qualities described in the Contract and
shall be approved by the Engineer in- charge.
Materials shall be transported, handled and stored in such a manner as to prevent
deterioration, damage or contamination failing which such damaged materials will be
rejected and shall not be used on any part of the Works under this contract.
1.3.1 Samples and Tests Of Materials

1. The Contractor should submit test certificates of the materials at the time of material
unloading on the site
2. The Contractor shall submit samples of such materials as may be required by the
Engineer-in-Charge and shall carry out the specified tests directed by the Engineer-
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
88

3.
4.
5.
6.
7.
in-Charge at the site, at the suppliers premises and at a laboratory approved by the
Engineer-in-Charge.
The Contractor should give Engineer-in-Charge seven days notice in writing about
the date on which any of the materials will be ready for testing or inspection at the
supplier's premises or at a laboratory as approved by the Engineer-in-Charge. The
Engineer shall attend the test at the appointed place within 7 days of the said date on
which the materials are expected to be ready for testing or inspection according to
Contractor, failing to which the test may proceed in his absence unless instructed by
Engineer-in-Charge to carry out such a test on a mutually agreed upon date in his
presence. The Contractor shall in any case submit to the Engineer-in-Charge within
seven days of every test such number of certified copies (not exceeding six) of the
test readings as the Engineer-in-Charge in charge may require.
Approval by the Engineer-in-Charge as to the placing of orders for materials or as to
samples or tests shall not prejudice any of the Engineer-in-Charge's powers under the
contract particularly as to the provisions under the conditions of contract.
The provisions of this clause shall also apply to materials supplied under any
nominated sub-contract.
In any case the Contractor shall not use any material without prior testing and
clearance by the Engineer-in-Charge. In case such material is used, this will be liable
for rejection either partly or fully.
If required rejected material shall be marked and stockpiled separately; and such
rejected material shall be taken out within a week from construction site.
The cost of the material testing at the supplier premises and as on the site shall be borne
by the Contractor and without prior testing and clearance of the Engineer-in-Charge, the
materials should not be used for the work.
1.4
STANDARDS
1. The special attention of the Contractor is drawn to the relevant sections and clauses
of the National Building Code of India 1984 & Maharashtra PWD specifications
and latest BIS Codes (Latest editions along with amendments) and should follow
them strictly in addition to the specifications & conditions stipulated in this volume.
2. Materials and workmanship shall comply with the relevant Indian Standards (with
amendments) current at the Tenth day of August, 2001, unless a more recent
amendment is specified hereinafter, or with the requirements of any other
authoritative standard approved by the Engineer-in-Charge which shall be no less
exacting in the opinion of the Engineer-in-Charge than the corresponding standard
quoted here in.
3. Where the relevant standard provides for the furnishing of a certificate to the NMC
on request, stating that the materials supplied comply in all respects with the
standard, the Contractor shall obtain the certificate and forward it to the Engineer-inCharge.
4. The specifications, standards and codes listed below are made a part of this
specification. All standards, tentative specifications, specifications, codes of practice
referred to herein shall be the latest editions including all applicable official
amendments and revisions.
5. If no standard is indicated, the relevant Indian Standard, if any, shall apply. Indian
standards are published by BIS.
6. HandBook (1990) shall be followed, wherever not specified in this Volume II:
Technical Specifications, Maharashtra PWD specifications (1990) and IS
specifications shall be applicable in case of discrepancy Engineer-in-Charges
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
89

decision will be final & binding. Specifications for different Materials as per IS
codes
1.5
LIST OF IMPORTANT INDIAN STANDARDS

The following list includes various Indian Standards which are IMPORTANT and are
referred to in the general specifications and used in construction works. These standards
are to be strictly adhered to unless otherwise is applicable in the relevant context. These
standards are to be followed both in respect of materials and construction of civil
engineering works included in the tenders.
Though the list of Indian Standards includes the year of Publication of the standard, it
may not in all cases be the latest. It is obligatory that only the latest edition of the
standard is referred to and followed, along with all amendments and revisions issued
with respect to the standard under consideration. This list is not exhaustive but contains
only the standards that are very frequently used on the construction works. If a standard
exists for a particular item of material or equipment or code of practice the same shall be
followed whether the same is included in this list, specifications, other parts of the tender
documents or not. Some Indian Standards are referred to in the specifications/ drawings/
other parts of the tender documents and they are supplementing this list if they do not
find a place in the list.
Table 1: List of IS
Sr.
IS Code No. /
Year
153-1950
2
3
4
5
6
7
8
9
10
11
12
13
14
15
171-1985
2062-1984
269-1976
383-1970
432(part1)-1982
455-1976
456
458-1971
516-1959
651-1981
783-1985
784-1978
800-1984
816-1969
16
17
18
19
20
21
22
23
24
25
1038-1983
1077-1986
1199-1959
1200 (part1-26)
1363 (part 1-3)
1367
1477 (part 1-2)
1542-1977
1726 (part 1,2 & 4)
1786-1985
CONTRACTOR
Title
Ready mixed paint, spraying, stoving, lead free, for general

purposes
Cotton and cotton regenerated cellulosic fibre blended grey yarn
Specification for Structural Steel (Fusion Welding Quality)
Ordinary and low heat Portland cement
Coarse and fine aggregates from natural sources for concrete
Mild steel and medium tensile steel bars
Portland slag cement
Code of practice for plain and reinforced cement concrete
Concrete pipes
Methods of test for strength of concrete
Salt-glazed stoneware pipes and fittings
Code of practice for laying of concrete pipes
Pre-stressed concrete pipes
Code of practice for general construction in steel
Code of practice for use of metal arc welding for general
construction in mild steel
Steel-doors, windows and ventilators
Common burnt clay building bricks
Methods of sampling and analysis of concrete
Method of measurement of building and civil engineering works
Hexagon head bolts, screws and nuts of product grade C
Technical supply conditions for threaded steel fasteners
Code of practice for painting of ferrous metals in buildings
Sand of plaster
Cast iron manhole covers and frames
High strength deformed steel bars and wires for concrete
NO.
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90

Sr.
IS Code No. /
Year
26
27
28
29
30
31
32
2074-1979
2116-1980
2212-1962
2250-1981
2339-1963
2386 (part I-VIII)
2502-1963
33
34
35
36
37
2720 (part IV,VIII)

3006-1979
3370 (part I-IV)
3696
3764-1966 (part 12)
4082-1977
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
4111 (part 1-4)

4127-1983
6248-1979
6909-1973
7293-1974
7969-1975
Code
4014
5121
2911-1980 Part III
& IV
3764
4082
7293
3114
5822
7364
Title
reinforcement
Ready mixed paint, air drying red oxide zinc chrome priming
Sand for masonry mortars
Code of practice for brickwork
Code of practice for preparation and use of masonry mortars
Aluminum paint for general purpose in dual container
Methods of tests for aggregate for concrete
Code of practice for bending and fixing of bars for reinforced
concrete
Methods of test for soil
Chemically resistant glazed stoneware pipes and fittings
Code of practice for concrete structures for the storage of liquids
Safety code for scaffolds and ladders
Safety code for excavation work
Recommendations on stacking and storage of construction
materials at site
Code of practice for ancillary structures in sewerage systems
Code of practice for laying of glazed stone ware pipes
Metal rolling shutters and rolling grills
Super sulphated cement
Safety code for working with construction machinery
Safety code for handling and storage of building materials
National Building Code of India
Code of practice for steel tubular scaffolding.
Code of practice for deep foundation
Code of practice for design and construction of pile foundation
Safety code for excavation work
Recommendations on stocking & storage material at site.
Safety code of working with construction machinery.
Code of practice for laying CI pipes
Code of practice for laying of welded steel for pipes
Plastic pipe work for potable water supply (part I-III)
Indian Standards Institution

Manak Bhavan
9, Bahadur Shah Zafar Marg
New Delhi - 110 002.
CONTRACTOR
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2.1
SPECIFIC CIVIL
REQUIREMENTS
DESIGN SUBMISSIONS
The Contractor shall submit complete detailed design calculations of foundations and
superstructure together with general arrangement drawings and explanatory sketches to
the NMC. Separate calculations for foundations or superstructures submitted
independent of each other should be deemed to be incomplete and will not be accepted
by the NMC.
The design considerations described herewith establish the minimum basic requirements
of plain and reinforcement concrete structures, masonry structures and structural steel
works. However, any particular structure shall be designed for the satisfactory
performance of the functions for which the same is being constructed. The Contractor
shall also take care to check the stability of structure partly constructed to comply with
design loads.
2.2
DESIGN STANDARDS
All designs shall be based on the latest International or Indian Standard (IS)
Specifications or Codes of Practice. The design standards adopted shall follow the best
modern engineering practice in the field based on any other international standard or
specialist literature subject to such standard reference or extract of such literature in the
English language being supplied to and approved by the NMC. In case of any variation
or contradiction between the provision of the IS Standards or Code and the specifications
given with the submitted tender document, the provision given in the Specification shall
be followed.
2.3
DESIGN LOADINGS
All building and structures shall be designed to resist the worst combination of the
following loads/stresses under test and working conditions these include dead load, live
load, wind load, seismic load, stresses due to temperature changes, shrinkage and creep
in materials, dynamic loads and uplift pressure.
2.3.1 Dead Load

This shall comprise all permanent construction including walls, floors, roofs, partitions,
stairways, fixed service equipment and other items of machinery. In estimating the loads
of process equipment all fixtures and attached piping shall be included, but excluding
contents shall be considered.
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The following minimum loads shall be considered in design of structures:

Sr. Parameter
Load
(i)
(ii)
(iii)
(iv)
(v)
Weight of water
Weight of soil (irrespective of strata available at site and
type of soil used for filling etc) However, for checking
stability against uplift, actual weight of soil as
determined by field test shall be considered
Weight of plain concrete
Weight of reinforced concrete
Weight of brickwork (exclusive of plaster)
(vi)
Weight of plaster to masonry surface
(vii)
Weight of granolithic terrazzo finish or rendering screed,

etc
Weight of sand (filter media)
(viii)
10.0 kN/cu.m
20.0 kN/cu.m
24.0 kN/cu.m
25.0 kN/cu.m
22.0 kN/cu.m
mm thickness
brickwork
18.0 kN/cu.m
mm thickness
24.0 kN/cu.m
mm thickness
24.0 kN/cu.m
per
of
per
per
2.3.2 Live Load

Live loads shall be in general as per IS 875. However, the following minimum loads
shall be considered in the design of structures.
Sr.
1.
2.
3.
4.
5.
6.
7.
Location
Office, Conference Hall
Floor supporting Pumping Machinery
Storage
Platform, Staircase, Corridors, Walkways
Administration Building Hall, Toilet
Laboratory
Roof Slab
Live Loads
400 kg/sq.m
1,000 kg/sq.m
750 kg/sq.m
500 kg/sq.m
200 kg/sq.m
400 kg/sq.m
150 kg/sq.m
In the absence of any suitable provisions for live loads in IS Codes or as given above for
any particular type of floor or structure, assumptions made must receive the approval of
the NMC prior to starting the design work. Apart from the specified live loads or any
other loads due to material stored any other equipment load or possible overloading
during maintenance or erection/construction shall be considered and shall be partial or
full whichever causes the most critical condition.
2.3.3 Wind Load
Wind loads shall be as per IS:875
2.3.4 Earthquake Load
This shall be computed as per IS:1893 considering in Zone-III.
CONTRACTOR
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EXECUTIVE ENGINEER
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2.3.5 Dynamic Load

Dynamic loads due to working of plant items such as pumps, blowers, compressors,
switch gears, travelling cranes, etc shall be considered in the design of structures.
2.3.6 Other Loads
In addition to earth pressure and water pressure etc., the surcharge of 1 Ton/sq.m shall be
taken into account in the design for channels, tanks, pit, sludge settler, etc.
2.4
JOINTS
Movement joints such as expansion joints, complete contraction joints, partial
contraction joints and sliding joints shall be designed to suit the structure as per relevant
IS code provisions. Expansion joints of suitable gap at intervals not more than 30 m
shall be provided in walls, floors and roof slabs of Liquid Retaining Structures.
Construction joints shall be provided at right angles to the general direction of the
member. The locations of construction joints shall be decided on convenience of
construction. To avoid segregation of concrete in walls, horizontal construction joints
are normally to be provided at every 2 m height, PVC waterstops of suitable type and
approved make, minimum 230 mm width, 6 m thick shall be used for walls and base
slabs.
2.5
DESIGN CONDITIONS FOR UNDERGROUND OR

UNDERGROUND LIQUID RETAINING STRUCTURES
PARTLY
All underground or partly underground liquid containing structures shall be designed for
the following conditions:
1. Liquid depth up to full height of wall : no relief due to soil pressure from outside to
be considered.
2. Structure empty (i.e. empty of liquid, any material, etc) full earth pressure including
saturated condition and surcharge pressure wherever applicable to be considered.
3. Partition wall between dry sump and wet sump to be designed for full liquid depth
up to full height of wall
4. Partition wall between two compartments to be designed as one compartment empty
and other compartment full
5. Structures shall be designed for uplift in empty conditions with the water table
indicated in the geotechnical report or high flood level, whichever is maximum. No
reduction factor for the uplift force shall be considered.
6. The dead weight of the empty structures should provide a safety factor of not less
than 1.2 against uplift pressures during construction and in service.
7. Wall shall be designed under operating conditions to resist earthquake forces from
earth pressure mobilisation and dynamic water loads;
8. Underground or partially underground structures shall be checked against stresses
developed due to any combination of full and empty compartments with appropriate
ground/uplift pressures from below to base slab
9. The walls and base slabs shall be designed for saturated earth/water pressure
corresponding to high flood level.
2.6
FOUNDATION
1. The minimum depth of foundations for all structures, equipments buildings and
frame foundations and load bearing walls shall be as per IS:1094.
CONTRACTOR
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2. The earthfill above virgin ground level till formation level shall be taken as a
surcharge load and shall be added in the loads coming on foundations appropriately
3. Maximum safe bearing capacity of soil strata shall be taken as indicated in
geotechnical reports.
4. Care shall be taken to avoid the foundations of adjacent buildings or structure
foundations, either existing or not within the scope of this Contract. Suitable
adjustments in depth, location and sizes may have to be made depending on site
conditions. No extra claims for such adjustments shall be accepted by the Employer.
5. Special attention is drawn to danger of uplift being caused by the ground water table
6. Plinth level of all structures/top of tanks shall be atleast 500 mm above high flood
level.
2.7
DESIGN REQUIREMENTS
The following are the design requirements for all reinforced or plain concrete structures:
1. All blinding and leveling concrete shall be minimum 100 mm thick in concrete grade
M10 for Building & minimum 150 mm thick for Water Retaining Structure.
2. All structural reinforced concrete shall be with a maximum 40 mm aggregate size for
footings and base slabs and with a maximum 20 mm aggregate size for all the Water
Retaining Structures & other structural members.
3. All liquid retaining structures shall be designed as per IS:3370 as Uncracked Section.
The minimum grade of concrete shall be M 25.
4. All new liquid retaining structures shall be form finished.
5. For all old liquid retaining structures inside finish shall be provided in CM 1:3
smooth cement plaster 20 mm thick and outside finish shall be 20 mm thick sand
face plaster CM 1:3. Snowcem shall also be applied for finishing the outer surfaces.
6. Minimum Cement Content shall be 360 kg/cu.m for M 25.
7. The maximum free water cement ratio shall not exceed 0.40 for all liquid retaining
structures.
8. The amount of reinforcement in each of the two directions at right angles within each
surface zone should not be less than the minimum specified as IS:3370 or IS:456
which ever is applicable for the type of structure.
9. Use of pressure relief valves to reduce uplift pressure due to ground water table shall
not be allowed.
10. All pipes and ducts laid below the structural plinth and road works shall be
surrounded with concrete of grade M15.
The following minimum thickness shall be used for different reinforced concrete
members irrespective of design thickness.
CONTRACTOR
NO.
OF
CORRECTIONS
EXECUTIVE ENGINEER
95

Sr.
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
2.8
Civil Member
Width (mm)
Walls for liquid retaining structures

Bottom slabs for liquid retaining structures
Wall foundation for wall of liquid retaining structures
Walls of Launders
Base slab of Launders
Roof slabs/Domes for liquid retaining structures
Floor slabs including roof slabs, walkways canopy slabs
Walls of cables/pipe trenches, underground pits, etc
Column footings Edge Thickness
Column footings - at Face of Column
Parapets, chajja
Precast trench cover
Beam
200
200
250
150
150
125
125
125
200
300
100
75
230 (width)
300 (depth)
MINIMUM COVER TO MAIN REINFORCEMENT

Sr.
Member
1.
Slab
2.
3.
4.
5.
6.
CONTRACTOR
Details
Cover
(mm)
Free Face
Face in contact with earth
Beam
Top/Bottom
Side
Column and pedestal
Super Structure
Retaining wall, Basement & Pit Face in contact with earth
wall
Free face
Liquid Retaining Structure
Face in contact with liquid
Free face
Foundation
Bottom
Top
Sides
NO.
OF
CORRECTIONS
20
30
40
30
40
40
40
30
30
40
40
40
60
60
50
EXECUTIVE ENGINEER
96

2.9
MINIMUM BAR DIAMETER

Sr.
Member
Diameter (mm)
Major Foundation
Block Foundation Main Bars
Block Foundation Tie Bars
Minor Foundation (Local Foundation etc.)
Column, Pedestal Main Bars
Column, Pedestal Ties
Beam Main Bars
Beam Anchor Bars
Beam Stirrups
Slab Main Bars
Slab Distribution Bars
Wall Main Bars
Wall Distribution Bars
Minor elements such as chajjas, Lintel Beams etc.
10
10
8
8
12
8
12
10
8
8
8
8
8
8
2.10 BAR SPACING

The bar spacing shall be as per design and conform to IS: 456 2000.
Sr. Member
Minimum (mm) Maximum (mm)
(i)
(ii)
(iii)
(iv)
(v)
Foundations
Slabs
Stirrups for Beams
Ties for Columns, Pedestals
Walls
100
100
100
100
100
200
250
250
250
250
* Bar spacing shall be provided in multiple of 25 mm.
2.11 MATERIALS
2.11.1
General
The term materials shall mean all materials, goods and articles of every kind whether
raw, processed or manufactured and equipment and plant of every kind to be supplied by
the Contractor for incorporation in the Works.
Expect as may be otherwise specified for particular parts of the works the provision of
clauses in Materials and Workmanship shall apply to materials and workmanship for
any part of the works.
All materials shall be new and of the kinds and qualities described in the Contract and
shall be at least equal to approved samples.
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As soon as practicable after receiving the order to commence the works, the Contractor
shall inform the NMC of the names of the suppliers from whom he proposes to obtain
any materials but he shall not place any order without the approval of the NMC which
may be withheld until samples have been submitted and satisfactorily tested. The
Contractor shall thereafter keep the NMC informed of orders for and delivery dates of all
materials.
Materials shall be transported handled and stored in such a manner as to prevent
deterioration damage or contamination failing which such damaged materials will be
rejected and shall not be used on any part of the Works under this contract.
2.11.2
Cement
The Cement shall be Ordinary Portland Cement grade-43 / 53, confirming to the relevant
BIS codes and approved by the NMC. Manufacturers Test Certificate shall have to be
furnished.
2.11.3
Reinforcement Steel
Reinforcement Steel shall confirm to BIS Specification 432-1966 (with up to date

revision) and B.I.S. Specification 1786-1985 (with up to date revision). All
reinforcement steel shall be Fe 500 TMT grade of TATA Tiscon make only.
2.11.4
Minimum Cement Content
The minimum cement content for each grade of concrete shall be as per table below.
Sr.
Grade of Concrete
Minimum Cement Content in Concrete

(kg/cum of finished Concrete)
(i)
(ii)
(iii)
(iv)
M 15
M 20
M 25
M 30
300
330
360
400
2.12 SAMPLES AND TESTS OF MATERIALS

The Contractor shall submit samples of such materials as may be required by the NMC
and shall carry out the specified tests directed by the NMC at the site at the Site at the
suppliers premises or at the laboratory approved by the NMC. All testing charges shall
be borne by the contractor.
Samples shall be submitted and tests carried out sufficiently early to enable further
samples to be submitted and tested if required by the NMC.
The Contractor shall give the NMC seven days notice in writing of the date on which
any of the materials will be ready for testing or inspection at the suppliers premises or at
a laboratory approved by the NMC. The NMC shall attend the test at the appointed place
within seven days of the said date on which the materials are expected to be ready for
testing or inspection according to the Contractor, failing which the test may proceed in
his absence unless instructed by the NMC to carry out such a test on a mutually agreed
CONTRACTOR
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date in his presence. The Contractor shall in any case submit to NMC within seven days
of every test such number of certified copies (not exceeding six) of the test results as the
NMC may require.
Approval by the NMC as to the placing of orders for materials or as to samples or tests
shall not prejudice any of the NMC powers under the Contract.
The provisions of this clause shall also apply to materials supplied under any nominated
sub-contract.
2.13 ORIENTATION
The works shall be laid out within the confines of the site in order to be compatible with
the existing infrastructure facilities, inlet and outlet pipe work /channels and nearby
water bodies. Underground services requiring being relocated in order to accommodate
the proposed site layout shall be relocated by the Contractor to alignments approved by
the Employers Representative.
2.14 ROADWAYS, PATHWAYS & HARDSTANDINGS

A comprehensive network of roadways shall be provided around the treatment plant to
link in with the existing approach road and permit access to the plant for necessary
maintenance, delivery of consumables and personnel access. All roads shall be of Water
Bound Macadam (WBM) with BM + AC of 4 m wide. Vehicular access shall be
provided for all Plant structures and buildings. All roads shall be provided with drainage
and shall be constructed to prevent standing water.
Paved pedestrian access ways shall be constructed to provide a network of logical routes
inter-linking plant areas. Damage to any existing roads, on account of their use by the
Contractor shall be made good to the satisfaction of the NMC.
Hardstanding areas shall be provided to permit the parking of vehicles involved in the
delivery of consumables from blocking site roadways during unloading or loading. The
road system shall be designed such that vehicles involved in the delivery of consumables
can follow a continuous route through the works and out again.
2.15 SITE DRAINAGE

The Contractor shall provide a site drainage system. The system shall comprise of the
following:
Storm Water Drainage
Foul Drainage
2.15.1
Storm Water Drainage
Storm water drains adjacent to the existing and proposed roads (under this Contract)
shall be sized for a rainfall intensity of 50 mm/hr, allowing for 100% runoff. Drains
adjacent to roads shall be in stone/brick masonry (1:5) of appropriate thickness topped
with 75 mm thick M10 concrete and internally flush pointed plastered in cement mortar
(1:4) mm thick.
CONTRACTOR
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The storm water drainage system shall be designed to cater for the run-off from the
existing plot areas and structures, if necessary.
2.15.2
Foul Drainage
The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be conveyed to the nearby sewer manhole.
2.16 CABLES AND PIPEWORK TRENCHES

Cables and pipe work trenches shall generally be constructed in reinforced concrete.
However, 500mm x 500mm size or small trenches, not on fill may be constructed in 350
mm thick brick masonry (1:4). The trenches will be plastered internally with cement
mortar (1:4) and externally in cement mortar (1:3).
Trenches within the buildings or Plant areas shall be covered with GI chequered plates,
suitably painted and that outside the buildings shall be covered with M20
premoulded/branded precast RCC covers. The trenches shall be suitably sloped to drain
rainwater.
Layout of trenches outside the buildings shall allow space for construction of future
trenches where necessary with due consideration for planning for future developments.
This aspect shall be brought to the notice of the NMC while planning the works.
2.17 PIPES AND DUCTS

RCC ducts for drainage shall have adequate cover while laid under roads. Access shafts,
where required shall not be of size less than not less than 600 mm x 1000 mm.
All drains (except storm water drains adjacent to roads) shall be covered and designed
structurally for appropriate loads.
2.18 SOIL DATA & GROUND WATER TABLE

Geotechnical assessment report is enclosed herewith for the reference. However the
contractor shall visit the site and should carry soil investigation and confirm the data at his
won cost.
2.19 BUILDINGS AND STRUCTURES

All the building and structure works shall generally comply with the following
Employers Requirements unless otherwise specified elsewhere:
1. All building works shall be reinforced concrete framework with concrete floors and
roofs.
2. All internal partition walls except for toilet shall be in 230 mm thick brick masonry
built in cement mortar 1:5 with transomes and mullions as in (2) above. Toilet
partition walls shall be in 115 mm thick brick masonry built in cement mortar 1:4
and shall have transomes and mullions similar to (2) above and shall form panels not
exceeding 1200 mm x 1200 mm in size.
3. Toilet floor slab shall be filled with brick bat cobs (broken bricks in lime) and
provided with waterproofing as per the specifications of an approved specialist
waterproofing company.
CONTRACTOR
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100

4. The finished floor level in toilet areas shall be 25 mm below general finished floor
level elsewhere in the building.
5. The toilet facilities shall be provided in Administration-cum-Laboratory building
separately for men and women which include at least :
i)
2 Nos. Toilet (1 no. for men and 1 no. for women) with white porcelain
Orissa pan minimum 580 mm long with flushing cistern of 10 litres capacity.
ii)
2 Nos. wash basins (1 no. for men and 1 no. for women) of size 510 mm x
400 mm in white porcelain with inlet, outlet and overflow arrangements.
iii)
2 Nos. mirrors (1 no. for men and 1 no. for women) of size 400 mm x 600
mm wall mounted type fitted over wash basins.
iv)
2 Nos. plastic liquid soap bottles (1 no. for men and 1 no. for women)
v)
2 Nos. chromium plated brass towel rails (1 no. for mean and 1 no. for
women) minimum 750 mm long.
vi)
All stopcocks, valves and pillar cocks shall be heavy-duty chromium plated
brass.
vii)
All fittings such as P or S traps, floor traps, pipes, downtake pipes etc.
viii)
The sewage from toilet blocks shall be led to the nearest NMC sewerage
network sewer line.
6. All staircase shall have 25 mm thick chequered mosaic tiles for treads and 25 mm
thick plain mosaic tiles of approved shade for risers set in cement mortar or lime
mortar to give an overall thickness of 50 mm.
7. All floor cut-outs and cable ducts, etc. shall be covered with precast concrete covers
in outdoors areas and mild steel chequered plates of adequate thickness in indoor
areas. All uncovered openings shall be protected with galvanised MS hand railing.
8. All staircases shall be provided with MS galvanised and MS hand railing for
protection.
9. For the entire finished roof surface shall have adequate slope to drain quickly the
rainwater to rainwater downtake inlet points.
10. For roofing drainage, CI rainwater downtakes with CI bell mouth and MS grating at
top shall be provided. For roof areas up to 40 sq.m. minimum two nos. 100 mm
diameter downtake pipes shall be provided. For every additional area of 40 sq.m. or
part thereof, at least one no. 100 mm diameter downtake pipe shall be provided.
11. Top surfaces of chajjas and canopies shall be made waterproof by providing a screed
layer of adequate slope or application of an approved roof membrane and sloped to
drain the rainwater.
12. All doors, windows, rolling shutters shall have lintels above. Chaija protection to
lintels on external walls shall be such as to prevent the rainwater splashing into the
building. The minimum width of chajja for doors, windows, and rolling shutter shall
be 750 mm, 600 mm, and 900 mm respectively.
13. All windows and ventilators shall have 25 mm thick Tandoor/Kota stone stills
bedded in cement mortar (1:3)
14. All concrete channels and ducts use for conveying liquid shall have inside width not
be less than 500 mm. All open channels shall be provided with hand railings. Also
all such channels, which are more than 1000 mm above finished plot level, shall be
provided with walkways for access.
15. Kerbs to be provided below the hand railing on the catwalks/pathways should be as
per relevant sections of Factor Act.
16. Wherever equipment and machinery are to be moved for inspection, servicing,
replacement etc., suitable movable gantry of minimum capacity of 2 tons or more as
required shall be provided with monorail and operating equipment.
CONTRACTOR
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17. The design of buildings shall reflect the climatic conditions existing on site. Process
buildings shall be as far as is possible permit the entry of natural light.
18. The Laboratory, Chlorine House and office building shall be provided with a sink
with two drinking water taps of 20 mm size with adequate inlet and outlet
connections.
19. The sidewalls of buildings shall, except those used for storage and handling of
Chlorine gas comprise at least 15% ventilation areas. Ventilated brickwork or
louvres shall not be used where the ingress of driven rain could affect plant or stored
materials.
20. All walkways, staircase, platforms etc, shall be minimum 1200 mm wide and will be
provided with handrailing on one or both sides as required.
21. The floor shall generally be made of 150mm thick concrete slab on grade with 230
mm thick rubble soling and polyethylene sheet. The grade slab shall be provided
with TOR 8 mm reinforcement Bars at 200 mm c/c bothways.
22. All hardware fittings and fixtures for doors, windows and louvers (e.g. Hinges, bolts,
locks, latches, stay doorstops, door closers, floor springs) shall be heavy type
matching to the size and weight of the door/window/ventilator shutters. These shall
operate easily without hindrance secure properly without jamming, require nominal
maintenance durable under prevailing site/weather conditions.
23. Suitable steps and/or ramp with overhead RCC Canopy shall be provided as per
requirement, at the entrances of the buildings.
24. 1,000 mm wide Plinth Protection (Apron) shall be provided all around the
Building/Sheds.
2.20 PRESSURE GROUTING
2.20.1
Products
All components used for grouting repair system are to be from one of the approved
makes of polymers. All components are to be of the same make. No components of
different makes can be used in conjunction with each other. Only be MC Bauchemie
product shall be used.
The product shall only be from the approved list of companies.
Proper care is to be taken when using the material to maintain the required consistency
and purity.
Only polymer latexes based on Styrene butadiene (SBR), acrylics, polyvinyl acetate or
expoxies can be used. The latex should have solid to a maximum of 50% and minimum
of 40%. The physical chemical and structural properties of the material used are to be
submitted and specific approval to be seek for the material/system, to be used.
2.20.2
Surface Inspection and Preparation
All surfaces to be treated are to be exposed to the base level with removal of all
claddings, plasters, facaders, waterproof layers etc. The surface is to be examined for
surface cracks, crevices and spalls and honey combing.
CONTRACTOR
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Concrete surface to which treatment is to be applied shall be freshly exposed parent

concrete free of loose and unsound materials. Prepare surfaces by mechanical abrasion
unless prohibited by environmental limitations in which case acid etching may be used.
Mechanical abrasion Use sandblasting or scarifying or water blasting or other approved
means.
ACID ETCHING - Etch surface with a commercial grade (22 deg. Baume) of
hydrochloric acid diluted at a ratio of 10:90 to 20:80. After this application, scrub
surface with a stiff bristled broom, or similar implement. Immediately after foaming
action of acid has subsided, flush surface with water jets until all residue is removed.
Repeat procedure until laitance is completely removed. Wash such areas with water at
least three times and allow to air dry prior to further treatment. This method of cleaning
is to be used only in exceptional cases and under normal cases permission will not be
given for use of this method.
Inspection of concrete surfaces prior to mortar application.
Inspect all concrete surfaces prior to application of mortar to ensure that requirements of
this Article are met.
Surfaces shall be free of any deleterious materials such as laitance, curing compounds,
dust, dirt and oil. Materials resulting, from surface preparation specified shall be
removed.
All concrete surfaces shall be dry as defined in Article 20.2.2.3.2 below unless a water
insensitive coating is used. Surface temperature shall be at least 40F to permit wetting of
concrete surface by polymer coating.
Valuate moisture content for concrete by determining if moisture will collect at surfaces.
This may be accomplished by taping a 4 x 4ft polyethylene sheet of concrete surface. If
moisture colelcts on underside of polyethylene sheet before polymer would cure, then all
concrete to dry sufficiently. Drying of the surfaces can be accomplished by either
heating the surfaces by blow lamps or by use of sawdust, sand or any other means so that
the surface is bone-dry.
2.20.3
Identification of Methods of Grouting
2.20.3.1 For All Surfaces having Cracks / Crevices:

Locate the cracks by either surface inspection or by scrubbing the surface. In case the
cracks are not visible to naked eye use compressed air to clear marks. Having identified
the cracks use light chisel or mechanical/electrical saw to clear the crack upto the depth
of the crack. In case widening of the crack is necessary to reach the depth of the crack it
is advisable to do so at this juncture.
After cleaning/widening the crack use compressed air/water jet to clean the opened crack
surface. Ensure that the surface is dried in case water jet is used.
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A method of grouting thorough rows of grout nipple is to be adopted for all such cases.
2.20.4
Grouting for Honey Combed Surfaces
For surface, which exhibits honeycombed concrete, the surface has to maintained in its
dry state and a method of grouting through triangular grout nipples is to be adopted.
The opposite side to the grouting surface has to be sealed for flowing grout by either
impervious cement plaster or by use of proper sealant as specified in the material to be
used for grouting.
2.20.5
Size and Spacing of Nipples
To determine the size of nipples use a standard caliper or a metric scale and measure the
width of the opened crack. The size of the nipple to be fixed within the crack has got to
be minimum half the surface width of the crack measured above, but should not exceed
s15 mm in dia.
The nipples to be used should be of metal with one end tapered and thickness should be
sufficient to withstand 5 m head of water. The spacing for the crack depends inversely to
the width of the crack and will not exceed more than 300 mm c/c and will not be less
than 125 mm c/c. The member of nipples along the crack will always be a less than two
rows of nipples that needs to be fixed parallel to the crack at the same distance as the
nipples spacing in the crack so as to form equilateral triangle with the apexes in the
crack.
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3.1
RELAVENT IS CODE
IS: 1200
IS: 3764
IS: 3385
IS: 2720
3.2
EARTHWORK AND
EXCAVATION
:
:
:
:
:
Method of Measurement for Building Works

Safety code for Excavation Work
Code of practice for measurement of civil engineering works
Part II - Determination of Moisture Content
Part VII - Determination of Moisture content dry density relation using
light compaction
: Part VIII - Determination of Moisture Content Dry Density using
heavy compaction
: Part XXVIII - Determination of Dry Density of soils, in place, by the
sand replacement method
: Part XXIX - Determination of Dry Density of soils, in place, by the
core cutter method.
EXCAVATION
3.2.1 Definitions
The following terms shall have the meanings hereby assigned to them:
Top Soil means any surface material, including turf, suitable for use in soiling areas
to be grassed or cultivated.
Excavation means excavation in open cut (excluding trench excavation) down to
levels required as per approved Drawings or otherwise as being the general levels
after completion of excavation.
3.2.2 Site Clearance
All area of the Site, marked in the Specification Drawings shall be cleared to the extent
required by the Engineer-in-Charge of all buildings, walls, gates, fence and other
structure and obstructions of all bushes, hedges, trees, stumps, roots and other vegetation
except for trees marked for preservation. Material so cleared shall so far as suitable be
preserved and stacked will be the property of NMC for further use but shall otherwise be
burnt to ash or disposed off the Site as directed by the Engineer-in-Charge.
Before starting the work the site shall be cleared of
1. All shrubs, grass, and other vegetation including large and small bushes, all stumps,
removal of roots, cutting and disposal of small trees up to 300 mm girth etc.
2. All the tress having girth above 300 mm. (the girth shall be measured at a height of
1.5 m above the ground level) by felling, logging, fashioning of timber and billeting
of all branches, trunks etc. including removal of all roots etc. complete as directed.
3. All serviceable reclaimed material shall be stacked separately at the site shown by
the Engineer In Charge near the site of excavation and/or transported as directed by
Engineer In Charge
4. After the tree is cut and roots taken out the potholes formed shall be filled with good
earth in 250mm layers and consolidated unless directed by the Engineer in Charge
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otherwise. The trees shall be cut in suitable piece as instructed by the Engineer In
Charge
3.2.3 General Excavation
1. General excavation means excavation in all types of soild like dry soil, wet soil,
murum, boulders, hard strata, rock of any type at different depth and lift required for
structures and from borrow areas, and shall not include trench excavation. General
excavation may also include miscellaneous isolated lengths of trenches beneath or
adjacent to other structures, trial pits along the structural layout or otherwise.
2. The ground shall be excavated by such methods and to such dimensions and depths
as shall allow for the proper construction of the works and safety of personnel and
equipment used on excavation. Slopes required for stable formation of sides shall be
provided.
3. The excavation in earth, murum, boulders, soft and hard rock shall be carried out to
the correct levels required and specified and no tolerance, plus or minus, shall be
permitted. However, if any depressions/Loose pockets are formed due to removal of
boulders, they shall be made good by filling with 1:5:10 concrete up to the bottom
layer of the footing/raft.
4. Payment for all types of excavation shall be made by detailed measurement
supported by ground levels recorded prior to and after completion of excavation,
subject to the limit for payment indicated by the slopes of excavation indicated in the
specification drawing. Any additional excavation will be at the Contractors
expense, unless specifically approved by the Engineer-in-Charge. Measurement for
excavation shall be done all as per dimensions of P.C.C. given in design drawings &
specifications. For concrete foundations same shall be paid on least dimensions at
bottom and Contractor shall cover any extra excavation required for workspace,
supports etc while quoting.
5. As far as possible excavation should be done by means of mechanical equipment.
The bidder should quote accordingly and nothing extra will be paid for mechanical
excavation and deployment of extra staff.
6. It will be the responsibility of the Contractor to obtain prior permissions from the
competent authority to use blasting device, if at all to be resorted to and the license
are to be obtained for the same.
7. The chance of blasting required shall be well decided with the expert, to avoid any
damage to the surrounding property. However for any such damage to the
surrounding property or public or additional excavation shall be the Contractor's
responsibility and the risks what so ever arising from the same will have to be borne
by the Contractor.
3.2.4 Lift and Lead
Lead for deposition of the excavated materials should be 5000 m. For the purpose of
measurement of lead, the area to be excavated or filled or area in which excavated
material is to be deposited /disposed off shall be divided into suitable blocks and for each
of the blocks, the distance between centerlines shall be taken as the lead which shall be
measured by the shortest straight line route on plan and not the actual route taken by
Contractor. No extra compensation is admissible on the grounds that the lead including
that for borrowed material had to be transported over marshy or kaccha land route.
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3.2.5 Excavation in Hard Rock

Excavation in hard rock may be done either by blasting or chiseling or by mechanical
means depending upon the site conditions. When excavation has reached within 300 mm
of the required formation level, further excavation shall be carried out carefully either by
blasting (if as directed by the Engineer-in-Charge) or chiseling. Where blasting is
resorted to, small charges shall be used to minimize occurrence of heavy over-cuts. The
Contractor shall make every effort to carry out the excavation to correct formation level
as far as practicable. In order to minimize the over break and loosening of materials at
the finished surfaces, final cutting for the last 450 mm to 600 mm in rock shall be carried
out by controlled blasting and trimming with the help of pneumatic or other power tools.
Unless otherwise specified, the over break shall not exceed 75 mm. The over breakage of
75 mm shall not be measured for payment and therefore the Contractor while quoting his
rates for rock excavation has to take this into account. Deduction of 40% or higher
percentage as may be decided by the Engineer-in-Charge shall be made to allow for the
voids. Stacks shall not be of width greater than 1.5 m wide or of height less than one
meter
1. Blasting shall be carried out by the licensed person only if permitted by the
Engineer-in-charge for which contractor shall obtain the required permission from
police commissioner.
2. The Contractor shall provide a method statement and shall comply fully with the
requirements of this clause, or any direction, order, requirement or instruction given
by the police department or any other relevant authorities as required by the law.
3. Contractor shall submit Blasting plan to the Engineer-in-charge and take approval
for the same on daily basis
4. Contractor shall plan the blasting activities in well advance and convey same to the
Project In-charge so as to co-ordinate with all the work groups at site.
5. If blasting is not permitted then contractor shall excavate the rock by manual
methods or by mechanical mean like needle breaker, poclain, rock splitter etc
without any extra cost.
This includes rock, which is easily excavated by blasting, but due to close proximity of
structures or any other reason that the Engineer-in-Charge may consider, will have to be
excavated by chiseling.
Hard rock excavation means excavation in all types of rock at any depth or lead required
as per design and drawings. The contractor shall ascertain the level and type of rock by
inspecting site, trial pits or trial bore at his cost before quoting the tender.
It should be noted that this clause does not override the Contractor's obligation to satisfy
the requirement of the relevant authorities but sets out the extent to which the engineer in
charge will exercise his control in approving the Contractor's use of explosive to ensure
that explosive are always used in a safe manner. It is the Contractor's sole responsibility
to ensure that his method of blasting is safe, that all statutory and imposed limitation are
adhered to, and to obtain a permit to use explosive from the relevant authorities and to
comply with the condition of issue of the permit.
The Contractor shall be solely responsible for obtaining the necessary licenses for the
procurement, possession, transport, storage and handling of explosive and for ensuring
the validity of such licenses at all times. Before starting work, the Contractor shall satisfy
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the engineer that all the requirement permits are in order and that this category of work is
adequately covered in the policies of insurance.
Explosives shall be used in the quantities and manner recommended by the
manufacturers. All necessary precautions shall be taken to preserve the materials below
in the soundest possible condition and also beyond the lines of all excavations.
Blasting by means of drill holes, tunnels or any other similar method shall be the
responsibility of the Contractor.
The Contractor shall take all necessary precautions during blasting operations to ensure
that no injure is caused to persons or damage to property or to the finished works. Shots
shall be properly loaded and capped and only appropriate charges shall be used in each
hole.
3.2.5.1 Storage and Transport
Proper building or magazine, with separate compartment for detonators in suitable
positions for the storage of explosive in the manner and quantities to be approved, shall
be provided. Separate vehicles or vessels for detonators shall also be used for the
transportation of explosives. The prevention of any unauthorised issue or improper use of
any explosive brought on to the site shall be the responsibility of the Contractor and only
experienced licensed short firers shall be employed to handle the explosive for the
purpose of the work the relevant security regulations dealing with the storage, handling
and transport of explosives shall be complied with.
3.2.5.2 Safety
The Contractor shall provide an approved system of warning and preparing the general
public and all site personnel of an impending blast by both audible & visual means and
shall ensure that the blasting area is cleared of all personnel immediately prior to
blasting. This system shall comply with all statutory requirements. The Contractors
attention I drawn to the need to devise adequate system for warning and clearing the
public from specified areas during blasting operations and to prevent persons entering
the blasting area.
When blasting is near to the proximity of existing public and private thoroughfares,
traffic is to be stopped just prior to firing. The operation is to be carried out I close
cooperation with the police department and in such a way as to cause minimum traffic
delay.
All operations involving explosives shall be suspended on the approach of a
thunderstorm and shall not be resumed until the storm has clearly passed.
Blasting screens shall be erected to conform with the permit conditions. Public roads,
private roads and property adjacent to the site and services within the site area shall be
protected by rock fall fences which will be subjected to the engineers approval.
The Contractor shall take all necessary precautions to avoid damage to permanent and
temporary works already completed. In all cases, delay blasting techniques will be
mandatory with the quantity of explosives restricted to ensure that the peak particle
velocity generated does not exceed the peak particle velocity of each component of the
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safe limits of the nearest structure subject to vibration damage. All operations shall stop
when these limits are exceeded until reports are made available to the engineer that no
damage has occurred and will not occur or corrective action has been taken to lower the
vibration. The sound level limit in areas where site personnel or public can access during
blasting operation must not exceed 110 dB.
The Contractor may not be permitted to use explosives in areas of the site immediately
adjacent to pylon positions. Particular limitations may apply in such areas depending on
the Contractors proposed method of working and a detailed method statement will
therefore be required from the Contractor. The method statement shall cover the methods
of excavation and protection systems proposed, all of which shall be subjected to the
approval of the relevant authorities and the Engineer.
In all such cases particular attention should be paid to the requirements stated above and
effects on these structures and installations shall be closely monitored and the quantities
of explosives limited accordingly.
Drilling rigs for shot hole shall be of the hydraulic type fitted with efficient silencers and
with means of dust separation.
The Contractor may report to any of the following methods to excavate rock by
chiseling:
Wedging by means of crowbars, pick axes or pneumatic drills
Heating and quenching
Controlled blasting with a small charge just sufficient to make a crack in rock which
will be subsequently removed by wedging
No extra payment shall be made for removal of rock by chiseling and controlled
blasting.
3.2.6 Excess excavation to be made good
The Contractor, at his own expense, shall, if directed, remove from the Site all excess
material resulting from excess excavation and shall make good the same with such kind
of fill material or in such class of concrete as may be reasonably required by the
Engineer-in-Charge having regard to the circumstances.
3.2.7 Stripping Top Soil
Where ordered by the Engineer-in-Charge, top soil shall be stripped to such depths and
over such areas as he may direct, as a separate operation prior to any further excavation,
which may be required.
3.2.8 Supporting Excavations
1. The Contractor shall properly support the sides and ends of all excavations to
prevent any fall or run from any portion of the ground outside the excavation and to
prevent settlement or damage to structures adjacent to the excavation. Any
excavation necessary to provide space for such support or other working space shall
be carried out. If, for any reason, any portion of the bottoms, sides or ends of any
excavations shall give way, the Contractor shall at his own expense take all
necessary remedial measures including the extra necessary excavation and removal
of excess material.
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2. Where the Contractor proposes and is permitted by the Engineer-in-Charge to

perform excavations with sloping faces (other than sloping excavations shown on the
Drawings or required as permanent features of the Works) and without shoring, the
excavated faces shall be to stable slopes and heights.
3.2.9 Trimming Excavations
1. When excavating to specified or required levels for the foundation of any structure
or to specified or required limits for the face of any structure required to abut
undisturbed ground, the Contractor shall not excavate the last 150 mm until
immediately before commencing the constructional work, except where the
Engineer-in-Charge shall permit otherwise. After getting the permission for the
commencement of the construction, if the Contractor delays on any account & the
formation level gets damaged he will have to do further excavation upto 150mm or
as per Engineer-in-Charges instructions at his own account.
2. Before commencement of any constructional work all shattered and loose materials
shall be removed from the excavations by hand so as to ensure that the work rests on
a solid and perfectly clean foundation or abuts against solid ground.
3.2.10
Inspection by the Engineer-in-Charge
1. When the specified levels or limits of excavation are reached the Engineer-in-Charge
will inspect the ground exposed, and if he considers that any part of the ground is by
its nature unsuitable he may direct the Contractor to excavate further. Such further
excavation shall be refilled to the specified levels or limits with concrete, selected
excavated material or selected imported material as directed by the Engineer-inCharge.
2. Should the material forming the bottom of any excavation, while acceptable to the
Engineer-in-Charge at the time of his inspection, subsequently become unacceptable
to him due to exposure to weather conditions or due to flooding or have puddles, soft
or loss during the progress of the works, the Contractor shall remove such damaged,
softened or loosened material and excavate without any extra cost.
3.2.11
Disposing Excavated Material
All excavated material shall remain the property of the Employer. The Contractor shall
ensure that no excavated material which is suitable for and is required for re-use in the
Works is transported unless so ordered by the Engineer-in-Charge.
3.2.12
Back-Filling General Site Grading And Sand Filling
3.2.12.1 Fill Material

1. All fill material whether such material is brought from outside borrow areas or
excavation within the site, will be subject to Engineer-in-Charges approval after
carrying required tests at Contractors Soil testing laboratory. Notwithstanding any
approval given to the fill material or borrow areas from which fill material is
proposed to be brought, the Engineer-in-Charge reserves the right to reject such
material which does not meet the specification requirements or unsuitable for the
purpose for which it is intended.
2. Roads, of a temporary nature, required to be constructed for access and for
movement of men, materials, equipment, transport vehicles, vehicles carrying fill
material, etc. to or over borrow areas and or to or over areas on which fill has to be
deposited shall be constructed by the Contractor. Such access roads shall be
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maintained in good condition during all seasons to ensure completion of the work
according to the time schedule. No separate payment shall be made for such items of
work.
3.2.12.2 Backfilling
1. Excavated material used as back filling to excavations or completed structures shall
be free from rubbish, vegetation, clods and lumps and shall be approved by the
Engineer-in-Charge. The approved materials shall be placed in layers, not exceeding
150 mm in depth before compaction and shall be compacted with watering,
consolidating and ramming. The maximum boulder size shall be of 150 mm for
filling material
2. Soft material shall not be used as back filling around structures in rock. The
Contractor shall backfill such excess excavation with concrete; rubble, stone or rock
fills as directed by the Engineer-in-Charge. Filling other than concrete shall be
placed in layers not exceeding 150 mm in thickness, shall be thoroughly compacted
and have adequate fined content to fill the voids.
3. Should the material being placed as back filling, while acceptable at time of
selection, become unacceptable to the Engineer-in-Charge due to exposure to
weather conditions or due to flooding or have become puddles, soft or segregated
during the progress of the works, the Contractor shall remove such damaged,
softened or segregated material and replace it with fresh approved material at his
expense.
4. The Contractor shall while placing the back filling make due allowance for any
settlement that may occur before the end of the Defects Liability Period, remove any
excess material or make up any deficiency by back filling to the specified levels. As
a rule material to be back filled shall be stacked temporarily at a suitable place.
5. General Site Grading: Site grading shall be carried out as directed by the Engineerin-Charge. Excavation shall be carried out as specified in the specification. Filling
and compaction shall be carried out as specified under (6) of this Clause unless
otherwise indicated below.
6. The approved material shall be placed in layers not exceeding 150 mm in depth
before compaction and shall be compacted to 90% of Proctor Density with water
contain at OMC.
7. The Contractor shall protect the earth fill from being washed away by rain or
damaged in any other way. Should any slip occur, the Contractor shall remove the
affected materials and make good the slip without any extra cost.
8. The fill shall be carried out to such dimensions and levels as directed by the
Engineer-in-Charge, after the compaction.
9. Sand filling below Plinth and other places
Back filling shall be carried out with sand at places as directed by the Engineer-inCharge. The sand used shall be clean, medium grained and free from impurities. The
filled-in-sand shall be kept flooded with water for 24 hours to ensure maximum
consolidation. Any temporary work required to contain sand under flooded conditions
shall be to the Contractors account. The surface of the Consolidated sand shall be
dressed to the required level or slope. Construction of floors or other structures on sand
fill shall not be started until the Engineer-in-Charge has inspected and approved the fill.
Where specified in the schedule of works, compaction of the plinth fill shall be carried
out by means of 12 tonne rollers smooth wheeled, sheep foot or wobbly wheeled rollers.
A smaller weight roller may be used only if permitted by Engineer-in-Charge. As rolling
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proceeds water sprinkling shall be done to assist consolidation. Water shall not be
sprinkled in case of sandy fill.
The thickness of each unconsolidated fill layer can in this case upto 300 mm. Engineerin-Charge will determine the thickness of layers in which fill has to be consolidated
depending on the fill material and equipment used.
Rolling shall commence from outer edge and progress towards the centre and continue
until compaction is to the satisfaction of the Engineer-in-Charge, but in no case less than
10 passes of the roller will be accepted for each layer.
The compacted surface shall be properly shaped, trimmed and consolidated to an even
and uniform gradient. All soft spots shall be excavated and filled and consolidated.
At some locations / areas it may not be possible to use rollers because of space
restrictions etc. Contractor shall then be permitted to use pneumatic tampers, rammers
etc and he shall ensure proper compaction.
3.2.13
Fill Density
The compaction, only where so called for, in the schedule of quantities /items shall
comply with the specified (proctor/modified proctor) density at moisture content
differing not more than 4 percent from optimum moisture content. Contractor shall
demonstrate adequately at his cost, by field and laboratory tests that the specified density
had been obtained.
3.2.14
Local Rules And Regulations
1. The Contractor shall familiarize himself with the local rules and regulations
governing the excavation, quarrying operations, etc. and the work shall be carried
out strictly in accordance with rules and regulations, if any. Whenever a quarry is
required to be opened in connection with the execution of work covered under this
Contract, the Contractor shall investigate that it shall yield stones and other materials
such as sand, murum, soil etc. of approved quality and shall satisfy himself as to the
availability in desired quantity. He shall supply necessary quantity of sand, stone,
metal aggregate etc. to the Engineer-in-Charge for carrying out tests as desired by
the Engineer-in-Charge and well in advance of its use so as to carry out tests and to
get approval. The cost of opening and operating the quarry & royalties and ant other
charges shall be borne entirely by the Contractor.
2. The Contractor shall obtain necessary permission from the concerned authorities
before opening the quarry. In case of quarries in private land on payment of
whatever charges as may be due to the owner.
3.3
DEWATERING
a. All excavations shall be kept free of water. Grading in the vicinity of excavations
shall be controlled to prevent surface water running into excavated areas. The
Contractor shall remove by pumping or other means approved by Engineer-inCharge any water inclusive of rain water and sub-soil water accumulated in
excavation and keep all excavations de-watered until the foundation work is
completed and back filled. Sumps made for dewatering must be kept clear of the
excavations/trenches required for further work. Method of pumping shall be
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approved by Engineer-in-Charge; but in any case, the pumping arrangement shall be

such that there shall be no movement of sub-soil or blowing in due to differential
head of water during pumping. Pumping arrangements shall be adequate to ensure
no delays in construction.
b. When there is a continuous inflow of water and quantum of water to be handled is
considered in the opinion of Engineer-in-Charge, as large, well point system: Singlestage or Multi-stage shall be adopted. Contractor shall submit to the Engineer-inCharge his scheme of well pointing system including stages, the spacing, number
and diameter of well points, headers etc. and the number, capacity and location of
pumps for approval.
c. The rates for excavation are inclusive of dewatering by any means and no extra
payment is allowed for excavation in wet condition.
3.4
TIMBER SHORING
The Timber Shoring shall be as per 3764-1966 safety code for excavation work.
a. Close timbering shall be done by completely covering the sides of the trenches and
pits generally with short, upright members called polling boards. The boards shall
generally be placed in position vertically side by side without any gap on each side
of the Excavation and shall be secured by horizontal walings of strong wood at
maximum 1.2 m spacing and suitably strutted. If the soil is very soft and loose, the
boards shall be placed horizontally against each side of the excavation and supported
by vertical walings, which in turn shall be suitably strutted. The lowest boards
supporting the sides shall be taken into the ground and no portion of the vertical side
of the trench or pit shall remain exposed, so as to render the earth liable to slip out.
b. The shoring material shall not be sizes less than those specified below unless steel
sheet piling is used or unless otherwise approved by the Engineer-in-Charge in
writing:
Planks
5 cm x 25 cm
Waling pieces
10 cm x 20 cm
Struts
15 cm x 20 cm
c. Timber shoring shall be close or open type, depending on the nature of soil and
the depth of pit or trench. The type of timbering shall be as approved by Engineerin-Charge. It shall be the responsibility of the Contractor to take all necessary steps
to prevent the sides of excavations, trenches, pits, etc., from collapsing.
d. Timber shoring may be required to keep the sides of excavations vertical to ensure
safety of adjoining structures or to limit the slope of excavations, or due to space
restrictions or for other reasons. Such shoring shall be carried out, except in an
emergency, only under instructions from the Engineer-in-Charge.
e. The withdrawal of the timber shall be done very carefully to prevent the collapse of
the pit or trench. It shall be started at one end and proceeded systematically to the
other end. Concrete or masonry shall not be damaged during the removal of the
timber. No claim shall be entertained for any timber, which can not be retrieved.
f. In the case of open timbering, the entire surface of the side of trench or pit is not
required to be covered. The vertical boards of minimum 25 cm X 5 cm sections
shall be spaced sufficiently apart to leave unsupported strips of maximum 50 cm
average width. The detailed arrangement, sizes of the timber and the spacing shall
be subject to the approval of the Engineer-in-Charge. In all other respects, the
specification for close timbering shall apply to open timbering.
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g. In case of large pits and open excavations, where shoring is required for securing
safety of adjoining structures or for any other reasons and where the planking across
sides of excavations/pits cannot be strutted against, suitable inclined struts supported
on the excavated bed shall be provided. Load from such struts shall be suitably
distributed on the bed to ensure no yielding of the strut.
3.5
RAIN WATER DISCHARGE
3.5.1 Scope
The scope covers the drainage of the rainwater in excavated areas.
Grading in the vicinity of excavation shall be such as to exclude rain/surface water
draining into excavated areas. Excavation shall be kept clean of rain and such water as
the Contractor may be using for his work by suitably pumping out the same at no extra
cost to the Owner. The scheme for pumping and discharge of such water shall be
approved by the Engineer-in-Charge.
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4
IS: 6313 1981
IS: 6313 (Part I) 1981
IS: 6313 (Part II) 1981
IS: 6313 (Part III) 1981
4.1
:
:
:
:
ANTI TERMITE TREATMENT

Code of Practice for Anti Termite Measure in Buildings
Construction Measures
Pre-Construction Chemical Treatment Measures
Treatment for existing Buildings
DELIVERY, STORAGE AND HANDLING

Deliver pesticides to the project site in sealed and labeled containers in good condition as
supplied by the manufacturer or formulator. Store, handle, and use pesticides in
accordance with manufacturers labels. Labels shall bear evidence of registration as per
the IS or appropriate regulations.
4.2
SAFETY REQUIREMENTS
Formulate, treat, and dispose of termiticides and their containers in accordance with label
directions. Draw water for formulating only from sites designated by the Contracting
Officer, and fit the filling hose with a backflow preventer meeting local plumbing codes
or standards. The filling operation shall be under the direct and continuous observation
of a Contractors representative to prevent overflow. Secure pesticides and related
materials under lock and key when unattended. Ensure that proper protective clothing
and equipment are worn and used during all phases of termiticide application. Dispose
of used pesticide containers off Government property
4.3
WARRANTY
Furnish an three-year written warranty against infestations or reinfestations by
subterranean termites of the buildings or building additions constructed under this
contract. Perform annual inspections of the building(s) or building addition(s). If live
subterranean termite infestation of subterranean termite damage is discovered during the
warranty period, and the soil and building conditions have not been altered in the
interim, the Contract shall :
1. Retreat the soil and perform other treatment as may be necessary for elimination of
subterranean termite infestation;
2. Repair damage caused by termite infestation; and
3. Reinspect the building approximately 180 days after the pretreatment.
4.4
QUALITY ASSURANCE
4.4.1 Application Report

Upon completion of this work, submit Pest Management Report, Identifying target pest,
type of operation, brand name and manufacturer of pesticide, formulation, concentration
or rate of application used. Maintain daily records using Pest Management Maintenance
Record, and submit copies of records when requested by the Engineer-in-Charge.
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4.5
PRODUCTS
4.5.1 Pesticides
Termiticides bearing current registration or approved for such use by the appropriate
agency of the host country. The Contractor shall comply with the requirements on
Contractors licensing, certification, and record keeping.
4.5.2 Execution
4.5.2.1 Verification of Conditions
At the time of application, the soil shall have sufficiently low moisture content to allow
uniform distribution of the treatment solution throughout the soil. Do not make
applications during or immediately following heavy rains or when conditions may cause
runoff and create an environmental hazard.
4.5.3 Application
4.5.3.1 Treatment Area
Apply termiticide to soil material which will be covered by or lie immediately adjacent
to the buildings and structures so as to provide a protective barrier against subterranean
termites.
4.5.3.2 Treatment Application
Apply termiticide as a coarse spray and in such matter as to provide uniform distribution
onto the soil surface. Apply treatment prior to placement of a vapor barrier or
waterproof membrane and prior to concrete pouring. Where treated soil or fill material is
not to be covered with a vapor barrier or waterproof membrane, exercise adequate
precautions to prevent its disturbance. If soil or fill material has been disturbed after
treatment, retreat as specified above before placement of slabs or other covering
structures. Coordinate treatment of the soil on the exterior sides of foundation walls,
grade beams, and similar structures with final grading and planting operations so as to
avoid disturbance of the treated barriers by such operations. Observe manufacturers
warnings and precautions in the handling and use of such materials. Exercise precaution
that these chemicals do not enter water supply systems or potable water supplies or
aquifers, and that they do not endanger plants and animals as well. Notify the
Contracting Officer at least 48 hours prior to beginning of treatment and perform
formulating, mixing, and application in the presence of the NMC.
4.5.4 Rates and Methods of Application
Apply in accordance with the pesticide label. Provide maximum application or dosage
rates. Resolve conflict between this specification and label direction in favor of the
label.
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5.1
CONCRETE AND ALLIED

WORKS
GENERAL
a. The quality of materials and method and control of manufacture and transportation
of all concrete work irrespective of mix, whether reinforced or otherwise shall
conform to the applicable portions of this specification.
b. The Engineer-in-Charge shall have the right to inspect the source/s of material/s, the
layout and operation of procurement and storage of materials, the concrete batching
and mixing equipment, and the quality control system. Such an inspection shall be
arranged and Engineer-in-Charges approval obtained, prior to starting of concrete
work. However, this shall not relieve the Contractor with any of his responsibilities
and all the materials, which do not conform to the specifications, will be rejected.
c. The minimum wall thickness for all RCC wall shall be 225 mm thick.
d. The liquid retaining structures will be in M 25 grade.
e. The Contractor will maintain all registers and formats for quantity qualitative and
quantitative measures of all concrete works on daily basis of steel consumed and
concreting done updated on daily basis.
f. As per site conditions, if required, contractor may use ready mix concrete of
approved mix design from approved ready mix plant without any extra cost.
5.2
APPLICABLE CODES
The following specifications, standards and codes, including all official
amendments/revisions and other specifications & codes referred to therein to therein,
should be considered a part of this specification. In all cases the latest
issue/edition/revision shall apply. In case of discrepancy between this specification and
those referred to herein this bid document, this specification shall govern.
MATERIALS
1.
2.
3.
4.
5.
6.
IS:269
IS:455
IS:1489
IS: 8112
IS: 12330
IS: 383
7. IS: 432
8. IS: 1786
9. IS: 1566
10. IS: 9103
11. IS: 2645
12. IS: 4990
CONTRACTOR
Specification for 33 grade ordinary Portland cement

Specification for Portland slag cement.
Specification for Portland-pozzolana cement.
Specification for 43-grade ordinary Portland cement.
Specification for sulphate resisting Portland cement.
Specification for coarse and fine aggregates from natural sources for
concrete.
- Specification for mild steel and medium tensile steel (Parts-I & II) bars
and hard-drawn steel wires for concrete reinforcement.
- Specification for high strength deformed steel bars and wires for
concrete reinforcement.
- Specification for hard-drawn steel wire fabric for (Part-I) concrete
reinforcement.
- Specification for admixtures for concrete.
- Specification for integral cement waterproofing compounds.
- Specification for plywood for concrete shuttering work.
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MATERIAL TESTING
1.
2.
3.
4.
5.
6.
IS: 4021
IS: 4032
IS: 650
IS: 2430
IS: 2386
IS: 3025
7. IS: 6925
Methods of physical tests for hydraulic cement. (Parts-1 to 13)

Method of chemical analysis of hydraulic cement.
Specification for standard sand for testing of cement.
Methods for sampling of aggregates for concrete.
Methods of test for aggregates for concrete. (parts-I to VIII)
Methods of sampling and test (physical and chemical) water used in
industry.
- Methods of test for determination of water-soluble chlorides in
concrete admixtures.
MATERIALS STORAGE
1. IS: 4082
- Recommendations on stacking and storing of construction materials at

site.
CONCRETE MIX DESIGN

1. IS: 10262 - Recommended guidelines for concrete mix design.
2. SP: 23
- Handbook on Concrete Mixes. (S & T)
CONCRETE TESTING
1. IS: 1199
2. IS:516
3. IS: 9013
4. IS: 8142
5. IS: 9284
6. IS: 2770
- Method of sampling and analysis of concrete.

- Method of test for strength of concrete
- Method of making, curing and determining compressive strength of
accelerated cured concrete test specimens.
- Method of test for determining setting time of concrete by penetration
resistance.
- Method of test for abrasion resistance of concrete.
- Methods of testing bond in reinforced concrete.
EQUIPMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
IS: 1791
IS: 2438
IS: 4925
IS: 5892
IS: 7242
IS: 2505
IS: 2506
IS: 2514
IS: 3366
IS: 4656
IS: 11993
IS: 7251
IS: 2722
14. IS: 2750
CONTRACTOR
Specification for batch type concrete mixers.

Specification for roller pan mixer.
Specification for concrete batching and mixing plant.
Specification for concrete transit mixer and agitator.
Specification for concrete spreaders.
General Requirements for concrete vibrators: Immersion type.
General Requirements for screed board concrete vibrators.
Specification for concrete vibrating tables.
Specification for pan vibrators.
Specification for form vibrators for concrete.
Code of practice for use of screed board concrete vibrators.
Specification for concrete finishers.
Specification for portable swing weigh batchers for concrete (single
and double bucket type).
- Specification for steel scaffoldings.
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CODES OF PRACTICE
1. IS: 456
2. IS: 457
- Code of practice for plain and reinforced concrete.

- Code of practice for general construction of plain and reinforced
concrete for dams and other massive structures.
3. IS:3370
- Code of practice for concrete structures for storage of liquids.(parts-I
to IV)
4. IS: 3935 - Code of practice for composite construction.
5. IS: 2204 - Code of practice for construction of reinforced concrete shell roof.
6. IS: 2210 - Criteria for the design of reinforced concrete shell structures and
folded plates.
7. IS: 2502 - Code of practice for bending and fixing of bars for concrete
reinforcement.
8. IS: 5525 - Recommendation for detailing of reinforcement in reinforced concrete
works.
9. IS: 2751 - Code of practice for welding of mild steel plain and deformed bars
used for reinforced concrete construction.
10. IS: 9417 - Specification for welding cold worked bars for reinforced concrete
construction.
11. IS: 3558 - Code of practice for use of immersion vibrators for consolidating
concrete.
12. IS: 3414 - Code of practice for design and installation of joints in building.
13. IS: 4326 - Code of practice for earthquake resistant construction of building.
14. IS:4014
- Code of practice for steel tubular scaffolding.(parts-I & II)
15. IS: 2571 - Code of practice for laying in-situ cement concrete flooring.
16. IS: 7861 - Code of practice for extreme weather concreting.
Part-I: Recommended practice for hot weather concreting.
Part-II: Recommended practice for cold weather concreting.
17. IS: 13920 - Ductile Detailing of Reinforced Concrete Structure subjected to 1993
seismic forces.
18. SP-16
- Design Aids for Reinforcement Concrete to IS:456-1978
(S&T) - 1980
19. SP-24
- Explanatory Handbook on IS:456-1978
20. SP-34
- Handbook on Concrete Reinforcement and Detailing
(S&T) - 1987
CONSTRUCTION SAFETY
1. IS:3696
2. IS:7969
3. IS: 8989
- Safety code for scaffolds and ladders.(Parts-I & II)

- Safety code for handling and storage of building materials
- Safety code for erection of concrete framed structures.
MEASUREMENT
1. IS: 1200
2. IS: 3385
5.3
- Method of measurement of building and engineering works.

