GAIL (INDIA) LIMITED

FINAL CONSOLIDATED REPORT FOR Project No.

“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

1. SCOPE OF WORK:

The scope of complete Civil, Structural and other Allied Works associated with “Installation
of Mounded Bullets at GAIL India limited, Vijaipur.

1.1 All civil works shall be carried out both below and above ground level strictly in accordance
with the “ Scope of work, Design basis for civil & structural work, Technical Specifications
for civil, structural & other allied work, relevant IS Codes & CPWD specifications.

a) Technical specifications for civil, structural works etc.; as per the requirements of specific
items.
b) Bureau of Indian Standard Codes (BIS Codes) with latest amendments & OISD.
c) Indian Road Congress (IRC) for road works and Central Public Works Department (CPWD)
for other works with latest amendments.

1.2 The complete civil, structural and allied works associated with the “Installation of Mounded
Bullets at GAIL India limited, Vijaipur” shall be, but not limited, to as below:

2. Mound for 3 Nos LPG storage vessels (LPG bullets) & 1 Nos of Propane bullets supported
on RCC Pile Cap along with RCC inspection trench, retaining wall, collection pits, stair case
as shown and detailed in enclosed drawings including installation of bullets in position.
3. Foundations and supporting structures for firefighting system.
4. Pipe sleepers are to be provided as required.
5. RCC peripheral water drain shall be provided all around the mounded bullet foundation after
1.0 m(min.) x 100mm thk. (min.) plinth protection. The size of drain shall be 500 x 600 mm
depth having precast cover with pot holes. The drain shall be suitable designed to connect
with the existing drain of the plant. If required collection pit/manhole shall be considered as
per codes. Storm water drains of min. 600mm width running along the mound and connected
to existing storm water drain.
6. Dressing and cleaning off areas.

2. MOUND:

2.1 SPECIFICATIONS FOR MOUND MATERIALS:

2.1.1 SAND BED:

The sand for the bullet bed, bullet surround and filling between bullets shall consist of
material complying with the following specifications:

1. Good quality clean, non-aggressive sand with a maximum organic material content of 3%
by weight.
2. A maximum silt content of 10% by weight (particles smaller than 0.063 mm).

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev
3. A maximum particle size of 5 mm.
4. A grain size distribution having Uniformity Coeff. (D60/D10) between 2 & 8.

2.1.2 SAND SURROUNDING BETWEEN BULLETS:

a. These shall have same specifications as mentioned in Cl. No.2.1.1.

o
b. Sand filling placed between bullets and line extending out at 45 from the center of the bullet
above the bullet center line shall be hand compacted and fill placed outside this line shall be
machine compacted (both to a minimum of 95% maximum dry density).

c. Compaction shall be sufficient to avoid significant settlements of the sand filling / mound
surfacebut shall be such as not to impose undue stresses on the tanks.

d. The sand filling shall be placed equally, in maximum 200 mm layers (uncompact depth), on
each side of the tanks so as to avoid any lateral displacement / rotation of the tanks during
compaction.
e. Sand filling shall be brought up to the levels and slopes as denoted on the drawings to below
the drainage layer.

2.1.3 PEA GRAVEL:

The pea gravel shall be surrounding perforated PVC drain these shall consist of clean
washed, size varying from 6 to 12 mm (average size 8 mm) round stone free from all organic
matter, dust or any other deleterious material.

2.1.4 NON-WOVEN GEOTEXTILE:

a. Non-woven geotextile sheet TERRAM 1000 or equivalent shall be used for separating two
different material layer. A layer is to be provided between stone finish and UPVC layer as
shown in drawing.
b. The textile shall be laid carefully to avoid damage/ tearing etc. Minimum 300 mm overlap
is to be maintained at the junctions of two rolls.

2.1.5 UPVC SHEET:

1.2 mm thick UPVC sheet as per BIS-2076 of Finolex brand or equivalent shall be provided
over the sand mound to prevent water percolation into mound. It shall be laid at the mound
slope. It has to take care about water tight stitching of the joints by providing minimum 300
wide laps.