- Code of practice for measurement of civil engineering works.
MATERIALS FOR STANDARD CONCRETE

a. The ingredients to be used in the manufacture of concrete shall consist solely of
Ordinary Portland Cement or Sulphate Resistant Cement of approved make clean
sand, natural coarse aggregate, clean water, and admixtures.
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b. Cement
1. The Contractor will have to make own arrangements for procuring cement and
steel.
Cement remaining in bulk storage at the mill, prior to shipment for more than 6
months or cement in bags in local storage in the hands of vendor for more than 3
months after completion of tests may be retested before use and may be rejected
if it fails to conform to any of the requirement of IS 269-1976.
2. The Contractor will have to make his own arrangements for transport from
supplier godown and storage of adequate quantity of cement. Contractor will
construct cement godown at site as per NMC rules. Cement in bulk may be
stored in bins or silos, in batches of 10x10, which will provide complete
protection from dampness, contamination and minimize caking and false set.
Cement bags shall be stored in a dry enclosed shed (storage under tarpaulins will
not be permitted), well away from the outer walls and insulated from the floor to
avoid contact with moisture from the ground and so arranged as to provide ready
access. Damaged or reclaimed or partly set cement will not be permitted to be
used and shall be removed from the site. The storage bins and storage
arrangement shall be approved by the Engineer-in-Charge. Consignments of
cement shall be stored as received and shall be consumed in the order of their
delivery. Stacking of cement shall be done as per IS and in such a way that first
come cement shall be used first.
3. Cement held in storage for a period of ninety (90) days or longer shall be tested.
Should at any time the Engineer-in-Charge have reasons to consider that any
cement is defective, then irrespective of its origin, date of manufacture and or
manufacturers test certificate, such cement shall be tested immediately at the
Contractors cost at an approved laboratory and until the results of such tests are
found satisfactory, it shall not be used in any work. Testing certificates for each
batch of cement should be submitted by the Contractor to the Engineer-inCharge, before starting the concreting work. The Contractor shall not be entitled
to any claim of any nature on this account.
4. Aggregates
i) General
Aggregate in general designates both fine and coarse inert materials used in the
manufacture of concrete (Vide BIS 456 & BIS 383) and confirming to tests as per BIS
2386 (Part I to VI)
Coarse Aggregate is aggregate most of which is retained when passed through on 4.75
mm BIS sieve.
All fine and coarse aggregates proposed for use in the works shall be subject to the
NMC Quality Control Department approval and after specific materials have been
accepted, the source of supply of such materials shall not be changed without prior
approval of the NMC Quality Control Department.
Aggregates shall consist of natural sands, stone (crushed or uncrushed) and gravel from a
source known to produce satisfactory aggregate for concrete and shall be chemically
inert, non-flaky, strong, hard, durable against weathering, of limited porosity and free
from deleterious materials that may cause corrosion of the reinforcement or may impair
the strength and or durability of concrete. The grading of aggregates shall be such as to
produce a dense concrete of specified strength and consistency that will work readily into
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position without segregation and shall be based on the mix design and preliminary
tests on concrete specified later.
ii) Sampling and testing
Samples of the aggregates for mixed design and determination of suitability shall be
taken under the supervision of the Engineer-in-Charge and delivered to the laboratory,
well in advance of the scheduled placing of concrete. Records of tests, which have been
made on proposed aggregates and on concrete made from this source of aggregates, shall
be furnished to Engineer-in-Charge in advance of the work, for use in determining
aggregate suitability. The costs of all such tests, sampling etc. shall be borne by the
Contractor.
iii) Storage of aggregates
All coarse and fine aggregates shall be stacked separately in stock piles in the material
yard near the work site in bins properly constructed to avoid inter mixing of different
aggregates. Contamination with foreign material and earth during storage and while
heaping the materials shall be avoided. The aggregates must be of specified quality not
only at the time of receiving at site but more so at the time of loading into mixer. Rakers
shall be piled in layers not exceeding 1.20 m in height to prevent coning or segregation.
Each layer shall cover the entire area of stockpile before succeeding layers are started.
Aggregates that have become segregated shall be rejected.
iv) Specific Gravity
Aggregates having a specific gravity below 2.4 (saturated surface dry basis) shall not be
used.
5.4
FINE AGGREGATE
a) Fine aggregate shall consist of natural or crushed sand conforming to BIS 383
confirming to tests as per BIS 2386 part I to VI. The sand shall be clean, sharp, hard,
strong and durable and shall be free from dust, vegetable substances, adherent
coating, clay, alkali, organic matter, mica, salt, or other deleterious substances,
which can be injurious to the setting qualities/strength/durability of concrete.
b) Screening and Washing: Sand shall be prepared for use by such screening or
washing, or both, as necessary, to remove all objectionable foreign matter while
separating the sand grains to the required size fraction.
c) Foreign Material limitations : The percentage deleterious substances in sand
delivered to the mixer shall not exceed the following:
Table 2: Foreign Material Limitations in Fine Aggregate
Sr.
1
2
3
4
Foreign material
Material finer than 75 micron BIS sieve
Shale
Coal & Lignite
Clay Lumps
Total
Percentage by weight
Uncrushed
Crushed
3.0
15.0
1.0
1.0
1.0
1.0
5.0
17.0
d) Gradation: Unless otherwise directed or approved by the Engineer-in-Charge, the

grading of sand shall be within the limits indicated hereunder:
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Table 3: Grading of Sand for Fine Aggregate

BIS :Sieve Designation
10 mm
4.75 mm
2.36 mm
1.18 mm
600 microns
300 microns
150 microns
Grading
Zone I
100
99-100
60-95
30-70
15-34
5-20
0-10
Grading
Zone II
100
90-100
75-100
55-90
35-59
8-30
0-10
Grading
Zone III
100
90-100
85-100
75-100
60-79
12-40
0-10
Grading
Zone IV
100
95-100
95-100
90-100
80-100
15-50
0-15
Where the grading falls outside the limits of any particular grading zone of sieves, other
than 600 microns IS sieve, by total amount not exceeding 5%, it shall be regarded as
falling within that grading zone. This tolerance shall not be applied to percentage
passing the 600 micron IS sieve or to percentage passing any other sieve on the coarser
limit of grading zone I or the finer limit of grading zone IV. Fine aggregates conforming
to grading zone IV shall be used. Mix designs and preliminary tests shall show its
suitability for producing concrete of specified strength and workability.
e) Fineness Modulus
The sand shall have a fineness modulus of not less than 2.0 or more than 3.5. The
fineness modulus is determined by adding the cumulative percentages retained on the
following IS sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 microns and 150 microns)
and dividing the sum by 100.
5.5
COARSE AGGREGATE
a) Coarse aggregate for concrete, except as noted above, shall conform to IS 383 & IS
2386. This shall consist of crushed stone and shall be clean and free from elongated,
flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag,
alkali, mica, organic matter or other deleterious matter.
b) Screening and Washing: Crushed rock shall be screened and or washed for the
removal of dirt or dust coating, if so requested by the Engineer-in-Charge.
c) Grading
i) Coarse aggregate shall be either in single size or graded, in both cases the grading shall
be within the following limits:
BIS
Sieve Percentage passing for single sized aggregate
Size (mm)
of normal size
40 mm 20 mm 16 mm 12.5mm 10mm
63
100
40
85-100 100
20
0-20
85-100 100
16
85-100 100
12.5
85-100 100
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Percentage Passing For Graded

Aggregate Of Normal Size
40 mm 20 mm 16 mm 12.5mm
100
95-100 30-70
95-100 100
90-100 90-100
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BIS
Sieve Percentage passing for single sized aggregate
Size (mm)
of normal size
40 mm 20 mm 16 mm 12.5mm 10mm
10
0-5
0-20
0-30
0-45
85-100
4.75
0-5
0-5
0-10
0-20
2.36
0-5
Percentage Passing For Graded

Aggregate Of Normal Size
40 mm 20 mm 16 mm 12.5mm
10-35
25-35
30-70
40-85
0-5
0-10
0-10
0-10
-
ii) The pieces shall be angular in shape and shall have granular or crystalline surfaces.
Friable, flaky and laminated pieces, mica and shale, if present, shall be only within
tolerance limits which will not affect adversely the strength and or durability of concrete.
The maximum size of coarse aggregate shall be 40 mm for M-7.5 and M-10 and 20mm
for M-15 to M-30 concrete, or as directed by the Engineer-in-Charge or specified. The
maximum size of coarse aggregate shall be the maximum size specified above but in no
case greater than 1/4th of the minimum thickness of the member, provided that the
concrete can be placed without difficulty so as to surround all reinforcement thoroughly
and fill the corners of the form. For plain concrete the maximum size of aggregate shall
be of 40 mm. For heavily reinforced concrete members, the nominal maximum size of
the aggregate shall be 5 mm less than the minimum clear distance between the
reinforcing main bars or 5 mm less than the minimum cover to reinforcement whichever
is smaller.
d) Foreign material limitations
The percentage of deleterious materials in the aggregate delivered to the mixer shall
not exceed the following:
Table 4 : Foreign Material Limitations in Coarse Aggregate
Sr.
Foreign Material
Percentage by Weight
Uncrushed
Crushed
1
2
3
4
5.6
Material finer than 75 micron BIS Sieve

Coal and lignite
Clay Lumps
Soft Fragments
3.0
1.0
1.0
3.0
3.0
1.0
1.0
-
Total
8.0
5.0
WATER
a) Water used for washing, mixing and curing shall be free from injurious amounts of
deleterious materials. Potable water is generally satisfactory for mixing and curing
concrete. Physical and chemical analysis of the water should be submitted to the
Engineer-in-Charge, before starting the work.
b) In case of doubt, the suitability of water for making concrete shall be ascertained by
the compressive strength and initial setting time test specified in BIS 456. The
sample of water taken for testing shall be typical of the water proposed to be used for
concreting, due account being paid to seasonal variation. The sample shall not
receive any treatment before testing other than that envisaged in the regular supply
of water proposed for use in concrete. The sample shall be stored in a clean container
previously rinsed out with similar water.
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c) Average 28 days compressive strength of at least three 15 cm concrete cubes

prepared with water proposed to be used shall not be less than 90% of the average
strength of three similar concrete cubes prepared with distilled water. The cubes
shall be prepared, cured and tested in accordance with the requirements of BIS 516.
d) The initial setting time of test block must be made with the appropriate test cement
and the water proposed to be used. It shall not be less than 30 minutes and shall not
differ by more than +/-30 minutes from the initial setting time of control test block
prepared with the appropriate test cement and distilled water. The test block shall be
prepared and tested in accordance with the requirements of BIS 4031.
e) Where water can be shown to contain an excess of acid, alkali, sugar or salt,
Engineer-in-Charge may refuse to permit its use. As a guide, the following
concentrations represent the maximum permissible values.
1)
To neutralise 200 ml sample of water, using phenolphthalein as indicator, it
should not require more than 2 ml of 0.1 normal NaOH. The details of test
shall be as given in BIS 3025.
2)
To neutralise 200 ml sample of water, using methyl orange as an indicator, it
should not require more than 10 ml of 0.1 Normal HCl. The details of test
shall be as given in BIS 3025.
3)
Percentage of solids, when tested in accordance with the method indicated
below shall not exceed the following:
Solids
Percent
Ref. to col. no in IS:3025) Organic
(organic solid = total solids minus ignited 0.02
residue)
Inorganic
0.03
Sulphates (as So4)
0.05
Alkali Chlorides (as Cl)
0.20
Suspended matter
0.20
The pH value of water shall not generally be less than 6.
5.7
Method of test
10 and 11
11(ignited residue)
20
24
12
STEEL AND ALUMINIUM MEMBERS ENCASED IN CONCRETE

Structural steel and aluminum ladders etc. to be encased in concrete shall be without
paint. Primer should be used for encasing purpose. The encasing shall be done in
concrete with 10 mm, maximum size aggregate and a works cube strength not less than
150 kg/sq.cm. at 28 days unless otherwise specified. The member shall be wrapped with
galvanized aluminum wire mesh of adequate size. The galvanized aluminum wire mesh
shall be kept 20 mm from the edge or surface of the member and shall be held in position
securely. The member will have a minimum cover of 50 mm unless otherwise indicated
in the drawings. Where the clear cover is more than 75 mm, concrete with 20 mm coarse
aggregate can be used.
5.7.1 Anchor Bolts, Anchors, Sleeves, Inserts,

The Contractor shall build in to concrete work all the items mentioned in Drawings or
Engineer In Charge and shall embed them partly or fully as directed and secure the same
as may be required. The materials if required to be supplied by the Contractor, shall be as
specified and be of best quality available according to relevant Indian standards of
approved manufacture and to the satisfaction of the engineer. Exposed surface of
embedded materials is to be painted with one coat of approved anti-corrosive paint and/
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or bituminous paint without any extra cost to the owner. If welding is to be done
subsequently on the exposed surface of embedded material the paint shall be cleaned off
the member to a minimum length of 50 mm beyond each side of the weld line.
Necessary templates, jigs, fixtures, supports etc. shall be used as may be required or
directed by the Engineer In Charge.
5.8
CONTROLLED CONCRETE
All concrete in the works shall be Controlled Concrete as defined in IS: 456 except for
M-7.5 and M-10 for which normal mix concrete shall be used. Whether reinforced or
otherwise, all concrete works to be carried out under this specification shall be divided
into the following classifications:
Minimum Compressive Strength Of 15 cm cubes at 7 days and 28 days after mixing,
conducted in accordance with IS: 516. Any operation of concrete done at atmospheric
temperature above 40 degree C or where the temperature of concrete at the time of
placement is expected to be beyond 40 degree C may be categorize as hot weather
concreting and should be confined to the requirement of IS 7861(Part-I) 1975 and SP-23
(S&T)-1982.
Class
At 7 Days
M40
M35
M30
M25
M20
M15
Works Test
N/mm2
Preliminary Test
N/mm2
33.5
30.0
25.0
22.0
17.5
13.5
At 28 days
50.0
44.0
38.0
32.0
26.0
20.0
At 7 days
27.0
23.5
20.0
17.0
13.5
10.0
Max. Size Of Locations

Aggregate mm For Use
At 28 days
40.0
35.0
30.0
25.0
20.0
15.0
20
20
40 or 20
40 or 20
40 or 20
40 or 20
As indicated
in
the
specifications
or as required
Note: It shall be very clearly understood that whenever the grade of concrete such as M20, etc. is specified it shall be Contractors responsibility to ensure the minimum
crushing strength stipulated for the respective grade of concrete is obtained at works.
5.9
MIX DESIGN
5.9.1 General
i)
This is essential for investigating the grading of aggregates, water-cement ratio,

workability and the quality of cement required to give preliminary and works cubes
of the minimum strength specified. The proportions of the mix shall be determined
by weight. Adjustment of aggregate proportions due to moisture present in the
aggregate shall be made. Determination of mix proportions shall be carried out
according to Recommended guidelines for Concrete Mix Design conforming to IS:
10262.
ii) Whenever there is a change either in required strength of concrete, or water-cement
ratio or workability or the source of aggregates and/or cement, preliminary tests shall
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be repeated to determine the revised proportions of the mix to suit the altered
conditions. While designing proportions, over-wet mixes shall always be avoided.
iii) Mix Design may be done without changing its minimum cement content mentioned
in NIT
iv) While fixing the value for water/cement ratio for preliminary mixes, assistance may
be derived from the graph (Appendix A, BIS 456 showing the relationship between
the 28 day compressive strengths of concrete mixes with different water/cement
ratios and the 7-day compressive strength of cement tested in accordance with IS:
269.
5.9.2 Preliminary Tests
Test specimens shall be prepared with at-least two different water/cement ratios for each
class of concrete, consistent with work ability required for the nature of the work. The
materials and proportions used in making preliminary tests shall be similar in all respects
to those to be actually employed in the works as the object of these tests is to determine
the properties of cement, aggregates and water necessary to produce concrete of required
consistency and to give the specified strength, it will be Contractors sole responsibility
to carry out these tests and he shall therefore furnish to Engineer-in-Charge a statement
of proportions proposed to be used for the various concrete mixes. For preliminary tests,
the following procedure shall be followed.
Materials shall be brought to the room temperature and all materials shall be in a dry
condition. The quantities of water cement and aggregates for each batch shall be
determined by weight to an accuracy of 1 part in 100 parts.
Mixing concrete shall be done by hand (for small quantities, as directed by Engineer-inCharge) or in a small batch mixer as per IS: 516 in such a manner as to avoid loss of
water. The cement and fine aggregate shall first be mixed dry until the mixture is
uniform in color. The coarse aggregate shall then be added, mixed and water added and
the whole batch mixed thoroughly for a period of not less than two minutes until the
resulting concrete is uniform in appearance. Each batch of concrete shall be such a size
as to leave about 10% excess concrete, after moulding the desired number of test
specimens.
The consistency of each batch of concrete shall be measured immediately after mixing,
by the slump test in accordance with IS: 1199. If in the slump test, care is taken to
ensure that no water or other material is lost, the material used for the slump test may be
re-mixed with the remainder of the concrete for making the specimen test cubes. The
period of re-mixing shall be as short as possible yet sufficient to produce a homogeneous
mass.
The samples for compression tests of concrete shall be made as per IS: 516 on 15 cm
cubes. Each mould shall be provided with a metal base plate having a plate surface so as
to support the mould during filling without leakage. The base plate shall be preferably
attached to the mould by springs or screws. The parts of the mould when assembled
shall be positively and rigidly held together. Before placing concrete, the mould and
base plate shall be cleaned and oiled. The dimensions and internal faces of the mould
shall be accurate within the following limits. Height and distance between the opposite
faces of the mould shall be of specified size +0.2 mm. The angle between the adjacent
internal faces and between internal faces and top and bottom faces of mould shall be 90-
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degree +0.5 degree. The interior faces of the mould shall be plane surfaces with a
permissible variation of 0.03 mm.
Concrete test cubes shall be moulded by placing fresh concrete in the mould and
compacted as specified in IS 516.
Curing shall be as specified in IS 516. The cubes shall be kept in moist air of at least
90% relative humidity at a temperature of 27 degree C + 2 degree C for 24 hours +2
hours from the time of adding water to the dry ingredients. Thereafter they shall be
removed from the moulds and kept immersed in clean, fresh water and kept at 27 degree
C +2 degree C temperature until required for test. Curing water shall be renewed every
seven days. A record of maximum and minimum temperatures at the place of storage of
the cubes shall be maintained during the period they remain in storage.
The strength shall be determined based on not less than five cube test specimens for each
age and each water cement ratio. All these laboratory test results shall be tabulated and
furnished to the Engineer-in-Charge. The test results shall be accepted by the Engineerin-Charge if the average compressive strengths of the specimens tested is not less than
the compressive strength specified for the age at which specimens are tested subject to
the condition that only one out of the five consecutive tests may give a value less than
the specified strength for that age. The Engineer-in-Charge may direct the Contractor to
repeat the tests if the results are not satisfactory and also make such changes as he
considers necessary to meet the requirements specified. All these preliminary tests shall
be conducted by the Contractor at his own cost in an approved laboratory of NMC.
5.10 PROPORTIONING, CONSISTENCY, BATCHING AND MIXING OF

CONCRETE
The determination of the water cement ratio and proportion of aggregates to obtain the
required strength shall be made from preliminary tests by designing the concrete mix.
Controlled concrete shall be used on all concrete work complying with all the
requirements of IS: 456. Cube tests shall be carried out by the Contractor on the trial
mixes before the actual concreting operation starts. Based on the strength of the concrete
mix sanction for the use has to be obtained from Engineer-in-Charge.
If during the execution of the works it is found necessary to revise the mix because of the
cube tests showing lower strengths than the required one due to inconsistency of quality
of material or otherwise, The Engineer-in-Charge shall ask for fresh trial mixes to be
made by the Contractor. No claim to alter the rates of concrete work shall be entertained
due to such change in mix variations, as it is the Contractors responsibility to produce
the concrete of the required grade.
Great care shall be exercised when mixing the actual works concrete using the
proportions of the selected trial mix. The final concrete mix shall have the same
proportions and same source of cement, fine and coarse aggregates and water as that of
the approved selected mix.
A reasonable number of bags should be weighed separately to check the Net weight,
where the weight of cement is determined by accepting the manufacturer's weight per
bag at the site. Proper control of mixing water is deemed to be of paramount importance.
If mixers with automatic addition of water are used, water should be either measured by
volume in calibrated buckets, tins or weighed. All measuring equipment shall be
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maintained in a clean serviceable condition and their accuracy periodically checked and
certified and the Engineer-in-Charges approval obtained.
The Engineer-in-Charge may require the Contractor to carry out moisture content tests in
both fine and coarse aggregates. The amount of the added water shall then be adjusted to
compensate for any observed variations in the moisture contents. BIS: 2386 shall be
referred to for determination of moisture content.
No substitution in material, used on the work or alteration in the established proportions
shall be made without additional tests to show that the quality and strength of concrete
are satisfactory. No alterations shall be permitted without the prior sanction of the
Engineer-in-Charge.
5.10.1
Mixing of Concrete
The mixing of concrete shall be strictly carried out in an approved type of mechanical
Concrete mixer. The mixing equipment shall be capable of combining the aggregates.
Cement and water within the specified time into a thoroughly mixed and uniform mass,
and of discharging the mixture without segregation. The entire batch shall be discharged
before recharging. Mixing periods shall be measured from the time when all of the solid
materials are in the mixing drum, provided that all of the mixing water shall be
introduced before one fourth of the mixing time has elapsed. The mixing time in no case
shall be less than two minutes. The mixer speed shall not be less than 14 nor more than
20 revolutions per minute.
Mixing shall be continued until there is a uniform distribution of the materials and the
mass is uniform in color and consistency. Hand mixing of concrete shall not be permitted
at all.
For quantities less than 1 cum of concrete, hand mixing may be permitted at the
discretion of the Engineer-in-Charge with 10% excess cement quantity.
5.10.2
Grade of Concrete
The different grades of concrete specified shall conform to the strengths as required by
IS: 456-1987.Standard deviation shall be calculated as stated in 14.5 of IS: 456-1978.
The acceptable criteria for concrete shall be as stated in clause 15 of IS: 456 -1978.The
assumed standard deviations as given in table 6 of IS: 456-1978 has to be followed and
are given here under. However, the minimum cement content shall be as per Table no. 7:
Minimum Cement Content in Concrete in this tender document.
Table 5: Grade of Concrete
Grade of Concrete
Assumed Standard Deviation N/sq.mm
M 10
M 15
M 20
M 25
2.3
3.5
4.6
5.3
In order to get a quick idea of quality of concrete the optional tests are conducted as
stipulated in 14.1.1 of IS: 456-1978 and the results are analyzed according to table 5 on
page 41 of IS: 456-1978.
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5.10.2.1 Controlled Concrete

Controlled concrete shall be used on all concreting works except where specified
otherwise the mix proportions for all grades of concrete shall be designed to obtain
strengths corresponding to the values specified in table below for respective grades of
concrete.
Table 6: Compressive Strengths at 28 days
Grade
Specified Characteristic Compressive Strength at 28 days (N/sq.mm )
M15
M20
M25
M30
15
20
25
30
The maximum Water : Cement ratio for all controlled concrete works shall be as
specified in IS: 456-1978 as Preliminary tests as specified in the BIS code and required
by the Engineer-in-Charge shall be carried out sufficiently ahead of the actual
commencement of the work with different grades of concrete made from representative
samples of aggregates and cement expected to be used on the job to ascertain the ratios
by weight of cement of total quantity of fine and coarse aggregates and the water cement
ratio required to produce a concrete of specified strength and desired workability.
The minimum cement content for each grade of concrete shall be as per table below.
Table 7: Minimum Cement Content in Concrete
Grade of Concrete Minimum Cement Content in Concrete
(kg/cum of finished Concrete)
M 15
M 20
M 25
M 30
300
330
360
400
At least 4 (four) trial batches are to be made and 7 test cubes should be taken for each
batch noting the slump on each mix. These cubes shall then be properly cured and two
cubes from each mix shall be tested in a testing laboratory approved by the Engineer-inCharge at 7 days and others at 28 days for obtaining the ultimate compressive strength.
The test reports shall be submitted to the Engineer in charge. The cost of mix design and
testing shall be borne by the Contractor. On the basis of the preliminary test reports for
trial mix, a proportion of mix by weight and water cement ratio will be approved by the
Engineer-in-Charge, which will be expected to give the required strength. Consistency
and workability and the proportions so decided for different grades of concrete shall be
adhered to during all concreting operations. If however at any time the Engineer-inCharge feels that the quality of material, being used has been changed from those used
for preliminary mix design, the Contractor shall have to run similar trial mixes to
ascertain the mix proportions and consistency.
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The mix once approved must not be varied without prior approval of the Engineer-inCharge. However should the Contractor anticipate any change in the quality of future
supply of materials than that used for preliminary mix design, he shall inform the same
to the Engineer-in-Charge and bring fresh samples sufficiently ahead to carry out fresh
trial mixes. The Engineer-in-Charge shall have access to all places and laboratory where
design mix is prepared. Design mix will indicate by means of graphs and curves etc. the
extent of variation in the grading of aggregates which can be allowed.
In designing the mix proportions of concrete, the quantity of both cement and aggregate
shall be determined by weight. All measuring equipment shall be maintained in clean
and serviceable condition and their accuracy periodically checked.
To keep the water cement ratio to the designed value, allowance shall be made for the
moisture contents in both fine and course aggregates and determination of the same shall
be made as frequently as directed by the Engineer-in-Charge. The determination of
moisture contents shall be according to IS: 2386 (Part III). Absorption of water by dry
aggregates shall not be more than 5%.
5.10.2.2 Strength Requirements
Where ordinary Portland cement conforming to IS: 269 or Portland blast furnace slag
cement conforming to IS: 455 is used the compressive strength requirements for various
grades of concrete shall be as shown in table below. Where rapid hardening Portland
cement is used the 28 days compressive strength requirements specified in Tablehereunder shall be met in 7 days. The strength requirements specified in table shall apply
to both controlled concrete and ordinary concrete.
Strength Requirements of Concrete
Grade of
Minimum Compressive Strength Concrete in
Concrete
Accordance with IS: 516 (In kg/cm)
As per IS: 456-1978
For 15 cm cube specimens
For 15 cm cube
at 7 days
Specimens at 28 days
Work Test
Preliminary
Work Test
M 15
100
200
150
M 20
135
260
200
M 25
170
320
250
M 30
200
380
300
Other requirements of concrete strength as may be desired by the Engineer-in-Charge
shall be in accordance with Indian Standard IS: 456 (latest revision). The acceptance of
strength of concrete shall be as per clause 5.4 Sample size and Acceptance Criteria of
IS: 456 (latest revision) subject to stipulation and/or modifications stated elsewhere in
this specification if any.
Concrete work found unacceptable shall have to be dismantled and replaced to the
satisfaction of the Engineer-in-Charge by the Contractor free of cost to the Owner. No
payment will be made for the dismantled concrete, the relevant formwork and
reinforcement, embedded mixtures etc. wasted in the dismantled portion shall be made.
In the course of dismantling if any damage is done to the embedded items or adjacent
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structures, the same shall also be made good free of charge by the Contractor to the
satisfaction of the Engineer in charge. If the water quantity has to be increased in special
cases, cement also has to be increased proportionately to keep the ratio of water to
cement same as adopted in trial mix design for each grade of concrete.
5.10.2.3 Workability
The workability of concrete shall be checked at frequent intervals by slump test. Where
facilities exist and if required by the Engineer-in-Charge, alternatively the compacting
factor test in accordance with IS: 1199 shall be carried out. The degree of workability
necessary to allow the concrete to be well consolidated and to be worked into the corners
of form work and round the reinforcement to give the required surface finish shall
depend on the type and nature of the structure and shall be based on experience and tests.
The limits of consistency for structures are as specified in the table below:
Table 8: Limits of Consistency
Placing Conditions
Concreting of shallow Sections

with vibration
Concreting of lightly Reinforced
sections With vibration
Concreting of lightly Reinforced
sections Without Vibration or
Heavily reinforced Section with
Vibration
Concreting of heavily
Reinforced
sections
compacting Without vibration
factor
5.10.3
Degree of
Workability
Very low
Low
Medium
High
Values of Workability
20-10 seconds Veebee time or

0.75-0.80 compacting factor
10-5 seconds or 0.80-0.85
compacting factor
5-2 seconds Veebee time or
0.85-0.92 compacting factor
or 25-75mm slump for 20
mm Aggregate
Above 0.92
compacting
factor
or 75-125 mm
slumps
for
20
mm
aggregate
Workmanship
All workmanship shall be according to the latest relevant standards. Before starting a
pour the Contractor shall obtain the approval of the Engineer-in-Charge and all other
concerned department including safety dept, in a Pour Card maintained for this
purpose. He shall obtain complete instructions about the material and proportion to be
used, slump, workability of water per unit of cement, number of test cubes to be taken,
finishing to be done and any admixture to be added etc.
5.11 SAMPLING AND TESTING OF CONCRETE IN THE FIELD

Sampling and Testing of Concrete shall conform to IS: 456 2000.
a)
Facilities required for sampling materials and concrete including whether proof buildings
to house the facilities in the field, shall be provided by the Contractor at no extra cost.
The following equipment with operator shall be made available in serviceable
conditions.
i.
Concrete cube-testing machine suitable for 15 cm cubes of
100 tonnes capacity with proving calibration ring
1 no.
ii.
Cast iron cube moulds 15 cm size
12 nos.
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iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
Slump cone complete with tamping rod

Laboratory balance to weigh upto
5 kg with sensitivity of 10 gm
BIS sieves for coarse and fine aggregates
Set of measures from 5 litres to 0.1 litre
Electric oven with thermostat upto 120 C
Flakiness gauge
Elongation index gauge
Sedimentation pipette
Calibrated glass jar 1.0 litre capacity
Glass flasks and metal containers
Chemical reagents like sodium hydroxide,
tannic acid, litmus paper etc. Laboratory balance of 2 kg capacity and
sensitivity of 1 gm Weighing Machine for cement bags of 6 Nos.:
Vernier Calipers
Thermometer for concrete
1 set
1 no.
1 set
1 set
1 no.
1 no.
1 no.
1 no.
2 nos.
As required
As required
1 no.
2 no.
As required.
1 no.
b)
No concrete of any kind may be placed until the field concrete testing laboratory as
specified is provided to the satisfaction of the Engineer. The Contractor shall notify the
Engineer in advance of all concrete and concrete material testing as provided in the
clause to provide the Engineer/his representative with an opportunity to witness all
prescribed tests.
c)
At least 6 test cubes of each class of concrete shall be made of every 50cum concrete or
part thereof or from different batches as directed by Engineer-in-Charge. Such samples
shall be drawn on each day for each type of concrete. Of each set of 6 cubes, three shall
be tested at 7 days age and three at 28 days age. The cubes must be casted from various
batches to arrive at an average strength. The laboratory test results shall be tabulated and
furnished to the Engineer. The Engineer will pass the concrete if average strength of the
specimens tested is not less than the strength specified, subject to the condition that only
one out of three consecutive tests may give a value less than the specified strength but
this shall not be less than 90% of the specified strength.
d)
Consistency: Slump tests shall be carried out as often as requested by the Engineer and
invariably from the same batch of concrete from which the test cubes are made. Slump
tests shall be done immediately after sampling.
5.12 CONCRETE TESTS

The Engineer-in-Charge, may order tests to be carried out on cement, sand, coarse
aggregate, water in accordance with the relevant Indian standards.
Tests on Cement shall include:
Fineness test
Test for normal consistency
Test for setting time
Test for soundness
Test for tensile strength
Test for compressive strength
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Test for heat of hydration (by experiment and by calculations) in accordance with
BIS 269
Tests on Sand shall include:

Sieve test
Test for organic impurities
Decantation test for determining clay and silt content
Specific gravity test
Test for unit weight and bulkage factor
Test for sieve analysis and fineness modulus
Tests on Coarse Aggregate shall include:
Sieve analysis
Specific gravity and unit weight of dry, loose and rodded aggregate
Soundness and alkali aggregate reactivity
Petrography examination
Deleterious materials and organic impurities
Test for aggregate crushing value
Any or all these tests would normally be ordered to be carried out only if the Engineer
feels the materials are not obtained and shall be performed by the Contractor at a test
laboratory approved by NMC. The Contractor shall bear the charges of these optional
tests.
Concrete not made to the requirements of specification in all respects may be rejected by
the Engineer-in-Charge in which case it shall be removed and reconstructed entirely at
the expense of the Contractor.
5.12.1
Load Test on Members or Any Other Tests
i)
In the event of any work being suspected of material or workmanship or both, the
Engineer-in-Charge requiring its removal and reconstruction may order, or the
Contractor may request that it should be load tested in accordance with the following
provisions.
ii) The test load shall be 125% of the maximum superimposed load for which the
structure was designed. Such test load shall not be applied before 56 days after the
effective hardening of concrete. During the test, struts strong enough to take the
whole load shall be placed in position leaving a gap under the members. The test
load shall be maintained for 24 hours before removal.
iii) If within 24 hours of the removal of the load, the structure does not show a recovery
of at least 75% of the maximum deflection shown during the 24 hours under load,
the test loading shall be repeated after a lapse of at least 72 hours. The structure
shall be considered to have failed to pass the test if the recovery after the second test
is not at least 75% of the maximum deflection shown during the second test. If the
structure is certified as failed by the Engineer-in-Charge, the cost of all the new
construction and the load tests shall be borne by the Contractor.
iv) Any other tests, e.g. taking out in an approved manner concrete cores, examination
and tests on such cores removed from such parts of the structure as directed by the
Engineer-in-Charge, sonic testing etc. shall be carried out by the Contractor, if so
directed, at no extra cost.
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5.12.2
Unsatisfactory tests
Should the results of any test prove unsatisfactory, or the structure shows signs of
weakness, undue deflection or faulty construction, the Contractor shall remove and
rebuild the member or members involved or carry out such other remedial measures as
may be required by the Engineer-in-Charge.
5.13 ADMIXTURES
5.13.1
General
Admixtures may be used in concrete where required, only with the approval of the
Engineer-in-Charge. How ever it should be seen that, with the passage of time, neither
the compressive strength nor its durability is reduced. Calcium chloride shall not be used
for accelerating set of the cement for any concrete containing reinforcement or
embedded steel parts. When calcium chloride is permitted to be used, such as in mass
concrete works, it shall be dissolved in water and added to the mixing water in an
amount not to exceed 1.5% of the weight of the cement in each batch of concrete. When
admixtures are used, the designed concrete mix shall be corrected accordingly.
Admixtures shall be used as per manufacturers instruction and in the manner and with
the control specified by the Engineer-in-Charge.
5.13.2
Air Entraining Agents
Neutralized Vinson resin or other approved air in the concrete mix agents shall conform
to the requirements of ASTM standard 6.260; Air Entraining Admixtures for Concrete.
The recommended total air content of the concrete is 4% + 1%. The method of
measuring air content shall be as per IS: 1199.
5.13.3
Water Reducing Admixtures
Water reducing lignosulfonate admixture may be added in quantities approved by the

Engineer-in-Charge. The admixtures shall be added in the form of a solution.
5.13.4
Retarding Admixtures
Retarding agents may be added to the concrete mix in quantities approved by the
Engineer-in-Charge.
5.13.5
Water Proofing Agent
Water proofing agents shall conform to IS: 2645.

5.13.6
Other Admixtures
The Engineer-in-Charge may at his discretion allow the Contractor to use any other
admixture in the concrete.
5.14 PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL

INSPECTION AND APPROVAL
a. Before the concrete is actually placed in position, the insides of the formwork shall
be inspected to see that they have been cleaned and oiled. Temporary openings shall
be provided to facilitate inspection, especially at bottoms of columns and wall forms,
to permit removal of sawdust, wood shavings, binding wire, dirt etc. Openings shall
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b.
c.
d.
e.
f.
g.
h.
i.
j.
j.
k.
be placed or holes drilled so that these materials and water can be removed easily.
Such openings/holes shall be suitably plugged later.
The various agencies shall be permitted ample time to install drainage and plumbing
lines, floor and trench drains, conduits, hangers, anchors, inserts, sleeves, bolts,
frames and other miscellaneous embedment to be cast in the concrete as specified or
required or as is necessary for the proper execution of the work as specified in the
drawings.
All embedded parts, inserts, etc. supplied by the NMC or the Contractor shall be
correctly positioned and securely held in the forms to prevent displacement during
depositing and vibrating of concrete.
All anchor bolts shall be positioned and kept in place with the help of properly
manufactured templates unless specifically waived in writing by the Engineer-inCharge.
Slots, openings, holes, pockets etc. shall be provided in the concrete work in the
position specified in drawing or required or as directed by the Engineer-in-Charge.
Reinforcement and other items to be cast in concrete shall have clean surfaces that
will not impair bond.
Prior to concrete placement, all work shall be inspected and approved by the
Engineer-in-Charge and if found unsatisfactory, concrete shall not be poured until
after all defects have been corrected.
Approval by the Engineer-in-Charge of any and all materials and work as required
herein shall not relieve the Contractor from his obligation to produce finished
concrete in accordance with the requirements of the specifications.
Rain or wash water
No concrete shall be placed in wet weather or on a water-covered surface. Any
concrete that has been washed by heavy rains shall be entirely removed, if there is
any sign of cement and sand having been washed away from the concrete mixture.
To guard against damage, which may be caused by rains, the works shall be covered
with tarpaulins immediately after the concrete has been placed and compacted before
leaving the work unattended. Any water accumulating on the surface of the newly
placed concrete shall be removed by approved means and no further concrete shall
be placed thereon until such water is removed. To avoid flow of water over/around
freshly placed concrete, suitable drains and sumps shall be provided. During summer
season, temperature of water should be maintained, as per the criteria and for the
same, icing should be done for concreting work.
Bonding Mortar
Immediately before concrete placement begins, prepared surfaces except formwork,
which will come in contact with the concrete to be placed, shall be covered with a
bonding mortar as specified.
The corrosive matters on the reinforcement should be removed by means of wire
brush.
Laitance should be removed by means of chiseling from top concrete layer which
was earlier concreted
5.15 TRANSPORTATION
5.15.1
General
All buckets, containers or conveyors used for transporting concrete shall be mortar-tight,
leak proof irrespective of the method of transportation adopted, concrete shall be
delivered with the required consistency and plasticity without segregation or loss of
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slump. However, chutes shall not be used for transport of concrete without the written
permission of the Engineer-in-Charge and concrete shall not be re-handled before
placing.
5.15.2
Retempered or Contaminated Concrete
Concrete must be placed in its final position before it becomes too stiff to work. On no
account, water shall be added after the initial mixing. Concrete, which has become stiff
or has been contaminated with foreign materials shall be rejected and disposed off as
directed by the Engineer-in-Charge.
5.15.3
Avoiding Segregation
Concrete shall, in all cases, be deposited as nearly as practicable directly, in its final
position and shall not be re-handled to flow in a manner which will cause segregation,
loss of materials, displacement of reinforcement, shuttering or embedded insets, or
impair its strength. For locations where direct placement is not possible, and in narrow
forms, the Contractor shall provide suitable drop and Elephant Trunks to confine the
movement of concrete. Special care shall be taken when concrete is dropped from a
height, especially if reinforcement is in the way, particularly in column and the walls.
5.15.4
Placing by Manual Labour
Except when otherwise approved by the Engineer-in-Charge, concrete shall be placed in

the shuttering by shovels or other approved implements, and shall not be dropped from a
height more than 1.0 m or handled in a manner, which will cause segregation.
5.15.5
Placing by Mechanical Equipment
The following specification shall apply when placing concrete by use of mechanical
equipment is warranted considering the nature of work involved. The control of placing
shall begin at the mixer discharge. Concrete shall be discharged by a vertical drop into
the middle of the bucket or hopper and this principle of a vertical discharge of concrete
shall be adhered to throughout all stages of delivery until the concrete comes to rest in its
final position.
5.15.5.1 Types of Buckets
Central-bottom-dump buckets of a type that provides for positive regulation of the
amount and rate of deposition of concrete in all dumping positions, shall be employed.
5.15.5.2 Operation of Bucket
In placing concrete in large open areas, the bucket shall be spotted directly over the
position designated and then lowered for dumping. The open bucket shall clear the
concrete already in place and the height of drop shall not exceed 1.0 m. The bucket shall
be opened slowly to avoid high vertical bounce. Dumping of buckets on the swing or in
any manner, which results in separation of ingredients or disturbance of previously
placed concrete, will not be permitted.
5.15.6
Placement of Restricted Forms
Concrete placed in restricted forms by barrows, buggles, cars, short chutes or hand
shoveling shall be subject to the requirement for vertical delivery of limited height to
avoid segregation and shall be deposited as nearly as practicable in its final position.
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5.15.7
Chuting
Where it is necessary to use transfer chutes, specific approval of Engineer-in-Charge

must be obtained to type, length slopes, baffles, vertical terminals and timing of
operations. These shall be so arranged that an almost continuous flow of concrete is
obtained at the discharge and without segregation. Concrete should flow smoothly in the
chute and there should not be any obstruction to the flow. To allow for the loss of mortar
against the sides of the chutes, the first mixes shall have less coarse aggregate. During
cleaning of chutes, the wastewater shall be kept clear of the forms. Concrete shall not be
permitted to fall from the end of the chutes by more than 1.0 m. Chutes, when approved
for use shall have slopes not flatter than 1 vertical, 3 horizontal and not steeper than 1
vertical, 2 horizontal. Chutes shall be of metal or metal lines end of rounded cross
section. The slopes of all chute sections shall be approximately the same. The slopes of
all chute sections shall be approximately the same. The discharge end of the chutes shall
be maintained above the surface of the concrete in the forms.
5.15.8
Placing by Pumping/Pneumatic Placers
Concrete may be conveyed and placed by mechanically operated equipment e.g., pumps
or pneumatic placers only with the written permission of the Engineer-in-Charge at no
extra cost. The slump shall be held to the minimum necessary for conveying concrete by
this method.
When pumping is adopted, before pumping of concrete is started, the pipeline shall be
lubricated with one or two batches of mortar composed of one part cement and two parts
sand. Care shall be taken to avoid stoppages in work once pumping has started.
When a pneumatic placer is used, the manufacturers advice on layout of the pipeline
shall be followed to avoid blockages and excessive wear. Restraint shall be provided at
the discharge box to cater for the reaction at this end. Manufacturers recommendations
shall be followed regarding concrete quality and all other related matters when pumping/
pneumatic placing equipment is used. It should be noted that no extra payment is made
for these items, if required and directed by Engineer-in-Charge.
5.15.9
Concrete in Layers
Concreting, once started, shall be continuous until the pour is completed. Concrete shall
be placed in successive horizontal layers of uniform thickness ranging from 15 cm to 45
cm directed by Engineer-in-Charge. These shall be placed as rapidly practicable to
prevent the formation of cold joints or planes of weakness between each succeeding
layer within the pour. The thickness of each layer shall be such that it can be deposited
before the previous layer has stiffened. The bucket loads or other units of deposit, shall
be spotted progressively along the face of the layer with such overlap as will facilitate
spreading the layer to uniform depth and texture with a minimum shoveling. Any
tendency to segregation shall be corrected by shoveling stones into mortar rather than
mortar on to stones. Such a condition shall be corrected by redesign of mix or other
means, as directed by the Engineer-in-Charge.
5.15.10 Cover Blocks
Cover blocks of required size depending on the cover of the reinforcement as mentioned
in the drawings shall be prepared in 1:3 cement mortar with fine aggregates and
minimum compressive strength of 300 kg/sq.cm.
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5.15.11 Bedding of Layers

The top surface of each pour and bedding planes shall be approximately horizontal
unless otherwise instructed. Top layer should be rough and with key for further extension
of work.
5.15.12 Compaction
Concrete shall be compacted during placing with approved vibrating equipment until the
concrete has been consolidated to the maximum practicable density, as specified in the
IS, is free of pockets of coarse aggregate and fits tightly against all form surfaces,
reinforcement and embedded fixtures. Particular care shall be taken to ensure that all
concrete placed against the form faces and into corners of forms against hardened
concrete at joints is free from voids or cavities. The use of vibrators shall be consistent
with the concrete mix and caution exercised not to over vibrate the concrete to the point
that segregation results.
5.15.12.1
Type of Vibrators
Vibrators shall conform to BIS specifications. Type of vibrator to be used shall depend
on the structures where concrete is to be placed. Shutter vibrators to be effective, shall
be firmly secured to the formwork which must be sufficiently rigid to transmit the
vibration and strong enough not to be damaged by it. Immersion vibrators in sufficient
numbers and each of adequate size shall be used to properly consolidate all concrete.
Tapping or external vibrating of forms by hand tools or immersion vibrators will not be
permitted.
5.15.12.2
Use of Vibrators
The exact manner of application and the most suitable machines for the purpose must be
carefully considered and operated by experienced men. Immersion vibrators shall be
inserted vertically at points not more than 450 mm apart and withdrawn when air bubbles
cease to come to the surface. Immersion vibrators shall be withdrawn very slowly. In no
case shall immersion vibrators be used to transport concrete inside the forms. Particular
attention be paid to vibration at the top of a lift e.g. in a column or wall.
5.15.12.3
Melding Successive Batches
When placing concrete in layers, which are advancing horizontally as the work
progresses, great care shall be exercised to ensure adequate vibration blending and
melding of the concrete between the succeeding layers.
5.15.12.4
Penetration of Vibrators
The immersion vibrator shall penetrate the layer being placed and also penetrate the layer
below while the under layer is still plastic to ensure good bond and homogeneity
between the two layers and prevent the formation of cold joints.
5.15.12.5
Vibrating against Reinforcement/Formwork
Care shall be taken to prevent contact of immersion vibrators against reinforcement steel.
Immersion vibrators shall not be allowed to come in contact with reinforcement steel
after start of initial set. They shall also not be allowed to come in contact with forms or
finished surfaces.
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5.15.12.6
Use of Form Attached Vibrators
Form attached vibrators shall be used only with specific authorization of the Engineer-inCharge.
5.15.12.7
Use of Surface Vibrators
The use of surface vibrators will not be permitted under normal conditions. However,
for thin slabs, surface vibrating by specially designed vibrators may be permitted, upon
approval of Engineer-in-Charge.
5.15.12.8
Stone Pockets And Mortar Pondages
The formation of stone pockets and mortar pondages in corners and against faces of
forms shall not be permitted. Should these occur, they shall be dug out, reformed and
refilled to sufficient depth and shape for thorough bonding, as directed by the Engineerin-Charge.
5.15.13 Placement Interval
Except when placing with slip forms, each placement of concrete in multiple lift work,
shall be allowed to set for atleast 24 hours after the final set of concrete and before the
start of a subsequent placement.
5.15.14 Special Provision in Placing
When placing concrete in walls with openings, in floors of integral slabs and beam
construction and other similar conditions, the placing shall stop when the concrete
reaches the top of the opening in walls or bottom horizontal surface of the slab, as the
case may be.
Placing shall be resumed before the concrete in place takes initial set, but not until it has
had time to settle as determined by the Engineer-in-Charge.
5.15.15 Placing Concrete Through Reinforcing Steel
When placing concrete through reinforcing steel, care shall be taken to prevent
segregation of the coarse aggregate. Where the congestion of steel makes placing
difficult, it may be necessary to obtain Engineer in-Charges permission for temporarily
moving the top steel aside for proper placement & for restoring reinforcement as per
drawing.
5.15.16 Bleeding
Bleeding or free water on top of concrete being deposited into the forms, shall be the
cause to stop the concrete pour and the conditions causing this defect corrected before
any further Concreting is resumed.
5.16 APPLICATION OF ARALDITE FOR BONDING OF NEW AND OLD

CONCRETE
5.16.1
General
Araldite epoxy resins will be used to bond fresh concrete to concrete that is fully cured,
to give a monolithic bond capable of transmitting high stresses when traditional bonding
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agents such as cement slurry cannot always be relied upon to provide good adhesion
which is particularly the case when large areas are involved.
a. The Araldite based formulation shall be applied to a suitably prepared concrete substrata and the fresh concrete poured as soon as possible, but always during the open
time of the adhesive.
b. Materials used shall be of best quality like CIBA, FOSROC or ROFF and approved
by the Engineer-in-Charge.
c. Manufacturers instructions shall be followed in all respects.
d. No separate payment shall be paid for this item of work.
5.16.2
Formulation
ARALDITE
Hardener
Hardener
Hardener
Silica Flour
5.16.3
GY250
HY825
HY830
HY850
100
20
20
20
20
Parts by weight
Parts by weight
Parts by weight
Parts by weight
Parts by weight
Application
The application of the adhesives shall be as per manufacturer standards.

5.16.3.1 Preparation of the Substrata
To obtain good adhesion, it is necessary to have clean and sound substrata. Preparation
can be carried out using a variety of techniques including chemical treatment and
mechanical methods such as grinding, milling, abrading, planing and sand blasting. Dust
and loose particles resulting from the pretreatment should be removed by vacuum
cleaning or oil-free or blast.
5.16.3.2 Mixing
The resin and hardener should be thoroughly mixed in the dry filler. The mixed, ready to
use adhesive should not contain lumps of unwetted filler and should be of uniform color.
For a total weight of 1 kg or less hand mixing should be sufficient. For quantities in
excess of 1 kg, the use of a mechanical mixer is recommended.
5.16.3.3 Pot life and Open time
The pot life is the period during which the ready to use ARALDITE based formulation
must be applied. After this period, the mix can no longer be worked and will have begun
to set in its container. The table below indicates the pot life at different temperatures:
Mix Temperature
25 C
30 C
35 C
Pot life in minutes

90 Minutes
60 Minutes
45 Minutes
(The figures in this table are for batches less than 1 kilogram).
The Open time is the maximum period of time allowable between application of the
ARALDITE adhesive and pouring the fresh concrete. Exceeding the Open time would
result in considerably reduced adhesion. The adhesive should be applied to the pre-
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treated substrata as soon as the components have been mixed and fresh concrete poured
immediately afterwards.
Accurate knowledge of the Open time is essential in case the work is interrupted.
Table gives the Open time of ARALDITE based formulations as a function of substrata
temperature. In all cases, the adhesives shall be applied immediately after mixing. Any
delay between mixing and application will reduce the Open time. Fresh concrete must
be poured before the adhesive begins to gel. New to old concrete bonding is not
recommended at temperatures below 5-Degree Centigrade, as curing cannot be assured
under these circumstances.
5.16.3.4 Methods of Application
The shape and size of the concrete structure will determine the method of application
used. The ARALDITE based adhesive may be applied by hand using brushed, brooms
or any other suitable applicator.
5.16.3.5 Suitability of Fresh Concrete
Best results are obtained when the water/ cement ratio of the new concrete is low as is
practicable.
5.16.3.6 Coverage
One kilogram of the mixed ARALDITE adhesive including hardeners and filler covers
an area of 2 to 3 sq.m. when applied with a stiff nylon bristle brush. However, the
coverage is very much dependent on the finish in the concrete.
5.17 HANDLING PRECAUTIONS

Epoxy resins can cause irritation of the skin in sensitive person if incorrectly handled.
Certain safety precautions must therefore be observed and those handling the resins and
hardeners should be given suitable instructions. Those working with epoxy resins
should, above all, be instructed that personal cleanliness at the place of work is essential.
The resin and hardener should not be allowed to come into direct contact with the skin.
The most effective protection is achieved by wearing rubber or polythene gloves, the
latter having the advantage that they can be replaced when dirty. They are more pleasant
to wear if cotton gloves are worn underneath. Parts of the skins, which have come into
contact with the resin or hardener, should be washed with lukewarm water and a mild
soap. Special cleaning creams may be used as they have proved to be highly suitable.
5.18 CONSTRUCTION JOINTS

a. A construction joint is defined as a joint in the concrete introduced for convenience
in construction at which special measures are taken to achieve subsequent continuity
without provision for further relative movement.
b. No concreting shall be started until the Engineer-in-Charge has approved the method
of placing the positions and form of the construction joints and lifts. The
construction joints shall be so located as not to impair the strength of the structure.
Water stops shall be inserted as per clause 3.20
c. Concrete placed to form the face of a construction joint shall have all Laitance
removed and the aggregate exposed prior to the placing of fresh concrete. The
Laitance shall wherever practicable be removed by spraying the concrete where it is
still green. The whole of the concrete surface forming part of the joint shall be
hacked to expose the aggregate to the 1/3rd size of maximum size of aggregate.
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Where aggregate is damaged during hacking, it shall be removed from the concrete
face by further hacking. All loose matter shall be removed and the exposed surface
thoroughly cleaned by wire brushing, air blasting or washing, leaving the surface
clean and damp. Immediately before fresh concrete is placed, a 12 mm thick layer of
sand/cement mortar mixed in the same proportions as in the concrete shall be spread
in the horizontal face of the construction joint. A drier mix shall be used for the top
lift of horizontal face of the construction joint. A drier mix shall be used for the top
lift of horizontal pours to avoid Laitance. The new concrete shall be well worked
against the prepared face before the mortar sets. Special care shall be taken to obtain
thorough compaction and to avoid segregation of the concrete along the joint plane.
5.19 MOVEMENT JOINTS

a. Movement joints are defined as all joints intended to accommodate relative
movement between adjoining parts of a structure, special provision being made
where necessary for maintaining the water tightness of the joint. The Contractor
shall comply with the instructions of manufacturers of proprietary jointing materials
and shall, if required by the Engineer-in-Charge, demonstrate that the jointing
materials can be applied satisfactorily.
b. The surface of set concrete in a movement joint shall, as shown on the drawings, be
painted with two coats of bituminous paint and new concrete shall be placed against
it only when the paint is dry. Expansion joints shall be formed by a separating strip
of approved preformed joint filler.
c. Caulking grooves shall be provided. At all joints where a caulking groove is formed,
immediately prior to caulking, the groove shall be wire brushed and loose material
removed and blown out by compressed air. After the groove has dried, it shall be
primed and caulked with approved sealing compound applied in accordance with the
manufacturers instructions. At all caulked joints, the face of the caulking strip and a
width of concrete on either side shall be painted with two coats of paint having the
same base as the sealing compound.
5.20 WATER STOPS AND JOINT FILLERS

5.20.1
Water stops
a. At all construction, contraction and expansion joints in the water retaining structures
and wherever specified or directed by the Engineer-in-Charge, water stops shall be
provided. The water stops shall be PVC type or of any other equivalent material as
approved by the Engineer-in-Charge. PVC water stops shall have a tensile strength
of not less than 14 MN/m2 and elongation at break of not less than 300%. Water
stops shall not be exposed to direct sunlight for long periods. Before being
concreted in water stops shall be cleaned of all foreign materials. Wherever
provided, water stops shall be placed in such a manner that they are embedded in the
adjacent sections of the panels for equal width.
b. As far as possible, jointing on site shall be confined to the making of butt joints in
straight runs of water stops and all the joints should be monolithic. Where it is
agreed with the Engineer-in-Charge that it is necessary to make an intersection or
change of direction of any joint, other than a butt joint in a straight run on site, a
preliminary joint, intersection or change of direction piece shall be made and
submitted to such tests as the Engineer-in-Charge may require.
c. Flexible water stops shall be fully supported in the form work, free of nails and clear
of reinforcement and other fixtures. Damaged water stops shall be replaced and
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during concreting care shall be taken to place the concrete so that water stops do not
bend or distort or displace.
d. The different types of water stops to be used in liquid retaining structures will be as
follows:
Table 9 : Types of Water Stops
Type of water stops
Sr. Type of Joint
1. Partial/complete Contraction joint in 230 mm wide, ribbed with hollow
walls and slabs
bulb & 6 mm minimum thickness
2. Expansion joints in walls and slabs
230 mm wide, ribbed with hollow
3. Construction joint in raft
4. Construction joint in wall
5. Expansion joint raft
6. Partial/complete Contraction joint in raft 230 mm wide, ribbed with hollow
5.20.2
centre
centre
centre
centre
centre
centre
Jointing fillers
Joint fillers shall be of durable, compressible and non-extruding material.

Details of jointing material required here. Type of joint, size or width of joint and joint
filler material to be used with preferred brands if any.
5.21 SEALING COMPOUNDS

Horizontal joints shall, where used in water-retaining structures be sealed with a cold
pouring polysulphide rubber sealing compound of quality equal to, or better than
serviced Paraseal. Horizontal joints in roofs, floors and other non-water retaining
structures shall be sealed with an approved sealant with properties equal to or better than
serviced Paraplastic 41. Vertical joints and joints in the soffits of slabs in both water
retaining as well as non-water retaining structures shall be sealed with a trowel or gun
applied polysulphide rubber sealing compound such as serviced Vertiseal or
equivalent. Sealing compounds shall be fully cured before water is permitted to come in
contact. At 40 C, the curing time would be approximately 7 weeks for polysulphide
compounds like CIBA, FOSROC or ROFF as approved by Engineer-in-Charge.
5.22 TOLERANCES IN CONCRETE SURFACES
Concrete surfaces for the various classes of unformed and formed finishes specified
in various clauses shall comply with the tolerances shown in Table hereunder, except
where different tolerances are expressly required by the specification.
In the table line and level and dimension shall mean the lines, levels and crosssectional dimensions as specified and required.
Surface irregularities shall be classified as abrupt or gradual.
Abrupt
irregularities include by shall not be limited to offsets and fins caused by displaced
or misplaced formwork, loose knots and other defects in formwork materials, and
shall be tested by direct measurement. Gradual irregularities shall be tested by
means of a straight template for plane surfaces and 1.5 m long formed surfaces.
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Class of
finish
Line & level
U1
U2
U3
F1
F2
F3
12
6
6
12
6
3
Maximum tolerance (mm) in:

Abrupt
Gradual
irregularity
irregularity
6
3
3
6
6
3
6
3
3
6
6
3
Dimension
+12-6
+12-6
+6-
5.23 CURING, PROTECTING, REPAIRING AND FINISHING

5.23.1
Curing
All concrete shall be kept continuously in a damp or wet condition by ponding or by

covering with a layer of sacking, canvas, hessian or similar materials and kept constantly
wet for atleast seven days from the date of placing concrete in case of OPC and 10 days
in case of mineral admixture or blended cements are used. The period of curing shall be
not less than 10 days for concrete exposed to dry and hot weather condition
5.23.2
Curing with Water
Fresh concrete shall be kept continuously wet for a minimum period of 10 days from the
date of placing of concrete, following a lapse of 12 to 14 hours after laying of concrete.
The curing of horizontal surfaces exposed to the drying winds shall however begin as
soon as the concrete has hardened. Water shall be applied to formed surfaces
immediately upon removal of forms. Quantity of water applied shall be controlled so as
to prevent erosion of freshly placed concrete.
5.23.3
Continuous Spraying
Curing shall be assured by use of an ample water supply under pressure in pipes, with all
necessary appliances of hose, sprinklers and spraying devices. Continuous fine mist
spraying or sprinkling shall be used, unless otherwise specified or approved by the
Engineer-in-Charge.
5.23.4
Alternate Curing Methods
Whenever in the judgement of the Engineer-in-Charge, it is necessary to omit the

continuous spray method, a covering of clean sand or other approved means such as wet
gunny bags, which will prevent loss of moisture from the concrete, may be used. No
type of covering will be approved which would stain or damage the concrete during or
after the curing period. Covering shall be kept continuously wet during curing period.
For curing of concrete in sidewalks, floors, flat roofs of other level surfaces, the ponding
method of curing is preferred. The method of containing the ponded water shall be
approved by the Engineer-in-Charge. Special attention shall be given to edges and
corners of the slabs to ensure proper protection to these areas. The ponded areas shall be
kept continuously filled with water during the curing period.
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5.23.5
Curing Compound
Surface coating type-curing compounds shall be used only by special permission of

Engineer-in-Charge. Curing compounds shall be liquid type white pigmented,
conforming to US Bureau of Reclamation specification. No curing compound shall be
used on surfaces where future blending with concrete, water of acid proof membrane or
painting is specified. Curing compound shall be used only after getting
sufficient/satisfactory test results at site.
5.23.6
Curing Equipment
All equipment and materials required for curing shall be on hand and ready for use
before concrete is placed.
5.23.7
Protecting Fresh Concrete
Fresh concrete shall be protected from defacements and damage due to construction
operations by leaving forms in place for an ample period as specified in section D3 of
this specification. Newly placed concrete shall be protected by approved means such as
tarpaulins from rain, sun and winds. Steps as approved by the Engineer-in-Charge shall
also be taken to protect immature concrete from damage by debris, excessive lading,
vibration, abrasion or contact with other materials, etc. that may impair the strength
and/or durability of the concrete. Workmen shall be warned against and prevented from
disturbing green concrete during its setting period. If it is necessary that the workmen
enter the area of freshly placed concrete, the Engineer-in-Charge may require that
bridges be placed over the area.
5.23.8
Repair and Replacement of Unsatisfactory Concrete
5.23.8.1 General
Immediately after the shuttering is removed, the surface of concrete shall be very
carefully gone over and all defective areas called to the attention of the Engineer-inCharge who may permit patching of the defective areas or also reject the concrete unit
either partially or in its entirety. Rejected concrete shall be removed and replaced by the
Contractor. Holes shall be filled with mortar composed of one part of cement to one and
half parts of sand passing 2.36 mm I.S sieve after removing any loose stones adhering to
the concrete. Concrete surfaces shall be finished as described in specifications or as
directed by the Engineer-in-Charge. Superficial honey combed surfaces and rough
patches shall be similarly made good immediately after removal of shuttering, in the
presence of the Engineer-in-Charge and superficial water and air holes shall be filled in.
The mortar shall be well worked into the surface with a wooden float. Excess water shall
be avoided. Unless instructed otherwise by the Engineer-in-Charge, the surface of the
exposed concrete placed against shuttering shall be rubbed down immediately on
removal of shuttering to remove fine or other irregularities, care being taken to avoid
damaging the surface. Surface irregularities shall be removed by grinding. If
reinforcement is exposed or the honeycombing occurs at vulnerable positions e.g. ends
of beams or columns, it may be necessary to cut out the member completely or in part
and reconstruct. The decision of the Engineer-in-Charge shall be final in this regard. If
only patching is necessary, the edges being cut perpendicular to the affected surface or
with a small under cut if possible. Anchors, tees or dovetail slots shall be provided
whenever necessary to attach the new concrete securely in place. An area extending
several centimeters beyond the edges and the surfaces of the prepared voids shall be
saturated with water for 24 hours immediately before the patching material is placed.
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For small repairs concerned Engineer-in-Charge shall permit to repair the same and shall
be repaired at his directions. For major repairs Contractor shall submit the method of
statement and on approval of same shall carry such repairs with strict compliance to the
method of statement.
5.23.8.2 Use of Epoxy
The use of epoxy for bonding fresh concrete used for repairs will be permitted upon
written approval of the Engineer-in-Charge. Epoxies shall be applied in strict accordance
with the instructions of the manufacturer.
5.23.8.3 Method of Repair
Small size holes having surface dimensions about equal to the depth of the hole, holes
left after removal of form bolts, grout insert holes and slots cut for repair of cracks shall
be repaired as follows.
The hole to be patched shall be roughened and thoroughly soaked with clean water until
absorption stops. A 5 mm thick layer of grout of equal parts of cement and sand shall be
well brushed into the surface to be patched, followed immediately by the patching
concrete which shall be well consolidated with a wooden float and left slightly protrude
of the surrounding surface. The concrete patch shall be built up in 10 mm thick layers,
after an hour or more, depending upon weather conditions, it shall be worked off flush
with a wooden float and a smooth finish obtained by wiping with hessian. A steel trowel
shall be used for this purpose. The mix for patching shall be of the same materials and in
the same proportion as that used in the concrete being repaired, although some reduction
in the maximum size of the coarse aggregates may be necessary and the mix shall be
kept as dry as possible. Mortar filling by air pressure (gunniting) shall be used for repair
of areas too large and/or too shallow for patching with mortar. Patched surfaces shall be
given a final treatment to match the colour and texture of the surrounding concrete.
White cement shall be substituted for ordinary cement, if so directed by the Engineer-inCharge, to match the shade of the patch with the original concrete.
5.23.8.4 Curing of Patched Work
The patched area shall be covered immediately with an approved non-staining, watersaturated material such as gunny bags which shall be kept continuously wet and
protected against sun and wind for a period of 24 hours. Thereafter, the patched area
shall be kept wet continuously by a fine spray, or sprinkling for not less than 10 days.
All fillings shall be tightly bounded to the concrete and shall be sound, free from
shrinkage cracks after the fillings have been cured and dried.
5.23.8.5 Approval by the Engineer-in-Charge
All materials, procedures and operations used in the repair work shall be subject to the
approval of the Engineer-in-Charge.
5.23.9
Finishing
5.23.9.1 General
The type of finish for formed concrete surfaces shall be as follows, unless varied by the
design/architectural drawings and specifications.
When the structure is in service all the surfaces shall receive no special finish, except
repair of damaged or defective concrete, removal of fine and abrupt irregularities, filling
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defective concrete, filling of holes left by form ties and rods and clean up of loose or
adhering debris. Surfaces which will be exposed to the weather and which would
normally be level, shall be sloped for drainage. Unless a horizontal surface or the slope
required is specified, the tops of narrow surfaces such as stair treads, walls, curbs and
parapets shall be sloped across the width approximately 1 in 30. Broader surfaces such
as walkways, and platforms shall be sloped about 1 in 50. Surfaces that will be covered
by backfill or concrete, subfloors to be covered with concrete topping, terrazzo or quarry
tiles and similar surfaces shall be smooth ascended and leveled to produce even surfaces.
Surface irregularities shall not exceed 6 mm. Surfaces which will not be covered by
backfill, concrete or tile toppings such as outside decks, floors of galleries and sumps,
parapets, gutters, side-walks, floors and slabs, shall be consolidated, screened and
floated. Excess water and laitance shall be removed before final finishing. Floating may
be done with hand or power tools and started as soon as the screened surface has attained
a stiffness to permit finishing operations and these shall be the minimum required to
produce a surface uniform in texture and free from screened marks or other
imperfections. Joints and edges shall be tooled as specified or as directed by the
Engineer-in-Charge.
5.23.9.2 Standard Finish For Exposed Concrete
Exposed concrete shall mean any concrete, other than floors or slabs, exposed to view
upon completion of the works. Unless otherwise specified, the standard finish for
exposed concrete shall be a smooth finish. A smooth finish shall be obtained with the
use of lined or plywood forms having smooth and even surfaces and edges. Panels of
forms shall be of uniform size and be as large as practicable and installed with closed
joints. Upon removal of forms the joint marks shall be smoothed off and all blemishes,
protections etc., removed leaving the surfaces smooth.
5.23.9.3 Integral Cement Concrete Finish
When specified, an integral cement concrete finish of specified thickness for floors and
slabs shall be applied either monolithic or bonded, as specified or directed by the
Engineer-in-Charge. The surface shall be tested with a straight edge and any high and
low spots eliminated. Floating or trowelling of the finish shall be permitted only after all
surface water has evaporated. Dry cement or a mixture of dry cement and sand shall not
be sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen
the mix.
5.23.9.4 Rubbed Finish
A rubbed finish shall be provided only on exposed concrete surfaces. Upon removal of
forms, all fins and other projections on the surfaces shall be carefully removed, offsets
leveled and voids and/or damaged sections immediately saturated with water and
repaired by filling with a concrete or mortar of the same composition as was used in the
surface. The surfaces shall then be thoroughly wetted and rubbed with carborundun or
other abrasive. Cement mortar may be used in the rubbing, but the finished surfaces
shall not be brush coated with either cement or grout after rubbing. The finished
surfaces shall present a uniform and smooth appearance.
5.23.9.5 Protection
All concrete shall be protected against damage until final acceptance by the Engineer-inCharge.
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5.24 HOT WEATHER REQUIREMENT

a. All Concrete work performed in hot weather shall be in accordance with IS:456,
except as herein modified.
b. Admixtures may be used only when approved by the Engineer-in-Charge.
c. Adequate provisions shall be made to lower give limit concrete temperatures by cool
ingredients, eliminating excessive mixing, preventing exposure of mixers and
conveyors to direct sunlight and the use of reflective paint on mixers, etc. The
temperature of the freshly placed concrete shall not be permitted to exceed 38
degrees centigrade.
d. Consideration shall be given to shading aggregate stockpiles from direct rays of the
sun and spraying stockpiles with water, use of cold water when available, and
burying, insulating, shading and/or painting white the pipelines and water storage
tanks and conveyance.
e. In order to reduce loss of mixing water, the aggregate, wooden forms, subgrade,
adjacent concrete and other moisture absorbing surfaces shall be well wetted prior to
concreting, placement and finishing shall be done as quickly as possible.
f. Extra precautions shall be taken for the protection and curing of concrete.
Consideration shall be given to continuous water curing and protection against high
temperatures and drying hot winds for a period of at least 7 days immediately after
concrete has set and after which normal curing procedures may be resumed.
5.25 PLACING CONCRETE UNDERWATER

a) Under all ordinary conditions, all foundations shall be completely dewatered and
concrete placed in the dry. However, when concrete placement under water is necessary,
all work shall conform to IS:456 and the procedure shall be as follows:
Method of Placement
Concrete shall be deposited underwater by means of tremises, or drop bottom
buckets of approved type.
Direction, Inspection and Approval
All work requiring placement of concrete underwater shall be designed, directed
and inspected with due regard to local circumstances and purposes. All
underwater concrete shall be placed according to specifications approved by the
Engineer-in-Charge.
b) Special precautions shall be taken for prevention of lifting of concrete due to uplift
pressure of subsoil water.
5.26 PRECAST CONCRETE

5.26.1
General
Precast concrete units, whether manufactured on or off site, shall comply in every way
with the provisions of the contract for in situ concrete. Wherever possible, precast units
shall be hydraulically pressed. When ready for incorporation in the works, precast units
shall be responsible for the accuracy of the level, shape of the bed or platform. A
suitable serial number and the date of casting shall be impressed or painted on each unit.
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5.26.2
Striking Forms
Side shutters shall not be struck in less than 24 hours after depositing concrete and no
precast unit shall be lifted until the concrete reaches strength of at least twice the stress to
which the concrete may be subjected to at the time of lifting.
5.26.3
Precast Units
The lifting and removal of precast units shall be undertaken without causing shock,
vibration or undue bending stresses to or in the units. Before lifting and removal takes
place, Contractor shall satisfy the Engineer-in-Charge or his representative that the
methods he proposes to adopt for these operations will not over-stress or otherwise effect
seriously the strength of the precast units. The reinforced side of the units shall be
distinctly marked.
5.26.4
Curing
All precast work shall be protected from the direct rays of the sun for at least 7 days after
casting and during that period each unit shall be kept constantly watered or preferably be
completely immersed in water if the size of the unit so permits.
5.27 SLOTS, OPENINGS, ETC.

5.27.1
General
Slots, openings or holes, pockets, etc., shall be provided in the concrete work in the
approved positions as per design drawings and as directed by Engineer-in-Charge and
extra reinforcement should be provided as per design requirement. Short pipes with
puddle collar shall be fixed in the side wall of suction pipes. They shall be supplied at
the appropriate time during construction. Any deviation from the approved drawings
shall be made good by Contractor at his own expense, without damaging any other work.
Sleeves, bolts, inserts etc., shall also be provided in concrete work where so required.
5.27.2
Grouting
5.27.2.1 Standard Grout

The proportions of grout shall be such as to produce a flowable mixture consistent with
minimum water content and shrinkage. The grout proportions shall be limited as
follows:
Table 10 : Proportions for Standard Grout
Sr.
Use
1.
Fluid
2.
General
3.
Stiff Mix
CONTRACTOR
Grout thickness
Mix proportions
W/c ratio
(max.)
Under 25 mm
One part Portland cement to 0.44

one part sand
25mm & over but One part Portland cement to 2 0.53
less than 50mm
parts of sand
50mm & over
One part Portland cement to 3 0.53
parts of sand
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Sr.
Use
Grout thickness
Mix proportions
W/c ratio
(max.)
Sand shall be such as to produce a flowable grout without any tendency to segregate.
Sand for general grouting purposes, shall be graded within the following limits:
Passing BIS 2.36 mm sieve 95 to 100%
Passing BIS 1.18 mm sieve 65 to 95%
Passing BIS 300 micron sieve 10 to 30%
Passing BIS 150 micron sieve 3 to 10%
Sand for fluid grouts, shall have the fine material passing the 300 and 150 micron sieves
at the upper limits specified above. Sand, for still grouts, shall meet the usual grading
specifications for concrete laitance. Anchor bolts, anchor bolt holes and the bottoms of
equipment and column base plates shall be cleaned of all oil, grease, dirt and loose
material. The use of hot, strong caustic solution for this purpose will be permitted. Prior
to grouting, the hardened concrete surfaces to be grouted shall be saturated with water.
Water in anchor boltholes shall be removed before grouting is started. Forms around
base plates shall be reasonably tight to prevent leakage of the grout. Adequate clearance
shall be provided between forms and base plate to permit grout to be worked properly
into place. Grouting, once started, shall be done quickly and continuously to prevent
segregation, bleeding and breakdown of initial set. Grout shall be worked from one side
of one end to the other to prevent entrapment of air. To distribute the grout and to ensure
more complete contact between base plate and foundation and to help release trapped air,
link chains can be used to work the grout into place. Grout throughout holes in base
plates shall be by pressure grouting. Variations in grout mixes and procedures shall be
permitted if approved by the Engineer-in-Charge.
5.27.2.2 Non-Shrinking Grout for Equipment Foundation
Non-shrinking grout shall be used for grouting of machine base plates, anchor bolts,
other anchoring devices and at locations where ordinary grouts are ineffective due to
shrinkage. It shall be composed of a type of expansive hydraulic sheeting binder and
select-graded aggregates. It shall have properties as mentioned below:
Table 11 : Proportions for Non-Shrinking Grout
Sr.
1
2
3
4
CONTRACTOR
Properties
Values
Maximum grain size

Water % (for 80% flow)
Density of hardened grout
Compressive strength N/mm2
Minimum 3 days
7 days
28 days
Expansion %
Free
Restrained
Restrained
6 mm
15.17
2.27 - 2.30 gm/m1
NO.
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23
34
45
0.10 - 0.20
0.08 - 0.12
0.08 - 0.12
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Mixing, batching, cleaning, preparation of surface and curing of non-shrinking grout

shall be done as per manufacturers instructions. Brands like FOSROC /
BUILDMASTER etc or equivalent brand as approved by Engineer-in-charge shall be
used as per manufacturer specifications.
5.28 INSPECTION
a. All materials, workmanship and finished construction shall be subject to continuous
inspection and approval of the Engineer-in-Charge.
b. All materials supplied by the Contractor and all work or construction performed by
the Contractor which is rejected as not being in conformity with the specifications
and requirements, shall be immediately replaced.
c. All concrete shall be protected against damage until final acceptance by the
Engineer-in-Charge.
5.29 CLEAN-UP
a. Upon completion of the concrete work, all forms, equipment, construction tools,
protective coverings and any debris resulting from the work shall be removed from
the premises.
b. All debris i.e. empty containers, scrap wood, etc., shall be removed to dump daily,
or as directed by the Engineer-in-Charge.
c. The finished concrete surfaces shall be left in a clean condition satisfactory to the
Engineer-in-Charge.
5.30 RECORDS OF CONCRETING

An accurate and up to date record showing times, dates, weather and temperature
conditions when various positions of all the concrete structures forming the works were
concreted will be kept by the Contractor and shall be countersigned by the Engineer-inCharge. If the Contractor fails to sign the Engineer-in-Charges record, it shall
nevertheless be regarded as correct and binding on the Contractor.
The Contractor has to submit concrete pour card in duplicate duly to be signed to the
Engineer-in-Charge for each type of concreting work. Contractor shall keep copy of it,
after Engineer-in-Charge has checked and signed the pour card.
5.31 SUPPLY OF CEMENT

Contractor shall procure / purchase the cement and shall be sacked and well maintained
as specified in the earlier sections. Contractor shall procure cement in those quantities
required for maximum one month of concreting work and more than the prescribed time
limit is not allowed. For any damage to cement NMC will not be responsible and the
damaged cement will not be used in the work.
5.32 FOUNDATION BEDDING, BONDING AND JOINTING

In no case foundation shall rest on any loose strata or loose pockets etc. even though it
has reached level shown on design drawings and referred back to design engineer /
Engineer-in-Charge
a. All surfaces upon or against which concrete will be placed shall be suitably prepared
by thoroughly cleaning, washing and dewatering, as specified or as the Engineer-inCharge may direct, to meet the various situations encountered in the work.
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b. Soft or spongy areas shall be cleaned out and backfilled with lean concrete or clean
sand fill compacted.
c. Prior to construction of formwork for any item where soil will act as bottom form,
approval shall be obtained from the Engineer-in-Charge for the suitability of the soil.
5.33 PREPARATION OF ROCK STRATA OF FOUNDATIONS

a. To provide tight bond with rock foundations, the rock surface shall be prepared and
the following general requirements shall be observed.
b. Concrete shall not be deposited on large sloping rock surfaces. Where required by
the Engineer-in-Charge, the rock shall be cut to form rough steps or benches to
provide roughness or a more suitable bearing surface.
c. Rock foundation stratum shall be prepared by picking, barring, wedging and similar
methods which will leave the rock in an entirely sound and unshattered condition.
d. Shortly before concrete is placed, the rock surface shall be cleaned with high
pressure water and air jet even though it may have been previously cleaned in that
manner.
e. Prior to placing concrete, the rock surface shall be kept wet for a period of 2 to 4
hours unless otherwise directed by the Engineer-in-Charge.
f. Before placing concrete on rock surfaces all water shall be removed from
depressions to permit thorough inspection and proper bonding of the concrete to the
rock.
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6
6.1
FORMWORK
FORMWORK, FIXING AND GENERAL

a) All formwork shall be constructed of waterproof plywood or preferably sheet metal.
Plywood used for form work shall be conforming to BIS:4990 i.e. Specification for
plywood for concrete shuttering works. The materials for formwork shall got
approved by the Engineer-in-Charge before starting the work. Formwork shall be
firmly supported, adequately strutted, braced and tied to withstand the placing and
vibrating of concrete and the effects of weather. The tolerance on line and level shall
not exceed 3 mm and the soffits of beams other than pre-stressed beams shall in the
absence of any specified camber, be erected with an upward camber of 6 mm for
each 3 meters of span.
b) The Contractor shall be responsible for the calculations and designs for the
formwork, and if required, shall submit them to the Engineer-in-Charge for approval
before construction. On form work to external faces, which will be permanently,
exposed, all horizontal and vertical formwork joints shall be so arranged that joint
lines will form a uniform pattern on the face of the concrete. Where the Contractor
proposes to make up the form work for standard sized manufactured form work
panels, the size of such panels shall be approved by the Engineer-in-Charge before
they are used in the construction of the Works. The finished appearance of the entire
elevation of the structure and adjoining structures shall be considered when planning
the pattern of joint lines caused by form work and by construction joint to ensure
continuity of horizontal and vertical lines.
c) Faces of form work in contact with concrete shall be free from adhering foreign
matter, projecting nails and the like, splits or other defects, and all form work shall
be clean and free from standing water, dirt, shavings, chippings or other foreign
matter. Joints shall be sufficiently watertight to prevent the escape of mortar or the
formation of fins or other blemishes on the face of the concrete and no bleeding
should be allowed through the joints.
d) Form work shall be provided for the top surfaces of sloping work where the slope
exceeds fifteen degrees from the horizontal (except where such top surface is
specified as spaded finish) and shall be anchored to enable the concrete to be
properly compacted and to prevent flotation, care being taken to prevent air being
trapped.
e) Openings for inspection of the inside of the form work and for the removal of water
used for washing down shall be provided and so formed as to be easily closed before
placing concrete. Before placing concrete, all bolts, pipes or conduits or other
fixtures which are to be built in shall be fixed in their correct positions, and cores
and other devices for forming holes shall be held fast by fixing to the formwork or
otherwise. Holes shall not be cut in any concrete without approval of the Engineerin-Charge.
f) All exterior angles on the finished concrete of 90 degree or less shall be given 20
mm x 20 mm chamfers unless otherwise ordered by the Engineer-in-Charge.
g) No ties or bolts or other device shall be built into the concrete for the purpose of
supporting formwork without the prior approval of the Engineer-in-Charge. The
whole or part of any such supports shall be capable of removal so that no part
remaining embedded in the concrete shall be nearer than 50 mm from the surface in
the case of reinforced concrete and 150 mm in the case of un-reinforced concrete.
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Holes left after removal of such supports shall be neatly filled with well rammed drypack mortar.
h) Formwork in contact with the concrete shall be treated with suitable non-staining
mould oil to prevent adherence of the concrete except where the surface is
subsequently to be rendered. Care shall be taken to prevent the oil from coming in
contact with reinforcement or with concrete at construction joints. Surface retarding
agents shall be used only where ordered by the Engineer-in-Charge.
i) No formwork shall be started or placed unless the requirement work is fully
completed and checked by Engineer-in-Charge.
j) Necessary cover blocks shall be provided before starting connection.
6.2
REMOVAL OF FORMWORK
a) Formwork shall be so designed as to permit any removal without resorting to
hammering or levering against the surface of the concrete.
b) The periods of time elapsing between the placing of the concrete and the striking of
the loads likely to be imposed on the concrete and shall in any case be not less than
the periods shown in Table below. Where soffit formwork is constructed in a
manner during and after such removal of a sufficient number of adequate supporting
props in an undisturbed condition, the Contractor may, with the agreement of the
Engineer-in-Charge, remove the formwork at the earlier times listed below provided
that the props are left in position.
Table 12 : Period for Formwork
Position of formwork
Days for striking
Walls
Sides of beams and columns
Slabs (Drops left under)
Props to slabs (span not exceeding 4.5m)
Props to slabs (span exceeding 4.5 m)
Beams soffits (props left under)
Props to beams (span not exceeding 6 m)
Props to beams (span exceeding 6 m)
Circular structures, domes ,cantilever portions etc.
1
2
3
7
14
7
14
21
21
c) Notwithstanding the foregoing, the Contractor shall be held responsible for any
damage arising from removal of formwork before the structure is capable of carrying
its own weight and any incidental loading.
d) Striking shall be done slowly with utmost care to avoid damage to projections and
without shock or vibration, by gently easing the wedges. If after removing the
formwork it is found that timber has been embedded in the concrete. It shall be
removed and made good as specified earlier.
e) Reinforced temporary openings shall be provided, as directed by the Engineer-inCharge, to facilitate removal of formwork which otherwise may be inaccessible.
f) The rods, clamps, form bolts, etc. which must be entirely removed from walls or
similar structures shall be loosened not sooner than 24 hours not later than 40 hours
after the concrete has been deposited. Ties, except those required to hold forms in
place, may be removed at the same time. Ties, withdrawn from walls and grade
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beams shall be pulled toward the inside face. Cutting ties back from the faces of the
walls and grade beams will not be permitted.
g) For liquid retaining structures, no sleeves for through bolts shall be used nor shall
through bolts be removed as indicated above. The bolts, in this case, shall be cut at
25 mm depth or more from the surface and then the hole shall be made good by
cement sand mortar of the same proportions as the concrete just after striking the
form work.
6.3
FORMED SURFACES - CLASSES OF FINISH

a) Finishes to formed surfaces of concrete shall be classified as F1, F2, or F3, or such
other special finish as may be particularly specified. Where the class of finish is not
specified the concrete shall be finished to Class F1.
b) Form work for Class F3 finish shall be lined with as large panels as possible of nonstaining material with a smooth unblemished surface such as sanded plywood or hard
compressed fiber board, arranged in a uniform approved pattern and fixed to back
form work by oval nails. Unfaced wrought boarding or standard steel panels shall not
be permitted.
c) Form work for Class F2 finish shall be faced with wrought tongued and grooved
boards or plywood or metal panels arranged in a uniform approved pattern free from
defects likely to detract from the appearance of the surface.
d) Form work for Class F1 finish shall be constructed in sheet metal. Surfaces
subsequently to be rendered, plastered or tiled shall be adequately scrabbled or
hacked as soon as the form work is removed to reduce the irregularities to not more
than half the thickness of such rendering, plastering or bedding for tiles and to
provide a satisfactory key.
6.4
DEFECTS IN FORMED SURFACES

a. Workmanship in formwork and concreting shall be such that concrete shall normally
require no making good, surfaces being perfectly compacted and smooth.
b. If any blemishes are revealed after removal of formwork, the Engineer-in-Charges
decisions concerning remedial measures shall be obtained immediately. These
measures may include, but shall not be limited to the following:
Fins, pinhole bubbles, surface discolouration and minor defects may be rubbed down
with sacking immediately after the formwork is removed.
Abrupt and gradual irregularities may be rubbed down with carborundun and water
after the concrete has been fully cured. These and any other defects shall be
remedied by methods approved by the Engineer-in-Charge which may include using
a suitable epoxy resin or, where necessary, cutting out to a regular dovetails shape at
least 75 mm deep and refilling with concrete over steel mesh reinforcement sprung
into the dovetail.
c. The form work shall be checked by the Engineer-in-Charge before the form work
starts and form found defective shall be rejected and the same can be used after
rectifying the defects and with due approval of the Engineer-in-Charge
6.5
HOLES TO BE FILLED
1. Holes formed in concrete surfaces by form work supports or the like shall be filled
with dry-pack mortar made from one part by weight of ordinary Portland cement and
one part fine aggregate passing BIS sieve 1.18 mm. The mortar shall be mixed with
only sufficient water to make the materials stick together when being moulded in the
hands.
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2. The Contractor shall thoroughly clean any hole that is to be filled with dry-pack
mortar and where the surface has been damaged, the Contractor shall break out any
loose, broken or cracked concrete or aggregate. The concrete surrounding the hole
shall then be thoroughly soaked after which the surface shall be dried so as to leave a
small amount of free water on the surface. The surface shall then be dusted lightly
with ordinary Portland cement by means of a small dry brush until the whole surface
that will come into contact with the dry-pack mortar has been covered and darkened
by absorption of the free water on the surface. The surface shall then be dusted
lightly with ordinary Portland cement by means of a small dry brush until the whole
surface that will come into contact with the dry-pack mortar has been covered and
darkened by absorption of the free water by the cement. Any dry cement in the hole
shall be removed.
3. The dry-pack material shall then be placed and packed in layers having a compacted
thickness not greater then 15 mm. The compaction shall be carried out by use of a
hardwood stick and a hammer and shall extend over the full area of the layer,
particular care being taken to compact the dry-pack against the sides of the hole.
After compaction, the surface of each layer shall be scratched the dry-pack fill and
striking the block several times. Steel finishing tools shall not be used and water
shall not be added to facilitate finishing.
6.6
TOLERANCES
Tolerance is a specified permissible variation from lines, grade or dimensions given in
approved drawings. No tolerance specified for horizontal or vertical building lines or
footings shall be construed to permit encroachment beyond the legal boundaries. Unless
otherwise specified, the following tolerances will be permitted:
Tolerances for RCC Structures
i. Variation from the plumb
In the lines and surfaces of columns, piers, walls 5 mm per 2.5 m or 25 mm, whichever is
less.
For exposed corner columns and other conspicuous lines
In any bay or 5 m maximum
5 mm
In 10 m or more
10 mm
ii. Variation from the level or from the grades indicated on the approved drawings
In slab soffits, ceilings, beam soffit, and in arises
In 2.5 m
5 mm
10 mm
In 10 m or more
15 mm
For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines
5 mm
In 10 m or more
10 mm
iii. Variation of the linear building lines from established position in plan and related
position of columns, wall and partitions
10 mm
In 10 m or more
20 mm
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iv. Variation in the sizes and locations of sleeves, openings in walls and floors Except in
the case of and for
5mm anchor bolts
v. Variation in cross sectional dimensions of columns and beams and in the thickness
of slabs and walls
Minus
5 mm
Plus
10 mm
vi. Footings
Variation in dimension in plan
Minus
Plus
5 mm
10 mm
vii. Misplacement or eccentricity 2% of footing width in the direction of misplacement

but not more than 50 mm Reduction in thickness: Minus 5% of specified thickness
subject to a maximum of 50 mm
viii. Variation in steps
In a flight of stairs
Rise
Tread
In consecutive steps
Rise
Tread
3 mm
5 mm
1.5 mm
3 mm
Tolerances in other Concrete Structures

ix. All structures
Variation of the constructed linear outlines from established position in plan
In 5 m
10 mm
In 10 m or more
15 mm
Variations of dimensions to individual structural features from established positions
In 20 m or more
25 mm
In buried construction
50 mm
Variation from plumb, from specified batter or from curved surfaces of all structures
In 2.5 m
10 mm
In 5 m
15 mm
In 10 m or more
25 mm
twice the above amounts
Variation from level or grade indicated on approved drawings in slab, beams, soffits,
horizontal grooves and visible arises
In 2.5 m
5 mm
In 7.5 m or more
10 mm
Twice the above amounts
Variation in cross-sectional dimensions of columns, beams, buttresses, piers and similar
members
Minus
5 mm
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Plus
10 mm
x. Footings for columns, piers, walls, buttresses and similar members

Variation of dimensions in plan
Minus
10 mm
Plus
50 mm
Misplacement or eccentricity
2% of footing width in the direction of misplacement but not more than 50 mm.
Reduction in thickness
5% of specified thickness subject to a maximum of 50 mm
xi. Tolerance in other types of structures shall generally conform to those given in
Clause 2.4 of Recommended Practice for Concrete Formwork (American Concrete
Institute Act 347).
xii. Tolerance in fixing anchor bolts shall be as follows:
Anchor bolts without sleeves
+ 5 mm
Anchor bolts with sleeves
+ 5 mm for bolts up to 20 mm dia
3 mm for bolts
above 32 mm dia
Embedded parts
+ 5 mm in all directions
6.7
BRACING, STRUTS AND PROPS

a. Form work shall be braced, strutted, propped and so supported that it shall not
deform under weight and pressure of the concrete and also due to the movement of
men and other materials. Bamboo shall not be used as props or cross bearers.
b. The formwork for beams and slabs shall be so erected that the formwork on the sides
of the beams and under the soffit of slabs can be removed without disturbing the
beam bottoms. Repropping of beams shall not be done except when props have to be
reinstated to take care of construction loads anticipated to be in excess of the design
load. Vertical props shall be supported on wedges or other measures shall be taken
whereby the props can be gently lowered vertically while striking the formwork.
c. If the formwork for a column is erected for the full height of the column, one side
shall be left open and built up in sections as placing of the concrete proceeds, or
windows may be left for pouring concrete from the sides to limit the drop of concrete
to 1.0 m as directed by the Engineer-in-Charge.
Contractor shall submit the detailed design and methodology with applicable drawings if
any of Formwork system for different members for approval of Engineer-in-Charge.
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7
7.1
REINFORCEMENT
RELEVANT IS CODES
IS:432
: Mild steel and medium tensile steel bars & hard drawn steel wire for
concrete reinforcement
IS:1786
: Cold twisted steel bars for concrete reinforcement (CTD).
IS:2502 (1963) : Code of practice for bending and fixing of bars for concrete
reinforcement
IS:55225(1969) : Recommendations for detailing of reinforcement in RCC works
IS:2751
: C.P. for welding of MS bars used for RCC
IS:9417
: Recommendations for welding cold worked steel bars for RCC
IS:10790
: Methods of sampling of reinforced steel
7.2
GENERAL
Reinforcement shall be CTD and high strength deformed corrosion resistant (CRS) bars
as per IS:1786 Fe415. Wire mesh or fabric shall be in accordance with IS:456.
Substitution of reinforcement will not be permitted except upon written approval from
the Engineer-in-Charge.
7.3
STORAGE
a. The reinforcement shall not be kept in direct contact with the ground but stacked on
top of an arrangement of timber sleepers or the like.
b. If the reinforcing rods have to be stored for a long duration, they shall be coated with
cement wash before stacking and/or be kept under cover or stored as directed by the
Engineer-in-Charge.
c. Fabricated reinforcement shall be carefully stored to prevent damage, distortion,
corrosion and deterioration.
d. It should be seen that the reinforcement will not be exposed to direct sunlight and
preventive measures should be taken for the same.
7.4
QUALITY
All reinforcements shall be clean, free from grease, oil paint, dirt, loose mill scale, loose
rust, dust bituminous material or any other substances that will destroy or reduce the
bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective
rods shall not be used. No welding of rods to obtain continuity shall be allowed unless
approved by the Engineer-in-Charge. If welding is approved, the work shall be carried
out as per IS:1786 - Fe415 according to the best modern practices and as directed by the
Engineer-in-Charge. In all cases of important connections, tests shall be made to prove
that the joints are of full strength of bars welded. Special precautions, as specified by the
Engineer-in-Charge, shall be taken in the welding of cold worked reinforcing bars and
bars other than mild steel.
7.5
LAPS
Laps and splices for reinforcement shall be as per IS:456-2000. Splices in adjacent bars
shall be staggered as mentioned in structural drawings and locations of all splices shall
be approved by the Engineer-in-Charge.
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Also Contractor shall submit the Bar bending schedule for approval of Engineer-inCharge and shall follow same unless and until changed by any design changes.
7.6
BENDING
a. Reinforcement bars supplied bent or in coils, shall be straightened before they are cut
to size. Straightening of bars shall be done cold and without damaging the bars.
b. All bars shall be accurately bent according to the sizes and shapes shown on the
approved detailed working drawings/bar bending schedules. They shall be bent
gradually by machine or other approved means. Reinforcing bars shall not be
straightened and re-bent in a manner that will injure the material; bars containing
cracks/splits shall be rejected. They shall be bent cold, except bars of over 25 mm in
diameter, which may be bent hot if specifically, approved by the Engineer-inCharge. Bars, which depend for their strength of cold working, shall not be bent hot.
Bars bent hot shall not be treated beyond cherry red colour (nor exceeding 845C)
and after bending shall be allowed to cool slowly without quenching. Bars
incorrectly bent shall be used only if the means used for straightening and re-bending
be such as shall not, in the opinion of the Engineer-in-Charge, injure the material.
No reinforcement shall be bent when in position in the work without approval,
whether or not it is partially embedded in hardened concrete. Bars having kinks or
bends other than those required by design shall not be used.
7.7
FIXING
Reinforcement shall be accurately fixed by any approved means and maintained in the
correct position shown in the approved Drawings by the use of blocks, spacers and
chairs, as per IS:2502 to prevent displacement during placing and compaction of
concrete. Bars intended to be in contact at crossing points shall be securely bound
together at all such points with number 16 gauge GI wire. The vertical distances
required between successive layers of bars in beams or similar members shall be
maintained by the provision of mild steel spacer bars at such intervals that the main bars
do not perceptibly sag between adjacent spacer bars. No binding wire shall protrude in
cover area and shall bent inside.
7.8
COVER
Unless indicated otherwise, clear concrete cover for reinforcement (exclusive of plaster
or other decorative finish) shall be as follows:
a. At each end of a reinforcement bar, not less than 25 mm nor less than twice the
diameter of the bar whichever is greater
b. For a longitudinal reinforcing bar in a column, not less than 40 mm, nor less than the
diameter of the bar. In case of columns of minimum dimension of 20 cm or under
with reinforcing bars of 12 mm and less in diameter, a cover of 25 mm may be used.
c. For longitudinal reinforcing bars in a beam, not less than 40 mm nor less than the
diameter of the bar, whichever is greater
d. For tensile, compressive, shear or other reinforcement in a slab, or wall, not less
than, 20 mm, nor less than the diameter of such reinforcement.
e. For any other reinforcement, not less than 20 mm, nor less than the diameter of such
reinforcement.
f. For footing and other principal structural members in which the concrete is poured
on a layer of lean concrete, the bottom cover shall be reduced to 60 mm.
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g. For concrete surfaces exposed to the weather or the ground after removal of forms,
such as retaining walls, grade beams, footing sides and tops, etc. not less than 40 mm
for bars larger than 16 mm diameter and not less than 30 mm for bars 16 mm
diameter or smaller.
h. For liquid retaining structures, the minimum cover to all steel shall be 40 mm or the
diameter of the main bar, whichever is greater.
i. The correct cover shall be maintained by cement mortar cubes or other approved
means. Reinforcement for footings, grade beams and slabs on subgrade shall be
supported on precast concrete blocks as approved by the Engineer-in-Charge. The
use of pebbles or stones shall not be permitted.
j. The 28 day crushing strength of cement mortar cubes/precast concrete cover blocks
shall be at least equal to the specified strength of concrete in which these
cubes/blocks are embedded.
k. The minimum clear distance between reinforcing bars shall be in accordance with
IS:456
7.9
INSPECTION
After final erection of reinforcement, it shall be intimated to Engineer-in-Charge in
writing or through pour cards. Erected and secured reinforcement shall be inspected and
approved by the Engineer-in-Charge prior to placement of concrete.
7.10 WELDING OF REINFORCEMENT

a. Reinforcement which is specified to be welded shall be welded by any process which
conforms with the requirements of IS:2751 and which the Contractor can
demonstrate by bend and tensile tests will ensure that the strength of the parent metal
is not reduced and that the weld possesses a strength not less than that of the parent
metal. The welding procedure established by successful test welds shall be
maintained and no deviation from this procedure shall be permitted.
b. Welds in positions other than those shown on the approved Drawings shall not be
permitted. Tack welding to lightly secure reinforcement in place will be permitted
subject to approval of the Engineer-in-Charge.
7.11 SUPPLY OF REINFORCING BARS

Steel reinforcement, such as MS bars HYSD bars etc. required for the works shall be
procured by Contractor. The Contractor shall arrange for transport, loading, unloading
and storage at the work sites. The Contractor should plan the procurement of steel in
such a way that at least required quantity of steel of specified sizes is available at site for
3 months period.
Steel brought on site shall be stored in proper manner as approved by Engineer In Charge
so as to avoid distortion, deterioration and corrosion. The Contractor shall maintain
proper register for the steel account, showing the steel received at site, steel used, and the
balance stock on site, to the entire satisfaction of the Engineer-in-Charge
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8
8.1
8.2
STRUCTURAL STEEL WORK
RELEVANT IS CODES
IS:2062
IS:800
IS:808
IS:814
IS:1148
IS:1363
:
:
:
:
:
:
IS:2062
IS:3954
SP-6 (I VII)
SP-40
:
:
:
:
Specification for Structural Steel (Fusion Welding Quality)
C.P. for general construction in steel

R.S. beam, channel and angel sections
Covered electrodes for metal arc welding of structural steel
Hot rolled steel rivet bars for structural purpose
Black hexagon bolts, nuts, and lock nuts (dia 6 to 39mm) & black
hexagon screws (dia 6 to 24mm)
Structural steel (fusion welding quality)
Hot rolled steel channel sections for general engineering purposes
ISI Handbook for Structural Engineers
Handbook on structures with steel portal frames (without cranes)
GENERAL
Structural steel fabrication work shall include all types of steel structural work required
for installation of platform for operation and installation of equipment where rolled steel
sections are joined together either by bolting or riveting or welding as specified in the
drawings/bill of quantities/directed by the Engineer. It shall also include fabrication and
installation of air vessels/pressure vessels etc. Covers for ducts for electrical panels along
with their seating arrangements are also classified under this heading unless they are
provided separately under a different heading. Reaction tanks or storage vessels are also
classified under this heading.
8.3
MATERIALS
The MS structural members such as MS angles, channels, flats, I sections etc. shall
conform IS 2062. Structural steel that is used for fabrication shall be conforming to any
of the following grades of steel as specified to each of the works:
IS:2062
: Specification for Structural Steel (Fusion Welding
Quality)
IS:1977-1975
: Structural steel (ordinary quality)
IS:2062-1980
: Weldable Structural steel (fusion quality)
Whenever the Contractor supplies steel, he shall on demand the test certificates from the
manufacturer.
The welding rods used for fabrication shall conform to IS:814-1974 (parts I and II). The
fasteners like bolts, nuts etc., shall conform to IS:1367. Rivets shall conform to IS:11841982. Plain washers shall conform to IS:2016-1967. Spring washers shall conform to
IS:3063-1972.
MS rivets shall conform to IS:1148 and IS:1929-1967 bolts and nuts shall conform to
IS:1363 - 1967.
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If metal arc welding is to be done as per design or as ordered by the Engineer-in-Charge

the electrodes used for strength welds shall conform to IS: 814 and shall be of such shape
and size approved by the Engineer-in-Charge and shall be prevented from oxidation and
shall be kept in clean condition.
Paints used shall be of approved manufacture and shade and shall conform to the ISI
standards.
8.4
FABRICATION AND ERECTION

All the shop drawings shall be prepared by the Contractor and submitted in advance of
atleast 15 days to the Engineer for his approval. The drawings shall be submitted in
triplicate. The fabrication work shall not be taken in hand until the shop drawings are
approved by the Engineer. Approval of the shop drawings however shall not relieve the
Contractor of his responsibility of correct conformation to the designs and fabrications of
the structure to meet the requirements of the contract. One copy of the approval
drawings shall be given to the Contractor for going ahead with the fabrication work.
In the shop drawings to be submitted by the Contractor, standard symbols as described in
the IS:813-1961 shall be followed.
Fabrication work shall be carried out as laid down in IS:800-1984 Code of practice for
general construction in steel.
Welding shall be carried out in accordance with the following specifications as
applicable:
IS:803 - 1976
: Code of practice for design fabrication and erection of vertical
mild steel cylindrical welded oil storage tanks.
IS: 816 - 1969
: Code of practice for use of metal and welding for general
construction in mild steel
IS:822 - 1970
: Code of practice for manual and welding of mild steel
IS:9595 - 1980
: Recommendations for metal are welding of carbon Radiographic
tests are required to be carried out as directed by the Engineer in
case of pressure vessels.
IS:818 - 1968
: Code of practice for safety and health requirements in electric
and gas welding and cutting operations
IS:3016-1982
: Code of practice for fire precautions in welding and cutting
operations
IS:7205 1973
: Safety code for erection of structural steel work
The sections shall be fixed absolutely vertical or to the specified angle as shown in the
drawings/as desired/directed by the Engineer.
All connections like angle brackets, cleats, gusset plates, anchor bolts, bearing plates
shall all be fixed as shown in the drawings or as directed by the Engineer.
The items of work shall include supply of materials, fabrication and erection in position
on site as shown in the drawings. This shall also include all labour consist, materials and
equipment required for all fabrication, hoisting, erection, and satisfactory completion of
the item of work.
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The supply of materials includes all structural members like rolled sections, plates,
brackets, rivets, bolts and nuts and welds.
The steelwork shall be painted as specified in the drawings, described in the bill of
quantities or as directed by the Engineer. Unless otherwise provided for in the bill of
quantities separately, the rate quoted for the item is inclusive of all costs for painting like
cost of paint, cost of labour, scaffolding etc. Welding work shall be done generally using
electric arcs welding. Where public electricity is not available, generators shall be
arranged by the Contractor shall be arranged by the Contractor himself.
Gas welding shall not be allowed to be resorted to for welding. Under special
circumstances if in the opinion of the Engineer it cannot be avoided, gas welding can be
done with the prior permission of the Engineer. However gas welding shall not be used
where structural strength is the criteria for consideration.
All arrangements shall be made by the Contractors for access for inspection by the
Engineer or his representative to the workshop where the welding work is being carried
out and necessary equipment like gauges, measuring instruments etc., shall be made
available to the inspecting personnel.
Painting work shall not be started without the express approval of the Engineer and the
painting shall be started only after his inspection and approval of the works after carrying
out surface preparations.
All holes shall be carefully marked. Holes shall have their axis perpendicular to the
surfaces bored through. Holes being made through two or more members shall be truly
concentric. Holes shall not be formed cutting process.
All the temporary connections of parts during assembly shall be done in the following
ways. For welded structures. Tack welding fixtures.
After welding is over, the surface on the joint should be ground and made smooth and
even. The welding should be so perfect so as to give required strength as taken for
designed purpose at joints in particular. The Contractor will make necessary
arrangements for testing of joints as required by Engineer in Charge.
Welded joints shall be free from defects that would impair the service performance of the
construction. All the welds shall be free from incomplete penetration, incomplete fusion,
slag inclusion, burns, un-welded creators undercuts and cracks in the welded metal,
porosity etc. All the defects shall be rectified as directed by the Engineer. Defective
portions shall be removed to the sound metal and re-welded. Rectification of the welds
by caulking shall not be permitted.
All welds shall be cleaned of stag and other deposits after completion.
8.5
PAINTING
Painting shall generally comply with IS subject to addition and alterations as may be
prescribed in the special provisions for any particular item. It shall also comply with the
requirements of the manufactures specifications. One priming coat of red lead shall be
applied immediately after fabrication. Two coats of oil paint of approved shade shall be
applied after complete erection. The structural steel to be embedded in concrete shall not
be painted.
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Inspection and testing shall be carried out in conformity with IS:800.

Riveting, welding and bolting shall not be started until such time as the Engineer has
personally satisfied himself that the alignment is correct, in the vertical plumb, the
camber correct with camber packs, screwed tight, all joints and cover plates fixed
tightened with service bolts and field rivet holes coinciding. While assembling holes in
different components shall be made concentric with the use of drills before service bolts
are fixed.
Welding if required shall be done as per standard practice and as approved by the
Engineer-in-Charge.
All permanent machine fitted nuts and bolts must be perfectly tight and shall be burred or
otherwise checked to prevent nuts from becoming loose. No unfitted rivet or bolt holes
are to be left in any of the structure.
Structural Steel
All structural steel shall conform to IS:2062-1984. The steel shall be free the defects
mentioned in IS given above and shall have a smooth finish. The material shall be free
from loose mild scale, rust pits or other defects affecting the strength and directly.
8.5.1 General
Engineers approval shall be obtained before commencing the painting work. All paints
and preserves shall be of approved make and colour and their application shall conform
to the manufactures instructions. Where more than one undercoat is specified it shall be
applied in coats of distinctive tints. Workmanship shall conform to the requirement of
IS:2395
Unless the manufacturers instructions state otherwise48 hours drying time shall elapse
between successive applications of any primer and 24 hours between applications of all
subsequent coats. The surface of bituminous paints shall be left at least 3 days before
further handling.
No paints in any coats shall be applied until the engineer is satisfied that the surface is
clean and dry. And that any previous coat is satisfactory and has hardened adequately.
When a surface has been approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper between coats. No paint shall be
applied to a surface, which is damp, dirty or otherwise inadequately prepared.
8.5.2 Ironwork and Ungalvanised Steelwork
Structural steelwork shall be shot blasted to a "white metal" finish, and grease and oil
removed prior to painting. Priming shall immediately follow blast cleaning and no
cleaned surface shall be left unprimed for more than four hours. Only primers that
chemically inhibit corrosion shall be used. Where the iron or steelwork is not in contact
with raw or treated water, the primer shall be red lead complying with IS: 57. Where
there is a possibility that the steel or ironwork may come in contact with water, the
priming treatment shall be non toxic, zinc chromate or equivalent. Where it is anticipated
that further welding will be required. an approved welding primer shall be applied to the
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areas to be welded and re primed with the main primer when welding has been
completed. Primer coats shall not be less than 0.05 mm each.
After erection, all damaged areas shall be made good, and re primed where the original
coat has spread under the primer, the affected surface shall be cleaned down to bare
metal to the satisfaction of the Engineer and then re primed.
Repainting shall be carried out as soon as possible after erection. If` it is to he exposed to
weather or condensation, it shall receive one further coal of primer.
Metalwork in intermittent or permanent contact with raw or treated water shall have two
finishing coats of an approved coal tar pitch epoxy paint such as "Epilux 5" by Berger
Paints, or equivalent. The total coating shall be minimum of 0.125 mm thick.
After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting
down to a smooth uniform surface. When the surface becomes dry, be undercoat of
synthetic enamel paint conforming-to IS:2932 of optimum thickness shall be applied by
brushing with minimum of brush marks. The coat shall be allowed to hard dry. The
under coat shall then be wet rubbed cutting down to a smooth finish, taking adequate
care to ensure that at no place the undercoat is completely removed. The surface shall
then be allowed to dry.
The first finishing coat of paint shall be applied by brushing and allowed to hard dry.
The gloss from the entire surface shall then be gently removed and the surface dusted
off. The second finishing coat shall then be applied by brushing.
At least 24 hours shall elapse between the application of successive coats. Each coat
shall very slightly in shade and this shall be got approved by the Engineer.
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BRICK WORK AND STONE

MASONRY
These specifications deal with all types of brickwork required for buildings, manholes,
drains, retaining walls or any construction made out of bricks.
9.1
RELEVANT IS CODES
IS:1077
:
IS:2180
:
IS:2212
:
IS:3495 (I IV) :
IS:5454
:
9.2
Common burnt clay building bricks

Heavy duty burnt clay-building bricks
C.P. for brickwork
Method of test for clay building bricks
Method of sampling of clay building bricks
MATERIALS
9.2.1 Bricks
Bricks used for the construction of brick masonry shall be sound, hard, rectangular in
shape and size and well burnt of uniform deep red, cherry or copper colour and shall
conform to IS:1077-1986.
The bricks shall be brought from approved brick kilns. The bricks shall be free from
cracks, chippings flaws, stones or lumps of any kind. The bricks shall not show any
signs of efflorescence and shall be homogeneous in texture.
They should emit a clear metallic sound on being struck and shall have a minimum
compressive strength of 50 kg/sq.cm. They shall not absorb water more than specified in
the Indian Standard Specifications, of its dry weight when soaked in cold water for 24
hours.
9.2.2 Mortar
The proportion of the cement mortar used for the masonry work shall be as specified on
the various drawings for different places/types of construction, bills of quantities,
specifications for each part of the work.
Mortar should be prepared by volume using boxes of appropriate sizes on clean platform
or this sheet to avoid mixing of foreign material and maintain consistency of mortar.
Sharp coarse sand is mixed with the required quantity of cement for the preparation of
the mortar. Mortar shall be prepared in accordance with IS:2250-1981. The sand used
for the masonry mortar shall meet the requirements as specified in IS:2116-1980. Sand
for masonry mortars. Sand and cement of required proportions are mixed in small
quantities in a dry state first and then water is added to make the mortar of required the
consistency suitable for the type of work it is required as directed by the Engineer-inCharge. No left over mortar shall be used and therefore only that much quantity of
mortar that can be consumed within 30 minutes shall be mixed in batches.
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9.3
CONSTRUCTION
The brick masonry shall be constructed as per the Indian Standard Code of Practice for
Brick Work - IS:2212-1962. The thickness of the joints shall not be thicker than those
specified in of the above Code of Practice.
The bricks shall be thoroughly soaked in water before using them on the work for at least
six hours and all the air bubbles shall come out during soaking process. The soaked
bricks shall be stacked on wooden planks/platforms so as to avoid sticking of the earth
and other materials on to the surfaces of bricks. Bricks required for construction in mud
mortar or lime mortar shall not be soaked. Brickwork shall be laid in English Bond
unless otherwise specified. Half bricks shall not be used except when need to complete
the bond. Each course shall be perfectly straight and horizontal. The masonry shall be
true to plumb in case of vertical walls and in case of battered construction the batter or
slope shall be truly maintained. The level of the courses completed shall be checked at
every metre interval or less as required.
The bricks shall be laid frogs upwards. While laying the bricks they shall be thoroughly
bedded and flushed in mortar and well trapped into position with wooden mallets and
superfluous mortar shall be removed.
No part of the structure shall be raised more than one meter above than the rest of the
work. In case it is unavoidable the brickwork shall be raked back at an angle of not more
than 45 degrees so as to maintain a uniform and effectual bond, but raking shall not start
within 60 cms from a corner.
In cases of construction of buttresses, counterforts, returns they are built course by
course carefully bound into the main walls. At all junctions of walls the bricks at
alternate courses, shall be carried into each of the respective walls so as to thoroughly
unite both the walls together. The brickwork shall not be raised more than 14 courses
per day.
All the beds and joints shall be normal to the pressures applied upon them i.e. horizontal
in vertical walls, radial in arches and at right angles to the face in battered retaining
walls.
Vertical joints in alternate courses shall come directly one over the other and shall be
truly vertical. Care shall be taken to ensure that all the joints are fully filled up with
mortar, well flushed up where no pointing is proposed, neatly struck as the work
proceeds. The joints in faces, which are plastered or painted, shall be squarely raked out
to a depth not less than 12 mm while the mortar is still green. The raked joints shall be
well brushed to remove the loose particles and the surfaces shall be cleaned with a wire
brush so as to remove any splashes of mortar sticking to the surfaces during the
construction.
All iron fixtures, pipes, bolts, conduits, sleeves, holdfasts etc., which are required to built
into the walls shall be embedded in cement mortar or cement concrete as shown in the
drawings/indicated in the specifications directed during the execution by the Engineerin-Charge as the work proceeds and no holes be left for fixing them at a later date unless
authorised by the Engineer-in-Charge.
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9.4
CURING
Fresh work shall be protected from rain by covering the work suitably. Masonry work as
it progresses shall be thoroughly kept wet by watering on all the faces for atleast 7
(Seven) days after completion of the parts of the work. Proper watering cans, flexible
pipes, nozzles shall be used for the purpose. The top of the masonry work shall be kept
flooded at the close of the days work by constructing fillets of mortar 40 mm high all
around the edges of the top course. In case of fat lime mortar curing shall start two days
after construction of masonry and shall continue for seven days. No additional payment
is admissible for curing and the rates quoted are deemed to be inclusive of the cost of
curing.
9.5
SCAFFOLDING
Double scaffolding sufficiently strong so as to withstand all loads that are likely to come
upon it and having two sets of vertical supports shall be provided. Where two sets of
vertical supports are not possible the inner end of the horizontal supporting pole shall
rest in a hole provided in a header course only. Only one header for each pole shall be
left cut. Such holes, however shall not be permitted in pillars under one meter in width
or immediately near the skewbacks of arches. Such holes shall be filled up immediately
after removal of the scaffoldings. Safety Code for Scaffolds and Ladders, IS:3696-1987
(Parts I and II) shall be followed. The cost of scaffolding is deemed to be included in the
rates quoted for brick masonry and no separate costs are payable.
9.6
STONE MASONRY FOR RETAINING WALLS

Stone masonry in general is to be used for retaining walls as per engineer in-charges
instructions and as per drawings, which will be supplied during course of construction to
suit site conditions.
Following Indian Standards shall be applicable:
IS:11221974
IS:1200
IS:1597
IS:1805
IS:4101
IS:1121
9.7
Methods of determination of specific gravity and porosity of natural

building stones
Method of measurement of stone masonry.
Code of practice of construction of rubble stone masonry.
Glossary of terms relating to stone quarrying and dressing
Stone facing
Determination of strength, properties of natural building stones
UNCOURSED STONE MASONRY

Uncoursed stone masonry shall be built in layers not exceeding 450 mm in height. No
stone shall be less in breadth than 14 times its height and less in length than twice its
height. Every stone whether large or small, shall be laid in its natural bed and set flush in
mortar, and the small stones used for wedging or filling being carefully selected to fit the
interstices between the large stones. Care shall be taken to see that no dry work or hollow
space is left in the masonry. The stones shall be so arranged as to break joints at least
every 80 mm and long vertical joints of joints shall be avoided. The joints at the face
shall be finished off neatly, being struck and smoothed with a trowel while the mortar is
fresh. The upper surface of the work shall be brought to a uniform level at the height of
each course. The faces of masonry walls shall be kept in perfect plumb and where batter
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has to be given it shall, be uniform. The stones at all comers and junctions of walls shall
be of large sizes and hammer dressed to the correct angle.
Each stone shall be thoroughly wetted before being used in the work. The masonry shall
be kept thoroughly wet during the progress of the work, (care being taken to water it
even on Sundays and Holidays, special labour being employed if so required for this
purpose) until it becomes hard. As far as practicable, the whole of the masonry shall be
raised in one uniform level and no part of the masonry shall he allowed to rise more than
1 metre above the rest to avoid unequal settlement. If raising one part of wall before the
other becomes unavoidable the end of the raised portion shall be racked back in steps to
prevent cracks developing at the junction of the old and new work. Care shall be taken to
see that the sides of the wall are not built separately from the hearting, the faces and
internal filling being done simultaneously .The stones shall overlap and cross each other
as much as possible. No course shall be laid unless the previous course is perfectly set.
Al least one header or through stone per square metre of` wall face shall be built into the
work. The headers or through stones shall be at least 0.05 m in area al face and shall
have at least 0.025 m area at the back face. Where the thickness of the wall is more than
600 mm a series of through stones shall be laid through the work so as to form a tie from
front to back, breaking joints or overlapping each other for at least 150 mm. No stone
whose length is less than 600 mm shall be used in such work as a header.
All the through stones shall be marked inside and outside and the marks shall be retained
until ordered by the Engineer to be removed. Sufficient number of headers shall be
collected on site before commencing any masonry work. Where adequate sized through
stones are not available in required quantities, the use of pre-cast plain concrete headers
in M-20 mix may be permitted at the discretion of the Engineer. No extra payment will
be made for the provision of substitute headers in concrete
Quoins shall be 150 mm high and formed of header stones at least 300 mm long. They
shall he laid lengthwise alternately along each face and square on their beds, which shall
be dressed to a depth of at least 80 mm.
Weep holes 80 mm wide and 150 mm in height shall be provided in retaining walls at the
rate of one per square metre as specified or directed. They shall he pointed with 1:2
cement sand mortar after raking the joints to a minimum depth of 25 mm.
Completed masonry shall be kept wet for a minimum period of 14 days. In wet weather
newly laid masonry shall be protected from the effects of heavy rainfall by tarpaulins or
other approved material.
9.7.1 Pointing of Uncoursed Masonry
Joints in exposed masonry faces shall be formed while the mortar is still green and shall
be finished as flush joints, weathered joints, round-recessed joints or square-recessed
joints as directed by he Engineer. Masonry which is to be rendered or plastered shall
have the joints raked out to a depth of 15 mm to form a key.
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9.8
STONE PITCHING
Stone pitching: to slopes shall be carried out where specified or as directed by the
Engineer. Stone for pitching shall be obtained from an approved source and shall be
hard, sound, durable, clean and generally as specified. The minimum dimension of any
stone shall be, at least equal to the specified thickness of the pitching.
After excavation and trimming, slopes to be pitched shall be spread with a 75mm thick
layer of crusher run rock or graded coarse aggregate ranging from 75mm particle size to
fines. The slope shall then be hand packed with hard broken rock to a total thickness of
150 mm, each stone being individually placed and rammed home, with smaller stones
edged into the cracks. 50mm dia weep-holes shall be provided where specified at
intervals not exceeding two meter's in both directions. Joints in stone pitching shall be
flushed up with sand/cement mortar on completion.
9.9
RUBBLE PACKING
Rubble used for packing under floors, foundations, etc. shall be hard and durable rock,
free from veins, flaws and other defects. The quality and size of the rubble shall be
subject to the approval of the Engineer.
Rubble shall be hand packed as directed by the Engineer. They shall be laid closely in
position on the sub-grade. All interstices between the stones shall be wedged in with
smaller stones of suitable size well driven to ensure tight packing and complete filling of
interstices. Such filling shall be carried out simultaneously with the placing in position
of rubble stones and shall not lag behind.
Small interstices shall be filled with hard clean sand and well watered and rammed.
9.10 CONCRETE BLOCK MASONRY

9.10.1
Materials
Masonry units of hollow and solid concrete blocks shall conform to the requirements of
IS : 2185 (Part I).
Masonry units of hollow and solid light-weight concrete blocks shall conform to the
requirements of
IS:2185(Part 3).
Masonry units of autoclaved cellular concrete blocks shall conform to the requirements
of IS:2l85(Part 3).
The height of the concrete masonry units shall not exceed either its length or six times its
width.
The nominal dimensions of concrete block shall be as under.
Length 400, 500 or 600 mm
Height 100 or 200 mm
Width 100 to 300 mm in 50 mm increments
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Half blocks shall be in lengths of 200, 250 or 300mm to correspond to the full-length
blocks. Actual dimensions shall be 10mm short of the nominal dimensions.
The maximum variation in the length of the units shall not be more than 5 mm and
maximum variation In height or width of the units shall not be more than 3mm.
Concrete blocks shall be either hollow blocks with open or closed cavities or solid
blocks.
Concrete blocks shall be sound, free of cracks, chipping or other defects, which impair
the strength or performance of the construction. Surface texture shall as specified. The
faces of the units shall be flat and rectangular, opposite faces shall be parallel and all
arises shall be square. The bedding surfaces shall be at right angles to the faces of the
block.
The concrete mix for the hollow and solid concrete blocks/light weight concrete blocks
shall not be richer than one part of cement to six parts of combined aggregates by
volume.
Concrete blocks shall be of approved manufacture, which satisfy the limitations in the
values of water absorption, drying shrinkage and moisture movement, as specified for
the type of block as per relevant IS code. Contractor shall furnish the test certificates and
also supply the samples for the approval of Engineer In Charge.
9.10.2
Workmanship
The type of the concrete block, thickness and grade based on the compressive strength
for use in load bearing and/or non-load bearing walls shall be as specified. The minimum
nominal thickness of nonload bearing internal walls shall be 100mm. The minimum
nominal thickness of external panel walls in framed construction shall be 200 mm.
The workmanship shall generally conform to the requirements of IS:2572 for concrete
block masonry, IS:6042 for light weight concrete block masonry and 15:6041 for
autoclaved cellular concrete block masonry works.
From considerations of durability, generally concrete block masonry shall be used in
superstructure works above the damp-proof course level.
Concrete blocks shall be embedded with a mortar, which is relatively weaker than the
mix of the blocks in order to avoid the formation of cracks. Cement mortar of proportion
1:6 shall be used for the works.
The thickness of both horizontal and vertical joints shall be 10mm. The first course shall
be laid with greater care, ensuring that it is properly aligned, leveled and plumb since this
will facilitate in laying succeeding courses to obtain a straight and truly vertical wall. For
the horizontal (bedding) joint, mortar shall be spread over the entire top surface of the
block including front and rear shells as well as the webs to a uniform layer of 10mm. For
vertical joints, the mortar shall be applied on the vertical edges of the front and rear
shells of the blocks. The mortar may be applied either to the unit already placed on the
wall or on the edges of the succeeding unit when it is standing vertically and then placing
it horizontally, well pressed against the previously laid unit to produce a compacted
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vertical joint. In case of two cellblocks with slight depression on the vertical sides these
shall also be filled up with mortar to secure greater lateral rigidity. To assure satisfactory
bond, mortar shall not be spread too far ahead of actual laying of the block as the mortar
will stiffen and lose its plasticity. Mortar while hardening shrinks slightly and thus pulls
away from the edges of the block. The mortar shall be pressed against the units with a
jointing tool after it has stiffened to effect intimate contact between the mortar and the
unit to obtain a weather tight joint. The mortar shall be raked to a depth of 10mm as each
course is laid to ensure good bond for the plaster.
Dimensional stability of hollow concrete blocks is greatly affected by variations of
moisture content in the units. Only well dried blocks should be used for the construction.
Blocks with moisture content more than 25% of' maximum water absorption permissible
shall not be used. The blocks should not be wetted before or during laying in the walls.
Blocks should be laid dry except slightly moistening their surfaces on which mortar is to
be applied to obviate absorption of water from the mortar.
As per the design requirements and to effectively control cracks in the masonry, RCC
bound beam/studs, joint reinforcement shall be provided at suitable locations. Joint
reinforcement shall be fabricated either from mild steel wires conforming to IS:280 or
welded wire fabric/high strength deformed basis.
For jambs of doors, windows and openings, should concrete blocks shall be provided. If
hollow units are used, the hollows shall be filled with concrete of mix 1:3:6. Hold fasts
of doors/windows should be arranged so that they occur at block course level.
At Intersection of walls, the courses shall laid up at the same time with a true masonry
bond between atleast 50% of the concrete blocks.
Curing of the mortar joints shall be carried out for atleast 7 days. The walls should only
be lightly moistened and shall not be allowed to become excessively wet.
Double scaffolding shall be adopted for execution of block masonry work.
Cutting of the units shall be restricted to a minimum. All horizontal and vertical
dimensions shall be in respectively, adopting modular co-ordination for walls, opening
locations for doors, windows etc.
Concrete blocks shall be stored at site suitably to avoid any contact with moisture from
the ground and covered to protect against wetting.
9.11 DAMP-PROOF COURSE

9.11.1
Materials and Workmanship
Where specified, all the walls in a building shall be provided with damp-proof course
cover plinth to prevent water from rising up the wall. The damp-proof course shall run
without a break throughout the length of the wall even under the door or other openings.
Damp-proof course shall consist of 50 mm thick cement concrete of 1:2:1 nominal mix
with approved water-proofing compound admixture confirming to IS: 2645 in proportion
as directed by the manufacturer. Concrete shall be with 10 mm down graded coarse
aggregates.
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If he surface of brickwork/stone masonry work shall be leveled and prepared before

laying the cement concrete. Side shuttering shall be properly fixed to ensure that slurry
does not leak through and is also not disturbed during compaction. The upper and side
surface shall be made rough to afford key to the masonry above and to the plaster.
Damp-proof course shall be cured properly for atleast seven days after which it shall be
allowed to dry for taking up further work.
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10 PLASTERING
10.1 RELEVANT IS CODES
IS:1542
IS:1661
IS:2394
: Sand for plaster

: C.P. for application of ferrous metals in building
: C.P. for application of lime plaster finish
10.2 PLASTERING
Cement mortar used for plastering shall be of the mix proportions and thickness as
specified on the drawings or bill of quantities or particular specifications for the various
different parts of the works.
The materials used i.e. cement, sand and water shall be of the same quality and of the
same specifications as indicated for plain and reinforced cement concrete works in the
Section D2 of this tender.
Sand further shall meet the specifications as laid down in IS:1542-1977 Specification for
sand for plaster.
For plastering on old existing surfaces polymers shall be added as bonding agents.
The surfaces that are to be applied with plaster shall be thoroughly cleaned to remove
dust, dirt, loose particles, oil, soil, slats etc. that may be sticking to the surfaces. The
surfaces shall be washed clean and watered properly for 4 hours before applying plaster.
Plaster shall not, in any case, be thinner than specified. It shall have uniform specified
thickness. When smooth finishing is required the cement plastering shall be floated over
with neat cement within 15 minutes after application of the last coat of plastering.
The plaster shall be protected from the sun and rain by such means as the Engineer-inCharge in charge may approve. The plastered surfaces shall be cured for 7 (seven) days.
Construction joints in plastering shall be kept at places approved by the Engineer-inCharge. When the thickness of the plaster specified is to be made up in more than one
layer, the second layer shall be applied only when the lower coat is still green. After
applying the first layer the surface should be roughed and wherever specified, approved
brands of additives like water proofing compounds shall be added in specified quantities
as recommended by the manufacturer of the compound, or as directed by the Engineerin-Charge.
Wherever scaffolds are necessary for plastering they shall be provided. Stage scaffolding
shall be provided for ceiling plaster. To ensure even thickness and true surface, patches
of plaster about 15 cms x 15 cms shall be first applied both horizontally as vertically 2 m
apart. Plastering shall be done from top to bottom and care shall be taken to avoid joints
on continuous surface.
Sand face plaster shall consist of first layer of 16mm average thick cement plaster in
cement mortar 1: 6 (One part cement and Six parts coarse sand). A second layer of 4
mm average thick in cement mortar 1:4 (one part cement and four part coarse sand) shall
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be applied. After the application of final coat, the surface shall be finished with the
application of sponge rubber or as directed to obtain a uniform sand particle surface
finish.
In case any other finish like rough cast finish or dry dash finish is specified in the
drawings the same shall be provided as directed by the Engineer-in-Charge. Surfaces,
which are to be plastered, shall be roughened while they are still green or raked so as to
give proper bond between the surface and plaster.
All corner, edges, junctions shall be truly vertical or horizontal as the case may be and
carefully finished. Rounding or chamfering of corners shall be carried out with proper
templates to the required size and shapes.
No additional charges for works like scaffolding curing etc. are payable over and above
the rates quoted for brickwork. The rates quoted shall be deemed to be inclusive of all
such works.
10.3 NEERU
10.3.1
Material
Neeru shall be made of the best description of lime slaked with fresh water and sifted.
The lime to be reduced to fine powder by grinding it on a stone or in a hand mill, with a
thick solution of mussalla to be made or as may be desired by the engineer. The neeru
thus prepared shall be kept moist until used and the quantity to be prepared at one time
shall be such that it can be consumed in eight days.
10.3.2
Workmanship
All stone or brick masonry shall be thoroughly wetted and joints raked out to a depth of
at least 20mm and walls washed before any plastering is done. The surface shall then
rendered with fine sand, to the specified thickness and roughness. The surface shall then
be floated or set with a thin coat, 3mm thick of cement and polished, well with a trowel
or flat board. The cement mortar shall be used within 30 minutes after it leaves the
mixing board or mill. Before any plasterwork is started patches of plaster 150mm x
150mm shall be put on at every 3 meters apart as gauges so as to ensure an even
thickness throughout the work. Cement plaster shall be done in even square or strips.
Care shall be taken to keep the whole surface thoroughly wetted for at least a week. The
finishing surface shall be as specified and directed. If neeru finish is specified then the
same shall be applied to the prepared and partially set but somewhat plastic surface with
steel trowel to a thickness slightly exceeding 1.5 mm and rubbed down to 1.5mm
thickness and polished to a perfectly smooth and even finish working from top to bottom.
The surface shall be then colored, if required with 3 coats of white or colour wash for
which no extra payment shall be made.
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11 FLOORING
IS:777
IS:1237
IS:1443
IS:2114
:
:
:
:
Glazed earthen ware tiles

Cement Concrete flooring tiles
C.P. for laying & finishing of cement concrete flooring tiles
C.P. for laying in-situ terrazzo floor finish
11.2 GENERAL
The materials and workmanship conform to the provisions of the following codes and
standards. In particular and with such other standards as mentioned hereinafter. BIS: 269,
385, 515, 653, 712, 809, 1077, 1195, 1196, 1197, 1198, 1237, 1344, 1443.
11.3 CEMENT CONCRETE FLOORING

11.3.1
General
Flooring shall consist of a sub-base laid on the compacted earth or sand fill as required, a
base course laid on the sub-base and then a finishing layer of concrete, Terrazzo or any
other material as specified to be laid. The materials for filling (Earth or sand as specified
in drawings) shall be brought from the source as approved by the Engineer-in-Charge.
11.3.2
Filling
The surface to receive the filling shall be first cleared free of all roots, vegetation and
wetted. Filling in plinth or other specified levels shall proceed in layers of 15 cm. Along
with the construction of building, it shall be watered and well rammed in layers as
mentioned above and compacted to the satisfaction of the Engineer-in-Charge.
Care shall be taken to remove all roots, vegetation, foreign matter, etc. from the earth
used for filling. After thorough consolidation, required quantity of the filling
corresponding to the thickness of floor shall be scrubbed to make space for the flooring.
Where sand filling is specified, the sand shall be clean, free from vegetation and other
deleterious materials and same procedure followed as for earth filling. In case of sand
filling, if required, flooding shall be done to achieve required compaction.
11.3.2.1 Preparation of Bed
The bed for flooring shall be prepared either level or sloped as per relevant drawings or
as instructed by Engineer-in-Charge. Care shall be taken that there are no roots,
vegetation, foreign matter, etc.
11.3.2.2 Sub-Base
On the prepared bed as indicated above, boulder, or gravel or broken bricks or sand or
cement concrete (1:4:8 as per BIS: 465) shall be laid to thickness as specified. This layer
shall be beaten with rammers until thoroughly consolidated. All the material used shall
conform to the required specifications.
The materials proportion, mixing, laying, and curing, etc. for cement concrete shall be
carried out as specified.
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The finished work shall be of uniform depth over the whole floor with surface even and
parallel to the prepared bed as per drawing or as directed by Engineer-in-Charge.
a. Boulders as Sub-base Course
Boulders shall be laid over the prepared bed as per general specification and shall be
of size 100 to 150 mm and shall be of approved quality. Boulders being used shall
be free from decay, weathering and be stacked in such heaps in place as directed by
Engineer-in-Charge, the thickness being as specified in the relevant drawings.
b. Sand Layer
Sand for sand layer to be laid over the prepared bond shall be clean, free from
admixture as per specification. Sand layer shall be spread in one or more layers to the
thickness as indicated in drawings or schedule of item watered and rammed.
11.3.3
Base Coarse
11.3.3.1 Cement Concrete

It shall be of specified mix and shall generally conform to Construction Specification
for Cement Concrete.
11.3.3.2 Panels
To prevent construction cracks, the floor space shall be divided into square or
rectangular panels. The base course of specified thickness shall be laid in alternate
panels or any other pattern as approved by Engineer-in-Charge. The panels shall be of
uniform size, not exceeding 4.0 m. in any direction for a floor having thickness 40 mm
and above. Alternate panels shall be laid on different days.
Construction joints shall be formed in between the sequential panels cast, with straight
edges, 20 mm deep and 12 mm wide in groove form. These joints on completion of
work, shall be cleaned and washed free of dust with the help of brush and shall be treated
with hot bitumen poured in the gap, over which fine sand shall be spread to arrest the
flow of bitumen.
11.3.3.3 Shuttering
The panels shall be bounded by glass strips having the same depth as the concrete floor.
These shall be fixed in position with their top at proper level, giving slope. The floors
shall butt against masonry of wall before it is plastered.
11.3.3.4 Concreting
Cement concrete shall be placed in position with or without MS reinforcements as shown
in drawings and beaten with trowel and finished smooth or left rough as directed by the
Engineer-in-Charge. Beating shall cease as soon as surface is found covered with cream
of mortar. The surface shall be checked with the help of straight edge and made true.
The shuttering shall be removed next day. Care shall be taken to see that edges are not
damaged and fresh mortar from adjacent panels is not splashed over them. The joints
between panels shall come out as fine straight line.
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MS reinforcement used for concrete base course with reinforcement shall conform to
relevant BIS Specifications as detailed in drawings. Before placing of those
reinforcements, they shall be cleared of scales with wire brush and oily stains removed.
11.3.4
Floor Finish Plain Cement Finish
Finishing of the surfaces shall follow immediately after the completion of base course.
The surface shall be left for some time till the moisture disappears from it. Use of dry
cement or cement and sand mixture sprinkled on the moisture shall not be permitted.
Fresh quantity of cement at 2.2 kg per square metre of flooring shall be mixed with water
to form thick slurry and spread over the surface, while the concrete is still green. It shall
be pressed twice by means of iron floats, once when the slurry is applied and second time
when cement starts setting.
The junction of floor with wall plaster, clods or skirting shall be rounded off uniformly
where so required upto 25 mm radius or as directed. The men engaged on finishing
operations shall be provided with raised wooden platform to sit on, so as floor finish is
specified, the top surface of floor finish shall be chequered with mesh or similar
impression before the finish has set.
11.3.5
Curing
Each finished portion of floor, on completion, shall be kept wet with ponding or moist
sand or moist gunny bags as per specifications. At no time, cement concrete layer, plain
or reinforced shall be allowed to dry during curing time.
11.4 GRANOLITHIC (IPS) FLOORING

The requirement for filling, preparation of bed, sub-base and base course concrete shall
be same as in clauses above.
11.4.1
Finished Layers
Granolithic finish of the thickness as indicated in drawings or as specified shall consist

of 2 layer of M15 grade cement concrete. The first layer of concrete shall be laid with 10
mm to 6 mm grade aggregate and well compacted. Within 15 minutes of laying this
course the second layer with 6 mm down aggregate shall be laid. The cement and
aggregates for the top layer shall be mixed dry.
Sufficient quantity of washed sand and water shall be mixed so as to make it plastic but
not flowing. This mixture shall be laid on the first layer so that the two layers firmly grip
together. The top layer shall be well tamped, spaded, trowelled and finished with neat
cement slurry or with non-skid finish as required. At the junction of adjoining panels a
thin string shall be given.
The casting of the granolithic finish layer shall be done in rectangular or square panels
not exceeding 1.8 M on any side, using glass strips of height equal to the specified
thickness of the floor finish. Required slope in the floor shall be given in the base course
concrete without reduction in thickness.
11.4.2
Curing
Curing shall be done as per above mentioned clause.
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11.5 TERRAZZO (MOSAIC) TILE

The tiles shall be approximately 22 mm thick of approved shade, color and chips. The
tiles shall be pressure made conforming to IS:1237 in all respects. The sizes of the tiles
shall be as given in table below:
Table 13 : Sizes of Terrazzo Tiles
Sr.
Nominal
Actual
Nominal
Actual
Length (cm) Length (cm) Breadth (cm) Breadth (cm)
1
2
3
11.5.1
20
25
30
19.85
24.85
29.85
20
25
30
19.85
24.85
29.85
Thickness
Not less than
(mm)
20
22
25
Tolerances
Tolerances on length and breadth shall be 1 mm. Tolerance on thickness shall be 5

mm. The range of dimension in any one direction of tiles shall not exceed 1 mm on
length and breadth and 3 mm on thickness.
11.5.2
Manufacture
The tiles shall be manufactured under hydraulic pressure of not less than 140 kg/cm2 and
shall be given the first grinding with machine before delivery to the site. The proportion
of cement to aggregate in the backing of the tiles shall not be leaner than 1:3 by weight.
Similarly the proportion of cement to marble chips aggregate in the wearing layer of the
tiles and the proportion of pigment to be used therein shall not exceed 10% by weight of
cement used in the mix. The finished thickness of the upper layer shall not be less than 5
mm for size of marble chips from the smallest upto 6 mm, and also, not less than 5 mm
for size of marble chips ranging from the smallest upto 12 mm, and not less than 6 mm
for sizes of marble chips varying from the smallest upto 20 mm.
11.5.3
Laying
The sub-grade concrete or the R.C.C slab on which the tiles are to be laid shall be
cleaned, wetted and mopped. The bedding for the tiles shall be with lime mortar of
either:
i. 1:1:2 (lime putty:surkhi :coarse sand)
ii. 1:3 (lime putty :surkhi)
iii. 1:3 (lime putty : coarse sand)
The bedding ingredients shall be thoroughly mixed by volume in the dry form. Care
shall be taken to ensure that there are no hard lumps present. Water shall then be added
and the ingredients thoroughly mixed. The average thickness of the bedding mortar shall
be 30 mm.
Lime mortar bedding shall be spread, tamed and corrected to proper levels and allowed
to be hardened for a day before the tiles are set. Over this bedding, neat grey cement
slurry of honey like consistency shall be spread at the rate of 44 kg of cement per sq.m.
over such an area as would accommodate about twenty tiles. Tiles shall be washed clean
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and shall be fixed in this grout one after another each tile being gently tapped with a
wooden mallet till it is properly bedded and in level with the adjoining tiles. The joints
shall be kept as thin as possible not exceeding 1.5 mm and in straight lines or to suit the
required pattern.
The surface of the flooring during laying shall be the frequently checked with a straight
edge atleast 2 m long, so as to obtain a true surface with the specified slope. In situations
where full size tiles cannot be fixed, these shall be cut (sawn) to the required size and
their edge rubbed smooth to ensure a straight and true joint. Tiles, which are fixed in the
floor adjoining the wall, shall enter not less than 12 mm under the plaster, skirting or
dado. The junction between the wall plaster and tile work shall be finished neatly and
without any waviness. After laying the tiles, the surplus cement grout shall be cleaned
off.
11.5.4
Curing, Polishing and Finishing
After laying the tiles the day after all the joints shall be cleaned of the grey cement grout
with a wire brush or trowed to a depth of 5 mm and all dust and loose mortar removed
and cleaned. Joints shall then be grouted with grey or white cement mixed with or
without pigment to match the shade of the topping of the wearing layer of the tiles. The
same cement slurry shall be applied to the entire surface of the tiles in a thin coat for
protecting the surface from abrasive damage and fill the pin holes that may exist on the
surface.
The floor shall then be kept wet for a minimum period of 7 days. The surface shall
thereafter be grounded evenly with machine fitted with coarse grade grit blocks No.60.
Water shall be used profusely during grinding . The surface shall be washed thoroughly
with water to remove all grinding mud, cleaned and mopped. Then it shall be corrected
with a thin coat of grey or white cement, mixed with or without pigment to match the
colour of the topping of the wearing surface in order to fill any pin hole that appear. The
surface shall be again cured, the second grinding shall then be carried out with machine
fitted with fine grade grit blocks No. 120.
The final grinding shall be carried out with the machine fitted with finest grade grit
blocks No. 320, the same day after the second grinding described above.
The small areas or where circumstances so required hand polishing may be permitted in
lieu of machine polishing after laying. For hand polishing coarse grade stone No. 60
Water shall be used for 1st rubbing stone of medium grade No.80 for second rubbing and
stone of fine grade No.120 for final rubbing and polishing.
After the final polish oxalic acid shall be dusted over the surface of 33 gm/sq.m
sprinkled with water and rubbed hard with a namdah block (pad or woolen rags). The
following day the floor shall be wiped with a moist rag and dried with a soft cloth and
finished clean.
If any tile is disturbed or damaged, it shall be refitted or replaced, properly jointed and
polished. The finished floor shall not sound hollow when tapped with a wooden mallet.
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11.6 TERRAZZO (MOSAIC) IN-SITU FLOORING

The requirements for filling, preparation of bed, sub- base and base course concrete shall
be same as above.
Trained worker shall carry out terrazzo works.
11.6.1
Material
Best quality marble chips of uniform tint and color, 6 mm maximum and 3 mm
minimum size, as approved by Engineer-in-Charge shall be used. They shall be machine
crushed, free from foreign matter and of approved quality.
11.6.2
Preparation of Surface and Laying Over Base Course Concrete
Total thickness of cast-in-situ Terrazzo shall be atleast 40 mm unless otherwise

indicated. This shall be in two layers bottom layer of M:15 concrete bedding with 10
mm down aggregate of specified thickness and the top layer of 10 mm thickness,
consisting of a mix of cement and marble chips in the proportion of 1:1/2 marble powder
: 2 marble chips). The bottom layer shall be laid in bays not exceeding 1.2 m on either
side and leveled 10 mm below the finished floor level.
The cement and marble chips including powder shall be mixed dry. Water shall be
added gradually after through mixing until the mix become plastic but flowing.
Within one hour of laying of the bottom layer of cement concrete the upper layer of
marble chips and cement paste shall be laid over a coat of cement slurry and the surface
tamped lightly and finished to the required level and slope.
While the bottom layer is still plastic glass dividing strips 35 mm wide x 16 SWG thick
shall be fixed on the base course concrete with proper anchoring features to allow top
edge to be flushed with the finished floor. The strip shall be laid, forming panels not
exceeding 1.2 m x 1.2 m size.
11.6.3
Curing, Polishing and Finishing
The floor shall then be kept wet for a minimum period of six days. The surface shall
thereafter be ground evenly to the satisfaction of the Engineer-in-Charge with machine
grinders in three phase with grade stones from coarse to fine grade. The surface shall
receive wash of neat cement mixed with or without pigment and cured before every
grinding operation.
After final grinding, surface shall be cleaned and oxalic acid shall be dusted over the
surface @ 35 grams. per sq.m. sprinkled.
11.7 GLAZED TILE FLOORING

11.7.1
White Glazed Tiles
The glazed tiles shall conform to IS:777-1970. They shall be flat and true to shape and
free from cracks, crazing spots, chipped edges and corners. The glazing shall be of
uniform shade.
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11.7.2
Size and Tolerance
The tiles shall be of nominal sizes such as 150 x 150 mm and 100 x 100 mm or as
specified. The thickness of the tiles shall be 5 mm, or 6 mm as specified. The tolerance
on facial dimension value shall be 1.0 mm and 0.5 mm on thickness.
The top surface of the tiles shall be glazed. The glaze shall be either glossy or matt as
specified. The underside of the tiles shall be completely free form glaze in order that the
tiles may adhere properly to the base. The edge of the tiles shall be preferably free form
glaze, however any glaze if unavoidable, shall be permissible on any one edge of the tile.
11.7.3
Coloured Tiles
The sizes and specifications shall be the same as for the white glazed tiles described
above. The only difference shall be in the colour.
11.7.4
Decorative Tiles
The type and size of the decorative tiles shall be as follows:
a. Decorated white background tiles shall be of 152 x 152 x 6 mm and 108 x 108 x 6
mm sizes.
b. Decorated and having coloured background shall be of 152 x 152 x 6 mm and 108 x
108 x 6 mm sizes.
c. Fantasy glazed tiles (108 x 108 x 6 mm) other specifications will be the same as that
of white glazed tiles.
11.7.5
Preparation of Surface and Laying
Sub grade concrete or the R.C.C slab on which the tiles are to be laid shall be cleaned,
wetted and mopped. The bedding for the tile shall be with 1:3 (cement: coarse sand)
mortar or as specified, having average 10 mm thickness. The bedding thickness under
the tiles shall not be less than 5 mm.
The mortar shall be spread, tamped and corrected to proper levels and allowed to harden
sufficiently to offer a fairly rigid cushion for the tiles to be set and to enable the mason to
place wooden plank across and square on it. Over this mortar bedding neat grey cement
slurry of honey - like consistency shall be spread at the rate of 3.3 kg of cement per sq. m
over such an area as would accommodate about twenty tiles. Tiles shall be soaked in
water washed clean and shall be fixed in this grout one after another each tile gently
being tapped with a wooden mallet till it is properly bedded and in level with the
adjoining tiles. The joints in between the tiles shall be kept as thin as possible and in
straight lines or to suit the required pattern.
The surface or the flooring during laying shall be frequently checked with a straight edge
about 2 m long, for obtaining a true surface with the specified slope. Where full size
tiles cannot be fixed these shall be cut (sawn) to the required size and their edge rubbed
smooth to ensure straight and true joints. The tiles, which are fixed in the floor adjoining
the wall, shall enter not less than 10 mm under the plaster, skirting or dado. After laying
the tiles the surplus cement grout shall be cleaned off.
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11.7.6
Pointing and Finishing
The joints shall be cleaned off the grey cement grout with wire brush or trowel to a depth
of 2 mm to 3 mm and all dust and loose mortar removed. Joints shall then be flush
pointed with white cement added with pigment if required to match the colour of the
tiles. The floor shall then be kept wet for 7 days. After curing, the surface shall be
washed and cleaned. The finish floor shall not sound hollow when tapped with a
wooden mallet.
11.8 KOTA STONE FLOORING

Kota Stone Slabs- shall be of selected quality hard, sound, dense and homogeneous in
texture, free from cracks, decay, weathering and flaws. They shall be hand or machine
cut to the requisite thickness and shall be of the colour indicated in the drawings or as
directed.
The top (exposed) face of the slabs shall be polished before being brought to site, unless
otherwise specified. The slabs shall conform to the size required and samples shall be
got approved before starting the work. 20, 30 or 40 mm or specified thickness slabs shall
be used.
11.8.1
Tolerances
Of 2 mm shall be allowed for the thickness. In respect of length and breadth of slabs, a
tolerance of 5 mm shall be allowed.
11.8.2
Dressing
Each slab shall be cut to the required size and shape and fine chisel dressed on the sides
to the full depth, so that a straight edge laid along the side of the stone shall be in full
contact with it. The sides (edges) shall be table rubbed with coarse sand or machine
rubbed before paving. All angles and edges of the tiles shall be true, square and free
from chipping and the surface shall be true and plane.
11.8.3
Surface Preparation and Laying
Sub-grade concrete on the R.C.C slab on which the slabs are to be laid shall be cleaned,
wetted and mopped. The bedding for the slabs shall be with cement mortar 1:4 or with
lime mortar 1:1:1 (lime putty : surkhi : coarse sand) as given in the description of item.
The average thickness of the bedding mortar under the slab shall be 20 mm and the
thickness at any place under the slab not be less than 12 mm.
Mortar of the specified mix shall be spread under the area of each slab, roughly to the
average thickness as specified. The slab shall be washed clean before laying. It shall be
laid on top, pressed, tapped with wooden mallet and brought to level with the adjoining
slabs. It shall be lifted and laid aside. The top surface of the mortar shall then be
corrected by adding fresh mortar at hallows. The mortar is allowed to harden a bit and
cement slurry of honey -like consistency shall be spread over the same at the rate of 4.4
kg of cement per sq.m. The edge of the slab already paved shall be buttered with grey or
white cement with or without admixture of pigment to match the shade of the kota stone
slabs as given or specified. The slab to be paved shall then be lowered gently back in
position and tapped with wooden mallet till it is properly bedded in level with and close
to the adjoining slabs with as fine joint as possible. All the subsequent slabs shall be laid
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in the same manner. After each slab has been laid, surplus cement on the surface shall be
cleaned off. The flooring shall be cured for at least 7 days.
Slabs, which are fixed in the floor adjoining the wall, shall enter atleast 12 mm under the
plaster skirting or dado. The junction between wall plaster and floor shall be finished
neatly and without any wavings.
11.8.4
Polishing and Finishing
Shall be done as described in the above article of Terrazzo Tile Flooring except that:
a. First polishing with coarse grade carborundun stone shall not be done.
b. Cement slurry with or without pigment shall not be applied on the surface before
polishing.
11.9 MOSAIC FINISHED DADO OR SKIRTING

For skirting and dado the brickwork or concrete surface shall be raked and shall be well
watered for four hours. A dubbing coat of cement mortar 1:3 (1 cement: 3 sand) of
sufficient thickness shall be applied so as to bring the surface in line with the plastered
surface. The surface shall be carried by lines with trowel so as to receive mosaic tiles or
the top layer or cement and marble chips in proportion of 1:1/2:2 (1 cement: marble
powder: 2 marble chips) of 7 mm thickness with 3-5 mm size for flooring including
dividing strips (20 mm x 15 SWG) @ 600 mm c/c.
11.10HARDONITE FLOORING
These specifications cover the guidelines for providing hardonite topping (industrial
flooring) for floor subjected to heavy wear and tear viz., workshop and stores, engine
room, and Generator room etc.
The item includes providing hardonite topping as specified to the thickness and
satisfaction of the Engineer-in-Charge, supply of all material, labour, tools and plant
required for completing the work in best workmanlike manner.
11.10.1 Workmanship
The person executing the topping shall be an experienced mason familiar with flooring
works of similar nature. Flooring shall be laid uniformly, the tolerance for variation of
level being + 3 mm.
Hardonite material shall be mixed with cement concrete thoroughly to give a uniform
mix.
11.10.2 Preparation of Surface
Hardonite shall be laid over a wet concrete surface screened to receive the topping. The
base shall be leveled to within + 12 mm.
11.10.2.1
Preparation of Topping
Hardonite shall consist of a mixture of cement concrete in proportion of 1:2:4 and well
graded iron fillings added in a proportion of 1.50 kg/bag of cement.
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11.10.2.2
Application
Hardonite shall be placed uniformly in a layer of specified thickness and finished with a
steel troned. Care shall be taken to place hardonite in a separate layer while the base
concrete is steel wet.
11.10.2.3
Trowelling
Surface of floor shall be finished with steel trowel only and trowelled just sufficient so as
to give a finished surface. The surface shall be left for some time till moisture disappears
from it. Trowelling shall be done three times at intervals so as to produce a uniform hard
surface in no case cement should come up to the surface.
11.10.2.4
Curing
The entire surface shall be kept uniformly wet for seven days.
11.10.2.5
Opening for use
The surface shall be allowed to be used only after curing period is over.
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12 DISTEMPERING AND
PAINTING
12.1 GENERAL
Engineers approval shall be obtained before commencing the painting work. All paints
and preserves shall be of approved make and colour and their application shall conform
to the manufactures instructions. Where more than one undercoat is specified it shall be
applied in coats of distinctive tints. Workmanship shall conform to the requirement of
IS:2395
Unless the manufacturers instructions state otherwise48 hours drying time shall elapse
between successive applications of any primer and 24 hours between applications of all
subsequent coats. The surface of bituminous paints shall be left at least 3 days before
further handling.
No paints in any coats shall be applied until the engineer is satisfied that the surface is
clean and dry. And that any previous coat is satisfactory and has hardened adequately.
When a surface has been approved, it must be painted immediately.
Paint work shall be rubbed down with a glass paper between coats. No paint shall be
applied to a surface, which is damp, dirty or otherwise inadequately prepared.
12.2 CONCRETE, BRICKWORK AND PLASTER

Where specified to be painted, concrete and plaster shall be rubbed smooth and any
cracks, blister holes and other imperfections cut out, filled and made good. The surface
shall be dried to the satisfaction of the engineer before painting is commenced and
drying time if at least 28 days shall be allowed after laying brickwork and plaster or
stripping formwork from concrete. The surface shall be brushed to remove any
efflorescence and then painted with the following:
1. for interior brick work and concrete, apply two coats of oil paint up to 1 meter height
and for remaining part two coats of plastic emulsion paint over a coat of primer.
2. For exterior brickwork and concrete, apply two coats of cement based paint over a
coat of primer with a water repellant coat of siliconate solution of app[roved make.
Where painting with plastic emulsion is specified, all uneven surface shall be made up by
use of putty of appropriate quality, after the surface has been thoroughly cleaned of all
dust and dirt and sand papered.
12.3 IRONWORK AND UNGALVANISED STEELWORK

Structural steelwork shall be shot blasted to a "white metal" finish, and grease and oil
removed prior to painting. Priming shall immediately follow blast cleaning and no
cleaned surface shall be left unprimed for more than four hours. Only primers that
chemically inhibit corrosion shall be used. Where the iron or steelwork is not in contact
with raw or treated water, the primer shall be red lead complying with IS: 57. Where
there is a possibility that the steel or ironwork may come in contact with water, the
priming treatment shall be non toxic, zinc chromate or equivalent. Where it is anticipated
that further welding will be required. an approved welding primer shall be applied to the
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areas to be welded and re primed with the main primer when welding has been
completed. Primer coats shall not be less than 0.05 mm each.
After erection, all damaged areas shall be made good, and re primed where the original
coat has spread under the primer, the affected surface shall be cleaned down to bare
metal to the satisfaction of the Engineer and then re primed.
Repainting shall be carried out as soon as possible after erection. If` it is to he exposed to
weather or condensation, it shall receive one further coal of primer.
Metalwork in intermittent or permanent contact with raw or treated water shall have two
finishing coats of an approved coal tar pitch epoxy paint such as "Epilux 5" by Berger
Paints, or equivalent. The total coating shall be minimum of 0.125 mm thick.
After the second coat of primer is hard dry, the entire surface shall be wet rubbed cutting
down to a smooth uniform surface. When the surface becomes dry, be undercoat of
synthetic enamel paint conforming-to IS:2932 of optimum thickness shall be applied by
brushing with minimum of brush marks. The coat shall be allowed to hard dry. The
under coat shall then be wet rubbed cutting down to a smooth finish, taking adequate
care to ensure that at no place the undercoat is completely removed. The surface shall
then be allowed to dry.
The first finishing coat of paint shall be applied by brushing and allowed to hard dry.
The gloss from the entire surface shall then be gently removed and the surface dusted
off. The second finishing coat shall then be applied by brushing.
At least 24 hours shall elapse between the application of successive coats. Each coat
shall very slightly in shade and this shall be got approved by the Engineer.
12.4 GALVANISED STEELWORK