2.1.6 PERFORATED PVC PIPES:

Perforated PVC pipes as per BIS-4985 (lying as per BIS-7634, Part- III), shall be placed to
collect water. It is to be laid above UPVC sheet. Min. slope to be maintained is 1:100. These
pipes shall be surrounded with pea gravel with size from 10 to 20 mm.

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

2.1.7 STONE PITCHING:

The sand mound slope is to be protected with stone pitching 300 thk. on inclined surface and
200mm thick on other places on 75 thick 1:6 cement mortar. The voids between boulders
shall be filled with 1:6 cement mortar. The top shall be flush pointed neatly with 1:6 cement
mortar to give aesthetic view of the mound. Proper drainage arrangement shall be made to
carry water from the outlet of perforated pipe to the drains.

2.1.8 STONE / CEMENT CONCRETE BLOCK FINISH:

The top layer of the mound shall be finished with 200 thick (min.) stone layer 10 to 50 mm
size over 200 thick. clean washed pebbles of size 10 to 40 mm laid over the geotextile sheet
or cement concrete block of 450x450x 200mm size of grade M25 over geotextile sheet as per
relevant specification.

2.1.9 RETAINING WALL:

An all-round RCC retaining wall shall be provided in around mounds. The height shall be as
per attached drawing. The inside face of wall shall be vertical and outside face shall be
tapered as per design requirement. One all around storm water channel on top of retaining
wall as shown in drawing is to be provided with sufficient no. of suitable no. of CI pipes ( as
per CPWD

specifications ) for disposal of rain water to nearest drainage system. 100 dia GI pipe sleeve
weep holes laid with downward inclination are be provided at a height of 300 mm above
ground at a spacing of 2500 mm (min.)for dissipating rain water during construction period in
all retaining walls. Suitable expansion joints as per standard engineering practices shall be
provided in retaining walls as per requirements. Insert plates on outer and inner faces of
retaining wall as per requirements shall be provided. The sub surface water shall not be
allowed to enter bullet mound and underground collection pits as shown in drawings shall be
provided to prevent entry for the same.

2.1.10 STEPS & STAIRCASES:

All retaining walls are to be provided with RCC staircase as per standard engineering
practices. RCC steps in M-30 grade are to be provided for negotiating from top of retaining
wall to mound top. These steps shall be cast along with 100 thick RCC base. The desired
tread and risers shall be 250 & 150 mm. The width of staircase & steps shall be 1500 mm.
M.S. hand rails as per details shown are to be provided on both sides.

2.1.11 RCC TRENCH

RCC trenches of height 2.0m( min.) X 1.7m width (min.) are to be provided for each bullet as
shown in drawing. Outlet nozzles (pipes) shall be placed off centre in this trench. The level of
raft of the trench shall not be less than pavement level. Elastomeric bearing (Neoprene

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev
padding) as per IRC: 83 shall be placed at contact surface of top slab and bullet shell to
protect bullet shell. The minimum thickness of neoprene padding shall be 75 mm. The height
of trench shall be sufficient, so that a person can move easily. This can be reduced near bullet
shell by making local adjustment. All trenches shall have provision of double panel steel
doors, openable from outside. These shall be fixed in retaining walls. The steel doors shall be
made with fabricated steel sections with M.S.

sheeting on both faces. While fabricating, the shape of door shall be designed, keeping in
mind, that stability of outlet pipe is not disturbed due to its operation. Locking arrangement
from outside shall also be provided in doors.

2.2 PIPE SLEEPERS

Pipe sleepers shall be provided for supporting various utilities. The length, height and width
of these shall be as per functional requirements. Modification in existing pipe sleepers,
construction of new supports, consequent to relocation of some of utilities or otherwise are
also included in scope.

DESIGN BASIS FOR CIVIL & STRUCTURAL WORK

1.0 INTRODUCTION
1.1 Scope

This engineering design basis defines the minimum design criteria that shall form the basis
for carrying out detailed design engineering of mound for LPG Bullets and associated
facilities. All structures shall be designed for the satisfactory performance of the functions for
which they are being constructed.