Newly galvanised steelwork shall be primed with an etch primer such as calcium
plumbate. Steelwork that has been galvanised for a long period so that the surface has
oxidised adequately to allow adhesion of under-coats, need not have an initial coat of
each primer.
After priming, galvanised steelwork in constant or intermittent contact with raw or
treated water shall be given two coats of an approved coat of tar pitch epoxy paint such
as "Epilux 5" by Berger Paints, or equivalent. The total coating shall have a minimum
thickness of 0.1 25 mm.
Protective coats for galvanised steelwork not in contact with water shall be:
1. One coat of micaceous iron oxide paint for interior galvanised steel work.
2. Two coats Of micaceous iron oxide paint for external galvanized steelwork.
Galvanised steelwork not in contact with water shall be finished with at least one coat of
gloss paint on top of an approved undercoat.
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12.5 BITUMINOUS SURFACES

Metalwork items that have been given a shop treatment of bituminous paint shall be
painted with two coats of` an approved anti-bleed paint before applying a coat of
decorative finishing paint.
12.6 ALUMINIUM SURFACES

Aluminum surfaces shall be worked clean, dried and thoroughly degreased before
painting, by an appropriate solvent (such as one consisting of equal parts of white spirit
and light solvent naptha). Flame cleaning shall not be permitted. The clean degreased
surface shall be treated to ensure paint adhesion either by mechanical roughening,
chemical adhesion, or etch primers or wash primers applied in strict conformity with the
manufacturer's instructions or by other treatment approved by the Engineer.
The pretreated surface shall receive a priming coat with an inhibiting pigment containing
not less than 20% by weight of fine chromate or other approved chromate in a suitable
water-resisting vehicle.
The priming coat shall not contain any copper or mercury compounds and it shall also be
free from graphite and carbonaceous materials and shall not contain any lead. Priming
coat shall consist of a tung-oil phenolicresin which is pigmented with equal parts of zinc
tetoroxy chromate and red iron oxide.
Aluminum surfaces in contact with concrete, or resting on pads on concrete, shall be
painted with two coats bituminous paint, and the concrete surfaces shall also receive two
coats bituminous paint.
12.7 WOODWORK
Woodwork for painting shall be carefully rubbed down, treated with preservatives and
knotted, stopped and primed in the shop. Care shall be taken to ensure that priming is
thoroughly brushed into every part of the surface and in particular at end grains, joint and
notches where two coats are to be applied. Primers for wood shall he of a standard
equivalent to, or better than "Aluminum Wood Primer Sealer A519-3697" by I.C.I.
Paints.
After the woodwork has been fitted and all defects in the surfaces have been made good
and re primed, one coat of approved undercoat shall be applied to internal surfaces and
two coats to external surfaces. An undercoat of quality equal to or better than "Delux
Undercoat A522 line" shall be used.
'Timber work shall be decoratively finished with one coat of finishing paint of standard
equal to, or better than "Delux Gloss Finish A365 line".
12.8 WATERPROOF CEMENT PAINT

12.8.1
Surface Preparation
The wall should be washed thoroughly with clean soft water and freed of all loose
particles, dust, dirt, lichen, moss, efflorescence and Lime wash by Scrubbing with a wire
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brush. Inequality and holes shall be filled up with cement paste, which should be allowed
to set. To get even uniform mat finish it is necessary to keep the surface damp
throughout the operation. In hot dry weather the wall should be frequently sprinkled with
water to keep it moist.
12.8.2
Mixing the paint
Loosen the contents by either rolling the drum or shaking the container before opening it.
Take one measure of water by volume in a clean pot and add two volumes of approved
quality waterproof cement paint conforming to IS: 5410. Stir well to make a paste of
high consistency then add one more measure of water constantly stirring the mixture.
The final composition of water and paint is now 1:1 by volume. Keep stirring the
mixture all the time and use it up within an hour. Do not use the mix if it is left over 'for
more than two hours.
12.8.3
Method of Application
Wet the surface by any convenient method. A small surface can be wetted by brush.
When applying paint surface should be damp and not wet. While applying the first coat
brush hard into the surface to cover pores and cavities to ensure better bond. Twelve
hours after applying the first coat cure the surface by sprinkling the water. Before
applying the second coat damp the surface and after the application of second coat cure it
as directed above. In hot climate repeat curing at least twice at the interval of six hours
for optimum best results.
12.8.4
Curing
After sprinkling fine spray of water should cure each application paint normally after
twelve hours when paint film is hardened satisfactorily. In summer when weather is hot,
curing may be done little earlier. Water marks may be left over the surface if a stream of
water is allowed to flow before the paint film is hardened.
12.9 SILICON PAINT

12.9.1
Preparation
A solution for application shall be prepared from Syltrit 1772 or equivalent. The
Manufacturer's instructions shall be followed. This solution shall be prepared to a
concentration of about 3 % solids by mixing 1 kg. of water dilatable solution of sodium
methyl siliconate with 9 kg. of water. Concentration higher than 3% solids are not
recommended as they may cause a white precipitate of sodium carbonate formation.
12.9.2
Application
A flooding technique should be used in applying to obtain the best penetration. When
spraying, the solution should not be atomized or misted, but flowed on in a solid stream,
with the spray gun held, at a distance just enough to eliminate foaming on the masonry
surface. If foaming is allowed then certain visible marks might appear after application.
The run down of 150 to 300 mm should be maintained with generous overlapping of
passes. Dipping and brushing methods are also suitable. After application of the solution,
the treated surface should be allowed to dry at least 24 hours to develop maximum water
repellency. This interval may be shortened somewhat by force drying at temperatures to
30 degree C. Though this removes the water quickly, time must still be allowed for the
curing. Reaction between the solution and the surface being treated. Until the reaction is
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complete the applied film still remains water soluble and any rain failing during this time
can wash it out. So application should be done in dry weather or at least in absence of
rain and fog.
12.9.3
Spraying Equipment
Spraying equipment shall be hand operated stirrup pump with stainless steel nozzle fitted
with PVC or polyethylene delivery pipe. Components of the spraying, equipment that are
in contact with the treating solution should be of black iron, mild steel, stainless steel,
Teflon, PVC or polyethylene. They should not be of aluminum or galvanised steel. .
12.9.4
Safety
The solution should always be applied in a liquid stream, not by misting or fogging. If
misting occurs, avoid inhalation. Contact with the eyes or skin should be treated
immediately by flooding the area with large quantities of water for at least 15 minutes.
12.10RELEVANT IS CODES
IS:63
IS:133
IS:2395
IS:5410
IS:5411
:
:
:
:
:
Whiting for paints

Enamel, interior, undercoating & finishing colour as required
C.P. for painting concrete, masonry & plaster surfaces
Cement paint, colour as required
Plastic emulsion paint for interior use
12.11DISTEMPERING
12.11.1 Type
Distempering shall be of the oil or water bound type as specified.
12.11.2 Material
Dry distemper or oil bound washable distemper of approved brand and manufacture for
water bound and oil bound respectively conforming to IS:426 shall be used. The
proportions of the mix shall be as per the approved manufacturers instructions.
The dry distemper shall be stirred slowly in clean warm water using 8.6 liters of water
per kg. of distemper or as specified by the approved makers. The mixture shall be well
stirred before and during use to maintain an even consistency.
Thinner as stipulated by approved manufacturer shall be used in case of distemper for oil
bound type.
Dry distemper shall not be mixed in larger quantity than is actually required for one day
work.
12.11.3 Preparation of Surface and Priming Coat
The surface shall be thoroughly brushed free from mortar dropping and other foreign
matter and sand papered smooth.
A priming coat of whiting shall be applied over the prepared surface in case of water
bound distempering and distemper primer or cement primer shall be applied in the case
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of oil bound distemper. The white washing coat shall be used as priming coat for
distemper.
12.11.4 Application
After the primer coat is dried for atleast four hours, the entire surface shall be coated
uniformly with proper distemper brushed in horizontal strokes, immediately followed by
vertical ones which together shall constitute one coat.
Subsequent coats shall be applied in the same way and only after the previous coat has
dried. Enough distemper shall be mixed to finish one room at a time. The finished
surface shall be even and uniform and shall no brush marks. After each days work, the
brushes shall be washed in hot water and hung down to dry. Old brushes, which are dirty
or caked with distemper, shall not be used.
12.12DECORATIVE FINISH CEMENT PAINT

12.12.1 Surface Preparation
Plastered surface shall be thoroughly cleaned of dust, dirt, grease, oil marks, etc. before
the coat is applied. All the holes and depressions should be filled with gypsum prior to
application of the paint. The surface shall be wet with clean water before paint is
applied. Application of primer shall be as per specifications recommended by approved
manufacturer and as directed by the Engineer-in-Charge.
12.12.2 Preparation of Mix and Application
Any approved cement paint shall be mixed in such quantities as can be used up within an
hour of mixing. The solution shall be applied on the prepared surface with good quality
brushes and no brush mark shall be visible on the finish work.
12.13PAINTING
12.13.1 Painting General
Paints, oils, varnishes etc. of approved brand and manufacture conforming to relevant
Indian Standard Codes shall be used. Ready mixed paints as received from approved
manufacturer without any admixture shall be used. The Contractor shall obtain
permission for the make and color of the paint he proposes to use and if required, polish
for wood work shall be tested as per IS:5807 (parts I and II).
Whenever thinning is necessary, the brand of thinner recommended by approved
manufacturer or as instructed by Engineer-in-Charge shall be used. Paints, oil,
varnishes, thinner, etc. shall be brought to the site in the original containers in sealed
condition and shall be kept in the joint custody of Contractor and Engineer-in-Charge.
12.13.2 Commencing the Work
Painting except priming coat shall generally be taken in hand after all other building
work is practically finished. Approval of Engineer-in-Charge shall be sought before
commencing the work.
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12.13.3 Workmanship
All the work shall be carried out wherever applicable as per IS:1477 (Parts I & II) and
IS:2338 (Part I)
The surface shall be thoroughly cleaned. All dirt, dust, scales and grease shall be
removed before painting is started. The surface shall be perfectly dry to permit good
absorption. The prepared surface shall receive approval from Engineer-in-Charge for
commencing the painting work. For wood surfaces, a priming coat without coloring
material should be applied after which all the holes, cracks etc shall be stopped with
putty and all knots properly killed with quick lime.
Specially for wood surface, knots if visible shall be covered with red lead conforming to
BIS:103. Holes and identification on the surface shall be filled with wood putty and
rubbed smooth. Surface should be thoroughly dry.
12.13.5 Application
Paint shall be thoroughly stirred in the container when pouring into smaller containers
for use. It shall be continuously stirred while applying on the surface. The painting shall
be applied evenly and smoothly in the direction of grains of wood and perpendicular to
it. Each coat shall be allowed to dry before the next coat is applied.
Specified number of coats shall be applied and atleast 24 hours shall elapse between
application of the first coat and the subsequent second coat. No painting shall be carried
out on exterior work in wet weather condition or on surface which are not entirely dry.
Each coat shall be lightly rubbed down with sandpaper or fine pumice stone and cleaned
of dust before the next coat is laid. No left over paint shall be put back into stock tins.
The finished surface shall be free from hair or brush marks, strokes, clogging of paint
puddles in the corners of panels, angles of moulding, etc.
12.14PAINTING WITH SYNTHETIC ENAMEL/ENAMEL PAINT

12.14.1 Material
Synthetic enamel/enamel paint of approved brand and manufacture and of required shade
shall be used for the topcoat only. The paint for under coat shall be of shade to match
the topcoat, as recommended by approved manufacturer shall be used.
The surface shall be thoroughly cleaned. All dirt, scales and grease shall be removed
before painting started. The surface shall be perfectly dry to permit good absorption.
The prepared surface shall receive approval from Engineer-in-Charge for commencing
the painting work.
Specially for wood surfaces, knots if visible shall be covered with red lead conforming to
IS:103. Holes and indentation on the surface shall be filled with good putty and rubbed
smooth. Surface should be thoroughly dry.
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12.14.3 Application
12.14.3.1
Under Coat
One coat of the specified paint of shade matching with the shade of the top coat shall be
applied and allowed to dry overnight. It shall be rubbed next day with the finest grade of
wet abrasive paper to ensure smooth and even surface, free from brush marks and all
loose particles dusted off.
12.14.3.2
Top Coat
Top coats of specified paint in the desired shade shall be applied after the under coat is
thoroughly dried. Additional finishing coat shall be applied if found necessary to ensure
a properly uniform glossy surface.
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13 EXPANSION JOINTS AND

CONSTRUCTION JOINTS
13.1 GENERAL
The item of providing expansion joints and construction joints in concrete includes all
the material, labour, tools and plants necessary for completing the item in best
workmanlike manner.
13.2 MATERIAL
The Material to be used in the joints shall be ribbed PVC water stop of specified width
approved by the Engineer, bitumen impregnated fibre board as filler conforming to
IS:10566 and approved sealant material (In case of movement joint only). In addition,
IS:12220-1987 and 1838 shall also be adhered.
13.3 JOINTS IN FLOOR

Joints in floor shall be provided as specified on drawings. In case of PVC water stops to
be provided horizontal position flat-footed PVC water stops shall be used. The water
stops shall be provided in such a way that half the portion of water stop (width wise) is
embedded in the concrete and half remains exposed for next concrete. Steel
reinforcement shall not be discontinued where construction joints in floor are provided.
13.4 JOINTS IN WALLS

13.4.1
Expansion Joint
Expansion joints shall be provided in the roof slab and wall and divide wall is of R.C.C.
The joints shall be so located that in no case the slab shall be more than 45 metres long in
one stretch. The general layout of roof slab showing the position of expansion joint is
given in the accompanying drawing. The two adjoining portions of the roof slab at the
expansion joints shall be separated by a gap of about 25 mm width which shall be
bridged by means of 230 mm wide water stop. These water stops shall be fixed in such a
manner that it is equally embeded in each portion of the slab on either side of the joint
and shall be located at mid section of the slab. The joint shall be continuous in length
and shall be properly joined together or welded at all junction along its length. The gap
between the adjacent slab below the water stops shall be filled with filler material like
thermocol or such compound which may be approved by the Engineer.
This may be achieved by placing a strip of filler material in position adjacent to the face
of concreted slab panel while concreting the adjoining panel. The space above, water
stop shall be filled with sealant material overlaid by filler material like thermocol and
polysulphide sealant as shown in the drawing.
The expansion joints in the end wall and divide wall shall be provided in such a manner
that the joint shall divide the structure longitudinally and transversely as shown in the
drawing. The two adjacent parts of the wall shall be separated by a gap of about 25 mm
width which shall be bridged by 300 mm wide PVC water stop. However, no gap shall
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be provided in the footing of the wall. The gap on water face shall be treated with
polysulphide sealant material as shown in the drawing. The water stops shall be either
PVC or either equivalent approved by the Engineer as per specifications given
hereinafter.
13.4.2
Construction Joint
The construction joints shall be generally provided at the end of the concreting or
colcreting operation of an element or a member of a structure, or at boundary of the
panels or segments or at pre-determined locations. The construction joints in the R.C.C.
slab shall be characterised by the continuance of the reinforcing steel, being a structural
R.C.C. member. The concreting of a slab at the joint shall be done by laying the
concrete against the vertical stopping off boards, the adjoining panels being cast butting
against each other.
Const6ruction joints in the side wall and the divide wall of reservoir shall be of two types
(I) horizontal construction joints and (ii) vertical construction joints.
The horizontal construction joints shall be serrated type where stones from the lower lift
of the wall shall be projecting out sufficiently and will be embedding into the over laying
lift of the wall masonry giving a well bonded, and consequently, a water tight joint.
The vertical construction joints in the wall shall be of tongue and groove type. The
groove of these joints shall be 300 mm x 300 mm and it shall be provided 300 mm away
from the water face of the wall. These joints shall be provided with PVC water stop at a
depth of 200 mm from water face which shall be primarily responsible for the water from
water face which shall be primarily responsible for the water tightness of the joints.
These joints shall have a plain finish for a depth of 300 mm from water face by virtue of
its casting against vertical face of the centering of vertical face of the previously cast
panels cast butting against each other while the remaining depth beyond300 mm shall
have masonry facing which will present a rough surface and thus provide a good bond
between the consecutive panels.
In the case of divide wall the water stop shall be located at the centre of the key which
shall be located at the centre of divide wall. The key shall be of the same dimensions as
that in the end walls.
The construction joints in the bottom layer of the floor which shall be case in colcrete
shall be cast against vertical stopping off boards. On the water face the vertical joints
shall have a groove provided with bitumen of 12 mm x 20 mm size which shall be filled
with polysulphide sealant material.
No such special treatment need be done for the joints provided in the roof slab, bottom
layer of the floor and the horizontal joints in the wall. The joints in roof slab and bottom
layer of the floor shall however, be staggered with those in the overlaying layers such as
brick bat coba, I.P.S. and top R.C.C. layer of the floor to minimise the chances of
leakage by increasing its path, if any.
13.4.3
Complete Construction Joints
These joints are provided in the top layer of the floor of the reservoir with a view to
localise shrinkage cracks at these joints. These joints are characterised by complete
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discontinuity of steel without any initial gap as in the case of expansion joints. The
joints between the adjacent panels of the floor shall be provided with a groove at top of
dimension 12 mm x 20 mm and it shall be filled with polysulphide sealant and they shall
be provided with water stops as specified earlier.
The joint between top layer of the floor and the walls or between the top layer of the
floor and the column footing, shall also be provided with a groove of 12 mm x 20 mm
which shall be filled with sealant material as per specifications given below:
Joint Fillers : Joint fillers shall be of durable, compressible and non-extruding material.
It shall be non-staining, non-absorbent and compatible with sealant material used.
Sealant Material : The joint sealing compounds should be capable of properly ensuring
water tightness in vertical and horizontal and inclined joints in water retaining and other
structures having severe service conditions in respect of anticipated movement or
exposure to weather. Typical uses include expansion joints in the walls of water tanks,
and in roof and deck slabs exposed to the weather.
The compound should be flexible, durable and weather proof and should have sufficient
elasticity to allow joint movements of the concrete components wherever necessary.
The sealant shall be polysulphide rubber sealing compound conforming to BS 4254 of
1967 or ASA-A 116-1-1960 or any other equivalent specifications. It shall be capable of
cold pouf application for horizontal joints and cold application of vertical and inclined
joints. The sealing compounds shall be suitable for use in the tropics where it will be
subjected to high ambient temperatures, humidity and very strong sunlight. It shall not
degrade under these conditions and shall be suitable for use with raw and treated water
including water dosed with chlorine. The sealant shall be odour and taint free from lead.
It shall be available in choice of colours and shall give a though, permanent seal, be
waterproof, non-staining and remain resilient. Sealing compounds for vertical and
horizontal joints shall be used complete with the appropriate quantity of primer as per
manufacturers instruction for use. The primers should ensure good adhesion to the
concrete and should be specially developed for respective sealing compounds. The
sealants shall be applied with pressure guns or without guns as specified by the
manufacturers. Sealing compound shall be fully cured before water is permitted to come
in contact.
The sealant material should be formulated as to have a storage period of one year at a
temperature of 40oC.
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14 EPOXY COATING,
BITUMINOUS, POLYMER
PAINTING
14.1 EPOXY COATING
14.1.1
General
Epoxy coating is to be applied to the internal surface of the unit wherever specified. The
thickness of epoxy film shall be 300 microns.
14.1.2
Materials
A solvent free epoxy coating like Araldite GY 255 manufactured by Hindustan CIBA
Geigy Limited, Bombay or equivalent product of FOSROC is to be used for forming the
film. Incase of use of an equivalent it should be got approved by the Employer placing
supply orders. Materials used and process of application to the concrete of other surfaces
should be strictly according to the instructions of the suppliers of the epoxy. Araldite GY
255 one part by weight is to be mixed with 1 part by weight of Hardener H Y 45. The
viscosity should be such that it is convenient for brush application.
14.1.3
Subsurface Preparation
The concrete surface should be cleaned thoroughly by sand blasting. The mild steel parts
also are to be cleaned to be free of grease and thoroughly sand blasted. The coverage
should not be more than 6 sq.m. for concrete and 5 sq.m. for mild steel per kg of epoxy
respectively.
The moisture content of concrete before application of epoxy coating shall be less than
4%. This has to be checked properly through a small sample. To achieve this epoxy
coating shall be done in hot season.
14.1.4
Curing
The curing should be done for 7 days at room temperature. if the temperature is less than
15c the space should be warmed up by incandescent lamps, heaters, blowers or infrared
lamp. The instructions of the supplier manufacturer of the product both as for use of
materials and application take priority over the above instructions and they should be
followed very rightly.
14.2 BITUMINOUS PAINTING

Two coats of bituminous paint of 80/100 grade, with 1.65 kg/m2 spread will be provided
on internal face of sludge sump.
14.2.1
Material
The material shall be of best quality un-pigmented bituminous base pain of such a
composition as to satisfy the requirements of IS-9862.with total volatile matter contained
in the paint shall not exceed 55% by weight.
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At least 95% of the solid materials shall be soluble, in carbon di-sulphide or in benzene,
and the closed flash point as determined in Abel's apparatus shall not be less than
(86F)30C. The paint shall remain liquid and retain its consistency at the ordinary
atmospheric temperature when packed in suitable containers. The drying time shall not
he less than 2 hours and not more than 8 hours, and after drying, paint shall not shoe any
surface cracks, tendencies to powder or discoloration due to weathering action or
expansion and contraction. It shall also be able to resist the action of acids and alkalis. It
shall not soften under the action of mineral turpentine.
The film resulting from brushing the material on a strip of tinned iron, 30 standard wire
gauge after being allowed to dry at room temperature not below (65F) 18.3C for 48
hours shall not, when bent double over a (quarter inch)6 mm dia rod, show any signs of
flaking or cracking. The time occupied for the actual bending shall not exceed one
second. When the paint has dried hard, a 4H pencil should not be capable of scratching
it. The weight of the paint shall be firm 0.83 to 1.25 kg per liter, the component of the
paint shall he such as not to react with water chlorinated or otherwise and develop
poisonous or harmful elements thereto.
The paint shall be of' Indian manufacture of approved make and quality
14.2.2
Application
All corners and junctions shall be properly rounded off to present a uniform and smooth
finish. After complete curing of the plaster, it will be allowed to day up. After drying
the moisture content shall be brought to a value less than 4% by using a below-lamp.
The surface should be well cleaned with smooth brush to make it dust free. The coating
shall be allowed to dry and kept in dry condition till final setting takes place.
14.3 POLYMER PAINTING

Polymer paint shall be elastomeric (450% elongation), thermoplastic, fire retardant,
coating skin tensile strength 18 to 21 kg/cm2, antifungal, antibacterial anticorrosive
graft polymer paint of approved make Meta Chem or equivalent.
Fire retardant coating shall confirm BS 3119 specifications
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15 DOOR, WINDOWS, GRILLS,

SHUTTERS, ETC.
IS:1003 (I)
IS:1003 (II)
IS:1038
IS:1081
IS:1361
IS:2202
IS:2202 (I)
IS:2202 (II)
IS:4020
IS:6248
IS:7452
IS:10451
IS:10521
:
:
:
:
:
:
:
:
:
:
:
:
:
Timber paneled and glazed door & ventilator shutters

Timber paneled and glazed window & ventilator shutters
Steel doors, windows & ventilators
Fixing & glazing of metal doors, windows & ventilators
Steel windows for industrial buildings
Wooden flush door shutter (solid core type)
Plywood face panels
Particle board and hardboard face panel
Methods of test for wooden flush doors
Metal rolling shutters & rolling grills
Hot rolled steel sections for doors, windows & ventilators
Steel sliding shutters
Collapsible gates
15.2 GENERAL
The items under this clause cover doors, windows, grills, rolling shutters, collapsible
gates etc. normally required to be provide in a building used whether for residential,
office, laboratory or industrial purpose.
Doors and windows Shutter shall be of Teakwood as specified in the bill of
quantities/drawings or as directed by the Engineer. The sizes of the above items and
locations of the same shall be as shown in the drawings.
The frames and shutters shall be of either steel or wood of thickness of members as
shown on the drawings. The material used shall be of good quality seasoned timber of
specified wood or rolled steel sections as the case may be.
They shall be provided with all necessary fittings like hold fasts, hinges, locking
arrangements stoppers, eyes and hooks, tower bolts, handles, fixing lugs etc., of sizes and
quality grade as specified.
They shall be provided in complete form including painting, glazing, fixing in position
true to level and plumb.
Steel rolling shutters shall be of approved make and shall conform to IS 6248 - 1979.
Metal rolling shutters and rolling grills.
The builders hardware shall all be as per relevant Indian Standards.
15.3 WOODWORK IN DOORS, WINDOWS, PARTITIONS, LOUVERS,

RAILINGS ETC.
Wood used for all work shall be the best of the respective class specified, and properly
seasoned by at least 6 months air drying, suitable for joiner's work, should be of natural
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growth, uniform in texture, straight grained, free from sapwood, dead knots, open
shakes, boreholes, rot, decay and any and all other defects and blemishes.
The thickness specified for joiner's wrought timbers are, unless otherwise specified, prior
to planning and 3 mm will be allowed from the thickness stated for each wrought faces.
All joining shall be wrought on all faces and finished off by hand with sandpaper, with
slightly rounded arises.
The joints shall be pinned with hard wood pins and put together with white lead. Jointing
shall be by means of mortise and tenor or dovetailed joints as approved.
Any joiner's work which shall split, fracture, shrink, or show flaws or other defects due
to unsoundness, inadequate seasoning or bad workmanship, shall be removed and
replaced with sound material at the Contractor's expense.
Doors, windows and ventilator frames, transoms and mullions shall be rebated. All
dimensions shall be as per drawings. The top framing member of doors and top and
bottom framing of windows and ventilators shall project about to mm below finished
floor. Surface coming in contact with brickwork shall be painted with bitumen as
directed by the Engineer-in-Charge. Each of the door and window frames shall be
provided with 3 Nos. M. S. 225 x 25 x 6 flat split holdfasts on each side. These holdfasts
shall be embedded in masonry of concrete work. The work shall conform to IS:4021.
The doors shall be paneled or solid flush doors as described in the item of work. All
flush doors shall be supplied with approved fittings such as hinges, mortise lock of
approved make with handles on both sides, oxidised brass tower bolts and latch
arrangements, door stops etc. and as shown in drawings but exclusive of door closers.
Door closers, where separately specified shall be of heavy duty hydraulic type to be
approved by Engineer-in-Charge Paneled doors shall have the same fittings except in
place of union lock, an aldrop shall be provided. Each door leaf shall have two 250 mm
tower bolts, two aluminum or oxidised brass handles, and one door stopper be made of
weatherproof plywood. Flush doors shall conform to IS:2202 (Part-I).
Doors will generally have no sills but if a few have to be provided, the Contractor shall
do so at no extra cost to the Owner.
The type of window shall be as specified. Each shutter shall have one pair of hinges, two
tower bolts (one 225 mm long and another 150 mm long), one handle and one hook with
eye and pegstay. Ventilators shall have two M. S. hold fasts and hinges, one handle and
one hook and eye at each and one small tower bolt in the centre. Where so directed by
the Engineer-in-Charge, the doors and windows shall be provided with parliamentary
type hinges at no extra cost.
The workmanship of all door and window shutters shall conform to the requirements of
IS:1003 (Part-I & II) and IS:2202 (Part-I). If required, flush door panels shall be got
tested as per IS:4020.
Cupboards, almirahs and shelves shall be provided as per Engineer-in-Charge. The doors
could be of either hinged type or sliding type as approved by the Engineer-in-Charge. All
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dimensions as furnished in the drawings shall be followed. Fixtures and fittings as shown
on drawings or as directed by Engineer-in-Charge shall be used.
Railings and architraves shall conform to the shape shown on drawings or as approved
and fixed by means of screws (counter sunk or otherwise) or bolts.
The finish expected is of a very high order and the work shall be all-inclusive weather or
not all detailed specifications have been spelt out and the work shall be free from
blemish.
No iron bars or grills are proposed to be provided in the windows or ventilators. Glass
louvred ventilators where specified shall be provided.
Glazed windows, louvres, ventilators and doors shall be provided with either clear or
pinheaded glass 5.5 mm thick which shall be free from all blemishes and shall conform
to IS:1761. It should be clearly understood that glass which does not have uniform
refractive index or which is wavy will be rejected. Woodwork shall not be painted, oiled
or otherwise treated before the Engineer has approved it.
15.4 STEEL DOORS, WINDOWS AND FITTINGS

The steel doors, windows, ventilators shall conform or IS:4351 and IS:1038. All steel
doors windows, ventilators, louvres etc. shall be of sizes as specified and conform to the
description in the respective item of work. Whether or not specifically mentioned, all
fixtures and fittings necessary for the satisfactory operation of the doors and windows
shall be provided. Doors, windows and ventilators shall be obtained from an approved
manufacturer. Specific approval for such purchase shall be obtained before hand. Sample
shall also be got approved before further manufacture starts, unless this is waived in
writing by the Engineer-in-Charge. All steel doors shall be of pressed steel (18 gauge)
flush type with or without removable transome. All doors shall be provided with a three
way bolting device and locking arrangement with duplicate keys and handles of both
sides and operable from either side. The Contractor shall obtain windows with friction
hinges in place of windows with pegstays if so directed by the Engineer-in-Charge. For
centre hung and top hung ventilators suitable spring catch/pulley and chord arrangement
shall be provided for facility of opening. Whenever fly mesh over windows have been
called for, they shall be fixed on the window and suitable lever type or rototype
arrangement shall be provided for opening or closing of the glazed panels from inside.
Prior approval of Engineer shall be taken before order is placed with the manufacturer.
Where specified, steel doors supplied shall be airtight. For this purpose, the Contractor
shall provide necessary padding material such as rubber, felt or any other approved
material.
15.5 ROLLING SHUTTERS

The rolling shutters shall conform to the size indicated in drawings and shall be of
quality specified in the Schedule of Quantities. The rolling slats shall be in one piece and
be made of heavy gauge steel sheets minimum 18 SWG in thickness. A cylindrical hood
shall be provided on the top to enclose the shutter when it is open. The rolling shutters
shall be provided with suitable locking arrangements and deep channel guides, In case
galvanised rolling shutters are specified the rolling shutter shall be made of hot dip
galvanised slats, hood, deep channel guides all preferably in one piece.
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In case of hand operated pull & push type rolling shutters of sizes larger than 10 sq.m. in
area and in case of very large gear operated and/or as directed by the Engineer, rolling
shutters shall be provided with ball bearings for smooth & efficient operation. In case of
large rolling shutters & depending upon local wind conditions, the rolling shutters should
be provided with special locking type of wider channel guides or it shall be provided
with central moveable channel supports to take up design wind pressures in the area.
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16 HAND RAILING
Hand railing and vertical posts shall be made from galvanised mild steel pipes and
fittings. The design of the railing shall be approved by the Engineer to whom the
Contractor shall submit manufacturer's drawings showing positions of vertical posts,
joints, expansion joints and joint details and all fixing details. Fabrication shall not start
until these drawings have approved by the Engineer.
Hand railing and vertical posts fabricated from galvanised mild steel pipes and fittings
shall conform to the following requirements.
The height of the top railing shall be 1000 mm above finished floor level unless
otherwise shown. There shall be total 3 horizontal rows. Top row shall be of 32 mm dia
and middle two rows shall be of 25 mm dia GI medium class pipe. The lower railing
shall 550 mm above finished floor and Toe plate should be provided at the bottom of the
rail of the size100mm wide x 5 mm thick subject to the Engineer's approval these and
other leading dimensions may be varied slightly to suit manufacturer's standard products.
a. Unless otherwise shown, vertical posts shall be made of galvanised mild steel tubes
(medium class) of 40 mm nominal bore and fittings such as Tees, Bends, Crossed
etc. of heavy class conforming to IS:1239.
b. Unless otherwise shown, top horizontal post shall be made of galvanised mild steel
tubes (medium class) of 32 mm nominal bore and fittings such as Tees, Bends,
Crossed etc. of heavy class conforming to IS:1239.
c. Unless otherwise shown, lower two horizontal post shall be made of galvanised mild
steel tubes (medium class) of 25 mm nominal bore and fittings such as Tees, Bends,
Crossed etc. of heavy class conforming to IS:1239.
d. In general the vertical posts shall be spaced at 1.5 metre c/c and shall be built into the
concrete or bolted to the MS plate embedded in concrete as shown on detailed
drawing.
e. Hand railing and vertical posts shall be painted with 2 coats of approved paint.
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17 RUNGS
Rungs shall be provided in all manholes/inspection chambers/pumping stations over 0.6
mm in depth and shall be of cast iron conforming to IS:5455. These rungs shall be fixed
staggered in two vertical runs, 300 mm apart horizontally and 300 mm c/c vertically. The
top rung shall be 450 mm below the manhole/inspection chamber cover and the lowest
not more than 300 mm above the benching. The rungs shall be of 20 mm diameter with
epoxy paint for corrosion resistance or equivalent as approved by Engineer in Charge.
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18 PIPING WORK
18.1 REINFORCED CEMENT CONCRETE PIPES (CLASS NP 3)
18.1.1
Applicable Codes
Laying of pipes and fittings/ special shall comply with all currently applicable statues,
regulation, standards and codes. In particular, the following standards, unless otherwise
specified herein, shall be referred to. In all cases the latest revision of the standards/
codes shall be referred to.
(a)
IS: 783
Code of practice for laying of concrete pipes
(b)
IS 458
Specification for precast concrete pipes (with

and without reinforcement)
(c)
IS 3597 of 1966 I.S.458
Method of tests for concrete pipes
(d)
IS 5382
Specifications for rubber sealing rings for gas

mains, water mains
ISI Marked RCC NP3 Socket and Spigot pipes conforming to IS: 458/1988 shall only be
used under this contract. Sulphate resistance cement shall be used in manufacturing of
the pipes. The Pipes to be used shall be perfectly cylindrical; sound without any damage.
The pipes shall be suitable for rubber jointing. The rubber shall be of good quality
conforming to relevant I.S. Specifications and duly inspected by the approved third party
inspecting agency.
18.1.2
Laying of Pipes
Care shall be exercised in loading, transporting, and unloading of concrete Pipes.

Handling shall be such as to avoid impact. Gradual unloading by inclined plane or by
chain block for higher, diameter is recommended.
Pipes shall be lowered into the trench carefully, mechanical appliances may be used.
Under no circumstances shall the pipes be dropped or dumped into the trench without
proper support.
All pipe sections and connections shall be inspected carefully before being laid. Broken
or defective pipes or connections shall not be used, and if such defective sections are
found, the same shall be removed by the Contractor at his cost and risk and shall have to
be rebuilt with good pipes and materials.
All lumps, blisters and excess coating materials shall be removed gently from the ends of
each pipes and they shall be wiped clean and dry before the pipe is laid.
For spigot and socket pipes, with rubber jointing rings, proper jointing shall be ensured.
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Every precaution shall be taken to prevent foreign materials from entering in to pipe
when it is being placed in the trench.
Pipes shall be laid true to line and grade as specified.
Laying of pipes shall always proceed upgrade of a slope. However, for pipes having
spigot and socket joints, the socket ends shall face upstream.
The pipe shall be secured in place with approved back fill material or concrete tamped
under it except at the joint portions.
At times when pipe laying is not in progress the open ends of pipe shall be closed by a
water tight plug or canvas or other means approved by the Engineer in charge.
Trench shall be kept free from water until the material in the joints has hardened. If
bailing out of water is required for excavation and laying of pipe no extra payment for
bailing out water shall be made in any form and this shall be done by the Contractor at
his own cost.
When the pipe is closed and the trench liable to be flooded by water, care shall be taken
to prevent the pipe from floating.
Walking or working on the completed sewer shall not be permitted until the trench has
been back filled to a height of at least 30 cm over a pipe.
The cutting of pipes for inserting fittings or closure shall be done in a neat and workman
like manner without danger to the pipe so as to leave a smooth surface and at right angles
to the axis of the pipe.
Before connecting a pipe to a manhole, a relieving arch or any other similar protection
device shall be made in the manhole for the safety of the pipe.
The pipe when laid shall not be subjected to super imposed load beyond what the pipe
can safely with stand
The pipe shall be laid along the side of the trench, each pipe in its proper position for
laying with an extra pipe after every 20 nos. to allow for cutting, if necessary. Where the
trench crosses a road or place where such distribution is inadmissible, the pipes shall be
stacked in heaps at each end, sufficient to fill in the length. As far as possible, pipe shall
be laid straight in rising gradient. It should be possible to empty the pipe readily and
completely. The socket end of the pipe shall be facing up hill. All the pipes shall be used
in standard length as far as possible. Cut length may be used only where necessary, to
make up to exact length. All the pipes shall be first inspected for any damage and cracks.
No cracked or damaged pipes shall be used.
The connection to an existing sewer shall be done through manhole chamber. However,
before connecting a pipe to a manhole, a relieving arch or any other similar protection
device shall be made in the manhole for the safety of the pipe.
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18.1.3
Pipe Bedding
The pipe bedding of class A, B, C will be provided as per requirement and instructions of
Engineer in charge according to approved design and drawings, as per site condition.
In places where the natural foundation is inadequate, the pipes shall be laid either in a
concrete cradle, supported on proper foundation or on any other suitable designed
structure, to be approved by the department.
Pipes laid in trenches in earth shall be bedded evenly and firmly and as for as the
haunches of the pipe so as to safely transmit the load expected from the back fill through
the pipe to the bed. This shall be done either by excavating the bottom of the trench to fit
the curve and around the curve of the pipe to form an even bed, necessary provision shall
be made for joints, wherever required.
When the pipe is laid in trench in rock, hard clay, shale or other hard material, the space
below the pipe shall be excavated and replaced with an equalising bed of sand or
compacted earth. In no case, shall the pipe be laid directly on such hard material.
Wherever required, the encasing of pipe shall be done with concrete. Suitable nos. of
manholes shall be provided at proper interval or at the places where there is change of
direction of the alignment and grade as per the direction of Engineer in charge.
18.1.4
Jointing
Each concrete pipe with the rubber ring accurately positioned on the spigot shall be
pushed well home into the socket of the previously laid pipe by means of uniformity
applied pressure with the aid of a jack or similar appliance.
Concrete pipes of the spigot and socket type with roll on rubber rings shall be used, and
the manufacturers instructions shall be deemed to form a part of this specification.
Rubber rings shall be lubricated before making the joint and the lubricant shall only be
soft soap water or an approved lubricant supplied by the manufacture.
In case of RCC Pipe entering or leaving a manhole a flexible joint may be provided at
least within 0.60 M from the outer end of the manhole.
The spigot and socket pipes shall be jointed with rubber joints for which rubber gasket
shall be arranged by Contractor and such rubber gaskets / rings shall confirm to relevant
I.S. Specifications. The department shall provide no jointing material.
The section of the pipe shall be jointed together in such a manner that there shall be as
little unevenness as possible along the inside of the pipe.
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18.1.5
Testing
All pipelines shall be subjected to a test pressure of at least 2.50 m head of water, at the
highest point of the section under test.
The tolerance of two liters per centimeter of diameter per kilometer shall be allowed
during a period of ten minutes.
Before commencing the hydraulic test the pipelines shall be filled with water and
maintained full for 24 hours by adding water, if necessary under a head of 60 cms of
water.
The test shall be carried out by suitably plugging the low end of the drains and the ends
of connections, if any and filling the system with water.
A knuckle bend shall be temporarily jointed in at the top end and a sufficient length of
vertical pipe jointed to it so as to provide the required test head, or the top end may be
plugged with a connection to a hose ending, in funnel which could be raised or lowered
till the required head is obtained and fixed suitably for observation.
If any leakage is found visible then the defective part of the work should be cut out and
made good. A slight amount of sweating which is uniform may be over looked but
excessive sweating form a particular pipe or joint shall be watched for and taken as
indicating a defect to be made good.
Any joint found leaking or sweating shall be rectified or embedded into 15 cm layer of
cement concrete (1:2:4) 30 Cm in length and the section re-tested.
The testing of the rubber rings shall confirm to I.S 3400 of 1965 and also I.S. 5382 of
1969.However, after the delivery of the pipes made at sites, the Contractor shall have to
arrange for visual tests for whole of the lot, received from time to time at site.
18.1.6
Inspection of the Joints
After the joints of any pipes in underground work have thoroughly set, the Engineer in
charge (or any person whom he may appoint) any inspect the joints and if he has any
doubt as to their soundness he may required the Contractors to cut open and clean away
the cement or lead as the case may be of any joint that he may select and to make good
the same at their expense provided that unless some defect be found, they shall not be
required to open more than one joint in 20 M of pipe length if the defect be found the
Engineer in charge may direct them to open as many joints as he may deem necessary.
18.1.7
Cleaning of the Pipes
As soon as a stretch of pipe whether of stoneware or Cast iron or R.C. Pipes has been
laid from manhole to manhole, the Contractor shall run through the pipes both
backwards and forwards a double disc or solid or closed cylinder 75 mm less in diameter
than the internal diameter of the pipes. The open end of an incomplete stretch of pipeline
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shall be securely closed as may be directed by the Engineer in charge to prevent entry of
mud or silt etc.
If as a result of the removal of any obstruction the Engineer in charge considers that
damages may have been caused to the pipelines, he shall be entitled to order the length to
be re tested at the expense of the Contractor. Should such retest prove unsatisfactory the
Contractor shall at his own expenses amend the work and carry out such further tests as
are required by the Engineer in charge.
It shall also be ascertained by the Contractors that each stretch from manhole to manhole
is absolute clear and without any obstruction by means of visual examination of the
interior of the pipe line suitably enlightened by projected sunlight or otherwise.
18.1.8
Fracture of Pipes
In the event of pipes being fractured after being laid whether due to imperfect loads have
or the material for refilling have been improperly selected or to any other cause, the
Contractor in every instance will be held responsible and will be called upon to replace
such defective pipes at his own cost, if such defect appears before the expiration of the
period of maintenance.
Any pipe or length of pipes found to be defective shall be immediately removed and
replaced at the Contractors expense and leaking joints shall be remade.The inspections
and tests shall then be repeated as often as necessary until the whole line under
inspection or test is accepted by the Engineer in charge.
18.1.9
All works to be clear clean and perfect
The Contractors shall after completion or whenever required by the Engineer in charge,
prove all pipes and fitting to be clear clean and perfect, and for this purpose shall at their
own expense and in the presence of the Engineer in charge or his appointee, provide
suitable instruments and appliances and pass them through the pipes and shall, if
required, throw in water and show that it passes freely through every portion of the work.
Brick, mortar and rubbish shall not be allowed to fall into the manholes of sewer lines
while fixing or if allowed, shall be removed by the Contractors at their own expense.
18.1.10 Measurement of Pipes

All pipes be measured according to the work actually done by them and no allowance
will be made for any waste in cutting to the exact length required. An exception to this
will be made only in the case of short branches of 100 mm dia stoneware pipe, which be
treated in the manner here after described with regard to fittings. The Contractors, shall
be under obligation to use the pieces or part of the pieces cut off from 100 mm stoneware
pipes, if it be deemed by the Engineer in charge practicable to do so; and no further
payments shall be made for the same to the Contractors. A socket attached to be straight
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pipe will not be measured, but a spigot end of a straight pipe whether such end be free
for entering into a socket will be measured to its full length.
A bend, junction, or any separate piece of fitting which may have necessarily been cut
for the exigencies of the work will be taken into account as if whole provided that the
cutting has been done properly and that the portion used in the work is sound. This
clause shall not apply to a straight pipe under any circumstances, except only at 100 mm
dia stoneware pipes as here in before described. In measuring the lengths of pipes laid
deduction shall be made for the lengths of channels between the inside face of the walls
of manholes.
18.2 CENTRIFUGALLY CAST (SPUN) DUCTILE IRON PIPE

The material of construction for the pipe line shall be Ductle Iron (DI) with internal
cement mortar lining (Class K7)
18.2.1
Scope of Work
Laying in trenches centrifugally cast (spun) ductile iron pressure pipes of class K7 as per
IS: 8329: 2000 (Code of practice for use and laying of ductile iron pipes) including
jointing (tyton push joint), bends of all degrees, tees, collars, tapers, crosses, flange
sockets & spigots, branched pipes, chamfering etc. where required. Testing of pipes
should be done as per IS: 8329: 1994.
18.2.2
Applicable Codes
Important IS codes applicable in case of Ductile iron pipes, fittings, jointing & laying
are:
18.2.3
Sr.
IS Codes
Description
8329
9523
3
4
12288
12820
Centrifugally cast (spun) ductile iron pressure pipes for water,

gas and sewage specification
Ductile iron fittings for pressure pipes for water, gas and
sewage
Code of practice for use and laying of ductile iron pipes
Dimensional requirements of rubber gasket for mechanical
joints and push-on joints for use with cast iron pipes and
fittings for carrying water, gas and sewage
Pipe & Pipe Joint
Ductile iron pipe of K7 class of socket & spigot end suitable for tyton push on joints or
mechanical joints is recommended for the project wherever required.
Push-on-Joint: A flexible joint in which an elastomeric gasket is located in the socket
and the joint assembly is effected by entering the spigot through the gasket into the
socket. Allowable angle of deflection for push on joints are tabulated below.
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Nominal Diameter,mm
80 to 200
250 to 350
400
450 to 600
700 to 900
Allowable angle of deflection

5.0 degree
4.0 degree
3.5 degree
3.0 degree
2.5 degree
Mechanical Joint: A flexible joint in which an elastimeric gasket is located in the

socket, sealing being obtained by applying pressure to the gasket by means of a gland
bolted to the socket. Allowable angle of deflection for mechanical joints is tabulated
below.
Nominal Diameter,mm
Allowable angle of deflection
80 to 300
5 degree
350
4 degree, 50 seconds
400
450
500
600
700
Ductile iron pipe having screwed on flanges and welded on flanges shall conform to the
requirement of Table 4 & 13 of IS 8329:1994. Shielded Nickel- iron electrodes is the
preferred material for manual arc welding of flanges. Flange shall preferably be of
ductile iron.
For screwed on flanged pipes, the method of screwing and the exact form of thread are
left to the discretion of the manufacturer in view of the fact that flanges are never
removed after screwing on the barrels of the pipes.
18.2.4
Rubber Gasket
Rubber gasket for use with push-on-joints or mechanical joints shall conform to IS
12820:1989.
Rubber gasket for use with flanged joints shall conform to IS 638: 1979.
Rubber gasket shall be compatible with the fluid to be conveyed for materials, pressure
and temperature. While conveying potable water the gaskets should not deteriorate the
quality of water or should not impart or odour.
18.2.5
Hydrostatic Test
All pipes shall be tested hydrostatically at a pressure specified below. To perform the
test, pressure shall be applied internally and shall be steadily maintained for a period of
minimum 15 seconds during which the pipes may be struck moderately with a 700 g
hammer. The pipes shall withstand the pressure test and shall not show any sign of
leakage, sweating or other defects of any kind.
Nominal Diameter, mm
80 - 300
350 600
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18.2.6
Class
K9
K9
Working Pressure
1.8 MPa
1.8 MPa
Max. works test pressure
5.0 MPa
4.0 MPa
Max. site test pressure
3.2 MPa
2.4 MPa
Pipe Lining
Lining of pipes & fittings are recommended for corrosion resistance & improved
hydraulic carrying capacity.
External surface of pipe & fittings is protected with epoxy coating material having a
minimum dry film thickness of 80 microns.
Pipe should be internally lined with sulphate resistance cement mortar of minimum
thickness as given below. The internal lining should be done by centrifugal method.
Dia of pipe, mm
Thickness of lining, mm
Upto 250
300 600
700 900
Cement lining of the fitting is done with spray gun and then by hand to give a smooth
and uniform thickness, as it is not practicable to utilise centrifugal methods.
18.2.7
Use and Laying of Ductile Iron Pipe
Excavation, backfilling, laying & jointing of pipe should be strictly as per IS: 122881987 (Code of practice for Use & laying of Ductile Iron Pipes).
The width of trench at bottom between the faces of sheeting shall be such as to provide
300mm clearance on either side of the pipe. Trenches may require extra width to permit
placement of timber supports, sheeting, bracing and appurtenances if they are employed.
Holes for pipe socket should be provided at each joint, but should be no longer than
necessary for joint assembly and for assurance that pipe barrels will lay flat on the trench
bottom.
Pipe bottom should be true and even in order to provide support for full length of the
pipe barrel.
Special consideration should be given to the depth of the trench. Minimum earth cover
over pipeline should not be less than 1000mm. It may be necessary to increase the depth
of pipeline to avoid land drains or in the vicinity of heavy traffic roads, railways or other
crossings.
A minimum earth cushion of 150mm depth should be provided below the pipe line to
protect the pipe and its coating. Earth cushion should be of sand or fine graded excavated
material.
Back Filling: For the purpose of back filling, the depth of the trench shall be considered
as divided into the following three zones from the bottom of the trench to its top.
Zone A : From the bottom of the trench to the level of the centre line of the pipe.
Backfilling in zone A shall be done by hand with sand, fine gravel or other fine graded
material placed in layers of 150mm and compacted by tamping. The back filling material
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shall be deposited in the trench for its full width of each side of the pipe, fitting and
appurtenances simultaneously.
Zone B : From the level of the centre line of the pipe to a level 300mm above the top of
the pipe. Backfilling in zone B shall be done by hand or approved mechanical methods in
layers of 150mm. The type of back fill material to be used and the method of placing and
consolidating shall be prescribed by the executing authority keeping in view the local
condition.
Zone C : From a level 300mm above the top of the pipe to the top of the trench. Back
filling in zone C shall be done by hand or approved mechanical methods. The types of
back fill material and method of filling shall be as prescribed by the executing authority.
When pipes are laid under roads and pavement subjected to heavy traffic loads, the
trenches may be covered with reinforced concrete slabs of suitable dimensions.
Laying of pipe: Pipes shall be lowered into the trench with tackle suitable for the weight
of pipes. For smaller sizes, up to 250mm nominal bore, the pipe may be lowered by the
use of ropes but for heavier pipes, either a well designed set of shear legs or mobile crane
should be used.
On gradients of 1:15 or steeper, precautions shall be taken to ensure that the spigot of the
pipe being laid does not move into or out of the socket of the laid pipe during the jointing
operations. As soon as the joint assembly has been completed, the pipe should be held
firmly in position while the trench is backfilled over the barrel of the pipe. The backfill
should be well compacted.
Supporting pipes above ground: It is recommended that above ground installations of
spigot and socket pipes be provided with one support per pipe, the supports being
positioned behind the socket of each pipe. If necessary, unsupported spans between 4 and
6 m may be obtained by positioning the pipe supports relative to the pipe joints. The
recommended maximum unsupported span for flanged pipe is 8m.
Pipe should be fixed to the supports with mild steel straps so that axial movement sue to
expansion or contraction resulting from temperature fluctuation, is taken up at individual
joints in the pipe line.
Cutting of pipe for inserting valves, fittings, etc, shall be done as per para 5.4 of IS:
12288 1987.
Pipeline Anchorage: All pipelines having unanchored flexible joints require anchorage at
the changes of directions and at dead ends to resist the static thrusts developed by
internal pressure. Anchorage is also required on steep slopes to resist pipe against
slippage.
18.2.8
Hydraulic Testing of Pipeline
After a new pipeline is laid and jointed, testing shall be done for:
Mechanical soundness and leak tightness of pipes and fittings,
Leak tightness of joints, and
Soundness of any construction work, in particular that of the anchorages.
The completed pipeline may be tested either in one length or in sections. The length of
section depends upon the availability of suitable water, number of joints to be inspected
and difference in elevation between one part of the pipeline and another. The maximum
field hydrostatic test pressure for ductile iron pipelines with flexible joints as per IS
12288: 1987 is tabulated below.
Nominal Bore,mm
Maximum field hydrostatic test pressure, N/mm2
Up to 300
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18.2.9
350 to 600
3.0
700 to 1200
2.1
Restoration and cleaning up
Where any road, payment, shrubbery, fences, poles or other property and surface
structures have been damaged, removed or disturbed during the course of work, such
property and surface structures shall be replaced or repaired after completion of work.
All roads, pavements, paved footpaths, curbing, gutters, shrubbery, fences, poles or other
property and surface structures removed of disturbed, as a part of the work shall be
restored to a condition equal to that before the work began.
All surplus materials, and all tools and temporary structures shall be removed from the
site as directed by the executing authority.
18.3 GENERAL SPECIFICATIONS FOR CI PIPING WORK

18.3.1
Cast Iron Pipe and Specials
1. All CI Pipes and specials supplied for this contract shall confirm to the following
specifications:
a. IS 1536 - 1976 Specification for centrifugal cast (Spun) iron pressure pipes for
water, gas and sewage.
b. IS 1538 - 1976 (Part V) Specification for cast iron fittings for pressure pipes.
Wherever reference is made for Indian Standard Specification the latest specification is
applied.
2.All cast iron pipes supplied shall confirm to class LA of Indian Standard specifications.
The work test pressure and the hydrostatic test pressure shall be as follows:
a. Hydrostatic Test pressure at works 3.5 N/mm2 (35 kg/sq.cm.)
b. Hydrostatic test pressure after installation 1.2 N/mm2 (12 kg/sq.cm.) All pipes to
be supplied in this contract shall have SBR quantity rubber gaskets rubber tyton
joints as per BIS 5282, 12820 with the spigot end suitably chamfered for smooth
entry of pipe in the socket fitted with SBR quality rubber gasket. Care shall be
taken to ensure that fittings fit easily into this pipe.
c. Each pipe shall be coated in accordance to Indian Standard specification. All
pipe shall be marked as under:
Manufacturers name or identification mark
The Nominal Diameter
Class Reference
Mass of pipe
The number of this Indian Standard and
The last two digits of the year of manufacture.
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18.3.2
Cast Iron fittings
All cast iron fittings supplied shall confirm to heavy class of IS:1538, Part 1 to 23. The
work of Test pressure and Hydrostatic test pressure shall be as follow:
18.3.2.1 Test Pressure
300 mm to 600 mm
2.5 N/sq.mm (25 kg/sq.cm)
600 mm to 1200 mm
1.0 N/sq.mm (10 kg/sq.cm)
Where non standard fittings are required in special locations, this shall be supplied of
steel of minimum plate thickness of 6 mm and fabricated as per drawings and directions
of Engineer-in-Charge. These mild steel fittings will be specially protected against
corrosion with painting as shown on drawing.
All Standard fittings marked as under:
a.
Manufacturers name or identification mark,
b.
The Nominal Diameter,
c.
Class Reference,
d.
Mass of pipe,
e.
The Number of this Indian Standard, and
f.
The last two digits of the year of manufacturer.
18.4 SPECIFICATION FOR LAYING, JOINTING & TESTING OF CI

PIPE
18.4.1
Stacking
The pipes and specials shall be handled with sufficient care to avoid damage to them.
These shall be lined up on one side of the alignment of the trench, socket facing uphill or
in the direction of flow of water.
18.4.2
Trench For CI Pipes and Specials
The trenches for the pipes shall be excavated to lines and levels as directed. The bed of
the trench shall have to be truly and evenly dressed throughout from one change of grade
to next. The gradient is to be set out by means of bonning rods and the required depth is
excavated at any point. The depth of the trench shall not be less than 1 meter measured
from the top of the pipe to the surface of the ground under roads crossing and not less
than 0.75m elsewhere.
The width of the trench shall be the nominal diameter of the pipe plus 40 cm. but it shall
not be less than 60 cm. in case of all kinds of soils excluding rock and not less than 55
cm. in case of rock. The bed of the trench, if in soft or made up earth, shall be well
watered and rammed before laying the pipes and the depressions if any shall be properly
filled with earth and consolidated in 20 cm. layers. If the rock is met with, it shall be
removed to 15 cm. below the level of the pipe and the trench will be refilled with
excavated materials and consolidated to the required grade.
The excavated materials shall not be placed within 1 meter or half of the depth of the
trench whichever is greater from the edge of the trench.
The materials excavated shall be separated and stacked so that in refilling they may be
re-laid and compacted in the same order to the satisfaction of the NMC. The trench shall
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be kept free of water. Shoring and Timbering shall be provided wherever required.
Excavation below water table shall be done after dewatering the trenches.
After the excavation of the trench is completed, hollows shall be cut at the required
positions to receive the sockets of the pipes and these hollows shall be sufficient depth to
ensure that the barrels of the pipes shall rest throughout their entire length on the solid
ground and that sufficient spaces left for jointing to underside of the pipe joint. These
socket holes shall be refilled with sand after jointing the pipe.
All types of pipes water mains, cables, etc. met within the course of excavation shall be
carefully protected and supported. Care shall be taken not to disturb the electrical and
communication cables.
18.4.3
Laying of Pipes and Specials
Before being laid the pipes shall be examined to see that there are no cracks or defects.
The cracked or defective pipes shall be summarily rejected. The pipes shall be
thoroughly cleaned of all dust and dirt and special care shall be taken to clean the inside
of the socket and outside of the spigots.
The pipes shall be lowered into the trench by means of suitable pulley blocks, sheet legs,
chains ropes etc. In no case the pipes shall be rolled and dropped into the trench. After
lowering, the pipes shall be arranged so that the spigot of one pipe shall be carefully
centered into the socket of the next pipe, and pushed to the full distance that it can go.
The pipeline shall be laid to the levels required. Specials shall also be laid in their proper
position as stated above. For pipe bedding PCC of grade M10 shall be used for which
payment shall be done as per PCC 1:3:6 item of work.
Where so directed, the pipes and specials may be laid on masonry or concrete pillars.
The pipe laid on the level ground shall be laid with socket facing the direction of the
flow of water. In all other cases, the sockets shall be laid facing up hill.
Any deviation either in plan or elevation less than 11 degree shall be effected by
laying the straight pipes round a flat curve, of such radius that minimum thickness of
lead at the face of the socket shall not be reduced below 6 mm. or the opening between
spigot and socket increased beyond 12 mm at any point. A deviation of about 2
degree can be affected at each joint in this way. At the end of each days work, the last
pipe laid shall have its open ends securely closed with a wooden plug to prevent entry of
water, soil, rats and any other foreign matter into the pipe.
Cement concrete thrust blocks of suitable design as approved by the Owner/ Consultants
shall be provided at 45 degree and 90 degree bands of the pipes and also at places where
there is likelihood of thrust so as to withstand the dynamic and static forces developed
due to water in the pipe line. The thrust blocks shall be made after the joints have been
made.
18.4.4
Jointing
Jointing shall be carried out using approved quality rubber rings.
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18.4.5
Testing of Joints
After laying and jointing, the pipes and fittings shall be inspected under working
conditions of pressure and flow. Any joint found leaking shall be redone and all leaking
pipes removed and replaced without extra cost. For hydraulic tests, all pipes shall be kept
under test for 15sec at works and shall withstand hydrostatic test pressure as specified in
BIS 1536/1989. The pipes shall be slowly and carefully charged with water allowing all
air to escape and avoiding all shock or water hammer.
The draw off takes and stopcocks shall then be closed and specified hydraulic pressure
shall be applied gradually. Pressure gauge must be accurate and preferably should have
been recalibrate before the test. The test pump having been stopped the test pressure
should maintain without loss for at least half an hour. The pipes and fittings shall be
tested in sections as the work of laying proceeds, keeping the joints exposed for
inspection during the testing.
18.4.6
Backfilling
The trenches prepared for laying of pipes shall be backfilled as described under Chap. 2.
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19 VALVES
Gate Valves shall be either solid wedge or knife gates unless specifically defined on the
drawings.
19.1 SOLID WEDGE GATE-TYPE SLUICE VALVES

19.1.1.1 General
All valves shall be double-flanged. Valves of Indian manufacture and in the size ranging
50mm to 300mm shall conform to BIS 780 and those of size ranging from 350 mm and
larger to BIS:2906. Imported valves shall conform to the relevant British or American
Standards. The materials used in construction, the design and all other relevant features
shall be such that the valves are entirely suitable for use on sewer/sludge pipelines, force
mains and within sewage pumping stations. Valve shall be of suitable pressure rating
which shall not be less than twice the normal operating pressure. PN rating
For duty heads below
100 m PN1.0
For duty heads above
100 m PN1.6
19.1.1.2 Design
The design of the valves will be such that erosion, cavitation, vibration and head loss (in
the fully open position) shall be a minimum external lubrication. The valves should be
capable of being opened and closed against working pressure which exceed the
maximum working pressures by 15 percent.
19.1.1.3 Materials
The materials used for the manufacture of each component shall be the best available for
the specific purpose and shall not, in any case be inferior to the following:
Cast Iron
Stainless Steel
Gun Metal
Cast Steel
:
:
:
:
BIS. 210 Grade 20

BIS. 1570 Grade, BS 970 Type EN, ASTM A 473.
BIS.1400-LG 2 -C or the equivalent Indian Std.
Plain Carbon Steel complying with BIS. 1570 Grade, or BS: 970
Grade 431 S 29.
19.1.1.4 Valve Bodies

a. Castings
The structure of the castings shall be homogeneous and free from non-metallic inclusions
and other injurious defects. All surfaces of castings, which are not machined shall be
smooth and shall be carefully fettled to remove all foundry irregularities.
b. Forgings
All major stress bearing forgings shall be made to a standard specification, which shall
be submitted if required to the Engineer-in-Charge for approval before work is
commenced. Forging shall be subjected to non-destructive tests to detect flaws if any.
Forging shall be heat treated for the relief of residual stresses. The name of the maker
and particulars of the heat treatment proposed for such forging shall be submitted to the
NMC. The Engineer-in-Charge or his inspector may inspect such forging at the place of
manufacture with a representative of the Contractor.
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c. Workmanship
Workmanship and general finish shall be of first class commercial quality and in
accordance with best workshop practice.
All similar items of the valve and their component parts shall be completely
interchangeable. Spare parts shall be manufactured from the same materials as the
originals and shall fit in place of all similar items.
All parts, which can be worn or damaged by dust shall be totally enclosed in dust proof
housings.
Protective coating shall comply with BS 1218 Clause 16, for use in tropics, or BIS 2906,
Clause 7.
19.1.1.5 Spindle Details
The spindles shall be of Bronze and to permit the solid wedge gate to be so raised as to
permit an unimpeded flow passage through the valve in open position. Where
handwheels are provided the direction of rotation and the words OPEN shall be
marked prominently on the upper side. All spindles contacting surfaces in the valve body
shall be bushed with gunmetal.
19.1.1.6 Valve Gates
Each face of the gate shall be lined with heavy gunmetal rings, which will match with
corresponding rings in the body. The rings shall be force fitted by special fixtures and
riveted in the case of valves in the size range 450 mm and larger. When finally
assembled, the body and wedge faces shall provide a watertight bearing surface. When
shut, the gates shall ride on the body seats, to allow for wear.
19.1.1.7 Operation
The tops of the spindles or gears operated with extension spindles or tee keys shall be
provided with caps of dimensions conforming to BIS 2906 Table III. The direction of
opening shall be indicated on the caps.
19.1.1.8 Lubrication
At the points where lubrication is needed the Contractor shall furnish full details of the
method to be employed. The requirement of the requisite lubricating equipment and
lubricants for commissioning and operating and maintaining the valves for one year shall
be furnished by the Contractor.
19.1.1.9 Spare Parts
One spare spindle and nut shall be supplied under this contract for each group of 10
sluice valves or less of the different sizes. The Contractor shall take this into account
while quoting the rates for individual items. No separate payment shall be made for this
work. In addition the Contractor shall submit a list of recommended spares for 5 years of
operation and maintenance of all mechanical, electrical and instrumentation works
covered under this contract. Spares supplied shall be new, unused and interchangeable
with the corresponding components they are intended to replace.
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19.1.1.10
Flanges
Valves of sizes from 80 mm to 300 mm shall have flat flanges as per BIS:1538 Part IV
Table I. Valves of sizes from 350 mm and larger shall have raised flanges as per BIS:
4504, Table 10/11 for 10 bar valves. The flange to flange distances shall be as per
BIS:780 for 80 mm - 300 mm valves and BIS : 2906 for 350 mm and larger valves.
19.1.1.11
Jointing Materials
Each valve shall be supplied under this Contract, with all-requisite joint rings, nuts, bolts
and washers for making the joints on all the valves to be installed under this Contract.
Jointing material between the connecting flanges shall conform to the requirements of
BIS 638- 1965. Unless otherwise specified bolting used for jointing exposed connections
shall be carbon steel, conforming to BIS 210 Grade 20 Grade B, with galvanized finish.
Bolting for buried joints and joints that could come into contact with raw sewage shall be
Stainless Steel, as per Clause 2.02 A3. Boltholes shall be off-centre and in correct
adjustment longitudinally.
19.1.1.12
Special Requirements - 450 mm and Larger Valves
Sluice valves in the size range 450 mm to 1200 mm shall have, in addition to the above
requirements, the following features.
a. The valves shall have machined gun metal gate slides. Hard bronze shoes shall be
provided on the gate and machined gunmetal channels in the body. The bronze shoes
will be machined accurately to give a close working clearance with the channels.
They shall provide corrosion resistant bearing surfaces and minimize sliding friction
and vibration while maintaining accurate alignment. The use of cast iron channels
with brass lining will be permitted if the lining is at least 6mm thick. The use of
other materials for holding the channels in position will not be permitted.
b. The valves shall be provided with spur gearing consisting of machined mild steel
pinions and cast iron wheels for valves installed underground. The pinion shafts shall
run in gun metal bushes in a cast iron bearing bracket with provision for lubricating
by a grease gun.
Gear wheel ratios will be such that a force of 270 Newton's applied on each end of a bar
in combination with a Tee Key or extension spindle at the following distances from the
key centre will permit smooth operation.
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Valve size range (mm)
Distance of application of force (mm)
450 - 900
1200
600
750
Valves installed above ground shall be provided with worm gearing. These shall be
machined cut, with bronze wheel and steel worm enclosed in a cast iron gear case which
shall be mounted on a fitting connected to the valve cover flange and shall be complete
with indicator column.
The worm shafts shall be equipped with ball thrust bearing and gunmetal bushes. The
gearbox shall be oil filled and sealed. The worm shaft bearing shall be provided with
grease gun nipples. The gear ratios shall be so selected that the maximum force required
to develop the requisite operating torque shall not exceed 180 Newton's.
All valves of size 450 mm or more shall have valve gate indicator columns with 10 mm
graduations and indicating the fully open and closed positions. The indicator assembly
should be sufficiently watertight to prevent entry of rainwater into the worm gear box in
outdoor valves.
19.1.1.13
Factory Tests
All the valves shall be tested at the factory for smooth, trouble free operation and
operating torque requirements by operating between fully open and fully closed position
three times.
The hydrostatic tests shall consists of a. Application of a pressure equal to 1 and a half times the maximum working pressure
specified in this section with both ends closed and valve fully open, for ten minutes.
No leakage of water should occur through the metal, flanged joints or valve packing
gland, nor should any permanent deformation of any part occur.
b. The pressure shall then be reduced to the working pressure and the wedge gate
lowered, thus closing the valve. The stipulated pressures shall then be maintained for
5 minutes on each side in turn during which no leakage should occur on the
downstream side of the valve seating.
19.2 KNIFE GATE VALVES

Knife gate valves shall be suitable for use at suction and delivery side of pumps. The
valve should be provided with gate made of stainless steel and the gate should have
beveled knife edge at the bottom to cut through and easily enter in the solids settled in
the bottom and ensure positive shut-off / closure in sewage environment. The valve
should be bonnet-less and suitable for face to face flange connection in between
pipelines. It should be suitable for uni-directional application.
The valve body should be of Cast Iron GR.FG 260. The body shall be designed to
withstand 6 bar pressure.
The valve shall be provided with replaceable type flexible seating seats to offer drop
tight shut off. The seals should be made of EPDM rubber and should be held in place by
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an easily removable type seal retainer ring. The seal retainer ring should be designed in
a manner so that the flow of the fluid should be away from the sealing perimeter and
towards the center of the valve
The valve housing should have integral as cast tapered lugs provided for pushing the gate
towards the flexible rubber seal only at the verge of closure with a view to avoid seal
wear and achieve drop tight shut off. The surface of the gate coming in contact with the
seal should be polished and buffed.
The valve shall be provided with sufficient ply of stuffing seals in the in built stuffing
box to seal the rear opening. The stuffing box should have internal tappers for pushing
the seals on to the gate. The seals should be of non-asbestos PTFE to reduce the friction
and offer higher life. Provision shall be made to enable tighten the stuffing seals by
means of a pusher arrangement to minimize the leakage through the back of the valve.
Replacement of stuffing seals should be done in installed condition of the valve.
The spindle should be double start threaded and non-rising type for compact and safe
operation. The gate movement area should be covered by protection shields. Gate
opening indicating arrangement should be provided to find out the extent of gate opening
/ closing.
Flange drilling suitable to mount between flanges as per IS 1538-1993
Body Cast Iron FG 260 as per IS 210

Knife gate : AISI:304 Gr: ASTM A240
Retainer ring: SS:304 ASTM A351 Gr. CF:8
Inlet Seal: EPDM
Spindle: AISI:410 Gr. ASTM A276
Spindle Nut: Cast Iron Gr. FG 200 as per IS 210
Stuffing plate: Cast Steel ASTM A216 Gr. WCB
Stuffing seal: Synthetic yarn with PTFE
Factory Test:
Body Test: The valves shall be hydrostatically pressure tested at specified pressure
without any visible leakage.
Seat test: The valve shall be hydrostatically pressure tested for seat leakage at 2.8 bar for
no visible leakage.
ZFT-STD-X-CI-F1-M
Cast Iron Gr. FG 260 as per IS 210
Suitable to mount between DIN PN 10/IS:1538-1993
flanges
Stainless Steel ASTM A 240 AISI:304
Cast Stainless Steel ASTM A 351 GR. CF:8
EPDM Rubber
Synthetic Yarn with PTFE
Cast Steel Galvanized
Stainless Steel ASTM A276 AISI:410
Cast Iron
Body (Housing)
Flange Drilling
Knife gate
Seal Retainer Ring
Inlet Seal
Gland Packing
Stuffing Plate
Spindle (Stem)
Spindle Nut
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Supporting channels
Adapter plate
Hand Wheel
Fasteners
Body test
Seat test
Painting Internal
Painting External
Mild Steel Painted

Cast iron / Mild steel painted
Cast iron as per IS 210 Grade 260
High Tensile Galvanized
10 bar (hydro-static)
2.8 bar (Hydro-static) generally as per MSS SP-81
Red Oxide
Two coats epoxy paint RAL 5022
19.3 CHECK VALVES

19.3.1.1 Cast Iron Check Valves
60 mm to 350 mm diameter valves shall be swing check- valves of the lever and spring
type, flanged, and shall have cast iron body and renewable bronze seat, bronze hinge,
stainless steel hinge shaft. The valve shall conform to IS 5312 and, where any of the
requirements specified are not covered therein, to U.S. Federal Specification WW-V-51
D, Type IV, Class A.
Cast Iron shall conform to ASTM A-126-66 and flanges to ANSI B 16.1. The valves
shall be designed for low head loss, shall be adjustable for non-slamming closure and
shall be seat-tight. An arrow showing direction of flow shall be prominently cast on body
of valve. The water working pressure shall be 10 kg/cm square except that the valve shall
have pressure rating same as the piping where the pipe class is higher. Valves shall be
from approved manufacturer only.
19.3.1.2 Pump Check Valves larger than 400 mm Diameter
All check valves larger than 400-mm diameter installed on the pump discharge shall be
flanged ductile iron body, cover disc, arm and levers. The seat shall be of renewable
bronze ASTM B 148. The disc shall be hinged on a stainless steel shaft. The gate pins
shall also be of stainless steel. The valves shall be designed for a working, pressure of
10kg/cm square. Valve operation shall be of the oil cushioned type such that the valve
swing to 90 percent closed immediately upon stoppage of flow and cushioning cylinders
shall control the final closure, to prevent mechanical slamming, within an adjustable
timing of one to three seconds. The valves shall be from approved manufacturers only.
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20 WATER SUPPLY AND

SANITARY WORKS
20.1 APPLICABLE CODES
The following standards and codes are made a part of this Engineer-in-Charge. All
standards, codes of practice referred to herein shall be the latest editions including all
official amendments and revisions.
IS : 210
IS : 269
IS : 383
IS : 432
IS : 456
IS : 458
IS : 516
IS : 554
IS : 651
IS : 774
IS : 775
IS : 781
IS : 783
IS : 1068
IS : 1077
IS : 1172
IS : 1786
IS : 1239
IS : 1536
IS : 1626
IS : 1703
IS : 1726
IS : 1729
IS : 1742
IS : 2065
IS : 2116
IS : 2212
CONTRACTOR
: Specification for grey iron castings

: Specification for ordinary and low heat Portland cement
: Specification for coarse and fine aggregates from natural sources
for concrete
: Specification for mild steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement
: Code of Practice for plain and reinforced concrete
: Concrete Pipes (with and without reinforcement)
: Methods of tests for strength of concrete
: Dimensions for pipe threads where pressure tight joints are required
on the threads
: Salt glazed stoneware pipes and fittings
: Flushing Cisterns for water closets and urinals (valveless siphonic
type)
: Cast iron brackets and supports for wash basins and sinks
: Sand-cast brass screw-down bib taps and stop taps for water
services
: Code of practice for laying of concrete pipes
: Electroplated coatings of nickel and chromium of iron and steel
: Specification for common burnt clay building bricks
:
: Code of practice for basic requirements for water supply, drainage
and sanitation
: Specification for high strength deformed steel bars and wires for
concrete reinforcement
: Mild steel tubes (Part I) and mild steel tubulars and other wrought
steel pipe fittings (Part II)
: Centrifugually cast (spun) iron pressure pipes for water, gas and
sewage
: Asbestos cement building pipes, gutters and fittings (spigot and
socket types)
: Copper Alloy float valves (horizontal plunger type) for water
supply purposes
: Cast iron manhole covers and frames
: Sand cast iron spigot and socket soil, waste and ventilating pipes,
fittings and accessories
: Code of practice for buildings drainage
: Code of practice for water supply in Buildings
: Specification for sand for masonry mortars
: Code of practice for brickwork
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IS : 2250
IS : 2326
IS : 2470
IS : 2556
IS : 2963
IS : 3306
IS : 3025
IS : 3311
IS : 5455
IS : 4127
IS : 3495
IS : 4111
IS : 5382
IS : 5329
IS : 5434
: Code of practice for preparation and use of masonry mortars

: Automatic flushing cisterns for urinals
: Code of practice for design and construction of septic tanks (Parts I
& II)
: Vitreous sanitary appliances (Part I to Part XV)
: Specification for copper alloy waste fittings for wash basins and
sinks
: Specification for chemically resistant glazed stoneware pipes and
fittings
: Method for sampling and test (Physical and chemical) for water and
waste water (Parts 1 to 44)
: Waste plug and its accessories for sinks and wash basins
: Specification for cast iron steps for manholes
: Code of Practice for laying of glazed stoneware pipes
: Methods of tests of burnt clay building bricks
: Code of practice for ancillary structures in sewerage system
manholes
: Specification for rubber sealing rings for gas mains, water mains
and sewers
: Code of practice for sanitary pipe work above ground for buildings
: Non-ferrous alloy bottle traps for marine use
20.2 SANITARY INSTALLATION

The work shall be carried out complying in all respects with any specific requirements of
the local body in whose jurisdiction the work is situated, and as approved by the
Engineer-in-Charge.
Any damage caused to the building, or to installations therein, either due to negligence
on the part of the Contractor, or due to actual requirements of the work, shall be made
good and the building or the installation shall be restored to its original condition by the
Contractor.
Licensed plumbers shall carry out all sanitary and plumbing work.
All sanitary appliance including sanitary fittings, fixtures, toilet requisites shall be of
size, and design as approved by the Engineer-in-Charge.
All white glazed porcelain fixtures, such as wash basin, sink drain board, water closet
pan, urinal, `P trap etc. shall have hard durable white glazed finish. They shall be free
from cracks and other glazing defects. No chipped porcelain fixtures shall be used.
Joints between iron and earthenware pipes shall be made perfectly air and watertight by
caulking with neat cement mortar.
20.3 INDIAN TYPE WATER CLOSET

Water closets shall be white porcelain Orissa type Indian soil pans, 690mm long
conforming to IS:2556 of approved make and pattern. Flushing cistern of 15b litres
capacity with accessories such as chain, handle, stop tap, brass unions, jamb nuts,
overflow pipe and bends, etc. shall be provided.
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20.4 URINALS
Urinals shall be white glazed flat back type of approved make and of size 430 mm x 260
mm x 350 mm conforming to IS 2556. High level automatic CI flushing cistern of 10
litre capacity as per IS 2326 with necessary CI brackets, GI pipes for water connection
from cistern to urinals, stop tap, waste pipe upto CI waste shaft etc. shall be provided.
20.5 WASH BASIN

Wash basin shall be of white glazed earthenware conforming to IS 2556 of approved
make and of size 560mm x 410mm. The wash basins shall be provided with water
supply GI pipe, chromium plated tap, stopcock, CP bottle trap, GI waste water pipe and
all necessary accessories and fittings.
20.6 SINKS
Sinks shall be of white glazed earthenware conforming to IS 2556 of approved make and
of size 450mm x 300mm x 150mm. The sink shall be provided with CP tap, water
supply GI pipe, non-ferrous waste fitting, waste plug and necessary accessories and
fittings.
20.7 CAST IRON SOIL WASTE AND VENT PIPES AND FITTINGS
All cast iron pipes and fittings shall be of uniform thickness with strong and deep
sockets, free from flaws, air holes, cracks, sand holes and other defects and conform to
IS:1536. The diameter approved shall be internal diameter of pipe. The pipe and fittings
shall be true to shape, smooth and cylindrical and shall ring clearly when struck over
with a light hand hammer. All popes and fittings shall be properly cleaned of all foreign
materials before being fixed.
All plug bends of drainage pipes shall be provided with inspection and cleaning caps,
covers, which shall be fixed with nuts and screws. Pipes shall be fixed to the wall by
W.I or MS holder bat clamps unless projecting ears with fixing holes are provided at
socket end of pipe. The pipes shall be installed, truly vertical or to the lines and slopes
as indicated. The clamps shall be fixed to the walls by embedding their hooks in cement
concrete blocks (1:2:4) 10 cm x 10 cm making necessary holes in the walls at proper
places. All holes and breakage shall be made good. The clamps shall be kept 25 mm
clear of the finished face of the walls to facilitate cleaning and painting of pipes.
The annular space between the socket and spigot shall be filled with a gasket of hemp or
spun yarn soaked in neat cement slurry. The joint shall then be filled with stiff cement
mortar 1:2 (1 cement : 2 fine sand) well pressed with caulking tool and finished smooth
on top at an angle of 45 . The joint shall be kept wet for not less than 7 days by tying a
piece of gunny bag kept moist. Joints shall be perfectly air tight as well as water tight.
C.I pipes and fittings which are exposed shall be first cleaned and then painted with a
coat of red lead primer. Two coats of zinc paint with white base and mixed with pigment
of required colour to get the approved shade shall be given over the base primer coat.
The thickness of fittings and their socket and spigot dimensions shall conform to the
thickness and dimension approved for the corresponding sizes of straight pipes.
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The connection between the main pipe and branch pipes shall be made by using branches
and bends with access for cleaning. Floor traps shall be provided with 25 mm Dia. Puff
pipe where the length of the waste is more than 1800mm or the floor trap is connected to
a waste stack through bends.
All cast iron pipes and fittings including joints shall be tested by a smoke test to the
satisfaction of the Engineer-in-Charge and left in working condition after completion.
The smoke test shall be carried out as stated under:
Smoke shall be pumped into the pipe at the lowest and from a smoke machine, which
consists of a bellow and a burner. The material usually burnt is greasy cotton waste,
which gives out a clear pungent smoke which is easily detectable by sight as well as by
smell if there is a leak at any point of the pipeline.
Water test and air test shall be conducted as stipulated in IS:5329
20.8 ASBESTOS CEMENT PIPES AND FITTINGS

All Asbestos Cement (AC) soil, waste, vent pipes, and fittings shall conform to IS 1626.
The pipes shall have spigot and socket ends. These shall be composed of an inert
aggregate consisting of clean asbestos fibre cemented together by ordinary Portland
cement conforming to IS:269, or Portland blast furnace slag cement conforming to
IS.455. No organic material shall be added to the composition.
The pipes shall be straight and the ends of the pipes and fittings shall be finished square
to their axes. The finished pipes and fittings shall be true and smooth, their inner and
outer surfaces shall be concentric. They shall be in all respects sound, homogenous and
free from impurities or other imperfections.
The permissible tolerance on the thickness and external dimensions of pipes and fittings
including hydraulic test pressure of the pipes and fittings shall conform to IS.1626.
All AC pipes and fittings shall be of approved make and with necessary accessories,
wherever required. The diameter wherever approved for pipes and fittings shall be clear
internal diameter. All gaps between pipes and fittings and walls shall be filled with
cement mortar 1:3 neatly finished. All pipes and fittings shall be supported with
standard fixing brackets.
The annular space between the socket and spigot shall be filled with a gasket of hemp
and spun yarn soaked in tar. The joint shall then be filled with stiff cement mortar 1:2 (1
cement: 2 fine sand) well pressed with caulking tools and finished smooth on top with
near cement paste at an angle of 45. The joint shall be kept wet for not less than 7 days
by typing a piece of gunny bag kept moist. Joint shall be perfectly airtight as well as
watertight.
Pipes and fittings shall be tested with a smoke test as approved.
20.9 GALVANISED MILD STEEL (GI) PIPES

The pipes shall be galvanised mild steel welded pipes and seamless screwed and sockets
tubes conforming to the requirements of IS.1239, for medium grade. These shall be of
the diameter (nominal bore) approved. The sockets shall be designated by the respective
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nominal bores of the pipes for which they are intended. The pipes and sockets shall be
finished neatly, well galvanised on both inner and outer surfaces, and shall be free from
cracks, surface flaws, laminations and other defects. All screws, threads shall be clean
and well cut. The ends shall be cut cleanly and square with the axis of the tube.
All screwed tubes and sockets shall have pipe threads conforming to the requirements of
IS.554. Screwed tubes shall have taper threads while the sockets shall have parallel
threads.
The fittings shall be of malleable cast iron or mild steel tubes complying with all the
appropriate requirements as approved for pipes. The fittings shall be designated by the
respective nominal bores of the pipes for which they are intended. The fittings shall
have screw threads at the ends conforming to the requirements of IS.554. Female
threads on fittings shall be parallel and male threads (except on running nipples and
collars of unions) shall be tapered.
The pipes and fittings shall be inspected at site before use to ascertain that they conform
to the specification. The defective pipes shall be rejected. Where the pipes have to be
cut or re-threaded, the ends shall be carefully filled out so that no obstruction to bore is
offered. The ends of the pipes shall then be threaded conforming to the requirements of
IS.554 with pipe dies and taps carefully in such a manner as will not result in slackness
of joints when the two piece are screwed together. The taps and dies shall be used only
for straightening bent and damaged screw threads and shall not be used for turning of the
threads so as the make them slack, water tight joint. The screw thread of pipes and
fitting shall be protected from damage until they are fitted.
The pipes shall be cleaned and cleared of all foreign matter before being laid. In jointing
the pipes, the inside of the socket and the screwed end of the pipes shall be oiled and
rubbed over with white lead and few turns of spun yarn wrapped around the screwed end
of the pipe. The end shall then be screwed in the socket, tee, etc, with the pipe wrench.
Care should be taken that all pipes and fittings are properly jointed so as to make the
joints completely water tight and pies are kept at all times free from dust and dirt during
fixing. Burrs from the joint shall be removed after screwing. After laying, the open ends
of the pipes shall be temporarily plugged to prevent access of soil or any other foreign
matter.
Any threads exposed after jointing shall be painted or in the case of underground piping
thickly coated with approved anticorrosive paint to prevent corrosion.
For internal work the galvanised iron pipes and fittings shall run on the surface of the
walls or ceiling (not in chase) unless otherwise specified. The fixing shall be done by
means of standard pattern holder bat clamps. Keeping the pipe about 1.5 cm clear of the
wall. Pipes and fittings shall be fixed truly vertical/horizontal. When it is found
necessary to conceal the pipes, chasing may be adopted or pipes fixed in the ducts of
recesses etc, provided there is sufficient space to work on the pipes with the usual tools.
The pipes shall not ordinarily be buried in walls or solids floors. Where unavoidable,
pipes may be buried for short distances provided adequate protection is given against
damage, but the joints in pipes shall not be buried MS pipe sleeve shall be fixed at a
place where a pipe is passing through a wall of floor for reception of the pipe and to
allow freedom for expansion/contraction and other movements maintenance. In case the
pipe is embedded in walls or floors it should be painted with anti-corrosive bitumastic
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paint of approved quality. The pipe should not come in contract with lime mortar or lime
concrete as the pipe is affected by lime. Under the floors the pipes shall be laid in layer
of sand filling or as approved by the Engineer-in-Charge.
GI pipes with socket and spigot ends shall be provided with lead caulked joints wherever
specified and the joints shall conform to the requirements of IS:3114.
The work of excavation and backfilling shall be done true to line and gradient in
accordance with general Employers requirements for earthworks in trenches for pipes
laid underground.
The pipes shall be laid on a layer of 10.0 cm sand and sand filled upto 15 cm above the
pipes. A sand cushion of 15 cm on either side of the pipe shall also be provided. The
remaining portion of the trench shall then be filled with excavated earth. The surplus
earth shall be got rid of as directed. When excavation is done in rock the bottom shall be
cut deep enough to permit the pipes to be laid on a cushion of sand 75 mm minimum.
The pipes and fittings after they are laid and jointed shall be subjected to hydrostatic
pressure test as approved by the Engineer-in-Charge and shall satisfactorily pass the test.
Pipeline system shall be tested in sections as the work proceeds, keeping the joints
exposed for inspection. Pipes shall be slowly and carefully charged with water allowing
all air to escape. All draw-off taps shall then be closed and water pressure gradually
raised to test pressure. Care shall be taken to ensure that pressure gauge is accurate and
preferably should have been recalibrated before the test. Pump used having been stopped
the section of the pipeline shall maintain the test pressure for at least half an hour. Any
joints or pipes found leaking should be removed and replaced by the Contractor.
The GI pipeline shall be cut to the required length at the position where the meter and
stopcock are required to be fixed. The ends of the pipes shall be threaded. The meter
and stopcock shall be fixed in position by means of connecting pipe, G.I nuts, sockets,
etc. The stopcock shall be fixed near the inlet of the water meter. The paper disc
inserted in the ripples of the meter shall be removed and meter installed exactly
horizontally or vertically and with the arrow cast on the body of the meter pointing in the
direction of flow. Care shall be taken that the factory seal of the meter is not disturbed.
Whenever the meter is to be fixed to a newly fitted pipeline, the pipeline will have to be
completely washed before fixing the meter. For the purpose, a connecting piece of pipe
equal to the length of the meter is to be fixed on the new pipeline. The water shall be
allowed to flow completely to wash the pipeline and then the meter installed as described
above by replacing the connecting piece.
20.10STONEWARE PIPE AND FITTINGS

All pipes with spigot and socket ends shall conform to IS.651/3006 and shall be of grade
`A. These shall be sound, free from visible defects such as fine cracks or hair cracks.
The glaze of the pipes shall be free from crazing. The pipes shall give a sharp clear note
when struck with a light hammer.
The following information shall be clearly marked on each pipe and fitting:
a. Internal diameter
b. Grade
c. Date of manufacture;
d. Name of manufacture or his registered trade-mark or both
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All pipes and fittings shall have ISI mark jointing of GSW pipes and fittings shall be
done as per the requirements of the following Employers Requirements and the relevant
IS. After jointing, extraneous material if any, shall be removed from the inside of the
pipes and fittings and the newly made joints shall be thoroughly cured. In cased, rubber
sealing rings are used for jointing, these shall conform to IS:5382.
20.10.1 Spigot and Socket Joint (Cement Joint)
The Spigot of each pipe shall be slipped home well into the socket of the pipe previously
laid and adjusted in the correct position. In each joint, spun yarn soaked in neat cement
slurry or tarred gasket shall be passed around the joint and inserted in it by means of
caulking tool. More skeins of yarn or gasket shall be added if necessary and shall be
well caulked. Yarn or gasket so rammed shall not occupy more than one fourth of the
depth or socket.
Cement mortar (1:1) shall be slightly moistened and carefully inserted by hand into the
remaining space of the joint after caulking of yarn or gasket. The mortar shall then be
caulked into the joint with a caulking tool. More cement mortar shall be added until the
space of joint has been completely filled with tightly caulked mortar. The joint shall
then be finished off neatly outside the socket at an angle of 45 degrees.
The cement mortar joints shall be cured at least for seven days before testing.
The approximate quantities of cement required for each joint for certain common sizes of
pipes are given below for guidance:
Nominal diameter of pipe (mm)
150
200
250
300
350
400
450
Cement (kg)
1.5
2.0
2.5
3.25
4.5
5.5
6.5
20.10.2 Spigot and Socket Joint (Rubber Ring Joint)

The pipe with the rubber ring accurately positioned on the spigot shall be pushed well
home into the socket of the previously laid pipe by means of uniformly applied pressure
with the aid of a jack or similar appliance. The rubber rings conforming to IS: 5382 shall
be used and the manufacturers instructions shall be deemed to form a part of this
Employers Requirements. The rubber rings shall be lubricated before making the joint
and the lubricant shall be soft soap water or an approved lubricant supplied by the
manufacturer.
20.10.3 Cleaning of Pipes
As soon as a stretch of GSW pipes has been laid complete from manhole to manhole or
for a length as approved by the Engineer-in-Charge, the Contractor shall run through the
pipes both backward and forward a double disc or solid or closed cylinder 50 mm less in
diameter than the internal diameter of pipes. The open end of an incomplete stretch of
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pipeline shall be securely closed as approved by the Engineer-in-Charge to prevent entry

of mud or silt etc.
If as a result of the removal of any obstruction the Engineer-in-Charge considers that
damage may have been caused to the pipelines, he shall be entitled to order the length to
be tested immediately. Should such a test prove unsatisfactory the Contractor shall
repair the pipeline and carry out such further tests as are required by the Engineer-inCharge.
It shall also be ascertained by the Contractor that each length from manhole to manhole
or the length as approved by the Engineer-in-Charge is absolutely clear and without any
obstruction by means of visual examination of the interior of the pipeline suitably
illuminated by projected sunlight or otherwise.
20.10.4 Testing at Work Site
After laying and jointing of GSW pipes is completed the pipeline shall be tested as per
the following Employers Requirements and as approved by the Engineer-in-Charge. All
equipment for testing at work site shall be supplied and erected by the Contractor.
Potable water for testing of pipeline shall be arranged by him. Damage during testing
shall be the Contractors responsibility and shall be rectified by him to the full
satisfaction of the Engineer-in-Charge. Water used for test shall be removed from pipes
and not released to the excavated trenches.
After the joints have thoroughly set and have been checked by the Engineer-in-Charge
and before backfilling the trenches, the entire section of the sewer or storm water drain
shall be proved by the Contractor to be water tight. Before commencing the hydraulic
test, the pipelines shall be filled with water and maintained full for 24 hours by adding
water. If necessary, under a head of 0.6 m of water. The test shall be carried out by
suitably plugging the low end of the drain and the ends of connections, if any, and filling
the system with water. A knuckle bend shall be temporarily jointed at the top end and a
sufficient length of vertical pipe jointed to it so as to provide the required test head, or
the top end may be plugged with a connection to a hose ending in a funnel which could
be raised or lowered till the required head is obtained and fixed suitably for observation.
The pipeline shall be subjected to a test pressure of at least 2.5 m head of water at the
highest point of the section under test. The leakage tolerance of two litres per centimeter
of diameter per kilometer may be allowed during a period of 10 minutes. Any leakage
including excessive sweating which causes a drop in the test water level will be visible
and the defective part of the work should be removed and made good.
If any damage is caused to the pipeline during the execution of work or while
cleaning/testing the pipeline as specified, the Contractor shall be held responsible for the
same and shall replace the damaged pipeline and re-test the same to the full satisfaction
of the Engineer-in-Charge.
Water for testing of pipeline shall be arranged by the Contractor.
20.11STOP COCK AND BIB COCK

Stopcocks and Bibcocks shall be of brass heavy class, chromium plated and of approved
manufacture and pattern complying with IS: 781. They shall be of specified size and of
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the screw down type. The cocks shall open in anti-clockwise direction and chromium
plating shall be done in accordance with IS: 1068.
20.12SOAK PIT
Soak pit shall be constructed at the location specified by the Engineer-in-Charge.
Earthwork excavation shall be carried out to the exact dimensions. Brick masonry lining
with open joints shall be constructed in the pit upto 150 mm below the outlet pipeline.
Brick masonry in cement mortar 1:6 shall be constructed above this level up to ground.
Well burnt brick aggregates of nominal size 40 mm to 80 mm and coarse sand shall be
filled within the chamber. Construction of pit lining and filling of the brick ballast shall
progress simultaneously.
20.13MANHOLES/INSPECTION CHAMBERS
20.13.1 Location
Manholes / Inspection chambers shall be constructed at places approved by the Engineerin-Charge.
20.13.2 Excavation
Excavation, shoring, dewatering etc. for the pits of manholes / Inspection chambers,
laying of pipes and fittings/specials shall be done in accordance with Engineer-in-Charge
requirements described elsewhere in the document.
20.13.3 Bed Concrete
The bed concrete (min grade M15) for manholes/Inspection Chambers shall be done in
accordance with Engineer-in-Charge's requirements described elsewhere in the
document.
20.13.4 Bricks
Bricks used for construction of manholes / Inspection chambers shall conform to the
relevant Indian Standards. They shall be sound, hard, homogeneous in texture, well
burnt in kiln without being vitrified, table moulded, deep red, cherry or copper coloured,
of regular shape and size and shall have sharp and square and parallel faces. The bricks
shall be free from pores, chips, flaws or humps of any kind. Bricks containing unground
particles and/or which absorb water more than 1/6th of their weight when soaked in water
for twenty-four hours shall be rejected. Overburnt or underburnt bricks shall be liable to
rejection. The bricks shall give a clear ringing sound when struck and shall have a
minimum crushing strength of 50 kg/sq.cm, unless otherwise noted in drawings. The
class and quality requirements of bricks shall be as laid down in IS: 1077.
The size of the brick shall be 23.0 x 11.5 x 7.5 cm unless otherwise specified; but
tolerance upto + 3 mm in each direction shall be permitted. Only full size brick shall be
used for masonry work. Brickbats shall be used only with the permission of Engineer-inCharge to make up required wall length or for bonding. Sample bricks shall be
submitted to the Engineer-in-Charge for approval and bricks supplied shall conform to
approved samples. If required by the Engineer-in-Charge, brick samples shall be tested
as per IS:3495 by Contractor. Bricks rejected by the Engineer-in-Charge shall be
removed from the site within 24 hours.
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20.13.5 Cement Mortar

Mortar for brick masonry shall be prepared as per IS:2250, Manholes / Inspection
chambers shall be constructed in brick masonry with cement mortar (1:3) unless
otherwise specified. Gauge boxes for sand shall be of such dimensions that one bag
containing 50 kg of cement forms one unit. The sand shall be free from clay, shale,
loam, alkali and organic matter and shall be of sound, hard, clean and durable particles.
Sand shall be as approved by the Engineer-in-Charge. If required by the Engineer-inCharge and shall be thoroughly washed till it is free of any contamination.
For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
condition. Water shall then be added and mixing continued to give a uniform mix of
required consistency. Cement mortar shall be used within 25 minutes of mixing. Mortar
left unused in the specified period shall be rejected.
The Contractor shall arrange for tests on mortar samples if so required by Engineer-inCharge. Retempering of mortar shall not be permitted.
20.13.6 Brick Masonry
All bricks shall be thoroughly soaked in clean water for at least one hour immediately
before being laid. Brick work 230 mm thick and over shall be laid in English Bond
unless otherwise specified. 115 mm thick brick work shall be laid with stretchers. For
laying bricks, a layer of mortar shall be spread over the full width of suitable length of
the lower course. Each brick shall be pressed into the mortar and shoved into final
position so as to embed the brick fully in mortar. Bricks shall be laid with frogs
uppermost.
All brickwork shall be plumb and square unless otherwise shown on drawing and true to
dimensions shown. Vertical joints in alternate courses shall come directly one over the
other and be in line. Horizontal courses shall be leveled. The thickness of brick course
shall be kept uniform. For walls of thickness greater than 230 mm both faces shall be
kept in vertical planes unless otherwise specified. All interconnected brickwork shall be
carried out at nearly one level (so that there is uniform distribution of pressure on the
supporting structure) and no portion of the work shall be left more than one course lower
than the adjacent work. Where this is not possible, the work shall be raked back
according to bond (and not saw-toothed) at an angle not exceeding 45 degrees. But in no
case the level difference between adjoining walls shall exceed 1.25 m. Workmanship
shall conform to IS:2212.
Brick shall be so laid that all joints are well filled with mortar. The thickness of joints
shall not be less than 6 mm and not more than 10 mm. The face joints shall be raked to a
minimum depth of 12 mm by raking tools daily during the progress of work when the
mortar is still green, so as to provide a proper key for the plastering to be done. When
plastering is not required to be done, the joints shall be uniform in thickness and be
struck flush and finished at the time of laying. The face of brickwork shall be cleaned of
all dirt before another course is laid on top. If mortar in the lower course has begun to
set, the joints shall be raked out to a depth of 12 mm before another course is laid.
20.13.7 Cement Plaster
All joints in masonry shall be raked to a depth of 12 mm with hooked took made for the
purpose when the mortar is still green and in any case within 48 hours of its laying. The
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surface to be rendered shall be washed with fresh clean water free from all dirt, loose
material, grease etc. and thoroughly wetter for 6 hours before plastering work is
commenced. Concrete surfaces to be rendered will however be kept dry. The wall
should not be too wet but only damp at the time of plastering. The damping shall be
uniform to get uniform bond between the plaster and the wall.
Cement shall be mixed thoroughly in dry condition and then just enough water added to
obtain a workable consistency. The quality of water, sand and cement shall be as per
relevant IS. The mortar thus mixed shall be used immediately and in no case shall the
mortar be allowed to remain for more than 25 minutes after mixing with water.
Curing of plaster shall be started as soon as the applied plaster has hardened enough so
as not to be damaged. Curing shall be done by continuously applying water in a fine
spray and shall be carried out for at least 7 days.
Plastering shall be done on both faces of brick masonry in cement mortar (1:2) and 20
mm thick unless otherwise specified.
Plastering work shall be carried out in two layers, the first layer being 14 mm thick and
the second layer being 6 mm thick. The first layer shall be dashed against the prepared
surface with a trowel to obtain an even surface. The second layer shall then be applied
and finished leaving an even and uniform surface, trowel finished unless otherwise
approved by the Engineer-in-Charge.
20.13.8 Cement Concrete Channel
The channel for the manhole shall be constructed in cement concrete of M15 grade.
Both sides of the channel shall be taken up to the level of the crown of the outgoing
sewer. They shall be benched up in concrete and rendered in cement mortar (1:1) of 20
mm thickness and formed to a slope of 1 in 12 towards the channel.
20.13.9 Pipe Entering or Leaving Manhole / Inspection Chamber
Whenever a pipe enters or leaves a manhole / inspection chamber, bricks on edge must
be cut to a proper form and laid around the upper end of the pipe so as to form an arch.
All around the pipes, there shall be a joint of cement mortar (1:2) 13 mm thick between it
and the bricks.
20.13.10
Cast Iron Steps
Cast iron steps shall be as per IS:5455. The steps shall be of grey cast iron of grade 15 as
per IS:210. The steps shall be clean, well cast and they shall be free from air and sand
holes, cold shuts and wrappings. The portion of the step which projects from the wall of
the manhole / inspection chamber shall have a raised chequered design to provide an
adequate non-slip grip CI steps shall weigh not less than 4.5 kg each and shall be of 150
mm x 375 mm overall dimensions. These steps shall be coated with a black bituminous
composition. The coating shall be smooth and tenacious. It shall not flow when exposed
to a temperature of 63 degrees C and shall not be brittle as a chip of at temperature of 0
degree C.
Where the depth of invert of manhole exceeds 800 mm, cast iron steps of approved
pattern shall be fixed in the brick work at the interval of 300 mm vertically and staggered
at 380 mm horizontally centre to centre. In case of pipe diameter greater than 600 mm,
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box type CI steps weighing 19 kg each shall be provided at 300 mm vertically in channel
of manhole / inspection chamber.
20.13.11
Frame and Covers
Frame and covers for manholes shall be of required type and dimensions as per the
relevant drawings prepared by the Contractor. Following information shall be clearly
marked on each cover.
Year of manufacture,
Identification mark of the purchaser
SEWERS/SWD
Arrow showing direction of flow
Approved Makes:
20.13.11.1
KK Manholes and Gratings

S.S. Manholes
Bharat Pipes and Covers
Cast Iron Frame and Cover
The cast iron frame and cover shall be of gray cast iron as per IS: 1726. The general
requirements for casting and coating of CI frame and cover shall be as specified for CI
steps in Clause 15.15.10. The covers shall have a raised chequered design to provide an
adequate non-slip grip. The rise of the chequer shall be not less than 4 mm. The locking
device for the cover shall be provided as approved by the Engineer-in-Charge. The CI
covers for the load test shall be selected at one for every lot of fifty or part thereof for
each type and size manufactured and as approved by the Engineer-in-Charge. The frame
shall be fixed in cement concrete of M15 grade all round and finished with neat cement.
The manhole frame shall have 560 mm diameter clear opening and shall weigh not less
than 208 kg. Including cover. In case of rectangular CI frame and cover of 900 mm x
600 mm clear opening, the total weight shall not be less than 275 kg. In case of scraper
manhole the frame shall have clear opening of 1200 mm x 900 mm and shall weigh not
less than 900 kg including cover. The manhole / inspection cover and frame shall be
painted with three coats of anti-corrosive paint after fixing in position.
20.13.11.2
Fibre Reinforced Concrete Frame and Cover
Fibre reinforced concrete frame and cover shall be capable of withstanding load of 35
tonnes. The frame shall be fixed in cement concrete of M15 grade all around and
finished with neat cement. The fibre-reinforced frame shall have clear opening of 560
mm diameter and weighing 103 kg. The cover shall have a minimum thickness of 100
mm and weighing 78 kg. The fibres shall constitute 1% of the weight of the concrete in
the form of 50 mm to 100 mm long high tensile steel wires. For the cover, MS sheet
lapping of 18 gauge shall be provided to avoid damage to the edges. Similarly for frame,
MS angle/flat shall be provided along the edge. Both MS sheet and angle shall be
painted with black bituminous paint. The cover should have suitable lifting arrangement.
The fibre reinforced frame and cover shall be manufactured as approved.
20.13.11.3
Reinforced Cement Concrete Frame and Cover
Reinforced cement concrete frame and cover for manholes shall be of required
dimensions and shape as shown on the drawing prepared by the Contractor and approved
by the Engineer-in-Charge. The frame and cover shall be cast in cement concrete of M20
grades. Minimum cover to the reinforcement shall be 40 mm. The edges of frame and
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covers shall be provided with mild steel angles to avoid damages to the corners. These
angles shall be painted with black bituminous paint. The covers should have suitable
lifting arrangement.
20.13.12
Drop Manhole
When a sewer connects a main sewer, and where the difference in level between water
line (peak flow levels) or main line and the invert level of branch lines is more than 600
mm or a drop of more than 600 mm is required to be given in the same sewer line and it
is uneconomical or impractical to arrange the connection within 600 mm, a drop
connection shall be provided for which a manhole shall be constructed as per relevant
drawing, incorporating a vertical drop pipe from the higher sewer to the lower one. This
pipe shall be provided outside the shaft and encased in concrete. A continuation of the
branch sewer should be built through the shaft wall to form a rodding and inspection eye,
which should be provided with a half blank flange. The diameter of the black drop
should be at least as large as that of the incoming pipe. The drop pipe should terminate
at its lower end with a plain or duck-foot bend turned so as to discharge its flow at 45
degrees or less to the direction of the flow in the main sewer. The pipe unless of cast
iron should be surrounded with 150 mm thick concrete.
In the case of sewers over 450 mm in diameter the drop in level may be accomplished by
one of the following approved methods.
a. A cascade,
b. A ramp,
c. By drops in previous manholes.
20.13.13
RCC Manhole
M20 grade of concrete used for construction of RCC manhole shall have min cement
content of 390kg/cum of concrete. Min cover to the reinforcement shall be 50mm.
20.14VENT SHAFTS
20.14.1 General
Vent shafts shall be erected at such places as approved by the Engineer-in-Charge.
20.14.2 GI Pipe Vent Shaft
GI pipe vent shall be of 100 mm diameter of C class as per IS: 1239 and 6 metre height
from ground level with slotted cap. The vent shaft shall be embedded in concrete of
M10 grade and anchored with a 6mm thick MS base plate of 200 mm x 200 mm. The
vent shaft shall be painted with one coat of silver paint over one coat of red lead oxide
paint. The vent shaft shall be connected to manhole by 150 mm diameter glazed
stoneware pipe encased by M10 concrete of 150 mm thickness all around as approved by
the Engineer-in-Charge.
20.14.3 RCC Vent Shaft
Reinforced cement concrete vent shaft shall be of M20 grade concrete, 200 mm diameter
at bottom and tapered to 100 mm diameter at top (both inside clear openings) and 6 m
height from ground level. The vent shaft shall be embedded in concrete of M10 grade
and anchored by 2 nos. of 16 mm diameter and 600 mm long MS bars. The vent shaft
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shall be connected to manhole as specified in (b) above through a brick masonry flue
chamber.
20.15SEPTIC TANK
The sewer line shall be connected to a septic tank of adequate capacity and design
including necessary soak pit. All the works involved, such as excavation, refilling,
accessories, fittings, vent pipe, cowl cap, etc. as specified & directed shall be carried out.
20.16MISCELLANEOUS
If any damage is caused to the other services such as water supply pipeline, sewer, cable,
etc. during the construction of manholes and erection of vent shafts, the Contractor shall
be held responsible for the same and shall replace the damaged services to the full
satisfaction of the Engineer-in-Charge. The interior of manholes shall be cleared of all
debris after construction and before testing the same for water tightness by the
Contractor.
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VOLUME II - B
MECHANICAL SPECIFICATIONS

Volume II C: Mechanical Specifications
Table of Content - Volume II C, Mechanical Specifications
SCOPE OF MECHANICAL WORKS ........................................................ 239
1.1
1.2
1.3
General ..................................................................................................................... 239

Mechanical Equipment ............................................................................................ 239
Spares........................................................................................................................ 239
MATERIALS & WORKMANSHIP ............................................................. 241
2.1
2.2
2.3
2.4
2.5
Introduction .............................................................................................................. 241

Compliance with Standards ..................................................................................... 241
Materials - General................................................................................................... 241
Workmanship - General ........................................................................................... 241
Welding..................................................................................................................... 242
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
Design Approval ................................................................................................................. 242

Qualification of Welders and Procedures .............................................................................. 242
General Welding Requirements ........................................................................................... 243
Pre-heating and Post - heating Treatment ............................................................................. 244
Electrodes ........................................................................................................................... 244
Examination/NDT/Radiography........................................................................................... 244
Stainless Steel Welding ....................................................................................................... 244
Castings..................................................................................................................... 245
Forgings .................................................................................................................... 245
Pipes and Specials..................................................................................................... 246
Valves........................................................................................................................ 246
Support of Pipenetwork and Valves ........................................................................ 247
Design Life ................................................................................................................ 247
Lubrication ............................................................................................................... 247
Name Plates .............................................................................................................. 248
Nuts, Bolts, Studs and Washers ............................................................................... 248
Allowance for Wastage ............................................................................................. 249
Painting - General .................................................................................................... 249
Painting at place of Manufacturer ........................................................................... 249
Painting at Site.......................................................................................................... 250
List of Standards ...................................................................................................... 250
MECHANICAL EQUIPMENT .................................................................... 253
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
General ..................................................................................................................... 253

Submersible Pumps ............................................................................................................. 253
Aluminium Gates ................................................................................................................ 257
Cast Iron Sluice Gates ......................................................................................................... 257
Mechanical Fine Screens ..................................................................................................... 260
Belt Conveyor ..................................................................................................................... 261
Manual Screens (10 mm, 20 mm and 40 mm)....................................................................... 261
Contractor
No of Corrections
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3.1.7 Mechanical Degritter ........................................................................................................... 262

3.1.8 Primary Clarifier ................................................................................................................. 262
3.1.9 Air Blowers ......................................................................................................................... 262
3.1.10
Air Diffusers ................................................................................................................... 263
3.1.11
Secondary Clarifier.......................................................................................................... 263
3.1.12
Horizontal pumps ............................................................................................................ 263
3.1.13
Chlorination System ........................................................................................................ 264
3.1.14
Sludge Thickener ............................................................................................................ 266
3.1.15
Mechanical Dewatering System (Centrifuge) ................................................................... 266
3.1.16
Biogas Flaring System ..................................................................................................... 267
3.1.17
Filtrate Transfer Pumps ................................................................................................... 274
3.1.18
EOT Crane ...................................................................................................................... 274
3.1.19
Monorail Trolley and Chain Pulley Block ........................................................................ 275
3.1.20
Instrumentation ............................................................................................................... 275
ERECTION, TESTING AND COMMISSIONING ....................................... 276
4.1
4.2
4.3
Testing - General ...................................................................................................... 276

Inspection at Manufacturers Premises ................................................................... 276
Tests at Manufacturers Premises............................................................................ 277
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.4
4.5
4.6
4.7
4.8
4.9
Pumps ................................................................................................................................. 277

Motors................................................................................................................................. 277
Pipe work ............................................................................................................................ 277
Valves ................................................................................................................................. 277
Hoists .................................................................................................................................. 277
Electrical Instruments .......................................................................................................... 277
Other Equipment ................................................................................................................. 277
Erection - General .................................................................................................... 278

Record, Procedures and Reports ............................................................................. 278
Completion of Erection ............................................................................................ 279
Setting to Work ........................................................................................................ 280
Installation Inspection .............................................................................................. 280
Commissioning ......................................................................................................... 281
4.9.1
4.9.2
4.9.3
4.10
4.11
4.12
4.13
4.14
4.15
Scope .................................................................................................................................. 281

Miscellaneous...................................................................................................................... 281
Commissioning Date ........................................................................................................... 281
Tender Drawings ...................................................................................................... 281

Drawings for Approval............................................................................................. 282
Construction Documents .......................................................................................... 282
As-Built Drawings .................................................................................................... 282
Information required on As-Built Drawings ........................................................... 283
Operating and Maintenance Manuals ..................................................................... 283
4.15.1
4.16
4.17
General ........................................................................................................................... 283
Submission of Documents and Drawings ................................................................. 284

Notice of Operations ................................................................................................. 285
APPROVED MANUFACTURER/MAKE FOR MAJOR ITEMS ................. 286
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32 MLD Capacity STP and SPS at Panchak, Nashik.

PREAMBLE
1.0
The Volume IIC : Mechanical Specifications are to be read for the purpose of pricing in
conjunction with "Volume-I : Conditions of Contract" of the Tender Documents
containing instructions to Tenderer and General Conditions of Contract; Volume IIA :
Scope of Work under this tender; Volume IIB : Civil Specifications, Volume IID :
Electrical Specifications and Volume-III : Financial Bid of this tender.
2.0
3.0
specified or not. If not specified work shall be carried out as per directions of
Owner/Engineer I/C.
4.0
The total amount entered in the Volume III : Financial Bid document shall be written in
ink and shall be entered both in figures and words.
5.0
Specifications of items of work are described in Section D for each item of Volume III :
Financial Bid shall read this in conjunction with other technical specifications and
specific technical requirements and quote accordingly.
6.0

during excavation, laying of PCC and RCC laying and jointing of pipes, construction of
manholes, testing and backfilling etc. and Contractor should quote accordingly.
7.0
If Tenderer needs any clarification, they shall obtain the same in writing from
Owner/Engineer. No notice will be taken of any verbal discussions in such matters.
8.0
Abbreviations used in the Volume IIC : Mechanical Specifications have the meanings
shown below:
mm
cm
m
km
sq.m
cu.m
M.T.
SWG
R.M.
nos.
MS
M.D
Contractor
Millimetre
Centimetre
Metre
Kilometre
Square Metre
Cubic Metre
Metric Ton
Standard Wire Gauge
Running Metre
Numbers
Mild Steel
CI
GI
GSW
BBCC
RCC
PCC
Wt
Kg
I.D.
C.M.
IS
SS
No of Corrections
Cast Iron
Galvanized Iron
Glazed Stone Ware
Weight
Kilogram
Internal Diameter
Cement Mortar
Indian Standards
Stainless Steel
Executive Engineer
iii

1 SCOPE OF MECHANICAL WORKS

The scope of the work shall include but not be limited to the following:
1.1
GENERAL
The contract includes design, manufacture, testing at works, supply and delivery at site,
unloading, storing till the time of erection, installation, testing and commissioning of
mechanical equipment as mentioned in the following sections.
1.2
MECHANICAL EQUIPMENT
The details of the Mechanical equipment required for this contract are presented under
Section 3 : Mechanical Equipment and to be read in conjunction with Volume IIA :
Scope of Work. This table below represents an extract of the said section for the
Tenderers reference.
1.3
Sr.
Particulars
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Raw Sewage Pumps

Screens for pumping station
Mechanical Fine Screen
Manual Bar screens
Mechanical Degritter
Primary clarifier
Air blowers and diffusers
Air piping
Secondary clarifier
SBR Decanter
Moving Bed Bio Reactor media
Chlorination System with cylinders, Booster Pumps and accessories
Primary sludge pumps
Return sludge pumps
Anaerobic sludge digester with mixers
Digester feed pumps
Centrifuge feed pumps
Centrifuge Press
Sludge agitator
Filtrate transfer pumps
Polyelectrolyte dosing tanks and pumps
SPARES
Sr.
Particulars
Quantity
1.
(i)
(ii)
(iii)
Pumps
Impeller
Bearings
Rubber bellows
1 set
1 set
1 set
Contractor
No of Corrections
Executive Engineer
239

Sr.
Particulars
Quantity
(iv)
(v)
Seals, gaskets
Pumpset Power Cables
1 set
1 set
2.
(i)
(i)
(iii)
Mixers
Oil seal for housing
Oil Seal for Gear Box
Gear Box Bearing
3.
(i)
(ii)
(iii)
Air Blower
Oil Seal
Bearing
Suction Filter
4.
(i)
(ii)
(iii)
General Utility
Racking Arms (M.S.)
4 Nos.
Wheel Barrows (M.S.)
2 Nos.
Tokari (Ghamela) Paras Miracle Brand Plastics of Versatile 6 Nos.
quality
1 set
1 no.
1 no.
1 set
1 set
1 set
1 set
Note:
1. Contractor should provide spares and list of spares required for one year after
handing over the plant.
2. All other miscellaneous items necessary for completing the installation and
commissioning of the equipment under this contract, as per the existing codes of
practice.
3. Technical specific requirements shall conform to Volume IIA Scope of Work and
Volume IID Electrical Specifications, if any should be brought out separately in
deviation schedule.
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2 MATERIALS & WORKMANSHIP

2.1
INTRODUCTION
1. This part of the specification sets out the general standards of materials to be
supplied and the workmanship required to be ensured by the Contractor and mention
of any specific material or plant does not necessarily imply that such is included in
the works. All component parts of the works shall, unless otherwise specified
comply with the provisions of this part or be subject to the approval of the Engineer.
2. The names of the manufacturers of materials and equipment proposed for
incorporation in the Works together with performance capacities, certified test
reports and other significant information shall be furnished by the Contractor.
2.2
COMPLIANCE WITH STANDARDS

1. Where reference is made in the Specification to the British Standard Specification
(hereinafter abbreviated to BS) issued by the British Standards Institution of 2,
Park Street, London W.I., or to an Indian Standard Specification (IS) issued by the
Bureau of Indian Standards, (earlier known as Indian Standard Institution), Manak
Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110 002, American Society for
Testing and Materials (ASTM) issued by ASTM 1916 Race Street, Philadelphia,
P.A., 19103, U.S.A or American National Standards Institute (ANSI) issued by
ANSI 1430, Broadway, New York, N.Y., 10018, U.S.A or to any other equivalent
standard it shall be to the latest revision of that standard at the tender opening date.
2. The Contractor may propose at no extra cost to the Employer, the use of any relevant
authoritative Internationally recognised Reference Standard, including Indian
Standard.
3. All details, materials and equipment supplied and workmanship performed shall
comply with these standards. If Contractors offer equipment to other standards, the
equipment/material should be equal or superior to those specified and full details of
the difference shall be supplied.
4. In the event of conflict between this specification and the codes for equipment,
provisions of this specification shall govern.
2.3
MATERIALS - GENERAL
1. All materials incorporated in the Works shall be the most suitable for the duty
concerned and shall be new and of reputed make/approved quality, free from
imperfections and selected for long life and minimum maintenance. Non-destructive
tests, if called for in the specification, shall be carried out.
2. All submerged moving parts of the Plant, or shafts spindles, etc. of the submerged
moving parts or faces etc. in contact with various chemicals, shall be corrosion
resistant materials. All parts in direct contact with various chemicals shall be
completely resistant to corrosion or abrasion by these chemicals and shall maintain
their properties without aging due to the passages of time, exposure to light or any
other cause.
2.4
WORKMANSHIP - GENERAL
1. Workmanship and general finish shall be of first class quality and in accordance with
best workshop practice.
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2. All similar items of the Plant and their component parts shall be completely
interchangeable. Spare parts shall be manufactured from the same materials as the
originals and shall fit all similar items. Machining fits on renewable parts shall be
accurate and to specified tolerances so that replacements made to may be readily
installed.
3. All equipment shall operate without excessive vibration and with minimum noise.
All revolving parts shall be truly balanced both statically and dynamically so that
when running at normal speeds at any load up to the maximum there shall be no
vibration due to lack of balance.
4. All parts, which can be worn or damaged by dust shall be totally enclosed in dust
proof housings.
5. All materials incorporated in the work shall be most suitable for duty concerned, free
from imperfections, selected for long life and minimum maintenance.
6. All necessary accessories required for satisfactory and safe operation of the plant
shall be supplied by the Contractor unless it is specifically excluded from his scope.
7. All valves shall be closing on clockwise rotation of the hand wheel. The effort
required to close/open under all operating conditions shall be limited to 7 kg. The
direction of opening/closing shall be cast on the hand wheel.
8. All flanges shall be drilled in accordance with requirements of IS: 1538.
9. All flanges shall be full or spot faced on the backside. The flange thickness be
uniform throughout.
10. Flange outside periphery shall be concentric with the bore. Flanges shall be finished
smooth on periphery also.
11. Castings and fabricated materials shall be finished smooth all over.
2.5
WELDING
2.5.1 Design Approval

Welding shall comply with the latest revision of the BS 5135 code. In all welded
fabrications, the Contractor shall submit to the Engineer-in-Charge before fabrication
commences, detailed drawings of fabrication with sizes of weld and weld preparation
together with the details of the application codes. The Engineer-in-Charge shall carry
out no welding before approval of the details. No alternations shall be made to any
previously approved details of weld preparation or size without prior approval of the
Engineer-in-Charge.
2.5.2 Qualification of Welders and Procedures
Welders shall be qualified in accordance with the requirement of the appropriate section
of BS 4871 part 1. The Engineer shall have the right to call for further qualification from
time to time from any welder who in the opinion of the Engineer does not produce weld
in accordance with the qualification. Each welder shall be assigned a number and letter.
Each weld shall clearly be identified as to its welder marking the welders code adjacent
to the welds. A record chart shall be maintained for each welder showing the procedures
for which he has qualified, the date of such qualification, the type of defects produced
and their frequency. The Engineer-in-Charge shall disqualify the welder whose work
requires a disproportionate amount of repairs. All procedures where required shall be
qualified as per BS 4870 Part 1.
Contractor
No of Corrections
Executive Engineer
242

2.5.3 General Welding Requirements

Inspection and quality of surveillance shall not be limited to the examination of finished
welds. All aspects of materials, fabrication procedures and examination procedures shall
be subject to the approval of the Engineer-in-Charge. The equipment used shall be
suitable for the quality of work specified. The techniques employed shall be based on
methods which are known to produce good results and which have been verified at Site
by actual demonstration.
Haphazard striking of the electrodes for establishing arc shall not be permitted. The arc
shall be struck either on the joint or on a starting tag. The starting tag shall be of the
same material or a material compatible with the base metal being welded. In case of any
inadvertent strike on place other than the welding, the area affected shall be ground
flushed and examined by liquid penetration method.
Generally, a stringer bead technique shall be used with a slight oscillation if necessary to
avoid slag and to minimise the number of beads needed to fill the joint. However, the
width of the deposited pass shall not exceed 3 times the wire diameter. Vertical welds
shall be made in upward direction. For all pipes above 300 mm dia., welding shall be
done whenever possible, by 2 welders working simultaneously along both sides of the
pipe.
All joint fit ups shall comply with the tolerances specified on the manufacturing
drawings. The root pass shall have less than 1.5 mm internal reinforcement. Defects
like icicles, burn through and excessive suck back etc. shall be cause for rejection of
welds.
Final welds shall be suitable for appropriate fabrication of the non-destructive
examination of the weld. If grinding is necessary, the weld shall be blended into the
parent metal without gouging or thinning of the parent metal in any way. Uneven and
excessive grinding may be a cause for rejection. Fillet weld shall preferably be convex
and free from undercutting and overlap at the toe of weld. Convexity and concavity shall
not exceed 1.5 mm.
The leg lengths shall not exceed the specified size by more than 1.5 mm.
All attachments such as lugs, brackets and other non-pressure parts shall also be done by
qualified welders in accordance with the design details and materials specifications.
Temporary attachments shall be removed in a manner that will not damage the parent
metal. Areas of temporary attachment shall be dressed smooth and examined by
ultrasonic or liquid penetration methods.
All tack welds shall be made using qualified procedure and welders, the number of size
of tack welds shall be kept as small as to consist of adequate strength and joint
alignments. All tack welds shall be examined visually for defects and if found defective
shall be completely removed. As welding proceeds, tack welds shall be either removal
completely or shall be properly prepared by grinding or filling their starting ends so that
they may be satisfactorily incorporated in the welds. Unacceptable defects shall be
removed by grinding machine or chipping or gouging. Flame gouging may be permitted
provided gouged surface are ground at least by 1.0 mm below the deepest indentation.
Contractor
No of Corrections
Executive Engineer
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All weld repairs shall be carried out using the approved welding procedures and welders.
Preparation of weld repair shall have the prior approval of the Engineer-in-Charge. Rewelded areas shall be re-examined by the methods specified for the original welds and
repair procedures shall be duly qualified by the Engineer-in-Charge.
2.5.4 Pre-heating and Post - heating Treatment
Pre-heating and post heating treatment shall conform to the relevant application codes.
Pre-heating not exceeding 121 Degree Celsius for all carbon steel construction above 25
mm thickness would be mandatory. Such pre-heating would be maintained during flame
cutting, flame or arc gouging, welding and repairs and may be done by gas heating by
gas torches/gas rings with neutral flame. The temperature shall be checked by
temperature indicating crayons. However, such pre-heating will not be necessary for
welds less than 6 mm size. In large diameter pipe fabricated out of plate materials,
production control test plates in accordance with the BS 4870 Part I Table 6 to represent
30% of the long seams and each welders performance would be mandatory.
2.5.5 Electrodes
The makes and type of electrodes to be used shall be submitted for approval of the
Engineer. All electrodes shall be stored in their original sealed containers under dry
conditions. Electrodes shall remain identified until consumed. All electrodes shall be
dried before use. Drying ovens shall be provided in work areas for drying purposes.
Electrodes withdrawn from oven shall be promptly used and excess unused electrodes
shall be promptly returned to oven.
2.5.6 Examination/NDT/Radiography
The various stages of examination and types shall be a stipulated in the respective
fabrication codes. Radiographic examination shall be carried out as per provision of BS
2600 or BS 2910 : Ultrasonic tests where called for shall be carried out as per provision
of BS 3923; magnetic particle tests shall be carried out as per BS 6072. Liquid
penetration tests shall be carried out as per BS 6443.
2.5.7 Stainless Steel Welding
All wires consumable such as electrodes, fillers wires, argon gas for shielding and
purging shall be of high quality and the proposed brand shall be furnished for approval of
the Engineer. Weld deposits shall have similar or higher physical properties and similar
chemical composition to the members joined.
All electrodes shall be purchased in sealed containers only and stored in their packing
intact. The packets opened shall be consumed as early as possible. The electrodes
removed from the containers shall be kept in holding ovens at temperature recommended
by electrodes manufacturer. Special care shall be taken in avoiding mixing of electrodes
in the oven.
The electrodes and filling wires shall be free from rust, oil, grease, earth and other
foreign matter.
Argon gas with purity 99.5% shall be used for shielding and purging.
manufacturers shall certify the purity of gas.
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Non destructive examination of these welds shall be carried out to ensure quality of
weld.
The electric current for welding shall be direct current, straight polarity (electrode
negative). The welding current shall be kept minimum possible to ensure minimum heat
affected zone in the parent material. Other side of the weld joint shall be periodically
flushed with argon gas.
2.6
CASTINGS
1. Cast iron shall be of standard grey close - grained quality. The structure of the
castings shall be homogenous and free from non-metallic inclusions and other
injurious defects. All surfaces of castings, which are not machined, shall be smooth
and shall be carefully fettled to remove all foundry irregularities.
2. Minor defects in depth not exceeding 12.5 percent of total metal thickness and which
will not ultimately affect the strength and serviceability of the casting may be
repaired by approved welding techniques. The Engineer-in-Charge shall be notified
of large defects and no repair welding of such defects shall be carried out without
prior approval of the Engineer-in-Charge. if the removal of metal for repair should
reduce the stress resisting across section of the casting by more than 25 percent, or to
such an extent that the computed stress in the remaining metal exceeds the allowable
stress by more than 25 percent, then that casting shall be rejected. Test coupons cast
simultaneously with the main casting shall be identified by the Engineer-in-Charge
to check physical, chemical analysis of casting.
3. Major defects on casting are not acceptable. Castings repaired by welding for minor
defects shall be stress-relieved after such welding. Castings subject to hydraulic
pressure shall be pressure tested to 1 times the rated pressure or, twice the working
pressure, whichever is higher and certified copies of test reports shall be forwarded
to the Engineer-in-Charge as soon as each test has been completed. Non-destructive
tests as directed by the Engineer-in-Charge will be required for any casting
containing defects whose extent cannot otherwise be judged, or to determine where
repair welds have been properly made.
4. Unless otherwise specified casting shall be produced to the following standards or
equal :
2.7
Sr.
Component
Grade
(a)
(b)
(c)
(d)
Grey Iron
Carbon Steel
Stainless Steel
Copper & Copper Alloy
:
:
:
:
BS 1452 Grade 220

BS 3100 Steel Alloy
BS 3100 Steel 316 C16
BS 1400
Group A Grade LG2
Group B Grade CT1, AB2
Group C Grade G1
FORGINGS
All major stress - bearing forgings shall be made to a standard specification. Forgings
shall be subjected to magnetic particle testing or dye penetration test at the areas of fillets
and change in section. The testing shall be conducted after rough machining (10
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microns). Any defect which will not machine out during the final machining, will be
gouged out fully, inspected by dye penetration or magnetic particle inspection to ensure
that the defect is fully removed and repaired using an approved repair procedure. Any
indication, which proves to penetrate deeper than 2.5% of the finished thickness of the
component, shall be reported to the Engineer giving the details like location, length,
width and depth. For the magnetic particle inspection the choice of wet or dry particles
shall be at the Contractors discretion. All forgings shall be damagnetised after test and
shall be heat-treated for the relief of residual stresses. The name of the maker and
particulars of the heat treatment proposed for each such forging shall be submitted to the
Engineer-in-Charge. The Engineer-in-Charge or the Inspector may inspect such forgings
and identify test coupons to check physical and chemical analysis and witness such tests
at the place of manufacture with a representative of the Contractor.
2.8
PIPES AND SPECIALS

All interconnecting piping included in these tenders are of CI except for potable water
supply and chemical piping. The pipe shall be as per the specifications. Use of tailpiece
will be allowed for adjustment of length.
Piping for water supply shall be GI Class C. The piping for chemical dosing shall be
HDPE/PVC/PP/SS316, whichever is best suited. The piping includes joints, gasket and
supports. The fasteners and washers used shall be of GI
2.9
VALVES
1. All the valves shall be hydraulically tested open ended. Valves bodies for all valves
shall be tested for either side (except for non return valves, where it will be one side)
to one and half times the maximum pressure or twice the working pressure,
whichever is higher, for a duration of 10 mts, during which there should not be any
leakage.
2. Sluice valves shall be double-flanged and shall have knife gates manufactured in
close-grained cast iron or equal material unless otherwise specified. The seats and
faces shall be of bronze and rings shall be forced fitted. Sluice valves of nominal dia
300 mm and above shall be provided with gunmetal shoe and channel
arrangement so that the gate shall be guided throughout its travel. Total side
clearance between shoe and channel shall be less than 1.5 mm. Valve spindles shall
have thrust flange to take up axial thrust.
3. The spindle shall be of high tensile brass.
4. The valves shall be suitably designed to protect the disk edge from corrosion and
erosion.
5. Non-return valves on the main pump delivery branches shall possess non-slam
characteristics with minimum shock on closing.
6. Packed glands shall be arranged for easy replacement of the packing, which shall be
accessible without removal of the valve from the pipe. Precautions shall be taken to
prevent corrosion of the valve spindles in contact with the gland packing. Sluice
valves shall have seat arrangement for ease of maintenance.
7. Each valve or its operating equipment shall bear an approved nameplate stating its
function. All operating spindles, gears and headstocks shall be provided with
adequate points for lubrication.
8. All gate valves shall have non-rising spindles.
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2.10 SUPPORT OF PIPENETWORK AND VALVES

All necessary supports, saddles, slings, fixing bolts and foundation bolts shall be
supplied to support the pipework and its associated equipment in an approved manner.
Valves, meters, strainers and other devices mounted in the pipework shall be supported
independently of the pipes to which they connect. All brackets or other forms of support,
which can conveniently be so designed, shall be rigidly built up of steel by reveting or
welding in preference to the use of castings. No point of passage of pipes through floor
or walls shall be used as a point of support, except with the approval of the Engineer in
charge.
2.11 DESIGN LIFE

1. The works as a whole shall be new, of sound workmanship, robustly designed for a
long reliable operating life and shall be capable of 24 hours per day continuous
operation for prolonged period in the climatic and working conditions prevailing at
the site, and with the minimum of maintenance. Particular attention shall be given to
temperature changes, the stability of paint finish for high temperatures, the rating of
engines, electrical machinery, thermal overload services, cooling systems and the
choice of lubricants for possible high and prolonged operating temperatures. The
Contractor shall be called upon to demonstrate this for any component part either by
service records or evidence of similar equipment already installed elsewhere or
relevant type test. Routine maintenance and repair shall as far as possible not
requires the services of highly skilled personnel.
2. The Plant shall be designed to provide easy access to and replacement of component
parts, which are subject to wear, without the need to replace whole units. No parts in
the contact with water shall have a life from new to replacement or repair of less than
five years. Where major dismantling is unavoidable to replace a part, the life of such
part shall not be less than ten years.
3. Design features shall include the protection of plant against damage caused by
vermin, dirt, dust and dampness and to reduce risk of fire. Plant shall operate
without undue vibration, and parts shall be designed to withstand the maximum
stresses under the most severe condition of normal service. Materials shall have a
high resistance to change in their properties due to the passage of time, exposure to
light temperature and any other cause, which may have a detrimental effect upon the
performance, or life of the works.
4. Plant located outside lockable areas/buildings shall have additional features to
prevent unauthorised operation.
2.12 LUBRICATION
1. A complete schedule of recommended oils and other lubricants shall be furnished by
the Contractor. The number of different types of lubricants shall be kept to a
minimum. The schedule and the name of the supplier of the lubricants shall be
submitted to the Engineer-in-Charge for approval before incorporation in the
Instruction Manuals. In the case of grease lubricated roller type bearings lithium
base grease is preferred.
2. Contractors shall indicate indigenously available equivalent lubricants, with
complete duty specification, to enable the Employer to arrange for regular supply.
3. Where lubrication is effected by means of grease, preference shall be given to a
pressure system, which does not require frequent adjustment or recharging.
Frequent, for this purpose, means more than once in a month and grease systems
having shorter periods between greasing should be avoided. Where necessary for
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4.
5.
6.
7.
accessibility grease nipples shall be placed at the end of the extension piping, and,
when a number of such points can be grouped conveniently, the nipples shall be
brought to a battery plate mounted in a convenient position. All grease nipples shall
be of the same size and type for every part of the plant. Arrangements shall be
provided to prevent bearings being overfilled with either grease or oil.
Where more than one special grease is required, a grease gun for each special type
shall be supplied and permanently labeled.
Oil containers shall be supplied complete with oil level indicator of the sight glass
type, or where this is not practicable, with dipsticks. The indicators shall show the
level at all temperatures likely to be experienced in service. The levels shall be
clearly visible in the sight glass type from the normal access floor to the particular
item of plant and they shall be easily dismantled for cleaning. All sight glasses shall
be firmly held and enclosed in metal protection in such manner that they cannot be
accidentally dislodged.
All lubrication systems shall be designed so as not to cause a fire or pollution hazard
and particular care shall be taken to prevent leakage of lubricants and to avoid
leaking lubricants coming into contact with any electrical equipment, heated surfaces
or any other potential source of fire.
The Contractor shall supply flushing oil for each lubrication system when an item of
plant is ready for preliminary running and a sufficient quantity of the approved
lubricants for the commercial operation of the plant for two years after the Takingover Certificate has been issued.
2.13 NAME PLATES

1. Each item of the plant shall have permanently attached to it in a conspicuous
position, a nameplate and rating plate, each of stainless steel. Upon these shall be
engraved or stamped, the manufacturers name, type and serial number of Plant,
details of the loading and duty at which the item of plant has been designed to
operate, and such diagrams as may be required by the Engineer-in-Charge. All
indicating and operating devices shall have securely attached to them or marked
upon them designations as to their function and proper manner of use.
2. Details of proposed inscriptions shall be submitted to the Engineer-in-Charge for
approval before any labels are manufactured. Such nameplates, rating plates and
designations shall be of stainless steel with engraved or stamped lettering items such
as valves shall have direction of rotation for closing and opening indicated.
3. Nameplates, rating plates and labels shall be of a non-flame propagating materials,
either non-hygroscope or transparent plastic with engraved lettering of a contrasting
colour. Fixing shall be by means of non-corrosive screws, drive rivets or adhesives
shall not be used.
4. Warning labels shall be provided where necessary to warn of dangerous
circumstances or substances. Inscriptions or graphic symbols shall be black on a
yellow background and to internationally recognised standards.
5. Instruction labels shall be provided where safety procedures such as wearing of
protective clothing are essential to protect personnel from hazardous or potentially
hazardous conditions. These labels shall have inscriptions or graphic symbols in
white on a blue background.
2.14 NUTS, BOLTS, STUDS AND WASHERS

1. Nuts, bolts, studs and washers for incorporation in the plant shall conform to the
requirements of the appropriate standard. Nuts and bolts shall be of the best quality
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2.
3.
4.
5.
6.
of specified grade, machined on the shank and under the head and nut. Bolts shall be
of one-piece construction and shall be of sufficient length so that only one thread
shall show through the nut in the fully tightened condition.
Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the
screwed portion of such a diameter that it will not be damaged in driving and shall be
marked in a conspicuous position to ensure correct assembly at Site.
Washers, locking devices and anti-vibrations arrangements shall be provided where
necessary and shall be subjected to the approval of the Engineer-in-Charge. Jointing
hardware for the entire plant shall be provided with sufficient spares to cater for site
losses.
Where bolts pass through structural members taper washers shall be fitted, where
necessary, to ensure that no bending stress is caused in the bolt. Where there is a
risk of corrosion, bolts nuts and studs shall be designed so that the maximum stress
does not exceed half the yield stress of the material under any conditions. All bolts,
nuts and washers which are subject to frequent adjustment or removal in the course
of maintenance and repair shall be made of nickel-bearing stainless steel.
The Contractor shall supply all holding down, alignment and leveling bolts complete
with anchorages, nuts, washers and packing required to attach the plant to its
foundations, and all bed plates, frames and other structural parts necessary to spread
the loads transmitted by the Plant to concrete foundations without exceeding the
design stresses.
The material of nut, bolts, studs and washers for wetted/submerged areas shall be of
SS:316 and others shall be of GI (specifically nut bolts of Aerators, bridge, Filter
press, gates, screens, CL2 doser, sludge agitator should be only of S.S. either
submerged stage or open in air).
2.15 ALLOWANCE FOR WASTAGE

The Contractor shall supply to the satisfaction of the Engineer-in-Charge reasonable
excess quantities to cover wastage of those consumable which will be normally subject
to waste during erection, commissioning and setting to work.
2.16 PAINTING - GENERAL

1. The Contractor shall be responsible for the cleaning, preparation for painting, and
priming or otherwise protecting, as specified, all parts of the plant at the place of
manufacture prior to packing.
2. Parts may be cleaned but surface defects may not be filled in before testing at the
manufacturers works. Parts subject to hydraulic test shall be tested before any
surface treatment. After test, all surfaces shall be thoroughly cleaned and dried out if
necessary by washing with an approved dewatering fluid prior to surface treatment.
Except where the specification provides to the contrary all painting materials shall be
applied in strict accordance with the paint manufacturers instructions.
3. All protective coatings shall be suitable for use in warm humid climates.
2.17 PAINTING AT PLACE OF MANUFACTURER

1. All stages in painting including cleaning and surface treatment in the manufacturers
works shall be available for inspection.
2. Steel and cast iron parts shall be sand blasted to near white cleaning before painting.
Edges, sharp covers etc. shall be ground to a curve before sand blasting.
3. A primer coat of a zinc rich epoxy resin based coating with at least at 75 microns dry
film thickness is to be provided. In addition the parts are to be provided with
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adequate number coats or coal tar epoxy polyamine coating to a dry film thickness of
175 microns including primer coating.
2.18 PAINTING AT SITE

1. Immediately on arrival at the site, all items of plant shall be examined for damage to
the paint coat applied at the manufacturers works, and any damaged portions shall
be cleaned down to the bare metal, all rust removed, and the paint coat made good
with similar paint.
2. Steel and cast iron parts received at site shall be provided with adequate number of
further coats of coal tar epoxy polyamine coating to a total dry film thickness of 275
microns including the primer coats. All sharp edges, nuts, bolts and other items
difficult to be painted shall receive a brush coat of specified paint before application
of each coat of epoxy based coal tar paint giving a total dry film thickness of at least
275 microns. In the case of fabricated steelwork this work shall be done after
assembly.
3. Before painting is commenced the Contractor shall submit for the approval of the
Engineer-in-Charge, full details of the paints he proposes to use together with colour
charts for the gloss finishes.
All paint and coating thickness shall be measured by approved Elcometer or coating
thickness gauge.
2.19 LIST OF STANDARDS

The titles of various standards referred to in the Specification are indicated hereunder for
ready reference. This list does not necessarily covers all the Standards referred to :
Standard No
Title
IS 5
Colours for ready mixed paints and enamels
IS 210
Grey Iron Castings
IS 318
Leaded Tin Bronze Ingots and Castings
IS 325
Three Phase Induction Motors
IS 807
Code of Practice for design, manufacture, erection and testing

(structural portion) of cranes and hoists
IS 1239
Mild Steel tubes, tubular and other wrought steel fittings.
IS 1536
Centrifugally cast (Spun) iron pressure pipe for water, gas and sewage
IS 1537
Vertically cast iron pressure pipes for water, gas and sewage
IS 1538
Specification for cast iron fittings for pressure pipes for water, gas and
sewage
IS 1554
PVC insulated (heavy duty) electric cables
IS 2062
Steel for general structural purposes
IS 2147
Degrees of protection provided by enclosures for low voltage switch

gear and control gear
IS 3109
Short link chain, Grade M (4)
IS 3177
Code of practice for electric overhead traveling cranes and gantry
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Standard No
Title
cranes other than steel work cranes.
IS 3618
Phosphate treatment for iron and steel for protection against corrosion
IS 3624
Vacuum and Pressure gauges
IS 3815
Point hooks with shank for general engineering purposes
IS 3938
Electric wire rope hoists
IS 4029
Guide for testing three phase induction motors
IS 4460
Method for rating of machine cut spur and helical gears
IS 4691
Degrees of protection provided by enclosure for rotating electrical

machinery
IS 6005
Code of practice for phosphating of iron and steel
IS 8329
Centrifugally cast (spun) ductile iron pressure pipes for water, gas and
sewage
IS 11592
Code of practice for selection and design of belt conveyors
IS 13349
Cast Iron Single faced thimble mounted sluice gates
BS 436
Spur and helical gears
BS 466
Specification for power driven overhead traveling crane, semi-Goliath

and Goliath cranes for general use
BS 545
Specification for bevel gears (machine cut)
BS 721
Specification for worm gearing
BS 970
Wrought steels for mechanical and allied engineering purposes
BS 1397
Specification for industrial safety belts, harnesses and safety
BS 1400
Specification for copper alloy ingots and copper alloy and high
conductivity copper castings
BS 1452
Specification for flake graphite cast iron
BS 1663
Specification for higher tensile steel chain Grade 40 (Short link and
pitched or calibrated) for lifting purposes.
BS 2573
Specification for classification, stress calculations and design of

mechanisms
BS 2600
Radiographic examination of fusion welded butt joints in steel
BS 2903
Specification for higher tensile steel hooks for chains, slings, blocks
and general engineering purposes
BS 2910
Methods for radiographic examination

circumferential butt joints in steel pipes
BS 3017
Specification for mild steel forged ram shorn hooks
BS 3100
Specification for steel castings for general engineering purposes
BS 3923
Methods for ultrasonic examination of welds
BS 4360
Specification for weldable structural steels
BS 4772
Specification for ductile iron pipes and fittings
BS 4870
Specification for approval testing of welding procedures.
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Standard No
Title
Part - I : Fusion Welding of Steel
BS 4871
Specification for approval testing of welders working to approved

welding procedures
Part - I : Fusion Welding of Steel
BS 4942
Short chain link for lifting purposes
BS 5135
Specification for arc welding of carbon and carbon manganese steels
BS 5316
Specification for acceptance tests Part - 2 for centrifugal, mixed flow

and axial pumps- Test for performance and efficiency
BS 6072
Method for magnetic particle flaw detection
BS 6405
Specification for non-calibrated short link steel chain (Grade 30) for
general engineering purposes: Class 1 & 2.
BS 6443
Method for penetrate flow detection
ASTM A-36
Specification for Structural Steel
ASTM A-216
Specification for Steel Castings, Carbon suitable for fusion welding for
high temperature service
ASTM A-276
Specification for stainless steel and heat resisting steel bars and shapes
ASTM A-351
Specification for castings, Austenitic - Ferritic (Duplex), for Pressure

Containing Parts
ASTM A-743
Specification for casting, Iron - Chromium, Iron - Chromium-Nickel,

and Nickel Base corrosion Resistant for General Application
ASTM A-744
Specification for casting, Iron Chromium - Nickel, Corrosion Resistant
ASTM B-148
Specification for Aluminum - Bronze Castings
IEC 189
Low frequency cables and wires with Parts 1 & 2 PVC insulation and
PVC sheath
AWWA C 501
Casting Iron Sluice Gates
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3 MECHANICAL EQUIPMENT
3.1
GENERAL
The contract includes design, manufacture, testing at works, supply and delivery at site,
unloading, storing till the time of erection, installation, testing and commissioning of
mechanical equipment as mentioned in the following sections. The scope of the work
shall include but not be limited to the following:
The equipment should be selected to suit the performance requirements and the
prevailing site conditions. The mechanical equipment includes electrical motor, wherever
applicable and shall meet the requirements as specified under electrical specifications.
The requirements of various mechanical equipment are described hereunder.
3.1.1 Submersible Pumps

3.1.1.1 General
(a)
The total head capacity curve shall be continuously rising towards the shut off
with the highest at shut off.
(b)
Pumps shall be suitable for single as well as parallel efficient operation at any
point in between the maximum and minimum system resistance.
(c)
The pumps shall be designed to handle solid sizes of upto 75 mm for handling
raw sewage and 50 mm for handling sludge.
(d)
Pumps shall run smooth without undue noise and vibration.
(e)
The pump set shall be suitable for starting with discharge valve open and/or
closed.
(f)
The pump set shall be capable of withstanding the accidental rotation in reverse
direction.
3.1.1.2 Features of Construction

(a)
Pump shall be centrifugal, vertical spindle, nonclog, wear resisting, single stage
type.
(b)
Pump casing shall be of robust construction. Liquid passages shall be finished

smooth and designed as to allow free passage of solids. The volute tongue shall
be filed to a smooth rounded edge.
(c)
Double Mechanical seals shall be provided to protect the motor from ingress of
sewage along the shaft. The preliminary and secondary seals shall be oillubricated with tungsten carbide or silicon-carbide faces and they shall be
equipped with an electrical monitoring system for seal failure detection.
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(d)
Impeller shall be non-clog enclosed type with smooth blunt edges and large
water ways so as to allow free passage of the large size solids. It shall be free
from sharp comers and projections likely to catch and hold rags and stringy
materials. The number of impeller vanes for pumps upto 1000 m3/hr shall be
limited to two and shall be limited to three for the pumps higher than 1000
m3/hr.
(e)
The critical speed of the rotor shall be atleast 30% above the operating speed.
(f)
Pumpsets shall have double bearings. The bearing life shall be minimum 40,000
hrs of operation.
(g)
Each pump shall be complete with a cast iron delivery connection arrangement
for fixing to the concrete floor of the suction well. The joint between the pump
discharge flange and the delivery piping shall be made by merely lowering the
pump into guide rails / rope from access level. It shall be provided with all
necessary fixings for guiding the pumps during lifting/lowering.
(h)
The pump delivery size shall not be less than 200 mm.
(i)
Each pump shall be provided with an automatic coupling device for attaching the
chain pulley block hook to the pump at low level, even whilst the pump is
submerged, without the need for personnel to enter the well. This automatic
coupling device shall easily and automatically couple and uncouple the hoist
hook and be complete with necessary accessories. All links and cables shall be
multi-stranded stainless steel.
j)
The materials of construction for submersible pumps shall be as follows:
Sr. No. Component

(i)
Impeller*
(ii)
Casing*
(iii)
(iv)
(v)
(vi)
Shaft*
Bush
Guide rail pipe
Fastens and Foundation Bolts
Material
Stainless steel: ASTM A 743 CF8M
Cast Iron to IS : 210 Gr. FG 200 with
1.5 to 2% Nickel
Stainless Steel: BS : 970Gr. 316
Bronze IS 318 Gr. L TB2..
Stainless Steel: BS : 970 Gr. 304
Stainless Steel : BS : 970 Gr. 316
* Material test certificates shall be furnished by the Contractor
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3.1.1.3 Induction Motor (Submersible Pump)