1.2 Units of Measurement

Units of measurement shall be in metric system.

1.3 Codes and Standards

The design shall be in accordance with established codes, sound engineering practices and
shall conform to the statutory regulations applicable to the country. The main codes and
standards and statutory regulations considered as minimum requirements are as follows
(Latest revision of these shall be followed): IS:456 Code of practice for plain & reinforced
concrete IS:800 Code of practice for general construction in steel IS:816 Code of practice for
use of metal arc welding for general construction IS:875 Code of practice for design loads
IS:1893 Criteria for earth quake resistant design of structures IS:2911 Code of practice for
design and construction of pile foundations IS:13920 Code of practice for ductile detailing of
reinforced concrete structures subjected to seismic forces. National Building Code Factory
Rules. All work shall comply OISD Norms and PW Specifications.

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

2.0 Design Loads

The following design loadings shall be considered:

1. Dead loads including self-weight

2. Live load
3. Wind load
4. Seismic load
These loadings shall be applicable to all structures irrespective of the material employed for
construction.

2.1 Dead Loads

Dead load shall comprise of the weight of all permanent construction including retaining
walls, filling material, floors, stairways and fixed services
Bullets shall be considered as full of water for test case.

2.2 Live Loads

Live loads shall, in general, be as per IS:875. However, the following minimum live loads
shall be considered in the design of structures to account for maintenance and erection
phases.

2.3 Wind Loads

Wind loads for structural design shall be as per IS-875 (Part-3). The design life span of all
structures, except temporary structures shall be taken as 50 years.

2.4 Seismic Loads

Seismic loads shall be as per IS: 1893 (Latest Revision).

3.0 DESIGN CRITERIA FOR REINFORCED CONCRETE STRUCTURES

3.1 General

All retaining walls, access tunnels, trenches, pits etc. shall be of RCC and designed based on
the applicable IS codes (latest revision with all amendments, issued there to).
Only limit state method as per IS: 456 shall be followed for the design unless otherwise
specified elsewhere for special structures.
Where the specified design depth of groundwater table so warrants, all underground pits,
tunnels, basements, etc. shall be leak-proof R.C.C. construction using water proofing
compounds.

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

3.2 Reinforcement Bars

All reinforcement bars for RCC works should be high yield strength deformed TMT steel
bars of grade Fe500D conforming to IS: 1786.

3.3 Minimum Cover to Reinforcement

Minimum clear cover shall be provided to all steel reinforcement as per IS:456 & IS:3370

3.4 Miscellaneous Applications

3.4.1 Admixtures

Generally, admixtures should not be used. If required, admixtures shall conform to IS:9103
and to be mixed with concrete strictly as per manufacturer’s recommendations.

3.4.2 Plinth protection

The peripheral area around bullet foundation & building shall be provided with minimum 1.0
m wide concrete M20, 100 thick laid on 75 mm thick M10 concrete with 8 Tor @ 250 c/c
both ways Reinforcement bars all round as plinth protection. A surface drain to be provided
along-with plinth protection which shall be connected to the drainage system of the plant.

3.0 DESIGN CRITERIA –GENERAL

4.1 Site Grading

The grading of the area shall be done by cutting and filling with the following:
1. Cutting Area: Thoroughly rolled and compacted.
2. Filling Area: Compacted in layers not exceeding 20cm to achieve minimum 95% of
maximum dry density.
3. The finished floor level (FFL) shall be as per the adjoining road level of existing plant.

4.2 Storm Water Drainage

The storm water drains shall be designed for maximum rain water intensity in the area or as
specified in metrological data elsewhere.
Storm water drains shall be sized for the higher discharge arising out of either rain water or
firefighting water. All drains should be of RCC.
Minimum width of drains: 500 mm X (depth > 600mm) shall be connected to storm water
drains.