Performance and Characteristics
(a)
The submersible motor shall conform to IS:9283: 1979 and the submersible
cable shall conform to clause no. 4.4 of the IS:9283: 1979.
(b)
Motors shall be capable of giving rated output without reduction in the expected
life span when operated continuously under the following supply conditions:
(i)
(ii)
(iii)
Variation of supply voltage from rated motor voltage

Variation of supply frequency from rated frequency
Combined voltage and frequency variation
: 10%
: 5%
: 10%
(c)
The starting current of motor shall not exceed 200% of rated full load current for
star/delta starting and 600% of rated full load current for DOL starting, under
any circumstances.
(d)
Motors shall be suitable for full voltage direct-on-line starting or star-delta

starting.
(e)
Motors shall be capable of starting and accelerating the load with the applicable
method of starting, without exceeding acceptable winding temperatures, when
the supply voltage is in the range 85% of the rated motor voltage to maximum
permissible voltage.
(f)
The locked rotor current of the motor shall not exceed 600% of full load current
(subject to tolerance as per the applicable standard) unless otherwise specified.
(g)
Motors shall be designed to withstand 120% of rated speed for two minutes
without any mechanical damage in either direction of rotation.
(h)
The motor vibrations shall be within the limits specified in applicable standard
unless otherwise specified for the driven equipment.
(i)
Except as mentioned herein, the guaranteed performances of the motor shall be

met with tolerances specified in applicable standard, IS:9283-1979.
(j)
The enclosure for motor shall be IP-68.
(k)
Protection against increase in stator winding temperature (150C) bearing

temperature, leakage in stator housing and terminal box shall be provided.
Minimum three number thermistors in series are to be provided to sense the
stator winding temperature. Sensors are to be provided to detect if leakage of
sewage into the oil housing is above 30% concentration.
(l)
Bimetallic thermal switch to trip the motor against increase in temperature shall
be provided.
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(m)
The power rating of the motor shall be larger of the following:
(i)
115% of the power input to the pump at duty point at a speed corresponding to
the frequency of 48.5 Hz.
Maximum Power input while operating single pump corresponding to the speed
of 50 Hz.
.
(ii)
3.1.1.4 Submersible Cable

(a)
The power cable shall be PVC insulated and PVC sheathed, flexible, 3.5 core flat type.
The size of the conductor shal1 be adequate for continuous use under water and air. The
half core shal1 be used for earthing.
(b)
The control cable shall be PVC insulated PVC sheathed, flexible, flat type and shall be
adequate for continuous use under water and air. The control cable for stator winding
temperature sensor (Thermistors) shall be 3 core x 2.5 sq. mm copper conductor and for
bimetallic thermal switch 2 core x 2.5 sq. mm copper conductor shall be provided.
(c)
In case a joint is required to be made between the lead cable supplied with the motor and
the user's cable connectors, a detailed procedure of cable jointing to make a watertight
joint shall be provided by the manufacturer.
(d)
The size of the conductor and length of cable should be suitably selected so that the
voltage drop at motor terminals does not exceed 3 percent of the rated voltage.
3.1.1.5 Earthing
(a)
Earthing of the motor shall be done in accordance with the relevant provisions of
18:3043: 1966.
(b)
For the purpose of earthing these motors, earthing connection may be made to discharge
pipe.
3.1.1.6 Insulation
(a)
Any joints in the motor insulation such as at coil connections or between slot and end
winding sections, shall have strength equivalent to that of the slot sections of the coil.
(b)
The insulation shall be given tropical and fungicidal treatment for successful operation of
the motor in hot, humid and tropical climate. The tropicalising treatment shall be as per
the applicable standard.
(c)
The stator winding shall be made from high conductivity annealed copper conductor.
PVC insulated winding wires conforming to IS:8783: 1978 for wet type motors. The
stator winding shall be of high conductivity annealed copper enamelled insulated wires
conforming to IS:4800 (Part - VII): 1970 for dry type motors.
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3.1.1.7 Temperature Rise

The temperature-rise test of the motor shall be taken with the motor coupled to the
suitable pump to give the full load output of the motor. When the various temperatures
are stabilized, the set is stopped and the temperature-rise of the stator winding by the
resistance method shall not exceed 35C. During the test, the temperature of the cooling
water may not exceed 35C. As the cable resistance will also be substantial, it is
necessary that while calculating the temperature rise by resistance method, due care is
taken to account for the correct hot and cold resistance of windings.
3.1.1.8 Constructional Features
The motor shall be suitable for continuous use in fully or partially submerged condition.
A built in cooling system must allow the motor to operate continuously at its rated output
regardless of whether the electric motor is submerged or not, by providing either external
or internal cooling arrangement.
3.1.1.9 Terminal Box
Terminal box shall be of weather proof construction to eliminate entry of water and
suspended matter. The terminals shall be of the stud type with necessary plain washers,
spring washers and check nuts. They shall be substantially designed for the current
carrying capacity and shall ensure ample phase to phase and phase to ground clearance.
3.1.2 Aluminium Gates
Gates are provided for the control of the flow and for maintenance of the mechanically
raked screens, grit removal system and flow division box. The gates and frame shall be
of Aluminum. The frame shall be suitable for channel mounting. The gates provided are
self-contained type with flush bottom and suitable for channel mounting. The water
sealing will be there at two vertical sides and bottom side of gate frame by means of
neoprene rubber seal mounted on shutter having forced contact with gate opening. The
gates shall be provided with manually operated headstock, which is to be mounted on
yoke of the gate frame.
The gate shall be suitable for operation by one person needing effort less than 20 kg. The
stem/spindle shall be of SS304. The operating/stem nut shall be of leaded tin bronze as
per IS318 grade LTB1 / LTB2. The fasteners and anchor bolts shall be of SS316.
The gates shall be shop tested for smooth operation of complete assembly and the
clearance between, which should be within the tolerance limit of the relevant IS.
3.1.3 Cast Iron Sluice Gates
The construction of cast iron sluice gate shall be in accordance with the specifications
mentioned hereunder and as per IS:13349-1992. The sluice gate shall be capable of
performing the duties set out in this specification without undue wear or deterioration.
They shall be constructed, so that maintenance is kept to a minimum. The sluice gate
shall be rising spindle type.
Contractor
No of Corrections
Executive Engineer
257

3.1.3.1 DETAILS OF CAST IRON SINGLE FACE THIMBLE MOUNTED SLUICE

GATE
1.
Applicable standard
IS: 13349-1992
2.
Shape of water way
Square / Rectangular / Circular
3.
Size (W x H) in mm
mm x mm
4.
Operating head from surface

of water to center line of
gate in meters
meters
5.
Design head in meters

Seating head
Unseating head
:
:
:
meters
meters
6.
Distance between center :

line of water way to base
of operating platform
meters
7.
Method of operation
Manually geared operated.
8.
Length and shape of wall

thimble
As per site requirement
9.
Stem
Rising type
10.
Type of closure
Conventional Closure / Flush Bottom

closure
11
Seating face
:
The maximum clearance between the
seating surface with the slide in the closed positions hall not exceed 0.10 mm. The
seating face should be fitted in dove tailed machined grooves.
12.
Side and Top wedges
Separately adjustable type
13.
Shop Testing
:
following shop test at manufacturer site
will be conducted as per procedure mentioned hereunder
a
Movement Test
Movement test should be conducted in horizontal/vertical assembled condition using

stems & headstock. The gate should be operated once from full close to full open and
back to full close condition with a max. force of 135 Newton-meter on the crank of hand
wheel.
b.
Shop leakage test
Shop leakage test by applying unseating hydraulic pressure will be conducted at

manufacturers shop. A hydrostatic pressure equal to maximum seating/unseating head
Contractor
No of Corrections
Executive Engineer
258

shall be applied to gate at center line of gate opening from the back, i.e. Unseating face
of the gate in closed position, through pump. The suitable sealed calibrated pressure
gauge put on the unseating face of the gate shall indicate constant reading equal to
unseating pressure head. The pressure gauge shall be placed at center line of the gate
and should indicate the actual pressure being encountered by the gate. It will not be
allowed to put pressure on any other location like delivery line of pump set, etc.
Water leakage through the gate under above condition shall be collected in a collection
pan and measured. The leakage so measured should not exceed the limit of 2.5, 3.5 and
4.5 litres per minute per meter sealing perimeter for class-I, class II and class III sluice
gates as stated in the IS:13349-1992.
No alternate testing arrangement will be permitted in place of above method.
c.
Hydrostatic Body test
After the leakage test hydrostatic body test will be conducted as manufacturers shop A
hydrostatic pressure equal to 1.5 times the maximum operating head should be applied
on the gate for 5 minutes continuously. No permanent deformation in casting should be
observed.
d.
Torque test at operating head
Torque test at operating head would be head conducted at applicable head at
manufacturers shop for gates upto 2000 x 2000mm size
e.
Dimensional Check
Important Dimensions shall be checked with reference to approved GA drawing.
f.
Seat clearance check
With the gate in closed condition 0.1 mm thick feeler gauge should not pass through
between seat facings
13.
Indicator on C.I. headstock to be provided for gate travel with transparent /
galvanized pipe hood and full scale and with additional mechanicals top nut on threaded
stem.
14.
Indicate number of hand wheel revolutions required to fully open the gate.
15.
Wall guide brackets, bearing and coupling with housing shall be provided as per
site requirement and/or as per I.S. 13349
16.
Gate Make
17.
Material Construction
Part
a.
Contractor
Material
Gate frame, shutter, wall

thimble, headstock, stem
guide bracket, wedging
device, stop nut, lifting
No of Corrections
Cast Iron IS-210 Grade FG-200
Executive Engineer
259

mechanism, pedestal gear

house and nuts
b.
Flush bottom seal

retainer bar, anchor bolts
and buts
Stainless Steel AISI-410
c.
Wedge, wedge facings,

seating face/seat facings
Naval Brass IS 291 Grade 1, Grade 2
d.
Flush bottom seal (if

required)
EPDM Rubber
Stem Nut & Lift Nut
Leaded Tin Bronze IS 318 Grade
e.
LTB-2
f.
All Fasteners & bolts
g.
Stem & stem extension,

stem coupling
18.
Painting
a.
Paint for gate assembly

and stem guide brackets
Ordinary Black Bituminous Paint
b.
Paint for headstock pillar
Grey Enamel Paint
3.1.4 Mechanical Fine Screens

Mechanical fine screen shall have bar screens, mechanical raking arrangement and
electrical drive for auto/manual operation. The bar screens shall be fabricated from
Stainless Steel 316 flats spaced at clear spacing of 6 mm with structural steel frame work
such that all bars project on upstream side and teeth of the rake engages within the
clearances of the bars without hindrance.
The cleaning rake shall be revolving rake type with minimum four steel combs or
reciprocating type. The rake shall be suitably sized for heavy duty and shaped to
effectively clean the bar screen. The sprocket chain used shall be split type. The
screenings shall be dropped on conveyor about 600 mm above the top of the screen
channel.
A dead plate 6 mm thick shall be provided from top of the bar screen to prevent falling
of screenings in the channel. It shall have pivot plate at the bottom for preventing
jamming of bottom shaft incase of revolving rake. The operating unit above the floor
shall be totally enclosed with hinged clean outs and inspection doors incase of revolving
rake.
The drive machinery shall include TEFC motor, speed reducer, head shaft, etc. All
fasteners will be of SS316 and the structure within channel shall be sand/ball blasted to
Contractor
No of Corrections
Executive Engineer
260

near white and epoxy painted after applying two coats of zinc rich primer. The guide
channel for the screen shall be of CI.
3.1.5 Belt Conveyor
A common belt conveyor shall be provided for collecting screenings from mechanised
fine screens and manual screen. The length of the combined belt conveyor will be as per
requirement of screen channel. The conveyor will drop the screening through chute in a
wheeled trolley of approximate 0.5 m3 capacity. This trolley will be housed in a roofed
enclosure with proper access.
Belt conveyor assembly shall consist of two pulleys with their shaft and bearings for
driving the belt and idler pulleys for supporting the belt. The upper level idler pulleys
shall have three roll twenty-degree troughing idlers. The bottom level idlers for belt
return shall be flat roll -type.
At the end of the belt drive, an adjustable scrapper shall be provided on the screening
hopper for diverting the screening through chute to the wheeled trolley.
The belt material shall be two - ply nylon or equivalent with 3 mm neoprene covering on
carrying side and 0.75 mm neoprene covering on pulley side. The speed of the belt will
be between 25m to 30 m per minutes. The width of the belt shall be minimum 600 mm.
The power transmission shall be by means of TEFC motor coupled to the reduction
gears. The gears shall have service factor of not less than 2.25.
The whole conveyor shall be supported on steel structure over the screen channel.
3.1.6 Manual Screens (10 mm, 20 mm and 40 mm)
The trash screen shall be rectangular in shape.
The screen shall be fabricated out of SS 316 flats and fixing bolts shall be of stainless
steel.
The rectangular trash screen shall comprise SS flats, 10 mm thick and 50 mm wide in
section.
The screen shall be rigidly fixed to the frame.
The trash screen shall move vertically up or down in guide channels that are securely
fixed to the sidewalls of the inlet chamber by means of suitably sized and spaced rag
bolts of approved material. Each screen shall have two lifting hooks, spaced sufficiently
apart from the centre at the top of the screen frame. An electric hoist of approved design
and quality for lifting each screen will also be provided. The side of the screen shall have
replaceable wear shoes of gunmetal.
Stainless steel roller shall be provided on the screen frame, two on each side, to enable
the screen to move smoothly in the guide channels. The framework shall be provided
only on the downstream side of the screens.
All the bypass screens shall be provided with 2 sets of cleaning rakes.
Contractor
No of Corrections
Executive Engineer
261

3.1.7 Mechanical Degritter

The grit removal system shall be provided for grit removal. It shall include Classifier
type grit-scraping mechanism, adjustable influent deflector and reciprocating rake
mechanism to remove the grit and organic return pump.
The grit scraping mechanism shall have fixed bridge with rotating scrapper arms. The
scrapper arms shall have adjustable squeezes, which shall scrap the grit to the grit sump.
An overload alarm shall be provided to trip the machine in case of overload.
The reciprocating rake mechanism shall lift the grit up. The reciprocating rake
mechanism shall be installed at about 350 inclination. Chute is located at the top through
which, grit will fall in a wheeled trolley of approximate 0.5 m3 capacity. This trolley will
be housed in a roofed enclosure with proper access, screen washing arrangement and
drain etc.
A grit cleaning arrangement shall be provided to remove organic particles from the grit
and shall be pumped back to the inlet by an organic pump. The grit pump shall have
volute and impeller of Ni-CI with Ni content of not less than 2%. Organic pump to have
separate drive including TEFC motor. The gears used shall have minimum service factor
of 2.50 for 3 HP motor.
3.1.8 Primary Clarifier
The Primary Clarifier Tank shall have central driven clarifier mechanism in MSEP with
sewage entry through the central column. The clarifier mechanism shall have fixed half
bridge resting on the central column with aluminium chequered plate and G.I. handrails
upto the wall.
The clarifier drive will have center mechanism / drive head TEFC motor and speed
reducing gearbox. The service factor for the gear will not be less than 2.5 The central
drive shall have slewing ring bearing located on the central column. The scrapers ring
will be attached to the lower end cage hung and driven by slewing ring drive on the top
of the central column. The inlet well shall be hung from the bridge. The MOC of the inlet
well shall be FRP. An overload alarm system shall be provided as an overload protection
for the drive
The mechanism shall have skimming arrangement. The squeezes will be of neoprene
rubber. The V-notch weir for the clarifier will be of FRP and fixed to the R.C.C launder
with adjustable S.S. fixtures for adjusting the level of the weir to have uniform flow
through out the periphery.
painted after sand/ball blasting to near white and after applying zinc rich epoxy primer.
3.1.9 Air Blowers
For specification please refer Volume II A, Scope of work
Contractor
No of Corrections
Executive Engineer
262

3.1.10 Air Diffusers

For specification please refer Volume II A, Scope of work
3.1.11 Secondary Clarifier
The Secondary Clarifier Tank shall have central driven clarifier mechanism in MSEP
with sewage entry through the central column. The clarifier mechanism shall have fixed
half bridge resting on the central column with aluminium chequered plate and G.I.
handrails upto the wall.
The clarifier drive will have center mechanism / drive head TEFC motor and speed
reducing gearbox. The service factor for the gear will not be less than 2.5 The central
drive shall have slewing ring bearing located on the central column. The scrapers ring
will be attached to the lower end cage hung and driven by slewing ring drive on the top
of the central column. The inlet well shall be hung from the bridge. The MOC of the inlet
well shall be FRP. An overload alarm system shall be provided as an overload protection
for the drive
The mechanism shall have skimming arrangement. The squeezes will be of neoprene
rubber. The V-notch weir for the clarifier will be of FRP and fixed to the R.C.C launder
with adjustable S.S. fixtures for adjusting the level of the weir to have uniform flow
through out the periphery.
painted after sand/ball blasting to near white and after applying zinc rich epoxy primer.
3.1.12 Horizontal pumps
The pumps shall be of end suction, horizontal dry-pit type, non-clog, centrifugal type.
The volute and impeller will be of cast iron with 1.5% to 2% Nickel. The pump shall be
capable of handling solids of not less than 40 mm sphere size.
The pump coupling shall be flexible type and shall be provided with coupling guard. The
suction and delivery shall be suitable for flange connection.
The pump shall include base frame, electric motor, coupling, coupling guard, etc. The
motor shall be TEFC, 415V, 3-phase AC 50 c/s. The base frame shall be fabricated from
structural steel sections. The motor HP shall be atleast 10% more than required at duty
point and shall be non-overloading at other points of Q-H curve.
Sr.
Unit
Details
A
(i)
(ii)
(iii)
(iv)
Data
Temperature
Specific Gravity
Total Head (m)
Capacity (lps)
Ambient
1.05
As per design
As per design
B
1
(i)
Pumping Machinery
Pump
Pump model
As per Manufacturer
Contractor
No of Corrections
Executive Engineer
263

Sr.
Unit
Details
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
Mounting
Type
Suction Size
Suction Location
Delivery Size
Delivery Location
Bearing
Lubrication
Type of Packing
Coupling
Horizontal
Centrifugal Non Clog
As per Manufacturer
End
As per Manufacturer
Top
Ball Bearing
Oil / Grease
Gland
Lovejoy
2
(i)
(ii)
(iii)
(v)
(vi)
(vii)
Pump Casing
Impeller
Pump Shaft
Shaft Sleeve
Base Plate
Hardware
Cast Iron CI IS 210 GR200

Cast Iron CI IS 210 GR200
Steel-IS-1570 C 40
Stainless Steel-AISI 410
Mild Steel, IS:226
Hot Dipped Galvanised
3
(i)
(ii)
(iii)
(iv)
Pump Performance
Pump Efficiency
NPHS R
BKW
BHP
As per manufacturer Min. 70%

As per design
As per manufacturer
As per manufacturer
C
(i)
(ii)
(iii)
(iv)
(v)
Prime Mover
Type
Hp
Rating, kW
Speed, RPM
Frame Size
TEFC, Squirrel Cage, Induction Motor

As per manufacturer
As per manufacturer
As per manufacturer
As per manufacturer
3.1.13 Chlorination System

3.1.13.1 Design
The chlorination system will consist of Vacuum type chlorinator. There shall be one
working chlorination system and one standby system. The solution type chlorinator is to
be vacuum type separately panel mounted. The chlorination system shall have 15 days
storage of tonner for chlorination. The system shall have manual reset visual indicator
signals when the chlorine gas supply is exhausted or interrupted. The material of
construction of the chlorinator shall be resistant to corrosive action of dry and moist
chlorine gas and chlorine solution.
The chlorinator shall be provided for a average flow of 32 MLD with a maximum dose
rate of 5mg/litre and achieve a residual chlorine of 0.5 mg/l. There shall be 2 chlorinators
for chlorination of which one will be operating and the other stand by.
Contractor
No of Corrections
Executive Engineer
264

Each chlorinator shall have the following facilities Manual adjustment of dose rate
Gas inlet pressure gauge
Injector vacuum pressure gauge
Gas filter
Internal gas inlet pressure reducing valve
Flexible connectors
Safety vent
The chlorinator and chlorine cylinder shall be arranged in chlorine house with partition.
Doorways to the room shall be shown as outward opening. Suitable storage for empty
drums should be provided. The chlorination system will work on 1 working and 1 stand
by basis and automatic switch over to standby chlorinator with alarm raising system
should be provided.
3.1.13.2 Chlorine Pipe Work
The standard required for the pipes and the fittings shall be as under:
Pipe work for chlorine gas near the chlorinators shall be of flexible copper pipe.
Valve shall be of globe type with forged steel body.
Gland packing shall be of Teflon.
Pressure gauges of silver diaphragm type.
3.1.13.3 Booster Pump
The Contractor shall supply one centrifugal booster pump for each chlorinator. Water
supply will be from the backwash water tank which is to be constructed by contractor at
his cost on chlorine house. The pump sets shall be complete with the following units:
Strainer
Sluice valve on suction side
Sluice valve on delivery side
Reflux valve on delivery side
Lot GI piping upto the injector
Pressure gauge on the header
For the post chlorinators the pumps will be so connected that any pump can work with
any chlorinator.
3.1.13.4 Safety Equipment
The Contractor shall provide the following safety equipment as a minimum:
2 canister type respirators with full face coverage mask suitable for chlorine gaseous
atmosphere
1 eye wash arrangement/shower and wash basin.
25 canisters for respirators
2 external wall mounted glass fronted cabinets for the breathing apparatus and for
the respirators
2 self-contained compressed air-breathing apparatus complete with warning whistle
and 2 spare air cylinders.
Emergency kit for attending chlorine gas leakages (three types)
Contractor
No of Corrections
Executive Engineer
265

3.1.13.5 Chlorine Tonners and Tonner Store

The Contractor shall supply chlorine tonners and rented tonners each of 900 kg for 15
days usage. The tonners shall be arranged in two rows. The centre to centre distance of
the drums and of the rows should be adhered to for safety aspects.
The Contractor shall provide a over head travelling gantry arrangement with safety type
hook and drum lifting beam to handle the drums. The pipe work from the drums shall be
rigidly fixed to the walls and supported on the lamp-posts.
One on line and stand by chlorinator will be supported on load cells to allow drum
contents to monitored.
3.1.13.6 Construction
The conceptual design envisages a structure of minimum 80 sq.m for the chlorination
room and chlorine cylinder store. Both the structures shall be covered with a flat RCC
slab. No intermediate columns shall be provided in the cylinder store.
One lime pit of sufficient dimension shall be provided adjacent to the cylinder store to
enable any leaking cylinder to be immersed in the same easily.
The Contractor shall so layout the units that the minimum handling is involved in
picking up the cylinder from the trucks and mounting them on saddles or handling of Cl2
tonner shall be easily/directly done by gantry girder from truck to room and vice-versa.
3.1.14 Sludge Thickener
The Thickener is to be provided for thickening of the sludge from the Primary and
Secondary Settling tanks. The scraper mechanism is provided in the thickener tank to
scrap the settled solids from the bottom of the tank such that the sludge moves to center
sludge pocket.
The thickener will have central drive, with inlet from the side. The bridge drive will have
TEFC motor and speed reducing gearbox. The service factor for the gear will not be less
than 2.5. The squeezes will be of neoprene rubber. The V- notch weir for the thickener
will be of FRP and fixed to the R.C.C launder with adjustable fixtures for adjusting the
level of the weir to have uniform flow through out the periphery.
3.1.15 Mechanical Dewatering System (Centrifuge)
Centrifuge shall be used as mechanical dewatering system
3.1.15.1 General
(a)
The centrifuge shall be of continuously operating, solid bowl centrifuge and horizontally
mounted. It shall be suitable to handle municipal sludge containing 1% to 4% dry solids
to be de-watered upto 20 % minimum and maximum 30% of dry solids per hour. The
frame shall be of open design with gravity discharge of the dewatered sludge.
Contractor
No of Corrections
Executive Engineer
266

(b)
The material of construction at all the parts coming in contact with the liquid shall be in
AISI: 316 grade (stainless steel).
3.1.15.2 Construction
(a)
Housing:
The housing shall consist of a welded frame with supporting feet, motor bracket, guards
and collecting vessel/catcher for the product discharges. Vibration absorbers shall be
provided for the machine to supporting feet to prevent most of the vibrations from the
machine being transferred to the foundation.
(b)
Bowl and conveyor screw:
The decanter shall be equipped with flat angle cone bowl with cylinder and cone. The
solids discharge shall have replaceable wear bushings and shall be protected against wear
and tear. The conveyor scroll shall be of single threaded design and wear protected.
.
(c)
Drive:
The bowl shall be driven by a V-belt transmission on the shaft at the conical end. Power
shall be transferred to the conveyor by a two stage planetary gear box at the opposite
end. An overload protection device shall be provided for the gear box.
(d)
Drive motor:
The motor shall conform to IS 325 and shall be of weatherproof, jetproof and
tropicalised construction.
The motor shall conform to the following date:
Type of motor
Type of duty
Class of insulation
Type of enclosure and cooling
Maximum motor speed
Method of starting
Motor protection
(e)
3 phase, 4 pole, 415 V, Squirrel Cage

Continuous (S I )
F
TEFC
IP55
1500 rpm
to suit the duty
Thermistor
The material of construction shall be as follows:
Sr.
No.
Component
Material
(i)
Bowl
Stainless steel: AISI 316
(ii)
Conveyor
Stainless steel: AISI 316 and wear protected
(iii)
Casing cover
Stainless steel: AISI 316
(iv)
Frame
M.S
3.1.16 Biogas Flaring System
Contractor
No of Corrections
Executive Engineer
267

Gas flaring system shall be installed to burn excess biogas generated at the STP. The
burning capacity of the flare shall be 100 m3/hr. The biogas flaring system shall consist
of the following equipment.
a)
b)
c)
d)
e)
f)
g)
h)
Moisture separator
Flame Arrestor
Check valve
Pressure regulating valve
Flare gas burner (6m height from ground level)
Pilot gas burner with push button ignition complete with ignition electrode
Diaphragm type pressure gauge
Low gas pressure switches.
3.1.16.1 Flare Gas Burner

The Flare Burner for biogas incinerates the biogas completely and releases environment
friendly gases after combustion. It thus protects the environment and surrounding
equipment.
Complete incineration can be done by having high temperature, stociometric gas
mixtures flame. To achieve this aspirator type pre-mixing burner is made for complete
combustion.
To start flare burner, spark igniter initiates the pilot burner. The pilot flame is checked
with the help of flame monitor (Flame Rod). As soon as the pilot flame is provided a
visual indication on the panel will appear than the main biogas control valve can be
opened. To prevent blow off at high winds the aerodynamically designed windshield is
provided.
3.1.16.2 Flare burner
Duty
Capacity
Quantity
Type
Inlet Mounting
Working pressure
To flare biogas completely

0 - 100 cum/hr
1 no.
Aspirator type
Flanged 6 NB as per BS Table 10D.
50 mm WC to 500 mm WC
Accessories
SS 316 Wind Shield to prevent blow off at high winds
Provision for fixing of Pilot Burner, HT Electrode and Thermal flame sensor.
Wind shield
Burner
Mounting Flange
Mounting
Contractor
SS 316
CI
CI
Flange mounted vertical position
No of Corrections
Executive Engineer
268

3.1.16.3 Pilot Burner & accessories

3.1.16.3.1 Pilot Burner
Duty
Type
Material of construction
Mounting
To ignite the biogas

Premixing type with air aspirations
SS 316
Threaded on to Flare Burner
3.1.16.3.2 Ignition System

It consists of SS 316 ignition electrode. The pilot burner will have flame proof solenoid
valve.
3.1.16.3.3 Pressure Gauge
Type
Range
Type
Dial size
Wetted Parts
Diaphragm type with isolation valve

0-1000 mm WC
Diaphragm type
6
SS 304
3.1.16.3.4 Check Valve

Size
Type
End flanges
6
Flap type
As per SS table 10D
Body
Valve seat
Flap
CI
Aluminum/SS/Bronze
SS 304 / Nylon
3.1.16.4 Gas Flowmeter with Indicator and Totaliser Unit

Flow Indicator / Totaliser Unit (Electronic Registration)
Flow indicator Totaliser is used to monitor the flow of gas. Input from venturi type gas
flow meter is processed linearly or square rooted to the requirement. Flow rate is
indicated on 3 digit 7 segment LED / LCD display and totalized value of flow on
Electromech / LCD / LED counter having reset facility. The general technical
specifications are given below:
Contractor
No of Corrections
Executive Engineer
269

Power supply
Operating temperature
Input
Flow rate
Display for flow rate
Polarity indication
Decimal point indication
Engineering unit selected
Accuracy
Relay contact rating
Specifications for totalizing
Specifications for square
Rooting
:
:
:
:
:
:
:
230/110V AC 10%, 50 Hz
0o C to 55o C
220 V AC / 24V DC 10%,
-3 digit 7 segment LED / LCD
Automatic
Factory set to suit range/scale of indication of
:
:
:
Better than 0.5% of span

1A one changeover at 230V AC resistive
Totalizing accuracy 0.5% of full scale, input
clipping i.e. flow cut-off 0 to 17% of span
Square rooting accuracy 0.5% of full scale.
Total 2 nos. of gas flow meters of suitable capacity shall be provided for measuring flow
rate of biogas at the STP before gas dome and before main line going to DFG station.
Each flow meter shall be provided with electronic gas flow registration unit. These
registration units shall be placed in a composite panel at the STP Panel room. Single
phase, 230 Volt AC supply shall be given to the composite panel for gas flow
registration units from STP MEP Panel.
Technical Specifications
Type
Input
Display
:
:
Totaliser
Rate of Flow
Alarm/Presets
preset batching
Control Output
:
:
:
Reset
Programming
Memory
:
:
:
Transmitter power
Output
Power Supply
Housing
:
:
:
:
Microprocessor based Panel mounted Flow

Indicator/Totaliser
Analog user configurable to 4-20 mA, 0.5V, and 0-10 V
LED, toggle between Rate of gas flow,
Totaliser, Peak and Valley
6 digit confurigable to reset/non-reset options
5 digit, configurable to any engineer unit or time base
10A relays configurable to Rate of flow of alarms or
2 potential free relays, configurable to flow rate alarms
or batching
From front keypad to remote pulse
User configured zero/span settings for input and output.
Upto 10 years memory retention in the event of main
failure
24 V DC transmitter supply available from 7000 TR.
4-20 m a, analog output linear to flow
230 V (10% 50 Hz AC)
Standard 1/8 D/N ABS panel mounting enclosure
3.1.16.5 Flame Arrestor

Flame arrestor is provided to prevent the passage of flames if formed accidentally in
gasholder or associated pipe network. The flame arrestor, a safety device is
Contractor
No of Corrections
Executive Engineer
270

recommended for use in venting vessels, storage or transport tanks, protection of fuel /
air supply line to gas burners and in industrial plants at temperatures not exceeding
above 200oC.
The flame arrestor shall be mounted with the axis vertical and as close as possible to the
potential source of ignition. The flame arrestors are provided at the top of each
Gasholder. Two nos. flame arrestors are also provided in gas pipeline going to the gas
burner and pilot ignition of the gas flare system.
Flame arrestor consists of a tube bank made of spirally wound alternate layers of flat and
corrugated stainless steel sheets built around a solid core. The tube offers a multiplicity
of small holes parallel to the line of flow. The tube element is retained between two
flanged end sections and contained within a steel outer shell. The arrestor assembly shall
be fitted with a weather hood. The flame arrestor shall be provided with crimped ribbon
design. This enables the unit to be manufactured to very low tolerances and hence can be
efficiently size selected to suit the range of application. Pressure drop across the arrestor
shall be very low and the unit shall be suitable to take high gas flow rates.
The flame arrestors are designed as per British Standards BS: 7244-1990 to ensure
maximum safety.
The flame arrestors mainly consist of an arrestor element, an arrestor housing and
associated fittings necessary for preventing flame de-flagration.
The flame arrestor has been designed specifically for biogas falling in Group 1 of British
Standards. (Classification of gases BS 4663 Part 2 and BS 5501 Part 1).
The flame arrestor element is a crimped metal element and is made up of SS 316 to have
long life and maximum quenching of flame.
3.1.16.5.1 Technical Specifications

Size
Element
End connections
Hydrostatic Test Pressure
Gaskets
:
:
:
:
:
6 NB line
Crimped metal element
Flanged as per BS Table 10D
5.0 kg/cm2
CAF Gaskets
:
:
:
:
CI
SS 316
CS
CI
3.1.16.5.2 Material of Construction

Housing
Flame bank
Nut & Bolts
Flanges
Contractor
No of Corrections
Executive Engineer
271

3.1.16.5.3 Quantity
6 for gas holders
6 for pipeline in main gas burner
2 for pipeline to pilot burner
:
:
:
1 No
1 No
1 No
3.1.16.6 Moisture Trap
The moisture trap is device used for separation of moisture/vapors in two-phase

flow in order to reduce corrosion, control problems, efficient and safe combustion of
biogas.
The biogas has H2O vapours and traces of H2S. The gas becomes acidic after H2O and
H2S combines thus starts corroding the piping and equipment. The presence of this
causes a deposition of surfaces and control valves thus affecting that function.
The effect of moisture in biogas burning is to have quenching of flame. Also, latent heat
of vaporization is consumed by the vapors during combustion thus reducing the
efficiency.
The moisture separation can be done by the following methods.
a)
b)
Centrifugal action
Impingement action
In centrifugal action the gas is made to rotate at high velocities. The centrifugal force
causes the vapours to hit the wall of the chamber. When the vapours hit the wall they
also coalesce together to form biogas droplets. These droplets get accumulated in the
reservoir just below the moisture separator chamber.
In impingement action the biogas is made to hit a perforated steel wall at high velocity.
Due to inertia the vapours do not accompany the biogas after it hits the wall. The
moisture vapours then coalesce together to form big droplets and get accumulated in the
reservoir. The water accumulated in the reservoir is taken out through auto or manual
drain valve. It is proposed to use impingement type moisture trap.
The material for the moisture separator conforms to IS 2062. An epoxy coating is done
after surface preparation by sand blasting. The Drip-trap is tested for a pressure of 3.5
kg/cm2 for any leakage or joints. Compressed asbestos gaskets are provided for strong
leak proof joints.
3.1.16.6.1 Installation and Operation

Moisture traps shall be installed as specified below in quantity and size.
Connect the drain line to a drain-pit through suitable pipe.
Observe the drain level in the peeping window and if the drain level is high open the
drain valve till all the accumulated water is drained.
Contractor
No of Corrections
Executive Engineer
272

3.1.16.7 Type
Impingement baffle type. The impingement of gas on specially designed perforated
baffles is used to achieve moisture separation. The baffles shall be to the drip trap tank
for easy accent for cleaning
3.1.16.8 Inlet & Outlet Connections
Flanged 4/6/8 NB. The flanges will be as per British Standard Table D. The flange
shall have two nos. joint grooves 25 mm apart.
3.1.16.9 Moisture Drain
1 NB outlet port with auto-drain valve.
Baffles
The baffling arrangement of perforated sheets of SS 304 to remove moisture from the
biogas. The baffle will have guides so that moisture will coalesce and the droplets are
drained and accumulated in the drip tank.
The baffling arrangement is fitted onto the tank so that it can be removed and cleaned for
routine maintenance. The top cover shall be flanged for easy access to internals of drip
trap.
Testing
The drip traps shall be pressure-tested up to 3.5 kg/cm2 with compressed
air/hydraulically
Painting
All the parts of the equipment shall be painted with two coats of epoxy primer. The
external surface shall be painted with epoxy paint. The paint will be done after proper
surface preparation i.e. sand blasting as per out standard practice.
3.1.16.10
Welding Joints
All the parts of the equipment All welding / joints shall be done as per IS
specifications.
Flanges and Gaskets
The flanges will be as per British Standard Table D CAP gaskets of 3 mm thickness
Quantity and Sizes
For common pipelines coming from each UASB Reactor
For main gas pipeline
For pipeline going to Gas Flare
For pipeline going to DF Gensets
Contractor
No of Corrections
:
:
:
:
4 nos.
4 nos.
1 no.
1 no.
Executive Engineer
273

3.1.17 Filtrate Transfer Pumps

Two units of filtrate transfer pumps with one working and one stand by shall be
provided.
The pumps shall be of end suction, horizontal dry-pit type, non-clog, centrifugal type.
The volute and impeller will be of cast iron with 1.5% to 2% Nickel. The pump shall be
capable of handling solids of not less than 40 mm sphere size. The speed of the pump
shall be less than 1,500 rpm.
The pump coupling shall be flexible type and shall be provided with coupling guard. The
suction and delivery shall be suitable for flange connection.
The pump shall include base frame, electric motor, coupling, coupling guard, etc. The
motor shall be TEFC, 415V, 3-phase AC 50 c/s. The base frame shall be fabricated from
structural steel sections suitably galvanised. The motor HP shall be atleast 10% more
than required at duty point and shall be non-overloading at other points of Q-H curve.
3.1.18 EOT Crane
It shall be single girder EOT crane with chain electric hoist.
Minimum capacity
Span
Height of lift
Type of operation
Gantry rail
Power supply
:
:
:
:
:
:
As per design
As per design
As per design
Pendent type
40 x 40 sq. bar
440 V, 3 PH, 50 Hz
Electric hoists shall be complete with hoisting motor, wire rope drum, wire rope, hook,
necessary gearing, sheaves, electromagnetic brake for hoisting motion, weather and dust
proof push button station, Contractor panel, all wiring, limit switches, etc.
Electric hoists shall conform to IS: 3938 and shall be suitable for outdoor application. All
the parts of the hoist shall be designed to withstand surrounding atmospheric conditions
without any deterioration.
Rope drums shall be either cast or welded to sustain concentrated loads resulting from
rope pull. Drums shall be machine grooved right and left with grooves of a proper shape
for the rope used.
Gears shall be cut from solid cast or forged steel blanks or shall be of stress-relieved
welded steel construction or built-up from steel billets and welded together to form a one
piece gear section.
Hoist ropes shall be extra flexible, improved plough. Steel rope with a well-lubricated
hemp core and having six strands of 37 wires per strand with minimum ultimate tensile
strength of 1.6 x 106 kN/sq.m.
Hooks shall be solid forged, heat-treated alloy or carbon steel or rugged construction of
the single hook type and provided with a standard depress type safety latch.
Contractor
No of Corrections
Executive Engineer
274

Hoisting motor shall be equipped with electrically released, spring set, fiction shoe type
brakes having torque capable of holding 125% of the full rated hook load. Brake shall
apply when either the motor controller or the main part switch is in the OFF position or
in the event of power failure.
Driver motor shall be designed for frequent reversal, breaking and acceleration and shall
be as per IS 325. Pendant control switch, controllers and resistors, controls, electrical
protective devices, cables and conductors, earthing guards, etc. shall be as per IS 3938.
Limit switches shall be provided for over hoisting and over lowering.
3.1.19 Monorail Trolley and Chain Pulley Block
Monorail trolley and the chain pulley block shall be provided for maintenance of, filter
press, sludge pumps, etc.. The trolley and the chain pulley block shall be hand driven.
The capacity of trolley and chain pulley block shall be sufficient to remove complete
unit; however, it shall not be less than 3 tonne.
The trolley shall be gearless and shall have four wheels to run on the lower flange of the
rolled steel joist. The wheels shall be of carbon steel casting. The trolley shall have
arrangement to fix the chain pulley block.
The chain pulley block shall have spur type gears, load sheave, brake unit, hand chain
wheel, load chain wheel and hooks for suspension on monorail trolley and load. Each
chain pulley block shall be provided with 2 m long GI sling and set of GI D-shackles.
3.1.20 Instrumentation
3.1.20.1 Level switches
Level switches shall be provided in the raw sewage sump. The operation of the raw
sewage pump shall be as per the level of the liquid in the sump. During peak flow both
the pumps shall be in operation and during lean flow only one pump shall be in
operation. The start and stop of the pump shall be automatic.
3.1.20.2 Ultrasonic flow meter
The ultrasonic flow meter shall be provided in the downstream side of the grit channel. It
shall have digital type indicator, integrator and recorder fixed in the admin block.
Contractor
No of Corrections
Executive Engineer
275

4 ERECTION, TESTING AND COMMISSIONING

4.1
TESTING - GENERAL
a) Testing of the plant at the manufacturers premises will be required in accordance
with the Conditions of Contract. All inspection, examination and testing shall be
carried out in accordance with appropriate standards.
b) All instruments used for such tests shall be calibrated and certified by an approved
independent testing authority not more than 2 months prior the test in which they are
used. The Engineer-in-Charge reserves the right to impound any instrument
immediately after test for independent testing. A certificate shall be produced by the
Contractor prior to carrying out every test showing the reading obtained calculations
and full details of the calibration certificates referred to.
c) If the Engineer-in-Charge witnesses a test he shall be given a copy of the test results
and certificates immediately. Whether he witnesses a test or not, copies of test
certificate shall be sent to the Engineer-in-Charge. No item of the plant shall be
forwarded to the site until its test certificate has been approved in writing by the
Engineer-in-Charge. Six copies of the test certificates shall be supplied in suitable
folders with proper index.
d) Certificates shall be clearly identified by serial or reference number where possible
to the material being certified and shall include information required by the relevant
Reference Standard or Specification clause.
4.2
INSPECTION AT MANUFACTURERS PREMISES

a) The inspection of all equipment required to be supplied to complete the works shall
be done as detailed in this specification. Only defect free and sound material
meeting the technical requirements of this specification and in accordance with a
high standard of engineering would be acceptable to the Engineer-in-Charge.
b) For meeting these requirements of inspection, testing (including testing for chemical
analysis and physical properties) shall be carried out by the Contractor and
certificates submitted to the Engineer-in-Charge who will have the right to witness or
inspect the above mentioned testing/inspection at any stage desired by him.
Calibration certificates or test instruments shall be produced for the Engineers
consent in advance of testing and if necessary instruments shall be recalibrated or
substituted before the commencement of the test. Items of plant or control systems
not covered by standards shall be tested in accordance with the details and
programme agreed between the Engineer and Contractor.
c) If during or after testing, any item of the plant fails to achieve its intended duty or
otherwise prove defective it shall be modified or altered as necessary, retested and
reinspected as required by the Engineer.
d) At least 15 days notice shall be given to the Engineer before the specified tests are
carried out.
e) No material is to be delivered to site without the above described inspection having
been carried out or officially waived in writing by the Engineer-in-Charge.
f) Third party inspection along with the Engineer In charge wherever necessary shall be
arranged by the Contractor at his cost
Contractor
No of Corrections
Executive Engineer
276

4.3
TESTS AT MANUFACTURERS PREMISES
4.3.1 Pumps
a. Hydrostatic testing: All pressure parts of pumps prior to assembly, shall be
subjected to hydrostatic tests to the satisfaction of Engineer-in-Charge at 1.5 times
the maximum pressure obtained with the delivery valve closed and suction pressure
at maximum, or twice the working pressure whichever is higher for a duration of 10
minutes.
b. Balancing Test: Impeller and pump rotating assembly shall be dynamically
balanced.
c. Performance Test: Each pump shall be tested for full operating range individually
to BS:5316: Part 2. Test shall be carried out for performance at rated speed with
minimum NPSH as available at Site.
Pump performance shall be within the tolerance limits specified in BS:5316 : Part 2.
4.3.2 Motors
Motors shall be offered for routine and type tests in accordance with IS : 4029 and
IS:325 at the manufacturers works. Test certificates shall be endorsed to the effect that
the motors are properly balanced and free from vibration. In addition, a test shall be
required to establish the maximum transient starting current.
4.3.3 Pipe work
Testing of pipes/fittings shall be carried out in accordance with relevant standard.
4.3.4 Valves
(a) All valves shall be hydrostatically tested close ended. Body, seat/door and back
seat-test pressure shall be 15 bar, 10 bar and 6 bar respectively.
(b) Valves shall be tested with associated actuators for general performance.
4.3.5 Hoists
(a) The hoist shall be completely assembled in the Contractors or sub-Contractors
works and shall be subjected to the tests as specified in IS:807/IS: 3177. The
Contractor shall provide the test weights.
(b) In addition a vertical deflection test shall be carried out with the Safe Working
Load suspended from the hook with the crab in the center of the span. The ratio of
deflection to span shall not exceed that specified in IS 807. Manufacturers test
certificates for mechanical items shall be furnished.
4.3.6 Electrical Instruments
All electrical instruments shall be tested as specified under electrical specifications.
4.3.7 Other Equipment
Other equipment like mixers, air blowers, agitators, etc. shall be tested at works as per
the relevant IS standards and test certificate furnished for approval before dispatch.
Contractor
No of Corrections
Executive Engineer
277

4.4
ERECTION - GENERAL
1
4.5
The Contractors staff shall include at least one competent erection engineer with
proven, suitable, previous experience on similar contracts to supervise the erection of
the Works and sufficient skilled, semi skilled and unskilled labour to ensure
completion of the works in time. The Contractor shall not remove any representative,
erector or skilled labour from the site without the prior approval of the Engineer-inCharge.
One erection engineer who shall be deemed to be the Contractors representative
shall be conversant with the erection and commissioning of the complete works.
Should there be more than one erector, one shall be in charge and the Contractor
shall inform the Engineer-in-Charge in writing which erector is designated as his
representative and is in charge. Erection engineer is to report progress and planning
to the Engineer or his representative who will have one mobile phone with him.
The Contractors erection staff shall arrive on the site on date to be agreed by the
Engineer-in-Charge. Before they proceed to the Site, however, the Contractor shall
first satisfy himself, as necessary, that sufficient plant of his (or his sub-Contractors)
supply has arrived on site so that there will be no delay on this account.
The Contractor shall be responsible for setting up and erecting the plant to the line
and levels of reference given by the Engineer in writing, and for the correctness
(subject as above mentioned) of the positions, levels dimensions and alignment of all
parts of the works and for provision of all necessary instruments, appliances and
labour in connection therewith. The checking of setting out of any line or level by
the Engineer or Engineer-in-Charge shall not in any way relieve the Contractor of his
responsibility for the correctness thereof.
Erection of Plant shall be phased in such a manner so as not to obstruct the work
being done by other Contractors or operating staff who may be present at the time.
Before commencing any erection work, the Contractor shall check the dimensions of
structures where the various items of Plant are to be installed and shall bring any
deviations from the required positions, lines or dimensions to the notice of the
Engineer. Plant shall be erected in a neat and workmanlike manner on the
foundations and at the locations shown on the approved drawings. unless otherwise
directed by the Engineer, the Contractor shall adhere strictly to the aforesaid
approved drawings. If any damage is caused by the Contractor during the course of
erection to new or existing plant or buildings or any part thereof, the Contractor
shall, at no additional cost to the Employer, make good, repair or replace the
damage, promptly and effectively as directed by the Engineer and to the Engineers
satisfaction.
During erection of the plant the Engineer will inspect the installation from time to
time in the presence of the Contractors site representative to establish conformity
with the requirements of the specification. Any deviations and deficiencies found or
evidence of unsatisfactory workmanship shall be corrected as instructed by the
Engineer.
RECORD, PROCEDURES AND REPORTS

1
The Contractors shall maintain records pertaining to the quality of

installation/erection work and inspection, testing, compliance with all technical
requirements in respect of all his work as described in the previous paragraphs. The
reporting formats shall be in the approved formats. The Contractor shall submit such
records to the Engineer after the completion of any particular work before submitting
the bill of shop inspection reports, shop testing reports, material test reports, based
Contractor
No of Corrections
Executive Engineer
278

4.6
on which dispatch clearances are provided, all the quality control reports of welding,
erection and alignment records.
All the above mentioned records shall be submitted in the final form duly
countersigned by the Engineer-in-Charge attesting conformity to specifications and
his approval of installation and duly incorporating all the additions, alternations, and
information as required by the Engineer, on the basis of preliminary reports giving
the progress of the work. Such records notwithstanding any records submitted
earlier with bill of supply/progress etc. shall be duly bound and submitted to the
Engineer in six copies by the Contractor on his notification of the mechanical
completion of erection.
COMPLETION OF ERECTION
1
4
5
The completion of plant under section by the Contractor shall be deemed to occur, if
all the units of the plant are structurally and mechanically complete and will include
among other such responsibilities the following :
Plant in the scope of the Contractor has been erected installed and grouted as per
specifications.
Installation checks are completed and approved by the Engineer.
The erected plant is totally ready for commissioning checks.
At the stage of completion of erection, the Contractor shall ensure that all the
physical, aesthetic and workmanship aspects are totally complete and the plant is fit
and sound to undergo commissioning checks/tests on completion.
Upon achieving the Completion as described above, the Contractor shall notify the
Engineer by a written notice intimating such mechanical completion of units and
notify the Engineer for inspection and acceptance of Mechanical Completion. The
Engineer/Engineer-in-Charge shall proceed with the inspection of such units within
14 days of such a notice. Thereafter:
The Engineer shall certify completion when there are no defaults in the works
and the plant is acceptable or
The Engineer shall inform the Contractor list of deficiencies for rectification
hereinafter referred as Punch List and the Contractor shall complete the
rectification work within a jointly agreed period before tests on or approval of
the same before proceeding with the Tests on Completion or
The Engineer may inform the Contractor that the Works are acceptable with
punch list (Items which do not hamper operability, safety or maintainability)
and allow the Contractors to proceed with the pre-commissioning checks
followed by Tests on Completion when the Contractor undertakes to complete
such outstanding works within an agreed time during Defects Liability Period.
Taking over shall be based on rectification of all deficiencies as advised by punch
lists.
The erection period indicated by the Contractor would be deemed to cover all the
activities up to completion as stipulated in previous paragraphs, notice of completion
by the Contractor, inspection by the Engineer for completion, and Contractor
rectification of all deficiencies as noticed by the deficiency/punch list, and
acceptance by the Engineer of such rectification, prior to Tests on Completion.
Minor defects, which in the opinion of Engineer which do not hamper operability
and maintainability will not be taken into account for deciding mechanical
completion. Such defects shall be rectified concurrent to commissioning checks
before Tests on Completion. However, the Engineers decision in this regard is
final.
Contractor
No of Corrections
Executive Engineer
279

4.7
SETTING TO WORK
1
2
4.8
The commissioning period as notified by the Contractor shall be deemed to occur

beyond the date of completion and shall include all periods of pre-commissioning,
trails and Tests on Completion.
It is in the Contractors interest to offer the sections/units/systems, progressively
under identified milestones within overall erection period, duly completed for
inspection by the Engineer-in-Charge, obtain his punch list, for rectification of any
deficiencies pointed out by the Engineer and to achieve Mechanical Completion
before undertaking the Tests on Completion within the specified erection period.
The Engineer also reserves a right to withhold the cost as estimated to be equivalent
to the rectification of deficiencies pointed out to the Contractor until such a time
such deficiencies are rectified to the satisfaction of the Engineer.
On completion of erection the Contractor shall request the Engineer-in-Charge to

carry out the installation inspection.
After the plant has been set to work the Contractor shall continue to operate the Plant
for a period of one week.
INSTALLATION INSPECTION
1. In addition to the progressive supervision and inspection by the Purchaser the
Contractor shall offer for inspection to Engineer, the completely erected Plant/Part of
Plant on which tests are to be carried out. After such inspection by Engineer-inCharge, each equipment/sub-system shall be tested by the Contractor in accordance
with the applicable standards in the presence of Engineer. Such tests shall include
but not be limited to the tests specified in following clauses.
2. Pumps, Piping and valves
The erected pipework shall be subjected to a hydraulic test at 1.5 times the
maximum pressure or twice the working pressure whichever is higher to test the
soundness of joints. Provision of necessary pumps, gauges, blank flanges,
tappings etc. for carrying out these tests shall be included in the Contract.
Leakage tests shall be carried out on all erected pipe work, pumps and valves
immediately after erection and where possible before being built in.
Operating tests shall be conducted on valves.
The pump set shall be tested for satisfactory operation. The vibration and noise
level shall be checked to be within specified limits.
3 Motors: Condition of winding insulation be tested and insulation values shall be
restored to required level by suitable heating arrangements locally.
4 Hoists: The hoist and lifting tackle shall be tested to 125% of the safe working load.
The Contractor shall arrange the test load.
5 Mixers, agitators, air blowers, etc. After erection, these shall be tested for its
performance.
Electrical Panels Insulation
Test High Voltage Power Frequency test
Performance Test
6 Cables
Insulation Test
Continuity Test
High Voltage Power Frequency Test
Instrumentation
Contractor
No of Corrections
Executive Engineer
280

Performance of the instrumentation shall be checked as per the design requirements.
4.9
COMMISSIONING
4.9.1 Scope
At the time of commissioning, the Engineer-in-Charge will appoint his representative as
commissioning engineer. The Contractor shall carry out commissioning tests in the
presence of the commissioning engineer. Though the mechanical completion may have
been checked and clarified by the site engineers, the commissioning engineer may verify
any mechanical completion checks to satisfy himself that the plant is fit and sound, if
such checks had not been witnessed by him. It will be the responsibility of the
Contractor to make all arrangement for carrying out these tests. The evaluation of test
results and decision passed by the commissioning engineer regarding the test results will
be final and binding on the Contractor. Any additional tests or repetition of tests to
establish satisfactory operation of any equipment shall be carried out by the Contractor at
no extra cost.
4.9.2 Miscellaneous
Completion checks and commissioning tests on items not covered under above , shall be
carried out by the Contractor as per the instructions of the Engineer-in-Charge.
4.9.3 Commissioning Date
No item of plant will be certified as commissioned by the Purchaser unless it has
successfully passed all the tests called for under the Contract and the following
documentation are duly complied and submitted in final formats in duly bound volumes.
(a) A completion of all shop inspection results/reports of the plant/machinery with due
attestation that the Plants have been manufactured to specified standards (6 copies)
(b) All erection/construction quality control checks in appropriate approved formats for
all installation works with attestation that installation has been carried out as per
acceptable/stipulated standards (6 copies).
(c) All As built drawing and O & M and Erection manuals. Soft copies of drawings
and documents will furnished by the Contractor.
4.10 TENDER DRAWINGS

The following drawing shall be submitted by the bidder with tender:
1. Plant Layout with unit sizing
2. Process Flow Sheet with process design/calculations
3. Hydraulic Flow Diagram with hydraulic design/calculations
4. Process & Instrumentation Diagram
5. Single Line Diagram for all Electrical Installations with load calculations
6. Outline dimensional drawing
a. Pumps
b. Gates-Motorised/Manual
c. Valves-Motorised/Manual
d. Chlorinators
e. Electrical Panels
7 Performance Curve for
a. Pumps
b. Aerators
Contractor
No of Corrections
Executive Engineer
281

c. Blowers
Instrumentation - Catalogues for all the instruments
4.11 DRAWINGS FOR APPROVAL

The following mechanical drawings shall be submitted for approval:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Knife gate valves

Non-Return valve
H.O.T./E.O.T. Crane
Gates
Manual and mechanical screens
Degritter
Primary and Secondary Clarifier
Diffusers
Air blowers
Submersible pumps
Chlorination system
4.12 CONSTRUCTION DOCUMENTS

The Construction Documents are certified Drawings submitted by the Contractor to the
Employer or Engineer-in-Charge during the course of the Contract for approval.
The Engineer-in-Charge may require the Contractor to submit for approval additional
drawings if they are necessary to enable him to satisfy himself that the items are well
designed, that they comply with the Employers Requirements and that they are suitable
for their intended purpose. These drawings shall form the agreed basis for the execution
of the Works. If an approved drawing is revised, revised copies shall be submitted for
approval as above and no such revised drawing shall be used for the purposes of the
Contract until it has been approved in place of the earlier issue of the drawing.
Approval of drawings by the Engineer-in-Charge shall not be held to relieve the
Contractor of his responsibilities under the Contract. Drawings should be got approved
from the Dy. Director & Chief Manager and Industrial Safety before starting the site
work.
Two nos. of `Approved copies of each drawing will be returned to the Contractor when
approval is given if the Contractor so requests.
The Engineer-in-Charge will not permit construction to start on a part or section of the
Works unless Construction Documents for that part or section have been approved.
4.13 AS-BUILT DRAWINGS

These drawings shall be complied by the Contractor and shall constitute a permanent
record of the Works as executed. These shall include all such drawings, schedules,
documentation and calculations as necessary for a complete understanding of the Work
design, operation and maintenance.
A3 and smaller sized As-Built Drawings shall be provided on durable paper for
reproduction by photocopier. As-Built Drawings larger than A3 shall be provided as a
paper copy and also produced in the form of black lines on a durable translucent film
Contractor
No of Corrections
Executive Engineer
282

from which further paper prints can be taken by others as required. In addition drawings
shall be provided as AutoCAD Revision 14 software copy.
Text shall be provided in an industry standard work processing, spreadsheet or database
format as appropriate.
4.14 INFORMATION REQUIRED ON AS-BUILT DRAWINGS

The As- Built Drawings shall consist of the fully up-dated versions of the approved
Construction Documents incorporating any additional information which will assist the
Employer in operating maintaining and if necessary modifying or extending the Works at
a later date. These drawings should extend and supplement the information given in
Operating and Maintenance Manuals.
4.15 OPERATING AND MAINTENANCE MANUALS

4.15.1 General
The Contractor shall compile operating, maintenance and overhauling instructions for the
whole of the Plant. The instructions shall consist of one volume of :
a. General descriptive text (including drawings for illustration) of the Works described
section by section.
b. Complete operational instructions for the treatment plant. This shall be termed the
Operators Manuals. It shall be aimed at the operational staff and shall be written in
clear unambiguous text complete with drawings which necessary for clarification of
any issues. The manual shall comprehensively detail what to do on a day to day
basis and also what to do in the event of fault develop. It shall in addition provide a
complete list of the process maintenance tasks the operator should carry out
including the intervals between these tasks.
c. Essential Instructions for mechanical and electrical maintenance of the Plant. These
instructions shall be short and concise and set out in consolidated schedule the
inspection, lubrication, cleaning and any other type of servicing operations required.
The Contractor shall prepare typical maintenance log sheets that the Employer can
subsequently use for daily, weekly, monthly or other periodic maintenance and shall
form record sheets of plant maintenance operations.
d. Instructions for use of skilled maintenance personnel in fault location, carrying out
routine replacement, withdrawing, dismantling, overhauling, re-assembling and
testing the various items of Plant.
e. Manufacturers Technical Documentation subdivided into categories for:
civil
process
electrical
electrical building services
mechanical building services
instrumentation and control
f. Civil As-Built Drawings
g. Comprising the FDS and PLC code
h. Electrical As-Built Drawings: The electrical drawings shall be complete sets
including all information necessary for maintenance and spares replacement.
Contractor
No of Corrections
Executive Engineer
283

i.
Electrical and mechanical building services As-Built Drawings: The drawings shall
be complete sets including all information necessary for maintenance and spare
replacement.
j. FAT records for the Plants and Works
k. SAT records for the Plants and Works
Each volume shall be subdivided (relating to areas of plant) into sub sections or subvolumes in order to ease the location of plant details. Each volume or sub volume shall
be provided with a comprehensive index for the volume or sub-volume concerned and
the O & M manuals as a whole.
Each volume shall be enclosed within A4 and A3 ring binders having tough grease
resistant cover suitable for use on site and designed to permit the easy removal and
insertion of the contents. The front cover and spine of each volume shall show details of
the project, Employer, Engineer-in-Charge and a volume title.
Text shall generally be enclosed in A4 ring binder except where they accompany A4 text
in which case they shall be folded. A1 drawings shall generally be folded and enclose in
A4 box files. Where A1 drawings accompany text they shall be folded and enclosed in
an A4 plastic wallet, one wallet per drawing.
4.16 SUBMISSION OF DOCUMENTS AND DRAWINGS

Eight (8) copies of each drawing and document shall be submitted by the Contractor to
the Engineer-in-Charge for approval. The Engineer-in-Charge will return two (2)
approved copies to the Contractor and retain six (6) for the Engineer-in-Charges office
and field use. The contractor, shall also arrange to get the approval on these drawings
from the Dy. Director of Industrial Safety and health at his own cost.
The Engineer-in-Charge will signify his approval or disapproval of the Preliminary
Phase Drawings within 15 calendar days of submission.
Construction Documents shall be submitted in accordance with the timetable set down in
the Program.
The Engineer-in-Charge will signify his approval or disapproval of the Construction
Documents within 15 calendar days of submission of each submission.
Draft copies of the O & M Manuals shall be submitted to the Engineer-in-Charge for his
approval at least 56 calendar days prior to the commencement of Tests on Completion.
The Engineer-in-Charge will signify his approval or disapproval of the O & M Manuals
within 28 calendar days of submission.
Draft As-Built Drawings shall be submitted 30 calendar days prior to the commencement
of Tests on Completion.
The Engineer-in-Charge will signify his approval or disapproval of the As-Built
Drawings within 15 calendar days of submission.
The Final As-Built Drawings shall be submitted prior to the issue of any Taking Over
Certificate.
Contractor
No of Corrections
Executive Engineer
284

To remove doubt the submission dates referred to above shall be the dates on which the
drawings and documents are received by the Engineer-in-Charge.
4.17 NOTICE OF OPERATIONS

The Contractor shall give full and complete written notice of all important operations to
the Engineer-in-Charge sufficiently in advance to enable the Engineer-in-Charge to make
such arrangements as the Engineer-in-Charge may consider necessary for inspection and
for any the purpose. The Contractor shall not start any important operation without the
written approval of the Engineer-in-Charge.
Contractor
No of Corrections
Executive Engineer
285

5 APPROVED MANUFACTURER/MAKE FOR

MAJOR ITEMS
The bidders are to consider the following list of Approved Manufacturer/Make for
Mechanical equipment as under:
Component
Manufacturer/Make
Gates
Mechanical Fine Screens
Mechanical medium
Screens
Manual Screens
Detritors
Air blowers
Primary / Secondary
Clarifiers
Sludge thickener
Agitators
Diffusers
Jash / Batty
Jash / Huber / Johnson
Jash / Huber / Johnson / Triveni
Chlorination System
VFD
Motor (excluding
Submersible)
Instruments (Excluding
Ultrasonic flow meter)
Horizontal Pumps
Submersible pumps
Knife Gate Valves
Ultrasonic Flow meter
DO measurement
Hoists EOT
Chain Pulley Block
Monorail
Contractor
Voltas / Geomiller / HDO / Batliboi / Triveni

Voltas / Geomiller/ HDO / Batliboi / Triveni
Usha / Kay / SWAM / KPT
Grindwell Norton / OTT system / Environmental
Dynamics
Metito / Pennwalt / RR Enterprises / Sumitra
Allen Bradly / Schneider / ABB / Siemens
Siemens /ABB / Crompton /Kirloskar
Fischer Rose Mont / Toshbro / Forbes Marshall /
Mikamchi / Alfa laval / Manas
Grundfos / Kirloskar /Johson /Jyoti / Mather & Platt
Grundfos / Kishor / KSB / Mather & Platt - EMU
Jash / Fouress / Dezurick
Siemense / Crohne Marshall / Forbes Marshall / Manas
Endress Hauser / Fischer Rosemont / Forbes Marshall /
Hach
Index / Elephant / Anupam / Speed
Hercules / Anupam / Smaco
No of Corrections
Executive Engineer
286
VOLUME II - C
ELECTRICAL SPECIFICATIONS

Volume II D: Specification for Electrical Work
TABLE OF CONTENT: VOLUME II D, ELECTRICAL SPECIFICATIONS
GENERAL REQUIREMENTS FOR ELECTRICAL WORKS ....................................................... 287

1.1
SCOPE OF WORK ............................................................................................................................ 287

2.1
2.2
2.3
2.4
POWER SUPPLY CONDITION .......................................................................................................... 291

UTILIZATION VOLTAGES ............................................................................................................... 291
DESIGN CONSIDERATION ............................................................................................................ 293

4.1
4.2
A]
4.3
4.4
4.5
ELECTRICAL EQUIPMENT .............................................................................................................. 287

ADDITIONAL SCOPE...................................................................................................................... 288
DRAWINGS AND DOCUMENTS ....................................................................................................... 288
STANDARD OF WORKMANSHIP ..................................................................................................... 290
POWER DISTRIBUTION NETWORK............................................................................................ 291

3.1
3.2
INTRODUCTION ............................................................................................................................ 287
DESIGN BASIS: ............................................................................................................................. 293

SIZING PHILOSOPHY ............................................................................................................... 293
Transformer Sizing .................................................................................................................. 293
SHORT CIRCUIT CAPACITIES................................................................................................. 293
PROTECTIONS .......................................................................................................................... 294
METERING ................................................................................................................................ 294
SELECTION CRITERIA FOR ELECTRICAL EQUIPMENT ....................................................... 296

5.1
5.2
5.3
5.4
5.5
5.6
SWITCHGEAR: .............................................................................................................................. 296

CABLES : ...................................................................................................................................... 296
LIGHTING SYSTEM ........................................................................................................................ 297
LIGHTING POWER SUPPLY AND DISTRIBUTION............................................................................... 298
SAFETY EARTHING ....................................................................................................................... 299
POWER FACTOR IMPROVEMENT .................................................................................................... 300
LAYOUT CLEARANCES AND SAFETY REQUIREMENTS........................................................ 301
GENERAL REQUIREMENTS OF ELECTRICAL EQUIPMENT................................................. 302

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
11 KV SWITCHGEAR ..................................................................................................................... 302

DC BATTERY & BATTERY CHARGER ................................................................................... 310
TRANSFORMER ............................................................................................................................. 314
415V BUS DUCT ........................................................................................................................ 329
415V SWITCHGEAR .................................................................................................................. 332
LOCAL PUSH BUTTON STATIONS ................................................................................................... 342
POWER CAPACITORS & CAPACITOR CONTROL PANEL .................................................................... 344
POWER & CONTROL CABLES ........................................................................................................ 348
LIGHTING SYSTEM :....................................................................................................................... 350
EARTHING SYSTEM ....................................................................................................................... 353
INSTALLATION & COMMISSIONING OF ELECTRICAL EQUIPMENTS .............................. 355

8.1
8.2
8.3
8.4
8.5
8.6
8.7
POWER TRANSFORMER ................................................................................................................. 355

SWITCHGEARS.............................................................................................................................. 357
CABLES TRAYS ............................................................................................................................ 359
CABLE INSTALLATION NOTES .................................................................................................... 361
LIGHTING ..................................................................................................................................... 363
EARTHING .................................................................................................................................... 366
FABRICATION WORK .................................................................................................................... 368
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
i

EQUIPMENT TESTING ................................................................................................................... 369

9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
HIGH VOLTAGE SWITCHGEAR ....................................................................................................... 369

POWER TRANSFORMERS ............................................................................................................... 369
11 KV HV CABLE ......................................................................................................................... 370
BUS-DUCTS ................................................................................................................................. 370
415 V SWITCHGEAR ..................................................................................................................... 370
AC MOTORS ................................................................................................................................ 371
MOTOR CONTROL CENTERS .......................................................................................................... 371
POWER DISTRIBUTION BOARD ...................................................................................................... 371
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
ii

GENERAL REQUIREMENTS FOR ELECTRICAL WORKS
1.1
Introduction
This chapter details the general requirements of electrical works proposed for the plant.
Unless specified to the contrary in the particular requirements electrical plant supplied by the
contractor shall comply in line with these standards.
SCOPE OF WORK
Design, manufacture, testing and inspection at places of manufacturer, painting, supply, delivery to
site, storage at site, installation / erection, final painting, testing and commissioning of the electrical
equipment listed below:
It is not the intent to specify herein all the details pertaining to the design, selection of material/
equipment, procurement, manufacture, installation, testing and commissioning, however, the same
shall be of high standard of engineering and shall comply to all currently applicable standards,
regulations and safety codes.
The scope of work starts from receiving 11 kV MSEDCL power at a suitable point of supply by
providing metering cubical room, main panel room, 4-pole structure (2-pole structure for MSEDCL
incoming line at point of supply and 2-pole structure on NMC side.) as per MSEDCL rules in the
plant premises. The scope also includes further power distribution, indoor & outdoor lighting system,
earthing system, cable carrier system, AB switch & DO, LA etc. The contractor shall work out the
details based on his equipments power consumption. The execution should take care of I.E. rules,
Electricity Boards requirement and other local authorities and site condition.
As the area is wide spread, sub-panels are to be provide as shown in the Single Line Diagram.
2.1
Sr.
1
2
3
4
5
6
7
8
9
10
11
12
13
Electrical Equipment
Equipment
4-Pole Structure
11 kV Swirchgear
11 kV/0.433 kV Power Transformer with OLTC
30V DC Sealed Maintenance free battery, battery Charge & DC Distribution
Board
415 V Metal enclosed Weatherproof AL. Bus duct
415 V Metal enclosed Main L.T. Panel/sub panels
Capacitor Control Panel with MD Capacitors and APFC relay
HV & LV Power & Control Cables and Termination Kits
Earthing System & Safety equipment
Indoor & Outdoor Lighting System
Cable Carrier System
Weatherproof Local Push Button Stations
All other miscellaneous items necessary for completing the installation and
commissioning of the equipment under this contract, as per the existing code of
practice
CONTRACTOR
NO OF CORRECTIONS
Qty.
Lot
1 No
1 No.
Lot
1 Nos.
As per SLD
1 No.
Lot
Lot
Lot
Lot
Lot
Lot
EXECUTIVE ENGINEER
287

2.2
Additional Scope
In addition to the above, the following services are included in the Scope of the Contract:
A.
The contractor shall assist the NMC in getting the working load sanction and power release from
MSEDCL by co-ordinating and liasioning with the MSEDCL authorities. The necessary
mandatory charges towards security deposits for load sanctions shall be paid by NMC.
B.
The contractor shall also be responsible for getting the complete installation approved by the
electrical inspector at his own cost.
C.
Supply of mandatory spare parts.
D. Supply of standard tools as follows

-
DE Hex open jaw fix spanners 6 32 mm (12 pieces)

Byhexagon ring spanner 6 32 mm (set of 12 pcs)
Ball pan hammer with handle 800 grms
Pipe wrench stillson pattern carbon steel 450 600 mm
Screw driver engineering pattern 6 x 300 mm, 8 x 200 mm
Screw driver with gren neon lamp line tester 3.6 x 60 mm
Bearing puller 3 legs 10
Tong tester of range 0 750 V, 0 300 Amps
HT megger 5 K
HRC fuse puller
Hand operated crippling tool with set of dies ranging from 6 to 185 sq.mm. Cable lug
including all accessories.
E.
Supply of Safety equipment such as Shock treatment Chart, Dry Co2 Fire Extinguisher for indoor
substation, Sand Bucket Stand for outdoor substation yard, Antiskid Insulated Rubbet Mats of
appropriate voltage grade, Danger Boards etc.
F.
Furnishing of drawings, documents, operation and maintenance manual
G. Supervising and training Employers staff in the operation and maintenance department.
H. Making good any damage done to the civil structure
2.3
Drawings and Documents
The Contractor shall submit the relevant drawings and documents as mentioned below:
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
288

Sr.
1
2
4
5
7
8
9
10
11
12
13
14
Drawing / Document
Title
Qty.
With Bid
Guaranteed technical particulars & 2

Data Sheets
General Arrangement drawing of
HT Switchgear
Transformers
DC Battery charger & battery bank
with DCDB
LT Bus Duct
Main LT Panel
Sub Panels
Control Panels
Local Push Button Station
Single Line diagrams showing 2
proposed metering, indications and
protection scheme
Control Schematic drawings for each
module of HT and LT switchgear
Bill of material for each switchgear
indicating type and make of each
component
Wiring diagrams HV/LV switchgear,
Transformer Marshalling Box, Local
push button stations, OLTC/RTCC
panels
Type test certificate for similar type
of switchegar / equipment
Technical
catalogues, 2
operation & maintenance manual and
Erection instructions
Routine test certificates for all
equipment
Contorl Cable termination schedule
for all control cables
Layouts:
Transformer yard Layout
Busduct Layout
HT & LT switchgear Layouts
Indoor/Outdoor Lighting Layouts
Earthing Layouts
Cable Layouts
Cable Schedules for all cables
Cable Sizing calculations
Lighting (Indoor & Outdoor) Design
Calculations alongwith Coefficient of
utilization chart for the proposed
fixtures
CONTRACTOR
NO OF CORRECTIONS
For
Approval
4
Final As built
6
4
(Sets each)
6
(Sets each)
4 Sets Each
6 Sets Each
4 each
6 each
4
4
2
6
6
6
EXECUTIVE ENGINEER
289

2.4
Standard Of Workmanship
The work shall be carried out in a neat and skilled manner.

All works shall be carried out in accordance with the requirements of:
i. Nashik Municipal Corporation
ii. Standard rules and regulations of Maharshtra State Electricity Board
iii. IE Rules, and
iv. The standards in this specification
The contractor shall ensure workmanship of best quality and shall assign qualified supervisor /
engineers and competent labour who are skilled, careful and experienced in carrying out similar
works.
NMC shall reserve the right to reject non-competent person/s employed by the contractor, if the
workmanship is found unsatisfactory.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
290

POWER DISTRIBUTION NETWORK
The plant power distribution network is considered to be supplied with power from 11 kV MSEDCL
power grid.
3.1
Power Supply Condition

Nominal System Voltage
Incoming Power Supply
11 kV, 3 ph,3 wire, 50 Hz AC
Voltage Variation
+ 10 %, -10%
Frequency
50 Hz 10%
Combined voltage and
3%
Three Phase Symmetrical Fault Level
500 MVA at 11 kV
Number of Incoming Power Supply

Lines to the Plant
Number of Independent Power
Source Supplying the Plant
3.2
Utilization Voltages
Levels of Utilization voltages in the plant shall comply with local standards.
Incoming Power Supply
11 kV, 50 Hz, 3 phase,3 wire
Plant power distribution voltage
415 V, 50 Hz, 3 phase,4 wire
Main LT Panel control voltage
230 V, 50 Hz, 1 phase,2 wire
DC alarm, control, protection
30 V DC, 2 wire
Potential transformer secondary
110 V, 3 phase, 50 Hz, AC
Motors < 0.37 kW
230V, 50Hz, 1 phase
Motors > 0.37 kW < 350 kW
415V, 50Hz, 3 phase
Electric Heaters < 3kW
230V, 50Hz, 1 phase
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
291

Welding Receptacles
415V, 50Hz, 3 phase, 4 wire
Lighting Power Distribution
Lighting Fixtures
Lighting Receptacles
Convenience Receptacles
System Earthing
a)
11 kV, 3 ph AC system
Neutral solidly earthed
b)
415 V, 3 ph, AC system
c)
240 V, 1 ph, AC system
d)
30 V, 2 wire DC system
Unearthed
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
292

DESIGN CONSIDERATION
4.1
Design Basis:
The electrical design shall be based on following factors:
Safety of personnel and equipment during operation and maintenance
Reduce fire and explosion hazards due to short circuits
Reliable, secure and efficient operation
Ease of maintenance
Maximum interchangeability of equipment
Latest technology
4.2
SIZING PHILOSOPHY
A]
Transformer Sizing
The entire plant shall have 1 no. adequatelly sized 11 kV/0.433kV Transformers with on load tap
changer contol cubicle.
Transformer sizing shall consider the following:
- The load of all the normal working equipment and auxiliaries of the plant.
- Transformer shall be rated for full working load of the plant.
The contractor shall submit the capacity sizing calculations in the prescribed format given in the
technical schedule.
B]
HT Cable Sizing
HT cable from 4-pole structure to the 11 kV Switchgear shall be sized for the present working load.
C]
HT Switchgear
HT Switchgear shall be single incoming outgoing type.

D]
DC Battery
DC battery bank, required for 11 kV switchgear control supply, shall be sized adequately considering
the DC load requirement of one no. 11 kV incoming outgoing panel.
4.3
SHORT CIRCUIT CAPACITIES
The equipment fault level for various voltages are as specified below:
11 kV system
415 kV system
CONTRACTOR
:
:
NO OF CORRECTIONS
500 MVA
20 MVA
EXECUTIVE ENGINEER
293

4.4
PROTECTIONS
Following protective relays shall be provided :

a.
HT Switchgear Incomer
i)
ii)
iii)
iv)
v)
b.
Inverse time phase over current relays

Inverse time earth fault relay
P.T. fuse failure relays
Under voltage relay
Over voltage relay
Transformers with OLTC
i)
Instantaneous short circuit protection on all the three phases for phase faults on HV side
( Source side)
ii)
Inverse time back up over-current protection on all the three phases on HV side for phase
faults.
iii)
Instantaneous earth fault protection on delta connected HV side.
iv)
Inverse time earth fault protection on star connected HV side
v)
Inverse time back up over current protection on all the three phases of secondary side for
phase faults
vi)
Inverse time back up earth fault protection of secondary side (relay shall be connected
through CT on directly earthed neutral or neutral earthed through a resistor)
vii)
Two stages (Alarm & Trip) gas protection ( Buchholz Relay)
viii)
Two stages (Alarm & Trip) oil temperature.
ix)
Two stages (Alarm & Trip) Winding temperature.
x)
Two stages (Alarm & Trip) Pressure Relief Device.
xi)
One stage (Alarm) Magnetic Oil Gauge
4.5
METERING
The following metering shall be provided.

a.
Incomer:
i)
ii)
iii)
iv)
v)
vi)
b.
Ammeters in all the three phases

Voltmeter with selector switch
Frequency meter
kVA, kW & kWh meter
Power factor meter
Load manager
Main Transformer HV Feeders

H.V. Side:
i)
ii)
CONTRACTOR

KVA meter
NO OF CORRECTIONS
EXECUTIVE ENGINEER
294

L.V. Side:
i)
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
295

SELECTION CRITERIA FOR ELECTRICAL EQUIPMENT
5.1
Switchgear:
H.V. Switchgear
a.
11 kV Switchgear shall be Indoor type with either Vacuum Circuit breaker. The
Circcuit breaker shall be draw out type and the switchgear shall be
compartmentalized with single front construction and protection degree IP4X.
L.V. Switchgear
5.2
a.
415 V Main LT Panel, Sub LT Panels etc. shall be of fixed, compartmentalized single
front construction, excepting Air circuit breaker modules which shall be of draw out
type and single front construction.
b.
The degree of protection for switchgear shall be IP 54 for indoor installation and IP
55 for outdoor installation.
Cables :
a.
HV Cable shall be 11 kV grade XLPE insulated and LT Cables shall be 600/1000V

grade PVC insulated aluminum cored. Manufacturing certificates shall be submitted
to the engineer-in-charge before commencing the installation.
b.
All cables less than 4 sq.mm. shall be copper conductor PVC insulated, PVC
sheathed, round G.I. wire armoured.All cables above and including 4 dq.mm. shall be
aluminum conductor PVC insulated, PVC sheathed, strip/round G.I. wire armoured.
c.
Where a neutral conductor is required, it shall be in the form of a core of half the
section that of the other cores.
d.
The control cables shall be copper conductor, minimum 1.5 sq.mm PVC insulated.
PVC sheathed and armoured type.
e.
The contractor shall ensure that each cable is of sufficient rating for its normal and
fault conditions. To access the rating and cross section required for each cable, the
following factors shall be considered
CONTRACTOR
Fault Level
Condition of ambient temperature relevant to method of laying
Voltage drop in motor circuits
Voltage drop in cables shall not exceed the following, in percent of system
nominal line-to neutral voltage:
Motor feeders (starting) 15%
Motors feeder (running) 3%
Over current setting of circuit breakers
Disposition of cabling whether in air or ground
The capacity claimed by the manufacturer shall be de-rated to 70% to avoid
overheating related problems of cables at end terminals, joints which may be due
to improper end connections.
NO OF CORRECTIONS
EXECUTIVE ENGINEER
296

The contractor shall submit the detail calculations of cable sizing for each type of power &
control cable.
5.3
f.
All power cable sizes shall be based on continuous current carrying capacity,
permissible voltage drop and short circuit rating. For short circuit rating of H.V.
cables, the fault clearing time shall be 1 second for H.V. plant feeders and for
equipment feeders. For S.C. rating of H.V. cables the fault clearing time shall be 1
second, for L.V. incomers 0.5 Second and L.V. outgoing feeders to equipment, 0.5
second.
g.
Rating factors for variation in ground temperature, variation in ambient air

temperature, grouping of cables, depth of laying etc. shall be based on the cable
manufacturer's recommendations/catalogues.
Lighting system
The lighting system inside and outside plant units shall be designed taking into consideration
the desired illumination level, architectural arrangement, building dimensions including
mounting height, environmental conditions, ease of maintenance and reliability of the lighting
distribution network. The contractor shall submit the detail lighting design calculations
confirming the selection of lighting fixture quantities.
The illumination system shall be designed to minimize direct glare and shall be free from
shadows. Maximum and minimum illumination at any point shall be within + 15% of the
average illumination of the area under consideration.
Lighting fittings shall be selected from the type and range given in the general specifications
for Lighting system.
The lighting system will comprise the following:
a.
Normal A.C. lighting.
All indoor and outdoor areas will be provided with A.C. lighting and the same will be
available as long as A.C. supply is healthy.
b.
Emergency D.C. Lighting
At important locations (such as Load Center Sub Station) built in battery operated instalite
fixtures will be provided which will come in service when A.C. supply fails.
c.
The wiring for lighting circuits shall be done by 3 x 2.5 YWY cables clamped on
walls/ structure for indoor areas. For outdoor lighting, armoured cables shall be used.
The illumination levels for various areas shall be as follows:
e.
Sr.
1
2
3
CONTRACTOR
Area
Pump house
Offices
H.V./L.V. switchgear rooms
NO OF CORRECTIONS
Illumination Level (Lux)

200
300
250
EXECUTIVE ENGINEER
297

Sr.
4
5
6
7
8
9
10
11
12
5.4
Area
Plant/Switchyard control rooms
Chemical House
Cable basement
All other indoor areas
Outdoor platforms and walkways
Building entrances
Outdoor plant areas
Switchyard and transformer yard
- General
- On equipment
Roads
Illumination Level (Lux)

300
200
100
100
50
100
20
10
30
10
f.
Lighting fixtures and fans will be grouped on the circuit wherever required.
However, separate circuits shall be used for receptacles wiring.
g.
For the purpose of calculating connected loads of various lighting circuits, a

multiplying factor of 1.25 will be assumed to the rated lamp wattage for mercury
vapour, sodium vapour and fluorescent lamp fixtures to take into account losses in the
control gear. Also a loading of 100 watts and 500 watts shall be assumed for single
phase 5 Amps and 15 Amps receptacles respectively.
h.
Lighting fixtures, receptacles, switches, conduits and junction boxes shall be properly
earthed using 12 SWG G.I. wire unless specified otherwise.
i.
Receptacles of 5A and 15A, single phase, 3 pin shall be provided with switch.
Receptacles in offices shall be decorative type and in other areas shall be industrial
type. Three phase receptacles shall be associated with TPN switch housed in the
same enclosure. The receptacle shall become live only when the associated switch in
"ON" position. The enclosure for all outdoor receptacle shall be provided with
degree of protection of IP-55.
j.
Generally maintenance factor of 0.8 shall be considered for all lighting fixtures.
k.
Except for corrosive areas such as clarifiers, filter galleries, chlorine plant etc. all
other indoor areas shall be illuminated using fluorescent tube fixtures of Industrial
type, complete with lamps, electronic ballast & necessary accessories for their
satisfactory operation. In corrosive areas, corrosion resistant fixtures with electronic
ballast shall be provided. Makes of the lighting fixtures shall be as given in the list of
approved makes.
Lighting Power Supply and Distribution

One Main Lighting Distribution Board (MLDB) shall be provided for lighting supply
provision. Each outgoing feeder of MLDB shall feed one miniature circuit breaker lighting
sub distribution boards. (SLDB)
a.
Each SLDB shall have 63A TPN MCB with ELCB (having 100mA current
sensitivity) on incomer side. Each 240V single phase circuit taken from SLDB shall
control a group of fittings with the loads equally distributed on all the three phases to
the extent possible. The rating of the outgoing MCB shall be selected on the basis of
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
298

lamp starting current, for lamps used in the lighting fittings, such that the total load
does not exceed about 70% of the MCB rating.
5.5
b.
Plant road and area lighting shall be fed from separate Lighting Distribution Board.
The road and area lighting system shall be provided with timer switch for automatic
switching of the street lighting.
c.
For road and area lighting 4-core underground cable shall be run along road side and
connection to individual poles will be given from alternate phase and neutral.
d.
Cable sizes for lighting circuits shall be selected based on the voltage drop
considering starting current of the lamps in circuit. The continuous current carrying
capacity of such cables shall in no case be less than the thermal trip setting of the
MCB protecting the circuit.
Safety Earthing
a.
The method adopted for system as well as equipment earthing shall be in accordance
with the Code of Practice for earthing IS 3043. It shall also comply with the relevant
clauses of Indian Electricity Rules.
b.
The CONTRACTOR shall do measurement of soil resistivity for earthing system.

After soil resistivity measurement; length & size of conductor and no. of earth pits
shall be finalized.
The material of earthing conductors will be as given below :
c.
Conductors above ground shall be Galvanized iron to prevent atmospheric corrosion
Conductors buried in ground or embedded in concrete shall be mild steel.
d.
Fault clearing time for sizing the earthing conductor shall be taken as three (3)
seconds.
e.
Maximum allowable temperature rise for steel welded joints will be taken as 50 0C
and ambient temperature as 40 0C.
f.
Plant earthing system will be designed to ensure effective operation of protective

gears in case of earth faults. The total earthing resistance shall be less than one (1)
ohm.
For plant building and indoor substations one Main Earthing Ring shall be provided
along the building periphery connected to required number of earth electrodes.
g.
h.
Entire plant area can be devided in to small sections and each section shal have its
own sub main earthing grid. Earthing system for different sections shall be
interconnected by inter-connectors of maximum size conductor.
i.
Main earthing conductors inside the building will be planned such that various
equipment are connected to earthing system in most economical and reliable manner.
j.
Earthing conductors shall be provided around the outside edge of switchyard fence at
a distance of approximately 1000 mm and every alternate fence post shall be
connected to the grid by one lead and gates by flexible braid to the earthed post.
CONTRACTOR
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k.
Distance between two earth pits shall be (minimum) twice the length of the earth rod
used for the earth pit.
5.6
Power Factor Improvement
a.
One separate Capacitor panel with adequate banks of power capacitors shall be provided on
415V bus with automatic switching to improve and maintain grid power factor to unity.
Power factor control shall be controlled automatically by an Automatic Power Factor
Correction relay of suitable steps.
Power capacitors shall be Mixed Dielectric type.
Minimum rating of the capcitor bank shall be 600kVar.
b.
c.
d.
CONTRACTOR
NO OF CORRECTIONS
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300

LAYOUT CLEARANCES AND SAFETY REQUIREMENTS

a.
For every switchgear, control panel etc. that requires back access, the space behind
the equipment shall generally be around 1000mm but in no case less than 750mm.
The space provided shall be adequate to permit at least 90 degree opening of doors or
hinged panels. In case where back clearances are required and provided, there shall be
a passage way from either end of the equipment clear to a height of 1800 mm. Where
the equipment are not required to be attended from the back, the equipment shall be
placed along the wall/ structure having clearances less than 200 mm.
b.
For all switchgear, control panels etc. a clear space of not less than 1000mm shall be
provided in front of the equipment. In case where the equipment is provided with
draw out units and the above clearance is not adequate, the front space shall be to suit
the draw out unit.
c.
For all electrical equipment a minimum clear head room of 500mm shall be
provided.
d.
All motors located away from the feeding end control panels, for which control desk /
posts are not within visible distance, shall be provided with readily accessible and
easily operable, locally mounted lockable type START-STOP push-buttons in the
control circuit.
e.
All electrical equipment having operating voltages, 415V and above, shall be
provided with Danger Boards of approved type and shall be affixed permanently in
a conspicuous position. Where a group of equipment is located within a switch /
control room or within a fenced area, the board shall also be affixed at the entrance.
Shock treatment charts shall be provided near such equipment for first aid during
shock treatment. The danger board and the shock treatment chart shall be in three
languages viz. English, Hindi and local language.
f.
All moving parts of equipment, which are exposed and are liable to cause hazard to
the operation/maintenance personnel, shall be suitably protected by metallic guards.
g.
750mm wide Anti-skid rubber mats shall be provided in front of all switchgear for
personnel safety. The rubber mats shall be rated for applicable voltage grade as per IS
5424 with amendments.
h.
Dry CO2 type fire extinguisher of suitable capacity shall be installed in each
switchgear / control room and a dry sand bucket type fire extinguisher shall be
installed in outdoor switchyard/ transformer yard etc.
i.
All switchgear / control rooms and substation building including cable cellars
basement shall be provided with minimum two entry/ exit doors.
CONTRACTOR
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GENERAL REQUIREMENTS OF ELECTRICAL EQUIPMENT
7.1
11 kV Switchgear
Applicable Standards
The switchgear and its components shall conform to the latest applicable standards specified
below. In case of conflict between standards and this specification, this specification shall
govern.
Code No.
Title
IS 13118 / BS 5311 / IEC 56, 694
Circuit Breakers
IS
IS
IS
IS
Metal Enclosed switchgear

Arrangement for Switchgear Busbars,
Main Connections and Auxiliary
wiring
3427 / BSEN60298 / IEC298

2705 / BS 7626
3156/BS 7625/IEC 186
5578, 11353
IS 2544 / BS 3297 / IEC 273

IS 13947 (Part 1) / IEC 947-1 / BSEN
60529
IS 3231, 3842 / BS 142 /
IEC 255
IS 1248 / BS 89 / IEC 51
Busbar Support insulators

Electrical Relays for Power system
protection
Electrical Indicating Instruments
IS 9385 / BS 2692 / IEC 282

High Voltage Fuses
IS 722, 8530 / BS 5685 /
IEC 145, AC Electricity Meters
211
IS 613
Specification for copper rods and bars
for electrical purposes
IS 6005 / BS 3189
IS 9920 / IEC 129, 265 & 298
IS 13703 / BS 1362 / IEC 269
IS 3452 / BS 3676
IS 10118
IS6875/BSEN 60947/IEC 947
CONTRACTOR
Code of practice for phosphating iron

and steel
Alternating current Switches for
voltages above 1000 V
Low voltage fuses
Toggle switches
Code of practice for selection,
installation and maintenance of
switchgear and control gear
Control switches
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CONSTRUCTIONAL FEATURES
Metal-clad switchgear and control gear shall comprise metal-enclosed switchgear and control gear in
which components are arranged in separate compartments with metal-enclosures intended to be
earthed. Compartments with doors for access to operating mechanism shall be so arrranged as not to
expose high voltage circuits.
The metal-clad switchgear and control gear shall have separate compartments for the following
components :
Each set of busbars
Current transformers
Voltage transformers on incomer side
Each main switching device
Cable chambers suitable for heat shrinkable type cable termination of cables indicated in single line
diagram.
Metering and relaying devices.
DEGREES OF PROTECTION:
Complete protection against approach to live parts or contact with internal moving parts i.e. IPH-6
class for all the above compartments except for each set of busbars. Compartments of each set of
busbars shall be provided with protection against approach to live parts or contact with internal parts,
by tools, wires or similar objects of thickness greater than 2.5 mm i.e. Class IPH-3.
Switchgear shall comprise indoor, metal-clad, Draw out type circuit breakers. The circuit breaker shall
be fully horizontally draw out type. The circuit breaker shall have distinct service and test positions.
In the test position the circuit breakers shall be capable of being tested for operation without
energising the power circuits. Four normally open auxiliary contacts shall be provided for each of the
service and test limit position switches.
The test position should preferably be obtained without the need to disconnect normal control
connections and use of extension cords for testing.
The switchgear shall fully house the breaker both in the service position as well as in the test position
Switchgear shall be dust, moisture and vermin-proof.
Separate removable gland plates with minimum thickness of 3 mm shall be provided for power and
control cables. The gland plate for the power cables shall be of non-magnetic material.
All doors, panels, removable covers shall be gasketted all around with neoprene gaskets. All louvers
shall have screens and filters. Vent openings shall be covered by fine mesh on the vertical face. The
screens and grills shall be made of either brass or galvanized iron wire mesh.
CONTRACTOR
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Metal-clad unit shall comprise rigid welded structural frame enclosed completely by metal sheets,
minimum 2.5 mm thick (hot rolled) or 2.0 mm thick (cold rolled), smooth finished, leveled and free
from flaws.
The current transformers shall be mounted on the fixed portion of the switchgear and not on the
breaker truck.
Each switchgear cubicle shall be fitted with a label in the front and rear of the cubicle. Each
switchgear shall also be fitted with label indicating the switchgear designation, rating and duty. Each
relay, instrument, switch, fuse and other devices shall be provided with separate labels.
PAINTING
All sheet steelwork shall be phosphated in accordance with the following procedure and in accordance
with relevant standards for phosphating iron and steel.
Oil, grease and dirt shall be thoroughly removed by emulsion cleaning.
Rust and scale shall be removed by pickling with dilute acid followed by washing with running water,
rinsing with slightly alkaline hot water and drying.
After phosphating, thorough rinsing shall be carried out with clean water, followed by final rinsing
with dilute dichromate solution and oven drying.
The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type
zinc chromate primer. The first coat may be 'flash dried' while the second coat shall be stoved.
After application of the primer, two coats of finishing epoxy paint shall be applied, with each coat
followed by stoving. The colour for the finishing paint shall be as specified.
The final finished thickness of paint film on steel shall not be less than 100 microns, and shall not be
more than 150 microns.
Structure, buses and control wiring troughs shall be so designed and arranged to make future
extensions readily feasible.
Instruments, relays and control devices shall be mounted flush on hinged door of the metering
compartment located in the front portion of cubicle. Panel door shall be supported by strong hinges
and braced in such a manner as to ensure freedom from sagging, bending and general distortion of
panel or hinged parts. All auxiliary relays not requiring manual resetting will be mounted inside the
L.T. compartment.
SAFETY INTERLOCKS
Switchgear shall be provided with following interlocks:
Compartment door of a breaker shall not open unless the associated breaker or an isolator is in open
position.
Caution name plate, 'Caution Live Terminals' shall be provided at all points where the terminals are
likely to remain live and isolation is possible only at remote end.
CONTRACTOR
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304

Circuit breaker cubicles shall be provided with safety shutters operated automatically by the
movement of the circuit breaker carriage to cover the exposed live parts when the breaker is
withdrawn.
MAIN BUSBARS
Main busbars shall be of copper conductor of hard drawn (HD) and high conductivity and
non-segregated type.
Busbars shall be located in air insulated enclosures and segregated from all other compartments of the
cubicle. Direct access or accidental contact with busbars and primary connections shall not be
possible. To provide a seal between adjacent cubicles, busbars shall be taken through seal-off
bushings or insulating pads.
All busbars joints shall be thoroughly cleaned and antioxide grease shall be applied. Plain and spring
washers shall be provided to ensure good contacts at the joints and taps. Wherever aluminium to
copper connections are required, suitable bimetallic connectors or clamps shall be used.
Busbars shall be rated in accordance with the service conditions and the rated continuous and short
time current ratings specified in the SLD. Maximum temperature of the busbars and busbar
connections, under operating conditions, when carrying rated normal current at rated frequency shall
not exceed 85 deg. C.(40 + 45 = 85)
Busbars shall be adequately supported on insulators, to withstand dynamic stresses due to short circuit
current. Busbar support insulators shall conform to relevant standards.
The busbar clearances in air shall be suitable for the short circuit levels.
Busbars shall not be painted and all performance characteristics specified shall be obtained with
unpainted busbars.
Busbars shall be fully insulated by encapsulation in epoxy resin, with mould caps protecting all joints
or heat shrinkable PVC sleeves and tapes
CIRCUIT BREAKERS
GENERAL
Circuit breakers shall be VCB type. These shall conform to relevant standards specified and shall be
of draw out type. Circuit breakers shall comprise three separate identical single pole units operated
through a common shaft by the operating mechanism.
Circuit breakers shall be suitable for switching duty of transformers whose capacities are furnished in
the single line diagram.
Isolating plugs and sockets for power as well as control circuits shall be of robust design and fully
self-aligning. Plugs and sockets for power circuits shall be silver faced and shall be insulated with
PVC or other insulating material shrouds.
SF-6 circuit breakers shall have completely sealed interrupting units for interruption of arc inside the
SF6 gas chamber. It shall be possible to isolate easily the SF6 interrupter unit from the breaker
operating mechanism for mechanical testing of the interrupter to check loss of SF6 gas.
CONTRACTOR
NO OF CORRECTIONS
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The circuit breakers shall be complete with surge arrestors to provide protection to the equipment
controlled by the breaker, against switching surges.
Breaker internal wiring up to the plug shall be similar for all breakers.
OPERATING MECHANISM
Circuit breaker shall be power operated, by a motor charged spring operated mechanism. Main poles
of the breakers shall be such that unless otherwise specified, the maximum difference between
instants of contacts touching during closing shall not exceed half cycle of rated frequency.
Operating mechanism shall be provided with non-pumping feature, electrically and mechanically.
Electrical anti-pumping feature shall be obtained by means of an auxiliary relay.
Main poles of the breaker shall operate simultaneously. There shall be no objectionable rebound and
the mechanism shall not require any critical adjustment. It shall be strong, rigid, positive and fast in
operation.
Mechanism shall be such that failure of any auxiliary spring shall not prevent tripping and will not
cause tripping or closing operation of the power operated closing devices. When the circuit breaker is
already closed, failure of any auxiliary spring shall not cause damage to the circuit breaker or
endanger the operator.
A mechanical indicator shall be provided to show open and closed positions of breaker. It shall be
located in a position where it will be visible to the operator standing on the front of the switchgear
with cubicle door closed.
The closing coil shall operate correctly at all values of voltage between 80 % and 110 % of the rated
voltage. A shunt trip shall operate correctly under all operating conditions of the circuit breaker upto
the rated breaking capacity of the circuit breaker and all values of supply voltage between 50 % and
110 % of rated voltage.
Mechanical trip and close devices shall be provided for manual operation of the breaker. Access to
mechanical closing device shall be only after opening the cubicle door. However, the mechanical trip
device shall be brought out to the front of the cubicle door.
Working parts of the mechanism shall be of corrosion resisting material. Bearings, which require
grease shall be equipped with pressure type, grease fittings. Bearing pin, bolts, nuts and other parts
shall be adequately pinned and locked to prevent loosening or changing adjustment with repeated
operation of the breaker.
Auxiliary switches mounted on the fixed portion of the cubicles and directly operated from the
breaker operating mechanism on each breaker having 8 'NO' and 8 'NC' potential-free contacts rated
for 10 amps. 240V AC and 10 amp (inductive breaking) 30 V DC shall be provided. The contacts
shall be in addition to those utilized in the control circuit of each breaker and shall be exclusively
meant for the use in external interlocks and controls.
SPRING OPERATED MECHANISM
Spring operated mechanism, shall be complete with motor, opening spring, closing spring with limit
switch for automatic charging and all necessary accessories to make the mechanism a complete
operating unit.
CONTRACTOR
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As long as power is available to the motor, a continuous sequence of closing and opening operations
shall be possible. After failure of power supply to the motor, at least one open- close-open operation
of the circuit breaker shall be possible.
Breaker operation shall be independent of the motor, which shall be used solely for compressing the
closing spring.
Closing action of the circuit breaker shall compress the opening spring ready for tripping.
When closing springs are discharged, after closing a breaker, closing springs shall automatically be
charged for the next operation.
Motor shall be such that it requires only about 30 sec. for fully charging the closing spring. Motors
shall be rated for or 240V AC and shall operate satisfactorily at all values of voltage between 80 % to
110 % of rated voltage.
Mechanical indicators to indicate charged and discharged condition of spring shall be provided.
OPERATING MECHANISM CONTROL
The closing and tripping control shall be by a control switch mounted on the cubicle door.
The mechanical trip and close devices shall be provided on the breakers in addition to above.
EARTHING
An earthing bus shall be provided and extend throughout the length of the switchgear. It shall be
bolted to the framework of each unit and each breaker earthing contact bar.
The earth bus shall have sufficient cross section to carry the momentary short circuit and short time
fault current for 1 second, without exceeding maximum allowable temperature rise.
Suitable clamp type terminals at each end of the earth bus shall be provided to suit the size of the
Main Earthing Grid conductor.
All non-current carrying metal work of the switch-board shall be effectively bonded to the earth bus.
Bolted joints, splices, taps etc. to the earth bus shall be made with at least two bolts.
Hinged doors shall be earthed through green colour flexible earthing braid.
Positive earthing of circuit breaker frame shall be maintained when it is in the connected position and
in all other positions whilst the auxiliary circuits are not totally disconnected.
CUBICLE MODULE ACCESSORIES AND WIRING
Cubicle accessories and wiring shall include the following:
Switchgear shall be supplied completely wired internally upto equipment and terminal blocks and
ready for external cable connections at the terminal blocks. Inner panel wiring between cubicles of
same switchgear shall be provided.
CONTRACTOR
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All auxiliary wiring shall be carried out with 650 volts grade, single core, stranded copper conductor
with PVC insulation. The sizes of wire shall be not less than 1.5 mm2.
Terminal blocks shall be of stud type, 650 grade, 10 amps, rated complete with insulated barriers.
Terminal blocks for CTs and VTs shall be provided with test links and isolating facilities.
All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal
blocks.
Accuracy class for indicating instruments shall be 1.0. Instruments shall be 110 mm square with 240o
scale for flush mounting with only flanges projecting.
Relays shall be suitable for flush mounting with only flanges projecting.
All protective relays shall be in draw-out cases with built-in test facilities. Necessary test plugs shall
be supplied loose. All auxiliary relays and timers shall be supplied loose. All auxiliary relays and
timers shall be supplied in non-draw-out cases. Externally operated hand reset flow indicators shall
be provided on all relays and timers. Timers shall be of electromagnetic or electronic type only.
Control and instrument switches shall be rotary type provided with escutcheon plates clearly marked
to show operating position and suitable for semi flush mounting with only switch front plate and
operating handle projecting out.
Breaker control switches shall be pistol grip black and selector switches shall be oval or knob and
black. Breaker control switches shall be three-position spring return to neutral type. Instrument
selector switches shall be of the maintained stay-put type. Contacts of the switches shall be spring
assisted and contact faces shall be with rivets of pure silver. The contact ratings shall be adequate to
meet the requirements of circuit capacity in which they are used.
All push buttons shall have two normally open and two normally closed contracts unless otherwise.
The contacts shall be able to make and carry 5 A at 110V DC and shall be capable of breaking 1 A
inductive load at 30V DC. They shall be provided with inscription plates engraved with their
functions.
Indicating lamps shall be panel-mounting type with series resistors. The wattage of lamps shall be 5
to 10 watts.
Provision shall be made for receiving, distributing, isolating and fusing of auxiliary D.C. and A.C.
supplies for controls, space heating, etc. The fuse ratings shall be so chosen as to ensure selective
clearance of sub circuit faults.
Fuses shall be HRC cartridge type mounted on plug in type fuse base
The D.C. and A.C. auxiliary supply shall be distributed inside the switchgear with necessary isolating
arrangements at the point of entry and with sub-circuit fuses as required.
CABLE TERMINATION COMPARTMENT
Necessary number of cable glands shall be supplied for terminating auxiliary power and control
cables. Glands shall be of heavy-duty brass castings, machine finished and complete with check nut,
washers, neoprene compression ring.
CONTRACTOR
NO OF CORRECTIONS
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Cable lugs for all power and control cable connections shall be supplied. The lugs shall be tinned
copper depending on cable conductor and of solderless crimping type.
All necessary materials required for terminating the power cables such as tapes, fillers, binding wires,
armour clamps, brass glands etc., shall be supplied.
INSTRUMENT TRANSFORMERS
The current transformers and voltage transformers shall conform to the requirements stipulated in
relevant standards specified.
The CTs and VTs shall be of cast resin type (insulation Class 'E') and shall be able to withstand the
thermal and mechanical stress resulting from the maximum short circuit and momentary current
ratings of the switchgear. These shall be completely encapsulated.
CTs shall have polarity marks indelibly marked on each transformer and at the associated terminal
block. Facility shall be provided for short circuiting and earthing the CT secondary at the terminal
blocks.
VTs shall be protected on their primary sides by current limiting HRC fuses with interrupting ratings
corresponding to breaker rating and on secondary side with MCB's. Provision shall be made such that
the primary fuses can be handled only in the de-energized position.
Miscellaneous Accessories
Space heaters of adequate capacity shall be provided inside each panel heater to prevent moisture
condensation within the enclosure. The space heater shall be suitable for 240V, 1 ph, 50 Hz supply
and complete with MCB for isolation purpose and thermostat to cut off heater at 45o C.
Each switchgear panel shall be provided with 240 Volts, 1 phase, 50 Hz, 5 amps. 3 pin receptacle with
MCB located at a convenient position.
An 20 W F.T. L. interior illuminating lamp together with operating door switch and protective fuse
shall be provided.
Annunciators
Fascia annunciators, suitable for operation on 30V DC shall be provided. Fascia annunciators shall
be:
Equipped with Sound Cancel, Acknowledge and Reset push buttons common to annunciators on
all switchgear aligned together and a Lamp test push button for each annunciator on individual
panels.
Provided with two lamps connected in parallel on each fascia window with series resistors
Suitable for normally open indicating contacts of either hand or self reset type
Suitable for annunciating subsequent faults with the specified sequence, immediately after
acknowledging the previous fault
Fascia Window of minimum size of 35 mm x 50 mm designed for an operating sequence indicated
below :
CONTRACTOR
NO OF CORRECTIONS
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309

Alarm Condition
Fault Contact
Audible
Alarm
Visual
Alarm
Normal
Abnormal
Sound cancel
Acknowledge
Open
Closed
Closed or Open
Closed or Open
Off
On
Off
Off
Off
Flashing
Flashing
Steady on
Back to Normal
Reset
Lamp Test
Open
Open
Open
Off
Off
Off
Steady on
Off
Steady on
TESTS AND TEST REPORTS

All routine tests shall be carried out as per the relevant standard.
Type test certificate shall be furnished along with routine tests reports.
7.2
DC BATTERY & BATTERY CHARGER
APPLICABLE STANDARDS
The battery charger and D.C. distribution board shall conform to the latest applicable standards
specified below. In case of conflict between the standards and this Specification, this Specification
shall govern.
Title
Code No.
Basic climatic and mechanical

durability tests for components for
electronic and electrical equipment
Environmental tests for electronic and
electrical equipment
Metal clad base material for printed
circuits for use in electronic and
telecommunication equipment
Transformers and inductors (power,
audio, pulse and switching) for
electronic equipment
Printed wiring boards
Environmental requirements for
semi-conductor devices and
integrated circuits
Terminals for electronic equipment
Factory built assemblies of
IS:9000
CONTRACTOR
IS:9000
IS:5921
IS:6297
IS:7405
IS 6553
IS:4007
IS:8623/BS: 5486 /IEC:439
NO OF CORRECTIONS
EXECUTIVE ENGINEER
310

Title
switchgear and control gear for
voltages upto and including 1000 V
AC and 1200 V DC
Air break switches
Miniature circuit breakers
HRC cartridge fuses
Contactors
Control switches/push buttons
Indicating instruments
Climate-proofing
of
electrical
equipment
Code of practice for phosphating
iron and steel
Semi-conductor converters
Semi-conductor rectifier
equipment safety code
Specification for copper rods
and bars for electrical purposes
Code No.
IS : 13947 (Part 3)BSEN60947-3

IS 8828/BSEN:60898
IS:9224/BS:88
IS:13947(Part3) /BS:775/ IEC:158-1
IS:6875
IS:1248/BC:89/ EC:51
IS:13947-(Part1)/IEC:947-1
BSCP:1014
IS:6005/BS:3189
IEC:146
IS:6619
IS : 613
Battery Charger
Battery charger shall be combined float-cum-boost type.
The charger shall be static type composed of silicon controlled rectifiers (SCRs) and diodes connected
in three phase full wave half controlled bridge circuit.
The rectifier transformers for float and boost chargers shall be indoor dry type, double wound with
delta-star connections. The Contractor shall ascertain if taps are required and provide adequate
number of primary and secondary taps, if necessary.
The float charger shall be designed for supplying :
i)
The D.C. loads as required for the system i.e. continuous load and short-time overload.
ii)
The trickle charging current of the battery.
The boost charger shall be designed for supplying the boost charging current of the battery.
If the battery and charger are to be supplied by separate contractors, the charger Contractor shall
coordinate with the battery. Contractor regarding the float/trickle and boost charging current and
voltages required by the battery,
CONTRACTOR
NO OF CORRECTIONS
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311

Performance
i)
Float Charger
The D.C. output voltage during float charging shall be stabilised within 1% of the set DC bus
voltage. There shall be provision for manual control if automode fails.
ii)
Boost Charger
For boost charging the discharged battery after a mains failure, the rectifier shall charge the battery at
high rate limited to the maximum boost charging voltage. After a specified number of hours
(adjustable) when the rated cell voltage is reached, the charger shall be returned to float charge status.
-
In case of combined float-cum-boost charger, the switching and control of high rate charge
and return to float charge shall be by automatic controller/regulator. There shall be provision
for manual control if auto-mode fails.
During boost charging following emergency measures shall be provided:
If the AC mains supply fails, an arrangement shall be made to automatically connect the
battery directly across the load.
If the separate or spare float charger supplying D.C. load fails, the load shall be fed from the
point of connection at the tapping of the battery via adequately rated blocking diodes.
Charger Panel and D.C. Distribution Board

a)
Battery charger panel and D.C. distribution board shall be sheet metal enclosure freestanding
type with cable entry from bottom.
b)
Indications, controls and output voltage setting adjustments shall be on front panel. The
Contractor shall submit a scheme for alarm and trip indication lamps on the cabinet and for
fault annunciation contacts paralleled for remote annunciation.
c)
The components shall be liberally rated and housed in a well ventilated sheet metal cubicle
complete with input and output terminals. Louvers shall be provided for ventilation backed
up by fine wire mesh so that the degree of protection shall be equal to or better than IP-42.
d)
Busbars shall be of copper conductor of hard drawn (HD) and high conductivity. Busbars
shall be fully insulated by encapsulation in epoxy resin with moulded caps protecting all
joints
e)
All printed circuit cards shall be plug-in type, interlocked to prevent insertion in a wrong slot.
Each card shall have LED indication on its front plate to indicate normal condition and
readily and marked test pins.
f)
All components shall be accessible to the maintenance technician for easy disassembly and
replacement. Access to parts of equipment shall be with minimum danger from all hazards.
g)
All components and modules shall be clearly and unambiguously marked and all wiring
colour-coded and tagged.
CONTRACTOR
NO OF CORRECTIONS
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h)
All power and control wiring within the cubicle shall be done with stranded copper wires.
The power wiring shall be adequately sized for the required rating. The minimum sizes for
control wiring will be 1.5 mm2 and for power wiring shall be 2.5 mm2.
i)
Ground terminals with isolating links shall be provided.
j)
Cable glands shall be provided to suit the incoming and outgoing cables.
Components/Accessories
The main items are listed below. However, additional items required for completeness or to
meet the specified performance or operational requirements of the charger, shall be deemed to
be included in the Contractors scope. Instead of incoming ON/OFF switches, stricker fuses
and contactors, the Contractor may provide suitably rated 3 pole MCBs with overload and
short circuit protection and auxiliary contacts.
i)
One (1) set - Three phase full wave half-controlled bridge rectifier circuit comprising silicon
controlled rectifiers and silicon diodes complete with resistor/capacitor network for surge
protection. The diodes/SCRs shall be individually protected by fuses with fuse fail indication.
ii)
One (1) Double wound, dry type, three phase suitably rated mains transformer.
iii)
One (1) set of suitably rated control transformers for electronic controller.
iv)
One (1) Electronic controller comprising of power supply card, soft start cum current limit
card, auto trickle mode card with facility for setting trickle charge current and monitoring
battery current, error amplifier cards and pulse generating cards for achieving the DC output
voltage stabilisation of 1% and also for achieving current limiting feature. The electronic
controller shall have protection features with indications for under-voltage, over-voltage, set
output voltage and phase failure or voltage unbalance.
The electronic controller shall be provided with following features.
Boost current stabilisation of 2% with AC input variation of voltage and frequency variation
of 10% and 5% respectively.
Boost charge current limiter with potentiometer to adjust the setting.
v)
Adequately sized necessary built-in accessories shall be provided such that on failure of the
controller in auto mode the voltage can be effectively controlled manually.
vi)
One (1) Filter circuit comprising of smoothing choke and condensers complete with HRC
fuse with trip indication for filter condenser circuit.
vii)
One (1) Auto/Manual selector switch for selecting the mode of operation of the controller.
viii)
One (1) front panel mounted potentiometer for set point adjustment of output voltage in auto
mode.
ix)
One (1) front panel mounted potentiometer for manual adjustment of voltage in manual mode.
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x)
One (1) TP AC ON/OFF switch for float charger incoming.
xi)
One (1) set of HRC fuses complete with fuse fittings for AC input with suitable ratings and
with trip indication.
xii)
One (1) set of the pilot lamps with series resistors to indicate float charger AC Mains ON
condition.
xiii)
One (1) AC contactor with suitably rated coil and three main and 2 NO + 2 NC auxiliary
contacts, suitably rated thermal overload relay and ON/OFF control switch.
xiv)
One (1) set of HRC fuses complete with fuse fittings for the DC output, and with trip
indication.
xv)
One (1) moving coil DC ammeter, with shunt, of size 96 x 96 mm and suitable range to read
the float charger output current.
xvi)
One (1) Double pole DC ON/OFF rotary switch for float charger output.
xvii)
One (1) pilot lamp with series resistor to indicate float charger DC ON condition.
xv)
Outgoing DC Distribution Board with MCBs.
Power Electronic Components

a)
Diode and thyristors shall be of mono crystalline type silicon, capable of continuous output at
specified voltages. It shall have high power efficiency.
b)
If many diode or thyristor assemblies are connected in parallel, care shall be taken to ensure
that each rectifier or thyristor operates within its rating and shares the load uniformly. This
may be achieved with the help of chokes. Also, care should be taken to select matched pairs
of rectifier heat sink units.
c)
Each diode or thyristor built in a multi-built assembly shall be provided with a short circuit
protection to avoid complete shut-down of the equipment because of a fault on single unit.
Suitable fuses shall be provided for such protection.
d)
Necessary spare capacity shall be built in the equipment to continuously supply full load even
with one unit out of circuit.
e)
The diodes or thyristor banks shall be natural air cooled.
f)
The diodes or thyristors shall be protected against over voltage due to chopping surges with
the aid of snubbers. It shall be ensured that normal load currents and especially fault currents
are shared equally between parallel links, within the specified limits. To achieve this, great
care shall be taken to design the layout of the rectifier links to ensure equal lengths of busbars
and as near as possible identical contact resistance in each current path.
7.3
Transformer
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Codes and Standards

The design, manufacture and performance of equipment shall comply with currently
applicable statutory, regulations and safety codes in the locality where the equipment will be
installed. Nothing in this specification shall be construed to relive vendor from his
responsibility.
Unless otherwise specified, equipment shall conform to the latest applicable Indian or IES
standards. Equipment complying with any other authoritative standards, such as British,
U.S.A., VDE etc. will also be considered if offered. The relevant Indian standards are :
Code No.
IS2026/BS171/IEC76
IS3639
IS1180
IS6600/BSCP.1010/IEC354
IS335/BS 148/IEC296
IS2099/BS223/IEC137
IS7421
IS13947 (Part 1) / IEC947-1
IS3637
IS 1271/BS2757/IEC85
IS 3202/ BSCP1014/ IEC354
IS 1886
IS 2705
Title
Power Transformer
Fittings and Accessories
Auxiliary Transformer
Loading of oil immersed transformer
Transformer Oil
Bushings for > 1000V, AC
Bushings for 1000V, AC
Buchholz Relay
Insulation Materials for Electrical Machinery
Climate Proofing
Installation & Maintenance of Transformers
Climatic Conditions
Ambient temperature
45 Deg. C outdoor
Performance & Characteristics

Transformer shall be capable of operating continuously and without adverse effects of
overheating under all specified conditions of operation including variation in system of + 10%
voltage and + 3% frequency or + 10% combined voltage and frequency unless otherwise
specified separately.
Transformer shall be suitable for parallel operation with other transformers of similar
characteristics.
Transformer shall be designed to withstand without any injury the thermal and mechanical
stress caused by the short circuit currents of magnitude and duration specified in the data
Sheet.
Transformer shall be designed for frequent direct on-line stating of motors having an
equivalent rating in KVA up to CMR of the transformer and shall be capable of withstanding
the forces arising from the starting current of these motors.
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Operation Over Overloads: It shall be possible to operate all transformers as per loading guide
IS: 6600 up to overloads of 150 %. There shall be no limitations imposed by bushing, tap
changers, auxiliary equipment etc. to meet this requirement.
Constructional Features
A)
General
Similar parts, particularly removable ones, shall be interchangeable. Screws, studs, nuts and
bolts shall be as per Indian Standards. Nuts, bolts, pins used inside the transformers and tap
changer compartments shall be locked.
Exposed parts shall not leave pockets where water can collect.
Internal design of transformer shall ensure that air is not trapped in any location.
Facility shall be provided for lubrication of bearings and mechanisms. Mechanisms shall be
constructed of non- corrodible material.
Material in contact with oil shall be such as not to contribute the formation of acid in oil.
Surfaces in contacts with oil shall not be galvanized or cadmium plated.
Labels, indelibly marked, shall be provided for all accessories like relays, switches, fans,
current transformers etc.
B)
Tank
Tank shall be made from good, commercial grade low carbon steel and shall be of electrically
welded construction type. Tank shall be designed to permit lifting, by crane or jacks of the
complete transformer assembly filled with oil. Suitable lugs and bosses shall be provided for
this purpose. Tank together with radiators, conservator, bushings and other fittings shall be
designed to withstand without permanent distortion the following conditions:
Full vacuum of 760mm of Hg for filling with oil by vacuum.
Internal gas pressure of 0.35Kg/sq.cm (5lbs/sq. in. with oil at operating level).
Adequate space shall be provided at the bottom of the tank for collection of sediment.
The transformer top shall be provided with a detachable tank cover with a bolted flanged
gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the cover
shall be suitably sloped so that it does not retain rainwater.
Manholes with bolted covers shall be provided in the top or sides of transformer for easy
access to the power ends of bushings, tap changers and to permit replacement of auxiliaries
without removing tank cover.
The material used for gaskets shall be cork-neoprene or approved equivalent. Gasket joints for
tank and manhole covers, bushings and other bolted attachments shall be so designed that the
gasket will not be exposed to the weather.
The transformer base shall be designed to permit skidding of the complete transformer unit in
any direction, when using plates or rails. The under base shall be detachable unless transport
facilities permit a fixed base
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C)
Core
The magnetic circuit shall be of core type constructions. The core shall be built out of high
grade, non-aging, low loss and high permeability, cold rolled grain oriented silicon steel
laminations.
The core laminations, shall be insulated from each other by a suitable high temperature
resistant, oil-proof, adherent coating material. The core clamps and clamping bolts shall be
heavily insulated from the core laminations.
The insulation of core bolt shall be minimum of Class B. The bottom and top frames shall
be connected with tie rods to make a complete structure rigid for carrying the weight of corecoil assembly without unduly stressing the laminations or windings.
All the core sections shall be bonded together with a metallic strip and connected to the tank
for earthing, to ensure earth return and operation of protective gear in the event of a winding
to core fault. The core shall be provided with lifting eyes/lugs suitable for lifting the complete
core and coil assembly from the tank.
Completed core shall be flash tested for insulation with 2500 Volts between the core and each
clamps for core bolts (core being connected to earth)
The finally assembled core shall be free from distortion. It shall be rigidly clamped to ensure
adequate mechanical strength and to prevent vibrations during operation.
The core clamped structure shall be designed to minimize eddy current loss.
The operating flux density shall be such that an over voltage of 10% shall not cause saturation
of the core.
D)
Windings
Winding shall be three phase with minimum Class A insulation.

Properly insulated and stacked high conductivity electrolytic grade copper (and not
aluminium) shall be used for winding. Windings shall be suitable braced to withstand the
dynamic forces due to short circuit.
The transformers shall be two winding type.
Winding shall be individually vacuum dried in hermetically sealed drying ovens and preshrunk fully under hot conditions. After assembly of windings on core, the complete assembly
shall again be vacuum dried until the desired insulation resistance of each winding is
obtained.
Windings shall be subjected to a shrinking and seasoning process, so that no further shrinkage
occurs during service. Adjustable devices shall be provided for taking up possible shrinkage
in service.
Coils shall be supported at frequent intervals by means of wedge type insulation spacers
permanently secured in place and arranged to ensure proper oil circulation. To ensure
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permanent tightness of winding assembly, the insulation spacers shall be dried and
compressed at high pressure before use.
Windings shall not contain sharp bends, which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times
the thickness.
Materials used in the insulation and the assembly of the windings shall be insoluble, noncatalytic and chemically inactive in the hot transformer oil, and shall not soften or be
otherwise affected under the operating conditions.
All threaded connections shall be locked. Leads from the winding to the terminal board and
bushing shall be rigidly supported to prevent injury from vibrations. Guide tubes shall be used
where practicable.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant material
which shall not be affected by acidity in oil.
Terminals of all windings including unloaded stabilizing windings shall be brought out of the
tank through bushing for external connections.
E)
Internal Earthing
All internal metals part of the transformers, with the individual clamping plates; shall be
earthed. Core clamps and core bolts shall be insulated form the core by class B insulation
unless other insulation is approved by purchaser.
The top clamping structure shall be connected to the tank by a copper strap.
The bottom clamping structure shall be earthed by one of the following methods.
By connection through vertical tie rods to the top structure.
By direct metal to metal contact with the tank base.
By a connection to the top structure on the same side of the core as the main earth connection
to the tank.
The magnetic circuit shall be connected to the clamping structure at one point only, through a
link placed in an accessible position beneath an inspection on the tank cover. The link shall be
on the same side of the core as the main earth connection.
When the magnetic circuit is sub-divided by oil ducts or insulated barriers above 0.25 mm
thick, tinned copper strip bridging pieces shall be inserted to maintain electrical continuity
between packets.
Coil clamping rings of metal at earth potential, shall be connected to the adjacent core
clamping structure on the same side as the main earth connection.
F)
CONTRACTOR
Under Carriage
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The undercarriage of the transformer shall be provided with detachable steel flanged heels or
flat rollers. Flanged wheels shall be spaced to allow specified rail gauge. Wheels shall be
provided with suitable bearings, which will resist rust and corrosion and shall be equipped
with fittings for lubrications. Unless otherwise approved, it shall be possible to swivel the
wheels or rollers in two directions, at right angles to or parallel to the main axis of the
transformer, thereby permitting movement in two directions. The wheels or rollers will be
swiveled after jacking the transformer and they shall be lockable in the two positions.
G)
Insulating Oil
Transformer oil will be mineral type (not synthetic, PCB based) confirming to IS: 335.
Comparatively small transformers shall be supplied Under Oil. For large transformers with
radiator banks, it may not be feasible to ship the transformer Under Oil, oil being supplied
separately. Tested insulating oil required for filling or topping up the transformers including
radiator banks and conservator shall be supplied loose, in non-returnable drums. The quantity
of oil shall be sufficient for filling at site with 10% extra quantity of oil in non-returnable
drums.
No inhibitors shall be used in the oil.
Terminal Arrangement
Terminal Chamber and Cable Box
When connection is by cable, terminals shall be brought out into a terminal chamber and a
suitable cable box shall be provided. A disconnecting chamber between the terminal chamber
and cable box shall be provided for easy isolation and removal of the transformer from
foundation without disturbing the cable box leaving the cable box behind on external support
to be provided by the contractor.
The terminal and disconnecting chamber may be air filled or oil filled. If oil filled, suitable
vent and drain plug shall be provided.
Terminals for connection to external cables shall be complete with compression/ solder type
copper/aluminium lugs and hardware (bolts, nut, plain & spring washers etc.) Where cable
boxes with stem type connections are provided, interconnecting strips from cable box stems
to the terminals shall be provided.
Cable box shall be suitable for accommodating specified type of cable and termination kit.
Sufficient space shall be available inside the cable box for heat- shrinkable type cable
termination kit.
Cable box shall be complete with un-drilled removable gland plate, access cover and earthing
terminals.
Separate Neutral Bushing for Earthing
Separate neutral terminal (other than that provided in the terminal chamber) of star connected
winding of transformer shall be brought out with an outdoor type bushing. The terminal shall
be suitable for connection of two flat earth conductors.
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a)
Marshalling Box
For the required fittings on the transformer, a dust-tight, vermin proof and weatherproof, sheet
steel (2 mm thick) enclosed, marshalling box with hinged door having padlocking facility
shall be provided on the transformer tank.
Marshalling box shall be provided with a rain hood at top, removable gland plate at bottom
and a hinged door at the front.
All doors covers and plates shall be fitted with neoprene gaskets. Bottom shall be at least
600mm from floor level.
All devices mounted on the transformer and requiring electrical connections, such as
Buchholz relay, oil & winding temperature indicator contacts, pressure release valve contacts,
cooler fan motors and their controls, shall be wired to marshalling box.
All interconnections between these devices and marshalling boxes shall be carried out with
either 1100/650V grade PVC insulated armoured cables OR PVC insulated wires in GI
conduits.
The size of the conductor shall be minimum 2.5 sq.mm. Copper.
All internal wiring with marshalling box shall be carried out with PVC insulated, copper
conductor wires of minimum size 2.5 sq.mm. Marked ferrules shall be provided at the wire
terminations.
All contacts for alarm, trip and indication circuits shall each be electrically free, wired for
auxiliary D.C. supply as specified and brought out to separate terminals at the terminal blocks
in the marshalling box.
Marshaling box shall have one door switch operated 230V AC fluorescent lamp; thermostat
controlled 20W space heater and one 5A plug socket.
Transformer Cooling Equipment
Radiators and coolers shall be designed to withstand the vacuum and pressure conditions
specified for the tank and made of pressed sheet steel of thickness not less than 1.4 mm. They
shall be so designed as to avoid pockets in which moisture may collect.
Built-In Radiators
Unless otherwise approved, tank mounted radiators shall be of the detachable type with bolted
and gasketted flanged connections. The following accessories shall be provided for each
radiator.
Shut-off valves and blanking plates on transformer tank at each point of connection. Up and
bottom shut-off valves and blanking plates on each radiator.
Lifting lugs.
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Top oil filling plug, 19mm size.

Air release plug at top.
Oil drain plug at bottom, 19mm size.
Tap Changing Gear
ON LOAD TAP CHANGING GEAR (OLTC)
The tap changer shall be suitable for connection to tapping brought out from H.T. winding
(Delta Connected) covering a range of sixteen steps from + 5% to 15% making a total of
seventeen positions (Taps). All taps shall be rated for maximum continuous KVA rating of
the transformer and shall be suitable for operation at sustained voltage of 110% of the rated
tap voltage.
OLTC gear shall be high-speed resistor transition type. Following fittings and accessories
shall be provided for the OLTC. Some of the accessories may not be necessary, depending on
the design and construction of the OLTC gear.
Local Control Panel

Remote Control Panel
Conservator with oil level gauge, oil filling hole and cap
Pressure wave protection device or Oil surge operated relay
Oil drain valve and vent plug
Silica gel breather
Filter valves at top and bottom
Air release plug
OPERATION
The tap changer shall change the taps by one step only at a time, when a tap change impulse is
given manually or automatically. Further tap changing operation should take place only if a
fresh impulse is given. Under auto-operation, the tap change should be initiated when the
actual voltage deviates from the reference voltage by more than one step and remains at that
level for more than a present time. (Time range : 30-180 seconds).
LOCAL CONTROL PANEL

The local control panel shall be of sheet steel weatherproof construction, mounted directly on
the transformer. It shall have lockable door, neoprene gaskets at all mating surfaces and a
removable gland plate at the bottom. The panel shall include the following equipment.
However, the contractor shall give the detailed list of equipment provided on the panel.
Main switch (TPN) for incoming supply, at 400-440V AC.

A Local/Remote Control selector switch.
HRC fuses (link type) separate for motor power and control circuits
Contactors, auxiliary relays, timers, limit switches and other devices, required for
intended operation.
Thermal overload protection for motor
Raise/Lower push buttons
Electric motor drive
Cranking handle for mechanism operation.
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Interlock between electrical and mechanical drives

Limit switches for extreme positions
Mechanical tap position indicator.
Potentiometer for remote tap position indicator
Operation counter
20W fluorescent Cubicle lamp with MCB
Convenience socket outlet 15A SP & E, 230V AC controlled by DP MCB
Thermostat operated 50W Space heater controlled by DP MCB
REMOTE CONTROL PANEL

The remote control panel shall be of dust-damp-vermin proof 14 SWG sheet steel
construction having lockable hinged door, neoprene gaskets at all mating surfaces. The panel
shall be suitable for indoor installation & floor mounted type. The panel shall have undrilled
gland plates at top & bottom for the cable entries. The panel shall be complete with
equipment required for an automatic tap changing operation, which shall include the
following. However, the contractor shall give the detailed list of equipment provided on the
panel.
Main switch for incoming supply
Auto / Off / Manual selector switch
Automatic voltage control relay
Auxiliary relays, timers, required for satisfactory operation
Tap position indicator
Raise / Lower push buttons
Tap change in Progress signal lamp for Raise & Lower
Supply ON signal lamp
Alarm hooter for OLTC trouble
20W fluorescent Cubicle lamp with MCB
Convenience socket outlet 15A SP & E, 230V AC controlled by DP MCB
Thermostat operated 50W Space heater controlled by DP MCB
All remote indications and alarms for forced cooling systems for transformer, if called for
Paralleling equipment, if called for, shall include the following
Sequence selector switch
Lockout relay
Out of step relay
Out of step signal lamp
Out of step alarm
Step correcting switch
Voltage chart indicating tap position verses secondary voltage
NOTES FOR LOCAL & REMOTE CONTROL PANELS
Nameplates for the panels, labels for the devices and legend plates for the devices
mounted on the door shall be provided for the control circuit.
Two internal & two external earthing terminals each complete with one spring and two
plain washers and nuts and bolts shall be provided on the opposite sides of each panel.
The local control panel shall be painted with the paint shade similar to the transformer,
but the remote control panel shall be painted with the color shade approved by the client.
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FITTINGS AND ACCESSORIES

Transformers shall be supplied with fittings and accessories as indicated in the table below
depending on the rating of the transformer.
R:=> Required
NR:=> Not Required
Sr.
Description
Rating of Transformer to which fitted

Up to 400 500 to 800 1000
to 2500 KVA
KVA
KVA
2000 KVA & above
1
2
Rating & diagram plate

Dial type magnetic oil level gauge
with low level alarm contacts
Silica Gel breather with a seal, &
connecting pipe, in a transparent
enclosure
Explosion Vent with diaphragm
Equalizing pipe
Conservator with filling hole, cap
and drain valve and isolating valve
for conservator.
Double floats buchholz relay with
alarm and trip contacts and a test
level for simulating operation of
buchholz relay and shut off valve
on tank side.
Dial
thermometer
for
oil
temperature marked in oC with
alarm and trip contacts (adjustable)
with a maximum reading pointer
Image coil with C.T. test
terminals, calibrating resistors etc.
for winding temperature with dial
type thermometer having alarm &
trip contacts (adjustable) with a
maximum reading pointer (for
4000 KVA & above)
Weatherproof marshalling box
with terminal blocks complete
with PVC armoured cables
terminated with glands from
buchholz relay, alarm/trip contacts
of oil level temperature gauge etc.
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
R
(4000
KVA
&
above)
NR
NR
4
5
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Sr.
Description
10
Thermometer pocket (for top oil

temp.)
Lifting lugs
Jacking pads 4 Nos.
Draw eyes
Top Filter valve
Bottom filter valve
Drain valve with plug
Oil sampling valve
Inspection cover
Air release vent
Bi-directional rollers
Two earthing terminals
Plain oil level indicator with
minimum marking
11
12
13
14
15
16
17
18
19
20
21
22
Rating of Transformer to which fitted

Up to 400 500 to 800 1000
to 2500 KVA
KVA
KVA
2000 KVA & above
R
R
R
R
R
NR
NR
R
R
R
NR
NR
R
R
R
R
R
NR
NR
R
R
R
NR
NR
R
R
R
R
R
R
R
R
R
R
NR
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
NOTES
a)
b)
All instruments shall not be less than 96 mm dia or sq.

All instruments shall be readable from ground level.
All alarm and trip contacts of instruments shall be suitable for 1A.250 Volts D.C. or 5A.250
Volts A.C.
Earthing pads : Two earthing pads of copper or other non-corrodible material on transformer tank
together with clamp type terminals suitable for Purchaser earthing conductors.
Suitable earthing terminals on cable boxes and separately mounted radiator banks.
Terminal marking and rating plates shall be as per IS : 2026.
REQUIREMENTS OF FITTINGS AND ACCESSORIES
Conservator (for transformer rating as per IS : 2026 ). The conservator shall be of sufficient volume to
maintain the oil seal from the minimum ambient temperature of 5 deg.C upto an oil temperature of
100 deg.C, with oil level varying within the minimum and maximum visible levels. The conservator
shall be provided with the following accessories :
Filling plug, sump and drain valve.
150 mm diameter magnetic type oil level gauge & oil sight gauge, both provided with markings for
minimum oil level, and oil level at 30 deg. C.
A bolted cover for cleaning.
Valve for shutting off oil to the transformer.
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Valves
The following valves shall be fitted on the transformer tank.
Main tank drain valve with flanged or threaded connection.
Top filtering valve with plug located on the same side as the main drain valve.
Bottom filter connection with plug to drain oil from the lowest part of the tank. This connection shall
not be tapped through the bottom of the transformer.
Oil sampling devices at top and bottom of the main tank. These shall be distinct from other valves.
Adequate number of air relief vents.
Two plugged pipe outlets at top for applying vacuum. All valve opening shall be plugged or blank
flanged.
Valves for the cooler systems are indicated in the respective sections. These valves shall be lockable
in closed or open positions and shall be provided with an indicator to show position of the valve.
Pressure Relief Devices
A pressure relief vent (explosion vent ) mounted on the tank shall be provided for relieving pressure
within the transformer. It shall operate for pressure less than the hydraulic test pressure for the tank.
The explosion vent shall be provided with diaphragm (s) and a screen to prevent fragments of a
shuttered diaphragm being sucked into the transformer under vacuum.
Equalization of air pressure in the vent may be achieved by a pipe connection to the conservator.
(This device shall be provided for all transformers rated 500 KVA and above.)
Gas And Oil Actuated Relay (Buchholz Relay)
A double float type Buchholz relay as per IS : 3637/8 shall be provided whenever called for in Data
Sheet A. All gas evolved in the transformer shall collect in this relay. The relay shall be provided
with a test cock suitable for a flexible pipe connection for checking its operation. A copper tube shall
be connected from the gas collector to a valve located about 1.25 M above ground level to facilitate
sampling with the transformer in service. The device shall be provided with two electrically
independent ungrounded contacts, one for alarm on gas accumulation and the other for tripping on
sudden rise of pressure.
TEMPERATURE INDICATORS
Dial type Thermometer
All transformers shall be provided with a 150 mm dial type thermometer for top oil temperature
indication. The thermometer shall have adjustable, electrically independent, ungrounded alarm and
trip contacts, maximum reading pointer and resetting device.
Winding Temperature Indicator
A device for measuring the hot spot temperature of the winding shall be provided.
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It shall comprise of the following:

a)
Temperature sensing element.
b)
Image coil
c)
Current transformer
d)
150 mm dia local indicating instrument with four adjustable electrically independent
ungrounded contacts, two for control of cooling equipment and two for winding
alarm and trip.
e)
Calibration device.
f)
Automatic ambient temperature compensation
g)
In addition to the above, the Analogue signal transmitter for remote indication and
remote indicating flush mounted instrument for mounting onclients panel shall be
provided (when specifically called for).
Painting
The interior of all transformer tanks and other oil filled chambers and internal structure steel work
shall be cleaned of all scale and dust by shot blasting unless otherwise approved. These surfaces
shall be painted with not less than two coats of heat resistance, oil insoluble and insulating varnish.
Steel surfaces exposed to the weather shall be thoroughly cleaned and applied a priming coat of zinc
chromate. The second coat shall be of an oil and weather resistant nature, preferably of distinct colour
from the prime and finish coats. The final coat shall be of glossy oil and weather resisting non fading
paint of specified shade.
All exposed bolts, nuts and washers shall be of galvanized steel unless otherwise approved.
Metal parts not accessible for painting shall be made of corrosion-resistant material. Machined
finished and bright surfaces shall be coated with a suitable compound and wrapped.
Interior surfaces of mechanism chambers and knocks shall receive three coats of paint after cleaning
the final coat shall be of a light-coloured anti-condensation paint.
Tests
All transformers shall be completely assembled at Works to ascertain that all parts fit correctly.
Routine Tests
Routine tests as per IS shall be performed on all transformers.
The following additional points may be noted:
Resistance of winding shall be measured at principal and the two extreme taps.
Impedance voltage shall be measured at principal and the two extreme taps.
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No load loss and exciting current shall be measured at rated frequency at 100 % and 110 % rated
voltage. These tests shall be done before and after impulse tests if the later are specified. Exciting
current shall be measured on each phase and recorded.
No load loss and exciting current shall be measured and recorded with 415 V, 3 phase, 50 Hz, input
on LV side (assuming LV is rated higher than 415 V).
Oil Pressure Test : All oil filled compartments shall be filled with transformer oil and subjected to a
pressure of 035 Kg/cm above the pressure that would obtain under normal conditions with full head of
oil. The pressure shall be maintained for 12 hours during which time no oil leakage shall occur. When
heat run test is specified, the oil pressure test shall be performed immediately after the heat run.
Otherwise the test may be performed at ambient temperature.
Power taken by cooling equipment shall be measured for all transformers.
Type test
Auxiliary equipment
All equipment shall be tested as per the relevant IS. Test certificates shall be submitted for bought out
items. High voltage withstand test shall be performed on auxiliary equipment and writing after
complete assembly.
Test Reports
Four copies of preliminary test results shall be submitted for Purchasers approval before dispatch of
transformer.
Additional bound copies as per enclosed distribution schedule of complete test results including all
tests on transformer, auxiliaries, current transformer characteristics shall be furnished with the
transformer.
Losses
If the measured losses on the transformer are found to exceed guaranteed loss figures by more than
the + 10% tolerance permitted, following penalties shall be levied on the contractor.
No Load Loss
Indian Rupees. 2,43,735.00 for every kW in excess of the tolerance on guaranteed losses., As per
CBIP Guidelines
Load Loss
Indian Rupees. 1,34,785.00 for every kW in excess of the tolerance on guaranteed losses, As per
CBIP Guidelines
Rejection
Purchaser may reject any transformer if during tests or service any of the following conditions arise :
No load loss exceeds the guaranteed value by 15% or more.
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Load loss exceeds the guaranteed value by 15% or more.

Impedance voltage at principal tapping not within the limits of tolerance (+ 10%)
value.
over guaranteed
Oil or winding temperature rise exceeds the specified value by 5 deg. C.