TECHNICAL SPECIFICATION FOR CIVIL & STRUCTURAL WORK

1.0 GENERAL

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

These technical Specifications shall be supplementary to the specifications contained

IS - 383 Coarse & Fine aggregates from natural sources for concrete.
IS - 432 Mild Steel & Medium tensile steel bars
IS - 456 Code of Practice for Plain and Reinforced Concrete
IS - 800 Code of Practice for General Construction in Steel
IS - 2116 Sand for masonry mortars.
IS - 4925 Concrete batching and mixing plant.
IS -10262 Recommended guidelines for concrete mix design.

in the IS codes and CPWD specifications, wherever at variance; these Particular

Specifications shall take precedence over the provisions in the IS Codes and CPWD
Specifications.

2.0REFERENCE STANDARDS

Wherever reference of BIS Specifications/ or BIS Codes of Practice are made in the
Specifications/ Schedule of Rates or Preambles, reference shall be to the latest edition of BIS
(Bureau of Indian Standards).

3.0 PLAIN AND REINFORCED CONCRETE WORK

This specification deal with cement concrete, plain or reinforced, for general use, and covers
the requirements for concrete materials, their storage, grading, mix design, strength & quality
requirements, pouring at all levels, reinforcements, protection, curing, formwork, finishing,
painting, admixtures, inserts and other miscellaneous works.

3.1 Materials

3.1.1 Water: Water used for mixing and curing concrete and mortar shall conform to the
requirements as of IS: 456: 2000. Seawater shall not be used for concrete work.
3.1.2 Aggregates: Coarse and fine aggregates for cement concrete plain and reinforced shall
conform to the requirements of IS 383 and / or IS 515. Before using, the aggregates shall be tested
as per IS: 2386.
3.1.3 Coarse aggregate: Coarse aggregate for all cement concrete work shall be broken or crushed
hard stone, black trap stone obtained from approved Quarries or gravel.
3.1.4 Sand: Fine aggregate for concrete work shall be coarse sand from approved sources. Grading
of coarse sand shall be within grading zones I, II or III be laid down in IS: 383, table 4. If required
the aggregates (both fine and coarse) shall have to be thoroughly washed and graded

4.0 Grades of Concrete

4.1 Grades of cement concrete shall be as given below:

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 GAIL (INDIA) LIMITED
FINAL CONSOLIDATED REPORT FOR Project No.
“AUGMENTATION OF LHC STORAGE FACILITY AT Document No.
GAIL-VIJAIPUR”
Rev

Grade Specified Characteristic compressive strength

At 28 days (N/mm2)
i M 7.5 7.5
ii M 10 10
iii M 15 15
iv M20 20
v M25 25
vi M30 30

4.2 A sieve analysis test of aggregates shall be carried out as and when the source of supply is
changed without extra charge notwithstanding the mandatory test required to be carried out as per
relevant IS codes.

5.0 PLASTERING

5.1 Sand for plastering: shall be 50% fine sand and 50% coarse sand from approved sources.
5.2 Preparation of surface shall be done as per specifications.
5.3 Cement mortar shall be of the mix as indicated in the items and shall be mixed as specified in
the specifications.
5.4 Joints in walls etc. shall be raked to a depth of 12 mm, brushed clean with wire brushes dusted
and thoroughly washed before starting the plaster work. The surface shall be thoroughly washed
with water cleaned and kept wet to saturation point before plastering is commenced.
5.5 All plaster work shall be cured for at least 7 days.
5.6 Integral water proofing compound shall be mixed with cement in the proportion recommended
by the manufacturer. Care shall be taken to ensure that the water proofing material gets well and
integrally mixed with cement. All other operations are the same as for general plaster work.
5.7 For sand face plaster undercoat of cement plaster 1:4 (1 cement: 4 sand) of thickness not less
than 12 mm shall be applied similar to one coat plaster work. Before the under coat hardens the
surface shall be scared to provide for the top coat. The top coat also of cement mortar 1:4 shall be
applied to a thickness not less than 8 mm and brought to an even surface with a wooden float. The
surface shall then be tapped gently with a wooden float lined with cork to retain a coarse surface
texture, care being taken that the tapping is even and uniform.

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