A transformer fails on impulse test.
Transformer fails on power frequency voltage withstand test.
The rejected transformer, shall be replaced by transformers complying with the requirements to this
specification at the contractors cost.
If the commissioning of the project is likely to be delayed by the rejection of a transformer, the
Engineer reserves the right to accept the rejected transformer until the replacement transformer is
made available. Transporting the rejected and replacement transformers as well as installation and
commissioning of both the transformers shall be at the contractors cost.
Spares
Bidder shall quote itemwise prices for recommended spares, including the following :
a)
One (1) completely wound limb comprising HV / MV / LV winding.
b)
Complete set of gaskets.
c)
One bushing of each type.
d)
One CT of each type.
e)
Cooler fan / fan motor.
f)
Dial type thermometer.
g)
Oil level Gauge.
h)
Complete set of winding temperature indicating equipment.
i)
One cable sealing end of each type.
j)
Explosion vent diaphragms.
k)
Silica gel breather.
l)
One valve of each type.
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7.4
415V BUS DUCT
CODES AND STANDARDS

Bus-duct shall be manufactured and tested according to the requirements of relevant Standards and
Codes of Practices published by Indian Standards. If Indian Standards have not been published for
any equipment, standard and code of practices published by following institutions shall governBritish Standards Institution
International Electro-technical Commission
American Standards Association
Some of the relevant Standards are as followsCode No.
Title
IS 375
Marking
& arrangement
for
switchgear,
busbars,
main
connection and auxiliary wiring
Climate- proofing of electrical
equipment
Aluminium Busbars
For Non-segregated phase bus-ducts.
IS 2147
IS 3202
IS 5082
IS 8081
CONSTRUCTIONAL FEATURES
GENERAL
The busduct shall be metal enclosed, non-segregated phase type, suitable for indoor/outdoor use as
per layout drawing enclosed.
The busduct shall be supported from the ceiling, as required. Drawings and details for supporting
arrangement shall be given by the supplier of the busduct, however actual supports will be provided
by the purchaser/ contractor.
ENCLOSURE
The enclosure of the bus-duct shall be fabricated from CRCA sheet steel enclosed of minimum 2-mm
thickness and shall undergo 7-tank treatment for removal of grease, rust, scale, oil by pickling
followed by phosphating and 2 coats of Zinc rich primer. The sheet steel shall be further provided
with epoxy based powder coating in light Green shade (shade 613 as per IS 5) from outside and Matt
Black painting on the inside.
The fabrication of bus-duct shall be so designed as to offer dust-proof and vermin proof enclosure
with IP 54 degree of protection for Indoor run IP 55 degree of protection for outdoor run. Adequate
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access shall be available for inspection/replacement/ tightening of busbars support/ fish plates /
fasteners.
Rain hood / Canopy shall be provided for outdoor portion of the bus-duct. Rain hood / canopy be
designed to offer complete protection form rain.
Non-deteriorating type gaskets shall be provided at all mating surfaces. The gaskets used for out door
portion of the bus-duct shall not deteriorate due to hostile climatic conditions and direct exposure to
sunlight.
BUSBAR
The bus-duct shall be provided with three phase and neutral busbars. The material of the busbars shall
be high conductivity electrolytic aluminium or copper confirming to relevant standards. Rating of the
Neutral bus bar shall be at least 50% that of phase bus bar.
All busbars joints shall be of the bolted type. Spring washers shall be provided to ensure good contact
at joints. Nut bolts of proper size and strength shall be used.
Busbars shall be air insulated with matt black painting. The clearance between phase and neutral shall
be as per BS 162.
Busbar supports shall be made of high quality non-hygroscopic insulating material such as FRP, DMC
or SMC. Hylam insulators are not acceptable. Surface of insulators shall be highly glazed and treated
to minimize accumulation of dust, condensation of moisture ad tracing. The design of busbar supports
shall be such that free thermal expansion of busbars shall be possible. In vertical run of the bus-duct,
suitable clamps/supports shall be provided to retain the busbars in position and distribute loading
evenly on supports.
When the busduct passes through building wall from indoors to outdoors, a wall frame assembly with
seal off partition at wall to segregate the indoor and outdoor runs, shall be provided to prevent
interchange of air between two sections. The seal off partition shall be of FRP with minimum
thickness of 10mm.
Flanged ends shall be provided to facilitate connection of bus-duct, both at transformer and
switchgear end. All hardware such as bolts, nuts, spring and plain washers shall be supplied alongwith
bus-duct to connect it at both ends.
Reinforcement / stiffeners shall be provided for the covers from inside on which supporting lugs are
provided.
TEMPERATURE RISE
Final temperature of the busduct when carrying the rated current under site condition.
For Enclosure
For Busbars
For Busbar joints
CONTRACTOR
:
:
:
70C (final temp)

85C (final temp)
90C (final temp)
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FLEXIBLE CONNECTORS
To take up mismatch of phase conductors during installation as well mechanical stresses due to
thermal expansion of the busbars, braided flexible connectors shall be provided at the end
terminations, both at transformer end and switchgear end and at intermediate places depending upon
length and configuration of the bus-duct.
The connectors shall preferably be laminated to cater for linear expansion of busbars. The material of
flexible shall be same as busbars. If different
The busbars shall be braced for electro-mechanical stresses arising out of short-circuit condition.
Two nos. of terminals shall be brought out at ends of the earth bus to facilitate connection of earthing
lead externally.
A space heater circuit comprising MCB, thermostat and a heater suitable for 230V AC supply shall be
provided in the bus duct. (if called for) The space heater shall be located at a suitable location to
maintain temperature of air 5C above ambient throughout the length of the bus-duct.
A drain plug shall be provided on the busduct at the lowest point to drain condensed water in the busduct if specifically called for.
A cross-over chamber with sufficient number of links and supports shall be provided (if called for).
The cross over chamber shall effect change of phase sequence to match with respective phase
sequence in the end equipment. The links, insulators and fasteners shall be located such that access for
replacement / tightening is available for all parts.
Suitable fabricated adapter box shall be provided wherever specified to interface with the termination
arrangement on the end equipment connection.
PERFORMANCE
Maximum operating temperature at any point shall not exceed 85C with the limiting ambient
conditions. Eddy current heating shall be taken into account while designing the enclosure.
Busbars and insulating supports shall withstand successfully thermal and dynamic stresses resulting
from the circuit currents.
DRAWINGS AND DOCUMENTS
Fully dimensioned, scale drawing showing general arrangement, assembly, installation configuration,
clearances, creepage distances and interfacing details at both ends shall be submitted for approval.
Calculations for bus bar capacity to carry rated current with specified maximum operating
temperature.
Calculations for short time thermal and dynamic withstand capacity under specified fault level.
Heat loss calculations
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INSPECTION & TESTING

All routine tests as per IS shall be carried out on the completed assembly of the busduct which will be
witnessed by the purchaser/his representative.
The following routine tests shall be carried out:
General Arrangement checks of the completed assembly.
Insulation resistance measurement test.
High voltage test (P.F. Voltage withstand test)
Milli volts drop test.
7.5
415V SWITCHGEAR
Codes & Standards

The design, construction, manufacture and performance of equipment shall conform to latest
applicable standards and comply with all currently applicable statutes, regulations and safety codes in
the locality where the equipment will be installed.
The relevant indian standards are :
Title
Switchgear General Requirements
Factory Built Assemblies of SWGR and
Controlgear for Voltages upto and
including 1000V AC & 1200V DC
Air Break Switches
Miniature Circuit Breakers
Low voltage Fuses
Contactors
Starters
Code No.
IS13947/BS5486/IEC947
IS8623/BS5486/IEC439
IS13947-P3 /BSEN60947 /IEC947-3

IS8828/BSEN60898
IS13703/BS1362/IEC269-1
IS13947/BS EN60947-4 /IEC947-1
IS13947/BS EN60947-4/ IEC2921TO 4
IS6875 / BSEN 60947
IS2705/BS7626
IS3156/BS7625/IEC44, 186
IS1248/BS89/IEC51
of IS11353/BS159
Control Switches / Push buttons

Indicating instruments
Marking
and
Identification
Conductors and Apparatus Terminals
A.C. Electricity Meters
IS722, 8530/BS5685 / IEC 145, 211
IS13947/IEC947-P1
Selection installation and maintenance IS10118
of switchgear and controlgear
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Features of Construction
The switchgear shall be metal enclosed, modular type suitable for indoor floor mounting and shall
have following features.
Height shall not exceed 2300 mm

Shall be Single front execution
Shall have designation labels both on front and rear sides
Shall be provided with proper gasketing for removable covers, doors, between panels and
base frame and all around the perimeter of adjacent panels.
The switchgear shall be divided into distinct vertical sections each comprising :
A completely metal enclosed busbar compartment running horizontally.
Individual feeder modules arranged in multi-tier formation. It is essential that the
modules are integral multiples of the basic unit size to provide for flexibility in changes,
if any, at site.
Enclosed vertical busbars serving all modules in the vertical section. For safety isolation
of the vertical busbars, insulating barrier with cut-outs shall be provided to allow the
power stab contacts to engage with vertical busbars.
A vertical cable alley covering the entire height. The cable alley shall be minimum 300
mm wide for motor control modules and 500 mm wide for circuit breaker controlled
modules.
A horizontal separate enclosure for all auxiliary power & control buses, as required, shall
be located so as to enable easy identification, maintenance and segregation from the main
power buses. Tap - off coonnections from these buses shall be arranged separately for
each vertical section.
The Switchegar shall be easily extendable on both sides by the addition of vertical sections after
removing the end covers.
Operating devices shall be incorporated only in the front of switchgear
Each shipping section shall have metal sheets at both ends
Cable alley shall be provided with suitable hinged doors
Rear of single front switchgear shall be provided with removable panels with captive screws
All doors shall be with concealed type hinges and captive screws
Each vertical section shall be equipped with a space heater controlled by thermostat
Each switchgear cubicle shall be provided with interior lighting with a 20 W fluorescent tube with
on/off switch.
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A 240 V, 1 phase, AC plug point shall be provided in the interior of each cubicle with on-off switch
for correction of head lamps
Interchangeability
All identical equipment and corresponding parts be fully interchangeable without any modifications.
Main And Auxiliary Buses
Main Buses & Taps
a.
Switchgear shall be provided with three phase or three phase and neutral
busbars.
b.
Busbars shall be of uniform cross section throughout the length of the

switchgear, and upto the incoming terminals of feeder circuit breaker /
switch.
c.
The busbars shall be made of high conductivity copper or aluminium alloy of

E91E grade as specified in the SLD
d.
Busbars shall be provided with at least the minimum clearances in air as per
applicable standards for a 500 V, 3 phase system.
e.
All bus-bars, bus-taps shall be insulated with close fittings sleeve of hard,
smooth, dust and dirt free plastic insulation of high dielectric strength (450
V/mil) to provide a permanent high dielectric non-ageing and non-tracking
protection, impervious to water, tropical conditions and fungi. The insulation
shall be non-inflammable and self-extinguishing and in fast colours to
indicate phases. The joints shall be insulated in such a way as to provide for
accessibility of contact bolts for maintenance. The dielectric strength and
properties shall hold good for the temperature range of 0 deg. C to 90 deg. C.
If the insulating sleeve is not coloured busbars shall be colour - coded with
coloured bands at suitable intervals.
f.
Busbars shall be adequately supported and braced to withstand the stresses

due to the specified short circuit currents for the associated switchgear.
Busbar supports shall be made of glass reinforced moulded plastic material or
DMC/SMC.
g.
Separate supports shall be provided for each phase of the busbars. If a

common support is provided for all three phases, antitracking barriers shall be
incorporated.
h.
Busbar joints shall be complete with high tensile steel bolts and Belleville
washers and nuts. Busbars shall be thoroughly cleaned at the joint locations
and a suitable contact grease shall be applied just before making a joint.
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Auxiliary Buses
Auxiliary buses for control power supply, space heater power supply or any other specified service
shall be provided. These buses shall be insulated, adequately supported and sized to suit specified
requirements. The material of control power supply buses shall be electrolytic copper/aluminium.
The material for space heater power supply buses shall be same as that for the main power buses.
Sheet Metal Work
The switchgear frame shall be fabricated using suitable mild steel structural sections or pressed and
shaped cold rolled sheet steel of thickness not less than 2.5 mm.
a)
Frames shall be enclosed by sheet steel of thickness not less than 2 mm cold rolled or 2.5 mm
hot rolled, smoothly finished, levelled, and free from flaws. Doors and covers shall be made
of sheet steel of thickness not less than 1.6 mm cold rolled or 2 mm hot rolled. Stiffeners
shall be provided wherever necessary.
b)
All panel edges and door edges shall be reinforced against distortion by rolling, bending or by
the addition of welded reinforcement members.
c)
Cut-outs shall be true in shape and avoid of sharp edges.
d)
The complete structure shall be rigid, self-supporting, free from vibration, twists and bends.
Painting
All sheet steel work shall be phosphated in accordance with the following procedure and in
accordance with applicable standards.
Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
Rust and scale shall be removed by pickling with dilute acid followed by washing and running water,
rinsing with slightly alkaline hot water and drying.
After phosphating, thorough, rinsing shall be carried out with clean water, followed by final rinsing
with dilute dichromate solution and oven drying.
a.
The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving
type zinc chromate primer. The first coat may be 'flash dried' while the second coat shall be
stoved.
b.
After application of the primer, two coats of finishing paint shall be applied, with each coat
followed by stoving. The second finishing coat for the exterior of panels shall be applied
after completion of tests.
c.
Each coat of primer and finishing paint shall be of a slightly different shade to enable
inspection of the painting.
d.
The final finished thickness of paint film on steel shall not be less than 100 microns, and shall
not be more than 150 microns.
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e.
Finished painted appearance of equipment shall present an aesthetically pleasing appearance,

free from dents and uneven surfaces.
Motor Starters
The selection of starters shall be made acording to th erating of the motor used with the equipment.
The selection shall be done as follows Upto 10 HP
:
Direct On line Starter
11 HP to 50 HP
:
Automatic star-Delta Starter
Above 51 HP
:
Auto Transformer Starters(ATS)
All starter feeders shall have individual ammeter with selector switch.
Each starters shall comprise
- One main TP Switch fuse unit/Moulded Case circuit breaker/Motor
Protection Circuit Breaker (as specified in SLD)
- HRC fuses for Power & Control
- Main power contactor, auxiliary contractor/s
- Bimetallic thermal overload relay with built in single phasing preventor
- Start/Stop / Reset Push Buttons
- On, Off, Trip indication lamps, and
- terminals
Direct On-Line Starters (DOL)

Direct on-line starters shall be suitable for Class AC 3 utilisation category suitable for type 2
coordination as specified in applicable standards. Each DOL starter feeder shall be complete with
Switch fuse unit, HRC fuse, contactor, Bimetallic overload relay with built in single phasing
preventor, ON-OFF-TRIP indication lamps, Start-Stop-Reset push buttons.
Automatic Star-Delta Starters

a.
Automatic star-Delta starters shall comprise three sets of contactors one for the line, one for
the star point and one for the delta, and a timer relay to automatically change the connections
from star to delta.
b.
Star-delta contactors shall be electrically interlocked to permit starting of the motor in the
proper sequence, namely star contactor closing, line contactor closing, timer energised, timer
contact de-energising the star contactor, and delta contactor closing.
c.
Start delta starters shall be suitable for Class AC 3 utilisation category suitable for type 2
coordination as specified in applicable standards.
d.
Each starter feeder shall be complete with Switch fuse unit, HRC fuse, contactor, Bimetallic
overload relay with built in single phasing preventor, ON-OFF-TRIP indication lamps, StartStop-Reset push buttons.
Auto Transformer Starter

a.
The autotransformer shall be sheet steel enclosed.
b.
The auto transformer starter shall comprise 3phase transformer of adequate KVA
rating.
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c.
d.
e.
f.
g.
The type of transformer cooling shall be either ONAN or ANAN

Transformer shall have Tappings at 50%, 65%, 80%
For transformer sizing purpose, maximum starting duration shall be considered as 20
seconds.
The transformer shall be suitable for maximum of 4 no of starts per hour.
The autotransformer shall be complete with Minimum Fittings and accessories as per
Statutory (IS / BS ) requirements.
Thermal Overload Relays

a.
Starters shall be complete with a three element, positive acting, ambient temperature
compensated, time lagged thermal overload relay with adjustable settings. The setting range
shall be properly selected in accordance with the rating of the motor.
b.
Thermal overload relays shall be hand reset type.
c.
'Stop' push button of the starter and hand reset device shall be separate from each other.
d.
Overload relay hand reset push button shall be brought out on the front of the compartment
door.
e.
Overload relay shall be provided with at least one 'NO' and one 'NC' or one change-over
contact.
Single Phasing Preventers
The relay shall be suitable for application to protect reversible and non-reversible motors. The relay
operation shall be independent of the motor KW rating, the loading conditions prior to the occurence
of the single phasing and rpm of the motor. The relay shall be of the fail-safe type and shall operate
to trip the motor when the relay internal wiring is accidentally open circuited.
a.
Electrically/Manually Draw out type Air circuit breakers with microprocessor based thermal
and magnetic releases (ACBs) shall be provided when called for in SLD. The ACBs shall
conform to the latest application standards.
b.
ACBs in AC circuits shall be of triple pole construction arranged for simultaneous three pole
electrical/manual closing and opening and for automatic instantaneous tripping on short
circuit. Operating mechanism shall be quick- make, quick-break and trip-free type. The ON,
OFF and TRIP positions of the ACB shall be clearly indicated and visible to the operator
when mounted as in service. Front of board operating handle shall be provided.
Moulded Case Circuit Breakers

a.
Moulded case circuit breakers (MCCBs) shall conform to the latest application standards.
b.
MCCBs in AC circuits shall be of triple pole construction arranged for simultaneous three
pole manual closing and opening and for automatic instantaneous tripping on short circuit.
Operating mechanism shall be quick- make, quick-break and trip-free type. The ON, OFF
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and TRIP positions of the MCCB shall be clearly indicated and visible to the operator when
mounted as in service. Front of board operating handle shall be provided.
c.
MCCBs shall be capable of withstanding the thermal stresses caused by overloads and locked
rotor currents of values associated with protective relays settings of the motor starting
equipment and the mechanical stress caused by the peak short-circuit current of value
associated with the switchgear rating. The maximum tripping time under short circuit shall
not exceed 20 milliseconds.
d.
MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes relevant
to circuit ratings.
All MCCBs shall be provided with Rotary handles for operational ease.
e.
a.
Current transformers shall be of the dry type resin cast.
b.
Current transformer shall have a short time withstand rating equal to the short time
withstand rating of the associated switchgear for one second.
c.
Unless otherwise specified, the minimum performance requirement of current

transformers are as follows :
Measuring CTs - 10 VA, accuracy class 1.0 and an instrument safety factor of 5.
Protective CTs - 15 VA, accuracy class 5P and an accuracy limit factor of 10.
d.
Test links shall be provided in both secondary leads of the CTs to easily carry out
current measurement tests.
e.
All current transformers shall be earthed through a separate earth link on the terminal
block to permit easy measurement of the current transformer insulation resistance.
Relays
The following clauses shall apply to the protective relays.
Relays shall be enclosed in dust proof flush mounting drawout type cases.
accessible for setting and resetting from the front
provided with positive acting hand-reset flat indicators visible from the front.
Access to setting devices shall be possible only after the front covers are removed. Access to
resetting devices shall be external to the case.
Auxiliary relays shall be rated to operate satisfactorily between 70 % and 110 % rated voltage.
Each relay shall be provided with at least two separate voltage free contacts.
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Indicating Instruments and Meters

Electrical indicating instlruments shall be of minimum 96 mm square size, suitable for flush
mounting.
Indicating instruments shall have provision for zero adjustment outside the cover.
Instrument dials shall be parallex free with black numerals on a white dial.
Ammeters provided on motor circuits shall be provided with a suppressed extended scale to indicate
motor starting current.
Watthour meters shall be electronic type.
All meters except watt hour meter shall be Analog type.
Indicating Lamps
Indicating lamps shall be :
of the filament type and of low watt consumption / LED Type
provided with series resistors.
provided with translucent lamp covers of colours 'Red', 'Green' and 'Amber' as required in
the control wiring diagrams.
Bulbs and lenses shall be easily replaceable from the front.
Control and Selector Switches
Control and selector switches shall be :
of the rotary type
adequately rated for the purpose intended (minimum acceptable rating is 10 A
continuous at 240 V AC and 1A (inductive break) 220 V DC.
provided with escutcheon plates clearly marked to show the positions.
Control switches shall be :
of the spring return to normal type
provided with pistol grip type handles.
Selector switches shall be :
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of the maintained contact stayput type. Switches in ammeter circuits shall have
make-before-break type contact.
provided with oval handle.
Push Buttons
Push buttons shall be :
of the momentary contact, push to actuate type rated to carry 10 A at 240 V AC a
1A (inductive breaking) at 220 V DC.
fitted with self reset, 2 NO and 2 NC contacts.
provided with integral escutcheon plates marked with its function.
'Start', 'Open', 'Close' push buttons shall be green in colour.
'Stop' push buttons shall be red in colour.
All other push buttons shall be black in colour.
'Emergency Stop' push buttons shall be of the lockable in the pushed position type and rotate to
release and shall be shrouded to prevent accidental operation.
Space Heaters
Space heaters for switchgear panels shall be :
suitable for operation on a supply system specified.
provided with single pole MCB with overload and short circuit release.
provided with thermostats to cut off the heaters at 45 deg. C.
Window Type Alarm Annunciators

The alarm annunciation scheme wherever specified in control wiring drawings shall incorporate the
following features :
visual indication of the fault by means of steadily lit alarm windows.
audible alarm on the occurence of the fault.
red facia units to differentiate trip alarm from non- trip alarms.
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acknowledgement of occurence of fault, incorporating audible alarm cancellation

features.
resetting the scheme after the faults have been cleared
facility to test the healthy condition of the lamps automatically excluding units
indicating existing faults.
prevention of maloperation of the scheme when the push buttons are pressed
incorrectly or in a wrong sequence.
initiation of the complete sequence of audiovisual alarms in the event of a new
fault occuring at the time of accepting an existing fault.
suitable for operation on a 2 wire, AC supply (voltage indicated in Data Sheet A) with a supply voltage variation between 80 % and 110 % of the rated voltage.
suitable for operation for fleeting (15 milli sec. duration) as well as the persistent
faults.
facility for a separate audio-visual alarm to indicate 'Alarm supply failure'.
facility for duplicating the audio-visual alarm at a second location.
Window alarm annunciators shall incorporate the following constructional features :
flush mounted facia units, each of which is provided with two lamps and a series
resistor and a ground glass plate in front
of the inscription.
plug in relays mounted behind the facia units
The alarm annunciation scheme shall comprise the following equipments.
a facia unit complete with relays for each fault.
a common alarm bell
'Accept' 'Reset' and 'Lamp Test' push buttons.
Alarm supply failure, 'Accept' and 'Reset' push buttons.
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7.6
Local Push Button Stations

Standards
a.
The design, manufacture and performance of the equipment to be supplied

under the scope of this specification shall comply with latest revisions of
relevant Indian Standards and rules.
b.
The design and workmanship shall be in accordance with best engineering

practices as applicable to industrial electrical equipment enclosures.
Construction
a.
Industrial Local Control Station enclosure shall be of Cast Aluminium LM6 alloy
enclosure having minimum 3 mm thickness.
b.
The enclosure shall be weatherproof, IP-55 suitable for outdoor installation. All
mating surfaces of industrial LCS shall be with continuous non-deteriorating type
special rubber gaskets/neoprene gaskets. An additional 2MM thick Aluminium
canopy shall be provided to give adequate protection against weather.
For ease in cable terminations, the minimum distance between the terminal blocks and the
cable entry gland plate shall be 50 mm for 1.5 sq,mm, size cables.
Cable Entries
Two threaded entries shall be of 20 mm shall be provided on each Local Control Stations at
the bottom for fixing the cable glands. Metallic/ rubber plug shall be provided for sealing
one of the cable entry.
Earthing
The enclosure shall be provided with two (2) nos. of external earthing terminals and one (1)
no. internal earthing terminal each of 2.5 mm diameter complete with nut, spring washers for
terminatio of 14 SWG G.I. wire.
Wiring
All internal wiring upto the terminal block in the Local Control Station shall be carried out
with 1.5 sq.mm. stranded copper conductors. Wires shall be PVC insulated type of
650/1100V grade. The wire shall be terminated with crimping type lugs only and shall be
provided with ferrules at both the ends.
Painting
The Local Control Stations shall be treated with two coats of epoxy primer after thorough
cleaning and treating of the surfaces and shall be finally provided with two coats of epoxy
paint. Shade of final paint shall be 631 to IS 5.
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Name Plate
Each LCS shall be provided wih name plate. Name plates shall be made from rear engraved,
perspex with letters of size minimum 6 mm on black background. All nemeplates shall be
identical in size and shall be fixed with serews on the cover.
Component Specifications
Push Button
a.
Each push button shall be provided with 1 NO + 1 NC contacts, each rated to carry,
make and break 10A at 240V AC.
b.
Colour of the actuators of STOP push button shall be RED and that of START
push button shall be GREEN. Stop Push Button actuator shall be mushroom head
type and shall have stay-put feature i.e. once the STOP push button is pressed, it
remains in pressed position untill its actuator is turned in either direction. START
push button shall be totally shrouded type to prevent accidental start of the motor.
Terminal Blocks
Voltage grade of terminal block shall be 660V. Current rating, their size and make shall be as
per the requirement specified. Two nos. spare terminals shall be provided in each local control
station.
Inspection & Testing
The LCS shall be routine tested at manufacturers works in the presence of Purchaser/ his
representative before despatch to site.
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Specific Technical Particulars

Sr
1
2
2.1
2.2
2.3
Description
Material of Enclosure
PUSH BUTTONS
Make element
Actuator
Type
2.4
3.
3.1
3.2
3.3
3.4
3.5
4.0
Standard to which equipments confirm

TERMINAL BLOCK
Make
Type
Size
Voltage grade
Current rating
INTERNAL WIRING
SIZE
7.7
Details
Die Cast Aluminium alloy LM6
L & T / Teknic / Siemens
GREEN for START, RED for STOP
Spring return for START , mushroom head
stayput for STOP
IS 8623 & IS 4237
As per List of Approved Vendors
Clip-on
2.5 sq.mm.
660V
10A
1.5 SQ.MM. Stranded copper conductor
Power Capacitors & Capacitor Control Panel

Codes and Standards
Title
Code No.
Shunt capacitors for power systems
IS : 2834
Internal fuses and internal overpressure IS : 12672
disconnectors for shunt capacitors
Metal enclosed switchgear
IS : 3427 / BSEN 60298
/ IEC : 298
Code of practice for phosphating iron IS : 6005/BS : 3189
and steel
Specification for copper rods and bars IS : 613
for electrical purpose
Code of practice for phosphating iron IS6005/BS3189
and steel
Specification for copper rods and bars IS613
for electrical purposes
Control transformers for switchgear and IS12021
controlgear voltage not exceeding
1000V AC
Design Features
Constructional Features
a.
CONTRACTOR
The capacitor banks shall be complete with all parts that are necessary or essential for
efficient operation. Such parts shall be deemed to be within the scope of supply
whether specifically mentioned or not.
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b.
The capacitor bank shall be complete with the required capacitors along with the
supporting post insulators, steel rack assembly, copper bus bars, copper connecting
strips, foundation channels, fuses, fuse clips, etc. The steel rack assembly shall be hot
dip galvanised.
c.
The capacitor bank may comprise of suitable number of single phase units in series
parallel combination. However, the number of parallel units in each of the series
racks shall be such that failure of one unit shall not create an overvoltage on the units
in parallel with it, which will result in the failure of the parallel units.
The assembly of the banks shall be such that it provides sufficient ventilation for
each unit. Necessary louvers shall be provided in the cubicle to ensure proper
ventilation.
d.
Each capacitor case and the cubicle shall be earthed to a separate earth bus in the
cubnicle.
e.
Each capacitor unit/bank shall be fitted with directly connected continuously rated,
low loss discharge device to discharge the capacitors to reduce the voltage to50 Volts
within one minute in accordance with the provisions of IS : 2834.
Individual Capacitor Uinit

a.
b.
The power capacitor shall be self healing Mixed Di-electric type.

Each unit shall be a self-contained, indoor/outdoor type unit, with a rating at 50
cycles of 5,10, 12.5, 20, 25, 50, 100 or 200 KVAr as required to give approximate
bank capacitors required. Other things being equal larger sized units shall be
provided.
c.
Bushings shall be porcelain type and shall be joined to the case by solder-welded or
other method which ensures an adequate and permanent seal.
d.
Each unit shall be non-inflammable dielectric immersed self cooled and hermetically
sealed.
e.
Each unit shall satisfactorily operate at 135 % of rated KVAr including factors of
overvoltage, harmonic currents and manufacturing tolerance. The units shall be
capable of continuously withstanding satisfactorily any overvoltage up to a maximum
of 10 % above the rated voltage, excluding transients.
f.
A weather-proof and corrosion-proof name plate shall be provided on each capacitor

unit. The nameplate shall contain the information setout in IS : 2834.
Series Reactors
The capacitor banks shall be provided with series reactors. The reactor design shall be such
that they will not be overloaded due to harmonics in the supply system. The reactor shall be :
i)
Indoor or outdoor type.
ii)
Completely sealed unit.
CONTRACTOR
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iii)
iv)
v)
Either dry type or non-inflammable dielectric immersed in case of indoor units.

Designed to have a linear V-I characteristic upto 150
% of rated capacitor current..
Designed to have temperature rise within limits as specified in IS : 2026.
Unit Protection
Each capacitor unit shall be individually protected by an HRC fuse suitably rated for load
current and interrupting capacity, so that a faulty capacitor unit shall be disconnected by the
fuse without causing the bank to be disconnected. Thus, the fuse shall disconnect only the
faulty unit and shall leave the rest of the units undisturbed. An blown fuse shall give visual
indication so that it may be detected during periodic inspection. The fuse blowing time shall
coordinate with the pressure built up within the unit to avoid explosion.
Control Requirements : Capacitor Control Panel
This shall generally conform to below mentioned specifications.
a.
The control equipment shall be mounted in a panel made of 14 gauge sheet

steel. The panel shall be of indoor or outdoor type as specified.
b.
The panel shall consist of Automatic power factor control relay

Isolating MCCB
Capcitor duty contactor
relays responsive to current/voltage/KVAR/PF as specified for automatic
switching.
sequencing devices, timer and auxiliary relays for automatic sequential
switching of the capacitors in and out of circuit.
Auto manual selector switches
Push button for opening and closing the power circuit.
Red and green lamps for capacitors ON/OFF indication.
Protective relays to protect the healthy capacitor units when one unit fails
in a series connection.
CONTRACTOR
c.
Contractor shall submit alongwith the bid typical control schematic for
automatic switching.
d.
Data Sheets of all relays shall be submitted alongwith the bid.
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Temperature Rise
The temperature rise above the specified ambient of any part of the capacitor and associated
equipment shall not exceed the maximum permissible temperature limit as specified in IS :
2834.
Tests and Test Reports
a.
All tests shall be conducted in accordance with the latest edition of IS : 2834
in addition to the tests specified, if any, in Data Sheet A.
b.
Type test certificates for similar capacitor units shall be furnished with the
bid.
c.
Extra price, if any, shall be specified under Price Schedule for perfoming any
of the tests.
d.
Tests on control panel as per specification shall be conducted.
e.
Routine test certificates for bought out components shall be submitted.
Spares
Contractor shall submit a list of spares recommended by him for the capacitor installation for
2 years of service. Itemwise price shall be quoted.
Rating Plate
The following information shall be given on the rating plate of each capacitor unit.
a)
Reference to IS.
b)
Manufacgurers name and or trade mark
c)
Manufacturers Identification Number
d)
Rated output in kVAr
e)
Rated Voltage
f)
Rated Frequency in Hertz
g)
Upper Limit of temperature category
h)
No. of phases
i)
Connection Symbol
j)
Discharge Device
k)
Type of Dielectric
CONTRACTOR
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7.8
l)
Reference to Self Healting Design
m)
Total Weight
n)
Type of Impregnant
Power & Control Cables

Codes And Standards
Title
PVC insulated cables (for
Voltage upto 1100 V)
HRPVC & PVC insulated cables
heavy duty
Cross linked polyethylene
Insulated PVC sheathed cables
Low frequency cables and wires
with PVC insulation and sheath
PVC insulation and sheath of
electric cables
Polyethylene insulation and
sheath for electric cables
Conductors for insulated electric
cables
Methods of test for cables
Specification for drums of
electric cables
Specification for PVC insulated
cables for electricity supply
Specification for PVC insulation
and sheath of electric cables
Code No.
IS:694
IS:1554
IS:7098
IEC:189-1 & IEC-189-2
IS:5831
IS:6474
IS:8130
IS:10810
IS:10418
BS:6346
BS:6746
Design Requirements of Cables

Cable shall be capable of operating satisfactory performmance when laid on trays, trenches, ducts,
and when laid directly buried in the ground.
Cables shall be capable of operating satisfactorily under a power supply system voltage variation of +
10% , frequency variation + 5% and a combined variation of + 10%.
Cables shall normally be laid under following conditions :
i.
In air
:
Ambient temperature of 45C
ii
In ground
:
Ground temperature of 35C
iii
Depth of laying in ground
:
1050 mm
iv
Thermal resistivity
:
120 deg cent cm / watt
v
In trays
:
single layer touching each other
CONTRACTOR
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The cable shall withstand all mechanical and thermal stresses under steady state and transient
operating conditions.
11 kV Grade XLPE Insulated Power Cables
11 kV XLPE aluminium conductor cable shall be confirming to IS 7908 Part-II. The cores shall be
screened by extruded semiconducting compound in combination with non-magnetic metallic tape.
The inner sheath over laid up cores and outer sheath over the armour shall be extruded PVC
compound conforming to the requirement of type ST2 of IS 5831 1984
XLPE construction
i
ii
Voltage grade
Conductor
:
:
iii
iv
Insulation
Insulation shield
:
:
Armour
11 kV unearthed
Well compacted stranded aluminium
grade H4, class 2 of IS 8130
Cross linked polyethelene
This shall preferably be of the
sippable triple extruded thermostat type
Galvanised flat steel strip
armoured
1100 V grade PVC Insulated Power cables

Cables shall be insulated with extruded PVC type A. The inner sheath over laid up cores and outer
sheath over the armour shall be extruded PVC compound type ST-1. The voltage rating shall be 1100
V and confirming to the latest IS: 1554 Part-I. The cables shall be of aluminium conductor, stranded
grade H4 class2 as per IS 8130.
1100 V Grade PVC Insulated Control Cables
Cables shall be insulated with extruded PVC type A. The inner sheath over laid up cores and outer
sheath over the armour shall be extruded PVC compound type ST-1. The voltage rating shall be 1100
V and confirming to the latest IS: 1554 Part-I. The cables shall be of stranded tinned annealed copper
conductors with a minimum size of 2.5 sq.mm.
Inspection & Testing
The cables shall be tested in accordance with the IS 1554/7098. The tests shall include :
Test for conductor
Test for thickness of insulation
Test for laying up
Test for thickness of laying up
Test for thickness of inner sheath
Test for armouring
Test for thickness of outer sheath
Test Equipments
Contractor shall ensure to use calibrated test equipment having valid calibration test certificate from
standard laboratories traceable to National Standards.
CONTRACTOR
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7.9
Lighting System:
Codes & Standadrds
Electrical lighting fittings general and Safety
Requirements
Code of practice for industrial lighting
Calculation of co-efficient of utilisation
Industrial lighting fittings with metal
reflectors
Decorative lighting outfits
Dust proof electric lighting fittings
Dust tight electric lighting fittings
Flood lights
Luminaries for street lighting
Water tight electric lighting fittings
Bayonet lamp holders
Edison screw lamp holders
Bi-Pin Lamp holders for tubular Fluorescent
lamps
Starters for fluorescent lamp
Holders for starters for tubular Fluorescent
lamps
Ballast for use in fluorescent lighting
IS:1913/BS:4533
IS:6665
IS:3646 (Part-III)
IS:1777
IS:5077
IS:4012
IS:4013
IS:10322/BS:4533
IS:10322 Part 5
IS:3553/BS:4533, 5225 (1)
IS:1258/BS:EN61184
/IEC:60061
IS:10276/BS:EN 60238
IS:3323
IS:2215/BS:EN 60155
IS:3324/BS:EN60400 /
IEC:60400
IS:1534 (Part 1)/BS:EN
60920 and 60921
Fittings
IEC:60082
Transistorised ballast for fluorescent lamps
IS:7027
Ballast for HP mercury vapour lamp
IS:6616
Capacitors for use in fluorescent, HPMV & IS:1569/BS:EN61048 and
LP sodium vapour discharge circuits
61049/IEC:60586
Vitreous enamel reflector for tungsten IS:8017
filament lamp
Tubular fluorescent lamps
IS:2418 (Part 1)/BS:EN
60081/IEC:60081
High pressure mercury vapour lamps
IS:9900/BS:3677/
IEC:60188
Tungsten filament general electric lamps
IS:418/IEC:60432
Cast acrylic sheets for use in Luminaries
IS:7569
Screwless terminal and electrical connections IS:10322
for lighting fittings
High pressure sodium vapour lamps
IS:9974
Emergency lighting units
IS:9583
Ignition proof enclosures, dust-tight for elect. IS:11005
Equipment
Luminaries (Part I to V)
IS:10322
CONTRACTOR
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Indoor lighting system

All indoor areas will be provided with A.C. lighting and the same will be available as long as A.C.
supply is healthy.
Normal A.C. Lighting.
All indoor and outdoor areas will be provided with A.C. lighting and the same will be available as
long as A.C. supply is healthy.
Emergency D.C. Lighting for other areas.
In other areas, at important locations, built in battery operated instalite fixtures will be provided which
will come in service when A.C. supply fails.
The wiring for lighting circuits shall be done by 2:1.5 sq.mm. copper flexible (red & black colour)
wires for phase & neutral and 1: 1.0 sq.mm. green wire for earthing, run in heavy duty GI conduits for
indoor areas. For outdoor lighting, wiring shall be done by armoured cables.
Outdoor lighting system
All outdoor areas will be provided with A.C. lighting and the same will be available as long as A.C.
supply is healthy.
Outdoor lighting shall be done with steel tubular poles of adequate height, at every 30meters to give
the required illuymination levels. Outdoor lighting shall be controlled from a lighting panel having a
timer switch for automatic switching On & Off the street lights. In case of failure of the timer switch
the panel shall have a provision by means of AUTO/MANUAL siwtch for Manual switching of the
street lights.
Illumination levels
The illumination levels shall be as given in the clasue no: 5.4.
Lighting Design & Distribution

Lighting Fixtures
The fixtures shall be suitable for operation on a nominal supply of 240V 1 ph 50Hz AC with a voltage
variation of + 10% (ie 216V to 264V).
All lighting fixtures shall be with lamps and all necessary accessories for their satisfactory operation.
Each capacitor shall be suitable for operation at 240V + 10% 1 ph 50Hz with a suitable value of
capacitance so as to correct the factor of its corresponding lamp circuit to the extent of 0.98 lag.
Each fixture shall be complete with 1 four way terminal block for the connection and looping of
incoming & outgoing supply cables. Each terminal shall be able to accept 2-1.5sq.mm. copper
stranded conductors.
CONTRACTOR
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Each lighting fixture shall be provided with agrounding terminal suitable for connecting 12 SWG G.I.
wire.
Type of Fixtures
Type A : 1 x 16W / 2 x 16W Industrial Indoor fluorescent lighting fittings :
The luminaire shall be complete with mounting bend pipe, electronic ballast & other accessories.
The luminaire shall consist of channel made from heavy gauge C.R.C.A. sheet seel. The fitting shall
be powder coated and provided with detachable stoved enamelled reflector made from heavy gauge
sheet steel. Accessories such as electronic ballast, P.F. improvement capacitor, and lamp holders etc.
are to be wired upto a terminal block with provision for earthing.
Type B :Emergency lighting fixtures :
Emergency lighting fixtures shall be 20W DC operated & rechargeable on AC supply. In normal case
these fixtures shall be connected to AC supply & remain OFF but in case of power failure the lamp
will be switched ON automatically.
Ceiling / exhaust fans:
Ceiling fans shall be 1200 mm sweep in size complete with electronic regulator. Domestic exhaust
fans shall be installed in admin block & laboratory and heavy duty industrial exhaust fans in MEP
room. The fans shall be complete with mounting frame. The fan opening shall be covered by netted
louvers to prevent the access of birds.
Outdoor Lighting
Street Light Pole
The material of construction of the tubular street light poles shall be either GI. The street light pole
shall comply to te following The pole shall conform to latest wind loading resistance.
The pole shall have an excellent resistance to atmospheric corrosion and ground rot.
The pole should withstand a minimum vertical load of 16kg per side at maximum wind speed.
The pole should not deflect more than 7.5% of the above ground height under full load and
maximum wind speed condition.
The pole shall have self draining dia. weeping hole at a height of 150mm from the ground.
A through hole of dia. shall be provided at a height of 300mm from the ground.
Street Light Pole Accessories
The street light pole shall be 9M long as per IS : 2713(Part II) and flood light pole of 12 M long as
per IS : 2713 ( Part-II). The poles shall be provided with 2 coats of black bitumen paint from inside as
well as outside and 1 coat of red oxide primer form outside. The pole shall be painted with 2 coats of
silver paint after completion of erection work. The installation scope includes excavation required for
pole, construction of 600x600mm concrete base for pole etc., earthing of pole, junction box &
luminaire & laying of 3x2.5 AYY cable from junction box to luminaire from inside of the pole.
CONTRACTOR
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The street light pole erection shall be complete with 1 no: 9M/12M long street light pole
1 no: 250W/400W luminaire with Energy saving lamp
2 nos : 50mm dia. G.I. conduit sleeves for incoming & outgoing cables upto J.B.
1.5 M long 20mm dia. Galvanised MS rod earth electrode for earthing of each pole
Loop-in-loop-out type weatherproof Junction box with terminal blocks suitable for terminating 4X16
sq.mm. AYFY incoming cable & fuse. The Junction box shall be earthed from the same rod by 25
sq.mm. G.I. stranded wire.
The lighting cable shall be laid underground at a depth of minimum 750 mm below ground level with
a protection of sand & bricks.
Street Light Luminaire :
The fitting shall be single piece drawn aluminium housing with built in bright anodized reflector with
a provision to control distribution of light on street side conforming to IS 10322 Part 5 / Sec1 : 1987
and complete with gasketing, heavy duty copper wound ballast & PF capacitor, die cast aluminium
pole mount arrangement having aesthetic finish and hinged toughned glass lamp shield.
U clamps are to be provided on to the control gear housing with 2 nuts for firm gripping to the
supporting pole bracket of maximum angle at which fitting can be installed.
Receptacle Units
Industrial type receptacle units of 5/15A, 15A, 30A sp/tp with switches/ MCBs shall be confirming
to latest IS 3854 and sockets confirming to IS 1293. The units shall be suitable for mounting on stove
enamelled sheet steel boxes generally confirming to IS 5133 Part-I.
5/15A, 5 pin convenient switch socket outlets with indication lamp & fuse mounted on a PVC surface
mounting box shall be installed in administration block & laboratory area. Wiring from lighting panel
to each socket is covered in point wiring.
15A single phase industrial sockets with 15A SP MCB & 2 earthing terminals shall be installed in rest
of the area. 3x4 sq,mm. AYWY cable shll be laid on wall from lighting panel to socket alongwith
earth wire.
7.10
Earthing System
To achieve total earth resistance to less than 1 Earthing shall be carried out as per IS 3043. The
scope includes supply of earthing conductors, earth electrode, installation and approval to the
satisfaction of electrical inspector.
Earthing system shall be provided to ensure equipment safety, personnel safety and to facilitate
designed operation of protective switching during earth fault conditions in the associated system.
Each earth pit shall be provided with Earth Pit marker.
Minimum no of earth pits for various installations/equipment shall be as follows4 pole structure
:
8 nos.
HT Switchgear
:
2 Nos.
Transformer Body earthing
:
2 Nos.
CONTRACTOR
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Transformer Neutral earthing

APFL Earthing
Common Earth Grid
CONTRACTOR
:
:
:
2 Nos.
2 Nos
As required to ensure the earth resistance to less than
1 Ohm
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INSTALLATION & COMMISSIONING OF ELECTRICAL EQUIPMENTS
8.1
Power Transformer
When lifting a transformer by the lugs or shackles provided for this purpose, simultaneous use should
be made of all such lugs and shackles, in order to avoid any unbalance while lifting. Before lifting,
complete transformer, it should be ensured that all cover bolts are tightened fully. In case where it is
necessary to use jacks for lifting, projections provided for the purpose of jacking should be used.
Jacks should never be used under valve or cooling tubes.
It may be necessary under certain circumstances to place jacks under stiffening curbs on the tank
base. For transporting transformers from stores to site, the transformers shall be
loaded on a suitable capacity truck or trailer.
Steel ropes and stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and
vibrations shall properly support the transformers. At no instance, a transformer shall be kept on bare
ground. Where it is not possible to unload the transformer directly on a foundation, these shall be
unloaded on a properly built wooden sleeper platform. A transformer shall never by left without
putting stoppers to the wheels.
Damages of any nature shall be brought to the attention of site engineer before lifting material from
stores failing which it will be contractors account. All loose items supplied along with the
transformer shall be assembled. After complete assembly of the transformer, oil level should be
maintained upto the conservator by topping up with oil. During topping up with oil, care should be
taken so that no air bubble is formed inside the transformer. Any air accumulation in the Buchholz
relay should be released.
Sample of oil from the transformer should be taken from the bottom of the tank. The sample of oil
taken should pass crackle test. The transformer oil should also have a breakdown value of minimum
30 kV for transformer upto 33 kV. Breakdown value (BDV) test should be carried out as per the
latest revision of IS 335.
If the transformer windings do not have high insulation resistance between the windings and between
windings and earth, drying out of the transformer shall be carried out as per the latest revision of IS1886. Normally a streamline filter will be used for transformer drying up.
Pre-commissioning check list
Before commissioning any transformer, the following points should be checked and ensured for safe
energizing of the transformer.
a.
That all the accessories have been fixed properly and transformers body and neutral are
properly earthed. The neutral of the transformer should be earthed to two separate earth pits.
The transformer dehydration is over and results are satisfactory and approved by the
Engineer-in-charge. In case transformers are idle for more than one month after dehydration.
The transformer oil has been given at least two circulations.
b.
That the oil level in the transformer conservator tank is up to the marked point and the oil has
been tested for break down value and acidity.
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c.
That the Silica gel is in reactivated condition. The breather pipe is clear from any blocking
and contains oil upto the proper level.
d.
That the explosion vent diaphragm does not have any dents and accumulation of any air has
been released.
e.
That the operation of off-load and on-load tap changers on all the tap positions is satisfactory.
The mechanical parts of the on-load tap changer mechanism are lubricated. Brake shoes are
o.k. Motor IR value taken and tap position mechanical indicator on the transformer and tap
position indicator meter on the control panel are reading the same tap positions. Tap changer
limit switch are operating all right on the maximum and minimum tap positions. Oil level of
tap changer tank if o.k. and oil has been tested for breakdown value.
f.
That the Buchholz relay has been tested for proper operation by injecting air through a cycle
pump. All the other protective relays, alarm and annunciation relays have been tested.
g.
That all the metering equipment have been tested. Polarity test of CT/PT and transformer
winding is all right. Connections have been checked for proper vector group.
h.
That the ratio test and winding resistance on all the tap position is alright.
i.
That primary injection tests have been carried out on HV and LV side panels and relay
operation and respective circuit breaker tripping verified.
j.
That the winding and oil temperature thermometer pockets contain oil.
k.
That tightness of all bolts, clamps, connecting terminals, oil leakages/level, cleanliness or
bushings have been checked and are all right.
l.
That the simulation tests for all the alarm, annunciation and trip circuits have been checked
and are all right.
m.
That the insulation resistance of all the control circuits and IR value of the transformer
windings and all the incoming and out going cables have been checked with 1000 V. megger.
n.
That all the valves in the cooling system and valve between that Buchholz relay and the
conservator tank are in open position.
o.
That the transformer has been cleaned from outside.
p.
That the temporary earth leads have been removed.
q.
That all the tools and other materials have been removed from the transformer vicinity.
r.
That the setting of all the protective relays is at the desired valve and D.C. trip supply is
available.
s.
That the fire fighting equipment is in position.
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Observations after commissioning:

After switching on the transformer the following points must be observed and recorded:
a.
The magnetizing in rush current and no load current
b.
Alarm if any or if any relay flag has operated.
c.
Voltage and Current on all the three phases.
d.
Transformer hum or abnormal noise.
e.
Circulation of oil and leakages.
f.
Record current, voltages, OLTC position, winding temperature and oil temperature readings,
hourly for 24 hours.
g.
Cable end boxes for any over heating.
8.2
Switchgears
These specifications shall be applicable to HT and LT switchgear panels, motor control centres and
other power and light distribution panels, instrument distribution and A.C /D.C.control supply panels
of various types and capacities. Manufacturers instructions,drawings and instruction of the Engineerin-in charge should be studied and strictly followed during handling, erection, testing and
commissioning of the switchgear. The switchgear should be handled with care by the experienced
riggers under the guidance of a competent supervisor. Dragging of the panels should be avoided and
use of a crane and trailor should be made for the handling purposes while transporting to various sites.
The switchboards should be properly supported on the truck or trailor by means of ropes to avoid any
chances of damage or tilting due to heavy vibrations. The switchboards should be lifted by making
use of lifting eyes bolts only, fully tightened and after ensuring that panel supports, nuts and bolts are
all in tact and tightened. When lifting panels in packed conditions, utmost care should be taken to
avoid any damage to any insulators, bushings, metering and protective equipment. The panels should
be preferably kept inside the packing cases till foundations are ready.
Base channels should be grouted, leveled, in cement concrete pad for H.T. and 415 V switchgear
panels and other cubicle panels. Pedestal type panels and MCCs shall be erected by grouting base
channels by bolts. A proper bonding surface should be made by chipping the floor while making
cement concrete bearing pad for the switchboards. After cement concreting, all such foundations,
grouted bolts shall be cured for a minimum period of 48 hours.
The switchboard panels should be taken from the packed cases and moved one by one to the proper
place. All the panels should be assembled, aligned and leveled and it should be checked that panel to
panel coupling bolts, bus bar links fit properly without any strain on any part. It should also be
checked up that lowering, lifting, racking in and out operation of the breaker and all other motions are
free from any obstruction. The fixing bolts should be grouted after satisfying all these equipments.
The panel shall be made dustproof and vermin proof with gaskets for inter panel joints and plugging
all holes/cutouts. Tightening of bus bar/link connection and terminal connection should be carried
out.
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After completion of the panel erection, all the cubicles, switches, starters, C.T. and P.T. chambers, bus
bar chamber, should be cleaned and checked for tightness of all the components. All the wiring
connections should also be checked with drawing and tightened. Metering and protective C.T.s
alarm, indication and protective relays should be fixed up if received loose. Polarity of P.T.s and
C.T.s should be checked. All the moving parts should be checked for easy and free movement.
Hinges of panel doors should be lightly lubricated to give free and noiseless movement.
Should the switchgear be wet or having a low IR value due to bad wiring, insulators, bushings or any
other insulated parts, the entire switchgear should be dried up, and the IR value shuld improve to a
safe level for commissioning the same. Care should be taken to protect the surrounding insulation
from direct local heating during the drying up process.
Earthing shall be with the proper size of the conductors as indicated in relevant drawing.
All the metering instruments, protective relays and other relays connections should be checked as per
relevant drawing.
All the control wiring, P.T.s, bushings, bus bars, other alive parts of switchgear, incoming and
outgoing cables should be meggered with 1000V. megger H.T. bus bars, circuit breakers, bushings on
the switch gear should be pressure tested at recommended voltage as per Indian standard.
Electrical simulation tests should be carried out for all the protective, alarm and annunciation relays
alongwith the manual operations of the circuit breaker.
Panels must be cleaned with vacuum cleaner.
Pre-commissioning checklist
Before commissioning any switch gear panel, circuit breaker, motor starters etc., the following points
must be checked and ensured for safe energizing of the switch board:
a.
That the erection of equipment to be commissioned is complete in all respect with its
auxiliaries and all other mountings including earthing.
b.
That all the openings in floor inside or outside the cubicle panels have been sealed off.
c.
That all the cubicles panel doors, gaskets are in tact and no other opening exists for vermin
entry.
d.
That all the metering instruments have been checked and calibrated.
e.
That all control circuit fuses and H.T. fuses for P.T. are of proper rating and showing
continuity.
f.
That all the indication lamps are healthy and in position.
g.
That the mechanical parts of breaker closing and tripping mechanism have been checked and
lubricated and circuit breakers have been tested for contact travel, contact pressure and
resistance and buffers are free and fully lubricated.
h.
That air vent pipe of C.B. is free and spouts/shutter mechanism is O.K.
i.
That auxiliary contacts have been checked for cleanliness and adequate contact pressure and
auxiliary contacts in series with tripping circuit open with opening of breaker.
CONTRACTOR
NO OF CORRECTIONS
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j.
That the polarity test and ratio test of all the P.T.s C.T.s is over.
k.
That the high voltage test of circuit breaker, bus bars and outgoing and incoming cables have
been conducted and are satisfactory.
l.
That all the protective relays have been tested for primary and secondary injection tests. All
thermal overload relays and the contractor coils and operation of all the current and voltageoperated relays have been tested.
m.
That the simulation tests for all protective, alarm and annunciation relaus are O.K. and all the
relays have been properly set.
n.
That the manual closing and tripping have been tried against shock and bouncing of the
mechanism.
o.
That I.R. value have been recorded for bus bars, ciruit breaker, incoming and outgoing cables,
control wiring, and potential transformers. Joints resistance of high capacity busbars have
been recorded and found to be satisfactory.
p.
That fire fighting equipment like C.T.C. , CO2 or Soda Ash Extinguisher are kept ready for
use.
8.3
Cables Trays
Mounting General Notes

Unless otherwise specifically mentioned on the relevant layout drawings, all cable tray mounting
works to be carried out as per notes given here.
Cable tray mounting arrangement type to be as marked on the layout drawing.
Assembly of cable tray mounting structure shall be fabricated, supplied, erected and painted by the
electrical contractor.
Civil contractor, will provide plate inserts in floor slabs at 1000 mm spacing for cable tray mounting
structure.
Cable tray mounting structure to be welded to the plate inserts or to structural beams.
Wherever embedded plates and structural beams are not available for welding the cable tray mounting
structure, electrical contractor to supply the M.S. plate and fix it to floor slab by Anchor fasteners of
minimum dia. 16 mm having minimum holding power of 5000 kg.
Spacing between cable tray mounting structures to be 1000 mm for horizontal straight runs of cable
trays.
Minimum loading on a horizontal support arm to be 120 kg/M of cable run.
CONTRACTOR
NO OF CORRECTIONS
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Width of the horizontal arms of the mounting structures to be same as the tray widths required in
cable layout drawings plus length required for welding to the vertical supports (maximum tray width
will be 900 mm) except where shown otherwise.
The length of the vertical supporting members, for horizontal cable tray runs, will be to suit the
number of cable tray tiers required in the cable layout drawings.
Spacing between horizontal support arms of vertical cable tray runs to be 600 mm.
Cable trays will be welded to tray mounting supports.
Minimum clearance between the topmost tray tier and structural member to be 300 mm.
Minimum vertical clearance below the bottom of the lowest cable tray tier and any structural member
to be 300 mm.
All structural steel supplied by the contractor and exposed surface of embedded steel for cable tray
mountings and shall be painted as follows:
For indoor installation one coat of red oxide zinc chromate primer and two coats of synthetic enamel
paint.
For outdoor installations painting with two coats epoxy based paint.
Where any cuts of holes are made or welding is done on finished steel work these shall be painted by
the manner specified above.
Cable Trays Construction Notes
Cable tray of ladder and perforated types and the associated accessories such as coupler plates, tees,
elbows etc. shall be hot dip galvanized fabricated from 12 gauge (2.5 mm thick) mild steel sheets.
Cable tray covers shall be fabricated from 16 gauge (1.70 mm thick) m.s. sheets.
The cable trays to be supplied in standard lengths of 2500 mm and clear inside width of trays shall be
as follows:
a)
b)
Perforated type trays:

Ladder type trays:
150, 300, 450 and 600 mm

300, 450, 600 and 900 mm
The spacing of rungs for ladder type of trays to be 250mm unless otherwise noted.
All finished cable trays and accessories shall be free from sharp edges and corners, burrs and
unevenness.
The details of accessories etc. shown are typical and do not cover the entire range of the same
Fabricaton of accessories not covered here shall be done with the help of relevant project drawings.
Cable Trays Installation Notes
Unless otherwise specifically mentioned, all cable tray mounting works shall be carried out as per
approved drawings.
The type and size of tray to be used will be as mentioned in the individual layout drawings.
CONTRACTOR
NO OF CORRECTIONS
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The maximum size of cable tray when used in trenches shall be of 600 mm width.
Cable trays shall be welded to the mounting/carrier structures.
Vertical trays (raceways) and all outdoor cable trays shall be provided with removable 16 gauge
painted m.s. sheet covers.
Each continuous laid out length of cable tray shall be earthed at minimum two places by M.S. flats of
minimum size 25 x 3 mm (unless otherwise noted) to the main earthing grid, the distance between
earthing points shall not exceed 10 meters.
The following shall be checked before laying the cables on trays.
Check for proper painting and identification nos. of the trays
Check for continuity of power and control cable trays over the entire route.
Check that all sharp corners, burrs and waste materials have been removed from the tray.
8.4
Cable Installation Notes
General
These notes in general cover cables upto and including 11 kV rating. All cables above ground shall be
laid in cable tarys. Where ever tray installation is not possible the cable above ground level shall be
clamped along the walls/railing etc. after getting approval by the engineer in charge.
Electrical installation work shall comply with all currently applicable statutes, regulations and safety
codes in the locality/country where the installation is to be carried out.
Installation of cable shall be carried out generally as per IS 1255 and as per the relevant project
drawings.
Installation of cables shall include, unloading, storing, laying, fixing, jointing, termination, supply of
glands and lugs and all other work necessary for completing the job.
Cables will be installed in trenches, trays, racks, conduits, duct banks or directly buried. The actual
cable layouts will be shown on the relevant project drawings. Any changes, if necessary, after
obtaining prior approval of the Purchaser/Engineer shall be carried out at site by the contractor and
shall be clearly marked by him on project drawings and forwarded for aproval of the purchaser.
Cable to each circuit shall be laid in one continuous length, cable jointing and splicing shall be done
after obtaining Site Engineers permission.
Outdoor Cable Installation
Cables laid in ground shall be laid on a 75 mm riddled earth bed. The cables shall then be covered on
top and at their sides with riddled earth of depth of about 150 mm. The RCC covers shall have one
hole at each end, to tie them to each other with GI wires to prevent displacement. The trench shall
then be backfilled with the excavated soil and well-rammed in successive layer of not more than 300
mm in depth, with the trenches being watered to improve consolidation wherever necessary. To allow
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
361

for subsidence, it is advisable to allow a crown of earth not less than 50 mm in the centre and tapering
towards the sides of the trench.
Cable route markers shall be provided at every 20 meters. At least one marker shall be provided if the
length of the buried cable is less then 15 meters. Buried cables in trefoil formation shall be bound by
plastic tapes of 1 mm dia. Nylon cord every 750mm.
Joint markers at each joint location shall identify joints in directly buried cables.
In each outdoor cable run, some extra cable length shall be kept at a suitable point to enable a straight
through joint to be made should the cable develop fault at a later date.
Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in RCC hume
pipes. For road crossing, the pipe for the cable shall be buried at not less than 600 mm unless
otherwise noted in the drawings.
Cables In Trays/On Racks
Different voltage grade cables shall be laid in separate trays when trays are arranged in tiers. H.V.
cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
362

Termination Clamping and Miscellaneous Details

Cable entry to motors, push button stations and other electrical devices shall be from the bottom as far
as possible or from the sides. Top entry shall be avoided particularly for outdoor equipment.
Identification tags made from aluminium sheet shall be attached to each end of each cable by means
of GI binding wire. Tags shall be additionally put at an interval of 30 metres on long runs of cables
and in pull boxes.
All cable terminations shall be solderless crimping type. The crimping tools shall be adequate for lug
sizes.
Testing and Commisisoning Of Cables
Cables shall be checked for insulation resistance before and after jointing. The voltage rating of the
meggers for cables of different voltage grades shall be as indicated below:
Voltage Grade of Cable

1.1 kV
11 kV
a.
Megger Rating
500 V
2.5 kV Motorised Megger
High Voltage Testing
All cables of 1.1 kV grade 400 mm2 and above and all HV cables shall be subjected to DC or AC
high voltage test after jointing and terminating but before commissioning as per the relevant
standards. Testing with DC voltage should be preferred as test equipment required in compact,
easily portable and requires low power. The DC test voltages applicable in India shall be as per
table 6 in IS 1255. The cable cores must be discharged on completion of DC high voltage test and
cable sahll be kept earthed until it in put into service.
Testing of Cable Installation
DC test voltages after installation (before commissioning) (REF IS 1255 83)
DC test voltage for cables is 1.5 times rated voltage.
In each test, the metallic sheath/screen/armour should be connected to earth.
Continuity of all the cores, correctness of all connections as per wiring diagrams, correctness of
polarity and phasing of power cables and proper earth connection of cable gland, cable boxes, armour
and metallic sheath shall be checked.
8.5
Lighting
General
Electrical installation work shall comply with all currently applicable standards, statutes, regulations
and safety codes in the locality/country where the installation is to be carried out.
Installation of lighting system shall be carried out generally as per the instructions in this document
and typical drawings and relevant project layout drawings to be furnished by the contractor.
CONTRACTOR
NO OF CORRECTIONS
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363

The scope of installation work shall include storing, unpacking, fixing of all items associated with
lighting system, laying and fixing conduits, wiring, termination, testing, commissioning and all other
work items necessary for completing the job. The supply of all mounting accessories hardware,
consumables like fixing saddles at the fixture fixing/suspension points, connectors, jointing ferrules,
all fixing brackets, screws and studs and earthing wires shall be deemed to be include in the scope of
installation work.
The scope and specification of the supply items like lighting distribution boards, lighting panels,
fixtures, street lighting poles, wires/cables, conduits, receptacles, switches, ceiling fans shall be as
indicated separately in schedule of items and rates.
Lighting panel, distribution boards, fixtures, fans switches, receptacles etc. shall be located as per the
PURCHASERS approved layout drawings. Any changes, if necessary after obtaining prior approval
of the PURCHASER/ENGINEER, shall be carried out at site by the CONTRACTOR and shall clearly
marked by him on the project drawings and forwarded to for purchasres approval.
The required conduits for lighting wiring shall be suitably routed at site by the CONTRACTOR with
due considerations to a neat layout and ease of maintenance.
Unless specifically noted otherwise, lighting panels, light control switches and receptaces shall be
installed at the following mounting heights from finished floor/ground levels:
Lighting panels 1200 mm to bottom of the panel
Light control switches 1200 mm
Receptacle units 500 mm for indoor and 1000 mm for outdoor.
Lighting Panels/Distribution Boards
All lighting panels located indoor/outdoor shall be installed by the CONTRACTOR on walls/columns
by fastening to suitably grouted stud.
Lighting Fixtures
Lighting fixtures of appropriate type as per PURCHASERs drawings shall be installed by the
CONTRACTOR as per the typical mounting arrangement drawings furnished to him.
Lighting fixtures installed on/under platforms/pedestals which are subject to vibrations (such as TG
pedestal) shall be provided with rubber cushions to minimise vibration reaching the fixtures.
Switches and Receptacles
Exact locations shall be finalised by the CONTRACTOR in consultation with the site ENGINEER/
PURCHASER.
Switches/receptacles which are to be wired on the same phase and to be located close by each other
shall be accommodated/housed in the same box.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
364

Conduits
Minimum size of rigid GI conduits used for wiring shall be of 20mm in case of exposed systems and
25 mm in case of concealed/embedded systems. The conduits shall be supported by means of saddles
as follows:
Rigid Metallic Conduits Spacing between saddles not to exceed 1 m in addition saddles shall be located on either ends of
couplers/bonds or similar fittings/accessories. In such cases the saddles shall be located at a distance
not exceeding 300 mm from the fittings/accessory.
Wires belonging to different phases shall not be run in the same conduit. However, more than one
circuit, consisting of phase and neutral wires, of the same phase can be run in the same conduit, for
every phase wire a separate neutral wire shall be run.
Wiring/Cabling
Unless otherwise stated, the mode of wiring will be as follows:
250/440V PVC insulated flexible 2 core wires used for indoor lighting wiring shall be laid in rigid GI
conduits.
Outdoor lighting cables shall be directly buried in ground at a minimum depth of 600 mm or routed in
the available cable trenches. Cables crossing road/rail shall be laid in RCChume pipes.
Size of wire shall be chosen to limit voltage drop to within 5%. Minimum area of conductor shall be
1.5 sq.mm coopper, unless otherwise stated, and density not to exceed 2.5A/sq.mm. Generally not
more than 8 to 10 points shall be wired in one circuit. For the purpose of calculating connected loads
of various circuits a multiplying factor of 1.25 will be assumed to the rated lamp wattage for mercury
vapour and fluorescent lamp fixtures to take into account losses in the control gear. A loading of 100
watts and 500 watts will be assumed for single-phase 5 Amps and 15 Amps receptacles respectively.
Ceiling Fans
Unless otherwise specified, all ceiling fans shall be installed not less than 2.75 m above the floor
level.
In rooms having fluorescent lamp lighting fixtures and ceiling fans, the fans shall be installed with
their blades at least 100 mm above the lighting fixtures.
Earthing
Lighting fixtures, receptacles, switches, conduits and junction boxes shall be properly earthed using
12 SWG. GI wire (unless otherwise specified) run along the entire length of the conduit between the
fixture and the corresponding lighting panel where it will be connected to the station earth.
The earth wire for each conduit length shall be efficiently fastened to the conduit at regular intervals
of not more than 750 mm.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
365

Testing and Commissioning

Before a completed installation or an extension to an existing installation is put into service it shall be
tested as per the relevant standars/codes of practices of the country where the installation is carried
out. Installation shall be tested in accordance with IS-732.
8.6
Earthing
All electrical equipment must be efficiently double earthed in accordance with the requirement of IS
3043 and relevant regulations of Electric Supply Authority.
The earth pits shall be as per Indian Standard with proper arrangement for testing.
All earthing conductors shall be hot dip galvanised/electrolytic grade base conductor. The main
earthing rings shall be done as per practice laid in Indian Standard.
The earthing of individual electrical equipment by two distinct strips/conducted shall be done as per
practice laid in Indian Standard.
The sizes of conductors for earthing various equipment shall be as follows:
.
Sr.
System
Earthing conductor
Material
a)
Main Earthing Grid
50 x 10 mm GS
b)
Transformer/HT Switchgear
LV Bus Duct
415V switchgear
Capacitor Control panel
Cable tray
Battery charger/Lighting Panel
Local Push Button Station
Outdoor Street Lighting
50 x 10 mm GS
50 x 6 mm MS
50 x 6 mm MS
50 x 6 mm GS
30 x 5 mm GS
25 x 3 mm GS
8 SWG GS wire
8 SWG GS wire
c)
L.T. Motors
up to 11 Kw
Above 11 kW upto 30 kW
Above 30 kW
8 SWG GS wire
25 x 3 mm GI Strip
50 x 6 mm GI Strip
d)
Earth Electrode
size
&
40 mm diameter 3000 mm long

heavy duty GI pipe electrode
All electrical equipment shall be connected to the earth bus at two points except the lighting fittings
and junction boxes where single earthing shall be provided. All other equipments in hazardous areas
shall be earthed at places.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
366

Following earthing resistances shall be measured and recorded in the presence of site engineer during
the dry season.
Resistance of each earth electrode with electrode isolated from the system.
Combined earth resistance of the installation measured at the substation, switchroom and any other
point as directed by the site engineer.
The method of testing shall be as per clause 10.1 and 10.2 of IS-3043. The contractor shall prepare
the test report and submit to the engineer in charge. The effective earth resistance of the system shall
be less than one Ohm.
The 415V neutral shall be solidly earthed by means of two separate and distinct connections to earth
using conductor of appropriate size. Each connection shall be connected to an independent earth
interconnected between themselves and the main earthing grid to form an earthing ring. The neutral
earthing leads shall be kept away from the transformer tank and protected inside wire mesh enclosure
to prevent accidental contact.
Terminal joints on the equipment shall be bolted.
The earthing conductors running underground shall be laid approximately 600 mm below the grade
level.
Removable test links shall be provided near the earth pits to facilitate testing of earth pits.
The quality of galvanising shall be subject to test in the presence of site engineer.
The vessels shall be earthed at two points.
The vessels to be earthed shall be connected to a common earth grid of power system
For equipment earthing, suitable GI bolts with spring and plain washers to suit the thread of earth boss
of vessels etc. shall be provided.
Earth pits:
The number of earth pits will depend upon soil resistivity and the voltage of the system. The earth pit
together with the electrode shall be constructed as per I.S. 3043 1987. The minimum distance
between two earth pits shall not be less than twice the length of the electrode. A bolted assembly link
shall be provided in the connection between earth electrode and the main earth conductor. GI pipe for
watering shall be included in the earth pit.
Earth bus and earth wires:
Framework and other non-current carrying metal work association with each system e.g. transformer,
tanks, switchgear frame work etc.shall be earthed. Extrenous metal framework not associated with
the power system. e.g. boundary fence, steel structure, sheaths of communication cables etc. will have
to be earthed.
Each incoming and outgoing cable shall be bound to the switchboard earth so that the armour and
sheathing with feeders and interconnection shall form an earth system. The complete earthing system
inside a substation shall be given a coat of black asphaltic varnish.
Earthing of transformer:
Unless otherwise specified, the transformer neutral shall be directly earthed at two points through the
neutral bushing provided on the transformer. Inside transformer cubicle and inside the switch rooms
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
367

where the neutral connection to earth is accessible. The resistance of the earth electrode in any case
shall not be more than 1 ohm.
Earthing of LT Panels:
Distribution boards and MCCs shall be provided with two visible, separate and distinct earth
connections from the ring main.
A separate earth bar shall be provided throughout the length of the MCC or distribution board, and
individual connections to various items of equipment in the distribution board or MCC shall emanate
from the above bus bar in the form of a ring.
Earthing of motors, starters and push buttons:
All the motors shall be provided with separate and distinct earth connection from ring main. Where
the terminal box is not part of the motor frame or where a mealing box is used, a bond shall be
provided from the gland plate or armour clamp to the motor frame.
Starters and push buttons shall be double earthed.
Testing of earthing system:
Resistance of all earth electrodes and total resistance of each group shall be tested to prove that the
value do not exceed that specified in the codes of practice or regulations and recorded. Earth pit
resistance shall not be more than 1 Ohm.
The continuity of earthing and resistance of each earthing connection to the equipment shall be tested
and recorded.
8.7
Fabrication Work
M.S. channels/angles of requisite size shall be used for cable tray supports/ push button station
mounting frames, panel frames etc. The fabricated work shall be provided with two coats of zinc rich
red oxide primer & 2 coats of enamelled paint of approved colour. The scope of fabrication work
includes supply of necessary hardware viz. anchor fasteners, M.S. base plate etc.
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
368

EQUIPMENT TESTING
9.1
All equipments shall be fully tested in accordance with the relevant clauses of applicable
standards. All components and devices shall be checked for correct operation before dispatch.
Tests to be carried out at Manufacturers works shall be as mentioned below.
For tests designated by symbol A:
the contractor shall furnish valid test certificates.
For tests designated by symbol B: Test shall be carried out in presence of the Purchaser or
Purchasers authorized representative.
High Voltage Switchgear

Sr.
Test Particulars
Type Test
Routine Test
a
b
c
d
Assembly inspection
Operation test
Temperature rise tests for main & auxiliary circuits
Power frequency voltage tests on main & auxiliary
circuits
Impulse voltage test
Verification of making & breaking capacity of
circuit breaker
Short time current withstand test on main circuit
Short time current test on earthing circuits
Verification of mechanical endurance of circuit
breakers
Operation tests of auxiliary electrical and
pneumatic devices (as applicable)
Measurement of resistance of main circuit of circuit
breakers
Verification of Wiring
Protection relay primary and secondary injection
test.
A
A
A
B
B
B
A
A
A
A
A
B
B
e
f
g
h
i
j
k
l
J
9.2
Power Transformers
Sr.
Test Particulars
Type Test
Routine Test
a
b
c
d
e
Visual inspection
Measurement of winding resistance
Measurement of voltage ratio
Check of voltage vector relationship
Measurement of impedance voltage, short-circuit
impedance and load loss
Short-circuit test
A
A
A
A
B
B
B
B
B
B
(Special
test)
A
B
A
g
h
i
CONTRACTOR
Measurement of no-load current

Temperature rise test
Measurement of insulation resistance
NO OF CORRECTIONS
B
B
EXECUTIVE ENGINEER
369

Sr.
j
k
l
m
n
o
9.3
Test Particulars
Separate source voltage withstand test
Impulse voltage test for oil immersed transformers
except for 220KV class transformers
Impulse voltage test including chopped waves for
220KV class transformers only
Induced over voltage withstand test
Test on on-load tap-changer
Transformer Oil Breakdown Voltage Test
a
b
Test Particulars
Hi-Pot Test
Insulation Resistance Test
A
-
B
B
B
Type Test
Routine Test
B
B
Type Test
Routine Test
B
A
A
B
B
B
-
Type Test
A
B
A
A
Routine Test
B
B
B
-
A
A
A
A
Bus-Ducts
Sr.
a
b
c
d
e
9.5
Routine Test
B
-
11 kV HV Cable
Sr.
9.4
Type Test
B
Test Particulars
Assembly inspection
Short time current test
Power frequency voltage test
Impulse voltage test
415 V Switchgear
Sr.
Test Particulars
a
Assembly inspection
b Operation test
c
d Di-electric test
e
Short-circuit making and breaking performance
test of circuit-breaker only
f
Short-time current withstand test
g Verification of overload performance of circuitbreaker only
h Verification of mechanical and electrical
endurance of circuit-breaker only
i
Verification of operating limits and characteristics
of over current opening release
j
Calibration of release
k Verification of terminal markings and polarity of
CT
l
Test for checking accuracy of CT
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
370

9.6
AC Motors
Sr.
Test Particulars
Type Test
Routine Test
a
b
c
Insulation resistance test

High voltage test
No-load running of motor and reading of voltage,
current power input and speed
Locked-rotor readings of voltage, current and
power input at a reduced voltage (Values of torques
are to be indicated in type test)
Reduced voltage running-up test
Open-circuit voltage ratio (for slip-ring motors
only)
Calculation of efficiency
Momentary overload test
Over speed test
A
A
A
B
B
B
A
A
B
B
A
A
A
A
e
f
g
h
i
j
9.7
Motor Control Centers

Sr.
Test Particulars
Type Test
Routine Test
a
b
c
d
e
Visual inspection
Electrical operation test
Di-electric test
Short-circuit withstand and peak withstand tests
on main and vertical bus bars
Temperature rise tests on main and vertical bus
bars
B
B
B
B
-
Type Test
Routine Test
B
B
B
B
9.8
Power Distribution Board

Sr.
a
b
c
d
CONTRACTOR
Test Particulars
Visual inspection
Operation test
High voltage test
NO OF CORRECTIONS
EXECUTIVE ENGINEER
371

LIST OF APPROVED MAKES FOR ELECTRICAL EQUIPMENTS

Sr.
A
Equipment
APPROVED MAKES
Power Transformer
Voltamp/ Crompton/Bharat Bijlee/Kirloskar
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
E
LV - ELECTRICAL SYSTEM
LV Switchgear / Busduct
Moulded
Case
Circuit
Breakers
Switch / Fuse Unit
Contactors AC / DC
Thermal O/L relay
Motor Starters
Current
/
Potential
Transformer
Automatic Power Factor
Correction Panel (APFCP)
Automatic Power Factor
Correction Relay
Power Capacitors
Protective relays
Numerical
Measurement + Auxiliary
(Electro magnetic & static )
Cables
- HT Cable
- LT Cable
Cable Gland
HT Cable Termination
Lugs
Indicating Meters
COMMON ITEMS
Indicating lamps
2
3
4
5
6
7
Push Buttons
Indicating meters
Terminal blocks
Lighting Fixtures
Lamps
Aluminium Steert
poles
Lighting Distribution Boards
CONTRACTOR
L & T/ SIEMNS/ INDUSTRIAL Switchgear & CONTROL /

L&T / SIEMENS / ABB
L & T / SIEMENS / ABB
L&T / SIEMENS / ABB
L&T / SIEMENS / ABB
L&T / SIEMENS / ABB
L & T / SIEMENS / ABB
ABB/KAPPA / SILKANS / GIBERT / AE / ASHMORE /
EPICAST
ELECMECH CORPN / INDUSTRIAL CONTROL /SAVIN
Neptune DUCATI/ L & T
MALDE / PRABODHAN / SAVIN / L & T
(MEHER ) / ASIAN
ALSTOM / ABB / SIEMENS / L & T
CCI / POLY CAB /AVOCAB
COMET / BRACO / 3D
RAY CHEM / MAHINDRA / CCI
DOWELL / 3D / BRACO
MECO / RISHABH / AEP / IMP
L&T / SIEMENS / GEC ALSTHOM / IEC / TECHNIK / RASS

CONTROLS
L&T / BCH / SIEMENS / TECHNIK / RASS
AE / IMP / MECO / RISHABH (L&T)
ELMEX / WAGO (C&S)/ Connectwell
WIPRO / THORN/HAVELLS
WIPRO / Philips / Crompton Greaves
Light IDS
MDS / ABB / L&T/ HAVELLS
NO OF CORRECTIONS
EXECUTIVE ENGINEER
372

Sr.
9
10
11
12
13
Equipment
APPROVED MAKES
Miniature Circuit Breakers

Annunciators
Energy Meters
MDS / L & T / SIEMENS / S & S/ABB

MINILEC / PEACON / ICA
ELECTRONIC: ENERCON / L & T / ALACRITY
ELECTROMECHANICAL: GEC-A / SIMCO / IMP
Electronic TVM
ENERCON / L&T / DUKE / SIMCO
Breaker Control / Selector EE / KAYCEE / SIEMENS / JYOTI
switches
CONTRACTOR
NO OF CORRECTIONS
EXECUTIVE ENGINEER
373

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NASHIK MUNICIPAL CORPORATION

Water Supply and Sewerage Department

E-Tender Notice No. 1 / 2010 - 11

TENDER DOCUMENT FOR

General Conditions of Contract

Tender Issued to:

32 MLD capacity STP at Panchak, Nashik

Scope of Work and Drawings. 1

Mechanical Specifications . 239

Electrical Specifications 287

32 MLD Capacity STP at Panchak, Nashik.

TABLE OF CONTENTS Volume II A, Scope of Work

PROJECT INFORMATION ........................................................... 1

GENERAL TECHNICAL REQUIREMENTS .................................... 6

32 MLD Capacity STP at Panchak, Nashik.

Plant Utilities .................................................................................................................... 27

START UP AND PERFORMANCE RUN ....................................... 36

OPERATION AND MAINTENANCE ............................................. 41

32 MLD STP at Panchak, Nashik

DATA SHEETS ........................................................................................... 48

Miscellaneous Information ...................................................................................................... 88

32 MLD Capacity STP at Panchak, Nashik.

32 MLD Capacity STP at Panchak, Nashik.

STP Site Topography

HFL at STP site is 554.50.

32 MLD Capacity STP at Panchak, Nashik.

PROPOSED SEWAGE TREATMENT PLANT

Sewage Treatment Plant Capacity (For all three schemes)

Raw Sewage Quality (For all three schemes)

Treated Sewage Quality (For all three schemes)

32 MLD Capacity STP at Panchak, Nashik.

Proposed Treatment Scheme

1.3.4.1 Activated Sludge Process

32 MLD Capacity STP at Panchak, Nashik.

1.3.4.2 Sequential Batch Reactor Technology

1.3.4.3 UASB followed by Aerobic treatment

32 MLD Capacity STP at Panchak, Nashik.

32 MLD Capacity STP at Panchak, Nashik.

2 GENERAL TECHNICAL REQUIREMENTS

SUBMISSION DURING EXECUTION OF THE PROJECT

A levelling / contour plan gradation plan of the site

Subsoil testing and investigations to be carried out by the contractor through a

32 MLD Capacity STP at Panchak, Nashik.

Design details for electrical and mechanical equipment, machinery including

32 MLD Capacity STP at Panchak, Nashik.

Revised drawings and design according to requirements of the Engineer.

EQUIVALENCY OF STANDARDS AND CODES

QUALITY ASSURANCE PROGRAMME/SAMPLE TESTS

32 MLD Capacity STP at Panchak, Nashik.

DISMANTLING OF THE EXISTING UNITS (IF APPLICABLE)

32 MLD Capacity STP at Panchak, Nashik.

2.10 READY MIX CONCRETE

32 MLD Capacity STP at Panchak, Nashik.

32 MLD Capacity STP at Panchak, Nashik.

BRIEF SCOPE OF WORK

32 MLD Capacity STP at Panchak, Nashik.

DETAILED SCOPE OF WORK FOR ACTIVATED SLUDGE PROCESS

32 MLD Capacity STP at Panchak, Nashik.

Minimum volume of the Inlet chamber shall be 50 m3

Grit Removal Channel

32 MLD Capacity STP at Panchak, Nashik.

Detritor tank chamber shall have the following:

32 MLD Capacity STP at Panchak, Nashik.